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Hydro Instruments VPH-10000-1 Series Instruction And Operation Manual

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Series VPH-10000-1
Vaporizer
Instruction and Operation Manual
VPH-10000-1 Rev. 9/11/19
1

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Summary of Contents for Hydro Instruments VPH-10000-1 Series

  • Page 1 Series VPH-10000-1 Vaporizer Instruction and Operation Manual VPH-10000-1 Rev. 9/11/19...

  • Page 2: Table Of Contents

    Hydro Instruments VPH-10000-1 Vaporizer Table of Contents I. Introduction ......................3 1. Safety Information 2. System Size, Capabilities, and Specifi cations 3. Units of Measurement II. Installation ......................5 1. Installation of the Vaporizer 2. Installation of Chlorine Pressure Piping 3.

  • Page 3: Introduction

    • Hydro Instruments cannot anticipate the specifi c safety procedures required at every facility. Accordingly, Hydro Instruments does not guarantee that safety procedures designed in accordance with this manual will completely eliminate hazards and thus assumes no liability for accidents that may occur in your facility.

  • Page 4: System Size, Capabilities And Specifi Cations

    When working with Chlorine • Ensure that approved, self-contained breathing and safety equipment are always available and ready for use and personnel are properly trained for its use. • Safety equipment should be inspected and maintained in accordance with the manufacturer’s instructions.

  • Page 5: Installation

    ⁄ " concrete anchor bolts through the bottom plate. If installing multiple vaporizers, Hydro Instruments recommends leaving at least 2 feet of clearance space between each vaporizer for ease of access. If using automatic water control, a ½" water pipeline should be installed to the water solenoid valve.

  • Page 6: Pressure Relief Valve Assembly

    3.2 Pressure Relief Valve Assembly The pressure relief valve assembly is a critical component to any chlorine vaporizer system and is required by ASME code for operation. This mechanical safety device limits the pressure of the chlorine pressure chamber to a maximum value. The rupture disc must be properly installed into the rupture disk holder prior to installing the rupture disk assembly onto the pipe.

  • Page 7: Electrical Installation

    4. Electrical Installation 4.1 Connecting the Main Power: The VPH-10000-1 requires three phase power. All power connections are made through the heater control box. Warning: Electrical shock hazard. Ensure all power is disconnected from the source before proceeding. Ensure that only qualifi ed personnel are working on this equipment. a.

  • Page 8: Modbus Information

    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 confi guring Hydro Instruments equipment onto SCADA systems, please refer to the Modbus Installation and Instruction manual.
  • Page 9 TABLE 3: Modbus Information Register Name Type Address Feature Value Gas Temperature Integer Gas Pressure Integer Gas Pressure Span Integer High Pressure Alarm Level Integer Superheat Temperature Integer Superheat Alarm Set Point Integer Control Water Temperature Integer Water Temperature Set Point Integer High Temperature Alarm Set Point Integer...

  • Page 10: Important Figures, Parts And Dimensional Drawings 1. Vaporizer Main Controller Photograph

    FIGURE 1: Vaporizer Main Controller Photograph...

  • Page 11: Wiring Diagrams

    FIGURE 2: Wiring Example: Heater Control Box for 480VAC Primary with 120VAC Secondary Conduit Port Conduit Port Vaporizer Vaporizer Controller Controller 4-20mA Signal from Vaporizer Controller to SCR Breaker Controller Toggle Switch Transformer and Toggle Switch Wiring Varies for Contactor Other Primary/ Secondary Power...
  • Page 12 FIGURE 3: Main Controller Wiring...
  • Page 13 FIGURE 4A: Relay Connections Box...
  • Page 14 FIGURE 4B: Signal Connections Box...
  • Page 15 FIGURE 5: Vaporizer Controller...

  • Page 16: Operation

    These residues can cause accelerated pipe corrosion and result in a leak. NOTE: Before performing this step, be sure to read Hydro Instruments “Nitrogen Purging” document for further information.

  • Page 17: Initial Start-Up

    2. Initial Start-Up Only refer to the start-up procedure outlined in this section if the previous Section III.1 leak test has already been completed and you are now performing the initial start-up, the piping has been changed, the vaporizer has just been cleaned, or in any other situation in which air/moisture has been allowed to enter the system.

  • Page 18: System Start

    4.1 Short Term Shut Down A short term shut down is defi ned as any situation where the chemical feed is only temporarily interrupted, and the heater and all control functions will remain on. Hydro Instruments recommends the following procedure: a.

