Pen Flourometer Operation Manual OM0208
3D TRASAR Boiler Technology 33 Installation and Operation Manual OM0211
Date 11-10-10 Version – 4.2 Nalco Global Equipment Solutions 1601 West Diehl Road Naperville, IL 60563-1198
Nalco Global Equipment Solutions
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211
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Nalco Global Equipment Solutions
3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________
Table of Contents 1.0 Introduction...................................................................................................... 9 3D TRSAR Boiler Technology............................................................................................ 9 3D TRASAR Boiler Models and Optional Component ...................................................... 11 About This Manual........................................................................................................... 12 Potential Applications ...................................................................................................... 12 1.4.1 Feedwater Treatment Programs............................................................................. 12 1.4.2 3D TRASAR Cycles Control ................................................................................... 13 1.4.3 Hardness Excursion Override................................................................................. 13 1.4.4 BT Phosphate / pH Product Line Control ................................................................ 13 1.4.5 Condensate Monitoring .......................................................................................... 13 1.5 Safety.............................................................................................................................. 14 1.5.1 Explanation of Symbols.......................................................................................... 14 1.6 Installation, Assembly, Start-Up and Control Tuning Overview ......................................... 15 1.1
1.2 1.3 1.4
2.0 System Installation ........................................................................................ 17 2.1
Unpack and Identify Parts................................................................................................ 17 2.1.1 Frames and Panels ................................................................................................ 17 2.1.2 Items Requiring Assembly...................................................................................... 18 2.1.3 Additional Items Shipped Loose ............................................................................. 18 2.2 Mount the Panel (or Frame)............................................................................................. 19 2.2.1 General Installation Instructions ............................................................................. 19 2.2.2 Wall Mounting ....................................................................................................... 20 2.2.3 Frame Mount Dimensions ...................................................................................... 21 2.2.4 Installation Overview Diagrams .............................................................................. 22 2.2.4.1 TRASAR Fluorometer and NCSM Feedwater Systems..................................... 22 2.2.4.2 TRASAR Fluorometer Feedwater Systems ...................................................... 23 2.2.4.3 NCSM Feedwater Systems .............................................................................. 24 2.2.4.4 TRASAR Fluorometer Blowdown Systems ....................................................... 25 2.2.4.5 Continuous Blowdown Conductivity Probe And Valves..................................... 26 2.2.4.6 Timed-Sample Blowdown Conductivity Probe And Valves ............................... 27 2.2.4.7 Condensate Monitor......................................................................................... 28 2.3 Plumb the System ........................................................................................................... 29 2.3.1 Plumbing Requirements ......................................................................................... 29 2.3.2 Plumbing Connections ........................................................................................... 30 2.3.3 Plumbing Notes...................................................................................................... 31 2.3.3.1 Sample Point ................................................................................................... 31 2.3.3.2 Sample Lines................................................................................................... 32 2.3.3.3 Discharge Line................................................................................................. 33 2.3.3.4 Cooling Water Lines......................................................................................... 33 2.3.3.5 Blowdown Conductivity Probe Assy, Control Valve & Flow Control Valves........ 34 2.3.3.6 Condensate Conductivity Probe Assy, Sample Take-Off, Control Valve & Flow Control Valves ................................................................................................. 37 2.3.3.7 Boiler NCM100 Probe Installation..................................................................... 38
3.0 Electrical Wiring and Connections............................................................... 39 3.1 3.2
Run Wires in the Control Box ......................................................................................... 39 Terminate Wires in the Control Box ................................................................................ 40 3.2.1 System Power Connections ................................................................................... 40 3.2.2 Internal Power Connection ..................................................................................... 40 3.2.3 Fuses..................................................................................................................... 40
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 3.2.4 Control Relay Connections ..................................................................................... 41 3.2.4.1 Control Relays – Powered and Non-Powered Wiring ........................................ 41 3.2.4.2 Relay Connections Inside Controller................................................................. 42 3.2.4.3 Blowdown Valve Relay Box Connections.......................................................... 43 3.2.5 Alarm Relay Connections ....................................................................................... 44 3.2.6 Fluorometer Connections ....................................................................................... 44 3.2.7 Conductivity Probe Connections............................................................................. 45 3.2.7.1 Compensating vs. Non-Compensating Probes................................................ 45 3.2.7.2 Conductivity Probe Wiring............................................................................... 47 3.2.8 High Impedance (pH/ORP) Connections................................................................. 54 3.2.9 Nalco Corrosion Monitor (NCM100) ....................................................................... 55 3.2.10 Analog Inputs ......................................................................................................... 55 3.2.11 Analog Input Module (Optional) .............................................................................. 57 3.2.12 Analog Outputs ...................................................................................................... 59 3.2.13 Interlock ................................................................................................................. 59 3.2.14 Temperature (RTD) Inputs ..................................................................................... 60 3.2.15 Digital Inputs .......................................................................................................... 61 3.2.16 Modem/Phone Line Connections ............................................................................ 62 3.2.17 Ethernet Connections ............................................................................................. 62 3.2.18 LAN Connections ................................................................................................... 63 3.2.19 USB ....................................................................................................................... 63 3.2.20 SCADA (RS232/485/Ethernet)................................................................................ 63 3.2.21 3D TRASAR Boiler Controller Terminal Connection Diagram .................................. 65 3.2.22 3D TRASAR Boiler Controller Default Wiring .......................................................... 66
4.0 Final Assembly and Start-up......................................................................... 67 4.1 4.2 4.3 4.4
Installation Check and Safety Check .............................................................................. 67 Shut all 3D TRASAR Boiler System Valves ................................................................... 67 Install and Connect the TRASAR Fluorometer................................................................ 68 Power Up Control System Without Sample or Cooling Water Flowing............................. 69 4.4.1 TRASAR Fluorometer and NCSM System .............................................................. 69 4.4.2 TRASAR Fluorometer Systems .............................................................................. 69 4.4.3 NCSM Systems...................................................................................................... 69 4.5 Configure System and Upload to 3D TRASAR Controller ................................................. 69 4.5.1 PC System Requirements ...................................................................................... 69 4.5.2 Installing the Software ............................................................................................ 69 4.5.3 Configurator Support .............................................................................................. 70 4.6 Reboot the 3D TRASAR Controller .................................................................................. 70 4.7 Verify the Configuration Using the Controller Keypad/Screens ......................................... 70 4.8 Calibrate the Fluorometer ................................................................................................ 71 4.8.1 Fluorometer Calibration Procedure ......................................................................... 71 4.8.2 Fluorometer Calibration Screen Instructions ........................................................... 71 4.8.2.1 Fluorometer 2-Point Calibration Screens Instructions (Successful Calibration).. 72 4.8.2.2 Fluorometer 2-Point Calibration Screens (Cancel Selected During Calibration). 72 4.8.2.3 Fluorometer 2-Point Calibration Screens (Calibration Fails) .............................. 72 4.9 NCSM Short Circuit Test.................................................................................................. 73 4.9.1 NCSM Short Circuit Test Procedure ....................................................................... 73 4.9.2 NCSM Short Circuit Test Screens Instructions........................................................ 73 4.10 Refurbish and Test the NCSM Reference Electrode......................................................... 74 4.10.1 NCSM Probes ........................................................................................................ 74 4.10.2 ORP/RTD Probes................................................................................................... 74 4.10.3 Reference Electrode............................................................................................... 75 4.10.4 NCSM Probe Cables .............................................................................................. 76 4.10.5 NCSM Probe Checkout .......................................................................................... 76
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ 4.10.6 Refurbishing the Reference Electrode .................................................................... 76 4.10.7 Reference Electrode Check.................................................................................... 79 4.10.8 Reference Electrode Check Screens ...................................................................... 80 4.10.9 Install the Reference Electrode............................................................................... 80 4.11 Feedwater pH and Conductivity Probe Installation ........................................................... 81 4.12 pH Probe Calibration ....................................................................................................... 81 4.13 Conductivity Probe Calibration......................................................................................... 83 4.13.1 Recommended Conductivity Standards .................................................................. 83 4.13.2 2-Point Calibration.................................................................................................. 84 4.13.3 1-Point Calibration.................................................................................................. 86 4.13.3.1 Continuous Sample – On/Off or PID Control .............................................. 86 4.13.3.2 Timed Sample – Continuous On/Off Control .............................................. 86 4.13.3.3 Timed Sample – Proportional Control......................................................... 87 4.13.4 Extracting a Conductivity Probe from the Blowdown Line of an Operating Boiler ..... 88 4.13.5 Installing a Conductivity Probe into the Blowdown Line of an Operating Boiler ........ 89 4.13.6 Cleaning a Fouled Conductivity Probe.................................................................... 89 4.14 System Leak Test and Final Piping Insulation .................................................................. 89 4.15 Startup ............................................................................................................................ 90 4.15.1 NCSM & Fluorometer Models – System Valve Identification ................................... 90 4.15.2 TRASAR Fluorometer and NCSM System Startup.................................................. 90 4.15.3 TRASAR Fluorometer Only System Startup............................................................ 92 4.15.4 NCSM Only System Startup (without Sample Conditioning System) ....................... 93 4.15.5 Condensate Monitor System .................................................................................. 93 4.16 Test Data Download to a USB Data Stick and Laptop Computer ...................................... 95 4.17 Verify Operation of the Control Outputs ........................................................................... 95 4.18 Test High-Temperature Shutdown & Pressure Relief ....................................................... 95 4.19 Check Remote Communications...................................................................................... 96 4.19.1 3D TRASAR Boilers Nalco Global Gateway Setup.................................................. 96 4.19.2 3D TRASAR Boilers Phone Line Verification .......................................................... 98
5.0 Tasks to Perform Before Control Tuning.........................................………102 5.1 5.2 5.3 5.4 5.5
Ensure an Interlock Is Connected or Shutdown Process Is Established.......................... 102 Verify Chemical Pump Capability ................................................................................... 102 Check Pump Responses and Measure Lag Times......................................................... 103 Control Selection ........................................................................................................... 104 NCSM Set Point Determination...................................................................................... 105 5.5.1 0-100% Scavenger Pump Test ............................................................................. 105 5.5.1.1 0-100% Pump Test by Manually changing the Output ................................. 105 5.5.1.2 Pump Test Using the NCSM PID Tuning Program ...................................... 106 5.5.2 Comfort Control NCSM Setpoint........................................................................... 106 5.5.3 Ideal Control NCSM Setpoint................................................................................ 107 5.6 TRASAR Setpoint.......................................................................................................... 107 5.7 Intermittent Operation.................................................................................................... 107 5.7.1 General Considerations........................................................................................ 107 5.7.1.1 Interlocks and Alarms .................................................................................... 107 5.7.1.2 Control Options.............................................................................................. 107 5.7.1.3 Control Expectations...................................................................................... 108 5.7.2 Special NCSM Considerations ............................................................................. 108 5.7.2.1 General Considerations ................................................................................. 108 5.7.2.2 Monitoring...................................................................................................... 110 5.7.2.3 Manual Feed.................................................................................................. 110 5.7.2.4 Control ........................................................................................................ 110 5.7.2.4.1 High & Low Temperature Interlock ................................................... 111 5.7.2.4.2 No Flow Switch................................................................................ 112
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 5.7.2.4.3 5.7.2.4.4 5.7.2.4.5
Slaved Control ................................................................................. 113 ON/OFF Control............................................................................... 113 PID Control ...................................................................................... 113
6.0 ON/OFF Relay Control ................................................................................. 114 6.1
ON/OFF Control Using the PID 4-20 Outputs ................................................................. 114
7.0 Proportional Control Configuration............................................................ 115 7.1 7.2
Blowdown Control (Cycle Control using 3D TRASAR Fluorometer) ................................ 115 Feedwater Flow-Based Proportional Control .................................................................. 117
8.0 PID Configuration and Tuning .................................................................... 119 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 9.9
Check PID Configuration................................................................................................ 119 When to Auto Tune........................................................................................................ 119 Before Starting Auto Tune.............................................................................................. 119 Checklist for Auto Tune.................................................................................................. 119 TRASAR PID Auto Tune................................................................................................ 120 NCSM PID Tuning ......................................................................................................... 122 Manual Tuning............................................................................................................... 124 Set PID to ON/OFF Control (or Manual) if PID Auto Tune Cannot Be Completed .......... 125 Monitor PID Control ....................................................................................................... 125
9.0 Blowdown Monitor and Control Setup ....................................................... 126 9.1 Conductivity Monitor & Blowdown Control Setup ............................................................ 126 9.1.1 Conductivity Control Mode Options....................................................................... 126 9.1.2 Temperature Probe Assignment ........................................................................... 126 9.1.3 Conductivity Control Mode.................................................................................... 127 9.1.4 Monitor Only Mode ............................................................................................... 129 9.1.5 PID Control Mode................................................................................................. 129 9.1.6 Continuous (ON/OFF) Control Mode..................................................................... 131 9.1.7 Time Sample (ON/OFF) Control Mode.................................................................. 132 9.7.1.1 Time Sample – Continuous Mode................................................................... 133 9.7.1.2 Time Sample – Proportional Mode ................................................................. 134 9.1.8 Interval Details ..................................................................................................... 135 9.1.9 Sample Schedule ................................................................................................. 135 9.1.10 Setting Up Timed Sample – Proportional Control .................................................. 138 9.1.11 Troubleshooting and Adjusting Tips for Interval Control ........................................ 141 9.1.12 Review Conductivity Control Setup....................................................................... 141 9.1.13 Notes on Control Modes, Alerts and Alarms.......................................................... 142 9.2 Fluorometer-Based Blowdown Control Setup ................................................................. 144
10.0
Condensate Monitor Control Setup ......................................................... 146
11.0
Controller Operation ................................................................................. 149
11.1 Display Panel Functions ................................................................................................ 149 11.2 The Keys ...................................................................................................................... 149 11.2.1 Ethernet and USB Connections and Power Switch ............................................... 149 11.3 The Graphic Icons ......................................................................................................... 150 11.4 Menu, Information, Actions and Alarms Keys Flow Diagram........................................... 150 11.5 Menu Key ...................................................................................................................... 151 11.6 Control Setting Screens ................................................................................................. 151 11.6.1 TRASAR Factors Screen...................................................................................... 151 11.6.2 PID 1-8 Screens................................................................................................... 152
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ 11.6.3 Relays 1-5 Screens.............................................................................................. 152 11.7 Alarm Setting Screens ................................................................................................... 152 11.7.1 Alarm Settings...................................................................................................... 152 11.7.2 Alarm Screens ..................................................................................................... 154 11.8 Network Screens ........................................................................................................... 154 11.9 Preference Screens....................................................................................................... 155 11.9.1 Units Screens ................................................................................................ 155 11.9.2 Date Screens................................................................................................. 155 11.10 Input Types Screens................................................................................................... 155 11.10.1 pH/ORP Input Screen........................................................................................... 156 11.10.2 Analog Input Screen............................................................................................. 156 11.10.3 TRASAR Fluorometer Screen .............................................................................. 156 11.11 Shortcut Keys............................................................................................................. 156 11.11.1 Calibrate .............................................................................................................. 157 11.11.2 Manual Control..................................................................................................... 157 11.11.3 Test Send ............................................................................................................ 157 11.11.4 Reboot ................................................................................................................. 157
12.0 Communications and Data Management ................................................... 158 12.1 3D TRASAR Boiler Optimizer ........................................................................................ 158 12.2 3D TRASAR Boiler Configurator .................................................................................... 158 12.3 3D TRASAR Boiler Controller ........................................................................................ 158 12.4 SCADA Systems ........................................................................................................... 158 12.5 3D TRASAR Web.......................................................................................................... 159 12.5.1 3D TRASAR Web Setup....................................................................................... 159 12.5.1.1 Create/Edit Users ....................................................................................... 160 12.5.1.2 Assign Controllers (Data Sources ............................................................... 160 12.5.1.3 Manage Controller (Data Source) Setup Information ................................... 161 12.5.2 3D TRASAR Web Data ........................................................................................ 161 12.5.3 3D TRASAR Web Reports ................................................................................... 162 12.5.4 3D TRASAR Web Alarms..................................................................................... 163 12.6 3D TRASAR Wireless Gateway ..................................................................................... 164
13.0 Shutdown and Maintenance ....................................................................... 165 13.1 Shutdown ...................................................................................................................... 165 13.1.1 Combination TRASAR Fluorometer and NCSM System Shutdown ....................... 165 13.1.2 TRASAR Fluorometer Only System Shutdown ..................................................... 165 13.1.3 NCSM Only System Shutdown (without Sample Conditioning System .................. 166 13.2 TRASAR Fluorometer Maintenance............................................................................... 166 13.2.1 Clean TRASAR Fluorometer Flow Cell ................................................................. 166 13.2.2 Calibrate TRASAR Fluorometer............................................................................ 167 13.2.3 Check/Replace TRASAR Fluorometer Desiccant.................................................. 167 13.3 NCSM Maintenance ...................................................................................................... 167 13.4 Sample Conditioning System Maintenance .................................................................... 167 13.5 Conductivity and pH Probe Maintenance ....................................................................... 168
14.0 Troubleshooting........................................................................................... 169 14.1 General System Troubleshooting................................................................................... 169 14.2 TRASAR Fluorometer Troubleshooting.......................................................................... 176 14.3 Alarm Screen Troubleshooting....................................................................................... 177 14.4 NCSM Troubleshooting ................................................................................................. 181 14.4.1 Factors That Affect Corrosion Stress and NCSM Control Ranges ......................... 182 14.4.2 Replacement NCSM Probes................................................................................. 183 14.4.3 Cables ................................................................................................................. 184
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 14.4.4 ORP TB11 and NCSM – 1024 mV Tests .............................................................. 185 14.4.5 REF Electrode...................................................................................................... 185 14.4.6 ORP Probe Check................................................................................................ 187 14.5 PID Troubleshooting ...................................................................................................... 188 14.5.1 PID Troubleshooting Table ................................................................................... 188 14.5.2 Interpreting & Troubleshooting Auto Tune Failure and Warning Messages............ 189 14.5.2.1 Warning Messages ........................................................................................... 189 14.5.2.2 Failure Messages.............................................................................................. 193 14.6 Blowdown Control Troubleshooting................................................................................ 197 14.7 Feedwater Conductivity Troubleshooting Flow Chart...................................................... 199 14.8 Blowdown Conductivity Troubleshooting Flow Chart ...................................................... 200
15.0 Specifications.............................................................................................. 201 16.0 Replacement Parts and Accessories ........................................................ 207 17.0 Warranty .................................................................................................... 211 18.0 Responsibility for Safe Delivery ................................................................ 211 APPENDICES A. B. C. D. E. F. G. H. I. J. K. L. M. N. O. P. Q.
Scale Control using 3D TRASAR for Boilers...................................................................... 212 NCSM Probe Technology and Advanced Field Tests ........................................................ 224 Pictorial Instructions of NCSM Reference Electrode Refurbishing...................................... 232 Advanced PID Control Settings ......................................................................................... 235 Sample Conditioning System ............................................................................................ 237 Notes On Control Modes, Interlocks, Control Overrides & Alarms...................................... 240 Electrical Grounding Test Procedure for 3D TRASAR Controllers...................................... 245 Panel and Frame System Dimensions............................................................................... 248 3D TRASAR Boiler Systems Features Table..................................................................... 251 Hardness Override Screens .............................................................................................. 254 Coordinated Phosphate Screens....................................................................................... 256 Boiler Blowdown Survey ................................................................................................... 261 Boiler Saturated Steam Tables.......................................................................................... 263 Modbus Communications Settings .................................................................................... 265 Replaceable Battery Removal & Installation ...................................................................... 268 Connecting 2 3D TRASAR Boiler Controllers to 1 NGG (ver. 1.0)...................................... 270 Connecting a 3D TRASAR Cooling Controller and a 3D TRASAR Boiler Controller to 1 NGG (ver. 1.0) ............................................................................................................... 274 R. 3D TRASAR Boiler Automation System Pre-Installation Checklist ..................................... 280
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________
1.0 Introduction 1.1
3D TRASAR Boiler Technology
3D TRASAR Boiler Technology is a complete boiler performance management system, intended to maximize safety, reliability, and operating costs associated with boilers and steam generation . It continuously measures key system parameters and, when upsets occur, takes immediate corrective action, preventing operational problems and maximizing boiler performance. The 3D TRASAR Boiler equipment also has the ability to communicate with system users via the 3D TRASAR Web, text messages or email, keeping the informed of changes or upsets.
Reliable production of steam •
Steam availability - no unplanned outages
•
Minimize scale & corrosion
Safe production of steam •
Food safety (FDA, NSF, Kosher)
•
Environmental / regulatory compliance
•
Minimize risk to plant personnel
Safety
Reliability
for Boilers
TCO
Cost Performance •
Maximize Equipment Life
•
Overall Lowest Total Cost of Operation
3D TRASAR Boiler System Capabilities •
3D TRASAR Controller & Configurator Software
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Communication for Remote Monitoring and Alarming
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Web Reporting & Data Management
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3D TRASAR Fluorometer for Scale Control
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Corrosion Stress Monitor (NCSM) for Pre-boiler Corrosion Control
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Conductivity-Based Blowdown Control
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3D TRASAR Technology-based Blowdown Control
•
Feedwater pH & Conductivity Monitoring
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Condensate Monitoring
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 Components There are 6 primary components to 3D TRASAR Boiler Technology:
3D TRASAR Boiler Technology Basic Components
Controller
NCSM
Sample Conditioning System (SCS)
Fluorometer (TRASAR 3)
Feed Water Monitoring Module (pH & Conductivity)
Blowdown Relay Box
Boiler Controller - This is the central component to 3D TRASAR Boiler Technology that defines and controls system parameters. The Controller is setup and managed by interfacing (locally or remotely) with Nalco’s advanced Boiler Configurator software. Nalco Corrosion Stress Monitor (NSCM) - This is Nalco’s innovative oxidation-reduction potential technology that directly measures the system’s corrosion stresses under actual high temperature and pressure operating conditions. This measurement is made continuously and on-line so the appropriate adjustments and responses to changes in corrosion stresses can be made in real time. The actual measurement is often referred to as AT ORP and is expressed in mV. 3D TRASAR Fluorometer - This is a new solid-state fluorometer that can measure all Nalco TRASAR 3 products, including all NexGuard internal boiler treatments. The controller uses these measurements to automatically respond to boiler system changes and maintain optimum treatment levels of highly effective scale and deposit inhibitors to keep boilers clean and free of scale and deposits.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ The patented 3D TRASAR on-line fluorometer consists of a “flow cell” and LED light source, filters, and detectors. The filters and detectors are tuned to specific light frequencies unique to Nalco products and resultant process reactions. The LED light source is extremely bright at the appropriate frequencies to reliably and precisely measure the chemical properties of the flowing water. This solidstate device provides years of trouble-free operation.
Sampling Conditioning System (SCS) – This system is designed to safely cool and reduce the pressure of the side stream sample prior to entering the Nalco fluorometer. There are two models, one for low-pressure samples (< 50 psig / 3.4 bar) and one for high-pressure samples (50 -1500 psig / 3.4 –103 bar). This system is not intended for use on steam samples. Feed Water Monitoring Module – The pH and conductivity of the feed water can be continuously measured using this module. The sensors are mounted on the piping connecting the SCS and the fluorometer. There are two models, one for high-purity samples (conductivities from 5-500 µS/cm) and one for low-purity samples (conductivities over 500 µS/cm). Blowdown Relay Box – Using the relay box the boiler controller can control up to four motorized boiler blowdown valves. The relay box provides the 4 SPDT relays needed to operate these types of valves. This option can be ordered pre-installed on the control system or separately for in-field upgrades. Note:
1.2
A conductivity probe assembly must be installed on each boiler where blowdown will be controlled based on conductivity.
3D TRASAR Boiler Models and Optional Components
The 3D TRASAR Boiler Systems are available in a variety of models. Talk to you Nalco representative about which model is right for your application. In addition to ordering the 3D TRASAR Boiler Control System you will need to order one or more of the following accessories:
• • • •
NCSM Accessories Kit (# 60189090) 3D Boiler TRASAR Startup Kit (# 500-BTSRKIT.88) Boiler Conductivity Probe Assembly (#060-BDP100.88) Motorized Blowdown Valve and Flow Control Valve (See SPEC-427)
The complete list of system model numbers, accessories and spare parts are listed in Section 16 and Appendix I.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211
1.3
About This Manual.
This manual provides step-by-step instructions to install and startup a 060-BL55XX.88 series system (3D TRASAR Fluorometer and Corrosion Stress Monitor) in the shortest amount of time. Skip any sections that are not applicable to the model ordered. The installation of optional sensors and equipment is also included. Models supplied in some regions require 240 VAC, 50Hz, power instead of 120 VAC, 60Hz (See Appendix I) Note:
Models designed for installation in hazardous areas have a slightly different panel layout and plumbing configuration. Therefore, the installation and startup/shutdown procedures are different. The controller is the same. See Manual OM0228 for details. A Nalco Technical Representative will configure the system. Don’t hesitate to contact that person if you have a question or problem.
1.4
Potential Applications
1.4.1
Feedwater Treatment Program Control
The Nalco Corrosion Stress Monitor (NCSM) is highly sensitive and reliable REDOX monitor that can be used in any aqueous system where corrosion stress is to be monitored or controlled. The NCSM is primarily used to control the reductive and oxidative state of boiler feed water (controlling the feed of an oxygen scavenger or metal passivator to the feed water or determining deaerator efficiency). In addition, corrosion stress can be monitored and controlled in regions of the condensate system. Illustrations of typical feed water installations are shown below. Additional 4-20 mA signals can be connected to the Boiler Controller and used to control pumps using the same control options available for the 3D TRASAR Fluorometer and NCSM, including intermittent operation. For example, a pH signal could be used for PID control an amine or caustic pump. Setup, configuration and control tuning of the 3D TRASAR Fluorometer and NCSM serve as examples of the steps that should be followed to incorporate other signals into control loops.
Deaerator
Deaerator PREFERRED N223XX Feed Point
PREFERRED N223XX Feed Point
PID or ON/OFF
Feed water Pump
Scavenger
Feed water Pump
PID or ON/OFF
Scavenge r N223XX PID or ON/OFF
PREFERRED Sample Point PID
N223XX
Sample Point (minimum 10) pipe diameters from product feed point)
Feed water Pump
PID or ON/OFF
PID
High-pressure sample point installation Note:
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Low-pressure sample point installation
Boiler internal treatment chemicals must be fed downstream of any attemperator take off points. Nalco Global Equipment Solutions
3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________
1.4.2
3D TRASAR Cycles Control
With the addition of a second fluorometer, the 3D TRASAR Controller can now be used to control the boiler cycles using TRASAR. It is important to note that one must have good PID control of TRASAR in the feedwater before starting cycles based control in the blowdown. The boiler cycles cannot be controlled if the feedwater does not have a consistent TRASAR value. Additionally, the boiler cycles should be chosen as to not have any potential scaling problems in the boiler. For help in determining the correct cycles value for your system contact the Nalco TRASAR Help Desk. This type of control can be configured using either On/Off or Proportional Control. For more information on setting up these control methods consult the help file in the Configurator. Note: Currently, this type of control can only be used for TRASAR 3 products.
1.4.3
Hardness Excursion Control Override
The 3D TRASAR Controller can utilize the signal from an on-line hardness analyzer to increase the feed of scale control product if the hardness concentration in the feedwater exceeds normal operating levels. Product feed can be increased to accommodate the hardness excursion via two methods: •
Fixed pump output level
•
Multiple of recent pump output history (multiple of Smart Failsafe Output)
1.4.4
BT Phosphate / pH Product Line Control
There are four different phosphate/pH control approaches used in high pressure boiler systems with the objective to prevent boiler corrosion. These approaches are: •
Coordinated Phosphate Control
•
Congruent Sodium Phosphate Control
•
Phosphate-Low Hydroxide (Tri-AD) Control
•
Equilibrium Phosphate Control
The 3D TRASAR Controller enables use of any of these control approaches. On line pH and traced phosphate (using the XE-2 fluorometer) measurements are needed to implement these controls. It is imperative to have good control over the boiler water pH.
1.4.5
Condensate Monitoring
There are now models of the 3D TRASAR Boiler System design to monitor condensate. Conductivity and pH are continuously monitored. If the condensate does not meet the user-specified conditions a relay is activated. This can be wired to a valve to dump the contaminated condensate and/or trigger an alarm. Optionally corrosion (Nalco Corrosion Monitor) can also be monitored.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211
1.5
Safety
Always follow the safety practices listed below: •
Never perform any installation procedures with electrical power engaged.
•
Never perform any repairs with electrical power engaged.
•
Never open the 3D TRASAR controller box or junction box with electrical power engaged.
•
Maximum water pressure to the 3D TRASAR Fluorometer should never exceed 90 psi (6.2 bar), unless equipped with a Nalco Sample Conditioning System.
•
Maximum water temperature should not exceed 110°F (43°C), unless equipped with a Nalco Sample Conditioning System.
•
Always wear the appropriate Personal Protective Equipment (PPE) when working on a 3D TRASAR system (i.e. gloves, protective eyewear, protective shoes, wearing a mask, etc.).
•
Always observe local and facility safety practices beyond those listed in this manual.
•
The 3D TRASAR Boilers systems 060-BLxxxx.88 Models are designed for use in non-hazardous areas. Contact NGES Help Desk for other installations. (Use 060-BXxxxx.88 Series Models)
•
The NCSM probe assembly (probes plus stainless steel cross and fittings) has been designed to handle water at 2800 psi (193 bar) and 500°F (260°C). Since measurements are made at the boiler feedwater pressure and temperature this probe assembly will be very hot and under high pressure. Extra care should be taken when servicing the system.
•
The NCSM reference probe is always installed vertically. So, the base of the reference electrode is at ambient temperature regardless of the water temperature flowing through the cell. The base portion of the electrode is still at system pressure. Do not assume the sample line has been closed and depressurized because the base of the reference electrode is not hot.
•
All piping should be insulated to maintain sample temperature and prevent accidental burns.
•
A lockable valve should be installed on the sample line to isolate the system for maintenance and prevent unauthorized energizing of the system. Follow all lock out, tag out requirements for servicing. WARNING: Always turn off power before making any electrical connections, which includes all interconnecting cables, otherwise permanent damage may occur to system components. SAFETY WARNING: The 3D TRASAR controller does not create sound above the 85 db noise level. Follow plant hearing protection regulations.
1.5.1
14
Explanation of Symbols WARNING:
Risk of damage to equipment
CAUTION-DANGER:
High temperature, high pressure or electrical safety risk.
SAFETY WARNING:
Safety equipment is needed or plant safety procedures must be followed.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________
1.6
Installation, Assembly, Startup and Tuning Overview There are 3 major steps to getting the system up and running: Installation, Assembly and Startup, and PID Tuning. The Installation can be performed by Nalco service technicians, a local contractor or by plant personnel. Nalco service technicians must perform Assembly and Startup. PID Tuning will be completed after the system has been monitored long enough to understand the boiler system dynamics and operation. Nalco service technicians will tune the system. The complete process includes the following tasks: • •
Boiler feedwater system, sample point and feed point survey Boiler blowdown piping and operation survey
1. Installation • Unpack system and identify parts • Mount panel (install frame) • Plumb the feedwater sampling system - Sample lines - Pressure test sample lines - Double-insulate the sample lines - Drain line - Sample cooler line • Flush the sample line for 30 minutes • Run wires to control box - Power - 4-20 mA control wires - Nalco Corrosion Stress Monitor (NCSM) wires (remote mount only) - Interlock (steam flow) - Phone line (optional) - Ethernet line (optional) - Optional analog and/or digital inputs • Install boiler blowdown equipment (optional) - Plumb conductivity probe assembly - Plumb blowdown flow control valve and motorized valve - Run probe wires to 3D TRASAR Controller - Run motorized valve wires to Relay Box 2. Assembly and Startup • Installation check and site safety check • Shut all 3D TRASAR Boiler System valves • Terminate wires in the control box • Install and connect TRASAR Fluorometer • Power up control system without sample or cooling water flowing • Configure system and upload to 3D TRASAR Controller - Customer information - Boiler information - Probes - 4-20 mA inputs - Digital inputs - Relays - 4-20 mA outputs - Communications • Reboot 3D TRASAR Controller • Verify configuration using controller keypad/screens Nalco Global Equipment Solutions
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 • • • • • • • • • • • •
• • • • •
Calibrate TRASAR Fluorometer Nalco Corrosion Stress Monitor (NCSM) short circuit test Refurbish and test reference electrode (NCSM) Install reference electrode (NCSM) System leak test and final piping insulation (NCSM) Test data download to USB and laptop computer Check remote communications –LAN –modem – Wireless Gateway Check Sample Conditioning System high-temperature shutdown Calibrate boiler conductivity probes (optional) Install and calibrate feed water pH and conductivity probes (optional) Verify operation of control relays Verify pump installation - Power and 4-20 mA wiring - Capability - Check pump and treatment level responses to 4-20 mA changes Measure system lag time Ensure interlock connected or shutdown process established Perform 0-100% oxygen scavenger pump test Determine control set points (Sales Representative) Manually open the blowdown control valve/relay and verify the blowdown conductivity set point can be reached as expected.
3. PID Tuning (second site visit – minimum 2 weeks monitoring required) • Check PID setup • Complete PID tuning (each loop) • Monitor PID control • Set PID to ON/OFF control if PID tuning cannot be completed (or leave in manual control).
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2.0 System Installation 2.1 2.1.1
Unpack and Identify Parts Frames and Panels
Wall mount:
Configured for wall attachment. Select when floor space is restricted.
Frame mount:
Configured for floor-mounted installation. Select when all space is restricted.
NCSM Module:
Enables installation of a second NCSM sensor.
Enclosed NCSM:
Provides weather resistant protection. Select for outdoor installations and wet environments.
HP Sample Conditioning System
Provides sample conditioning ahead of the fluorometer for samples up to 1500 psi (103 bar) and 500 °F (260 °C).
LP Sample Conditioning System
Provides sample conditioning ahead of the fluorometer for samples up to 50 psi (3.4 bar) and 250 °F (122 °C). Select when sampling from deaerator storage tank or before the boiler feedwater pump.
Nalco Global Gateway:
Enables wireless communication of important information such as alarms and performance indicators.
Fluorometer:
Packed separately to prevent damage during shipping
NCSM Reference Probe
Packed separately to prevent damage during shipping
Blowdown Relay Box
Provides SPDT relays needed to operate motorized ball valves
Feed water pH and conductivity probes
Packed separately to prevent damage during shipping. Install on piping module between SCS and fluorometer
Blowdown conductivity probe assemblies
Packed separately to prevent damage during shipping. Install on boiler blowdown piping. Rated for 250 psi (17.2 bar) and 392°F (200°C).
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211
2.1.2
Items Requiring Assembly
Fluorometer Qty. (1) Part # 060-BT3220.88 (Scale Control Models)
Fluorometer Outlet Assembly Qty. (1)
Ethernet Crossover Cable (8 ft., orange) Qty. (1)
Part # 991-05047661.88
Fluorometer Inlet Valve and Tubing Connector Qty. (1)
Service (Power) Cord 12/3 SJOW Qty. (1)
Part # 991-01928722.88
ORP/RTD Cable (6ft) Qty (1) Part # 6026390
ORP/RTD Cable with pre-amp (6ft) Qty (1) – remote installations only (1) Part # 6031277
2.1.3
Additional Items Fuses (4), Part #991-50473718
Installation Manual, Part # 521-OM0211.88
Reference Probe (NCSM) Qty. (1) Part# 991-05058543.88
Fluorometer Cable Qty Part# 060-TR5221.88
Additional Items Shipped Loose
060-TLM100.88 991-05058543.88 6026028 6018909 * 6018911 6018912 6018913 6018914 6018930 6018931 6031275 6031276 Literature
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Feedwater pHSJOW and Pigtail 16/3 conductivity sensors Qty. (5) (Optional) Part # 991-05053481.88
Tank Level Monitor NCSM – Reference probe Insulation wrap, 50 ft roll (2 each) NCSM Accessory Kit - includes the parts listed below 10 cc plastic syringe Special 14” SS hypodermic needle Electrode, ½” cell, with BNC, for calibration High-vacuum grease, 5.3 oz tube 0.1 N KCl Solution, 250 ml bottle 3.8 M KCl, Solution, 250 ml bottle BNC BA80 Adapter Cotton Tip Grease Applicators (10/pkg) Installation DVD, Blowdown DVD, NCSM DVD, Installation Checklist,Spec B-950
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ 500-BTSRKIT.88 * 460-S0980.75 460-S0726.75 500-P2817.88 500-P0116.88 500-P2147.88 500-BTSRKITLA.88 * 460-S0980.75 500-P2817.88 500-P0116.88 500-P2147.88
3D TRASAR Boiler Startup Kit – includes the parts listed below TRASAR 3 Calibration Solution, 1L Bottle Hydrochloric Acid, 1:1, 1L bottle Flow cell brush, 16” Beaker, 800 ml, plastic (3 each) Syringe, 60cc, plastic (2 each) 3D TRASAR Boiler Startup Kit, less acid – includes parts listed below TRASAR 3 Calibration Solution, 1L Bottle Flow cell brush, 16” Beaker, 800 ml, plastic (3 each) Syringe, 60cc, plastic (2 each)
* Note: Must be ordered separately
2.2
Mount the Panel IMPORTANT: The 3D TRASAR controller is designed to meet NEMA 4X standards for weather resistance. It is recommended that the unit be installed in a sheltered area to minimize the chance of water or debris entering the enclosure when the cover is opened for wiring and maintenance. If the NCSM will not be installed in an indoor, protected area the Enclosed Model must be used. In order to maintain the NEMA 4X rating: • Unused cord grips must remain plugged • Enclosure cover must be tightly closed at all times. • Ethernet port cover must also be in place when this
2.2.1
General Installation Instructions
1. Avoid installing the 3D TRASAR controller close (within 10 ft) to any high voltage source(s), large motors, or any known generator of electrical noise. Boiler feedwater pumps are not a problem. 2. The mounting location should be well lit and dry. 3. If mounting outside, provisions must be made to protect the controller from direct sunlight and driving rain. The enclosed NCSM model must be used. 4. In cold weather climates, provision must be made to prevent any cooling water piping (for sample cooling coil) from freezing. 5. The mounting location should be accessible to sample water (250-500 ml/min) and an electrical power source (20 amp circuit at 85-250 VAC). 6. If installing a model that includes a Sample Conditioning System mount the system where there is access to cooling water, typically 0.5-2.0 gpm (2-7.6 LPM). 7. Chemical feed pumps should also be located conveniently to the 3D TRASAR controller and chemical feed tanks. 8. Mount the controller as close as possible to the feedwater sample point to minimize lag time. A maximum distance of 100 ft (30 m) is desirable. 9. NCSM modules (no controller) can be mounted up to 1000 ft (305 m). (3 twisted pair, shielded 22 AWG cable required) 10. Do not mount on vibrating walls or surfaces. Damage to critical components can occur .
