Hydro Instruments VPH-10000 Series, Instruction And Operation Manual

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

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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 ...

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

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

Page 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 ...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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 ...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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 ...

Page 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...

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: ...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...

Page 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 ...

Page 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 ...

Page 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 ...

Page 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 ...

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

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

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