Spirax Sarco BPS32 Installation And Maintenance Instructions Manual
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Spirax Sarco BPS32 Installation And Maintenance Instructions Manual

Spirax Sarco BPS32 Installation And Maintenance Instructions Manual

Pressurised thermophysical deaerator with operator manual for the control unit
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3.635.5275.275
IM-P537-01
EMM Issue 1
Pressurised Thermophysical deaerator
with operator manual for the control unit
Installation and Maintenance Instructions
Pressurised Thermophysical deaerator with operator manual for the control unit
© Copyright 2021
1
IM-P537-01 EMM Issue 1
Printed in GB

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  • Page 1 3.635.5275.275 IM-P537-01 EMM Issue 1 Pressurised Thermophysical deaerator with operator manual for the control unit Installation and Maintenance Instructions Pressurised Thermophysical deaerator with operator manual for the control unit © Copyright 2021 IM-P537-01 EMM Issue 1 Printed in GB...

  • Page 2: Table Of Contents

    Contents Safety information General product information Description Product identification Identification of components Project conditions Operating limits Consumption Dimensions and weights Transport and unpacking the package unit Installation Installation environment Handling, positioning and fastening Process connections and draining Pneumatic section connection Power supply connection Commissioning Pre-commissioning inspection (initial start-up)
  • Page 3 Operation Control unit Operator panel STATUS Alarms and locks Graph Ramp Settings Troubleshooting Maintenance General information Replacement parts Appendix A Recommended inspections Scheduled Spirax Sarco maintenance Pressurised Thermophysical deaerator with operator manual for the control unit IM-P537-01 EMM Issue 1...
  • Page 4 All rights reserved. In accordance with the legislation in force, Spirax Sarco reserves all ownership rights of this document, which may not be reproduced or transferred to third parties without prior written permission. Spirax Sarco also reserves the right to change product specifications without prior notice.

  • Page 5: Safety Information

    1. Safety information Safe operation of these products can only be guaranteed if they are properly installed, commissioned, used and maintained by qualified personnel in accordance with the manufacturer's operating instructions. General safety installation instructions for the construction of pipes and systems, as well as the appropriate use of safety tools and equipment must also be observed.
  • Page 6 The assembled unit hazard category has been determined according to the increasing hazard criteria based on Pressure (bar) per Volume (litres) or Design Pressure per ND (nominal diameter). It is understood that Spirax Sarco also used components with a higher category than the minimum required for manufacturing the pre-assembled unit.
  • Page 7 1.11 Protective clothing Consider whether you and/or others need protective clothing to protect against hazards, such as chemicals, high/low temperature, radiation, noise, falling objects and eyes and face hazards. 1.12 Work permit All work must be carried out or supervised by a qualified person. Installation and operating personnel must be trained in the correct use of the product according to the Maintenance and Installation Instructions.
  • Page 8 1.16 Return of products When returning products to Spirax Sarco, customers and retailers are reminded that pursuant to the EC Health, Safety and Environment Act they must provide information on hazards and precautions to be taken because of contamination residues or mechanical damage that may present a hazard to health, safety and environment.
  • Page 9 Steam Mains - Do's and Don'ts: Flow Flow Steam Steam Pressurised Thermophysical deaerator with operator manual for the control unit IM-P537-01 EMM Issue 1...
  • Page 10 Prevention of tensile stressing Pipe misalignment: Installing products or re-assembling after maintenance: Do not over tighten. Use correct torque figures. Flange bolts should be gradually tightened across diameters to ensure even load and alignment. Pressurised Thermophysical deaerator with operator manual for the control unit IM-P537-01 EMM Issue 1...
  • Page 11 Thermal expansion: Guides Axial movement Short Fixing point distance Axial movement Guides Guides Small Limit Large lateral lateral rods movement movement Medium Fixing point distance Large lateral Limit rods Small lateral movement movement Guides Pressurised Thermophysical deaerator with operator manual for the control unit IM-P537-01 EMM Issue 1...

  • Page 12: General Product Information

    2. General product information 2.1 Description The thermophysical deaerator is used in most systems requiring removal of gases that can damage boilers and pipes. The theories involved in the removal of gases dissolved in liquids are based on tables and chemical principles, such as Dalton's and Henry's Law.

  • Page 13: Product Identification

    2.2 Product identification The product is identifiable by the nameplate fastened to the frame. Fig. 2 Pressurised Thermophysical deaerator with operator manual for the control unit IM-P537-01 EMM Issue 1...
  • Page 14 2.2.1 Example of nameplate The unit has an identification plate fastened to the frame. All identification data such as model, factory number and year of construction are summarized on the nameplate. N.B. all correspondence concerning the unit must include the above-mentioned data. The design conditions (circuit pressure and temperature), weight, fluid group and device category are also specified.