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 Note:
Sample points should be chosen based on many considerations: - Sampled after the product has been applied to the system and has been mixed - Water sample should be characteristic of that seen by as many boilers as possible - The sample lag time must be minimized - Existing customer sample spigots - Cooling water availability The preferred sample point is after the Feedwater pumps where the product has been mixed thoroughly (See Section 1.4 and Appendix XX for additional information).
2.2.2
Wall Mounting
Panels should be mounted on a flat wall so that the controller is at eye level. All SCS panels must be mounted 1-1/2” below the controller and sensor panel. Wall Mount Controller & Sensor Panel Dimensions: 12” D x 33” W x 42” H (31 cm x 84 cm x 107 cm) Material: PVC back panel Mounting Holes: 7/16” diameter Sample Conditioning System Dimensions: 8” D x 33” W x 22” H (21 cm x 84 cm x 56 cm) Material: PVC back panel Mounting Holes: 7/16” diameter
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2.2.3
Frame Mount Dimensions
Frame Mounted System Dimensions: Material:
29” D x 33” W x 66” H (74 cm x 84 cm x 168 cm) PVC back panel on SS frame
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22 Piping isolation valve
1/4" Tubing connection
Cooling water supply line (approx. 0.5-2 gpm)
1/2" FNPT cooling water connections
Cooling water to drain
psi
1/4" SS tubing (100 ft max) Mustbe 2X insulated!
Pressure gauge
Frame Mounted System (29"D x 33"W x 66"H)
SS filter purge line to drain
} 1/4" MNPT connection (1/4" or 1/2" tubing to unpressurized drain)
22 AWG shielded cable minimum
Power 120 VAC, 60Hz, 10A (Optional Blowdown Relay Box)
N/O+N/C+Neutral to Motorized Valves
Relief valve dischargeto drain
}
NOTE: 060-BLMxx.88, 060-BLLCxx.88 and 060-BLPCxx.88 Models require 240 VAC, 50Hz, 10A power
Install check valve if there is a chance of backflow
Scavenger pump - 4-20mA NexGuard pump - 4-20mA
Boiler interlock - dry contact
Power 120 VAC, 60Hz, 20A - MUST BE GROUNDED!
2.2.4
Lockable valve
Feed water header sample: 250-500 cc/min at 1500 psi (103 bar), 500 deg. F (260 deg. C) max.
3D TRASAR Boiler Technology Installation and Operation Manual OM0211
Installation Overview Diagrams
Refer to the drawing in this section for general installation overviews
2.2.4.1 TRASAR Fluorometer and NCSM Feedwater Systems
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Nalco Global Equipment Solutions Piping isolation valve
1/2" FNPT cooling water connections
Cooling water to drain
psi
Cooling water supply line (approx. 0.5 - 2 gpm)
1/4" SS tubing (100 ft max) Mustbe 2X insulated!
Pressure gauge
Lockable valve
Frame Mounted System (29"D x 33"W x 66"H)
SS filter purge line to drain
1/4" Tubing connection
}
Power 120 VAC, 60Hz, 10A (Optional Blowdown Relay Box)
N/O+N/C+Neutral to Motorized Valves
Relief valve dischargeto drain
}
1/4" MNPT connection (1/4" or 1/2" tubing to unpressurized drain)
22 AWG shielded cable minimum
NOTE: 060-BLMxx.88, 060-BLLCxx.88 and 060-BLPCxx.88 Models require 240 VAC, 50Hz, 10A power
Install check valve if there is a chance of backflow
Scavenger pump - 4-20mA NexGuard pump - 4-20mA
Boiler interlock - dry contact
Power 120 VAC, 60Hz, 20A - MUST BE GROUNDED!
Feed water header sample: 250-500 cc/min at 1500 psi (103 bar), 500 deg. F (260 deg. C) max.
3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________
2.2.4.2 TRASAR Fluorometer Feedwater Systems
23
24
1/4" SS tubing (100 ft max) Mustbe 2X insulated!
Pressure gauge
psi
Discharge (1/4" tubing)
1/4" tubing connection
Piping isolation valve
Wall Mounted System (8"D x 33"W x 42"H)
} 22 AWG shielded cable minimum
RTD (4-wires)
AT ORP/REF (2-wires)
NOTE: Sample with SCS: 250-500 cc/min at 1500 psi (103 bar), 500 deg. F (260 deg. C) max.
NOTE: 060-BLMxx.88, 060-BLLCxx.88 and 060-BLPCxx.88 Models require 240 VAC, 50Hz, 10A power
If equipped with an SCS the RTD (4-wire) and solenoid valve (H/N/G) wires must be run from the SCS junction box to the 3D TRASAR Controller in separate conduit.
NOTE: When installing remoteAT ORP modules signal wires must be run from the junction box to the 3D TRASAR Controller.
Scavenger pump - 4-20mA
Boiler interlock - dry contact
Power 120 VAC, 60Hz, 20A - MUST BE GROUNDED!
}
2.2.4.3
Lockable valve
Feed water header sample: 250-500 cc/min at 2000 psi (137 bar), 500 deg. F (260 deg. C) max.
3D TRASAR Boiler Technology Installation and Operation Manual OM0211
NCSM Feedwater Systems
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1/4" Tubing connection
Piping isolation valve
1/2" FNPT cooling water connection
NOTE: Sample line from boiler must be plumbed following the "Continuous Blowdown" diagram (sample takeoff where conductivity probe is located on diagram)
1/2" FNPT cooling water connection
Cooling water supply line (approx. 0.5 - 2 gpm)
Cooling water to drain
1/4" SS tubing (100 ft max)
Pressure gauge
Frame Mounted System (29"D x 33"W x 66"H)
SS filter purge line to drain
1/4" MNPT connection (1/4" or 1/2" tubing to unpressurized drain)
(22 AWG shielded cable minimum )
Relief valve discharge to drain
Power 120 VAC, 60Hz, 10A (Blowdown Relay Box)
N/O+N/C+Neutral to Motorized Valves
NOTE: 060-BLMxx.88, 060-BLLCxx.88 and 060-BLPCxx.88 Models require 240 VAC, 50Hz, 10A power
Install check valve if there is a chance of backflow
Modulating Blowdown Valve (4-20mA)
Power 120 VAC, 60Hz, 20A - MUST BE GROUNDED!
2.2.4.4
Lockable valve
Blowdown sample: 250-500 cc/min at 1500 psi (103 bar), 500 deg. F (260 deg. C) max.
3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________
TRASAR Fluorometer Blowdown Systems
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211
2.2.4.5
Continuous Blowdown Conductivity Probe and Valves
Notes: 1. The gate valve upstream from the conductivity probe should be fully open when the boiler is running (to prevent flashing at the probe). 2. Flow control valves downstream of the conductivity probe must be throttled back to create backpressure to prevent flashing at the probe and/or control valve). 3. If a fluorometer will be used to control blowdown the sample takeoff point should be located where the conductivity probe is shown in the diagram.
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2.2.4.6
Timed-Sample Blowdown Conductivity Probe and Valves
Notes: 1. The gate valve upstream from the conductivity probe should be fully open when the boiler is running (to prevent flashing at the probe). 2. Flow control valves downstream of the conductivity probe must be throttled back to create backpressure to prevent flashing at the probe and/or control valve).
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28
psi
Piping isolation valve
Cooling water to drain
1/2" FNPT cooling water connections
Cooling water supply line (approx. 0.5 - 2 gpm)
1/4" Tubing connection
1/4" SS tubing (100 ft max) Mustbe 2X insulated!
Pressure gauge
Lockable valve
Frame Mounted System (29"D x 33"W x 66"H)
Relief valve dischargeto drain
Power 120 VAC, 60Hz, 10A (Blowdown Relay Box)
N/O+N/C+Neutral to Motorized Valves
Install check valve if there is a chance of backflow
1/4" MNPT connection (1/4" or 1/2" tubing to unpressurized drain)
Power 120 VAC, 60Hz, 20A - MUST BE GROUNDED!
Condensate sample: 250-500 cc/min at less than 50 psi (3 bar), 250 deg. F (121 deg. C) max.
3D TRASAR Boiler Technology Installation and Operation Manual OM0211
2.2.4.7 Condensate Monitor
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2.3
Plumb the System
2.3.1
Plumbing Requirements
The 3D TRASAR Boilers Systems have the following plumbing requirements, depending on the components included in the specific model ordered.
Feedwater or Fluorometer-Based Systems Plumbing Requirement Sample line
Discharge line
Cooling water line
Plumbing Requirement Sample
Models with Sample Conditioning Systems
NCSM Models without Sample Conditioning Systems
¼” SS tubing, rate for 1500 psi (103 bar), 500°F (260°C) minimum.
¼” SS tubing, rate for 2800 psi (193 bar), 500°F (260°C) minimum.
Pressure tested
Pressure tested
Flushed prior to system connection
Flushed prior to system connection
Double insulated up to system
Double insulated up to system
Lockable valve at take off point
Lockable valve at take off point
Pressure gauge at take off point
Pressure gauge at take off point
¼” tubing or pipe run to unpressurized drain or flash tank
¼” SS tubing, rate for 2800 psi (193 bar), 500°F (260°C) minimum.
NA
Pressure tested
NA
Plumbed to system able to accept 500 cc/min sample at 2800 psi (193 bar), 500°F (260°C) minimum.
½” tubing or pipe
NA
Blowdown or Condensate Conductivity Probe Assembly Piping reduced to ¾” at assembly cross. Rated for 250 psi (17.3 bar) at 392°F (200°C) maximum.*
Note: A Sampling Conditioning System will be needed if the sample pressure and temperature exceeds the conductivity probe limits.
Plumbing Requirement Sample line
Condensate Monitor ¼” SS tubing, rate for 50 psi (3 bar), 250°F (121°C) minimum. Pressure tested Flushed prior to system connection Insulated up to system Lockable valve at take off point Pressure gauge at take off point
Discharge line
¼” tubing or pipe run to unpressurized drain or flash tank
Cooling water line
½” tubing or pipe
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211
2.3.2
Plumbing Connections
The 3D TRASAR Boilers Systems have the following plumbing connections, depending on the components included in the specific model ordered.
Feedwater System Components
Connection Type
NCSM
Fluorometer
Sample Conditioning System
X
X
X
¼” Tube Fitting
¼”FNPT
½” FNPT
X
¼” Tube Fitting
¼” MNPT
½” FNPT
¼” Tube Fitting
¼” Tube Fitting
NA
¼” Tube Fitting
½” FNPT
½” FNPT
X X X
X
Sample Inlet
Sample Outlet
Cooling Water Inlet & Outlet
Condensate System Components pH & Conductivity
NCM100
X X
30
X
Connection Type Sample Inlet
Sample Outlet
Cooling Water Inlet & Outlet
¼” Tube Fitting
¼”FNPT
½” FNPT
¼” Tube Fitting
¼”FNPT
½” FNPT
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2.3.3
Plumbing Notes
2.3.3.1 Sample Point The feedwater sampling point must be located where adequate mixing of the NexGuard and oxygen scavenger has occurred. A sample point downstream of the feedwater pump is preferred. If a sample tap cannot be installed at this location the sample point should be located at least 10 pipe diameters from the chemical injection point, preferably after at least one pipe bend. The condensate sample point should be located downstream of potential contamination sources where the condensate line will be full. Condensate receiver tanks offer a convenient sample location. It is extremely important to eliminate entrapped air or particulates in the feed water line. This can be accomplished by sampling from pipe approximately 2” from the internal pipe wall using a stainless steel sample quill inserted through the side of the pipe (see Replacement Parts and Accessories). Be sure to select a sample point where the feedwater pipe will be fully flooded. Avoid vertical pipe runs for sample points unless the flow is upwards. It is usually acceptable to use the deaerator drop leg for a sample point. Since it is typically flooded. Never sample from the bottom of a horizontal pipe run. Particulates be carried into the sample line and clog filters and/or valves Install an approved lockable valve on the sample line at the sample point (for lock out, tag out). A secondary isolation valve is installed at the sensor assembly to facilitate maintenance. The NCSM sample point for utility boilers should be prior to the deaerator. Probe locations will vary according to plant type and configuration. Conduct a full plant feedwater audit to identify NCSM sample locations where the measurement of reduction-oxidation (REDOX) stress will provide the most benefit. Contact the 3D TRASAR Help Desk.
4
2 Sample Point Sample Point
5 1
5
3 Horizontal pipe
1. 2. 3. 4. 5.
1 Vertical pipe
Vertical pipe
Guidance for Selection of Suitable Sample Points: Select point that provides best opportunity for a reliable sample Minimize potential for vapor in sample Avoid locations that could introduce excessive suspended solids Vertical piping OK if it is the deaerator dropleg since no bubbles present Use a SS sample quill that extends approx. ¼” of the radius (2” maximum) into the pipe.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211
2.3.3.2
Sample Lines
Sample water flow of 250-500 ml/min is typically required. If the flow drops below 200 ml/min the control will cease and the unit will alarm. Use ¼” OD 316 stainless steel tubing for all sample lines. Larger diameter tubing or the use of piping will greatly increase sample lag time and adversely affect control. Pitch the sample line downward at least 10º towards the sample outlet. Minimize the number of valves, fittings and elbows. Bend tubing rather than installing a fitting. Avoid traps or pockets where fluid or sludge can collect. Throttle the sample flow at the Sample Conditioning System rotameter or NCSM discharge (NCSM only models). The NCSM probe should ideally be located within 40 ft (12.2 m) of the sample take-off point. A distance of 100 ft (30 m) is tolerable (total piping length). Long distances create temperature losses, which affect probe performance. The NCSM measurements are made directly on the un-cooled sample and are not temperature compensated. All sample lines must be well insulated (2X wrapped) to ensure that the temperature of the water reaching the probe is as hot as possible and has a constant temperature. Insulation is also needed to protect personnel from the hot tubing. The sample flow rate must be kept constant to ensure accurate measurements and obtain good dosage control. Keeping a constant temperature and flow rate will also help troubleshoot any questionable NCSM values. Insulating should be performed after it has been ascertained that there are no leaks. Be sure to insulate the NCSM probe as described in this manual. A pressure gauge must be installed on the sample line downstream from the lockable valve. So, the pressure in the line can be checked prior to any maintenance. It is recommended that a valve be installed on the end of the sample line. This will allow the control panel to be completely isolated. A Nalco Corrosion Monitor (NCM100) probe can be installed on the 3D TRASAR System inlet plumbing providing the sample temperature is under 250ºF (121ºC) and under 1000 psi (69 bar). The probe must be installed in the special 1” x 3/8” tee such that the probe tips are pointing down into the sample flow. The discharge from the tee must be upward (discharge form 3/8” side port) to ensure the tee remains flooded. Strip insulation should be double and triple wrapped to minimize heat loss from the sample line and NCSM probe. The NCSM cell (cross) should be insulated last with a small piece of insulation that can easily be removed when the probes need to be refurbished or checked. Be sure to leave access to the SS fittings on the probes (that connect the probes to the cross). Do not insulate the ORP/RTD and Reference probes. The picture shows the cross after insulation has been applied.
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During initial startup, the sample is likely to contain solids (such as oxides of iron, grease, dirt, etc.) that settle in the sample tubing. It is very important that these solids be flushed out to avoid plugging of the system. The incoming sample line should be purged for 15 to 20 minutes prior to connecting it to the sample conditioning system
CAUTION-DANGER: The discharge from the line will be flashing steam. It must be directed to a drain capable of accepting water at the system’s operating temperature and pressure. Maximum for NCSM is 2800 psi (193 bar0, 500°F (260°C).
2.3.3.3
Discharge Line
Sample discharge should flow unrestricted to a free-falling drain/vessel with no backpressure that can damage the fluorometer. Pipe rises greater than 10 feet [3m] should be avoided. If the discharge must be located above the system install a check valve on the discharge line. NOTE:
Ensure that if there is no feedwater flow (FW pumps turned off) boiler water does not siphon back through the 3D TRASAR skid. There should be FW check valves in place to prevent this from occurring (do not assume that they exist or are working – they need to be checked). This siphoning could cause a high temperature alarm and control suspension and skid-flow shut down even if the SCS is in operation.
Do not combine the discharge from other controllers.
CAUTION-DANGER: Do not combine the fluorometer or NCSM sample discharge with the SS filter purge line, pressure relief vent, or NCSM pressure bleed vent into a single manifold. This will prevent the safety devices from functioning properly. The sample water outlet flow can be plumbed into a containment vessel and pumped to an unpressurized condensate receiver to minimize waste. On NCSM models without sample coolers, the sample discharge line must be insulated to protect personnel from the hot tubing.
CAUTION-DANGER: The discharge from a NCSM not equipped with a Sample Conditioning System must be cooled and depressurized unless the system receiving the discharge can safely accept 500 cc/min at 2800 psi (193 bar), 500°F (260°C).
2.3.3.4
Cooling Water Lines
Chilled water should be used. The cooling water inlet is at the bottom of the sample cooler and cooling water outlet is at the top. The purpose of the sample conditioning system is to cool the sample below 110°F (43°C) and depressurize the sample to below 50 psig. So, it is safe for workers and the instrumentation. Typical cooling water flow rate will be in the 0.5 to 2 gallons per minute range. It is recommended that both the cooling water inlet and outlet lines be fitted with a tee and two valves. This will to allow the cooling water to be drained and cooler shell to be flushed with acid to remove any scale. Cooling water to be used should be of good quality, free from suspended solids and miscellaneous debris. Cooling water must flow continuously and at a constant pressure.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211
2.3.3.5
Blowdown Conductivity Probe Assembly, Control Valve and Flow Control Valve
A conductivity probe, control valve (motorized ball valve) and flow control valve must be installed on each boiler where blowdown will be controlled using conductivity. All are ordered separately. The plumbing arrangement is dependent on the blowdown requirements. The diagrams below illustrate the installation for “continuous sampling”; recommended for systems blowing down > 5000 lbs/hr (2273 kg/hr) and “intermittent sampling”; recommended for systems blowing down < 5000 lbs/hr (2273 kg/hr).
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________
IMPORTANT NOTES: 1. The maximum temperature and pressure the conductivity probe can handle is 392ºF (200ºC) and 250 psig (17.2 bar). If the boiler operates above these conditions a sample conditioning system must be installed upstream of the conductivity probe to reduce the temperature and pressure. CAUTION-DANGER: DO NOT install the conductivity in a boiler above 392ºF (200ºC) and 250 psig (17.2 bar). Probe failure and serious personal injury will result. 2. Both flow control valves downstream of the conductivity probe must be throttled back to maintain backpressure in the lines. The valves cannot be in the wide-open position. Otherwise, flashing in the line will occur if the line discharges to atmospheric pressure. WARNING:
Flashing will damage the conductivity probe and valve seals.
3. Restrictions in the piping upstream of the conductivity probe can cause a pressure drop and flashing. This will result in erratic readings and damage the probe and valve seals. All upstream isolation valves should be full-port and set to fully open. Nalco Global Equipment Solutions
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 4. The motorized ball valve and flow control valve must be installed downstream from the conductivity probe. DO NOT install the conductivity probe between the valves. Flashing will occur. 5. The flow control valve must be installed downstream from the motorized ball valve to prevent flashing. Mount within 12-18” (0.3-0.5 m) of the motorized ball valve to avoid water hammer. DO NOT exceed 18” (0.5 m) or flashing may still occur inside the ball valve. 6. To ensure the piping remains full at the conductivity probe run a segment of piping downstream of the probe above the level of the probe cross (see diagram). 7. Likewise, wide spots (small diameter piping bushed up to larger piping) upstream of the probe will cause flashing. Larger diameter piping from the boiler should transition down to the ¾” cross and probe without reverting to pipe segments of increased diameter. In addition, larger diameter piping should not be installed immediately downstream the ¾” cross. 8. Ensure the flush valve installed on the bottom of the cross and probe closes properly. Leaking will cause flashing at the probe or improper flooding of the conductivity probe. 9. The conductivity probe must be installed so the flow-through hole in the probe is in line with the sample flow. The K-factor is stamped on the probe and is aligned with the hole (see photo).
10. Mount the probe cross in a horizontal pipe run at least 2 ft (0.6 m) downstream of any elbows or fittings that may cause turbulence. DO NOT mount the probe on a vertical pipe run. 11. Piping can be reduced to ½” diameter downstream of the conductivity probes on boilers with blowdown rates under 5000 lbs/hr (2273 kg/hr). So, a ½” motorized ball valve and flow control valve can be used. 12. Mount the motorized ball valve away from the boiler. So, it does not overheat the electronics. 13. Follow pipe length guidelines shown on the diagrams. Piping that is too lengthy will require longer flush times for the piping and probe to reach boiler water temperatures (required for accurate measurements). On smaller boiler systems this may result in excessive boiler blowdown.
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2.3.3.6
Condensate Conductivity Probe Assembly/Sample Take-Off, Control Valve and Flow Control Valve
Condensate lines can be monitored using a conductivity probe assembly installed directly into the condensate line. Alternately, a sample line can be run to the 3D TRASAR Condensate Monitor where pH, conductivity and corrosion (via NCM100) are monitored. In either case a flow control valve must be installed on the sample line to ensure the probe sample lines are full. A 3-way motorized control valve can be installed on the condensate line to dump contaminated condensate. Conductivity Probe or Sample Take-Off 3-Way Valve
Condensate Receiver Tank
Throttling Valve
Condensate Storage Tank
Condensate Pump Condensate Dump
Notes: 1.
The condensate probe assembly (P/N 060-BCP100.88) is similar to the blowdown probe assembly except it is designed for measuring lower levels of conductivity (up to 500 µS/cm) and includes an RTD for temperature compensation. Follow the probe plumbing guidelines in Section 2.3.3.5.
CAUTION-DANGER:
2.
DO NOT install the conductivity probe in a condensate line above 392ºF (200ºC) and 250 psig (17.2 bar). Probe failure and serious personal injury will result.
Use ¼” SS tuning for the sample take-off for the 3D TRASAR Condensate Monitor. Follow the sample line guidelines outlined in Section 2.3.3.2. CAUTION-DANGER:
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Samples supplied to the 3D TRASAR Condensate Monitor must have a pressure below 50 psi (3.4 bar). If the Condensate Monitor is equipped with the optional NCM100 the sample temperature must also be below 250ºF (121ºC).
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211
2.3.3.7
Boiler NCM100 Probe Installation
The high-temperature, high-pressure NCM100 probe must be used for boiler feedwater applications (Nalco P/N 400-NCCMP6.88). A ¾” NPT compression fitting is included with the probe. There are two ways of installing the boiler probe assembly. • •
Into a stainless steel housing Into system piping
Note: The boiler NCM100probe is rated for 1000 psi (69 bar) and 250°F (121ºC) maximum. Note:
The boiler NCM100is recommended for samples over 5µ S/cm and over 200°F (93ºC)
CAUTION-DANGER:
Installation of a bleed valve with the boiler corrosion probe assembly is highly recommended to allow proper and safe depressurization of system lines prior to probe removal. If system lines are not properly depressurized, probe ejection may occur upon removal.
Installing into a Tee Fitting The probe assembly 400-NCMP6.88 can be installed in a 1” stainless steel housing (Nalco P/N 400-NCMAC13.88). Insert the probe assembly into the housing carefully. The probe should be oriented vertically as shown below. It is crucial that the electrode tips are flooded and positioned against the direction of the oncoming flow. An alignment notch can be found on the probe body. The notch must be in line with the direction of water flow. If using the 1” stainless steel housing the nut on the housing can be tightened down when 3-9/16” of the probe body protrudes above the nut. See illustrations Installing into System Piping The boiler NCM100 probe assembly (Nalco P/N) 400-NCMP6.88 can also be installed directly in system piping using the ¾”NPT compression fitting included with the probe. Carefully insert the probe assembly into a pipe tee as shown below. The probe should be oriented so that the electrodes are flooded and are perpendicular to the direction of the water flow. An alignment notch can be found on the probe body. This notch must be in line with the direction of the water flow. See illustration below. The length of the probe body protruding above the nut will change with pipe size. The boiler NCM100 probe has an adjustable insertion length that is limited by the overall probe length (8”) Pipe reducers needed for installations on pipes over 1” OD will reduce the distance the probe can actually be inserted into the pipe. Note:
38
A flow rate of 5 gpm (19 lpm) is recommended. Lower flow rates can result in higher (pitting) corrosion rates.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________
3.0
Electrical Connections and Wiring
3.1
Run Wires to the Control Box
Wires for the following items must be connected at their source and run to the control box. DO NOT terminate the wires inside the 3D TRASAR Controller. These will be completed during startup. IMPORTANT NOTE: The 3D TRASAR Boiler Control System MUST BE PROPERLY GROUNDED! Measurements will drift badly or be erratic if the unit is not grounded. See Appendix for testing procedure. •
Controller supply power must be 120 VAC, 60Hz at 20 amps or 240 VAC, 50 Hz at 10 amps on a dedicated GFCI protected circuit (install lockable disconnect if hardwired). See Appendix I for power requirements by model number.
•
A separate power circuit is required for the blowdown relay box; 120 VAC, 60Hz at 10 amps or 240 VAC, 50 Hz, at 5 amps.
• • • • • • •
4-20 mA control wires (Scavenger pump and NexGuard pump) NCSM wires (remote mount module only) Interlock (steam flow) Phone line (optional) Ethernet line (optional) Optional analog or digital signals Blowdown conductivity probes and motorized ball valves (See Section 3.2.7 for details)
CAUTION-DANGER: Always turn power OFF before making any electrical connections or connecting or disconnecting wires, cables or connectors or permanent damage may occur to components. Follow plant lock out, tag out procedures. •
All electrical connections must conform to applicable state and local codes.
•
A power cord without termination has been provided. A proper plug for 20-amp service must be provided or the unit may be hard wired (using 12 AWG wire). If an extension cord is used, it must be a grounded 3-prong type. Using an ungrounded 2-prong plug will result in inaccurate readings. Failure to provide 20-amp (dedicated) service could result in intermittent operation, caused by circuit breaker overload. Signal wires must be brought into the controller via waterproof cable glands.
• • • •
Pump connections (ON/OFF control only) can be made via supplied “pigtails” with receptacles or hardwired (using 14 AWG wire) directly to the terminals inside the control box as appropriate.
•
There are 5 control relays individually fused at 2.5 amps (designed to operate at 2 amps maximum). In cases where more amperage is required, the control relays can be wired as dry contacts for motor starters.
• •
The alarm relay is fused at 1 amp. Each control output and alarm output is fused. A fuse holder is located adjacent to each relay. To replace a fuse, remove the snap-on cover. Replacement fuse is rated 2.5 amps for control outputs and 1 amp for alarm outputs. Make sure the power is disconnected. Use 22 AWG shielded cable (minimum) for remote NCSM, analog and digital signal, RTD, and blowdown conductivity probe wires.
• • • •
Each conductivity probe installed in the blowdown line will require 4 wires (8 wires if temperature compensating). Use 2 or 4 shielded twisted pair 22 AWG cable. (See Section 3.2.7.2) The phone line connection is located inside the controller box. A RJ11 analog phone jack must be provided. Do not overtighten power supply terminal strip connections. This may damage the terminal strip.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211
3.2
Terminate Wires in the Control Box
Note:
Wires should only be connected in the 3D TRASAR Controller by a qualified Nalco Service Technician.
Refer to diagrams and charts for details on wiring connections. Cables for the NCSM probes and Sample Conditioning System will be wired in the controller at the factory. Connect the remaining wire and cabling as follows:
3.2.1
System Power Connections
Connection Description Line Power Neutral Ground
Controller Box Board Reference TB1-1 TB1-2 TB1-3
Controller Box Terminal L N Gnd
Wire Color Black or Brown White or Blue Green
IMPORTANT NOTE:
The 3D TRASAR Boiler Control System MUST BE PROPERLY GROUNDED! Measurements will drift badly or be erratic if the unit is not grounded. See Appendix for testing procedure.
IMPORTANT NOTE:
Verify the NEUTRAL is properly connected. Measurements will be erratic and RTD failures will result if the neutral is lost or improperly connected.
3.2.2
Internal Power Connections
Connection Description Power Switch Neutral Power Switch Line Switched AC Neutral Switched AC Line
3.2.3
Controller Box Terminal N L N L
Wire Color White Black White Black
Fuses
Fuse Description Main Power Fuses (2) Alarm Fuse (1) Relay Fuses (5)
40
Controller Box Board Reference E1 E2 E3 E4
Rating 1 Amp 1 Amp 2.5 Amp
Supplier Information 5x20 mm, Slo-Blow (Littlefuse 218 1.00) 5x20 mm, Slo-Blow ( Littlefuse 218 1.00) 5x20 mm, Slo-Blow (Littlefuse 218 2.50)
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3.2.4 3.2.4.1
Control Relay Connections Control Relays – Powered and Non-Powered Wiring
There are five control relays in the 3D TRASAR Boiler controller that can be wired for powered or non-powered operation. Follow the wiring diagrams below to connect metering pumps and valves for powered control relay outputs (120/240 VAC, fused at 2.0 amps). Note 1:
Connecting the control relays to a “capacitive-type” load (such as a motor-driven pump) will damage the relay contacts. Always follow the manufacturer’s pump and valve wiring connection guidelines.
Note 2:
The factory wired jumper must be removed from control relay terminals “C” and “L” in the controller box in order to remove power from the relay output. 2.5 A Fuse Contact
NO
C
L
BLK
GRN
WHT
N
3D TRASAR Boiler Controller
Figure 1: Typical Powered Relay from Controller Box (pumps below 2.0 amps) 2.5 A
External Power (+)
Fuse
Motor Starter Contact
Contact External Neutral (-) N
NO
C
GRN
BLK
WHT
WHT
L Earth Ground
GRN
BLK
3D TRASAR Boiler Controller Motor Starter Motor Starter
External Motor Starter Neutral (-)
External Motor Starter Power (+)
Figure 2: Typical Non-Powered Relay from Controller Box (pumps over 2.0 amps)
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211
3.2.4.2 Relay Connection Inside Controller. The table below lists the five control relays and their associated terminal connections. Note:
Terminal strip connections are not the same as those in the 3D TRASAR Cooling Controller.
Connection Description Control Relay 1
Control Relay 2
Control Relay 3
Control Relay 4
Control Relay 5
Note:
42
Controller Box Board Reference TB2 TB2 TB2 TB2 TB2 TB3 TB3 TB3 TB3 TB3 TB4 TB4 TB4 TB4 TB4 TB5 TB5 TB5 TB5 TB5 TB6 TB6 TB6 TB6 TB6
Controller Box Terminal (GND) N NO C L (GND) N NO C L (GND) N NO C L (GND) N NO C L (GND) N NO C L
Description Earth Connection AC Neutral Normally Open Contact 1 Common Contact 1 AC Hot (Line) Earth Connection AC Neutral Normally Open Contact 2 Common Contact 2 AC Hot (Line) Earth Connection AC Neutral Normally Open Contact 3 Common Contact 3 AC Hot (Line) Earth Connection AC Neutral Normally Open Contact 4 Common Contact 4 AC Hot (Line) Earth Connection AC Neutral Normally Open Contact 5 Common Contact 5 AC Hot (Line)
Be careful not to overtighten wiring connections. Damage to the relay may result.
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3.2.4.3
Blowdown Valve Relay Box Connections
The optional Blowdown Valve Relay Box provides 4 single-pole, double-throw relays that can be used to power open and power closed motorized ball valves. It will be pre-wired to relays 1-4 in the 3D TRASAR Boiler controller. All connections to the valve are made in the Blowdown Valve Relay Box. Note:
Although the blowdown valve is grounded via the piping local regulations may require a ground wire to be run from the valve to the relay box. There is a grounding strip in the box.
3D TRASAR Controller Relay Connections
Blowdown Relay Box (4 Relays) Motor Actuator Connections 5
NO
SPDT Relay R1
Coil + (5)
115 Relay Coil
1
N
Coil - (1)
NO (3)
3
To motorized ball valve N/O 1
NC (2)
2
To motorized ball valve N/C 1
Common (4)
4
OMRON G2R-1-S-AC120R
5
NO
SPDT Relay R2
Coil + (5)
115 Relay Coil
1
N
Coil - (1)
NO (3)
3
To motorized ball valve N/O 2
NC (2)
2
To motorized ball valve N/C 2
Common (4)
4
OMRON G2R-1-S-AC120R
5
NO
SPDT Relay R3
Coil + (5)
115 Relay Coil
1
N
Coil - (1)
NO (3)
3
To motorized ball valve N/O 3
NC (2)
2
To motorized ball valve N/C 3
Common (4)
4
OMRON G2R-1-S-AC120R
5
NO
SPDT Relay R4
Coil + (5)
115 Relay Coil
1
N
Coil - (1)
NO (3)
3
To motorized ball valve N/O 4
NC (2)
2
To motorized ball valve N/C 4
Common (4)
4
Fuse 10A, SloBlo
OMRON G2R-1-S-AC120R
120 VAC Power Supply Connections 120 VAC Hot
To motorized ball neutral 1 To motorized ball neutral 2 To motorized ball neutral 3 To motorized ball neutral 4
120 VAC Neutral Earth Ground Attached to Back Plate
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211
Note:
Wire 3-way valve “right” and “left” connections to the “NO” and “NC” terminals (check valve positions).
3.2.5
Alarm Relay Connections
There is one alarm relay in the 3D TRASAR Boiler controller. It is initiated by the user alarm (firmware) configuration. It is not wired to a power source and is fused at 1.0 Amps. C
NO NC
Figure 3: Alarm Relay Diagram Connection Description Alarm Relay 1
3.2.6
Controller Box Terminal C NO NC
Description Common Normally Open Contact Normally Closed Contact
Fluorometer Connections
Connection Description FW Fluorometer
BD Fluorometer
44
Controller Box Board Reference TB7 TB7 TB7
Controller Box Board Reference TB20 TB20 TB20 TB20 TB21 TB21 TB21 TB21
Controller Box Terminal 6V GND 1B 1A 6V GND 2B 2A
Description White with Blue Stripe Blue with White Stripe Orange with White Stripe White with Orange Stripe White with Blue Stripe Blue with White Stripe Orange with White Stripe White with Orange Stripe Nalco Global Equipment Solutions
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3.2.7 3.2.7.1
Conductivity Probe Connections Compensating vs. Non-Compensating Conductivity Probes
There are two types of conductivity contacting probe models supported.
Compensating These probes are used for boiler blowdown monitoring where the sample temperature varies significantly or for condensate line monitoring. They have a built-in 4-wire RTD to measure the sample temperature. The controller corrects the conductivity measurement based on its temperature. •
A probe with a cell constant of 1.0 (conductivity = 5 - 10,000 µS/cm) is used for blowdown measurements.
•
A probe with a cell constant of 0.1 (conductivity = 1 – 500 µS/cm) is used for condensate measurements
Note:
A maximum of 3 RTD’s can be connected to the 3D TRASAR Controller (1 is required for the NCSM (RTD 2) and 1 is required for the Sample Conditioning System (RTD 1)).
Note:
Nalco Best Practices is to use a compensating probe if there is only one boiler to control. The integral RTD can then be wired to the RTD 3 input.
Non-compensating These are the standard probes used for blowdown and feed water monitoring where the sample temperature does not vary significantly. They do not include a built-in 4-wire RTD for temperature compensation. •
A probe with a cell constant of 1.0 (conductivity = 5 - 10,000 µS/cm) is used for blowdown and high-conductivity feedwater measurements.
•
A probe with a cell constant of 0.1 (conductivity = 1 – 500 µS/cm) is used for high-purity feed water monitoring.
Note:
The 0.1 cell constant probe should be used on high-purity samples (conductivity < 100 µS/cm).
Note:
The conductivity probe for feedwater monitoring (room temperature) has a PVC cover on the wires. The wiring and probe potting cannot withstand high temperature samples.
Note:
When monitoring boiler feedwater the RTD on the sample conditioning system can be used for temperature compensation.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 Conductivity Probe Identification
•
High range probes (K = 1.0) have a flow-through hole that exposes only a small amount of the electrode. Range: 5-10,000 µS/cm.
•
Low range probes (K= 0.1) have a large oval-shaped flow-through hole. The entire electrode element is exposed. Range: 0-500 µS/cm.
•
Conductivity probes rated for high temperature (condensate or blowdown) have 8” Teflon coated leads and high-temperature potting. Maximum Limits: 250 psi (17.2 bar) and 392ºF (200ºC).
Blowdown Probe (Non-compensating) Nalco P/N 6035384
•
Blowdown Probe (Compensating) Nalco P/N 6034004
Conductivity probes rated for lower temperatures/pressures (cooled feedwater) have 48” PVC coated leads. Maximum Limits: 200 psi (13.8 bar) and 158ºF (70ºC)
Feedwater High-Range Probe (Non-compensating) Nalco P/N 6035385 Note:
46
Condensate Probe (Compensating) Nalco P/N 6034005
Feedwater Low-Range Probe (Non-compensating) Nalco P/N 6035386
Some conductivity probes are supplied with 2 Black Wires and 2 Red Wires (and 2 Green and 2 White Wires on Compensating Probes) to eliminate the need for jumpers.
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3.2.7.2
Conductivity Probe Wiring
Conductivity Probe Wires and Jumpers •
Correct wiring of the probes is very important. Use a minimum of 22 AWG, shielded wire (each pair is shielded). Probes wire lengths cannot exceed 1000 ft (305 m).
•
PROBES MOUNTED ON THE CONTROLLER PANEL (feedwater) Probe red and black wires are jumpered inside the 3D TRASAR Controller.
•
ALL REMOTE MOUNTED PROBES (blowdown or condensate) The red and black wires must be jumpered at the J-box. Wires must be jumpered on the probe input side of the terminal strip inside the J-box.
•
Jumpering the wires at the probe end enables 4 wires for the conductivity and 4 wires for the RTD (if using a probe with an integral RTD) to be sent back from the probe to the controller. Since the conductivity probe is normally installed a distance away from the controller, sending the conductivity/RTD signal through 4 wires will compensate for the length of the cable that is used.
•
Signal loss will occur if the conductivity or RTD signal is sent through 2 wires (instead of four wires) over a distance. Wires from probe (with jumpers)
Input
J-box
Output
Wires connected to controller IMPORTANT NOTE: Probes supplied in 2010 are equipped with 2 red and 2 black wires (and 2 green and 2 white wires for temperature compensating probes). This eliminates the need to add jumpers in the field. All 4 (or 8) wires must be connected in the controller.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 Feedwater Conductivity Probe Wiring (non-compensating): Since the feedwater conductivity probe is very close to the controller (mounted on same panel) connections are made in the controller (TB13-15).
•
Connect the probe red wire to the (-) terminal (this wire is physically attached to the body of the probe). Add a jumper wire from (-) to (S-).
