VI Instruction manual for boiler plant, volume 1 ©ollor lyiio: I K AQ1H 1H000 K<|/li »**«• äs M :••«»«ilW ^^r '" ©umoMypi»: KIJSA ItîfîO HJMn "' "'^fliiiiiimü KJ ' ^KH! l ta '*' l^iojMui Nu,: y;uMim>, y 30m;:,!, /uowwi, 7:ir»«»r>G. 737033/5, 737929/31 °m•t* 21 1 Hull Nø,! Oll 130007, 031300011. 0313000'.), 03130010/1/2, 04130001/2 OUMluMMîf < UlrMI(|/ll •mm WïMrtii i fr yî— i AALBORG flHfllSSSSKniSR^^^^^^B INDUSTRIES ^ÊÊÊÊÊÊSÊÊÊÊÊÊÊÊÊÊÊÊÈ^KÊÊKII^^^ÊÊÊÊÊ Table of contents System concept (vol. 1) Technical data 1 Flow diagrams 2 AQ-18 boiler/accessories (vol. 1) General descriptions 3 Operation and maintenance 4 Feed and boiler water 5 Water level gauge 6 Safety valves 7 Feed water system 8 Regulating feed water valve 9 Feed water pumps 10 Chemical dosing unit 11 Salinity alarm equipment 12 Oil detection equipment 13 Drawings.... 14 Datasheets 15 KBSA burner/accessories (vol. 1) Descriptions, operation and maintenance 16 Oil flow regulating valve 17 Oil flowmeter 18 Differential pressure transmitter 19 Regulating valves 20 Ignition pump 21 Combustion air fan 22 Fuel oil pump unit 23 Fuel oil heater 24 KBSA burner/accessories (vol. 2) Drawings 1 Datasheets 2 Language UK Page 1/2 AALBORG INDUSTRIES Performance curves 3 Control system/electrical equipment (vol. 2) Control system 4 Operating instructions for control system 5 Process controller, SIP ART DR21 6 Process controller, SIPART DR 24 7 Controller hardware for BMS-system 8 Hand programming unit FTX 117 9 Dual trip amplifier 10 F/I-F/F converter 11 Flame safeguard 12 List of settings for single controllers, SIPART DR 21 13 Configuration list for electronic limit switches 14 List of settings for air/oil combustion controllers, SIPART DR 24 15 PLC documentation 16 Electric drawings for boiler control panel 17 Set points 18 Datasheets 19 Spare parts (vol. 2) Spare parts for boiler 20 Spare parts for burner 21 Spare parts for control system 22 Language UK Page 2/2 Oo OOO o O o o o OOO o Oo AALBORG gngiaaaaasHBH^^^^^^B INDUSTRIES ^mugji^g^^giimii^^^^^^^^^^ii^g Table of contents Technical data for boiler unit General data 1 Dimensions for boiler unit 2 Water/steam process data 3 Combustion process data 4 Data for atomising steam 5 Data for electric systems 6 Data for pressure part 7 Data for burner 8 Data for water level operation :. 9 Data for steam pressure operation 10 Manuals 11 Language UK Page 1/1 • • • • • jilllllii AALBORG gHÜBHIilBHSCilSIJBIIHSIBIU INDUSTRIES ^m^mu^m^gQ|m£g|^^ø|gjjyg^||m| Technical data for boiler unit 1 General data • ProjectNo.: 736950, 736952 • Hull No.: 03130007,03130008 • Classification society: LRS • Pressure gauge calibration: MPa • Thermometer calibration: °C • Language for signs: UK 2 Dimensions for boiler unit • Height to top of local control panel incl. retraction of burner: 8,650 mm • Diameter excl. insulation: 3,050 mm • Weight of boiler unit excl. water: 26,900 kg • Weight of boiler unit incl. water: 37,900 kg 3 Water/steam process data • Steam output: 18,000 kg/h • Working pressure: 0.7 MPa • Max. allowable working pressure: 0.9 MPa • Working temperature: 170°C • Feed water operation: Modulating • Feed water temperature, operation: 85-95°C • Feed water temperature, layout: 60°C 4 Combustion process data • Min. calorific value of diesel oil: 42200 kJ/kg • Min./max. viscosity of diesel oil: 6-8 cSt at 50°C • Density of diesel oil: 890 kg/m3 • Min. calorific value of fuel oil: 40200 kJ/kg Language UK Page 1/3 AALBORG INDUSTRIES • Max. viscosity of fuel oil: 700 cSt at 50°C • Density of fuel oil: 980 kg/m3 • Fuel oil temperature before pre-heater: 55°C • Fuel oil viscosity at burner inlet: 15 cSt • Fuel oil temperature at burner inlet: 140°C • Ambient air temperature: 45°C • Air excess No. at 100% load: 1.15 • Flue gas temperature (clean boiler): 336°C • Air consumption at 100% load: 20,227 kg/h • Flue gas flow (approx.): 21,590 kg/h • Expected back pressure from stack at full load: 15 mmWG 5 Data for atomising steam • Atomising steam pressure at burner, max.: 0.6 MPa • Atomising steam consumption, max.: 78 kg/h • Atomising air pressure at burner, max.: 0.7 MPa • Atomising air consumption, max.: 138 kg/h 6 Data for electric systems • Power supply: 3 x 440 V, 60 Hz • Control voltage: 1 x 220 V, 60 Hz • Pilot voltage: 24V • Insulation class: B • Degree of protection: IP 44 7 Data for pressure part • Boiler type: Large oil fired boiler • Model: AQ-18 • Test pressure: 1.35 MPa • Max. allowable shrink: 0.82 m3 • Max. allowable swell: 0.39 m3 Language UK Page 2/3 AALBORG flSflSBESHS INDUSTRIES ^m^gnn^m^g^n^i^ • Burner type: Steam atomising, modulating 8 •Dat Modela fo: r burner KBSA 1550 • Burner capacity on diesel oil, minVmax.: 155 - 1291 kg/h • Burner capacity on fuel oil, minVmax.: 155 - 1355 kg/h 9 Data for water level operation • Too high water level alarm: + 200 mm • High water level warning: + 150 mm • Normal water level: 0 mm • Start stand-by feed water pump: not AI supply • Low water level warning: -120 mm • Too low water level alarm and burner off: -145 mm • Too low water level alarm and burner off: -145 mm 10 Data for steam pressure operation • Safety valve: 0.87 MPa • High steam pressure alarm and burner off: 0.85 MPa • Burner start/stop: 0.72 / 0.80 MPa • Burner operation: 0.7 MPa • Low steam pressure warning: 0.4 MPa 11 Manuals • Language for manuals: UK • Set of approval manuals:..... 12 • Set of working manuals: 8 • Set of instruction manuals: 8/ship • Document revision date: 19 OCT 2004 Language UK Page 3/3 • AALBORG TABLE OF CONTENTS INDUSTRIES Table of contents Flow diagrams— Steam/water system X01:024262d List of parts for steam/water flow diagram X01:024262d Oil system X02:028451d List of parts for oil system X02:028451d Burner unit 92X02:028394a List of parts for burner unit flow diagram 92X02:028394a Language UK Page 1/1 Part list updated 041117 HeU Changed according to order 040503 GKa SøK Description Index Date Drawn Appr. Hull nos 03130011, 03130012, 04130001 & 04130002 added 040625 GKa SøK Revised according to order a 03.10.2003 BUa SøK / .QN Service lOOOl 10001 ^""^ steam LP Cooling water Control air ax. 10 bar (ompresse d air from m.e. starting air system -ÇD Condensate Max.85°C -Çn Make-up Signatures: Steam I Title: Date Water Overboard \ ISk 22.11.2002 Chemicals x AQ-1818000 kg/h+1 x AQ-10/16W 3000/1000 kg/h Appr. Date Air NOTE: Customer Guangzhou Shipyard Steam/water system JKP 22.11.2002 Blow down/drain lines - Components specified by item no. are supplied by AI Society LRS LRS LRS LRS LRS LRS LRS LRS iiSiii Feed water regulation modulating Weight Scale: Size External wiring - Items: see separate list of parts. 1:1 A2 - For electrical connections, see actual electrical wiring diagrams. Newb. No. 03130008 03130009 03130010 03130011 03130012 04130001 Oil 03130007 04130002 Flow diagram - * Instrument air Article/Drawing No: Exhaust gas AALBORG - For connections [x]see burner arr. drawing Project No. 736950/51 736952/53 736954/55 736956/57 737633/34 737635/36 737929/30 737931/32 INPUSTIIES TW9 DRAWING AMD DESIGN SHOWN HEREW IS THE PROPERTY OF AALBORG INDUSTRIES Boiler No. 13368/69 13370/71 13372/73 13374/75 14116/17 14118/19 14487/88 14489/90 AND MUST NOT BE USED BY OR REPROOUCEO FOR THIRD PARTY X01:024262 AALBORG INDUSTRIES List of Parts for Oil Fired Boiler Type AQ-18 Rev:d Class.: "SteamAVater Flow Diagram", Drawing No.: X01:024262d Date: 17 NOV 2004 LRS Item Qty Dim. Applications Type Data Sheet No DN or Drawing 1C l Oil fired boiler 18t/h- 0.8-1.0 MPa 45Y:028399 CI 2 65/100 Safety valve Boiler 261 1174 C2 1 200 Main steam valve Stop valve 6010 000087 C3 2 65 Feed water valve inlet Stop valve 6010 000090 C4 2 65 Feed water valve inlet Stop-check valve 6030 000023 C5 1 40 Scum valve Stop-check valve 6030 000013 C7 2 40 Blow-down valve Stop-check valve 6030 000016 C9 1 1/2" Sample valve 6220 000002 CIO 1 1/2" Air escape valve 6220 000002 Cll 1 1/2" Gauge board valve 6220 000002 **C13 1 20 Atomising valve Stop-check valve 264 1087 *C14 1 200 Main steam check valve 6020 000022 C15 1 25 By-pass steam valve Stop valve 250 1088 *C16 1 80 Stop valve Furnace drain 6010 000042 C17 1 25 Water level gauge left Water level indicator 7010 000151 C18 1 25 Water level gauge right Water level indicator 7010 000150 C23 1 Heating coil C24 1 25 Stop valve for heating coil 250 1088 C25 1 25 Stop valve for heating coil 250 1088 C26 1 15 Safety valve for heating coil 261 1358 C27 2 25 Stop valve DP-unit 250 1088 C28 2 25 Stop valve Low water level switch 250 1088 C30 1 Gauge board Boiler C179 1 1100 Smoke uptake TAO supply CI 84 2 65/100 Expansion joints for safety valve TAO supply 85Y:013427 •C189 1 High pressure cleaner 8500 000464 (Not shown on flow diagram) C191 1 Water washing hose 8500 000016 (Not shown on flow diagram) C196 1 Î4" Stop valve Drain for soot blower 6220 000002 C211 1 Counter flanges incl. gasket & bolts V..-' K16:004096 C212 set (Slip-on) / \ C213 Gaskets in steam line: spiral wound \.y C214 •C227 4 1 Vi" Solenoid valve 6240 000006.-. /" \ /• \ ) i •> • \ *L2 Control panel 63X03:028295; O ,'"X: 'Y W14 2 High & low water level switch x 8100 000008 x7 r\ ( . r~\ , V:\Marine\OrdeA736xxx\736950,51,52,53,54,55,56,57\1300 Documentation\1310 Flow.diagrams -steam water\RQ020148Adoc 17-11-04 / AALBORG INDUSTRIES List of Parts for Oil Fired Boiler Type AQ-18 Rev: d Class.: "SteamAVater Flow Diagram", Drawing No.: X01:024262d Date:17 NOV 2004 LRS Item Qty Dim. Applications Type Data Sheet No DN or Drawing 1C l Oil fired boiler 18 t/h- 0.8-1.0 MPa 45Y:028399 W16 l DP-unit Feed water control 70Z:019538 ** 31/01-2005 changed to DN 20 w.'~ \ V:\Marine\OrderY736xxx\736950,51,52,53,S4,55,56,57\1300 Documentation\1310 Flow diagrams - steam water\RQ020148A.doc 17-11-04, 2/6 AALBORG INDUSTRIES List of Parts for Oil/Exhaust Gas Fired Boiler Type AQ-10/16W Rev:d Class.: "Steam/Water Flow Diagram", Drawing No: X01:024262d Date: 17 NOV 2004 LRS Item Cll 1 Vi" Stop valve Pressure gauge 6220 000002 C12 1 V? Stop valve Max. pressure switch 6220 000002 *C16 1 65 Furnace drain valve 6010 000066 C17 1 25 Water level gauge left Water level indicator 7010 000136 C18 1 25 Water level gauge right Water level indicator 7010 000135 C23 1 Heating coil C24 1 25 Stop valve for heating coil 250 1088 C25 1 25 Stop valve for heating coil 250 1088 C26 1 15 Safety valve for heating coil 261 1358 *C27 2 25 Stop valve 250 1088 *C28 2 25 Stop valve 250 1088 C123 1 50 Pneumatic stop valve with limit switches and Soot blower air flow K.1053 solenoid valve C124 1 %" Filter regulator with automatic drain 291 5101 C125 1 50 Soot blower C127 1 3/8" Low pressure switch (interlock) Soot blowing B.3001 C128 1 Pressure gauge 0-40 bar 8050 000027 C129 1 3/8" Low pressure switch (safety) Soot blowing B.3001 C135 2 •/i" Instrument stop valve 1254 1002 C179 1 Smoke uptake TAO supply Q C184 2 32/50 Expansion joints for safety valve TAO supply ( } 85Y:013421 *C198 1 65 Stop valve Exhaust gas section drain 6010 000066, x valve w x y C211 1 Counter flanges incl gaskets & bolts K16:004096 { v J \ J •. y -. y ' .y C212 se (slip-on) o ( ^ f~"\ C213 t ..y 'y_y v. y C214 yy r ~\ /'"'N . ~-y • / \ ./ \ / • , \ -y v./ V:\Marine\Order\736xxx\736950,51,52,53,54,55)56,57\1300Documentation\1310 Flow diagrams -steam watei\RQ020148A.doc 17-11-04 ^ N x 3/6 O \ [ ) : ' ; ; ,' ) : ) ," ) \ ' \ y y y \ y \ / \ J \ y ,-~ "~yy"^ < /" ' y.- " 'X/'' ' O " vX (> ( AALBORG INDUSTRIES L2 Control panel L5 Control panel for soot blower *W14 1 25 Low water level switch 8100 000008 W16 1 25 DP-unit Feed water control 70Z:028277 O V:\Marine\Order\736xxx\736950,51,52,53,54,55,56,57\1300 Documentation\1310 Flow.diagrams - steam water\RQ020148A.doc 17-11-04 , 4/6 - AALBORG INDUSTRIES List of Parts Boiler Type AQ-18 & AQ-10/16W Rev:d Class.: "SteamAVater Flow Diagram", Drawing No.: X01:024262d Date:17 NOV 2004 LRS Item No Qty Di Description Applications Data Sheet m. or Drawing DN 1H2 i Remote steam pressure indication 8000 000034 1K5 i Temperature switch 632 0110 1M4 2 Feed water pump CR 32-5-2 1M7 2 Pressure gauge suction side 663 3118 1M8 2 Pressure gauge 663 3121 1M9 1 Pressure switch 6310340 *1M10 4 Instrument stop valve 666 6006 *1M11 1 Instrument stop valve 254 1002 *1M12 2 Orifice Kl 8:003559 1M23 1 Chemical dosing unit 9296 000002 1M25 1 Sample cooler 875 0005 *1M130 1 Remote start /stop box 8000 000036 1M142 5 Check valve Feed water pumps 6020 000028 1W1 1 40 Feed water control valve 6050 000050 1W32 1 Remote water level indication 8000 000034 1W3 1 Filter regulator with automatic drain 2915101 2H2 1 Remote steam pressure indication 8000 000034 2K5 1 Temperature switch 632 0110 2M4 2 Feed water pump CR 5-13 2M7 2 Pressure gauge suction side 663 3118 2M8 2 Pressure gauge 663 3120 *2M9 1 Pressure switch 6310330 *2M10 4 Instrument stop valve 666 6006 2M11 1 3/8" Instrument stop valve 87D3050 2M12 2 Orifice Kl 8:005874 2M23 1 Chemical dosing unit 9296 0000002 2M25 1 Sample cooler 875 0005 *2M130 1 Remote start /stop box •'' x :8000 000036 2W1 1 15 Feed water control valve '6050 000026 2W3 1 Filter regulator with automatic drain 291 5101 rs V J 2W32 1 Remote water level indication 8000 00003 V - C) O ß \ i \ } M77 1 Water test equipment, 880 0050, / x AGK 100 with armerzine V .J V J . y '• J V ./ \ / \ / \ / \ ,' \ V / V '' \ / V / \ v' V../ V:\Marine\Order\736xxx\736950.51,52,53,54,55,56,57\1300 Documentation\1310 Flow diagrams -steam water\RQ020148A.doc 17-11-04 ,- --\ 5/6 C) •' '• '' • / W \ •' )! ' ! ) v -- v y \ y K-, y x-., y \ y y y c 'N / ''v' " :' \^ N../'' \f ^, ^ x. ( /'"" ^/" ",/ ' V '-*} \) '\? '-•/ '\/ AALBORG INDUSTRIES M82 1 40 Stop valve for steam injection 64Z:027665 M83 40 Strainer for steam injection 64Z:027665 M84 40 Steam injection control valve 64Z:027665 M85 1 Control system 121 with pocket Temperature transmitter 64Z:027665 M86 40 Check valve for steam injection 64Z:027665 M87 Vi" Vacuum breaker for steam injection 64Z:027665 M88 1 Steam injector 64Z:027665 Vi" M89 1" Steam injector 64Z:027665 N5 1 40 Steam dump control valve with pneumatic 6050 000050 actuator N6 1 Filter regulator with automatic drain 2915101 M146 1 Salinity alarm equipment 8210 000005 8620 000003 M145 1 Oil detection alarm equipment 8210 000025 8310 000005 • r\ C) O (J y y o o y y v* „y r\v y (V ^J y V:\Marine\Order\736xxx\736950,51,52,53,54,55,56,57\1300 Documentation\1310 Flow diagrams - steam watei\RQ020148A.doc 1,7-11-04 / 6/6 Tag No./ Item Pes. Designation Dimension Article No. 1F Burner unit, chosen by project 91Y:028380 1F.1 Burner front plate incl. lance G17 Pressure switch, oil sucsion 631 0340 G18 Instrument stop valve 87D3050 G19 Filter for steam 7040 000042 G20 Temperature control valve 6050 000061 1G22 Fuel oil heater 8640 000119 1G23 Pressure relief valve 87S0041 1G24 Heater drain valve - oil side 87D3062 G28 Temp, transmitter PT100 8060 000007 G38 Temp, gauge HFO from tank 88T0003 G42 Temp, gauge HFO heated 88T0003 G43 Instrument stop valve 87D3050 G44 Press, gauge HFO from tank 663 3118 G47 Press, gauge HFO heated 663 3122 G48 Instrument stop valve 87D3050 G51 Three way valve heater bypass 6070 000027 G78 Pressure relief valve DO 87D3059 G99 Pressure transmitter FO press. 663 8234 G99.1 Gasket for G99, not shown 291 1602 G100 Control valve - FO press. 6050 000093 G105 Instrument stop valve 254 1002 G111 Three way ball valve FO return,DN20 87D3178,solval230,663 8652 G114 Air filter/regulator for G111 291 5101 G115 Three way ball valve HFO/DO, DN40 87D3074,BoxM 1G145 Ignition oil pump 71Z:024019 G147 Fuel oil supply pump 5750 000020 1G224 Remote start/stop box 8000 000011 2G224 Remote start/stop box 8000 000011 L2 Boiler power panel 1R Fan unit chosen by project 9220-2286.B G40 Air vent valve, heater 87N6003 G354 4 Check valve 6020 000028 G355.1 4 Check valve 6020 000028 • Title Drawn Date Flow diagram BiJa 08.10.2003 Appr. Date 1 x steam atomising KBSA 1550 Weight Scale Size oil system 1:1 A2 Article / Drawing No: Affix This drawing and design shown herein is the property of Aalborg Industries X02: 028'15 1 d Pagel 17/11-2004 and must not be used by or reproduced for third party Description Index Date Drawn Appr. Hull nos 03130011, 03130012, 04130001 & 04130002 added 040625 GKa SøK NOTE: - Components: see separate list of parts • For electrical connections, see actual electrical wiring diagrams - All heavy fuel oil piping to be steam traced piping and Insulated - Steam tracing to be temperature controlled • For connections: \x\ - see burner arrangement drawing Customer Guangzhou Shipyard Society LRS LRS LRS LRS LRS LRS LRS LRS Newb. No. 03130007 03130008 03130009 03130010 03130011 03130012 04130001 04130002 Project No. 736950 736952 736954 736956 737633 737635 737929 737931 Signatures: Boiler No. 13368 13370 13372 13374 14116 14118 14487 14489 Steam Title: Data Water 1 x KBSA BiJa 08.10.2003 Chemicals Appr. Date Air Standard STh 08.10.2003 Blow down/drain lines Burner unit Weight Scale: Size External wiring iiiiiiiii 1:1 A3R Flow diagram Oil AALBORG Article/Drawing No: Exhaust gas INDUSTRIES THIS DRAWMO AND DESIGN SHOWN HEREIN IS THE PROPERTY OF AALBORG INDUSTRIES AND MUST MOT BE USED BY OR REPRODUCED FOR THIRD PARTY 92X02:028394 Tag No./ Item Pes. Designation Dimension Article No. C31 Instrument stop valve 87D3050 C33 Pressure gauge 6632998 C35 Pressure switch max. steam 6310330 C48 Pressure transmitter 6638232 C50 Drain valve C431 Instrument stop valve 87D3050 C331 Instrument stop valve 87D3050 F1 Steam atomising burner F17 Stop valve, ball - oil ign burner 6666006 F18 Solenoid valve - oil ign burner 6638146 F19 Solenoid valve - oil ign burner 6638146 F31 Ignition burner F33 Flame scanner auto/man 6639045 F36 Temp, switch - fire in windbox 6638211 F41 Stop valve, ball atom, steam 87D3064 F42 Stop valve, ball - atom, steam 87D3064 F43 Water separator atom, steam 6638601 F44 Shut off valve - purge steam 87D3064 F45 Non return valve - purge steam 87D3093 F50 Instrument stop valve 87D3050 F51 Press, transm. atom, steam 8010000006 F56 Solenoid valve, air for F57 6666233 F57 Pneumatic actuator for F42 6638651 F58 Pneumatic actuator for F44 6638651 F59 Solenoid valve, air for F58 6666233 F60 Pneumatic actuator for F75 6638652 F61 Solenoid valve, air for F60 6666233 F62.1 Manometer 6633015 F62.2 Filter regulator, for F148 6639046 F63.1 Filter regulato, for valve actuator 6639046 F63.2 Manometer 6633015 F64 Stop valve, ball FO to burner 87D3064 F65 Solenoid valve for F66 6666233 F66 Pneumatic actuator for F67 6638651 F67 Ball stop valve, FO to burner 87D3064 F68 Pressure gauge FO nozz. pr. 6633121 F69 Instrument stop valve 87D3050 F73 Stop valve 6666006 F74 Position switch, lance in position 6614712 Title Drawn Date 1 x KBSA BiJa 08.10.2003 Appr. Date Standard Weight Scale Size Burner unit 1:1 A3R Flow diagram Article / Drawing No: Affix This drawing and design shown herein Is the property of Aalborg Industnes 92X02 :02)339 4 a Pagel 17/11-2004 and must not be used by or reproducedfo r third party Tag No./ Item Pes. Designation Dimension Article No. F75 Three way valve, FO return 87D3071 F76 D.P. transmitter, airflow 8020000001 F77 Non return valve 6638103 F78 Solenoid valve 6638146 F80 Non return valve 6638103 F85 Micro switch on F67 6638660 F86 Micro switch on F75 6638660 F87 Stop valve, ball 87D3064 F91 Pressure control valve 87A3033 F93 Stop valve, ball 87D3064 F94 Control valve 6635198 F95 l/P converter 6635210 F96.1 Filter regulator 6639046 F96.2 Manometer 6633015 F97.1 Filter regulator 6639046 F97.2 Manometer 6633015 F99 Three-way valve 87D3085 F100.1 Flow meter, oil 7060000013 F100.2 Pick-up for flow meter 8310000006 F106 Flame scanner - ign. burner 6639035 F108 Non return valve 87D3093 F135 Pressure gauge 6633120 F148 Actuator 6666109 F149 Position switch 6666110 F150 Solenoid valve 6666232 F151 Solenoid valve 6666232 F152 Throttle valve 6641220 F153 Solenoid valve 6639040 F157 Temperature indicator 88T0003 F166 Transformer for Ignition Burner 6639100 L10 Junction box Title Drawn Date 1 x KBSA BiJa 08.10.2003 Appr. Date Standard Weight Scale Size Burner unit 1:1 A3R Flow diagram Article / Drawing No: Affix This drawing and design shown herein is the property of Aalborg Industries 92X02 :02)339 4 a Page 2 17/11-2004 and must not be used by or reproduced for third party 1 INDUSTRIES ^mn^^g^g^gnmii^^^mg^^^^^mi Table of contents Descriptions AQ-18 boiler general description 1 Water level control 2 Language UK Page 1/1 AALBORG INDUSTRIES Vertical Water -Tube Boiler TYPEAQ-18 GENERAL DESCRIPTION Instruction K.7140.0 JOI/30S/gs 21 FEB 94 1 - 1 - BOILER DESCRIPTION The AQ-18 boiler is an all-welded vertical water tube boiler and consists in the main of the following components. (Please see figure 1). From the top the steam/water drum, below this drum the furnace room and in the bottom the water drum. STEAM/WATER DRUM The steam/water drum consists of a circular shell limited by two flat tube plates. Because of the increased internal pressure, the tube plates are mutually connected by vertical solid stays. The main connections to the boiler are located at the steam/water drum which is also furnished with necessary internals to ensure an even distribution of feed water and circulating water from the exhaust gas boiler. Access is obtained by the manhole located at the top plate/shell. In the centre of the steam/water drum, the vertical positioned central furnace opening for the steam atomizing burner is located. Accordingly, access to the furnace room is possible from there. FURNACE ROOM The furnace room consists of both internal polygonal shaped membrane walls and of an outer casing wall of the same shape. This construction is gas tight and between the walls the generating tube bank is located. The generating tube bank consists of vertical tubes arranged in a staggered configuration. All the tubes and panel walls are welded on to the tube plates in the steam/water drum and water drum, respectively. The flue gas leaves the furnace room through the deflected tubes at the bottom and passes through the generating tube bank before leaving the boiler. JOI/4710/jbn 20 DEC 93 " - 2- An effective circulation in the boiler is achieved by the fact that a number of tubes in the cold area acts as down comers. Access is also possible through the access door at the bottom side as well as the access door provided on the smoke outlet box. Further, access to the generating tubes is possible at the four access doors provided on corners of the casing wall. The bottom tube plate is first covered with coat of insulating refractory and above with castable refractory. WATER DRUM The water drum is constructed similar to the steam/water drum and is supporting the boiler. Inside a heating coil is installed to ensure a quick starting up of the boiler and to maintain a higher temperature during standstill securing the boiler against corrosion. Access is obtained by the manhole located at the shell. For the foundation the boiler is provided with four support feeds, one as fixed food and the others constructed with possibility of thermal expansions. Counter plates are provided for welding to deck. Sketch of AQ18-B0ILER Steam atomizing burner Steam/water drum Smoke outlet Membrane wails Generating tube bank Furnace room Water drum Heating coil Fig. 1 AALBORG WATER LEVEL CONTROL SD9230#17.1 INDUSTRIES Water level control 1 Description The water level control is a modulating system at this type of boiler. The system is illustrated in Figure 1. The safety device system for too low water level shut down and burner stop consists of a level float switch mounted as an external unit. For measuring and control of the water level, the boiler is equipped with a dp water level transmitter unit, which includes external reference and variable legs, and a dp- transmitter. The continuous 4-20 mA output signal from the dp-transmitter is processed in the control system, which provides level alarms/shut downs and control of the regulating feed water valve. Water level control system Instrument air Regulating feed water valve Reference leg Variable leg Valve manifold dp-transmitter Feed water pumps [p=^<3=Q=iX}=j =Kf=Q=txM Figure 1 dp_l_mod.cdr Language UK Page 1/1 •iiii». AALBORG ÆHIiilBBHHIiHI^^^^MI INDUSTRIES ^•••••••BlMIIIBIIMHHHHHIHi^H Table of contents Operation and maintenance General 1 Language UK Page 1/1 AALBORG INDUSTRIES 3.2 OPERATION DESCRIPTION 3.2.1 Flue gas flov/ The ignition and combustion take place vertically down in the furnace. From here the flue gas flows through the deflected tubes in bottom of the furnace. The flue gas is distributed in the height of the convection section in the cavity at the furnace outlet. In the convection section the flow takes place horizontally through the convection section. After passage of the convection section the flue gas flows horizontally out through the flue gas outlet. 3.2.2 Water-steam flow The heat input is transferred to the water through the heating surfaces in the furnace room and the convection section. The heat transfer in the furnace takes mainly-place by means of radiation,' while convective heat transfer mainly takes place in the convection part. The natural circulation in the boiler provides that water flows from the steam drum and down to the water drum through the tubes least heat effected i.e. generating bank tubes and casing v/all tubes nearest the flue gas outlet. From the v/ater drum the water rises through the other tubes (the furnace membrane walls and the generating bank tubes strongest effected of heat), where an evaporation takes place on the way up through the tubes. The v/ater-steam mixture rises to the steam drum. In the steam drum steam and water are separated, and then the saturated steam leaves the boiler through the steam dryer to the main steam socket. V J v J \ s O v.i K.) n ••' *X' • V/' \ f \ / Sketch of AQ18-B0ILER Feed water inlet Steam atomizing burner Main steam Steam dryer Steam drum Manhole Furnace Flueqas outlet Membrane v/atls Generating tube bank Sockets for water washing nspection door View A-A users/orrlrp?70/aaia/arochure/tecn;ncsr/sl<3 AALBORG INDUSTRIES 3.3 Lighting-up Before lighting-up of the boiler the whole boiler plant is to be prepared and tested. The preparations and processes mentioned here are normally only carried out in connection with the first lighting-up and after large repairs. 3.3.1 Preparation When the steam plant has been installed it is to be inspected before lighting-up and start. The following description and check list are to be considered as inspection manual. When each single component in this manual has been inspected and found functional, the plant is ready for lighting-up. 3.3.1.1 Furnace In the furnace it is to be tested that refractory at the burner and on the furnace bottom plate is in position and in order. If damage has been noted, this is to be repaired before lighting-up. 3.3.1.2 Burner The boiler is equipped with steam atomizing burner intended for firing with D.O. and H.O. The burner consists of a windbox with guide vanes and throttle, an ignition burner, lance with atomizer nozzles, cone and a gas ring. The arrangement, position and state of these components are to be tested before lighting-up. Please see burner instructions. 3.3.1.3 Combustion air The combustion air volume is adjusted by the throttle in the burner air inlet. Blower rotor and shaft are to be able to turn freely by manual force without binding or scratching. The direction of rotation is to be as marked on the blower casing. C C) O 3.3.1.4 Fuel pipes _ _, w k J O The diagrams of the fuel pipes in the separate manualjs to "be stildied) thoroughly for understanding of the structure of the system, pipelines and^ flanged connections are to be absolute tight. w \J x-r-/ v c7 :: A f \ / AALBORG INDUSTRIES 3.3.1.5 Feed water line It is to be tested that all joinings are tight, the valves are placed correctly and that the flow direction through them are right. The feed water regulating valve function is to be tested (please see speciel instruction). 3.3.1.6 Steam lines It is to be tested that the valves have been placed correctly and the flow direction through them are right. All drain lines on the steam boiler to the blow dov/n tank are to be inspected. It is to be ensured that no restrictions betv/een boiler and blow down tank are available. 3.3.1.7 Water level supervision The safety equipment in connection with alarm and disconnection of the firing at low water level and feed water regulation is vital for the operation of the boiler and is therefore to be inspected thoroughly. The water level supervision equipment is to be tested according to the prescribtions of the approval authorities. 3.3.1.8 Safety valves Normally safety valves have been adjusted from the factory. The opening pressure is to be tested at lighting-up (please see instruction). • 3.3.2 Drying of refractory After repair of refractory or other big repair/cleaning it is very important to secure that the refractory is totally dry before lighting-up. In order to secure that.the refractory is totally dry and formation of cracks does not take place, the following procedure is to be used: 1. The boiler is to be filled v/ith water to normal water level with open air relief valve. ^ ^ --' C) O C) 2. The burner is lighted-up at minimum load for a^few minutes at a time and the whole procedure lasts total 8 hours: 3 w ^ .; ^ r ") V. .J V J v. J o i r^ /" "\ r~\ -'"'"" "\ ,-'"* "X AALBORG INDUSTRIES Hour no. . 1 2 3 4 5 6 7 8 9 Burner on fire, minutes 2 3 4 5 5 10 10 15 60 Burner out, minutes 8 10 10 10 5 5 5 5 The lighting-up continues after this for 2 hours with gradually increasing load. 3.3.3 Boiling out The boiler is to be boiled out to clean the surfaces on the v/ater side. If oil film or dirt exist on the steel surface the heat transmission to the water side is reduced, the steel is superheated and tube failure can occur. The chemicals used for boiling out can be led-in through the manhole in the upper drum. NB: A certain caution must be exercised regarding the chemicals used when boiling out. The operator or the person working with the chemicals must be dressed to the job, which is going to be made. Overclothes and a mask are recommended. 1) The v/ater voiume at normal v/ater level is stated in the data para graph in this manual. Do not add the chemical solution until everything is ready for carrying through of the boiling out. Crystallized trisodium phosphate (NA3POJ is to be used. On the basis of 18.8% 5 kg/m3 water is used. Before addition the chemicals are to be resolved in hot water. 2) Boiling out procedure a) The air relief valve is to be opened and the boiler is to be filled with water to just above lov/ v/ater level. b) The chemicals are to be added and all'the valves except the air valve to be closed. o Q Q c) The boiler safety equipment must be vconn acted" when boiling out. O Q (J (J O d) The boiler is to be lighted-up as, described :(n the next : : paragraph. O K'J \ j l_/ v j •,,._ e) When steam comes from the air relief valve it is partly closed and the pressure is increased in accordance with the lighting-up procedure. f) The pressure is to be keept for approx. eight (8) hours by means of discontinuous firing. g) After the initial eight hours period the v/ater level is increa sed to 75 mm above normal water level. h) The burner is to be stopped and the water level is blown down to the lowest point visible in the v/ater level glass by means of the scum valve and the blow-off valve. i) Then the air relief valve is to be opened and the boiler to be drained. j) The boiler is to be examined inside and might be rinsed with a high pressure cleaner. All surfaces must be cleaned for mud and impurities. If the internal surfaces not are satisfactory, the boiling out procedure is to be repeated. k) When the boiler has been closed down the valves are to be adjusted in accordance with the list of valves, and the boiler is to be filled v/ith fresh treated v/ater up to approx. 50 mm below the normal operation level, and the boiler is ready for operation. Filling of water The boiler is slowly to be filled v/ith feed water. The v/ater level is to be approx. 50 mm below normal water level out of regard for the water expansion during the following heating. Liqhtinq-up During lighting-up. Procedure: Q 3. Q 1) Feed pump is to be started AALBORG INDUSTRIES 2) The water level in the steam drum is to be adjusted at high level: opening of scum valve at low level: opening of feed valve 3) The burner is to be started, please see separate instruction and the firing capacity is to be adjusted, so that the lighting-up curve will be followed. 4) The air relief valves are to be closed, when clear steam outflow is observed. 5) When the boiler pressure is near the working pressure the water gauge fittings are to be blown through. 6) The main relief valve is to be opened and the lighting-up has been completed. If the steam line after the main relief valve has no pressure the valve is to be opened very slowly for heating of the steam line. 7) When the boiler after this supplies steam to the steam system continuous feeding is established. n AALBORG INDUSTRIES LIGHTING-UP CURVE FOR AQ18-B0ILER Boiler pressure (barg) Temperature (C° ) #-3 200 h 175 •\- 150 -~j - —I- 125 L_ iOO h 15 \- 50 -4- 25 O 1 i i T n i 45 60 75 90 105 110 135 O Time (min ) O y.j O t : Boiler temp, at start. \_/ v... \ I / \ AALBORG INDUSTRIES 3.3.6 Adjustments of valves The following list shows the adjustment of the valves in various situations both during lighting-up and operation. VALVE DRAINING BOILING OUT LIGHTING-UP | OPERATION Main relief valve - Closed Closed Closed Open steam Feed water regualting Closed Closed Open Open valve Main feed valve Closed Closed Closed Open Auxiliary feed valve Closed Closed Closed Closed Air relief valve (1) Open Open/closed Opea'closed Closed Safety valve(s) Free Free Free Free Blowing down Closed Open/closed Closed Closed Chemical dosing Closed Closed Closed Open Drain, water level Closed Closed Closed Closed indicator Closing valve for Open Open Open Open manometer (2) (1) This valve is to be open during filling of water. (2) Use a test manometer before pressure test. O y y y-\ c O yj y J y~\ r "\ /' ~"\ ry /' '"">. •v j W y y v.^ /' "\ /'^. y"~\ O /"" O y y v.. y \ \ * x /"~\ y 'y /' -, /' ~\ / V. y v y V, y f"~% / S, v y / -, f !. AALBORG INDUSTRIES 3.4 OPERATION 3.4.1 Generel operation manual 3.4.1.1 Levels for HW. LW and LLW At high water level (HW) an alarm is released and the feed pumps are stopped. In this way it is secured that the water level will not be so high that the steam quality is damaged. At low water level (LW) an alarm is released and the firing is stopped. In this way damage, due to non-cooling, is avoided. At low low water level (LLW) an alarm is released and further safety stop of the lighting-up is made. 3.4.1.2 Feed water The water level in the boiler is automatically regulated by a feed water regulator, which is to be adjusted in such a way that the water leve.l is maintained at normal water level. The same is to be aimed at by manual operation, if any. 3.4.1.3 Combustion control The combustion control is to be adjusted according to separate instruction (please see that instruction), so that optimum combustion is obtained. 3.4.1.4 Temperature The temperatures, exhaust gas and feed water are to be supervised with regard to trouble-shooting. An increasing exhaust gas temperature indicates the demand for boiler cleaning. Concerning water washing of boilers, please see paragraph 3.6. 3.4.2 Periodical control and maintenance It is recommended that a thourough maintenance program 4s carried through. As minimum the following is recommended: 0 ,~, 1. Daily ../ v./ \y a) Test the oil pressure at the burner. Inspect^the jlame,. pattern through the sight glass in burner, furnace wall and access door. . b) Blow the v/ater level glass through. AALBORG INDUSTRIES c) Blowing down is to be made according to the heat treatment result. d) Clean the fuel filters (only when working on heavy fuel oil). e) Operate soot blowers (only when working on heavy fuel oil). f) Test water shortage equipment g) Take tests of the feed water, boiler v/ater and steam con densate for supervision of water and steam quality. Please see description of water quality in paragraph 3.4.4. Concerning chemical dosing, please see instruction manual for SRO-plants. 2. ; Weekly a) Clean the flame scanner. 3. Periodical a) Clean and inspect the furnace room inside in order to avoid deterioration of refractory and bad thermal conduction. b) Make quarterly checks of the v/ater shortage equipment according to the rules of Arbejdstilsynet. 3.4.3 Boiler blow down Mud is to be blown out through the blow dov/n valve once a day. Scum blov/ out by means of the scum valve is made when required. There is to be blov/n until the outflowing water is clean. Kj v„../ v,.- \_/f o o o o /' ~\ /"N /—\ .-" \ i ' '. AALBORG INDUSTRIES Units of measurement Concentrations are usually expressed in "ppm" i.e. parts solute per millio solution by weight; this is the same as "mg/iitre". Specific gravity: As a guidance the following conversion can be used: 1 Be° = 10,000 mg/1 total dissolved solids (TDS) 1 mg/1 total dissolved solids = 2 jiS/cm 1 u.S/cm = 1 micromho 9 V..' '••.J AALBORG INDUSTRIES • 3.5 CLOSING DOWN 3.5.1 General It is possible to close the boiler down at any load, without special prepara tions, if absolute necessary. When closing down sudden temperature and pressure drops are to be avoided, as they can expose accessories, pipe lines and the boiler plant to inadmissible temperature gradients. 3.5.2 Procedure for closing down # When obtaining minimum load regulating circuits (feed water, steam pressure) are to be disconnected. The burner is to be stopped. The v/ater level is to be kept at the centre line of the v/ater level indicator until the boiler stops producing steam. The feed pump is to be stopped and valves on the feed water pipe are to be closed. The main steam valve and other valves on the pressure system are to be closed. When closed down for a long time boiler and economizer are to be preserved, both from the water and exhaust gas side. Regarding preservation, please see the next paragraph. 3.5.3 Preservation of boiler during standstill Steam boilers which are taken out of operation for a short or long time, should be preserved in order to avoid corrosion damage. 3.5.3.1 Preservation of the flue aas side The soot deposited on the flue gas side during operation can contain sulphuric acid and water, which can result in corrosion. Therefore the flue gas side is to be preserved in the following way: y /' \ \ /' "\ /• v.../ ^ _-'' V y Water washing: /"\ r V.../ K.j /' \ /' N /" ~*\ ,'•' The boiler is to be water washed. Then the boiler is slowly to be lighted-up (please see lighting-up) for boiling out. AALBORG INDUSTRIES Dry preservation If the water side of the boiler is preserved by keeping the super pressure, the boiler temperature will keep the flue gas side dry in the whole standstill period. In connection with the other v/ater side preservation methods, the exhaust gas side is to be closed as tight as possible after boiling out. 3.5.3.2 Preservation of water/steam side Presence of oxygen may result in corrosion, which shows as "pittings" inside surfaces. Preservation can be made in the following ways: Dry preservation By this method the boiler is totally to be emptied of v/ater and boiled out. The boiler is emptied of water by blov/ down of the boiler with a pressure of 3-5 bar, then the boiler is to be opened and drained for remaining water, if any. Boiling out of the boiler can be carried out by circulation of dried air from an air blower or by placing a bag of silicagel in the boiler drums. Alternatively some inhibitor can be supplied to the boiler drums after cooling 'down and thorough draining, and then the boiler is totally to be closed. Wet preservation Wet preservation is carried out by filling the water totally with treated feed water added oxygen binding agent in a quantity corresponding to 100-200 ml/m3 hydrazine or sulphite. At the same time the pH-value is to be adjusted to 10-10.5. When the boiler is lighted-up again, the water is to be drained off until normal water level has been established. The boiler can now be lighted-up in usual way. Nitrogen preservation Q Q Q The boiler is to be filled with treated feed v/ater up to normalV/ater level. The v/ater has been supplied oxygen binding agent as(d,esçfibed m the; above mentioned point. Steam chamber and superheater, if any, are to be., filled with nitrogen, and the pressure is to be kept on 0i2 barg! When lighting-up the nitrogen supply is to be stopped and the boiler immediately be lighted-up. " ' AALBORG INDUSTRIES The nitrogen is to be blown down through the air valve, as described in the paragraph "Lighting-up". Maintaining super pressure For short standstill periods the water side of the boiler can be protected by maintaining the super pressure by means of steam heating coil or electrical heating element. 3.5.4 Selection of preservation method Preservation method can be selected as follows: Out-of-service period Preservation method > 30-45 days Dry preservation < 30 days Wet/nitrogen preservation < 30 days Maintaining steam super pressure AALBORG INDUSTRIES 3.6 Repair and maintenance 3.6.1 Inspection For inspection on the flue gas side, access to the furnace is possible through the door at the bottom of the furnace. For inspection of the flue gas side of the tubes there are several possibili ties: Through the access door mentioned above, at the flue gas outlet from the flue gas channel, and through the four (4) inspection openings at the bottom of the tube section, placed at the panel wall corners. From here it is possible to see, whether the tubes are covered with soot or possible to locate a damaged tube in the area. For inspection inside the steam drum and water drum, manholes in both shells are available, through which access to the internal parts is possible. Inside the drums it is possible to see all the details and to plug some tubes, if necessary. O .J \.J v./- AALBORG INDUSTRIES 3.6.2 General maintenance of boiler pressure part Part Interval Maintenance/check Comments 1. Shell 6 months, Check of Precautions, maybe 12 months x) Deposits cleaning and repair x) Damage of damage. 2. Valves Daily Check of tightness In case of leakage at the spindle the stuNing box is to be adjusted. If occasion should arise, change the stuffing box at the next standstill. 3 months Valve spindle is to be According to the cleaned. instructions of the • factory. 3. Safety valves 12 months Operation check According to the instructions of the factory. Daily Tightness check. When leaky there is to be started corre sponding repair ar rangements at the following boiler ,. standstills. 4. Water level Daily Check of damage o! in case of damage indicator water level indicator exchange is carried out during operation (the valve is to be shut off). O f r\ ( AALBORG INDUSTRIES 3.6.3 Water washing Generally there will be a selfcleaning effect of the generating tube bank due to a high flue gas velocity. However, after long term operation, especially during part load, deposits can be formed on the tubes, which can be removed by means of either soot blov/ing (with air) or water washing. During combustion of oil of a poor quality or with a reduced combustion quality, deposits can be formed, which cannot be removed by means of normal soot blowing. The heating surface is to be washed with an alkaline solution (10% soda solution) and/or freshwater. As most of the deposits mainly consist of non-soluble particles, which are held together by a water soluble bonding material, water under pressure will have the following purposes: a) to dissolve the bonding material b) to wash the loosened insoluble remainders away. The AQ-18 boiler is provided with a sufficient number of fixed cleaning sockets in two levels, facilitating removal of soot deposit, when necessary. Water washing is carried out with a manually operated lance, which is to be mounted on a handle for a high pressure washer (see fig. 1). -By water washing the boiler must be out of operation and max. boiler temperature is to be 110°C. By v/ater washing the following procedure is to be used (fig. 2): 1) At bottom of the boiler furnace a drain has been mounted, which is to be opened and connected to an accumulation tank. 2) On the boiler walls (panel walls) a number of cleaning sockets have been mounted in different levels. The threaded socket is to be unscrewed from these and the lance is to be led.through the cleaning socket. Q 3) The handle is to be activated in order to lead high-pressureCwater to the lance. ,o ^ 4) Lead slowly the lance to full depth and back again. (Rèpeat) thiP process several times for approx. 2 minutes, in'each' socket, to) ensure good cleaning. j AALBORG INDUSTRIES 5) The cleaning is to be repeated for all cleaning sockets and caps to be mounted after cleaning. 6) After cleaning in all the sockets, soot blowing can also be done through the inspection doors at the bottom of the tube section. The doors are removed and the lance is to be inserted between the convection tubes. Cleaning is done in the same way as described above. After cleaning the doors are to be mounted again. 7) After water washing the refractory at the furnace bottom must be cleaned with alkaline water, as the water is very corrosive. It has to be observed that all washing v/ater and removed deposits are taken out of the boiler. If water washing is started, it has to be continued in order to remove all deposits, as some deposits get hard and difficult to remove, v/hen they get wet and later dry out. 8) The plant is to be boiled out immediately after the v/ater washing has been completed in order to avoid damage on refractory and heating surfaces. The boiler is to be lighted-up and pressure to be raised, as described in paragraph 3.3 "Lighting-up". When the water v/ashing has been started it has to be carried through, so that all deposits are removed, as some types of coatings hardens and get difficult to remove, when they first have been saturated and then dry out. The plant is to be boiled out immediately after the v/ater v/ashing has been completed in order to avoid damage on refractory and heating surfaces. The boiler is to be lighted-up and pressure to be raised as described in paragraph 3.3 "Lighting-up". /' \ /•""'"N / "\. v.. J v. j Water washing for AQ18 - Boiler Fig 1. Steam drum Furnace 16 pes. of sockets for waterwashing (4 pes. in L, corners) Membrane walls Generating tube bank Sockets for water washing nspecfion door View A-A 600 I 00= Lance for water washing Supplied by Al AI supply Water washing for AQ18 - Boiler Fig 2. Detail B Sockets for waterwashing Water washing trough sockets View D-D Water washing trough inspection doors Detail C D AALBORG INDUSTRIES 3.6.4 Repair 3.6.4.1 Instruction for plugging of tubes In case of leakage on a boiler tube, the burner is to be stopped and the pressure to be removed from the boiler. If the tube in question cannot be located immediately, the boiler is to be set on pressure by means of the feed water pump, so that the leakage will indicate the tube which has been damaged. The boiler is to be emptied of v/ater and the manhole covers in the steam drum and the water drum are dismantled. When a damaged tube has been located, the tube is to be plugged with a conical tube plug. Before the conical tube plug is mounted, the tube ends are to be cleaned inside, so that no deposits are present in the tube. When a tube has been plugged, a new tube should be mounted as soon as possible. When tubes are plugged, the efficient heating surface is reduced and the boiler efficiency v/ill go down. r \.y \.J v. ./ v j v._y o AALBORG INDUSTRIES Plugging of furnace tubes When a furnace tube has been plugged, the furnace side of the damaged tube is to be cut vertically along the connections with the fins between the tubes in the membrane wall (sketch no.1). Inside the rest of the tube and on the fins next to the damaged tube a number of anchors of heat resistant or stainless steel are to be welded on. Hereafter refractory is to be placed against the damaged tube and the neighbouring fins in the full height in the furnace. Plugging of convective tubes and outside membrande wall tubes Sketch no. 2 shows plugging of convection tubes and tubes in outside membrane walls. When the tube has been located, it is to be plugged in both ends. After this operation the boiler can be filled up with water and the normal boiler use can continue, until the tube can be replaced by a new tube. 3.6.4.2 Repair of refractory Normally, routine maintenance is carried out of all refractory. In case of often lighting-ups and closing downs of the plant increased maintenance of the refractory is required. As the refractory not is elastic, a sudden load can make it crack. Peeling can occur, if pieces of the refractory is loosened. Peeling is acceptable, provided that the material loss does not exceed more than the half of the thickness of the original casting. Peeling is to be patched with own refractory at the next closing down of the boiler. Normally, cracks in the refractory do not need repair, unless the size and extent cause direct fatigue of the refractory. Light cracks indicate that the crack is a natural expansion and these are not to be repaired. O Dark cracks are to be repaired, however, it is pointed out that expansion cracks in time get darker. v '\J v J O AALBORG INDUSTRIES Plugging of tubes Sketch of AQ18-B0ILER Steam atomizing burner Manhole Steam drum Fluegas outlet Furnace tube Convection tube Outer walls Furnace O Wbter'drum Ù U O / \ y y y C) y / \ y~"~y /"' AALBORG INDUSTRIES Sketch no. 1 Tube plug \':2V! B-B uGW n A/ivro?4 Y„-"'' \ J vx s\ i /" "A v„,y V J v_X /"""\ r "\ r"\ V ~x'' K J /' '""-. f "-\ r N AALBORG 4fc INDUSTRIES Sketch no. 2 Tube plug Convectionom tubes Outside mem brane walls O AALBORG INDUSTRIES TECHNICAL DATA PLISTIX 14 Type* ' Repair material - also for large thicknesses - for application by casting or gunning. Thermal Values: Operating temperature: 100 - 1420°C Max. operating temperature: 1470°C Melting point: SK 33 1730°C Thermal conductivity (kcal/in h°C) at S40°C: o,67 at 815°C: o,72 at 1090°C: o,77 Expansion coefficiency: o,St at 1000°C. Chemical Data: % e Ti0 Ca0 M Na K A1203 Si02 F 2°3 2 2° 2° 2° 48 43 1,2 1,9 4,8 o,2 o,l o,2 Granulating: 6 mm Physical Data: Consumption of material: 1,85 t/m Bulk density at U00°C: 1,85 kg/dm-5 Porosity at 1100°C: • 321, Setting hydraulic •Temp°C Shrinkage Bending Strength Cold Crushing after firing Strength kp/cm psi kp/cm psi 110 o,lo 49,5 700 100 1420 600 o,4o 25,3 360 60 852 1100 o,8o 24,6 350 60 852 1500 o,8o 52,8 750 110 1560 1400 o,5o 52,8 750 110 1560 General Properties: ~~ Water required: +16 - 171 Working time after casting: 10 minutes^ Min. time before heating up: immediately" or later. Application by gunning: good r, r> r. Waste: less thin Ï0\ Packing: 20 kgs buckets - or 50 kgs bags. '•--' Storage time: For 50 kgs bags: 12 months. For 2:0) kgsy buckets: O f-\ ,/--2 4 months .,•--< in particular:Follow installation instructions. v ' ' y vy This material is also very suitable for t'rowelLing v / moulding balls first by hand, ô ( x- ( \ /' \ ' \ \ N r -12- AALBORG INDUSTRIES INSTRUCTION FOR REPAIR with PLISTIX 14 refractory plastic service mix Repair of worn-rdown brickwork. The part of the brickwork needing repair to be cleaned of slag, The existing brickwork must not be moistened with water. PLISTIX 14 is mixed with water - abt. 3 - 3j litres per bucket (20 kg) - to e proper consistency and trowelled upon the worn-down areas without glazing. 2_. R.epair of burned-through brickwork. The part of brickwork needing repair is cleaned of slag. The area which has to be filled out with service mix is formed like a dovetail in order to prevent the mix from falling out. The existing anchorage to be renewed if necessa.ry. PLISTIX 14 is mixed with water - abt. 3-31 litres per bucket (20 kg) - to a proper consistency. The existing brickwork must not be moistened with water In case of a larger repair work abt-. 1 square meter is cast at the time and expansion material - 1 - 2 mm cardboard or equal - is installed between the sections. $_. Heating-up. O The heating up of the- boiler can take place already 50 minutes after the repair work is finished. (} () Q The rise of temperature - 50-60°C per hour - as dependent upon the thickness of the installed material. / , r\ > %, > AALBORG WATER LEVEL CONTROL SD9230#17.1 INDUSTRIES Water level control 1 Description The water level control is a modulating system at this type of boiler. The system is illustrated in Figure 1. The safety device system for too low water level shut down and burner stop consists of a level float switch mounted as an external unit. For measuring and control of the water level, the boiler is equipped with a dp water level transmitter unit, which includes external reference and variable legs, and a dp- transmitter. The continuous 4-20 mA output signal from the dp-transmitter is processed in the control system, which provides level alarms/shut downs and control of the regulating feed water valve. Water level control system Instrument air Regulating feed water valve Reference leg Variable leg Valve manifold dp-transmitter Figure 1 dp_l_mod.cdr Language UK Page 1/1 AALBORG gsgiaaaaagnasHS^^^^^M ^••••••^••••••••^HIIH^HlHi^^H Table of contents Feed and boiler water General 1 Layout of the treatment system 2 Feed and boiler water characteristics 3 Feed and boiler water maintenance 4 Treatment systems / injection points 5 Language UK Page 1/1 AALBORG FEED AND BOILER WATER OM9210#99.2 INDUSTRIES Feed and boiler water 1 General Note: The recommended feed and boiler water characteristics are only valid for boilers with a working pressure below 20 barg. There is a number of ways to produce good quality feed water for boiler plants. Methods such as e.g. reverse osmosis plants or ion exchange plants produce good quality distillate. Also evaporators generally produce good distillate. The important thing is that the distillate used should be clean and without foreign salt contamination. In practice most distillates used contain minor parts of various salt combinations which can and must be chemically treated away. Furthermore, the distillate may contain dissolved gases like for example oxygen (O2) and carbon dioxide (CO2) which may lead to corrosion in the boiler, steam, and condensate system. Important: Boiler and feed water must be chemically treated in order to avoid corrosion and scaling in the boiler. Layout of the treatment system The condition of the feed and boiler water is an essential part of the boiler operation and operation philosophy. The design and construction of the treatment system should therefore be considered carefully during layout of the plant. Aalborg Industries gives some general requirements and recommendations regarding the conditions of the feed and boiler water. However, there is several ways to obtain this results, or similar, by using different treatment systems. The following should therefore be considered already at the layout stage: — Choose the treatment system that should be used. — Present the condensate and feed water system to the supplier of the treatment system and inform about the operation philosophy of the plant. — Let the supplier indicate where the injection points should be located and also inform if special equipment is required. — Let the supplier inform about which test facilities is needed. — Purchase the recommended equipment and install it in the correct way. — Use the treatment system as soon as the boiler is taken into operation. Language UK Page 1/14 AALBORG FEED AND BOILER WATER OM9210#99.2 INDUSTRIES Feed and boiler water characteristics The following text regarding feed and boiler water treatment is the normal recommendations given by Aalborg Industries. These recommendations should be followed strictly in order to have the best working conditions for the boiler plant and to extend the working life of the plant. The requirements/recommendations of the various values for feed and boiler water are listed in Table 1 below. "-"",, Requirements for feed and boiler water Unit Feed water Boiler water Appearance - Clear and free of mud Clear and free of mud Hardness ppm CaC03 0-5 - Chloride content ppm Cl" <15 <100 "P" alkalinity ppm CaC03 - 100-150 Total (T) alkalinity ppm CaC03 - <2 x "P" - Alkalinity PH-valueat25°C - 8.5-9.5 10.5-11.5 Hydrazine excess ppm N2rL, - 0.1-0.2 Phosphate excess ppm PO4 - 20-50 Specific density at 20°C Kg/m3 - <1.003 Conductivity at 25°C (xS/cm - <2000 Oil content - NIL NIL Table 1 If hydrazine (N2H4) is not used, sodium sulphate (Na2S04) can be used instead, and the excess should be 30 - 60 ppm. In cases where other kinds of oxygen binding agents are used, it is recommended that an excess of oxygen binding agents can be measured and indicates that no oxygen has been dissolved in the boiler water. If it is requested to measure the content of dissolved oxygen directly, it is recommended to keep the value < 0.02 ppm. In addition to the above values, the various water treatment companies will add further demands, depending on the method used for treatment of feed and boiler • water. However, the most important point is that the above values or their equivalents are observed and that a regular (daily) test of feed and boiler water is carried out. 3.1 Units of measurement Concentrations are usually expressed in "ppm" i.e. parts solute per million. Concentrations for parts solution by weight are the same as "mg/litre". 3.1.1 Specific gravity As guidance the following conversion can be used: • 1 Be° = 10.000 mg/1 total dissolved solids (TDS) • 1 mg/1 total dissolved solids = 2 u,S/cm • 1 nS/cm = 1 (xmho Language UK Page 2/14 AALBORG FEED AND BOILER WATER OM9210#99.2 INDUSTRIES Feed and boiler water maintenance The following are recommended water maintenance instructions. More exact details concerning analyses and blow downs should be set up together with the supplier of chemicals for water treatment. 4.1.1 Daily Step A: Analyses of feed and boiler water. 4.1.2 Weekly Step A: Skimming (surface blow down) according to analyses, but at least once per week (2 minutes with fully open valve). Step B: Blow down (bottom blow down) according to analyses, but at least once per week (each blow down valve 1 minute in low load condition). 4.1.3 Monthly Step A: Check the functions for salinity and oil detection systems. 4.1.4 Every six months Step A: The boiler water side (interior) must be carefully inspected at least twice a year. 4.1.5 Yearly Step A: Check of the water side of the boiler and hotwell/deaerator for corrosion and scaling. Step B: Check the chemical pump unit. Language UK Page 3/14 AALBORG FEED AND BOILER WATER OM9210#99.2 INDUSTRIES Treatment systems / injection points In the following tables and illustrations a number of different feed and boiler water treatment systems are shown together with the recommended location for the injection point of the individual chemicals as stated by the manufacturer. The general information regarding the injection point principle can be used as guidelines for the most common systems. But should there be any doubt for a specific system the manufacturer/supplier should be consulted in order to obtain the correct result. Notes for tables/illustrations: • Note No. 1: the preferred injection point of chemicals stated by the manufacturer/supplier. • Note No. 2: the alternate injection point of chemicals stated by the manufacturer/supplier. • Note No. 3: Valid for modulating feed water systems. • Note No. 4: valid for on/off operating feed water systems. The chemical pump starts/stops together with the feed water pump. • Note No. 5: valid for two boiler installation. Control of the chemicals in question work properly at an equal load condition (feed water flow) on the two boilers. How to use the tables: The tables can be used in different ways but the main idea is to do following: Step A: Discover which manufacturer and type of chemicals that should be used for the actual boiler plant. Step B: Use the name of the manufacturer and type of chemicals to select which tables that can be used. Step C: Check the flow diagrams (Figure 1, Figure 2, or Figure 3) to find a diagram that matches the actual boiler plant. Step D: Find in the selected tables the table which includes the matching diagram. Step E: If more than one table is found to match the actual boiler plant in question it is recommended to use the method/table which includes note No. 1. Step F: If no table is found to match the actual boiler plant in question it is recommended to seek assistance by the chemical manufacturer/supplier. Language UK Page 4/14 AALBORG FEED AND BOILER WATER OM9210#99.2 INDUSTRIES Chemical injection points I Table No. 1 Manufacturer / supplier: Ashland Chemical / Drew Marine Division Product name / method: Standard with Drewplex OX Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Adjunct B 3, 3a, 3b X 1 GC 3, 3a, 3b X 1 1,2,3 SLCC-A 3, 3a, 3b X 1 Drewplex OX 2, 2a, 2b X 1,3,4 I Table No. 2 Ashland Chemical / Drew Marine Division Product name / method: Standard with Amerzine Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Adjunct B 3, 3a, 3b X 1 GC 3, 3a, 3b X 1 1,2,3 SLCC-A 3, 3a, 3b X 1 Amerzine 2, 2a, 2b X 1,3,4 Table No. 3 Ashland Chemical / Drew Marine Division Product name / method: Standard with Amerzine Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Adjunct B 3 X GC 3 X 1 SLCC-A 3 X Amerzine 1 X 2,3,4 I Table No. 4 Ashland Chemical / Drew Marine Division Product name / method: Standard with Amerzine Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Adjunct B 3a, 3b X GC 3a, 3b X 2,3 SLCC-A 3a, 3b X Amerzine 1 X 2, 3, 4, 5 Table No. 5 Ashland Chemical / Drew Marine Division Product name / method: Drewplex AT / OX Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Drewplex AT 3, 3a, 3b X 1 Drewplex OX 2, 2a, 2b X 1,3,4 1,2,3 Language UK Page 5/14 AALBORG FEED AND BOILER WATER OM9210#99.2 INDUSTRIES Chemical injection points (continued) I Table No. 6 Manufacturer / supplier: Ashland Chemical / Drew Marine Division Product name / method: Drewplex AT/OX Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Drewplex AT 2, 2a, 2b X 2,3,4 Drewplex OX 2, 2a, 2b X 3,4 1,2,3 Table No. 7 Manufacturer / supplier: Ashland Chemical / Drew Marine Division Product name / method: Drewplex AT with Amerzine Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Drewplex AT 3, 3a, 3b X 1,3,4 Amerzine 2, 2a, 2b X 1,3,4 1,2,3 I Table No. 8 Manufacturer / supplier: Ashland Chemical / Drew Marine Division Product name / method: Drewplex AT with Amerzine Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Drewplex AT 2, 2a, 2b X 2,3,4 Amerzine 2, 2a, 2b X 3,4 1,2,3 I Table No. 9 Manufacturer / supplier: Ashland Chemical / Drew Marine Division Product name / method: Drewplex AT with Amerzine Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Drewplex AT 2, 2a, 2b X 2,3,4 Amerzine 1 X 2, 3, 4, 5 1,2,3 I Table No. 10 Manufacturer / supplier: Ashland Chemical / Drew Marine Division Product name / method: AGK-100 with Amerzine Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. AGK-100 2, 2a, 2b X 1,3,4 Amerzine 2, 2a, 2b X 1,3,4 1,2,3 Language UK Page 6/14 AALBORG FEED AND BOILER WATER OM9210#99.2 INDUSTRIES Chemical injection points (continued) I Table No. 11 Manufacturer / supplier: Ashland Chemical / Drew Marine Division Product name / method: AGK-100 with Amerzine Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. AGK-100 2, 2a, 2b X 3,4 Amerzine 1 X 2, 3, 4, 5 1,2,3 ' I Table No. 12 Manufacturer / supplier: Ashland Chemical / Drew Marine Division Product name / method: AGK-100 with Amerzine Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. AGK-100 1 X 2, 3, 4, 5 Amerzine 1 X 2, 3, 4, 5 1,2,3 I Table No. 13 Manufacturer / supplier: Marichem Product name / method: Standard Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Alkalinity control 3, 3a, 3b X 1,3,4 Phosphate 3, 3a, 3b X 1,3,4 1,2,3 Oxycontrol 2, 2a, 2b X 1,3,4 Marichem CCI 2, 2a, 2b X 1,3,4 Table No. 14 Manufacturer / supplier: Marichem Product name / method: Standard Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Alkalinity control 1 X 2,3,4 Phosphate 1 X 2,3,4 1 Oxycontrol 2 X 3,4 Marichem CCI 2 X 3,4 I Table No. 15 Manufacturer / supplier: Marichem Product name / method: BWT new formula Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. B.W.T. new formula 2, 2a, 2b X 1,3,4 Marichem CCI 2, 2a, 2b X 1,3,4 1,2,3 Language UK Page 7/14 AALBORG FEED AND BOILER WATER OM9210#99.2 INDUSTRIES Chemical injection points (continued) I Table No. 16 Manufacturer / supplier: Marichem Product name / method: BWT new formula Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. B.W.T. new formula 1 X 2, 3, 4, 5 Manchem CCI 2, 2a, 2b X 3,4 1,2,3 I Table No. 17 Manufacturer / supplier: Marichem Product name / method: BWT Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. B.W.T. powder 2, 2a, 2b X 1,3,4 Manchem CCI 2, 2a, 2b X 1,3,4 1,2,3 • Table No. 18 Manufacturer / supplier: Marichem Product name / method: BWT Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. B.W.T. powder 1 X 2, 3, 4, 5 Manchem CCI 2, 2a, 2b X 3,4 1,2,3 Table No. 19 Manufacturer / supplier: Unitor Chemicals Product name / method: I Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Hardness control 3, 3a, 3b X 1 Alkalinity control 3, 3a, 3b X 1 1,2,3 Oxygen control 2, 2a, 2b , X 1,3,4 Condensate control 2, 2a, 2b X 1,3,4 Table No. 20 Manufacturer / supplier: Unitor Chemicals Product name / method: I Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Hardness control 1 X 2 Alkalinity control 1 X 2 1 Oxygen control 2 X 3,4 Condensate control 2 X 3,4 Language UK Page 8/14 AALBORG FEED AND BOILER WATER OM9210#99.2 INDUSTRIES Chemical injection points (continued) | Table No. 21 Manufacturer / supplier: Unitor Chemicals Product name / method: II Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Hardness control 3, 3a, 3b X 1 Alkalinity control 3, 3a, 3b X 1 1,2,3 Cat sulphite L (CSL) 2, 2a, 2b X 1,3,4 Condensate control 2, 2a, 2b X 1,3,4 Table No. 22 Product name / method: II Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Hardness control 1 X 2 Alkalinity control 1 X 2 1 Cat sulphite L (CSL) 2 X 3,4 Condensate control 2 X 3,4 Table No. 23 Product name / method: Liquitreat Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Liquitreat 3, 3a, 3b X 1 Condensate control 2, 2a, 2b X 1,3,4 1,2,3 (Oxygen control) 2, 2a, 2b X 1,3,4 Table No. 24 Product name / method: Liquitreat Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Liquitreat 1 X 2 Condensate control 2, 2a, 2b X 3,4 1 (Oxygen control) 2, 2a, 2b X 3,4 I Table No. 25 Product name / method: Combitreat Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Combitreat 3, 3a, 3b X 1 Condensate control 2, 2a, 2b X 1,3,4 1,2,3 Oxygen control 2, 2a, 2b X 1,3,4 Language UK Page 9/14 AALBORG FEED AND BOILER WATER OM9210#99.2 INDUSTRIES Chemical injection points (continued) I Table No. 26 Manufacturer / supplier: Unitor Chemicals Product name / method: Combitreat Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Combitreat 1 X 2 Condensate control 2 X 3,4 1 Oxygen control 2 X 3,4 ; 1- Table No. 27 Product name / method: I Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Hardness control 3, 3a, 3b X 1 Alkalinity control 3, 3a, 3b X 1 1,2,3 Hydrazine 2, 2a, 2b X 1,3,4 Condensate control 2, 2a, 2b X 1,3,4 I Table No. 28 Product name / method: I Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Hardness control 1 X 2 Alkalinity control 1 X 2 1 Hydrazine 2 X 3,4 Condensate control 2 X 3,4 Table No. 29 Product name / method: II Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Hardness control 3, 3a, 3b X 1 Alkalinity control 3, 3a, 3b X 1 1,2,3 Oxygen control 2, 2a, 2b X 1,3,4 Condensate control 2, 2a, 2b X 1,3,4 | Table No. 30 Product name / method: II Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No. Hardness control 1 X 2 Alkalinity control 1 X 2 1 Oxygen control 2 X 3,4 Condensate control 2 X 3,4 Language UK Page 10/14 Ull: AALBORG 'NDUSTRiEs • Language UK Page 11/14 AALBORG FEED AND BOILER WATER OM9210#99.2 INDUSTRIES Flow diagram No.: 1 OZJ Condensate Single boiler operation with or without forced circulation exhaust gas boiler Figure 1 flowdiag_l.cdr Language UK Page 12/14 AALBORG FEED AND BOILER WATER OM9210#99.2 INDUSTRIES Flow diagram No.: 2 <^p Condensate Double boiler operation with separate feed water pumps with or without forced circulation exhaust gas boiler Figure 2 flowdiag_2.cdr Language UK Page 13/14 AALBORG FEED AND BOILER WATER OM9210#99.2 INDUSTRIES Flow diagram No.: 3 Double boiler operation with common feed water pumps with or without forced circulation exhaust gas boiler Figure 3 flowdiag_3.cdr Language UK Page 14/14 ; INDUSTRIES ^••••••••••••••^^^•••••ilH Table of contents Water level gauge Maintenance and service instructions 1 Language UK Page 1/1 AALBORG WATER LEVEL GAUGE OM7010#01.1 INDUSTRIES Water level gauge 1 Maintenance and service instructions This section describes the maintenance and service instructions for the water level gauge. Illustration of the water level gauge Nut Box heads Joint rings Box heads Tubes Screws Screws 8 - Cock plug D - Drain cocks G - Gauge body S - Cocks W - Cocks Figure 1 kli Ole.cdr 1.1 Maintenance The item nos. mentioned in the following maintenance instructions refer to Figure 1. When out of service with the gauge body in cool and depressurised condition the hexagon screws (6) can be re-tightened. Language UK Page 1/5 AALBORG WATER LEVEL GAUGE OM7010#01.1 INDUSTRIES Step A: Start at the centre, working to opposite sides alternately. Max torque: 26 Nm in cold and under working conditions. 1.1.2 Maintenance during service check-up Step A: Tighten the nuts (1). Step B: Bolts on boiler flanges. Step C: Union nuts (4). Step D: Bolt form screws (7) with cocks in open positions. If a leak cannot be stopped by tightening the bottom screws (7), the sealing surface of the cock plug (8) may be damaged or corroded. It can also be necessary to change the packing (3). 1.2 Blowing down The item nos. mentioned in this following blowing down procedures refer to Figure 1. Step A: The gauge should be blown down before lighting up the boiler and just before closing down the boiler. 1.2.2 Cleaning the water side: Step A: Shut the cock S and open the cock W. Step B: Open the drain cock D for a short time. This sucks the water out of the glass without, however, totally depressurising the gauge body. Step C: Shut the cock D and then water is forced upwards into the glass again. Step D: Repeat this procedure several times, opening and shutting the cock D. The water level in glass rises and falls. 1.2.3 Cleaning the steam side: Step A: Shut the cock W. Step B: Open the cock S. Step C: Blow through the steam side and gauge body by opening the drain cock D for 1-2 seconds. Step D: A steam blowing of longer duration is not advisable considering the service life of glass. Step E: Turn the cocks to operating position. Language UK Page 2/5 AALBORG WATER LEVEL GAUGE OM7010#01.1 INDUSTRIES 1.3 Dismantling The following dismantling instructions refer to Figure 1 and Figure 2. Sectional view of the water level gauge 6 - Screws 9 - Wedge piece 10-Centre piece 11 - Reflex 12-Sealing gasket 13-Cushion gasket 14 - Cover plate Figure 2 kli 05e.cdr Step A: Shut the cocks S and W. Step B: The drain cock D to be opened until the glass is completely emptied. Step C: Remove nuts (1) and lift off stuffing box heads (2) together with the gauge body from the cocks S and W. Step D: Slacken the union nuts (4) and pull off the stuffing box head (2). Step E: Place the gauge body (G) horizontally with the screws (6) turning upwards and loosen the screws. Step F: Move the wedge piece (9) length wise and lift upwards. Step G: Lift off centre piece (10) reflex glass (11) and gaskets (12 and 13). Step H: Clean sealing surface of cover plate (14) and centre piece (10) and examine for through going scars. 1.4 Assembling The following assembling instructions refer to Figure 2. Step A: Insert following items into the centre piece (10): sealing gasket (12) reflex glass (11) cushion gasket (13). Language UK Page 3/5 AALBORG WATER LEVEL GAUGE OM7010#01.1 INDUSTRIES Step B: Place cover plate (14) on top. Step C: Insert wedge piece (9) and move length wise for correct position. Step D: Tighten screws (6) evenly starting at the centre, working to opposite alternately. Max torque: 26 Nm in cold and under working conditions. 1.5 Maintenance of the straight-through cock 1.5.1 Operation principle and maintenance The following assembling instructions refer to Figure 3. Detail drawing of the straight-through cock 15-Screw 16-Split ring 17- Packing sleeve 18-Plug 19- Bottom screw Figure 3 kli 06e.cdr The cylindrical plug (18) is sealed with a resilient packing sleeve (17). Should leakage arise during service the packing sleeve must be further compressed by tightening the bottom screw (19) until the leakage is stopped. This must only be done with the cock in open position. 