Xylem WEDECO EFFIZON SMOevo Series, Manual

Page 1: ...English translation of the original German manual Manual WEDECO EFFIZON Ozone Generating System SMOevo Series Atchison_P 1138 Rev 1 0...

Page 2: ...09 2013 Date 26 01 2015 File Manual_SMOevo610_Atchison_P 1138 doc Xylem Water Solutions Herford GmbH 2013 The reproduction distribution and utilization of this document as well as the communication o...

Page 3: ...15 3 3 1 Emergency Stop 15 3 3 2 Main Switch 16 3 3 3 Gas Detectors Ambient Air Monitoring 16 3 3 4 Technical Ventilation System 16 3 3 5 Door Switch 16 3 3 6 Protective Covers 16 3 3 7 Safety and Wa...

Page 4: ...pply 43 5 3 2 Subassembly 02 Ozone Generation 45 5 3 3 Subassembly 03 Process Gas Line 46 5 3 4 Subassembly 07 Cooling System 47 5 3 5 Subassembly 23 Converter 49 Options 51 5 3 6 Option CL Closed Loo...

Page 5: ...Cleaning Personnel 73 8 3 Requirements for Safe Cleaning 73 8 4 Cleaning the Ozone System 73 8 4 1 Cleaning during Operation 74 8 4 2 Cleaning with the System Disconnected form Power Supply 74 9 Maint...

Page 6: ...l help design our manuals even more user friendly 2 1 Contact Addresses If you have any queries please contact your regional Sales Company for WEDECO products You will find a current list of contact p...

Page 7: ...country was done by certified translators Any warranty becomes void if the information given in this manual is not or not sufficiently observed the ozone generating system is used not according to it...

Page 8: ...e This section gives an outline of the information given in the individual sections of his manual Name of the section Contents of the section About this Manual section 2 How is this manual organized l...

Page 9: ...osing of the ozone system Appendices 11 Form Confirmation of Briefing Example Operating Directives Swagelok Assembly Instructions for External Connections Where and how do I order spare parts Spare Pa...

Page 10: ...le and bears unforeseeable risks for the safety of the operating personnel Disclaimer of warranty The manufacturer is not liable for any damage or consequential damage in terms of the Product Liabilit...

Page 11: ...his manual are explained 3 2 1 Action Related Hazard Warnings When operating the ozone generating system hazards may occur in certain situations or due to certain behavior Relevant procedures are prec...

Page 12: ...Signs Warning Signs Pictograph Description Danger Hazardous voltage Warning of ozone Warning of suspended loads when loading and unloading Warning of poisonous toxic substances Warning of explosion ha...

Page 13: ...rohibiton Signs Pictograph Description Smoking and open flames forbidden Do not spray water Do not touch live parts Mandatory Signs Pictograph Description Wear ear protection Wear safety gloves Wear s...

Page 14: ...poisonous substances Ozone plant Access for authorized personnel only No persons with pacemaker Smoking and open flames forbidden Safety Signs on the Ozone System Symbol Description Warning of ozone...

Page 15: ...nt of the ozone system is equipped with a red Emergency push button The operator can connect an additional Emergency Stop device by which the ozone production will be stopped The control is provided w...

Page 16: ...are equipped with a technical ventilation system guaranteeing an air exchange of at least three times per hour An extraction type ventilation with the intake opening located directly above the floor...

Page 17: ...es of the authorized personnel of his company Qualified person A qualified person is a person who due to his or her technical training knowledge and experience as well as his or her knowledge of the r...

Page 18: ...rooms in which ozone may escape in case of a hazardous incident The owner operator is obliged to install fully functional gas detectors in rooms in which oxygen may escape in case of a hazardous inci...

Page 19: ...measuring the ozone concentration in the ambient air and for detecting leakages Ozone System Check The owner operator is obliged to have the ozone system checked for proper condition by a qualified p...

Page 20: ...its intended use safely and aware of potential hazards Rectify any faults immediately which could impair your safety or the safety of the ozone system 3 5 1 Personal Protective Equipment Some work on...

Page 21: ...places or work stations in rooms housing ozone systems If the installation site of the system cannot be separated from the workplace for technical processing reasons reliably monitor the ozone concent...

Page 22: ...ne The handling of ozone requires special safety measures which are described in the following section Ozone contains three oxygen atoms is heavier than air is a colorless to blue gas has an intensive...

Page 23: ...rate into deeper sections of the respiratory tract Physical strain and a rise in the ambient temperature increase the toxicity of ozone An increase of the room temperature by e g 8 C doubles the toxic...