•
Connect the probe black wire to the (+) terminal (as this wire is physically attached to the center conductor of the probe). Add a jumper wire from (+) to (S+).
Note:
The Sample Conditioning System RTD can be used for temperature compensation of feedwater conductivity measurements. This is normally wired to the RTD 1 input (TB-9) and is assigned in Configurator.
22 AWG shielded wire Black wire
Red wire
Conductivity probe
Note:
48
+ S+ S+ S+ S-
2
22 AWG shielded wire
Black wires
1
Conductivity Inputs (TB13-TB15)
Red wires
+ S+ S+ S+ S-
2
1
Conductivity Inputs (TB13-TB15)
Conductivity probe
Some conductivity probes are supplied with 2 Black Wires and 2 Red Wires to eliminate the need for jumpers. Connect all 4 wires to the controller.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ Blowdown Conductivity Probe (non-compensating): Since the blowdown conductivity probe is installed at a distance away from the controller, 4 wires are needed to compensate for the length of the cable that is used. Connections must be m ade in the Jbox and in the controller.
Black wire Black Black Red Red Red wire
+ S+ S+ S+ S-
2
1
Conductivity Inputs (TB13-TB15)
J-Box 22 AWG shielded wire
Conductivity probe (2-wire)
Note:
Some conductivity probes are supplied with 2 Black Wires and 2 Red Wires to eliminate the need for jumpers. Connect all 4 wires to the controller.
Black wires Black Black Red Red Red wires
+ S+ S+ S+ S-
2
1
Conductivity Inputs (TB13-TB15)
J-Box 22 AWG shielded wire
Conductivity probe (4-wire)
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 •
•
On the input side of the J-box terminal strip, connect the probe’s red wire to the first terminal. Add a jumper wire across the first and second terminals. On the output side of the terminal strip, connect a signal wire to each of the 2 terminals (opposite the probe’s red wire and jumper). On the input side of the J-box terminal strip, connect the probe’s black wire to the fourth terminal. Add a jumper wire across the third and fourth terminals. On the output side of the terminal strip, connect a signal wire to each of the 2 terminals (opposite the probe’s black wire and jumper).
•
Connect the 2 wires from the probe’s red wire to TB13-15 (-) and (S-) terminals in the controller.
•
Connect the 2 wires from the probe’s black wire to TB13-15 (+) and (S+) terminals in the controller.
Note:
To minimize wiring errors between the J-box and controller, use color coded wires. Two separate twisted pair cables can be used (2 red wires and 2 black wires). See photo at the beginning of this section.
Blowdown/Condensate Conductivity Probe (compensating): Since the blowdown/condensate conductivity probe is installed at a distance away from the controller 4 wires for conductivity and 4 wires for temperature are needed to compensate for the length of the cable that is used. This probe has an integral 4-wire RTD (2 white & 2 green wires). Connections must be made in the J-box and in the controller. However, since the RTD already has 4 wires, only the conductivity wires (red & black) must be jumpered in the J-box. Use separate cables for conductivity and temperature. S22 AWG shielded wire
n ee Gr n ee Gr te hi W e hit W Green wires
White wires
Black Black
Black wire
Red Red
Red wire
J-Box
+ S+ S+ S+ S-
2
S+ + SS+ + SS+ +
3
2
1
RTD Inputs (TB9)
1
Conductivity Inputs (TB13-TB15)
Conductivity probe (6-wire)
50
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ Note:
Some conductivity probes are supplied with 2 Black Wires and 2 Red Wires to eliminate the need for jumpers. Connect all 8 wires to the controller via the J-box. S22 AWG shielded wire n ee Gr n ee Gr te hi W e hit W
Green wires
White wires
Black Black
Black wires
Red Red Red wires
J-Box
+ S+ S+ S+ S-
2
S+ + SS+ + SS+ +
3
2
1
RTD Inputs (TB9)
1
Conductivity Inputs (TB13-TB15)
Conductivity probe (8-wire)
•
On the input side of the J-box terminal strip, connect the probe’s red wire to the first terminal. Add a jumper wire across the first and second terminals. On the output side of the terminal strip, connect a signal wire to each of the 2 terminals (opposite the probe’s red wire and jumper).
•
On the input side of the J-box terminal strip, connect the probe’s black wire to the fourth terminal. Add a jumper wire across the third and fourth terminals. On the output side of the terminal strip, connect a signal wire to each of the 2 terminals (opposite the probe’s black wire and jumper).
•
On the input side of the J-box terminal strip, connect the probe’s 2 white wires to the fifth and sixth terminals. On the output side of the terminal strip, connect a signal wire to each of the 2 terminals (opposite the probe’s white wires).
•
On the input side of the J-box terminal strip, connect the probe’s 2 green wires to the seventh and eighth terminals. On the output side of the terminal strip, connect a signal wire to each of the 2 terminals (opposite the probe’s green wires).
•
Connect the 2 wires from the probe’s red wire to TB13-15 (-) and (S-) terminals in the controller.
•
Connect the 2 wires from the probe’s black wire to TB13-15 (+) and (S+) terminals in the controller.
•
Connect the 2 wires from the probe’s white wires to TB9 (+) and (S+) terminals in the controller.
•
Connect the 2 wires from the probe’s green wires to TB9 (-) and (S-) terminals in the controller.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 3D TRASAR Conductivity Inputs (TB13-TB15) All conductivity probes are connected in the 3D TRASAR Controller on terminal strip TB13-15.
•
Feedwater probes (located on the same panel as the controller) are wired directly to the terminal strip.
•
Remote probes (blowdown or condensate) probes are first wired to a J-box. Wires (noncompensating 4-wires, compensating 8-wires) are then run from the J-box to the controller
Note:
Note:
52
The conductivity probe RTD wires (white and green) are connected in the controller on terminal strip TB9
Feedwater conductivity probe with jumpers
Remote conductivity probe (jumpers in J-box)
When connecting the conductivity probe wires into the controller, it is important to note which input the conductivity probe is being wired into. This is critical when conductivity is being configured in the Configurator, especially, when multiple probes are being used.
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Connection Description
Controller Box Board Reference
Conductivity Probe 6
Conductivity Probe 5
Conductivity Probe 4
Conductivity Probe 3
Conductivity Probe 2
Conductivity Probe 1
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Controller Box Terminal
Description
TB15-6
6+
Pos. Cond. 6 (Red C+)
TB15-6
S6+
Positive Sense 6
TB15-6
S6-
Negative Sense 6
TB15-6
6-
Neg. Cond. 6 (Black C-)
TB15-5
5+
Pos. Cond. 5 (Red C+)
TB15-5
S5+
TB15-5
S5-
Negative Sense 5
TB15-5
5-
Neg. Cond. 5 (Black C-)
TB14-4
4+
Pos. Cond. 4 (Red C+)
TB14-4
S4+
Positive Sense 4
TB14-4
S4-
Negative Sense 4
TB14-4
4-
Neg. Cond. 4 (Black C-)
TB14-3
3+
Pos. Cond. 3 (Red C+)
TB14-3
S3+
TB14-3
S3-
Negative Sense 3
TB14-3
3-
Neg. Cond. 3 (Black C-)
TB13-2
2+
Pos. Cond. 2 (Red C+)
TB13-2
S2+
Positive Sense 2
TB13-2
S2-
Negative Sense 2
TB13-2
2-
Neg. Cond. 2 (Black C-)
TB13-1
1+
Pos. Cond. 1 (Red C+)
TB13-1
S1+
TB13-1
S1-
Negative Sense 1
TB13-1
1-
Neg. Cond. 1 (Black C-)
Positive Sense 5
Positive Sense 3
Positive Sense 1
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3.2.8
High Impedance (pH/ORP) Connections
The 3D TRASAR Boiler controller can read two high impedance signal inputs (either pH or ORP). Note:
Make sure the probes are connected correctly. They will display a reading even if connected improperly.
Note:
A ground wire must be run from the high-purity pH probe to the grounding terminal inside the controller (SCADA ground TB17 can be used).
Connection Description pH/ORP 1 pH/ORP 2
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Controller Box Board Reference TB11 TB11 TB12 TB12
Controller Box Terminal 1+ 12+ 2-
Description Positive Input 1 Negative Input (Shield) 1 Positive Input 2 Negative Input (Shield) 2
NCSM Description ORP 1 (white) REF 1 (black) ORP 2 (white) REF 2 (black)
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3.2.9
Nalco Corrosion Monitor (NCM100)
The controller is capable of reading one NCM100 probe. It will automatically detect the type of probe (mild steel). The table below lists the internal connections (factory installed). The Nalco NCM100 cable plugs into a receptacle on the side of the control box. Connection Description Corrosion 1
Controller Box Board Reference J4 J4 J4 J4 J4 J4 J4
Controller Box Terminal Removable Removable Removable Removable Removable Removable Removable
Description Not Used Not Used Black Blue Green Brown Orange
3.2.10 Analog Inputs The 3D TRASAR Boiler can read four analog inputs. Each analog input can be (individually) configured to read 4-20 mA or 0-10 volt signals (via dip switch setting and firmware configuration). Connection Description Analog Input 1
Analog Input 2
Analog Input 3
Analog Input 4
Note:
Controller Box Board Reference TB10 TB10 TB10 TB10 TB10 TB10 TB10 TB10 TB10 TB10 TB10 TB10
Controller Box Terminal 24V 1+ 124V 2+ 224V 3+ 324V 4+ 4-
Description 24 VDC Source AI1+ AI124 VDC Source AI2+ AI224 VDC Source AI3+ AI324 VDC Source AI4+ AI4-
Additional analog input can be wired into the controller using the optional Analog Input Module (See Section 3.2.11)
Below are analog 4-20 mA and 0-10 V wiring diagrams for powered and non-powered connections.
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-N
AMP
Sensor
+N
+
-N
-
AMP
+
+N
+
24V
24V
24 VDC
+ -
24 VDC 3DT Boiler Controller
Sensor +
+ 3DT Boiler Controller
Self-Powered Input (No Loop Power Needed)
Loop-Powered Input (24 VDC Loop Power Needed)
Analog 4-20 mA Input (User) Wiring Diagram
-
-N
+
+N
AMP
Sensor +
24V
24 VDC
+ 3DT Boiler Controller Analog 0-10V Input (User) Wiring Diagram
Note 1:
N = 1, 2, 3, or 4 (Analog Input Channel) mA / V SELECTOR
4-20 mA 1234
0-10 V
Figure 6: mA / V Dip Switch Selector Note 2: Note 3:
56
Set each input dip switch (SW1) to 4-20 mA or 0-10 V operation All analog inputs are factory set to “4-20 mA” operation
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3.2.11 Analog Input Module (Optional) The Analog Input Module allows the user to connect up to 8 additional analog inputs to the 3D TRASAR Controller. It can be mounted on the back of the 3D TRASAR skid or on a wall nearby. A 24 VDC enables connection of signals that require power. The module requires 115 VAC, 50 Hz power (power cord provided).
Installation 1.
The Analog Input Module connects to the 3D TRASAR controller via the RS-485 .Connect the supplied cable to the 3D TRASAR controller: • • •
Note:
Red to TB20 A Black to TB20 B Green to TB20 Gnd TB20 is located inside the 3D Boiler Controller. The Analog Input Module cannot be used if a second Fluorometer is attached (cannot share this wiring connection).
3D TRASAR cable connections
Analog Input Module cable connections
2. Connect 4-20 mA inputs on the ADAM module. Note:
4-20 mA signal loops are not powered from the Adam module. Use the supplied 24V terminal strip if required.
3. Plug in the Analog Input Module power cord and the hardware installation is complete.
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ADAM - 4117 Analog Input 6+
Vin 5+ 1
Vin 4-
Analog Input 5-
Analog Input 6-
Vin 5-
Vin 4+
Analog Input 5+
Analog Input 7+
Vin 6+
Vin 3-
Analog Input 4-
Analog Input 7-
Vin 6-
Vin 3+
Analog Input 4+
Analog Input 8+
Vin 7+
Vin 2-
Analog Input 3-
Analog Input 8-
Vin 7-
Vin 2+
Analog Input 3+
TB20* 2A
(Y) DATA+
Vin 1-
Analog Input 2-
TB20* 2B
(G) DATA-
Vin 1+
Analog Input 2+
(R) +Vs
Vin 0-
Analog Input 1-
Vin 0+
Analog Input 1+
TB20* GND
(B) GND
20
10
Earth Gnd
11
Loop Power Connections
120 VAC Line 1 Amp Slo Blow Neutral
-
Earth Gnd
NEMA 4X Enclosure
Note:
58
24 VDC + 0.5 A
+24 VDC
Common
The ADAM-4117 module is configured at the factory for 4-20 mA inputs and communication with the 3D TRASAR Boiler Controller.
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3.2.12 Analog Outputs The 3D TRASAR Boiler controller has eight self-powered 4-20 mA analog outputs, 600 ohms. Connection Description 4-20 mA Output 1 4-20 mA Output 2 4-20 mA Output 3 4-20 mA Output 4 4-20 mA Output 5 4-20 mA Output 6 4-20 mA Output 7 4-20 mA Output 8
Controller Box Board Reference TB22 TB22 TB22 TB22 TB22 TB22 TB22 TB22 TB22 TB22 TB22 TB22 TB22 TB22 TB22 TB22
Controller Box Terminal 1+ 12+ 23+ 34+ 45+ 56+ 67+ 78+ 8-
Description AO1+ AO1AO2+ AO2AO3+ AO3AO4+ AO4AO5+ AO5AO6+ AO6AO7+ AO7AO8+ AO8-
3.2.13 Interlock The controller has one system interlock input. It is primarily used for systems that operate intermittently. A jumper is installed at the factory. Keep it in place unless an external interlock signal is connected. Removal of this jumper will suspend operation of ALL control relays and 4-20 mA outputs and will also initiate an “interlock” alarm. Connection Description Interlock
Note:
Controller Box Board Reference TB16 TB16
Controller Box Terminal + -
Description Interlock + Interlock -
All digital input or analog inputs can now also be used as interlocks, permitting intermittent operation based on the operation of more than one boiler feedwater pump. See Appendix F.
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3.2.14 Temperature (RTD) Inputs The 3D TRASAR Controller has three 1000 ohm, platinum RTD inputs.
Desc. RTD Probe 3
RTD Probe 2
RTD Probe 1
Controller Board Terminal
RTD Wires Labels & (Color) Description NCSM
SCS
Conductivity
TB9–3
3-
Neg. RTD 3
TC- com (Green)
(Black or White)
TC (Green)
TB9-3
S3-
Neg. Sense 3
TC(White)
(Black or White)
TC (Green)
TB9-3
S3+
Pos. Sense 3
TC+ (Red)
(Red)
TC (White)
TB9-3
3+
Pos. RTD 3
TC+ com (Black)
(Red)
TC (White)
TB9-2
2-
Neg. RTD 2
TC- com (Green)
(Black or White)
TC (Green)
TB9-2
S2-
Neg. Sense 2
TC(White)
(Black or White)
TC (Green)
TB9-2
S2+
Pos. Sense 2
TC+ (Red)
(Red)
TC (White)
TB9-2
2+
Pos. RTD 2
TC+ com (Black)
(Red)
TC (White)
TB9-1
1-
Neg. RTD 1
TC- com (Green)
(Black or White)
TC (Green)
TB9-1
S1-
Neg. Sense 1
TC(White)
(Black or White)
TC (Green)
TB9-1
S1+
Pos. Sense 1
TC+ (Red)
(Red)
TC (White)
TB9-1
1+
Pos. RTD 1
TC+ com (Black)
(Red)
TC (White)
Note:
If the RTD has only 2 wires, connect one RTD wire to (+) and jumper (+) to (S+). Connect the other RTD wire to (-) and jumper (-) to (S-).
Note:
RTD wire colors vary by device. See above table for devices used on standard 3D TRASAR Systems.
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3.2.15 Digital Inputs The 3D TRASAR Controller has four digital inputs. Each digital input will be capable of reading an open contact to ground (snap-acting), contact closure device (mechanical water meter action) or open collector NPN transistor/FET (5mA sink, 24 VDC, signal to ground). The counters will be capable of reading and totalizing low frequency (water meter) pulse type inputs. Each of the four inputs will have software reset capability. For water meter inputs, each pulse represents a pre-defined amount of water usage (i.e., 10 gallons/pulse, 100 gallons/pulse, etc.). The gallon-scaling factor is user-defined in the Configurator. Note:
The minimum on-time and off-time pulse width is 5 milliseconds for a valid pulse. The maximum number of pulse counts is 50 per second.
Note: All digital input can now also be used as interlocks, permitting intermittent operation based on the operation of more than one boiler feedwater pump. Connection Description Digital Input 1
Controller Box Board Reference TB8 TB8 TB8 TB8 TB8 TB8 TB8 TB8
Digital Input 2 Digital Input 3 Digital Input 4
Controller Box Terminal 1+ 12+ 23+ 34+ 4-
Description DI1+ DI1DI2+ DI2DI3+ DI3DI4+ DI4-
Below are typical water meter connection diagrams. 3DT Boiler Controller Digital Inputs DI + DI -
Water Meter (Reed Switch) NO Contact Common Contact
“Snap-acting” Contact Closure Water Meter 3DT Boiler Controller Digital Inputs +24 VDC
Water Meter (Transistor/FET) Power (+24 VDC)
DI +
Signal
DI -
Ground
“Transistor/FET (sinking)” Contact Closure Water Meter
Note:
Use the Analog Inputs (TB10) +24 VDC terminals for the +24 VDC power source.
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3.2.16 Modem/Phone Line Connections A modem card is installed in the 3D TRASAR Controller. The modem works globally. Through this modem connection you can upload firmware updates, upload/download configurations, download data/alarm files, send out alarms and data files, and view live data. The phone line connection is located inside the controller box and can be connected through the RJ11 analog phone jack or hardwired to terminals 1 & 2. Connection Description Modem (Phone Line)
Controller Box Board Reference TB1
Controller Box Terminal (or Phone Jack) 1
TB1
(J1) RJ11 Analog Phone Jack
2
Description Telco/PSTN Ring/Tip Telco/PSTN Ring/Tip
1 2 (TELCO/PSTN) Hard Wire Analog Phone Connection
Figure 8: Modem Phone Line Connection Diagram Note:
Connect the analog “Tip” and “Ring” phone wires from the telephone company to pins 1 and 2. The modem input is not polarity sensitive, so it does not matter which order the wires are connected.
3.2.17 Ethernet Connections There are two Ethernet ports inside the 3D TRASAR Controller. Ethernet port 1 is primarily used for direct connections with a laptop. Ethernet port 1 is available via an external connector with waterproof cap. The cap must be in place whenever the port is not in use. Use the supplied Ethernet Crossover Cable for direct PC connections. Ethernet port 2 is primarily used for wireless gateway or customer LAN connectivity. The connection is made internally in the controller. Through either Ethernet port, you can upload firmware updates, upload/download configurations, download data/alarm files, send out alarms and data files, and view live data.
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3.2.18 LAN Connections The 3D TRASAR Controller can be connected to a LAN system, however, it is required that a Router be used to isolate the controller from the rest of the LAN network. Processing extraneous broadcast messages will significantly impact the controller operation.
3.2.19 USB The 3D TRASAR Controller supports an external USB Data Stick. The USB is available via an external connector with waterproof cap. The cap must be in place whenever the port is not in use. Using the USB port, you can upload firmware, upload/download configurations, and download data/alarm files.
3.2.20 SCADA General Description SCADA systems can be used to monitor and modify data variables within the 3D Boiler Controller configuration. The 3D Boiler controller supports (Slave Mode) Serial Modbus RTU (half-duplex) or “Modbus RTU over Ethernet” (ModTCP). For Serial Modbus RTU applications, an RS-232 or RS-485 connection is available. The 3D Boiler Controller Modbus implementation conforms to the “Modicon Modbus Protocol Standard” as described in the Modicon Modbus Protocol Reference Guide PI-MBUS-300 Rev. J Dated June, 1996. Longs and Float Points are also supported (two consecutive 16 -bit registers). The SCADA Modbus implementation supports Coil, Input, and Holding registers. Register types include: Boolean (Coil), Integer (16 bit), Longs (32 bits), and Floats (IEEE format, 32 bit, single precision). Single and block polls are supported (block polls are preferred to minimize Controller communication traffic). Byte and Word orientation is configurable (defaults are High/Low Byte, Low/High Word ordering). The Modbus Register Mapping Table is not hard coded. The user configures the Modbus Mapping Table via the 3D Boiler Configurator. The user assigns (maps) data variables from the 3D Controller configuration to Modbus addresses. This makes address mapping extremely flexible. Configuration details are described in the Configurator help files. Note:
The 3D Boiler Controller does not support Modbus ASCII, Modbus Plus, or Daniel’s Floating Point Extension.
Note:
See Appendix N for Modbus communications settings.
Serial Wiring Connections Controller SCADA 232 TX RX GND
RS-232 (DB9, PC Connection) RX (Pin 2) TX (Pin 3) GND (Pin 5)
Table 1: RS-232 Connection
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RS-485 DCS/Control System + GND RS-485 DCS/Control System + GND
Table 2: RS-485 Connections
Ethernet Connection There are two Ethernet ports (on separate networks in the 3D Boiler Controller) available for Mod/TCP communications. Typically, Port 2 would be assigned for Mod/TCP communications. The Ethernet port will need to be set with the correct IP address and Subnet Mask for SCADA Master access.
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2
N NO C L Control RLY 1 TB2
Line 1 (L) Fuse
TB12
TB11
N NO C L Control RLY 2 TB3
N NO C L Control RLY 3 TB4
RELAY CONNECTIONS
+2-
+ 1-
pH/ORP pH/ORP
CONDUCTIVITY INPUTS N NO C L Control RLY 4 TB5
N NO C L Control RLY 5 TB6
1
2
3
4
5
C NO NC ALARM TB7
+
TX RX GND
1B 1A GND
2B 2A GND
6V GND 1B 1A
6V GND 2B 2A
TB16 TB17 TB18 TB19 TB20 TB21
Note: Factory-installed jumper between “C” and “L” to provide 115 VAC power is not shown.
90-240 VAC 50/60 Hz TB1
3
1
L
N
Line 2 (N) Fuse
Key L : Line AC (Hot) N : Neutral AC : Earth Ground NO : Normally Open NC : Normally Closed C : Relay Common
TB15 TB14 TB13
6
INTER SCADA 232 LOCK
SCADA 485
MODBUS MASTER
MODEM CARD + S+ S+ S+ S+ S+ S+ S+ S+ S+ S+ S+ S-
4-20 mA OUTPUTS DIGITAL INPUTS
81-0027-00012
+ + + +
+ + + + + + + +
1
2
3
4
1
2
3
4
5
6
7
8
TB22 TB8
Fuse Ratings 5x20 mm Slow Blow Main Power (2) = 1.0A SB Alarm Relay = 1.0A SB Control Relays = 2.5A SB
1
2
3
S3 S+ + SS+ 2 + SS+ 1 +
4
0-10 V
4-20 mA
+ 24V + 24V + 24V + 24V
mA/V SELECTOR 1234
TB10
3D TRASAR BOILER CONTROLLER TERMINAL CONNECTIONS
ANALOG INPUTS RTD INPUTS
Nalco Global Equipment Solutions TB9
AC Input Power 90-240 VAC, 50/60 Hz 15A @ 120V, 15A Service 7.5A @ 240 VAC
3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________
3.2.21 3D TRASAR Boiler Controller Terminal Connections Diagram
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3.2.22 3D TRASAR Boiler Controller Default Wiring Most of the 3D TRASAR Boiler System is pre-wired at the factory. Be sure to connect these components to the terminal strip at the points listed below (Configurator assumes the following wiring connections).
Configurator Default Wiring Connections BL55xx or BL55xx0x
BL54xx or BL54xx0x
BL531x or BL532x (w/ SCS)
BL520x or BL530x (w/o SCS)
BL613x0
BL603xB
Flourometer
Fluorometer Input #1
Fluorometer Input #1
NA
NA
Fluorometer Input #1
Fluorometer Input #2
SCS Temp
RTD Input #1
RTD Input #1
RTD Input #1
NA
RTD Input #1
RTD Input #3
SCS Solenoid Valve
Relay Output #5
Relay Output #5
Relay Output #5
NA
Relay Output #5
Relay Output #4
Flow switch
Digital Input #1
Digital Input #1
Digital Input #1
“Jumpered”
Digital Input #1
Digital Input #2
NCSM Probe
AT ORP Input #1
NA
AT ORP Input #1
AT ORP Input #1
NA
NA
NCSM RTD
RTD Input #2
NA
RTD Input #2
RTD Input #2
NA
NA
Interlock
“Jumpered”
“Jumpered”
“Jumpered”
“Jumpered”
“Jumpered”
“Jumpered”
Options
BL55xxBx
BL54xxBx
NA
NA
BL613xB
BL603xB
Relays Box
Relays Outputs #1-4
Relays Outputs #1-4
NA
NA
Relays Outputs #1-4
Relays Outputs #1-3
Device
Note: Conductivity and pH sensors must be protected during shipping. So, they are not wired to the controller at the factory. Sensor input connections must be selected during installation.
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4.0
Final Assembly and Startup
4.1
Installation Check and Safety Check
Before assembling the unit be sure to familiarize yourself with the area that you are working in, the operation of the boiler and plant safety procedures. The following items should also be checked: • •
System meets boiler pressure and temperature ratings System meets area hazard rating requirements (060-BLxxx models are not rated for hazardous areas) Ensure all installation tasks have been completed Check all plumbing lines for leaks
• •
4.2
Shut all 3D TRASAR Boiler System valves
Note: Pressure regulator must be fully turned counterclockwise to close.
3-way outlet valve NCSM Inlet valve TRASAR Fluorometer inlet valve NCSM pressure bleed valve Pressure regulator Cooler sample inlet valve
Rotometer needle valve
SS Filter purge valve Grab sample valve
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4.3
Install and Connect the TRASAR Fluorometer
The fluorometer is shipped unattached to prevent damage. Install as follows: STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 -
Locate and unpack the fluorometer, fluorometer inlet valve, tubing connector, and fluorometer outlet assembly (comprised of flow switch housing and three-way ball valve). Attach the inlet valve and tubing connector to the fluorometer inlet using TEFLON tape. Do not over tighten. Thread the fluorometer outlet assembly to the outlet of the fluorometer. Do not over tighten. Remove the end cap from the sample supply tubing. Connect the supply tubing to the fluorometer inlet tubing connector. Mount the fluorometer (and outlet assembly) to the back panel with the screws provided. DO NOT FORCE! IMPORTANT: The length of the sample supply tubing may need to be adjusted to attain proper alignment of the mounting screws with the back panel. DO NOT BEND sample tubing. Excessive force may break fluorometer inlet fitting and internals. A broken inlet fitting will necessitate the purchase of a new fluorometer that will not be covered under warranty.
STEP 6 -
Connect the flow switch shuttle (prewired to the controller) to the flow switch housing.
STEP 7 -
Connect the preinstalled fluorometer cable to the fluorometer.
3-Way Ball Valve Fluorometer
Fluorometer Inlet Valve
Flow Switch
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4.4
Power Up Control System without Sample or Cooling Water Flowing
CAUTION: 4.4.1 -
4.4.2 -
4.4.3 -
4.4.4 -
4.5
Before the 3D TRASAR controller is powered up the following valves must be in the fully closed position:
TRASAR Fluorometer and NCSM Systems Sample inlet needle valve to the NCSM unit NCSM pressure bleed line valve Sample inlet needle valve to the sample cooler Pressure regulator (fully turned counterclockwise) Sample cooler drain valve (if installed) SS Filter purge valve Rotometer needle valve Fluorometer inlet valve 3-way sample outlet valve Grab sample valve
TRASAR Fluorometer Systems Sample inlet needle valve to the sample cooler Pressure regulator (fully turned counterclockwise) Sample cooler drain valve (if installed) SS Filter purge valve Rotometer needle valve Fluorometer inlet valve 3-way sample outlet valve Grab sample valve
NCSM Systems Sample inlet needle valve to the NCSM unit NCSM sample drain valve
Condensate Monitor Systems Sample inlet needle valve to the sample cooler 3-way sample outlet valve
Configure System and Upload to 3D TRASAR Controller
Screen details and latest updates are kept in “Help” section of the Configurator. The Configurator is used to: • Initially configure the controller • Upload changes to controller settings • Establish direct and modem connections to the controller • Download Data • Update Firmware
4.5.1
PC System Requirements • For direct connection to a 3D TRASAR controller an Ethernet adapter is required • For remote dial up access to a 3D TRASAR controller a modem is required.
4.5.2
Installing the Software • Software and Software Updates for Nalco personnel will be available via SMS.
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4.5.3
Configurator Support
All user functions have been made as self-explanatory as possible. Additional important information can be accessed for each Configurator screen by pressing the F-1 function key. Help functions will continue to be improved to address additional user requirements as they are identified. Many functions and settings have default values. It is important that you review these default settings to make sure they are appropriate for your specific systems requirements. •
You should upload your initial configuration while using a “Direct Connect” connection method. Connect your computer directly to the controller using the crossover cable supplied with the controller. After you verify your wiring is connected correctly, you may upload your configuration to the controller by selecting “Connect and Upload”.
•
All uploaded Configurator settings and subsequent changes will require a “Re-Boot” of the controller before they will become effective on the controller. Changes in PID control tuning functions are the only parameters that will not require a “Re-Boot”. (Changing the time of day and manual pump control do not require a reboot).
•
When you connect to the controller, the Configurator will compare the configuration on your computer to the configuration loaded onto the controller. You must decide which version you want to accept and work with by uploading your computer setting to the controller, or downloading the Controller settings to your configuration.
4.6
Reboot the 3D TRASAR Controller
•
After the configuration has been uploaded into the 3D TRASAR Controller it must be rebooted for the configuration to take effect. Reboot the system using the ACTION key on the front panel and selecting Reboot. (See Controller Operation Section of this manual)
•
Remember, any setting changes you make in the Configurator will not be made to the controller unless you upload the new settings to the controller. Any changes you have uploaded to the controller will not become effective until after you Re-Boot!
•
“Re-Booting” the controller may take up to 5 minutes or longer. Connecting to the controller is not possible during a “Re-Boot”. Additionally, all control functions are not operational during the system “Re-Boot” process. It is important to carefully make changes in the Configurator so that you can upload them, and Re-Boot as few times as possible to minimize the time waiting around while the controller is in a Re-Boot.
•
Your computer and the Configurator will lose the connection to the controller while the controller Re-Boots
Note:
4.7
WAIT until the controller has finished Re-Booting before you try to “Connect” via the “Connect” function!
Verify The Configuration Using The Controller Keypad/Screens
Scroll through the various screens on the controller to be sure the configuration was uploaded correctly. Check inputs, outputs, relays, etc.
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4.8
Calibrate the Fluorometer
4.8.1
Fluorometer Calibration Procedure
STEP 1
Close fluorometer inlet valve and turn 3-way fluorometer discharge valve to sample position.
IMPORTANT: Bubbles trapped in fluorometer during injection can cause instrument error. With the syringe in a vertical position, tap the syringe against a solid object to move the bubbles to the needle end of the syringe. Then, force the bubbles out by pushing a small amount of solution through the needle end of the syringe. STEP 2
(Optional – as needed) Clean the fluorometer by injecting acid with syringe (P/N 500PC2147.88) into the flow cell. Fill the syringe with 60 ml of dilute acid. 1:1 HCl, P/N 460S0726.75 is recommended for boiler applications. 10% Sulfuric Acid, P/N 460-S0800.75 is acceptable but may not readily remove iron. Screw the syringe onto the fitting, inject the dilute acid at a slow, steady rate into the flow cell, and allow it to stand for 2 minutes. Using the flow cell brush, carefully clean the cell. The cell should be rinsed after use.
CAUTION:
Wear the appropriate personal protective equipment when cleaning the flow cell. Check reagent MSDS for details.
STEP 3
Following the screen prompts, use a second clean 60 ml syringe and slowly flush the flow cell with 180 ml of blank solution. Then slowly inject another 180 ml blank solution and allow it to remain in the flow cell by leaving the syringe attached. Press Continue.
STEP 4
Following the screen prompts, use a third clean 60 ml syringe and slowly inject the flow cell with 180 ml of calibration solution (P/N 460-S0980.88) and allow it to remain in the flow cell by leaving the syringe attached. Press Continue.
STEP 5
Successful calibration will be indicated and must be “accepted”. Controller will automatically re-boot after accepting calibration. Turn valves back to operating positions. A failed calibration is most likely caused by insufficient flushing, contaminated/incorrect standards, air bubbles in the cell, excessive cell fouling, or a bad probe connection.
4.8.2 1) 2) 3) Note:
4) 5)
Note:
Fluorometer Calibration Screen Instructions Press Actions key on control panel Select Calibrate Enter PASSWORD 12345 (default) if requested A password must be entered to access all Actions submenus. The password has to be reentered after 10-minutes of inactivity. Select Fluorometer and follow directions on screen To calibrate the Fluorometer, follow the menu selections on the display panel. Calibration is necessary for proper balance in the system. The need to clean and calibrate is usually indicated by drift in readings or an error between test results and readings. Large errors are usually indications of failing probes or loose connections. Investigate the cause before recalibrating (check for alarms). If probes are removed for cleaning, check calibration before reinstalling probes.
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4.8.2.1
Fluorometer 2-Point Calibration Screens Instructions (Successful Calibration Sequence) Actions → Calibrate → Fluorometer Fluorometer Calibrate
Fluorometer Calibrate
Inject 180 ml Blanking Solution into flowcell.
Fluorometer calibration was successful. Accept new values?
Cancel
Cancel
Continue
Fluorometer Calibrate Measuring blank values. Please Wait. . . .
Fluorometer Calibrate Fluorometer calibration values saved.
Cancel
Done
Fluorometer Calibrate Inject 180 ml SO980 into flowcell. Use no other standards. Cancel
Accept
System Reboot Rebooting in 5,4,3,2,1 seconds
Continue
Fluorometer Calibrate Measuring Standard values. Please Wait. . . . Cancel
4.8.2.2
Fluorometer 2-Point Calibration Screens (If “cancel” is selected during the calibration sequence) Fluorometer Calibrate Fluorometer calibration canceled. Done
System Reboot Rebooting in 5,4,3,2,1 seconds
4.8.2.3
Fluorometer 2-Point Calibration Screens (If calibration fails) Fluorometer Calibrate Fluorometer calibration failed. Done
System Reboot Rebooting in 5,4,3,2,1 seconds
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4.9
NCSM Short Circuit Test
Prior to connecting the cables to the electrodes, perform a quick test of the cabling and controller.
4.9.1
NCSM Short Circuit Test Procedure
STEP 1
Short out the central core of both male BNC cable fittings (“ORP’ and “Ref”) to one another using the female-to-female BNC (provided in the Accessories Kit). The reading on the controller should read an “ORP” of zero millivolts.
STEP 2
Connect the cables to the respective electrodes. The male BNC cable marked “Ref” should now be reconnected to the female BNC on the base of the refurbished NCSM Reference Electrode. The cable end marked “ORP” should be reconnected to the female BNC on the Platinum Electrode (“ORP”).
Note: Under reducing boiler feedwater conditions the NCSM numbers should be negative after a stabilization period. Positive numbers may be an indication that the cabling is reversed and should be checked. If the cables are connected properly most likely the system transitioned into an oxidizing condition. Adding oxygen scavengers and reducing the amount of dissolved oxygen in the system should result in lower NCSM numbers.
4.9.2 1) 2) 4)
NCSM Short Circuit Test Screen Instructions Press Actions key on control panel Select Calibrate Enter PASSWORD 12345 (default) if requested
Note: A password must be entered to access all Actions submenus. The password has to be reentered after 10-minutes of inactivity 5) 6)
Select Short Circuit Test and follow directions on screen. Connect ORP and REF cables using the supplied BNC connector. Select Continue.
7)
Is the voltage 0 ± 5mV? Select Yes or No. a. If No is selected controller will display:”Short Circuit test failed. Check wiring and retry.” Select Cancel or Retry. b. If Yes is selected controller will display: “Short Circuit test passed” Select Continue.
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4.10
Refurbish and Test the NCSM Reference Electrode ORP Cell
Sample Inlet Valve
ORP/RTD Probe Pressure Gauge
Reference Electrode
Pressure Bleed Valve
Protective Shield
Nalco Corrosion Stress Monitor with NCSM
4.10.1
NCSM Probes
The NCSM Probe System consists of an ORP/RTD combination probe, Reference electrode, 3/8” cross. There is an ORP/REF combination cable and RTD probe cable. The 3/8” stainless steel cross acts as the ORP cell.
4.10.2
ORP/RTD Probe
The ORP/RTD combination probe is shipped connected to a 3/8” stainless steel cross and wired to the controller. The ORP probe can be temporarily removed during installation and lightly cleaned with isopropyl alcohol. The ORP probe must be re-inserted to the exact same depth as originally provided. This ensures the ORP probe is positioned in the cross within design tolerances. Remove the probe from cross by undoing the nut closest to the 3/8” cross and removing the “L” shaped electrode combination. This is a delicate electrode and care should be taken in handling the probe. Figure 2 shows the disassembled ORP cell. ORP Cell Internal Configuration Platinum and RTD Electrodes
Water Out
Disassembled ORP Cell RTD + BNC Connector
A
Platinum (ORP) Electrode + BNC Connector
Protective Shipping Cap
Water In Exposed Active Platinum Tip
RTD + BNC Connector
B
Platinum (ORP) Electrode + BNC Connector
Figure 1.
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Active Platinum Electrode
Platinum (ORP) and RTD Electrodes
3/8” Stainless Steel ORP Cell with Reducing Unions Active RTD Location
Reference Electrode Ceramic Junction
3/8” Stainless Steel ORP Cell with 1/4” Reducers
Reference Electrode
Figure 2.
Figure 3.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ The platinum electrode is visible as a band (approximately 1/8” in diameter) formed about the end of a hollow electrode wrapped with heat shrink Teflon (see Figure 1). The RTD is encased in the end of the hollow 1/8” stainless steel tube. The ORP probe cable connection is the female BNC that points downward and the RTD connection is the female BNC connection that protrudes parallel to the ground when assembled correctly. When assembled, the active portions of the RTD and ORP probe are all located in the center of the 3/8” stainless steel cross (ORP cell). The actual arrangement of the probes is shown in Figure 3. The cross has been cut open to reveal the ORP cell internals. The true ORP at actual system temperature and pressure is the potential difference measured on the platinum band as measured against the silver/silver chloride reference electrode. A replacement ORP/RTD combination probe is also available (Figure 1). The protective shipping cap (“black boot”) must be removed prior to using the probe. If the ¼” tube connectors are removed and replaced with 3/8” fittings care must be taken to ensure that the fittings and any tubing are not pushed too far into the cross as this will damage the ORP probe. There could also be interference with the strict tolerances for the positioning of the ORP probe and reference electrode probe.