1.5.2 Dismantling Step A: Remove bottom screw (19). Step B: Remove screw (15), washer and handle. Step C: Knock the plug (18) together with split ring (16) and packing sleeve (3) out of the cock body by means of a soft mandrel. Step D: Remove split ring and knock plug out of the packing sleeve. Step E: Clean all sealing surfaces carefully and lubricate threads with a high temperature grease before installation. Language UK Page 4/5 AALBORG WATER LEVEL GAUGE OM7010#01.1 INDUSTRIES 1.5.3 Assembly Step A: Place the split ring (16) in the recess of the plug (18). Step B: Push new packing sleeve onto plug. Step C: Press the complete unit into cock body. Note: Turn the packing sleeve until the ridge fits with the groove in the cock body. The eyelets of the packing sleeve must neither protrude nor be tilted. Step D: Screw in bottom screw (19). Step E: Place the handle and washer on the plug and fit screw (15). Step F: Tighten the bottom screw (19) and check if the plug can be turned. Language UK Page 5/5 AALBORG ggfliaaaaswnang^^^^^M INDUSTRIES ^HHÉJi^felHMÉÉlIlIlBflH^H^^^^H^H Table of contents Safety valves General 1 Maintenance and start-up of boiler 2 Adjustment and dismantling 3 Temporary locking of a safety valve General 1 Language UK Page 1/1 AALBORG SAFETY VALVES OM6040#01.0 INDUSTRIES Safety valves 1 General In the following the measures required to achieve a safe and reliable maintenance of the safety valves will be described, together with adjustment and dismantling instructions. An example of an installation of the safety valve is shown in Figure 1. Mounting of safety valves, example Waste steam pipe Drip pan Drain Figure 1 safe Ola.cdr Maintenance and start-up of boiler A regular inspection of the safety valve is recommended at least once a year. Some media and appliances require a more frequent inspection, this is according to the experience of the supplier. Warning: Before handling and dismantling of the safety valve ensure that the system is NOT pressurised! Before lighting-up the boiler the pipe connections must be thoroughly cleaned for dirt and foreign bodies. Language UK Page 1/4 AALBORG SAFETY VALVES OM6040#01.0 INDUSTRIES If the valve is not completely tight, which often happens after starting up the plant, this is usually caused by impurities between the seat and the cone. In order to remove these impurities the valve must be heavily blown out by means of the lifting device. If the valve is not tight after several blows, it may be due to the fact that a hard foreign body has got stuck between the cone and the seat, and it will then be necessary to dismount the valve for overhaul. Warning: In case of a leaking safety valve the valve must be inspected and over-hauled at earliest possible opportunity. It must be ensured that the boiler is totally depressurised before dismounting the valve. Note: Before dismantling the safety valve in the workshop the position of the adjusting screw must be measured and noted which will facilitate the adjustment later when the valve is to be adjusted when in service. If the facings between the cone and the seat have been damaged, they must be grinded. Step A: The cone can be grinded against a cast iron plate, using a fine grained carborundom stirred in kerosene. Step B: The seat in the valve body can be grinded in the same way by using a cast iron punch of suitable size. Note: Never use the cone itself when grinding the seat. Warning: The spindle and the valve cone must always be secured against turning as the seat and the cone may thus be damaged. Step C: Before assembly the valve must be thoroughly cleaned, and all traces of grinding material and impurities must be removed. When the valve has been mounted the boiler is commissioned, and the valve is then checked for leakage and adjusted to the set pressure. Step D: The adjustment screw is secured by means of its lock nut, and the valve is sealed. 2.2 Routine check The following should be regarded as recommendations of routine checks on the safety valves, in order to keep a proper functioning. Language UK Page 2/4 AALBORG SAFETY VALVES OM6040#01.0 INDUSTRIES Yearly Step A: The safety valve should be tested in operation by raising the boiler pressure. Step B: Expansion and exhaust pipe should be examined at the same time. Monthly Step A: Examine the safety valves for any leaking, such as: • Is water seeping from the drain plug at the valve body? • Is the escape pipe hot due to seeping steam from the valve seat? Step B: Examine the drain and expansion device at the escape pipe. Step C: Examine the lifting gear device, i.e. clean up and grease all sliding parts. Adjustment and dismantling Safety valves are delivered with the required spring setting and sealed against unauthorised adjustment. Adjustments are only allowed in the spring margins. Outside the margin a new spring is required. The pressure in a system should not exceed 90% of the set pressure. All item nos. mentioned in the following sections refer to Figure 2. 3.1 Dismantling of lifting device Safety valve with open cap Step A: Remove bolt(39) and remove lift lever (41) 3.2 Set Pressure change without spring change Note: Pay attention to spring range Step A: Spindle (14) must be held fast by all alterations Step B: Loosen lock nut (21) Step C: Turn the adjusting screw (17) clockwise for higher and anticlockwise for low set pressures Step D: Secure the new setting with the lock nut (21) and Reassemble lifting device 3.3 Spring change Step A: Spindle (14) must be held fast by all alterations Language UK Page 3/4 AALBORG SAFETY VALVES OM6040#01.0 INDUSTRIES Step B: Loosen lock nut (21) and turn adjusting screw (17) anticlockwise, then the spring (37) is not under tension Step C: Loosen the nuts (8) and remove the bonnet (42) Step D: Remove the upper spring plate (26) and spring (37) Step E: Remove the spindle (14) with disc (12), guide plate (4) and lower spring plate (26) Step F: Clean the seat (2) and disc (12) Step G: Remount the spindle unit with the new spring and upper spring plate Step H: Assemble bonnet (42) and adjust to the spring range Step I: Secure the spring setting through the lock nut (21) and remount lifting device Assembling drawing of safety valve 47 Ball 42 Bonnet 41 Lifting lever 40 Split pin 39 Bolt 38 Screw 37 Spring 29 Cap 27 Gasket 26 Springplate 23 Lead seal 22 Drain screw 21 Lock nut 18 Ball 17 Adjusting screw 16 Slotted pin 15 Gasket 14 Spindle 13 Lift aid 12 Disc 10/25 Split cotters 9 Lift limitation ring 8 Hex. nut 7 Gasket 4 Spindle guide 3 Stud 2 Seat 1 Body Figure 2 safe 03a.cdr Language UK Page 4/4 AALBORG TEMPORARY LOCKING OF A SAFETY VALVE OM6040#02.0 INDUSTRIES Temporary locking of a safety valve 1 General During commissioning work or later tests of the opening pressure for the safety valves, only one safety valve should be checked at a time. This means that the other safety valve must be locked. The following instruction describes the temporary locking of a safety valve. 1.1 Procedure for locking of a safety valve Step A: Remove the bolt (39) and split pin (40), see Figure 1. Step B: Remove the lifting lever (41). Step C: Unscrew the screw (38) and break the lead seal (23), if provided. Step D: Unscrew the cap (29). Step E: Place one or two bolts (48) on top of the spindle. The height of the bolts should be approximately 1-2 mm higher than the normal distance between the top of the spindle and the inside top of the cap (29). Step F: Carefully screw on the cap until the spindle and bolts are locked. The safety valve will be completely locked when the bolts cannot be moved anymore. Step G: The other safety valve can now be tested without any interference from the locked safety valve. 1.2 Procedure for unlocking of a safety valve Warning: As soon as the test procedure for the safety valve has been carried out the locked safety valve must be unlocked. Step A: Unscrew the cap (29) and remove the bolts (48). Step B: Mount the cap (29) again and screw in the screw (38). Step C: Mount the lifting lever (41), bolt (39), and split pin (40). Step D: Provide the safety valve with a lead seal (23), if necessary. This depends on the local rules of the classification society. Language UK Page 1/2 AALBORG TEMPORARY LOCKING OF A SAFETY VALVE OM6040#02.0 INDUSTRIES Temporary locking of a safety valve Figure 1 safe 06.cdr Language UK Page 2/2 AALBORG cBsfläsggssnajRg^^^^^H INDUSTRIES ^HHÉBHÉBÉMHIIIIHH^^^^HH^^^H Table of contents Feed water system Water level control 1 Dp water level transmitter unit 1 Level float switch 1 Language UK Page 1/1 AALBORG WATER LEVEL CONTROL SD9230#17.1 INDUSTRIES Water level control 1 Description The water level control is a modulating system at this type of boiler. The system is illustrated in Figure 1. The safety device system for too low water level shut down and burner stop consists of a level float switch mounted as an external unit. For measuring and control of the water level, the boiler is equipped with a dp water level transmitter unit, which includes external reference and variable legs, and a dp- transmitter. The continuous 4-20 mA output signal from the dp-transmitter is processed in the control system, which provides level alarms/shut downs and control of the regulating feed water valve. Water level control system Instrument air Regulating feed water valve Reference leg Variable leg Valve manifold dp-transmitter Feed water pumps Figure 1 dp_l_mod.cdr Language UK Page 1/1 AALBORG DP WATER LEVEL TRANSMITTER UNIT OM8210#16.1 INDUSTRIES dp water level transmitter unit General The dp water level transmitter unit controls and supervises the water level in the boiler. The complete unit is installed in a vertical position and connected to the boiler sockets, provided for this purpose, by means of shut-off valves (see Figure 1). The dp water level transmitter unit includes reference leg, variable leg, transmitter connection valves mounted on a manifold, and a differential pressure transmitter. The differential pressure transmitter converts the detected water level into an analogue signal (4-20 m A) which is transmitted to the control system. The signal can also be used for remote level indication in the engine control room. Illustration of the dp water level transmitter unit Shut-off valves Filling plug Reference leg Drain valve Equalising valve dp-transmitter— Figure 1 dpunit.cdr The differential pressure transmitter is installed with the process connections upward to prevent trapping of air. The pipes are mounted with continuous fall (at least 5°) from the boiler connections to the transmitter also to prevent trapping of air. The reference impulse leg (upper connection point) is connected to the high pressure connection (+), and the variable impulse leg (lower connection point) to the low pressure connection (-). Note: The dp water level transmitter unit or any part of it must not be insulated to ensure the correct function. Language UK Page 1/10 AALBORG DP WATER LEVEL TRANSMITTER UNIT OM8210#16.1 INDUSTRIES Commissioning 2.1 Initial commissioning Before the boiler is pressurised and started for the first time some initial commissioning procedures can be performed with regard to the valves of the dp water level transmitter unit. The shut-off valves, transmitter connection valves, and equalising valve should be operated in the following sequence during the initial commissioning: Step A: Initial setting; all valves of the dp water level transmitter unit closed (see Figure 1). Step B: Open the equalising valve located on the valve manifold. Step C: Unscrew the filling plugs for the reference leg and variable leg. Fill the legs with feed water. Step D: Open the transmitter connection valve and venting facility on the reference leg side of the transmitter. Step E: Close the venting facility on the reference leg side of the transmitter when no more air escapes. Step F: Open the venting facility on the variable leg side of the transmitter. Step G: Close the transmitter connection valve on the reference leg side of the transmitter when no more air escapes. Step H: Open the transmitter connection valve on the variable leg side of the transmitter. Step I: Close the venting facility on the variable leg side of the transmitter when no more air escapes. Step J: Close the transmitter connection valve on the variable leg side of the transmitter. Step K: Close the equalising valve. Step L: Refill the legs with feed water and screw on the filling plugs for the reference leg and variable leg. Step M: Open both transmitter connection valves fully. 2.2 Commissioning of the differential pressure transmitter The differential pressure transmitter can be commissioned either through "blind calibration" or "live calibration". In the following sections both methods are described. Language UK Page 2/10 AALBORG DP WATER LEVEL TRANSMITTER UNIT OM8210#16.1 INDUSTRIES 2.2.1 Blind calibration Blind calibration of the differential pressure transmitter can be performed if no pressure source is available. This means when the boiler cannot be operated at normal working pressure and the water level cannot be increased/decreased. The "start of scale" and "full scale" differential pressures are calibrated on the basis of calculated values. The start of scale value should be calibrated to obtain a 4 mA output signal from the transmitter when the water level is at the lower connection point and the full scale value to obtain a 20 mA output signal when the water level is at the upper connection point. To ensure an accurate calibration it is necessary to take the density difference between the water in the reference leg and in the boiler into consideration when calculating the differential pressure values. 4 mA output signal from the differential pressure transmitter: — When the water level in the boiler is at the lower connection point the pressure difference over the transmitter is equal to the height between the connection points (column of water) corrected with the density of the water in the reference leg. The value must be specified and entered in engineering unit, e.g. in mm H20. 20 mA output signal from the differential pressure transmitter: — When the water level in the boiler is at the upper connection point the pressure difference over the transmitter is equal to the height between the connection points corrected with the density difference between the water in the reference leg and in the boiler. The value must be specified and entered in engineering unit, e.g. in mm H20. Figure 2 indicates the calculation procedures of the differential pressures. As standard it is assumed that the temperature in the reference leg (condensate receiver) is 40°C. Table 1 shows the calculated values for some standard heights between the connection points. If the actual boiler plant does not fit any of the standard calculations the specified calculated values can be entered in the table for calibration record purpose. If the boiler plant is intended to operate at different set points (high/low pressure mode) the differential pressure transmitter must be calibrated so that the minimum indicated "Too low water level" on the control system not is lower than the actual "Too low water level" mark. Because of the density difference in the boiler water at different working pressures/temperatures the indicated water levels will not be identical. This means that the differential pressures for start of scale and full scale should be calculated using the parameters from operation in high pressure mode. When the differential pressures corresponding to the "start of scale" and "full scale" have been calculated carry out the following work steps (please also see the specific instruction for the differential pressure transmitter): Step A: Unscrew the screws that hold the protective cover of the differential pressure transmitter for access to the push buttons. Step B: Use the "M" key to select modes on the differential pressure transmitter. When a mode is selected, the keys T and i are used to change the mode value. Language UK Page 3/10 AALBORG DP WATER LEVEL TRANSMITTER UNIT OM8210#16.1 INDUSTRIES Step C: Set the values in mode 4 (electrical damping), 9 (output in error situation), 10 (pushbuttons functions), 11 (characteristic), 13 (value displayed), and 14 (engineering units). In mode 14 select e.g. "mm H20" as engineering units. Step D: Select mode 5 using the "M" key. Step E: Use the t or i key to set the start of scale in the selected engineering unit. If mm H2O is selected as engineering units, then set the start of scale to the calculated value in mm H2O (differential pressure at 4 mA). Step F: Press both the t and -l keys simultaneously for about 2 seconds, and the start of scale is set to zero (in the selected engineering unit). Step G: Select mode 6 using the "M" key. Step H: Use the T or 4 key to set the full scale in the selected engineering unit. If mm H20 is selected as engineering units, then set the full scale to the calculated value in mm H2O (differential pressure at 20 mA). Step I: Press both the t and X keys simultaneously for about 2 seconds, and the full scale is set to the upper limit (in the selected engineering unit). Step J: Mount the protective cover of the differential pressure transmitter again. Calibration of differential pressure transmitter ' Height between Working pressure Transmitter output, Differential pressure 2 Connection point connection [mm] [barg - kg/cm ] fmAl calibration [mm H20| Calculations for standard heights, working pressures, and ambient temperature (40 XI) Lower connection 4 521 7.0 Upper connection 20 50 525 Lower connection 4 521 16.0 Upper connection 20 70 Lower connection 4 695 7.0 Upper connection 20 67 700 Lower connection 4 695 16.0 Upper connection 20 93 Lower connection 4 794 7.0 Upper connection 20 76 800 Lower connection 4 794 16.0 Upper connection 20 106 Calculation records for other heights, working pressures, and/or ambient temperatures Lower connection 4 Upper connection 20 Lower connection 4 Upper connection 20 Lower connection 4 Upper connection 20 Lower connection 4 Upper connection 20 Lower connection 4 Upper connection 20 Lower connection 4 Upper connection 20 Table 1 Language UK Page 4/10 AALBORG DP WATER LEVEL TRANSMITTER UNIT OM8210#16.1 INDUSTRIES Calculation of the differential pressures ^ = 40°C, density: 992.2 kg/m3 t, = not existing / Differential pressure between connections: Height between 525 X 0.9922 = connections, e.g.: 525 mm 521 mmH,0(at4mA) ,, Water level \ t3=170°Cat7barg, 204°Cat16barg 3 t2 = 40°C, density: 992.2 kg/m t, = not existing Water level Differential pressure between connections (at 7 barg): 525 x (0.9922 - 0.8970) = Height between 50.0 mm H20 (at 20 mA) connections, e.g.: 525 mm Differential pressure between connections (at 16 barg): 525 X (0.9922 - 0.8596) = 69.6 mm H,0 (at 20 mA) t,= 170°Cat7barg, density 897.0 kg/m3 204°Cat16barg, density 859.6 kg/m3 Figure 2 dpunit_calil.cdr 2.2.2 Live calibration Live calibration of the differential pressure transmitter can be performed when a pressure source is available. This means when the boiler can be operated at normal working pressure and the water level can be increased/decreased. The "start of scale" and "full scale" output signals of the differential pressure transmitter are set during actual operating conditions. It is therefore not necessary to take the density difference between the water in the reference leg and in the boiler into consideration. However, if the boiler plant is intended to operate at different set points (high/low pressure mode) the differential pressure transmitter must be calibrated so that the Language UK Page 5/10 AALBORG DP WATER LEVEL TRANSMITTER UNIT OM8210#16.1 INDUSTRIES minimum indicated "Too low water level" on the control system not is lower than the actual "Too low water level" mark. Because of the density difference in the boiler water at different working pressures/temperatures the indicated water levels will not be identical. This means that the differential pressure transmitter should be calibrated when the boiler plant operates in high pressure mode. When the boiler operates at normal working pressure carry out the following work steps (please also see the specific instruction for the differential pressure transmitter): Step A: Unscrew the screws that hold the protective cover of the differential pressure transmitter for access to the push buttons. Step B: Use the "M" key to select modes on the differential pressure transmitter. When a mode is selected, the keys T and i are used to change the mode value. Step C: Set the values in mode 4 (electrical damping), 9 (output in error situation), 10 (pushbuttons functions), 11 (characteristic), 13 (value displayed), and 14 (engineering units). In mode 14 select "mA" as engineering units. Step D: Ensure that the boiler cannot be filled with feed water by closing the feed water valves or stopping the feed water pumps. Step E: Slowly decrease the water level in the boiler until the lower connection point is reached (socket centre line of the variable leg). The water level can be decreased by means of the blow down valves. Step F: The upper and lower connection points will normally be beyond the visual indication area of the water level gauges. It is therefore impossible to see when the water level is at these points. However, the rising/falling rate of the water level can be controlled, by throttling the feed water valves/blow down valves. By clocking the rate it can be calculated when the water level has reached the connection points. Step G: Select mode 2 using the "M" key. Step H: Set the output current corresponding to the start of scale using the Î and i keys. Or set the output current to 4 mA by pressing the t and i keys simultaneously for about 2 seconds. Step I: Slowly increase the water level in the boiler until the upper connection point is reached (socket centre line of the reference leg). The water level can be increased by means of the feed water pumps. Step J: When the water level is increased operate the burner so that the boiler pressure is kept at normal working pressure. Step K: Select mode 3 using the "M" key. Step L: Set the output current corresponding to the full scale using the T and i keys. Or set the output current to 20 mA by pressing the T and i keys simultaneously for about 2 seconds. Language UK Page 6/10 AALBORG DP WATER LEVEL TRANSMITTER UNIT OM8210#16.1 INDUSTRIES Step M: Mount the protective cover of the differential pressure transmitter again. 2.3 Final commissioning During final commissioning a function test of the dp water level transmitter unit must be performed before the boiler plant is put into normal operation. The purpose of the function test is to check that the output signals from the differential pressure transmitter are correct. Furthermore, it should be checked that the connected alarms/shut downs and control functions are operational. The boiler should be operated at normal working pressure during the test to provide for correct indications. When the boiler is at normal water level and the burner is in operation, carry out the following work steps: Step A: Slowly increase the water level in the boiler by forcing operation of the feed water pump until the water level has risen to the "High water level" level. The control system should indicate an alarm, (if provided). Note: Note that shut downs, alarms, and cut out functions can be delayed via timers in the control system. Step B: Increase the water level somewhat until the "Too high water level" mark is reached. The burner should stop, and a shut down should be indicated on the control system, (if provided). Step C: Increase the water level somewhat until the upper connection point is reached (socket centre line of the reference leg). Check that the output signal from the differential pressure transmitter is at 20 mA or the full scale value in the selected engineering units. Step D: The upper and lower connection points will normally be beyond the visual indication area of the water level gauges. It is therefore impossible to see when the water level is at these points. However, the rising/falling rate of the water level can be controlled, by throttling the feed water valves/blow down valves. By clocking the rate it can be calculated when the water level has reached the connection points. Step E: Ensure that the boiler cannot be filled with feed water by closing the feed water valves or stopping the feed water pumps. Step F: Decrease the water level in the boiler by means of the blow down valves until the water level has fallen to the " Low water level " level. The control system should indicate an alarm. Step G: Decrease the water level somewhat until the "Too low water level" mark is reached. The burner should stop, and a shut down should be indicated on the control system. Step H: Decrease the water level somewhat until the lower connection point is reached (socket centre line of the variable leg). Check that the output signal Language UK Page 7/10 AALBORG DP WATER LEVEL TRANSMITTER UNIT OM8210#16.1 INDUSTRIES from the differential pressure transmitter is at 4 mA or the start of scale value in the selected engineering units. Step I: After completion of the function test open the feed water valves or start the feed water pumps. Operation and maintenance Attention: Both shut-off valves between the boiler and impulse legs must always be fully open and the reference leg must be totally filled with water during normal operation of the boiler. To ensure a safe and reliable operation of the boiler plant check the dp water level transmitter unit whenever an opportunity occurs by comparing the water level indicated by the control system with the level indicated in the water level gauges. A great difference in the water levels may indicate blocked connections to the differential pressure transmitter. Therefore it is recommended to blow-through the impulse legs and connection pipes frequently. The blow-through procedures can be performed, e.g. in connection with stopping the boiler plant, in order to get rid of dissolved particles that could settle during the stop periods. In case of prolonged standstill the dp water level transmitter unit should be checked for the correct function before the boiler plant is restarted. 3.1.1 Blow-through procedure of the impulse legs The blow-through procedure should be performed as describe below when the boiler plant is in operation and in steady load condition. The procedure should be carried out at least once each month. When the blow-through procedure is carried out, it is very important that the water level in the boiler is carefully and continuously supervised by the ship engineering personnel. The feed water control valve must be operated manually, if necessary. Step A: Isolate the differential pressure transmitter by closing the two transmitter connection valves in the manifold. The equalising valve must remain closed during the blow-through procedure and normal operation. Step B: Slowly open the drain valves of the impulse legs, and allow the legs to blow-through for a few seconds. Step C: Close the shut-off valve for the reference leg. Step D: Close the drain valves again when the reference leg is completely depressurised. Step E: Unscrew the filling plug of the reference leg and fill the leg with feed water. Step F: Screw on the filling plug and slowly open the shut-off valve for the reference leg. Step G: Open the two transmitter connection valves in the manifold. Language UK Page 8/10 AALBORG DP WATER LEVEL TRANSMITTER UNIT OM8210#16.1 INDUSTRIES Step H: After performing the blow-through check that the dp water level transmitter unit and feed water control valve are fully operational. In case of contaminated boiler water, e.g. sludge, mud, etc., the blow-through procedure of the impulse legs must be done more often. 3.1.2 Blow-through procedure of the connection pipes The blow-through procedure should be performed as describe below when the boiler plant is stopped, but still pressurised. The procedure should be carried out at least once each year. Step A: Open the venting facilities located on the valve manifold for the impulse legs. The transmitter connection valves must remain open and the equalising valve closed during the blow-through procedure. Step B: Close the venting facilities on the valve manifold when only clean water escapes. Step C: Close the shut-off valve for the reference leg. Step D: Slowly open the drain valve of the reference leg. Step E: Close the drain valve again when the reference leg is completely depressurised. Step F: Unscrew the filling plug of the reference leg and fill the leg with feed water. Step G: Screw on the filling plug and slowly open the shut-off valve for the reference leg. In case of contaminated boiler water, e.g. sludge, mud, etc., the blow-through procedure of the connection pipes must be done more often. 3.1.3 Function test of the dp water level transmitter unit During normal operation of the boiler plant a function test of dp water level transmitter unit should be carried out at least once each month. The purpose of the function test is to check that the connected alarms/shut downs and control functions are operational. The boiler should be operated at normal working pressure during the test to provide for correct indications. When the boiler is at normal water level and the burner is in operation, carry out the following work steps: Step A: Slowly increase the water level in the boiler by forcing operation of the feed water pump until the water level has risen to the "High water level" level. The control system should indicate an alarm, (if provided). Note: Note that shut downs, alarms, and cut out functions can be delayed via timers in the control system. Step B: Increase the water level somewhat until the "Too high water level" mark is reached. The burner should stop, and a shut down should be indicated on the control system, (if provided). Language UK Page 9/10 AALBORG DP WATER LEVEL TRANSMITTER UNIT OM8210#16.1 INDUSTRIES Step C: Ensure that the boiler cannot be filled with feed water by closing the feed water valves or stopping the feed water pumps. Step D: Decrease the water level in the boiler by means of the blow down valves until the water level has fallen to the "Low water level" level. The control system should indicate an alarm. Step E: Decrease the water level somewhat until the "Too low water level" mark is reached. The burner should stop, and a shut down should be indicated on the control system. Step F: After completion of the function test open the feed water valves or start the feed water pumps. Language UK Page 10/10 AALBORG LEVEL FLOAT SWITCH OM8210#15.1 INDUSTRIES Level float switch 1 General The level float switch of type RBA 24 supervises the water level in the boiler. It is installed in a vertical position and connected to the boiler sockets, provided for this purpose, by means of shut-off valves. A float and float rod carry a transmitting magnet which runs in a stainless steel transmitting tube. The transmitting magnet operates the externally installed magnet switches. When the magnet switches have been triggered, they remain in that position until trigged again. Figure 1 illustrates the level float switch. Illustration of the level float switch Shut-off valves Figure 1 rba24.cdr Commissioning 2.1 Electrical connection When installing the level float switch use acetic acid-free silicon cable in the internal part of the switch housing. Step A: Unscrew the switch housing and check for correct assembly and wiring. Language UK Page 1/4 AALBORG LEVEL FLOAT SWITCH OM8210#15.1 INDUSTRIES 2.2 Adjusting the switch point The switch point of the level float switch should be pre-adjusted before the boiler is pressurised and started for the first time. Step A: Open both shut-off valves and close the drain valve. Step B: Open the feed water valves and the air valve. Fill the boiler with evaporated water until the "Too low water level" mark has been reached and adjust the magnet switch to the switch point. It should be moved in upwards direction until the switch is trigged and secured in this position. The magnet switch must rest against the transmitting tube. Note: If the temperature difference between the boiler and feed water exceeds approximately 50°C, the boiler must be filled very slowly. When filling a pressure less boiler, the shut-off valve after the feed water pump must be throttled. Otherwise the pump motor will be overloaded. 2.3 Function test During commissioning a live test of the level float switch must be carried out before the boiler is put into normal operation. The purpose of the live test is to check that the shut down for too low water level and cut out function of the burner is operational. When the boiler is pressurised and the burner is in operation carry out the following work steps: Step A: Slowly decrease the water level in the boiler by means of the blow down valves until the water level has fallen to the "Too low water level" mark. Ensure that the boiler is not refilled with water by closing the feed water valves. Step B: Note that both the shut down and cut out function is delayed via a timer in the control panel. Step C: Adjust the switch point, if necessary. Step D: After completion of the function test open the feed water valves fully and raise the water level to the normal level. Operation and maintenance Attention: Both shut-off valves must always be fully open during normal operation of the boiler. To ensure a safe and reliable operation of the boiler plant check the level float switch whenever an opportunity occurs by comparing the magnetic switch function with the level indicated in the water level gauges. Language UK Page 2/4 AALBORG LEVEL FLOAT SWITCH OM8210#15.1 INDUSTRIES A great difference in the water levels may indicate either blocked connections to the float chamber or a water filled level float. Therefore it is recommended to blow- through the level float switch and connection pipes frequently (see below). The blow-through procedures can be performed, e.g. in connection with stopping the boiler plant, in order to get rid of dissolved particles that could settle during the stop periods. In case of prolonged standstill the level float switch should be checked for the correct function before the boiler plant is restarted. 3.1 Blow-through procedure The blow-through procedure with cleaning of the float chamber should be performed as describe below when the boiler plant is in operation. The procedure should be carried out at least once each week. Step A: Slowly open the drain valve to fully open position, and allow the chamber to blow-through for a few seconds. Step B: Close the drain valve again. In case of contaminated boiler water, e.g. sludge, mud, etc., the blow-through procedure of the level float switch must be done more often. 3.2 Blow-through and test procedure The blow-through procedure with test of the shut down and burner cut out function should be performed as describe below when the boiler plant is in operation. The procedure should be carried out at least once each month. Step A: Fully close the upper shut-off valve. Step B: Slowly open the drain valve to fully open position, and allow the chamber to blow-through for a few seconds. Step C: Then close the drain valve and open the upper shut-off valve again. Step D: Fully close the lower shut-off valve. Step E: Slowly open the drain valve to fully open position, and allow the chamber to blow-through for a few seconds. As the water level falls inside the float chamber check that the shut down function is activated and the burner cuts out. Please note that both the shut down and cut out function is delayed via a timer in the control panel. Step F: After performing the blow-through and test procedure close the drain valve and open the lower shut-off valve again. In case of contaminated boiler water, e.g. sludge, mud, etc., the blow-through procedure of the level float switch must be done more often. 3.3 Cleaning The float chamber, transmitting tube, and transmitting magnet must be opened, checked, and cleaned from dirt at least once a year. Carry out the following work procedures: Language UK Page 3/4 AALBORG LEVEL FLOAT SWITCH OM8210#15.1 INDUSTRIES Step A: Perform a blowing-through procedure as described above. Step B: Close the two shut-off valves and slowly open the drain valve. Step C: Remove the top flange of the chamber. Step D: Loosen the float and float rod with transmitting magnet from the top flange. Step E: Clean the transmitter tube and transmitting magnet. Step F: Clean the float chamber for any fossilised mud. Step G: Check the condition of the float and that it is not water filled. Step H: Check the condition of the electrical wiring. Exchange damaged wires if necessary. When the cleaning procedure is completed the level float switch must be assembled as follows: Step I: Assemble the transmitting magnet in the top flange. Step J: Assemble the top flange on the float chamber. Step K: Perform a function test as described previously when the boiler is pressurised. Language UK Page 4/4 • «a, AALBORG gsaigRHggffnasns^^^^^M INDUSTRIES ^••••••••••••^•^^•i Table of contents Regulating feed water valve Control valves, type 470/471 General 1 Operation 2 Maintenance 3 Pneumatic actuator, type DP General 1 Reversal of the actuator action 2 Manual operation device 3 Maintenance 4 Positioner, SIPART PS2 6DR5000 General 1 Mechanic connection of the positioner 2 Electric connection of the positioner 3 Pneumatic connection 4 Commissioning 5 Diagnosis 6 Service and maintenance 7 Language UK Page 1/1 AALBORG CONTROL VALVES, TYPE 470/471 OM6010#02.0 INDUSTRIES Control valves, type 470/471 1 General This type of control valve is suited to regulate fluids, gases and steams. The valve plug is normally a parabolic plug, but can also be supplied in a perforated design. Both types of plugs can have either linear or equal percentage flow characteristic. The flow direction for parabolic plugs is always against the closing direction. However, with perforated plugs for steam and gases, it is in the closing direction. If a valve with a perforated plug is operated by means of a pneumatic actuator with the flow in the closing direction, the pneumatic actuator should have a stronger thrust force. This is necessary to prevent thumping near to the closing position. All control valves can be fitted alternately with manual-, pneumatic-, electric- or hydraulic operation devices. Illustration of control valves type 470 and 471 Control valve, type 470 Control valve, type 471 Figure 1 val47x.tif Language UK Page 1/5 AALBORG CONTROL VALVES, TYPE 470/471 OM6010#02.0 INDUSTRIES Table of position numbers in Figure 1 Part Designation Part Designation Part Designation 1 Body 7 Gland flange 15.1 Studs 2 Seat ring 7.1 Screw joint 17 Hexagon nuts 3 Mounting bonnet 8 Spindle guiding 17.1 Hexagon nuts 3.1 Mounting bonnet 10 Stuffing box 19 Spring-type straight pin 4 Guiding bush 10.1 Stuffing-box packing 21 Set-pin 5 Plug 14 Gasket 25 Bellow housing 6 Spindle 14.1 Gasket 26 Bellow unit 6.1 Spindle 15 Studs Table 1 Operation 2.1 Fitting instructions The valve should be inserted so that the spindle has a vertical position together with the actuator. The valve can also be tilted to a maximum horizontal position if the installation point does not allow any better condition. To guarantee a disturbance free function of the control valve, the inlet and outlet stretches of the piping should be of straight piping length (min. two times the pipe diameter by inlet and six times by outlet). The piping should be rinsed to clear out any pollution, welding beads, rust, etc. before inserting the control valves. A strainer should be fitted in front of the control valve to catch the remaining particles. Bolts should be tightened after taking into operation. The flow direction is signalled by an arrow on the valve body. The valves should be insulated against high temperatures to guard the actuator. 2.2 Actuator assembly The control valves are normally delivered with actuators already fitted. For alternations or maintenance of actuator, the assembly should occur in accordance with the operation instructions for the actuator. 2.3 Setting into operation When the piping system is filled, the spindle sealing should be checked for leakage and, if necessary, tightened. A PTFE-V-ring unit does not require any tightening as the spring tension maintains the necessary force. The bolts must be tightened gradually in steps, diametrically in pairs, but not tighter than it is necessary for the sealing. Flange connection bolts should never be loosened or tightened when the valve is under temperature or pressure even if a leakage may arise. For actuators please see to the appropriate actuator operation instructions. Language UK Page 2/5 AALBORG CONTROL VALVES, TYPE 470/471 OM6010#02.0 INDUSTRIES Maintenance Before any maintenance of the control valve is carried out, the piping system must be shut off and pressure free. 3.1 Exchange of the stuffing-box packing A leak stuffing-box packing should initially be carefully tightened to stop the leakage. If this does not help, a new layer should be inserted, or the complete packing should be replaced. 3.1.1 Additional packing layer Step A: Open the valve fully and unscrew the hexagon nuts (17). Step B: Lift the gland flange (7) and the spindle guiding (8) upwards. Step C: Insert adequate quantity of packing rings (split ring-displacement, splitting at 180° to avoid overlapping). Step D: Fix the hexagon nuts (17) properly. 3.1.2 Exchange Step A: Drive the actuator into middle position and dismantle the actuator. Step B: Unscrew the hexagon nuts (17) from the studs (15). Step C: Remove the gland flange (7), the spindle guiding (8) and the old stuffing box (10) and clean the packing compartment. Step D: Clean the valve spindle and check for damage and if necessary replace. If the damaged spindle is not replaced, the new packing will leak after a short period. StepE: Insert the new packing rings (split ring-displacement, splitting at 180° to avoid overlapping). Step F: Fix the hexagon nuts (17) properly. Note: Strenuous tightening will prevent leakage, but will also have a brake effect on the spindle which aggravates the movement of the spindle. 3.2 Exchange of a PTFE-V-ring sealing unit A PTFE-V-ring unit is spring loaded and has enough set pressure to ensure a good seal even by low operation pressures. It is replaced as mentioned above. The PTFE-V-ring sealing unit should be lubricated before it is inserted. The sealing lips must face against the pressure direction. Language UK Page 3/5 AALBORG CONTROL VALVES, TYPE 470/471 OM6010#02.0 INDUSTRIES Note: Special care should be given to the spindle surface. Rough surfaces wear the sealing lips enormously and can be due to failure of the packing unit. 3.3 Exchange of the bellow unit Step A: Drive the actuator into middle position and dismantle the actuator. Step B: Unscrew the screw joint (7.1). Step C : Unscrew the hexagon nuts (17) and remove the bellow housing (25). Dismantle the plug as described in the next section. Step D: Unscrew the hexagon nuts (17.1) and dismantle the mounting bonnet (3.1). Step E: The bellow unit (26) is removed from the bellow housing (25). Step F: Replace the two gaskets (14.1) and the gasket (14). Step G: When the bellow unit (26) is replaced, the proper position of the anti- twisting device must be observed. Step H: The set pins (21) have to drive within the slots of the anti-twisting device. Check for friction-free movement. Step I: Replace mounting bonnet (3.1) and screw down the hexagon nuts (17.1) crosswise. 3.4 Exchange of the plug-spindle unit Step A: Drive the actuator into middle position and dismantle the actuator. Step B: Unscrew the gland flange (7). 3.4.2 Control valve type 470 Step A: Unscrew the hexagon nuts (17) and dismantle the mounting bonnet (3). Step B: Pull out the plug with the spindle and exchange this unit. Step C: Remove the spring-type straight pin (19) and unscrew the spindle (6). Step D: Replace the old parts and assemble it. Step E: Drill a hole through the plug shaft and insert a new pin. Step F: Replace the gasket (14) and assemble the mounting bonnet (3). Step G: Tighten the nuts (17) evenly, crosswise. Language UK Page 4/5 AALBORG CONTROL VALVES, TYPE 470/471 OM6010#02.0 INDUSTRIES 3.4.3 Control valve type 471 Step A: Unscrew the hexagon nuts (17) and dismantle the bellow housing (25) with plug (5). Step B: Drive the spindle in the bottom position and remove the spring-type straight pin (19). Step C: Unscrew the plug. Step D: Screw a new plug at the spindle and drill through the shaft. Drive the spring-type straight pin (19) into the hole. Step E: Replace the gasket (14). Step F: Assemble the bellow housing (25) with plug (5) together with the body (1) and fix it by screwing the hexagon nuts (17) crosswise. The spindle can only be completely replaced together with the bellow. 3.5 Changing the seat ring The seat ring is screwed into the valve body. The seat ring can be obtained after removing the bonnet and can then be refinished or replaced as required. Step A: Clean and lubricate the thread and conical sealing surface before insertion. Language UK Page 5/5 AALBORG PNEUMATIC ACTUATOR, TYPE DP OM5520#01.0 INDUSTRIES Pneumatic actuator, type dp 1 General The pneumatic linear actuator is designed to be mounted directly on a control valve. The pneumatic actuator converts positioning command signals into stem thrust forces. The required back setting force is produced by the spring arrangement inside the actuator. The rolling-diaphragm produces linear spindle movements over the complete stroke. The preferred mounting position is with the actuator and valve spindle in vertical position. The mode of operation for the actuator depends on how the springs are inserted when the actuator is assembled. Even when the actuator is fitted in a piping system, the mode of operation can be changed. The pneumatic actuator can be operated as: • Spring opens valve/air closes valve operation mode • Air opens valve/spring closes valve operation mode Illustration of a pneumatic actuator Operation mode: Spring opens - Air closes Air opens - Spring closes Figure 1 dpactuat.tif Language UK Page 1/6 AALBORG PNEUMATIC ACTUATOR, TYPE DP OM5520#01.0 INDUSTRIES Table 1 below shows a list of the position numbers in Figure 1 and Figure 2. Table of position numbers in Figure 1 Part Denomination Part Denomination 1 Rolling diaphragm 15 Stroke indicator 2 Diaphragm housing 16 Hexagon nut 3 Diaphragm lid 17 Mounting rod 4 Diaphragm plate 18 Bellow 5 Spindle 19 Collar nut 7 Spring 21 O-ring (spindle) 10 Coupling flange 22 O-ring (bushing) 11 Guide flange 26 Slotted guide bearing 12 Rotation guard 27 Spindle guide 13 Socket screw 30 Hexagon nut 14 Threaded bushing 31 Hexagon nut Table 1 1.1 Pneumatic connection The air supply should be dry and at a low service temperature. A heat-guard should be installed to prevent high service temperature. The pneumatic supply tube must be connected to the diaphragm housing (2) by operation mode "spring closes" and to the diaphragm lid (3) by operation mode "spring opens". By air failure the stem automatically returns into the original position caused by the inserted springs. Warning: The actuator diaphragm may only be pressure loaded on the side opposite of the springs. The vent hole in the other connection must remain open. 1.2 Assembly of the actuator on the valve The assembling of the actuator on the valve is shown in Figure 2. For both "spring closes" and "spring opens" operation modes the following assembling procedure should be followed: Step A: If the actuator and the valve are separated, press the plug and spindle unit (5) into the closed position for operation mode "spring closes" or into the open position for operation mode "spring opens". Warning: Make sure that the plug does not turn while pressing on the seat during assembly. Step B: Loosen the socket screws (13), remove the rotation guard (12) and the guide flange (11). The threaded bushing (14) is now free. Language UK Page 2/6 AALBORG PNEUMATIC ACTUATOR, TYPE DP OM5520#01.0 INDUSTRIES Step C: Turn the locking hexagon nut (30) onto the valve spindle. Place the rotation guard (12) and the guide flange (11) over the valve spindle and then turn the threaded bushing (14) onto the valve spindle. Step D: Check the actuator for proper operation mode and connect the pneumatic supply to the connection piece in the diaphragm housing (2) for operation mode "spring closes" or in the diaphragm lid (3) for operation mode "spring opens". Step E: Drive the actuator into approximately mid-stroke position over the air supply and mount it onto the valve (read the value from the pressure gauge - middle of the spring range). Step F: Tighten the hexagon nuts (31). Assembly of the actuator on the valve Operation mode: Spring closes valve - Air opens valve Operation mode: Spring opens valve - Air closes valve Pneumatic connection rf i ! i \ i i i i i t\ f / i i i i-j TrffTtv 1 * X—-r-^m vU I 1 ' ^ 1 T ^01 J ' m ' _^ v I y ' W 1 • WC ' m 1 "** LJppLœ Pneumatic connection \ U 13 16 11 10 15 •;>— 13 U 12 1 30 ^ U 31 5 ~^^sö" Figure 2 dpactspr.tif Language UK Page 3/6 AALBORG PNEUMATIC ACTUATOR, TYPE DP OM5520#01.0 INDUSTRIES 1.3 Adjustment of the starting pressure signal Step A: Drive the actuator to the required spring-starting point over the air supply. Step B: Turn the threaded bushing (14) up against the coupling flange (10) so that the collar enters into the flange and presses against it. Make sure that the plug is lying on the valve seat. Attention: Note that sufficient thread of the valve spindle is inside the threaded bushing (14). If not, turn the coupling flange (10) downwards from the actuator spindle and pull the threaded bushing (14) against it. Step C: For operation mode: "spring closes": — Attach the guide flange (11) and the rotation guard (12) with the socket screws (13) to the coupling flange (10). — Check that the plug lifts off the seat at the required spring starting point. Step D: For operation mode: "spring opens": — Check that the plug leaves the end position at the required spring starting point, and finishes the valve stroke at the spring-range end value. — The plug must then also press on the valve seat. Step E: After the test operation set the stroke indicators (15) into the end positions. Step F: Lock the hexagon nuts (16 + 30) at the valve mid-stroke. Step G: Do not turn the plug on the seat when it is under force. Reversal of the actuator action The actuator action can be reversed even when the valve is installed in a piping system. The position numbers mentioned in this section refer to Figure 1 and Figure 2. Step A: Drive the actuator into approximately mid-stroke position with the air supply. StepB: Loosen and remove the socket screws (13) from the coupling flange (10) and drop the rotation guard (12) over the valve spindle. Step C: Remove the hexagon nuts (31) from the actuator and lift off the valve. Step D: Reduce the air supply until the chamber is pressure free. Language UK Page 4/6 AALBORG PNEUMATIC ACTUATOR, TYPE DP OM5520#01.0 INDUSTRIES Step E: Loosen and remove the diaphragm lid screws. Step F: Remove the diaphragm lid (3). Warning: The actuators DP 32 and DP 33 have two longer screws when fitted with stronger spring ranges. The actuator DP 34 has four. These screws should be the last screws to be loosened, and must be loosened evenly to reduce the high spring tension. Step G: For reversal from "spring closes" into "spring opens": — Remove the springs (7) and the diaphragm plate (4) with the diaphragm (1) and the spindle (5). — Loosen and remove the seal lock nut (19) and remove the spindle (5). Turn over the diaphragm plate (4) with the diaphragm (1) and the diaphragm clamping flange, and place it over the spindle (5). — Tighten with the seal lock nut (19). Make sure that the spindle surface is not damaged. — Grease the spindle surface and the 0-ring. — Place the diaphragm plate (4) with the diaphragm (1) into the diaphragm lid (3). — Arrange the springs (7) onto the moulds pressed into the diaphragm plate (4). — Place the diaphragm housing with the spindle sealing unit over the spindle, and screw it together. Make sure that the springs stay properly arranged. — Turn the hexagon nut (16) and the coupling flange (10) onto the spindle (5). — Mount the actuator as described previously, and connect the air supply tube to the diaphragm lid (3). Step H: For reversal from "spring opens" into "spring closes": — Remove the diaphragm (1) and the diaphragm plate (4) with the spindle (5) and the springs (7). — Loosen and remove the seal lock nut (19) from the spindle (5). Turn over the diaphragm plate (4) with the diaphragm (1) and the diaphragm clamping flange, and place it on the spindle (5). — Tighten with the seal lock nut (19). Make sure that the spindle surface is not damaged. — Grease the spindle surface and the 0-ring. — Stick the diaphragm plate (4) with the diaphragm (1) and the spindle (5) into the diaphragm housing (2). — Arrange the springs (7) onto the moulds pressed into the diaphragm plate (4). Language UK Page 5/6 AALBORG PNEUMATIC ACTUATOR, TYPE DP OM5520#01.0 INDUSTRIES Place the diaphragm lid (3) on the top, and screw it together. Make sure that the springs (7) stay properly arranged. — Turn the hexagon nut (16) and the coupling flange (10) onto the spindle (5). — Mount the actuator as described previously, and connect the air supply tube to the diaphragm housing (2). Manual operation device Some actuators are fitted with a manual operation device. The device is connected to the actuator by means of a new diaphragm lid, a spindle extension with a USIT-ring and a spindle sealing unit. The manual operation device is equipped with stroke indicators. The stroke indicators of both the actuator and the manual operation device must be in the same end positions when the actuator is pressure free. The manual operation device must be set into neutral position when the actuator is running automatically. The locking device of the manual operation device must be unlocked before operating. The locking device prevents an unwanted disarrangement of the setting during operation, e.g. due to vibration, etc. Maintenance The pneumatic actuator is maintenance free. To maintain a disturbance free operation, the air should be supplied by an air-supply station. The diaphragm, spindle sealing unit and springs are wear parts and should be replaced when necessary. 4.1 Exchange of spindle sealing When the spindle sealing is changed, the slotted PTFE-guide bearing and the 0-ring should be replaced. The spindle surface must be clean and undamaged. Before the actuator is assembled, the spindle unit and the spindle must be greased. Language UK Page 6/6 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Positioner, SIPART PS2 6DR5000 1 General The following instruction is a general description of SIPART positioners and covers the complete range in the PS2 6DR5000 series. The electronic pneumatic positioner is used as the final control element of a pneumatic linear actuator or a part-turn actuator (rotary movements). The positioner converts a current output signal (4 to 20 mA) from a process controller or control system to a set point value and into a corresponding movement. The positioner changes the pressure in a pneumatic actuator chamber or cylinder until the position corresponds to the set point value. The positioner can be set up either as a single-action positioner or a double-action positioner. The single-action positioner is mainly used together with a control valve. The opposite movement for the control valve is supplied by means of springs. The double-action positioner is mainly used to control an air damper via a pneumatic cylinder (actuator). All movements of the pneumatic cylinder are supplied by the positioner. An illustration of the function diagram for the positioner is shown in Figure 1. The function diagram is shown with option modules. 1.1 Mode of operation Comparison of the set point and the actual value takes^place electronically in a micro controller. If the micro controller detects a deviation, it uses a 5-way switch procedure to control the piezoelectric valves, which in turn regulate the flow of air into the actuating chambers. When connected in a two-wire system, the SIPART PS2 draws its power exclusively from the 4 to 20 mA set point signal. The piezoelectric valve converts the command into a pneumatic positional increment. The positioner outputs a continuous signal in the area where there is a large control deviation (high-speed zone). In areas of moderate control deviation (slow-speed zone) it outputs a sequence of pulses. No positioning signals are output in the case of a small control deviation (adaptive or variable dead zone). Commissioning (initialisation) is carried out automatically to a large extend. During initialisation, the micro controller automatically determines the zero, full-scale value, direction of action, and positioning speed of the actuator. It uses these to determine the minimum pulse time and dead zone, thus optimising the control. The positioner can also be operated manually by the pushbuttons and the LCD of the SIPART PS2. The installation of the positioner must be carried out in the following order: • Mechanic connection • Electric connection • Pneumatic connection • Commissioning Language UK Page 1/16 „m. AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Illustration of a function diagram ffëSuppl y air •^B- «—E>H Exhauurt -t>Kj- f-t>k} > j | ks)p Eiduurt U I «y «^ jw P2-J-n. Lt_ -N -1- P7 i -tÆ— 1 Motherboard with microcontroller and input circuit 2 Control panel with LC-display and momentary action switch 3 Rezo-vatve unit, always built-in 4 Valve unit with double action positioner always built-in 5 ly-modute torpositione r SIPART PS2 6 Alarm module torthre e alarm outputs and one digital input 7 SIA-modu)e(Slotlnitiator-Alarm-module) & Spring-loaded pneumatic actuator (single action) 9 Spring-loaded pneumatic actuator (double action) Figure 1 sips2_5a.tif Mechanic connection of the positioner Normally the positioner is pre-mounted on the actuator or cylinder. If not, follow the installation guide lines below. 2.1 Mechanic connection to an actuator Figure 2 shows the mechanic connection of the positioner to an actuator for a control valve. Step A: Mount clamping assembly (3) with hexagon socket cap screws (17) and lock washers (16) on the actuator spindle. Step B: Insert the pick-up bracket (2) into the recesses of the clamping assembly. Set the necessary length and tighten the screws so that the pick-up bracket can still be shifted. Language UK Page 2/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Step C: Push the roll (5), spring (13), and guide washer (22) onto the pin (4). Step D: Insert the pin in the lever (6) and assemble with nut (18), spring washer (14), and U-washer (12). Step E: The value of the stroke range specified on the actuator should be set or if this does not exist as a scaling value, the next greatest scaling value should be set. The centre of the pin must be in line with the scaling value. The same value can be set later under parameter "3.YWAY" in commissioning to display the way in [mm] after initialisation. Step F : Assemble the hexagon socket cap screw (17), spring washer (16), washer (12), and square nut (19) on the lever. Step G: Push the pre-mounted lever onto the positioner axis up to the stop and fix with the hexagon socket cap screw (17). Step H: Fit the mounting bracket (1) with two hexagon head screws (9), lock washer (10), and flat washer (11) on the rear of the positioner. Step I: Selection of the row of holes depends on the width of the actuator yoke. The roll (5) should engage in the pick-up bracket (2) as close as possible to the spindle but may not touch the clamping assembly. Step J: Hold the positioner with the mounting bracket on the actuator so that the pin (4) is guided within the pick-up bracket (2). Step K: Tighten the pick-up bracket. Step L: Position the mounting parts according to the type of actuator. — Actuator with ledge: hexagon head screw (8), flat washer (11), and lock washer (10). — Actuator with plane surface: four hexagon head screws (8), flat washer (11), and lock washer (10). — Actuator with columns: two U-bolts (7), four hexagon nuts (21) with flat washer (11), and lock washer (10). Step M: Secure the positioner onto the yoke using the previously positioned mounting parts. Note: Set the height of the positioner so that the horizontal lever position is reached as close to the stroke centre as possible. The lever scale can be used as orientation. It must be guaranteed that the horizontal lever position is passed through within the stroke range. Language UK Page 3/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Mechanic connection of the positioner (linear actuator) 2) 4 3) Mounting on yoke Mounting on yoke with plane surface 11 with ledge Mounting on yoke with columns As required Figure 2 sips2_5b.tif Language UK Page 4/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES 2.2 Mechanic connection to a pneumatic cylinder The positioner is connected to a pneumatic cylinder by means of fixing bracket, lever arm with Allen screw, extension arm, and roller. The pneumatic piston is connected to a guide rail with an oblique angle via a linkage. The guide rail moves together with the piston, and the roller/lever connection senses the position of the piston. By operating both sides of the pneumatic cylinder, the set point is reached. A spring inserted between the fixing bracket and the lever arm secures that the roller is pressed down against the guide rail. 2.3 Mechanic connection to a rotary actuator Figure 3 shows the mechanic connection of the positioner to a rotary actuator. Step A: Attach the mounting console (9, actuator specific) onto the rear of the positioner and secure using the hexagon head screws (14) and lock washers (15). Step B: Adhere pointer (4.2) onto the mounting console in the centre of the centring hole. Step C: Push coupling wheel (2) onto the positioner axis, pull back by about 1 mm and tighten the hexagon socket head screw (18) with the Allen key provided. Step D: Place the carrier (3) onto the end of the actuator and secure using Fillister head screw (16) and washer (17). Step E: Carefully place the positioner with mounting console onto the actuator such that the pin of the coupling wheel engages in the driver. Step F: Align the positioner/mounting console assembly in the centre of the actuator and screw tight (screws are not included in the delivery, they are part of the actuator mounting console). Step G: Follow the start-up sequence as described later. Drive the actuator to the end position and adhere the scale (4.1) onto the coupling wheel (2) according to the direction of rotation and rotary actuator. The scale is self- adhesive. Language UK Page 5/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Mechanic connection of the positioner (rotary actuator) Figure 3 sips2_5c.tif Language UK Page 6/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Electric connection of the positioner When the positioner is connected in a two-wire system, the positioner draws its power exclusively fromth e 4 to 20 mA set point signal. Figure 4 indicates the input circuits for the positioner. View of the controls and connections 14 fär 13 y • * *» j M 12 iMi •-mil'11' '* M«V~. 61 6.2 1 11 ..10 1 Input: Supply air 7 Silencer 2 Output: Actuating pressure Yi 8 Transmission ratio selector 3 Display 9 Adjusting wheel slip clutch 4 Oulput: Actuating pressure Y2 *) 10 Terminals options modules S Operating keys 12 Dummy plug 6 Restrictor 13 Screw-type cable gland 6.1 Restrictor Yl 14 Terminal plate on cover 6.2 Restrictor Y2 "> 15 Purging air switch Figure 4 sips2_5d.tif Pneumatic connection Ensure that the air quality is suitable. Grease-free instrumental air with a solid content < 30 um and a pressure dew point 20 K below the lowest ambient temperature must be supplied. Warning: For reasons of safety, pneumatic power may only be supplied after assembly when the positioner is switched to operating level "P manual" operation with electrical signal applied. 4.1.1 Selection of P manual mode Before pneumatic power is connected, the positioner must be in P manual mode. The display must show "NOINIT" in the bottom line. Language UK Page 7/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES 4.1.2 Pneumatic connections Figure 4 shows a view of the positioner controls and connections. Step A: If required, connect a manometer block for supply air and actuating pressure. Step B: The silencer in the exhaust output can be removed if necessary. Step C: Connect actuating pressure Yl and/or Y2 (Y2*} is only used with double- acting actuators) according to the desired safety position. Step D: Connect the supply air (1). The pressure should be between 1.4 to 7 bar. Note: In order for spring-loaded pneumatic actuators to be able to reliably exploit the maximum possible actuating path, the supply pressure must be sufficiently greater than the maximum required final pressure of the actuator. 4.1.3 Safety position when the electric power supply fails For a single-action actuator is Yl deaerated. For a double-action actuator is Yl equal to the supply air pressure and Y2 is deaerated. 4.1.4 Restrictors To increase the positioning times for fast actuators when necessary, the air flowca n be reduced with the restrictors Yl and Y2 (only for double-action valves). Turning the restrictors in the clockwise direction reduces the air flow until it is shut off. To set the restrictors it is recommended to first close them and then open them again slowly (see initialisation process RUN 3). 4.1.5 Purging air switchover The purging, air changeover switch located above the pneumatic terminal block on the valve manifold can be accessed when the housing is open. When the switch is in position "IN" the interior of me housing is purged with very small quantities of clean and dry instrument air. In position "OUT" the purging air is led directly out of the instrument. Commissioning Commissioning (initialisation) is carried out automatically to a large extend. During initialisation, the micro controller automatically determines the zero value, full-scale value, direction of action and positioning speed of the actuator. It uses these to determine the minimum pulse time and dead zone, hereby optimising the control. The positioner can also be operated manually by the pushbuttons and the LCD of the SIPART PS2. The commissioning of the positioner can be divided into the following steps: • Preparation for initialisation Start the automatic initialisation procedure Language UK Page 8/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES • Set additional parameters if required • Select automatic mode Figure 5 shows the possible operation modes for the positioner and gives an overview of how to change between them. The levels are P-manual mode, configuration and initialisation, manual mode, automatic mode, and diagnostic display. From these modes it is possible to select operation mode, set operation parameters, restore to factory setting, run an automatic initialisation, etc. Operation levels Mode Display P-manual mode Polanliome'er setting [" Change RûsilK.n "'ing 77/ ' -1 P315 Not initia1! luen be reache..ad d I ninirn ua ng prêt«!'«•)" --*• iiiuiim Configure St Change parameter name using g^ Parameter number Change value Parameter ^ VA _ name Manua mode Portion TW —. Change posl'ici Error code ^ 9W L usinq \ ""/ J Automatic Mode and Setpoint [%] Diagnosis »a» V I >2t Dlagnoal» value' Diagnosis < fuirnber » Figure 5 sips2_5e.tif 5.1 Preparation for initialisation Step A: Check and set the gear transmission switch to the correct position. Figure 4 (position 8) indicates the location of the switch. For linear actuators the gear transmission switch is set according to the stroke range as described in Table 1 for the parameter "3.YWAY". For part-turn actuators 90° must be selected. Step B: Check that the pneumatic supply power (inlet air) is present. The operating pressure should be at least one bar greater than is necessary for closing/opening the valve during initialisation. Language UK Page 9/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Step C: Without initialisation the positioner is in "P manual mode" and "NOINIT" flashes in the display. This level can also be reached by using "55.PRST" function (see Table 1). Step D: Check the free running of the mechanics in the whole actuating range by moving the actuator with the keys "f " and "J." and driving to the respective end position. Step E: With linear actuators drive the actuator to horizontal lever position. The display must indicate 48% to 52%. If necessary, correct the value by adjusting the sliding clutch. After the check is completed, the actuator must be approximately half way along its stroke. This is due to establishment of the action direction during automatic initialisation. 5.2 Automatic initialisation Figure 6 shows the configuration mode including the operation in this mode and Table 1 shows the parameter/configuration list. Figure 7 shows the initialisation process of the positioner. The initialisation process is stored in the microprocessor. This means that an additional initialisation only is necessary if any parts of the unit have been changed. Note: The numerical values used in Figure 5, Figure 6, and Figure 7 are examples. Step A: Call the configuration mode by pressing the hand symbol key for longer than 5 seconds. Step B: Set the actuator type, linear or part-turn, in the menu item line "1 .YFCT". Step C: Switch to the second parameter by pressing the hand symbol key briefly. Step D: Set the rated angle of rotation for feedback in the menu item line "2.YAGL". It is vital that this value corresponds to the setting of the gear transmission ratio selector (Figure 4, position 8), 33° or 90°. Step E: Switch to the next parameter by pressing the hand symbol key briefly. Step F: This parameter ("3.YWAY") is only set for linear actuators and if the total stroke in mm should be displayed at the end of the initialisation phase. To do this, select the same value in the display to which the carrier pin to the scale on the lever is set to. Step G: Switch to the following parameter by pressing the hand symbol key briefly. Step H: Start the initialisation ("4.INITA") by pressing the "f key for longer than 5 seconds. Language UK Page 10/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Step I: During the initialisation phase "RUNl" to "RUN5" appear one after another in the bottom of the display. Please note that the initialisation process may last up to 15 minutes depending on the actuator. Note: The ongoing initialisation can be aborted at any time by pressing the hand symbol key. The previous settings are retained. All the parameters are reset to the factory setting only after performing a preset "55.PRST". Step J: If problems occur, carry out the measures as described in the table "Possible messages" shown in Figure 7. Step K: The initialisation is completed when "FINSH" appears in the bottom of the display. Step L: When pressing the hand symbol key briefly the menu item line "4.INITA" is displayed. Step M: To exit the configuration operating mode, press the hand symbol key for longer than 5 seconds. The software version is displayed after about 5 seconds. The instrument is in manual operation after releasing the key. Step N: The positioner can be changed to automatic mode by pressing the "j" key once as indicated in Figure 5. Step O: The automatic mode is the normal mode. In this mode the positioner compares the set point current with the current position and moves the actuator until the control deviation reaches the dead zone. Operation in the configuration mode V A BflBBB B8 iffifl at the same time <2_^ at the same time i at the same time ^^•^ i at the same time BBBBB DO œBMsiï) Figure 6 sips2_5f.tif Language UK Page 11/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Initialisation process Automatic initial sort-up (starting with factory setting) Possible messages Step Meaning Display Meaning Measures Acknowledge message Partium turn 90° using the hand syrrod key actuator 1 YFCT 2 YAGL P 324 Actuator does RUN 1 not move Check restrictor (6) and open Linear WAY 33° St rt if necessary actuator 1 YFCT 2 YAGL 3 YVÄY P 324 Drive actuator to working range ERROR using the up and down keys Strt Press tte up key tor > 5 sec. Restart initialisation 4 INTA Remaining steps are carried out automatical/ Change gearing (7) P 324 Continue using up key 3.) Diiecticn of action is determined D RUN 1 P 884 Down tolerance Or adjust sliding clutch up todsplay S diu IU band violated Checking of travel and adjustment of P 6.4 4) P 924 S diOIU Q RUN 2 zero andstroke(from stop to stop) Détermination and display of positioning time Then only 5.) P 824 down(dxx.x), up (uxxx). Stop with the down key Con time ushg the down key r, RUN 3 Pressing t he up key inllates leakage measurement Linearactuator. set pick-up Once the slipp Ing lever h to ID montai position P 324 SB dutch has been using the up and down keys 6.) Determination of mhimum here ment length MIDDL adjusted D RUN 4 3 Continue ushg hand symbol key P 524 7) Optimisation of transient response Acknowledge message D RUN 5 P 98.3 Up tot era nee band using the hand symbol key Inl'alisaion terminated successfuly h UP > violated Set the next highest travel 324 (travel in m mfor linear actuators) value on the lever «-> (angleofrotatlon for part-turn ætuators) FIN3H Restart iri« alisäbn Ccntinueushg hand symbol ley Additionally possible with rotary actuators: Adjust using up and down keys up to dspla y: 923 80 95 Continue u shg hand symbol key Acknowledge message using the hand symbol key Up/down span P 19.8 Set the nect lowest travel violated Adjust positioning time ushg 1.3 Actuator does resrictcrfs) NOZZL not move. Positioning Continue ushg the time Is possibl e up or down key 1.8 to adjust NOZZL Figure 7 sips2_5g.cdr 5.3 Parameters After the initialisation process, the positioner can be configured to meet the requirements of a specified task. The factory settings correspond to the requirements for a typical application. This means that normally only a few parameters will need to be changed. Table 1 shows the parameter list for the positioner. The parameter name is written in plain text in the "menu line" column. The function of the parameter is described briefly in the "Function column". In addition, the possible parameter values, the physical unit and the factory setting of the parameters are shown. Language UK Page 12/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES : •ti- *- \V 'Parameter-list \J -;,x ' *''* v " . • "-.'"' Customer Menu line Function Parameter values Unit Factory setting setting turn (part-turn actuator) WAY (linear actuator) LWAY (linear actuator without sine correction) l.YFCT Type of actuator WAY ncSt (part-turn actuator withNCS) -ncSt (part-turn actuator with NCS, inverted) Rated angle of rotation for feedback 90° 2.YAGL0 Degrees 33° (must correspond to gear ratio) 33° Stroke range (optional setting) OFF 5,10,15,20 When used, the value must correspond with (short lever 33°) the set of the leverage ratio on the actuator 3.YWAY2» 25 ,30, 35 mm OFF Driver pin must be set to the value of the (short lever 90°) actuator travel or, if this value is not scaled, 40, 50 , 60, 70, to the next lager scale value 90,110,130 (long lever 90°) 4.INITA Initialisation (automatically) noini/no/###.