Page 24: ...ith ozone or are soiled with grease or oil Breathing Protective Devices Only enter rooms in which ozone is accumulating or can be expected to accumulate wearing a breathing protective device to rescue...

Page 25: ...gnition of oil and grease This also applies to clothing soiled by oil and grease An increased oxygen concentration causes a considerable increase in the combustion speed Furthermore technical safety c...

Page 26: ...alation of high oxygen concentrations will usually disappear after exposure to fresh air 3 8 2 Precautions Fire naked light and smoking is prohibited in rooms where O2 is handled Ventilation Ensure th...

Page 27: ...stible or self igniting materials within a safety area of 5 m surrounding possible outlet points of liquid oxygen Rooms in which oxygen is handled must be located in that way that they can easily be e...

Page 28: ...ive parts by covers Inform the operating personnel of the duration of the planned work Place an appropriate tagout label on the ozone system as long as work is performed on the equipment DANGER Live c...

Page 29: ...al Ozone Generating System SMOevo Safety Rev 1 0 Page 29 of 91 CAUTION Hot System Components Risk of explosion Hot System Components must never get in contact with explosive or highly flammable chemic...

Page 30: ...ate of the art 4 1 Type and Identification of the System The ozone generators of the SMOevo series are systems for the generation of ozone in the concentration range of up to 15 by weight Depending on...

Page 31: ...portant operating data dimensions and weights of the ozone systems of the SMOevo series 4 2 1 Dimensions and Weights Type Width Height Depth Dry weight kg Operating weight kg PSU 3010mm 2160mm 986mm 1...

Page 32: ...ing water temperature 25 C 35 C Cooling water temperature Heat dissipation to place of installation Recommended air rate for place of installation C max m h max m h kW m h system SMOevo 610 35 12 19 9...

Page 33: ...T of TT must be agreed with WEDECO prior to placing the order A suitably dimensioned power output see list below is to be provided by the site operator The power output must comply with local regulati...

Page 34: ...nual Ozone Generating System SMOevo Error Use the Home tab to apply berschrift 1 to the text that you want to appear here Rev 1 0 Page 34 of 91 4 2 5 Signal Transfer example of electrical wiring diagr...

Page 35: ...ontact 24 V DC if this operating mode is pre selected on the touch panel Operating mode Dose Control Required ozone mass 0 X g h or reference value untreated water 0 X m h Additionally four signal swi...

Page 36: ...Ozone Generating System SMOevo Error Use the Home tab to apply berschrift 1 to the text that you want to appear here Rev 1 0 Page 36 of 91 If necessary one more Emergency push button contact can be in...

Page 37: ...ation 99 5 99 8 Vol 85 95 Vol Standard 93 Vol 1 21 Vol Water content 2 6 ppmV 2 6 ppmV 2 6 ppmV Atm dew point 70 C 70 C 70 C Content of hydrocarbons 60 ppmV 60 ppmV 60 ppmV Nitrogen Argon content 1000...

Page 38: ...n particles sediment The following table shows the coolant requirements Contents Unit Suspended solids 1 mg l Iron 0 3 mg l Manganese 0 05m g l Chloride 100 mg l Conductivity 600 S cm Hardness 8 dH Ge...

Page 39: ...ccuracy class 2 was used for the measurement Calibration of the sound level meter was carried out before and after the measurement Measurements were carried out in a room with acoustically unfavorable...

Page 40: ...f as an environmentally friendly oxidizing agent in many areas of application Ozone is technically produced through silent electrical discharge from oxygenic feed gases typically air or oxygen by spec...

Page 41: ...is split into two parts from type SMOevo 510 on In this case the complete converter unit is mounted on one of these skids The ozone generator of the WEDECO ozone generating system SMOevo series produc...

Page 42: ...DECO EFFIZON HP electrodes made of stainless steel and borosilicate glass form the core of the ozone generating module Control The local Programmable Logic Control PLC controls and monitors the ozone...

Page 43: ...valve Isolation valve for PIT310 PIT310 07 0 112 Pressure indicator transmitter Measures indicates and transmits feed gas inlet pressure PSH310 1 01 0 113 Pressure switch Monitors the gas inlet press...

Page 44: ...10 01 0 120 Flow meter Measures the gas volume flow in cubic meters with flowing conditions The scale is designed from 0 100 The flow meter signal is pressure compensated in the PLC and converted to n...