4.10.3
Reference Electrode Porous Ceramic Membrane
1/4” Stainless Steel Tubing
Teflon Tube Insert
Split in Teflon Tube Insert
Internal Silver Rod BNC Connector
Figure 4
Reference Electrode
The Reference Electrode is shipped loose to prevent damage. It must be refurbished prior to use (see Reference Electrode Refurbishing Section). The electrode is then inserted into the bottom of the cross. The fitting should be tightened as with any standard high-pressure fitting (do not over-tighten – see below). Users must be familiar with the correct tightening and loosening procedures for stainless steel fittings. The ¼” SS tubing housing the Reference electrode is thin-wall tubing (0.028” wall thickness). The fitting affixed to this tube (about 15” long) must not be over-tightened. This will lead to excessive crimping of the tubing. Review the installation papers that are inside the supplied Reference electrode box along with the QC sheet for the probe. A copy of this picture is shown in Figure 5.
Figure 5 Nalco Global Equipment Solutions
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4.10.4
NCSM Probe Cables
Two cables are provided to connect the probes to the 3D TRASAR controller. • The 4 wire “RTD” cable connects to the RTD input for the 3D TRASAR controller. It is already wired to RTD #2 terminal strip connection in the controller and RTD. • The second cable is a special spliced cable. One male BNC fitting (“ORP”) connects to the female BNC fitting on the ORP probe. The other male BNC (“Ref”) connects to the female BNC fitting at the base of the Reference Electrode. The cable is pre-wired to the pH/ORP 1 connections in the 3D TRASAR controller. The white wire is the ORP (1+) lead and the black wire is the REF (1-) lead. Note:
In cases where the distances from the NCSM probe to the 3D TRASAR controller is over 6ft a special cable with an integral operational amplifier is used (060-BL52XX.88 models). This Op-Amp is lithium-battery powered. The battery should last for several years.
Note:
The battery should be replaced every 2 years to ensure uninterrupted quality NCSM readings. Change battery with the controller switched off and the cable unplugged.
4.10.5
NCSM Probe Checkout
Both probes should be checked and the Reference electrode refurbished on start-up and when the NCSM has been inactive and open to air.
Removing Reference Electrode Internals
A
B
Maintenance and probe verification checks should be preformed routinely, even when the boiler system is in normal operational. All of the probes should look as they do in the photographs contained within this manual. The probes should be physically inspected prior to use. During use the probes also need to be checked periodically to ensure there are no system leaks and there are no other obvious issues. Everything needed to perform the probe checks and refurbish the Reference Electrode is included in the Accessory Kit (provided with NCSM System).
Slip out the Teflon insert attached to the base fitting
Undo the top 1/4” nut
Reference Electrode Base with BNC Fitting
Figure 6 (A and B)
4.10.6 Refurbishing the Reference Electrode The Ag/AgCl Reference Electrode is an external pressure balanced reference electrode (EPBRE). It is to be installed in the bottom of the ORP cell (3/8” Cross). The silver/silver-chloride rod resides in a 0.1N KCl solution and is in contact with the high temperature environment via a Teflon tube and a ceramic membrane (frit). The Teflon tube has been designed so that the bottom portion of the electrode can be removed from the stainless steel tube for refurbishing (Figure 6).
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ Note: The base of the reference electrode is at ambient temperature but the internals are at system pressure during operation. Be sure the NCSM probe has been isolated, depressurized and valve locked and tagged out before servicing. Allow time for the cell to cool down (to avoid creating air bubbles) prior to removing the probe. 1. There are two SS nuts on the base portion of the reference electrode (see Figure 6). The top most nut is used to affix the internals of the electrode to the ¼” SS tubing (see Figure 5 and 6A). This nut is loosened to remove the internal electrode assembly from the ¼” SS tubing (see Figure 6B). The Teflon-electrode-insert can now be slipped out of the ¼” SS tubing. Note: The long ¼” SS tube will usually remain affixed to the 3/8” SS cross after it has been installed the first time. Note: The top nut is often loosened and tightened. In successive tightening operations the nut just needs to be snugged-up with wrenches and should not be over tightened. If over-tightened the internal portion of the reference electrode cannot be extracted. The second nut (smaller nut) is welded to the lower square bracket. The bracket houses the female BNC fitting and is used to prevent the silver rod from ejecting under pressure (see Figure 6). This smaller SS nut (affixed to the square bracket) is used to tighten the bracket to the SS tube fitting. There are 3 Teflon ferrules which are crimped down between the SS fitting and heat shrink Teflon, over the silver rod. This fitting should never need to be adjusted. However, if the fitting is leaking from this location then the fitting can be tightened (snugged-up only). Note: There will not be much resistance to tightening this fitting as Teflon is being compressed. The fitting should not be over-tightened and only snugged up to eliminate any leak. 2. After removing the Teflon tube and base portion of the reference electrode the Teflon tube can be separated into two parts. So, “old” electrolyte can be removed from the reference electrode and replaced with fresh electrolyte. A Teflon insert holds the two portions together (see Figure 7A). It is about 3-4 inches above the stainless steel base fitting. 3. Grasp both sides of the Teflon insert and separate the Teflon tube into two parts. This might require some slight twisting of the Teflon tubing. With a little force the probe will separate at this junction (see Figures 7B and 7C).
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A
Reference Electrode Disassembly (continued)
Separate Teflon insert at this location
B Resulting in two Teflon pieces
C Internal Teflon sleeve
D Top portion contains the ceramic membrane Figure 7
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The longer piece of tubing will house the porous ceramic junction. The shorter section of tubing will contain the tapered Ag/AgCl rod, base fitting and female BNC connector.
Two separated Teflon pieces
Note: Do not pull the two pieces of Teflon apart with too much force. This will stretch the Teflon and the ORP/RTD and REF probe may short out in the cross. The two Teflon parts must be twisted apart while applying a small amount of pulling.
Two separated Teflon pieces with electrolyte - filling syringe
Figure 8 4. Using the 10-ml syringe and supplied long hypodermic needle (see Figure 8), extract the internal filling solution from both portions of the Teflon tubing. When extracting the solution from the shorter piece of Teflon tubing make sure that the hypodermic needle is not “rammed” into the Ag/AgCl rod, damaging the silver chloride layer on the rod. Once all the 0.1N KCl solution has been removed from the reference probe it is ready to be re-commissioned.
The base portion of the Reference Electrode can be stood upright for filling with fresh electrolyte Teflon tube separation point
5. Clean the Teflon insert (the small section of Teflon tubing exposed at the point where the Teflon tube separates - see Figure 9) by wiping with a towel. All remaining vacuum grease should be removed. Make sure not to smear the grease into the hollow Teflon tubing. This will contaminate the 0.1N KCl Refill Solution.
Tapered Silver/Silver Chloride Rod within the Teflon Tube
6. Apply a very small amount of fresh vacuum grease (tube supplied) to the Teflon insert (Figure 10). This will make it easier to slide the two Figure 9 sections of the Teflon tubing together after filling and to separate after many months of use. Set aside these two Teflon pieces.
7. Fill the syringe with about 5 ml of fresh 0.1N KCl Refill Solution (supplied) and fill the two sections of Teflon tubing. Make sure that there are absolutely no bubbles in the Teflon tubes. It is easiest to place the syringe into the Teflon-tube and retract the syringe while dispensing fresh electrolyte into the tube. Leave a small meniscus of fresh KCl on the open ends of the Teflon tubes. Fill the bottom portion first. After filling the bottom portion of the Teflon tube prop this section up vertically (Figure 9). Then fill up the remaining Teflon tube with KCl Refill Solution.
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High vacuum grease applied to the Teflon insert
Figure 10
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ 8. With a section of filled Teflon tube in each hand recombine the pieces into one continuous electrode by slipping the one portion of the Teflon electrode over the smaller Teflon insert (which was previously greased). Make sure not to introduce any bubbles at this stage. This is accomplished by matching up the meniscus levels creating liquid-to-liquid contact before squeezing the two electrode sections together. Maintain pressure to force the two parts to stay together. There will be one or two drops of KCl electrolyte that will emanate from the porous ceramic frit as the two sections of Teflon are pushed together. This also provides reassurance that the porous ceramic frit is working as desired (it also cleans the frit). 9. Wipe off any excess vacuum grease that will have accumulated at the Teflon-to-Teflon junction. The Teflon tubing should now be in its original configuration (Figure 7A) prior to removing the Teflon tube from the ¼” stainless steel tube. Note: Electrodes should not be allowed to sit open to the atmosphere for long periods of time (several minutes), as bubbles will form in the electrode causing a loss of electrochemical continuity in the KCl solution. The electrode must be reinserted back into service immediately after the electrode is filled with new KCl solution and the Reference Electrode Check is quickly performed (see below).
4.10.7 Reference Electrode Check The electrochemical potential of the reference electrode is now ready to be checked against a “standard” saturated KCl Ag/AgCl half-cell (provided). The check should be performed when the reference electrode is used for the first time, after extended use, or when it is refurbished. The check can also be performed when the reference electrode is extracted from service, to check for reference electrode degradation. Note: During normal operation the NCSM cables are connected as follows. In this configuration the reference electrode is connected to the negative terminal in the controller. Cable connections for normal “measurement” operation Male BNC fitting (“Ref”) Male BNC fitting (“ORP”) STEP 1
NCSM Reference Electrode NCSM Platinum Electrode
When the potential of the newly refurbished electrode is to be measured against another known reference standard, the cables should be connected as follows: Cable connections for reference electrode check Male BNC fitting (“Ref”) Male BNC fitting (“ORP”)
“Standard” reference electrode AT NCSM Reference Electrode.
STEP 2
Immerse both the refurbished Reference Electrode and the standard reference half-cell in the same bottle of saturated KCl Test Solution (provided).
STEP 3
Record the potential difference between the refurbished electrode and the standard half cell. The potential difference is a function of temperature. The temperature effect is relatively small at ambient temperature (2 mV span from 0 to 50°C). The Reference Electrode should read a voltage of +90 mV +/- 10 mV against the “standard” half-cell. A significant deviation could be a result of the following.
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4.10.8 1) 2) 3)
The 0.1N KCl Refill Solution is ‘bad’. NCSM Reference Electrode is going bad and might need to be refurbished at the factory. If these reference electrodes are not abused they should last for many years. Poor refurbishing procedure (e.g. bubbles in the electrode) Standard half-cell electrode has gone bad. It might no longer be filled with saturated KCl. If these electrodes are stored “wet” (in saturated KCl) they can last for years without diminished performance. Controller malfunction.
Reference Electrode Check Screens
Press Actions key on control panel Select Calibrate Enter PASSWORD 12345 (default) if requested
Note: A password must be entered to access all Actions submenus. The password has to be reentered after 10-minutes of inactivity 4) 5) 6) 7) 8) 9)
Select Reference Test and follow directions on screen. Refurbish the REF electrode as described in the User Manual. Select Continue. Connect the ORP cable to the REF electrode. Select Continue. Connect the REF cable to the Reference half-cell supplied in the accessory kit. Select Continue. Immerse both electrodes in the saturated KCL (Test) solution supplied in the accessory kit. Select Continue. The voltage is displayed. Is the voltage 90 ± 10mV? Select Yes or No. c. If No is selected controller will display: ” Reference test failed. Refurbish and retry.” Select Cancel or Retry. d. If Yes is selected controller will display: “Reference test passed” Select OK.
4.10.9
Install The Reference Electrode
After performing the NCSM Reference Electrode Check install the electrode. This electrode should always be the last electrode to be installed, just prior to opening the sample line valves. The electrode is then inserted into the bottom of the cross. The fitting should be tightened as with any standard high-pressure fitting (do not over-tighten).
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4.11
Feed Water pH and Conductivity Probe Installation
If ordered, the feed water pH and conductivity module piping will be installed on the system in at the factory. There are two slightly different module configurations:
Low-Purity Module (Conductivity > 100 µS/cm)
High-Purity Module (Conductivity 1 < 100 µS/cm)
The feed water pH and conductivity probes are shipped in their packaging for protection. They must be installed into the plumbing module before startup. See Section 3.2.7 and 3.2.8 for wiring connections.
Module Location 4.12
Note:
Remember to remove the protective cap from the pH probe before screwing the probe into the tee.
pH Probe Calibration
IMPORTANT NOTE:
On new installations a 2-point calibration must always be performed.
To perform a pH calibration, use the Actions key and select Calibrate. Highlight the pH probe you wish to calibrate and hit Select. You will be notified that you have selected a pH calibration sequence. Select CONTINUE 1-Point Calibration utilizes the system water as the calibration point. It is best used to fine-tune your calibration to compensate for minor drifting. Leave the probe in the process water. 2-Point Calibration utilizes pH standards that cover the range of measurement. It is best utilized when installing a new probe or if a major error has developed due to excessive fouling. The user may select between two 2 point calibration options that are available: Calibration using 4 and 7 pH standards, OR Calibration using 7 and 10 pH standards. Highlight the desired 1 or 2 point calibration process and hit SELECT
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2-Point Calibration STEP 1
Isolate the probe from the system. For feedwater installations, close the sample inlet valve to the sample cooler. Remove the pH probe from the cross or tee fitting.
STEP 2
Clean the probe with deionized water to remove any deposits or contaminants.
STEP 3
Select the temperature source to be used for the calibration temperature compensation by highlighting Select Temp and pressing Edit. The options are None, Temp 1, 2, 3 or USER SET. Use the ⇓⇑ arrows to toggle between choices. Select ACCEPT after making a selection and you should be directed to the FIXED TEMP line.
STEP 4
Fixed Temp represents the temperature of the calibration solution being used. This selection is only used in the USER SET temperature mode. To modify the temperature being used, select EDIT. Enter a temperature for the pH standard solutions and select Accept. Note:
If using Temp 1, 2, 3, or NONE, any temperature setting in this section will be ignored during the calibration process.
STEP 5
Use the ⇓⇑ arrows to toggle to START CALIBRATION. Hit SELECT to enter the 4/7 or 7/10 calibration sequence
STEP 6
Follow the on-screen prompts and place the probe in a beaker of clean, fresh 4 or 7 pH standard as directed. Press CONTINUE.
STEP 7
The controller will measure the pH of the calibration solution.
STEP 8
After the prompt, rinse the probe well in clean deionized water.
STEP 9
Place the probe in a beaker of clean, fresh 7 or 10 pH standard. Press CONTINUE.
STEP 10 After successful calibration, select DONE, and install the probe back into the pipe cross or tee fitting. STEP 11 Establish flow through the pH probe. For feedwater installations, slowly open the sample inlet valve to the sample cooler. If no leaks are observed, open the valve ¼ turn from the fully wide-open position. If probe calibration is unsuccessful, check the standards, wiring connections, or handheld pH meter for accuracy and recalibrate. CAUTION-DANGER A lockable valve should be installed on the sample line to isolate the system for maintenance and prevent unauthorized energizing of the system. Follow all lock out, tag out requirements for servicing.
1-Point Calibration STEP 1 Leave the probe in the cross or tee with water flowing. Probe should have been installed at least 20 minutes for equilibrium. STEP 2 Using a handheld instrument of known accuracy and calibration, locally sample the process water and determine the pH value. STEP 3 Select Edit to change pH value. STEP 4 Enter the measured pH value and select Accept. Note: Selecting Accept will perform the 1-point calibration sequence. To ensure that the calibration has been performed correctly, return to the Operating Data screen and confirm that the pH now reads the value just entered. 82
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4.13
Conductivity Probe Calibration
IMPORTANT NOTE:
On new installations a 2-point calibration must always be performed.
To perform the conductivity calibration, select the Actions key on the 3D TRASAR controller and Select Calibrate. Highlight the conductivity probe you wish to calibrate and hit Select. -Point Calibration utilizes the boiler water or feedwater as the calibration point. It is recommended to perform this step after a 2-point calibration has been performed to fine-tune the calibration. The probe is left in the blowdown line or 3D TRASAR system while a representative (cooled) sample is measured from a reliable handheld meter. 2-Point Calibration utilizes conductivity standards that cover the range of measurement. A 2-point calibration is required for all new installations. When a major error in the conductivity measurement has developed due to excessive fouling on the probe, a 2-point calibration is also recommended.
4.13.1
Recommended Conductivity Calibration Standards
The table below lists the conductivity calibration solutions that are available through Nalco. Calibration Standards 0 µS/cm (dry in Air) 40 µS/cm 200 µS/cm 600 µS/cm 3000 µS/cm 5000 µS/cm 10,000 µS/cm
Part Number -460-S0299.75 460-S0743.75 460-S0298.75 460-S0297.75 001-H07642.88 001-H07641.88
The recommendation for conductivity calibration is to choose two standards that encompass the expected conductivity range of measurement for the system. The tables below list the combinations of standards that are required for boiler feedwater and blowdown applications. Feedwater & Condensate: K = 1.0 Calibration Calibration Solution #1 Solution #2 0 40 40 600 0 600
IMPORTANT NOTE:
K = 0.1 Calibration Calibration Solution #1 Solution #2 0 40 40 200
Blowdown: K = 1.0 Calibration Calibration Solution #1 Solution #2 600 3000 600 5000 3000 5000 3000 10,000 5000 10,000
If combinations other than those listed are used, (i.e., 40 µS/cm and 10,000 µS/cm) the calibration will fail. This is due to the fact that the resulting conductivity counts for the incorrect combination of standards will fall outside of the 3D TRASAR controller’s calibration range.
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4.13.2
2-Point Calibration
Notes:
STEP 1
•
Place the probe in the center of a beaker (container) during 2-point calibration, to avoid wall effects.
•
Do not stir the probe in the calibration solutions as this may cause air bubbles to form inside the electrode.
•
Verify there are no bubbles inside the probe during calibration.
•
If extracting the probe from a boiler blowdown line, ensure that its temperature has equilibrated before performing the calibration. For new installations, proceed to Step 2. For probes that are currently installed and in service, extracting the conductivity probe from the system is the first step. Isolate the probe from the system to allow safe extraction. For feedwater installations, close the inlet valve to the sample line. Remove the conductivity probe from the cross or tee fitting.
CAUTION-DANGER:
Note:
If the probe is being extracted from the blowdown line of an operating boiler see Section 4.13.4 for safety precautions and procedures.
To prevent excessive twisting of the wires during probe extraction: Feedwater Installations: The conductivity wires can be pre-twisted upon installation into the tee fitting to compensate for the twisting of the wires upon removal. Blowdown Installations: The signal wires can be disconnected from the output side of the terminal strip inside the Jbox. This will allow the probe to be freely loosened from the pipe cross without twisting the signal wires. Once the probe has been extracted from the pipe cross, reconnect the signal wires to the output side of the terminal strip. This re-establishes the electrical connection to the controller.
STEP 2
Clean the probe with deionized water to remove any deposits or contaminants. If the probe is severely fouled, see section 4.13.6 on cleaning the conductivity probe.
STEP 3
On the 3D TRASAR controller, select 2-point (Standards) calibration.
STEP 4
Select the temperature source to be used for the calibration temperature compensation by highlighting Select Cal Temp and pressing Edit. The options are None, RTD or a Fixed. Use the ⇓⇑ arrows to toggle between choices. The entry for the Fixed temp value should be the actual temperature of the calibration solutions. This can be measured with an external thermometer. This entry will influence the calibration accuracy so it is important that the correct temperature is entered. If a conductivity probe with an integral RTD is being used, select the RTD input were the integral RTD is wired to. After selecting the temperature enter Accept.
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The temperature value that is entered by the user is in degrees Celsius (°C). Nalco Global Equipment Solutions
3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ STEP 5
Select Choose Standards. Then select Edit to enter the High and Low conductivity calibration solutions to be used. The default values are 3000 µS/cm and 600 µS/cm. Select Accept. Select Start Calibration.
STEP 6
Place the probe in a beaker of clean, fresh Low conductivity solution (In this example, 600 µS/cm buffer solution is used, P/N 460-S0298.75). Ensure that no air bubbles are trapped inside the electrode. Press Continue.
STEP 7
The controller will take 60 seconds to measure the conductivity of the calibration solution.
STEP 8
After the prompt, rinse the probe well in clean deionized water.
STEP 9
Place the probe in a beaker of clean, fresh High conductivity solution. (In this example a 3000 µS/cm buffer solution is used, P/N 460-S0197.75). Ensure that there are no air bubbles trapped inside the electrode. Press Continue. If probe calibration is unsuccessful, check the standards, wiring connections, or handheld conductivity meter for accuracy and then recalibrate. If calibration is successful, proceed to Step 10.
STEP 10
Install the probe back into the pipe cross or tee fitting. Ensure that the electrode’s flowthrough hole is in line with the sample flow. The K factor that is stamped on the probe’s hex fitting is aligned with the hole. This probe orientation is critical and will affect the measurement if it is oriented incorrectly. (See Section 2.3.3.4)
Note:
For feedwater installations, it is recommended to pre-twist the wires to compensate for the twisting that occurs upon installing into the tee fitting. For blowdown installations, disconnect the signal wires again from the output side of the terminal strip inside the J-box. Install the probe into the cross fitting. Once installed, reconnect the signal wires back into the output of the terminal strip. This will re-establish electrical connections to the controller.
STEP 11
Establish flow through the conductivity probe. For feedwater installations, slowly open the inlet valve to the sample line. If no leaks are observed, open the valve ¼ turn from the wide-open position. For blowdown installations, see section below for safety precautions and procedures. CAUTION-DANGER A lockable valve should be installed on the sample line to isolate the system for maintenance and prevent unauthorized energizing of the system. Follow all plant lock out, tag out requirements for servicing.
STEP 12
Allow the probe to equilibrate to system conditions. Proceed to the 1-Point Calibration (Section 4.13.3).
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4.13.3
1-Point Calibration
IMPORTANT NOTE:
A 1-point conductivity calibration must be performed after a 2-point calibration as part of every field start–up. This is important because the 2point calibration is performed under static conditions. The 1-point calibration will compensate for the flowing sample and the dynamics of the system. Follow the calibration procedure that corresponds to the control mode in use.
4.13.3.1
Continuous Sample – On/Off or PID Control On the 3D TRASAR controller, highlight 1-point (Process) calibration then hit Select.
STEP 1
Leave the conductivity probe in the cross assembly. For systems using Continuous (On/Off) control, allow several minutes for the probe to equilibrate to the conditions of the boiler water that is continuously flowing through the cross assembly.
STEP 2
Using a handheld, temperature-compensating conductivity meter of known accuracy and calibration, locally sample the boiler water and measure the (non-neutralized) conductivity value. For boiler blowdown, sample cooling is required.
STEP 3
After the probe has equilibrated to the blowdown sample, compare the Current conductivity reading on the display screen to the reading obtained from the handheld meter in Step 2. These values should be relatively close (i.e., this should not be a 50% offset). Proceed to Step 4.
STEP 4
Select Edit to change the Enter New conductivity value.
STEP 5
Enter the measured conductivity value and select Accept.
Note:
Selecting Accept will perform the 1-point calibration sequence and leave you at the 1-point calibration menu. The Current reading should now reflect the new conductivity value entered.
STEP 6
Select Back to return to the Operating Data screen.
4.13.3.2
Timed Sample – Continuous On/Off Control On the 3D TRASAR controller, highlight 1-point (Process) calibration then hit Select.
STEP 1
For systems using Timed Sample - Continuous On/Off Control, the blowdown control valve will need to be manually opened to allow sample to flow past the conductivity probe. To do this, set the corresponding Relay Output for the motorized valve to “Manual On” (Actions => Manual Control => (corresponding) Relay => Manual On). This will allow water to flow through the conductivity probe. Allow the same amount of time for the probe to equilibrate to the boiler water conditions as it would during the control cycle.
STEP 2
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Therefore, let the sample flow for a time equal to the Flush Time value entered in the control screen setup. Immediately, using a handheld, temperature-compensating conductivity meter of known accuracy and calibration, locally sample the boiler water and measure the (non-neutralized) conductivity value. For boiler blowdown, sample cooling is required. Nalco Global Equipment Solutions
3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ STEP 3
Compare the Current conductivity reading on the display screen to the reading obtained from the handheld meter in Step 2. These values should be relatively close (i.e., this should not be a 50% offset). Proceed to Step 4.
STEP 4
Select Edit to change the Enter New conductivity value.
STEP 5
Enter the measured conductivity value and select Accept.
Note:
STEP 6 Note:
Selecting Accept will perform the 1-point calibration sequence and leave you at the 1-point calibration menu. The Current reading should now reflect the new conductivity value entered. Select Back to return to the Operating Data screen. Selecting Accept will perform the 1-point calibration sequence and leave you at the 1-point calibration menu. The controller will display the last reading obtained during a control cycle measurement.
STEP 7
Once calibration is completed set the corresponding Relay Output for the motorized valve back to “Auto” (Actions => Manual Control => (corresponding) Relay => Auto.)
Note:
It is critical to remember to switch back the Relay Output from Manual to Auto after the 1-point calibration step.
4.13.3.3
Timed Sample – Proportional Control On the 3D TRASAR controller, highlight 1-point (Process) calibration then hit Select.
STEP 1
For systems using Timed Sample – Proportional Control, the blowdown control valve will need to be manually opened to allow sample to flow past the conductivity probe. To do this, set the corresponding Relay Output for the motorized valve to “Manual On” (Actions => Manual Control => (corresponding) Relay => Manual On). This will allow water to flow through the conductivity probe. Allow the same amount of time for the probe to equilibrate to the boiler water conditions as it would during the control cycle.
STEP 2
STEP 3
Therefore, let the sample flow for a time equal to the Flush Time value entered in the control screen setup. Immediately, using a handheld, temperature-compensating conductivity meter of known accuracy and calibration, locally sample the boiler water and measure the (non-neutralized) conductivity value. For boiler blowdown, sample cooling is required. The control valve will need to be closed to trap the blowdown sample, in order to prevent the sample from flashing. A stable Current conductivity reading can then be obtained. To do this, set the corresponding Relay Output for the motorized valve from “Manual On” to “Manual Off” (Actions => Manual Control => (corresponding) Relay => Manual Off). Allow 15 seconds to elapse then compare the Current conductivity reading on the display screen to the reading obtained from the handheld meter in Step 2. Proceed to Step 4.
STEP 4
Compare the Current conductivity reading on the display screen to the reading obtained from the handheld meter in Step 2. These values should be relatively close (i.e., this should not be a 50% offset). Proceed to Step 5.
STEP 5
Select Edit to change the Enter New conductivity value.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 STEP 6 Note:
STEP 7 Note:
Enter the measured conductivity value and select Accept. Selecting Accept will perform the 1-point calibration sequence and leave you at the 1-point calibration menu. The Current reading should now reflect the new conductivity value entered. Select Back to return to the Operating Data screen. Selecting Accept will perform the 1-point calibration sequence and leave you at the 1-point calibration menu. The controller will display the last reading obtained during a control cycle measurement.
STEP 8
Once calibration is completed set the corresponding Relay Output for the motorized valve back to “Auto” (Actions => Manual Control => (corresponding) Relay => Auto.)
Note:
It is critical to remember to switch back the Relay Output from Manual to Auto after the 1-point calibration step.
4.13.4
Extracting a Conductivity Probe from the Blowdown Line of an Operating Boiler:
Note:
The use of thermal gloves is highly recommended when working on boiler blowdown lines. 1. Close the 1” isolation gate valve on the blowdown line, located upstream the conductivity probe cross assembly. For safety reasons, allow the conductivity probe to cool down to safer temperatures before proceeding. 2. Once the blowdown line has cooled down, depressurize the cross by slowly opening the ½” flushing valve at the bottom of the cross. If this line suddenly becomes hot, this would be an indication that boiler water is leaking by the 1” isolation gate valve. If this is the case, DO NOT PROCEED. 3. Once the cross assembly has been safely isolated, cooled and depressurized, open up the junction box at the top of the conductivity probe. Disconnect the signal wires from the output side of the terminal strip. This frees up the probe/J-box from the signal wiring. 4. One can now safely and freely extract the probe from the pipe cross without twisting the signal wires. 5. If the conductivity probe requires cleaning, follow the cleaning procedures below. 6. Before proceeding with the 2-point calibration, the signal wires will need to be wired back into the terminal strip of the J-box to re-establish a connection with the controller. 7. Once the wiring is done, follow the procedures for the 2-point calibration. Note that the conductivity probe and the controller may be a distance away from one another. Therefore, calibration will require one to walk back and forth between the controller and the conductivity probe when performing the 2-point calibration. If possible, it would be easier to have two people perform the calibration – one person at the probe end and the other person at the controller. CAUTION-DANGER A lockable valve should be installed on the sample line to isolate the system for maintenance and prevent unauthorized energizing of the system. Follow all plant lock out, tag out requirements for servicing.
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4.13.5
Installing a Conductivity Probe into the Blowdown Line of an Operating Boiler:
Note:
These procedures can be followed for a new installation, after performing a 2-point calibration, or after probe servicing.
Note:
The use of thermal gloves is recommended when working on boiler blowdown lines. 1. At this point, the probe/J-box is intact and only the signal wiring is disconnected from the output of the terminal strip inside the J-box. 2. Apply Teflon tape to the threads of the conductivity probe. 3. Install the probe into the top port of the conductivity probe cross assembly. 4. Ensure that the electrode’s flow-through hole is in line with the sample flow. The K-factor that is stamped on the hex fitting of the probe is aligned with the hole. This probe orientation is critical and will affect the measurement if it is oriented incorrectly. 5. Once installed, reconnect the signal wires to the terminal strip inside the J-box. Ensure that the correct electrical connections are made. 6. Close the ½” flushing valve at the bottom of the cross. 7. Slowly open the 1” isolation gate valve on the blowdown line, located upstream the conductivity probe cross assembly. If no leaks are observed around the probe, slowly open the gate valve approximately ¼ turn from the wide-open position. 8. At this point, a 1-point calibration will need to be done. Refer to the 1-Point Calibration (Section 4.13.3).
4.13.6
Cleaning a Fouled Conductivity Probe 1. Wipe the electrode surface with a paper towel to remove excess solids. 2. If significant fouling remains on the electrode, immerse the electrode into a beaker of dilute sulfuric acid. CAUTION-WARNING: Use appropriate PPE when handling acid. Check reagent MSDS. 3. Thoroughly rinse the probe with deionized water. 4. Proceed to performing a 2-point calibration, followed by a 1-point calibration.
4.14
System Leak Test and Final Piping Insulation
Before starting up the 3D TRASAR system ensure that the following steps have been completed. • • • • • • • • • • •
All the probes have been wired into the controller. All other electrical connections have been made. There are no leaks in the piping to and from the unit. NCSM Short circuit test completed NCSM Reference Electrode has been refurbished and checked. NCSM Reference Electrode has been properly installed into the SS cross. All hot sample lines have been insulated. Calibration has been performed on the fluorometer (and optional pH and conductivity probes) All the stainless steel fittings are tight. Confirm cooling water is available at the sample cooler. 3D TRASAR Controller is turned OFF.
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4.15 4.15.1
Startup NCSM and Fluorometer Models– System Valve Identification
Locate all the valves on the specific model installed . The picture below shows the valves on a unit equipped with a TRASAR Fluorometer and NCSM. Other models may not have all the components.
3-way outlet valve
NCSM Inlet valve
TRASAR Fluorometer inlet valve
NCSM pressure bleed valve
Rotometer needle valve
Sample cooler Inlet valve
Grab sample valve
Pressure regulator
Note:
The fluorometer-based blowdown systems have the same valve configuration as the feedwater models.
4.15.2
TRASAR Fluorometer and NCSM System Startup
CAUTION-DANGER: 90
Before the 3D TRASAR controller is powered up the following valves must be in the fully closed position:
Sample inlet needle valve to the NCSM unit NCSM pressure bleed line valve Sample inlet needle valve to the sample cooler Pressure regulator (fully turned counterclockwise) Sample cooler drain valve (if installed) SS Filter purge valve Rotometer needle valve Fluorometer inlet valve 3-way sample outlet valve Grab sample valve Nalco Global Equipment Solutions
3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ 1. Open the cooling water isolation valve. NEVER open the sample inlet valve without ensuring cooling water is flowing through the sample cooler.
CAUTION-DANGER:
When the 3D TRASAR controller is powered up, the solenoid valve is energized and will open.
2. Turn on the 3D TRASAR controller. 3. Replace the NCSM (Lexan) protector shield back on its mounting posts. 4. Once the protector shield is installed, with caution, slowly open the NCSM inlet needle valve. This line will be a high pressure and high temperature sample line so take caution. Carefully check for leaks, including the base of the Reference Electrode.
CAUTION-DANGER: ALWAYS slowly open the sample line as a sudden pressure surge can be disastrous if there is a leak, resulting in possible serious injury especially with high-pressure boiler water or steam. 5. If a leak is observed, close the NCSM inlet needle valve. Snug up the fitting that was leaking. Do not over tighten Swagelok fittings. 6. If water is leaking out of the base of the Reference Electrode, snug up the ¼” fitting as shown in the picture below. This picture is also included with the Reference Electrode.
Since the Reference Electrode tube is thin-walled stainless steel tubing, it is important that the ¼” nut is not over-tightened. This can be accomplished by turning the 9/16” wrench 1/16 th of a turn at a time in the clockwise direction, while keeping the ½” wrench stationary. If there is water leaking out of the 3/8” nut of the Reference Electrode, which is the fitting that is connected to the 3/8” cross, snug this fitting up 1/16th of a turn at a time. 7. Repeat step 5. If no leaks are further observed, proceed to step 8. 8. Slowly open the NCSM inlet needle valve all the way to a quarter turn from the fully open position. 9. Slowly open the needle valve to the inlet of the sample cooler. Check for leaks up to the pressure regulator of the sample conditioner. Although the sample is cooled after the sample cooler, take caution since this is still a high-pressure sample. If there are no leaks, open up the sample cooler inlet needle valve all the way to a quarter turn from the fully open position. 10. Adjust the pressure regulator (clockwise) until the pressure gauge reads 10 to 20 psig.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 11. Open the rotometer needle valve, the fluorometer inlet valve, and finally the ½” FPT sample outlet valve. 12. Opening up the last three valves will cause the pressure to drop. Adjust both the pressure regulator and the rotometer needle valve to establish a pressure of 10 to 20 psig and 300 ml/min of flow. Note:
If flows over 500 ml/min are needed to obtain good PID TRASAR control, separate 3D TRASAR Boiler TRASAR Fluorometer and NCSM sample lines must be plumbed.
13. Ensure proper sample drainage.
4.15.3
TRASAR Fluorometer Only System Startup
CAUTION-DANGER: Before the 3D TRASAR controller is powered up the following valves must be in the fully closed position: -
Sample inlet needle valve to the sample cooler Pressure regulator (fully turned counterclockwise) Sample cooler drain valve (if installed) SS Filter purge valve Rotometer needle valve Fluorometer inlet valve 3-way sample outlet valve Grab sample valve
1. Open the cooling water isolation valve. NEVER open the sample inlet valve without ensuring cooling water is flowing through the sample cooler.
CAUTION-DANGER:
When the 3D TRASAR controller is powered up, the solenoid valve is energized and will open.
2. Turn on the 3D TRASAR controller. 3. With caution, slowly open the needle valve to the inlet of the sample cooler. This sample will be a high pressure and high temperature sample so take caution. Check for leaks up to the pressure regulator of the sample conditioner.
CAUTION-DANGER: ALWAYS slowly open the sample line as a sudden pressure surge can be disastrous if there is a leak, resulting in possible serious injury especially with high-pressure boiler water or steam. 4. If there is a leak, close the sample cooler inlet valve. Snug up the fitting that was leaking. Do not over tighten Swagelok fittings. 5. Once the leak has been addressed, repeat step 3. 6. If there are no further leaks, proceed to step 7. 7. Although the sample is cooled after the sample cooler, take caution since this is still a highpressure sample. Slowly open up the sample cooler inlet needle valve all the way to a quarter turn from the fully open position. 8. Adjust the pressure regulator (clockwise) until the pressure gauge reads 10 to 20 psig. 9. Open the rotometer needle valve, the fluorometer inlet valve, and finally the ½” FPT sample outlet valve. 10. Opening up the last three valves will cause the pressure to drop. Adjust both the pressure regulator and the rotometer needle valve to establish a pressure of 10 to 20 psig and 300 ml/min of flow. 11. Finally, ensure proper sample drainage. 92
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4.15.4
NCSM Only System Startup (without Sample Conditioning System)
CAUTION-DANGER: Before the 3D TRASAR controller is powered up the following valves must be in the fully closed position: -
Sample inlet needle valve to the NCSM unit NCSM sample pressure bleed valve Sample outlet needle valve
1. Replace the NCSM (Lexan) protector shield back on its mounting posts. 2. Once the protector shield is installed, with caution, slowly open the NCSM inlet needle valve. This line will be a high pressure and high temperature sample line so take caution. Carefully check for leaks, including the base of the Reference Electrode.
CAUTION-DANGER: ALWAYS slowly open the sample line as a sudden pressure surge can be disastrous if there is a leak, resulting in possible serious injury especially with high-pressure boiler water or steam. 3. If a leak is observed, close the NCSM inlet needle valve. Snug up the fitting that was leaking. Do not over tighten Swagelok fittings. If water is leaking out of the base of the Reference Electrode, snug up the ¼” fitting (See Section 4.10) 4. Repeat step 2. If no leaks are further observed, proceed to step 5. 5. Slowly open the NCSM inlet needle valve all the way to a quarter turn from the fully open position. 6. Slowly open the NCSM outlet needle valve all the way to a quarter turn from the fully open position. 7. If the NCSM sample is being sent to the plant’s sample conditioning system, adjust the plant’s flow control valve to establish 300 ml/min through the NCSM probe. 8. Turn on the 3D TRASAR Controller
4.15.5 Condensate Monitor System CAUTION-DANGER: Before the 3D TRASAR controller is powered up the following valves must be in the fully closed position: -
Sample inlet needle valve 3-way sample outlet valve
1. Open the cooling water isolation valve. NEVER open the sample inlet valve without ensuring cooling water is flowing through the sample cooler.
CAUTION-DANGER: Note:
When the 3D TRASAR controller is powered up, the solenoid valve is energized and will open.
If the Condensate Monitor is configured for intermittent operation the interlock input must be jumpered to test the system.
2. Turn on the 3D TRASAR controller. 3. With caution, slowly open the needle valve on the sample inlet. This sample will be a high pressure and high temperature sample so take caution. Check for leaks up to the pressure regulator of the sample conditioner.
