Spirax Sarco BPS32 Installation And Maintenance Instructions Manual Download Page 3

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IM-P537-01

EMM Issue 1

Pressurised Thermophysical deaerator with operator manual for the control unit

5. Operation

5.1

Operation

5.2

Control unit

5.3

Operator panel

5.4

STATUS

5.5

Alarms and locks

5.6

Graph

5.7

Ramp

5.8

Settings

6. Troubleshooting

7. Maintenance

7.1

General information

7.2

Replacement parts

7.3

Appendix A

7.4

Recommended inspections

7.5

Scheduled Spirax Sarco maintenance

Summary of Contents for BPS32

Page 1: ...ysical deaerator with operator manual for the control unit Copyright 2021 Printed in GB 3 635 5275 275 Pressurised Thermophysical deaerator with operator manual for the control unit Installation and Maintenance Instructions IM P537 01 EMM Issue 1 ...

Page 2: ...limits 2 6 Consumption 2 7 Dimensions and weights 16 2 8 Transport and unpacking the package unit 17 3 Installation 18 3 1 Installation environment 3 2 Handling positioning and fastening 19 3 3 Process connections and draining 24 3 4 Pneumatic section connection 25 3 5 Power supply connection 26 4 Commissioning 28 4 1 Pre commissioning inspection initial start up 4 2 Commissioning procedure 29 4 3...

Page 3: ...ion 31 5 1 Operation 5 2 Control unit 33 5 3 Operator panel 36 5 4 STATUS 47 5 5 Alarms and locks 48 5 6 Graph 50 5 7 Ramp 51 5 8 Settings 6 Troubleshooting 52 7 Maintenance 55 7 1 General information 7 2 Replacement parts 56 7 3 Appendix A 57 7 4 Recommended inspections 58 7 5 Scheduled Spirax Sarco maintenance ...

Page 4: ...ll rights reserved In accordance with the legislation in force Spirax Sarco reserves all ownership rights of this document which may not be reproduced or transferred to third parties without prior written permission Spirax Sarco also reserves the right to change product specifications without prior notice ...

Page 5: ...re insulated before performing any installation and maintenance procedure 4 Ensure that the residual pressure inside the system and connection pipes is vented to atmospheric pressure 5 To avoid the risk of burns allow all parts to cool before starting any procedure 6 Always wear adequate protective clothing before performing any installation or maintenance work 1 1 Intended use Check the Installat...

Page 6: ... flammable materials substances hazardous to health extreme temperature 1 6 Hazardous working environments Take into account explosion hazard areas lack of oxygen e g tanks wells hazardous gases temperature limits hot surfaces fire hazard e g during welding excessive noise moving machinery 1 7 System Consider the possible effects of the planned work on the entire system Consider whether the intend...

Page 7: ...straps are needed they should be placed around the base plate to prevent damage to the unit 1 14 Freezing Care must be taken to protect from freezing damage the products that are not self draining in environments where they may be exposed to temperatures below freezing 1 15 Disposal Since the product may contain PTFE and Viton special precautions should be taken to avoid potential health hazards a...

Page 8: ...eets for any substance identified as hazardous or potentially hazardous 1 17 Working safely with cast iron products for steam lines Cast iron products are commonly found in many steam systems When installed correctly according to best engineering practices the devices are totally safe However due to its mechanical properties the cast iron is less malleable than other materials such as nodular cast...

Page 9: ...IM P537 01 EMM Issue 1 9 Pressurised Thermophysical deaerator with operator manual for the control unit Steam Mains Do s and Don ts Steam Steam Flow Flow ...

Page 10: ...r the control unit Prevention of tensile stressing Pipe misalignment Installing products or re assembling after maintenance Do not over tighten Use correct torque figures 1 1 4 2 3 8 2 6 3 7 Flange bolts should be gradually tightened across diameters to ensure even load and alignment 5 4 ...

Page 11: ...r manual for the control unit Thermal expansion Guides Guides Limit rods Limit rods Fixing point Medium distance Small lateral movement Small lateral movement Large lateral movement Large lateral movement Short distance Fixing point Axial movement Axial movement Guides Guides ...