#/Strt no 5.INITM Initialisation (manually) noini/###.#/Strt no „ . . . . 0 to 20 mA 0MA 6.SCUR Current range oef set point . ^ „„ . 4MA ° 4 to 20 mA 4MA riSE 7.SDIR Set point direction fir riSE FALL 8.SPRA Set point for start of split range 0.0 to 100.0 % 0.0 9.SPRE Set point for end of split range 0.0 to 100.0 % 0.0 Auto 10.TSUP Set point ramp up s 0 0 to 400 ll.TSDO Set point ramp down 0 to 400 s 0 Set point function Linear Lin 12.SFCT Equal-percentage 1:25,1:33, 1:50 1-25 ,1-33 ,1-50 Lin Inverse equal-percentage 1:25,1:33,1:50 nl-25 , nl-33 , nl-50 Freely adjustable FrEE 13.SL03) Set point turning point at 0% 0.0 14.SL1 5% 5.0 to to 0.0 to 100.0 % to 32.SL19 95% 95.0 33.SL20 100% 100.0 Auto 34.DEBA Dead zone of controller % Auto 0.1 to 10.0 35.YA Start of manipulated variable limiting 0.0 to 100.0 % 0.0 36.YE End of manipulated variable limiting 0.0 to 100.0 % 100.0 Standardisation of To mech. travel MPOS 37.YNRM MPOS manipulated variable To flow FLOW Direction of manipulated Rising riSE 38.YDIR riSE variable for display Falling FALL Without no Tight closing with Top only UP 39.YCLS no manipulated variable Bottom only do Top and bottom uPdo 40.YCDO Value for tight closing, bottom 0.0 to 100.0 % 0.5 41.YCUP Value for tight closing, top 0.0 to 100.0 % 99.5 Language UK Page 13/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Parameter list continued Customer Menu line Function Parameter values Unit Factory setting setting Function of BI1: None OFF Only message (NO/NC contact) on / -on Block configuring (NO contact) bLocl 42.BIN14) OFF Block configuring and manual (NO contact) bLoc2 Drive valve to pos. up (NO/NC contact) uP/-uP Drive valve to pos. down (NO/NC contact) doWn/-doWn Block movement (NO/NC contact) StoP / - StoP Function of BI 2: None OFF Only message (NO/NC contact) on / -on 43.BIN24) OFF Drive valve to pos. up (NO/NC contact) uP/-uP Drive valve to pos. down (NO/NC contact) doWn/-doWn Block movement (NO/NC contact) StoP / -StoP Without oFF .. „ Al=min. A2=max. N,NA 44.AFCT5) Alarm function .. , „ OFF Al=min. A2=min. N,N Al=max. A2=max. NA.NA 45.A1 Response threshold of alarm 1 0.0 to 100.0 % 10.0 46.A2 Response threshold of alarm 2 0.0 to 100.0 % 90.0 Function of alarm output On fault h - 47.4FCT6) Fault + not automatic SnA h Fault + not automatic + BI SnAb ("+" means logical OR operation) Monitoring time for fault message Auto 48. STIM s Auto "control deviation" 0 to 100 Response threshold for fault message Auto 49. h LIM % Auto "control deviation" 0.0 to 100.0 OFF 50.SSTRK Limit for stroke integral OFF 1 to 1.00E9 OFF 51-SDCHG Limit for direction change OFF 1 to 1.00E9 OFF 52. h ZERO Limit for end stop monitoring, bottom % OFF 0.0 to 100.0 OFF 53. h OPEN Limit for end stop monitoring, top % OFF 0.0 to 100.0 OFF 54. S DEB A Limit for dead zone monitoring % OFF 0.0 to 100.0 Preset (factory setting) "no" nothing activated no "Strt" start of factory setting after pressing 55.PRST key for 5 sec. Strt "oCAY" display following successful factory setting oCAY CAUTION: preset results in "NO INIT" Table 1 !) If turn is selected it is not possible to set 33°. 2) Parameter does not appear if 1 .YFCT = turn has been selected. 3) Turning points only appear with selection 12.SFCT = FrEE. 4) Alternatively "no" if initialisation has not yet been carried out 5) NC contact means; action with opened switch or low level. NO contact means; action with closed switch or high level. 6) Normal means: high level without fault. Inverted means: low level without fault. Language UK Page 14/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Diagnosis In the diagnostic mode the current operating data (such as number of strokes, number of changes in direction, number of fault messages, etc.) can be displayed. From the automatic or manual modes the diagnostic mode can be reached by simultaneously pressing all three keys for at least 2 seconds. Table 2 shows an overview of the displayable values. The diagnostic display has a similar structure as the parameter menu displays. The respective next diagnostic value can be selected with the hand symbol key. Certain values can be set to zero by pressing the "Î" key for at least 5 seconds. These are menu item line "1,2, 3, and.4". Some diagnostic values may be greater than 99999. In this case the display switches to exponential display. Diagnostic list No.: Abbreviation Meaning Displayable Unit value 1 STRKS Number of strokes 0 to 4.29E9 - 2 CHDIR Changes of direction 0 to 4.29E9 - 3 hCNT Fault counter 0 to 4.29E9 - 4 A1CNT Alarm counter 1 0 to 4.29E9 - 5 A2CNT Alarm counter 2 0 to 4.29E9 6 HOURS Operating hours 0 to 4.29E9 Hours 7 WAY Determined actuating path 0 to 130 mm or0 8 TUP Travel time up 0 to 1000 s 9 TDOWN Travel time down 0 to 1000 s 10 LEAK Leakage 0.0 to 100.0 % 11 P0 Potentiometer value below stop (0%) 0.0 to 100.0 % 12 P100 Potentiometer value bottom stop (100%) 0.0 to 100.0 % 13 IMPUP Impulse length up 2 to 100 ms 14 IMPDN Impulse length down 2 to 100 ms 15 DBOP Dead zone up 0.1 to 100.0 % 16 DBDN Dead zone down 0.1 to 100.0 % 17 SSUP Short step zone up 0.1 to 100.0 % 18 SSDN Short step zone down 0.1 to 100.0 % 19 TEMP Current temperature -45 to 85 °C 20 TMIN Minimum temperature -45 to 85 °C 21 TMAX Maximum temperature -45 to 85 °C 22 Tl Number of operating hours in Temperature range 1 0 to 4.29E9 Hours 23 T2 Number of operating hours in Temperature range 2 0 to 4.29E9 Hours 24 T3 Number of operating hours in Temperature range 3 0 to 4.29E9 Hours 25 T4 Number of operating hours in Temperature range 4 0 to 4.29E9 Hours 26 T5 Number of operating hours in Temperature range 5 0 to 4.29E9 Hours 27 T6 Number of operating hours in Temperature range 6 0 to 4.29E9 Hours 28 T7 Number of operating hours in Temperature range 7 0 to 4.29E9 Hours 29 T8 Number of operating hours in Temperature range 8 0 to 4.29E9 Hours 30 T9 Number of operating hours in Temperature range 9 0 to 4.29E9 Hours 31 VENT1 Number of cycles pre-control valve 1 0 to 4.29E9 - 32 VENT2 Number of cycles pre-control valve 2 0 to 4.29E9 - Store current values as "last maintenance" 33 STORE - - Press the up key for at least 5 seconds (store) Table 2 Language UK Page 15/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Service and maintenance The positioner is largely maintenance-free. The positioner is fitted with filters in the pneumatic connection as protection against coarse particles of dirt. If the pneumatic energy supply contains particles of dirt, the filters may be clog and impair the function of the positioner. In this case the filters can be cleaned as follows: Step A: Switch off the pneumatic power supply and remove the pipes. Step B: Unscrew the cover. Step C: Remove the three screws from the pneumatic connector strip. Step D: Remove the filters and O-rings behind the connector strip. Step E: Clean the filters (e.g. with compressed air). Step F: After cleaning first insert the filters in the recesses in the housing and then place the O-rings on the filters. Step G: Align the pneumatic connector strip on the two lugs and screw tight with the three self-tapping screws. Note: Make sure that the same thread is used. To do this, turn the screws anti clockwise until they snap into the thread audibly. Only then should the screws be tightened. Language UK Page 16/16 • • • • • •iiiiiii. ^^^^_^^^^ AALBORG ^UBIUIlBiBBMHI^BMiM INDUSTRIES ^ÊÊÈÊÊÊÈ^ÊÊÊÈÊÊÈÈÊÈÈÈÈÈ^ÊÊE^^K^^ÊÊÊi Table of contents Feed water pumps Technical data for feed water pumps General data 1 Data for feed water pumps 2 Data for pump motor 3 Pumps, type CR, CRN General 1 Calculation of minimum inlet pressure 2 Start-up 3 Maintenance 4 Frost protection 5 Fault finding chart 6 Spare parts Spare parts 1 Language UK Page 1/1 AALBORG TECHNICAL DATA FOR FEED WATER PUMPS SD9010#23.0 INDUSTRIES Technical data for feed water pumps 1 General data Project No.: 736950, 736952 Project name: 03130007,03130008 Classification society/local authority: LRS Pressure gauge calibration: MPa Thermometer calibration: °C Language for signs: UK Data for feed water pumps Pump: Vertical multistage centrifugal pump Pump type: CR 32-5-2 Delivery head: 120 m Pump capacity: 24m3/h NPSH: 1.8 m Feed water temperature, operation: 60°C Feed water temperature, maximum: 120°C Data for pump motor Motor make: Grundfos Power supply: 3 x 440 , 60Hz Rated output for motor: 15 kW Rated current: 26 A Starting method: Starting current: 202 A Revolutions: 3500r.p.m. Ambient air temperature: 40°C Insulation class: F Degree of protection: IP55 Language UK Page 1/1 AALBORG PUMPS, TYPE CR, CRN OM5540#20.3 INDUSTRIES Pumps, type CR, CRN 1 General The multistage in-line centrifugal pumps are used as condensate, make-up, and feed water pumps in boiler plants. To have a proper functioning of the centrifugal pumps it is essential that the pumped liquid does not contain any steam, air, solid particles or fibres. Furthermore the liquid must not attack the pump material chemically. 1.1 Technical data • Electrical data: see motor nameplate. • Ambient temperature: Max. 40°C. • Minimum inlet pressure: see section 2. • Maximum inlet pressure: see Table 1. However, the actual inlet pressure + pressure when the pump is running against a closed valve must always be lower than the "maximum permissible operating pressure". Maximum inlet pressure 50 Hz 60 Hz CR, CRN 1 CR, CRN ls-2 -> CR, CRN ls-36 10 bar CR, CRN ls-2 -» CR, CRN ls-27 lObar CR, CRN 1-2 -» CR, CRN 1-36 10 bar CR, CRN 1-2 -> CR, CRN 1-25 10 bar CR, CRN 1-27 15 bar CR, CRN 3 CR, CRN 3-2 — CR, CRN 3-29 10 bar CR, CRN 3-2 -> CR, CRN 3-15 10 bar CR, CRN 3-31 -> CR, CRN 3-36 15 bar CR, CRN 3-17 -* CR, CRN 3-25 15 bar CR, CRN 5 CR, CRN 5-2 -> CR, CRN 5-16 10 bar CR, CRN 5-2 ->• CR, CRN 5-9 lObar CR, CRN 5-18 -» CR, CRN 5-36 15 bar CR, CRN 5-10 ->• CR, CRN 5-24 15 bar CR, CRN 10 CR, CRN 10-1 -> CR, CRN 10-6 8 bar CR, CRN 10-1 -* CR, CRN 10-5 8 bar CR, CRN 10-7 -* CR, CRN 10-22 10 bar CR, CRN 10-6 -• CR, CRN 10-17 lObar CR, CRN 15 CR, CRN 15-1 ->• CR, CRN 15-3 8 bar CR, CRN 15-1 -» CR, CRN 15-2 8 bar CR, CRN 15-4 -* CR, CRN 15-17 10 bar CR, CRN 15-3 -* CR, CRN 15-12 10 bar CR, CRN 20 CR, CRN 20-1 -»• CR, CRN 20-3 8 bar CR, CRN 20-1 8 bar CR, CRN 20-4 ->• CR, CRN 20-17 10 bar CR, CRN 20-2 -* CR, CRN 20-10 10 bar CR, CRN 32 CR, CRN 32-1-1 -»• CR, CRN 32-4 4 bar CR, CRN 32-1-1 -• CR, CRN 32-2 4 bar CR, CRN 32-5-2 -» CR, CRN 32-10 lObar CR, CRN 32-3-2 -» CR, CRN 32-6 lObar CR, CRN 32-11-2 -* CR, CRN 32-14 15 bar CR.CRN 32-7-2 -• CR.CRN 32-10-2 15 bar Language UK Page 1/10 AALBORG PUMPS, TYPE CR, CRN OM5540#20.3 INDUSTRIES Maximum inlet pressure, continued SO Hz 60 Hz CR, CRN 45 CR, CRN 45-1-1 -• CR, CRN 45-2 4 bar CR, CRN 45-1-1 • • CR, CRN 45-1 4 bar CR, CRN 45-3-2 -» CR, CRN 45-5 10 bar CR, CRN 45-2-2 • • CR, CRN 45-3 10 bar CR.CRN 45-6-2 -> CR,CRN 45-13-2 15 bar CR, CRN 45-4-2 - • CR, CRN 45-7 15 bar CR, CRN 64 CR, CRN 64-1-1 • CR, CRN 64-2-2 4 bar CR, CRN 64-1-1 4 bar CR, CRN 64-2-1 • CR, CRN 64-4-2 10 bar CR, CRN 64-1 — CR, CRN 64-2-1 10 bar CR, CRN 64-4-1 • CR, CRN 64-8-1 15 bar CR, CRN 64-2 -> CR, CRN 64-5-2 15 bar CR, CRN 90 CR, CRN 90-1-1 -* CR, CRN 90-1 4 bar CR, CRN 90-1-1 - • CR, CRN 90-2-1 10 bar CR, CRN 90-2-2 -* CR, CRN 90-3-2 10 bar CR, CRN 90-2-2 - • CR, CRN 90-4-2 15 bar CR, CRN 90-3 -> CR, CRN 90-6 15 bar Table 1 • Maximum permissible operating pressure: see Table 2. r L- • Maximum permissible operating pressure Frequency Pump type Temperature range Operating pressure CR,CRNls, 1 25 bar CR, CRN 3 25 bar CR, CRN 5 25 bar CR, CRN 10-1 -> CR, CRN 10-22 25 bar CR, CRN 15-1 -• CR, CRN 15-17 25 bar CR, CRN 20-1 -»• CR, CRN 20-17 25 bar CR, CRN 32-1-1 -* CR, CRN 32-7 16 bar CR, CRN 32-8-2 -> CR, CRN 32-12 25 bar 50 Hz -20°C to +120°C CR, CRN 32-13-2 -> CR, CRN 32-14 30 bar CR, CRN 45-1-1 — CR, CRN 45-5 16 bar CR, CRN 45-6-2 -• CR, CRN 45-9 25 bar CR, CRN 45-10-2 — CR, CRN 45-10 33 bar CR, CRN 64-1-1 — CR, CRN 64-5 lobar CR, CRN 64-6-2 -+ CR, CRN 64-7-1 25 bar CR, CRN 90-1-1 -+ CR, CRN 90-4 lobar CR, CRN 90-5-2 -» CR, CRN 90-6 25 bar CR, CRN ls, 1 25 bar CR, CRN 3 25 bar CR, CRN 5 25 bar CR, CRN 10-1 -> CR, CRN 10-17 25 bar CR, CRN 15-1 -* CR, CRN 15-12 25 bar CR, CRN 20-8 -» CR, CRN 20-10 25 bar CR, CRN 32-1-1 -> CR, CRN 32-5 lobar 60 Hz CR, CRN 32-6-2 -* CR, CRN 32-8 -20°C to +120°C 25 bar CR, CRN 32-9-2 -» CR, CRN 32-10-2 40 bar CR, CRN 45-1-1 -» CR, CRN 45-4 lobar CR, CRN 45-5-2 -+ CR, CRN 45-6 25 bar CR, CRN 64-1-1 -» CR, CRN 64-3 lobar CR, CRN 64-4-2 -» CR, CRN 64-4-1 25 bar CR, CRN 90-1-1 -» CR, CRN 90-3 lobar CR, CRN 90-4-2 25 bar Table 2 Language UK Page 2/10 •••#••• AALBORG PUMPS, TYPE CR, CRN OM5540#20.3 INDUSTRIES Minimum flow rates: See Table 3. Minimum flow rates Liquid temperature Pump type Up to + 80oC + 80°C to + 120-C CR,CRNls 0.1 m3/h 0.2 m3/h CR, CRN 1 0.1 m3/h 0.3 m3/h CR, CRN 3 0.4 m3/h 0.8 m3/h CR, CRN 5 0.6 m3/h 1.3m3/h CR, CRN 10 1.2m3/h 2.6 m3/h CR, CRN 15 1.8 m3/h 3.8 m3/h CR, CRN 20 2.4 m3/h 5.0 m3/h CR, CRN 32 3.8 mJ/h 7.6 m3/h ?CR,CRN45 5.4 m3/h 11.0m3/h CR, CRN 64 7.7 m3/h 16.0 m3/h CR, CRN 90 11.0m3/h 24.0 m3/h Table 3 • Liquid temperature: -20°C to 120°C. See also Table 2 which indicates the relationship between liquid temperature and maximum permissible operating pressure. Note: In condensate and feed water systems where an open hot-well is used it is recommended to keep a temperature in the hot-well of 85-95°C. • Further technical data can be found on the data sheet related to the pumps. Calculation of minimum inlet pressure The minimum inlet pressure "H" in metres head required to avoid cavitation in the pump is calculated as follows: H = pb x 10.2 - NPSH - Hf - Hv - Hs • pb = barometric pressure in bar (barometric pressure can be set to 1.0 bar). In closed systems pb indicates the system pressure in bar. • NPSH = net positive suction head in metres head (to be read from the NPSH curves in Figure 2 and Figure 3 at the highest flow the pump will be delivering). • Hf = friction loss in suction pipe in metres head at the highest flow. • Hv = vapour pressure in metres head, see Figure 1. Tm = liquid temperature • Hs = safety margin = 0.5 metres head. If the calculated "H" is positive, the pump can operate at a suction lift of maximum "H" metres head. If the calculated "H" is negative, an inlet pressure of minimum "H" metres head is required. There must be a pressure equal to the calculated "H" during operation. Language UK Page 3/10 AALBORG PUMPS, TYPE CR, CRN OM5540#20.3 INDUSTRIES Example: 3 Pump type = CR 20 - 60 Hz, flow rate = 24 m /h, pb = 1.0 bar. Hf = 3.0 metres head, liquid temperature = + 90°C. Hv (from Figure 1) = 7.5 metres head. NPSH (from Figure 2) = 2.5 metres head. H = pbxl0.2-NPSH-Hf-Hv-Hs H = 1 x 10.2 - 2.5 - 3.0 - 7.5 - 0.5 = -3.3 metres head. This means that an inlet pressure of minimum 3.3 metres head is required. Relationship between Hv and Tm Ml Hv PC) m- HO- -35 •30 130 •25 120I'- .20 110- •« •12 100< -10 •8,0 SO- -40 80--W K0 70 •3fi 80' •2» 80' 1.0 40 •0,8 •0,8 30' •OA •0,3 20' •0,2 10' •0,1 0' Figure 1 cr02a.tif Language UK Page 4/10 AALBORG PUMPS, TYPE CR, CRN OM5540#20.3 INDUSTRIES NPSH curves H OR 15, CR115, CRN 15 [«••I M CR1s.CRI1s.CRN1» W; 1 w. 60 Hz - i ! 50 Hz 60 Hz 50 Hz , 32- y/ „-*• 3£l ^ 16- 0- • 1 l 1 n ' PI 1 î 0.0 02 ' ] < r otrt] H CR 20, CRI20, CRN 20 Itfa» l ."1 . CR 1. CRU. CRN 1 B™ [W* w. 50Hz 60Hz J ' I OHz / < u 60 Si z / y f te- tr ^^ ^> -a* SS! r =s= =* 0- "i 1 1 ' 1 \ ' \ • ao HA o.« \a i.» u> M 0 4 6 12 16 20 24 28 Q[n*H] 1 ' ' ' I ' l l | I l I | l l I | I I I | 4 6 6 0[WJ t*MailM CR 3, CRI 3, CRN 3 tu*) ("4 CR 32. CRN 32 7/ 50 Hz 50Hz i à ' // '/ 1-6 &y A 10 é 4- o- "1 \ i 4- ao H» IJI 24 U U U QlmWi] o » •unnotaaiss« 1 44 atom] I 1 1 1 1 V T 1 T I 1 1 1 1 1 1 T OLO 02 0.« OA M 1.0 u 14 a (ni 0 2 4 8 0 10 18 Opta] P H «Ml M CR 45, CRN 45 Hz— ao 1.0 20 3.0 4.0 5.0 6.0 7.0 6.0 8.0 1&0Q[«m] i 1 r H -r aim op»l 0.8 CRI :RI 10, CRN 10 p H o,< gm H CR 64, CRN 64 iw«: W' I reo Hz t ' • bU H] > ' « / 50 Hz * • /-, • / J" • 10 J 1JO-J iË 0- 1 1 1 0 1 i 3 4 5 6 7 S 9 10 11 12 1n3 "Q[mWl ] 0 10 20S040BOa070BOSO Q{nffll| T I—I—I—I—I— T—r 00 0.5 1.0 M 20 2S 30 36 a 0*1 Figure 2 cr03b.tif Language UK Page 5/10 AALBORG PUMPS, TYPE CR, CRN OM5540#20.3 INDUSTRIES NPSH curves, continued p H {kp*l W CR 90, CRN 90 l ' " 60 Hz * * * 50 Hz,y in * 20 a- 0 20 «0 60 80 tt» 120 Qlnrthl I 1 1 1 1 1 Figure 3 cr07a.tif Start-up Note: The pump is not allowed to run against a closed discharge valve as this will cause an increase in temperature/formation of steam in the pump which may cause damage to the pump. If there is any danger of the pump running against a closed discharge valve, a minimum liquid flow through the pump should be ensured by connecting a by-pass / drain to the discharge pipe. The drain can for instance be connected to a hot-well / tank. Warning: Do not start the pump until it is filled with liquid and has been primed and vented. 3.1 Priming Note: The following does only apply to systems where the liquid level is above the pump inlet Step A: Close the discharge isolating valve and loosen the vent screw in the pump head, see Figure 4. Note: Pay attention to the direction of the vent hole and take care to ensure that the escaping water does not cause injury to persons or damage to the motor or other components. In hot water installations, special attention should be paid to the risk of injury caused by scalding hot water. Language UK Page 6/10 AALBORG PUMPS, TYPE CR, CRN OM5540#20.3 INDUSTRIES Step B: Slowly open the isolating valve in the suction pipe until a steady stream of liquid runs out the vent hole. Step C: Tighten the vent screw and completely open the isolating valve(s). Illustration of the centrifugal pumps Vent Screw/ Priming Plug J^^T, Vent Screw/ Drain Plug/ Priming Plug Bypass Valve iW _\ a Drain Plug Figure 4 cr06.tif 3.2 Checking direction of rotation Do not start the pump to check direction of rotation until it has been filled with liquid. Note: The direction of rotation should not be checked with the motor alone, as an adjustment of the shaft position is required when the coupling has been removed. The correct direction of rotation is shown by arrows on the pump head and/or on the motor fan cover. When seen from the fan, the pump should rotate counter clockwise. 3.3 Starting Before starting the pump: Step A: Open the isolating valve completely on the suction side of the pump and leave the discharge isolating valve almost closed. Step B: Start the pump. Step C: Vent the pump during starting by loosening the vent screw in the pump head until a steady stream of liquid runs out the vent hole, see Figure 4. Language UK Page 7/10 AALBORG PUMPS, TYPE CR, CRN OM5540#20,3 INDUSTRIES Warning: Pay attention to the direction of the vent hole and take care to ensure that the escaping water does not cause injury to persons or damage to the motor or other components. In hot water installations, special attention should be paid to the risk of injury caused by scalding hot water. When the piping system has been filled with liquid: Step D: Slowly open the discharge isolating valve until it is completely open. When pumping liquids containing air, it is advisable to vent the pump regularly. To vent the pump: Step E: Loosen the vent screw in the pump head during operation. 3.4 Frequency of starts and stops Motors smaller than 4 kW should not start more than 100 times per hour. Other motors should not start more than 20 times per hour. Maintenance Caution: Before starting work on the pump, make sure that no power is supplied to the pump and that it cannot be accidentally switched on. Before removing the cover of the electrical terminal box and before any removal/dismantling of the pump, make sure that the electricity supply has been switched off. Pump bearings and shaft seal are maintenance-free. If the pump is to be drained for a long period of inactivity then: Step A: Remove one of the coupling guards to inject a few drops of silicone oil on the shaft between the pump head and the coupling. This will prevent the shaft seal faces from sticking. When fitting the coupling guards, make sure that they are centred vertically in the recesses in the pump head. 4.2 Motor bearings Motors which are not fitted with grease nipples are maintenance-free. Motors fitted with grease nipples should be lubricated with a high-temperature lithium-based grease. In the case of seasonal operation (motor is idle for more than 6 months of the year), it is recommended to grease the motor when the pump is taken out of operation. Language UK Page 8/10 AALBORG PUMPS, TYPE CR, CRN OM5540#20.3 INDUSTRIES Frost protection Pumps which are not used during periods of frost should be drained to avoid damage. Step A: Drain the pump by loosening the vent screw in the pump head and by removing the drain plug from the base. Warning: Care must be taken to ensure that the escaping water does not cause injury to persons or damage to the motor or other components. In hot water installations, special attention should be paid to the risk of injury caused by scalding hot water. Do not tighten the vent screw and replace the drain plug until the pump is to be used again. Step B: Before replacing the drain plug in the base, screw the by-pass valve out against the stop, see Figure 4. Step C: Fit the drain plug by tightening the large union nut followed by the bypass valve. Language UK Page 9/10 AALBORG PUMPS, TYPE CR, CRN OM5540#20.3 INDUSTRIES Fault finding chart Before removing the terminal box cover and before any removal/dismantling of the pump, make sure that the electricity supply has been switched off. Fault finding chart Fault Cause Remedy 1. Motor does not run when a) Supply failure. Connect the electrical supply. started. b) Fuses blown. Replace fuse. c) Motor starter overload has tripped out. Reactivate the motor protection. d) Main contacts in motor starter are not making contact or the coil is faulty. Replace contacts or magnetic coil. e) Control circuit fuses are defective. Repair the control circuit. f) Motor is defective. Replace the motor. 2. Motor starter overload trips a) One fuse is blown/automatic circuit breaker is blown. Cut the fuse. out immediately when supply is b) Contacts in motor starter overload are faulty. Replace motor starter contacts. switched on. c) Cable connection is loose or faulty. Fasten/replace the cable connection. d) Motor winding is defective. Replace the motor. e) Pump mechanically blocked. Remove blocking of the pump. f) Overload setting too low. Set the motor starter correctly. 3. Motor starter overload trips a) Overload setting too low. Set the motor starter correctly. out occasionally. b) Low voltage at peak times. Check the electrical supply. 4. Motor starter has not tripped a) Check 1 a), b), d) and e). out but the pump does not run. - 5. Pump capacity not constant. a) Pump inlet pressure is too low (cavitation). Check the suction conditions. b) Suction pipe/pump partly blocked by impurities. Clean the pump or suction side. c) Pump draws in air. Check the suction conditions. 6. Pump runs but gives no a) Suction pipe/pump blocked by impurities. Clean the pump or suction side. water. b) Foot or non-return valve blocked in closed position. Repair the foot or non-return valve. c) Leakage in suction pipe. Repair the suction pipe. d) Air in suction pipe or pump. Check the suction conditions. e) Motor rotates in the wrong direction. Change the direction of rotation of the motor. 7. Pump runs backwards when a) Leakage in suction pipe. Repair the suction pipe. switched off. b) Foot or non-retum valve defective. Repair the foot or non-return valve. 8. Leakage in shaft seal. a) Shaft seal is defective. Replace the shaft seal. 9. Noise. a) Cavitation occurs in the pump. Check the suction conditions. b) Pump does not rotate freely (frictional resistance) because of incorrect pump shaft position. Adjust the pump shaft. Table 4 Language UK Page 10/10 CR(N) 32 50/60 Hz SHAFT SEAL KIT 9641658 9641658 9641658 9641658 9641658 9641658 9644002 9644003 Kit no.: 96417021 96417022 2 3 4 5 6 7 9 0 Pos. Description EUHE EUHV EUBE EUBV EUUE EUUV HUBE HUBV EQQE EQQV 105 Shaft seal 1 1 1 1 1 1 1 1 1 1 GASKET KIT BOTTOM BEARING KIT Kit no.: 96416597 96416598 Kit no.: 96416580 Pos. Description EPDM FKM Pos. Description 1-14 37 O-ring 2 2 6g Bearing ring (stationary) 1 38 O-ring 4 4 31 Hex. soc. head screw 1 60 Spring (rubber) 4 4 32 Washer 1 100 O-ring 2 2 47b Bearing ring (rotating) 1 109 O-ring 1 1 66 Washer 1 110 O-ring 1 1 66b Lock washer 1 Distance tool (shaft seal) 1 1 67 Hex. soc. head screw 1 D+E Puller compl. 1 WEAR PARTS KIT BEARING KIT Kit no.: 96416728 96416729 96416730 96416731 9641657 Pos. Description 1-2 3-7 8-11 12-14 kit no.: 96416574 6 45 Neck ring 2 7 11 14 Pos. Description 3-7 8-14 47 Bearing (PTFE) 1 2 2 47a Bearing 1 2 47 Bearing bron. 1 2 2 Distance tool 1 1 47c Sleeve 2 6 9 11 47d Lock ring 2 7 11 14 49c Wear ring 2 7 11 14 65 Seal carrier 2 7 11 14 Distance tool 1 1 1 1 COUPLING COMPLETE Kit no.: 96416589 96416590 96416591 96416592 96416593 96416594 96475477 | 96475478 For shafts with key and keyway D shaft Motor/Pump: 24/22 28/22 38/22 42/22 48/22 55/22 42/22 48/22 Pos. Description 10a Coupling half 2 2 2 2 2 2 2 2 9 Hex. soc. head screw 4 4 4 4 4 4 4 4 •- i 9a Hex. soc. head screw 1 9b washer 1 1 Distance tool 1 1 1 1 1 1 1 1 COUPLING COMPLETE NEMA Kit no.: 96417000 96417001 96417004 96417020 D shaft Motor/Pump: 28.6/22 34.9/22 41.2/22 47.6/22 Pos. Description 10a Coupling half 2 2 2 2 9 Hex. soc. head screw 4 4 4 4 Distance tool 1 1 1 1 ROTATING UNIT COMPLETE (pump stack) Kit no. CRN 32: 96416290 96416291 96416918 96416292 96416293 96416919 96416294 96416920 96416295 Kit no. CR 32: 96416273 96416274 96416905 96416275 96416276 96416906 96416277 96416907 96416278 Pump type 32-1-1 32-1 32-2-2 32-2-1 32-2 32-3-2 32-3 32-4-2 32-4 Rotating unît 1 1 1 1 1 1 1 1 1 Krt no. CRN"32": 96416921 96416296 96416922 96416297 96416923 96416298 96416924 96416299 96416925 Kit no. CR 32: 96416908 96416279 96416909 96416280 96416910 96416281 96416911 96416282 96416912 Pump type 32-5-2 32-5 32-6-2 32-6 32-7-2 32-7 32-8-2 32-8 32-9-2 Rotating unit 1 1 1 1 1 1 1 1 1 Kit no. CRN 32: 96416300 96416926 96416301 96416927 96416302 96416928 96416303 96416929 96416304 Kit no. CR 32: 96416283 96416913 96416284 96416914 96416285 96416915 96416286 96416916 96416287 Pump type 32-9 32-10-2 32-10 32-11-2 32-11 32-12-2 32-12 32-13-2 32-13 Rotating unit 1 1 1 1 1 1 1 1 1 Kit no. CRN 32: 96416930 96416305 Kit no. CR 32: 96416917 96416288 Pump type 32-14-2 32-14 Rotating unit 1 1 SO/60 Hz CR(N) 32 49d/49e h6b 203 201 CR 32 60 Hz RECOMMENDED SPARE PARTS FOR 2 AND 5 YEARS' OPERATING TIME for 5 years' operating for 2 years' operating -^- 3-phase motors H Wear Intermediate Shaft seal Bottom Chamber Motor bearings Type Casket kit Motor make part kit bearing kit kit bearing kit stack ND-side DE-side CR 32-1-1 96416728 Table 1 Table2 96416580 96416273 ID9990 ID9989 Grundfos CR 32-1 96416728 - - 96416580 96416274 ID9990 ID9988 - CR 32-2-2 96416728 - - 96416580 96416905 ID7920 ID7044 - CR 32-2-1 96416728 - - 96416580 96416275 ID7920 ID7044 - CR 32-2 96416728 - - 96416580 96416276 ID7920 ID7044 - CR 32-3-2 96416729 96416574 - - 96416580 96416906 ID3139 ID0583 - CR 32-3 96416729 96416574 - - 96416580 96416277 ID3139 ID0583 - CR 32-4-2 96416729 96416574 - - 96416580 96416907 ID3139 ID0583 - CR 32-4 96416729 96416574 - - 96416580 96416278 ID6705 ID0583 Siemens CR 32-5-2 96416729 96416574 - - 96416580 96416908 ID670S ID0583 - CR 32-5 96416729 96416574 - - 96416580 96416279 ID6705 ID0583 - CR 32-6-2 96416729 96416574 - - 96416580 96416909 ID6705 ID0583 - CR 32-6 96416729 96416574 - - 96416580 96416280 ID6705 ID0583 - CR 32-7-2 96416729 96416574 - - 96416580 96416910 ID6705 ID0583 - CR 32-7 96416729 96416574 - - 96416580 96416281 ID6705 ID0583 - CR 32-8-2 96416730 96416576 - - 96416580 96416911 ID6719 ID0375 - CR 32-8 96416730 96416576 - - 96416580 96416282 ID6719 ID0375 - CR 32-9-2 96416730 96416576 - - 96416580 96416912 ID6719 ID0375 - CR 32-9 96416730 96416576 - - 96416580 96416283 ID6719 ID0375 - CR 32-10-2 96416730 96416576 - - 96416580 96416913 ID6719 ID0375 - CR 32-10 96416730 96416576 - - 96416580 96416284 ID6719 ID0375 - CR 32-11-2 96416730 96416576 " - 96416580 96416914 ID6719 ID0375 - Table 1 Shaft seal type EUHE EUHV EUBE EUBV EUUE EUUV HUBE HUBV EQQE EQQV Part number 96416582 96416583 96416584 96416585 96416586 96416587 96417021 96417022 96440029 96440030 Table 2 Casket kit type EPDM FKM Part number 96416597 96416598 Recommended spare parts for tenders. Number of Wear part Intermediate Shaft seal Bottom Motor bearing Casket kit Chamber stack pumps kit bearing kit kit bearing kit ND-side DE-side 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 2 3 2 2 2 2 2 2 3 3 4 2 2 2 2 2 2 4 4 5 2 2 2 2 2 2 5 5 6 3 3 3 3 3 3 6 6 7 3 3 3 3 3 3 7 7 8 3 3 3 3 3 3 8 8 9 3 3 3 3 3 3 9 9 10 3 3 3 3 3 3 10 10 Example: Spare parts for 4 units CR 32-6 with EUBE shaft seal and EPDM gaskets 2 years of operating: 5 years of operating: 2 off wear part kits: 96416729 2 off shaft seal kits: 96416584 2 off intermediate bearing kits: 96416574 2 off gasket kits: 96416597 2 off shaft seal kits: 96416584 2 off bottom bearing kit: 96416580 2 off gasket kits: 96416597 2 off chamber stacks: 96416280 4 off ND motor bearings: ID6705 4 off DE motor bearings: ID0583 •iiiiüi. AALBORG düBIlillBiBflBHSMW^^M Table of contents Chemical dosing pump General 1 Installation 2 Operation and maintenance 3 Fault location procedures 4 Language UK Page 1/1 SUMMARY I GENERAL Page 1.1 Introduction G1.1 1.2 Operating principle G1.1 1.3 Technical characteristics G1.2 II INSTALLATION 2.1 Unpacking and storage G2.1 2.2 Recommendations for installing the pump G2.1 2.3 Electrical installation G2.2 2.4 Hydraulic system G2.2 2.5 Installation sketches G2.3 2.6 Installation of accessories G2.5 2.7 Calculations for installation G2.6 III OPERATION AND MAINTENANCE 3.1 Checking before switching on G3.1 3.2 Start up G3.1 3.3 Routine checks G3.1 3.4 Preventive maintenance G3.1 3.5 Ordering spare parts G3.2 3.6 Product identification G3.2 3.7 Servicing and maintenance of the liquid end G3.3 3.8 Servicing and maintenance of mechanical assembly G3.8 3.9 Lubrication G3.14 IV FAULT LOCATION PROCEDURES G4.1 Ä DOSAPRO w MILTON ROY INSTRUCTION MANUAL FOR INSTALLATION, OPERATING, AND MAINTENANCE. Ci Dosing pump mROY A & B This manual should be made available to the person responsible for installation, operating and maintenance. Date : 12/99 O / Ref : T.160.0401.001.Rev. E «t I GENERALITES 1.1 -INTRODUCTION The mRoy pump is a dosing pump with incorporated hydraulic diaphragm, oil-lubricated with sealed housing, with a variable swept-volume adjustment which can be set when stopped or running. It is designed for continuous service in industrial operation. 1.2 - OPERATING PRINCIPLE - Worm (052A) / tangent wheel (052) pair drives connecting rod (214) through means of the eccentric of wheel (052). - Connecting rod (214) gives piston (012) a reciprocating motion with constant stroke. - Through means of oil contained in chamber (D), the piston drives diaphragm (298A) held fast between 2 contour plates (298). - Relief valve (212A) protects the pump. Suction phase: Piston (012) draws back and sucks in the oil (H) behind diaphragm (298A). The differential pressure which is created is transmitted by flexible diaphragm (298A) enabling the pumped fluid to be drawn in with perfect separation between the pump mechanical parts and the pumped fluid. When adjusting sleeve (E) linked mechanically to piston (012) opens orifice (B) of oil bypass (C), the additional oil is supplied by housing (081). Discharge phase: Piston (012) moves forward and forces the oil back to housing (081) through by-pass (C) and orifice (B) until this orifice is blocked by adjustment sleeve (E). The oil then pushes diaphragm (298A) which moues forward proportionally to the fraction of remaining swept-volume, after blocking orifice (B). The dosed liquid is pushed back by the diaphragm through the discharge check-valves. Flowrate adjustment: The discharge flowrate is adjustable when running, from 0 to 100%, by turning adjustment knob (255) which displaces, in the oil bath, and thus without any effort, adjustable liner (012A) and thus the position of orifice (B). Fig.1 A = stroke. I = backward G1.1 GB 1.3 - TECHNICAL CHARACTERISTICS The nominal pump flow depends on the piston diameter and the actual pumping stroke speed. The influence of pressure is low, on the order of -2% per section of 10 bars. 1.3.1 Technical characteristics for mRoy A Type of pump mRoy A piston diameter _0 11.1 15.9 27 (1) (2) Maximum discharge pressure in bars relative 123 123 46 59 21 (4) Maximum suction pressure in bars (Pa) 35 17.5 6 (3) Maximum flow in UH (Q): at pressure of 10 b 2.6 10 5.5 22 66 at maximum pressure 1.95 7.8 4.1 19.8 64.5 Speed in strokes / min 29 112 29 112 112 Motor power in kW 0.25 Motor speed in rpm 1440 Motor mounting: Flange F130 Shaft 14x30 (5) Maximum height of suction in mce (Ha) 2 Volume of pulsation dampener in suction 0.13 L Volume of pulsation dampener in discharge 0.13 L Pre-expansion of pulsation dampener in discharge 60% of service pressure Noise level: Acoustic pressure < 70 dB (A) Simplex pump weight 25 Duplex pump weight 40 1.3.2 Technical characteristics for mRoy B with 015 piston Type of pump mRoy B piston diameter 0 15 (1) (2) Maximum discharge pressure in bars relative 105 (4) Maximum suction pressure in bars (Pa) 35 (3) Maximum flow In L/H (Q): at pressure of 10 b 14 21 34 53 at maximum pressure 11 17 27 42 Speed in strokes / min 36 56 90 140 Motor power in kW 0.55 0.75 0.55 0.75 Motor speed in rpm 900 1440 900 1440 Motor mounting: Flange F165 Shaft 19x40 (5) Maximum height of suction in mce (Ha) 1.5 Volume of pulsation dampener in suction 0.13 Volume of pulsation dampener in discharge 0.13 L Pre-expansion of pulsation dampener in discharge 60% of service pressure Noise level: Acoustic pressure < 70 dB (A) Simplex pump weight 65 Duplex pump weight 85 G1.2 1.3.3 Technical characteristics for mRoy B with a 0 22.2 piston Type of pump mRoy B piston diameter 0 22.2 (1) (2) Maximum discharge pressure in bars relative 49 70 49 70 49 70 49 70 (4) Maximum suction pressure in bars (Pa) 17.5 (3)Maximum fiowrate in UH (Q):at pressure of 10b 30 30 46 46 74 74 114 114 at maximum pressure 27 26 42 40 68 65 105 100 Speed in strokes / min 36 56 90 140 Motor power in kW 0.55 0.75 0.55 0.75 0.55 0.75 0.75 1.1 Motor speed in rpm 900 1440 900 1440 Motor mounting: Flange F165 Shaft 19x40 24x50 19x40 19x40 19x40 24x50 19x40 24x50 (5) Maximum height of suction in mce (Ha) 1.5 Volume of pulsation dampener in suction 0.13 L Volume of pulsation dampener in discharge 0.13 L Pre-expansion of pulsation dampener in discharge 60% of service pressure Noise level: Acoustic pressure < 70 dB (A) Simplex pump weight 65 Duplex pump weight 85 1.3.4 Technical characteristics for mRoy B with a 0 36.5 piston Type of pump mRoy B piston diameter 0 36.5 (1) (2) Maximum discharge pressure in bars relative 14 28 14 28 14 28 14 28 (4) Maximum suction pressure in bars (Pa) 6 (3)Maximum fiowrate in L/H (Q):at pressure of 10b 80 80 124 124 200 200 310 310 at maximum pressure 79 77 123 119 198 192 307 298 Speed in strokes / min 3 6 56 90 140 Motor power in kW 0.55 0.75 0.55 0.75 0.55 0.75 0.75 1.5 Motor speed in rpm 91) 0 1400 900 1400 Motor mounting: Flange F165 Shaft 19x40 19x40 19x40 19x40 19x40 24x50 19x40 19x50 (5) Maximum height of suction in mce (Ha) 0.6 Volume of pulsation dampener in suction 0.5 L Volume of pulsation dampener in discharge 0.5 L Pre-expansion of pulsation dampener in discharge 60% of service pressure Noise level: Acoustic pressure < 70 dB (A) Simplex pump weight 65 Duplex pump weight 85 (1) Contact us for higher oressures (2) 10 bars for the "P" versions (3) Flow obtained on standard configuration, with water (4) 6 Bars for "P" versions (5) mce = Water column meter II. INSTALLATION 2.1 - UNPACKING AND STORAGE The packing must be carefully examined at reception in order to ensure that the contents have not suffered any obvious damage. Open the packing carefully; one should be careful not to damage certain accessories which may be fastened to the inside of the packing. Examine the contents and check them against the delivery slip. The packing contains: - One pump. - Oil, depending on versions (see chapter 3.9) - A list of wear-and-tear parts, accompanied by section drawings and space-requirement drawings. - An instruction manual for pump installation, upkeep and maintenance Storage precautions For storage less than 6 months: Storage is to be carried out preferably in the original packing and protected from inclement weather conditions. For storage longer than 6 months: Preserve the original packing. Also provide packing under plastic heat-sealing wrapping and dehydrating bags. Store the pump in protected, covered premises with full oil charge. 2.2 - RECOMMENDATION FOR INSTALLING THE PUMP 2.2.1 Manutention Put the sling under the motor terminal box and under the motor flange. Cross the two ends of the sling and close the loop (see diagrams). Before attempting to move it, check that the entire unit is well balanced. Nota: As soon as the pump is in position, fasten it down. 2.2.2 - Installing the pump - Fasten the pump to a horizontal support using its fastening holes. Arrange enough free space around the pump so as to be able to have easy access, and to ensure the upkeep and adjustments (accessibility to the liquid end, filling, and housing oil draining). - Connect the priming drain of the liquid end to a drip-collecting tank - If the service pressure is greater than 3.5 bars, remove the spring located in the discharge check-valve box. CAUTION: Pumps installed outdoors must be protected from the elements. 2.2.3 Oil filling (Fig. 1A). - Unscrew the oil filler plug located on top of the pump. Oil filler plug. - Unscrew the level indicator located on the Oil level indicator side of the pump. - Pour the oil in until it reaches the threading of the level indicator. Drain plug - Screw the level indicator back in. Fig.lA - Fill up with oil to the middle of the level indicator. - Screw the oil filler plug back on. 2.3 - ELECTRICAL INSTALLATION Verify the motor data against your available mains supply for the plant before carrying out connections. Connect the motor according to the indications given in the terminal box. For 230 V delta connection OOP For 400 V star connection 0 0 0 Before operating the pump, check the direction of rotation of the motor which must be according to the arrow stamped on the motor (Counter-clockwise direction when seen from top). To reverse the direction of rotation, just reverse A and B or A and C. CAUTION : DO NOT FORGET TO CONNECT THE PUMP TO EARTH c=> Electric protection of the motor (thermic protection or by means of fuses) is to correspond to the rated current indicated on the motor data plate. 2.4 - HYDRAULIC SYSTEM Pipework - Generalities As far as possible, avoid exerting stresses due to incorrect alignments between rigid pipes and the centreline of valve boxes. Provide facilities for disassembly (union-pieces, and so forth...). Clean piping before assembly. 2.4.1 Suction pipings The pump is to be located as close as possible to the suction point and the piping is to be as short and as direct as possible. If possible, have the suction point located slightly above the pump; in the event of long period of rest, the pump will not unprime. The diameter of the piping must be bigger or equal to the connection diameter of the liquid end. The suction piping is to be ABSOLUTELY AIR TIGHT (check after assembly). When it is not possible to avoid long suction pipework, use a RESERVOIR tank or a balancing column located as close as possible to the suction aperture of the pump. 2.4.2 Delivery pipework The diameter of the piping is to be bigger or equal to the connection diameter to the liquid end. Be sure that the piping and accessories fitted on the delivery line are sufficiently strong to withstand the delivery pressure. 2.5 - INSTALLATION SKETCHES 2.5.1 Installation on suction side 2.5.1.1 Recommended installations a a Ha Fig.4 Fig.2 Fig.3 Fig.2: The pump in suction placed above the tank(Ha = maximum 2.5 m water column) is equipped with a foot valve fitted at the suction end (F). Vertical suction. Fig.3: Long sized pipework (L) requires the installation of a damper which is to be placed as close as possible to the pump. L1 = Maximum 10 metres water column. Fig. 4: The pump "in suction" offset in relation to the tank (Height [Ha] see chapter 1.3), is equipped with a foot valve (F). 2.5.1.2 Installations to be avoided ^ Fig.5 Fig.6 Fig.7 Inclined suction pipe, risk of Suction piping long. Suction Accumulation of gas (goose un-priming (See Fig. 4, Chap. height too great. neck) and risk of unpriming. 2.5.1.1) 2.5.1.3 Special installation Degassing liquids. 1 : Max level 2: Min level V: Valves G: Vent R:degassing vessel Fig.8 Fig. 8: Setting up a degassing vessel (Chap. 2.6.3.) at the pump suction (one thus avoids frequent un priming). Connection between the pump and the inclined degassing vessel in order to facilitate degassing. reëi 2.5.2 Installations on delivery line 2.5.2.1 Recommended installation // c-/ fft( V1 •* -:--:":;Y-.:ti; Fig.10 Fig.9 Fig. 9: Long pipe lengths and delivery in a pressurized conduit (P): Install an injection pipe (E), a buffer tank (D) and a safety valve (C). Fig. 10: Long pipe lengths and delivery in a non-pressurized conduit: Install a nonreturn valve (B) or check valve (A) and a buffer tank (D). For short lengths of discharge pipe (L), the buffer tank (D) can be dispensed with although it increases the service life of the metering pump and of the installation. If the delivery pressure is less than 2 bars, an injection pipe or nonreturn valve should be used. 2.5.2.2 Installations to be avoided D / s. [ V \; f-'-. Fig.11 Fig.12 Fig. 13 Pulsation dampener (D) not very Pulsation dampener (D) inefficient. Siphoning. efficient, (pulsation dampener (D) (nonreturn valve installed before too far from the liquid end) pulsation dampener (D)). G2.4 2.6 - INSTALLATION OF ACCESSORIES Proper functioning of the pump depends on whether certain accessories available from DOSAPRO MILTON ROY are fitted or not. The salesman is at your disposal to determine the accessories which are best adapted to your plant. 2.6.1 Non return valve (F) Necessary when the pump is fitted above the suction point. Thus minimizing the risk of unpriming; it is fitted with a filter. 2.6.2 Filter It is very CAUTION when there is gravity feed; it avoids accumulation of solid particles in the valve assemblies and guarantees precision and pump life. 2.6.3 Safety valve (C) The safety valve is to be vertically installed just above the liquid end, after the damper and before any other accessory. The return line of the valve should be connected to the drainage tank or to the sump. The safety valve protects the metering pump, the piping and accessories in the event of accidental overpressure (e.g. shutting off of valve). This accessory contributes to safety for users by eliminating risks of the bursting or rupture of components under pressure. It is recommended that a safety valve should be fitted on all installations. 2.6.4 Damper (D) Compressible gas-reserve device; this dampens the flow and pressure pulsations caused naturally by the dosing pump. It is absolutely essential that the pulsation dampener be installed vertically on the discharge and/or suction piping of the dosing pump, as near as possible to the latter, before any other accessory and for it to be placed in the flow. For the volume and the pre-expansion of the dampener, see chapter 1.3. CAUTION: Dampener construction materials must be compatible with the liquid to be pumped and with the pumping pressure. 2.6.5 Non return valve (A) The non-retum valve is to be installed in line on the delivery piping. Its operation may be improved by installing a dampener located upwards on the line. 2.6.6 Injection nozzle (E) Fitted at the injection point, it acts as a non-return valve. It isolates the processed fluid from the main fluid (often water). 11 2.6.7 Insulation Valve (F) When the pump is not running, it is essential to insulate it from the pressure circuit with a manual or automatic valve, to prevent any return pressure in the liquid end, which could damage the pressure plate of the oil- actuated diaphragm. 2.7 - INSTALLATION CALCULATIONS 2.7.1 General Sizing of the plant suction line corresponds to the NPSH calculation (Net Positive Suction Head) and it aims to avoid any risk of cavitation. Very often when processing non viscous liquids (typically less than 50 cp), the NPSH calculation is needed to verify the following condition: W d1 with W- Liquid density. Pa = Suction pressure (bars absolute). Tv = Vapour pressure (in bars). Ha = Suction height (in m). (Ha is negative with the pump placed above the suction point; it is positive when gravity fed). L = Length of the piping (in m). Q = Max flowrate of the pump (in l/h). N = No of pump strokes (in strVmin). d = Inside diameter of the piping (in mm). 2.7.2 Example Calculation carried out to deliver a flow of 200 L/H. W 1 L 1 Pa 1 Q 560 Tv 0.025 N 144 Ha :1 d :12.5 10.2 1x144x560 This condition shows: (1-0.025)+ 1> 2 + 0.016 1 v ' 12.52 thus: 10.945 > 4.064 The condition is met and the pump will not give rise to cavitation. When the NPSH condition is not obtained, the installation conditions must be improved by making or envisaging the following modifications: - Place the pump under load: Ha increases - Place the pump near the tank : L decreases - Increase the diameter of the piping: d increases (the most effective solution) - Place an pulsation dampener at the suction (see chapter 1.3) Do not hesitate to consult your usual DMR representative for complete calculations. III OPERATION AND MAINTENANCE 3.1 - CHECKING BEFOR SWITCHING ON - Check that the pump is properly mounted on its base - Check the oil level. - Check that the pump is set at 0% - Check that all the isolating valves on the suction and discharge circuits are open. - Check that the pump is properly supplied with liquid. - If hot cold machine parts lead to a potential danger, check that the these parts are protected against accidental constact at site. 3.2 - STARTUP - Tun the pump ON - Place the vernier on the 50% position, for 10 minutes. - Untighten by around 1/4 turn, drain plug (B) located on the liquid end (Fig. 19) and (Fig. 20). Thus, the air trapped in the suction piping and the pump head can escape via the drain. Wait until the liquid comes up to the evacuation level of this drain. Let it flow for a few seconds in order to degas it completely, then retighten the drain plug. 3.3 - ROUTINE CHECKS Periodically, it is necessary to check: - The level and cleanliness of the oil. - Leaks or unusual noises. 3.4 - PREVENTIVE MAINTENANCE Before any servicing operation on the pump, it is necessary to turn the motor power supply OFF. 3.4.1 Servicing-intervention principles for preventive maintenance*: Intervention Fréquence ** - Renewal of check-valve boxes (Chap. 3.7.1. to Chap. 3.7.3). 8000 h - Renewal of diaphragm(s) (Chap. 3.7.4 and Chap. 3.7.5). 8000 h - Renewal of safety valve assembly (Chap. 3.8.1 and Chap. 3.8.2). 8000 h - Renewal of worm bearings (Chap. 3.8.10). 20000 h - Renewal of worm and wheel (Chap. 3.8.11). 20000 h - Renewal of sleeve liner O-rings (Chap. 3.8.3). 16000 h * See list of wear parts for the ordering of the various parts. ** Approximate no of hours when operating under max performance and normal conditions of use. 3.5 - ORDERING OF SPARE PARTS To simplify your order and ensure the best delivery times of spare parts, we recommend giving our services the correct code of your pump and its DOSAPRO MILTON ROY serial no. This information is shown on the Nameplate fixed on the side of the pump. ( Mi DOSAPRO PONT ST PIERRE ^ Pump code —-—~__^^ 'MILTON ROY Z7360 FRANCE TYPE A112F3 H21 1 1 Dmax lll/hll MGPHIII/h I Pmax Nborll IIPSI llutafl DOSAPRO MILTON ROY —^^^ Date 1 serial no N* 92.01.100A.01.01 1 Item 1 ^N'serie ' , 3.6 - PRODUCT IDENTIFICATION Our product identification tells us precisely the kind of equipment involved and gives us details on each item comprising it. Code : | A | 112 | F | 3 | H I 21 Zone : 1 2 3 4 5 6 The makeup of a standard mRoy pump is divided up into 6 zones: Zone 1 : Type of pump (A: mRoy A; B: mRoy B) Zone 2 : Stroke rate of the pump in spm Zone 3 : Motor power Zone 4 : Piston diameter Zone 5 : Type of liquid end Zone 6 : Service pressure and, where applicable, a seventh zone which will be "DX" for a duplex pump. 3.7 - SERVICING AND MAINTENANCE OF LIQUID END Before carrying out any servicing operation on the metering unit or pipes, take the necessary steps to ensure that the harmful liquid they contain cannot escape or come irto contact with A personnel. Suitable protective equipment must be provided. Check that there is no pressure before proceeding with dismantling. 3.7.1 Renewal of check-valve boxes - General Before any other servicing operation on the check-valve boxes place the vernier on the 0% position, check that the isolating valves are closed, then disconnect the piping. When putting the check-valve boxes back in place, systematically replace all the seals. 3.7.2 Renewal of seals / balls / valves _ metallic version Fig.14 Discharge check väve assembly Fig. 15 Suction check valve assembly Suction check valve assembly Discharge check valve assembly Disassembly Disassembly - Unscrew counternut (209) by one-quarter - Unscrew cap (013) of the check-valve of a turn, box by one-quarter of a turn - Completely unscrew the cartridge of - Completely unscrew the cartridge of check-valve box (021A), check-valve box (021B). - Remove circlips (080) and balls (437A) - Completely unscrew cap (013) from the (437) check-valve box. - Clean the box completely. - Remove spring (080A), ball guide (003), balls (437), seat (024). - Clean the check-valve box completely. Reassembly Reassembly - Fit ball (437), then ball (437A) and - Fit O-ring (438) on seat (024) circlips (080) - Fit balls (437), seat (024), ball guide - Position spiral seal (408) in the sink of (003), spring (080A). counternut (209) - Fit O-ring (438A) on cap (013) - Fit O-ring (438B) against spiral seal (408). - Hand-tighten cap (013) on the check- - Screw the box cartridge in the liquid end valve box. so as to align it with the piping. - Fit O-ring (438B), screw the check-valve - Screw on counternut (209).* box on the liquid end. - Tighten the cap on the check-valve box* - Connect the piping making sure of perfect watertightness. Note: O-rings (438B) and spiral seals (408) of the check-valve bo>es must be replaced with new seals each time they are removed. * For information concerning tightening torque as well as which spanners to use, see Chapter 3.7.7.* 3.7.3 Renewal of check-valve boxes _ plastic version Fig. 18 _. . „ Suction check valve assembly Fig.16 Plastic liquid end Disassembly - Unscrew both nuts (435) located on pressure plate (004). - Remove pressure plate (004) with both washers (434) - Remove the Discharge check valve assembly. - Pull on strap bolt (032) to release the suction check valve assembly - Remove box cap (013), spring (080), ball guide (003), seal (438), ball (407). Reassembly - Fit spring (080), ball guide (003) and seal (438) on box cap (013), and mount ball (407) on its seat (A). - Fit seals (438B) and (438A) on the check-valve boxes. - Fit the check-valve boxes onthe liquid end. - Fit the pressure plate on strap bolt (032) with two washers (434). - Hand-tighten screws (435) by pressing on the pressure plate. - Orient the suction check valve assembly, then tighten two nuts (435).* Connect the piping making sure of perfect watertightness. Note: The items comprising the suction check valve assembly cannot be taken apart; this is also the case for ball (B) and seat (A) of the Discharge check väve assembly. * For information concerning tightening torque as well as which spanners to use, see Chapter 3.7.7. 3.7.4 Diaphragm Renewal Before carrying out any operations, place the vernier on the 0% position, check that all the isolating valves are closed, then disconnect the piping. Disassembly Reassembly - Drain the pump (Chapter 3.9.2). - Mount contour plate (298B). It is CAUTION for - Lay the pump on the side opposite one of holes in the contour plate to be placed at the liquid end the highest point (see detail C). - Remove suction check valve assembly (A) (Chapter 3.7.2 or CAUTION: For metallic versions, contour plate (298B) on Chap. 3.7.3) the mechanical side is made of steel and contour plate - Remove screws (405A) (Fig. 19) or (298) on liquid end side is made of stainless steel. (405) (Fig. 20) from the liquid end. - Fit diaphragm (298A). - Remove diaphragm (298A) and - Fit contour plate (298). It is CAUTION for one pressure plates (298), (298B) using a of the holes in the contour plate to be placed at pointed object. the highest point (see C detail) - Clean all the parts. - Fit the liquid end and tighten screws (405A) or (405) in star-pattern (Fig. 22).* - Refit the suction check valve assembly (Chap. 3.7.2 or Chap. 3.7.3). - Fill up with oil (Chap. 3.9.2). - Put into serviœ (Chap. 3.1, Chap. 3.2) 405 Fig. 19 Fig.20 Metallic version Plastic version In order to prime the pump, it is necessary to purge the liquid end (to release air) by opening A purge nozzle (B). For toxic liquids, it is recommended to collect this fluid to safe drain point during this operation. * For information concerning tightening torque as well as which spanners to use, see Chap. 3.7.7. 3.7.5 Renewal of double diaphragm, "C" type Before carrying out any operation, place the vernier on the 0% position, check that all the isolating valves are closed, then disconnect the piping. Disassembly - Drain the pump (Chap. 3.9.2). - Untighten ring pipe fitting (432A) by 1/2 turn. - Lay the pump on the side opposite the liquid end - Remove suction check valve assembly (A) Chap. 3.7.2 or Chap. 3.7.3) - Unscrew the tightening screws from liquid end (405A), beginning with those in support lug (050A). - Remove the two diaphragms (298) and the 2 contour plates (098). - Clean all of the parts. Reassembly - Fit contour plate (098) on the mechanical side. - Centre diaphragm (298) on contour plate (098). - Fit double-diaphragm body (050) on diaphragm (298). - Centre second diaphragm (298) on double diaphragm body (050). - Centre second pressure plate (098) on double diaphragm body assembly (050) - Fit the liquid end and hand-tighten 2 tightening screws (405A) diametrically opposite. - Fit support lug (050A) and its detection. - Connect the detection pipe of double-diaphragm body (050) to ring connection (432A). - Hand-tighten the connection and tighten by 1/4 to 1/2 turn. - Pre-screw in star-pattern (Fig. 22) tightening screws (405A) of the liquid end (torque: 2 Nm) - Tighten tightening screws (405A)of the liquid end in star-pattern. * - Refit the suction check valve assembly (Chap. 3.7.2 or Chap. 3.7.3). - Fill up with oil (See Chapter 3.9.2). - Put into service (Chap. 3.1, Chap. 3,2) - Degas the double diaphragm (Chap. 3.7.6) oso 298 Fig.21 Type "C" double diaphragm, metallic version For information concerning tightening torque as well as which spanners to use, see Chapter 3.7.7. 3.7.6 Degassing of double-diaphragm body, "C"type - Remove the detection (A) - Remove the retaining ring (092) - Remove the ball (437) - Put a little oil in the body of nonreturn valve (432). èr-^^® - Set the adjustment knob on 10%, then start the pump up - Allow to run for 10 minutes - Fit the ball (437) - Allow to run for 10 minutes - Fit the retaining ring (092) - Fit the detection (A) on the nonreturn valve (432) Fig.21A B detail of Fig. 21 If the degassing can not be done by the above procedure there some possibility to perform this operation with a syringe. This syringe is available on request at the Spare rart Departement Degassing with syringe - Fit the syringe (1+2) on the nonreturn valve (432) - Inject and pump 4 or 5 time slowly the degassing liquid - Remove the syringe and fit the ball (437) and the retaining ring (092) - Fit the syringe (1) witout his plunger - Put the pump into service and adjust the capacity until 100% - Allow to run for 10 minutes - Remove the syringe (1) with the degassing liquid - Fit the detection (A) on the nonreturn valve (432) 3.7.7 Tightening torque table Tiqhteninq torque (Nm) Spanner used m Roy A m Roy B m Rov A m Rov B Screw /Nut HP BP HP BP HP&BP HP BP H head screw of liquid end for metallic versions 20 20 40 60 13 16 18 H head screw (l/3/5/7/6/8)of liquid end for plastic versions 15 15 15 15 13 16 18 H head screw (2/4) of liquid end for plastic versions 15 15 15 15 13 16 18 Check-valve box nut, metallic version 50 50 32 41 Check-valve box, metallic version 50 50 32 38 Strap bolt nut for liquid ends, plastic version 10 13 H head screw of lantern 7 8 He head-screw of relief valve 3/16" 3/16" He head-screw of connectinq rod shaft 3 3 He head-screw pointed end of connectinq rod shaft / 2 Nut for He screw of connectinq rod shaft / 7 He screw (402) of duplex housing (Flq. 27) / 10 Fig.22 Tightening in star-pattern-shape 3.8 - SERVICING AND MAINTENANCE OF THE MECHANICAL ASSEMBLY 3.8.1 Relief valve CAUTION: Set in the plant, it must in no case be put out of adjustment, since it protects your pump. 3.8.2 Renewal of relief valve (Fig. 23) Disassembly - Place the vernier on the 0% position - Clean the threaded hole of screw (023) to make it appear - Note dimension H - Completely unscrew and remove screw (023) with the hexagonal spanner (Chap. 3.7.7). - Remove spring (080) and its valve (212A). Reassembly - Cause new valve (212A) to adhere to spring (080) using a little grease. - Lower the assembly into its housing. - Screw in tightening screw (023) to the H measurement with the hexagonal spanner (Chap. 3.7.7). -023 Fig.23 Disassembly of the relief valve 3.8.3 Renewal of adjustment liner 0-rings(Fig. 24, Fig. 25, Fig. 26) Disassembly - Place the vernier on the 0% position - Drain the pump (Chap. 3.9.2). - Remove the lantern (Chap. 3.8.8) - Remove circlips (434) (Fig. 25). - Completely unscrew adjustment knob (255). - Unscrew screw (256). - Pull liner (012A) of housing toward you. (Fig. 26) - Remove 3 O-rings (438B) located on liner (012A) (Fig. 24). - Remove sleeve (E) from drive pin (214A) (Fig. 26) - Clean the housing as well as the liner / sleeve assembly Reassembly - Refit the 3 O-rings (438B) using the tool (011) (Fig. 24): - Reference 0110031071 for the mRoy A. -Reference 0110032071 for the mRoy B. - Coat the 3 O-rings (438B) with tallow. - Fit sleeve (E) on drive pin (214A) (Fig. 26). - Insert liner (012A) very slowly in the housing, turning it whilst holding sleeve (E) in the axis of liner (012A). - Screw in screw (256). - Screw in adjustment knob (255) (Fig. 25) - Fit circlips (434). - Fit lantern (Chap. 3.8.8) - Fill up with oil (see Chap. 3.9.2). -438B Fig.24 Liner / sleeve Adjustment knob 3.8.4 Renewal of eccentric shaft seals (Fig. 26). For disassembly and reassembly of the eccentric shaft, the pump adjustment knob must be opposite you. Disassembly - Place the vernier on the 0% position - Drain the pump (Chap. 3.9.2). - Remove the 2 circlips (434A) from eccentric shaft (068) - Drive out eccentric shaft (068) to the right to release seal (438A). - Remove seal (438A) - Drive out eccentric shaft (068) to the left to release seal (438A) - Remove the other seal (438A) Reassembly Before reassembly, degrease all parts - Fit an O-ring (438A) on eccentric shaft (068) - Put glue (loctite 638) on the end of eccentric shaft (068) until it exceeds the other side of the housing by one centimetre. - Fit the other O-ring (438A) on eccentric shaft (068); put glue (loctite 638) on the end of eccentric shaft (068) - Position eccentric shaft (068) in the centre of the housing (see Fig. 26) - Fit circlips (434A) on each end of eccentric shaft (068) - Allow the glue to harden for 30 minutes - Fill up with oil (see chap. 3.9.2). Fig.27 Duplex pump 3.8.5 Renewal of connecting rod and shaft for mRoy A, simplex and duplex (Fig. 26, Fig. 28). Disassembly - Place the vernier on the 0% position - Drain the pump (Chap. 3.9.2). - Remove the lantern (Chap. 3.8.8) - Remove eccentric shaft (068) (Chap. 3.8.4) - Unscrew screws (435) and remove drive pin (214A) (Fig. 26)* - Remove plunger assembly (012) / connecting rod (214) / wheel (052) from the housing, by lifting wheel (052) - Drive out connecting rod shaft (011) - Clean the housing and the parts removed Reassembly - Refit piston (012) / connecting rod shaft (011) / connecting rod (214) assembly by gluing the end of connecting rod shaft (011) with loctite glue 556 and being careful to position the lubricating groove (detail: A) of connecting rod (214) opposite the threaded holes of the piston (Fig. 28) - Insert piston / connecting rod assembly in housing - Fit wheel (052) with connecting rod (214) (Fig.26) - Fit concentric shaft (068) (Chap. 3.8.4) - Fit drive pin (214A), then screw in and glue (loctite 221) the two screws (435) - Refit the lantern (Chap. 3.8.8). - Fill up with oil (Chap. 3.9.2). - Put into service (Chap. 3.1, Chap. 3.2) 012 011 Fig.28 Piston / connecting rod assembly * Fur information concerning which spanners are to be used, see Chapter 3.7.7. 3.8.6 Renewal of connecting rod and shaft for mRoy B, simplex (Fig. 26, Fig. 28). Disassembly Reassembly - Drain the pump (Chap. 3.9.2). - Refit piston (012) / connecting rod shaft (011) / - Remove the lantern (Chap. 3.8.8) connecting rod (214) assembly, being careful to - Unscrew nut (435F) and screws position the lubricating groove (detail: A) of (435), (435E) Fig. 26)*. connecting rod (214) opposite the threaded holes of - Remove eccentric shaft (068) the piston. (Fig. 28) (Chap. 3.8.4) - Screw in and glue (loctite 566), locking screw (435E) - Remove drive pin (214A) on the side where the groove of connecting rod shaft - Remove plunger assembly (012) / (011) is located connecting rod (214)/wheel (052) - Insert piston / connecting rod assembly in housing from the housing, by lifting wheel - Fit wheel (052) with connecting rod (214) (Fig.26) (052) - Fit eccentric shaft (068) (Chap. 3.8.4) - Drive out connecting rod shaft (011) - Fit drive pin (214A), then screw in and glue (Fig. 28) (loctite 221) screw (435) and nut (435F) - Clean the housing and the parts - Refit lantern (chap. 3.8.8) removed. - Allow glue to harden 30 minutes - Fill up with oil (Chap. 3.9.2). - Carry out startup and operating procedures (Chap. 3.1, Chap. 3.2). 3.8.7 Renewal of connecting rod and shaft for mRoy B, duplex (Fig. 26, Fig. 27, Fig. 28). Disassembly Reassembly - Drain the pump (Chap. 3.9.2). - Place plunger (012) in the housing tapped holes up - Remove the lantern (Chap. 3.8.8) ward - Unscrew 2 screws (402) (Fig. 27) - Assemble connecting rods (214) with wheel (052) - Unscrew nut (435F) and screws being careful to position the lubricating groove (435), (435E) (Fig. 26). (detail: A) of connecting rod (214) downwards - Remove drive pin (214A) (Fig. 26) (Fig. 28) - Drive out the 2 shafts of connecting - Place excentric wheel (052) / connecting rod (214) rod shaft (011) by the threaded holes assembly in the housing of screws (402) - Fit eccentric shaft (068) (Chap. 3.8.4) - Remove eccentric shaft (068) - Fit the 2 shafts of connecting rod shaft (011) by the (chap. 3.8.4) threaded holes of screws (402) (Fig. 27) - Remove excentric wheel (052) / - Screw in and glue (loctite 566) locking screws connecting rod (214) assembly in the (435E) of the side where the groove of connecting housing rod shaft (011) is located - Remove plunger assembly (012) / - Fit drive pin (214A) then screw in and glue connecting rod (214)/wheel (052) (loctite 221) screw (435) and nut (435F) (Fig. 26)* - Remove plunger (012) off the housing - Refit the lantern (Chap. 3.8.8). - Clean the housing and the parts - Screw in and glue screws (402) with loctite glue 221 removed. (Fig. 27). - Allow the glue to harden 30 minutes. - Fill up with oil (Chap. 3.9.2). - Carry out startup and operating procedures (Chap. 3.1, Chap. 3.2). * For information concerning which spanners are to be used, see Chapter 3.7.7. 3.8.8 Disassembly of the lantern (Fig. 26, Fig. 29) Disassembly * - Disconnect the power supply cables from the motor - Unscrew 4 screws (435A), (434C) from lantern (072) and turn while pulling up the lantern vertically with the motor Reassembly - Put sealing compound on side B (Fig. 26) - Fit lantern (072) being careful not to bump drive pin (214A) with the worm shaft - Screw in screws (435A) (434C) - Connect the motor power supply cables 3.8.9 Renewal of the worm shaft (Fig. 29). Disassembly - Remove the lantern (Chap. 3.8.8) - Unscrew screw (435B) from coupling (052D). - Remove the 2 washers (280) and washer (219) being careful not to separate them. - Remove the worm. Reassembly - Fit washers (280) / washer (219) - Fit coupling (052D) on the screw whilst adhering to measurement H (H = 5 mm for the mRoy B, or fit coupling (052D) in mechanical thrust block for the mRoy A) - Screw in screw (435B) - Fit the lantern (Chap. 3.8.8) - Mount the motor 3.8.10 Renewal of worm bearing. Same procedure as for the Renewal of the worm shaft (Chap. 3.8.9), but by replacing bearings (409A) and (409). 3.8.11 Renewal of the wheel / worm. Same procedure as for Renewal of the connecting rod and shaft (Chap. 3.8.5 to Chap. 3.8.7), but without removing connecting rod shaft (011) (Fig. 28) for the mRoy A 435D/434B/435C 072 Fig.29 Motor lantern For information concerning which spanners are to be used, see chapter 3.7.7. G3.6 3.9 - LUBRICATION The oil level must be checked every month. Fill the housing up to the middle of the level indicator. Use the oil supplied with the pump or an equivalent oil (see table below). The oil must be changed every 2500 hours of operation or every six months. The pump must be placed in a zone where the ambient temperature is between -5°C and 50°C. 3.9.1 Table of oils ISO.VG 150 oil. Pure mineral oil QUANTITY: mROYA mROYB Simplex 1 L 3L Duplex 2L 4L TABLE OF CHARACTERISTICS Viscosity to 40°C 151 Cst Viscosity to 100° 15Cst Viscosity Index 100 ISOVG 150 Density to 15° C 0.897 k/l Flash-point 244°C Pour-point -12°C EQUIVALENCY TABLE Make Type COFRAN MECANEP 150 B.P. GRXP150 CASTROL ALPHA SP 150 ELF REDUCTELFSP150 FINA GIRAN 150 IGOL DYNAM SP 150 MOBIL OIL MOBILGEAR 629 SHELL OMALA 150 TOTAL CARTER EP 150 ESSO SPARTAN EP 150 3.9.2 Draining the pump To drain the pump, unscrew the filler plug and the drain plug completely (Fig. 1 A). To fill up with oil, screw the drain plug back on with Teflon strip to ensure proper impermeability, and see Chapter 2.2.2. Note: For information concerning how much oil to use, see the table in Chapter 3.9.1. IV FAULT LOCATION PROCEDURES If, during the initial startup, the pump does not work properly, check the pump installation (SECTION: INSTALLATION II). 4.1 - THE PUMP DOES NOT DELIVER: CAUSE REMEDY A - Motor stopped A- - The thermal relay has been overloaded and has tripped. - Reset the thermal relay (Check the reason for the overload) B - No more product to pump. B - Check the product level C - Piping clogged up. C - Unclog the piping D - Filter blocked. D - Clean the filter E - Suction piping valve closed. E - Open the valve F - Diaphragm pierced. F - Change the diaphragm 4.2 -THE PUMP DOES NOT DELIVER AT THE SPECIFIED FLOWRATE: CAUSE REMEDY A - The pump flow is improperly adjusted A - Set the vernier on the right percentage B - Poor impermeability in the suction piping B - Change the piping seals - Pumped liquid level too low (air intake) C - suction piping dirty C - Clean the piping D - Filter dirty D - Clean the filter E - Check-valve box seat dirty or worn E - Clean or change the check-valve box F - Operating-pressure too high F - Use the pump at the pressure specified on the data-plate Connecting diagram for chemical dosing pump unit. 012 Dosing line not A I supply. The distances between the dosing pump and feedwater line max. 4 mtrs. Fitting Dosing line ø12 x 1.5mm. Standless steel or (steel). J A I supply. Shutdown valve 3/8"BSP. 4 pes of fittings 3/8'BSP / ø12 as sketch. t i \if!./ -txX- y" "s Controlvalve boiler feed water i I Oil fired boiler Hotwell Feed water pump AALBORG ggiaiaaagggngffns^^^^^M INDUSTRIES ^migg^g^^gnimi^^mii^^mi^^^m Table of contents Salinity alarm equipment Conductive electrode, ERL 16 1 Conductivity limit switch, LRS l-5b 1 Language UK Page 1/1 AALBORG CONDUCTIVITY ELECTRODE, ERL 16 OM8620#02.0 INDUSTRIES Conductivity electrode, ERL 16 1 Description The conductivity electrode, type ERL 16 is used for monitoring the conductivity of the feed/boiler water and can be installed in the condensate system, feed water system, or directly into the boiler. The conductivity of the water produces a proportional current when the measuring surface and voltage supply remain constant. The conductivity electrode is provided with an electrode rod completely insulated by a PTFE tubing with the exception of the measuring surface. A pressure-tight sealing between the electrode rod and body is ensured by means of a Teflon tube. An illustration of the conductivity electrode is shown in Figure 1 together with an installation example. The electrode can be used in connection with a salinity monitoring system or a continuous blow down system. When used in a salinity monitoring system the electrode is connected to a conductivity limit switch type LRS l-5b or a salinity controller type LRR l-5b, which continuously monitors the conductivity of the water and give alarm if the set limit value is exceeded. When used in a continuous blow down system the electrode is connected to a salinity controller type LRR l-5b and a continuous blow down valve type BAE. The system provides fully automatic control of the blow down wastage. Automatic closing of the blow down line is ensured during boiler shut down. Illustration of the conductivity electrode, type ERL 16 Pg 11 -*• Flow direction 3/4" BSP Measuring pot Conductivity electrode, ERL 16 - Electrode tip Figure 1 erll6a.cdr Language UK Page 1/2 AALBORG CONDUCTIVITY ELECTRODE, ERL 16 OM8620#02.0 INDUSTRIES 1.1 Installation The conductivity electrode may be installed vertically, horizontally, or radial inclined. However, it is recommended that the electrode is installed in a measuring pot as illustrated in Figure 1. The electrode tip must be constantly submerged by approximately 100 mm. Wiring The electrical connection is carried out by means of a four-pole connector with screw terminals, cable strain relief, and cable gland Pg 11. The maximum permissible ambient temperature at terminal box is 60°C. Figure 2 illustrates the wiring diagram. Wiring diagram Terminals rr\ rr\ rt\ rt\ Measuring tip Figure 2 erll6b.cdr 1.2 Maintenance The electrode does not require any particular maintenance. It is, however, recommended to check the electrode tip every six months. Cleaning is possible by carefully grinding the measuring surface. Language UK Page 2/2 AALBORG CONDUCTIVITY LIMIT SWITCH, LRS 1-5B OM8210#30.0 INDUSTRIES Conductivity limit switch, LRS 1-5b 1 Description The conductivity limit switch, type LRS l-5b is used to amplify and transform signals from a conductivity electrode, type ERL 16 or LRG 16-4, for continuous monitoring of the conductivity in feed and boiler water. An illustration of the front panel can be seen in Figure 1. The conductivity limit switch is provided with two LEDs. The green LED (lb) indicates a < limit value and the red LED (la) indicates a > limit value. By means of the switch (3) the measuring range can be selected between 0-10000 |o,S/cm and 0-1000 |uS/cm. The limit value is continuously adjustable on the switch point adjuster (2) within the ranges of 400-10000 uS/cm or 40-1000 uS/cm. The switching hysteresis of the limit switch is 1%. The temperature influences can be compensated on the adjuster (4) up to max 250°C. Basic adjustment applies to 25°C. Illustration of the conductivity limit switch LRS l-5b 1a. Red LED 1b. Green LED 2. Switch point adjuster 3. Measuring range switch 4. Adjuster for temperature compensation 5. Screw to fasten the cover base Figure 1 lrsl 5bl.cdr 1.1 Wiring The wiring should be carried out in accordance with the wiring diagram shown in Figure 2. The mains voltage is indicated on the name plate. The maximum permissible ambient temperature for the limit switch is 55°C. For wiring to the electrode screened cable is required, and the length and properties of the cable stated in Table 1 must be observed. The screen should only be connected to terminal 12 of the LRS l-5b limit switch, and not at the electrode. The screen must not have contact with any metal part of the plant. Language UK Page 1/3 AALBORG CONDUCTIVITY LIMIT SWITCH, LRS 1-5B OM8210#30.0 INDUSTRIES Wiring diagram LRS 1-5b T 10 11 12 Alarm L N Mains m/ti/t\ß Conductivity electrode, ERL16orLRG16-4 Figure 2 lrsl_5b2.cdr LRS 1-5b Nominal measuring range 400 -10000 uS/cm 40 - 1000 uS/cm Linear in the range 0 -10000 uS/cm 0-1000nS/cm Cable length - 50 m Cable capacity <100nF <10nF Line resistance per conductor <30Q - Table 1 1.2 Commissioning When the conductivity limit switch is commissioned or re-calibrated carry out the following work steps: Step A: Take sample of the liquid that should be monitored via a sample cooler and determine the conductivity with a conductivity meter. Step B: Select the measuring range by means of the switch (3) provided on the front panel, see Figure 1. The possible selection ranges are 0-10000 uS/cm or 0- 1000 u.S/cm. Step C: Turn the adjuster (4) onto scale division "7". Step D: Adjust the switch point adjuster (2) to the conductivity level found. Step E: When reaching the service temperature of the boiler, turn the adjuster (4) slowly to the left until the red LED (la) extinguishes and the green LED (lb) lights up. The temperature is thus compensated. Language UK Page 2/3 AALBORG CONDUCTIVITY LIMIT SWITCH, LRS 1-5B OM8210#30.0 INDUSTRIES Note: Gases dissolved in water, such as carbon dioxide or ammonia, increase the conductivity and simulate a higher salt content (TDS) of the boiler water. 