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Warning: Ensure that the water tank temperature is 180˚F (82˚C). Liquid chlorine should
never be allowed into the vaporizer without the water tank temperature being in the
operating range.

i. Bring the vaporizer up to 50% and allow the system to reach equilibrium. Do the same at 75% of

scale and 100 % of scale.

3.

System

Start

This procedure may only be used after the initial start-up has been completed or if restarting the
system and the user is sure that no moisture has been allowed into the system and that no leaks are
present. If unsure, use the start-up procedure outlined in Section III.2.

Warning: When performing this step, ensure that all protective equipment for handling chlorine
gas is available.

a. Ensure that the chlorine container valves are closed and there is no chlorine in the piping. Turn on

the vaporizer, check to make sure that the water has fi lled up and the water tank temperature is at
operating level. Check that all appropriate alarms have turned off.

b. Connect piping to the chlorine gas container valves and allow chlorine gas into the system. Close

the gas container valves and check for leaks using a 26 Baume solution of ammonia. If white
smoke appears, a leak is present and corrective action must be taken.

c. Run the ejector(s) to remove chlorine from the pipeline. Close 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 reached. Then bring up

to 50%, 75% and full scale making sure equilibrium has been established each time (when
temperature and pressure readings are constant over a set period of time).

Warning: Do not introduce liquid chlorine into the vaporizer without the water tank
temperature at operating conditions.

4. System Shut Down

4.1 Short Term Shut Down

A short term shut down is defi ned as any situation where the chemical feed is only temporarily
interrupted, and the heater and all control functions will remain on. Hydro Instruments recommends
the following procedure:

a. If applicable, temporarily stop chemical feed at the vacuum regulator and allow liquid to fi ll back

into the container.

b. Once equilibrium has been reached (when temperature and pressure readings are constant over a

set period of time), shut the liquid & gas chlorine container valves. Keep all manifold valves open.

c. Run the ejector to remove all the chlorine from the pipeline until the chlorine pressure reading

reads zero. Wait for 30 minutes to ensure pressure readings hold at 0 psi (0 bar) and then repeat
this step as necessary.

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Содержание VPH-10000-1 Series

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

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

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

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

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

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

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

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

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