Hydro Instruments VPH-10000-1 Series Instruction And Operation Manual Download Page 29

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V. TROUBLESHOOTING:

Refer to Table 5 for common problems and troubleshooting techniques for the vaporizer system. For
questions please consult Hydro Instruments.

TABLE 6: Troubleshooting Chart

Problem

Probable Cause(s)

Corrective Action

• Liquid chlorine in

vacuum piping

• Damaged vacuum

piping and equipment
(vacuum regulator)

• Demand has exceeded design capacity

• Heater power has been reduced

• Fouling of pressure chamber

• Faulty chlorine temperature or pressure

sensor did not allow PRV to close

• Supply pressure too high

• Low water temperature/level and

failed switches

• By-pass piping through PRV is open

• Lower capacity to within design fl ow

rate

• Check all 3 phase power components,

terminals, etc. Tighten and check all
terminals of 3 phase power wiring

• Clean inside and outside of chlorine

pressure chamber (follow appropriate
shut down and cleaning procedures)

• Reduce cylinder pressure

• Check and replace equipment

• Check that by-pass piping is not open

• High pressure in

chlorine pressure
chamber

• Inlet chemical pressure is too high

• Valves closed before and after

vaporizer

• Blockage in supply line

• Lower the room temperature or

decrease the amount of gas padding.

• Open the supply valves

• Evacuate and shut down system.

Clean/replace piping

• Leaking chlorine

through pressure relief
valve (pressure switch
activated)

• Rupture disc has burst due to

overpressure

• Follow long term shutdown to

evacuate chemical. Replace rupture
disc

• Pressure switch

activated from
expansion chamber
assembly

• High pressure in

liquid pipeline

• Rupture disc has burst due to

entrapment of liquid chlorine

• Follow the long term shut down

procedure and replace the broken
rupture disc

• High water

temperature

• Failed/improperly wired temperature

control circuit

• Failed/improperly wired heater

• Check wiring. Replace equipment if

correct

Summary of Contents for VPH-10000-1 Series

Page 1: ...1 Series VPH 10000 1 Vaporizer Instruction and Operation Manual VPH 10000 1 Rev 9 11 19 ...

Page 2: ...System Shut Down 1 Short Term Shut Down 2 Long Term Shut Down 5 Navigating the Controller 1 Explanation of Main Controller Screens 6 Operating Controls and Components 1 Chlorine Gas Temperature Thermocouple 2 Chlorine Gas Pressure Transmitter 3 Water Tank Temperature 4 Water Level Control 5 Water Refill Solenoid 6 Cathodic Protection System 7 Water Heater 7 Alarms and Features IV Maintenance 25 1 ...

Page 3: ...ke all necessary precautions when handling This manual is not intended to replace or limit safety procedures in your facility Safety procedures must be designed in accordance with all governmental regulations and national safety codes after giving full consideration to the specific needs of the facility involved Under no circumstances should the information in this manual be construed as substitut...

Page 4: ...arance space required 24 61 cm on all sides 12 3 7 m floor to ceiling Chlorine pressure chamber dry weight roughly 360 lb 163 kg Water tank dry weight roughly 430 lb 195 kg Total assembled dry weight roughly 790 lb 358 kg Rated working pressure 560 psi 38 6 bar hydrostatically tested to 825 psi 56 9 bar Supply pressure 38 210 psi 2 6 14 5 bar Cl2 and SO2 48 210 psi 3 3 14 5 bar NH3 Maximum capacit...

Page 5: ...and the chlorine gas outlet port is off center For added convenience the ports are also stamped IN for the liquid inlet and OUT for the gas outlet 2 Installation of Chlorine Pressure Piping Connections to the vaporizer are made through the use of 1 ammonia type unions Chlorine pressure piping should be made of seamless schedule 80 carbon steel and fittings must be 3000 lb forged type For more info...

