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172-65608MA-03 (RGDS) 5 Oct 2021

Troubleshooting

In the event of any abnormality, stop the system and utilities supply

(steam, water, air and electricity). Investigate the cause of the

abnormality and take countermeasures. Prevent the supply of utilities to

the system until the countermeasures have been implemented.

WARNING

Use hoisting equipment for heavy objects (weighing approximately

20 kg (44 lb) or more). Failure to do so may result in back strain or other

injury if the object should fall.

CAUTION

Take measures to prevent people from coming into direct contact with

product outlets. Failure to do so may result in burns or other injury from

the discharge of fluids.

CAUTION

When disassembling or removing the system, wait until the internal

pressure equals atmospheric pressure and the surface of the product

has cooled to room temperature. Disassembling or removing the system

when it is hot or under pressure may lead to discharge of fluids, causing

burns, other injuries or damage.

CAUTION

Be sure to use only the recommended components when repairing the

system, and NEVER attempt to modify the product in any way. Failure to

observe these precautions may result in damage to the system or burns

or other injury due to malfunction or the discharge of fluids.

CAUTION

Make sure the power supply is OFF before carrying out work on the

wiring or inspections involving disassembly. If such work is carried out

with the power on, there is a danger that components may malfunction

or electric shock may occur, leading to injury or other accidents.

CAUTION

Make sure that installation work requiring a special license is carried out

by qualified personnel. Improper work may cause falls, dropped items,

overheating and electrical leaks, leading to injury, burns, fires, damage

and other accidents.

CAUTION

When using this system, NEVER stand close to, or leave tools anywhere

near moving parts, such as the shaft. Contact with moving parts or

objects becoming caught in moving parts could lead to injury, damage

or other accidents.

CAUTION

Do NOT touch terminals when power is on. This may lead to system

breakages, erroneous operation, electrical shock or fires.

CAUTION

When the system fails to operate properly, use the following table to locate the cause
and remedy.

Item

Cause

Diagnostic

Remedy

The pump
does not start

A current is not
applied to the
pump

The power is not turned on

Turn on the power

The wiring is disconnected or not
connected

Connect the wiring

The power is cut off

Apply current to the
pump

The non-fuse
breaker is
operating

There is a short in the sequence

Fix the control system
then reset the non-
fuse breaker

The pump
cannot be
activated

A thermal relay has tripped or the
wiring is disconnected

Disassemble and
clean the pump
If the motor is broken,
replace the motor
Reset the thermal
relay

Continued on the next page

Содержание RGDS

Страница 2: ...d this manual carefully before use and follow the instructions to be sure of installing and using the system properly by following the installation and operating procedure After the completing the installation work our technical personnel will explain the commissioning and operation of this system Please keep this manual commissioning report specification and all documents related to this system f...

Страница 3: ...tuation which poses a threat of death or serious injury Indicates that there is a potential threat of death or serious injury Indicates that there is a possibility of injury or equipment product damage In the event of any abnormality stop the system and utilities supply steam water air and electricity Investigate the cause of the abnormality and take countermeasures Forbid the supply of utilities ...

Страница 4: ...carrying out work on the wiring or inspections involving disassembly If such work is carried out with the power on there is a danger that components may malfunction or electric shock may occur leading to injury or other accidents Make sure that installation work requiring a special license is carried out by qualified personnel Improper work may cause falls dropped items overheating and electrical ...

Страница 5: ...injected for temperature reduction Water mixing and separation section consist of static mixer and condensate separator in order to desuperheat reduce the temperature from the steam with the cooling water by passing the flow through 2 static mixers connected in series and later on through a cyclone separator to remove the excess water that could exist System Features The following are some feature...

Страница 6: ... Injector Static Mixer Size Connection 50 200 mm 2 8 in JIS 10K 20K 30K ASME JPI Class 150 300 Condensate Separator Model DC3 Size 50 150 mm 2 6 in For 200 mm 8 in water injector static mixer 150 mm 6 in separators installed in parallel Steam Trap Model JS X series JH series Size Connection Depends on specifications Pump Section 2 Pump Model CRN 1 Non Ex proof CRN 1 eG3 d2G4 Size Connection Depend...

Страница 7: ...temperature as required The strainer prevents clogging of the water injector s internal nozzle by dirt rust and scale The check valve reduces the risk of water hammer due to steam flowing into the desuperheating water line D Temperature sensor E Strainer F Check valve Water mixing and separation section G Water injector Injects water and mixes it with steam for desuperheating Discharges excess des...

Страница 8: ...by qualified personnel Improper work may cause falls dropped items overheating and electrical leaks leading to injury burns fires damage and other accidents CAUTION After all piping work has been performed according to the system flow diagram check that all connections are tightened all gaskets have been installed and for unsecure installations Improper piping work may lead to discharge of fluids ...

Страница 9: ...or body G see right Make sure this engraving is on the downstream side of the injector when installing the desuperheating water piping b The static mixer H is shipped as two separate pipe shaped products Each static mixer has a flow direction indicated on the flange L Left R Right Make sure the second mixer starts with the same direction as the first mixer i e LR LR and RL RL Note L and R do not d...