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CAUTION-DANGER: ALWAYS slowly open the sample line as a sudden pressure surge can be disastrous if there is a leak, resulting in possible serious injury especially with high-pressure boiler water or steam. 4. If there is a leak, close the sample cooler inlet valve. Snug up the fitting that was leaking. Do not over tighten Swagelok fittings. 5. Once the leak has been addressed, repeat step 3. 6. If there are no further leaks, proceed to step 7. 7. Although the sample is cooled after the sample cooler, take caution since this is still a highpressure sample. 8. Open up the 3-way valve on the sample discharge 9. Finally, ensure proper sample drainage.
3-way outlet valve
Sample inlet valve
Pressure relief valve
Cooler water solenoid valve
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4.16
4.17
Test Data Download to a USB Data Stick and Laptop Computer •
Using the Configurator download data to the laptop following the on screen instructions. Verify that the data was transferred correctly
•
The USB is available via an external connector with waterproof cap. The cap must be in place whenever the port is not in use. Using the USB port download data/alarm files following the on screen instructions. Verify that the data was transferred correctly by loading it on the laptop.
Verify Operation Of The Control Outputs • • •
Using the keypad on the controller manually turn on and off the relays. Manually set the Analog Outputs to 0% and 100%. Verify that the relays and pumps actually perform as expected.
CAUTION-DANGER:
4.18
Be careful to return the SCS relay to automatic control mode after testing its operation.
Test High-Temperature Shutdown & Pressure Relief
The 3D TRASAR Boiler Automation requires the sample stream to be cooled before being sent to the TRASAR Fluorometer or pH probes. If the temperature exceeds 110ºF or 43ºC, then the safety solenoid automatically closes (normally closed valve) shutting off the hot sample flow before it reaches the fluorometer. During the initial startup verify the proper/expected behavior of this safety feature. 1. While the system is in operation and with sample flow passing through the lines, the cooled sample temperature should be shown on the main display screen of the controller. 2. While actively watching the unit (do not walk away or become distracted by phone or personal conversation) begin the test by slowly reducing the cooling water flow to the sample cooler. Eventually the flow of cooling water will become reduced enough that sample temperature from the boiler system should begin to rise. This may take several minutes due to the cold water already in place in the sample cooler shell. The goal is to cause a rise of the sample temperature ABOVE the point where flow is automatically shut off (110°F/43°C). CAUTION-DANGER:
DO NOT allow the sample to STEAM by completely turning off cooling water.
If the temperature rises above 140°F (60ºC) without closing the valve, quickly restore cooling flow and check all wiring connections and configuration of the solenoid safety shut off. 3. With proper and expected activation of the solenoid shut off feature at high temperature, restore the sample cooling water flow. Since there is no sample flow it may take several minutes for the sample near the temperature probe to cool down (ice pack will help). 4. The (high temperature) alarm must be manually cleared (it is not self clearing). The system should then re-establish flow. 5. Once normal flow is re-established VERY SLOWLY, incrementally increase the sample pressure (using the sample pressure regulator). 6. Observe the sample pressure on the pressure gauge. The relief valve should start to open around 60 psi. (4 bar) This verifies that the relief valve is working properly.
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7. Reduce the pressure to the normal range (20-30 psi, 1-2 bar). The relief should close. Note:
The relief valve has a metal ball to metal ring seal. It may drip. If so, repeat steps 8 and 9 to re-seat until the leaking stops.
4.19
Check Remote Communications
If the 3D TRASAR web service is in use, verify that data and alarms can be sent to the 3D TRASAR website via phone, wireless gateway or LAN.
4.19.1 1.
3D TRASAR Boilers Nalco Global Gateway Setup
Verify the controller settings are correct using the keypad. From the keypad go to Menu > Network > Ethernet 1 Ethernet 1 Enabled IP address 169.254.001.002 Gateway 0.000.000.000 Subnet 255.255.000.000 Ethernet 1DHCP Disabled From the keypad go to Menu > Network > Ethernet 2 Ethernet 2 Enabled IP address 192.168.001.002 Gateway 192.168.001.001 Subnet 255.255.255.000 Ethernet 1DHCP Disabled
2. Verify that the wireless gateway is installed correctly.
•
Connect Nalco Global Gateway to internal Ethernet port #2
•
Two Ethernet cables come with the Nalco Global Gateway. Only one is needed and it does not matter which one is used. Continue to configuration.
Note:
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The 3D TRASAR Boiler Controller IN NOT WIRED to the Nalco Global Gateway the same way as 3D TRASAR Cooling Controllers.
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•
Connect your Nalco laptop to the controller as shown using the Ethernet crossover cable supplied with the controller.
•
Launch the 3D TRASAR Boiler Configurator and Click on the Communication Settings button.
•
Choose Connection method and Select the Advanced Communication Settings
•
Choose the appropriate Alarm Notification Settings. All other setting should be left as default.
•
Select OK on both windows and upload changes to the controller.
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4.19.2
3D TRASAR Boilers Phone Line Verification
1. Verify the following. •
The phone line is a dedicated analog phone line.
•
If an analog line is not available and the phone line is digital. Ask the customer what prefix is needed to dial to an outside line from the phone line that will be connected to the 3D TRASAR. (Example: 9, 1 and the area code or other prefix).
2. Verify the controller network settings from the controller keypad. •
The correct Network settings for Ethernet 1 and Ethernet 2 are listed below. From the controller keypad go to Menu > Network > Ethernet 1 Ethernet 1 Enabled IP address 169.254.001.002 Gateway 0.000.000.000 Subnet 255.255.000.000 Ethernet 1DHCP Disabled From the controller keypad go to Menu > Network > Ethernet 2 Ethernet 2 Enabled IP address 192.168.001.002 Gateway 192.168.001.001 Subnet 255.255.255.000 Ethernet 1DHCP Disabled
3. Verify the 3D TRASAR Boiler Configurator Communication settings.
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•
Open the 3D TRASAR Boiler Configurator and click on Communication Settings.
•
Verify that the Connection method is set for Modem.
•
Choose the Controller Country from the drop down.
•
Enter the Controller Phone #.
•
Click on Find Internet Access #.
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Choose your Country from the drop down menu.
•
Choose State from the drop down menu.
•
Select the local ISP number from the list provided.
•
Click OK.
Note:
If no local access number is listed check the AT&T Global Network dialer for a local access number.
•
The local Internet Access # will populate in the Internet Access # field.
•
Click OK and upload the changes to the 3D TRASAR controller.
4. Using a Slimline analog phone to verify the dial out string •
Connect the phone line that will be connected to the 3D TRASAR to the Slimline phone.
•
Dial the Internet Access # with the dial out string required (Example: 9,1 and area code).
•
When you have the correct dial out string and internet access number you will hear a fax machine sound.
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Enter this dial out string into the 3D TRASAR Boiler Configurator.
•
Click OK and upload the changes to the 3D TRASAR controller.
5. Using your computer dialer.exe to verify the dial out string.
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§
Turn up the sound on your computer.
§
Connect the phone line that will be connected to the 3D TRASAR to your computers modem connection.
§
Go to Start and click Run.
•
In the open field enter dialer.exe and click OK.
•
The Phone Dialer will open.
•
Click Dial.
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Enter the Internet Access # with the dial out string required. (Example: 9,1 and area code) in the connect field.
•
Change the Dial as to Phone call.
•
Click Place Call.
•
When the correct dial out string and internet access number is correct the computer will make a fax machine sound.
•
Enter this dial out string into the 3D TRASAR Boiler Configurator.
•
Upload the changes to the 3D TRASAR Boiler Controller.
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5
Tasks to Perform Before Control Tuning
The 3D TRASAR Boiler System must be in “monitor” mode for several weeks to obtain enough data to set up PID control of the scale inhibitor and oxygen scavenger (minimum of 30 days suggested). The boiler system will need to be operating at a steady feedwater flow rate (for at least 1 hour per control loop) for the PID tuning to be completed. Feedwater flow rate (i.e. steam flow) changes make PID tuning difficult or impossible to accomplish. Note:
5.1
All the following tasks should be completed during the monitor phase. DO NOT wait until the day PID tuning will be attempted.
Ensure An Interlock Is connected or Shutdown Process Is Established
The 3D TRASAR Boiler System will continue to feed chemical as long as sample flow to the system is over 200 cc/min even if the boiler is not operating. The controller must be either shut down:
• • •
Manually - A plant standard operating procedure must be established. Automatically – Digital interlock signal must be sent from the customer’s DCS to the controller. Steam Flow – If an analog steam flow signal is used the 3D TRASAR Controller must be configured to interpret and utilize the data to provide a shutdown process.
5.2 Verify Chemical Pump Capability During the “monitoring” mode the capabilities of the chemical feed pumps to be used during “automatic” mode should be verified. Review the TRASAR readings and observed feedwater flow rates to be sure the pump is sized to obtain the target dosage under all conditions (normal, low, and highest feedwater flow rates). This verification should be done for all pumps; internal treatment, scavenger and for any slaved treatment pumps. •
Ensure the proper size pump has been installed for each scavenger and scale inhibitor feed point. As a general rule, the pump should be selected that will output three times (2-3X) the average expected feed rate with the pump stroke length set at 50% and the pump stroke rate at 100%.
•
If the system has extremely wide load swings (seasonal or due to process demands) verify that the pump will provide the maximum expected feed rate with the pump stroke length set between 20% and 80% and the pump speed set to 100%.
Note: During PID tuning a Pump Stroke Calculation Tool will recommend the pump stroke length setting that should be used. However, this tool can only be accessed when connected to the controller. The suitability of the pump can be checked for various expected feedwater flow rates by using the following calculation. The result should be between 20% and 100%. Pump Stroke Length % = Feedwater (gpm) x TRASAR Setpoint (ppm) x (0.0072) Pump Capacity (gph) The feedwater rate is not measured it can be estimated from the steam production rate. Feedwater (gpm) = Steam Production (lbs/hr) x 0.002
•
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If PID control will be used pumps should be selected that feature manual stroke length adjustment and remote stroking rate adjustment (via 4-20 mA). Pumps equipped only with stroke speed adjustment are acceptable provided they have a wide turndown ratio (1000:1). Nalco Global Equipment Solutions
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If ON/OFF relay-based control will be used be sure the pumps are connected to the TRASAR Controller relay outputs (directly if under 2 amps, via a motor starter contact if over 2 amps)
5.3
Check Pump Responses and Measure Lag Times
1. Make sure the 4-20mA wires are connected to the pump and 3D TRASAR Controller. 2. Make sure the pumps are set up to respond to a remote 4-20 mA signal. 3. Testing the effect of chemical pump output changes and measuring the lag time for that control loop can be accomplished at the same time. All controlled pumps should be tested to identify potential problems. However, the loop can still be tuned without a lag time measurement. Note:
Record the measured lag time for each chemical feed system. Record the stroke length % and stroke speed % of the pump used when the pump was in manual control.
•
Using the controller keypad or Configurator set the pump (analog output) control to manual control. Adjust the % output to the same setting used on the pump stroke speed control knob. Allow the measurement (TRASAR ppm or mV) to stabilize.
•
Increase the % output signal by approximately 50%. Record the time. Observe how long it takes for the treatment level to just start to change and record the level and time. If the measurement does not change check the pump wiring, controller configuration and pump manual/remote setting.
•
Subtract the start time from the stop time and record the lag time (seconds). This value will be used later in the PID Auto Tune program and for troubleshooting.
• Conduct a pump drawdown test to be sure the pump is functioning properly. Note: In this manual Lag Time is defined as the time it takes to first observe a change to the measure parameter (TRASAR, conductivity, etc) after a change to the feed pump or blowdown valve is made. It is not the time for the measurement to stabilize after a change is made.
Parameter
TRASAR Manual Remote Step Control Change Parameters Parameters
Oxygen Scavenger Manual Control Parameters
Remote Step Change Parameters
Pump Capacity (gpd) Stroke Length (%) Stroke Speed (%) TRASAR or mV Start Time (hh:mm:ss)
NA
NA
Stop Time (hh:mm:ss)
NA
NA
Loop Lag Time (sec)
NA
NA
Note:
There is a Pump Stroke Calculation Tool that will recommend the pump stroke length setting that should be used for the TRASAR pump when in PID control. This is accessed via the TRASAR Auto Tune section in the Configurator. TRASAR PID loop tuning time will be minimized if that tool is used and recommended stroke length is applied to the pump while it is still in manual control (a corresponding pump stroke speed adjustment must be made).
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 Lag Time Reduction Minimizing the lag time is essential for obtaining good PID control. If the lag time is over 5 minutes (300 seconds) the controller will have difficulty maintaining control during rapid boiler load swings. However, control is possible despite long lag times if the boiler load changes are not abrupt or frequent. The follow actions can be taken to help reduce lag time.
• • • • •
Change standard size 5-micron canister filter to optional short filter. Reduce sample line length and/or diameter (1/4” SS tubing recommend maximum diameter). Increase the same flow rate (500 cc/min maximum for NCSM, approx. 2000 cc/min maximum for TRASAR only). Move 3D TRASAR Boiler System. Change chemical feed and/or sample points.
5.4
Control Selection
The Configurator must be used to set up all control functions and run the PID Auto Tune program. Minor adjustments or manual tuning can subsequently be made using the keypad. • If the product is being applied to the feedwater line where there is good mixing and short residence time, then PID control is recommended • If product is being applied to the deaerator where there is greater residence and mixing time prior to sampling, ON/OFF control (via 4-20 mA or relay) or PID control can be used. Although, PID control is preferred. If the lag time is over 5 minutes either control mode may not provide optimal results. Note:
Chemical metering pumps that accept a 4-20 mA control signal are necessary for PID control. Pumps that accept a 4-20 mA signal can also be used for ON/OFF control (via a relay or using the 4-20 mA signal).
Deaerator
PREFERRED N223XX Feed Point
PID or ON/OFF
Feed water Pump Scavenger
PREFERRED Sample Point N223XX PID or ON/OFF
PID
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5.5
NCSM Set Point Determination
5.5.1
0-100% Scavenger Pump Test
During the monitoring phase the user must run a 0-100% scavenger pump speed test to define the range of readings and create a system process response curve (see below). This data will help to: • • • • •
Verify that the system is responding Understand the possible NCSM control zones Learn about system response times for control Help with alarm setting Perform a deaerator study
5.5.1.1
0-100% Pump Test by Manually Changing the Output.
Decreasing AT ORP Increasing Reduced Conditions
1. Turn the scavenger pump off. Allow the NCSM mV readings to stabilize (may be positive or slightly negative number). 2. Turn on the scavenger pump to 100% speed (and 100% stroke length and allow the NCSM mV reading to stabilize (should be very negative number). 3. SAVE THIS DATA LOG (“Initial NSCM 0-100% System Response Data”) to a separate file. It will be needed for future reference.
0% pump speed
100% pump speed
Average NCSM value Comfort control setpoint Set ideal control setpoint in this range
Increasing Dissolved Oxygen Scavenger Increasing Dissolved Oxygen Example of 0-100% scavenger pump speed curve and set point determination The NCSM control is direct acting. An increasing NCSM values (more positive) will cause the controller to increase the oxygen scavenger dosage (increase pump output %).
AT ORP vs EPBRE (mV) at 400oF + 300 + 200 + 100 0 -100 -200 -300 -400 -500 -600 -700
Preferred Broader Broadest
DA+Scav +Cu
Typical NCSM control zones These are the general control zones for a systems with a deaerator that feed oxygen scavenger. The control zones will be lower if yellow metals are present.
Note:
The minimum data log interval on the controller is 10 minutes. The resolution of the graph can be increased by using the NCSM PID Auto Tune program to create the graph. The Auto Tune program can only be used if the pump accepts a 4-20 mA signal.
Note:
The graph can also be created utilizing ON/OFF control using the PID 4-20mA output. PID control provides a fast local data log for up to 3 days (data every 5 seconds). It can be downloaded via USB stick or direct connection to the controller.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 Note:
Certain oxygen scavengers (especially sulfite based scavengers) can reduce the pH of the feedwater to a point that can appear as an ORP stress event. When feeding acidic sulfite oxygen scavengers start the initial NCSM control at a higher NCSM set point instead of trying to drive NCSM values to very low set points. This will assure that acidic scavenger products like bisulfites are not over fed, leading to pH depression of boiler feedwater. Example: If the average boiler feedwater NCSM value was -400 mV during the monitoring phase, a good NCSM initial set point would be -350 mV (or -300 mV). Lower NCSM setpoints (for corrosion control) could be chosen at a later stage once it had been verified that control could be achieved at the higher set point without overfeed of the acidic sulfite chemistry. Use caution to ensure that the pH of the boiler system does not fall below what would be deemed best practice.
5.5.1.2
0-100% Pump Test using the NCSM PID Tuning Program.
Data is logged every 5 seconds when using the NCSM PID Auto Tune program. This will provide a detailed graph of the system response and corresponding NCSM values to chemical pump changes. It can also be used to calculate the true system lag time. 3. Record the current scavenger pump stroke length and speed settings. 4. Set the pump stroke length to zero. Wait for at least 3X the system lag time, possibly much longer. The Scavanger must be purged from the system. Use discretion, as the system should not be left without scavenger feed for too long. (Some systems have been left without feed for days). 5. Follow the instructions in Section 6.6 using the following Auto Tune Settings:
• • • •
The Baseline Output % = 0% The Baseline Duration = approximately 1X the system lag time The Step Output % = 100% The Step Duration = approximately 6X the system lag time
3. Start the Auto Tune cycle and observe the NCSM values. Stop the test once the NCSM values has dropped and is no longer dropping. (There is no need to over feed the chemical treatment). 4. When the Auto Tune cycle is completed capture the graph by using the “Print Screen” function and “copy/paste” into a Word Document. Alternately an editing tool like “Snagit” can be used. 5. Exit the Auto Tune program. Do not upload the PID values into the controller. 6. Reset the pump stroke length and speed settings to their original settings on the scavenger pump. (recorded in step 1 above).
5.5.2
Comfort Control NCSM Setpoint
Using the average NCSM value determined in the monitoring phase as a starting setpoint permits optimization of the control tuning parameters without a dramatic change to the treatment program. Determine the average value (green data point in example curve) after extracting known discontinuities like oxidizing spikes of known origin.
•
Normally, round down to the nearest 25 mV increment from the calculated average NCSM value. For example, if the average reading was –363 mV, the setpoint should be –375 mV.
•
If a system is in a highly reduced state (very negative reading), round up to the nearest 25 mV increment. For example, the setpoint is –525 mV if the average reading was –536 mV.
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5.5.3
Ideal Control NCSM Setpoint
The ideal control setpoint can be determined after developing a full understanding of the system NCSM response, corrosion knowledge and other issues such as cost, boiler system specifics and preferences. The NCSM setpoint (actual values shown in above table) will fall into the zones shown for syste m corrosion protection.
5.6
TRASAR Setpoint
Refer to the product CPP (Confidential Product Profile) to determine the dosage for the system.
5.7
Intermittent Operation
5.7.1
General Considerations
Boiler feedwater operation can be continuous or intermittent. Higher capacity boilers have continuous feedwater pumps with modulating feedwater regulators which feed water continuously at varying flow rates to maintain the boiler water level consistently. But in systems with sporadic steam demand, there are times when minimal (or no) water is being sent to the boiler. Smaller ( fire tube) boilers often have water level sensors which turn on the feedwater pumps when the water level is low and turns them off when the water level reaches the high state. In these cases the water level in the boiler varies continuously. Again, in these cases there are periods when no water is being sent to the boiler When the feedwater pump is off or the feedwater flow regulator is forcing a low or no flow situation, the 3D TRASAR sensors are unable to obtain a representative sample of the water in the system. The chemicals being pumped into the line are sitting in stagnant pools and the sensors cannot detect their presence. It is necessary to have an intermittent operation control strategy.
5.7.1.1
Interlock & Alarm
To control systems where the feedwater flow is intermittent the 3D TRASAR controller must be provided with a signal representing the status of the feedwater flow. This input is used to generate a feedwater flow off alarm •
For boilers with modulating feedwater regulators a 4-20mA analog input signal from the regulating valve is necessary. The user must define a threshold value at which chemical application should be suspended.
•
For boilers with water level sensors which turn the feedwater pump on and off, a digital input signal representing the feedwater pump state is needed The feedwater flow off alarm is not logged in the event log but it will show up in the alarm display. This is because the flow situation is a normal part of the system operation. These signals should be added to the configuration and designated as the signal used for intermittent feedwater (please use the Boiler Configurator Help system to configure intermittent operation).
5.7.1.2
Control Options
There are two options for TRASAR or NCSM based chemical feed in intermittently operating systems: • On/Off Control: When the feedwater flow off alarm is engaged, On/Off control of internal treatment or scavenger feed is suspended. When the alarm is cleared, standard On/Off control resumes. For On/Off control it is important that the user adjusts the stroke of the pump if it is found that the measured value routinely over/under shoots the set point.
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5.7.1.3
PID Control: When the feedwater flow off alarm is engaged, PID control of internal treatment or scavenger feed is suspended. When the alarm is cleared, standard PID control resumes. o The Integral or I term in the PID equation is retained through the alarm so that the control resumes in the same place as it was when it was suspended. Retaining the I-term through the alarm allows the control to stitch together the snippets of incoming valid data (data collected when the feedwater pump is running). o For intermittent systems it is important to do the PID tuning only after configuring the feedwater flow off alarm By using PID control, it is no longer necessary for the user to carefully adjust the pump to reach the set point—the control algorithm adjusts automatically.
Control Expectations
For both on/off or PID control in intermittently operating systems, the control will be more variable than that we typically obtain in continuously flowing systems. A part of this variability will be cosmetic -segments in the logged data will be measurements taken from a stagnant or nearly stagnant stream. But even the valid data will show less precise control than if the sample stream was continuous. The tightness of control will depend on: • variability of the steam load or feedwater flow in the system •
fraction of the time that the system remains stagnant
• lag time between the detected signal and the applied chemistry. The measure of control for these systems will be how close the average signal is to the set point. This is particularly true for the TRASAR, where the applied internal treatment is active in the boiler drum.
5.7.2 5.7.2.1
Special NCSM Considerations General Considerations
IMPORTANT NOTE: Feeding bisulfite to low alkalinity boilers may depress the pH. Lower pH waters will detected by the NCSM as “stress” causing the controller to increase bisulfite feed, further depressing the pH. If the boiler does not have good pH control, add a pH “override” to the NCSM control loop and consider slaving caustic feed to the NCSM or TRASAR pump. (See 3D TRASAR Boiler Technology Help Desk FAQ# 29) Additional factors must be considered when monitoring corrosion stress or controlling oxygen scavenger in intermittently operating systems. Applying feedwater chemistry control in systems that are operated intermittently requires a more detailed understanding than constantly operating systems under well-defined and more stable baseline conditions. Definition Note:
Down-time: Period when active control is not possible, or makes little sense to run. Up-time: Period when control is possible.
Intermittently operated systems are bound to produce higher variability in response and possibly higher corrosion rates than comparably full time, flowing, operating and controlled systems. Users must know what portions of the system are idle during down time and which portions of the plant are operational during up-time. Diligent thought needs to be given to where the NCSM is located and how that pertains to system control. Control is only possible if during up-time the control variable (NCSM value) can be achieved. This means that there must be enough time to capture a true NCSM value, and then have the time to react to that value and preferably time to see the NCSM response to the pump action. So during the up-time 108
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the NCSM value will have to transition from down-time measurement, through a transition phase, and then into full NCSM measurement/control during the up-time. Complete NCSM ‘control’ can only be instituted with success in the phase when the true NCSM value (with full representative FW flow) is measured. There will be cases where the up-time will be too short to be able to institute NCSM control in an intermittently operated system. In these cases the NCSM value can be gained as a monitoring tool only to verify current operations. The period of time that is defined as ‘too short’ will be system specific and cannot be fully defined without knowledge of the system (including lag times for water to flow and reach the NCSM probe). Factors that will play a role include: Baseline FW conditions; air in leakage (system tightness); scavenger pump capabilities; system design; system volume; 3D TRASAR water flow rates; chemical feed half lives and residence times; chemical type; temperatures; FW flow; REDOX stresses present and their variability, system lag times/dead times, amongst others. Control will clearly be non-optimal if the delay time is long relative to the up-time cycle as not enough time will transpire between obtaining a relevant NCSM value, making of the control decision and seeing the effect of that control decision in NCSM terms. If the system delay time is longer than the up-time, then true ‘control’ will not be possible. Care needs to be given in any system scoping and setup. In the Figure below the boiler and pump might have different duty cycles. There are three possible locations for the 3D TRASAR Boiler skid with NCSM technology. The duty cycle, presence of check valves, recirculation line functionality, etc will all play into what the skid locations sees: 1) flowing water all the time; 2) flowing water some of the time; 3) flowing water that might not be representative water (e.g. location num ber ‘2’ if the boiler is not operating (‘calling’ for water) but the FW pump is operating. Reductant Feed FW Storage Tank 1
3
Boiler 2 Pump
The goal is to get representative water to the 3D TRASAR Boiler skid and capture REDOX stress. Lag times should be as short as possible with short sample run lengths and appropriate 3D TRASAR skid sample flow rates. There might not be an optimal 3D TRASAR skid location/tap point and compromises may be needed. The configuration and setup will vary on the nature of flow to the 3D TRASAR skid and the nature of system operations. Controlling intermittently operating systems with the current boiler configuration operations is in and of itself a compromise. This manual can help define and bracket control. The user ultimately has to decide whether good control is possible for their specific installation. If good control is not possible is control that is better than current operations achievable?
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Ensure that if there is no feedwater flow (FW pumps turned off) boiler water does not siphon back through the 3D TRASAR skid. There should be FW check valves in place to prevent this from occurring (do not assume that they exist or are working – they need to be checked). This siphoning could cause a high temperature alarm and control suspension and skid-flow shut down even if the SCS is in operation. This alarm can only be cleared manually. Also, if there is no High Temperature alarm setting on the NCSM temperature control could still be occurring, even if there is no FW pump flow. This control would be trying to control the NCSM value in the boiler feedwater by affecting chemistry flow into a different part of the cycle not being sampled at that time.
IMPORTANT NOTE:
5.7.2.2
Make sure that all installations ensure that the NCSM probe remains wetted (not allowed to siphon dry) during down-times. This will ensure the NCSM probe remains functional and it will return quickly to active measurement of the true and real NCSM values once the system starts operation again.
Monitoring
During the monitoring phase the user will obtain an understanding of how the NCSM will respond to the plant conditions. How is the system ‘controlled’ now and how do NCSM conditions vary with time? Users will need to understand the NCSM response with respect to up-time and down-time and the transition between the two. This is especially important to understand within the “Factors” discussed above. At this stage hard questions need to be asked about whether NCSM control will be feasible or should be attempted. If feasible, then how will the control and bracketing of the control be setup? NCSM monitoring to understand, document and improve the system has great value even if direct NCSM control might not be possible or not optimal. Remember that a ‘control approach’ might be better than what is currently practiced in the plant and could be very important for corrosion control. The monitoring process can often lead to the discovery of novel solutions to complex issues affecting plants with intermittent operations.
5.7.2.3
Manual Feed
The manual feed of chemistry (oxygen scavengers and reductants) based on fixed pump speeds is always a possibility with the 3D TRASAR Controller. Manual feed rates override all interlocks, alarms, etc.
5.7.2.4
Control
There is no prescriptive solution for NCSM based reductant feed in every case. In those systems where there is adequate time during the up-time to institute NCSM control, the following set-up can be instituted with the new 3D TRASAR Boiler Configurator, NCSM probe and control schemes. The following factors should be considered during control: 1. 2. 3.
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Is there adequate sample flow to the NCSM probe? Is the plant running - adequate FW flow but no plant steam flow/FW flow interlock signal? Is it just the boiler stopping its call for FW or is FW flow stopping too? a. Does the boiler stop and flow to the NCSM probe stops too? b. Does the boiler stop but flow to the skid is maintained as FW is diverted back to the DA storage tank (or some other storage tank), when the boiler is not calling for water. This system is easier to control, as control is unchanged, regardless of whether the boiler is calling for water or not. Nalco Global Equipment Solutions
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What is the duration of the stop flow condition (minutes, hours, days, weeks, months?). How is it related to how long the boiler is off line? 5. Is the temperature in the NCSM cell appropriate for control to be active? The NCSM temperature data in a control phase can be as important as the NCSM voltage value itself. 6. Does the NCSM value itself achieve a controllable regime during the up-time? How long does it take the NCSM probe to stabilize? (Temperature and ORP) 7. Does the NCSM probe remain wetted during no flow conditions? Might add complexity if it is air bound. 8. Is the system opened to atmosphere – or becomes highly oxidizing, or does it remain reduced? 9. How does control look like? 10. How is control deactivated during off times and activated during on times (digital switch or 420 mA input signal)? Remember that with NCSM control it is possible that water conditions in the first water to enter the NCSM probe (during the up-time) might have an NCSM value far removed from the set point. As such the aggressiveness of control needs to be understood. This has implications for PID control and ON/OFF control and chemical pump sizing and stroke setting. The full set of NCSM alarms, control settings (like minimum and maximum pump settings) and pump time out features to further enhance the control of any system. Goodness of control: A user will need to decide on the NCSM setpoint and control parameters. Ultimately the user will need to determine how good control is about the set point, what is considered poor, adequate and good control for the system. Such conclusions can be based on NCSM values and variability during the monitoring phase and during various control phases where different control scenarios might be tested. It is assumed that during intermittent operations that sound boiler best practices are still followed as they pertain to pH control as well. One option might be to have pH monitoring that disables NCSM control if boiler FW pH declines too much. This is more of an issue in systems where acidic reductant chemistries are fed. For better control all aspects of the MOC must be considered. This includes a detailed understanding of where the chemistries are fed and why. Determine if there is a better approach for the feed and control of corrosion with the NCSM. This includes chemical pump and pump capacities and setup. 5.7.2.4.1
High & Low Temperature Interlock
The NCSM temperature needs to achieve an acceptable level during the up-time before the NCSM value can be accepted for NCSM control. This is not the case with TRASAR control, as in this case the NCSM temperature is a critical part of the NCSM reading. The below Figure shows the System Interlocks screen:
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 In the Configurator, if the High or Low Temperature Interlock is Enabled the alarm response can be set as Forced Off, Fixed Output or Smart Failsafe. The default condition is to have the interlock unchecked and this might not be the preferred state for your system. Remember too that the System Interlock and Steam Flow/Feedwater Flow Interlock have the same alarm response options. These will have overriding precedence in system control. The Low Temperature Limit can be set to a temperature that is consistent with the NCSM temperature and NCSM control. In the above example a deaerated FW sample line that usually operates with a 240ºF (115ºC) feedwater temperature has the Low Temperature Limit set to 180ºF (82ºC). This means that if the FW temperature drops to below 180ºF (82ºC) then the NCSM control will be rendered inoperable and the reductant feed pump will be turned OFF (RTD #2, in this case). Control would only be re-established once the NCSM temperature came back above 180ºF in this case. Re-iterating: An NCSM set point has to be chosen with due diligence applied to the temperature at which the set point is chosen. As such, if the temperature falls outside of the determined control range, then NCSM control to the set point has to be suspect and should not be attempted. The low temperature interlock only becomes active after 300 seconds, so control will still be in effect for a further 5 minutes after the activation of this interlock. The interlock is cleared after 1 second if the temperature rises above the low temperature interlock value. Options: If there is a system flow or process signal used to limit control (digital switch or 4-20 mA signal) it could serve as the interlock for NCSM control. 5.7.2.4.2
No Flow Switch
In systems with an SCS attached with a flow switch, there is the No Flow Alarm which can also be enabled (after 300 seconds of activation). This will activate when flow through the 3D TRASAR skid flow switch drops below about 100 ml/min. The appropriate response (Forced off, Fixed Failsafe, Smart Failsafe) for the desired signals needs to be set (see example Figure below).
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Slaved Control
Reductant feed can be slaved to the TRASAR signal but this is not true NCSM controlled feed of reductant. It is direct feed of chemistry based on feedwater flow rate. However, proportionately more scavenger than TRASAR feed may be needed. For example A TRASAR feed range corresponding to a chemical pump speed of 1% to 20% might correspond to a desired scavenger pump speed of 5% to 75%. The NCSM values must be monitored during a steady state to see if the above settings provided a semi-constant NCSM value. One way to counter this current limitation is to size pumps so that stroke settings can be used to feed proportionately more scavenger than TRACED product. In this case active REDOX stress management is not being practiced but it is being attempted. Reductant feed cannot be slaved to a FW flow signal as the FW flow is not a ‘controlled’ signal output, even though it can be a recorded input. Note:
A ratio factor can be applied to the Slaved Control output to better meet dosage requirements.
5.7.2.4.4
ON/OFF Control
ON/OFF control logic and the setup are no different from ON/OFF control in constant operations. Control should probably be deactivated during down times and activated in up times based off an input Interlock (this might not always be the case). ON/OFF controlled feed of reductant might be more appropriate in some systems that operate i n an ON/OFF fashion, like intermittent boiler feedwater systems. However, PID controlled feed of scavenger should be the desired control methodology with pumps that are driven by 4-20 mA signals. Remember that PID pumps can be setup with small P and I parameters that essentially put the pump into ON/OFF control. The reverse is not true: That is ON/OFF driven pumps cannot be operated as 4-20 mA accepting PID capable pumps. As such, when in doubt, purchase pumps to handle 4-20 mA signals. Setting P=0.01 and I=0.01 will turn those PID pumps into ON/OFF pumps. 5.7.2.4.5
PID Control
The basic logic of set point choice and control still need to apply during up-time. That is, can the setpoint chosen be achieved, does the set point make sense for corrosion control, and are pumps sized and set up correctly to address baseline control and REDOX stress event control? A start might be to choose a set point based on the concepts of “comfort control’. The question needs to be asked whether this provides adequate corrosion protection and/or system control for your specific system. ‘Comfort control’ should give way to more ‘ideal setpoint control’ for the right reasons. These might be better corrosion control and/or optimized use of chemistry via chemical feed on demand for the right reasons (corrosion and REDOX stress control). o
o
PID control could be different in intermittently operating systems as the time in the control phase might dictate that control might need to be more aggressive (Lower P and I settings) in order to achieve some form of control in a time limited control loop. More aggressive PID parameters are probably going to be the norm versus PID parameters for constantly operating systems. Also users might have to perform more iterations of fine tuning PID parameters for intermittently operating systems in order to obtain ‘good’ control.
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6.0 ON/OFF Relay Control If ON/OFF control is chosen, the user will be asked to set: 1. Setpoint: Target value of the input 2. Acting: Controller Action Direct Acting: Controller output increases in response to an increase in the signal input. .e.g. NCSM control is direct acting because an increase of NCSM reading will result in more scavenger being applied (increased pump output). Reverse Acting: Controller output increases in response to a decrease in the signal input. .e.g. TRASAR control is reverse acting because a decrease in TRASAR reading will result in more product being applied (increased pump output) 3. Range: This is the deadband control range. •
For direct acting control, the output is turned on when the input signal exceeds (setpoint + range) and remains on until the input signal is below the (setpoint –range). For reverse acting control, the output is turned on when the input signal falls below (setpoint – range) and remains on until the input signal reading is above (setpoint + range).
•
6.1 ON/OFF Control using the PID 4-20 Outputs The 3D TRASAR Boiler Controller allows the user to quickly switch between PID and ON/OFF control without rewiring the treatment pumps (pumps must be controlled via the 4-20 mA signal). Use the PID setting listed below (Advanced PID Setting Screen) to control the treatment pump as if the system was in ON/OFF control. This type of control may be very effective when feeding scale control treatment to the deaerator where the lag time is usually very long. Settings for ON/OFF Control Using 4-20 mA Outputs Set: Set: Set: Set:
P = 0.01 I = 0.0 D = 0.0 Setpoint = to desired set point
The minimum and maximum pump output percentages must be changed to a span less than a full 0100%. This will reduce the over shoot and under shoot as the pump % output cycles up and down to simulate ON/OFF control. Set: Output Min. = (% pump output to reach set point at minimum feedwater flow) Set: Output Max. = (% pump output to reach set point at maximum feedwater flow) Set: Max. Change = 100% The width of the control band will be determined by several factors including: • • • •
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Sample lag time Pump maximum and minimum output percentages (pump stroke rate %) Pump stroke length setting of the pump Rate of feed water flow changes
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7.0 Proportional Control Configuration 7.1
Blowdown Control (Cycle Control Using 3D TRASAR Fluorometer)
The 3D TRASAR Boiler system can be used to control blowdown based on fluorescence where you have automated control of TRASAR 3 internal treatments. This control strategy uses a setpoint to trigger blowdown (does not do automatic cycle calculations). Actual cycles will depend on how tightly the feedwater and blowdown control loops are established. Therefore good PID control of TRASAR 3 program in the feedwater is needed to achieve accurate blowdown control. For example, if the feedwater treatment PID setpoint is entered as 6 ppm and you want 50 cycles of concentration, the blowdown setpoint is 300 ppm. Carefully choose the boiler cycles to avoid any potential scaling problems in the boiler. For help in determining the correct cycles value for your system contact the Regional Help Desk. When using proportional control the blowdown valve will ramp up to a maximum value as the fluorometer reading climbs above the setpoint. Before setting up proportional control, there are a few things to consider. •
Is the sample point for the fluorometer located on a line where the 4-20mA control valve will need to be open to get a sample? If so, a minimum output will be needed to ensure a f resh sample is always going to the fluorometer. Note:
Utilizing the Continuous Blowdown Sampling plumbing configuration is recommended (See Section 2).
•
Should there be an upper limit on the output? Some boilers may not be able to handle the blowdown control valve open 100% because it will shock the boiler.
•
Determine the setpoint – multiply the feedwater TRASAR setpoint by the number of cycles desired.
•
What should the Alert points be? A good method is to use the number of cycles you want to control within.
Setup Procedure 1. Selection “proportional” on the fluorometer configuration screen.
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3. Click on the Advanced PID Settings •
Enter the maximum and minimum output %.
•
Use the equation below to calculate the proportional band.
Proportional =
(Alert Point – Setpoint) x 10000 Maximum Output x (Scale High - Scale Low)
Alert Point = Upper Control Limit of 3D TRASAR wanted in the boiler, usually High Alert value (or slightly below) Scale High & Scale Low = Use default values from Advanced PID Setting screen EXAMPLE (shown on all screens in this section): Proportional = (312 – 300) x 10000 100 x (1000 - 0)
= 120000 = 1.2 100000
4. Enter the calculated Proportional Band and click OK to accept the control parameters.
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7.2
Feedwater Flow-Based Proportional Control
The flow signal (steam or feedwater) can be used to proportionally feed chemicals to the boiler system. Using proportional control the pump output will ramp up as the flow input signal (4-20 mA) increases. Before setting up proportional control, there are a few things to consider. •
What is the lowest flow value expected when the boiler is actually running (Example – flow meter may display 20,000 lbs/hr steam flow when the boiler is idle).
•
Is there a minimum pump output value (% speed) that must be achieved as soon as the flow signal exceeds its minimum valve to achieve the desired ppm dosage of chemical?