Page 45: ...ve Opens in case of pressure rise to 3 5 bar g in order to prevent excess pressure in the ozone generator during operation as well as during OFF state 02 0 10 Ozone generator In the ozone generator th...

Page 46: ...case of fault or outage the valve closes automatically CV310 03 0 20 Check valve To secure the system against flow in opposite direction BV310 4 03 0 25 Ball valve Open in normal operation To be close...

Page 47: ...tion for generating ozone heavily depends on the cooling water temperature among other factors an efficient cooling of the ozone generator is of utmost importance The specified water quantity and qual...

Page 48: ...LC and hard wired if the temperature exceeds 50 C The setting of the temperature transmitter must not be changed at any time BV310 8 07 0 45 Ball valve Isolation valve for PI310 3 PI310 3 07 0 50 Pres...

Page 49: ...ed single phase AC voltage is transferred to a medium voltage level by means of a step up transformer A pulse converter with variable operating frequency with a dynamic range of 0 1 100 is used corres...

Page 50: ...6 pulse rectifier designed as a network driven bridge circuit and IGBT power block DC link Digital control unit DICON Winding material medium voltage transformer intermediate circuit choke network com...

Page 51: ...water line isolation valve Must be closed during normal operation BV310 3 07 0 125 Ball valve Isolation valve for ET 330 Must be full yopen during normal operation AV330 1 07 0 130 Air relieve valve...

Page 52: ...210 Temperature indicator Indicates cooling water flow to generator temperature BV330 9 07 0 215 Ball valve To drain water from the system Must be fully closed during normal operation BV330 10 07 0 2...

Page 53: ...r side BV330 13 07 0 265 Ball valve Isolation valve for DPI330 2 BV330 14 07 0 270 Ball valve Isolation valvbe for PI330 5 PI330 5 07 0 275 Pressure gauge Indicates open loop cooling water outlet pres...

Page 54: ...ure a hazard free discharge of the off gas a residual ozone destructor COD must be installed In order to prevent humidity from entering into the COD and the blower the customer must provide a demister...

Page 55: ...ption M1 M2 and M3 Ozone Monitoring M3 Measurement display and control of ozone concentration by ozone monitor HC 400 plus 5 3 9 Option Z1 Nitrogen Boost The option Nitrogen Boost includes addition of...

Page 56: ...centration g Nm NTP The ozone mass per norm cubic meter depends on the set converter output and the set gas volume flow VG Gas volume flow Nm h NTP The gas volume flow in norm cubic meter per hour is...

Page 57: ...ncentration respectively due to very low or very high ozone mass to be required the PLC independently corrects the preset setpoints in order to ensure optimum operation of the Ozone System The value c...

Page 58: ...ent of the Redox potential in the process water When falling below or exceeding a certain limit value the ozone production is reduced or increased in pre defined stages in order to ensure a process op...

Page 59: ...y during Transport and Storage 6 1 1 Safety Instructions WARNING Hazard due to falling loads Risk of serious injury or death Only use lifting aids and slings permitted to the total weight Never stand...

Page 60: ...f the ozone system is indicated in section Technical Data Only use ropes and hang equipment ensuring sufficient safety and bearing capacity Always use load beams when transporting the system by a cran...

Page 61: ...observe the following instructions In order to prevent damage pack and unpack the different System Components according to their function and depending on their sensitivity with regard to damage Prote...

Page 62: ...e generating system 7 1 Installation 7 1 1 Safety Instructions DANGER Live components Danger to life due to electric shock Prior to installation work ensure that the ozone system is disconnected from...

Page 63: ...1 4 Operating Room Refer to section Requirements for the Installation Place Refer to section Safety particularly with regard to how to handle oxygen and ozone Closed room Operating rooms for ozone gen...

Page 64: ...he manometers used in the generator indicate the pressure of the system in relation to the barometric air pressure in the operating room Depending on the ambient pressure the operating pressure must b...

Page 65: ...d 90 during continuous operation higher values are possible for brief periods 1h Ensure that there is no condensation resulting from moisture dew in or on the system With regard to EMC emission standa...

Page 66: ...e sure that only ozone resistant connecting parts like cables fittings and sealings are used Use the materials listed in the table below for in house connections Connections Recommended Materials Ozon...

Page 67: ...nd equal load distribution of all supporting points to avoid stress on the system 3 Ensure strain free connection of the system to in house piping for the feed gas 4 Ensure strain free connection of t...