1.3 Performance test The conductivity limit switch can be tested performing the following work procedures: Step A: Short-circuit terminals 3 and earth of the electrode. The red LED (la, Figure 1) on the conductivity limit switch should light up independently of the position of the switch point adjuster (2). StepB: Short-circuit terminals 9 and 12 of the conductivity limit switch. The red LED (la) should light up independently of the position of the switch point adjuster (2). Step C: Unplug the terminal box of the electrode. The green LED (lb) should light up independently of the position of the switch point adjuster (2). 1.4 Maintenance Deposits on the electrode tip produce an error in the measurement. If the electrode is used in fluids prone to form deposits, it is recommended to clean the electrode tip every six months. 1.5 Faultfinding Performance test error If the performance test is negative check for the correct wiring of the conductivity limit switch and electrode according to the wiring diagram shown in Figure 2. Record error If the conductivity limit switch does not record the adjusted conductivity limit value then re-calibrate it. Clean the measuring surface of the conductivity electrode. Language UK Page 3/3 AALBORG m-.njtiJtsmrasns^^^^^M INDUSTRIES ^HHBHIBHIIIHIIHHII^^H^^^^^^^I Table of contents Oil detection equipment General 1 Sensor installation 2 Control unit installation 3 Applications 4 Spares and fault finding 5 Language UK Page 1/1 AALBORG OIL DETECTION EQUIPMENT OM9410#01.0 INDUSTRIES Oil detection equipment 1 General This chapter contains installation, operation, and maintenance instructions for the ultrasonic interface detection system, type 402 SD, using control unit type MCU200. Each Mobrey ultrasonic control system requires a sensor to suit the specific application, plus a control unit. These instructions cover the control units in the MCU200 series. Sensor installation 2.1 General description The ultrasonic sensor contains two piezoelectric crystals. A high frequency signal (3.7 MHz) generated by the control unit is transmitted to one piezoelectric crystal by coaxial cable. This crystal converts the electrical signal into an ultrasonic oscillation. The sensor design allows the ultrasonic oscillation to pass from the transmitter crystal to the receiver piezoelectric crystal. The sensors of type 402 are "gap" type sensors, where the two piezoelectric crystals are separated by a gap. When the gap is in liquid the signal reaches the receiver, because of the low ultrasonic attenuation of the liquid. When the gap is filled with air, no ultrasonic signal can pass from transmitter to receiver. See Figure 1. Working principle of the oil detection equipment Sensor Cap Wet Control u- . Unit *'ReU)' The ultrasonic beam teaches receiver crystal ^dual k co-axial cable Transmitter Receiver Crystal Crystal Control ^ Relay Unit 7 The ultrasonic beam will not reach receiver crystal Figure 1 mobrey01.tif Language UK Page 1/10 AALBORG OIL DETECTION EQUIPMENT OM9410#01.0 INDUSTRIES When the gap is filled with liquid, the piezoelectric receiver crystal converts the ultrasonic wave into an electrical signal, which is transmitted back to the control unit using a second coaxial cable. Usually the two coaxial cables to the sensor are in one overall sheath. The control unit circuitry is a feedback amplifier, which oscillates when the sensor is wet, and is quiescent for the sensor dry. The "oscillating" or "non-oscillating" sensor states dictate the output relay states of the MCU200. For interface detection the sensor "oscillates" in a clear liquid, and is "non- oscillating" at the interface. 2.2 Switching levels and orientation The gap sensors should normally be mounted with the gap vertical, to avoid build up of solids on the sensor faces on either side of the gap. In this condition the switching level will be halfway up the face: if the sensor is mounted from the side of the tank this is normally on the centreline of the cylindrical body. Occasionally such sensors are mounted with the sensor faces horizontal, either to avoid air bubbles passing through the gap or for convenience of installation. In this case the switching level will be at the sensor face at the top of the gap. 2.3 Installation of sensor The sensor must be handled with care - it is a measuring instrument. Before installation, check that sensor, cable and control unit have not been damaged in transit. Drill and tap a hole with a suitable thread. It is advisable to use a boss or similar on thin walls. The sensor has a tapered thread. Use Ptfe tape or similar to seal the thread. Mark the sensor hexagon to identify the gap orientation of the sensor, if appropriate. Take care not to damage the sensor cable during tightening. The cable should be laid on cable trays and separated from any high voltage or mains cables. The normal cable termination is a plastic gland (to fit the MCU200 control box drilled hole) and crimped terminal pins to suit the MCU200 terminals. 2.4 Extensions cables Extension cables up to 50 metres long can be fitted to most Mobrey ultrasonic sensors in the factory to special order but a better site arrangement is to have a separate extension cable. Table 1 shows a list of suitable extension cables. Suitable extension cables SO m 50 -100 m Above 100 m RG174 URM76 Consult Aalborg Industries RG178 RG58 Table 1 When double coaxial cable needs to be extended, two sets of coaxial plugs and sockets will be needed, one set for transmit and one receive. Care must be taken that the connectors are not connected to earth or shorted together in any way, to prevent cross-talk or pick-up. The coaxial connections must be made in a waterproof junction box. Terminal blocks should not be used. Language UK Page 2/10 ••••••• AALBORG OIL DETECTION EQUIPMENT OM9410#01.0 INDUSTRIES The extension cable needs to be of 50 Ohm characteristic impedance. Suitable dual coaxial extension cables can be purchased from Aalborg Industries. For extensions over 50 metres it is recommended two runs of single coaxial low loss cable is used, with the transmit and return cable runs separated by 0.15 metres to minimise cross talk. If several sensor cables are being run together then all the transmit cables (those connected to E2) should be grouped together and all receive cables (those connected to IE) grouped together maintaining the separation specified above. Two cables are required per sensor. The RG178 should be used where the cable itself is subject to temperatures exceeding 74°C. Control unit installation 3.1 Mechanical The control unit is supplied with three holes drilled in the bottom (longer) side of the box. Two glands are supplied for the power input cable and relay output cable. The sensor is normally supplied fitted with a suitable gland on the cable. Two further holes can be drilled in the bottom side of the box should these be needed: it is recommended that the circuit board is removed whilst drilling extra gland holes. Figure 2 shows the dimensions of the MCU200 housing box. MCU200 Housing dimensions Mounting Holes Figure 2 mobrey04.tif All cable connections are made to the terminal blocks along the bottom edge of the pcb, see Figure 3. Release the terminal screw before inserting the wire. Language UK Page 3/10 AALBORG OIL DETECTION EQUIPMENT OM9410#01.0 INDUSTRIES MCU201 PC board Output Logic Switches • LED Indicators Cain Controls ILLI H I II I is 'mi Figure 3 mobrey05.tif 3.2 External connections 3.2.1 AC mains AC mains is connected between the "N" terminal for neutral and one of the "115V" or "230V" terminals depending on the voltage supply available - BEWARE - the terminal not connected externally will be "live" once the transformer is powered via the other terminals. 3.2.2 Mains earth Mains earth should be connected to the terminal marked "E". This provides an earth contact for the pcb mounting pints. 3.2.3 The relay The relay output connections are labelled: • NC - Normally closed (relay de-energised) • C - Common • NO - Normally open (relay de-energised) There are also two sets of contacts for DPCO relay, labelled 1 & 2. 3.2.4 The sensor The sensor connections are labelled "1", "E" for the receiver crystal and "2", "E" for the coax cable to the transmitter crystal. The screens of these coax cables are connected to the terminals marked "E". Language UK Page 4/10 AALBORG OIL DETECTION EQUIPMENT OM9410#01.0 INDUSTRIES 3.2.5 The auxiliary input The auxiliary input is a terminal which can be connected to a "push to reset" button to achieve a latching alarm, or to another Mobrey Control unit, to give a pump control from the MCU200 unit relay output. If a short circuit is connected between terminals 3 & 4, the MCU200 relay, once de-energised, is held de-energised. Even if the sensor attached to the MCU200 changes state, to that which should energise the output relay, this relay will not energise until the link between terminals 3 & 4 is broken in the circuit external to the MCU200. 3.3 Switch settings in MCU200 series 3.3.1 Gain switch and potentiometer See section 4. 3.3.2 Frequency selection This slide switch is labelled "FREQ" and is located between the sensor terminal block E2, and the Aux. input terminals. This selects the operating frequency of the MCU200 oscillator, which for the present installation must be set to 3.7 MHz (switch in the "up" position). The setting required is dictated by the sensor type connected to the control unit. 3.3.3 Cable check option selection This slide switch is located directly above the sensor terminal block E2. It is labelled "Cable Check" and the ex factory setting is "OUT" with the slide switch to the right. By sliding this switch to the left, the cable check circuitry is brought into action. This circuitry monitors the continuity of the screens of the two coaxial cables attached to the sensors: normally these are linked at the sensor to the metal body of the fitting (or to each other in the case of non metallic sensors). If this continuity is broken, the "FAULT" LED" will illuminate giving an indication that the sensor cable is damaged, and the MCU200 will give the "ALARM" output relay state (see Figure 4). 3.3.4 Relay output and LED logic selection The bank of six slide switches towards the top of the pcb sets the relay output state logic relative to the sensor state, associated time delays and the LEDs. These are slide switches, best adjusted with a pencil, and the ex factory wetting is with all switches to the right. Each switch is colour coded as shown in Figure 4, and the PC board labels give brief function information. Language UK Page 5/10 AALBORG OIL DETECTION EQUIPMENT OM9410#01.0 INDUSTRIES Relay output and LED logic switch Colour Code No. / Brown 1 30s Red 2 Orange 3 \ E = Red Yellow 4 Delay to E Green 5 OSC = NE Blue 6 Figure 4 mobrey77.tif Note: At Figure 4 OSC means sensor oscillating. £ means relay energised, NE means de-energised. Set the switches in the following order, starting at the bottom and working upwards: BLUE: If the MCU200 relay is to be energised (E) when the sensor is oscillating (OSC) then set the No 6 blue switch to the right (OSC=E). This is the preferred setting, to give a de-energised relay in the ALARM state for a gap sensor as a low level alarm. GREEN: This selects the relay change which is subject to the time delay selected on the top switches. When the No.5 green switch is set to the right, the delay occurs between the sensor changing state and the relay de-energising or becoming "not energised" (NE). This time delay is a minimum of 0.15 seconds, (achieved by switching the top BROWN switch to the right) and is used to prevent relay chatter at the changeover point. Longer time delays are selected on the top three slide switches as shown in Figure 5. The relay change in the opposite direction is immediate (within 50 milliseconds). Language UK Page 6/10 •#•••#• AALBORG OIL DETECTION EQUIPMENT OM9410#01.0 INDUSTRIES The top three slide switches Colour Code No. Hk Hh -*•> i Brown 1 .j_ HH ^ 2 Red 2 HK -i- Hh 3 Orange 3 2 seconds* 8 seconds' 30 seconds* Figure 5 mobrey08.tif YELLOW: Only one of the GREEN or RED LEDs will be illuminated at any one time. These LEDs show the state of the MCU200 output relay. The RED LED is labelled "ALARM" and the GREEN LED is labelled "NORMAL". The yellow slide switch (Number 4) determines which LED will be illuminated when the relay is energised (E). It is usual to have the GREEN/NORMAL condition occur with the relay energised, i.e. with switch Number 4 to the right (E=GREEN). Applications 4.1 Gain adjustment Correct adjustment of the gain (HI/LO switch and potentiometer) is essential for proper operation of any ultrasonic sensor system. This adjusts the gain of the feedback amplifier in the control unit, which produces oscillation of the sensor when the coupling between the ultrasonic crystals is sufficient. Therefore the higher the gain setting, the lower the coupling needed to produce an oscillating sensor. The universal control unit of the MCU200 operates with many sensors, so the correct setting for the particular sensor and application should be found on site by experiment, if possible. This will take account of particular site conditions like RF coupling between extension cables, which can affect the maximum allowed gain. Other liquid characteristics, such as presence of suspended solids, or air bubbles, can mean that for reliable operation the MCU200 gain must be set as high as possible, to overcome future solids build up, but at least one potentiometer division below the maximum allowed level, to ensure temperature and component ageing stability. The particular procedures outlined below for gain adjustments give the mid point gain settings, which may need to be adjusted to meet specific site/sensor future requirements as indicated above. Language UK Page 7/10 AALBORG OIL DETECTION EQUIPMENT OM9410#01.0 INDUSTRIES 4.2 Interface detection 4.2.1 Interface detection between two dissimilar liquids Viscous liquids, emulsions and liquids containing solid particles have a greater ultrasonic attenuation than clear liquids. This technique is used to detect which liquid is present at the sensor, for example for the separation of oil and water. For this duty Mobrey 402 sensors are used, operating at 3.7 MHz to produce the maximum ultrasonic difference between two liquids monitored. The gain is adjusted so that the sensor oscillates only in the liquid with the lower ultrasonic attenuation: this is usually the clearer liquid (water in the example of Figure 6). Note that the signal when oil is present in the sensor gap will be the same as that for air in the gasp, and that emulsion layers give a very high attenuation. Mobrey 402 Sensor as oil/water interface / / / OIL • it 111 tu i il Receiver Transmitter Crystal Crystal Sensor in Oil. The ultrasonic beam is attenuated and will not reach receiver crystal. WATER^ I if iiiimmimimm a — -Receiver Transmitter Crystal Crystal Figure 6 mobreyl5.tif Step A: Reduce the gain potentiometer with the sensor immersed in one of the liquids until a "false dry" indication is obtained. Note the position of the pot. Step B: Repeat for the sensor immersed in the other liquid. Step C: Set the potentiometer half way between these two values. Correct performance requires a total difference between the two set points of at least 3 divisions. Language UK Page 8/10 AALBORG OIL DETECTION EQUIPMENT OM9410#01.0 INDUSTRIES Interface detection between two immiscible similar liquids When liquids are ultrasonically very similar - as happens for example with paraffin or oil and water - the procedure in section 4.2.1. produces very little difference between the two "false dry" points. In this case the "reflection" method of interface detection is used. An illustration of this method is shown in Figure 7. Note: The Mobrey 402 sensor in the hot well tank is installed as shown in Figure 7. If an ultrasonic beam is transmitted from one liquid to another at a suitable angle (10%) it is split at the interface into a reflected and a refracted beam, so that it does not reach the receiver crystal. If there is no interference in the gap, but only one liquid, the beam is received and the sensor oscillates. Interface detector by reflection method Paraffin =.*L*JQL Water Sensor at interface level. The ultrasonic beam is reflected/refracted and will not reach receiver crystal. Paraffi Transmitter Crystal i Receiver Crystal Figure 7 mobreyl6.tif The gain adjustment is made so that the gain is 3 divisions higher than the highest false dry position obtained, as in section 4.2.1. Performance at the interface should then be checked. Note: That the non oscillating state of the sensor, at the interface, also occurs throughout any emulsion layer at the interface, and also when the sensor is in air. Language UK Page 9/10 *•••••* AALBORG OIL DETECTION EQUIPMENT OM9410#01.0 INDUSTRIES Spares and fault finding 5.1 Spares The following parts are suitable for replacements on the MCU201 : • Main pcb complete: K2641 • LED indicator pcb: K2643 • LED pcb spacers: K2623 • LED pcb connector: K2624/50 • Box assembly: K2662 • Gland Assembly: K746/K747/K748 There are no consumable items such as fuses. 5.2 Fault finding Step A: At least one LED should be illuminated. If not check the power supply to the unit. Step B: If the "Fault" LED is on, check the coax cable to the sensor for incorrect wiring or damage. Particularly check continuity of extension cables, connection of crimped connectors on cable ends. The pcb board can be checked by linking the two terminals labelled E on the sensor terminals - this should cancel the fault indication LED. Step C: If the sensor is giving incorrect indications check the gain adjustment (see section 4.0"). Check for correct sensor operation whenever the gain is adjusted away from the normal set point. Assume an overlap of 2 divisions between the "LO" and "HI" gain ranges. Step D: Check that the incorrect operation has not been produced by incorrect setting of the frequency selection switch, or an external short circuit on the Auxiliary input terminals. Step E: The circuit board can be checked by linking the sensor terminals 1 and 2 with a wire, to simulate an oscillating sensor. Language UK Page 10/10 AALBORG dSzSSSSSäfiSfi^^^^^^M INDUSTRIES ^migg^g^^giiigii^^g^^g^^^^m Table of contents Drawings Arrangement of sockets 45Y:028399d DP water level control unit 70Z:019538b Language UK Page 1/1 Atonjlon Affi* tao Drawn Appr. OuOøtbQK ttWKIQßd, 031030 KJN PSO Forward ship b• 0403Û8 PSO 4 po. ol IM 31 add«* wni tan 30 rnoMd. c 0405(2 rea d 0408» PSG TCO F* foot ViewC-C ViewE-E DM OOP) DIN 86044 Outletbox supplied loose To be welded by yard mm I pta_: m 001 HahctBWn X"40mm Feed mbrL-Fuit kngh Sam IsFuBiengBi CtaJdeninM/auJM LaFidtenotfi SIZE •01 •02 2Î 0N15 Socket for atomizing « OW32 DN20 ümo DN50 Alrrtng lootbkNW Internal ecvnptpi Internai *baamapnbr~~ Fixing Iron/uiengkron 31,5 ta Measuring tockettor öumer Socket tor drain of «moka o DN SO PN 20 Fixing tran / letting iron Manhoto 420x320x150 Socket* ^'aeéttfawina™ Atxaia door / mpecoon Socket f. nesting coi dudaT~ ON 25 3öc£iiitf. heeling col He* socket tor i^ water regulator DN25 m Socket tor water tevoi regutator PN 25 SockeTtor air" X* BSP leftwnd socket tor sampling cooler varva " Socket tor water ami gauge ON 25 AQ18 View A-A Guangzhou Shipyard Vertical water tut» boler Sodoty LRS LRS 1S0rMKg/h 0,9 MPs »3050 03130009 Afiangement of sockets Project No, AALfiOM» iHawtiaiie 45Y: 028399 Description Index Date^BBraw Appr. Item 3 changed BZ + and - side reversed )30327f JA BZ Allen screw 3000000009 M10x55 A2 Washer 3090000004 M10 A 2-70 Gasket 3520000013 018.64x3.53 Rubber/viton Diff. pressure transmitter 8020000001 2.5-250 mBar Tube for upper level tube DIN 1629 4000000390 012 L=1446 St.37.4 Lower level tube DIN 17175 70Z:012095 3.1 C DN25 St.35.8 I Upper level tube 70K02:012084 DIN 17175 3.1C DN25 St.35.8 I Designation Material code Article No. Cert. Dimension Material type Detail drawing No. Title: DP water level control unit JA 020117 Appr. Note! - side to be connected to lower level tube Socket distance: BZ 020117 + side to be connected to upper level tube 525-1300 Weight Scale: Size ifjjjjiji 1:5 A3 Assembly drawing * - Drain connection: ø12 tube AALBORG Article/Drawing No: INDUSTRIES THIS ORAWtNQ AND DESIGN SHOWN HEREIN a THE PROPERTY OF AALBORQ INOUSTRJES AND MUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY 70Z:019538 c=3 AALBORG gggiaaigasngsHS^^^^^^^^^^^^^^B INDUSTRIES ^••••HiflMllllSIIMii^H^^H^^^^HIil^H^^^HBH^HIIH Table of contents Data sheets for boiler and steam/water system Safety valve, DN 65/100, PN 40/16 261 1174 Stop valve, angle, DN 200, PN 25 6010 000087 Stop valve, angle, DN 65, PN 40 6010 000090 Stop valve straight, non return DN 65, PN 40 6030 000023 Stop valve, angle, non return, DN 40, PN 40 6030 000013 Stop valve, straight, non return, DN 40, PN 40 6030 000016 Stop valve, straight, DN 8, PN 160 6220 000002 Stop valve, straight, non return, DN 20, PN 25 264 1087 Check valve, DN 200, PN 25 6020 000022 Stop valve, straight, DN 25, PN 25 250 1088 Stop valve, straight, DN 80, PN 10 6010 000042 Water level gauge, left, model 28, DN 25, PN 25 7010 000151 Water level gauge, right, model 28, DN 25, PN 25 7010 000150 Safety valve, DN 15, PN 40 261 1358 Expansion joint for safety valve 85Y:013427a Water washing hose with nozzle 8500 000016 Counter flange K16:004096 Solenoid valve (C227) data sheet Level float switch RBA 24, DN 25, PN 40 8100 000008 Temperature switch ATHs-20/a 632 0110 Feed water pumps (1M4) data sheet Pressure gauge, ø 63 , 663 3118 Pressure gauge, ø 63, Type PI 116 663 3121 Pressure switch, KPS 45 631 0340 Full bore ball valve, EURO-SFER, 1720 666 6006 Needle valve, straight, V2" x '/a", PN 400 ...254 1002 Orifice K18:003559 Chemical dosing unit 9296 000002 Sample cooler 875 0005 Check valve (1M142) 6020 000028 Pneumatic control valve, DN 40, PN 25 w/DP actuator + I/P positioner.6050 000050 Filter regulator with automatic drain 291 5101 Water testing equipment. 880 0050 Steam injection system 64Z:027665a Stop valve, DN 40, PN 16 6010 000043 Language UK Page 1/2 •iiiüii. AALBORG ^BBHHlBBBBBM^M^BI^MBI^^^^fc INDUSTRIES ^mgg^ø^^øumu^g^^^^^^j^^^^g^^^^^^^^^^^^^ Cast iron strainer, DN 40, PN 16 7040 000016 Control valve, DN 40, PN 16 6000 000042 Temperature switch, 40-105°C 8070 000010 Wafer check valve, DN 40, PN 40 6020 000006 Vacuum breaker, BSP YT 6000 000010 Steam injector, BSP VA" 7000 000014 Steam injector, BSP 1" 7000 000020 Control device, LRS l-5b 8210 000005 Conductive electrode, ERL 16-1 8620 000003 Control unit for oil detection equipment 8210 000025 Ultrasonic sensor for oil detection equipment 8310 000005 Differential pressure transmitter 8020 000001 Language UK Page 2/2 AALBORG DATASHEET INDUSTRIES Type: • Safety valve, full lift • 25.912 Size: • Nominal diameter: DN 65/100 Application: • To blow off saturated steam, air or water Material: • Body: GGG 40.3 DIN-Material No.: 0.7043 • Seat: X6 Cr Ni Mo Ti 17122 DIN-Material No.: 1.4571 • Disc: X35 Cr Mo 17 DIN-Material No.: 1.4122.05 Technical data: • Nominal pressure: PN 40/16 • Weight: 40 kg • Flanges according to DIN • Inlet: DN 65, PN40 • Outlet: DN 100, PN 16 Type No.: 6040 Version: A Safety valve, DN 65/100, PN 40/16 261 1174 Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Type: Material: • Stop globe valve, angle • Body:GS-C25N • 34.007 with stellited seat and cone Din-Material No. 1.0619.1 • Seat: X5CrNiNb 19 9 with stellite Size: Din-Material No. 1.4551 • Nominal diameter: DN 200 • Disc:X20Crl3 Application: DIN-Material No. 1.4021.05 • For steam and/or water flow Technical data: • Nominal pressure: PN 25 • Weight: 138 kg • Flanges according to DIN 400 Disc Seat Body Type No.: 6010 Version: B Stop valve, angle DN 200, PN 25 6010 000087 Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Type: Material: • Stop globe valve, angle • Body:GS-C25N • 35.007 with stellited seat and cone DIN -Material No. 1.0619.01 • Seat: X5CrNiNb 19 9 with stellite Size: DIN-Material No. 1.4551 • Nominal diameter: DN 65 • Disc:X20Crl3 Application: DIN-Material No. 1.4021.05 • For steam and/or water flow Technical data: • Nominal pressure: PN 40 • Weight: 20 kg • Flanges according to DIN Disc Seat Body Type No.: 6010 Version: A Stop valve, angle, DN 65, PN 40 6010 000090 Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Type: Material: • Stop check globe valve, screw down non • Body:GS-C25N return, straight DIN-Material No. 1.0619.01 • 35.006 R with stellited seat and cone • Seat: X5CrNiNb 19 9 with stellite DIN-Material No. 1.4551 Size: • Disc:X20Crl3 • Nominal diameter: DN 65 DIN -Material No. 1.4021.05 Application: Technical data: • For steam and/or water flow • Nominal pressure: PN 40 • Weight: 23.5 kg • Flanges according to DIN 0 180 Body Type No.: 6030 Stop valve, straight, non return 6030 000023 Version: A DN 65, PN 40 Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Type: Material: • Stop check globe valve, screw down non • Body:GS-C25N return, angle DIN-Material No. 1.0619.01 • 35.007 R with stellited seat and cone • Seat: X5CrNiNbl9 9 with stellited DIN-Material No. 1.4551 Size: • Disc:X20Crl3 • Nominal diameter: DN 40 DIN -Material No. 1.4021.05 Application: Technical data: • For steam and/or water flow • Nominal pressure: PN 40 • Weight: 12.4 kg • Flanges according to DIN 0 160 CM L • i ^~^4J-i/^ f f 20 0 ~7~~Z^i> U fejDisc Sfeat 11 5 |?. Bady / 'Z^ Z /// '/, ^.0 40 0 110/4x0 18 0 150 U 115 Type No.: 6030 S top valve, angle, non return, 6030 000013 Version: A DN 40, PN 40 I J Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Type: Material: • Stop check globe valve, screw down non • Body:GS-C25N return DIN -Material No. 1.0619.01 • 35.006 R with stellited seat and cone • Seat: X5CrNiNb 19 9 with stellited DIN-Material No. 1.4551 Size: • Disc:X20Crl3 • Nominal diameter: DN 40 DIN -Material No. 1.4021.05 Application: Technical data: • For steam and/or water flow • Nominal pressure: PN 40 • Weight: 11.5 kg • Flanges according to DIN 0 160 Body Type No.: 6030 Stop valve, straight, non return 6030 000016 Version: A DN 40, PN 40 Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Type: Material: • Instrument stop cone valve, straight • Body: C 22.8 DIN-Material No. 1.0460 Size: • Seat:X20Crl3 • G'/2"xøl2 DIN-Material No. 1.4021 • Nominal diameter: DN 8 • Needletip:X35CrMol7 Application: DIN-Material No. 1.4122 • For steam, water and/or air Technical data: • Nominal pressure: PN 160 • Inlet: G W male DIN 19207, form R • Outlet: For steel tube ø 12 • Weight: 0.8 kg 0 80 Type No.: 6220 Version: D Stop valve, straight, DN 8, PN 160 6220 000002 Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Type: Material: • Stop check globe valve, screw down non • Body: GGG 40.3 return, straight DIN -Material No. 0.7043 • 23.006 R • Seat:X20Crl3 DIN -Material No. 1.4021.05 Size: • Disc:X20Crl3 • Nominal diameter: DN 25 DIN-Material No. 1.4021.05 Application: Technical data: • For steam and/or water flow • Nominal pressure: PN 25 • Weight: 5.4 kg • Flanges according to DIN 0 140 Body Type No.: 6030 Stop valve, straight, non return, 2641088 Version: A DN 25, PN 25 Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Type: • Opening pressure at horizontal flow (60° • Wafer check valve, type WCV 6100 open): 19 mbar Application: • Opening pressure at vertical flow upwards: 22 mbar • For steam and liquid media • Standard Kv value: 1205 m3/h Design: • Operating temperature max.: 250°C • The wafer check valve is designed to be • Operating temperature min.: -10°C sandwiched between welding neck • Weight: 7.5 kg flanges or slip-on flanges, with Installation: horizontal flow or vertical flow • The check valve can be installed upwards. The disc is eccentrically sandwiched between welding neck placed in relation to the body to obtain a flanges or slip-on flanges self-centring effect at installation • Determine the correct installation Size: situation and the direction of flow. It • Nominal diameter: DN 200 must be installed either in a horizontal flow or where the flow is vertically Connection requirements: upwards • Min. inline diameter of connection • The valve is self-centring. However, it pipe/flange: 206.5 mm must always be ensured that it is • Length of required min. inline diameter: completely centred in relation to the 160 mm connection pipe/flange. Use the body rim (external) diameter for this purpose Material: • The check valve can be installed directly • Body: carbon steel on a valve, but a distance of 2-3 times • Waferdisc:AISI316L the pipe diameter is preferable. • Disc seating: metallic • In case of a steam system with vertical installed check valve a steam trap should Technical data: be installed for drainage of condensate • Operating pressure max: 25 bar • Max. cold hydraulic test pressure: 37.5 bar Type No.: 6020 Version: B Check valve, DN 200, PN 25 6020 000022 Language UK Page 1/2 AALBORG DATA SHEET INDUSTRIES Installation examples: Welding neck flange Welding neck flange installation installation with recessed pipe Slip-on flange Slip-on flange installation i i installation with fl[ recessed pipe ! f 1 J |! • il Mln . 0206. 5 Mi i 1 V i ,: • 1 1 i : fi- IL P, t j - 1 a m 60 Type No.: 6020 Version: B Check valve, DN 200, PN 25 6020 000022 Language UK Page 2/2 AALBORG DATA SHEET INDUSTRIES Type: Material: • Stop check globe valve, screw down non • Body: GGG 40.3 return, straight DIN -Material No. 0.7043 • 23.006 R • Seat:X20Crl3 DIN -Material No. 1.4021.05 Size: • Disc:X20Crl3 • Nominal diameter: DN 20 DIN-Material No. 1.4021.05 Application: Technical data: • For steam and/or water flow • Nominal pressure: PN 25 • Weight: 4.3 kg • Flanges according to DIN 0 120 Body Type No.: 6030 Stop valve, straight, non return, 264 1087 Version: A DN 20, PN 25 Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Type: • Stop valve, gate straight Size: • Nominal diameter: DN80 Application: • Sea water, fresh water, oil, steam etc Material: • Body: GG25 Technical data: • Nominal pressure: PN 10 • Max. temperature: 150 °C • Weight: 19 kg 160 Type No.: 6010 Version: A Stop valve, straight, DN 80, PN 10 6010 000042 Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Type: Material: • Body: Carbon steel • Reflective water level gauge, left • Drain valve body: ASTM A105 • Model 28 Size: Technical data: • Nominal pressure: PN 25 • Nominal diameter: DN 25 • Weight: 25 kg Application: • Connections between body and cocks are • For boiler water level indicator made by end tubes and stuffing boxes 160 Drain connection ø 10 x 2.5 mild steel Type No: 7010 Water level gauge, left, model 28 7010 000151 Version: B DN 25, PN 25 Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Type: Material: • Body: Carbon steel • Reflective water level gauge, right • Drain valve body: ASTM A105 • Model 28 Technical data: Size: • Nominal pressure: PN 25 • Nominal diameter: DN 25 • Weight: 25 kg Application: • Connections between body and cocks are • For boiler water level indicator made by end tubes and stuffing boxes 160 oo CM CO f •a c a> J2 .o loi Drain connection ø 10 x 2.5 mild steel Type No: 7010 Water level gauge, right, model 28 7010 000150 Version: B DN 25, PN 25 Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Type: • Safety valve, full lift /^zr7771 • 25.941 Size: • Nominal diameter: DN 15 Application: • To blow off steam and/or air. Material: • Body: GGG 40.3 • DIN-Material No.: 0.7043 Technical data: • Nominal pressure: PN 40 • Weight: 3.5 kg Body Type No.: 6040 Version: A Safety valve, DN 15, PN 40 261 1358 Language UK Page 1/1 'Flange DN100-PN 16 Flange DN25PN16 Title: Drawn Date Expansion Joint MRJ 20.09.2000 Appr. •ate ••••••• for safety valve LD 30.11.2000 ••••••• DN65/100, PN 16 outlet flange Weight Scale: Size 48kg 1:5 A4R iiiitiiiå General arrangement AALBORG Article/Drawing No: Index INDUSTRIES THIS DRAWING AND DESIGN SHOWN HEREIN IS THE PROPERTY OF AALBORG INDUSTRIES Plot Date: AND MUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY 85Y:013427 AALBORG DATA SHEET INDUSTRIES Type: . vl Couplings (2" Storz) Hose J r Nozzle • Water washing hose with nozzle •Size V-nozzle: : 12 mm n- i i / • Length: 15 metre (hose) • Inner diameter 52 mm (hose) L J Application: • For spraying of water m K A • « lfh Material: • Hose: full-synthetic materia l (polyester) ^^ '-F woven in 1/1 binding, ^wit h inner rubber ^^ \ lining 2" connection (male) Couplings (2" Storz) Technical data: • Max allowable working pressure: 20 bar • Water temperature area -30°C-+60°C • Weight: 5.5 kg l/min Water flow 210 200 190 180 170 160 150 140 130 120 110 100 90 80 70 60 50 40 30 20 10 2345 67 89 10 Bar Type No.: 8500 Version: A Water washing hose with nozzle 8500 000016 V J Language UK Page 1/1 Description Index | Date \ Drawn | Appr. Yard piping Supplied loose DN øA øD <9K øB øL C Bolt Number 15 21.3 95 65 22.0 14 14 4 / M12 20 26.9 105 75 27.5 14 16 4 / M12 25 33.7 115 85 34.5 14 16 4 / M12 32 42.4 140 100 43.5 18 18 4 / M16 40 48.3 150 110 49.5 18 18 4 / M16 50 60.3 165 125 61.5 18 20 4 / M16 65 76.1 185 145 77.5 18 22 8 / M16 80 88.9 200 160 90.5 18 24 8 / M16 100 114.3 235 190 116.0 22 '26 8 / M20 125 139.7 270 220 141.5 26 28 8 / M24 150 168.3 300 250 170.5 26 30 8 / M24 200 219.1 360 310 221.5 26 32 12 / M24 250 273.0 425 370 276.5 30 35 12 / M24 300 323.9 485 430 327.5 30 38 16 / M28 Title: Drawn Date MRJ 970910 Appr. Date Counter Flanges MSO 981016 DN15 - DN300 PN25 Weight Scale: Size iiiiiiiii 1:1 A4R BS4504 type B AALBORG Article/Drawing No: Affix INDUSTRIES THIS DRAWING AND DESIGN SHOWN HEREIN IS THE PROPERIY Of AALBORG INDUSTRIES AND UUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY ' K16:004096 C 22? 2/2-way-valves ND12 to 50 85000 for neutral gaseous and liquid fluids 85010 Solenoid actuated, with forced lifting Piston seat valves Internal threads G1/2 to G 2 or 1/2" NPT to 2" NPT Operating pressure 0 to 25 bar Description (standard valve) Solenoid valve for air, water and oil Switching function: Normally closed Flow direction: determined Fluid temperature: -10 °C to max. +90 °C Ambient temperature: -10 °C to max. +50 °C Mounting position: optional, solenoid preferably vertical on top Material Material Body: Brass Seat seal: NBR (Perbunan) Internal parts: Stainless steel, Brass, Gun metal For contaminated fluids insertion of a strainer is recommended (see accessories). Features Flat piston valve Valve operates without pressure differential (Ap) High flow rate Damped operation Suitable for vacuum Symbol EH tZrVW Ordering information To order, quote model number from table overleaf; e. g. 8500200.8301 for a G1/2 valve with standard solenoid. Characteristic data See page 2 valve and solenoid informations D106102.01 Vdlvc Technology and System!» Buschjost 11/01 liVI NORGRCN BUSCHJOST GMBH- CO KG ttuucbloit Series 85000/85010 2/2-way valves ND12 to ND 50 Characteristic data Valves Catno .. " • Catno. v ND ".Connection Operating pressure * kv-value** '? Weight - ' Solenoid DC Solenoid AC (mm) min max (bar) (Båse m'/h) (kg) 8500200.8301 8500200.8304 GI/2 12 0 25 3,80 1,45 8501200.8301 8501200.8304 1/2- NPT 8500300.8401 8500300.8404 G 3/4 20 0 25 11,00 3,65 8501300.8401 8501300.8404 3/4' NPT 8500400.8401 8500400.8404 GI 25 0 25 13,00 3,50 8501400.8401 8501400.8404 T NPT 8500500.8401 8500500.8404 G 11/4 32 0 25 30,00 5,30 8501500.8401 8501500.8404 1 1/41 NPT 8500600.8401 8500600.8404 GI 1/2 40 0 25 31,00 5,10 8501600.8401 8501600.8404 1 1/2" NPT 8500700.8401 8500700.8404 G2 50 0 25 46,00 6,60 8501700.8401 8501700.8404 2" NPT * with gaseous and liquid fluids up to 40 mmVs (cSt) State voltage [V] and frequenzy [Hz] ** Cv-value (US) - kv-value x 1,2 18301/8304 and 8401/8404 Solenoid Further models (valves) Standard voltages XXXXX01 .XXXX Normally open, mounting position: solenoid vertical on top a DC AC :• 40 Hz to 60 Hz XXXXX02.XXXX Manual override, from G 3/4 (3/4" NPT) XXXXX03.XXXX Seat seal FPM, 24 V 24 V max. fluid temperature +110 °C " - 110V XXXXX06.XXXX Seat seal PTFE, max. fluid temperature +110 °C1), 205 V 230 V max. operating pressure 16 bar Design acc. to VDE 0580 XXXXX14.XXXX Seat seal EPDM, Voltage rage ±10% max. fluid temperature +110 °C 100 % duty cycle XXXXX17.XXXX Normally open, Protection class acc. to DIN EN 175301-803 (10/00) IP65 seat seal FPM, max. fluid temperature +110 °C, Socket acc. to DIN 43 650-A mounting position: solenoid vertical on top2| AC solenoid with rectifier XXXXX22.XXXX max. operating pressure 40 bar2) XXXXX23.XXXX Position indicator with two solenoid switches2) Power consumption XXXXX25.XXXX Seat seal FPM with larger bleed orifices in the pis According to VDE 0580 at coil temperature +20 °C. In operating the ton, for e. g. fuel and oil, viscosity max. 80 mm2/s solenoid decrease the power consumption appr. 30%. (cSt),max. fluid temperature +110 °C " XXXXX28.XXXX Temperature design; < -10 °C, all materials suitable Solenoid DC AC XXXXX34.XXXX Enlarged closing force at 20 % kv-value-reduce - Inrush Holding advisable at low flow rate and low switching cycles 8301 22 W _ _ On request further versions 8304 - 25 VA 25 VA Further models (solenoids) 8401 40W - _ XXXXXXX.8402 Solenoid for higher temperature, max. fluid temper 8404 - 45 VA 45 VA ature +200 °C, mounting position: vertical, with so lenoid underneath, only for DC Attention! XXXXXXX.8406 Same as 8402, only for AC Restricted temperature range for explosion proof solenoids XXXXXXX.8436 Solenoid in protection class EEx me T4, begin at For technical details see catalog register „Solenoids" DN20 XXXXXXX.8900 Solenoid in protection class EEx de MC T4 and T5 XXXXXXX.8920 Solenoid in protection class EEx d MC T4 und T5 On request Overexcitation, protection class EEx d I, protection class EEx de I resp. Special connections 1) max. fluid temperaturen +200 °C see solenoid for higher temperatures 2) G 1/2 with solenoid 8401/8404 D106102.02 Subject to change 11/01 Series 85000/85010 2/2-way valves ND12 to ND 50 Bn««li|o«t Sectional drawings to G1/2 resp. 1/2" NPT from G 3/4 resp. 3/4" NPT 101 Valve body 1400 Socket *102 O-Ring 1501 Hexagon screw *103 Valve plate 1502 Round plate *104 Grooved ring 1504 Gasket *105 Valve spindle 1505 O-Ring *106 Screw piece *107 Pressure spring, at G 3/4 (3/4" NPT) * These individual parts form a complete wearing unit. 108 Body cover 109 Spring washer When ordering spare parts please state Cat. No. and series-No. 110 Cheese head cap screw 111 Hexagon nut 400 Solenoid 701 Core tube 702 Core 704 Round plate *705 Pressure spring *712 0-Ring,justG1/2and1/2"NPT 11/01 Subject to change D106102.03 BiMchlost Series 85000/85010 2/2-way valves ND12 to ND 50 Dimensional drawing Solenoid may be rotated 360° Socket turnable 4 x 90° Cat.-No. AxB C DD E H H1 L R T 8500200.830X G 1/2 14,0 52x65 65 45 26 160 145 67 8501200.830X VT NPT 13,5 8500300.84OX G 3/4 12,5 72x92 75 70 31 196 172 95 8501300.840X 3/4' NPT 14,0 85004 00.840X Gl 14,0 72x92 75 70 31 196 172 95 8501400.840X T NPT 17,0 8500S00.840X Gl 1/4 18,0 72x92 75 96 31 220 187 132 8501500.840X 11/4" NPT 17,0 85006 00.840X G 11/2 18,0 72x92 75 96 31 220 187 132 8501600.840X 1 1/2- NPT 17,0 8500700.840X G2 20,0 72x92 75 112 31 238 198 160 85O17O0.840X 2" NPT 17,5 EU Manufacturer's Declaration Note as denned in EU Machinery Guideline 98/37/EC, Appendix II B These flat piston valves are intended for fitting in a machine. They must not We hereby declare that the flat piston valves were developed and designed be commissioned until it has been established that the machine as a whole using the following harmonised standards: conforms to the EU guideline. EN 292 Machine Safety Note on Ell guideline The valves shall be provided with an electrical circuit which ensures the limits EN 983 Pneumatic Systems of the harmonised standards EN 50081-1 and EN 50082-1 are observed, and hence the requirements of the Electromagnetic Compatibility Guideline EN 60204-1 Electrical Equipment for Machinery (89/336/EEC) satisfied. Buschjost and the picture Czi_Ju are registered trademarks of the IMI Norgren Buschjost GmbH + Co. KG, Germany. D106102.04 Subject to change 11/01 AALBORG DATA SHEET INDUSTRIES Type: • Level float switch • RBA 24 Size: • DN25 Application: • Low water level switch Material: • St. 35.9 • C 22.8 Technical data: • Drain connection: ø 12 mm • Cable connection: PG 11 • Nominal pressure: PN 40 • Max. working pressure: 32 bar • Max. working temperature: 239°C • Flanges according to DIN 263 5-C • Magnetic switch: 2 x M130 • Switching voltage: 6-250V • Switch current max: 1A ac; 0.5A dc • Protection of switch housing: IP 54 Type No.: 8100 Version: C Level float switch RBA 24, DN 25, PN 40 8100 000008 Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES m m Type: i • Temperature switch • ATHs-20/a (O 1 \ (O Application: • For exhaust gas | =1 E« Material: , • Steel * i ' i Technical data: • Measuring range: + 20 - +500 °C lO • Protection: IP54 00 • Cable entry: PG 13.5 % \ ' , t \-f G1/2" 30 0 ' „8 An Il M II 4 1 2 Type No.: 8070 Version: A Temperature switch ATHs-20/a 632 0110 Language UK Page 1/1 WH Technical data CR 32 Dimensional sketches Dimensions and weights Dimensions [mm] Net Pump type weight B1 B2 B1 + 82 D1 D2 D3 [kg] CR 32-1-1 505 281 786 178 110 135 79 CR 32-1 505 335 840 178 110 143 85 CR 32-2-2 575 391 966 220 134 298 103 CR 32-2-1 575 391 966 220 134 298 103 CR 32-2 575 391 966 220 134 298 107 CR 32-3-2 755 464 1219 260 172 350 148 CR 32-3 755 464 1219 260 172 350 148 CR 32-4-2 825 464 1289 260 172 350 158 CR 32-4 825 478 1303 306 197 350 185 CR 32-5-2 895 478 1373 306 197 350 189 CR 32-5 895 478 1373 306 197 350 199 CR 32-6-2 965 478 1443 306 197 350 203 CR 32-6 965 478 1443 306 197 350 203 CR 32-7-2 1035 600 1635 364 269 350 260 CR 32-7 1035 600 1635 364 269 350 260 CR 32-8-2 1105 667 1772 404 306 400 342 CR 32-8 1105 667 1772 404 306 400 342 CR 32-9-2 1175 667 1842 404 306 400 346 CR 32-9 1175 667 1842 404 306 400 346 CR 32-10-2 1245 667 1912 404 306 400 350 Electrical data 3 x 220-277/380-480 V, 60 Hz Motor Full load current Power factor Motor efficiency 'start Pump type P [kW] li/1 [A] Cos q>„, n [%] 2 '1/1 CR 32-1-1 2.2 8.05-6.95/4.65-4.00 0.90-0.81 83.0-84.5 6.50-9.50 CR 32-1 3.0 10.6-9.00/6.10-5.20 0.90-0.83 85.0-86.0 7.40-11.0 CR 32-2-2 5.5 18.8-15.6/10.8-9.00 0.92-0.85 86.5-88.5 8.20-12.4 CR 32-2-1 5.5 18.8-15.6/10.8-9.00 0.92-0.85 86.5-88.5 8.20-12.4 CR 32-2 7.5 25.5-22.6/14.6-13.0 0.92-0.80 87.5-89.0 9.50-11.6 CR 32-3-2 11 38.0-32.5/22.0-18.8 0.92-0.86 89.0-91.0 6.80-8.60 CR 32-3 11 38.0-32.5/22.0-18.8 0.92-0.86 89.0-91.0 680-8.60 CR 32-4-2 11 38.0-32.5/22.0-18.8 0.92-0.86 89.0-91.0 6.80-8.60 CR 32-4 15 48.8-41.0/28.1-23.7 0.91-0.86 90.0-92.0 5.40-9.15 CR 32-5-2 15 48.8-41.0/28.1-23.7 0.91-0.86 90.0-92.0 5.40-9.15 CR 32-5 18.5 58.7-56-8/34-0-32-8 0.87 91.0-93.0 6.0-7.9 CR 32-6-2 18.5 58.7-56-8/34-0-32-8 0.87 91.0-93.0 6.0-7.9 CR 32-6 18.5 58.7-56-8/34-0-32-8 0.87 91.0-93.0 6.0-7.9 CR 32-7-2 22 75.0-61.0/43.0-35.0 0.86 91.0-93.0 5.1-7.9 CR 32-7 22 75.0-61.0/43.0-35.0 0.86 91.0-93.0 5.1-7.9 CR 32-8-2 30 100-78.0/58.0-45.0 0.87 91.0-93.0 5.0-8.1 CR 32-8 30 100-78.0/58.0-45.0 0.87 91.0-93.0 5.0-8.1 CR 32-9-2 30 100-78.0/58.0-45.0 0.87 91.0-93.0 5.0-8.1 CR 32-9 30 100-78.0/58.0-45.0 0.87 91.0-93.0 5.0-8.1 CR 32-10-2 30 100-78.0/58.0-45.0 0.87 91.0-93.0 5.0-8.1 General data Vertical multistage centrifugal pumps CR 32, 45, 64 and 90 CRN 32, 45, 64 and 90 Materials: CR Materials: CRN Pos. Description Materials DIN W. -Nr. AISI/ASTM Pos. Description Materials DIN W- Nr. AISI/ASTM Cast iron ASTM 1 Pump head Stainless steel 1.4408 AISI-316UN 1 Pump head EN-JS1050 EN-GJS-500-7 80-55-06 Cast iron 2 Motor stool EN-JL1030 ASTM 25B Cast iron EN-GJL-200 2 Motor stool EN-JL1030 ASTM 25B EN-GJL-200 3 Shaft Stainless steel 1.4462 3 Shaft Stainless steel 1.4057 AISI 431 4 Impeller Stainless steel 1.4401 AISI 316 4 Impeller Stainless steel 1.4301 AISI 304 5 Chamber Stainless steel 1.4401 AISI 316 Chamber 5 Stainless steel 1.4301 AISI 304 6 Outer sleeve Stainless steel 1.4401 AISI 316 6 Stainless steel 1.4301 AISI 304 Outer sleeve O-ring for 7 EPDM or FKM O-ring for outer outer sleeve 7 EPDM or FKM sleeve 8 Base Stainless steel 1.4408 AISI316LN Cast iron ASTM 8 Base EN-JS1050 9 Neck ring Acoflon 215 EN-GJS-500-7 80-55-06 10 Shaft seal 9 Neck ring Acoflon 215 11 Bearing ring HY49 10 Shaft seal Bottom 11 Bearing ring 12 TC/TC * Bronze bearing ring Bottom 12 Terre* Cast iron EN- ASTM bearing ring 13 Base plate EN-GJS-500-7 JS1050 80-55-06 Rubber parts EPDM or FKM Stainless steel * TC= Tungsten Carbide (cemented) Rubber parts EPDM or FKM * TO!= Tungsten Carbide (cemented) Performance curves CR 32 P -I n - [MPal [m]- CR 32 60 Hz 260- --9— ISO 9906 Annex A 2.4- —-8 —8-2— 2.0- 200- —"1—— -7-2 ~ 1.6- 140- -5 5 2 1.2- -4-2 3 0.8- -3-2 60- —2 •2-1 -—: 0.4- _-1 •11 20- 0.0 J 1 1 ' 1 ' ' ' ' ' ' ' ' 81 ' 12 16 20 24 28 32 36 40 44 Q [m3/h] 1^ 10 12 Q [l/S] P2 P2 Eta [hp] [kW]- - [%] 32 80 4- P2 1/1 Eta •60 3- P2 2/3 •40 2 ———' 1 - •20 y^ 0- 1 ' ' ' 1 1 12 16 20 24 28 32 36 40 44 Q [rtfVh] P H NPSH [kPa] [m] NPSH [m] 32- QH 3500 rpm 1/1 240- 24 QH 3500 rpm 2/3- 160- 16- 80 8- 0-1 12 20 24 28 32 36 40 44 Q [m3/h] AALBORG DATA SHEET INDUSTRIES Type: • Pressure gauge, type P1116 Size: • 0 63 Application: • For all gaseous and liquid media Material: • Case: Stainless steel • Socket: Cu-alloy • Liquid filling: Glycerine Technical data. • Connection: G l/4"-m • Measuring range: -1 to + 5 / - 0.1 to 0.5 [bar], [kg/cm2], [MPa] • Pressure utilisation: Static pressure: 75% of Pmax Dynamic pressure: 66% of Praax • Operating temperature: -20 to +80°C • Accuracy: EN 837 Class 1,6 32 0 00 CO o G 1/4" -m Type No.: 8050 Version: A Pressure gauge, ø 63 663 3118 Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Type: • Pressure gauge, type P1116 Size: • ø63 Application: • For all gaseous and liquid media Material: • Case: Stainless steel • Socket: Cu-alloy • Liquid filling: Glycerine Technical data: • Connection: G l/4"-m (1/4 BSP) • Measuring range: 0 - 25 / 2.5 [bar], [kg/cm2], [MPa] • Pressure utilisation: Static pressure: 75% of Pmax Dynamic pressure: 66% of Pmax • Operating temperature: -20 to +80°C • Accuracy: EN 837 Class 1,6 32 oo (O D G1/4"-m Type No.: 8050 Version: A Pressure gauge, ø 63 663 3121 Type P1116 Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Type: • Pressure switch • KPS45 Application: • The units are pressure-controlled switches. The pressure controls are suitable for use in alarm and regulation system. Enclosure: • IP 67 to IEC 529 and DIN 40050. • The pressure control housing is enamelled pressure die cast aluminium (GD-AISi 12). The cover is fastened by four screws which are anchored to prevent loss. The enclosure can be sealed with fuse wire. Adjustment: " • When the pressure control cover is removed, and the locking screw (5) is loosened, the range can be set with the spindle (1) while at the same time the scale (2) is being read. In units having an adjustable differential, the: spindle (3) must be used to make the adjustment. The differential obtained can be read direct on the scales (4). 1 Range spindle • To ensure that the plant functions 2 Range scale properly, a suitable differential pressure 3 Differential spindle is necessary. Too small a differential 4 Differential scale will give rise to short running periods 5 Locking screw with a risk of hunting. Too high a differential will result in large pressure oscillations. Technical data: • Operating pressure: 4-40 bar • Differential: 2.2 - 11 bar • Test pressure: 180 bar • Pressure connection: G 1/4 -f • Cable entry: Pg 13.5 for cable diameters 5 to 14 mm. • Weight: 1.3 kg Type No.: 8030 Version: A Pressure switch 631 0340 KPS45 Language UK Page 1/1 AALBORG DATASHEET INDUSTRIES Type: • Full bore ball valve, • EURO-SFER 1720 Size: • Nominal diameter: DN 8 Application: • Assembly in rigid pipe system • Direction of flow in both directions Specification: • Nominal pressure: PN 30 • Thread ends: female - female UNI ISA 7/1 -rp • Lever: aluminium handle UNI 5076 painted black with epoxy powder DN I L I H CH , M , > ,'Ky FN" i ii ' "if* VA 8 11 51,5 23 20 50 42 5,4 64 0,13 Type No.:6666 Version:A Full bore ball valve 666 6006 EURO-SFER, 1720 Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Type: • Pressure gauge valve needle straight. Size: • 1/2" x 1/2" Application: • For instrument connections Material: • Body:C22.8 • DIN-material No. 1.0460 Technical data: • Nominal pressure: PN 400 • Test connection: M20 x 1.5 mm threaded male • Weight: 0.4 kg . G W.- f Type No.: 6210 Version: F Needle valve, straight, 1/2" x 1/2", PN 400 2541002 Language UK Page 1/1 Description Index Date Drawn Appr R w////////,\ v/////////, R To be stamped: DN 65/ø10 0127 Plate ø127x6 AISI316/GB4238 Designation Material code Article No. Item Pes. Cert. Dimension Material type Detail drawing No. Title: Drawn Date LD 970616 Appr. Date Orifice DN 65/010 MRJ 970616 ••••••• Weight Scale: Size iiiiiiiii 1:1 A4R AALBORG Article/Drawing No: Affix INDUSTRIES THIS DRAWING AND DESIGN SHOWN HEREIN IS TOEPROPERT Y OF AALBORG INDUSTRIES AND MUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY K18:003559 AALBORG DATA SHEET INDUSTRIES Technical data: Type: Max pressure: 123 bar • Dosing pump P.E. 100 with chemical Capacity: 2.5 1/h tank Max pressure suction side: 35 bar Application: Max operating temperature: 50°C • For chemical dosing Enclosure rating: IP 44 Insulation class: F Material: Chemical tank volume: 100 1 Pump Colour: RAL 1028 Liquid end: PVC Weight: 28 kg Check valve cartridge: PVC Seats: PVC Balls: Glass Contour plate: PVC Seals: Viton Chemical tank: Polyethylene Dosing head: Stainless steel Chemical dosing unit item 9296 000002 Feed water line to boiler ntSngs, item 246 2707 Max 4.0 m from dosing pump to feed water line ratings, item 246 2707- Tank ventilation Dosing valve, item 257 3307 Riling connection DN 15, PN 16, DIN 2633 ratings, item 246 2707 Dosing line ø12 x 1.5 mm stainless steel or steel pipe Yard supply Chemical tank Dosing pump Fittings, item 246 2707 Pressure valve Suction valve Filter 680 Type No.: 9296 Version: A Chemical dosing unit 9296 000002 Language UK Page 1/2 AALBORG DATA SHEET INDUSTRIES Dosing valve item 257 3307 Fitting item 246 2707 12 12.5 L 0 a 0 5 —i • Performance curves 2f CO O 20 — 10 1/h 10- 8l/h 10 20 40 80 100 Pressure (bar) Type No.: 9296 Version: A Chemical dosing unit 9296 000002 Language UK Page 2/2 AALBORG DATA SHEET INDUSTRIES Material: Type: • Sample cooler: austenitic stainless steel • Sample cooler grade316L Size: • Cooling water inlet valve: stainless steel • SCS 20 • Sample inlet valve: stainless steel. • Compression fitting: carbon steel Application: Technical data: • The sample cooler is designed for taking manual samples of boiler water for • Coil design pressure: 32 bar g analysis. The cooling water is turned on • Coil design temperature: 300°C and the sample inlet valve is adjusted • Body design pressure: 10 barg until a sample of boiler water is obtained • Body design temperature: 100°C at a suitable temperature. For manual sampling it is not normally necessary to measure sample or cooling water flow rates. 0 90 Sample in a 6 mm O/D Customer supply 2. Sample inlet valve 1/4" BSP (each ends) Compression fittings for sample in 1/4" BSP Cooling water out 1/2" BSP Customer supply . 1. Sample cooler 4. Cooling water Sample out inlet valve 1/2" BSP Cooling water in 1/2" BSP Customer supply Type No.: 7050 Version: A Sample cooler 875 0005 Language UK Page 1/2 AALBORG DATA SHEET INDUSTRIES • Allow the sample to run for a while Installation: before collection. This will ensure that a • Fit the SCS 20 so that the bottom of the true sample is collected for analysis. unit is accessible for the collection of • When enough liquid has been collected the cooled sample. close the sample inlet valve first and • Connect the cooling water inlet in !4" then the cooling water inlet valve. nominal bore pipe via an inlet valve. • After closing the sample inlet valve the • The cooling water outlet should be piped sample out connection may drip for a to an open drain or tundish. few minutes while the coil drains. • The sample inlet pipe should be in 6 mm O/D tubes. Performance: • The sample inlet to the cooler can be • When it is required to predict the taken direct from a boiler or steam line performance of the sample cooler isolating valve. system, the table below gives the sample outlet temperature to be expected for Operation: two boiler pressures an for two cooling • Sample pipe work will become very hot water flow rates. under normal working conditions, and will cause burns if touched. Example • Open the cooling water inlet valve first • A sample flow rate of 30 1/h is required and ensure that a flow can be seen at the from a boiler operating at 10 barg. For a cooling water outlet. cooling water flow rate of 0.4 1/s, from • It is essential that cooling water is the table the sample outlet temperature flowing before opening the sample inlet would be 4K (4°C) above the cooling valve. water inlet temperature. If the cooling • Gradually open the samples inlet valve water is 15°C, the sample temperatures and regulate the flow to achieve a would be 19°C. cooled sample at about 25°C. Cooling water flow rate Cooling water flow rate 0.25 1/s (900 1/h) 0.4 1/s (1440 1/h) Sample flow rate Boiler pressure 10 barg 20 barg 10 barg 20 barg 1/h 1/min Sample outlet temperature above cooling water inlet temperature K (°C) 10 0.17 3 3 1 1 20 0.33 5 5 2 3 30 0.50 7 9 4 5 40 0.67 8 10 5 7 50 0.83 10 12 6 8 60 1.00 11 13 7 10 80 1.33 12 16 8 12 100 1.67 15 19 9 14 120 2.00 17 22 10 16 Type No.: 7050 Version: A Sample cooler 875 0005 Language UK Page 2/2 4M1V2, Excess flow check valves, 399669 • Am DN 6 - 3/8" RG AVN HYDRAULIK A-S sw3 Body and poppet valve steel galvanized - Valve guide brass - Seals elastomere. All galvanized parts passivated for additional surface protection. Application for fluid-lines with hydraulic fluids on mineral oil basis according to DIN 51524 and DIN 51525. For hydraulic fluids not easily inflammable according to VDMA 24317, for Compressed air and other gases as well as for water hydraulics in adequate materials On request. Temperature range: from -30° up to +100° C. Symbol —OV\A^- Design poppet lifted from the seat by a spring with metallic seat Fitting position any Flow direction indicated with arrow Pressure media mineral oils -30° up to +150° C, other media and temperatures on request Working pressure up to 400 bar Viscosity up to 400 cSt (53° E) Closing pressure l/min see schedule at 35 cSt (4,7° E) max. Dimensions in mm Order numbers t, SW Closing pressure DN PN l2 3 d mm mm mm l/min 2 6 400 14 50 22 5 3/8" 39 96 69 /4rf/c/e A/o. éoZO 0ÛDOZ& AALBORG DATASHEET INDUSTRIES • Input signal: 4-20 m A Type: • Ambient temperature: -30°C to +80°C • Control globe valve, straight with • Protection: IP 65 pneumatic actuator and I/P positioner • 23.470, DP 33 Technical data unit: • Design closing pressure: 25 bar Size: • Weight: 34 kg • Nominal diameter: DN 40 Installation: Application: • Only as shown in the picture • For cooling, water, steam, brine and/or gas flow 0 300 Material valve: • Body: GGG 40.3 DIN -Material No. 0.7043 • Seat:X20Crl3 DIN -Material No. 1.4021.05 • Plug:X20Crl3 DIN -Material No. 1.4021.05 • Stuffing box: PTFE V-ring unit (-10°C to + 220°C) Technical data, valve: • Nominal pressure: PN 25 • Positioning ratio: 50:1 • Flow characteristic: Equal percentage 3 • Standard kv value: 25 m /h • Stroke: 30 mm • Plug type: Parabolic shaft guided • Flanges according to DIN Stuffing box Technical data, actuator: • Spring range: 1.5 - 3.0 bar • Diaphragm area: 400 cm2 • Filling volume: 2.3 1 • Max air pressure: 6 bar • Action: Normally closed valve on air failure Technical data, I/P positioner: • Air connection: G %" • Inlet air supply: 1.4 to 7 bar, instrument air • Air inlet consumption in stable state: O.ôxKPNmVh • Cable inlet: M20 x 1.5 Pneumatic control valve DN 40, PN 25, Type No.: 6050 Version: B with DP actuator 6050 000050 and I/P positioner Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Type: • Filter regulator with automatic drain Size: • Connections ports 1/4" BSP • Gauge ports 1/8" BSP Application: • Instrument air for regulating pressure Technical data: • Medium: instrument air only • Max. inlet pressure: 17 bar • Operating temp.: -20 °C to + 65 °C • Filter element: 5 f^m • Recommend pressure regulating range: 0.14-7.0 bar • Pressure gauge: 0-10 bar • Weight: 0.4 kg Connections ports i Material: /y-J-j\ B • Body: Steel ftJP • • Bin: Steel i i • Handle: Acetal 41 J SW19 Flow characteristics In let pre«su r e7 oar ba r 6 P 3 h re s 4 Q. ti e 3 3 \ O 2 Xl 1 23456789 10 Ar flow [dm3/s] Type No.: 8000 Version: A Filter regulator with automatic drain 291 5101 Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Conductivity kit, loose supply. Type: Consisting of: • Test kits Drew AGKIOO supplemented Power supply: AC 110V or 220V with Amerzine test. 1 Conductivity meter Size: 1 Low range cell, white band, range 1-500 1 High range cell, range 20-10.000 • Dimension of box for AGK 100 test kit: 1 Conductivity cylinder, 100 ml Height 105 mm, length 270 mm, 1 Thermometer width 185 mm 1 Gallic acid • Dimension of box for amerzine test kit: 1 Brass spoon Height 45 mm, length 195 mm, Weight: 4 kg width 155 mm • Dimensions of box for hardness test kit: Height 145 mm, Length 250 mm, Width 165 mm • Dimensions of conductivity meter: Height 230 mm, length 140 mm, width 130 mm Application: • Test kits for boiler water treatment. • Test kit AGKIOO should only be used with Amerzine test kit Technical data: • AGKIOO test kit. Consisting of: 1 Comparator, phosphate, 0-20 ppm. 1 Snapping cup. 1 Plastic vial. 1 Glass tube vial. 1 Dropper. 30 Phosphate test tubes. 2 Hydrate alkalinity, rgt. A. 1 Hydrate alkalinity, rgt. B. 1 Phenolphthalein • Amerzine Test Kit. Consisting of: 1 Cylindrical comperator, Amerzine 1 Sample cup 30 Ampoules. • Hardness test kit. Consisting of: 1 Snapping cup 2 Boxes ampoules, 30 each Type No.: 8500 Water testing equipment, AGK 100 with 880 0050 Version: D amerzine test Language UK Page 1/1 Description Index Date Lor|_ Drawa n Appr. Pipe dim. DN 100 -726 Pipe dim. DN80 M87 VENT. TO DECK OPEN AIR f==r~~i ,-lø~ ^ /i—. STEAM 6-7 bar g -u *VJ—' 1055 kg/h [20 t/h] 1266kg/h[24t/h] 1319 kg/h [25 t/h] HOT WELL TANK 7000000020 2.2 Injector 7000000014 -v7 M88 2.2 o 1 1/2" o fc£ Vacuum breaker 6000000010 OJ M87 2.2 ç 1/2" Brass 6020000006 'E M86 Check valve 2.2 DN40 PN40 SS WS 1.4313 Temp.switch+pocket+4m cap.tube 8070000010 M85 40-105 "C M89 6000000042 M84 Control valve 2.2 DN40 PN16 Cast Iron 7040000016 l— M83 Filter 2.2 ± DN40 PN16 Cast Iron Counter flange (not shown) 8500000347 -i M82.6+M86.6 DN40 o screw and nut (not shown) 3000000024 o M82.2-M86.2 20 M16 8.8 / Gasket (not shown) 3520000067 \ M82.1-M86.1 DN40 Graphite CM M88 v- $ Stop valve DIN 1693 6010000043 M82 2.2 DN40 PN16 GGG-40.3 Designation Material code Article No. Tag No. Detail drawing No. ea Dimension Material type rn --/ Title: 030828 c BiL Steam injection system Appr. for steam amount of 20, 24 and 25 t/h BZ 030828 Weight Size Steam pressure: 6 bar 5 1:10 A3 Injectors seen from above AALBORG (Type E) Article/Drawing No: INDUSTtlES TWS DRAWWG AND DESIGN SHOWN HEREIN IS THE PROPERTY OF AALBORO INDUSTRIES AND MUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY 64Z:027665 Version: C Date: 1998-09-11 Pos. M 82 Description A flanged bellows sealed stop valve, type BSAl, for use on steam, condensate and water systems. Limiting conditions Body design conditions PN 16 Max. design temperature 300°C Max. hydraulic test pressure 24 bar g Size and pipe connection DN40, Flanged DIN 2533/BS4504/ISO 7005 PN16. Material specification 1 Body Cast iron DIN GG25 2 Bonnet SG iron DIN GGG 40.3 3 Seat Stainless steel AISI420 4 Disc Stainless steel DIN 17440 X30 Cr 13 5 Bellows Stainless steel DIN 17440 X6 Cr Ni Ti 1810 6 Stem Stainless steel AISI 420 7 Handwheel Pressed steel BS 1449 CR4 8 Stem packing Graphite 9 Bonnet screw Steel DIN931Gr5.6 10 Body/ Bonnet gasket Graphite laminate with stainless steel insert Dimensions in mm DN 40 A 200 B 243 C 200 Weight, kg 10 Data Sheet Stop Valve DN40,PN16 6010 000043 Page 1 of 1 AALBORG INDUSTRIES Version: B Date: 1998-09-11 Pos. M 83 Description Standard screen stainless steel 0.8 mm perforations, type Fig. 33. Limiting conditions Body design conditions PN 16 Max. design temperature 300°C Max. hydraulic test pressure 24 bar g Size and pipe connection DN40. Standard flange: DIN PN 16. Materials 1 Body Cast iron DIN 1691 GG20 2 Cap SGiron DIN 1693 GGG40 3 Cap gasket Reinforced exfoliated graphite 4 Strainer screen Stainless steel ASTMA240 316L 5 Cap studs Steel BS 4439 Gr 8.8 Cap nuts Steel BS 3692 Gr 8 Dimensions (approximate) in mm DN 40 A 200 B 145 C 240 Screening area, cm 164 Weight, kg 7.2 Installation Thé strainer should be installed in the direction of flow as indicated on the body, in a vertical or horizontal pipe line. Data Sheet Cast Iron Strainer, DN40 PN16 7040 000016 1 Page 1 of 1 AALBORG INDUSTRIES Version: A Date: 2003-01-13 Pos. M 84 Available type Normally open, single seat with phosphor bronze balancing bellows with flanged connections, type KB33. Limiting conditions Max. differential pressure, DN 40 8.2 bar Size and pipe connection Standard flange BS 4504, PN 16. Material specification 1 Body Cast iron DIN 1691 GG 20 2 Bonnet Cast iron DIN 1691 GG 20 3 Valve closure Member Stainless steel BS 970 431 S29 4 Valve seat ring Stainless steel BS 970 431 S29 5 Valve seat gasket Reinforced exfoliated graphite 6 Return spring Stainless steel BS 2056 302 S26 7 Stem Brass BS 2874 CZ 121 8 Bonnet gasket Reinforced exfoliated graphite 12 Bonnet studs Steel BS 4439 Gr 8.8 Bonnet nuts Steel BS 3692 Gr 8 DN40 MIO x 35 mm 13 Bellows Phosphor Bronze 14 Bellows gasket Reinforced exfoliated graphite 15 Bonnet bush Brass BS 2874 CZ 121 16 Plunger Brass BS 2874 CZ 121 Dimensions (approximate) in mm DN 40 B 200 Cl 152 Weight, kg 11.2 Installation The valve should be fitted in a horizontal line with the actuator vertically below the line. • • • • • • • • • • Data Sheet Control Valve, DN40, PN 16 6000 000042 Page 1 of 1 AALBORG INDUSTRIES Version: A Date: 2003-09-05 Description A range of self powered control systems that -Z incorporate sensor, actuator, set point controller / indicator, type 121. Temperature range40 to 105°C -1" BSP Material specification 1 Sensor Brass 2 Actuator Brass 3 Capillary tube Copper PVC Covered 4 Adjustment head Polypropylene 5 Union kit Brass 6 Mounting bracket Steel 7 Clip Polypropylene 8 Adaptor plate Steel 9 Pocket Stainless steel BS3605CFS316S18 Dimensions (approximate) in mm Control system A 271 B 148 C 424 D 25 3 4000 Weight, kg 2.0 Pocket F 430 G 28 Error! Not a valid link. Pocket Data Sheet Temperature switch, 40-105°C 8070 000010 Page 1 of 1 AALBORG INDUSTRIES Version: C Date: 2002-09-26 Description DCV2 Wafer check valves are designed to be sandwiched between flanges. They are suitable for use on a wide range of fluids for applications in process lines, hot water systems, steam and condensate systems etc. Material specification 1 Body Ferritic Stainless steel WS 1.4313 2 Disc Austenitic Stainless steel BS 1449 316 S 11 3 Spring retainer Austenitic Stainless steel BS 1449 316 S 11 3 4 2 1 4 Heavy duty spring Austenitic Stainless steel BS 2056 316 S 42 Dimensions in mm DN 40 A 101 B 85 C 79 D 31.5 E 65.5 F 40 Weight, kg 0.74 Installation DCV Wafer Check Valves must be fitted in accordance with the direction of flow arrow indicating correct fluid flow direction. Flange Joint When fitted with a spring they can be installed in any Gasket (Supplied plate. When supplied without a spring these must be by Installer) fitted in a vertical flow line with the flow from bottom to top. The "cam" design of the body allows the various flange types to be accommodated. The body is rotated to touch the flange joint bolts ensuring that the valve is centred in the pipeline. Note: Dies Check valves are not suitable for use where heavily pulsating flow exists, such as close to a compressor. » • « • • • • • • • Data Sheet Wafer Check Valve, DN40, PN40 6020 000006 Page 1 of 1 AALBORG INDUSTRIES Version: B Date: 1998-09-11 Pos. M87 Description The VB14 is a small purpose designed vacuum breaker for general purpose applications on condensing vapour (steam) or liquid systems. Limiting conditions Body design conditions PN 16 Max. design temperature 260°C Max. cold hydraulic test pressure 24 bar g Size and pipe connection 1/2" (System connection) Screwed BSP or NPT. Material specification 1 Cap Brass CU ZN 39 PB2 2 Valve Stainless steel Z 100 CD 17 3 Valve seat Stainless steel Z15 CN 16 02 4 Body Brass CU ZN 39 PB2 5 Gasket Stainless steel AISI304 Dimensions (approximate) in mm Size 1/2" A 55 B (A/F) 34 C 39 Weight, kg 0.35 Installation The VB14 Vacuum Breaker must be installed in a vertical position with the system connection at the bottom. • • * • • • • • • Data Sheet Vacuum Breaker, BSP 1/2' 6000 000010 Page 1 of 1 AALBORG INDUSTRIES Version: A Date: 2000-10-30 Pos. M88 Description • Steam injectors use steam to raise the temperature of water or other liquids. They work by using a jet of steam to draw in the liquid through radial ports, mix it, and distribute the heated liquid throughout the tank or vessel. The circulation induced by the injector ensures thorough mixing and avoids temperature stratification. Limiting conditions • Body design rating: PN25 • Max. saturated steam condition: 17 bar g at 207°C • Maximum heated liquid temperature (tank/vessel vented to atmosphere): 90°C • Weight: 1.6 kg Materials • Austenitic stainless steel grade 316L. 115 Installation Steam injector type IN40M • Steam supply pipework must be firmly anchored to prevent vibration and stress in the tank wall. For more, information, see drawing "Steam injection system". • • • • • • • • • • Data Sheet 7000 000014 Steam Injector, BSP VA" Page 1 of 1 AALBORG INDUSTRIES Version: A Date: 2000-10-30 Pos. M89 Description • Steam injectors use steam to raise the temperature of water or other liquids. They work by using a jet of steam to draw in the liquid through radial ports, mix it, and distribute the heated liquid throughout the tank or vessel. The circulation induced by the injector ensures thorough mixing and avoids temperature stratification. Limiting conditions • Body design rating: PN25 • Max. saturated steam condition: 17 bar g at 207°C • Maximum heated liquid temperature (tank/vessel vented to atmosphere): 90°C • Weight: 0.8 kg Materials • Austenitic stainless steel grade 316L. Steam injector type IN25M Installation • Steam supply pipework must be firmly anchored to prevent vibration and stress in the tank wall. For more information, see drawing "Steam injection system". • • • • • • • • * Data Sheet Steam Injector, BSP 1" 7000 000020 Page 1 of 1 AALBORG INDUSTRIES Purpose and Application Electrode supply voltage Delta voltage 0.5 V„/1000 Hz for LRS1 -5b Continuous monitoring of the conductivity of liq delta voltage 1.3 Vp/67 Hz for LRS 1 -6b uids with the AI conductivity electrode Mains supply types ERL 16, LRG 16-4, LRG 17 or LRG 19. 120 V/60 Hz, 220V/50 Hz, 240V/50 Hz, 3.5 VA Signalling of preselected conductivity limit value. (please state voltage when ordering) Application in steam boiler plants for feedwa- Protection ter and condensate monitoring; for conden IP 40 sate monitoring in district heating plants, in the paper and pulp industry and in catering kitch Permissible ambient temperature ens; for conductivity monitoring in water 0...55°C treatment plants; for monitoring of cooling Case materials towers; for dyebath monitoring in dye works. Base: ABS plastic, black Cover: ABS plastic, stone-grey Design Weight Approx. 0.5 kg Plug-in unit in plastic case for installation in control cabinets. The terminals in the case are accessible after loosening two screws and un Important Notes Conductivity limit switch LRS 1 -5b, LRS 1-6b plugging the unit from its base. The avoid con Cable required for wiring to the electrode: fusion with other plug-in units of the AI 2 range, inserts are fitted in the bases so that Screened cable, e. g. 4 x 0.8 mm , cable length only the correct unit may be plugged into each base. The plug-in units may be snapped onto a 35 mm supporting rail or screwed into position on a mounting panel. Field enclosures for several plug-in units are available on request. Technical Data Function Measuring transducer with switch contact for conductivity used with the conductivity elec trode types ERL 16, LRG 16-4, LRG 17 or LRG 19, manual temperature compensation at operating point Input Four connections for one conductivity elec trode ERL or LRG Output 1 volt-free relay contact; max. contact rating: 250 V, 500 W, 3 A resistive with a life of 4 x 105 switching cycles or 0.35 A inductive with a life of 2 x 106 cycles; contact material silver, hard-gold plated Limit value Continuously adjustable within the respective range 0.4...10mS/cmor0.04...1 mS/cmforLRS1-5b, selection between the two ranges by switch on front panel, values referred to 25 °C Temperature influence can be compensated with the aid of adjuster up to max. 250 °C on reaching service temperature, initial position calibrated to 25 °C Switching hysteresis 1 % Indicators Two LEDs: green for 0 < limit value red for o > limit value Cell constant of conductivity electrode C - 1,0 [1 /cm] Aalborg Industries Data sheet No. 8210 000005 1/2 Dimensions Side view Base with termina l s Front view Base Cover j-H r" —• " 0 4,3 1 0 igJ i fP-2 0 BHLRS1-...b 3 0 ^ D3I»0 4 0 5 0 CM u 6 0 c\t, ^ 7 0 (o) 8 0 cr[s] <5> 9 0 10 0 c.OT- O T=25°C 1 1 'J 0 12 0 / -J- m \ Cable ^r Screws to fasten entries cover to base Mounting clip for 35 mm supporting rail 4 i— - 51 • -( J- holes to be drilled to 4.3 mm dia for installation of unit in boiler panel - hole drilled for mounting clip Dimensions of conductivity limit switch types LRS 1-5b Wiring Diagrams LRS 1-5b 1 Ù I 10 12 n Alarm U N Mains ( 15 Conductivity electrode /*» f\ /\ /*\ ERL16orURG16-4 |3 |2 |1 |l A AAA Conductivity electrode | LRG17orLRG19 | C - 1 cm"' J Wiring diagram for conductivity limit switch type LRS 1 -5b, illustrated position of contact: relay de-energized, i.e. alarm Aalborg Industries Data sheet No. 8210 000005 2/2 Technical data for conductive electrode ERL 16-1 Technical data: Max. service pressure: 32 barg at saturation temperature 238 degr. C (higher pressures available on request) Connection: Thermal ERL 16-1: screwed 3/4" BSP, PN 40 to DIN 228 y insulation Length (L) supplied: jj Screwed %" ERL 16-1: 99 mm - DN228 Materials: Body: X 6 CrNiMoTi 17 12 2 (1.4571) Electrode rod: X 6 CrNiMoTi 17 12 2 (1.4571) Electrode tip: X 6 CrNiMoTi 17 12 2 (1.4571) Conductivity electrode type ERL 16-1, 3h° Insulating sleeving: PTFE Terminal box and connector: plastics Permissible conductivity range: From 1 micro S/cm Max. permissible ambient temperature at terminal box: 60 degr. C Electric connection: Via four-pole connector with screw terminals, cable strain relief and cable gland Pg 11. Approx. weight: 0.9 kg Design: The conductivity electrode is provided with an electrode rod completely insulated by a PTFE sleeving except for the measuring surface. A pressure-tight sealing between electrode rod and body is ensured by a Teflon tube. Installation: The conductivity electrode can be installed vertically, horizontally, or radially inclined. The electrode tip must be constantly submerged by at least 100 mm. Installation on a side connection (measuring pot) is highly recommended. Aalborg Industries Data sheet No. 8620 000003 AALBORG DATA SHEET INDUSTRIES Type: • Control unit for oil detection equipment Application: • The control unit is operated together with an ultrasonic sensor. • The equipment provides for oil detection in feed/make-up water. Material: • Control device cabinet: Polycarbonate Technical data: • Power supply (selector switch): 110/120Vor220/240VAC • Relay output: DPCO • Enclosure: IP 65 • Holes for glands 3 of ø 16 1. G O Normal O O Alarm O Fault oc •0 ' 188 Holes for mounting in <&- ©©• o r ^ Holes for glands « 40 . 