Page 6: ... The pressure relief valve assembly also includes a pressure switch that may be wired into the signal output connections box of the vaporizer for Modbus indication of rupture disc failure It will be wired into the V and DI4 input terminals 3 3 Expansion Chamber Assembly The expansion chamber assembly is a mechanical safety device used on liquid chemical lines to prevent pipe rupture in the event o...

Page 7: ...he ground block The three phase power is for the heater which is a delta wiring arrangement and thus no neutral wire is needed f Close the heater control box and insert screws g Connect power to main source h Ensure that the manual contactor override switch is in the enable position i Turn the single phase and three phase disconnect switches on 4 2 Wiring Relays and Alarm Outputs Warning Electrica...

Page 8: ...ommunicate with a SCADA system using Modbus RS 485 communication The baud rate node number and data format of the VPH 10000 1 must match that of the master SCADA system See Section III 5 for information on how to access and edit these features A table of Modbus integers and their corresponding parameters can be seen in Table 3 For more information on configuring Hydro Instruments equipment onto SC...

Page 9: ...Point Integer 9 Low Temperature Alarm Set Point Integer 10 Aux Water Temperature Integer 11 Water Level Integer 12 0 Normal 1 High 2 Low 3 Low Low Heater Power Output kW Integer 13 Heater Power Output Integer 14 Heater Element Temperature Integer 15 Temperature Units Integer 16 0 Celsius 1 Fahrenheit Pressure Units Integer 17 0 PSI 1 Bar Alarm Status Integer 18 0 Normal 2 Low Water Temperature 3 H...

Page 10: ...ZER MAIN CONTROLLER AC Power Inlet Micro SD Card Slot 24VDC Power Output Modbus Terminals V A B V Power Supply Board MB220 Display Board Ribbon Cable from Membrane Switch Water Level Controller Terminal Block Ribbon Cable from MB220 Circuit Boards Two Levels See Figure 3 Main Controller Wiring ...

Page 11: ...porizer Controller Conduit Port at Right Wall Conduit Port at Left Wall Conduit Port at Bottom 4 20mA Signal from Vaporizer Controller to SCR Fuse Terminal Block Connections 2T1 4T2 6T3 1L1 3L2 5L3 1 2 3 GND 4 5 6 1 3 5 2 4 6 Toggle Switch Transformer 1 2 3 4 5 6 6 5 4 3 2 1 7 8 8 7 3 Phase Primary Power Supplied By User 3 Phase Power to Heater Transformer and Toggle Switch Wiring Varies for Other...

Page 12: ... Wiring 72 9 6 1625 72 7 5 21752 2 72 6 7 502 283 72 7 502 283 81 7 21 2 72 225 32 5 6833 72 5 211 7 216 2 7 9 21 8 725 5 72 6 1 211 7 216 2 72 225 63 2 5 72 35 6685 6 1625 72 7 5 21752 2 7 5 21752 72 225 63 2 5 72 5 211 7 216 2 ...

Page 13: ...13 FIGURE 4A Relay Connections Box ...

Page 14: ...14 FIGURE 4B Signal Connections Box ...

Page 15: ...15 FIGURE 5 Vaporizer Controller KEd dKZ E dKZ d dh KE с E Z Ϳ D Eh KEd dKZ Ks ZZ t d Z s E dKZ d K WZKd d KE KEdZK Θ DD d Z D E KEdZK Z d Z KEdZK Ky WZ D Zz WKt Z dK t d ...

Page 16: ...ately purged pressurize the piping to 150 psi 10 bar using dry air or nitrogen Then close the air or nitrogen supply valve and record the pressure reading Watch to ensure that the pressure reading does not drop Any drop in pressure indicates the presence of a leak that must be identified and corrected before proceeding further f Check the entire manifold for leaks using soapy water all the way up ...

Page 17: ...mmeter Operating current should be between 50 250 mA Add lb 113 g of sodium sulphate to increase the conductivity if the requirement cannot be met NOTE Due to the enamel painting of the chlorine pressure chamber a low no current reading may appear during the first 6 months of operation This is normal and the vaporizer is still being protected g Connect the manifold to the chlorine container gas va...