•
Is an upper limit on the pump output needed? The chemical pump must be sized so it delivers chemical at the needed dosage over the entire flow signal range (at a fixed pump stroke length).
Setup Procedure 1. Selection “PID” on the Analog Input configuration screen.
2. Enter the unit of measure, 4mA value and 20 mA value for the input flow signal. 3. Enter the 4 mA value as the setpoint and disable all alarms. Note:
To start feeding chemical at an input value greater than the 4 mA value use a control override (Example: Steam Flow of 30 Klbs/hr)
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4. Click on the Advanced PID Settings •
Enter “Direct” Acting
•
Enter: P = 100, I = 0, D = 0
•
Enter the maximum and minimum output %.
•
Enter Scale High & Scale Low (same as on the Analog Input screen).
EXAMPLE (shown on all screens in this section): Scale Low: 4 mA = 20 (Klbs/hr) Scale High: 20 mA = 100 (Klbs/hr)
5. Click OK to accept the control parameters. Note: If the chemical pump stroke is set so that 100% pump speed will deliver the correct dosage at the maximum flow input signal, the proportional term will be 100. Otherwise, use the equation below: Proportional =
10000 Maximum Pump Output
Maximum Pump Out = % Pump Speed to get correct dosage when flow input signal is 20 mA. EXAMPLE: •
% Pump Speed to get correct dosage when flow input signal is 20 mA = 80%.
Proportional = 10000 = 200 50
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8.0 PID Configuration and Tuning 8.1
Check PID Configuration
Using the Configurator follow the on screen commands to make sure the PID parameters are correct. • Determine the setpoint for TRASAR or NCSM before starting the tuning procedure. Ensure that the correct values have been entered. • Ensure that the TRASAR and scavenger pumps are wired to the analog output channel selected in the Configurator.
8.2
• • • •
8.3
• • • •
When to Auto Tune Setting up control on a new controller After changing the feed pump with a different model After changing the feed pump stroke length % There is a change in system conditions and manual tuning adjustments don’t improve control. o Sample line modification o Sample flow rate change o Product feed line modifications Before Starting Auto Tune Start the Configurator Connect to the controller If using a laptop, ensure it is connected to A/C power. PC Setup - Check “Power Option” settings in the “Control Panel” and change the settings so the laptop will not go into “standby” or “hibernate” mode for at least 3-4 hrs (the duration of the tuning process).
IMPORTANT NOTE:
8.4
Before Auto Tune put the pump in manual mode and adjust the % output so it is dosing at approximately ½ of the desired ppm dosage (baseline output used in Auto Tune). This will reduce the overall time needed to perform the tune.
Checklist for Auto Tune
• • •
Pumps in analog control mode (4-20mA) and powered. Pumps are connected to the correct analog outputs as configured in the PID settings. Stroke length is set on the pump (prior to tuning). o Stroke length is typically not changed once chosen unless system conditions change drastically. If the stroke length is changed after tuning, Auto Tune must be run again. o Stroke rate (0-100% pump speed) is controlled by the PID algorithm and under typical operating conditions and load variations should vary between 10-90%. If after tuning the PID the stroke rate is predominantly outside the 10-90% range, change the stroke length and run Auto Tune again.
•
Steam load is as steady as possible during tuning. o A key to successful tuning is the steady operation of the boiler system feedwater flow rates during the tuning process. o Large variations in the steam load during the tuning process could result in failure to tune the PID loop. (See Section 12.5 for PID troubleshooting.) Note: Those experienced with PID control tuning may want to input initial “guesses” for P, I and D, then monitor the system and adjust the parameters to improve performance.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 8.5 TRASAR PID Auto Tune The TRASAR tuning procedure is comprised of three steps. The three steps are baseline, first step and second step. During each step the pump output % is held at a fixed value over a chosen duration. The TRASAR data is collected after the tuning procedure and fitted to a mathematical model in the Configurator software. A set of PID values will be computed and can be uploaded to the controller to begin PID control. For systems configured as intermittent feed systems, the chemical pump will suspend feeding the internal treatment during the feedwater down-time (off-time). This will not interrupt the tuning process.
Tuning Steps 1. Select Edit Fluorometer in the Configurator 2. Select Tune PID Controller in the input configuration screen. 3. On the PID tuning dialog box , select Auto Tune to start the auto tune process. In the Auto Tune PID loop screen, enter the Auto Tune Settings before starting Auto Tune. The Configurator Help Screens provide detailed information on the steps and parameters. • • •
Ensure that the pump to be controlled has the optimum stroke setting. Click on Calculate Pump Stroke and enter the required data. It will give the suggested stroke %. The actual feed rate is shown so that the user can verify by doing a drawdown to confirm the stroke setting. Confirm the Setpoint is correct. A Baseline Output value should be entered for the baseline step. The user should choose this value such that the TRASAR readings will be between the setpoint and 50% of the setpoint during the baseline duration.
EXAMPLE: If the setpoint is 10 ppm then the Baseline Output should be chosen so that the TRASAR reading will be between 5 ppm and 10 ppm. So, if the TRASAR pump output is currently set at 50% to maintain 10 ppm. A Baseline Output of 35% would provide a TRASAR reading of approximately 7ppm.
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The Baseline Duration is set to 15 minutes by default and can be changed by the user. The baseline duration should be greater than the system lag time to allow the TRASAR reading to stabilize.. For intermittent systems, the baseline duration should follow the recommendation, above as well as exceed the average off-time (down-time) by at least 4 times. EXAMPLE: If the boiler feed water is off for an average of 5 minutes during an on-off cycle, then the baseline duration should be at least 20 minutes.
•
The Step Output is automatically calculated from the baseline output such that the TRASAR reading goes higher than the setpoint at some point in the tuning process. The setting can be changed if needed. •
•
The Step Duration is equal to or greater than the baseline duration but can be changed if needed. The first and second step output durations must always equal to each other. For intermittent systems, the step duration must follow the above recommendations as well as exceed the off-time (down-time) by at least 4 times
4. After all the tune settings are entered, click on the Start Auto Tune button to begin the tuning process. The analog pump output will automatically change as shown in the plot.
Graphing of the tuning data will be displayed (example) Note:
When the Auto Tune cycle is completed capture the graph by using the “Print Screen” function and “copy/paste” into a Microsoft XL document. Alternately an editing tool like “Snagit” can be used. The graph can be used to calculate the true system lag time.
5. After all three stages of tuning are complete the Configurator will analyze the data and calculate a set of PID values. Any errors or warnings will be listed on the tuning calculations screen. If any errors appear, the Upload button will be grayed out. Warnings are indicate whether the tune followed all the recommended conditions. Click on Upload and the values will be uploaded to the controller and PID control will initiate. NO REBOOT IS NEEDED. Note:
TRASAR PID Auto Tune always sets “D” = 0. This means the controller is truly PI control.
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OM0211 The “I” value will typically be equal to or greater than the system lag time (in seconds). This should have been measured before tuning (see Section 5.3)
6. If the Configurator is unable to calculate a satisfactory set of values error messages will indicate the cause. .
• • •
TRASAR reading did not rise when pump speed increased. Check for problems in controlling the pump. Check for air-locked pump. Steam load variation was too high during the tuning process. Repeat the tuning when conditions in the boiler are more stable. If the variation in the steam load seen during tuning is typical, increase the first step output by 5% and the first step duration by 5 minutes. Then repeat the Auto Tune procedure.
Note:
“Warning” messages will permit the user to upload these PID values with the understanding that the values may need some additional manual tuning after monitoring control performance Note: PID parameters can also be entered manually via the keypad or 3D TRASAR Configurator.
•
For TRASAR tuning, ensure that the change in TRASAR values during the tuning process are greater than when the pump output is held at a constant output.
Note:
See Section 12.5 for additional PID Troubleshooting.
8.6
NCSM PID Tuning
NCSM tuning is comprised of two steps. They are the baseline and first step. During the baseline, the pump output % is held at a low value for a chosen duration. During the first step, the pump output % is held at a higher value for a chosen duration. The NCSM data is collected and a set of PID values is computed. They are uploaded to the controller to begin PID control.
1. Select Edit AT ORP (NCSM) in the Configurator 2. Select Tune PID in the control page and select Auto tune in the PID tuning screen. 3. Scavenger feed pump must be set to the optimum stroke setting such that it can account for all changes in load expected in the system. This setting can typically be determined by analyzing data from the monitoring mode.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ 4. On the Auto Tune PID Loop screen enter the Auto Tune Settings before starting Auto Tune. The Configurator Help Screens provide detailed information on the steps and parameters. • • • • •
Confirm the Setpoint is correct. The Baseline Output % is chosen such that the ORP values during the baseline duration are higher (more positive) than the setpoint. The Baseline Duration is set to 15 minutes by default and can be changed by the user. The baseline duration should be greater than the system lag time, although this time should be less than 1 hour. In intermittent systems, the baseline duration should follow the above recommendations as well as exceed the off-time (down-time) by 4 times. For example, if the off-time (down-time) is on average of 5 minutes, the baseline durations should be at least 20 minutes. The Step Output % is chosen such that the ORP reading will decrease (more negative) by at least 30 mV to 50 mV during the tuning process.
•
The Step Duration is chosen such that the pump output is held long enough at the chosen value to observe the minimum change in ORP values (greater than the system lag time).
•
For intermittent systems, the step durations should follow the above recommendations as well as exceed the off-time (down-time) by at least 4 times.
•
The total tune duration of baseline and step duration is not recommended to exceed 90 minutes.
Note:
The pump speed is set to 0% after Auto Tune. So, the pump speed and setpoint can be changed after Auto Tune.
5. After all the tune settings are entered, click on the Start Auto Tune button to begin the tuning process. The analog pump output will automatically change as shown in the plot
Graphing of the tuning data will be displayed (example) 6. After the two stages of tuning are complete, the Configurator will analyze the data and calculate a set of PID values. They can be uploaded to the controller to begin PID control. For AT ORP control, clicking on the “Upload” button only uploads the PID parameters and does not start PID control. NO REBOOT IS NEEDED. • • •
At the end of NCSM Auto Tune, the scavenger pump will be turned off (manual 0%) PID control will resume only when you switch the output from “manual” to “auto” via the Configurator or the controller keypad (analog output controls). A timer is available to delay switching to auto.
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NCSM PID Auto Tune always sets “D” = 0. This means the controller is truly running PI control.
Note:
The “I” value will typically be a little greater than the system lag time (in seconds). This should have been measured before tuning (see Section 5.3)
7. If the Configurator is unable to calculate a satisfactory set of values it will display error message(s) to indicate why the calculation failed.
•
• •
ORP tuning will typically fail if the ORP readings do not decrease (more negative) when the scavenger feed is increased. Various factors can cause this behavior and looking at the tuning log data and knowledge of the condition of the boiler during tuning will help troubleshooting. Check for problems in controlling the pump. Check for air-locked pump. Steam load variation was too high during the tuning process. Repeat the tuning when conditions in the boiler are more stable. If the variation in the steam load seen during tuning is typical, increase the first step output by 5% and the first step duration by 5 minutes. Then repeat the Auto Tune procedure.
If the tuning process does not satisfy certain quality criteria “Warning” messages will be displayed but the user will be permitted to upload these PID values.
• • •
Note:
Choose the baseline output % such that while the scavenger is being fed the ORP reads close to the desired setpoint (more positive than the setpoint). During the tuning process, the ORP values should change greater than if the pump was held at a constant output. It is recommended that the baseline output be some value higher than zero. The first step output is automatically calculated for the user but can be changed if the user is concerned about “fogging” the system with scavenger. Even if the setpoint is not reached during the tuning process, the PB and I terms can still be used as long as there is a 30 to 50 mV drop during the tuning process and there aren’t any other error messages. See Section 14.5 for additional PID Troubleshooting.
8. Steps to complete after putting the system in ORP PID control. a. Monitor the system for the first week after control is implemented to determine whether the system is controlling at the setpoint. A PID autotune is meant to be a starting point and will likely require some adjustment to recover good control. What is perceived as “good control” will vary from site to site and is largely limited by the operational characteristics of the boiler. The overall goal is to minimize excursions away from setpoint.
b. If it is determined that a setpoint change is in order, a small change can be made without running an additional PID autotune. However, a larger change (>100 mV) may require another autotune.
8.7
Manual Tuning
•
Use manual PID tuning to make the control more or less aggressive. Make changes and upload (no reboot is needed). o Make the control more aggressive (smaller P) if it takes a long time to reach the set point after a load swing. o Make the control less aggressive (larger P) if the measured value constantly oscillates about the set point while the system load is fairly stable.
• •
Making control more aggressive increases the proportional response to error. The PB, I, and D parameters can also be changed independently.
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Note:
See Section 14.5 for additional PID Troubleshooting. 30 i_tra = TRASAR3
70 o_a1 = Analog 1
25 60
Less aggressive
More aggressive
50
40 15
Pump %
TRASAR ppm
20
30 10 20
5 10
0 0 4/1/2008 21:36:00 4/2/2008 0:00:00 4/2/2008 2:24:00 4/2/2008 4:48:00 4/2/2008 7:12:00 4/2/2008 9:36:00 4/2/2008 12:00:00 4/2/2008 14:24:00 4/2/2008 16:48:00
8.8
Set PID to ON/OFF Control (or Manual) If PID Auto Tune Cannot Be Completed
If the PID Auto Tune cannot be completed on the system due to boiler feed fluctuations (also see PID troubleshooting first) the controller can be put into ON/OFF control (see Section 6.1 for instructions) and tuned at a later date. Those familiar with PID tuning may manually select parameters.
8.9
Monitor PID Control
After tuning has been completed the system must be monitored (locally or remotely) to be sure it is being properly controlled. If the boiler system operational parameters change dramatically the system may require retuning.
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9.0
Blowdown Monitor and Control
9.1
Conductivity Monitor and Blowdown Control Setup
The Configurator is used to set up conductivity monitoring and control. The settings are described in the Configurator Help Screens. Alarms are described in Appendix F.
9.1.1
Conductivity Control Mode Options
Up to 6 conductivity probes can be configured. For each conductivity measurement a temperature probe and control mode must be selected.
9.1.2
Temperature Probe Assignment
Since the conductivity of water varies significantly with temperature, a conductivity probe must have a temperature probe or a temperature value assigned to it for temperature compensation. An RTD or a User Set temperature must be selected in the Control and Alarms Settings screen. Note: The controller is limited to only three RTD inputs. In the BL5500 series, two RTD inputs are already assigned. Therefore, only one RTD input remain for connection of a conductivity probe with an integral RTD. If there is only one boiler to control use a conductivity probe with an integral RTD. If there are multiple boilers to control, use a probe with an integral RTD on the boiler where water temperature varies the most. This RTD is usually wired to the RTD 3 input (TB 9-3). If a feedwater conductivity probe is used, RTD 1 (TB 9-1), which is located on the Sample Conditioning
System RTD, is usually selected as the temperature probe. If a blowdown probe without an RTD is being used, Select User Set for the Temperature Probe. The sample water temperature at the probe must be manually entered in the Conductivity Control screen. In the example above, select Edit for Conductivity 2 to get to this screen. 126
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ The temperature of the boiler water can be determined from the operating pressure of the boiler. Refer to Appendix B for the Boiler Saturated Steam Table. The boiler water temperature remains constant as long as pressure remains constant. Note: The sample temperature will drop between the boiler and conductivity probe. It is best to measure the actual sample temperature at the probe for accurate readings.
Note: Entering the correct temperature is very important. The conductivity measurement will be off by approximately 11% for every 10°F (5.5°C)
9.1.3
Conductivity Control Mode
In the Boiler Configurator there are 4 control options that can be selected for each conductivity probe. The typical uses and type of sample stream required for each option are listed in the table below. Boiler blowdown is most often controlled using Timed Sample Control (blowdown rate < 5000 lbs/hr) or Continuous (On/Off) Control (blowdown rate > 5000 lbs/hr). Only these two control modes are explained in this manual. There are two Interval Monitor Mode options under Timed Sample Control. Both are for intermittent sampling.
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Sample Flow Requirement
Typical Applications • Feedwater
Monitor Only
Continuous or Intermittent
• Condensate stream • Boiler blowdown Applications where no control action is desired.
PID Control
Continuous (On/Off) Control
Continuous
• Boiler blowdown on large high-pressure utility boilers. A variable flow control valve that accepts a 4-20 mA signal must be used. The control valve can be on the sample line or on a separate blowdown line. Sample flow must be continuous.
Continuous
• Boiler blowdown (blowdown rate > 5000 lbs/hr) An On/Off motorized ball valve is installed on the main blowdown line. The conductivity probe is installed on a separate continuous blowdown line. The boiler blowdown requirements must be great enough to permit continuous blowdown for conductivity measurement. • Boiler blowdown (blowdown rate < 5000 lbs/hr) An On/Off motorized ball valve and conductivity probe are installed on the same blowdown line. Timed Sample Control is used on boilers where continuous sampling will cause excessive blowdown. Interval Monitor Mode
Timed Sample Control
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Intermittent
Continuous For systems where the conductivity readings are stable when the control valve is open. The conductivity is measured. If the conductivity is below the setpoint the control valve will close. If the conductivity is above the setpoint the blowdown valve remains open while the conductivity is being continuously measured. When the conductivity level drops below the setpoint the valve will close.
Proportional This control method is only used in systems with erratic conductivity readings due to turbulent flow or steam flashing. A trap time is used to stop flashing before the conductivity is measured. After the conductivity is measured, if the conductivity is above the setpoint the controller calculates how long to re-open the valve in order to blowdown the boiler. This calculated time interval is proportional to the difference between the measured value and the setpoint.
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9.1.4
Monitor Only Mode
It is recommended to select this method initially for new installations. Monitoring the boiler blowdown conductivity for a short period of time before going into control, allows the user to get a better feel for what control method to use and what parameters are needed to achieve good boiler cycle control. The Conductivity Name, Operating Temperature (if User Set is selected, enter the boiler water temperature) and Alarm Settings are entered in the Conductivity Control – Monitor Only screen. If a probe with an integral RTD is used, the Operating Temp field will be disabled.
9.1.5
PID Control Method
PID Control is used for large high pressure utility boilers were boiler blowdown is on a continuous basis. A variable flow control valve is used to accept a 4-20 mA signal from the 3D TRASAR controller. PID control of the blowdown conductivity is based on PID parameters that are manually entered by the user. Only manual PID tuning is available for this control method. For conductivity, the recommendation is to use Proportional control (Integral and Derivative terms are set to 0). To use Proportional Control with Conductivity, first select PID as the control method for the Conductivity device. The Conductivity Name, Output, Output Name, Operating Temperature (if User Set was selected, enter the boiler water temperature), Control Settings and Alarm Settings must be entered in the Conductivity Control – PID screen. The PID parameters are entered in the Advanced PID Settings screen. If a probe with an integral RTD is used, the Operating Temp field will be disabled.
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PID Control Notes: •
Proportional conductivity blowdown control is Direct Acting.
•
Set the Integral and Derivative terms to 0.
•
If the conductivity probe is installed on the same blowdown line as the control valve, the Output Min must be set to a value large enough to ensure a constant sample flow across the conductivity probe.
•
The Output Max is used to prevent the control valve from opening so wide that the boiler blows down too rapidly, upsetting boiler operation.
•
The Max Change % is used to slow down the response of the control valve to simulate the response of a pneumatic valve (default = 10%). If the Update Interval is left at the default 5 seconds it will take 50 seconds to fully close the valve from fully open.
•
The Scale High and Scale Low must be set above/below any alert or alarm values.
•
The Proportional value is calculated using the following equation:
Proportional =
[Acting x (Setpoint – Cond.Max.) x 100] x 100 [(Output Max – Output Min) x (Scale High – Scale Low)]
Example: Setpoint = 3000 µS/cm CondMax = 6000 µS/cm Output Min = 5% Output Max = 40% Acting = -1 (Direct Acting PID equation for Conductivity Blowdown Control) Scale Low = 1500 Scale High = 5500 Calculation:
P=
[ -1 x ( 3000 - 6000 ) x 100] x 100 [( 40 – 5 ) x ( 5500 – 1500 )]
= 214.29
See the Configurator Help Screens (F1) for detailed instructions.
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9.1.6
Continuous (ON/OFF) Control Method
Continuous method enables traditional ON/OFF control. It is often used to control boiler conductivity levels in systems where a small amount of boiler water is continuously bled off from a secondary blowdown line. This stream is continuously monitored, providing a real-time conductivity reading. When the measured conductivity increases above the setpoint, the control valve, which is installed on the main blowdown line, is opened to increase the blowdown rate and reduce the measured conductivity to below the setpoint. This method, which is the easiest method to employ, is used f or systems were the blowdown rate is greater than 5000 lbs/hr. In Section 4.1 there is a schematic of a system set up in a Continuous (On/Off) control mode. A tee is installed on the main blowdown line so a small amount of blowdown sample continuously fl ows through the conductivity probe assembly, past a flow control valve and then to drain. The main blowdown extends to the motorized ball valve, which will be wired to and controlled by the 3D TRASAR controller. IMPORTANT NOTE: Both flow control valves must be throttled back to maintain backpressure in the lines. The valves cannot be in the wide-open position. Otherwise, flashing in the line will occur if the line discharges to atmospheric pressure. In the Configurator, the Conductivity Name, Output, Output Name, Operating Temperature (if User Set was selected, the boiler water temperature is entered), Control Settings and Alarm Settings must be entered in the Conductivity Control – Continuous screen. If a conductivity probe with an integral RTD is used, the Operating Temp field will be disabled. The +band must also be entered. The control valve will open when the conductivity level rises to the Set Point +band and close when the conductivity level falls to the Set Point .
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9.1.7
Timed Sample (ON/OFF) Control Method
Timed Sample control method is used on boilers were continuous sampling will cause excessive blowdown. This method is used for systems were the blowdown rate is less than 5000 lbs/hr. In Section 2.3.3.4 there is a schematic of a system that is set up in a Time Sample (On/Off) Control mode. Timed Sample enables ON/OFF control of boiler blowdown conductivity. The conductivity probe is mounted on the same line as the control valve. The control valve is periodically opened on a predetermined (timed) schedule. If the conductivity level is above the setpoint, the valve remains open. How long the valve remains open depends on the Monitor Mode selected. There are two Interval Monitor Modes available for Timed Sample Control – Continuous and Proportional. The table below explains the differences between the two modes. Interval Monitor Mode
Typical Applications
Continuous
For systems where the conductivity readings are stable when the control valve is open. After the conductivity is measured, the controller compares the measurement to the setpoint. If the conductivity is below the setpoint, the control valve will close. If the conductivity is above the setpoint, the control valve remains open while the conductivity is being continuously measured. When the measured conductivity drops below the setpoint, the control valve will close.
Proportional
This control method is only used in systems with erratic conductivity readings due to turbulent flow or steam flashing. In these systems, a trap time is used to prevent the blowdown sample from flashing while the conductivity is measured. After the conductivity is measured, the controller compares the measurement to the setpoint. If the conductivity is above the setpoint, the controller calculates how long to re-open the control valve in order to blowdown the boiler. This calculated time interval is proportional to the difference between the measured value and the setpoint. See Section 9.1.7.2 on how to set up Timed Sample - Proportional control.
Note:
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When using Timed Sample Control (either Continuous or Proportional monitor mode) a Sample Schedule must be defined.
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9.1.7.1
Timed Sample – Continuous Mode
In the Configurator, the Conductivity Name, Output, Output Name, Operating Temperature (if User Set was selected, enter the boiler water temperature), Control Settings, and Alarm Settings must be entered in the Conductivity Control – Timed Sample screen. If a conductivity probe with an integral RTD is used, the Operating Temp field will be disabled. The +band is also disabled in this mode. The Interval Details and Sample Schedule need to be configured (see Sections 8.8 and 8.9 for more details). The defaults that have been built into these screens are realistic starting values for most systems. The user can choose to use these default values initially, or change them. Some of the parameters have Minimum and Maximum limits to prevent the user f rom entering unrealistic values.
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9.1.7.2
Timed Sample – Proportional Mode
In the Configurator, the Conductivity Name, Output, Output Name, Operating Temperature (if User Set was selected, the boiler water temperature is entered), Control Settings, and Alarm Settings must be entered in the Conductivity Control – Timed Sample screen. If a conductivity probe with an integral RTD is used, the Operating Temp field will be disabled. Note:
The Band field is now active and MUST be calculated. See Section 8.10 for details.
As with the Continuous mode, the Interval Details and Sample Schedule need to be configured (see Sections 8.8 and 8.9 for more details). The defaults that have been built into these screens are realistic starting values for most systems. The user can choose to use these default values, initially, or change them. Some of the parameters have Minimum and Maximum limits to prevent the user from entering unrealistic values.
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9.1.8
Interval Details
The following inputs are required for both Timed Sample – Continuous and Timed Sample – Proportional control methods:
•
Sample Average Time: Enter the number of seconds over which the sample measurement will be averaged. By averaging the measured conductivity over a period of time, the effect of measurement spikes is minimized. The averaging should be the shortest time needed to attain an accurate conductivity reading. In the case of Timed Sample - Proportional control where the control valve is closed when the average conductivity is being measured, it is crucial to note that the trapped blowdown sample will start to cool shortly after the control valve is closed. Therefore, large Sample Average Times are not recommended. The default value is 30 seconds.
•
Maximum On Time %: Enter the maximum % of the remaining sample interval (Decision Interval – Flush – Trap – Sample Average Time) that the control valve can remain open. This should be set to accommodate the highest expected blowdown rate under any condition. The default value is 85%.
•
Minimum On Time:
9.1.9
Enter the minimum amount of time the control valve should remain open during each Decision Interval after the Flush, Trap, and Sample Average Time interval has occurred. This should be set to provide the minimum desired blowdown under any circumstances. A typical value for this field is 30 seconds.
Sample Schedule
A Sample Schedule needs to be configured for Timed Sample – Continuous and Timed Sample – Proportional control. Up to 4 Sample Schedules can be configured. The Sample Schedule defines the time interval that will be used for sampling conductivity. Each probe can be uniquely configured to a different Sample Schedule. They can be enabled or disabled as desired. However, a Sample Schedule cannot be disabled if it is being used by a control loop
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 Output: A unique relay must be selected for each Sample Schedule. In the case of blowdown control, the Sample Schedule Output is usually set to the same relay chosen on the Conductivity Control Timed Sample screen. The control valve that is wired to the chosen relay output is used for both sampling and control. Sample Rate: Select the sampling rate based on when high load periods are expected for the boiler. The Sample Rate needs to be chosen to match the times when the boiler is operating at peak output. Some manufacturing facilities only operate Monday through Friday and leave the boiler in a low load or standby state over the weekend. A Daily High MTWTF sample rate would best fit this plant that operates under peak conditions during the week and goes on standby mode on the weekends. If Normal 24/7 is chosen for a facility, the sampling interval will remain the same over any time period. The options are: § § § Note:
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Normal 24/7 Daily High 7 Days Daily High MTWTF If “Normal 24/7” is selected then “High Rate Start”, “High Rate End” and “High Decision Int” fields are disabled because they do not apply to a “normal” load situation
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ High Rate Start: Starting time for a high load sampling period. High Rate End: Ending time for a high load sampling period. High Decision Int: Length of time for the complete Sample Schedule (cycle) in minutes for high load periods. Normal Decision Int: Length of time desired between sampling in minutes for normal load periods. If the boiler operates in a Normal 24/7 mode, this is the only decision interval that is entered. If this value is set too low, sampling of the boiler blowdown will be too frequent, which may cause the boiler water conductivity to decrease over time. Under this condition, the sampling is enough to inadvertently blowdown the boiler. If this value is too large, sampling will be too infrequent, causing the boiler water conductivity to increase over time. This will result in over cycling. The default value is 60 minutes. Note:
During the initial setup, it is better to choose a low decision interval. This may waste a small amount of energy until a final value is determined, but will greatly reduce the chance of over cycling and damage to the system.
Enable Trap Time: A sample trap is used to stabilize samples when turbulent flow or entrained steam prevents accurate conductivity measurements. The sample Trap Time is in seconds. An important consideration is that too long of a trap time will result in a decrease in the sample temperature. The default value is 10 seconds. This field is only enabled when Timed Sample – Proportional control is chosen. Flush Time: The minimum time needed (seconds) to flush the sample line and ensure the sample will reach its maximum temperature. A value between 0 and 86,400 seconds can be entered. If flush time is too short the sample will not be at its maximum temperature and the conductivity value will continue to rise as the sample is measured. If this time interval is too large, the boiler could blow down too much as a result of the sampling alone. The default value is 180 seconds. Note:
Certain rules have been established covering the allowable entries for the time intervals. An error message will appear if one or more of the entered values are invalid.
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9.1.10
Setting Up Timed Sample – Proportional Control
The control values entered in the Configurator should closely mimic how the system is currently operated. Otherwise, the boiler will likely blowdown too much or not enough. Below is a diagram of the conductivity measurement-control cycle. At the beginning of the Decision Interval the valve opens (Decision Point) to flush the blowdown line, providing a fresh sample to the conductivity probe (Flush Time). Next, the control valve is closed to trap the sample and establish an accurate conductivity reading (Trap Time). The conductivity is measured and averaged (Sample Average Time). Finally, a decision is made as to how long the valve should be re-opened (Calculated Valve On Time). See the table below for more details on the controller response.
To determine the correct values it is important to understand how the (Blowdown) Valve On Time is calculated. The Maximum Calculated (Blowdown) Valve On Time acts as a first defense against blowing down a boiler too much. This value establishes a time limit on how long the control valve can remain open after the conductivity has been measured. It is calculated as follows: Max. Calc. Valve On Time = (Decision Interval – Flush –Trap – Average) x Maximum On Time %
Example: Decision Interval = 60 minutes Flush Time = 240 seconds = 4 minutes Trap Time = 30 seconds = 0.5 minutes Sample Average Time = 30 seconds = 0.5 minute) Maximum On Time % = 20% Max. Calc. Valve On Time = (60 – 4 – 0.5 –0.5) x 0.20 = 11 Minutes The Calculated Valve On Time is a portion of the Maximum Calculated Valve On Time. The higher the conductivity measurement is above the Setpoint, the longer the blowdown valve will be open. It is calculated as follows. Calc. Valve On Time = (Max. Calc. Valve On Time) x (Conductivity Value Above Setpoint) +band
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Example: Decision Interval = 60 minutes Flush Time = 240 seconds = 4 minutes Trap Time = 30 seconds = 0.5 minutes Sample Average Time = 30 seconds = 0.5 minutes Maximum On Time % = 20% Conductivity Setpoint = 5000 µS/cm
Max. Calc. Blowdown Valve On Time
Averaged Conductivity = 5050 µS/cm +band = 100 µS/cm Calc. Valve On Time =
(60 – 4 – 0.5 –0.5) x 0.20
x (5050-5000) = 5.5 minutes 100
Note: The +band value calculation is presented later in this section of the manual. How is Valve Open Time Determined?
Note:
Measured Conductivity
Controller Output Response (Valve Action)
Avg. Cond. < Setpoint
Minimum On Time
Avg. Cond. > Setpoint and (Avg. Cond – Setpoint). < Band
Calculated Valve On Time
Avg. Cond. > Setpoint and (Avg. Cond – Setpoint). > Band
Maximum Calculated Valve On Time
Minimum On Time (seconds) and Maximum On Time (%) are entered by the user on the Timed Sample – Continuous or Timed Sample – Proportional screen, under Interval Details section.
Determining Values To Enter Into The Configurator. The first step to determine the appropriate values for your system is to perform a Blowdown Test. This test is used to measure the time it takes to blow down the boiler from a conductivity value above setpoint. 1. Determine the time-based intervals (Decision Int, Flush Time, Trap Time, and Sample Average Time). The Boiler operators will be an excellent resource. They know their systems very well and can aide in the determining an acceptable time interval and the required blowdown time. Note:
The default values can be used initially. Over time, as the user becomes more comfortable with the control, these values can be changed accordingly.
2. Perform a Blowdown Test. This test is performed to determine the actual time it takes for the boiler water to drop from a starting conductivity value to some ending conductivity value. 3. Perform calculations to determine Maximum On Time % and +band values.
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Example: It is determined that the following values are acceptable. Decision Interval = 120 minutes Flush Time = 180 seconds = 3 minutes Trap Time = 15 seconds = 0.25 minutes Sample Average Time = 45 seconds = 0.75 minutes Conductivity Setpoint = 3500 µS/cm Additional information was provided by the boiler operators. •
Boiler is generally blown down the when the conductivity is approx. 100 µS/cm above setpoint. (“Conductivity Value Above Setpoint”) • The boiler is never blown down more than 30 minutes at a given time. (“Max. Calc. Valve On Time”). This prevents shocking the boiler with cold feed water and allows the deaerator to maintain its level. The Blowdown Test gave the following result. •
At a conductivity value of 3600 µS/cm, it took 12 minutes to blow down the boiler until the conductivity read 3500 µS/cm. Calc. Valve On Time = 12 minutes Blowdown Test = (3600 – 3500) µS/cm = 8.33 µS/cm 12 min min
1. First, calculate the Maximum On Time %. Max. Calc. Valve On Time = (Decision Interval – Flush –Trap – Average) x Maximum On Time %
30 = (120 – 3 – 0.25 – 0.75) x Maximum On Time % Maximum On Time % = 0.259 or 25.9% (Round 25.9% to 26%) 2. Next, calculate the +band parameter. Band = (Max. Calc. Valve On Time) x (Blowdown Test)
Band = (120 – 3 – 0.25 – 0.75) x 0.26 x (3600-3500) 12 Band = (116 x 0.26 x 8.33) = 251.3 µS/cm Therefore, the values entered into the Configurator would be as follows: Decision Interval = 120 minutes Flush Time = 180 seconds = 3 minutes Trap Time = 15 seconds = 0.25 minutes Sample Average Time = 45 seconds = 0.75 minutes Conductivity Setpoint = 3500 µS/cm Maximum On Time % = 26% Band = 251 µS/cm
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Note:
Monitor the system very closely for the first few weeks and make adjustments to ensure boiler blowdown control is operating successfully. The values input by the user are not going to be perfect. Every blowdown cycle is slightly unique and the calculated blowdown time is not going to be the exact amount of time needed for every cycle. The values must be adjusted after multiple decision intervals have occurred (unless there is an extreme response occurring). The results should be trended to determine what adjustments are needed.
Note: Review all the configured devices and control outputs on the Control and Output Summary screen to be sure no input errors have been made. Print the screen for reference. Save and Close (for future Uploading) or Upload the settings to the controller.
9.1.11
Troubleshooting and Adjustment Tips for Interval Control
1. The boiler conductivity continues to decrease over multiple decision intervals (too much blowdown). Solution 1: Decision interval needs to be increased. Note: Changing the decision interval causes a change in the maximum blowdown time and the Maximum On Time % will need to be adjusted accordingly. Solution 2: Slightly close the Flow Control Valve (decrease “turns open”). 2. Boiler conductivity continues to increase over multiple decision intervals in Timed Sample Proportional Mode (too little blowdown). Solution 1: Increase the Maximum On Time %. If the Maximum On Time % is already large (>85%), shortening the decision interval or making changes to the Band parameter may need to be considered. Note: Changing the decision interval causes a change in the maximum blowdown time and the Maximum On Time % may need to be adjusted. Solution 2: Slightly open the Flow Control Valve (increase “turns open”). Note: Be careful not to open the valve too much as to cause flashing. 3. Boiler conductivity is only a few percent above setpoint, but the control valve remains open long enough to reduce the conductivity where it takes multiple decision intervals to reach setpoint again. Solution: Reduce the Maximum On Time %.
9.1.12
Review Conductivity Control Setup
Review all the configured devices and control outputs on the Control and Output Summary screen to be sure no input errors have been made. Print the screen for reference. Save and Close (for future Uploading) or Upload the settings to the controller
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9.1.13 Notes on Control Modes, Alerts and Alarms Control Modes •
“Continuous” control is otherwise referred to as ON/OFF Control. The term “continuous” control is used here specifically in the place of ON/OFF control for Conductivity Devices as it is an Industry Standard term for use of the ON/OFF control method for Conductivity.
•
Timed Sample Control must be used in conjunction with a sample schedule. Timed Sampling minimizes water loss in small systems. The user is prompted during the configuration set-up to associate this control with a sample schedule to be used as part of a control “cycle”. Within “Timed Sample Control” are 2 separate control options:
•
Proportional control: Where the control output is turned on for a calculated period of time that is proportionally based on how far away the process reading is from set-point (the farther from setpoint the longer the control output is on).
•
Continuous Control: Similar to ON/OFF control in that the control output is turned on until the setpoint value is satisfied. A difference is that the control output will turn OFF when the maximum time “ON” for the sample is reached, regardless of whether the set-point value has been satisfied or not.
Alarms and Alerts •
Alarms and Alerts are individually selectable options where appropriate on each configuration screen. If you have previously selected a communication method, you may also individually select to be notified, (or not) when reaching any Alarm or Alert value by checking the Notify on Alert (Alarm). User sets the alarm set point.
•
Alert: An “Alert” is a notification alarm. It provides an indication that the input signal is at a value outside the range of normal operation and the system needs attention. User can enable high or low alerts for each input signal. Alerts can be set for all input signals whether they are used for control of outputs or not. During an “Alert”, an output associated with the signal continues in automatic control.
•
Failsafe Alarms: Failsafe Alarms are allowed where signals will control an output. When you reach a Failsafe alarm level, the output exits automatic control and is placed into timer control (see failsafe responses). Some overriding alarm conditions such as low steam flow and system Interlock can place multiple outputs into failsafe operation.
•
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•
Failsafe Low Conductivity - For an operating boiler, is not recommended to ever shut off blowdown flow totally, even if below the desired conductivity set points. A forced output response for Failsafe Low Conductivity may be the best option. The fixed output should be set to provide approximately the minimal suggested mass flow from the boiler as recommended by the boiler manufacturer or by the plant's specific standard operating procedures.
•
Failsafe High Conductivity - Should never be set to FORCED OFF. If conductivity is high, the boiler should be blowing down. The Smart Failsafe is likely not optimum either as it will provide only the average amount of flow from the boiler. During a High Failsafe condition, the blowdown rate should be higher than normal. Running the Smart Failsafe (average output) may only tend to allow for further concentration of the species in the boiler. A fixed output at the maximum recommended blowdown mass flow (per boiler manufacturer specs) would be the best practice. In a High Failsafe condition, the boiler conductivity must be lowered quickly and safely by allowing for the highest safe mass flow from the boiler.
Clearing of Alarms: Some alarms self clear when the input signal returns to normal operating range. Other alarms (e.g. Temperature High Override or Pump Timeout) can only be cleared by the user.