  • Page 19: Long Term Shut Down

    Wait for 30 minutes to ensure pressure readings hold at 0 psi (0 bar) and then repeat this step as necessary. d. Purge the system with dry air or nitrogen according to the instructions in the Hydro Instruments Nitrogen Purging document. Then operate the ejector again to remove all gas from the system until the pressure gauges read zero.
  • Page 20 FIGURE 6: Operating/Confi guration Screens T=100F P= 85 psi Select PRV on Duty Superheat = 32 F PRV#1/Relay1 Control Water Temp Modbus Baud=250000 180 F Node=1 Data=8/N/1 Aux Water Temp Pressure Span 170 F 300 psi Heater Power T180 S=180 O=50 E00 9.0 kW (50%) G=3.0 I=1.0 LT=5...

  • Page 21: Explanation Of Main Controller Screens

    5.1 Explanation of Main Controller Screens 1. Operation Screen: This screen displays a live reading of the pressure chamber operating conditions. These parameters include: gas temperature, gas pressure and superheat. 2. Water Temperature: This screen displays a live reading of the water tank temperature. This is the temperature reading that is used for PID control of the water temperature and all appropriate water temperature alarms.
  • Page 22 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 vaporizer.

  • Page 23: Operating Controls And Components

    6. Operating Controls and Components 1. Chlorine Gas Temperature Thermocouple: The chlorine gas outlet temperature is monitored by a K-type thermocouple through the top fl ange of the chlorine pressure chamber. For added corrosion protection it is installed with a Hastelloy-C thermowell. Its main function is to provide visual indication of the chlorine gas outlet temperature, and together with the chlorine gas pressure transmitter, is used to calculate and then display the superheat value.

  • Page 24: Water Heater

    7. Alarms and Features Refer to Table 4 for a description, and action of all alarms incorporated into the vaporizer unit. Note that while some alarms take preventative action themselves, an operator should always monitor an alarm situation and take preventative action if need be or the situation persists. For information on troubleshooting techniques see Section V.

  • Page 25: Maintenance

    IV. MAINTENANCE 1. Yearly Maintenance 1.1 Chlorine Pressure Chamber Cleaning It is important to inspect and clean the chlorine pressure chamber for signs of corrosion, buildup of debris and clogging. It is recommended to be done on a yearly basis. Ignoring this maintenance step can lead to serious malfunctions of the vaporizer.

  • Page 26: Alarms And Switches Testing

    m. Check and tighten all 3 phase power wire terminals in the heater control box and top of the heater. Check continuity throughout the three phase power section. Re-install all electrical connections/ instruments, connect the power, and reconnect the chlorine manifold piping with new lead gaskets. n.

  • Page 27: Component Preventative Maintenance

    Water Level Alarm Testing a. Turn on the vaporizer unit and allow the water to automatically fi ll the tank. b. The low water level alarm should be on until the water in the sight glass reaches the low water alarm level marking.
  • Page 28 " (0.3 cm) depth anywhere on the chamber, it must be replaced. This weight includes the top fl ange, fl ange bolts, and lead gasket. Original weight is stamped on the pressure chamber and also stored with Hydro Instruments for future reference. d. Complete Section IV.1 steps i through n.

  • Page 29: Troubleshooting

    V. TROUBLESHOOTING: Refer to Table 5 for common problems and troubleshooting techniques for the vaporizer system. For questions please consult Hydro Instruments. TABLE 6: Troubleshooting Chart Problem Probable Cause(s) Corrective Action • Liquid chlorine in • Demand has exceeded design capacity •...
  • Page 30 Problem Probable Cause(s) Corrective Action • Low water • Chemical capacity exceeded • Lower feed capacity temperature • Improper wiring/failed heater. • Check wiring/replace or clean heater Fouling of heater surface • Improper wiring/failed temperature • Check wiring/replace PID controller controller •...

  • Page 31: Assembly Diagrams

    VI. IMPORTANT FIGURES FIGURE 7a: Vaporizer Parts Diagram...
  • Page 32 FIGURE 7b: Vaporizer Parts Diagram Hydro Part Number Description Qty. VPH-10000-PT-300 pressure transmitter VPH-10000-PT-300A pressure transmitter VPH-10000-TC-K-GAS Gas temperature thermocouple. Type K VPH-10000-TC-TW thermowell VPH-10000-TC-TWA thermowell VPH-10000-3 Pressure chamber top fl ange VPH-10000-FB-1 Pressure chamber fl ange bolts VPH-10000-FN-1 Pressure chamber fl ange nuts VPH-10000-MRA Magnesium anode adapter VPH-10000-1-MAG-SET...
  • Page 33 FIGURE 8: VPH-10000-1 Dimensional Drawing...

  • Page 34: Vapor Pressure Curves

    FIGURE 9: Chlorine Vapor Pressure Curve...
  • Page 35 FIGURE 10: Sulfur Dioxide Vapor Pressure Curve...
  • Page 36 FIGURE 11: Ammonia Vapor Pressure Curve...

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