130 160 200 ^ Type No.: 8210 Version: A Control unit for oil detection equipment 8210 000025 Language UK Page 1/1 AALBORG DATA SHEET INDUSTRIES Type: • Ultrasonic sensor for oil detection equipment Application: • The ultrasonic sensor is operated together with a control unit. • The equipment provides for oil detection in feed/make-up water. Material: • Sensor: Stainless steel Technical data: • Temperature: -70°C to 150°C • Design of duty: Chemical interface • Liquid type: Clean, viscous with solids • Cable: 6 metre 258 .20.1.25, 152 .26 T - Type No.: 8310 Ultrasonic sensor 8310 000005 Version: A for oil detection equipment Language UK Page 1/1 Technical data for differential pressure transmitter, type 7MF4433 Mode of operation Measuring principle Piezo-resistive Input Measured variable Differential pressure and flow Measuring range • Span (continuously adjustable) - Nominal pressure PN 32 1 mbar to 20 mbar - Nominal pressure PN 160 1 mbar to 30 bar - Nominal pressure PN 420 2.5 mbar to 30 bar • Lower measuring limit - Measuring cell with silicone oil filling -100 % of max. span or 30 mbar (absolute) - Measuring cell with inert filling liquid For process temperature -20 "C < i» < 60 °C 30 mbar (absolute) For process temperature 30 mbar (abs.) + 20 mbar (abs.) {-a - 60 °C)/°C +60 "C < i3 S 100 "C (max. +85 °C for 30-bar measuring cell) • Upper measuring limit 100 % of max. span (max. 160 bar with oxygen measurement and inert filling liquid) • Start-of-scale (continuously adjust.) Between the measuring limits Output Output signal 4 to 20 mA • Lower limit (continuously adjustable) 3.55 mA, factory-set to 3.84 mA • Upper limit (continuously adjustable) 23.0 mA, factory-set to 20.5 mA or optional 22.0 mA • Ripple (without HART communication) /pp s 0.5 % of max. output current • Electric damping - Adjustable time constant (T63) 0 to 100 s in steps of 0.1 s, factory-set to 0.1 s • Current transmitter Adjustable from 3.55 to 23 mA • Signal on alarm Adjustable from 3.55 to 23 mA Load • Without HART communication RB S (UH -10.5 V) / 0.023 A in ft UH: power supply in V Characteristic Linear rising or falling or square-rooted Accuracy Reference conditions Increasing characteristic, start-of-scale value 0 bar, stainless steel seal diaphragm (with level: mounting flange without tube), silicone oil filling and room temperature (25 °C) r = max. span/set span = span ratio Error in measurement with fixed-point setting (including hysteresis and repeatability) - Linear characteristic rslO s 0.1 % 10 • Repeatability Included in error in measurement • Hysteresis Included in error in measurement Response time Approx. 0.2 s. approx. 0.3 s with 20- and 60 mbar measuring cells (T63, without electric damping) < m i . A o/ 20-mbar measuring cell < (0.2 r) % Ambient temperature effect • At-10 to+60 °C ä (0.1 r + 0.2) "/o1* • At -40 to -10 °C and +60 to +85 °C < (0.1 r + O.ISr/o/IOK11 Aalborg Industries Data sheet No. 8020 000001 1/3 Technical data for differential pressure transmitter, type 7MF4433 Influence of static pressure • On start-of-scale <, (0.15 r)% per 100 bar - 20-mbar measuring cell <. (0.15 r)% per 100 bar • On span <, 0.2% per 100 bar - 20-mbar measuring cell <, 0.2 % per 32 bar Influence of mounting position < 0.7 mbar per 10° inclination Influence of power supply 0.005 % per 1 V change in voltage Rated operating conditions Installation conditions • Installation instructions Any mounting position Ambient conditions • Ambient temperature (observe temperature class in potentially explosive atmospheres) - Measuring cell with silicone oil filling -40 to +85 °C 30-bar measuring cell -20 to +85 °C - Measuring cell with inert filling liquid -20 to +85 "C - Digital display -30 to +85 °C • Ambient temperature limits See ambient temperature • Storage temperature -50 to +85 °C • Climate class - Condensation Permissible • Degree of protection (to EN 60 529) IP 65 • Electromagnetic compatibility - Emitted interference To EN 50 081-1 - Noise immunity To EN 50 082-2 and NAMUR NE 21 Medium conditions • Process temperature - Measuring cell with silicone oil filling -40 to +100 °C 30-bar measuring cell -40 to +85 °C (-20 to +85 "C for 7MF4533) - Measuring cell with inert filling liquid -20 to +100 °C 30-bar measuring cell -20 to +85 °C • Process temperature limits See process temperature • Process pressure limits Nominal pressure (PN) Design Weight (without options) Approx. 4.5 kg Dimensions See drawing Material • Wetted parts materials - Seal diaphragm Stainless steel, mat. No. 1.4404. Hastelloy C276, mat. No. 2.4819, Monel, mat. No. 2.4360, tantalum or gold - Process flanges and sealing screw Stainless steel, mat. No. 1.4408, Hastelloy C4. mat. No. 2.4610 or Monel. mat. No. 2.4360 - O-ring FPM (Viton) or as option: PTFE, FEP, FEPM and NBR • Non-wetted parts materials - Electronics housing Die-cast aluminium, low in copper, GD-ALSi 12, or stainless steel precision casting, polyester-based lacquer, stainless steel rating plate - Process flange screws Steel, galvanized and yellow-passivized, or stainless steel - Mounting bracket (option) Steel, galvanized and yellow-passivized, or stainless steel Measuring cell filling Silicone oil or inert filling liquid (max. 160 bar with oxygen measurement) Process connection Female thread 'A -18 NPT and flange connection to DIN 19 213 with mounting thread M10 (M12 for PN 420) or 7/16-20 UNF Electrical connection Screw terminals, cable inlet via screwed gland Pg 13.5 (adapter), M20 x 1.5 or Vz -14 NPT, or Han 7D/Han 8U pluq Displays and controls Input keys 3 for local programming directly on transmitter Digital display Built-in, cover with window (option) Power supply (U H) Terminal voltage on transmitter DC 10.5 to 45 V and DC 10.5 to 30 V in intrinsically-safe mode Ripple Upp S 0.2 V (47 to 125 Hz) Noise Urms<1.2mV(0.5to10kHz) Aalborg Industries Data sheet No. 8020 000001 2/3 Technical data for differential pressure transmitter, type 7MF4433 Certificates and approvals Exclusively decisive are the data in the official EU prototype test certificate and the respectively valid supplements CENELEC To DIN EN 50 014: 1997, EN 50 020: 1994 and EN 50 284:1999 • Intrinsic safety © H1/2GEExiallCT4/T5/T6 - EU prototype test certificate TÜV99ATEX1494 - Max. ambient temperature +85 °C temperature class T4 +70 °C temperature class T5 +60 °C temperature class T6 - Connection to certified intrinsically- L/| = 30V, /|= 100 mA, safe circuits with maximum values Pi = 750 mW, R, = 300 n - Effective internal inductance /-i = 0.25mH - Effective internal capacitance Q = 6nF • Explosion-proof ©H1/2GEExdllCT4/T6 - Conformity certificate PTB99ATEX1160 - Max. ambient temperature +85 °C temperature class T4 +60 °C temperature class T6 S)v^yc± 11 —<. fl^i > 15 * 45 for Pg 13.5 68 120 1 a Process connection of low-pressure side V* 18NPT 5 Terminal side 1b Process connection of high-pressure side V4 -18 NPT 6 Electronics side, digital display 7 2 Mounting thread M10, M12 or /16 - 20 UNF 7 Protective cover over keys 3 Blanking plug 8 Sealing screw with valve 4 Electrical connection: 9 Vent on side for liquid measurements screwed gland Pg 13.5 (adapter), M20 x 1.5 or 10 Vent on side for gas measurement (suffix H02) 14-14 NPT or Han 7D/Han 8U plug 11 Mounting bracket (option) Aalborg Industries Data sheet No. 8020 000001 3/3 AALBORG duHflMBflWHIB^^^^^M Table of contents Operation and maintenance Steam atomising burner General 1 Steam atomising burner, type KBSA Precautions with fuel oil 1 General system description 2 Functional description 3 Operation instruction 4 Commissioning 5 Manual operation 6 Maintenance instructions 7 Faults and rectifying faults 8 Steam atomising burner settings 9 Photo cell Description 1 Viscosity - temperature chart Description 1 Language UK Page 1/1 AALBORG STEAM ATOMISING BURNER OM5580#01.0 INDUSTRIES Steam atomising burner 1 General The steam atomising burner is capable of burning both diesel oil and heavy fuel oil. As the burner is a very vital component of the boiler plant, the operating staff should be thoroughly instructed with regard to the operation of the equipment and the safety regulations. This is due to the fact that burner problems are often caused by incorrect burner operation. With frequently occurring burner faults, the nearest service centre should be consulted. To ensure a safe and reliable function of the burner it must be inspected at least once a year, in addition to the normal maintenance intervals. The inspection should be carried out by a representative of the supplier or by another competent and qualified person. It should be clearly understood that for a plant of this complexity it is not practicable to anticipate all the possible circumstances which may arise during the operation life of the plant. Therefore, should circumstances arise in plant operation and maintenance which are not specifically covered by these instructions, the matter should be referred to Aalborg Industries for consideration and advice. Repairs, adjustments, alterations or changes to plant operations not covered by these instructions should not be effected without reference in writing to Aalborg Industries. Information in this manual is subject to changes without notice and does not represent a commitment on the part of Aalborg Industries. It is not allowed to copy this manual or part hereof for any purpose other than the purchaser's personal use. Aalborg Industries shall not be held responsible for any damage or losses caused by the use of this manual. 1.1 Safety regulations Caution: To ensure a safe burner operation, the burner has to be installed and commissioned by qualified personnel, and all guidelines in these instructions have to be followed. All safety equipment such as flame sensor equipment and correcting elements may only be replaced by qualified personnel. Warning: Repair of any of the safety components is NOT permitted. Failure to comply may result in serious injury or death and may cause considerable damages to the boiler plant. Language UK Page 1/2 AALBORG STEAM ATOMISING BURNER OM5580#01.0 INDUSTRIES If any unexpected plant behaviour, deterioration or similar event should occur giving rise to any reasonable doubt as to the continued safety of the plant, the matter should be reported at once to Aalborg Industries for their advice. 1.2 Qualified personnel Qualified personnel according to these operating instructions are persons, who are confident in installing, regulating and commissioning the burner, and who have qualifications to carry out this work, i.e.: • Persons who are trained to operate electric circuits and units according to the safety standards. • Persons who are qualified in the use of dangerous fuel according to the relevant laws and regulations. Language UK Page 2/2 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES Steam atomising burner, type KBSA 1 Precautions with fuel oil Fuel oil is usually the residue of crude oil after the removal by distillation of the most volatile oils and gases. Fuel oil in its liquid state is very difficult to ignite in bulk and not capable of spontaneous combustion. The vapour, however, is explosive when mixed with air, and being heavier than air, tends to accumulate in low levels, such as bilges and bottoms of tanks where it may remain undiscovered until ignited. It is always present in a partly filled oil tank, or in a tank which has contained fuel oil and from which the vapour has not been removed by artificial means, and is given off through the vents from tanks in process of being filled. A leak in any part of the oil burning system, if allowed to continue, may result in an accumulation of this explosive vapour. Ignition of the vapour has been caused by an open light, electric spark, smoking, spark caused by striking metal, heat from the filament of a broken electric lamp, sparks from funnel, or has been communicated from galley or fires under boilers. Warning: An oil fire cannot be extinguished by water but may be extinguished by sand, steam or chemical fire extinguishers. An intelligent appreciation of the properties of fuel oil, as described above, is a better preventative of accident than adherence to any set of rules that may be prescribed. The following precautions, however, should be rigidly enforced: • When oil is being received no naked light, or electrical apparatus liable to spark should be permitted within 20 m of the oil hose, tank, or compartment containing the tank, or the vent from the tank, excepting when special arrangements are carried out. • While receiving fuel oil the storage tank must be closely watched for leaks and care must be taken that all outlets from tank, except the vents, are closed. No naked lights or electrical apparatus, liable to spark should be permitted at any time in a compartment containing a fuel oil tank. Electric lamps used in such compartments should have a wire protector around the bulb, or be of a type that will ensure the breaking of a circuit through the lamp in the event of the lamp being broken. • No one should be allowed to enter a fuel oil tank until it has been gas freed, and any person then entering the tank must have a life line around his body properly tended in order that he may be hauled out if overcome by gas. Electrical fuses and switches, unless of the enclosed type, should not be permitted in compartments containing fuel oil pumps or piping. Care must be taken that the wire-gauze protectors in vent pipes from fuel oil tanks are at all times intact. Language UK Page 1/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES • Dampers fitted in the uptakes of the boilers, must be kept fully open while burning oil. Otherwise gas may accumulate dangerously in the furnace with a resultant blowing out into the boiler or engine room. • The valves on glass gauges on fuel oil storage or settling tank should be kept habitually shut. When a reading of the gauge is desired the valves may be opened, but must at once be closed again. • In each boiler or engine room fitted for oil burning there should be fire extinguishing apparatus in accordance with the requirements/rules of the authorities and classification societies in question. The fire extinguishing apparatus can for example be a fire hose, permanently coupled and of sufficient length to reach all parts of the boiler or engine room and either: — a box containing at least 85 litres of dry sand with a large scoop, or — chemical fire extinguisher of the tank type. • When the fuel oil system has not been in use for a longer period or after joints in the piping have been re-made, the system should be tested "cold", under a pressure at least equal to the working pressure, before fires are lighted. During the test a careful inspection for leaks should be carried out. • Fuel oil should not be habitually heated above 65°C for light oils and 120°C for heavy oils and never above the flash point of the oil in any part of the system. Care must be taken to prevent accumulation of oil or vapour in any place outside the system, and in ships, particularly in bilges under the furnace. This can be accomplished by rigid cleanliness. • In the event of a considerable accumulation of oil in the furnace, such as may be caused by a sudden extinguishing of the burners, the vapour must be blown out through the boiler into uptake and funnel by fan or steam hose before the fires are again lighted. Note: This furnace purge is done automatically when the burner is operating in "auto-mode", but has to be done manually when the burner is in "manual-mode". General system description The following contains a general description of the components in the burner unit. The burner unit consists of a steam atomising burner and supply systems for oil, steam, and combustion air with the required data for correct burner performance. The burner is mounted on the top or the side of the boiler, and the combustion air fan must be connected to the burner via an air duct. The burner is capable of burning both diesel oil and heavy fuel oil. An illustration of the KBSA burner is shown in Figure 1. Language UK Page 2/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES Illustration of a KBSA burner Figure 1 kbsal.cdr 2.1 Burner design The steam atomising burner gives the thermal input to the oil-fired boiler in order to achieve the specified steam demand in the operating range. The burner is designed so that the flame fits the actual furnace dimensions and gives a correct combustion provided the supply conditions of fuel, air and steam are correct. The burner consists of a wind box and an air register with divided swirler. The guide vanes of the inner swirler have a fixed design whereas the guide vanes of the outer annular swirler have a design depending on the furnace geometry. 2.1.1 Wind box design The steel wind box is the main structural part of the burner unit and is provided for mounting or welding onto the boiler. On the burner wind box the front plate is mounted in which for lance, ignition burner, flame scanner and peep-hole are incorporated. The valve arrangement for fuel oil and atomising steam is mounted directly on wind box, flexible hoses connect the valve arrangement to the lance. 2.1.2 Burner register The burner register is the duct between the wind-box and the furnace. The ignition burner, the burner lance with the atomiser, and the flame stabiliser are placed in the burner register. For maintenance and inspection purposes the burner lance can be dismounted from the front plate, making cleaning and replacement of the atomiser very easy. Language UK Page 3/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES The flame stabiliser is designed to create an internal re-circulation of hot gases to provide continuous ignition, and hereby to stabilise the flame which results in less pulsation. 2.1.3 Burner lance The burner lance, illustrated in Figure 2, contains the Y-jet atomiser, where steam and fuel are mixed and ejected. This oil mist is then mixed with primary and secondary combustion air, and the combustion is completed. Ignition is achieved by a flame from the ignition burner. Both lance and ignition burner are purged during normal stop to prevent drip and build-up of carbon deposits. Burner lance Steam inlet Figure 2 gun.cdr 2.1.4 Y-jet Atomiser The Y-jet atomiser, illustrated in Figure 3, operates on the principle of the atomising medium [B] (steam or compressed air) and fuel oil [A] at high velocity, impacting within the intersecting atomising medium and oil passage of the nozzle. To achieve this, passages are in an Y-configuration and disposed radial around the nozzle, and the dimension and number of passages are dependent on the oil burner capacity. This has the advantage of maintaining the high passage velocity right up to the point of impact. Further atomisation takes place in the combined mixing and ejection of the atomiser. Y-jet atomiser Figure 3 Y-jet.cdr Language UK Page 4/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES Atomisation is almost independent of oil pressure and consequently the excellent quality is maintained down to the minimum firing rate. The atomising medium and oil are supplied from the shut-down valves through flexible hoses to the burner lance. In addition to the very low consumption of the atomising fluid (approx.1% of the oil weight at full load), the Y-jet burner has a high turndown ratio, up to 10:1, dependent on size. 2.1.5 Flame failure equipment Flame failure during light up and normal operation is detected by a photo electric cell mounted on the burner unit and coupled to an amplifier mounted inside the control panel. On loss of flame this flame failure equipment will automatically shut down the burner. The number of photo cells for automatic service and manual service depends on the classification society. 2.2 Atomising steam/air system Steam for atomising is supplied from the boiler drum or common steam line, and the steam pressure is reduced to 6 bar or lower. The steam pressure at the burner is automatically lowered for stabilisation of flame when the burner load is decreased. When the burner is stopped normally, the purge valve will open automatically and the oil remaining in the burner lance will be atomised and fired into the furnace and the burner lance is cleaned. The atomising steam valve is closed after the end of the -purge period.- If steam is not available, compressed air at a pressure of approximately 7 bar can be used as atomising medium for starting up. 2.2.1 Atomising steam pressure control The steam pressure is controlled by an electrically operated regulating valve, and the corresponding controller keeps a pre-set pressure according to the fuel flow to the burner. 2.2.2 Atomising steam pipe - drain A thermostatic steam trap can be fitted to drain the condensate in order to have dry steam at the burner. 2.3 Ignition oil system The diesel oil is supplied by a pump which is only running during ignition. In plants which consist of two boilers each burner has its own ignition oil pump, and a solenoid valve between these two pumps which is normally closed. 2.3.1 Ignition oil pump The ignition oil pump is a gear pump fitted with a pressure limiting valve and a filter inside the housing. The pump pressure should be adjusted to give 8-10 barg at the ignition burner. If a pump fails, in a double boiler plant, the other can be selected to supply diesel oil for ignition to both burners, and in this mode the solenoid valve must be open. Language UK Page 5/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES 2.3.2 Ignition burner The ignition burner, illustrated in Figure 4, operates on the principle of mechanical pressure jet atomisation. The ignition burner is retractable and inserted/retracted by an air cylinder. Combustion air for the ignition burner is supplied from the compressed air system, and can be adjusted by means of the throttle valve, placed after the solenoid valve. The ignition burner is automatically purged by compressed air. At the end of the furnace purge period the solenoid valves for diesel oil and combustion air to the ignition burner are released and the ignition burner is ignited by means of an electric high-tension spark. The ignition burner is simultaneously moved into ignition position. When the ignition flame is stable the pick-up of this release the oil for the main burner. The ignition burner must ignite the main burner within the pre-set ignition period. At the end of the ignition period the solenoid valves to the ignition burner are switched off and closed, the ignition burner is purged with compressed air and returns to starting point in the retracted position. Ignition burner -UL Oil inlet ^H3^ 3G Air inlet * L Figure 4 ignitor.cdr 2.4 Combustion air system The combustion air system supplies air to the burner according to the demands of the control system. The draft loss of the burner air register is measured by a differential pressure transmitter, which converts the signal to a flow signal used by the control system for automatic air/oil ratio control. The combustion air is supplied by a directly driven centrifugal fan. The fan is mounted on a common bed frame with motor, inlet vanes, and servo-drive unit. The air flow to the burner is regulated by inlet vanes mounted on the fan suction side. The inlet vanes are of a multi-blade design and regulated by a servo-driven unit comprising an air cylinder and an I/P positioner. A silencer can be mounted on the fan suction side. 2.5 Oil supply system This section describes the oil system in general terms together with some of the requirements needed to have a safe and reliable burner operation. The burner and the oil system are designed for both diesel oil and heavy fuel oil operation. A diagram of the oil system for steam atomising burners is shown in Figure 5. The diagram shown is for a plant with two steam atomising burners. Please note that the oil system can be designed somewhat differently from plant to plant depending on the requirements. Language UK Page 6/28 AALBORG STEAM ATOMISING BURNER. TYPE KBSA OM5580#02.1 INDUSTRIES The oil system consists of oil tanks for diesel oil and heavy fuel oil, mixing tube, oil pumps, heaters, ignition oil pumps, and equipment for oil pressure and temperature control. The automatic shut-off valves, re-circulation valve, solenoid valves, and the rest of the necessary burner mountings are all fixed on the wind-box. All shut-off valves are ball valves, and the automatic valves are with electric/pneumatic actuators. The arrangement of the components on the burner is made as simple as possible and is hence very user friendly regarding operation and maintenance. To avoid blockage, all pipelines carrying heavy fuel oil must be traced either by means of steam or electrically. The oil flow control valve is fitted with a pneumatic converter/positioner. To obtain a very accurate regulation of the oil, which is very important to have a large turn down ratio, the valve is also fitted with an adjustable Cv-adjuster. This Cv-adjuster makes it possible to adjust the pressure loss coefficient of the valve whereby the oil flow regulation can be optimised to each single installation. The oil flow is measured by a screw-type flow meter. The fuel oil temperature before the burner inlet is kept precisely at the desired value by means of an electric actuated control valve, a single loop PID-controller, and a PtlOO temperature transmitter. The fuel oil pressure control loop includes an electric actuated control valve to ensure the correct pressure at the fuel oil inlet of the burner, and thereby providing a larger turn-down ratio of the control valve. A single loop PID-controller and a standard 4-20 mA pressure transmitter ensure optimum and accurate functionality. 2.6 Mode of operation The air/oil ratio is controlled automatically. The oil flow is measured by a screw- type flow meter and the air flow is measured as a differential pressure across the burner air register. The modulation of the burner is fully automatic on each fuel type. The operator can change to manual operation. The change from diesel oil to heavy fuel oil and the change from air atomising to steam atomising and vice versa are achieved by manual operation. Functional description This section contains a functional description of the burner plant and the flow ways in the system. 3.1 Fuel oil supply system To give a clear picture of the fuel oil supply system the system is split into two separate systems, a part ("Part one") containing the accessories connected to the fuel oil tanks, pumps and heaters, and a part ("Part two") containing accessories related to the burner and regulating system. The two subsystems of the fuel oil system are described in the following two subsections and they are illustrated schematic in Figure 5 and Figure 6 respectively. Language UK Page 7/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES 3.2 Fuel oil supply system, "Part one" "Part one" of the fuel oil supply system is characterised as the part of the system which is connected to the fuel oil tanks and heater. The primary system is schematic illustrated in Figure 5. The oil system is shown as a plant with two boilers, but is also valid for a plant with only one boiler. Schematic illustration of fuel oil supply system, "Part one" Figure 5 F_oilsys.cdr 3.2.1 Oil tanks The heavy fuel oil tank may be provided with a heating coil for heating up the fuel oil in the tank to at least 50°C, at which temperature it will be possible to pump the oil. The oil temperature in the tank should not heated too much in order to keep the oil temperature controlled by the heater units. Whenever a boiler plant is intended to operate on heavy fuel oil, all pipes carrying fuel oil must be insulated and traced in order not to cool the oil if the circulation is stopped. The tracing can be done either by means of steam heating or by means of electric heating cables. Language UK Page 8/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES 3.2.2 Fuel selection The fuel type is selected by manually operating the three-way valve (Gl 15) in the oil system. The heavy fuel oil can be taken from both the service tank and settling tank. If the heavy fuel oil is taken from the settling tank the suction level from the tank must be arranged in a sufficient level height to prevent e.g. water, sand, or particles from entering the oil system. 3.2.3 Return flow from the burner When the burner is in stand-by mode, a minimum of fuel oil is returned via the oil return line to the three-way valve (Gill). From here the fuel oil is either led to the pump suction side via the mixing tube (Gl 10) for degassing or to the heavy fuel oil settling tank. The three-way valve normally returns the fuel oil to the mixing tube. The three-way valve is a pneumatically operated actuator controlled by a solenoid valve (Gl 13). The solenoid valve has a manual operator screw-type slot for emergency operation. If the fuel is changed from diesel oil to heavy fuel oil by means of the three-way valve (Gl 15), the three-way valve (Gill) automatically changes position and returns the oil to the heavy fuel oil settling tank for a period of time. This arrangement is necessary to avoid that diesel oil is heated by the pre-heater in this specific operating sequence. The viscosity of the re-circulated diesel oil will decrease and hereby also the lubrication characteristic. If the oil is led to the pumps this will cause damage to the pumps. After the pre-set time period has expired, the three-way valve (Gill) returns to normal position, and the fuel flows to the mixing tube (Gl 10). The time period must be set with regard to oil pressure and the quantity of oil in the pipe system. 3.2.4 Fuel oil supply pump The oil system is fitted with one set of supply oil pumps suitable for both diesel oil and heavy fuel oil (G05 and G12). The supply oil pumps (Gl47) is a twin type package in which two screw spindle pumps with driving motors are connected by a cross over arrangement to the valve housing. Each pump is fitted with a pressure relief valve, a filter (G02 and G09), a mano/vacuum gauge (G04 and Gl 1) at the filter, and stop valves (G07 and G14). The pumping capacities for each of the pumps are calculated in such a way that there will be sufficient oil flow to the burner(s) and the pressure regulating valve in full load condition. The control system receives a signal from the pressure transmitter (G99). If the pressure drops below the pre-adjusted set point, the operating pump stops, and the stand-by pump starts. If the pressure continues to drop, the control system gives alarm for low oil pressure and stops the burner(s). 3.2.5 Fuel oil pressure control A part of the fuel oil returns to the pump suction side through the oil pressure control valve (Gl00) which keeps a pre-set pressure in the fuel oil system. The fuel oil pressure control loop includes an electric control valve (Gl00) to ensure the correct pressure at the fuel oil inlet of the burner. This provides larger turn-down ratio of the control valve. A single loop PID-controller and a standard 4-20 mA pressure transmitter (G99) ensure optimum and accurate functionality. Language UK Page 9/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES 3.2.6 Pre-heater The oil system is provided with pre-heater(s) (G22) heating the heavy fuel oil to the correct temperature/viscosity by means of steam. The fuel oil is changed by means of the manually operated three-way valve (Gl 15). When diesel oil is selected, the stop valve (G51) must be opened, and the stop valve(s) (G25) must be closed. When heavy fuel oil is selected, the stop valve(s) (G25) must be opened, and the stop valve (G51) must be closed. 3.2.7 Fuel oil temperature control The heavy fuel oil temperature after the pre-heater(s) is kept at the desired value by means of a flow control valve (G20), a single loop PID-controller, and a PtlOO temperature transmitter (G28). 3.2.8 Ignition oil system The ignition system always operates on diesel oil no matter if the steam atomising burner operates on diesel oil or heavy fuel oil. This secures a reliable ignition. The diesel oil is supplied by an ignition oil pump (G72) with filter (G70). The pump is only operated in ignition mode. The ignition oil pump is a gear pump fitted with a pressure limiting valve and a filter inside the housing. The pump should be set to 8- 10 bar. A plant with two boilers is provided with two ignition oil pumps. If a pump fails, the other can be selected to supply diesel oil for the ignition to both burners. 3.3 Fuel oil supply system, "Part two" "Part two" of the fuel oil supply system is the part of the system which is situated next to or on the burners. The secondary system is schematic illustrated for a single burner in Figure 6. Schematic illustration of the fuel oil supply system, "Part two" 1 - Stop valve 2 - Isolating valve 3 - By-pass valve 4 - By-pass valve 5 - Stop valve 6 - Fuel flow transmitter 7 - Stop valve 8 - Stop valve 9 - Fuel oil flow control valve 10 - Stop valve 11 - Fuel oil thermometer 12 - Fuel oil pressure gauge 13 - Air filter/reduction 14 - Stop valve 15 - Isolating valve Fuel oil supply from 16 - Fuel oil pressure gauge heaters/pumps 17-Shut-offvalve 18 - Air filter/reduction 19 - Three-way valve Return flow to mixing tube Figure 6 B_sys03c.cdr Language UK Page 10/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES From the fuel oil heater or by-pass line the fuel flows to the stop valve (5), fuel flow transmitter (6), stop valve (7), stop valve (8), fuel oil flow control valve (9), and stop valve (10). The by-pass valves (3 and 4) is arranged for the fuel flow transmitter and the fuel oil flow control valve. At the burner the fuel is either re-circulated directly back to the mixing tube (if the burner is stopped) or into the burner (if the burner is in operation) through the three- way valve (19). If the burner is in operation, the fuel flows through the shut-off valve (17) and stop valve (14) and finally enters the burner lance. If the burner is stopped, the fuel will flow through the three-way valve (19) to the throttle valve (1), which directs the flow back to the diesel oil tank or the heavy fuel oil tank. 3.4 Atomising steam system The atomising steam system is illustrated schematic in Figure 7, and is described in the following. Steam is supplied from the boiler drum valve or the common steam line, and flows through the stop valve (1), the pressure regulating valve (2), the non-return valve (3), and the stop valve (4). At the burner the steam enters the condensate separator (12), and flows through the shut-off valve (23), and the stop valve (16), and finally enters the burner lance. Atomising steam system BURNER 1 - Stop valve 2 - Pressure regulating valve 3 - Non-return valve 4 - Stop valve 5 - Non-return valve 6 - Stop valve 7 - Stop valve 8 - Steam trap 9 - Stop valve 10 - Non-return valve 11 - By-pass valve 12 - Condensate separator 13 - Purge valve 14 - Non-return valve 15 - Stop valve 16 -Stop valve 17 - Isolating valve 18 - Pressure gauge 19 - Isolating valve 20 - Low pressure switch 21 - Isolating valve 22 - Pressure transmitter 23 - Shut off-valve From boiler Atomizing steam, 7 to 12 barg / , Compressed air (7 bar) Figure 7 B_sys05a.cdr Language UK Page 11/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES The purge valve (13) is opened automatically, when the burner is stopped normally, in order to clean the burner lance for oil. The condensate from the condensate separator (12), flows through the stop valve (7), the steam trap (8), the stop valve (9), and the non-return valve (10). The by-pass valve (11), is arranged for the steam trap. When steam is not available (for example at start-up), compressed air can be used by opening the stop valve (6) and then air flows through the non-return valve (5), the shut-off valve (23), and the stop valve (16), and finally enters the burner lance. 3.5 Combustion air system A general schematic illustration of the combustion air system is shown in Figure 8. Combustion air system AIR INLET Compressed air, 7 bar 20- Silencer 21- Air cylinder 22- Inlet vanes Fan 40- Air filter regulator 41 • I/P positioner 42- Limit switch DPT25 - Diff. Pres. Transmitter Furnace pressure Figure 8 B_sys06.cdr The combustion air is taken directly from the engine room through the silencer (20), if provided, reducing the noise level from the suction side to approximately 95 dB(A). The inlet vanes (22), regulates the air flow to the fan. The inlet vanes are regulated by an air cylinder (21), which is controlled by an I/P positioner (41). The I/P positioner receives a 4-20 mA signal from the combustion control system. The inlet vanes closed positions are proven by a limit switch (42). The control air pressure for the I/P positioner is controlled by the air filter regulator (40). From the fan discharge side the combustion air flows through the air duct to the burner wind box. Language UK Page 12/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES 3.5.1 Air Register The combustion air enters the wind box through the inlet flange and then the burner air register after passing a perforated plate to give an even air distribution. Passing through and leaving the burner air register tube, the air passes the primary air swirler, giving air mixture with oil/steam mist and flame stabilisation, and the secondary air swirler respectively, giving air for combustion zone. Both swirlers give the air a rotation and the correct distribution of air flow between primary air and secondary air. The burner air register draft loss is measured by a differential pressure transmitter (DPT25). The signal is converted to a combustion air flow signal in the control system. Operation instruction 4.1 Start in working mode The following text contains a description of how to start the burner in working mode with both diesel oil and heavy fuel oil. The item numbers mentioned in the text are referring to Figure 5, Figure 6, and Figure 7. 4.1.1 Diesel oil mode - start When the oil supply system is supplying diesel oil for the burner, the following procedure must be followed, with reference to Figure 5: Step A: Open the stop valve (G49) and the stop valve after the diesel oil tank. Furthermore, the stop valve to the heavy fuel oil settling tank must also be opened. Step B: Select diesel oil on the three-way valve (Gl 15). Step C: Open the stop valves on the suction and discharge side of the oil pumps. Step D: Open the needle valve for the pressure transmitter (G99). Step E: Open the stop valves before and after the pressure regulating valve (Gl00). Step F: Close the by-pass valve at the pressure regulating valve (Gl00). Step G: Close the inlet valves (G25) to the pre-heaters. Step H: Open the stop valve (G51) to by-pass the pre-heaters. Step I: Open the stop valve placed just before and after the ignition pumps. Step J: Open the stop valves placed just before the ignition burner. The item nos. mentioned in the following work steps (K-M) refer to Figure 6. Step K: Open the stop valves (5, 7, 8, and 10). Step L: Close the by-pass valves (3 and 4). Language UK Page 13/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES Step M: Open the stop valves (1 and 14). The item nos. mentioned in the following work steps (N-Q) refer to Figure 7. Step N: Open the stop valves (1,4, and 16). Step O: Open the stop valves (7 and 9). Step P: Close the by-pass valve (11). Step Q: If atomising steam pressure (6 bar) is not available, open the stop valve (6) and close the stop valve (4). Make sure that the system has been inspected in accordance with the recommended periodical maintenance. For the automatic control of start up and normal running, see separate instruction for control system. 4.1.2 Heavy fuel oil mode When the oil supply system to supplying heavy fuel oil to the burner, the following procedure must be followed, with reference to Figure 5: Step A: Open the stop valve (G49) and the stop valve after the heavy fuel oil tank. Furthermore, the stop valve to the heavy fuel oil settling tank must also be opened. Step B: Select diesel oil on the three-way valve (G115). Step C: Open the stop valves on the suction and discharge side of the oil pumps. Step D: Open the needle valve for the pressure transmitter (G99). Step E: Open the stop valves before and after the pressure regulating valve (Gl00). Step F: Close the by-pass valve at the pressure regulating valve (Gl00). Step G: Close the drain valves for the pre-heaters. Step H: Open the inlet valve (G25) for the pre-heater which should be in service. Step I: Close the by-pass valve (G51) for the pre-heaters. Step J: Open the stop valves before and after the steam trap for the pre-heaters. Step K: Open the stop valves placed just before and after the temperature regulating valve (G20). Step L: Close the by-pass valve placed at the temperature regulating valve (G20). Step M: Open the stop valves placed just before and after the ignition pumps. Step N: Open the stop valves placed just before the ignition burner. The item nos. mentioned in the following work phases (O-Q) refer to Figure 6. Language UK Page 14/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES Step O: Open the stop valves (5, 7, 8, and 10). Step P: Close the by-pass valves (3 and 4). Step Q: Open the stop valves (1 and 14). The item nos. mentioned in the following work steps (R-U) refer to Figure 7. Step R: Open the stop valves (1,4, and 16). Step S: Open the stop valves (7 and 9). Step T: Close the by-pass valve (11). Step U: If atomising steam pressure (6 bar) is not available, open the stop valve (6) and close the stop valve (4). Make sure that the system has been inspected in accordance with the recommended periodical maintenance. For the automatic control of start up and normal running, see separate instruction for control system. Commissioning The following commissioning instructions are valid for steam atomising burners type KBSA with Y-atomisers and with a standard delivery of individual parts for the burner unit and supply systems from AALBORG INDUSTRIES. Prior to the commissioning, the instructions for the individual parts of the burner unit and supply systems should be studied. The special instructions for the boiler and the control system should also be consulted. The instructions should only be considered as a guideline. This is due to the fact that each plant should be commissioned individually to obtain the best burner performance for the specific plant. During the commissioning of the burner unit and supply systems, it might be necessary to adjust some regulation parameters or timer settings in the control system to optimise the function of the plant. These adjustments are not described in the following sections, but should be carried out as the optimisation requirements emerge. Please see the instructions for the control system. 5.1 Commissioning start When the system is started at commissioning, the following procedure must be followed: 5.1.1 Boiler Step A: Check that the boiler is ready for operation according to the special instructions for the boiler Step B: Increase or decrease the water level in the boiler to approximately 50 mm below normal water level. Language UK Page 15/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES 5.1.2 Electrical installation Step A: Check that the wiring is correct. Step B: Rotate all oil pumps, and the combustion air fan(s) by hand to ensure a free rotation. Step C: Set all motor starter overloads to suit the motor full load current. See motor identification plate and/or electrical diagrams. Step D: Install the fuses and check the rotation direction. Note: Oil pumps must be primed with oil before power is switched on. Step E: Check/adjust limit switches in the following items: Fuel oil pressure control valve (Gl00), Figure 5 Fuel oil temperature regulating valve (G20), Figure 5 Fuel oil regulating valve (9), Figure 6 Atomising steam regulating valve (2), Figure 7 Three-way valve (Gill and Gl 15), Figure 5 Shut-off valve (three-way valve) (19), Figure 6 Shut-off valve (two-way valve) (17), Figure 6 Lance in position Ignition burner in position Air damper in closed position Step F: Check/adjust all interlocks and alarms for burner plant as follows: Start of stand by fuel oil pump Fuel oil temperature, high/low Low fuel oil pressure Low atomising steam pressure Flame scanner, automatic Flame scanner, manual Other safety interlocks 5.1.3 Oil system - diesel oil mode Item nos. mentioned in the following mainly refer to Figure 5. An exception to this rule is item nos. referred to in work steps (J-M), where the mentioned item nos. are described in Figure 6. Step A: Check that the piping system is according to the flow diagrams. Language UK Page 16/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES Step B: Open the stop valve (G49) and the stop valve after the diesel oil tank. Furthermore, the stop valve to the heavy fuel oil settling tank must also be opened. Step C: Select diesel oil on the three-way valve (Gl 15). Step D: Open the stop valves on the suction and discharge side of the oil pumps. Step E: Open the needle valve for the pressure transmitter (G99). Step F: Open the by-pass valve at the pressure regulating valve (Gl00). Step G: Close the stop valves before and after the pressure regulating valve (G100). Step H: Open the stop valve (G51) to by-pass the pre-heaters. Step I: Close the stop valves (G25) to the pre-heaters. Step J: Close the stop valves (5, 7, 8, and 10). Step K: Open the by-pass valves (3 and 4). Step L: Open the stop valve (1). Step M: Close the stop valve (14). Step N: Make sure that the oil pump is primed with diesel oil. Caution: Water must under no circumstances come to the pump as water will damage the pump. Check that the pump and installation are in accordance with the pump instructions. Step O: Start one of the fuel oil pumps and flush the piping system for a few hours. Step P: Open the stop valve (G25) to one of the pre-heaters and close the by-pass valve (G51). Continue flushing of piping system for at least one hour. Warning: The heaters must not be heated. Step Q: Open the stop valve (G25) to the other pre-heater and close the stop valve (G25) to the first pre-heater. Continue flushing of piping system for at least one more hour. StepR: Open the by-pass valve (G51) and close the stop valve (G25) to the pre- heater being flushed. Step S: Stop the pump. Language UK Page 17/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES Step T: Open the stop valves before and after the pressure regulating valve (Gl00), and close the by-pass valve. Step U: Adjust the set point for the fuel oil pressure control valve (Gl00) to approximately 20-25 bar when the pump has been started again. Flush the piping system for another few hours. When continuing the flushing, by-passing of the flow meter and the fuel oil regulating valve is not necessary. The item nos. mentioned in work steps V through X refer to Figure 6. Step V: Open the stop valves (5, 7, 8, and 10). Step W: Close the by-pass valves (3 and 4). Step X: Check and adjust Cv (valve characteristic) to fit the plug and seat ring by moving the adjustment knob along the Cv scale. Table 1 shows the Cv setting for each burner size. Adjustment of Cv Burner size Maximum flow coefficient Cv Setting Cv KBSA 600 0.6 0.5 KBSA 750 1.2 0.85 KBSA 950 1.2 0.85 KBSA 1050 1-2 0.95 KBSA 1200 1.2 1.2 KBSA 1550 2.3 1.4 KBSA 1900 2.3 1.5 KBSA 2250 2.3 1.6 KBSA 2650 2.3 1.85 KBSA 2950 2.3 2.3 KBSA 3350 2.3 2.3 KBSA 4200 3.8 3.4 Table 1 When flushingth e oil system, the minimum and maximum oil flow through the fuel oil regulating valve (9) can be checked and adjusted. Step Y: After completing the flushing,th e internal spring loaded by-pass valves of the fuel oil pumps must be adjusted to a pressure of approximately 3 bar above the set point of the oil pressure control valve (Gl00) (this may be readjusted after the final commissioning). The set point of the fuel oil pumps must be below the set point (30 bar) of the safety valves, on the fuel oil heater. Step Z: Clean the fuel oil pump filters. 5.1.4 Burners - diesel oil mode On delivery from Aalborg Industries, the burner unit has been pre-adjusted to fit the task. Even though the burner unit has been pre-adjusted, it is advisable to carry out additional checks during commissioning. These checks should be carried out with Language UK Page 18/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES regard to adjustment of the atomiser and flame stabiliser distance, ignition electrodes, etc. This means that it is necessary to pull out the burner lance, flame stabiliser, and ignition burner. Before the burner unit is assembled, check and note the commissioning measurements. The obtained measurements should be inserted in the "measurement and settings scheme". Step A: Check that the burner gun and nozzle are clean. Step B: The nozzle tip should be adjusted to approximately 40 mm in front of swirler. Step C: If no atomising steam is available, the burner can be started with compressed air 3-6 barg for atomising. From 3 barg in low load up to approximately 30% load and then the air pressure should be increased gradually up to 6 barg at approximately 60% load and kept constant at higher loads. Step D: When atomising steam is available, the controller for atomising steam must be checked and adjusted to 3-6 bar depending on the burner load. Step E: Close the stop valves (14, Figure 6) and check burner start/stop sequence. Attention: Before and during start-up, the furnace must be checked with regular intervals for oil spillage. If an oil spillage is present in the furnace, the cause must be determined and the failure must be rectified. The furnace should be purged until it is free of oil. Step F: To facilitate the commissioning, switch to "Burner - manual operation" on the control panel and follow the instruction. Note: During commissioned, the boiler pressure and temperature must not be intensified too rapidly as this might cause stresses in the boiler. The burner should be kept in minimum firing position during the first commissioning period. Step G: Check and adjust the diesel oil/air ratio. The combustion air flow signal and the fuel oil flow signal must be set in the controller on the control panel to obtain an O2 content of approximately 3-4% and a soot number of 1-3 Bachrach at loads above 30%. At lower loads the O2 content is higher. When the controller is set up, there is a function key on the control panel marked "Air/fuel ratio" where the normal adjusting of air/oil ratio can be carried out. This could be necessary if the bunker type is changed. In the same controller the max./min. oil flow and the ignition oil flow are set. Oil flow for ignition will be found during commissioning, typically 15% of full load. Step H: Check/adjust all interlocks and alarms for burner. Language UK Page 19/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES Step I: Check the burner in automatic mode by switching the detachable key switch to "Automatic operation". Step J: Check the master-slave function, for plants intended to operate in this mode (see the instructions regarding the control system). 5.1.5 Oil system - heavy fuel oil mode When the burner has been commissioned on diesel oil and when steam is available for heating, the commissioning on heavy fuel oil can be carried out. Caution: Heating of diesel oil in the piping system must be avoided. The change of fuel from diesel oil to heavy fuel oil is achieved by manually operating the three-way valve (Gl 15). When heavy fuel oil is selected, the three- way valve (Gill) automatically changes position and returns the oil to the heavy fuel oil settling tank for a period of time. This arrangement is necessary to avoid heating of the re-circulated diesel oil when the burner is in stop mode. The viscosity of the re-circulated diesel oil decreases and with it also the lubrication characteristic. This will cause damage to the oil pumps. After the pre-set time period has expired, the three-way valve (Gill) returns to normal position. The time period must be set with regard to minimum oil flow and the quantity of oil in the system. To operate the oil system in heavy fuel oil mode the procedure mentioned below must be followed (the stated item numbers refer to Figure 5): Step A: Check that the burner is stopped. Step B: Check that oil is present in the heavy fuel oil tank. Check that the stop valve which connects the heavy fuel oil tank to the oil system is open. To avoid cavitation of the oil pumps, the viscosity of the oil in the heavy fuel oil tank should not exceed 400 cSt. If necessary, the oil tank should be heated. Step C: Check and adjust the switchover time for the three-way valve (Gill). Step D: Select heavy fuel oil on the manually operated three-way valve (Gl 15). Step E: Check that the three-way valve (Gl 11) changes position. It should also be checked that the valve is changed back to normal position when the time period has expired. Step F: Select one of the pre-heaters for operation. The other pre-heater should be in stand-by mode. Step G: Open the stop valves for the operational pre-heater and check that the stop valves are closed for the stand-by pre-heater. Step H: Close the stop valve (G51). Step I: Close the drain valves for the pre-heaters. Step J: Open the stop valves before and after the steam trap for the pre-heaters. Language UK Page 20/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES Step K: Open the stop valves placed just before and after the temperature regulating valve (G20). Step L: Close the by-pass valve placed at the temperature regulating valve (G20). Step M: Open the stop valve, placed in the steam pipe just before the pre-heater, for the operational pre-heater and close the stop valve for the stand-by pre- heater. Step N: Adjust the temperature set point for the temperature regulating valve (G20) in the control system. The viscosity of the oil at the atomiser should be between 15-20 cSt. The pre-heating temperature can be determined by means of the "viscosity-temperature chart" found in this manual. Step O: Check that the steam regulating valve (G20) for the pre-heaters is operational and that the temperature is raised to the desired set point. Adjust if necessary. Step P: Check that the tracing systems for the oil system and the burner unit are operational. Step Q: Bleed air from fuel oil heaters by opening air valve on heater until fuel oil is observed at air bleed outlet pipe. Step R: Check the alarm set points for too low oil temperature, low warning, high warning, and too high oil temperature. Adjust if necessary. 5.1.6 Burners - heavy fuel oil mode When the burner is commissioned on heavy fuel oil, final adjustments of the combustion process should be carried out to achieve high quality performance data. The aim is to operate the burner with lowest possible O2 content and highest possible CO2 content without the risk of an uncompleted combustion (black smoke). At the same time the reliability of the burner must be ensured. A number of initiative actions can be performed to improve and optimise the combustion process such as adjusting the air/fuel ratio, the steam atomising pressure, etc. Adjustments of the air/fuel ratio and the steam atomising pressure are made by settings in the control system. The air/fuel ratio should be checked and adjusted through the entire burner load range to ensure a correct combustion. The air/fuel ratio can be checked by measurements of the soot spot No. and the 02 content and/or the C02 content in the flue gas. The visual appearance of the flame should also be checked. If the amount of combustion air to the burner for a given oil flow is too low, the combustion will be uncompleted, and it produces black smoke. Although the 02 content is low and the CO2 content is high, the air flow should be increased. If, on the other hand, the O2 content is high and the C02 content is low, it indicates that the air flow for the combustion process must be decreased. It is not only the air/fuel ratio which is an important factor for the combustion process, but also the pressure of the atomising steam. The steam atomising pressure should be adjusted and optimised to suit the combustion process through the complete burner range. The pressure can be checked by measurements of the soot spot No. and visible control of the flame. If the steam Language UK Page 21/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES atomising pressure is too low at a given burner load, the flame has a tendency to sparkle and the soot spot No. increases. Furthermore, the flame becomes unstable at low loads due to poor atomisation of the oil. If the steam atomising pressure is too high, the combustion zone is cooled and the flame becomes unstable at low loads. The following commissioning steps imply that the lighting-up procedure of the boiler is completed and that a sufficient load demand is present to carry out adjustments at 100% load. Step A: Check that the correction factor of the air/fuel ratio is in neutral position on the control panel. The correction factor is used to adjust the air/fuel ratio if the calorific value of the oil is changed, e.g. when the bunker type is changed. Step B: Start the burner and check that it ignites when the oil valves open and remains ignited when the ignition burner is shut-off. Adjust the ignition oil flow, the air/fuel ratio, or the steam atomising pressure if necessary. Step C: Start the burner several times to ensure a reliable ignition of the burner. Step D: Set the oil flow regulation valve into manual mode after start-up and adjust the oil flow to minimum. Step E: Check that the flame is stable and carry out measurements of the soot spot No. and O2 content and/or CO2 content. Adjust the minimum oil flow, the air/fuel ratio, or the steam atomising pressure if necessary. Step F: Carry out the same measurements through the burner load range in steps of 10%. Adjust the air/fuel ratio and/or the steam atomising pressure if necessary. Step G: The measurements obtained for the combustion process through the complete range together with a number of comparable combustion data should be noted and inserted in the "measurements and settings" scheme. Step H: When the burner is in operation, increase or decrease the load until the oil pressure at the atomiser and the steam atomising pressure are identical. Step I: Set this load as the steam purge position load in the control system. Step J: Stop the burner and check it during steam purging. The burner must not produce black smoke or blow out the flame before the combustion is completed. Adjust the steam purge position load if necessary. 5.2 Normal stop In modulation free mode, the control system attempts to maintain the steam pressure at the desired set point by regulation of the burner load. The burner can be regulated through the complete load range from minimum firing load to full load. However, should the steam demand decrease below the minimum firing load of the burner, the steam pressure will increase to the set point for burner stop. The burner stops and remains stopped until the set point for burner operation is reached again. Language UK Page 22/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES 5.3 Prolonged stop When the boiler plant is stopped for a long period of time, the oil system including the pre-heaters should be flushed with diesel oil before the plant is shut-down. Furthermore, the tracing must be switched off. Manual operation In the rare event of a total break down of the control system, the burner unit with belonging systems can be operated in manual operation (also called emergency operation). Due to the fact that the majority of the safety interlock trips and alarms are overruled in emergency mode, the safety precautions for the plant must be observed very carefully. Please note that in emergency operation mode the safety interlocks are reduced to: Too low water level Flame failure Warning: When the burner operates in emergency mode, it is very important that the boiler plant is carefully and continuously supervised by the ship engineering personnel. Pay special attention to the steam pressure and water level. The emergency equipment comprises the following components: • Key switch for emergency operation • Control and signalling components • Additional flame detector • Push buttons for ignition and operating of the electric/pneumatic oil and steam valves Both "manual" and "automatic" flame scanners must be clean and placed in position at burner front to monitor the flame. When changing to manual operation, the following operations are necessary. Step A: Turn the key-operated switch on control panel to "Manual operation". Step B: Start the combustion air fan manually on the control panel. Step C: Switch the load controller to "Manual". Step D: Purge the furnace by increasing the combustion air flow to maximum and keep flow in maximum position for approximately 60 seconds. Step E: Open the steam atomising valve (16, Figure 7). Step F: Reduce the air flow to ignition load, approx. 15% load. Language UK Page 23/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES Step G: Push the ignition button on the local burner panel. When the ignition flame has been established, push the button for oil valve. Step H: When the lamp (flame on) flashes up, release the ignition button. Step I: The burner can now be operated from the control panel by increasing/decreasing the oil and air amount on the load controller. Step J: Check the flame monitoring equipment by pulling out the "manual" flame scanner from its mounting flange and by covering the cell window by hand. The fuel oil supply must then be cut off automatically. Note: Only flame failure and too low water level cut the burner off automatically in this mode. Maintenance instructions To ensure a safe and reliable function of the burner, inspection must take place with frequent intervals as described below. The inspection should be carried out by competent and properly trained personnel familiar with the operating and maintenance procedures relevant for this type of plant. 7.1 Safety regulations for maintenance work Always ensure that the electrical power is off and that nobody can start the boiler unit before commencing maintenance work. All pipes, drums, etc. must be depressurised before any maintenance work is carried out on these. 7.2 Continuous maintenance • Control panels and other electrical equipment should be kept clean and dry. Check that no foreign matter accumulates in or around them. • Replace lamps, contactors, and other components when they cease to function or show signs of deterioration. A part, replaced before it actually fails, could save a costly delay. 7.3 Periodical maintenance The following check list should be followed every two weeks. Dependent on the operation conditions, however, some items may need more frequent attention. For maintenance work procedures, we refer to the separate instructions concerning each item. 7.3.1 Periodical maintenance - burner and fuel oil supply system • Check that all connections are tightened and that the wiring is in a good condition. Language UK Page 24/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES • Check that the fan inlet is kept clean of unintended obstructions. • Check pipe work for leaks, particularly on flanges, joints, and connections. Repair any leaks which may cause safety risks. • Check the general condition of pipe work, lagging, and tracing. • Check that the glands of manual valves are tight enough to prevent easy operation of the valve. • Oil filters should be inspected and cleaned. • Manually operated valves should be periodically operated, if possible, to ensure free movement. • Check the pneumatic shut-off valves, placed just before the burner lance, for leaks. • Check and clean the flame scanner. 7.3.2 Burner air register and swirler If the burner plant is to perform according to the specification, it is important that the burner register is kept clean and in good condition. Inspection should be carried out at regular intervals. Large quantities of dust-laden air will pass through the register, and inevitably this tends to build up deposits. These deposits should be brushed off. The primary and secondary swirlers as well as all other surfaces exposed to radiation heat should be checked for being free of carbon or heat erosion. The refractory should be inspected for general condition and examined for being free of carbon deposit, cracks, and heat erosion. 7.3.3 Atomiser Before any examination can be made, the atomiser must be cleaned. This is normally done by soaking in a paraffin or carbon remover to wash any oil films. This also has the purpose of loosening carbon deposits. It may also be necessary to use a soft metal scraper to lift away any heavy carbon deposits. A hardened scraper should not be used as it could possibly damage the atomiser. The cleaned atomiser should then be examined for damage, and the nozzle holes checked for wear. The O-ring must be replaced every time the atomiser is disassembled. Before fitting the cap nut, the thread should be covered with an un-hardening high temperature compound. 7.3.4 Ignition burner The ignition burner is one of the most exposed items and needs a frequent maintenance. • The electrodes should be cleaned and the insulation material checked for any damage. Be careful not to damage the ceramic insulation pieces. • The nozzle should be checked and cleaned. • If the spray pattern hits the other parts of the ignition burner despite it is cleaned, the nozzle should be changed. Language UK Page 25/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES Note: Be careful not to change position of nozzle and electrodes as this may cause problems with, e.g. ignition instability, or build-up of carbon deposit. 8 Faults and rectifying faults The trouble shooting list is based on a proper set-up of the burner plant during commissioning and/or service and that no further adjustments of the air/fuel ratio, etc. have taken place. Please note that the trouble shooting list is general for steam atomising burners and has not been made for any particular plant, but is based on several years of experience. Therefore, the cause for your specific problem may not be mentioned and vice versa. You are always welcome, however, to contact our service department for advice or service assistance. Check availability of power and fuel supplies before commencing detailed checks. Ensure that burner plant wiring diagrams relevant to the particular installation are available. When the cause of a lockout should be located, it can be of assistance to know the start/stop cycle or at which point of operation the lockout occurred, e.g. modulating. The trouble shooting list can be seen in Table 2. Fault finding chart Fault Possible causes Remedy No ignition/ignition flame Ignition burner oil pump faulty Repair or Replace oil pump/ motor failure Oil pressure too low Restore oil pressure Oil nozzle blocked/worn out Clean/replace nozzle Ignition electrodes dirty/out of adjustment Clean/readjust Ignition transformer faulty Replace ignition transformer Solenoid valve faulty Exchange solenoid valve unit Burner control faulty Replace/repair control unit Smoke during ignition Ignition oil pressure too high/low Check ignition oil pressure, adjust to 8-10 barg measured at the ignition burner Flame failure of main flame Ignition flame not established See above during ignition Oil valves not open Check air pressure/replace oil valve Atomising air/steam pressure too low Check air/steam pressure Purge steam valve open Check purge valve Oil temperature too high/low Adjust temperature Oil flow too low Adjust oil flow/clean atomiser Unstable main flame Oil amount too low Raise the oil amount Oil temperature too low/high Readjust oil temperature Blocking of some of the steam/oil holes in the atomiser Clean atomiser Water in the atomising steam Check the water trap, if provided Flame smoky or red Too much fuel oil or too little air Readjust air/oil ratio Flame white or colourless Too much air or too little oil Readjust air/oil ratio Flame with starlets or Poor atomisation, low oil temperature or atomising Reset fuel oil temp, to correct value/ensure sparks air/steam incorrect pressure condensate-free steam Damaged atomiser nozzle Replace nozzle Flame flutters and goes out Too little oil in min. load Reset fuel quantities Burner shut down Shut down due to safety circuits or faulty Please refer to the electrical layout/diagram components for specific information Table 2 Language UK Page 26/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES Steam atomising burner settings Each plant has its individual service conditions depending on the actual design and layout of the burner and the boiler plant. Exact values for the burner cannot be given, but have to be determined at the commissioning or by later adjustments. The following tables show the standard measurements and settings for a plant which includes a KBSA burner. This enables the user to obtain some of the most important measurements and settings related to the burner for later reference. It is recommended that the user completes the scheme shortly after the commissioning when normal service conditions have been established. Burner settings chart Ship's name: Boiler type/No.: Burner type/No.: Atomiser ID. No.: 1 Date 2 Time 3 Oil type /viscosity/density 4 Load Min. 25% 50% 75% Max. 5 Oil amount 1/h 6 Oil temp, inlet burner °C 7 Oil press, at burner barg 8 Atomising steam press. barg 9 Atomising steam temp. °C 10 Oil press. Before fuel oil valve bar 11 Oil temp, after pre-heater °C 12 Oil temp, before pre-heater °C 13 Oil temp, in tank °C 14 Air temp, inlet combustion air fan °c 15 Static pressure after combustion air fan mmWC 16 Static pressure in wind box mmWC 17 Static pressure in furnace mmWC 18 Static pressure in uptake mmWC 19 Temp, in uptake 20 02 in uptake % 21 C02 in uptake % 22 Soot (Bachrach) No. 23 Drum pressure barg 24 Feed water temp. °c 25 Feed water flow m3/h 26 +/- Normal drum level mm Table 3 Language UK Page 27/28 AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1 INDUSTRIES During commissioning an adjustment of some measures related to the ignition burner, burner lance, and burner register may be necessary. These measures are shown in Figure 9. In the following table is the original measures written and a column is reserve for writing the measures established during commissioning. Commissioning measures Top mounted Wall mounted Figure 9 kbsa2.cdr table for commissioning measures Yard & hull No.: Guangzhou Shipyard International Co. Ltd. Hull Nos. 03130007, 03130008 Date of commissioning: Project No.: 736950, 736952 Mounting position: Top mounted Measures Original Commissioning A 25 mm mm B 205 mm mm C 140 mm mm D 80 mm mm E 5 mm mm Nozzle type 6666062 Table 4 Language UK Page 28/28 AALBORG PHOTO CELL OM8630#01.0 INDUSTRIES Photo cell 1 Description The RAR7 detector is used for supervision of yellow burning oil flames. If the photo cell detects a missing flame, the burner stops instantaneously. It is not possible to start the burner before the control system has been reset. With this type of detector, the radiation of the oil flame in the visible band of the light spectrum is used to generate a flame signal. The light-sensitive element is a selenium photo cell. When illuminated, it generates DC voltage which causes a current to flow to the input of the flame signal amplifier in the control unit. Hence, the selenium photo cell is an active detector. The cell is insensitive to infrared radiation. If the burner is started with an illuminated combustion chamber, e.g. due to glowing firebrick, the start sequence of the burner commences, but an alarm for flame failure will be indicated. The number of photo cells for automatic operation and emergency operation depend on the classification society. 