Page 12: ...ed gases at 100 C saturation temperature at atmospheric pressure or 120 4 C at 1 bar assuming sea level conditions 2 General product information Fig 1 The PDA unit consists of the following main parts 1 Primary steam assembly 2 Thermophysical deaerator and instrumentation accessories protection safety devices 3 Make up water assembly 4 Electrical control panel For detailed parts list and specifica...

Page 13: ...M P537 01 EMM Issue 1 13 Pressurised Thermophysical deaerator with operator manual for the control unit 2 2 Product identification The product is identifiable by the nameplate fastened to the frame Fig 2 ...

Page 14: ...ve mentioned data The design conditions circuit pressure and temperature weight fluid group and device category are also specified Fig 3 Note the above mentioned nameplate refers to a CSG it is necessary to have the PDA s nameplate given by the U T 2 2 2 Labelling EC Directive Depending on the residual risks such as the risk of burns risk of electric shock and the requirements prohibitions and ins...

Page 15: ...5 Operating limits Unit without pump Unit with pump Production Clean saturated steam up to 5 bar 159 0 C Primary fluid Plant saturated steam up to 12 bar 191 7 C Feedwater P minimum P steam generation 0 5 bar P minimum NPSHR see below P maximum 8 bar T maximum 110 C Note report only Primary fluid Saturated steam maximum 12 bar g 191 7 C before pressure reduction assembly Make up water maximum 6 ba...

Page 16: ... 965 mm 3 931 mm 1 770 kg 5 270 kg PDA 08 8 000 l 4 515 mm 2 180 mm 4 316 mm 2 600 kg 8 200 kg PDA 10 10 000 l 4 892 mm 2 290 mm 4 439 mm 3 200 kg 10 200 kg PDA 12 12 000 l 5 419 mm 2 435 mm 4 966 mm 3 500 kg 11 900 kg PDA 15 15 000 l 5 469 mm 2 610 mm 5 233 mm 3 900 kg 14 400 kg Notes 1 In order to allow easy access to the unit it is recommended to leave an obstacle free zone of at least 800 mm a...

Page 17: ...Spirax Sarco deaeration systems are very bulky units and are not commonly packaged while protecting the unit during transport All units are equipped with lifting and handling eyebolts The unit must be lifted using only the areas indicated on the packing case or by using the clearly marked lifting eyebolts Improper lifting methods can damage the unit ...

Page 18: ...hould be placed on a flat surface no more than 0 5 gradient able of supporting the total unit weight when full Choose an installation site sufficiently accessible allowing subsequent visits and periodic maintenance drainage cleaning checking the good working order of all installed accessories All external circuits e g piping must be designed as to prevent from carrying electric charge to the packa...

Page 19: ... the tank saddles using anchor bolts to the existing structure During this lifting operation make sure that the crane arm s opening range and the surrounding area are free of any obstacles or the presence of unauthorised personnel Warning For the lifting operation make sure to hook the handling ropes to the two lifting eyebolts indicated by orange arrows All the operations described above must be ...

Page 20: ...ts During this lifting operation make sure that the crane arm s opening range and the surrounding area are free of any obstacles or the presence of unauthorised personnel Finally fasten the safety valve red arrow to the tank nozzle Warning For the lifting operation be sure to hook the handling ropes to the two lifting eyebolts welded to the bottom of the deaerator head indicated by orange arrows A...

Page 21: ...ling system During this lifting operation make sure that the crane arm s opening range and the surrounding area are free of any obstacles or the presence of unauthorised personnel Fasten the steam injection spool to the tank nozzle green arrow then fasten the stripping steam spool to the deaerator turret nozzle red arrow Warning All the operations described above must be carried out only by qualif...

Page 22: ...ten the make up water inlet spool yellow arrow to the deaerator head nozzle and then fasten it to the outlet spool already fastened to the frame green arrow Warning All the operations described above must be carried out only by qualified personnel respecting all the rules and using the safety devices required by law ...

