Related Manuals for Hydro Instruments VPH-10000 Series
Summary of Contents for Hydro Instruments VPH-10000 Series
- Page 1 Series VPH-10000 Vaporizer Instruction and Operation Manual VPH-10000 Rev. 7/21/14...
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Page 2: Table Of Contents
Hydro Instruments VPH-10000 Vaporizer Table of Contents I. Introduction ......................3 1. Safety Information 2. System Size, Capabilities, and Specifications II. Installation ......................5 1. Installation of the Vaporizer 2. Installation of Chlorine Pressure Piping 3. Installation of Auxiliary Components 1. -
Page 3: Introduction
The contents of this manual are intended to provide information regarding the installation, operation, maintenance and troubleshooting of Hydro Instruments’ VPH-10000 vaporizer. It is critically important to read and become familiar with the contents of this entire manual before proceeding to install or operate the unit. -
Page 4: System Size, Capabilities And Specifications
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 installed prior to installation. -
Page 7: Electrical Installation
4. Electrical Installation 4.1 Connecting the Main Power: The VPH-10000 requires both three phase and single phase power. Depending on the model chosen, the voltage requirement will vary. All power connections are made through the heater control box. Warning: Electrical shock hazard. Ensure all power is disconnected from the source before proceeding. -
Page 8: Modbus Information
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. - 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...
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Page 10: Important Figures, Parts And Dimensional Drawings 1. Wiring Diagrams
FIgurE 1a: Heater Control box diagram for 120 VAC Single Phase Power FIGURE 1b: HEATER CONTROL BOX DIAGRAM (240 VAC SINGLE PHASE) FIgurE 1b: Heater Control box diagram for 240 VAC Single Phase Power... - Page 11 Figure 2. Main Controller Wiring FIgurE 2: Main Controller Wiring...
- Page 12 FIgurE 3: relay Output box Figure 3. Relay Output Box...
- Page 13 FIgurE 4: Vaporizer Controller MAIN CONTROLLER HEATER CONTROL BOX THREE PHASE DISCONNECT SWITCH SINGLE PHASE DISCONNECT SWITCH CONTACTOR INDICATOR STATUS (ON = ENERGIZED) MANUAL CONTACTOR OVERRIDE...
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Page 14: 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 15: 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 any other situation in which air/moisture has been allowed to enter the system. -
Page 16: System Start
4.1 Short Term Shut Down A short term shut down is defined 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. If applicable, temporally stop chemical feed at the vacuum regulator and allow liquid to fill back into the container. -
Page 17: Long Term Shut Down
Wait for 30 minutes to ensure pressure readings hold at 0 psi 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 18 FIgurE 5: Operating/Configuration Screens Figure 5. Operating/Configuration 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=100 E00 9.0 kW (50%) G=3.0...
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Page 19: 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. Control 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 20 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.
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Page 21: 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 flange 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 22: Water Heater
7. Water Heater: The water heater is a 4-inch flanged type 18 kW electric heater. The heater is housed in a self-insulating chamber to minimize heat losses and includes an over temperature thermocouple to shut off the heater in case of malfunction. The heater will also be shut off by the controller in the case of a low water level or high water temperature alarm. -
Page 23: 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. This should be done on a yearly basis at minimum. Ignoring this maintenance step can lead to serious malfunctions of the vaporizer. -
Page 24: Alarms And Switches Testing
1.2. Alarms and Switches Testing Alarms and switches should be tested at least once a year. Before proceeding to perform any testing or maintenance ensure that all chlorine has been completely purged from the system and that the chlorine container valves and inlet manifold piping valves are closed. Please refer to Section III.4.2 for long term system shut down before performing any of the below procedures. -
Page 25: Component Preventative Maintenance
⁄ " deep anywhere on the chamber, it must be replaced. 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 26: Troubleshooting
V. TrOubLESHOOTIng: Refer to Table 5 for common problems and troubleshooting techniques for the vaporizer system. For questions please consult Hydro Instruments. TAbLE 5: Troubleshooting Chart Problem Probable Cause(s) Corrective Action • Liquid chlorine in • Demand has exceeded design capacity •... - Page 27 • 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 • Pump failure/clogging • Check pump for clogging. If failed replace pump •...
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Page 28: Assembly Diagrams
VI. IMPOrTAnT FIgurES FIgurE 6a: Vaporizer Parts diagram... - Page 29 FIgurE 6b: Vaporizer Parts diagram...
- Page 30 FIgurE 6c: 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 temperature thermocouple. Type K VPH-10000-TC-TW thermowell VPH-10000-TC-TWA thermowell VPH-10000-3 Pressure chamber top flange VPH-10000-FB-1 Pressure chamber flange bolts VPH-10000-FN-1 Pressure chamber flange nuts VPH-10000-MRA Magnesium anode adapter VPH-10000-MAG...
- Page 31 FIgurE 7: VPH-10000 dimensional drawing FIGURE 7: VPH-10000 DIMENSIONAL DRAWING 34.000 REAR Ø0.750 11.000 14.000 (4 PLACES) 22.000 38.000 44.866 11.000 2.000 (TYP.) 13.938 15.558 2.000 (TYP.) 16.063 25.000 FRONT GAS OUTLET LIQUID INLET 1" AMMONIA TYPE UNION 1" AMMONIA TYPE UNION "...
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Page 32: Vapor Pressure Curves
Figure 6. Chlorine Vapor Pressure Curve FIgurE 8: Chlorine Vapor Pressure Curve Vapor Pressure... - Page 33 Figure 7. Sulfur Dioxide Vapor Pressure Curve FIgurE 9: Sulfur dioxide Vapor Pressure Curve Vapor Pressure Min. Superheat...
- Page 34 Figure 8. Ammonia Vapor Pressure Curve FIgurE 10: Ammonia Vapor Pressure Curve Vapor Pressure Min. Superheat...
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