Страница 10: ... Install flexible tubing on both the suction side and discharge side of the pump K to prevent vibrations from the pump from transmitting through the piping Make sure to use vibration absorbing type flexible tubing for use with pumps 3 Install a strainer to prevent foreign matter from entering the suction side of the pump K 4 Set a minimum flow line for the pump K and make sure not to operate the p...

Страница 11: ...ng burns other injuries or damage CAUTION Checking the System 1 Preparation 1 1 Items to prepare System equipment list Flow diagram Product specifications Control box diagrams terminal connection diagrams sequence diagrams Applicable equipment documents drawings specifications etc Instruction manuals for each products 1 2 Items to verify Verify whether commissioning can be performed Installation p...

Страница 12: ... pressure has reached approximately 0 2 MPaG less than the target value and switch to automatic operation 2 Verify that the steam pressure is stable at the target value Operating Procedures Desuperheating Section 3 Pressure reducing section 3 1 Preparation 1 Supply electricity air and water to the system 2 Turn on the power for the control box 3 Check whether the temperature sensor values are norm...

Страница 13: ...l box Unnecessary if sharing the same control box as the pressure reducing section Shutdown Procedures Desuperheating Section 1 Verify that the pressure reducing section has stopped If a pump is installed stop the pump 2 Close the temperature control valve fully 3 Verify that the temperature control valve is fully closed and then close the manual valve on the primary side of the temperature reduci...

Страница 14: ... this system NEVER stand close to or leave tools anywhere near moving parts such as the shaft Contact with moving parts or objects becoming caught in moving parts could lead to injury damage or other accidents CAUTION Periodically inspect and check the following items as preventive maintenance For details regarding maintenance considerations refer to the individual instruction manual for each comp...

Страница 15: ...ing to replace consumable parts Part Replacement Timing Pump Mechanical seal When liquid leakage is observed or after 8000 hours operation Shaft bearings Every 2 to 3 years Gaskets When liquid leakage is observed or when disassembling Refer to individual instruction manuals for other maintenance and inspection procedures ...

Страница 16: ...rying out work on the wiring or inspections involving disassembly If such work is carried out with the power on there is a danger that components may malfunction or electric shock may occur leading to injury or other accidents CAUTION Make sure that installation work requiring a special license is carried out by qualified personnel Improper work may cause falls dropped items overheating and electr...

Страница 17: ...ler wire connections check the input signal wiring for incorrect connections Check the electrical wiring diagram and correct the wiring Check that a signal of 4 20 mA is being received by the CV at the connection terminals Adjust the controller or positioner or replace with a new controller or positioner Check the secondary pressure of the steam pressure control valve if the electrical wiring and ...

Страница 18: ...o the positioner Repair any air leakages between the temperature control valve actuator and positioner The PID set values are incorrect Check the PID set values Correct the PID set values The temperature sensor is malfunctioning Check the temperature value reading from the sensor and compare with the temperature gauge if the electrical wiring and signal are normal then the temperature sensor is ma...

Страница 19: ...lace with a new temperature sensor Component s inside the pressure control valve positioner are broken Check for abnormal sounds from the positioner Replace with a new positioner Investigate whether the valve aperture changes frequently or the ambient temperature is too high There is a problem with the input current of the temperature control valve Check that a signal of 4 20 mA is being received ...

Страница 20: ...yond the control of TLV TII or TLV group companies or 6 improper storage maintenance or repair or 7 operation of the Products not in accordance with instructions issued with the Products or with accepted industry practices or 8 use for a purpose or in a manner for which the Products were not intended or 9 use of the Products in a manner inconsistent with the Specifications or 10 use of the Product...

Страница 21: ...ASSEMBLY AND SHIPMENT OF THE DEFECTIVE PRODUCT INJURY TO OTHER PROPERTY DAMAGE TO BUYER S OR THE FIRST END USER S PRODUCT DAMAGE TO BUYER S OR THE FIRST END USER S PROCESSES LOSS OF USE OR OTHER COMMERCIAL LOSSES WHERE DUE TO OPERATION OF LAW CONSEQUENTIAL AND INCIDENTAL DAMAGES UNDER THIS WARRANTY UNDER ANY OTHER EXPRESS WARRANTY NOT NEGATED HEREBY OR UNDER ANY IMPLIED WARRANTY NOT NEGATED HEREBY...

Страница 22: ...d Nunawading Victoria 3131 Australia Tel Fax 61 0 3 9873 5610 61 0 3 9873 5010 In East Asia 36 Kaki Bukit Place 02 01 02 Singapore 416214 Tel Fax 65 6747 4600 65 6742 0345 Room 5406 No 103 Cao Bao Road Shanghai China 200233 Tel Fax 86 0 21 6482 8622 86 0 21 6482 8623 No 16 Jalan MJ14 Taman Industri Meranti Jaya 47120 Puchong Selangor Malaysia Tel Fax 60 3 8065 2928 60 3 8065 2923 252 94 K L 17th F...

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