1.1 Commissioning The intensity of the light radiation can be checked by measuring the detector current by means of a DC ammeter (internal resistance 5000 W). Figure 1 shows the measuring circuit. The photo cell is adjusted by changing the position in proportion to the oil flame in order to obtain the maximum detector current. Note: If the wiring of the photo cell is connected incorrectly, it is not possible to start the oil burner. Measuring circuit 10 LAE10 24 LAL2...,LOK16... I Ammeter connection Figure 1 photcirc.cdr Language UK Page 1/1 AALBORG VISCOSITY - TEMPERATURE CHART OM9280#01.1 INDUSTRIES Viscosity - temperature chart 1 Description The preheating temperature can be determined by means of the viscosity - temperature chart shown in Figure 1. In order to use the chart, the viscosity of the fuel oil must be known at a reference temperature. It should be noted that the preheating temperature should be set somewhat higher than the temperature shown in the chart due to the heat loss between pre-heater and nozzle/cup. 1.1 Example The example is based on a pressure jet burner. Known: Oil viscosity: 380 cSt. at 50°C Required: Preheating temperature in °C Procedure to be followed: Step A: Follow the reference temperature line at 50°C vertically down to the intersection with the 380 cSt. viscosity line. Step B: From this point move parallel down with the nearest fuel grade line. Step C: When the line meets the recommended nozzle viscosity line, go vertically up to the temperature axis. Step D: At this point read the desired preheating temperature of 150°C. Language UK Page 1/2 AALBORG VISCOSITY - TEMPERATURE CHART OM9280#01.1 INDUSTRIES Viscosity - temperature chart H TEMPERATURB -15 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 ISO 160 170 I« Q'OM 9ÖÖO 40,0001- 8tø» *K„~ 7,000 30,000- _,_1_Mta. 6,000 20000- 5,000 4,500 15,000- 4,000 inm 3.500 3,000 2J00 10,000- 2^00 8,000- 2,000 uoo 5,000- 4,000- 900 3,000- 800 700 700 600 600 2,000- m 400 1,500- 400 350 350 300 moo- s 25° 800- 200 S 20° S 600- ISO iiso J 100 g 90 œ 1 ^ '' ^N. ~ "„> , 200- " SO © 45 150- 40 35 35 30 30 100- 25 90- 20 80- V ', *>C r' ^V ' "^ 70- S«c •' "S-^L 'ft' " IS 0 'S (?) !"j>-»^, 7 5 4 1 i i 1 1 1 1 I 1 1 1 1 1 1 1 1 1 1 1 i 1 1 1 1 1 1 j i 1 1 1 10 20 30 40 5 70 80 90 100 110 121Ï 130 1 10 ISO 160 170 200 21C 10 240 250 260 270 280 290 3«) 310 3 !0 330 340 3S0 0 60 1B0 190 220 2 TEMPERATURE Q Recommended cup viscosity for rotary cup burners (2) Recommended nozzle viscosity for steam atomising burners (y Recommended nozzle viscosity for pressure atomising burners Figure 1 viscl.cdr Language UK Page 2/2 AALBORG ^JSBH8H8BMBSHS^^^W^B INDUSTRIES ^ÊÈÈÈÊMÈ^ÊBKÊÈÈÈÈËÈÈ^^^^^^^^^^KËM Table of contents Oil flow regulating valve General 1 Cv-adjustment 2 Installation 3 Commissioning 4 Manual operation 5 Calibration 6 Maintenance 7 Language UK Page 1/1 AALBORG OIL FLOW REGULATING VALVE OM6050#04.0 INDUSTRIES Oil flow regulating valve 1 General The burner load is controlled by the control system, which receives a continuous signal from a steam pressure transmitter. This signal is compared with different set points, feed back signals, and parameters in the control system. The output from the control system is used to control the oil flow regulation valve, which is pneumatically operated by an I/P converter. To obtain a very accurate regulation of the oil flow, which is very important to have a large turn-down ratio, the valve is fitted with an adjustable Cy-adjuster. This Cy- adjuster makes it possible to adjust the pressure loss coefficient of the valve whereby the oil flow regulation can be optimised to each single installation. The position numbers referred to in the following sections appear from the illustrations shown in Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, and Figure 6. Cv-adjustment 2.1 Mid band setting During calculation of the valve sizing, a trim set should be chosen so that the mean estimated Cv will be at the mid band setting. This is called the risk-free setting since it provides the means to either increase or decrease the available Cv if the actual conditions change. Figure 1 shows an example of the possible settings for a trim set. A mean Cv of 0.07 for a trim No. 5 allows subsequent adjustment to Cv 0.10, if the flow coefficient is increased, or to Cv 0.04 in the opposite case. 2.2 Adjustment setting at maximum Cv The adjustment knob should be set towards maximum Cv making it possible to scale downwards, if desired. This should be done if valve sizing calculations and actual service conditions indicate that the full rated Cv of the valve will initially be required but may subsequently lessen 2.3 Adjustment setting at minimum Cv The adjustment knob should be set towards minimum Cv making it possible to scale upwards, if desired. This should be done if valve sizing calculations and actual service conditions indicate that initial conditions require a relatively low Cv but will then increase to a higher maximum Language UK Page 1/17 AALBORG OIL FLOW REGULATING VALVE OM6050#04.0 INDUSTRIES Example of a valve adjusted at mid band setting Cv/signal Cv plate Recommended Example Adjustment adjustment of application option Nominal Cv to 0.10 <Ù3 ^Max||2;|! be subsequently // reduced 0.09 // • 0.08 // >/ Mid band setting: / n Service conditions 0.07 n <3 ft E1 may vary, Cv to be Cv // adjusted upwards ts 0.06 —Æ- or downwards • 0.05 / J f // i—ip Nominal Cv to // 0.04 <*=Jq be subsequently // v increased •;/ Cv adjustment knob à Signal 200 400 600 800 1000 mbar 3 6 9 12 15 psi 4 8 12 16 20 MA Figure 1 cvsignal.cdr Illustration of the name plate m là ISÏZETOiMNoL 1" AIRTC OPEN ISOPPLYl 18 PSI XXXXX MIN. CV MAX. CV Jiiiiiic 0.04 0.1 tiBOBYi XXXXX o XXXXX o |l||Iipijl!l XXXXX 3-15 PSI XXXXX SERIAL No I XXXXX n w Figure 2 namevari.cdr Language UK Page 2/17 AALBORG OIL FLOW REGULATING VALVE OM6050#04.0 INDUSTRIES Illustration of the oil flow regulation valve (front view) 26 184 114 25 24 23 116 117 115 120 119 118 121 122 112c 124 22 Figure 3 vari 04.cdr Language UK Page 3/17 AALBORG OIL FLOW REGULATING VALVE OM6050#04.0 INDUSTRIES Illustration of the oil flow regulation valve (side view) 138a Figure 4 vari 07.cdr Language UK Page 4/17 AALBORG OIL FLOW REGULATING VALVE OM6050#04.0 INDUSTRIES Illustration of the coupling details of lever No. 1 and 2 „112b 112a 21 Lever No. 1 105 Pivot pin No. 1 184 Pivot pin No. 2 18' 22 ' Pivot pin No. 3 Lever No. 2 Figure 5 vari 06.cdr Illustration of the air connections I YY © 109 O 137 1/4" NPT 1/4" NPT instrument supply port signal port Figure 6 vari 05.cdr Language UK Page 5/17 AALBORG OIL FLOW REGULATING VALVE OM6050#04.0 INDUSTRIES Position numbers referring to Figure 3, Figure 4, Figure 5, and Figure 6 No. Part name No. Part name No. Part name 2 Seat ring gasket 104 a,b Clevis 138a Union elbow Seat ring at different 105 Pivot pin No. 1 139 Cover cap screw 3 a,b,c,d,e Cv values 106 Conical comp. Spring 140 Tubing 3f Spacer, Cv max. < 0.10 107 Grommet 141 a,b Screw 4 Seat ring retainer 108 Actuator bracket 142 Output gauge 5 Packing spacer 109 Cover screw 143 Instrument gauge 6 Packing 110 Cover 144 Manifold block 7 Packing flange stud U2a,b,c Retainer clip 145 Shim 8a Packing flange nut 114 Force balance spring 146 Gaskets 8b Mounting nut 115 Spring clamp 147 Positioner block 9 Packing follower 116 Take-up screw 148 Slotted flat c. screw 10 Packing flange 117 Lock nut 149 Binding head screw 11 Safety pin 118 Hand wheel lock nut 150 Lock wasker Plug stem at different 119 Hand wheel bushing 151 Spring bracket 12 a,b,c,d Cv values 120 Hand wheel 152 Positioner diaphragm 13a,b Body 121 Hand wheel lock 153 O-ring 18 Pivot pin No. 3 122 Lever arm stop 154 Spring 21 Lever No. 1 124 Pivot pin No. 4 155 Sleeve 22 Lever No. 2 125 Lock nut 156 Spool 23 Cv adjustment pin 126 Indicator 157 Spring 24 Cv adjustment knob 127 Indicator plate 158 Spring 25 C adjustment plate 131 Piston Retainer ring v 182 26 Adjustment plate screw 134 Actuator spring (Cvmax. <0.1) 101 Grommet plate 135 Serial plate 184 Pivot pin No. 2 102 Spring button 136 Diaphragm - - 103 Lock nut 137 Diaphragm cover - - Table 1 Installation The oil flow regulating valve must be installed as flange connected. Place the gaskets according to the process between the valve body and the pipe flanges. 3.1.1 Alignment Hold the valve body during installation of the studs. Special bosses are provided to centre the valve in the line and prevent rotation before final tightening of the studs. The valve must be installed with the flow tending to open. The flow arrow stamped on the valve body must be pointing in the direction of the flow. Install bolting and tighten evenly in a cross fashion. 3.1.2 Air piping Install pipe supply and instrument signal lines to the appropriate connections in the positioner Block (144), see Figure 6. Use 1/4" O.D. tubing or equivalent for air lines Important: Air supply to the oil flow regulating valve must be instrument air. Language UK Page 6/17 AALBORG OIL FLOW REGULATING VALVE OM6050#04.0 INDUSTRIES Commissioning In the following the work procedures for commissioning of the oil flow regulation valve are described: Step A: Check that the output signal range from the I/P converter corresponds to the input signal range on the oil flow regulation valve. The pressures appear from the identification plates. Step B: Loosen the cover screws (109). Back off the hand wheel lock (121) and turn the hand wheel anti-clockwise until the cover floats free. Remove the cover (110). Step C: Check and adjust the valve characteristic (Cv). To adjust the Cv, loosen and move the adjustment knob (24) along the scale (25) fixed to the top of lever No. 1 (21). The adjustment scale (25) shows the available Cv values for the specified valve, and Table 2 shows the Cv setting for each burner size. When the knob (24) is at the required position, tighten the knob. Adjustment of Cv for each burner size Burner type/size Maximum flow coefficient Cv Setting Cv KBSA 600 0.6 0.5 KBSA 750 1.2 0.85 KBSA 950 1.2 0.85 KBSA 1050 1.2 0.95 KBSA 1200 1.2 1.2 KBSA 1550 2.3 1.4 KBSA 1900 2.3 1.5 KBSA 2250 2.3 1.6 KBSA 2650 2.3 1.85 KBSA 2950 2.3 2.3 KBSA 3350 2.3 2.3 KBSA 4200 3.8 3.4 KBSD 950 1.2 0.85 KBSD 1200 1.2 1.2 KBSD 1500 2.3 1.4 KBSD 1900 2.3 1.5 KBSD 2250 2.3 1.6 KBSD 2650 2.3 1.85 KBSD 3000 2.3 2.3 KBSD 3350 2.3 2.3 KBSD 4150 3.8 3.4 Table 2 Step D: Apply air to the I/P converter. Adjust the air pressure at the belonging filter/reduction unit. The pressure setting appears from the identification plate on the converter. Step E: Apply supply air to the oil flow regulation valve. Adjust the air pressure at the belonging filter/reduction unit. The pressure setting appears from the identification plate on the valve. Language UK Page 7/17 AALBORG OIL FLOW REGULATING VALVE OM6050#04.0 INDUSTRIES Step F: Set the oil flow regulation valve into manual mode on the control system. Step G: Set the regulation output for the oil flow to 0% (4 mA) on the control system. StepH: Adjust the pressure indicated on the instrument gauge (143) to the low input signal range by means of the zero adjustment screw on the I/P converter. The instrument gauge (143) is the left pressure gauge on the oil flow regulation valve. The input signal range appears from the identification plate. Step I: Set the regulation output for the oil flow to 100% (20 mA) on the control system. Step J: Adjust the pressure indicated on the output gauge (142) to the high input signal range by means of the span adjustment screw on the I/P converter. The output gauge (142) is the right pressure gauge on the oil flow regulation valve. The input signal range appears from the identification plate. Step K: Set the oil flow regulation valve into automatic mode on the control system. Step L: Start one of the oil pumps. Set the stand-by oil flow to 0% on control system. Step M: Adjust the turn take-up screw (116) of the oil flow regulation valve until the piston (131) just begins to move. The control system must indicate 0% oil flow. Tighten with the lock nut (117). Step N: Set the stand-by oil flow back to the original set point. Note: If the Cv setting is changed after the above-mentioned work procedures have been carried out, a new zero adjustment might be required to recalibrate the closing point. Manual operation 5.1 Hand wheel The oil flow regulation valve can be manually operated in case of a failure on the control system by means of the hand wheel. The hand wheel is located on top of the cover and fitted with a locking lever. Direct access to it does not require removal of parts. It basically consists of a threaded rod fitted with a hand wheel (120) and a lever arm stop (122). The threaded rod freely rests on the actuator bracket (108) and is guided through the cover (110) by means of the hand wheel bushing (119). The stop (122) Language UK Page 8/17 AALBORG OIL FLOW REGULATING VALVE OM6050#04.0 INDUSTRIES consists of a block screwed on the threaded rod guided in translation by the actuator bracket (108). Clockwise rotation of the hand wheel (120) moves the stop (122) up along the threaded rod and drives up the lever No. 2 (22) compressing the spring (134). This action provides for the opening of the valve if it is an open-on-air actuator and also the closing of the valve if it is a close-on-air actuator. The return to automatic operation (neutral position) is accomplished by turning the hand wheel anti-clockwise until the stop (122) contacts the bracket (108). Note: During this operation the compression releases when the stop (122) no longer contacts the lever (22). Then, continue this operation until a slight tension reappears and tighten the hand wheel lock (121). Calibration The oil flow control valve is factory calibrated. If, for some reason, the calibration has been disturbed (e.g. due to repair, change of parts, etc.), it is necessary to carry out some adjustments. In the following the work procedures for adjustments are described: 6.1.1 Adjustment of the piston rod clevis (104b) Note: This adjustment should not be changed unless the piston (131) has been disassembled. Then, it should be made during assembly before coupling the levers to the clevises. Step A: With the piston against the diaphragm cover (137), turn the clevis (104b) in such a manner that the distance between the actuator bracket top (108) and the indicator bottom (126) is between 0.5 mm and 1 mm. The use of a shim will facilitate the operation. Step B: Couple lever No. 2 to the clevis. Admit sufficient air pressure to disengage the nut (125) and tighten it against the indicator. Take care that the indicator (126) is correctly positioned. Release the air pressure. 6.1.2 Plug stem adjustment With levers No. 1 and 2 coupled, proceed as follows: Step A: Admit sufficient air pressure to the actuator to extend the piston rod and place a shim under the indicator (126). Use a 1.5 mm shim for air-to-open actuators or a 25 mm shim for air-to-close actuators. Release the air pressure after placing the shim. Language UK Page 9/17 AALBORG OIL FLOW REGULATING VALVE OM6050#04.0 INDUSTRIES Note: At this closing point without seating force, the slides of levers No. 1 and 2 must be strictly parallel. This characteristic permits to change the adjustment knob position to obtain the truly required Cv. Step B: Loosen the adjustment knob (24) and slide over the lever No. 1 to the position of maximum Cv on the Cv adjustment plate (25). Tighten the knob (24). Step C: Loosen the lock nut (103) by using a screwdriver applied to the plug stem end, and turn it until the plug slightly touches the seat ring. If the valve was removed from the pipe, a bubble leakage test performed on a calibration bench will permit a very accurate adjustment. By using the screwdriver, keep the plug stem in position and tighten the lock nut (103) against the clevis (104a). Step D: Admit air pressure again to disengage the shim, and release the air pressure again. Note: On air-to-open actuators, the shim thickness can be changed plus or minus 0.1 - 0.2 mm so that the levers No. 1 and 2 are in parallel position. This is done to obtain the required tightness at closing. 6.1.3 Positioner start-up pressure adjustment Step A: Pipe air supply and instrument signal lines to the positioner. Set the supply pressure in relation to the valve Cy. See Table 3. Step B: Set the signal to minimum value if it is an air-to-open actuator, or set the maximum value if it is an air-to-close actuator. Turn take-up screw (116) until the piston rod just begins to move. Tighten the lock nut (117). Spring ranges and supply pressures Spring ran ?e Supply max. C v m bar psi Colour code m bar psi 3.8 to 1.5 414 2.3 to 0.9 6-24 Red 2100 30 1.2 to 0.5 1660 0.6 to 0.25 0.25 to 0.10 0.10 to 0.04 207 0.050 to 0.020 3-15 Green 1250 18 0.025 to 0.010 1035 0.010 to 0.004 0.004 to 0.0016 Table 3 Language UK Page 10/17 AALBORG OIL FLOW REGULATING VALVE OM6050#04.0 INDUSTRIES Maintenance Warning: Maintenance and/or disassembly should be performed with the valve, actuator, and positioner free from all pressures. 7.1 Actuator diaphragm replacement Step A: Unscrew the two pressure connection nuts (138a) and pull the tubing (140) out. Remove the four cap screws (139), the diaphragm cover (137), and the diaphragm (136). Step B: Form a new diaphragm and insert it over the piston (131). Place the diaphragm roll into the bracket groove. Take the necessary steps not to twist or bend the diaphragm during its replacement. Step C: Replace the diaphragm cover (137) with the four screws (139) and reconnect the pressure connection nuts (138a). Check the tightness of the connections. 7.2 Adding packing Step A: To add a ring of packing, dépressurise the valve, and back off the packing flange nuts (8b) all the way. Step B: Lift the packing flange and follower and insert one ring of packing. Tighten the nuts (8b) finger tight plus one full turn. 7.3 Disassembly In some cases, it may be necessary to disassemble the valve, e.g. to replace the plug and seat ring assembly or to change packing in case of a Cv max. < 0.6. Note: In the case of a Cv max. > 0.6 a quick way to replace the packing prevents full disassembly of the valve (see the section "Packing quick change method"). Step A: Loosen the cover screw (109). Back off the hand wheel lock (121) and turn the hand wheel anti-clockwise until the cover floats free. Remove the cover (110). Step B: Adjust the signal for closing of the valve. Slightly change the signal so that the plug barely moves off the seat ring. Turn the adjustment knob (24) to minimum Cv position. Language UK Page 11/17 AALBORG OIL FLOW.REGULATING VALVE OM6050#04.0 INDUSTRIES Step C: Loosen lock nut (103) and turn anti-clockwise through 1 3/4 turns by using a screwdriver applied at the plug stem end. Shut off the signal and pressure supplies. Slightly retighten the lock nut (103) against the clevis. Step D: Loosen the lock nut (117) and fully unscrew the take-up screw (116). Remove the spring clamp (115) from lever No. 2 and force the balance spring (114) from the positioner. Step E: Remove the retainer clips (112b) from the two pivot pins (184) and pull them out from lever No. 1 and clevis (104a). Note: This operation will be facilitated by relieving the load on the plug clevis exerted by the conical compression spring (106). While driving out the pins, using a screwdriver, push on the plug stem end. Step F: Remove the two retainer clips (112c) from pivot pin No. 4 (124) and disengage it to the uncouple piston clevis (104b) from lever No. 2 (22). Step G : Remove the two retainer clips (112a) from pivot pin No. 1 (105) and disengage it to the uncouple lever No. 1 from the actuator bracket (108). Disengage the adjustment pin smooth end (23) from the lever line No. 2 and remove the adjustment knob (24) and adjustment pin (23) from lever No. 1. Step H: Drive out the pivot pin No. 3(18) and remove lever No. 2 (22). Step I: Hold the plug stem in place by using a screwdriver put to its end and unlock the nut (103). Unscrew the clevis (104a) and lock nut (103). Remove the spring button (102), spring (106), and grommet plate (101). Step J: Remove the two packing flange nuts (8b), packing flange (10), and packing follower (9). Remove the two bracket securing nuts (8a) as well as the bracket (108). Step K: By using a packing hook, remove the largest number of packing rings (6) from the packing box. Remove the safety pin (11) and pull the plug stem to remove the packing spacer (5), plug and stem, together with the rest of the packing rings. Step L: By using a 9/16" or 14 mm piece of hex stock and a wrench, unlock and pull out the seat ring retainer (4). Step M: Pull out the seat ring (3) and then the gasket (2) by using a hook made from steel wire (diameter approximately 3 mm). Carefully fettle the hook end. Language UK Page 12/17 AALBORG OIL FLOW REGULATING VALVE OM6050#04.0 INDUSTRIES Note: The seat ring with a Cv max. < 0.10 consists of two parts; The seat ring proper (3e) and a spacer (3f). The small size of the orifice of these parts does not allow for their removal by means of a hook. Therefore, it is necessary for this operation to remove the body from the pipe and turn it over and, if needed, to hit the bottom by means of a wooden mallet. Should the seat ring be jammed in its housing, it is possible to move it using a screwdriver inserted through the outlet orifice. Valves with Cv max. 3.8 do not feature any seat ring gasket (2). 7.4 Assembly Before assembly, clean thoroughly the inside of the valve body and parts. Gasket seating surfaces and surfaces in contact with others must be thoroughly cleaned. On assembly, a new seat ring gasket (2) and a new packing (6) must be used. Step A: Place a new seat ring gasket (2) in the valve body (13) and install the seat ring (3) taking care to correctly centre the gasket on the seat ring shoulder. Orient it in such a manner that one of its ports lines up with the body outlet orifice. Note: In the event of a maximum Cv smaller than 0.10, the seat ring (3e) must first be positioned on the new gasket (2) taking the same precautions as shown above. Secondly, engage the spacer (3f) and orient one of its ports towards the body outlet orifice. Valves with Cv max. 3.8 do not feature any seat ring gasket (2). Carefully apply grease (Never Seez or equivalent) on the threads and bottom of the retainer (4). With a 9/16" or 14 mm piece of hex stock and a wrench, torque the retainer to 8 Nm if equipped with a graphite gasket st. reinforced, or to 5.5 Nm if equipped with a glass filled P:T:F:E: gasket. Note: In case of a valve with maximum Cc 3.8, torque the retainer to 2 Nm. Step B: Engage the plug and stem assembly in the seat ring. In the case of a maximum Cv < 0.10, ensure that there is no hard point during the stocking of the plug. In case of a hard point, loosen the retainer (4) and replace the seat ring (3e) in the correct position until the stem smoothly slides. Align the hole in the spacer (5) with the safety pin (11) hole in the valve body. Note: In the event of a maximum Cv smaller than 0.10 ensure that the retaining ring (182) is placed on the plug before engaging it in the spacer (3f). If the retainer ring is damaged, replace it. Step C: Wrap the safety pin (11) with two turns of P:T:F:E: tape (Teflon). Screw it into the bonnet five and a half to six turns from where the thread Language UK Page 13/17 AALBORG OIL FLOW REGULATING VALVE OM6050#04.0 INDUSTRIES engagement starts. To find the start of the thread engagement screw on the safety pin about one turn and pull the safety pin outwards while unscrewing it. Step D: Install packing, positioning the skive cut of each packing ring 120° away from the cut of an adjacent ring. Slightly push down the rings one after another by using a tube Vz" sch. Size 160. Install the packing follower (9) on the plug stem. Step E: Install the actuator bracket (108) and secure it with the two nuts (8a). Install the packing flange nuts (10) on the plug stem. Hand tighten the two packing flange nuts (8b) adding one full turn with a wrench. Step F: In the following sequence, place the grommet plate (101), spring (106), and its spring button (102). Screw the nut (103) and clevis (104a) on the plug stem. Adjust the nut and clevis without locking them together until the clevis holes are about 1.5 mm above the alignment of the pin holes in the actuator bracket (108). Note: Measuring this distance can be made easier by engaging the pins (105, 184, and 18) in their respective hole. Step G: Pin lever No. 2 (22) to the bracket (108) by using the pin (18). Ensure that the hole of lever No. 2 destined for spring clamp (115) is located on the top and aligned with the force balance spring (114). Step H: Place the adjustment pin (23) in the slide of lever No. 1 and screw the knob (24) on its threaded end. Engage the pin smooth end (23) into the slide of lever No. 2 and mount lever No. 1 on the bracket (108). Couple lever No. 1 to the bracket (108) by using the pin (105) and the two retainer clips (112a). Note: Ensure that the clevis (104a) is correctly positioned before placing lever No. 1 on the actuator bracket (108). Step I: Set the adjustment knob (24) on minimum Cv position. Step J: If the piston rod clevis (104b) has not been disturbed during disassembly, couple it to the end of lever No. 2 by using the pin (124) and the two retainer clips (112c). Note: This operation will be facilitated by placing the piston rod in an intermediate position by admitting air to the diaphragm and by setting the knob in a position where the end of lever No. 2 is left most accessible. If the clevis (104b) has been disturbed, proceed with adjustment and coupling as described in the section "Calibration". Language UK Page 14/17 AALBORG OIL FLOW REGULATING VALVE OM6050#04.0 INDUSTRIES Step K: Couple the clevis (104a) to lever No. 1. To perform this operation push to align the holes in the clevis and lever No. 1 by means of a screwdriver on the plug stem end. Couple by means of the two pins (184) and retainer clips (112b). Note: Insert the clips on the pins between the slides of the clevis and lever No. 1. Step L: With the take-up screw (116) fully unscrewed from the spring clamp (115), place the latter in position after hooking the force balanced spring (114) first on the positioner spring bracket (151) and secondly on the spring clamp (115). Note: The spring clamp (115) has two holes. If it is a close-on-air failure actuator the spring must be hooked in the upper hole. In case of valve open-on-air failure, the spring must be hooked in the lower hole. Step M: Admit supply and signal pressures and complete the calibration. Replace the cover (110) and turn the hand wheel clockwise to engage it in the lever arm stop (122). Tighten the cover screws (109). Step N: If the valve has been removed from the line, reinstall it according to the section "Installation" and then set the valve back into service. 7.5 Packing quick change method The fastest and simplest way to replace the packing is to remove the entire actuator without disturbing the actuator parts or calibration. However, this is not recommended for valves with a small Cy (Cy < 0.6) due to the very fineness of their plug. Vent the valve pressure and proceed as follows: Step A: Be sure that the plug is off the seat ring. With an air-to-open valve, admit air pressure under the diaphragm or turn the hand wheel to move the plug off its seat ring. StepB: Remove the safety pin (11) from the body. The safety pin engages the packing spacer (5). The function of the safety pin and spacer is to prevent the plug from being pushed out if the actuator is removed while the valve is still pressurised. The valve internal parts cannot be removed unless the safety pin is removed first. Remove the two packing flange nuts (8b) and back off the two mounting nuts (8a) as far as possible. Step C: With a block of wood and a mallet, tap the actuator plug assembly off the valve. Clean the packing box and plug stem and carefully place the new rings of packing around the stem. Position the skive cut of each packing ring 120° from that of the adjacent ring. Language UK Page 15/17 AALBORG OIL FLOW REGULATING VALVE OM6050#04.0 INDUSTRIES Step D: Assemble the actuator/plug assembly to the valve taking care to align the hole in the spacer (5) with the safety pin hole and to replace the two mounting nuts (8a) during assembly. Take extra care in guiding each ring into the packing box. Step E: Wrap the safety pin (11) with two turns of P.T.F.E. tape (Teflon). Screw it into the bonnet five and a half to six turns from where the thread engagement starts. To find the start of the thread engagement screw the safety pin about one turn and pull the safety pin outwards while unscrewing it. Step F: Replace the packing follower, packing flange, and flange nuts (8b). Tighten the nuts finger tight plus one full turn. With an air-to-open actuator, vent the air pressure or turn the hand wheel to move the plug back in contact with the seat ring. Set the valve back into service. 7.6 Positioner maintenance Note: Shut off supply and signal pressures. By-pass and dépressurise the valve body. Step A: Unscrew the two pressure connection nuts (138a) and pull out the tubing (140). Step B: Unscrew the cap screws (141a) and remove the manifold block (144), spring (158), gasket inclusive three O-rings (146), pilot valve assembly (155, 156, 157), shims (145), and O-ring (153). Caution: Handle the shims (145) carefully. Step C : Loosen lock nut (117) and take-up screw (116) and unhook the spring clamp (115) from the lever (22). Step D: Unscrew the cap screws (141b) from the positioner block (147) and remove it from the actuator bracket. Remove the screws (148) to separate the positioner diaphragm assembly (152) and spring (154) from the positioner block. Examine all parts for wear and replace, if necessary. Step E: Assemble the positioner diaphragm assembly (152) with the spring (154) to the block and tighten the screws (148). Be sure that the small signal port O- ring is in its recess in the diaphragm assembly. Step F: Assemble the block assembly to the actuator bracket. Note: Orient the block (147) so that when the manifold block (144) is bolted on, the gauges will face in the right direction. Language UK Page 16/17 AALBORG OIL FLOW REGULATING VALVE OM6050#04.0 INDUSTRIES Step G: Install O-ring (153), shims (145), pilot valve assembly (155, 156, 157), gasket including three O-rings (146), spring (158), and manifold block (144). Tighten the cap screws (141a), replace the tubing (140), and tighten the pressure connection nuts (138a). Note: Gasket ports in (146) must align with the ports in the block (147). StepH: Hook up the spring (115) on lever No. 2 (22). Admit supply and signal pressures. Adjust start-up pressure as described in the section "Calibration". Set the valve back into service. Language UK Page 17/17 • • • • • iijjijjji AALBORG ^BîlH8H9ilWH!HSW^^^MI Table of contents Oil flow meter General 1 Commissioning 2 Dismounting and mounting instructions 3 Trouble shooting 4 Language UK Page 1/1 AALBORG OIL FLOW METER OM8160#01.4 INDUSTRIES Oil flow meter General The oil flow meter unit is equipped with a set of spindles (M), pole wheel (P), and pick-up sensor (I), see also Figure 1. The measuring principle is positive displacement. The oil flow causes the measuring spindles (M) to rotate, and in front of the pick-up sensor (I) the pole wheel (P) is turning in an exactly defined distance (a). The pick up sensor (I) records an impulse for every pole which moves along. This electronic impulse is then sent to the control system. With each rotation an exact volume is given, and by settings in the control system the impulses are converted into a 4-20 mA flow signal. Illustration of the oil flow meter unit Figure 1 omg03a.cdr The oil flow meter can be installed in any position. But it must always be free from tensions to prevent distortion of the oil flow meter. Furthermore, it should be located in a position from where it is possible to dismount the pick-up sensor. As shown on the nameplate indicated in Figure 2, both flow directions are possible. But the preferable flow direction is indicated by the all white arrow symbol. The accuracy of the oil flow meter depends on the momentary flow. Figure 3 shows the characteristic for the oil flow meter. The oil flow meter is very sensitive towards larger objects in the oil, and these objects can cause a total blockage of the oil flow meter. To prevent large objects from entering the oil flow meter, the oil system must be provided with a filter (max. 0.3-0.5 mm mesh). The filters located in the oil pump unit will usually provide for an adequate filtration. The dry sleeve is mounted, adjusted, and tested with the pick-up sensor as a unit. The pick-up sensor, including the milled nut and spring, is screwed into the dry Language UK Page 1/7 AALBORG OIL FLOW METER OM8160#01.4 INDUSTRIES sleeve. The spring must be able to press the pick-up insert smoothly to the front side of the dry sleeve. It is important for the function of the sensor system that the dry sleeve is free of foreign substance. The sensor system is shown in Figure 4. The sensor system (pick-up sensor and cable) must not be in an area of electromagnetic field pulses with high intensity. This could cause measuring errors or even destruction of the sensor system. Illustration of the nameplate OM G XXX No. XX P/l 231.1 \ I II II II II > l/min 1 - 36 °c - 150 bar - 40 mm2/s 4 - 25 V Figure 2 omg02.cdr Accuracy - diagram +0.3 +0.2 +0.1 .-TÏ. m: —= T=S> -TÏ r-m-i Tl». 2 o 0 +& 1 1000 mm /s CO •j? i 150mm7s •s ^ * *«- — 2 Ü -0.1 40 mm /s o / ^ 5 mm7s < -0.2 -0.3 50 100 150 Flow rate (% Qmax.) Figure 3 omg01.cdr Illustration of the sensor system ,12 ,3 4 1. Dry sleeve 2. Pick-up sensor 3. Spring 4. Milled nut Figure 4 beg44.cdr Language UK Page 2/7 AALBORG OIL FLOW METER OM8160#01.4 INDUSTRIES Illustration of the oil flow meter, type OMG 20 Flange Head bolt Socket screw End cover O-ring O-ring Grooved pin Pole wheel Spacer Circlip Circlip Spacer Spacer Deep groove Deep groove ball bearing ball bearing Spindle set Measuring casing Deep groove ball bearing Deep groove ball bearing Socket screw O-ring End cover Circlip Circlip Head bolt Flange Y, '/. Figure 5 omg04a.cdr Illustration of the oil flow meter, type OMG 32 Socket screw Flange O-ring End cover Head bolt Pole wheel Grooved pin O-ring Spacer Circlip Spacer Circlip Spacer Deep groove ball bearing Deep groove ball bearing Measuring casing Spindle set Deep groove Deep groove ball bearing ball bearing O-ring Socket screw End cover Head bolt Circlip Circlip Flange Figure 6 omg05a.cdr Language UK Page 3/7 AALBORG OIL FLOW METER OM8160#01.4 INDUSTRIES Commissioning Step A: Ensure that the oil system has been thoroughly flushed for impurities and that it is free from air. Note: Impurities cause the oil flow meter to be blocked, and air affects the accuracy of the oil flow meter. Step B: Check that the oil flow meter and pick-up sensor are installed correctly. Step C: Set the values for max. oil and beats/10 litre in the control system. The max. oil value is the maximum oil flow in 1/h at 100% burner load on heavy fuel oil (provided this is the main fuel). The value for beats/litre can be taken from the identification of the oil flow meter (see Figure 2). Step D: Unscrew the pick-up sensor from the oil flow meter. Step E: Tap the pick-up sensor quickly against an object and check that the control system records the signals. Step F: Mount the pick-up sensor again. Step G: Check and adjust the oil flow settings for minimum load, ignition load, etc. in the control system. Dismounting and mounting instructions For dismounting and mounting the oil flow meter and sensor system please also see Figure 1, Figure 4, Figure 5, and Figure 6. 3.1 Oil flow meter 3.1.1 Dismounting Step A: Remove the oil flow meter from the pipe line. Step B: Remove the flange covers and end covers. Step C: Press out the spindle set with rolling bearings and distance sleeve from the measuring casing. Note: If the spindle set or measuring casing must be replaced, the oil flow meter must be re-calibrated. Language UK Page 4/7 AALBORG OIL FLOW METER OM8160#01.4 INDUSTRIES 3.1.2 Change of bearings Step A: Remove the pressed-on pole wheel from the measuring spindle. Step B: Remove the circlips, spacers, and rolling bearings. Step C: Remove the O-rings. Note: The O-rings are specially designed for the oil flow meter. If a replacement is necessary, only original O-rings must be used. Step D: Clean all parts carefully, take care not to scratch the sealing surfaces. 3.1.3 Mounting Step A: Mount the O-rings. Step B: Press the rolling bearings on the measuring spindle and mount the circlips and spacers. Step C: Press on the pole wheel. Step D: Insert the spindle set into the measuring case. Step E: Press the distance sleeve into the measuring case. Step F: Mount the end covers and flange covers. Step G: Tighten the screws crosswise. Step H: Install the oil flow meter in the pipe line again. 3.2 Pick-up sensor 3.2.1 Cleaning/replacing the pick-up sensor Step A: Dismount the pick-up sensor by unscrewing the milled nut. Step B: Clean or replace the pick-up sensor. The pick-up sensor can be changed without performing any regulation of the distance between the pick-up sensor and pole wheel. Step C: Mount the pick-up sensor and screw on the milled nut. Note: The dry sleeve must not be turned. Language UK Page 5/7 AALBORG OIL FLOW METER OM8160#01.4 INDUSTRIES 3.2.2 Dismounting of the dry sleeve Step A: Empty the oil flow meter. Step B: Dismount the pick-up sensor. Step C: Note the position of the gap in the dry sleeve. From factory a red painting dot marks the sleeve screw-in depth and position. Step D: Open the counter nut by means of a wrench size 24. Step E: Turn out the dry sleeve by means of a wrench size 15. 3.2.3 Mounting of the dry sleeve Step A: Turn in the dry sleeve until the O-ring is sealing. Step B: Fill the oil flow meter with oil and start one of the oil pumps. Step C: Turn the dry sleeve carefully until it gazes softly on the rotating pole wheel. Then turn it one full turn back and tighten the counter nut. Use the red marking dot as guidance. The distance of the dry sleeve to the pole wheel must be 1.00 mm and the position of the gap has a maximum deviation tolerance of ± 10°. Step D: Mount the pick-up sensor again. Step E: Check that the signal from the pick-up sensor is functioning. If not, adjust the distance between the pole wheel and pick-up sensor again. Language UK Page 6/7 AALBORG OIL FLOW METER OM8160#01.4 INDUSTRIES Trouble shooting If a fault occurs, the basic and necessary conditions for operation must be checked: • Is electric power supply available? • Is oil available in the tanks? • Are the oil pumps running correctly? • Are all the regulating controls correctly adjusted? If the cause of the fault is not due to any of these conditions, the fault finding chart in Table 1 can be consulted. Fault and rectifying faults Failure Reason Remedy Viscosity of the medium and/or Raise the temperature (check the allowed temperature Too high pressure flow rate is too high range) drop Reduce flow rate Use a different size oil flow meter Seal is not tightened enough Tighten screws Leakage Seal is damaged Change seal Check chemical resistance Foreign substance Clean oil flow meter Use filtration Blocked flow meter Pick-up sensor mounted too far Adjust pick-up sensor inside Not enough inlet pressure Raise inlet pressure Air lock Remove air Degassing Raise system pressure, reduce temperature Too high pulsation Change oil pump, modify system Operation: Change of operating conditions Too high measuring • high flow fluctuation default • Quantity too small • Differing operating data High wear New oil flow meter Filtration of abrasive material Defective pick-up insert Screw out the pick-up and check it by tapping 1he pick-up sensor quickly against an object (control system records) No signal from pick Defective connection Luminous diode up sensor Check connections Wrong power supply Adjust electronics Defective pick-up insert New pick-up insert Defective contacts Check contacts No ordinary signal External interference Install cables from pick-up sensor Distance to the pole wheel not correct Correct distance Table 1 Language UK Page 7/7 •itiiiii. AALBORG dj5flllill98fiHI8fiE^M^^M INDUSTRIES ^••••HlBHIIIIBIlHi^^H^HH^I^H Table of contents Differential transmitter General 1 Technical description 2 Installation 3 Commissioning 4 Operation of the transmitter 5 Maintenance 6 Language UK Page 1/1 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES Dp-transmitter, type 7MF4433 1 General The following description is valid for a differential pressure transmitter SITRANS P, type 7MF4433. Warning: This device may only be assembled and operated after qualified personnel has ensured, by providing suitable power supplies, that no hazardous voltages can get into the device in normal operation or in the event of a failure of the system or parts thereof. Warning: The device may be operated with high pressure and corrosive media. Therefore serious injuries and/or considerable material damage cannot be ruled out in the event of improper handling of the device. The perfect and safe operation of this equipment is conditional upon proper handling, installation, and assembly as well as on careful operation and commissioning. Technical description 2.1 Application The SITRANS P transmitter can be used to measure: • the differential pressure, e.g. the active pressure, • a small positive or negative excess pressure, • flow q ~ p°5 (together with a flow control valve) of non-corrosive and corrosive gases, vapours, and liquids. Measuring spans are possible between 1 mbar and 30 bar depending on the type. The output signal is a load-independent direct current of 4 to 20 mA. A linear (proportional to the differential pressure) or square rooting characteristic (proportional to the rate of flow) can be selected. Transmitters conforming to the type of protection "Intrinsic safety" and "Explosion- proof may be installed within potentially explosive atmospheres zone 1 or zone 0. The transmitter is provided with an EU prototype test certificate and comply with the corresponding harmonised European standards of the CENELEC. Language UK Page 1/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES 2.2 Mode of operation Figure 1 shows a function diagram of the SITRANS P differential pressure and flow transmitter. The item numbers referred to in the following description are those mentioned in the in the figure. The differential pressure is applied via the diaphragms (4) and the filling liquid (3) to the silicon pressure sensor (7). If the measuring limits are exceeded, the overload diaphragm (6) is flexed until one of the diaphragms (4) rests on the measuring cell body (2), thus protecting the silicon pressure sensor (7) from overloading. The measuring diaphragm of the silicon pressure sensor is flexed by the applied differential pressure. The resistance of four piezo-resistors fitted in the diaphragm in a bridge circuit th+us changes. This change in resistance results in a voltage output from the bridge proportional to the differential pressure. This voltage is amplified and converted into a frequency by means of a voltage-to-frequency converter (9). This signal is evaluated by a micro controller (10), and its linearity and temperature effect corrected. The processed signal is converted by a digital-to-analogue converter (11) into an output signal of 4 - 20 mA. The data specific to the measuring cell as well as the parameters of the transmitter are stored in a non-volatile memory (EEPROM). The cable termination point and the electronics are arranged opposite one another. Parameterisation of the transmitter is performed using a laptop, PC, HART® Communicator, or the input keys. Normally the input keys are used to set-up the transmitter. Function diagram 12 13 -JiÔO-ÔÔÔob] rf^Ti o'A.l/H Differential pressure 5 O-Ring :i as input variable 6 Overload diaphragm /A Output signal 7 Silicon pressure sensor UH Power supply 8 Instrument amplifier 9 Voltage-to-frequency converter 1 Process flange 10 Microcontroller 2 Measuring cell body 11 Digital-to-analog converter 3 Filling liquid 12 LCD (option) 4 Diaphragm 13 Analog indicator (option) Figure 1 7mf33 01.tif Language UK Page 2/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES The following parameters can be set or their current interrogated: • measuring range • measured value in mA, %, and unit of pressure unit of pressure linear or square rooting characteristic application point of the square rooting characteristic electric damping current transmitter output current in the event of an error disabling input keys and/or functions 2.3 Dimensions SITRANS P, differential pressure and flow transmitter, dimensions HŒH3£» f:^ 161 foraeriae DSwHh PROFIBUS-PA • 45 forP g 13,5 with adapter 1 Process connection V4 - 18 NPT 5 Connection side tor absolute pressure (+) side 6 Electronics side, digital display 7 2 Mounting thread M10.M12 or /16-20 UNF (greater length for cover with window) 3 Dummy plug 7 Protective cover over keys 4 Electrical Connection: 8 Sealing screw Screwed gland Pg 13.5 (adapter) 9 Side vent for measuring liquid M20x1.5ortt-14NPTor 10 Side vent for measuring gas (supplement H02) Han 7D/Han 8 U plug 11 Mounting bracket (optional) Figure 2 7mf33 02.tif Language UK Page 3/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES Installation 3.1 Place of installation The transmitter can be installed above or below the pressure tapping point. When measuring gases, it is recommended to install the transmitter above the pressure tapping point and the pressure pipe to be laid so it runs down to the pressure tap. This will permit any condensation in the pipe to drain off and not affect the measurement. When measuring liquids, the transmitter should be installed below the pressure taping point and the pipe laid so it rises up to the pressure tap, thus enabling any gas in the pipe to dispersed. The point of installation should be easily accessible, preferably close to the measuring point and free from vibration. The permitted ambient temperature limits must not be violated. Protect the transmitter from direct heat sources. Before installing the transmitter, compare the process data against the data on the rating plate. Keep the transmitter closed during the installation process. The transmitter can be fitted directly to the valve manifold or secured with a mounting bracket. 3.2 Fixing with a mounting bracket The mounting bracket is fixed to either • a wall or mounting frame using 2 screws, or to • a vertical or horizontal mounting pipe (50 to 60 mm in diameter) using a U-bolt (see Figure 3). The transmitter is fastened to the mounting bracket using the four screws supplied. Fixing the transmitter using a mounting bracket Figure 3 7mß3 03.tif Language UK Page 4/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES 3.3 Rotating the measuring cell in relation to the housing If necessary, the measuring cell of the transmitter can be rotated in relation to the electronics housing, so that the digital display is visible and/or access the input keys and the current connection for an external measuring instrument is possible. Only a limited rotation is permitted. The range of rotation (7), see Figure 4, is marked at the base of the electronics housing. At the neck of the electronics housing there is an orientation mark (6) which always must be within the marked range when rotated. Step A: Loosen the locking screw (8). Step B: Rotate the electronics housing in relation to the measuring cell (only within the marked area. Step C: Tighten locking screw (torque 3.5+u ' Nm) Rotating the measuring cell in relation to the housing ./ Figure 4 7mi33 04.tif 3.4 Electrical connection Warning: Observe the relevant regulations during the electrical installation. In hazardous areas, pay particular attention to: the regulations governing electrical systems in hazardous areas (Elex V), the specifications regarding the installation of electrical systems in hazardous areas (VDE 0165), and, the EC type examination certificate Language UK Page 5/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES Warning: Check that the auxiliary power supply matches that specified on the rating plate. The transmitter should be powered from a SELV (safety extra-low voltage) source. If other power sources are used, it is recommended to earth the transmitter housing and PE connection. The earth terminal in the connection box must be connected internally to the PE connection. Please note that: • The sealing caps in the cable entries have to be replaced by relevant cable glands or blanking plugs, which must be certified when using transmitters conforming to protection type "Flame-proof enclosure". • The following general guidelines apply when laying terminal (maximum cross section 2.5 mm2)/signal cables: — lay the signal cable separately from cables carrying voltages > 60 V — use twisted-pair cables — do not lay cables close to large electrical systems, or use screened cable 3.4.1 Connection to screw terminals Electrical connection .. . _ Figure 5 7mß3 05.tif Step A: Unscrew the cover of the connection box (marked "FIELD TERMINALS" on the housing). Step B: Insert the connecting cable through the cable gland. Step C: Connect the wires the "+" (2) and "-" (3) to the terminals, see Figure 5 and observe the polarity. Position (4) is a test plug for an external DC amp- meter. Step D: Connect the screen (1) to the screen screw, if necessary. Step E: Screw on the housing cover. Language UK Page 6/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES Note: In explosion-proof transmitters the housing cover must be screwed on tightly and secured with the cover catch. 3.4.2 Connect with plug The contact parts for the coupling socket are enclosed packed in a bag. Please note that these must not be used for explosion-proof transmitters. Step A: Push the sleeve and screwed gland onto the cable. Step B: Insulate the cable ends approximately 8 mm. Step C: Crimp or solder the contact parts to the cable ends. Step D: Assemble the coupling socket. Connection with plug lA output current VH auxiliary power Figure 6 7mß3 06.tif 3.5 Turning the digital display If the device cannot be operated in a vertical position the digital display can be turned to make it easier to read. To do this, proceed as follows: Step A: Unscrew the cover from the electronics housing. Step B: Unscrew the digital display. Depending on the position of the transmitter it can be screwed back in four different positions (rotation by ±90° or ±180° are possible). Step C: Screw on the housing cover. Language UK Page 7/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES Commissioning The process data must correspond to that on the rating plate. The transmitter functions as soon as the power is turned on. Warning: Serious injury or considerable material damage may result if: • the venting valve and/or the sealing screw are missing or not tight enough and/or • the valves are operated wrongly or improperly Warning: When working with a hot medium, the individual steps described below must be performed in quick successions, otherwise the valves and transmitter may overheat and be damaged. 4.1 Measuring gases The isolating valves should be operated in the following sequence, see Figure 7: Measuring gases ^xx^ 1 Transmitter 2 Equalizing valve < * \ 3 Pressure Inlet valves 4 Impulse lines 5 Isolating valves -DXl- 7 Outlet valves -IX- 9 Condensate traps SB, 3A 10 Pressure source t t 3A XI ûiz 7B 10 Transmitter above Transmitter below pressure source pressure source (normal configuration) (non-standard) Figure 7 7mf33 07.tif Language UK Page 8/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES Step A: Initial setting: all valves closed. Step B: Open both isolating valves (5) at the pressure tapping points. Step C: Open the equalising valve (2). Step D: Open the pressure inlet valve (3A or 3B). Step E: Check the zero point (4 mA) at start of scale (0) and correct if necessary. Step F: Close the equalising valve (2). Step G: Open the other pressure inlet valve (3A or 3B). 4.2 Measuring liquids The isolating valves should be operated in the following sequence, see Figure 8: Measuring liquids 1 Transmitter 2 Equalizing valve 3 Pressure inlet valves 4 Impulse lines 5 Isolating valves 7 Outlet valves 8 Venting valves 10 Pressure source 12 Gas trap Transmitter below Transmitter above pressure source pressure source (normal configuration) (non-standard) Figure 8 7mß3 08.tif Step A: Initial setting: all valves closed. Step B: Open both isolating valves (5) at the pressure tapping points. Step C: Open the equalising valve (2). Language UK Page 9/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES Step D: If the transmitter is below the pressure source: open both outlet valves (7) slightly, one after the other, until no more air escapes. Step E: If the transmitter is above the pressure source: open both venting valves (8) slightly, one after the other, until no more air escapes. Step F: Close both outlets (7) or venting valves (8). Step G: Open the pressure inlet valve (3 A) and venting on the positive leg of the transmitter (1) slightly until no more air escapes. Step H: Close the venting valve. Step I: Open the venting valve on the negative leg of the transmitter slightly until no more air escapes. Step J: Close pressure inlet valve (3 A). Step K: Open the pressure inlet valve (3B) slightly until no more air escapes, close after. Step L: Close the venting valve on the negative leg of the transmitter (1). Step M: Open the pressure inlet valve (3 A) Vi a rotation. Step N: Check the zero point (4 mA) against start of scale (0) and correct if necessary. Step O: Close the equalising valve (2). Step P: Open the pressure inlet valves (3A and 3B) fully. 4.3 Measuring steam The isolating valves should be operated in the following sequence, see Figure 9: Caution: The result will only be correct when the impulse lines (4) contain an identical head of condensate at identical temperatures. Zero point calibration should be repeated, if necessary, when this condition is satisfied. Caution: The flow of steam may damage the transmitter if the equalising valve (2) is opened when both the isolating valves (5) and pressure inlet valves (3) are open! Language UK Page 10/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES Measuring steam 1 Transmitter 2 Equalizing valve 3 Pressure inlet valves 4 Impulse lines 5 Isolating valves 7 Outlet valves 10 Pressure source 13 Condensate reservoir 14 Jacket Figure 9 7mO3_09.tif Step A: Initial setting: all valves closed. Step B: Open both isolating valves (5) at the pressure tapping points. Step C: Open the equalising valve (2) Step D: Wait until the steam in the impulse line (4) and in the condensate reservoirs (13) has condensed. Step E: Open the pressure inlet valve (3 A) and venting valve on the positive leg of the transmitter slightly until no more air escapes. Step F: Close the venting valve. Step G: Open the venting valve on the negative leg of the transmitter slightly until no more air escapes. Step H: Close pressure inlet valve (3 A). Step I: Open the pressure inlet valve (3B) slightly until no more air escapes. Step J: Close the venting valve on the negative leg of the transmitter. Step K: Open the pressure inlet valve (3A) lA a rotation. Step L: Check the zero point (4 mA) against start of scale (0) and correct if necessary. Step M: Close the equalising valve (2). Step N: Open the pressure inlet valves (3A and 3B) fully. Language UK Page 11/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES Operation of the transmitter 5.1 General The differential pressure and flow transmitter is adjusted in the field by three input keys, located on the outside of the instrument, with which the start of scale and full scale values are set or adjusted. By means of the digital indicator (optional) additional parameters can be adjusted. The input keys can be accessed, by undoing the two screws holding the protective cover in place, which can then be moved out of the way. Transmitter controls and displays O * [ ^ JLOOOPv 1) o t au.u ü u O ! y • J'JÆU ^> Symbols for Input keys 1 Digitaldisplay 2 Connecting plug for digital display 3 Mode key 4 Increment key 5 Decrement key Figure 10 7mt33 10.tif The functions listed in Table 1 can be selected using the "M" key. When pressing the "M" key (Mode) 2 appears in the bottom left corner on the LCD display. Every additional key press increases the mode by one. The parameters, the current value, or the unit of pressure can be modified using the Ï and 4- keys. In case of error situations "Error" is displayed on the display, (see section 5.2.7). It generally applies that: • The transmitter changes to function "Measured value", if mode 14 is passed by pressing the "M" key or if 2 minutes elapse without a key being pressed. In case of the 2 minutes being passed the setting is automatically saved. • The key lock must be released for keyboard operation. • Numerical values are always set from the least significant digit still displayed. In the case of an overflow in the key repetition mode it switches to the next significant digit and only this continues to be counted. This procedure serves for fast rough setting over a wide numeric range. For fine setting the desired key (t Language UK Page 12/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES or i) have to be released and pressed again. Exceeding of the upper and lower measured value limits are shown on the display with the signs t or I. If the input pressure is displayed, selected in mode 13 (see section 5.2.10), and the square rooting characteristic in mode 11 (see section 5.2.9) the differential pressure corresponding to the flow and additionally the sign "V" is displayed on the display. Functions of the dp-transmitter, type SITRANS P 7MF4433 Key function Function Model) Display, explanation Section t 4- t and>P Output current in mA or % or input pressure in unit Measured value 5.2.10 of pressure "Error", if the transmitter is disturbed. Moving text Error display 5.2.7 indicating reason for disturbance Current Current Set to Start of scale 2 Output current in mA 5.2.2 greater smaller 4mA Current Current Set to Full scale 3 Output current in mA 5.2.2 greater smaller 20 mA Damping Damping Time constant T in seconds Electrical damping 4 63 5.2.3 greater smaller Parameter range: 0.0 to 100.0 Start of scale Pressure Pressure Set to start 5 Start of scale in selected unit of pressure 5.2.4 "blind setting" greater smaller of scale 0 Set to upper Full scale Pressure Pressure 6 measuring Full scale in selected unit of pressure 5.2.4 "blind setting" greater smaller limit Zero adjustment Vent transmitter (start of scale remains unaffected). (position 7 -- -- Execute 5.2.5 Measuring value in unit of pressure correction)2* Constant output current in mA Current Current Current transmitter 8 Switch on 3.6 - 4.0 -12.0 - 20.0 - 22.8 5.2.6 greater smaller Switch off by "M" key Output current in Change between the Selected output current 9 -- • 5.2.7 the event of an error two values Possible: fault current limits set by user "O" = none "LA" = all disabled "LO" = all disabled except start of scale Keys and/or Change between the 10 -- "LS" = all disabled except start of scale and full 5.2.8 function disable five functions scale "L" = write protection, operation by HART® not possible "Lin" = liniar "SrLin" = square rooting Change between the Characteristic 11 -- (linear up to application point) 5.2.9 three functions "SroFF" = square rooting (switched off up to application point) Application point of the square rooting 12 Greater Smaller -- Parameter range 5 to 15% flow 5.2.9 characteristic Measured value Select from three Unit of pressure (input value) or output current in 13 5.2.10 display possibilities mA or % Unit of pressure 14 Change Technical units of pressure 5.2.11 l} Change mode by pressing the "M" key. 2) The start of scale is in a vacuum in absolute pressure transmitters. The zero adjustment in ventilated transmitters leads to mis-adjustments. Table 1 Language UK Page 13/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES 5.2 Operation with LCD display 5.2.1 General • Please note that the input keys might be disabled. To cancel a set keyboard disable press the "M" key for 5 seconds. Step A: Undo the two screws holding the protective cover in place, which can then be moved out of the way. Step B: On completion of calibration replace the protective cover and tighten both screws. 5.2.2 Set/adjust start of scale and full scale The start of scale and full scale can be set or adjusted with the input keys. Modes 2 and 3 (see Table 1 ) are available for this. This allows implementation of rising or falling characteristics. Setting (theoretical relationship) In setting, a desired start of scale and/or a desired full scale are assigned to the standard current values (4 mA/20 mA). Pre-requirements: two reference pressures (Pri, Pß) provided by the process or generated by a pressure transmitter. Note: The measuring span is not changed when setting the start of scale. By setting the full scale the start of scale remains unchanged. Therefore the start of scale should be set first and then the full scale. The relationship between the measured pressure and the generated output current is linear. Please note that this does not apply if square rooting characteristic is selected. In case of linear relationship the output current can be calculated with the following equation shown in Figure 11 : Equation for calculation of current output I = output current p = pressure p-MA ME-MA *16mA + 4mA MA=start of scale ME = full scale Figure 11 7mf33 12.tif Example Given a transmitter with a measuring span of 0 to 16 bar. Set to a measuring span of 2 to 14 bar. Step A: Apply 2 bar process pressure. Set the device to mode 2 with the "M" key. The display shows the set mode at the bottom left. Set the start of scale by pressing the T and 4 keys on the value for about 2 seconds. An output current of 4 m A is then generated at 2 bar input pressure. Language UK Page 14/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES Step B: Apply 14 bar process pressure. Set the device to mode 3 with the "M" key. The full scale is set by pressing the t and i keys on the value for about 2 seconds. An output current of 20 mA is then generated at 14 bar input pressure. Step C: The output current for any input pressure can be calculated with the specified equation shown in Figure 11. Adjusting (theoretical relationship) When adjusting, the start of scale and/or the full scale can be assigned to any desired current value using one reference pressure. This function is particularly suitable if the pressures necessary for start of scale and full scale are unavailable. Requirements: applied pressure (reference pressure) and the set start of scale and full scale are known. Please note that after adjusting, the measuring range specified on the measuring point plate may no longer match the setting. Using the following equation shown in Figure 12 the current that should be adjusted for the desired start of scale and full scale can be calculated. Equation for calculation of current (set the start of scale and full scale) current tob« P_ -MA «8»* M* non, ME^-MAK, current to be p_j -MA__ MlatMEr«, l„ r-rd nom •16mA + 4tnA ME»,nom- MA„nom„ I »output current p . = applied reference pressure MA^, »old start of scale ME,,,,, -new(idscale MAJ^ »new start of scale 11 To calculate the output currents when sating start of scale and full scale, the reference pressure must be »elected so that a value between 4 and 20 mA Is obtained for the current. Figure 12 7mt33 13.tif Example Given a transmitter with a measuring span of 0 to 16 bar. Adjust to a measuring span of 2 to 14 bar. A reference pressure of 11 bar is available. Step A: Set the device to mode 2 with the "M" key. Using the equation from Figure 12 first calculate the current that should be adjusted for the desired start of scale (2 bar) at the applied reference pressure and then adjust it with the f and i keys (13 mA in this example). Step B: Set the device to mode 3 with the "M" key. Using the equation from Figure 12 calculate the current that should be adjusted for the desired full scale (14 bar) at the applied reference pressure and then adjust it with the t and i keys (16 mA in this example). Language UK Page 15/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES Set start of scale and full scale (practical application with actual pressures available) The device sets the output current for the start of scale to 4 mA and the full scale to 20 mA when the input keys are pressed according to the following instructions. The start of scale is set by: Step A: Apply the corresponding pressure. Step B: Select mode 2 using the "M" key. Step C: Set the start of scale to 4 mA with the t and i keys. StepD: Save with "M". The full scale is set by: Step E: Apply the corresponding pressure. Step F: Select mode 3 using the "M" key. Step G: Set the full scale to 20 mA with the T and i keys. Step H: Save with "M". Set start of scale and full scale (practical application with reference pressure available) If the output current is not set but adjusted continuously, the currents must be calculated so they can be adjusted mathematically. It is possible to make an adjustment for the start of scale, the full scale, or both values one after the other. The start of scale is adjusted by: Step A: Apply the reference pressure. Step B: Select mode 2 using the "M" key. Step C: Adjust the output current for the start of scale with the T and 4- keys. Step D: Save with "M". The full scale is adjusted by: Step E: Apply the reference pressure. Step F: Select mode 3 using the "M" key. Step G: Adjust the output current for the full scale with the t and 1 keys. Step H: Save with "M". 5.2.3 Electric damping The time constant of the electric damping can be set in steps of 0.1 second between 0 and 100 seconds with the input keyboard. This damping acts additionally to the device-internal basic damping. The electric damping is set by: Language UK Page 16/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES Step A: Select mode 4 using the "M" key. Step B: Set the desired damping with the T and i keys. Step C: Save with "M". 5.2.4 Blind setting of start of scale and full scale In modes 5 and 6 the start of scale and full scale can be set/adjusted with the input keys and without applying pressure. It is also possible to change between rising and falling characteristics. Theoretical relationship First select the desired physical unit. The two pressure values can then be set/adjusted with the T and -l keys and saved in the device. These theoretical pressure values are assigned to the standard current values 4 mA and 20 mA. The relationship between the measured pressure and the generated output current is linear. Please note that this does not apply if square rooting characteristic is selected. Example Given a transmitter with a measuring span of 0 to 16 bar. Adjust it to a measuring span of 2 to 14 bar without applying pressure. Step A: Set the device to mode 5 with the "M" key. Set the start of scale to 2 bar by pressing the t or 1 key. If 2 bar input pressure are applied later, an output current of 4 mA is generated. Step B: Set the device to mode 6 with the "M" key. Set the full scale to 14 bar by pressing the Î or •I key. If 14 bar input pressure are applied later, an output current of 20 mA is generated. Set start of scale and full scale, blind (practical application) The device sets the start of scale to the lower and the full scale to the upper sensor limit when the keys are operated as follows: The start of scale (blind) is set by: Step A: Select mode 5 using the "M" key. Step B: Press the t and -l keys simultaneously and hold for 2 seconds. The start of scale is set to the lower sensor limit. The full scale (blind) is set by: Step C: Select mode 6 using the "M" key. Step D: Press the T and 1 keys simultaneously and hold for 2 seconds. The full scale is set to the upper sensor limit. Adjust start of scale and full scale, blind (practical application) If the pressures for the start of scale and full scale are not to be set but adjusted continuously, the keys should be operated as follows: The start of scale (blind) is adjusted by: Step A: Select mode 5 using the "M" key. Language UK Page 17/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES Step B: Adjust the pressure value of the start of scale with the T or X keys. Step C: Save with "M". The full scale (blind) is adjusted by: Step D: Select mode 6 using the "M" key. Step E: Adjust the pressure value of the full scale with the T or i keys. Step F: Save with "M". 5.2.5 Zero adjustment (position correction) The zero error resulting from the installation position can be corrected with a zero adjustment. To do this, the device must be ventilated to correct the existing offset so that the value 0 bar (or other unit of pressure) appears in the display. The setting of the start of scale and full scale remain the same. The zero adjustment is set by: Step A: Vent the transmitter. Step B: Select mode 7 using the "M" key. Step C: Set zero with the Ï and 4 keys. Step D: Save with "M". 5.2.6 Current transmitter The transmitter can be switched to constant current mode with the "M" key. In this case the current no longer corresponds to the process variable'. The following output currents can be set independently of the input pressure: — 3.6 mA - 4.0 mA - 12.0 mA - 20.0 mA - 22.8 mA The current transmitter function can be cancelled again with the "M" key. The constant current is set by: Step A: Select mode 8 using the "M" key. Step B: Activate the constant current mode by pressing the Î and i keys simultaneously for about 2 seconds. Step C: Activate the constant current level by pressing the t or 4 key. Step D: Turn off the constant current mode with the "M" key. Step E: Exit the constant current mode with the "M" key. 5.2.7 Failure current In mode 9 it is possible to select whether the upper or lower fault current should be the output in the event of a fault or an alarm. The current can be set to 3.6 m A or 22.8 mA. The default is the lower fault current. The fault current is set by: Language UK Page 18/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES Step A: Select mode 9 using the "M" key. Step B: Select the fault current with the t or i key. Step C: Save with "M". 5.2.8 Key and/or function disable In mode 10 it is possible to disable several functions which are generally possible with keyboard operation. In addition a write protection to protect the saved parameters can be activated. The following settings are possible: "0" no disabling. "LA" input keys disabled, operation via HART® possible. "LO" input keys disabled, only start of scale can be set. Operation via HART® possible. "LS" input keys partly disabled, only start of scale and full scale can be set. Operation via HART® possible. "L" write protection, operation via HART® not possible. A set keyboard disable (LA, LO, LS) or a write protection for HART® (L) can be cancelled with the input keys. To do this, press the "M" key for 5 seconds. Note: If the "LO" or "LS" disable is selected, it is recommended to select the measured value display "Current" in mA or % first in mode 13. Otherwise a change in the output variable is not detected when pressing the t and 4- keys. The key/function disable is set by: Step A: Select mode 10 using the "M" key. Step B: Select the disable mode with the t or i key. Step C: Save the disable mode with the "M" key. Note: When delivered with a blanking cover, the disable mode "LS" is active, i.e. only zero and span can be changed. If the device permanently is operated with a blanking cover, make sure that the disable mode "LS" remains set. 5.2.9 Flow measurement The characteristic of the output current can be selected as: • Linear (proportional to the differential pressure), or • Square rooting (proportional to the flow) Below the application point of the square rooting characteristic the output current can either be output linearly or switched off. When "SrLin" is selected the output Language UK Page 19/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES current is linear up to the application point (see Figure 13 a) and when "SroFF" is selected the output current is switched off up to the application point. The application point can be set between 5% to 15% of the flow. The characteristic is set by: Step A: Select mode 11 using the "M" key. Step B: Select the characteristic type with the t or 4- key. Step C: Save with "M". The root application point is set by: Step D: Select mode 12 using the "M" key. Step E: Select the application point between 5% and 15% with the T or 4- key. Step F: Save with "M". Note: Mode 12 cannot be selected when the "linear" measuring mode 11 is set. If the input pressure is selected as a display in mode 13 and square rooting characteristic in mode 11, the differential pressure corresponding to the flow and root sign are displayed. Transition point of square rooting characteristic Outputl%! square ^^^ root s^ square y^ / so- root / / 15 yS Adjusting f/ Transition range for 10 60- transition / point / / pressure point / / linear // linear pressure 5- •j-j linear 40- - — '% s 0 fL-""""''^ '• 20- 0 12 3 4 a: linear below transition point ; o- 0' '; 20 40 60 80 100 pressure (%} 0 12 3 4 b: cut-off below transition point Figure 13 7mf33 ll.tif Language UK Page 20/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES 5.2.10 Measured value display In mode 13 one of three display types can be set with the input keys. • Display in mA. • Display in % (of the set measuring range). • Display in a unit of pressure (selectable in mode 14). The unit type is set by: Step A: Select mode 13 using the "M" key. Step B: Select the type unit with the T or i keys. Step C: Save with "M". 5.2.11 Selection of unit of pressure In mode 14 it is possible to select a desired unit of pressure for the display from a list with the input keys. The following unit of pressure can be chosen: Bar, mbar, mm HzCP, in HbCP, ft U20'\ mm Hg, in Hg, psi, Pa, kPa, Mpa, g/cm , kg/cm2, Torr, ATM, in WC, mm WC. ** Reference temperature 20°C. The unit of pressure is set by: Step A: Select mode 14 using the "M" key. Step B: Select the unit of pressure with the t or 4 key. Step C: Save with "M". If the display capacity of the digital display is exceeded, "9.9.9.9.9" appears in the display. Please note that in the measuring mode the selected unit is only visible in the display if a unit of pressure display is selected in mode 13. Otherwise "mA" or "%" is displayed. 5.3 Operation without LCD display 5.3.1 Setting start of scale and full scale without LCD display • Please note that the input keys might be disabled. To cancel a set keyboard disable press the "M" key for 5 seconds. Step A: Undo the two screws holding the protective cover in place, which can then be moved out of the way. Set start of scale (4 mA) and full scale (20 mA) Assuming the input keys are pressed as described below, the transmitter sets the start of scale to 4 mA and the full scale to 20 mA. An ammeter is not required. Start of scale Step A: Apply a differential pressure corresponding to the start of scale to the transmitter. Language UK Page 21/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES Step B: Press the t and i keys simultaneously for about 2 seconds. Full scale Step A: Apply a differential pressure corresponding to the full scale to the transmitter. Step B: Press all three input keys, making sure that the "M" key is pressed first, hold it, and press both the other keys (t and i). Calibrate start of scale and full scale If the output current is not to be set but freely adjusted continuously, the currents must be calculated for mathematical adjustment. It is possible to make an adjustment for the start of scale, the full scale, or both values one after the other. Warning: It is forbidden to screw off the transmitter cover when working in hazardous locations and using transmitters conforming to protection type "Flame-proof enclosure" (Explosion-proof). Step A: Clean the transmitter to prevent the ingress of dirt. Step B: Unscrew the cover from the electrical connection box. Step C: Connect a DC meter to the test plug (see Figure 5). Warning: For intrinsic safe current circuits only certified current meters are permitted. Start of scale Step A: Apply a differential pressure corresponding to the start of scale to the transmitter. Step B: Set the output current for start of scale using the Î and i keys. Step C: The set output current is saved automatically when the key is released. Full scale Step A: Apply a differential pressure corresponding to the full scale to the transmitter. Step B: Set the output current for full scale using the "M" key and the Î key or the "M" key and the i key. Always press the "M" key first, hold it, and press either the t or the i key. Step C: The set output current is saved automatically when the key is released. Language UK Page 22/23 AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0 INDUSTRIES Maintenance The transmitter requires no maintenance. However, the start of scale value should be checked occasionally. If an error occurs: • the output current is set to 22.8 mA or 3.6 mA, depending on the selection (see section 5.2.7) • using SIPROM P an appropriate message is displayed in the "Measured values" field • "Error" is displayed on the LCD display Language UK Page 23/23 AALBORG TABLE OF CONTENTS INDUSTRIES Table of contents Regulating valves Electrical actuator, type Premio General 1 Description 2 Installation 3 Settings 4 Starting up 5 Care and maintenance 6 Dismantlement of the thrust actuator 7 Troubleshooting 8 Control valves, type 470/471 General 1 Operation 2 Maintenance 3 Language UK Page 1/1 *#####• AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES Electrical actuator, type Premio 1 General These operating instructions contain information necessary to install and operate the thrust actuator both safely and effectively. If problems arise which cannot be solved with the aid of this operating instruction, please contact Aalborg Industries for further information. 