  • Page 15: Identification Of Components

    2.3 Identification of components For the identification of the components installed on the unit, refer to the P&ID and the technical documentation of the project. 2.4 Project conditions Design pressure (PS) 0.5 bar Tank and turret Design temperature (TS) 160 °C Safety valve calibration 0.5 bar Design pressure (PS)

  • Page 16: Dimensions And Weights

    2.7 Dimensions and weights (approximate in mm and kg) Model - Size Empty weight Operating weight Length Width Height PDA.03 - 3.000 l 3.400 mm 1.890 mm 3.531 mm 1.350 kg 3.450 kg PDA.05 - 5.000 l 3.869 mm 1.965 mm 3.931 mm 1.770 kg 5.270 kg...

  • Page 17: Transport And Unpacking The Package Unit

    2.8 Transport and unpacking the package unit Spirax Sarco deaeration systems are very bulky units and are not commonly packaged, while protecting the unit during transport. All units are equipped with lifting and handling eyebolts. The unit must be lifted using only the areas indicated on the packing case, or by using the clearly marked lifting eyebolts.

  • Page 18: Installation

    3. Installation 3.1 Installation environment If the PDA unit is to be installed outdoors, it must be adequately protected against adverse weather conditions and freezing, paying special attention to the protection of the electrical control panel. All installed instrumentation has a minimum IP55 level of protection. The unit is NOT suitable for installation in potentially hazardous areas with ATEX classification.

  • Page 19: Handling, Positioning And Fastening

    3.2 Handling, positioning and fastening Step 1 Lift and unload the equipped tank body from the articulated lorry (as shown in the figure), using a crane or suitable authorised handling system and then anchor the tank saddles (using anchor bolts) to the existing structure.
  • Page 20 Step 2 Lift the deaerator head using a crane or appropriate authorised handling system (yellow arrows), then attach the head to the tank nozzle using tie bolts (green arrow). IMPORTANT remember to insert the gasket before tightening the anchoring bolts. During this lifting operation, make sure that the crane arm's opening range and the surrounding area are free of any obstacles or the presence of unauthorised personnel.
  • Page 21 Step 3 Lift the steam injection and water inlet assembly skid using the four lifting eyebolts (yellow arrow) welded to the support frame using a crane or adequate authorised handling system. During this lifting operation, make sure that the crane arm's opening range and the surrounding area are free of any obstacles or the presence of unauthorised personnel.
  • Page 22 Step 4 Fasten the make-up water inlet spool (yellow arrow) to the deaerator head nozzle and then fasten it to the outlet spool, already fastened to the frame (green arrow). Warning All the operations described above must be carried out only by qualified personnel, respecting all the rules and using the safety devices required by law.
  • Page 23 Completing the installation. Installation of the Spirax Sarco system is now complete. All documentation provided with the system must be handed over to the personnel responsible for maintenance.

  • Page 24: Process Connections And Draining

    Therefore, refer to the dimensional drawing for the specific unit. In general, Spirax Sarco integrated systems are installed following this simple procedure: Note: Before making any connection make sure that all pipes are clean and free from foreign bodies or waste matter.

  • Page 25: Pneumatic Section Connection

    3.3.4 Safety valves connection. Spirax Sarco integrated systems are equipped with one or more safety valves. On the primary side, it is assumed that the safety valve is installed on the deaerator. The connection of the safety valve to a suitable vent and discharge system serves both to prevent damage to the device and to reduce the risk of accidents that may be caused by water.

  • Page 26: Power Supply Connection

    3.5 Power supply connection For the supply voltage refer to the wiring diagram provided with the unit. Potential danger, even deadly. Before connecting to the power supply, check that the master power switch and the system’s on/off selector are in position 0 (OFF). Unless otherwise indicated in the documentation provided with the unit, the power supply must be connected directly to the main isolation breaker (MS) of the control panel (removing the protection) and to the grounding terminal.
  • Page 27 Electrical specifications For electrical data, refer to the wiring diagram provided with the unit. The following are generic electrical data that may not fully match the specific data of the supplied unit. Control panel power supply Input voltage: 3x400V + N or 1x230V - 50 Hz 0.5kW (Inst.) Feedback: Output contacts: 3 A - 220V for inductive loads...

  • Page 28: Commissioning

    Check that the condensate has enough pressure to return to the turret. Provide room for operation to allow for easy maintenance if not already included in the Spirax Sarco package, insulate the equipment and all "hot" lines of the unit 4.1 Pre-commissioning inspection (initial start-up)

  • Page 29: Commissioning Procedure

    4.1.1 Cleaning before commissioning Before commissioning a new unit, it is recommended to flush the deaerator tank or carry out other procedures required by the operating or plant regulations. 4.2 Commissioning procedure Ensure that all isolation valves are closed. Ensure that the master switch and the system’s start-up selector on the control panel are set to 0/OFF. Ensure that the emergency button is released.

