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Water Tank Temperature Alarm Testing

a. Remove the thermocouple located at the heater outlet (control water temperature).

b. Place in a bath of room temperature water, allow the sensor to reach equilibrium and check the low

water temperature alarm will activate.

c. To check the high water temperature alarm, boil water in a separate container. Place the

thermocouple in the nearly boiling water (approximately 210ºF / 99ºC) to verify that the high water
temperature alarm will activate.

d. Re-install the thermocouple into the piping system.

Superheat Alarm Testing

The superheat alarm can be tested by placing the chlorine gas temperature probe in ice during the

pressure switch alarm testing.

Cathodic Protection Testing

Disconnect the red anode wires. The current value should then drop to zero.

1.3 Component Preventative Maintenance

All rupture discs should be replaced on a yearly basis. O-rings and gaskets should also be replaced

yearly or sooner if they appear cracked/damaged in any way. Before proceeding to perform any test-
ing or maintenance ensure that there is no chlorine in the system and that the chlorine inlet piping is
shut off. Please refer to Section III.4.2 for system shut down.

Water Recirculating Pump

The water recirculating pump has a replaceable internal cartridge, which should be replaced if the

pump is noisy, leaking, and/or not circulating water.

Magnesium Anode Replacement

Based on normal operating conditions, the four (4) sacrificial magnesium anodes will need to be re-

placed yearly or more often if necessary. This is a very important step as it prevents the chlorine pres-
sure chamber and all other system components from corrosion.

a. Remove wires connected to the anodes.

b. Remove anodes.

c. Install new anodes into the respective locations and attach the anode wires.

2. 5-Year Chlorine Pressure Chamber Cleaning and Inspection

This step should be conducted at least every five years or if signs of corrosion exist.

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 pounds less than the original weight, or corrosion

pits exceeds more than

1

⁄

8

" deep anywhere on the chamber, it must be replaced. Original weight is

stamped on the pressure chamber and also stored with Hydro Instruments for future reference.

d. Complete Section IV.1 steps i through n.

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Содержание VPH-10000 Series

Страница 1: ...1 Series VPH 10000 Vaporizer Instruction and Operation Manual VPH 10000 Rev 7 21 14 ...

Страница 2: ...4 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 Re Fill Solenoid 6 Cathodic Protection System 7 Water Heater 8 Water Pump 7 Alarms and Features IV M...

Страница 3: ... 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 substitutin...

Страница 4: ...tion and suitability of the system for which it is intended Qualified personnel should also perform routine equipment checks and maintenance in accordance with manufactures recommendations and instructions 2 System Size Capabilities and Specifications Overall height 64 Clearance space required 24 on all sides 12 floor to ceiling Chlorine pressure chamber dry weight 360 lbs approx Water tank dry we...

Страница 5: ...op flange 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...

Страница 6: ...o 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 of an over pressure condition Thus an ex...

Страница 7: ... delta wiring arrangement and thus no neutral wire is needed f Bring the single phase cable and conduit into the conduit fitting Ensure fitting is air tight g Connect the single phase power supply to the appropriate terminals Figure 1a b Be sure to tie the ground to the ground block h Close the heater control box and insert screws i Connect power to main source j Ensure that the manual contactor o...

Страница 8: ...data format of the VPH 10000 must match that of the master SCADA system See Section III 5 for information on how to accesses 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 SCADA systems please refer to the Modbus Installation and Instruction manual Vaporizer Alarm Rela...

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: ...10 Figure 1a Heater Control Box Diagram for 120 VAC Single Phase Power Figure 1b Heater Control Box Diagram for 240 VAC Single Phase Power FIGURE 1b HEATER CONTROL BOX DIAGRAM 240 VAC SINGLE PHASE ...

Страница 11: ...11 Figure 2 Main Controller Wiring Figure 2 Main Controller Wiring ...

Страница 12: ...12 Figure 3 Relay Output Box Figure 3 Relay Output Box ...

Страница 13: ...13 MAIN CONTROLLER HEATER CONTROL BOX THREE PHASE DISCONNECT SWITCH SINGLE PHASE DISCONNECT SWITCH CONTACTOR INDICATOR STATUS ON ENERGIZED MANUAL CONTACTOR OVERRIDE Figure 4 Vaporizer Controller ...