Page 18: ...se the isolation valves and connect the manifold to the liquid chlorine container valves d Close all valves in the manifold pipeline Open the isolation valves and slowly open the liquid chlorine container valves and introduce liquid chlorine into the manifold piping e Open the remaining valves one by one until they are all open f Operate the vaporizer at 25 of full scale until equilibrium has been...

Page 19: ...Close the isolation valves f Once established that all the chlorine is evacuated pressure readings hold at zero disconnect all power to the vaporizer Switch to the stand by unit if necessary g Open the drain valve to allow the water in the water tank to drain Warning The water and vaporizer components equipment will be very hot 180 F 82 C so be careful when handling and or give the water time to c...

Page 20: ...eat Alm Type Non latching Select PRV on Duty PRV 1 Relay1 Modbus Baud 250000 Node 1 Data 8 N 1 Cl2 Pressure Span 300 psi T180 S 180 O 50 E00 G 3 0 I 1 0 LT 5 Heater Sheath Temp 300 F Enabled Select Gas Type Cl2 1 2 15 14 13 12 11 10 9 8 7 6 5 4 3 18 17 16 These menus are referred to as hidden screens and are not visible under normal operation To access these screens go to screen 14 and with the no...

Page 21: ...he password for the VPH 10000 1 is 100 and can be entered using the and keys Once the correct password is blinking the user may press the key to access the remaining screens 8 Vaporizer Units This screen allows the user to adjust the operating units used Temperature values can be displayed in either degrees Fahrenheit F or in degrees Celsius C Pressure values can be displayed in either psig psi or...

Page 22: ... adjusted on this screen to match the incoming 4 20 mA signal Consult Hydro Instruments before changing pressure ranges or pressure transmitters 16 PID Control Setting This screen displays and allows the user to adjust the PID control settings of the vaporizer The user can adjust the control water temperature set point S the gain G the integral I and the lag time LT Live values are also displayed ...

Page 23: ...on with the water refill solenoid to open or close the solenoid and maintain the water level For manual control there is a clear glass sight tube on the front panel for the user to determine the operating level When the sight glass is below 1 3 full water should be added When the water is above 2 3 full water should be stopped Water may be manually refilled using the 3 through hole on the collar p...

Page 24: ...r Temp The water temperature is above the alarm value Water heater is shut off until water temperature is below the alarm value Low Water Level Water height is below the minimum operating level Shut off heater and pressure reducing valve Open water solenoid until desired water level is achieved Water Overfill The water level is too close to the tank s ceiling None Action must be taken by user See ...

Page 25: ...the pressure chamber Using a flashlight inspect the lead gasket seal areas and the interior of the inner chlorine pressure chamber for corrosion and residue If signs of corrosion exist proceed to Section IV 2 g Using water or appropriate cleaner purge the internal surfaces of the inner chlorine pressure chamber until all residue has been removed A 2 000 PSI water pressure washer can be used to cle...

Page 26: ...relief and expansion chamber assemblies b Apply air pressure at approximately 50 100 psi 3 7 bar to each pressure switch to verify operation c Replace any pressure switches that fail this testing d Install tested pressure switches back into each assembly using an appropriate thread sealant Chlorine Gas High Pressure Alarm Testing a Remove the pressure transmitter assembly with diaphragm protector ...

Page 27: ...Place the thermocouple in the nearly boiling water approximately 210ºF 99ºC to verify that the high water temperature alarm will activate d Reinstall the thermocouple onto the water tank flange Superheat Alarm Testing The superheat alarm can be tested by placing the chlorine gas temperature probe in ice water during the pressure switch alarm testing Cathodic Protection Testing At the top of the wa...

Page 28: ...lorine have passed through a Complete Section IV 1 1 chlorine pressure chamber cleaning perform steps a through h only b Weigh the inner chlorine chamber assembly less the process instrumentation water tank bolts anodes and fittings and inlet outlet pipe and record the weight c If the weight of the inner pressure chamber is 10 or more pounds lower than the original weight or corrosion pits exceed ...