  • Page 30: Procedure For Decommissioning (Shut-Down)

    4.3 Procedure for decommissioning (shut-down) The following procedure must be followed if the deaerator is switched off for longer periods of time, such as the weekend, or for maintenance purposes. Close the primary fluid isolation valve. Stop the unit operation: set selector 1-0-REM to 0. Wait for pressure to drop to approx.

  • Page 31: Operation

    5. Operation 5.1 Operation The PDA deaerator unit consists of a complete, safe and functional package system able to eliminate the gases dissolved in the feedwater of steam generators. The deaeration system operates as follows: The condensate and make-up water are fed into the upper part of the deaerator head, are mixed and fall on a series of plates with which the turret has been sized.
  • Page 32 5.1.1 Pressure regulation The pressure of the deaerator is maintained by the related pressure regulator (PIC-01) of the PLC control unit. The process variable is detected by the gauge pressure transmitter (PT-01) installed on the deaerator body, which sends the 4-20 mA signal, corresponding to the 0-2.5 bar range, to the regulator/PLC which controls the stripping steam valve of the deaerator head.

  • Page 33: Control Unit

    5.2 Control unit The electrical control panel on the "deaerator" unit provides complete control of the deaerator system. All the electrical components of the unit are properly wired to the panel. 5.2.1 Front panel controls/lights Touchscreen This is the PLC control and the touchscreen panel. L1: led When it is on, it indicates that the unit is on and the voltage is present (230 Vac).
  • Page 34 5.2.2 Auxiliary circuit protection The auxiliary circuit is protected against overloads by a circuit breaker. Each solenoid valve or actuated valve is also protected by a fuse on corresponding terminals panel. 5.2.3 Protection interlocks The electromechanical protections with partial/total system interlocks are the following: High pressure →...
  • Page 35 5.2.5 Terminal block A terminal block is housed inside the panel for wiring of: electronic components on pre-wired unit panel digital I/Os analogue I/Os The power supply (from the mains) must be connected directly to the master switch terminals, unless otherwise indicated in the documentation provided with the unit.

  • Page 36: Operator Panel

    5.3 Operator panel 5.3.1 Initial screen The control unit is equipped with a touchscreen display. When the unit is turned on, the display shows the following image (Fig.1): Fig. 1 To interact with the control screens, simply press the screen surface with your fingertips. Select the icon and Fig.2 will appear: Fig.
  • Page 37 Select the icon; the start menu (Fig.3) will appear, showing: Information about Spirax Sarco. Status: contains start/stop and information on the operation of the deaerator. Protected parameters: device configuration parameters necessary for the operation of the deaerator. Fig. 3 Pressurised Thermophysical deaerator with operator manual for the control unit...
  • Page 38 5.3.2 Protected parameters Pressing the PROTECTED PARAMETERS icon, Fig.4 will appear. Fig.4 Enter Password = 3. then press ENTER to confirm. When you enter, Fig.5 will appear. Fig.5 Pressurised Thermophysical deaerator with operator manual for the control unit IM-P537-01 EMM Issue 1...
  • Page 39 Pressing the Machine Settings icon, Fig.6 will appear. Press the icon to change the settings (the lock opens). Then use the side buttons to enable or disable the displayed functions. When the configuration is complete, press the icon to save the settings (the lock closes).
  • Page 40 Pressing the Panel Regulations icon, Fig.7 will appear. Fig.7 Select the desired brightness by pressing the corresponding icon. Press the icon to return to Fig.5. Pressing the Select Language icon, Fig.8 will appear. Fig.8 Choose your language. A check mark will appear on the chosen flag.
  • Page 41 Pressing the Date & Time icon, Fig.9 will appear. Fig.9 Press the respective Day/Month/Year and Hours/Minutes/Seconds boxes to set the current date and time. If you want to automatically update the time during the change between daylight saving and summer time and vice versa, press the white box.
  • Page 42 Press the icon to see the status of the "Digital output" (Fig.10b). Fig.10b Press the icon to see the status of the "Digital input" (Fig.10c). Fig.10c To get back to Fig. 5. press the icon several times. Note: returning to Fig. 5. the manual forcing is reset to zero. Pressurised Thermophysical deaerator with operator manual for the control unit IM-P537-01 EMM Issue 1...
  • Page 43 Pressing the Change Password icon, Fig.11 will appear Fig.11 If you want to change the default value, assigned by default, press on the number beside the description and, using the numeric keypad displayed, enter the new password value. Then confirm by pressing the RET button. Then press the button to return to the previous screen (Fig.
  • Page 44 Pressing the Analog I/O Parameters icon, Fig.12 will appear. To change the page, press the icon To change any value, just press on it: a keyboard will appear. To confirm the new value, press RET. Press the icon to return to Fig.5.
  • Page 45 Pressing the Plant Parameters icon, Fig.13 will appear. To change the page, press the icon To change any value, just press on it: a keyboard will appear. To confirm the new value, press Set the value of Δ LEVEL PV < SV STOP PUMP always lower than the value of Δ...
  • Page 46 By pressing the Timer Start Automatic Cycle icon, Fig.14 will appear and it is possible to set the daily automatic start time of the deaerator. Fig.14 To set the start time, press on the square next to the desired day: the check mark will confirm your choice.