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Alarm Delay: An input signal must persist in the alarm state for a set time period before the alarm is called. This value cannot be user set. When an alarm is cleared by the user, the alarm delay is automatically increased by a factor of 5 to allow the system to be in automatic control for an extended period so that the system can exit the alarm condition.
•
Alarm Deadband: Each alarm has an associated dead band. Alarms will persist until the signal value differs from the alarm setpoint by the alarm deadband.
•
Control Timeout Alarm: If a relay based valve is activated for longer than a user set period of time, the alarm is called. This alarm does not self clear. When applied to Timed Sample blowdown control it is cumulative over more than one “decision interval”.If the signal used for automatic control of the output goes to low or high failsafe, the time out alarm will be cleared. CAUTION-DANGER:
* SCS HIGH-TEMPERATURE ALARM *
All systems should be configured to alarm on high SCS temperature. Frequent high sample temperatures are an indication of cooling water supply problems that must be corrected. Repeatedly subjecting the solenoid valve to high temperatures will cause a valve failure and a safety risk.
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9.2 Fluorometer-Based Blowdown Control Setup PID Control is used for large high pressure utility boilers were boiler blowdown is on a continuous basis. A variable flow control valve is used to accept a 4-20 mA signal from the 3D TRASAR controller. PID control of the blowdown using fluorescence is based on PID parameters that are manually entered by the user. Only manual PID tuning is available for this control method. The recommendation is to use Proportional control (Integral and Derivative terms are set to 0). To use Proportional Control, first select PID as the control method for the fluorometer. The Name, Output, Output Name, Operating Temperature (if User Set was selected, enter the boiler water temperature), Control Settings and Alarm Settings must be entered in the Fluorometer Control – PID screen. The PID parameters are entered in the Advanced PID Settings screen.
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PID Control Notes: •
Proportional conductivity blowdown control is Direct Acting.
•
Set the Integral and Derivative terms to 0.
•
If the conductivity probe is installed on the same blowdown line as the control valve, the Output Min must be set to a value large enough to ensure a constant sample flow across the conductivity probe.
•
The Output Max is used to prevent the control valve from opening so wide that the boiler blows down too rapidly, upsetting boiler operation.
•
The Max Change % is used to slow down the response of the control valve to simulate the response of a pneumatic valve (default = 10%). If the Update Interval is left at the default 5 seconds it will take 50 seconds to fully close the valve from fully open.
•
The Scale High and Scale Low must be set above/below any alert or alarm values.
•
The Proportional value is calculated using the following equation:
Proportional =
[Acting x (Setpoint – TRASAR .Max.) x 100] x 100 [(Output Max – Output Min) x (Scale High – Scale Low)]
Example: Setpoint = 300 ppm TRASAR Max = 324 ppm Output Min = 5% Output Max = 40% Acting = -1 (Direct Acting PID equation for Conductivity Blowdown Control) Scale Low = 100 Scale High = 1000 Calculation:
P=
[ -1 x ( 300 - 324 ) x 100] x 100 [( 40 – 5 ) x ( 1000 – 0 )]
= 6.86
See the Configurator Help Screens (F1) for detailed instructions.
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10.0
Condensate Monitor Control Setup
The 3D TRASAR Boiler Controller can be configured to control condensate return using a relay. The system can be set up to activate a relay and dump the returning (contaminated) condensate if any of several user-specified conditions are met. Generally, conductivity is used as the primary control, with secondary control from pH, and any 4-20 mA inputs. 1.
Using the Configurator add a conductivity probe to the Control and Alarm Settings section. Set the control method to continuous.
2.
Open the edit screen for the conductivity probe, and set the output to the relay that you want to control the condensate return. Also, under control settings put in a set point value, and set acting to direct. This will set up the controller to activate the relay if the conductivity rises above the set point. The conductivity must be above the set point + deadband for 5-10 seconds for the relay to switch on.
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Additional variables can also be used to control the same relay. To add a pH control to the relay, first add the pH probe to the Control and Alarm Settings section in Monitor mode.
4.
Then add the pH input to the Control Overrides section. Name the override, and input the value that you want to activate the relay. Next, set the type to low or high. (For example setting the input value to 5, and the type to low will activate the relay if the pH drops below 5). You can set up a high and a low pH override to trip the relay by setting up 2 individual overrides (one for “high pH” and one for “low pH”).
5.
For each override click on Edit. Then click the box to activate it, set the output to the same name as the conductivity probe, set the response to fixed failsafe, and the duty to 100%. Control override values will switch the relay on after the value has surpa ssed the set point for 5 minutes. An analog input (particle monitor) can also be set up as a control override.
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Note:
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If monitoring condensate receiver tanks with an intermittent pump an interlock from the pump must be assigned to the dump valve as an override.
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11.0
Controller Operation
The keypad and display on the control panel is shown to the right. This panel is used to perform the basic operations quickly and conveniently, including setting control ranges, performing calibrations, manual relay operation, auto control adjustments and manually feeding chemicals.
11.1
Display Panel Functions
The display panel is a 6-line, backlit LCD graphical display. The display panel is used to edit numeric data and show status information for the various system parameters, alarms, and pumps.
11.2
The Keys
The functions of the 20 keys on the control panel’s keypad are summarized to the right: Pressing any of these keys will change the information shown on the display and let you quickly check the status of the unit or change its configuration.
Information
Actions Alarms Numbers 0-9 Menu Help Up/Down Back Soft Keys
11.2.1
Indicates viewing of operating data, digital inputs, control relays, analog outputs, software version, and diagnostics Allows calibration, changing output status, and for reboots Shows active alarms Provide for the entry of numerical listings Provides complete main menu list Provides contact information help Used for menu navigation Returns to previous screen Used to make selections shown on the display panel
Ethernet and USB Connections and Power Switch
RJ-45 Ethernet Connection USB Flash Drive Connection Power Switch
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11.3
The Graphical Icons
The graphical icons that appear in the display are listed below with a brief explanation of their meaning.
11.4
• • • • •
Move to next/previous screen (use arrow keys) Scroll through list of choices (use arrow keys) One or more alarms are active (press Alarms to view) Modem connection is established (incoming or outgoing) No flow condition exists (delay for alarm)
•
Interlock contact is opened (immediate alarm)
Menu, Information, Actions and Alarms Keys Flow Diagram
The flow diagram below shows all of the different screens that can be accessed through the controller display panel. The remainder of this section gives detail on each of these screens. Certain menu options will only appear if the related input or output device is connected to the controller. Menu
Control Settings
Alarm Settings
Network
Preferences
Information
Actions
Alarms
Operating Data
Calibrate
Current Alarms
Digital Inputs
Manual Control
Control Relays
Test Send
Analog Outputs
Reboot
Input Types
TRASAR Factors
Fluorometer
Ethernet 1
Units
ORP/pH 1
PID 1
AT ORP 1
Etherner 2
Dates
ORP/pH 2
PID 2
AT ORP 2
Modem
AI 1
PID 3
pH 1
Internet
AI 2
PID 4
pH 2
SCADA
AI 3
PID 5
Temp 1
AI 4
PID 6
Temp 2
AI 5
PID 7
Temp 3
AI 6
PID 8
Analog 1
AI7
Relay 1
Analog 2
AI 8
Relay 2
Analog 3
Relay 3
Analog 4
Relay 4
NCM
Versions Diagnostics
Relay 5
Navigation is controlled by the keypad next to the display panel. The main Shortcut Keys are listed below. Information
Indicates viewing of operating data, digital inputs, control relays, analog outputs, software version, and diagnostics
Actions
Allows calibration, changing output status, performing a test data send for verifying communications and for reboots
Alarms
Shows active alarms
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11.5
Menu Key Menu
Control Settings
Network
Alarm Settings
Preferences
Input Types
The Menu Key provides access to 5 submenus.
• • • • •
Control Settings – Set control parameters. Alarm Settings – Set alarm parameters. Preferences – Set time and date. Network – Network settings Input Types – Set analog inputs to either 4-20mA or 1-10 VDC (internal dip switch change also need)
A password must be entered to access all submenus.
Enter Password ….12345 (Default Password)
The password has to be re-entered after 10 minutes of inactivity.
11.6
Control Setting Screens Menu
Control Settings
11.6.1
Alarm Settins
Network
Preferences
Input Types
TRASAR Factors Screen
Displays and permits changes to the current settings: Fluorometer Gain, TRA Value, Product Factor and phosphate factor (for coordinated phosphate control). • Highlight the parameter to be changed. Enter Select. • Use the ⇓⇑ arrows to select the parameter. Enter Edit. • Use the desired value (use ⇓⇑ arrows to toggle between choices or 0-9 to enter a value. • Enter ACCEPT
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11.6.2
PID 1-8 Screens
Displays and allows changes to the set point and P, I and D values for each the PID loop configured. Also permits changes to the current settings: Auto/Manual, Manual % and Auto after (time) See section 6 for setup and tuning details.
• • • •
Highlight the PID control to be changed. Enter Select. Use the ⇓⇑ arrows to select the parameter. Enter Edit. Use the desired value (use ⇓⇑ arrows to toggle between choices or 0-9 to enter a value. Enter ACCEPT
11.6.3
Relays 1-5 Screens
Displays and permits changes to the current settings: Auto/Manual, Manual On/Off and Auto after (time) of the each of the 5 control relays.
• • • •
Highlight the Relay control to be changed. Enter Select. Use the ⇓⇑ arrows to select the parameter. Enter Edit. Use the desired value (use ⇓⇑ arrows to toggle between choices or 0-9 to enter a value. Enter ACCEPT.
11.7
Alarm Setting Screens Menu
Control Settings
11.7.1
Alarm Settings
Network
Preferences
Input Types
Alarm Settings
Alarms are usually set up using the Configurator. However, they can also be set using the controller keypad. The user can configure the system to raise alarms under certain conditions. Setting up alarms is optional but recommended for functional control. What alarms are available to the user depends upon the inputs and the control method. Alarms can be set up for the following: Input Alarms: High Failsafe Alarm: An alarm is raised when the input value exceeds a set level for a period of time. It can only be set for inputs that are in control of an output. If this alarm is raised, the output that was being controlled will transition to user set failsafe response. High Alert Alarm: An alarm is raised when the input value exceeds a set level for a period of time. This is a notification alarm, and does not need to be associated with an output. If there is an associated output, the output continues in designated control mode.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ Low Alert Alarm: An alarm is raised when the input value falls below a set level for a period of time. This is a notification alarm, and does not need to be associated with an output. If there is an associated output, the output continues in designated control mode. Low Failsafe Alarm: An alarm is raised when the input value falls below a set level for a period of time. It can only be set for inputs that are in control of an output. If this alarm is raised, the output that was being controlled will transition to user set failsafe response. Examples of Input alarms include: - TRASAR - Turbidity
- NCSM - Cell Fouling
- pH - Analog Inputs
- Temperature - Digital Inputs
If an output is being controlled an additional alarm is available: Pump Time Out Alarm: This alarm is activated when the output has been energized at an Average Duty Cycle exceeding a user-set value for a time exceeding the Pump Timeout limit Other Available Alarms Sample Conditioning System: - This alarm controls the relay connected to the solenoid for the sample conditioning system. - The (high temperature) alarm must be manually cleared (it is not self clearing). The system may also have to be rebooted. - The alarm is set by the temperature input signal and has high failsafe, high alert, low alert and low failsafe options analogous to other level alarms System Interlock Alarms: The interlock digital input provides the ability to use a signal, for example from the feed water pumps, to enable or disable the 3D TRASAR control outputs. - If the feed water pumps are turned off, the contact is opened, and the interlock alarm occurs, disabling all the control relays. - Control is restored when the feed water pumps are turned back on and the contact is closed. Alternatively, a switch in the control room can be used to activate or deactivate this alarm. - The alarm may be enabled or disabled. - The alarm response is always the same—all outputs are disabled. - The user may choose to be notified. Low Temperature Interlock: The temperature reading from the NCSM probe can be used to determine if there is flow going past the probe. - If the temperature drops significantly (approaches room temperature), it indicates of no sample flow. - The user can enable the alarm and set the low temperature limit to a value below which it would be indicative of a no-flow condition. Steam Flow/Feedwater Flow Interlock: If the Boiler system can provide a 4-20mA input from a steam or Feedwater flow meter, this signal can be used to enable or disable the 3D TRASAR Boiler control outputs when the boiler is not operating or on standby. - The user can enable the alarm and set the flow limit to a value below which it would be indicative of the Boiler being on standby.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 Sensor Alarms: Sensor alarms are activated when an error is detected in the sensor inputs. These alarms are typically the result of improper or loose wiring or faulty probes. Inaccurate or fluctuating readings are another indicator of miswired or faulty probes. Note:
pH and ORP are high impedance measurements and the sensor alarm is not always triggered.
Control Overrides Screen: pH can have an effect on ORP readings. If both a pH and ORP probes are installed, control of ORP can be overridden if pH exceeds certain high/low limits. These limits are set up on the Control Overrides screen in the Configurator. • • • •
No flow Zone Interlock pH/ORP Other overrides can be added
IMPORTANT:
11.7.2
Whenever any alarm condition occurs the general system alarm relay is activated. A specific alarm email is sent (i.e. “pH High 7.9”) if the controller is connected to the Nalco web site.
Alarm Screens
Alarms can be set for two fluorometers, two pH or NCSM sensors, three RTD’s, and four analog inputs. High and Low Alerts and Failsafe Alarms can be set up for all inputs. High and Low Failsafe Alarms cannot be set up for inputs used for monitoring only.
• • • •
Use the ⇓⇑ arrows to desired sensor. Enter Select Use the ⇓⇑ arrows to select the parameter. Enter Edit Use the desired value (use ⇓⇑ arrows to toggle between choices or 0-9 to enter a value. Enter ACCEPT.
Note:
Make sure all alarm parameters have been set prior to startup. Improper settings will adversely affect performance of controller and boiler system
Note:
Additional information on setting up Alarms and Alerts is provided in Appendix H.
11.8
Network Screens Menu
Control Settings
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Alarm Settings
Network
Preferences
Input Types
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ The Network submenu screen accesses the network settings of the two Ethernet ports. Before making changes to the network settings check with your local Network administrator or ISP provider. Any changes made must also be made in the configuration program! IP 1 or 2……………………… Mask 1or 2………………… Gateway 1 or 2………………
Displays the current controller IP address. Indicates the controller subnet address. Indicates the controller default gateway address.
SCADA mb_baud …… mb_bits …….. mb_par ……... mb_stop ….… Note:
11.9
Selects the SCADA Serial Baud Rate (1200, 2400, 9600, 19200, 38400, 57600, 115,200) Selects the SCADA Serial Data Bits (7 or 8) Selects the SCADA Serial Parity (0=None,1=Odd, 2=Even) Selects the SCADA Serial Stop Bits (1 or 2)
Default is 19200 baud, no parity, 8 data bits, 1 stop bit (19200, n, 8, 1)
Preference Screens Menu
Control Settings
Alarm Settings
Network
Preferences
Input Types
. 11.9.1
Units Screens
This screen is used to change from gpm to lpm, °F to °C, etc
11.9.2
Date Screens
This submenu is used to display and edit general settings. The arrow keys can be used to navigate between fields with more than one setting (i.e., the time field has both hours and minutes). Time: Displays the clock setting in hours and minutes (24 hour format). Date: Shows the date setting in the format configured through the PC. Date Format: Selects the date format (M/D/Y, D/M/Y, Y/M/D).
11.10 Input Types Screens Menu
Control Settings
Alarm Settings
Network
Preferences
Input Types
Sensor input screens can be edited. They must be initially set up using the Configurator.
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• • •
Use the ⇓⇑ arrows to desired sensor. Enter Select Use the ⇓⇑ arrows to select the parameter. Enter Edit Use the desired value. Enter ACCEPT.
11.10.1 pH/ORP Input Screen There are two inputs for high impedance sensors. They can be set up as a pH or ORP input.
11.10.2 Analog Input Screen There are four input connections. They can be set up as 0-10 V or 4-20 mA (internal dip switches must also be changed).
11.10.3 TRASAR Fluorometer Screen There are two fluorometer input connections. The gain on the fluorometer can be set up as “High” for feedwater or “Low” for blowdown (future) Information
Actions
Alarms
Operating Data
Calibrate
Current Alarms
Digital Inputs
Manual Control
Control Relays
Test Send
Analog Outputs
Reboot
Versions Diagnostics
11.11
Shortcut Keys
Pressing the Actions key allows access to the following options.
Information
Actions
Alarms
A password must be entered to access all Actions submenus.
Enter Password….12345 (Default Password) The password has to be re re-entered after 10 minutes of inactivity.
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11.11.1 Calibrate Accesses the calibration screens for the fluorometer, pH, NCSM and conductivity. (See fluorometer and NCSM calibration procedures in Section 4. Conductivity and pH calibration procedures are included in the appendices)
11.11.2
Manual Control
Relays • Select the desired relay output. • Selects control relay mode (Manual – Off – Auto). • Manually activate or shut off relay • Set output to return to Auto after a period of time (m:ss) 4-20 mA Outputs • Select the desired 4-20 mA output • Selects control mode (Manual – Off – Auto). • Manually output a value (0-100%) • Set output to return to Auto after a period of time (m:ss) 11.11.3
Test Send
This communication test can be initiated from the controller display. A test data file using the configured setting is sent. 11.11.4
`Reboot
Enables a quick system reset.
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12.0
Communications and Data Management
The overall 3D TRASAR program incorporates a number of software programs and hardware systems to manage all of the information associated with the control of a boiler system. The diagram below shows the flow and interaction of this data with the various components.
12.1
3D TRASAR Boiler Optimizer
The 3D TRASAR Boiler Optimizer is a software program used to determine the right treatment program for your boiler system. Information entered in the 3D TRASAR Boiler Optimizer can be transferred to the 3D TRASAR Boiler Configurator to avoid duplicate data entry. Contact your Nalco representative for questions about the 3D TRASAR Boiler Optimizer.
12.2
3D TRASAR Boiler Configurator
The 3D TRASAR Boiler Configurator is a software program used to configure the controller, establish remote communication, download data, update controller firmware, and change control methods. Contact your Nalco representative for questions about the 3D TRASAR Boiler Configurator.
12.3
3D TRASAR Boiler Controller
The 3D TRASAR Boiler Controller is the hub for data collection used for reports, graphs, and alarms.
12.4
SCADA Systems
SCADA systems can be used to monitor various parameters of the 3D TRASAR Boiler Controller via 4-20 mA signals or RS-232-485 Modbus.
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12.5
3D TRASAR Web
The 3D TRASAR Web is a convenient way to check the status of your 3D TRASAR cooling water and boiler applications. Use the 3D TRASAR web to: • • • • •
View overall system performance. Create user account profiles and assign them to specific controllers. View alarm detail and enable alarms to be sent via e-mail. Generate customized reports. Download data to PC.
Downloaded data is compatible with Vantage V100. Data is sent to the 3D TRASAR Web every hour from the 3D TRASAR Boiler Controller via direct file transfer.
12.5.1
3D TRASAR Web Set Up
3D TRASAR Web is accessed through Nalco’s website (http://extranet.nalco.com/Extranet/start.asp). You must have a Nalco Extranet Account to enter the side. Contact your Nalco representative for information on how to obtain an extranet account. Click 3D TRASAR Web
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12.5.1.1 Create/Edit Users Create and edit user profiles in the personal information page. Select which e-mail addresses are to receive reports and/or alarm messages. Assigning a user to a controller (see section 12.5.1.2) will automatically request Nalco Extranet access for that user.
12.5.1.2
Assign Controllers (Data Sources)
Assign users access to view data on the website, grant or revoke Manager access to assigned users. You can also assign users to receive alarm emails (see Section 12.5.4)
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12.5.1.3
Manage Controller (Data Source) Setup Information
The data source management screen provides a view of important controller information such as facility location, serial number and communication settings. Enter a Customer Number (Sold To) and click Save to approve any Unapproved Controllers.
12.5.2
3D TRASAR Web Data
Use the 3D TRASAR Web to review multiple systems performance or view specific operating parameters for one controller. The “Performance Summary” page provides a high-level view of the state of every controller assigned to a user. You can filter on Customer Name and Data Source Type
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Both pages can be modified to display the parameters and information that you want to show.
12.5.3 3D TRASAR Web Reports The “Basic Report” page allows users to preview graphs, reports, and download data.
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Reports can be printed, emailed to the customer, exported to an Excel spreadsheet, or saved to 3D TRASAR Web for future use. Saved Reports can also be added to a Report Schedule to be generated automatically and emailed on a routine basis.
12.5.4 3D TRASAR Web Alarms Alarm information generated by the 3D TRASAR controller will be sent in an email to the 3D TRASAR web site where it will be forwarded to the specified user’s email address identified in their user profile on the Personal Information Page (see section 12.5.1.1).
Details on the last 50 alarms will also be available on the 3D TRASAR Web, along with information on probable causes and troubleshooting tips.
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12.6
3D TRASAR Wireless Gateway
The Nalco Global Gateway (Wireless) allows connectivity without the cost and trouble of a phone line installation. The gateway communicates through the public Cellular/PCS network via the Ethernet port of the controller. The gateway provides advanced security including NAT, plus a built in firewall to protect the controller from unauthorized access via the Internet. When properly installed and configured, the functionally of both the modem and local Ethernet port remain unchanged. It is important to verify that the gateway is right for your application. Verifying the site for the gateway is similar to finding a place in an industrial environment to make a cell phone call. Even the best cell phone on the market is of little use without an adequate, interference free, stable signal. Use the guidelines below to determine signal availability in your area. •
If you have access to a GSM/GPRS cell phone and can make a web/data connection from the location where the controller will be installed, there is a very high probability that the gateway will work from that location.
•
If you have a non-data GSM phone and can make a voice call from the location that the controller will be installed, there is a good probability that the gateway will work from that location.
•
If you cannot make a data connection or phone call, you will probably need the indoor/outdoor high gain antenna option (P/N 060-TR5284.88). The antenna does not come with a cable, which is sold separately in 25-foot (P/N 060-TR5284C25.88) and 100-foot lengths (P/N 060TR5284C100.88). This usually occurs when the controller is installed in basements, metal buildings, or next to electrical equipment.
Detailed installation and configuration instructions are included with the unit. Contact your local Nalco Representative for ordering information.
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13.0 Shutdown and Maintenance CAUTION-DANGER: 13.1
Before performing maintenance to any portion of the 3D TRASAR Boiler System shut down the unit following the procedures.
Shutdown
13.1.1 Combination TRASAR Fluorometer and NCSM System Shutdown Note:
The NCSM cell should be allowed to cool well below boiling water temperatures while under pressure. This will prevent the formation of bubbles in the reference electrode.
1. Slowly close the sample inlet valve on the top of the sample cooler. This line will be a high pressure and high temperature sample line so take caution. 2. Allow the NCSM assembly to cool before performing maintenance. Removing some of the insulation about the 3/8” stainless steel cross will hasten probe cooling. The NCSM probe should be less than 180°F. Cooler is better. 3. Remove the protective shield on the NCSM panel. When the NCSM temperature reads below 180°F (82°C) slowly close the NCSM inlet needle valve. There should be a double blocking valve arrangement upstream of the NCSM needle valve. Close these valves as well. CAUTION-DANGER:
Although the sample is cooled after the sample cooler the line is still under high pressure.
4. Slowly close the fluorometer inlet valve and the ½”, 3-way sample outlet valve. 5. Relieve the pressure in the high-pressure section of the sample line by very slowly opening the pressure bleed valve located below the pressure gauge on the NCSM assembly. Make sure the pressure gauge shows no gauge pressure in the NCSM cell before disassembling. Note:
If the pressure in the NCSM is relieved rapidly air bubbles will form in the Reference Electrode. It will need to be “Refurbished” before it can be put back on line.
6. Relieve the pressure in the low-pressure section of the sample line by slowly opening the grab sample valve located below the pressure gauge on the Sample Conditioning System. Make sure the pressure gauge shows no gauge pressure in the line. CAUTION-DANGER: The 3D TRASAR Controller must be “ON” until after pressure is relieved in the low-pressure section of the sample line. If not, the solenoid valve will be closed (normally closed valve) and the high-pressure section of the sample line will remain under pressure. 7. If maintenance is to be performed on the sample cooler. Shut off water to the cooler.
13.1.2 TRASAR Fluorometer Only System Shutdown 1. Slowly close the sample inlet valve on the top of the sample cooler. This line will be a high pressure and high temperature sample line so take caution. CAUTION-DANGER:
Although the sample is cooled after the sample cooler the line is still under high pressure.
2. Slowly close the TRASAR fluorometer inlet valve and the ½”, 3-way sample outlet valve.
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3. Relieve the pressure in the low-pressure section of the sample line by slowly opening the grab sample valve located below the pressure gauge on the Sample Conditioning System. Make sure the pressure gauge shows no gauge pressure in the line. CAUTION-DANGER: The 3D TRASAR Controller must be “ON” until after pressure is relieved in the low-pressure section of the sample line. If not, the solenoid valve will be closed (normally closed valve) and the high-pressure section of the sample line will remain under pressure 4. If maintenance is to be performed on the sample cooler. Shut off water to the cooler.
13.1.3 Note:
NCSM Only System Shutdown (without Sample Conditioning System) The NCSM cell should be allowed to cool well below boiling water temperatures while under pressure. This will prevent the formation of bubbles in the reference electrode.
1. Slowly close the needle valve on the discharge line. This line will be a high pressure and high temperature sample line so take caution. 2. Allow the NCSM assembly to cool before performing maintenance. Removing some of the insulation about the 3/8” stainless steel cross will hasten probe cooling. The NCSM probe should be less than 180°F. Cooler is better. 3. Remove the protective shield on the NCSM panel. When the NCSM temperature reads below 180°F (82°C) slowly close the NCSM inlet needle valve. There should be a double blocking valve arrangement upstream of the NCSM needle valve. Close these valves as well. 4. Relieve the pressure in the high-pressure section of the sample line by very slowly opening the pressure bleed valve located below the pressure gauge on the NCSM assembly. Make sure the pressure gauge shows no gauge pressure in the NCSM cell before disassembling. Note:
If the pressure in the NCSM is relieved rapidly air bubbles will form in the Reference Electrode. It will need to be “Refurbished” before it can be put back on line.
13.2
TRASAR Fluorometer Maintenance
The 3D TRASAR Boiler Fluorometer should be cleaned and calibrated every 90 days.
13.2.1
Clean TRASAR Fluorometer Flow Cell
1. Unscrew pipe plug on the tee located on top of the fluorometer. 2. Using the flow cell rush (P/N 500-P2817.88) provided with the Start-up Kit (P/N 500-BTSRKIT.88 or 500-BTSRKITLA.88, gently push the brush down through the opening and scrub the full length of the flow switch and fluorometer tube. CAUTION:
Be sure to wear the appropriate PPE (Personal Protective Equipment) when cleaning the flow cell. Check the reagent MSDS for details.
3. Flush the fluorometer cell with 60cc (twice) of deionized water using the syringe.
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13.2.2
Calibrate TRASAR Fluorometer
After cleaning is complete, calibrate the fluorometer (Refer to Section 4.8).
13.2.3
Check/Replace TRASAR Fluorometer Desiccant
The fluorometer uses a desiccant canister and a color-coded humidity indicator to ensure that the optics are not exposed to condensation. Monthly, check the color of the desiccant indicator on the front of the 3D TRASAR fluorometer.
• •
If the indicator is blue, desiccant does not need to be replaced. If the indicator is pink, unscrew the desiccant cover from the fluorometer and replace both the indicator (P/N 060-TR5223.88) and the desiccant canister (P/N 060-TR5222.88).
13.3
NCSM Maintenance
The NCSM probe requires little if any maintenance. See Sections 4.10 and Appendices B and C for additional information.
13.4
Sample Conditioning System Maintenance
The high-pressure SS filter and low-pressure cartridge filter should be cleaned (or replaced) periodically to ensure adequate flow to the fluorometer. On new installations purge the highpressure SS filter every day and inspect the low-pressure filter cartridge once a week. After the system has been in operation for a while they can be inspected less frequently. High-Pressure Filter Purge 1. Close the sample isolation valve on the inlet of the sample cooler. 2. Open the valve on the bottom of the SS filter housing for a maximum of 2 seconds. This short purge should dislodge any excess debris on the filter screen. CAUTION-DANGER:
The discharge line from the bottom of the SS filter MUST BE PLUMBED TO A SUITABLE DRAIN. DO NOT leave the valve open for more than 2 seconds. This may overcome the sample cooler’s ability to adequately cool the sample (trip the high temperature alarm) and may result in flashing
3. Close the valve on the fitting bottom of the SS filter housing. 4. Open the isolation valve on the inlet of the sample cooler. High-Pressure Filter Cleaning 1. Close the sample isolation valve on the inlet of the sample cooler. 2. Loosen the fitting bottom of the SS filter housing. Be careful to support the strainer body to minimize strain on the connecting tubing/piping. 3. Slide the purge line valve and tubing out from the fitting so the housing can be removed. 4. Unscrew the housing. 5. Unscrew the retaining screw that holds the filter element in place. Note:
The retaining screw, filter element, and upper and lower gaskets will drop from the filter when the bolt is removed. Be careful not to lose any parts.
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Slowly twist the housing (counterclockwise) to relieve pressure in the cartridge. Remove the housing by pulling downward. Pull the old filter cartridge out of the housing. Clean the housing. Install a new cartridge by sliding it over the center post.
6. Re-assemble the housing to the head and tighten securely. 7. Open the sample isolation valve on the inlet of the sample cooler. Sample Cooler Cooling coils require minimal maintenance other than periodic cleaning and regular checks for leaks. If hard water is used for cooling purposes, acid cleaning of the cooling waterside of the coil every 3 months is recommended. •
Use a dilute acidic solution consisting of 1 part acid to 3 parts water. Sulfuric acid (460S0800.75, 10% Sulfuric Acid) is preferred to minimize corrosion of stainless steel. DO NOT USE concentrated hydrochloric acid for cleaning, as high chlorides will pit stainless steel.
•
Occasional flushing of the sample lines is also recommended when a cooling coil is taken out of service. Note: Cleaning the sample cooler is facilitated if a tee with two isolation valves is installed on the inlet and outlet of the cooling water connections on the sample cooler. CAUTION-DANGER: If isolation valves are installed on the cooling water connections of the sample cooler the valves must be appropriately tagged and operators trained to ensure that cooling water flow is not stopped while hot boiler water is flowing through the sample line.
13.5
Conductivity and pH Probe Maintenance
Conductivity and pH probes should be inspected, cleaned and recalibrated once every month. (See Appendices F & G) CAUTION:
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Be sure to close sample isolation valves, carefully depressurize the line and cool the probes before performing maintenance.
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14.0
Troubleshooting CAUTION-DANGER: Remember the system you will be troubleshooting is under high temperature and pressure conditions in addition to the normal electrical hazards associated with the 3D TRASAR Boiler Control System. SAFETY-WARNING: Always keep Safety in the forefront of your mind and in every Troubleshooting activity you do. When it comes to your Safety, there is no room for risk taking, complacency, shortcuts and poor judgment when working around boiler systems
14.1
General System Troubleshooting
Problem
Possible Cause(s)
Solution
Controller does not power up when power switch is turned on.
Controller is not plugged in.
Plug in controller and switch it on.
GFI or circuit breaker is tripped or fuse(s) blown.
Reset breakers or replace fuse(s) as needed. Check power fuse inside controller box and replace if blown.
No Sample Flow
Controller not powered.
Connect controller to power AC power source, and turn power switch to On position.
One or more valves on the skid are closed.
Open all valves.
Sample filters or pressure regulator plugged.
Check in-line filter, cartridge filter, pressure regulator, faulty pressure relief valve, and other valves Clean or replace as needed.
High temperature solenoid closed.
Make sure cooling water is flowing through sample cooler at the required rate. Check to see if there is a high temperature alarm. Clear this alarm, if present. Verify the sample flow RTD is functioning correctly. Check the relay fuse for the sample conditioning control relay. Verify the solenoid switch is functional.
Flow switch nonfunctional.
Clean flow switch if fouled. Check flow switch wiring for proper contact. Replace flow switch. Confirm the Boiler system is operating.
Feed water pump is not operating.
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Problem There is No flow but the “No Flow Alarm” is not active
Possible Cause(s)
Solution
The 10-minute delay period has not passed.
The flow signal (as reflected on the display) must be absent for 10 min before the alarm will activate.
The flow is near the 200 cc/min setting of the flow switch, resulting in intermittent flow/no flow indications.
This will cause the 10-minute delay timer to reset each time flow is detected, preventing the alarm. Increase the flow.
Backlight turns off with keypad inactivity (to conserve power).
Press any key and verify the display lights.
Faulty display.
Replace controller.
The controller configuration is corrupt or missing.
Reload the controller configuration.
The controller operating firmware is corrupt.
Reload controller firmware. Replace controller.
All relays (and possibly) analog outputs are off
Interlock is active.
Verify the Interlock connection is connected properly (or jumpered, if not being used). Verify the mechanism connected to the controller interlock is working properly.
One or more relays or analog outputs are in Failsafe Mode
There is an alarm condition overriding normal operation of the associated relay or analog output.
Determine the alarm condition(s), and fix the operational problem causing the failsafe condition. Check the active alarms and adjust settings if needed.
One or more relays or analog outputs are not operating the chemical pumps
The jumper supplying power to the relay contact closure has been removed. In this case, the display will still indicate that the relay is On.
Check to be sure the relay (Hot) power jumper is connected properly.
The product level is above (or below for blow down control) the set point and control range.
The relay or analog output does not need to be on. This is the correct control response.
For Analog Outputs, the PID response may lag behind the system error. The pumps may not immediately turn On or Off, due to a long system delay response.
This may be normal. It is due to the system’s long lag time response. Retune the PID. Adjust the PID “I Term” factor (with caution).
Display backlight is off
Display blank but backlight is on
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Problem One or more relays or analog outputs are not operating the chemical pumps (continued)
Possible Cause(s)
Solution
There is a “No Flow” Alarm or “No Steam Flow” Alarm condition during which the relays and analog outputs may not operate (configuration dependent). In this case, the display will still indicate that the relay is Off and/or the Analog Outputs are in failsafe mode.
Check the active alarms and increase flow if needed.
A calibration is underway, during which the relays and analog outputs will not operate (respond to the process control variable). In this case, the display will indicate that the relay(s) are Off.
The associated relay(s) are in Manual Off mode. The associated analog outputs will be in Failsafe Mode.
The affected relay(s) is in Manual Off mode. In this case, the display will indicate that the relay is in Manual Off mode.
Using the keypad Menu item Manual Relay Control, return the relay to Auto mode.
Erratic Probe Faulty electrical respons connection(s) or e(s) incorrectly wired probes.
Check and correct any electrical wiring connection problems. Be sure to look at both ends of the probes. Verify the probe cable ends are attached to the correct terminals inside the controller. Check the probe wire (or cable) itself. If possible, perform a continuity test on the wiring connections. Replace defective connectors, wires, or cables.
Probe response/readings are not in a normal operating range, or are erratic.
Recalibrate probe.
Bad or missing Earth Ground connection.
Check all electrical connections from the plant electrical connection. Verify the controller has a good Earth Ground connection.
Sample Flow is erratic.
Increase or decrease the sample flow rate as needed to achieve a proper (constant) sample flow. Check system for filter debris, partially closed or plugged valves, and pressure relief value. Check in-line filter, cartridge filter, pressure regulator, faulty pressure relief valve, and other valves
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Problem
Possible Cause(s)
Solution Clean or replace as needed.
Erratic Probe respons e (Contin ued)
Feed Water sample line probe has leaks
Chemical pump not pumping when controller is powered up and turned on
Configurator cannot communicate with controller using a direct connection
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Feed Water sample line is not insulated or poorly insulated.
Check Feed Water sample line to be sure it is properly insulated from sample take-off to the 3D TRASAR Feed Water sample cooler inlet.
Wrong sample location.
Verify the sample point is correct and is located downstream the proper length after injection of DO scavenger and/or TRASAR products.
Loose nut, loose fitting, over-tightened fittings, or improperly aligned fitting.
Tighten all leaking fittings.
Feed Water sample line develops pinhole leak.
Valve off the section with leak and replace with new stainless steel tubing and proper fittings. Open closed valve(s) upon completion to confirm leak is fixed.
Chemical pumps not wired into the controller. Faulty or bad wire or terminal connection.
Verify the pump(s) are wired correctly to the controller. Verify pumps work in manual mode.
Chemical feed pump(s) broken/pump fuse blown/ vapor locked etc.
Check to see if pump is working. Fix any vapor lock problems/blown fuses etc. If pump is not operational, replace with new one
Controller Relay is faulty and/or fuse blown
Replace relay and/or blown fuse. Pump amp draw is too high (over 2 amps). A “motor starter” relay box must be added.
Controller is not configured properly to activate pumps
Check the configuration to be sure it is set up properly to have chemical feed pumps active in either manual, on-off or PID control with proper set points/pump limiters, alarms etc.
A standard network cable is being used instead of a crossover network cable.
Replace the network cable with a crossover network cable for connections between the Ethernet Controller (bulkhead) and PC.
The Ethernet crossover cable is not connected securely to the controller (connector on the side of the controller) and/or the PC Ethernet port.
Check all connections and replace the external Ethernet cable if damaged
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Problem
Possible Cause(s)
Solution
The internal Ethernet jumper (straight-through) cable is not connected securely to the Ethernet bulkhead connector or circuit board connector.
Disconnect and reconnect each end of the Ethernet cable.
The PC network adapter (Local Area Connection adapter) is not configured properly.
The default network settings for the controller direct connection are IP Address 169.254.1.2, Subnet 255.255.0.0.
The IP Address being used by the Configurator is incorrect.
The default IP address for the controller direct connection is 169.254.1.2. In the Configurator's Connection Window, verify this is the IP address being used in the connection attempt.
The analog phone cable is not connected securely to the controller, PC, and/or wall jacks.
Check all connections and replace the phone line if damaged.
The phone line is not functional for dial in.
Try dialing the number using a landline or cell phone to see if the controller answers. If it does not, connect an analog phone to the line in place of the controller and dial the number again using the same landline or cell phone. The phone should ring if the call is coming through.
The phone line is in use.
This can happen if the controller is dialing out to send an email or if another party is connected to the controller via modem. Try again later
The phone number used by the PC is incorrect
Check the phone number you are dialing.
With a modem connection established, the Configurator cannot communicate with the controller
The IP Address being used by the Configurator is incorrect.
The default IP address for the controller modem connection is 192.168.2.1. In the Configurator's Connection Window, verify this is the IP address being used in the connection attempt.
Connection can not be established to controller remotely via Wireless Gateway
Wireless signal interrupted due to Carrier related problems or weather etc
Call carrier to see if they are having a problem. Wait a while and try accessing the controller again
Configurator cannot communicate with controller using a direct connection
A connection cannot be establis hed to the controll er via modem
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Problem
Problem downloading and/or uploading using USB connection
Alarm emails are not being received from Nalco web site.