1.1 Qualified personnel This refers to personnel possessing corresponding qualifications and familiar with the processes of installing and assembling the product as well as with putting the product into service and operating the same, e.g. — Training, instruction, or authorisation to switch on and off electric circuits and equipment/systems and to disconnect, ground, and identify the same in accordance with VDE 0100, the regulations stipulated by the local electricity generating boards as well as technical safety standards. — Instruction and obligation to comply with all regulations and requirements pertaining to use as well as regional and in-house regulations and requirements. — Training or instruction in accordance with technical safety standards in the use and maintenance of pertinent safety equipment including job-safety equipment. 1.2 Handling Storage • Storage temperature: -20°C to +70°C dry, free of dirt. • Do not damage packing. • A desiccant or heating to prevent condensation is necessary in damp rooms. Transport • Transport temperature: -20°C to +70°C. • Protect against external force (impact, vibration, etc.). • Do not damage packing. Handling before installation • Protect against atmospheric conditions e.g. wetness. • Correct handling protects against damage. • Do not soil or damage type identification plate and wiring diagram on the controller. Language UK Page 1/21 AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04,2 INDUSTRIES Description 2.1 Field of application The PREMIO linear thrust actuators are employed to actuate control or shut-off valves requiring a nominal linear stroke distance of up to 80 mm and thrust from 2.2 kN to 15 kN. The thrust actuators are set to the thrust forces specified in the technical data. If supplied with the valve, the lift of the thrust actuator will be set to the stroke distance of the valve. Selection of the proper actuator version in alignment with the corresponding fitting as well as use of the thrust actuator in accordance with the specified technical data is the responsibility of the systems engineer. Attention: Any use of the thrust actuator beyond the specified technical data or improper use of the actuator is deemed to be not for the intended purpose. The ambient conditions have to be conformed to the actual electromagnetic compatibility directives. Additional the compatibility to this directive has to be maintained in case of expansion or other changing of the ambient conditions. 2.2 Method of functioning The thrust actuator, fitted with a yoke or columns, is mounted to the valve. Transfer of force is affected via a coupling safeguarded against torsion. The torsion safeguarding feature also serves as a lift indicator. The lift settings can be read off on a lift dial attached to the yoke or between the 2-ear clamps mounted to the column. The electrical components are accommodated separately from the gearbox underneath a sealed hood, thus being protected against operating and environmental effects. Following removal of the hood, easy access is provided to the switch gear and indicating feature. The rotary motion of the motor is transmitted to the spindle nut by means of spur gear. The drive spindle, which is safeguarded against torsion, screws its way into the spindle nut and thus performs a pull or push motion depending on the sense of rotation. In the final positions of the valve, the spindle nut is pressed against a set of springs so as to produce closing force. The motor is switched off by means of two load-dependent switches and one stroke- dependent switch. The load-dependent switches will also switch off the motor if foreign bodies have lodged themselves between the valve seat and cone. The load-dependent switches serve to protect the valve and thrust actuator against damage. 2.3 Technical data The technical date for the thrust actuators is appears from Table 1. Actuator diagrams are illustrated in Figure 1 and Figure 2 and the part list is shown in Table 2. Finally a dimension drawing can be found in Figure 3. Language UK Page 2/21 AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES | Technical specifications for Premio actuators Type Actuator type Thrust force [kNl 2.2 | 5.0 12.0 | 15.0 Stroke distance max. [mm] 50 80 Duty classification in accordance SI - 100% duty cycle; S4- 50% SI - 100% duty cycle; S4 - 80% duty cycle 1200 c/h with DIN VDE 0530 duty cycle 1200 c/h Control speed [mm/sec] 0.25 | 0.38 | 0.38 1.0 079 | 0.38 Motor voltage 230 V-50 Hz/60Hz* 230V,50Hz 230 V-50 Hz/60 Hz* Power consumption [W] 10.3 | 11.7 | 25.3 52.9 109 | 96 2 only, permanently wired switching capacity 2 pes., permanently wired Torque switch 10 A, 250 V~ switching capacity 16 A, 250 V~ 1 only, permanently wired switching capacity 1 pes., permanently wired Travel switch 10 A, 250 V~ switching capacity 16 A, 250 V~ Enclosure IEC 60529 IP 65 Max. permissible ambient -20°C to +70°C temperature Hand wheel Yes (rotating during operation) | Yes (can be engage) Mounting position Any. Exception: motor must not be suspended downwards 50/50 Klüber Isoflex NBU15 Ultra Gear lubricant Kliiber Unigear LA 02 or similar and Klüber Nontrop KR291 or similar Weight fkgl 5.4 | 6.0 | 6.5 10.5 Accessories Additional travel switches 2 additional travel switches, zero potential, switching capacity 10 A, 250 V~ Additional travel switches for low- 2 additional travel switches, zero potential, with gold contacts, switching capacity max. voltage / electronic system 0.1 A,4-30Vdc Potentiometer Max. 2 only. Ohmage optional: 100, 200, 500,1000 ohm; 1.5 W 0 (2) -10 V, 0 (4) - 20 mA - only 1 potentiometer possible. Electronic position indicator RI21 Using the temperature controller, installation is only possible in the control cabinet. Electronic position controller ES 0 (2) -10 V, 0 (4) - 20 mA - only 1 potentiometer possible. 11 Not compatible for use with the temperature controller. Heating resistor (with automatic switching) 230 V - 50 Hz, 115 V - 50 Hz, 24 V - 50 Hz, 15 W 24V,50Hz 24 V-50/60 Hz 24V,60Hz 24 V - 50/60 Hz 115 V-50/60 Hz Additional voltages / frequencies 115V,50Hz 115 V-50/60 Hz 3-400 V-50 Hz 115V,60Hz 3-440 V-60 Hz 230V,60Hz 2 torque switches and 1 travel switch, zero potential, for Standard-voltage connection PA -- free wiring, switching capacity 10 A, 250 V ~ 2 torque switches and 1 travel switch, zero potential, for Low-voltage connection board free wiring, with gold contacts, switching capacity max. -- (electronic system), NA 0.1 A,4-30Vdc Temperature controller (three-point controller) in micro process technologies. Three-step temperature-controller in microprocessor-technology. Integrated temperature-controller Control range: -200°C to 850°C (resistance thermometer). dTRON 16.1 Voltage: 24 V, 115 V, or 230 V 50/60 Hz. Compatible with resistance thermometers and thermocouples (provided by customer), or standardised active current or voltage signals. Actuator with 400 V - 50 Hz and Integrated reversing contactor -- 440 V-60 Hz. Only 1 electronic module possible. Only in addition with integrated Phase control relay -- reversing contactor * Control speed and power consumption are 20% higher at frequency of 60 Hz Table 1 Language UK Page 3/21 AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES Diagram for actuators type 2.2 - 5.0 kN Yoke Version Column Version /— 50.47 50.53 50.52 50.51 5056 50.55 50S8- 5057 50X2 Figure 1 premio_l.tif Language UK Page 4/21 AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES Diagram for actuators type 12.0 -15.0 kN 50.12 50.12.1 50.1 50.2 50.56 50.<0 50.38 50.36 Figure 2 premio_2.tif Language UK Page 5/21 AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES Part list Pos. Designation Pos. Designation Pos. Designation 50.1 Gearbox Hexagon head screw DIN EN 50.40 Synchronous motor, complete 50.18 50.1.1 Gearbox cover plate 24017-M10x45 50.41 Head cap screw DIN 912-M4 Cable conduit fitting 50.19 T-head bolt DIN 261-M12x40 50.42 Board support 50.2 2.2-5.0 kN: 2 xPGll 50.20 Washer DIN 125-13 50.43 Standard board 12-15 kN: 2 x PG13.5/1 x PG9 50.21 Spring washer DIN 128-A12 50.45 Shift lever 50.4 Sealing plug lxPG 11 50.22 Hexagon nut DIN 24032-M12 50.46 Washer 50.5 Gasket 50.23 Lift dial 50.47 Wiring diagram sticker, std. 50.6 Hood 50.24 Distance column 50.48 Connector, 3-pole (standard) 50.7 Hood seal 50.25 Hexagon nut DIN 980-V-M16 50.50 Trip slide Counter-sunk screw DIN 7991- 50.26 2-ear clamp (stroke indicator) 50.51 Setting spindle for switch S3 50.8 M5x20 50.27 Coupling 50.52 Setting spindle for switch S4 50.9 Sealing washer DIN 125-5.3 50.30 Driving spindle 50.53 Setting spindle for switch S5 50.10 Column 50.31 Spindle safety feature 50.54 Trip cam 50.12 Hand wheel 50.32 Torsion safety feature 50.55 Lock washer DIN 6799-2.3 50.12.1 Turning handle of hand wheel 50.34 Bellow 50.56 Spring PREMIO for trip slide 50.14 Yoke 50.35 Grub screw M6 Head cap screw DIN 912- 50.57 50.15 Flange 50.36 Set collar M4xl0 50.16 Spring washer DIN 128-A10 50.37 Grub screw DIN 913-M3x5 50.58 Protective conductor terminal 50.38 Guide spindle 50.59 Head cap screw DIN 912-M4x6 Hexagon head screw DIN EN 50.17 50.87 Threaded bush 24017-M10x30 50.39 Hexagon nut DIN 24034-M5 50.101 Connector, 8-pole Table 2 Dimensions diagram //////////MW////// ISHJ5HiiSi*'iT"iT ARI.PREMIOM-SkN ARI-PREMIOV-5kN ARI-PREMIOUlSkN Nominal itroke max. 30 mm Nominal stroke > 30 mm • 50 mm Nommai stroke max. 80 mm Figure 3 premio_3.tif Language UK Page 6/21 AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES Installation Note: Safe operation of the actuator is only ensured if it is installed, put into operation, and maintained by qualified personnel. In addition, care must be taken to ensure that the general equipment and safety regulations for electrical lines and installations are complied with and that tools and protection devices are used professionally. The operating instructions for the electronic actuator must be observed when carrying out all work on and when handling the electronic actuator. Disregard of these instructions can result in injury to persons or damage to property. 3.1 General installation notes In addition to general installation guidelines, the following points are required to be observed: — Existing operating instructions for valve. — Complete valve with cross-arm. — Valve cone approximately in mid lift position - on no account supported inside a seat. — Electrical installation in accordance with DIN VDE 0100 and regulations of the local electricity generating board. — Conductor cross-section selected to correspond to the given drive power and existing line length. — Mains fuse rating max. 6 A. — Circuit breakers to EN 60335-1 in the plant to cut off the mains supply to the actuator. — Conformity of technical data on thrust actuator with field conditions. — Mains voltage in accordance with data specified on rating plate of thrust actuator. — Thrust actuator complete with yoke or distance columns and coupling parts intended for mounting to the corresponding valve. — Qualified personnel possessing knowledge of the regulations pertaining to the erection of power installations. — Ease of access to installation site and adequate clearance space above the thrust actuator for removing the hood. — Install where there is protection against high-energy heat radiation. — The ambient temperature must not exceed +70°C. — In case of widely fluctuating ambient temperatures and high atmospheric humidity, user is recommended to install a heating resistor to minimise condensation build-up in the actuator. Language UK Page 7/21 AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES — Thrust actuator mountable in any position except in downward suspended position. — If installed with a horizontal connecting rod, the thrust actuator must be mounted so that both legs of the yoke or columns are on top of one another in the vertical plane. 3.2 Manual operation For actuators type 2.2 -5.0 kN With the motor in the stationary state, the thrust actuator can be run in the open and closed state with the hand wheel firmly meshed with the gear. Proceed as follows: Step A: Swing out lever (50.12.1) from hand wheel (50.12), see Figure 4. — Turning in clockwise direction —> closes valve. — Turning in counter-clockwise direction --> opens valve. Hand wheel operation (actuator type 2.2 - 5.0 kN) Open Close 50.12.1 50.12 Figure 4 premio_4.tif In the manual operating mode pay careful attention in the final positions that the hand wheel is only turned to the point where the torque switch trips (audible click) as otherwise damage will be caused to the thrust actuator. Since the hand wheel always follows during motor-driven operation (running indication), never operate by hand while the motor is running -potential injury hazards. For actuators type 12.0 -15.0 kN With the motor in the stationary state, the thrust actuator can be run in the open and closed state with the engage able hand wheel. Proceed as follows: Step A: Fold the turning handle out of the hand wheel (A), see Figure 5. Step B: Turn the hand wheel slightly and push in the engaging button for manual mode (B) --> the button engages. — Turning in clockwise direction —> closes valve. — Turning in counter-clockwise direction —> opens valve. The motor is no longer in mesh when the hand wheel is engaged. The hand wheel is automatically disengaged when the motor starts and the hand wheel is once more in mesh. Language UK Page 8/21 AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES Hand wheel operation (actuator type 12.0 - 15.0 kN) Engaging button for manual mode 50.12.1 Open Close Figure 5 premio_5.tif In the manual operating mode pay careful attention in the final positions that the hand wheel is only turned to the point where the torque switch trips (audible click) as otherwise damage will be caused to the thrust actuator. 3.3 Installation instructions for mounting to valves 3.3.1 Mounting for valve-lift up to 30 mm (yoke version) To mount the thrust actuator to a valve having a nominal lift of up to 30 mm, proceed as follows (Fig. and position numbers refer to Figure 6): Step A: Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator (not illustrated). Step B: Set valve cone position to approximately mid lift position. Step C: Turn flat hexagon nut if not present on valve spindle (Fig. A). Step D: Slip coupling (50.27) over valve spindle (Fig. A-B). Step E: Screw threaded bush (50.87) matching the valve onto the valve spindle in accordance with setting dimension (Y) and lock with hexagon nut. Setting dimension (Y) for fitting-projection (X) are 60 and 83 mm = 102 mm. Step F: Place thrust actuator (50) on valve (Fig. C). Mount thrust actuator on fitting with two T-head bolts (50.19), two washers (50.20), two spring washers (50.21), and two hexagon nuts (50.22). Step G : Swing out hand wheel lever (50.12.1) and use it to move out the thrust actuator until the driving spindle (50.30) comes to rest on the threaded bush (50.87), (FIG. D-E). Step H: Screw the coupling (50.27) firmly into the torsion safety feature (50.32) and secure in place using grub screw M6 (50.35), (Fig. F). Step I: Run valve to lowest position. Step J: Clip lift dial (50.23) onto yoke in such a way that top edge of torsion safety feature is in alignment with tip of arrow mark on lift dial. Language UK Page 9/21 AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES Step K: Run valve to both final positions and check to ensure that these are safely reached. Step L: Carry out electrical connection (see section 3.4) and set travel switch S3 (see section 4.3). Mounting for valve-lift up to 30 mm (yoke version) B 50—. tura 50.12.1 •HeugonmH •\Wve spindle 50.19 JJL-50.20 ••!•• i ,-i.' 50.21 T)-U,1P 50.22 ^^ Figure 6 premio_6.tif 3.3.2 Mounting for valve-lift over 30 mm to 80 mm (column version) To mount the thrust actuator to a valve having a nominal lift of over 30 mm to 80 mm, proceed as follows (Fig. and position numbers refer to Figure 7): Step A: Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator (not illustrated). Step B: Set valve cone position to approximately mid lift position. Step C: Turn flat hexagon nut if not present on valve spindle (Fig. A). Step D: Slip coupling (50.27) over valve spindle (Fig. A-B). Step E: Screw threaded bush (50.87) matching the valve onto the valve spindle in accordance with setting dimension (Y) and lock with hexagon nut. Setting dimension (Y) for fitting-projection (X) is 83 mm =102 mm or 98 mm = 116 mm. Step F: Slip 2-ear clamp (50.26) onto a distance column (50.24) press on very lightly (Fig. C). Step G: Screw distance column with 2-ear clamps on opposite side of hand wheel into the flange in such a way that one of the 2-ear clamps is situated above the torsion safety feature (50.32) and the other below. Step H: Screw the other distance column into the flange likewise. Language UK Page 10/21 AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES Step I: Place thrust actuator (50) with distance columns onto valve and fix into position with two self-locking hexagon nuts (50.25). Step J: Fold out turning handle of hand wheel (50.12.1), slightly turn the hand wheel and press in the engaging button for manual mode (only 12-15 kN) (button engages). Having done this, move out the thrust actuator until driving spindle (50.30) comes into contact with threaded bush (50.87), (Fig. D-E). Step K: Screw coupling (50.27) firmly into torsion safety feature (50.32) and secure using grub screw M6 (50.35), (Fig. F). Step L: Move the valve to the lowest position. Step M: Press 2-ear clamps (50.26) into position according to the stroke so they cannot slip, with the bottom clamp in the lowest valve position located directly below torsion safety feature (50.32) and the top clamp in the highest valve position located directly above the torsion safety feature. Step N: Move the valve to both travel positions and check that it reaches them reliably. Fold turning handle of hand wheel (50.12.1) back in. Step O: Make the electrical connection (see section 3.4). The engaging button for manual mode (only 12-15 kN) disengages when the motor starts up. Step P: Set standard travel switch S3 (see section 4.3) Mounting for valve-lift over 30 mm to 80 mm (column version) BCD E 50.87 50.27 " &~"Vtlve spindle UÊI u1 Figure 7 premio_7.tif Language UK Page 11/21 AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES 3.4 Electrical connection Figure 8 and Figure 9 illustrate the wiring diagrams for actuators type 2.2 - 5.0 kN and actuators type 12.0 - 15.0 kN respectively. To connect the thrust actuator up to the electrical power supply, proceed as follows: Step A: Run the thrust actuator a few mm out of the lower final position applying the manual mode. Step B: Loosen countersunk screw in hood, carefully remove hood in upward direction. Step C: Screw out one of the two cable inlets and re-assemble in the same way without the supplied blank flange. Step D: Insert the connection line through this cable inlet until sufficient conductor length is available up to the corresponding terminals. Then tighten the cable inlet until the connecting cable is clamped in place inside it. Step E: Strip connecting cable approx. 1 - 1.5 cm above cable inlet. Step F: Strip the individual conductors approx. 5 mm away from the end and fit with conductor end sleeves. Step G: Connect protective conductor of connecting cable up to protective conductor terminal of thrust actuator. Step H: Connect neutral N/MP conductor of connecting cable up to terminal 1/N of thrust -actuator terminal strip. Step I: Connect pulse line for move-out connecting rod up to terminal 11 of thrust- actuator terminal strip. Step J: Connect pulse line for move-in connecting rod up to terminal 14 of thrust- actuator terminal strip. Step K: Place hood on carefully from above and mount firmly onto thrust actuator with countersunk screw and rubber gasket. Step L: Connect supply line to mains and run thrust actuator to each of the final positions so as to check whether the final-position travel switches effect switching off, also checking to see whether the direction of movement on the thrust actuator corresponds to the desired direction. Step M: If the directions of movement are contrary to those desired, the pulse lines governing the move-in and move-out connecting rod will need to be exchanged. Language UK Page 12/21 ARHPREHO 22-Sdi. Stondord accessoires 4^ 4^ 4^ era Straightway valve i r i r "i r s IM NtFI WE WE POT re Si (S20 S3 (S2S) R1 00 It 1 dosed K j open 3-way valve with mixing phig w NJPl « |A-AB°P™ u Iß-AB open 3-way valve with diverting plag w Nid 11 JA8-BOpa K 1 AS-A open KtporâlBiput value Hipat f Option PA SS (S231 Ril r® HZ Heating resistor • WE Travel switch for traveling the stroke distance fi" (S3) in opening direction DE OE" StIISZI SQGZZ1 t>f\"I OfV Option NA: same design but no RC circuit and switches with gold contacts llûn (Switching capacity 0.1 A, 4-30VDC) „. Standard-voltage connection board, Jr zero potential iX X2S • ^ô WE Travel switch, zero potential 00 ARI-PREWO 12-gkN, Tti- Slqndofd Accessories TTR dTRON 16.1 H •* H -vr TT IT Œ t' DEKj,!. WE WE WE TOT SI * S2 •> r S3 HZ S< tS2 »»» Hl Option ld= unvNua untNuz Wire connections of the différent valve types 3-way valve 3-way valve Straightway valve wilfa mbdag plog with ffivertmg plug V» MW) l/X N»PI 1* NHP) 1 A-ABopen J closed 11 f AB-Bopén ARJ-PREMO 12-ISkN. 3Ph- Standard n n u J op» u i B-AB open S AB-Aopra Œ •» DDEE 4Î . we *• HZ Heating resistor St* S2->r S3 WE Travel switch for traveling the stroke (S3) distance in opening direction © Û" 0 "1 ES 11 Electronic position controller lu a ut ii External rcveraing contactor. IOJO LI, L2, L3 - actuator spindle drives in L3, L2, LI - actuator spindle drives out L-U Standard-voltage connection In all external reversing circuits the tœque PA switches SI and S2 have to be used to board, zero potential switch off the actuator motor. external WE Travel switch, zero potential levcfnng r Please check the operating direction contactor JT F* of the actuator! L1L2LÎ U U WS Reversing contactor AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES Settings 4.1 Torque and travel switches -standard feature Thrust actuators are as standard equipped with a load-dependent travel switch for the closing direction (SI), a load-dependent travel switch for the opening direction (S2), and a stroke-dependent travel switch for the opening direction (S3). The load- dependent travel switches (SI, S2) switch off the motor as soon as the factory-set thrust force is attained. Note: The settings of the load-dependent travel switches must on no account whatsoever be changed. The stroke-dependent travel switch (S3) switches off the motor as soon as the lift or stroke is attained. If the thrust actuator is supplied on a straight-way valve, the stroke-dependent travel switch S3 is set in such a way that the motor of the thrust actuator is switched off as soon as the maximum valve-lift is attained. If the thrust actuator is supplied on a three-way valve, the trip cam belonging to travel switch S3 is set in the opening direction in the trip slide to such a downward extent that the upper final position of the valve is attained prior to travel switch S3 being reached, thus causing the load-dependent travel switch S2 to switch off the motor. For this function, all three switches reveal interlock-controlled circuitry on the board. If the standard travel switches are to be integrated directly into the facility control system, the standard board can be replaced by optional boards PA or NA (only 2.2-5.0 kN). 4.2 Connection boards PA or NA (only 2.2 - 5.0 kN) On connection boards PA or NA, the standard travel switches S11/S21, S12/S22, and S13/S23 do not reveal interlock-controlled circuitry and can be integrated individually into the facility control system. The 3 contacts on each of the switches SI 1/S21, S12/S22, and S13/S23, designed as double-throw contacts, are, in the case of these boards, brought out on terminals 40 - 48 and can be freely connected. The switches on the PA optional board (standard-voltage connection board) are designed for switching capacities of up to 10 A, 250 Vac. The switches on the NA optional board (low-voltage connection board) are designed for switching capacities of up to 0.1 A, 4 - 30 V (gold contacts). The optional boards may only be installed at the factory due to the switching points of the load- dependent switches having to be reset following installation of these boards. Note: When using optional boards PA or NA, it must be warranted -due to the operator's individual circuitry- that, when switching the load-dependent travel switches Sll/21, S12/S22, and S13/S23 the motor of the thrust actuator comes to a standstill without delay. This function is not provided for on the optional boards PA and NA in the supplied state. Language UK Page 15/21 AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES 4.3 Setting of standard travel switch (S3) On delivery of the thrust actuator, the standard travel switch (S3) is already set to the existing valve-lift and the setting spindle for the travel switch (S3) is sealed with screw glyptal. This setting needs no changing for normal operation. If reinstalling the thrust actuator on a straight-way valve, the travel switch (S3) needs to be set as follows: Step A: Move valve out of the lowest position so as to run valve-lift to up position. Step B: Using a screw driver, proceed to turn setting spindle for switch (S3) until the trip cam arriving from below trips the switch (audible click). Step C: Run thrust actuator briefly in closing direction and then in opening direction once more, checking to see whether the thrust actuator is switched off at the desired point (nominal lift). Step D: If needed, correct the setting as described. If reinstalling the thrust actuator on a three-way valve, the travel switch (S3) needs to be set as follows: Step E: Run valve in both final positions and check in each final position whether the valve switches off via the load-dependent switches. Step F: Carry out a check in the top final position the see whether, after switching off the thrust actuator, the trip cam of the travel switch (S3) is situated below switch (S3) and has not tripped the latter. If the trip cam is situated above the travel switch (S3) or trips the same, the setting spindle governing the travel switch (S3) needs to be turned until the trip cam is situated below travel switch (S3) without tripping it. Step G: Run the thrust actuator in both final positions once more and check whether thrust actuator switches off in both final positions via the load-dependent switches. Step H: If needed, correct the setting as described above. 4.4 Potentiometers The potentiometers are used for electrical position acknowledgement on the facility control system or for the options, electronic position controller ES11 or electronic position indicator RI21. A maximum of 2 potentiometers can be installed (= 1 double potentiometer). The potentiometers can be supplied with different resistance values. For the electronic position controller ESI 1 and the electronic position indicator RI21 use must be made solely of 1000 ohm potentiometers. Conversion of the relevant valve-lift to the potentiometer angle of rotation is effected by means of transmission determined in respect of each valve-lift between the toothed rack on the trip slide and the pinion on the potentiometer shaft. Use must only be made of the pinion specified for the valve-lift. Language UK Page 16/21 AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES If the thrust actuator is supplied with the valve and built-in potentiometer, the potentiometer is assembled and set ready for operation. To achieve optimal electromagnetic compatibility it is recommended to use shielded cables for connecting potentiometers or standardized active current or voltage signals. 4.4.1 Installing the potentiometer If retrofitting the potentiometer, proceed as follows: Step A: Switch off mains voltage and safeguard to prevent it from being switched back on again accidentally. Step B: Loosen countersunk screw in hood, carefully remove hood. Step C: Plug in the flat connectors on grey potentiometer cables onto the middle connector pins, those of the red cables onto the upper connector pins and those of the yellow cables onto the lower connector pins of the potentiometer (see Figure 10, Figure 11, and Table 3). Step D: Insert the potentiometer into the guide in the way that the pinion (50.73) of the potentiometer meshes with the gear stick of the trip slide. Step E: With a valve lift up to 30 mm, hook spiral spring (50.70) into the left-hand window of board support (50.42) above the potentiometer guide, insert into the guide between the slide block and the potentiometer guide and hook into the cut-out below the potentiometer. Step F: With a valve lift between 30 mm and 50 mm, hook spiral spring (50.70) into the right-hand window (for 12.0 - 15.0 kN middle window) above the potentiometer guide, insert into the guide between the slide block and the potentiometer guide and hook into the cut-out below the potentiometer. Step G: With a valve lift between 50 mm and 65 mm, hook spiral spring (50.70) into the middle window in board support (50.42) above the potentiometer guide, insert into the guide between the slide block and the potentiometer guide and hook into the cut-out below the potentiometer. Step H: Check to see whether pinion (50.73) is pressed into toothed rack by spiral spring (50.70) and is positioned free from backlash. Step I: If this is not the case, remove spiral spring (50.70), readjust by bending a little, and place back in position again. Step J: Screw jack strip of connecting cable (50.68) to board support (50.42) with two self-tapping screws (50.69), (single potentiometer connectors 25-27). Step K: Insert additional 3-pole connector (50.74) in jack strip of connecting cable (50.68). Step L: Set potentiometer. Step M: Place hood carefully onto thrust actuator and fasten it on the actuator with rubber gasket and countersunk screw. Language UK Page 17/21 • • • f • AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES Installation of potentiometer 50.67.1 50.73 50.72 50.95 Figure 10 premio_10.tif Potentiometer connection cable yellow Figure 11 premio_ll.tif Part list for potentiometer Pos. Designation Pos. Designation Pos. Designation 50.42 Board support Connecting cable for Pinion (selection depends on 50.68 50.73 50.47 Circuit-diagram sticker potentiometer valve lift 20,30, 50,65, 80) 50.67.1 Hexagon nut 50.69 Self-tapping screw Connector, 3-pole 50.74 50.67.2 Tooth lock washer 50.70 Spiral spring (potentiometer) (potentiometer) 50.67.3 Potentiometer 50.71 Slide block (potentiometer) 50.95 Spring washer 50.67.4 Washer from PA 50.72 Set collar Table 3 4.4.2 Setting the potentiometer To set the potentiometer, proceed as follows: Step A: Move thrust actuator to closing position. Step B: Switch off mains voltage and safeguard to prevent it from being switched back on again accidentally. Language UK Page 18/21 AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES Step C: Using a screw driver, turn slotted potentiometer shaft in counter-clockwise direction until reaching the travel stop. This places the potentiometer in the initial position (approx. 0 ohm). Step D: For checking purposes, the resistance of the potentiometer needs to be measured using an ohmmeter. Step E: Measure the resistance on potentiometer 1 between terminals 25 and 26. Step F: Measure the resistance on potentiometer 2 between terminals 28 and 29. Step G: In this position of the actuator, the measured value should be approx. 0 ohm. Step H: Run thrust actuator to upper final position and read off corresponding resistance value on ohmmeter. Step I: The resistance values thus measured need to be taken into account for the settings to the facility control system. Starting up Check the following before starting up a new system or restarting a system after repairs or conversion: • Correct completion of all installation/assembly work. • Circuits of the system in accordance with DIN VDE regulations and regulations of the relevant power supply company as well as compliance with all safety regulations. • Hood of thrust actuator assembled. • Start up only by qualified personnel. Warning: While in operation, the thrust actuator has moving and rotating parts as well as being integrated in an electrical network system. Improper handling or failure to observe the operating instructions or the valid regulations may lead to death, grievous bodily injury or substantial property damage When placing into service proceed as follows: Step A: Use the hand wheel, to run the thrust actuator to approximately mid lift position. Step B: Apply brief pulses to the thrust actuator for each direction of movement and check whether the directions of movement correspond to those desired. If this is not the case, the pulse lines governing the opening and closing action must be exchanged on the thrust actuator. Language UK Page 19/21 AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES Step C: Run thrust actuator to the final position in each direction of movement and check whether it switches off automatically and whether all externally moving parts are able to move freely. Step D: If failing to function properly, check all installation and setting work previously carried out, correcting if necessary, and afterwards place into service once again. Care and maintenance The thrust actuator requires very little maintenance. Accordingly maintenance in specified intervals is not necessary. The thrust actuator must not be cleaned with high-pressure equipment or aggressive solvents or detergents injurious to health or highly inflammable. During and after cleaning, an inspection should be carried out of the sealing points on the thrust actuator. If there is any sign of lubricant escaping or dirt having accumulated, the sealing elements must be repaired. Dismantlement of the thrust actuator In addition to general installation guidelines, the following points are required to be observed: • Dismantlement of the thrust actuator from the fitting must only to be carried out by suitably qualified personnel. • The supply line for connecting up the thrust actuator must be in the dead state i.e. disconnected while dismantlement work is being carried out. After being disconnected, the mains power must be prevented from being switched back on again accidentally. • The system must be run down (depressurised state) as the valve cone is not held without the thrust actuator and would thus be conducted by the system pressure. • Valve cone approximately in mid lift position - on no account supported inside a seat. To dismantle the thrust actuator proceeds as follows: Step A: Loosen counter-sunk screw in hood, carefully remove hood. Step B: Disconnect all cables led into thrust actuator from outside and remove from thrust actuator. Step C: Place hood on carefully from above and fix in place with counter-sunk screw and rubber gasket. Step D: Loosen grub screw inside torsion safety feature; screw coupling out of torsion safety feature. Step E: Loosen clamping bolts connecting the thrust actuator to the fitting. Step F: Remove thrust actuator from valve. Language UK Page 20/21 AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2 INDUSTRIES 8 Troubleshooting In the event of malfunctions or disturbances in operation, first check whether the installation and adjustment work has been carried out and concluded in accordance with these operating instructions. Compare the data referring to operating voltage, actuating signal and temperature to the data specified on the layout drawing of the control system. Also check whether the given operating conditions correspond to those specified on the type identification plate. Warning: AH relevant safety regulations must be observed when carrying out the troubleshooting procedure. Contact the supplier/manufacturer if faults cannot be rectified on the basis of the following troubleshooting table: Troubleshooting table tuuli Possible causes Remedy Power failure Ascertain and eliminate cause Fuse has blown Replace fuse Rectify connection on thrust actuator in Thrust actuator not properly connected accordance with wiring diagram Short circuit due to: Ascertain exact cause, -moisture Dry the thrust actuator and eliminate leakage -wrong connection Rectify connection on thrust actuator in accordance with wiring diagram Thrust actuator fails to move -motor has burned out Check whether the mains voltage agrees with the voltage specified on the rating plate. Have motor changed. Connector contacts not plugged in/ not Insert connector firmly in jack strip thus properly plugged into jack strip affected Unscrew the motor mounting screw (Only for 12.0-15.0 kN) closest to the cable feed-through. Hand wheel is still engaged and does (Manual release of the hand wheel not disengage when the motor starts up disengagement mechanism) Thrust actuator alternates between Have motor operating capacitor clockwise and counter-clockwise Motor operating capacitor defective replaced rotation Load-dependent travel switches out of Remove thrust actuator and send to adjustment / defective factory for repair Voltage drop due to excessively long Lay connecting cables in accordance Thrust actuator fails to run to final connecting cables or inadequate with requisite output positions and also produces chatter conductor cross-section Mains fluctuations beyond permissible Arrange for "clean" mains system tolerance travels within requisite tolerances System pressure too high Reduce system pressure Periodic failure on thrust actuator Loose connection on feed line Tighten connections on terminal strips Thrust actuator is switched off in Travel switch (S3) not set Set travel switch (S3) in accordance opening direction prior to load- corresponding to use with operating instructions dependent switch (three-way valve) Table 4 Language UK Page 21/21 AALBORG CONTROL VALVES, TYPE 470/471 OM6010#02.0 INDUSTRIES Control valves, type 470/471 1 General This type of control valve is suited to regulate fluids, gases and steams. The valve plug is normally a parabolic plug, but can also be supplied in a perforated design. Both types of plugs can have either linear or equal percentage flow characteristic. The flow direction for parabolic plugs is always against the closing direction. However, with perforated plugs for steam and gases, it is in the closing direction. If a valve with a perforated plug is operated by means of a pneumatic actuator with the flow in the closing direction, the pneumatic actuator should have a stronger thrust force. This is necessary to prevent thumping near to the closing position. All control valves can be fitted alternately with manual-, pneumatic-, electric- or hydraulic operation devices. Illustration of control valves type 470 and 471 Control valve, type 470 Control valve, type 471 Figure 1 val47x.tif Language UK Page 1/5 AALBORG CONTROL VALVES, TYPE 470/471 OM6010#02.0 INDUSTRIES Table of position numbers in Figure 1 Part Designation Part Designation Part Designation 1 Body 7 Gland flange 15.1 Studs 2 Seat ring 7.1 Screw joint 17 Hexagon nuts 3 Mounting bonnet 8 Spindle guiding 17.1 Hexagon nuts 3.1 Mounting bonnet 10 Stuffing box 19 Spring-type straight pin 4 Guiding bush 10.1 Stuffing-box packing 21 Set-pin 5 Plug 14 Gasket 25 Bellow housing 6 Spindle 14.1 Gasket 26 Bellow unit 6.1 Spindle 15 Studs Table 1 Operation 2.1 Fitting instructions The valve should be inserted so that the spindle has a vertical position together with the actuator. The valve can also be tilted to a maximum horizontal position if the installation point does not allow any better condition. To guarantee a disturbance free function of the control valve, the inlet and outlet stretches of the piping should be of straight piping length (min. two times the pipe diameter by inlet and six times by outlet). The piping should be rinsed to clear out any pollution, welding beads, rust, etc. before inserting the control valves. A strainer should be fitted in front of the control valve to catch the remaining particles. Bolts should be tightened after taking into operation. The flow direction is signalled by an arrow on the valve body. The valves should be insulated against high temperatures to guard the actuator. 2.2 Actuator assembly The control valves are normally delivered with actuators already fitted. For alternations or maintenance of actuator, the assembly should occur in accordance with the operation instructions for the actuator. 2.3 Setting into operation When the piping system is filled, the spindle sealing should be checked for leakage and, if necessary, tightened. A PTFE-V-ring unit does not require any tightening as the spring tension maintains the necessary force. The bolts must be tightened gradually in steps, diametrically in pairs, but not tighter than it is necessary for the sealing. Flange connection bolts should never be loosened or tightened when the valve is under temperature or pressure even if a leakage may arise. For actuators please see to the appropriate actuator operation instructions. Language UK Page 2/5 AALBORG CONTROL VALVES, TYPE 470/471 OM6010#02.0 INDUSTRIES Maintenance Before any maintenance of the control valve is carried out, the piping system must be shut off and pressure free. 3.1 Exchange of the stuffing-box packing A leak stuffing-box packing should initially be carefully tightened to stop the leakage. If this does not help, a new layer should be inserted, or the complete packing should be replaced. 3.1.1 Additional packing layer Step A: Open the valve fully and unscrew the hexagon nuts (17). Step B: Lift the gland flange (7) and the spindle guiding (8) upwards. Step C: Insert adequate quantity of packing rings (split ring-displacement, splitting at 180° to avoid overlapping). Step D: Fix the hexagon nuts (17) properly. 3.1.2 Exchange Step A: Drive the actuator into middle position and dismantle the actuator. Step B: Unscrew the hexagon nuts (17) from the studs (15). Step C: Remove the gland flange (7), the spindle guiding (8) and the old stuffing box (10) and clean the packing compartment. Step D: Clean the valve spindle and check for damage and if necessary replace. If the damaged spindle is not replaced, the new packing will leak after a short period. Step E: Insert the new packing rings (split ring-displacement, splitting at 180° to avoid overlapping). Step F: Fix the hexagon nuts (17) properly. Note: Strenuous tightening will prevent leakage, but will also have a brake effect on the spindle which aggravates the movement of the spindle. 3.2 Exchange of a PTFE-V-ring sealing unit A PTFE-V-ring unit is spring loaded and has enough set pressure to ensure a good seal even by low operation pressures. It is replaced as mentioned above. The PTFE-V-ring sealing unit should be lubricated before it is inserted. The sealing lips must face against the pressure direction. Language UK Page 3/5 AALBORG CONTROL VALVES, TYPE 470/471 OM6010#02.0 INDUSTRIES Note: Special care should be given to the spindle surface. Rough surfaces wear the sealing lips enormously and can be due to failure of the packing unit. 3.3 Exchange of the bellow unit Step A: Drive the actuator into middle position and dismantle the actuator. Step B: Unscrew the screw joint (7.1). Step C : Unscrew the hexagon nuts (17) and remove the bellow housing (25). Dismantle the plug as described in the next section. Step D: Unscrew the hexagon nuts (17.1) and dismantle the mounting bonnet (3.1). Step E: The bellow unit (26) is removed from the bellow housing (25). Step F: Replace the two gaskets (14.1) and the gasket (14). Step G: When the bellow unit (26) is replaced, the proper position of the anti- twisting device must be observed. Step H: The set pins (21) have to drive within the slots of the anti-twisting device. Check for friction-free movement. Step I: Replace mounting bonnet (3.1) and screw down the hexagon nuts (17.1) crosswise. 3.4 Exchange of the plug-spindle unit Step A: Drive the actuator into middle position and dismantle the actuator. Step B: Unscrew the gland flange (7). 3.4.2 Control valve type 470 Step A: Unscrew the hexagon nuts (17) and dismantle the mounting bonnet (3). Step B: Pull out the plug with the spindle and exchange this unit. Step C: Remove the spring-type straight pin (19) and unscrew the spindle (6). Step D: Replace the old parts and assemble it. Step E: Drill a hole through the plug shaft and insert a new pin. Step F: Replace the gasket (14) and assemble the mounting bonnet (3). Step G: Tighten the nuts (17) evenly, crosswise. Language UK Page 4/5 AALBORG CONTROL VALVES, TYPE 470/471 OM6010#02.0 INDUSTRIES 3.4.3 Control valve type 471 Step A: Unscrew the hexagon nuts (17) and dismantle the bellow housing (25) with plug (5). Step B: Drive the spindle in the bottom position and remove the spring-type straight pin (19). Step C: Unscrew the plug. Step D: Screw a new plug at the spindle and drill through the shaft. Drive the spring-type straight pin (19) into the hole. Step E: Replace the gasket (14). Step F: Assemble the bellow housing (25) with plug (5) together with the body (1) and fix it by screwing the hexagon nuts (17) crosswise. The spindle can only be completely replaced together with the bellow. 3.5 Changing the seat ring The seat ring is screwed into the valve body. The seat ring can be obtained after removing the bonnet and can then be refinished or replaced as required. Step A: Clean and lubricate the thread and conical sealing surface before insertion. Language UK Page 5/5 AALBORG TABLE OF CONTENTS INDUSTRIES Table of contents Ignition burner pump Technical data for ignition oil pumps General data 1 Data for ignition oil pump 2 Data for pump motor 3 Ignition burner pump Description 1 Data sheet Data sheets for pump 1 Language UK Page 1/1 INDUSTRIES ^mj^gnn^m^gnm^g^^g||||^g|^g|^^||||^^mii^^^^ Technical data for ignition oil pumps 1 General data • Project No.: 736950, 736952 • Hull No./Project name: 03130007,03130008 • Classification society/Local authority: LRS • Pressure gauge calibration: MPa • Thermometer calibration: °C • Language for signs: UK • Colour of ignition oil pump unit: Munsell 10GY 8/4 • Weight of ignition oil pump unit: 10 kg 2 Data for ignition oil pump • Pump type: Gear pump, typeRSA • Delivery head: 0.7 - 1.4 MPa • Inlet pressure, maximum: 0.4 MPa • Inlet pressure, minimum (at pipe bore 12 mm, length 50 m): 1.0 mWC • Pump capacity at 4 cSt, 7 bar: 61 1/h • Viscosity range: < 1.3 - 12.0 cSt • Oil temperature, maximum: 70°C • Filter mesh: 150 mu 3 Data for pump motor Motortype: BF7 63 M22 Power supply: 3 x 440V, 60Hz Rated output for motor: 0,22 kW Revolutions: 3300 r.p.m. Ambient air temperature: 45°C Starting method: Direct Starting current: 2.2 A Operating current (full load): t 0.6 A Language UK Page 1/2 AALBORG IGNITION BURNER PUMP OM5540#10.1 INDUSTRIES Ignition burner pump 1 Description The ignition burner pump supplies the ignition burner with diesel oil. The pump is operated by the control system or the manual operating system. The ignition burner pump is only in operation during the ignition sequence. An illustration of the ignition burner pump is shown in Figure 1. Illustration of the ignition burner pump To burner From diesel oil tank 1 Pump 2 Manometer 3 Connection 4 Coupling 5 Motor 6 Ball valve 7 Tee-pice 8 Bend Figure 1 ignibup_a.cdr 1.1 Function When the pump is started, oil is drawn through the suction side port "S" via the filter "H" to the suction side of the gearwheel set "C" as shown in Figure 2. The gearwheel set pumps the oil to the pressure side. Language UK Page 1/3 AALBORG IGNITION BURNER PUMP OM5540#10.1 INDUSTRIES The pressurised oil is led to the cut-off and regulating valve "V". When the opening set point is reached, the valve opens. Hereby oil is distributed to the nozzle port "P" and to the pump return side "R" via the shaft seal "F". The pressure is controlled and maintained at a constant level by the regulating valve "V". The opening set point can be adjusted by means of an Allen key. The quantity of oil supplied to the nozzle port "P" is determined by the pressure set on the regulating valve "V" and the resistance in the nozzle line and the oil nozzle. When the pump is stopped, the pump output drops and produces a drop in the oil pressure. The spring in the regulating valve presses the regulating piston forward until it seats in port "P". This cuts the oil flow to the nozzle and ensures that the line is effectively shut off. Sketch of the oil pump system Figure 2 ignibupl.tif If the pump is overloaded, i.e. more oil is demanded than the gearwheel is able to pump under the given conditions, the oil pressure falls below the set value because the regulating valve piston moves towards its closed position and partially or wholly cuts off the return oil via port "O". This condition can be remedied by: • Reducing the pump pressure • Reducing the capacity, i.e. smaller oil nozzle or larger resistance • Changing to a pump with higher capacity Language UK Page 2/3 AALBORG IGNITION BURNER PUMP OM5540#10.1 INDUSTRIES 1.2 Commissioning When the pump is commissioned, the pump and the pipe system must be filled with oil and ventilated. The pump can be ventilated on the ventilating screw "M". If the pump is running without oil for more than five minutes, it may cause damage to the pump. 1.3 Pipe systems One pipe system is used when the pump is placed lower than tank level (positive suction head). Two pipe system is used when the pump is placed higher than tank level (negative suction head). In two-pipe systems the oil is returned direct to the oil tank. In one-pipe systems the setting screw "A" must be removed to give free flow to the suction side via by-pass "G" with return port "R" closed. Normally the pump is delivered as a one-pipe system. The pump is delivered with two suction ports and two return ports. Language UK Page 3/3 Description Index Dat^^krowr Appr. Coble glond si~chonged. JMN 17 170 PG 13.5 o O.D. 12mm. Bite-type-joint *-To burner Built in o m Strainer o 80 40 145 115 50 350 O.D. 12mm. Bite-type-joint 12 HEXAGON NIPPLE 6638104 11 HEXAGON NIPPLE 6638136 10 STRAIGHT MALE 12mm 6641065 STRAINER (INTERNAL) 8 BEND 6638135 TEE-PIECE 6638134 Final colour : Ace. to spec. BALL VALVE 6666006 Title: Drown Date MOTOR 400/460 V - 50/60 Hz 6638133 Ignition oil pump SLJ 05.09.2002 6638132 Appr. Date COUPLING Type 2 JMN 05.09.2002 6638131 Weight Scale: Size CONNECTION «iiiiiiit G145 MANOMETER 0-25 Bar \ Kq/cm2 \ 0-2,5 MPa 6633121 1:2.5 A3 AALBORG 4810000001 Article/Drawing No: PUMP 6638130 INDUSTRIES THIS DRAWING AND DESIGN SHOWN HERDS rS THE PROPERTY OF AAL80RC INDUSTRIES ITEM OBJECT PART NO. Plot Dote: W0 MUST NOT BE USED Br OR REPRODUCED FOR THIRD PARTY 71Z:024019 • AALBORG ggjgisBiaaswnasns^^^^^M Table of contents Combustion air fan Technical data for combustion air fan General data 1 Data for combustion air fan 2 Data for fan motor 3 Data for pressure loss layout 4 Combustion air fan General 1 Storage 2 Installation 3 Prior to start-up 4 Initial start-up 5 Normal operation 6 Vibration control 7 Maintenance 8 Positioner, SIPART PS2 6DR5000 General 1 Mechanic connection of the positioner 2 Electric connection of the positioner 3 Pneumatic connection 4 Commissioning 5 Diagnosis 6 Service and maintenance 7 Language UK Page 1/1 • • • AALBORG GBGSÊÊÊBSIÊSSIÊBÊUBBIIIKKÊSÊKWM INDUSTRIES ^g^ømmg|^gnm^||^^g|||g^^ngm||mm^^ig^gi Technical data for combustion air fan 1 General data • Project No.: 736950, 736952 • Hull NoTProject name: 03130007, 03130008 • Classification society/Local authority: LRS • Pressure gauge calibration: MPa • Thermometer calibration: °C • Language for signs: UK • Colour of combustion air fan unit: Munsell 10GY 8/4 2 Data for combustion air fan • Fan type: , HN 670-560/D • Actual position designation: RD 0 • Static pressure: 800 mmWC • Air flow at 45°C: 19891 m3/h • Silencer type: CA 560x1500 • Noise level for fan with silencer: 100 db(A) • Vibration damper type: s AR 200 • Numbers of vibration dampers: 6 3 Data for fan motor Motor make: AEG Motortype: AM 280 Power supply: 3 x 440 V, 60 Hz Rated output for motor: 82 kW Revolutions: 3575 r.p.m. Ambient air temperature: 45°C Starting method: Star/delta Starting current: 585 A Operating current (full load): 137 A Language UK Page 1/2 AALBORG ^BSmiBSESSSSSESSESßBßlKXUKStBBBIIlBEn • Power consumption at 15°C: 65.2 kW • Power consumption at 45°C: 61.6 kW • Numbers of cable entries: 2 • Cable gland size: M 63 • Heating element (standstill): ,...134 W • Thermostat protection: None • Insulation class: F • Degree of protection: IP54 4 Data for pressure loss layout • Air duct system (from fan to wind box): 35 mmWC • Boiler (from furnace to outlet at full load): 188 mmWC • Flue gas system: 15 mmWC Language UK Page 2/2 AALBORG COMBUSTION AIR FAN OM5550#01.2 INDUSTRIES Combustion air fan 1 General The purpose of the combustion air fan is to supply combustion air to the burner. The air is supplied by a directly driven centrifugal fan. The fan is mounted on a common bed frame with motor, inlet vanes, and servo-drive unit. The fan impeller inside the spiral housing is mounted directly on the motor shaft. The air flow to the burner is regulated by inlet vanes mounted on the fan suction side. The inlet vanes are of a multi-blade design and regulated by a servo-driven unit comprising an air cylinder and I/P positioner. A silencer can be mounted on the fan suction side. Figure 1 shows an illustration of the combustion air fan (shown without silencer) and the location of markings and warning signs. Illustration of the combustion air fan il 1 EÜ criitziC€ Nameplate Front of casing Inlet vanes Vibration dampers ' Flexible connection Figure 1 bar 02a.cdr Storage If the combustion air fan unit is stored for a period of time prior to installation, a number of initiatives must be observed and considered. They are described in the following sections. 2.1.1 Combustion air fan (normal conditions) When the combustion air fan unit is delivered, it is provided with the correct quantity and type of grease. The optimum storage temperature is 15°C. Language UK Page 1/6 AALBORG COMBUSTION AIR FAN OM5550#01.2 INDUSTRIES The impeller axle must be rotated at regular intervals during storage. This prevents the motor bearings from being damaged if the axle is kept in the same position constantly. The maximum rotation interval is 4 to 5 weeks. 2.1.2 Combustion air fan (extreme conditions) Storage at temperatures above +35°C and below -5°C have a negative effect on the state of the bearing grease. By storage in these conditions the maximum rotation interval is 2 to 3 weeks. After start-up of the combustion air fan the motor bearings (if provided with lubricating nipples) should be greased with a small quantity of grease (4 to 5 grease gun shots). 2.1.3 Prolonged standstill Rotate the impeller axle at the intervals described above. Installation The fan unit must be placed on a plane and sufficiently strong surface. For repair purposes the distance from the fan unit to the surrounding walls must be sufficient to disassemble any parts of the fan unit. Normally the combustion air fan is fixed to the bed at delivery. However, the vibration dampers are supplied loose. Before installing the fan unit, the vibration dampers must be fixed to the bed by means of the included bolts. The position of the vibration dampers can be seen in the fan drawing. After fixing the vibration dampers to the bed, place the fan unit on the installation place and mark out the bolt holes which fix the dampers to the surface. This will prevent twisting of the rubber compartment. When fixing the fan unit to the surface, use an adequate size of bolts. 3.1.1 Connection of the motor Figure 2 shows the possible wiring connections at the terminal rows of the motor. The electrical wiring diagram indicates the actual connection of the motor for the specified plant. Electrical connection diagrams Y A Y/à L2 L3 L1 W2 U2 V2 W2 U2 V2 * W2 * U2 * V2 O O O O o o O O O U1 V1 W1 W1 U1 V1 W1 o o o o o o O O O î î î î î t I Lt2 tL3 L1 L2 L3 L1 L2 L3 Figure 2 bar 07.cdr Language UK Page 2/6 AALBORG COMBUSTION AIR FAN OM5550#01.2 INDUSTRIES Prior to start-up Prior to the first start-up of the combustion air fan, the following procedures must be performed: • Check that the combustion air fan and the air duct system have been installed and supported correctly. If possible, an inside inspection of the air duct system should also be carried out to ensure that it is free from obstacles, e.g. loose parts, insulating material, etc. • Check that the inlet net has been mounted. • Check that the electrical wiring at the terminals of the combustion air fan is performed according to the wiring shown in the electrical diagrams. • Adjust the circuit breaker for the combustion air fan to suit full load current of the motor. The current appears from the motor identification plate and/or the electric diagrams. • Commission the I/P positioner and dp-transmitter and check that the micro switch, which controls the closed position of the inlet vanes, is activated. • Rotate the combustion air fan by hand to ensure a free and an uninterrupted rotation. • Ensure that all safety circuits are activated and functional. • Ensure that all loose items have been removed in the proximity of the suction side of the combustion air fan. • Ensure that the operating personnel have been notified about the coming start-up and that the location of the emergency switches is known to the personnel. Initial start-up When the combustion air fan is started for the first time, the following procedures must be performed: • Start the combustion air fan and check that it is running with the correct direction of rotation (see the direction arrow). • Check that the combustion air fan and the air duct system do not produce any abnormal mechanical noise. • Check the combustion air fan and the air duct system for any abnormal vibrations. • Check the air duct system for leaks. • Set the fan load to approximately 10-15%. Check the temperature of the fan bearings. The bearing temperature must be at a constant level after approximately 30 minutes of operation. If the temperature continues to increase, stop the combustion air fan and check the bearings. Language UK Page 3/6 AALBORG COMBUSTION AIR FAN OM5550#01.2 INDUSTRIES • Set the fan load to 100%. Check the current consumption of the combustion air fan. The current must not exceed the full load current stated on the motor identification plate and/or the electric diagrams. • Set the fan load to 0% (inlet vanes closed) and stop the combustion air fan. Normal operation To ensure a safe and reliable function of the combustion air fan, inspection must take place with frequent intervals as described below. Step A: Check the motor temperature (maximum 80°C). Step B: Check for vibrations by touching the combustion air fan. Step C: Check that the vibration absorbers and flexible connection are intact. Note: If a fault is observed, it must be corrected at once. Vibration control If the fan is operating in a dusty and/or fatty air environment, coats may occur on the impeller. This might cause abnormal vibrations, which eventually will cause break down of the combustion air fan. The cause must be examined immediately. At the factory the fan has been weighed statically and dynamically in accordance with the VDI 2056 - G, Standard. Figure 3 shows vibration curves for the fan according to VDI 2056-G Standard. Vibration curves for fan peak 2S0 1 - —1 VIBRATION CURVE FOR FAN ACC TOVPIMM-0 Irc ( No M-* r "* vM ï'TIjr r TERM > • ' 300- 1 <~ Jit."' it. W-* Si C = \,'5RATrr" NTE-TRU'J LL* NJ3 A~, jiSLENi C- ,ll>i< 1 -No 150 - " "\ I 1 ' 1 1 loo —^2 - 1 1 \^ 1 i" EO 1 SO ' ~ ^^^ __ I 70 — J i i _ . B0 ! ^-^ I- 1 - SO - - 1 1 ,^"^] L s^l i 1 1 40 13,- V ^^ -4 30 - - -_>^ ~ - ^•-»^N-^- - l""" • 20 1 10 - i - ">^H-^—1 h— _ _• ! c 1 0 600 1O0O 15« 2Q0O 2500 3000 3500 «X» 4K0 SOO Figure 3 bar 03a.cdr Language UK Page 4/6 * 4994V* AALBORG COMBUSTION AIR FAN OM5550#01.2 INDUSTRIES 8 Maintenance 8.1 Cleaning of impeller Step A: Ensure that the combustion air fan is not unintentionally started during this repair work. Step B: Access to the impeller is obtained by dismounting the clean-out door. Step C: The cleaning procedure can be performed with a high-pressure cleaner combined with scraping of the rebellious coat. In connection with this ensure that any water in the spiral casing is drained off. Step D: Before starting the combustion air fan again, it is important to check that the impeller is clean and that the dismounted parts have been remounted. Note: If the impeller has not been carefully cleaned, the residual coat might cause a lack of balance. If the vibration level exceeds the maximum level of 11 mm/s, it might result in a breakdown of the combustion air fan. Therefore, it is important to take precautions by inspecting the impeller before starting up. 8.2 Dismounting of impeller The impeller is mounted directly on the motor shaft. The dismounting of the fan impeller are described below and illustrated in Figure 4. Step A: Ensure that the combustion air fan is not unintentionally started during this repair work. Step B: Dismount the nuts which fix the front plate. Remove the front plate by means of a lifting device or tackle. Step C: Dismount the end bolt and plate of the shaft, and replace the end bolt by a similar short bolt. Step D: Mount a wheel-puller. The impeller is provided with threaded wholes (MIO) located on the hub plate. Tighten the wheel-puller until the impeller is loose. Step E: Then dismount the wheel-puller and end bolt. Finally, the impeller can be pulled out from the spiral casing. Language UK Page 5/6 * ####** AALBORG COMBUSTION AIR FAN OM5550#01.2 INDUSTRIES Illustration of fan impeller dismounting Figure 4 bar ll.cdr 8.3 Electric motor Normally, electric motors need no special maintenance except cleaning and lubrication of the bearings. If motors and/or bearings are dismantled, please contact an expert (electromechanical workshop). 8.3.1 Lubrication of bearings Motors without grease nipples are pre-lubricated for approximately 10,000 hours or three years of operation. Motors with grease nipples should be lubricated at the monthly intervals shown in Table 1 : Lubrication intervals in months >- Speed r.p.m. Running hours per Motor size 50 Hz day 160 180 200 225 250 280 300 8 75 69 63 51 27 24 12 970 24 25 23 21 17 9 8 4 8 48 45 39 30 15 15 6 1450 24 16 15 13 10 5 5 2 8 21 18 15 9 6 ' 3 3 2900 24 7 6 5 3 2 1 1 If the operating frequency is 60 Hz with subsequent 20% higher r.p.m., the greasing intervals are reduced to 2/3 of the above stated intervals (e.g., lubrication interval at 50 Hz = 3 months, lubrication interval at 60 Hz = 2 months. Table 1 Note: Suitable lubrications must be used, such as e.g., SKF-LGMT 2. Language UK Page 6/6 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Positioner, SIPART PS2 6DR5000 1 General The following instruction is a general description of SIPART positioners and covers the complete range in the PS2 6DR5000 series. The electronic pneumatic positioner is used as the final control element of a pneumatic linear actuator or a part-turn actuator (rotary movements). The positioner converts a current output signal (4 to 20 mA) from a process controller or control system to a set point value and into a corresponding movement. The positioner changes the pressure in a pneumatic actuator chamber or cylinder until the position corresponds to the set point value. The positioner can be set up either as a single-action positioner or a double-action positioner. The single-action positioner is mainly used together with a control valve. The opposite movement for the control valve is supplied by means of springs. The double-action positioner is mainly used to control an air damper via a pneumatic cylinder (actuator). All movements of the pneumatic cylinder are supplied by the positioner. An illustration of the function diagram for the positioner is shown in Figure 1. The function diagram is shown with option modules. 1.1 Mode of operation Comparison of the set point and the actual value takes place electronically in a micro controller. If the micro controller detects a deviation, it uses a 5-way switch procedure to control the piezoelectric valves, which in turn regulate the flow of air into the actuating chambers. When connected in a two-wire system, the SIPART PS2 draws its power exclusively from the 4 to 20 mA set point signal. The piezoelectric valve converts the command into a pneumatic positional increment. The positioner outputs a continuous signal in the area where there is a large control deviation (high-speed zone). In areas of moderate control deviation (slow-speed zone) it outputs a sequence of pulses. No positioning signals are output in the case of a small control deviation (adaptive or variable dead zone). Commissioning (initialisation) is carried out automatically to a large extend. During initialisation, the micro controller automatically determines the zero, full-scale value, direction of action, and positioning speed of the actuator. It uses these to determine the minimum pulse time and dead zone, thus optimising the control. The positioner can also be operated manually by the pushbuttons and the LCD of the SIPART PS2. The installation of the positioner must be carried out in the following order: • Mechanic connection • Electric connection • Pneumatic connection • Commissioning Language UK Page 1/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Illustration of a function diagram Supply air •i-fflfiBLJ S-ra î-ra 1 1 Motherboard with microcontroller and Input circuit 2 Control panel with LC-disptay and momentary action switch 3 Plezo-valve unit, always built-in 4 Valve unit with double action positioner always built-in 5 ly-moduie for positioner SIPART PS2 6 Alarm module for three alarm outputs and one digital input 7 SIA-modute (Slot Iniöator-Alarm-module) 8 Spring- loaded pneumatic actuator (single action) 9 Spring-loaded pneumatic actuator (double action) Figure 1 sips2_5a.tif Mechanic connection of the positioner Normally the positioner is pre-mounted on the actuator or cylinder. If not, follow the installation guide lines below. 2.1 Mechanic connection to an actuator Figure 2 shows the mechanic connection of the positioner to an actuator for a control valve. Step A: Mount clamping assembly (3) with hexagon socket cap screws (17) and lock washers (16) on the actuator spindle. Step B: Insert the pick-up bracket (2) into the recesses of the clamping assembly. Set the necessary length and tighten the screws so that the pick-up bracket can still be shifted. Language UK Page 2/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Step C: Push the roll (5), spring (13), and guide washer (22) onto the pin (4). StepD: Insert the pin in the lever (6) and assemble with nut (18), spring washer (14),andU-washer(12). Step E: The value of the stroke range specified on the actuator should be set or if this does not exist as a scaling value, the next greatest scaling value should be set. The centre of the pin must be in line with the scaling value. The same value can be set later under parameter "3.YWAY" in commissioning to display the way in [mm] after initialisation. StepF: Assemble the hexagon socket cap screw (17), spring washer (16), washer (12), and square nut (19) on the lever. Step G: Push the pre-mounted lever onto the positioner axis up to the stop and fix with the hexagon socket cap screw (17). Step H: Fit the mounting bracket (1) with two hexagon head screws (9), lock washer (10), and flat washer (11) on the rear of the positioner. Step I: Selection of the row of holes depends on the width of the actuator yoke. The roll (5) should engage in the pick-up bracket (2) as close as possible to the spindle but may not touch the clamping assembly. Step J: Hold the positioner with the mounting bracket on the actuator so that the pin (4) is guided within the pick-up bracket (2). Step K: Tighten the pick-up bracket. Step L: Position the mounting parts according to the type of actuator. — Actuator with ledge: hexagon head screw (8), flat washer (11), and lock washer (10). — Actuator with plane surface: four hexagon head screws (8), flat washer (11), and lock washer (10). — Actuator with columns: two U-bolts (7), four hexagon nuts (21) with flat washer (11), and lock washer (10). Step M: Secure the positioner onto the yoke using the previously positioned mounting parts. Note: Set the height of the positioner so that the horizontal lever position is reached as close to the stroke centre as possible. The lever scale can be used as orientation. It must be guaranteed that the horizontal lever position is passed through within the stroke range. Language UK Page 3/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Mechanic connection of the positioner (linear actuator) 2) 4 3) Mounting on yoke Mounting on yoke with plane surface 11 with ledge | 'f/l/Oh J Mounting on yoke U\Zp>P J with columns Figure 2 sips2_5b.tif Language UK Page 4/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES 2.2 Mechanic connection to a pneumatic cylinder The positioner is connected to a pneumatic cylinder by means of fixing bracket, lever arm with Allen screw, extension arm, and roller. The pneumatic piston is connected to a guide rail with an oblique angle via a linkage. The guide rail moves together with the piston, and the roller/lever connection senses the position of the piston. By operating both sides of the pneumatic cylinder, the set point is reached. A spring inserted between the fixing bracket and the lever arm secures that the roller is pressed down against the guide rail. 2.3 Mechanic connection to a rotary actuator Figure 3 shows the mechanic connection of the positioner to a rotary actuator. Step A: Attach the mounting console (9, actuator specific) onto the rear of the positioner and secure using the hexagon head screws (14) and lock washers (15). Step B: Adhere pointer (4.2) onto the mounting console in the centre of the centring hole. Step C: Push coupling wheel (2) onto the positioner axis, pull back by about 1 mm and tighten the hexagon socket head screw (18) with the Allen key provided. Step D: Place the carrier (3) onto the end of the actuator and secure using Fillister head screw (16) and washer (17). Step E: Carefully place the positioner with mounting console onto the actuator such that the pin of the coupling wheel engages in the driver. Step F: Align the positioner/mounting console assembly in the centre of the actuator and screw tight (screws are not included in the delivery, they are part of the actuator mounting console). Step G: Follow the start-up sequence as described later. Drive the actuator to the end position and adhere the scale (4.1) onto the coupling wheel (2) according to the direction of rotation and rotary actuator. The scale is self- adhesive. Language UK Page 5/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Mechanic connection of the positioner (rotary actuator) Figure 3 sips2_5c.tif Language UK Page 6/16 iiUU. AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Electric connection of the positioner When the positioner is connected in a two-wire system, the positioner draws its power exclusively from the 4 to 20 m A set point signal. Figure 4 indicates the input circuits for the positioner. View of the controls and connections 14 15 to,- 2 W 3/4 W 90" • 3 3 - ï<< i * * e s 1 Input: Supply air 7 Silencer 2 Output: Actuating pressure Yl 8 Transmission, ratio selector 3 Display 9 Adjusting wheel slip clutch 4 Output: Actuating pressura Y2 ** 10 Terminals options1 modules 5 Operating keys 12 Dummy plug 6 Restrictor 13 Screw-type cable gland 6.1 RestrlctorY! 14 Terminal: plate on cover 6.2 Restrictor Y2 *) 15 Purging air switch Figure 4 sips2_5d.tif Pneumatic connection Ensure that the air quality is suitable. Grease-free instrumental air with a solid content < 30 um and a pressure dew point 20 K below the lowest ambient temperature must be supplied. Warning: For reasons of safety, pneumatic power may only be supplied after assembly when the positioner is switched to operating level "P manual" operation with electrical signal applied. 