Hydro Instruments VPH-10000-2 Series, Instruction And Operation Manual

Page 1: ...1 Series VPH 10000 2 Vaporizer Instruction and Operation Manual VPH 10000 2 Rev 5 7 15 ...

Page 2: ... Up 3 System Start 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 7 Alarms and Feature...

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: ...tructions 2 System Size Capabilities and Specifications Overall height 64 163 cm Clearance 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 pres...

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: ...5 communication The baud rate node number and data format of the VPH 10000 2 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 SCADA systems please refer to the Modbus Installati...

Page 9: ...t Integer 9 Low Temperature Alarm Set Point Integer 10 NOT USED IN MODEL VPH 10000 2 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...

Page 10: ...10 Figure 1 Heater Control Box Diagram for Power 3PH Power In ...

Page 11: ...11 Figure 2 Main Controller Wiring PRESSURE RELIEF VALVE PRESSURE SWITCH EXPANSION CHAMBER PRESSURE SWITCH MB181 MB122 MB140 MB114 NOT USED ...

Page 12: ...mp Alarm High Water Temp Alarm Water Level Alarm Superheat Alarm Optional PRV 2 Heater Contactor Not Used Solenoid PRV 1 High Pressure Alarm Ground Green Line 1 Black Connect PRV 1 Here Line 2 Red Solenoid Line 2 Contactor Line 2 Red Line 2 Red Line 2 Red ...

Page 13: ...NTROLLER CATHODIC PROTECTION CONTROL AMMETER HEATER CONTROL BOX MANUAL CONTACTOR OVERRIDE WATER LEVEL INDICATOR THREE PHASE DISCONNECT SWITCH CONTACTOR INDICATOR STATUS ON ENERGIZED SINGLE PHASE DISCONNECT SWITCH FIGURE 4 Vaporizer Controller ...

Page 14: ...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 15: ...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 16: ...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 b...

Page 17: ...se 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 cool...

Page 18: ...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 Select Gas Type Cl2 1 2 14 13 12 11 10 9 8 7 6 5 4 3 17 16 15 These menus are referred to as hidden screens and are not visible under normal operation To access these screens go to screen 13 and with the node number blinking press and hold the...

Page 19: ...he password for the VPH 10000 2 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 20: ...S Communication Manual for details 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 contro...

Page 21: ...n with the water re fill 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 22: ... heater Action must be taken by user to reduce pressure See troubleshooting Low Water Temp The water temperature is lower than the alarm value Shut off pressure reducing valve until desired water temperature is achieved High Water 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 m...

Page 23: ... 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 been...

Page 24: ...ate at 250 psi 17 bar 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...

Page 25: ...intenance 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 Magnesium Anode Replacement Based on normal operating conditions the four 4 sacrificial magnesium anodes will need to be replaced yearly or more often if necessary This is a very important step as it protects the chlorine pressure chamber and ...

Page 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 ...

Page 27: ...en 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 in water Anodes are consumed Circuitry imprope...

Page 28: ...28 14 13 12 11 10 8 22 19 30 9 23 28 27 29 15 16 17 7 8 26 24 23 2 1 3 4 5 6 19 FIGURE 6a Vaporizer Parts Diagram VI IMPORTANT FIGURES Figure 6a Vaporizer Parts Diagram ...

Page 29: ...0 FN2 Water tank flange nuts 8 12 VPH 10000 002 Water bath flange gasket 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 19 VPH 10000 2 H 240 Heater 18kW 240VAC 3PH 1 19 VPH 10000 2 H 380 Heater 18kW 380VAC 3PH 1 19 VPH 10000 2 H 480 Heater...

Page 30: ...NODE ADAPTOR 4 PLACES GAS TEMPERATURE THERMOCOUPLE WATER LEVEL PROBE 4 DEPTHS 22 559 71 5 16 1812 5 127 16 1 4 413 17 5 16 440 22 7 8 581 55 3 8 1407 18 KW HEATER 2 5 8 67 6 5 8 168 3 3 4 95 2 11 16 68 56 3 8 1432 64 15 16 1649 1 2 NPT SOLENOID 1 1 2 NPT DRAIN LIQUID INLET 1 AMMONIA TYPE UNION GAS OUTLET 1 AMMONIA TYPE UNION 1 1 4 NPT OVERFLOW CABINET 95 5 16 2422 HEADROOM REQUIRED TO REMOVE GAS C...

Page 31: ...31 Figure 8 Chlorine Vapor Pressure Curve Figure 6 Chlorine Vapor Pressure Curve Vapor Pressure ...

Page 32: ...32 Figure 9 Sulfur Dioxide Vapor Pressure Curve Figure 7 Sulfur Dioxide Vapor Pressure Curve Vapor Pressure Min Superheat ...

Page 33: ...33 Figure 10 Ammonia Vapor Pressure Curve Figure 8 Ammonia Vapor Pressure Curve Vapor Pressure Min Superheat ...