Page 23: ...ow Connect the electrical cables to the terminal strip housing of the pressure transmitter grey arrow and the safety pressure switch blue arrow Connect the electrical cables to the terminal strip housing of the temperature transmitter brown arrow Warning All the operations described above must be carried out only by qualified personnel respecting all the rules and using the safety devices required...

Page 24: ...llation commissioning and maintenance to avoid possible accidents Make sure that a manual isolation valve is installed upstream of the steam line power source and that it functions properly If there is any doubt about the integrity of the isolation valve replace it before starting the installation 3 3 1 Primary industrial steam line connection Connect the inlet of the unit s primary steam line to ...

Page 25: ...ischarge drainage with manual valve installed at the bottom of the tank This valve discharges at the same pressure and operating temperature as the deaerator and it can cause serious physical injury or even death if not properly connected It is therefore recommended to connect the drainage of the deaerator to the system s discharge network in accordance with the regulations in force 3 3 6 Other bl...

Page 26: ...les in the control panel cabinet to connect the power cables and any interface with the external system open the door very carefully and check that there is no interference with the parts inside it Ensure that metal residues from the perforation do not come into direct contact with the electrical components inside the cabinet Signal cables must not be laid together with power cables outside the un...

Page 27: ...s Output contacts 6 A 220V for resistive loads Operating conditions Operating ambient temperature minimum 0 C maximum 50 C Relative humidity RH 5 to 95 non condensing LCD display with energy saving dimmer function Note If ambient conditions lead to exceeding the maximum temperature inside the control panel cabinet conditioning devices are available Electrical specifications for unit s components p...

Page 28: ...new installations dirt is inadvertently collected inside the pipes during construction of the pipes and system installation It is essential to carefully remove all impurities and residual dirt from inside before starting the commissioning Ensure that all manual isolation valves on primary steam condensate drain clean steam inlet and feedwater are closed Clean the filters upstream of the control va...

Page 29: ...ic parameters SP Ignore potential low level alarm and where necessary reset other alarms using the block reset button The make up water control valve begins to modulate Wait for the automatic loading of the deaerator up to the SP level the low level alarm will automatically reset when the minimum level threshold is exceeded Open the isolation valves on the primary steam line drainage assembly wher...

Page 30: ... water cooling the deaerator faster Then shut off the system Close the isolation valve on the make up water line Close all other isolation valves Allow to cool and then drain the deaerator completely through the drainage valve Switch off the control panel using the master switch 0 OFF and disconnect the power supply upstream After prolonged shut down of the assembly it is recommended to completely...

Page 31: ...high pressure level transmitter with limit switch for high and low level contacts The venting of the non condensable gases is done through the vent valve located on top of the deaerator turret For a good thermophysical deaeration it is necessary 1 Heat the water to a temperature close to the saturation temperature However the saturation temperature alone does not ensure complete gas removal 2 It i...

Page 32: ...hen triggered and stop the heating process The control valve is fail safe N C and closes in case of interlocking due to alarm system off absence of electrical or pneumatic power supply where applicable 5 1 3 Water level control The water level of the deaerator is maintained by the corresponding regulator LIC 01 of the PLC control unit The process variable is detected by the level transmitter LT 01...

Page 33: ...nit is on and the voltage is present 230 Vac 3 L2 led 8 Flashing When it is on it indicates that the system has been stopped due to one or more alarms 4 Block reset This is the block reset button 5 MAS selector This is for automatic or manual cycle selection 6 ES Emergency This is the emergency shut off button 7 MS Master switch This is a four pole switch with a door locking handle that turns the ...

Page 34: ...osition closed shutting off the supply of technological steam and feedwater After a blackout the system is prepared to be restarted manually This functionality can be changed automatic restart via the PLC Pneumatic air supply shut off or low pressure where pneumatically actuated control valves are provided the pneumatic supply shut off or insufficient pressure closes or limits the opening of the c...

Page 35: ...he documentation provided with the unit The serial bus communication link where applicable must be made directly to the PLC communication port 5 2 6 Control functions Control panels with PLC logic offer features such as synoptic on 7 touchscreen panel with process data user friendly interface PV trend alarm history interfacing with external automation via serial bus such as MODBUS TCP IP Modbus RT...