Page 68: ...g the System for Drying Out Purposes Prior to commissioning the ozone system for the first time or after carrying out modifications to the connection lines ensure that all moisture is removed from the...

Page 69: ...mode Make sure that the system has been given enough time to adapt to the climatic conditions of the location before it is activated for the first time 7 2 2 Requirements for the Commissioning Staff T...

Page 70: ...em carefully in order to be able to detect any potential hazardous situations at an early stage Make yourself familiar how to operate the touch panel Refer to section Operation 7 Switch on the ozone s...

Page 71: ...8 1 Safety 8 1 1 Safety Instructions DANGER Live components Danger to life due to electric shock Do not use water for cleaning live components Do not spray rooms housing ozone generating systems with...

Page 72: ...m until no more ozone can be detected however at least 30 minutes NOTICE Dust on circuit boards and electrical components Malfunctions and short circuits may occur Use a vacuum cleaner for cleaning th...

Page 73: ...ualified person according to the applicable rules of electrical engineering only are electrically instructed and under the supervision of an electrically qualified person have read and understood this...

Page 74: ...cted form Power Supply Preparation Ensure the system is isolated from the power supply Secure the system against unintended restart Close all openings to prevent cleaning agent from ingressing into th...

Page 75: ...ave a periodic test carried out for the container by an approved accreditation body zugelassene berwachungsstelle Z S 5 years after commissioning the system If the periodic test does not detect any de...

Page 76: ...taining System Components purge the system until no more ozone can be detected however at least 30 minutes Work which requires opening the ozone generator may only be carried out by authorized qualifi...

Page 77: ...tructions in section Cleaning prior to starting any maintenance or repair work Observe the product related precautions when handling oil grease and other chemical substances Prior to maintenance work...

Page 78: ...s Wear safety harnesses when performing maintenance work at heights Replace the specified wear and safety parts in the event of damage If the system must be started during maintenance work test run th...

Page 79: ...ually Assembly Gas inlet PCV310 01 0 105 Pressure reducer Visual inspection Adjusting required operating pressure if necessary weekly PSH310 1 01 0 113 Pressure switch Settings check every 6 months PS...

Page 80: ...0 2 07 0 40 Temperature sensor Visual inspection every 6 months PI310 3 07 0 45 Pressure gauge Visual inspection weekly CV310 2 07 0 65 Actuated butterfly valve Visual inspection monthly FSL310 07 0 7...

Page 81: ...Manual Ozone Generating System SMOevo Error Use the Home tab to apply berschrift 1 to the text that you want to appear here Rev 1 0 Page 81 of 91...

Page 82: ...berschrift 1 to the text that you want to appear here Rev 1 0 Page 82 of 91 9 6 Disposing of Components and Materials Dispose of all the components and materials which have been replaced in a proper...

Page 83: ...ilable power supplies and external voltages prior to starting any work on it WARNING Hazard due to not sufficiently qualified personnel Danger to life or serious injury may result Work on electrical s...

Page 84: ...e ozone system against tilting Make sure that nobody stands under suspended loads Secure the hazard area against unauthorized access WARNING Storage tanks piping and ozone generators are pressurized C...

Page 85: ...Depressurize all the piping and system components 3 Close the feed gas inlets 4 Seal the gas lines 5 Discharge the cooling water 6 Disconnect the system from the media supply connections Make sure th...

Page 86: ...ronment and for your own safety observe the following instructions Observe all local regulatory requirements regarding the environment Dispose of materials in a safe and environmentally friendly manne...

Page 87: ...rift 1 to the text that you want to appear here Rev 1 0 Page 87 of 91 11 Appendix 11 1 Confirmation of Briefing I hereby confirm that I have completely read and understand the manual related to the oz...

Page 88: ...ar here Rev 1 0 Page 88 of 91 11 2 Operating Directives Operating Directives must be issued by the owner operator of the ozone system The Directives must be attached well visible for the personnel in...

Page 89: ...Manual Ozone Generating System SMOevo Error Use the Home tab to apply berschrift 1 to the text that you want to appear here Rev 1 0 Page 89 of 91 Example Directive Handling of Ozone...

Page 90: ...al Ozone Generating System SMOevo Error Use the Home tab to apply berschrift 1 to the text that you want to appear here Rev 1 0 Page 90 of 91 11 3 Swagelok Installing Instructions for External Connect...

Page 91: ...thus impairing active and or passive safety characteristics Any damage caused by the use of parts other than the original WEDECO spare parts and accessories will void all liability and guarantee obli...