4.1.1 Selection of P manual mode Before pneumatic power is connected, the positioner must be in P manual mode. The display must show "NOINIT" in the bottom line. Language UK Page 7/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES 4.1.2 Pneumatic connections Figure 4 shows a view of the positioner controls and connections. Step A: If required, connect a manometer block for supply air and actuating pressure. Step B: The silencer in the exhaust output can be removed if necessary. Step C: Connect actuating pressure Yl and/or Y2 (Y2*} is only used with double- acting actuators) according to the desired safety position. Step D: Connect the supply air (1). The pressure should be between 1.4 to 7 bar. Note: In order for spring-loaded pneumatic actuators to be able to reliably exploit the maximum possible actuating path, the supply pressure must be sufficiently greater than the maximum required final pressure of the actuator. 4.1.3 Safety position when the electric power supply fails For a single-action actuator is Yl deaerated. For a double-action actuator is Yl equal to the supply air pressure and Y2 is deaerated. 4.1.4 Restrictors To increase the positioning times for fast actuators when necessary, the air flow can be reduced with the restrictors Yl and Y2 (only for double-action valves). Turning the restrictors in the clockwise direction reduces the air flow until it is shut off. To set the restrictors it is recommended to first close them and then open them again slowly (see initialisation process RUN 3). 4.1.5 Purging air switchover The purging air changeover switch located above the pneumatic terminal block on the valve manifold can be accessed when the housing is open. When the switch is in position "IN" the interior of the housing is purged with very small quantities of clean and dry instrument air. In position "OUT" the purging air is led directly out of the instrument. Commissioning Commissioning (initialisation) is carried out automatically to a large extend. During initialisation, the micro controller automatically determines the zero value, full-scale value, direction of action and positioning speed of the actuator. It uses these to determine the minimum pulse time and dead zone, hereby optimising the control. The positioner can also be operated manually by the pushbuttons and the LCD of the SIPART PS2. The commissioning of the positioner can be divided into the following steps: • Preparation for initialisation Start the automatic initialisation procedure Language UK Page 8/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Step C: Without initialisation the positioner is in "P manual mode" and "NOINIT" flashes in the display. This level can also be reached by using "55.PRST" function (see Table 1). Step D: Check the free running of the mechanics in the whole actuating range by moving the actuator with the keys "Î" and " j" and driving to the respective end position. Step E: With linear actuators drive the actuator to horizontal lever position. The display must indicate 48% to 52%. If necessary, correct the value by adjusting the sliding clutch. After the check is completed, the actuator must be approximately half way along its stroke. This is due to establishment of the action direction during automatic initialisation. 5.2 Automatic initialisation Figure 6 shows the configuration mode including the operation in this mode and Table 1 shows the parameter/configuration list. Figure 7 shows the initialisation process of the positioner. The initialisation process is stored in the microprocessor. This means that an additional initialisation only is necessary if any parts of the unit have been changed. Note: The numerical values used in Figure 5, Figure 6, and Figure 7 are examples. Step A: Call the configuration mode by pressing the hand symbol key for longer than 5 seconds. Step B: Set the actuator type, linear or part-turn, in the menu item line "l.YFCT". Step C: Switch to the second parameter by pressing the hand symbol key briefly. Step D: Set the rated angle of rotation for feedback in the menu item line "2.YAGL". It is vital that this value corresponds to the setting of the gear transmission ratio selector (Figure 4, position 8), 33° or 90°. Step E: Switch to the next parameter by pressing the hand symbol key briefly. Step F: This parameter ("3. Y WAY") is only set for linear actuators and if the total stroke in mm should be displayed at the end of the initialisation phase. To do this, select the same value in the display to which the carrier pin to the scale on the lever is set to. Step G: Switch to the following parameter by pressing the hand symbol key briefly. Step H: Start the initialisation ("4.INITA") by pressing the "f" key for longer than 5 seconds. Language UK Page 10/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Step I: During the initialisation phase "RUNl" to "RUN5" appear one after another in the bottom of the display. Please note that the initialisation process may last up to 15 minutes depending on the actuator. Note: The ongoing initialisation can be aborted at any time by pressing the hand symbol key. The previous settings are retained. All the parameters are reset to the factory setting only after performing a preset "55.PRST". Step J: If problems occur, carry out the measures as described in the table "Possible messages" shown in Figure 7. Step K: The initialisation is completed when "FINSH" appears in the bottom of the display. Step L: When pressing the hand symbol key briefly the menu item line "4.INITA" is displayed. Step M: To exit the configuration operating mode, press the hand symbol key for longer than 5 seconds. The software version is displayed after about 5 seconds. The instrument is in manual operation after releasing the key. Step N: The positioner can be changed to automatic mode by pressing the "j" key once as indicated in Figure 5. Step O: The automatic mode is the normal mode. In this mode the positioner compares the set point current with the current position and moves the actuator until the control deviation reaches the dead zone. Operation in the configuration mode V A aaaaa < • aaaaa B8 Hill BB HS 2 tie same time the same time 4P V A 4 1? aaaaa < • aaaaa 88 IIÜI DO !£ffiii£i tc 2 he same time "Û he same time A 8,868,8 BflBfiB • DQ ©EJEHSCg BB 1IÜI w DO üüi)®Ä Figure 6 sips2_5f.tif Language UK Page 11/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Initialisation process Automatic initial start-up (starting with factory setting) Possible messages Step Meaning Display Meaning Measures Acknowledge message 11 ParU urn tum 90° usingthe hand syrrbol key actuator 1 YFCT 2 YAGL P 324 Actuator does RUN 1 not move Check restrictor (E) and open Linear WAY 33° Strt if necessary actuator 1 YFCT 2 YAO. 3 YWAY P 324 Drive actuator to working range fftROR usingthe up and down keys Press tre up key for > 5 sec. Restart initialisation 2.) Strt 4 INTA Remaining steps are carried out automaticaly Crengegearing (7) P 324 Ccnfinueushg up key 3) Direction of action is determined D RUN 1 P 884 Down tolerance Or adjust sliding dutch up h dit» IU band violated to display Checking of travel and adjustment of P 6.4 «.) P 924 S d< O IU 0 RUN 2 zero andstroke (from stop to stop) Determination and display of psitioning time Then only Centime using the down key 5) P 824 down(dxx.x), up (uxx.x). Stop with thedown key r, RUN 3 Pressing t he up key inliates leakage measurement Linearactuator set pick-up Once the slipping lever hto horizontal position S Et dutch has been usingthe ip and down keys 6) P 324 Détermina Bon of minimum here ment length MIDDL Li RUN 4 adjusted Continue using hand symbol key 7.) P 524 Optirrisati on of transient respon se Acknowled ge massage O RUN 5 98.3 Up tolerance band usingthe hendsymbol key Intialisafon terminated successfuly UP > violated Set the next highest travel 324 (travel in m mfor linear actuatcrs) valueonthe lever 8) (angjeofrotation for part-turn actuators) FINSH Restart initialisdbn Continueusiig hand symbol key Additionally possible with rotary actuators: Adjust using up and down keys up to dspla y: P 92.8 s a>_95 Continue u sing hand symbol key Acknowledge message using the ha nd symbol key Up/down span P 19.8 Set the next lowest travel violated h U-d < value on tte lever Restart initialisation Adjust positioning timeushg 1.3 Actuator does resrictor(s) NOZZL not move. Positioning Conti nue ushg the Urne is posslbl e up or down key 1.8 to adjust NOZ2L Figure 7 sips2_5g.cdr 5.3 Parameters After the initialisation process, the positioner can be configured to meet the requirements of a specified task. The factory settings correspond to the requirements for a typical application. This means that normally only a few parameters will need to be changed. Table 1 shows the parameter list for the positioner. The parameter name is written in plain text in the "menu line" column. The function of the parameter is described briefly in the "Function column". In addition, the possible parameter values, the physical unit and the factory setting of the parameters are shown. Language UK Page 12/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Parameter list Customer Function Parameter values Unit Factory setting Menu line setting turn (part-turn actuator) WAY (linear actuator) LWAY (linear actuator without sine correction) l.YFCT Type of actuator WAY ncSt (part-turn actuator withNCS) -ncSt (part-turn actuator with NCS, inverted) Rated angle of rotation for feedback 90° 2.YAGL0 Degrees 33° (must correspond to gear ratio) 33° Stroke range (optional setting) OFF 5,10,15,20 When used, the value must correspond with (short lever 33°) the set of the leverage ratio on the actuator 3.YWAY2) 25 , 30, 35 mm OFF Driver pin must be set to the value of the (short lever 90°) actuator travel or, if this value is not scaled, 40, 50, 60, 70, to the next lager scale value 90,110,130 (long lever 90°) 4.INITA Initialisation (automatically) noini/no/###.#/Strt no 5.INITM Initialisation (manually) noini/###.#/Strt no „ . . . . 0 to 20 mA 0MA 6.SCUR Current range off set point . „„ . 4 MA ° 4 to 20 mA 4MA riSE 7.SDIR Set point direction „ ... ° riSE r falling FALL 8.SPRA Set point for start of split range 0.0 to 100.0 % 0.0 9.SPRE Set point for end of split range 0.0 to 100.0 % 0.0 Auto 10.TSUP Set point ramp up s 0 0 to 400 ll.TSDO Set point ramp down 0 to 400 s 0 Set point function Linear Lin 12.SFCT Equal-percentage 1:25, 1:33, 1:50 1-25 ,1-33 ,1-50 Lin Inverse equal-percentage 1:25,1:33,1:50 nl-25 , nl-33 , nl-50 Freely adjustable FrEE 13.SL0J) Set point turning point at 0% 0.0 14.SL1 5% 5.0 to to 0.0 to 100.0 % to 32.SL19 95% 95.0 33.SL20 100% 100.0 Auto 34.DEBA Dead zone of controller % Auto 0.1 to 10.0 35.YA Start of manipulated variable limiting 0.0 to 100.0 % 0.0 36.YE End of manipulated variable limiting 0.0 to 100.0 % 100.0 Standardisation of To mech. travel MPOS 37.YNRM MPOS manipulated variable To flow FLOW Direction of manipulated Rising riSE 38.YDIR riSE variable for display Falling FALL Without no Tight closing with Top only UP 39.YCLS no manipulated variable Bottom only do Top and bottom uPdo 40.YCDO Value for tight closing, bottom 0.0 to 100.0 % 0.5 41.YCUP Value for tight closing, top 0.0 to 100.0 % 99.5 Language UK Page 13/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Parameter list continued Customer Function Parameter values Unit Factory setting Menu line setting Function of BI 1 : None OFF Only message (NO/NC contact) on / -on Block configuring (NO contact) bLocl 42.BIN14' OFF Block configuring and manual (NO contact) bLoc2 Drive valve to pos. up (NO/NC contact) uP / -uP Drive valve to pos. down (NO/NC contact) doWn / -doWn Block movement (NO/NC contact) StoP / - StoP Function of BI 2: None OFF Only message (NO/NC contact) on / -on 43.BIN24) OFF Drive valve to pos. up (NO/NC contact) uP / -uP Drive valve to pos. down (NO/NC contact) doWn / -doWn Block movement (NO/NC contact) StoP / -StoP Without oFF .. _ Al=min. A2=max. N,NA 44.AFCT5) Alarm function .. . „ OFF Al=min. A2=min. N,N Al=max. A2=max. NA,NA 45.A1 Response threshold of alarm 1 0.0 to 100.0 % 10.0 46.A2 Response threshold of alarm 2 0.0 to 100.0 % 90.0 Function of alarm output On fault h 47.SFCT6' Fault + not automatic hnA h Fault + not automatic + BI hnAb ("+" means logical OR operation) Monitoring time for fault message Auto 48. h TIM s Auto "control deviation" 0 to 100 Response threshold for fault message Auto 49. h LIM % Auto "control deviation" 0.0 to 100.0 OFF 50.SSTRK Limit for stroke integral OFF 1 to 1.00E9 OFF 51.hDCHG Limit for direction change OFF ltol.00E9 OFF 52. S ZERO Limit for end stop monitoring, bottom % OFF 0.0 to 100.0 OFF 53. h OPEN Limit for end stop monitoring, top % OFF 0.0 to 100.0 OFF 54.L,DEBA Limit for dead zone monitoring % • OFF 0.0 to 100.0 Preset (factory setting) "no" nothing activated no "Strt" start of factory setting after pressing 55.PRST key for 5 sec. Strt "oCAY" display following successful factory setting oCAY CAUTION: preset results in "NO INIT" Table 1 !) If turn is selected it is not possible to set 33°. 2) Parameter does not appear if 1 .YFCT = turn has been selected. 3) Turning points only appear with selection 12.SFCT = FrEE. 4) Alternatively "no" if initialisation has not yet been carried out 5) NC contact means; action with opened switch or low level. NO contact means; action with closed switch or high level. ' Normal means: high level without fault. Inverted means: low level without fault. Language UK Page 14/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Diagnosis In the diagnostic mode the current operating data (such as number of strokes, number of changes in direction, number of fault messages, etc.) can be displayed. From the automatic or manual modes the diagnostic mode can be reached by simultaneously pressing all three keys for at least 2 seconds. Table 2 shows an overview of the displayable values. The diagnostic display has a similar structure as the parameter menu displays. The respective next diagnostic value can be selected with the hand symbol key. Certain values can be set to zero by pressing the "Î" key for at least 5 seconds. These are menu item line "1,2, 3, and 4". Some diagnostic values may be greater than 99999. In this case the display switches to exponential display. Diagnostic list No.: Abbreviation Meaning Displayable Unit value 1 STRKS Number of strokes 0 to 4.29E9 - 2 CHDIR Changes of direction 0 to 4.29E9 - 3 SCNT Fault counter 0 to 4.29E9 - 4 A1CNT Alarm counter 1 0 to 4.29E9 - 5 A2CNT Alarm counter 2 0 to 4.29E9 6 HOURS Operating hours 0 to 4.29E9 Hours 7 WAY Determined actuating path 0 to 130 mmor° 8 TUP Travel time up 0 to 1000 s 9 TDOWN Travel time down 0 to 1000 s 10 LEAK Leakage 0.0 to 100.0 % 11 P0 Potentiometer value below stop (0%) 0.0 to 100.0 % 12 P100 Potentiometer value bottom stop (100%) 0.0 to 100.0 % 13 IMPUP Impulse length up 2 to 100 ms 14 IMPDN Impulse length down 2 to 100 ms 15 DBOP Dead zone up 0.1 to 100.0 % 16 DBDN Dead zone down 0.1 to 100.0 % 17 SSUP Short step zone up 0.1 to 100.0 % 18 SSDN Short step zone down 0.1 to 100.0 % 19 TEMP Current temperature -45 to 85 °C 20 TMIN Minimum temperature -45 to 85 °C 21 TMAX Maximum temperature -45 to 85 °C 22 Tl Number of operating hours in Temperature range 1 0 to 4.29E9 Hours 23 T2 Number of operating hours in Temperature range 2 0 to 4.29E9 Hours 24 T3 Number of operating hours in Temperature range 3 0 to 4.29E9 Hours 25 T4 Number of operating hours in Temperature range 4 0 to 4.29E9 Hours 26 T5 Number of operating hours in Temperature range 5 0 to 4.29E9 Hours 27 T6 Number of operating hours in Temperature range 6 0 to 4.29E9 Hours 28 T7 Number of operating hours in Temperature range 7 0 to 4.29E9 Hours 29 T8 Number of operating hours in Temperature range 8 0 to 4.29E9 Hours 30 T9 Number of operating hours in Temperature range 9 0 to 4.29E9 Hours 31 VENT1 Number of cycles pre-control valve 1 0 to 4.29E9 - 32 VENT2 Number of cycles pre-control valve 2 0 to 4.29E9 - Store current values as "last maintenance" 33 STORE - - Press the up key for at least 5 seconds (store) Table 2 Language UK Page 15/16 AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0 INDUSTRIES Service and maintenance The positioner is largely maintenance-free. The positioner is fitted with filters in the pneumatic connection as protection against coarse particles of dirt. If the pneumatic energy supply contains particles of dirt, the filters may be clog and impair the function of the positioner. In this case the filters can be cleaned as follows: Step A: Switch off the pneumatic power supply and remove the pipes. Step B: Unscrew the cover. Step C: Remove the three screws from the pneumatic connector strip. Step D: Remove the filters and O-rings behind the connector strip. Step E: Clean the filters (e.g. with compressed air). Step F: After cleaning first insert the filters in the recesses in the housing and then place the O-rings on the filters. Step G: Align the pneumatic connector strip on the two lugs and screw tight with the three self-tapping screws. Note: Make sure that the same thread is used. To do this, turn the screws anti clockwise until they snap into the thread audibly. Only then should the screws be tightened. Language UK Page 16/16 • • • • • AALBORG ^BJHiBBSiHIW^^M^^W Table of contents Fuel oil supply pump Technical data for fuel oil supply pumps General data 1 Data for fuel oil pumps 2 Data for pump motor 3 Fuel oil supply pump, type SPZ General 1 Structural design 2 Mode of operation 3 Preservation and storage of the pumps 4 Foundation design/fastening type 5 Mounting of the twin aggregate 6 Preparation for start-up 7 Start-up 8 Stopping and restarting 9 Control of operation and maintenance 10 Troubles, causes and remedial action 11 Dismounting and mounting instructions 12 Spare parts 13 Language UK Page 1/1 AALBORG ^HSBlBSIlîinSHilSBIBlSIllIE^B Technical data for fuel oil pumps 1 General data • Project No.: 736950, 736952 • Hull NoTProject name: 03130007, 03130008 • Classification society/Local authority: LRS • Pressure gauge calibration: MPa • Thermometer calibration: °C • Language for signs: UK • Colour of fuel oil pump unit: Munsell GY10 8/4 2 Data for fuel oil pumps • Pump: Horizontal three screw pump • Pump type: SPZ 20-R46 G8.3 FW8 • Delivery head: 2.5 MPa • Relief valve set point (factory set): 2.85 MPa • Oil temperature, maximum: 150°C • Pump capacity at 4 cSt: 2154 1/h • Pump capacity at 380 cSt: 2796 1/h • NPSH at 4 cSt: 3 mWC • NPSH at 380 cSt.: 7 mWC • Weight of fuel oil pump unit: 120 kg 3 Data for pump motor • Motor make: AEG • Motor type: AM 100 LS 2 • Power supply: 3 x 440 V, 60 Hz • Rated output for motor: 3.6 kW • Revolutions: 3400 r.p.m. • Ambient air temperature: 45°C • Starting method: Direct Language UK Page 1/2 • • • • • ^ijilfi. AALBORG gSBIWBIffiliHJBIBIHIBIlSBBKBIilliHEl • Starting current: 41 A • Operating current (full load): 6.3 A • Power consumption at 4 cSt: 2.27 kW • Power consumption at 380 cSt: 2.88 kW • Numbers of cable entries with reliefer: 2 • Heating element (standstill): None • Thermostat protection: None • Insulation class: F • Degree of protection: IP44 Language UK Page 2/2 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES Oil pumps, type SPZ 1 General The SPZ pumps series are employed for handling light and heavy fuel oil. The twin aggregate is constructed as a compact type in which two screw pumps are interconnected by way of a reversing valve casing. 1.1 Abbreviation The abbreviation of the screw pump twin aggregates is set up according to the following scheme: Example: SPZ 10 R 38 G 8.3 FE-W20 Where: • SPZ: series • 10: size (theoretic delivery in [1/min] with 1450 1/min and 46 degrees pitch angle • R: direction of screw pitch (R = right) • 3 8 : angle of screw pitch (degrees) • G: kind of bearing (internally slide bearing) • 8.3 : shaft sealing by mechanical seal • F: design with filter • E: design with electric filter-heating of the filter casing • W20: material design 1.2 Warranty Our liability for shortcomings in the supply is laid down in our delivery conditions. No liability will be undertaken for any damages caused by non-compliance with the operating instructions and service conditions. If at any later date the operating conditions happen to change (e.g. different fluid conveyed, speed, viscosity, temperature, or supply conditions), it must be checked by us from case to case and confirmed, if necessary, whether the pumps are suited for these purposes. In case no special agreements were made, the pumps supplied by us may, during the warranty period, only be opened or varied by us or our authorised contractual service stations; otherwise, our liability for any defects will expire. 1.3 Testing Prior to leaving our factory, all aggregates are subjected to a thorough test run and performance test on the test stand. Only properly operating pumps leave the factory Language UK Page 1/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES achieving the performances assured by us. Thus, compliance with the following operating instructions ensures proper operation and full delivery. 1.4 Performance data • Delivery, Q: up to 6.7 m3/h (with n = 2900 l/min and v = 750 mm2/s.) • Temperature of the fluid pumped, t: up to 150°C (with higher temperatures, please inquire) • Inlet pressure, ps: up to 5 bar • Pump outlet pressure, pa: up to 40 bar (For the attainable delivery pressure as a function of viscosity and speed, please refer to the individual characteristics. The pressure data only apply to nearly static pressure load. With dynamic pressure change load, please inquire.) • Viscosity range,v = 3 to 750 mm2/s • Pressure flange, DNj = 20 to 40 mm The exact performance data applicable to the pump can be taken from the layout and/or acceptance certificate, and are engraved on the rating plate. 1.5 Application and installation The screw pump twin aggregates of series SPZ for a pump outlet pressure up to 40 bar are three-screw, self-priming, rotary positive displacement pumps for handling lubricating fluids. The fluids must not contain any abrasive particles nor chemically attack the pump materials. Both pumps of the aggregate are designed as flange-mountedpump s and via pump bracket each connected with the driving motor. Attention: The aggregates are provided for horizontal installation or wall mounting. For safety purposes, the arrangement with ''motor down wards" is not admissible. Structural design The screw pump twin aggregates of series SPZ consist of two screw pumps. Sectional drawings of the pump are shown in Figure 1 and Figure 2. The item numbers referred to in this section are those indicated on these drawings. Via a reversing valve casing (301), the two pumps are connected with each other. The screw pumps are of the three-screw type. A double-threaded driving spindle (12) and two double-threaded idler spindles (13) are enclosed by the bores in the pump casing insert (2) with a narrow running clearance. The pump casing (1) accommodates the pump casing insert (2) and is closed by the pump cover, drive side (3) and by the pump cover, non drive side (4) and the filtercasin g (9). Language UK Page 2/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES Sectional drawing of the SPZ pumps, without filter Section A-B 126 12( U1 205 355 «7 301 123 20( 356 108 «0 206 12S 236 (75 222 1(2 t» 333 3(0 331 12 330 • O 120 «6 200 250 (SS (71 217 231 Section C-D 201 ( 1 2 151 263 165 161 122 160 290 900 901 } \ ) ) 1(5 370 1(7 372 21 976 280 215 (60 Pump size 10 and 20 Denomination Part No. Denomination Part No. Denomination Part No. Denomination Part No. Pump casing 1(D Joint ring 1420 Socket-head cap screw 222 Stop valve 363 Pump casing insert 2(1) Gasket 1450 Socket-head cap screw 227 Connector 370 Pump cover Joint ring 147 0 Hexagon nut 231 Casing 372 drive side 3 CD Sealing washer 1480 Hexagon nut 236 Hollow screw 373 non-drive side 4(0 Sealing washer 151 CD Hexagon nut 238 Manometer Bearing ring 10 CD Joint ring 156 0 Clrcllp 2500 connecting branch 374 Driving ecrew 12 CD Joint plug 160 Circllp 2510 Blank flange 440 Idler screw 13 (D Joint plug 161 Supporting washer 263 Blank flange 441 Distance sleeve 20 (D Joint tape 165 0 Rivet 280 Pump bracket 460 Socket-head cap screw 24 Mechanical seal 186 0 Key 290 Foot angle 471 Gasket 100 Figure 1 spz01.tif Language UK Page 3/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES Sectional drawing of the SPZ pumps, with filter Section A-B 143 157 U6 126 124 441 205 355 107 301 123 204 356 106 440 206 125 236 Section E-F 362 159 30 475 222 142 CO 333 340 331 12 3» 13 D 120 166 200 250 495 471 217 231 Section C-D 9 201 29 1 2 151 263 165 161 122 160 290 900 901 •V*-—-^ 374 ^-148 ——373 145 370 «7 372 292 20 3 Pump size 10 and 20 22s 24 976 280 215 460 Pump size 40 251 Denomination Part No. Denomination Part No. Denomination Part No. Denomination Part No. Pump casing 1 ® Joint ring 143® Screw plug 222 Connector 364 Pump casing Insert 2® Gasket 145® Venting screw 223 Connector 370 Pump cover Gasket 146® Screw plug 227 Casing 372 drive side 3 6) Joint ring 147® Hexagon nut 231 Hollow screw 373 Casing cover 7® Sealing washer 14B® Screw plug 235 Manometer Filter casing 9 CD Sealing washer 151® Hexagon nut 236 connecting branch 374 Bearing ring 10® Joint ring 152® Hexagon nut 238 Blank flange 440 Driving screw 12® Joint ring 156® Circlip 250® Blank flange 441 Idler screw 13® Gesket 157® Clrcllp 251® Pump brocket 460 Distence sleeve 20® Joint ring 159® Supporting washer 263 Foot angle 471 Socket-head cap screw 24 Joint plug 160 Rivet 280 Oil trough (removable) 475 Pipe 29 Joint plug 161 Key 290 RBdial screen filter 481® Pipe 30 Joint tape 165® Groove ball bearing 292® Clamping sleeve 495 Gasket 100® Mechantcat seal 186® Reversing velve ceslng 301 Coupling half Joint ring 107® Socket-head cap screw 200 Valve cone 330® pump side 900 Joint ring 108® Socket-head cap screw 201 Valve spring plate 331 drive side 901 O-rlng 119® Hexagon screw 204 Adjusting screw 333® Driving motor 910 O-ring 120® Hexagon screw 205 Valve spring 340® Heating shell 962 CD® O-ring 122® Socket-heed cap screw 206 Stop valve 3S5® Neme plate 976 Gasket 123® Hexagon screw 207 Lockable non-return velve 358® Gasket 124® Socket-head cap screw 208 Manometer 360® (D A heating shell for each pump Gasket 125® Socket-head cap screw 215 Manometer 361® is supplied on request only Gesket 126® Hexagon screw 216 Ball valve 362 (at extra charge). Joint ring 142® Hexagon screw 217 Stop valve 363 ® Spare parts Figure 2 spz02.tif Language UK Page 4/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES 2.1 Shaft seal The pump has a maintenance-free mechanical seal of the unbalanced type. Material design of the mechanical seal: • Rotating seal ring: tungsten carbide • Stationary seal ring: tungsten carbide • Joint ring: Viton • Spring: stainless steel • Metal parts: stainless steel 2.2 Bearing and lubrication The radial and axial bearing of the driving spindle of a screw pump is effected by the bearing ring. At the same time, the delivery chamber is separated from the sealing chamber by the gap between the compensating piston and bearing ring. The bearing is lubricated by the fluid pumped. 2.3 Flanges / connections Blank flanges with screw and gaskets. • Suction side: PN 16, DIN 2633 • Outlet side: PN 40, DIN 263 5 • Connections: — SPZ without filter: Ml, M2 manometer — SPZ with filter: B7 draining filter casing, E7 venting filter casing, Ml, M2, M3 manometer 2.4 Filter As a protection against contamination, the pumps can be equipped with a filter casing and an incorporated filter.Filte r mesh size 0.4 mm. The mano/vacuum-meters being part of the scope of supply show the pressure behind the filter. By means of these, the pressure loss in the respective filter can be detected, and an inadmissible contamination recognised. 2.5 Electric heating In case of design with filter,rin g heaters may be provided for filter heating. Pump size Connection for ' ' Heating capacity SPZ 10 220 V 165 W SPZ 20 220 V 205 W Table 1 Language UK Page 5/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES 2.6 Pressure relief valve As an overload protection, a pressure-relief valve is installed in each pump, which is serially set to a response pressure approx. 10% above the operating pressure. 2.7 Non-return valves / stop valves In the reversing valve casing, a non-return valve and a stop valve are provided for each pump. The non-return valves operate automatically and can be locked by hand. 2.8 Operation control Manometers: • SPZ pump without filter: — Outlet side: a manometer (included in the scope of supply). If a mano/vacuum meter is requested on the suction side, this must be provided at the side. For connection, the bore for the screw plug (227) is provided. • SPZ pump with filter: — Suction side: two mano/vacuum-meters — Outlet side: one manometer Reversing unit: If a reversing unit was supplied for operation control, its circuitry is such that in case of failure of the operating pump the stand-by pump is automatically switched on. Signal lamps denote the respective operating conditions. Reversing unit Ul: for motors up to 3 kW (380 V operating voltage) for across-the- line-starting. Reversing unit U3: for motors up to 3.0 and 5.5 kW (380 V operating voltage), suited for star delta-starting. 2.9 Oil trough The twin aggregate is provided with a separately supplied oil trough. 2.10 Drive / coupling Via the pump brackets flanged to the pumps, electric motors of the most varied designs are connected with the pumps. In the normal case, these are attached: Surface-cooled three-phase squirrel-cage induction motors, IMVl type of construction, enclosure IP 44 according it IEC Standard, class B insulation, performances and main dimensions according to DIN 42 677. Motors which are rated for 50 Hz can, without change, be operated also in 60 Hz mains, speed and performance are changed as shown in Table 2. Power transmission is effected via a flexible coupling. Additional radial forces must not act on the driving spindle. The pump brackets serve as protection against accidental contacts according to DIN 24 295. Attention: Drive via belt or gear wheel is not admissible. Language UK Page 6/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES ; Motor wound for SO Hz Connection for 60 Hz Conversion factor for operation at 60 Hz ] V V Speed Performance 220 V 220 V 1.2 1.0 380 V 380 V 1.2 1.0 380 V 440 V 1.2 1.15 440 V 440 V 1.2 1.0 Table 2 Mode of operation 3.1 Mode of operation of the screw pump twin aggregate Switching diagrams showing the screw pump twin aggregate can be seen in Figure 3. Switching diagrams Series SPZ without filter Series SPZ with filter 1 Operating and stand-by pump 1 Operating and stand-by pump 2 Three-phase motor (910) 2 Three-phase motor (910) 3 Stop valve (3SS) 3 Stop valve (3SS) 4 Filter (481) 5 Lockable non-return valve (356) 5 Lockable non-return valve (356) 7 Manometer with ball valve (360) and (363) 6 Mano-vacuumeter with ball valve (361) and (362) 7 Manometer with ball valve (360) and (363) Figure 3 spz03.tif Both screw pumps are jointly attached to the reversing valve casing (301). While one pump is in operation, the stand-by pump is at standstill. The pumps can be connected alternately by hand or automatically by means of a reversing unit (Ul or U3). By way of two separate connecting chambers in the reversing valve (301), the respective two suction flanges and the two pressure flanges of the two pumps are connected with one another. Uninterrupted delivery during the reversing process is thus ensured. During operation, the two lockable non-return valves (356) and the two stop valves (355) must be opened so that reversal is optionally possible from the one pump to Language UK Page 7/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES the other. The respective connected pump draws the fluid in through the suction chamber of the reversing valve casing (301). The operating pressure built up in the delivery chamber of the pump opens the non-return valve (356) of the operating pump and, through the pressure in the delivery chamber of the reversing valve casing (301), closes the non-return valve (356) of the non-operating pump. This prevents the stand-by pump from running in reverse motion. 3.2 Mode of operation of the screw pumps Through the suction chamber in the reversing valve casing, the material to be pumped is conveyed into the suction chamber of the pump in operation. From here, the fluid flows into the spindle chambers which are constantly formed by the rotary motion at the spindle end on the suction side. By the translatory rotary motion, the chambers filled with the fluid to be conveyed move from the suction side to the outlet side. During this process, the closed chamber volume does not change. At the spindle end on the outlet side the chamber opens towards the delivery chamber. The fluid conveyed is steadily pushed out into the delivery chamber from where it is transported, through the delivery chamber, into the pressure pipeline. The axial thrust acting on the faces of the profile flanks on the outlet side is hydraulically balanced by an appropriate dimensioning of the compensating piston of the driving spindle. Thus, the bearing is relieved from the hydraulic axial thrust. By appropriate dimensioning of the spindles, the drive of the idler spindles is hydraulic. Only the torque resulting from the liquid friction is transmitted via the profile flanks; therefore, they are practically stress-free and not subject to any wear. The axial thrust of the idler spindles is absorbed by the pump cover, non-drive side or by the filter casing. Sealing chamber and suction chamber are interconnected via a return bore. Therefore, irrespective of the delivery pressure, only the suction pressure acts on the shaft seal. All sliding parts are lubricated by the fluid to be pumped and are within the range of full liquid friction. In spite of spindle rotation, there is no turbulence. The constant chamber volume excludes squeezing. The structural design and the mode of operation of the screw pumps ensure a very low noise level and an almost pulsation-free delivery. Preservation and storage of the pumps 4.1 Preservation If required, the screw pumps delivered by us are already provided with the requested preservation protection according to the storage time specified by the customer. Also in case of prolonged shutdown, the screw pumps must be protected against corrosion. In those cases, an outside and inside preservation is to be provided. The durability of the protection against corrosion which is limited in time, depends on the composition of the preservative to be applied. It is therefore recommended to use such preservatives only which have a minimum durability of 12 months. Below is listed preservative which can be applied for both outside and inside preservation. Language UK Page 8/24 AALBORG OiL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES 4.1.1 Outside preservation All bright and unvarnished parts such as: shaft ends, couplings, flange facings, valve and manometer connections can be preserve with one of the following preservative: • TECTYL 506 • A mixture of TECTYL 506 and TECTYL 511-M1 This preservative is to be applied by painting or spraying with a spray gun. 4.1.2 Inside preservation Pump casing inside, screw spindles, ball bearing, pressure-relief valve, mechanical seal can be preserve with: • Mixture of: TECTYL 506 and TECTYL 511-M1 Note: The preservative listed above is to be regarded as a recommendation. Preservatives having the same preserving properties can also be used. The preservative is to be applied by filling the pump. For these purposes, the suction side of the pump must first be closed with a dummy flange. During filling, the pressure flange must be on a higher level than the suction flange. During the filling process, the driving spindle must be slowly cranked against the sense of rotation. Filling must be continued until the preservative reaches the sealing strip of the delivery flange, bubble-free. Thereafter, the outlet side is to be closed with a dummy flange. 4.1.3 Control of preservation In case of prolonged storage, the preservation of the pump must be checked by the customer at regular intervals. Step A: Every six months, the pump level must be checked, if necessary, preservative must be topped up to the sealing strip at the pressure flange. Step B: At the same time, the packing must be checked for destruction, and repaired, if necessary. Note: Liability for damages caused by improper preservation cannot be predicted. 4.1.4 Durability of the preservative According to the preservative manufacturer, the durability of TECTYL 506 is 4 to 5 years in case of indoor storage, and 12 to 24 months in case of outdoor storage, and of TECTYL 511-M approx. 18 months in case of indoor storage. When mixing TECTYL 506 and TECTYL 511-M in the same proportion, a durability of 254 to 4 years in case of indoor storage, and a maximum of 12 months in case of outdoor storage under roof can be expected. With additional packing, the service life is increased. Language UK Page 9/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES The active ingredients contained in this preservative provide sufficient protection against corrosion even in high air humidity (sea, tropical climate). Therefore, a temperature limitation (+ and -) does not exist. 4.1.5 Degreasing Prior to setting the screw pump in motion, the preservative applied must be removed. The preservative applied for inside preservation can normally be removed by flushing the pump with the fluid to be conveyed. In addition, a suitable solvent may be applied for removing the inside and outside preservation. Appropriate solvents can be: Petroleum, benzene, Diesel fuel, spirit, alkalis (industrial cleaners) or any other wax solvents. Steam jet cleaning devices with appropriate admixtures can also be used (allow wax solvent to react previously). Attention: Prior to start-up, the pump must be filled with fluid to be conveyed so as to avoid seizing of the spindles during starting. Note: If on the plant side, the pipelines, (oil) tanks and gear parts in circulation are wetted with the paraffin-containing preservative, the entire plant must be degreased as paraffin deteriorates the air separating capability of the (oil) filling. This may result in unsteady operation of the pump, connected with a loud noise development. 4.2 Storage During storage of the screw pump, the suction and outlet branches and all other supply and discharge branches must always be closed with dummy flanges or dummy plugs. Storage should be in a dust-free and dry room. Step A: During storage, the screw pump should be cranked at least once a week. Step B: During this process, the screw spindles should each time change their turning position. After prolonged storage, all elastomers (O-rings, mechanical seals) must be checked for their elasticity of shape. Step C: Embrittled elastomers must be exchanged. Note: Only proper storage and packing ensure the durability of the preservatives applied. Language UK Page 10/24 AALBORG OIL PUMPS. TYPE SPZ OM9295#02.2 INDUSTRIES Foundation design/fastening type The foundation must be designed so that it can take the weight of the pump aggregate. Fastening is effected via the foot angle screw-connected to the intermediate lantern. Mounting of the twin aggregate 6.1 Control of the sense of rotation at the driving motors The sense of motor rotation must correspond to the directional marker of the pumps. For a control of the sense of rotation, the motors may be alternately switched in temporarily in an uncoupled condition. The sense of rotation being wrong, the pumps do not prime. This will result in damages to the pumps. The sense of rotation of the respective three-phase motor can be changed by interchanging any two phases. 6.2 Installation of a complete twin aggregate A twin aggregate supplied complete was carefully assembled at the works. As the pumps and the driving motors are centred in the pump bracket, re-alignment of the couplings is normally not required. Note: Improper handling, for example, during transportation, may affect the alignment provided between pumps and motors. In this case, the respective motor must be dismounted from the pump bracket. Exact examination of the alignment is effected by means of a dial gauge with retaining clip and clamping device fixed to the driving spindle and motor shaft end. The examination covers the admissible circular and axial run-out between the shaft ends and the centring diameters and the plane faces at the pump brackets (0.05 mm admissible as a maximum). 6.3 Installation and assembly of pump and driving motor The aggregate being completed at the place of service only, the coupling must be assembled as follows: Step A: Cover pump and motor shaft ends with a filmy coat of molybdenum disulphide (e.g. Molykote), and insert keys. Step B: By means of a mounting device, push coupling halves onto pump and motor shaft end. Language UK Page 11/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES Attention: Axial shock loads on the driving spindle of the pumps and the anti friction bearings of the driving motors must be excluded during mounting of the couplings. Step C: Re-alignment of the couplings is not necessary (please refer to section 6.2). 6.4 Laying the pipelines 6.4.1 Nominal widths If possible, the nominal widths of the suction and outlet pipeline should be rated so that the rate of flow does not exceed 1 m/s in the suction line and 3 m/s in the pressure pipeline as a maximum. Note: The nominal diameter of the suction and pressure pipeline must be of the same size as the nominal pump diameter or one nominal diameter greater. The nominal diameter on the suction side must never be smaller than the nominal pump diameter, as suction may otherwise be difficult. 6.4.2 Change of cross-sections and directions Sudden changes of cross-sections and directions, as well as hairpin bends, must be avoided. 6.4.3 Supports and flange connections By way of the flange connections, the pipelines must be connected to the pump stress-free. They must be supported close to the pump and should allow easy screwing to avoid deformations. After the screws have been slackened, the flanges must neither be inclined nor springy nor rest on top of one another under pressure. Any thermal stresses that may occur at the pipelines must be kept away from the pump by taking appropriate measures, e.g. by the installation of compensators. 6.4.4 Cleaning of pipelines prior to attachment Prior to assembly, all pipeline parts and valves must be thoroughly cleaned. Especially in the case of welded pipelines, burrs and welding beads must be removed. Flange packing must not protrude inwards. Water residues, still in the pipeline network from pressing-out or steeping for example, must be removed. Delivery of water destroys the pump. The pump relies on the fluid being conveyed for its lubrication. At the pressure test of the pipe system the customer is responsible for any damages and their consequents. 6.4.5 Non-return valves / stop valves In the reversing valve casing, a non-return valve and a stop valve are provided for each pump. Language UK Page 12/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES Note: With the non-return valve and stop valve closed, filter cleaning of those pumps may be effected which operate under supply pressure. 6.4.6 Venting The pumps without filter can be vented via the screw plug (227). In case of pumps with filter, the venting screw (223) in the filter and the screw plug (227) serve for venting. In addition, a vent valve must be provided at the highest point in the pressure pipeline. Note: In case of horizontal aggregate installation and with the suction and pressure flange turned sideways, the filling and venting bores and/or connections for the manometers must point upwards. 6.4.7 Filtering In case of aggregates which do not have filters attached at the factory, it is recommended to mount a filter in the suction pipeline to protect the pump against solid contamination. Filter mesh and/or gap size 0.1 to 0.5 mm depending upon the degree of contamination of the fluid to be pumped. Preparation for start-up 7.1 Filling the pumps with the fluid to be conveyed Attention: Prior to initial operation, the two pumps must be filled with the fluid to be conveyed. At the same time, the sealing required for suction is imparted to the spindles. The pump must not run dry. 7.1.1 Filling and venting of a pump without attached filter The with fluid to be pumped is filled in through a filling hole at the suction flangeo f the pump. For these purposes: Step A: The screw plug (227) with the joint ring (156) must be removed. The pump must be topped up with the fluid to be pumped until this fluid emerges at the vent hole of the pressure flange,bubble-free . In case of supply pressure, manual topping-up is not required. The pump is topped up via the supply pipeline, and vented via the filling and venting hole. 7.1.2 Filling and venting of a pump with attached filter Pumps in horizontal installation with attached filter are topped up via the fillinghol e in the (filter) casing cover (7) until the fluid pumped emerges at the vent hole of the pressure flange, bubble-free. Language UK Page 13/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES For these purposes: Step A: The vent screw (223) and the screw plug (227) with the joint rings (143) and (156) must be removed. Pumps in vertical installation with attached filter are topped up with fluid to be pumped via the filling and vent holes in the casing as described under section 7.1.1. Note: Instead of the screw plugs (227), manometers may be mounted in the suction and pressure flange of the pump casing (1). Please refer to section 2.3. 7.2 Heating of the fluid to be pumped When pumping heavy fuel oils or other fluids to be pumped congealing when getting cold, it is necessary to provide a heating system in the plant (e.g. pipe steam trace). At the time of pump starting, the fluid to be pumped must be in a flowable and pumpable condition to avoid damages to the operating pump as well as the stand-by pump. Step A: Prior to the pump start-up, heavy fuel oil, for example, must be heated to at least 10°C above the solidifying point. Step B: For twin aggregates, with filters attached at the factory, a filter heating may be provided. A ring heater serves to heat the filter. The heating capacity of the ring heaters is designed so that with an initial temperature of 20°C, a minimum heating-up time of 120 min. is necessary. The temperatures being lower (below 0°C), an appropriately longer heating time must be expected. The heating system is not appropriate for achieving during operation a marked temperature increase of the fluid to be pumped. The ring heaters must be connected to 220 V (provide parallel connection, no series connection). 8 Start-up 8.1 Starting the operating pump Prior to starting the operating pump: Step A: The two stop valves on the suction side and the two lockable non-return valves on the outlet side of the reversing valve casing, and gate valves, if any, must be opened in the plant. A pressure-relief valve is installed in each pump which is serially set on our test field to a response pressure which is approx. 10% above the operating pressure. Step B: By means of the adjusting screw (333), the opening pressure can be changed within narrow bounds. Language UK Page 14/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES Attention: When starting and stopping the pump under pressure load, make sure that the speed and viscosity-dependent pressure load is not exceeded. If this is not ensued, the pump must be started at zero pressure or disconnected. This also applies to pumps with speed- controlled driving motors. The pressure-relief valve must not be used for regulating the delivery flow. Step C: During starting, a vent valve on the outlet side of the plant must be opened until the air has escaped from the suction side of the pump. As soon as fluid to be pumped emerges, the vent valve may be closed. The pump is self- priming and is automatically vented without counter-pressure. 8.2 Motor Step A: Switch motor of operating pump in. 8.3 Checking the delivery values Step A: After the motor has reached its operating speed, inlet pressure and outlet pressure of pump must be checked via vacuum gauge and manometer. The motor must not be overloaded. The power consumption can be checked by means of an ammeter. In this connection, temperature and viscosity of the fluid must be checked. The values read must be checked against the layout and/or acceptance report. Note: Pressure gauges such as vacuum gauges and manometers are normally equipped with stop valves. The stop valves are to be opened only during start-up for pressure control purposes. During permanent operation, these must be kept closed. Stopping and restarting 9.1 Stopping 9.1.1 Motor Step A: Switch off motor of the operating pump. Attend to even and smooth slowing-down of the pump. 9.1.2 Reversing valve casing The non-return valves and stop valves in the reversing valve casing remain open. Language UK Page 15/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES 9.2 Restarting After proper initial operation, the pumps are ready for operation at any time and can be started without filling. 9.3 Measures in case of prolonged interruption If a prolonged interruption is projected, the pumps must be drained as described below. Step A: The screw plug (222) must be removed from the draining bore. Draining of the filter is effected after loosening of the screw plug (235). Step B: Thereafter, the pumps must be preserved (please refer to section 4). Note: After the screw plug (222) has been turned out, the adjusting screw (333) of the pressure-relief valve must be turned out for drainage. Previously, by means of a depth gauge, the thread reach of the adjusting screw (333) in the pump casing (1) must be recorded. When screwing the adjusting screw (333) in again, this thread reach must be considered in order to reach the response pressure of the pressure-relief valve again (normally 10% above the operating pressure). 10 Control of operation and maintenance Regular control and maintenance works performed at the twin aggregate will extend the service life. The below-listed details apply in general. 10.1 General control • The pumps must not run dry. • The driving motors must not be overloaded. • Check suction and pressure pipelines for tightness. The admission of air into the delivery system must be avoided. • The mechanical seal must not be heavily leaking. • Pressure and temperature monitoring instruments must be observed. 10.2 Control of components Item numbers mentioned in this section refer to the sectional drawings of the SPZ pump in Figure 1 and Figure 2. 10.2.1 Bearing and lubrication Bearing of the driving spindle of each pump is by means of a maintenance-free sliding bearing lubricated by the fluid pumped. Language UK Page 16/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES Under normal operating conditions, the service life of the sliding bearing corresponds to the lifetime of the screw pump. It depends on the degree of contamination of the fluid to be handled. 10.2.2 Check couplings At regular intervals, the couplings must be checked for wear. A worn-out coupling must be replaced. 10.2.3 Shaft seal Each pump is equipped with a maintenance-free mechanical seal of the unbalanced type whose mode of operation corresponds to the requested operating conditions. A minimum functional leakage in case of non-volatile fluids such as oils must in principle be expected. In case of heavy leakage due to wear, the mechanical seal must be replaced. Attention: As dry operation of the mechanical seal must be avoided, the pumps may be started in a filled and vented condition only. 10.2.4 Pressure-relief valve The pressure-relief valves of the two pumps must temporarily, especially after prolonged idle times, be checked for workability and function. Leaky pressure-relief valves may result in damages to the pump. If necessary, damaged parts must be exchanged or replaced. The pressure-relief valves of both pumps were set to the opening pressure requested by the customer (normally 10% above the operating pressure). If the opening pressure is to be changed then: Step A: The screw plug (222) in the pump cover, non-drive side (4) and/or in the filter casing (9) must firstb e removed. Thereafter, the adjusting screw (333) is accessible. Step B: Clockwise rotation increases, anti-clockwise rotation decreases the opening pressure. Re-adjustment should be effected with a perfect manometer only. 10.2.5 Filtering The twin aggregates of series SPZ...R..G8.3F have attached filters. The filter casing (9) is equipped with a mano/vacuum-meter (361) displaying the pressure behind the filter (481). The pressure loss suggests the degree of filter contamination. For an exact determination of the differential pressure, it is recommended to install a manometer in the front of each filter at the suction flange of the pumps or in the suction and/or supply pipeline. In case of noticeable differential pressure, the filter (481) must be cleaned or replaced. Step A: Before the filter of a pump can be cleaned, it must be switched over to the stand-by pump. Thereafter, the lockable non-return valve (356) and the stop valve (355) of the pump at rest are to be closed. Language UK Page 17/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES Step B: Filter cleaning is effected in that the filter (481) is removed from the filter casing (9), cleaned, and the dirt particles deposited at the filter casing bottom are flushed out. Step C: After the hexagon screws (207) have been slackened, the (filter) casing cover (7) can be removed and the filter (481) dismounted from the filter casing (9). Step D: Draining of the filter casing (9) is possible via the screw plug (235). For these purposes, use collecting tank. For cleaning and for dissolving any encrustations, the filter can be put into an appropriate tank and placed into a cleansing agent, however, the container may be submerged in the fluid only to the upper brim as otherwise, the dissolved dirt would get onto the clean side. Step E: After draining, blow filter off with compressed air from the clean side to the dirty side (from the inside to the outside, not the other way round!). Appropriate cleansing agents are benzene, benzine, Diesel fuel or a solvent-free cold cleaner. Other special cleansing agents may be used with the concentration depending on the kind and thickness of the dirt deposits to be removed. A soft brush may service as a cleansing tool. Do not use sharp objects. In case of excessive contamination, it is recommended to replace the filter (481) at certain intervals. StepF: After cleaning the filter (481) is loosely mounted on the pipe (30) in the filter casing bottom. Step G: The (filter) casing cover (7) is fixed to the filtercasin g (9) again. Note: The O-ring (119) must lie in its groove and not be damaged. Replace, if necessary. Step H: The (filter) casing cover (7) must be closed air tight, so that the pump may not draw in any air. Step I: The non-return valve (356) and the stop vale (355) are to be opened again. Step J: In case of supply pressure, the filter casing (9) must be vented via the screw plug (223) for re-starting the pump (please refer to section 9). 11 Troubles, causes and remedial action The screw pumps operate without trouble, provided they are properly mounted and the fluid to be pumped and the operating conditions correspond to the right values listed under section 1. Language UK Page 18/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES 11.1 Troubles and causes By means of the table below, the cause of troubles, if any, can be determined. In case of troubles not listed herein or if they cannot be traced back to any of the causes listed, it is recommend to check with Aalborg Industries. I Trouble and cause scheme Trouble Cause Action nos. Pump does not deliver Wrong sense of pump rotation 1 Pump without fluid to be handled 2 Stop valves closed 6 Pump is not vented No venting facility 7 Pump operates at minimum output Suction pipeline leaky 3 Filter clogged 12 Pump operates noisily Suction pipeline leaky 3 Geod. suction height to great 4 Air inclusions in the fluid pumped 8 Suction pipeline resistance to great 5 Filter clogged 12 Motor gets warm Power consumption of motor too great 9 Pump is seized Liquid level in tank too low 10 Viscosity too low, pressure too high 11 Filter clogged 12 Table 3 11.2 Measures to be taken for clearing the troubles The table below shows a list of measures to be taken for clearing the troubles. Measures scheme \ction nos. Measures 1 Change any two phases at the motor. 2 Fill pump with fluid to be handled. 3 Retighten flange joints, replace gaskets, if necessary. 4 Raise liquid level in tank. Lower pump. 5 Reduce suction pipeline resistance, e.g. by a greater pipeline cross-section and/or a design providing a more favourable flow. 6 During operation, the stop valves / gate valves / non-return valves in the pipeline and at the reversing valve casing must be completely open. 7 Mount vent valve in pressure pipeline. 8 • Attend to better air separation in tank. 9 Check speed and power consumption of the motor. Compare voltage and frequency with the motor type plate. 10 Dismount pump and check for wear. Fill tank. Replace set of spindles and rotor housing. Replace other parts as required. 11 Dismount pump and/or have pump overhauled at the works. 12 Clean and/or replace filter insert. Table 4 Language UK Page 19/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES 12 Dismounting and mounting instructions 12.1 General The most important dismounting and mounting operations are described in these instructions. The mounting steps described in the individual sections must be consistently observed. Item numbers mentioned in this section refer to the sectional drawings of the SPZ pump in Figure 1 and Figure 2. 12.2 Dismounting of screw pump Prior to commencing the dismounting, the following operations must be performed. Step A: Close non-return valve and stop valve of the pump to be dismounted, and switch over to the stand-by pump. With the stand-by pump, the operation can be maintained without any troubles. Step B: Pinch off power supply cable to the motor of the pump to be dismounted. Motor must not be capable of being started. Step C: Drain fluid to be pumped in flowable condition from the pump. For these purposes, turn out screw plugs for draining. Note: Use collecting tank. Step D: Let screw pump cool down to ambient temperature. Step E: Dismount manometer lines, manometer and holding device fromth e pump. 12.2.2 Dismounting of a screw pump from the twin aggregate Step A: Loosen socket-head cap screws (215) at the pump bracket (460), and screw out. Step B: Loosen hexagon nuts (236) and (238) at the suction and pressure flange, and unscrew. Step C: Remove socket-head cap screws (206) and (208). Step D: Withdraw pump from the centre bore of the pump bracket (460) and remove fromth e reversing valve casing (301). Step E: Remove gaskets (125) and (126), and clean sealing surfaces. Language UK Page 20/24 •••••#• AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES 12.2.3 Dismounting of the shaft seal G 83 Step A: Withdraw coupling half from the driving spindle (12). Use detaching device. Step B: Remove key (290) from the driving spindle (12). Step C: Loosen socket-head cap screws (200) at the pump cover, drive side (3), and screw out. StepD: Dismount pump cover, drive side (3) with stationary seal ring (186) over the driving spindle (12) from the pump casing (1). Step E: Dismount circlip (250) from the pump cover, drive side (3). Step F: By means of an auxiliary tool, dismount stationary seal ring (186) and O- ring from the pump cover, drive side (3). Note: Particularly see to it that the stationary seal ring is pressed out concentrically to avoid any damages. Step G: Remove rotating part of the mechanical seal (186), consisting of rotating seal ring, O- ring, and spring fromth e driving spindle (12). 12.2.4 Dismounting of the sliding bearing (bearing ring) with set of spindles Step A: Dismount supporting washer (263) from the driving spindle (12). Step B: Pull set of spindles with bearing ring (10) out of the pump casing insert (2). Step C: Remove both idler spindles (13) from the driving spindle (12). Step D: Remove bearing ring (10) from the driving spindle (12). Step E: Loosen socket-head cap screws (201) at the pump cover, non-drive side (4) and filter casing (9), and screw out. Step F: Withdraw pump cover, non-drive side (4) and/or filter casing (9) from the pump casing (1). Step G: Remove gasket (100) and clean sealing surfaces. Step H: Screw out socket-head cap screw (24) laterally at the pump casing (1). Note: This socket-head cap screw serves to fix the pump casing insert (2) in the pump casing (1). Language UK Page 21/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES Step I: By means of an appropriate tool, press pump casing insert (2) from the pump non-drive side out of the pump casing (1). In case of pumps with filter, previously remove pipe (29) from the pump casing (1). 12.3 Mounting of the screw pump 12.3.1 Mounting of the slide bearing (bearing ring) with set of spindles Step A: Slightly oil the locating surfaces at the pump casing insert (2). Step B: By means of an appropriate tool, press the pump casing insert (2) from the drive side into the pump casing (1). Note: The bore holes for the idler spindles must be arranged vertically and symmetrically in the pump casing. That means the location of the upper bore must form a vertical axis with the suction and outlet branch in the pump casing. Step C: Via the lateral bore hole for the socket-head cap screw (24), pin pump casing (1) together with the pump casing insert (2). Bore diameter: 4 mm. Bore depth: 6 mm. StepD: Screw socket-head cap screw (24) with sealing washer (151) laterally into the pump casing (1), and tighten. Step E: Push bearing ring (10) over the driving spindle (12) against the collar. StepF: Slightly oil driving spindle (12) and, together with the bearing ring (10), press into the pump casing (1) from the drive side. Note: The driving spindle is concentrically guided through the bearing ring in the pump casing. Step G: Insert new joint tape (165) between the bearing ring (10) and the pump casing (1). Note: Slight oiling facilitates mounting. Step H: Turn both idler spindles (13) from the pump end side into the pump casing insert (2). Step I: In case of pumps with filter, install pipe (29) in the pump casing (1). Step J: Place new gasket (100) onto the pump casing (1). Language UK Page 22/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES Step K: Fix the pump cover, non-drive side (4) and filter casing (9) with the socket- head cap screws (201) to the pump casing (1). Step L: Place supporting washer (263) in front of the collar of the driving spindle (12). 12.3.2 Mounting of the shaft seal G 8.3 Note: Mechanical seals are high-quality precision parts. Careful handling and extreme cleanliness during mounting are a condition of proper functioning. To facilitate mounting, a suitable lubricant must be used (e.g. oil, no grease). Step A: Push rotating part of the mechanical seal (186) consisting of rotating seal ring, O-ring and spring onto the driving spindle (12) in front of the supporting washer (263). StepB: Press stationary seal ring (186) with new O-ring into the cleaned pump cover, drive side (3). Apply appropriate auxiliary tool. Note: In particular see to it that the rotating seal is concentrically pressed into the delivery casing and not canted to avoid any damages. Step C: Insert new O-ring (122) in front of the return bore hole into the pump casing (1). Step D: Fix pump cover, drive side (3) with new O-ring (120) and pressed-in stationary seal ring (186) with the socket-head cap screws (200) to the pump casing (1). Note: In doing so, the joint tape (165) is pressed into its end position. Step E: Install circlip (250) in the pump cover, drive side (3). Step F: Insert key (290) in the driving spindle (12). Step G: Mount coupling half on the driving spindle (12). Use mounting device! 12.3.3 Mounting of a screw pump into the twin aggregate Step A: Place gasket (125) onto the pressure flange and gasket (126) onto the suction flange. Language UK Page 23/24 AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2 INDUSTRIES Note: To facilitate mounting, we recommend to coat the gaskets with a suitable adhesive. Step B: Push pump into the centre bore of the pump bracket (460). Step C: Fasten pump with the socket-head cap screws (206) and (208) and the hexagon nuts (236) and (238) to the reversing valve casing (301). StepD: Fasten pump with the socket-head cap screws (215) to the pump bracket (460). Following the installation of the pump in the twin aggregate, the following operations are to be performed: Step E: Attach manometer lines, manometer and holding devices to the pump. Step F: Connect power supply cable to the motor. See to sense of rotation. Step G: Prior to re-starting, fill pump with the fluid to be handled. 13 Spare parts Parts marked (2) and/or (3) in the parts list, see Figure 1 and Figure 2, are provided as spare parts. Driving spindle (12) and idler spindles (13) are supplied as spare parts as complete sets of spindles only. Language UK Page 24/24 AALBORG gBjaiaaaaamasns^^^^^w INDUSTRIES ^m^igg^g^^giiimi^^gm^^^^mi^^^ Table of contents Heat exchanger Technical data for heat exchanger General data 1 Data for heat exchanger 2 Heat exchanger General description 1 Operation 2 Maintenance and cleaning 3 Data sheets for heat exchanger Dimension drawing 1 Spare parts 2 Language UK Page 1/1 AALBORG TECHNICAL DATA FOR HEAT EXCHANGER SD9010#16.1 INDUSTRIES Technical data for heat exchanger General data Project No.: 736950,736952 Hull Ne/Project name: 03130007,03130008 Classification society/Local authority: LRS Pressure gauge calibration: MPa Thermometer calibration: °C Language for signs: UK Colour of heat exchanger unit: Heat resistant Silver RAL 9006 Data for heat exchanger Heat exchanger type: MX15 T32 Number of heaters: 1 Fuel oil capacity: 1663 1/h Design pressure (oil side): 1.9 MPa Design temperature (oil side): 165°C Fuel oil inlet temperature: 50°C Fuel oil outlet temperature: 145°C Steam consumption: 131 kg/h Design pressure (steam side): 3.2 MPa Design temperature (steam side): 212°C Min. steam working pressure: 0.7 MPa Max. steam working pressure: 0.9 MPa Steam inlet temperature: 165°C Steam/condensate outlet temperature: 165°C Weight of heat exchanger unit: 150 kg Language UK Page 1/1 AALBORG HEAT-EXCHANGER OM8640#01.0 INDUSTRIES Heat-exchanger General description This chapter describes the operation and the maintenance of the heat-exchanger. An illustration of the heat-exchanger is shown in Figure 1. The heat-exchanger is of the shell and tube type with u-bent tubes. The heat-exchanger has been hydrostatically tested before delivery. The heat- exchanger is type approved by all major classification societies. Illustration of the heat-exchanger - Socket for safety valve Steam inlet Oil outlet - Socket for air screw i ' i ' i Insulation Steam outlet Oil inlet Figure 1 heatexcl.cdr Operation Before proceeding with start-up of the heat-exchanger make sure that all connections to the heat-exchanger are securely tightened. Start-up of the heat-exchanger: Step A: Adjust the safety valve to the maximum design pressure. The safety valve can be set to a lower set point. Step B: Fill the heat-exchanger with oil. Step C: Ventilate the heat-exchanger. Make sure that the heat-exchanger and all connecting pipes are completely free of air. Step D: Remember to tighten the air ventilation plug after ventilation. Step E: Establish oil flow through the heat-exchanger. Language UK Page 1/3 AALBORG HEAT-EXCHANGER OM8640#01.0 INDUSTRIES Step F: Establish steam flow through the heat-exchanger. Step G: Operate the heater for approximately one hour. Step H: Stop the heat-exchanger by closing the steam inlet valve. Note: When the heat-exchanger is stopped, it is very important to maintain the oil flow through the heat-exchanger for at least ten minutes in order to remove the accumulated energy in the heating elements. It is also important to make arrangements to ensure oil flow through the heat- exchanger during emergency stops of the heat-exchanger. Step I: Stop the oil flow after ten minutes and tighten all screws again. To obtain the full output of the heat-exchanger, it must be supplied with dry saturated steam at the correct pressure. The steam pressure appears from the section "Technical data". It is important that the condensate system has a suitable outlay and that a correct type of steam trap is used to secure against the negative effect of counter pressure. Maintenance and cleaning The heat-exchanger should be cleaned every six month and in the event of a drop in the output which is not related to other causes. Step A: Stop the heat-exchanger as mentioned above. Step B: Empty the heat-exchanger. Step C: Remove the tube insert. Step D: Check for deposits inside and outside the tube insert. Step E: The outside tube system should be cleaned by using a sharp liquid jet (use e.g. citric acid or water). Step F: The inside tube system should be cleaned by flushing the tubes with e.g. citric acid. Step G: If the heat-exchanger is heavily contaminated with carbon deposits, it is recommended to chemically clean the heat-exchanger with a carbon remover. Step H: The heat-exchanger must be flushed carefully with clean water and dried after the tubes have been cleaned. Step I: After the tube insert has been replaced, the bolts must be securely fastened and the heat-exchanger checked for leaks. Step J: Once every year the set point of the safety valve must be checked. Language UK Page 2/3 AALBORG HEAT-EXCHANGER OM8640#01.0 INDUSTRIES 3.2 Dismantling and installation of the tube section The tube section is inserted into the heater and fastened tightly between the shell flange and the end flange. The back end of the tube section is free to move. The steam connections must be dismantled before dismantling the tube section for inspection, cleaning, etc. The tube flange has threaded holes for dismantling screws and for mounting eye bolts for lifting device. Packing surfaces should be cleaned and protected against damages. A new packing must be mounted every time the flange connection has been dismantled. When the flange connection is mounted again, all bolts should be tightened evenly and crosswise. A pressure test will show if the joint leaks. Operate the heat-exchanger for one hour, stop and tighten all screws. 3.3 Conservation during shut-down periods Corrosion which occurs in shut-down periods is mainly caused by oxygen. The corrosion appears where non-distilled or even slightly alkaline water has remained in the heat-exchanger. However, even when empty, the heat-exchanger is exposed to corrosion caused by water residues or condensation. For this reason an unused heat- exchanger should be given an anti-corrosion treatment. In the event of prolonged off-cycle periods - in particular during winter time with frost - the heat-exchanger must be carefully emptied. Open the air valve and check for clogging. 3.4 Spare parts When spare parts are ordered, please state the serial No. (See the name plate of the heat-exchanger). For spare parts and further information please contact Aalborg Industries. Language UK Page 3/3 I li n li i H j^^^t I Drawn \ Appr. 1100 975 448 450 250 250 150 125 I . I , I 1/2- BSP 1/2" BSP m z T Ë "\ J- 1-^ -J——g_ i 1/2"BSP 1/2" BSP -+ Dimension (length of tubes) 1200 mm Design pressure shellside 32 bar/195°C Design pressure tubeside 19bar/212°C Test pressure shellside 51.5 bar Test pressure tubeside 28,5 bar Volume on the shellside 0,01692 m3 Volume on the tubeside 0,00624 m3 A/B shellside in- and outlet DN 25/25 Flanges ace. to DS/EN 1092-1 (DIN 2635) C/D tubeside in- and outlet DN 20/20 Flanges ace. to DS/EN 1092-1 (DIN 2635) Heat Exchanger MX15 T32 L=1200 3015120 Desl nation Material code Article no. Item 9 Pes. Cert Dimension Material type Detail drawing no. Remarks: The minimum withdrawal length of heater insert, is: length of tubes + shell diameter. Foundation details Order number No. of heaters: Classification: Painting: Insulation: 1 LRS Heat resistant silver Yes Heater weight Boiler Data 150 kg pr. heater Scale Project Dept HEAT EXCHANGER 3200 1 : TYPE VESTA™ MX15 T32 Drawn Date Size Withdrawal length Dimension Drawing Mdu 09-02-2004 A2 AALBORG Approved Date No. INDUSTRIES The tolérance dass In accordance with ISO 2768-1 c 15 K 4555 | Tolaranceklasse Ifølge OS/ISO 2768-1 c This Drawing and Design shown herein, is the property of Aalborg Industries AÆ, and must not be used or reproduced for third party. Description Index Date Drawn Appr. Type number changed 250900 JBL Drawing opdated 30-04-04 MDu Option 5. Tube Insert 1. Safety valve 87S0038 - 4 Bar / 0,4 Mpa Ref. serial No. 87S0020 - 5 Bar / 0,5 Mpa 87S0029 - 7 Bar / 0,7 Mpa 6. In- and outlet flange gaskets 8750042 - 9 Bar / 0,9 Mpa 8750043 - 12 Bar /1,2Mpa 8913005 (00 0660 042) DN 32 13,5 Bar /1,35 Mpa 8750040 - 8913006 (00 0660 048) DN 40 8750041 - 32 Bar / 3,2 Mpa 8913007 (00 0660 060) DN 50 2 2. Manometer triple scale (Bar+Mpa+Kg/cm ) 8913008 (00 0660 076) DN 65 6633118 - -1 - +5 Bar / -0,1 - +0,5 Mpa 6633119 0-10 Bar/0-1,0 Mpa 8913009 (00 0660 089) DN 80 6633120 0-16 Bar/0-1,6 Mpa 6633121 0-25 Bar/0-2,5 Mpa 6633122 0-40 Bar / 0-4,0 Mpa 7. Steam and condens flange gaskets 3. Thermometer Straight/Angle 6633008/88T0012 0-120° 8913002 (00 0660 027) DN 20 6633004/88T0001 0-160° 8913003 (00 0660 034) DN 25 88T0003/62T4001 0-200° 88T0007/88T0004 0-300° 8913005 (00 0660 042) DN 32 8913006 (00 0660 048) DN 40 4. Flange gaskets Ref. serial No. Please state the serial number when ordering spare parts. Project Boiler data Scale HEAT EXCHANGER Weight kg. Dept. ••••••< 1:15 Type MX tUttiib Drawn Date Size AALBORG JBL 25.09.2000 A4R Spare parts INDUSTRIES Approved Date No. MT 25.09.2000 15 14003 B This Drawing and Design shown herein, is the property of Aalborg Industries A/S, and must not be used or reproduced for third party ^,
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