Page 36: ... 1 Initial screen The control unit is equipped with a touchscreen display When the unit is turned on the display shows the following image Fig 1 Fig 1 To interact with the control screens simply press the screen surface with your fingertips Select the icon and Fig 2 will appear Fig 2 Note This image shows the installed firmware ...

Page 37: ...he control unit Select the icon the start menu Fig 3 will appear showing 1 Information about Spirax Sarco 2 Status contains start stop and information on the operation of the deaerator 3 Protected parameters device configuration parameters necessary for the operation of the deaerator Fig 3 ...

Page 38: ...Thermophysical deaerator with operator manual for the control unit 5 3 2 Protected parameters Pressing the PROTECTED PARAMETERS icon Fig 4 will appear Fig 4 Enter Password 3 then press ENTER to confirm When you enter Fig 5 will appear Fig 5 ...

Page 39: ...ll appear Press the icon to change the settings the lock opens Then use the side buttons to enable or disable the displayed functions When the configuration is complete press the icon to save the settings the lock closes It is possible to display the total running time of the pumps Then press the button to return to the previous screen Fig 5 Fig 6 ...

Page 40: ...sing the Panel Regulations icon Fig 7 will appear Fig 7 Select the desired brightness by pressing the corresponding icon Press the icon to return to Fig 5 Pressing the Select Language icon Fig 8 will appear Fig 8 Choose your language A check mark will appear on the chosen flag Press the icon to return to Fig 5 ...

Page 41: ...er time and vice versa press the white box The check mark will confirm your choice Then press the button to return to the previous screen Fig 5 Pressing the I O Status icon Fig 10a will appear Fig 10a When the deaerator is not active DEGASSING IN MANUAL it is possible to force the output status by pressing the associated icon it becomes green to reset the command press the corresponding icon again...

Page 42: ...manual for the control unit Press the icon to see the status of the Digital output Fig 10b Fig 10b Press the icon to see the status of the Digital input Fig 10c Fig 10c To get back to Fig 5 press the icon several times Note returning to Fig 5 the manual forcing is reset to zero ...

Page 43: ... Change Password icon Fig 11 will appear Fig 11 If you want to change the default value assigned by default press on the number beside the description and using the numeric keypad displayed enter the new password value Then confirm by pressing the RET button Then press the button to return to the previous screen Fig 5 ...

Page 44: ...h operator manual for the control unit Fig 12 Pressing the Analog I O Parameters icon Fig 12 will appear To change the page press the icon To change any value just press on it a keyboard will appear To confirm the new value press RET Press the icon to return to Fig 5 ...

Page 45: ...on it a keyboard will appear To confirm the new value press RET Set the value of Δ LEVEL PV SV STOP PUMP always lower than the value of Δ LEVEL PV SV START PUMP otherwise the pump will never start by setting Δ LEVEL PV SV STOP PUMP to 0 and Δ LEVEL PV SV START PUMP higher than 0 the pump will always stop when the set point Level is reached by setting both values to 0 the pump will continue to run ...

Page 46: ...on Fig 14 will appear and it is possible to set the daily automatic start time of the deaerator Fig 14 To set the start time press on the square next to the desired day the check mark will confirm your choice To enter and or modify any value simply press on it a keyboard will appear To confirm the new value press RET Press the icon to return to Fig 5 ...

Page 47: ...el set point In regard to the temperature the set point value is automatically calculated based on the pressure set point During the operating cycle all the alarms High temperature Low level Inverter error etc are displayed with the corresponding caption When the alarm does not cause the cycle to stop DEGASSING STOPPED the system automatically resets itself once the problem has been solved If the ...

Page 48: ...en will be displayed Fig 16 For each alarm the DAY MONTH YEAR HOUR and MINUTE of start 1 and end 0 is indicated Press the button to display the first alarm in the stored list Use the button to display the last alarm in the stored list Use the buttons to scroll through the list of alarms Use the buttons to move from one page to another in the alarm menu By pressing the key all alarms in the history...