Страница 14: ...uately purged Pressurize the piping to 150 psi using the 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 to...

Страница 15: ... to the ammeter Operating current should be between 50 250 mA Add a lb 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 g...

Страница 16: ...ose 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 bee...

Страница 17: ...ion 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 and heater drain to allow the water in the water tank pump and heater 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 th...

Страница 18: ...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 100 E00 G 3 0 I 1 0 LT 5 Heater Sheath Temp 300 F 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 node number blinking press...

Страница 19: ...to all the editable features of the VPH 10000 To access the configuration screens the correct password must be entered on this screen The password for the VPH 10000 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 ...

Страница 20: ...SCADA system 15 Pressure Range Screen If desired a different scale pressure transmitter may be used to monitor pressure The new span must then be 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 vapo...

Страница 21: ...erence for measuring the amount of heat transfer 4 Water Level Control Water level in the water tank can be controlled both automatically and or manually For automatic control there are four conductive level sensors in the water tank one low level one low fill one high fill and one overfill alarm Each alarm is then used in conjunction with the water re fill solenoid to open or close the solenoid a...

Страница 22: ...ion All relevant alarms will appear on the alarm screen in two second intervals should multiple alarm conditions exist Alarm Description Action Taken by Controller Low Superheat The temperature of the outlet gas is less than the alarm value Shut off the electronic pressure reducing valve until desired superheat is achieved High Cl2 Pressure Pressure in the chlorine pressure chamber exceeds the ala...

Страница 23: ...ly to a well ventilated location f Remove the top flange of the inner chamber assembly 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...

Страница 24: ... activate at 250 psi on the vaporizer controller c Replace the pressure transmitter assembly if it fails this testing if the corresponding relay on the controller fails then take corrective action d Install tested pressure transmitter assembly with diaphragm protector back onto the top flange of the inner chlorine chamber assembly using an appropriate thread sealant Pressure Relief Valve a Remove ...

Страница 25: ...on III 4 2 for system shut down Water Recirculating Pump The water recirculating pump has a replaceable internal cartridge which should be replaced if the pump is noisy leaking and or not circulating water Magnesium Anode Replacement Based on normal operating conditions the four 4 sacrificial magnesium anodes will need to be re placed yearly or more often if necessary This is a very important step...

Страница 26: ...ylinder 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 ...

Страница 27: ...ater level is 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 c...

Страница 28: ...28 VI IMPORTANT FIGURES 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Figure 6 Vaporizer Parts Diagram Figure 6a Vaporizer Parts Diagram ...

Страница 29: ...29 18 19 20 21 23 24 25 18 26 27 28 28 29 30 Figure 6 Vaporizer Parts Diagram 22 Figure 6b Vaporizer Parts Diagram ...

Страница 30: ...s 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 chamber 1 21 VPH 10000 MB 1 Top heater ...

Страница 31: ... 558 Ø0 750 4 PLACES 71 343 64 433 11 000 16 132 3 749 2 625 LIQUID INLET 1 AMMONIA TYPE UNION GAS OUTLET 1 AMMONIA TYPE UNION 1 1 4 NPT OVERFLOW 1 2 NPT SOLENOID 1 1 2 NPT DRAIN 1 1 4 NPT VENT REAR FRONT 11 000 1 1 2 CONDUIT CONNTECTION FOR 3 PHASE POWER 1 2 CONDUIT FOR SINGLE PHASE POWER FIGURE 7 VPH 10000 DIMENSIONAL DRAWING ...

Страница 32: ...32 Figure 8 Chlorine Vapor Pressure Curve Figure 6 Chlorine Vapor Pressure Curve Vapor Pressure ...

Страница 33: ...33 Figure 9 Sulfur Dioxide Vapor Pressure Curve Figure 7 Sulfur Dioxide Vapor Pressure Curve Vapor Pressure Min Superheat ...

Страница 34: ...34 Figure 10 Ammonia Vapor Pressure Curve Figure 8 Ammonia Vapor Pressure Curve Vapor Pressure Min Superheat ...

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