Page 29: ...amber follow appropriate shut down and cleaning procedures Reduce cylinder pressure Check and replace equipment Check that by pass piping is not open High pressure in chlorine pressure chamber Inlet chemical pressure is too high Valves closed before and after vaporizer Blockage in supply line Lower the room temperature or decrease the amount of gas padding Open the supply valves Evacuate and shut ...

Page 30: ... above operating set point Solenoid failed open Solenoid is stuck open Clean or replace Replace water level control circuitry Electronic PRV is closed while trying to chlorinate No power to the actuator Alarm condition exists Actuator failed Restore power to unit Check operating parameter and adjust improper conditions Inspect and replace actuator No cathodic protection Insufficient conductivity i...

Page 31: ...31 VI IMPORTANT FIGURES FIGURE 7a Vaporizer Parts Diagram ϭϰ ϭϯ ϭϮ ϭϭ ϭϬ ϮϮ Ϯϴ Ϯϳ Ϯϵ Ϯϯ ϴ ϮϬ ϭϵ Ϯϭ Ϯϱ ϭϴ Ϯϲ ϭϱ ϭϲ ϭϳ ϳ ϴ Ϯ ϭ ϯ ϰ ϱ ϲ Ϯϯ Ϯϰ Ϯϱ ϭϴ ϭϴ ϴ ϵ ϮϬ ϭϵ ...

Page 32: ...1 13 VPH 10000 LE Lifting eyebolts 2 14 VPH 10000 001 Pressure chamber flange gasket 1 15 VPH 10000 003 Level sensor mounting assembly 1 16 VPH 10000 LP Water level sensor 1 17 VPH 10000 PP 3 View port cap 1 18 VPH 10000 TC K H2O Water bath thermocouple Type K 2 19 VPH 10000 H 480 480 VAC 3 Ph Heater 18 kW 1 19 VPH 10000 H 240 240 VAC 3 Ph Heater 18 kW 1 20 VPH 10000 H 001 Heater insulation chambe...

Page 33: ...ϰϱ ϵ ϭϲ Η ϭϭϱϴ D E hD EK Θ WdKZ ϰ W Ϳ d DW Z dhZ d ZDK KhW t d Z s WZK ϰ Wd Ϳ ϱΗ ϭϮϳ ϳϭ ϱ ϭϲ Η ϭϴϭϮ ϮϮΗ ϱϱϵ ϭϲ ϭ ϰ Η ϰϭϯ ϭϳ ϱ ϭϲ Η ϰϰϬ Ϯϭ ϯ ϰ Η ϱϱϮ ϱϱ ϯ ϴ Η ϭϰϬϳ ϭϴ t d Z d D Khd d ϱϲ ϯ ϴ Η ϭϰϯϮ ϲϰ ϭϱ ϭϲ Η ϭϲϰϵ Ϯ ϱ ϴ Η ϲϳ Ϯ ϭϭ ϭϲ Η ϲϴ ϯ ϯ ϰ Η ϵϱ ϱΗ ϭϮϳ ϭ ϮΗ EWd K EK t d Z E dͿ ϭ ϭ ϮΗ EWd Z E t d Z Z EͿ Yh E d ϭΗ DDKE dzW hE KE Khd d ϭΗ DDKE dzW hE KE ϭ ϭ ϰΗ EWd Ks Z Kt t d ZͿ E d ϭϬϯ ϭ ϭϲ Η Ϯϲϭϵ Z...

Page 34: ...34 FIGURE 9 Chlorine Vapor Pressure Curve Vapor Pressure ...

Page 35: ...35 FIGURE 10 Sulfur Dioxide Vapor Pressure Curve Vapor Pressure Min Superheat ...

Page 36: ...36 FIGURE 11 Ammonia Vapor Pressure Curve Vapor Pressure Min Superheat ...

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