Page 49: ...ssure and temperature control valves when one of the following alarms occurs analogue DG temperature transmitter error analogue DG pressure transmitter error analogue DG level transmitter error minimum DG level Pressing the emergency button during automatic operation will stop the cycle all active functions will be cancelled and the corresponding alarm will be activated To resume automatic operati...

Page 50: ... in the control panel memory select the graph to display pressing RET to confirm the selected graph will be shown pressing the button displays the list of graphs saved in the control panel memory select the graph to delete pressing RET to confirm the selected graph will be deleted Press the key to return to the Status screen Fig 15 5 6 Graph On the Status page Fig 15 you can access the graph page ...

Page 51: ...ts However some settings can be optimised to better adapt the operation of the unit to the system conditions For units with PLC logic control please refer to the information provided in the additional documentation 5 8 1 Electromechanical protection settings The settings of the electromechanical protections are factory presets However some settings can be optimised during commissioning to better a...

Page 52: ...on the line is completely open The deaerator is loading Wait until loaded and the automatic alarm reset The water supply control valve is not working correctly Check the solenoid valve mounted on the pneumatic regulation valve and relative control panel protection fuse Check the air pressure is correct If necessary replace the solenoid valve or fuse Fault malfunction of level controller LIC 01 Che...

Page 53: ...age to level measuring instrument Check the transmitter signal and that it corresponds to the measure of the level indicator Check that the level display does not remain stationary If necessary replace the instrument Deaerator pressure too high The deaerator is in a state of alarm The primary steam control valve CV1 does not close correctly Inspect the valve housing to identify any damage If neces...

Page 54: ...rator remains cold when switching it on When working the pressure of the deaerator falls drastically heating interruption Primary steam blocked for the low water level See the part regarding the problem water level low deaerator in alarm The primary steam control valve is not working correctly Check the solenoid valve mounted on the regulating pneumatic valve and relative control panel protection ...

Page 55: ...ance of the individual components making up the system must be carried out according to the individual Installation and Maintenance IM manuals 7 1 1 Replacing components Any part of the unit connected in any way to the component to be replaced must be carefully examined before starting the maintenance procedure We recommend the replacement of all components showing signs of wear or improper operat...

Page 56: ...this configuration corresponds to the regulations in force in terms of system safety If the safety system does not work and needs to be replaced follow the following procedures The assembly drawing provided with the unit gives an exact location and any interlocks with other components Follow the instructions in these documents before removing or replacing a control valve Steam or water can be very...

Page 57: ... Sequential order Rotational order 1 2 1 1 2 1 3 4 5 3 4 5 5 6 3 5 6 9 7 8 7 7 8 3 2 9 10 7 6 11 12 11 4 2 8 6 10 4 8 12 Sequential order Rotational order Sequential order Rotational order 1 2 1 1 2 1 3 4 5 3 4 13 5 6 3 5 6 5 7 8 7 7 8 17 9 10 2 9 10 9 11 12 6 11 12 3 13 14 4 13 14 15 15 16 8 15 16 7 17 18 19 19 20 11 2 14 6 18 10 4 16 8 20 12 8 bolts 12 bolts 16 bolts 20 bolts ...

Page 58: ...off valve Safety circuit Filters Other 7 5 Scheduled Spirax Sarco maintenance Upon request Spirax Sarco can provide scheduled maintenance contracts with the following operations The maintenance contract generally provides for two visits per year Type of inspection Every 6 months Every year Every 2 years Disassembly of control valves cleaning visual inspection of inside parts Visual inspection of p...

Page 59: ...tly Spirax Sarco S r l Assistance Service Via per Cinisello 18 20834 Nova Milanese MB Italy Tel 39 0362 4917 257 39 0362 4917 211 Fax 39 0362 4917 315 E mail support it spiraxsarco com LOSS OF WARRANTY Failure to comply with these rules in whole or in part will result in the loss of all warranty rights Spirax Sarco S r l Via per Cinisello 18 20054 Nova Milanese MI Tel 0362 49 17 1 Fax 0362 49 17 3...

Page 60: ...IM P537 01 EMM Issue 1 60 Pressurised Thermophysical deaerator with operator manual for the control unit ...

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