  • Page 47: Status

    5.4 STATUS Pressing the STATUS icon, Fig.15 will appear. Fig.15 Automatic Cycle Before starting the automatic cycle, you must enter the set points (pressure and level). To enter the pressure set point in the screen shown in Fig. 15. tap the corresponding box (indicating the set value) and a keyboard will appear where you can enter the password.

  • Page 48: Alarms And Locks

    5.5 Alarms and locks All the alarms, besides being displayed, are stored in a dedicated area. To access it, press the key on the Status page (Fig.15). The following screen will be displayed Fig. 16 For each alarm, the DAY, MONTH, YEAR, HOUR and MINUTE of start (1) and end (0) is indicated Press the button to display the first alarm in the stored list.
  • Page 49 In detail for the operating cycle of the deaerator: Block of the DG feedwater valve when one of the following alarms occurs: analogue DG level transmitter error maximum DG level Block the DG pressure and temperature control valves when one of the following alarms occurs: analogue DG temperature transmitter error analogue DG pressure transmitter error analogue DG level transmitter error...

  • Page 50: Graph

    5.6 Graph On the Status page (Fig.15), you can access the graph page (trend) Fig.17 where the temperature and pressure measurement and the corresponding set point values trends are displayed by pressing symbol. Fig.17 buttons to shorten/lengthen the displayed time interval. By using keys, you can move the cursor to see the set/actual values at a certain time.

  • Page 51: Ramp

    5.7 Ramp On the Status page (Fig.15), ramp page Fig.18 can be accessed by pressing the symbol. On this page, at the start-up of the operating cycle, it is possible to limit the percentage of the steam control valve opening, depending on the temperature range detected by the transmitter. Fig.18 To change any value, just press on it.

  • Page 52: Troubleshooting

    6. Troubleshooting Problem Possible causes Corrective action No power Check the input power The unit does not Check the automatic switch of start Auxiliary circuit protection on the auxiliary circuit protection in the control board. Check the conditions of the water supply.
  • Page 53 Problem Possible causes Corrective action Inspect the valve housing The water control valve does not close to identify any damage. If correctly necessary repair the valve. Check the settings. Check that the I/P convertor or valve positioner reaches the Water level in Fault/malfunction of level regulator regulating signal.
  • Page 54 Problem Possible causes Corrective action Check the opening of the manual valve for non- Condensate temperature too high condensable gas discharge on deaerator head. If necessary, open the exhaust more. The deaerator is not able to Check the primary steam pressure is correct and there maintain the are no pressure losses when...

  • Page 55: Maintenance

    The information in this section covers service and maintenance procedures for the inspection and replacement of Spirax Sarco system components. If any maintenance procedures are unclear, please contact Spirax Sarco, having the unit's model and factory number on hand. Before starting any maintenance work, carefully read the general safety information in chapter 1 of this document.

  • Page 56: Replacement Parts

    Follow the start-up procedures to restart the system. Check connections for possible leaks. 7.2 Replacement parts If not offered when purchasing the product, please contact the Spirax Sarco Service for recommended replacement parts necessary for maintenance. Replaceable parts may vary depending on the unit and particular design specifications.
  • Page 57 7.3 Appendix A. Bolt tightening procedure Sequential Rotational Sequential Rotational order order order order 1 - 2 1 - 2 3 - 4 3 - 4 5 - 6 5 - 6 7 - 8 7 - 8 9 - 10 11 - 12 8 bolts 12 bolts...

  • Page 58: Recommended Inspections

    Shut-off valve Safety circuit Filters Other 7.5 Scheduled Spirax Sarco maintenance. Upon request, Spirax Sarco can provide scheduled maintenance contracts with the following operations. The maintenance contract generally provides for two visits per year. Type of inspection Every Every Every...
  • Page 59 LOSS OF WARRANTY Failure to comply with these rules in whole or in part will result in the loss of all warranty rights. Spirax Sarco S.r.l. - Via per Cinisello, 18 - 20054 Nova Milanese (MI) Tel.: 0362 49 17.1...
  • Page 60 Pressurised Thermophysical deaerator with operator manual for the control unit IM-P537-01 EMM Issue 1...

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