Controller data cannot be viewed at Nalco web site.
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Possible Cause(s)
Solution
USB thumb drive out of space
Clear sufficient memory space on the USB thumb drive. Use a USB thumb drive, which has sufficient memory.
USB thumb drive version may not be supported
Use a different USB thumb drive brand.
Analog phone line is not connected.
Check all connections and replace the phone line if damaged.
Phone line is not functional for dialing out.
Connect an analog phone to the line in place of the controller and attempt a local call.
Controller is not configured to send alarm emails.
Check the Alarm Settings to be sure the email checkboxes are checked.
Email addresses are misspelled/incorrect.
Recheck email addresses for spelling or other errors. An example of the email address format is
[email protected].
ISP access phone number is entered in wrong format.
Check the phone number to ensure that it is entered exactly as the controller will dial it, including prefixes (8 or 9, 1+area code). The character ‘p’ may be used as a pause.
Controller email address is invalid.
Although the controller cannot receive emails, it has an email address that is used in the “from” field of the emails it sends out. Often, the ISP will require that this address be the one issued to the ISP account as a security measure (i.e.
[email protected]). In all cases, the domain of this address (earthlink.net in the example above) must be an actual domain, or the emails will fail.
ISP settings are incorrect.
Check the following settings: username, password, DNS server, access phone number.
Analog phone line is not connected.
Check all connections and replace the phone line if damaged.
Phone line is not functional for dialing out.
Connect an analog phone to the line in place of the controller and attempt a local call. Enter cell phone number as the ISP access number. Remove the system interlock jumper. Your cell phone will ring if the phone line is functional
Controller is not configured to send data emails.
Check the Email Settings to be sure the Send Data Email parameter is set to Yes.
ISP access phone
Check the phone number to ensure that it is entered
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Problem
Possible Cause(s)
Solution
number is entered in wrong format.
exactly as the controller will dial it, including prefixes (8 or 9, 1+area code). The character ',' (comma) may be used as a pause.
Controller email address is invalid.
Although the controller cannot receive emails, it has an email address that is used in the "from" field of the emails it sends out. Often, the ISP will require that this address be the one issued to the ISP account (i.e.
[email protected]). In all cases, the domain of this address (earthlink.net in the example above) must be an actual domain, or the emails will fail.
ISP settings are incorrect.
Check the following settings provided by your Nalco Rep: username, password, access phone number.
Controller has not been registered at 3D TRASAR Web
The controller must be registered at 3D Trasar.com in order to view the data. The user should be prompted to do this during initial configuration. In the Configurator, this is also accessed through the Edit menu. Call 630-305-CHEM
Probe reading is displayed as dashes
A Sensor Error is active
Check probe connections in controller.
Product levels (ppm) are displayed as dashes.
A Fluorometer Communication Error is active.
Tighten the connector on the Fluorometer probe and check the Fluorometer cable connections in the controller. Replace cable if damaged.
Value of -999 is logged in data log.
The measurement is invalid.
A sensor error or some other condition is present, which is causing the measurement to be invalid. Check the active alarm list on the display.
System rebooting/not fully powered up after restart
If reboot occurs close to normal logging time, a value of –999 may be found.
Controller data cannot be viewed at Nalco web site.
Check probe is calibrated and working properly, if not replace probe
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14.2
TRASAR Fluorometer Troubleshooting
Problem Display does not show TRASAR reading when controller is powered and on
Wrong sample point hooked to the 3D TRASAR unit
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Possible Cause(s)
Solution
Chemical feed pump not pumping TRASAR product.
Check that the chemical feed pump is pumping chemical into FW and if not fix it. Confirm TRASAR is present in FW sample using a recalibrated handheld or pen Fluorometer.
Wrong sample take-off point hooked to 3D TRASAR for Boilers system.
Confirm take-off point is the FW or blow down line. FW take-off location should be downstream of the TRASAR injection point at least 10 pipe diameters.
Fluorometer not wired into the controller or the wiring is loose/disconnected and/or poor electrical contact at terminal junction
Check cable/wire is attached properly at Fluorometer. Check for loose/disconnected wires and fix. Make sure Controller is shut off and unplugged before inspecting for loose wires and reconnecting them. Remove any unnecessary insulation form wire to insure good electrical contact. Afterwards plug in controller and turn it on.
Fluorometer cable/wire is faulty
Check Fluorometer cable/wire and if bad replace it
Fluorometer is faulty, Fluorometer cell fouled
Check calibration, clean cell and recalibrate Fluorometer as needed. Follow troubleshooting procedures in Fluorometer manual/section. If found faulty replace it.
These measurements do not appear in Operating Data if the probes are configured as Not Installed
Configure these probes as Monitor Only or Controlling.
Sample point is not on the correct boiler feedwater or boiler blow down line
Change sample point to correct location
Sample point is on the correct boiler FW line but not located down steam of the TRASAR or DO scavenger injection point.
Move sample take-off point downstream of TRASAR product and/or DO scavenger feed point the proper length to achieve complete mixing of the products in the FW.
Sample point is down stream of DO scavenger and/or TRASAR product injection point but is not far enough away to achieve proper mixing of the product(s).
Move sample point further downstream to allow complete mixing to occur.
Sample point is too far down stream of the product injection points and/or the sample lines are to long creating excessive lag time affecting monitoring and control performance.
Relocate the sample point and or shorten sample line length to reduce lag time.
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14.3
Alarm Screen Troubleshooting
1.)
Upon initial start-up measured levels may be low causing nuisance alarms. To prevent nuisance alarms see Start-up alarm suppression Appendix F.
2.)
To reset an alarm it is necessary to eliminate the alarm condition by either • Placing the control mode in “Off” temporarily • Adjusting the variable within the alarm limits • Or Changing the alarm limits
3.)
Always, check the source of all alarms. Many alarms are triggered by system conditions or valid measurements.
General Alarms Alarm Type Interlock Override
Low Sample Flow Failsafe
Indication The Interlock input has been deactivated
Insufficient water flow past the flow switch
Cause
Corrective Action
The Interlocking device is not active
Check. This may be expected operation
Interlock is not used and jumper is not in place
Replace jumper (refer to wiring diagram for location and direction)
Interlock wiring is loose or not making good connection
Check and correct wiring connections
Flow rate too low or blocked
Check and correct. Flow may be impeded by fouled filters.
A valve is partially closed/fouled
Open, clean and/or replace valve.
Flow switch is fouled
Clean flow switch
Flow switch wiring is loose or not making good connection
Correct wiring problem, replace flow switch as needed
Low Steam Flow Override
4-20mA input signal from Steam flow sensor indicates low steam flow
Boiler is not making sufficient steam
Check system. If alarm set point is too high, change the alarm set point.
Temp 1 High Alert Temp 1 High Override
Temperature of sample water exceeds alarm set point. Safety high temperature solenoid cut-off
The RTD following the sample cooler has detected sample water temperature exceeding alarm set point at some point.
Ensure cooling water is flowing and properly cooling the sample stream. Then, clear the alarm using the keypad or Configurator. The alarm must be cleared (does not automatically reset when cooling water resumes)
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General Alarms Alarm Type
Indication
Cause
Corrective Action
Temp 1 Low Alert
Temperature of sample water below alarm set point.
Cooling water temperature is low
Alert for possible freezing
Nubio Comm Error
The internal boards are not communicating.
There is a loose interboard connection
Turn power off, and gently press on all the white inter-board connectors inside the controller to verify connections
Component failure
Reboot system by cycling the power. If unsuccessful contact Help Desk at 630-305CHEM.
NCSM Alarms Alarm Type
Indication
Temp 2 High Alert
Sample temperature exceeds alarm set point.
Temperature 2 Low Alert Temperature 2 Low Override
Sample water temperature below alarm set point
ORP High Alert ORP High Failsafe
The measurement exceeds high alarm threshold
Cause
Corrective Action Check if system operation has changed
There is no sample water flow past the ORP probe.
Check if Boiler system is down and there is no feedwater flow. Check if sample flow is restricted (before and after the probe). Check for fouled valves and filters.
The RTD is faulty
Verify probe by checking the temperature of a known sample. Check wiring.
Scavenger feed cannot keep up with REDOX stress
Check if scavenger tank is empty/pump has lost prime/faulty pump or valve Check if pump rate is too low Check if there is operational stress on the Boiler water
ORP reading inaccurate
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Check ORP probe and detection as described
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TRASAR Alarms Alarm Type Fluor Comm Error
TRASAR High Failsafe Alarm
Indication Controller is unable to communicate with the fluorometer.
TRASAR fluorescence measurement exceeds high alarm threshold
TRASAR High Alert
TRASAR Low Failsafe
TRASAR fluorescence measurement below low alarm threshold
TRASAR Low Alert
Cause
Corrective Action
Cable connection on fluorometer is loose
Disconnect and inspect for bent pins or other damage and reconnect
Fluorometer wiring is loose or miswired
Check and correct (see wiring diagram)
Component failure
Reboot system by cycling power. If needed contact Help Desk at 630-305CHEM.
Chemical feed rate too high causing overshoot
Reduce chemical feed rate (pump)
Chemical being fed to a low flow area, when circulation resumes, there is overfeed
Move chemical feed point to a location with less lag time
Chemical pump siphoning causing overfeed
Eliminate condition causing siphoning
Fluorometer is out of calibration, fouled or faulty.
Check calibration. Clean and recalibrate. Replace if faulty.
Product container empty
Refill / replace product inventory
Chemical feed rate too low causing overshoot
Check feed line or increase chemical feed rate
Fluorometer is out of calibration, fouled or faulty
Check calibration, clean and recalibrate. Replace if faulty
Low Alarm threshold set too high
Readjust alarm threshold/set-point
Cell Fouling High/TRASAR FS Cell Fouling High Alert
Measurement exceeds high alarm threshold
Fluorometer flow cell is fouled
Clean fluorometer flow cell brush and cleaning solution. Recalibrate.
Turbidity High/TRASAR FS Turbidity High Alert
Measurement exceeds high alarm threshold
Particulates in sample water— filter fouled.
Check cartridge filter and replace if necessary.
Sample water has air bubbles
Adjust positions of fittings to prevent bubbles in sample line.
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Conductivity, pH, Temperature, NCM100, Analog inputs High/Low Level Alarms
Alarm Type High Alert High Failsafe
Low Alert Low Failsafe
Indication Measurement exceeds High Alarm threshold
Measurement below Low Alarm threshold
Cause
Corrective Action
Chemical feed rate too high/Low
Adjust pump feed rate. Refill chemical tank.
Process leak or other contaminant in system
Confirm (with other data) and eliminate source
Chemical pump siphoning causing overfeed
Eliminate siphoning
Sensor probe is out of calibration, fouled or faulty
Clean and recalibrate if needed. Replace if faulty
Chemical feed rate too high/Low
Adjust pump feed rate. Refill chemical tank.
Process leak or other contaminant in system
Confirm (with other data) and eliminate source
Chemical pump siphoning causing overfeed
Eliminate siphoning
Sensor probe is out of calibration, fouled or faulty
Clean and recalibrate if needed. Replace if faulty
Wiring or other connection is loose.
Retighten wires. Make sure insulation is not impeding electrical contact
Probe failure
Replace probe
Sensor alarms Sensor Error
Error detected with indicated sensor probe
Control Outputs (Relays or analog outputs) Relay Timeout Analog Output Timeout
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Duty cycle for relay or analog output exceeds alarm limit for the timeout period.
Tank empty/Pump lost prime/faulty pump or valve
Check tank, pump, valve, feed line. Repair as needed Confirm with other data and correct/eliminate problem(s)
Relay timeout limit/duty cycle set too low
Readjust alarm threshold/duty cycle
Feed rate too low for demand
Readjust pump rate
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14.4
NCSM Troubleshooting
NCSM Field Troubleshooting * NCSM Accessory Kit * NCSM mV Tester * Multmeter
Initial Installation Problem?
Replacement probes and acclimation
Probe reads (-/+) opposite of expected ?
Check for proper electrical grounding.
NO
Check configuration vs. wiring.
Check system MOC factors
* Ensure insulation stripped and connections tight * Ensure TB11 used for ORP #1
Correct wiring
Is wiring correct?
Intentional configuration change?
Remote NCSM (BL5200)?
YES NO Check probe response to pump change.
YES * Must use pre-amp cable * Check/replace battery (6V) * Check J-Boxes for mixup * Wire must be < 1000 ft
NO
NO
YES
Cables passed test?
Test REF, ORP & RTD cables.
Ensure proper NCSM configuration and correct wiring
YES NO
YES Reading OK when pump turned off? NO
YES
Check pump: * No chemical, valve closed * Air locked * Off or in manual control * Wiring damaged * AC drive setup changed/wrong * Fuse or motor problem
Check sample line: * Valve open * Flow 200-500 cc/min * Flow steady * No leaks * 1/4" line < 100 ft
Passed REF probe test?
NO
Passed REF probe test?
Defective REF probe, replace
Test ORP probe continuity
YES
Refurbish REF probe & Test
YES
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Defective circuitry, replace controller
Clean ORP probe & test with mV stds
ORP probe passed continuity test? Passed test with mV std?
YES NO
Ver 2.2 12-22-08
Replace the defective cable or wire.
Passed TB11 and -1024mV tests? NO
NO Refurbish REF probe & Test
Perform TB11 short circuit & -1024mV tests
YES
Correct pump problem
NO
YES
System MOC explains readings?
NO
Check for correct BNC connections. ALL must be completely dry.
Swap TB11 ORP wires
YES
YES
Visually inspect probe for damage or debris.
Pump OK?
Existing Unit 1. System MOC 2. Scavenger Pump 3. Probe Cables 4. Probes
NO Must use most recent configurator version.
New Probes?
Probes OK
New Install 1. Grounding Problems 2. Wiring & Configuration 3. Sample Line 4. Scavenger Pump 5. Probes
* Alcohol & 1:1 HCl * Fresh ORP mV Stds * Beakers (3) & swabs * DI water squirt bottle
YES
NO
YES
Problem Cause Probability Ranking
Troubleshooting Equipment
Start
Defective ORP probe, replace
NO
YES ORP Probe OK
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14.4.1
Factors that Affect Corrosion Stress and NCSM Control Ranges
MOC Factors
Factor Condition #1
Affect on Corrosion Stress
Factor Condition #2
Affect on Corrosion Stress
System design
For example no DA
Tend to be in higher NCSM operational zones
Have DA
Lower NCSM achievable
System design
Complicated flow patterns
Increases
Simple flow path
Decreases
Metallurgy (copper)
No copper
Can operate at higher NCSM zones
Copper used
Need to operate at lower NCSM zones
Dissolved oxygen ingress levels (baseline)
High
Increases
Low
Decreases
Dissolved oxygen level of makeup and condensate return
Increasing DO Levels
Increases
Decreasing DO Levels
Decreases
Other chemical additions (e.g. pH)
Lower pH(T) metallurgy specific
Increases
Higher pH(T) metallurgy specific
Decreases
Metal passivator levels
Decreasing
Increases
Increases
Decreases
Process contaminant leaks (system and contaminant specific)
Oxidant in leakage
Increases
Reductant in leakage
Decreases
Temperatures of makeup and condensate return
Decreasing
Increases
Increasing
Decreases
NCSM Temperature
Lower
Increases NCSM values
Higher
Decreases NCSM values
Flow
Often Increasing flow
Increases
Often Decreasing Flow
Decreases
Increases
Good mechanical operations
Decreases
Mechanical effects (e.g. Deaerator (DA) tray Bad DA Operations alignment DA venting
Poor
Increases
Good venting
Decreases
DA steam supply
Bad DA Operations
Increases
Good supply
Decreases
Condensate versus makeup ratio
Often Low
Increases
Often High
Decreases
Feedwater pump problems
Air in leakage
Increases
None
Decreases
Changes in feedwater (FW) flow
Often High
Increases
Often Low
Decreases
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MOC Factors
Factor Condition #1
Affect on Corrosion Stress
Factor Condition #2
Affect on Corrosion Stress
Changes in feedwater (FW) steam load
Often High
Increases
Often Low
Decreases
Scavenger residence times
Low
Increases
High
Decreases
Scavenger concentrations (system specific)
Decreasing
Increases
Increases
Decreases
Scavenger used
Weaker
Increases
Stronger
Decreases
Catalyst presence
NO
Increases
YES
Decreases
Scavenger pump issues
Problems (in leakage/binding)
Increases
None
Decreases
Real time system variations (minutes seasonal – yearly)
Variable conditions
Increases
Stable Conditions
Decreases
Real time system variations (minutes seasonal – yearly)
Frequent startup and load changes
Increases
Base loaded, stable operations
Decreases
High purity demin boiler FW (all iron based metallurgy)
Anion ingress (chlorides and sulfates)
Increases (must operate at lower NCSM)
Higher purity water
Decreases (can operate at higher NCSM)
14.4.2
Replacement NCSM Probes
When NCSM probes are replaced there will probably be differences between the readings from the probes that have been in the system for months and the readings from the new (freshly installed) probes. Any new NCSM probe will take some brake-in time to become acclimated to the boiler feedwater system. This is usually several days. The virgin probes are at their most sensitive state when first installed. This explains in part why they do not line up perfectly with the old probes. In fact the new probes are more accurately reading the oxidizing power of the feedwater than the old probes. This is especially true if the older probes haven't been refurbished in several months and the Pt probe has not been cleaned except for a light wiping off with a paper towel. Probes should be cleaned and refurbished every 6-12 months. The older probes are bound to also have copper and iron corrosion products silted on the active Pt portions. Over time difference between the new probes and old ones should decrease as the new probes become more conditioned to the system.
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14.4.3
Cables
There are various cables and options: • •
RTD cable wired directly to controller. NCSM combination cable wired directly to the controller. The cable is labeled “ORP” and “Ref” to indicate probe connections. • RTD cable wired to a junction box and signal wiring from the junction box to the controller (up to 1000 ft away). • NCSM combination cable wired to a junction box and signal wiring from the junction box to the Controller (up to 1000 ft away). This NCSM combination cable contains an integral operational amplifier (‘black box’ with a 6V battery). Are cables wired-up correctly to ensure electrical signal transference? Verify the connections, look for wiring insulation inside the green 2-pin connector (bad connection), make sure the stripped wire is not broken off, make sure the connections are tight, make sure the exposed input wires cannot touch each other above the green 2-pin connector, etc. ORP/REF Cable Short Circuit Test Connect the REF and ORP cables using the female-to-female BNC fitting supplied (in accessories kit). Controller should read 0 mV +/- 2 mV. • •
If the reading is zero, then the ORP cable should be OK. If the voltage is not 0 mV in the short circuit test then run the following test: Remove the (+) and (–) inputs to the ORP input (green 2-pin connector) and short circuit the connector with a paper clip (or small piece of wire). Re-insert the green 2-pin connector into the appropriate ORP input slot. The ORP reading should be zero. o o
If this reading is non-zero the 3D TRASAR controller is defective - return to Nalco. If this reading is zero (± 2 mV) then suspect a problem with the NCSM cable. Recheck the cable and all connections (including the battery in the integral Op Amp cable) before requesting an alternative cable.
For long wired installations: >6 ft where the integral operational amplifier is in use, the same continuity checks are needed. Added issues that are of concern here are checking all connections in the ‘6-wire wiring junction box’ and also making sure that no wires have been crossed from the junction box to the 3D TRASAR controller. • •
Failed short circuit test with long wires and female-to-female BNC fitting across the “ORP” and “REF” BNC cables. Replace the 6V battery and repeat the test. Failed tests with long leads but not the short circuit test right at the controller. Start by replacing the 6 ft ORP/REF cable with integral Op Amp and repeat the test. Next check/replace the long signal wire from the 6-wire junction box to the controller.
RTD Cable What does the controller read with disconnected RTD leads? • It should display “---“ for a temperature. If user cannot read temperature correctly once RTD leads are connected? • Make sure that all four RTD wires are connected correctly within the controller. • Make sure that the RTD BNC cable is connected to the correct portion of the integral ORP/RTD probe. That is the BNC will be in the horizontal alignment with the floor. o
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Now does the RTD reading give a temperature reading (sample temperature or ambient temperature if no water is flowing through the skid)? YES – OK. No, continue…
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•
Make sure the Configurator is properly configured with the appropriate 4-wire RTD inputs. Make sure that the RTD wires are correctly wired into the 3D TRASAR controller RTD inputs. Recheck this as wiring inputs can often be wired incorrectly as well as come loose. Long cable installs (> 6 ft): Make sure that if the wiring junction box is used that all wires are correctly translated and not crossed-over, from the local junction box to the remote controller. Still problems, then user can plug any other 4-wire RTD (like the RTD #1 used for the SCS sample conditioning temperature), into the respective RTD input (like RTD #2). If this reads the SCS temperature correctly (now on RTD #2 output), but the NCSM, RTD cannot be read correctly, then there must be a failure with the NCSM, RTD (assuming all RTD cables appear OK and are wired correctly) and the RTD/ORP combination probe will need to be replaced.
14.4.4
ORP TB11 and NCSM –1024 mV Tests
•
Open Circuit – No wires connected, or BNC fittings on cables unattached and loose (very slow movement of NCSM reading to -1246 to -1250 mV)
•
Shorted NCSM leads using the female to female BNC fitting supplied in the Accessories Kit leads (Controller should read 0 mV +/- 2 mV)
•
Shorted inputs on green-2-wire NCSM input in the controller box itself, on the high input impedance ‘red’ board (can use a wire or paper clip) (Controller should read 0 mV +/- 2 mV)
•
Insert the NCSM calibration tester (Nalco P/N 6033766) into the NCSM inputs, within the controller box (Controller should read -1024 mV +/- 2 mV when calibrator is turned on – green LED illuminated; Controller should read 0 mV +/- 2 mV when calibrator is turned off – green LED not illuminated). The –1024 mV voltage signal (from the ‘calibrator’) is not a high input impedance signal, so just because the voltage reads –1024 mV on the 3D TRASAR Controller does not mean that the NCSM will be displayed correctly if the ‘PROBLEM’ is with the high input impedance circuitry itself. Would need to return the Controller if it was suspected that the high input impedance circuitry had failed.
14.4.5
REF Electrode
An operational leak check: • •
Visually verify there are no leaks from any part of the REF Electrode. Is the base of the REF probe at ambient temperature during operation? The long SS tube, housing the REF probe should be at ambient temperature from its base to within about two inches of the SS cross cell. If YES it means that there is no leakage of sample water down the SS tube internals. If NO then suspect leakage from the REF base – and double-check. Resolve the leak. Replace the probe if needed. Verification checks on probe disassembly: • • • •
Follow the manual instructions for shut down (keep the NCSM under pressure as it cools below 180F). Remove the electrode and wipe off any extraneous material from the Teflon tube and probe top ceramic portion. Has the probe physical appearance changed from expected? Does the dark black/grey, silver/silver chloride tapered portion at the base of the electrode look good? It might be a flaky, browning, and scabbed in appearance (as viewed through the Teflon tube). While this REF might still work it is coming to the end of its useful life and a replacement is needed.
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§ •
If the electrode looks OK it is always good practice to check its reference potential (as in the refurbishing procedure) in this ‘removed state”. o If bubbles have developed check the electrode as described in the manual o Is the potential still about +90 mV during this check (must be at ambient temperature). If not the electrode might be too hot, so wait a while. This is a check prior to refurbishing the electrode for re-use. Refurbish the REF probe
Probe Refurbishing: • •
When was the REF probe last refurbished? What were the test results? (+90 mV +/- 15 mV?) If results were -90 mV +/- 15 mV suspect the wrong wiring configuration was used to check the probe (see next).
During normal operation the NCSM cables are connected as follows. In this configuration the reference electrode is connected to the negative terminal in the controller. Cable connections for standard operation Male BNC fitting (“Ref”)
NCSM Reference Electrode
Male BNC fitting (“ORP”)
NCSM Platinum ORP Electrode
When the potential of the newly refurbished electrode is to be measured against another known reference standard, the cables should be connected as follows: Cable connections for reference electrode check
•
• •
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Male BNC fitting (“Ref”)
“Standard” glass reference electrode
Male BNC fitting (“ORP”)
NCSM EPBRE Reference Electrode.
Is the porous ceramic junction, leaking electrolyte on refurbishing? – Do a few drops of 0.1 N KCl drip from the tip of the ceramic frit when mating the two portions of the electrode together? YES – OK NO - Soak electrode tip in DIW - must have electrochemical continuity through the porous ceramic junction. Replace the REF probe if this junction is plugged. Refurbish the probe and test.- OK? NO – Refurbish again. If there are still issues replace. A significant deviation from the desired (+90 mV +/- 15 mV, EPBRE versus glass, saturated KCL/ silver/silver chloride electrode supplied) could be a result of the following. o The 0.1N KCl solution is ‘bad’ – not really 0.1 N KCl anymore. – get new solutions. o NCSM REF Electrode is going bad and might need to be refurbished at the factory (rechlorodize the silver). If the reference electrode is not abused it should last for over 5 years. See physical appearance check above. o Poor refurbishing procedure (e.g. bubbles in the electrode – this tends to give open circuit responses). o Standard glass half-cell electrode has gone bad. It might no longer be filled with saturated KCl. If the electrode is stored “wet” (in saturated KCl) it can last for years. The internal filling solution can be replaced with the provided saturated KCl, also using the syringe, long SS filling tube, and refilling hole in the side of the glass electrode, usually covered with a rubber sleeve. o Controller malfunction. o Probes older than 5 years suggest replacing.
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14.4.6
ORP Probe Check
A standard multi-meter can be used to make sure that there is electrical continuity from the platinum band to the ORP central BNC pin (once the ORP probe has been removed from the 3/8” cross). A dry electrode should have no electrical continuity from the BNC central pin (of the ORP electrode) to any other part of the electrode housing which is made of stainless steel.
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14.5
PID Troubleshooting
14.5.1
PID Troubleshooting Table
Problem TRASAR PID tuning fails
NCSM PID tuning fails
Possible Cause(s)
Solution
TRASAR signal did not increase sufficiently during the first step change of tuning.
Increase the step change pump output value by 5% and/or the step duration by 5 min then repeat the tune.
Large variation in steam loads caused variation in TRASAR signal during tuning.
Repeat the tuning under steady steam load conditions. If the system typically operates with large steam load variation then repeat the tune with larger step change pump output %.
ORP values did not decrease sufficiently during the step change of the tuning.
Increase the step output value by 5% and/or decrease the baseline output (some value greater than 0%) and repeat the tuning. Examine historical data and consider if increasing the stroke length of the pump is a suitable option. If so, increase the stroke and repeat the tune.
TRASAR or NCSM is oscillating under PID control
No changes seen in TRASAR or NCSM during tuning
Unable to start PID control
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Significant change in steam load and operating conditions in the boiler.
If steam load shift or operational change is verified, then increase PB using the Configurator making it less aggressive.
Drop in sample flow rate through the skid. This can be confirmed by looking for a decreasing trend in sample temperature flowing through the NCSM probe
Adjust the sample flow rate. If desired flow rate cannot be established increase PB using the Configurator.
Pump may be in manual control set at the pump
Ensure that the pump is under analog control and connected to the analog output (4 to 20 mA) from the controller
Pump might be air locked. Chances are high if the pump stroke is low (typically less than 25%)
Increase the stroke temporarily and attempt to remove the air lock. Once pumping has been established return the stroke to the previous value.
There might be an alarm condition that is restricting PID control
If possible clear the alarm or wait for the alarm to clear by itself and then PID control will initiate automatically
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14.5.2
Interpreting and Troubleshooting Auto Tune Failure and Warning Messages
There are two types of messages appear at the end of an Auto Tune: •
Warning
•
Failure
14.5.2.1
Warning Messages
Warnings are only meant to indicate that the Auto Tune log did not observe the recommended conditions for a “good” tune. It indicates that though PID values were calculated, they may be less than ideal for the system. The user can proceed with the calculated values and upload them after understanding the warnings presented to them. a. TRASAR Product Warning Messages
Figure 1. TRASAR Product Tuning steps
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 Baseline Warning Messages: All display on the first line “Baseline data does not conform to recommendations”. A more specific message appears on the second line. Several warnings can be triggered at once. 6
80 TRASAR ppm Pump % 70
5
Warning message data
60
4
Pump %
TRASAR ppm
50
3
40
30 2 20 1 10
0
0
2/28/08 16:12
2/28/08 16:19
2/28/08 16:26
2/28/08 16:33
2/28/08 16:40
2/28/08 16:48
2/28/08 16:55
2/28/08 17:02
2/28/08 17:09
Time
•
“Baseline Zero TRASAR error”: If the baseline pump output is >0% and the TRASAR is reading 5000 lbs/hour (2268 kg/hr) use Continuous (On/Off) Control
•
If the Blowdown Rate < 5000 lbs/hour (2268 kg/hr) use Timed Sample Control •
If conductivity readings are stable when the control valve is open use Timed Sample Control – Continuous Interval Monitor Mode
•
If conductivity readings are inconsistent due to turbulent flow or steam flashing use Timed Sample Control – Proportional Interval Monitor Mode
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Boiler Blowdown Plumbing Survey OK
Fix The maximum temperature and pressure the conductivity probe can handle is 392ºF (200ºC) and 250 psig (17.2 bar). If the boiler operates at higher levels a sample conditioning system must be installed upstream of the conductivity probe to reduce the temperature and pressure. The motorized ball valve and flow control valve are installed downstream from the conductivity probe. Conductivity probe NOT installed between the valves. The flow control valve installed downstream from the motorized ball valve. Flow control valve installed within 12-18” (0.3-0.5 m) downstream of the motorized ball valve. Segment of piping downstream of the probe plumbed above the level of the probe cross to keep probe flooded. All isolation valves upstream of the conductivity probe are full-port and set to fully open. Larger diameter piping from the boiler transitions to the ¾” cross and probe without pipe segments of increased diameter (no wide spots in the blowdown line upstream and immediately downstream from the conductivity probe cross).. Flush valve installed on the bottom of the cross and probe closes properly. Conductivity probe installed such that flow is through the hole in the probe. The K-factor is stamped on a probe face with a hole. Probe cross in a horizontal pipe run at least 2 ft (0.6 m) downstream of any elbows are fittings that may cause turbulence. Probe NOT mounted on a vertical pipe run. Piping can be reduced to ½” diameter downstream of the conductivity probes on boilers with lower blowdown rate requirements if blowdown rate is less than 5000 lbs/hr (2268 kg/hr). Motorized ball valve mounted away from the boiler. So, it does not overheat the electronics. Piping runs upstream of conductivity probe kept short. So, flush times do not result in excessive boiler blowdown.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________
APPENDIX M
Boiler Saturated Steam Tables
Saturated Steam Tables Steam Pressure
Saturated Temperature
PSIG
Bar
Deg. C
Deg. F
10
0.69
116
240
15
1.03
121
250
20
1.38
126
259
25
1.72
131
267
30
2.07
134
274
35
2.41
138
281
40
2.76
142
287
50
3.45
148
298
60
4.14
153
308
70
4.83
158
316
75
5.17
160
320
80
5.52
162
324
90
6.21
166
331
100
6.90
170
338
110
7.59
173
344
125
8.62
178
353
130
8.97
180
356
140
9.66
183
361
150
10.34
186
366
160
11.03
188
371
170
11.72
191
375
175
12.07
192
377
180
12.41
193
380
190
13.10
196
384
200
13.79
198
388
225
15.52
203
397
250
17.24
208
406
275
18.97
212
414
300
20.69
216
421
325 350
22.41 24.14
221 224
429 436
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APPENDIX N
Modbus Communication Settings
Description The 3D Boiler SCADA application supports a very flexible Modbus addressing scheme. This configuration tool provides the User with the ability to translate 3D Boiler registers (data items) to Modbus registers with assignable addresses.
Modbus Communication Settings Modbus Node: The Node address is needed to uniquely identify the 3D Boiler controller slave device on the Modbus (serial) network. A Node address is needed for serial (RS-232 or RS-485) Modbus RTU half-duplex connections, but not for “Modbus over Ethernet” connectivity. Connection Type: This field is used to capture the Modbus connection type. The serial adapter converter options are: 1. Mod-TCP 2. RS-485 – Note: The IP Addr. and the Modbus Node text boxes are disabled for this setting because they do not apply to this communication method. 3. RS-232
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ Baud Rate: This is the number of distinct events made to the transmission medium per second in a digitally modulated signal or a line code. The list options are: 1. 1200 2. 2400 3. 9600 4. 19200 5. 38400 6. 57600 7. 115200 Parity: A method of error checking. The options are: 1. Odd 2. Even 3. None Data Bits: The number of data bites in the byte. The options are: 1. 7 2. 8 Note: RTU mode requires 8. ASCII mode is usually 7 but may be 8. Stop bits: The number of stop bits for each byte sent. The options are: 1. 1 2. 2 Note: The Modbus Node, Baud Rate, Data Bits, Parity, and Stop Bit input boxes are not active for ModTCP operation.
Modbus/SCADA Mapping Swap words within float and long data types: The Modbus message word order is configurable. The default (unchecked) order is Low Word/High Word ordering (Modicon default). Reverse byte order within words: The Modbus message byte order is configurable. The default (unchecked) order is High Byte/Low Byte ordering (Modicon default) Enabled: When the “Enabled” field is selected, the associated tag is enabled for Modbus register access. Signal Description: This is the User selection of 3D Boiler controller data tags. Signal ID: This is the default identification name given to the signal. Format: If the signal is enabled the options here would be: 1. Word 2. Float 3. Long Register Type: The memory address register type for the connection. The options are: 1. Holding Register (read only - integer/word variable) 2. Input Register (read only integer/word Boolean) 3. Coil Register (read/write - Boolean/bit variable) Note: This field is only enabled if the signal is enabled, otherwise the default option will be Input Register. Register Number: User assigned address number. This number must be between 0000 and FFFF (0 – 65535 decimal).
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 Scale Factor: A Floating Point number with a default value of 1.0. Notes: If “reading from” the 3D Boiler controller to the Master, the number pointed to by the associated “Signal ID” is “multiplied by” the Scale Factor. If “writing to” the 3D Boiler controller from the Master, the number pointed to by the associated “Signal ID” is “divided by” the Scale Factor. Remove: This button removes the device associated with the selected row. Add Mapping: The “Add New” button will add a new row to the grid. Only 1 blank row will be allowed in the grid at a time. Ok: Select this to save settings to the current configuration in memory. Cancel: Closes the current screen. NOTE: No pending changes made on this screen will be saved.
Misc Notes Modbus “Reference to Zero” Addressing All data addresses in Modbus messages are referenced to zero. For example, the Coil known as Coil 1 in a PLC is addresses add as Coil 0000 in the data address field of a Modbus message. So, all addresses are offset by one. Casting The “Signal ID” value can be cast to a different Modbus data type. Care must be taken when casting 3D Controller data types to different Modbus data types. Usually, a scaling factor must be included. Note: In most instances, Scaling and Casting data types should not be needed unless the end user does not support Longs and/or Floating Point numbers.
Register Types Coils: Boolean Words: 16 bits Longs: 32 bits, sent as 2 consecutive 16-bit words Floats: 32 bits, IEEE Single Precision Format, sent as 2 consecutive 16-bit words
Function Call Supported Coils Function Code 1: Read 1 or more coils Function Code 5: Write a single coil Function Code 15: Write multiple coils Input Registers Function Code 4: Read 1 or more input registers Holding Registers Function Code 3: Read 1 or more holding registers Function Code 6: Write a single holding register Function Code 16: Write multiple holding registers Register Types: Integers, Longs, Floats
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ Diagnostics Function Code 8 Diagnostics Code 00 Note: Return Query Data command loop-backs whatever data was sent it. ModTCP The 3D Boiler controller has 10 Megabit networks. There are two Ethernet ports (on separate networks in the 3D Boiler Controller) available for Mod/TCP communications. The Ethernet port will need to be set with the correct IP address and Subnet Mask for SCADA Master access. For ModTCP Slave mode, the controller Node address is not needed.
General Addressing Comments There are many different Modbus addressing schemes. Many systems use a numbering scheme to understand how to process the data (5000 = Longs, 7000 = Floats, etc.). The 3D Boiler will respond to the entered register number (be sure and remember the “Offset by One” rule specified by the Modbus specification). In many cases, it will be necessary to experiment with the configuration address mapping. The intent of the configuration tool is to let the end user select the Modbus addresses (no hard coded table). Assistance To assist in troubleshooting, a captured communications session (via 3 rd party tools) should be provided for analysis.
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APPENDIX O
Replaceable Battery Removal and Installation
WARNING: DO NOT attempt to service the unit at any time unless it has been powered OFF. Please follow Nalco’s and Site specific safety procedures before servicing this electronic device. Requires 2 Lithium Batteries Rayovac BR2335
Battery Removal Steps: Step 1: Before starting any work ensure gloves are worn and electrostatic protection is used.
Step 2: Locate power switch on side of unit and turn to ‘O’ (OFF) as shown.
Step 3: Remove power source for unit by dis-connecting wiring or simply unplug-ging, depending on how the unit is installed.
Step 4: Open the cover and locate the two battery assemblies in the upper left corner of the enclosure.
Step 5: Unplug the cable located directly above the batteries and set them aside.
Step 6: To remove the upper battery, grasp the top edge as shown and gently remove.
Step 7: To remove the lower battery, place a hooked object (90 degree pick) under-neath the exposed edge.
Step 8. Gently pull up the edge of the battery.
Step 9. Use a pick to grab the back edge of the battery and completely remove it.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ Step 10: To install the upper battery, hold the battery with “+” or positive side visible.
Step 12: To install the lower battery, hold the battery with the “+” or positive side visible.
Step 11. Gently slide it under the retaining clip until it is fully inserted into the holder.
Step 13: Gently slide the battery under the retaining clip.
Step 14: The battery must be fully inserted into the holder.
Step 15: Reinsert the cable battery assemblies. Check and confirm all steps have been correctly done. Turn the controller back ‘ON’. This completes the battery replacement procedure.
*Above procedure applies to 3D TRASAR Boiler Water Controllers with Serial #10561 and greater.
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APPENDIX P – Connecting 2 3DTRASAR Boiler Controllers to 1 NGG ver 1.0 Install the NGG The NGG must be powered and have 3 to 4 yellow signal bars and a cellular link light. Each 3DT boiler water controller will require 1 CAT5E LAN cables for each controller. Connect each CAT5E cable to Ethernet port #2 on both controllers See photo below for controller connections. The CAT5E cable for the 2nd controller will need to be connected to the NGG port switch.
Use the controller keypad to set the Network settings. Controller #1 Verify the IP settings on the controller. Press the Menu key on the control panel. Enter password. Select Network 2 by using the up & down arrows on the keypad to verify the settings below. DHCP is Disabled IP Address 192.168.001.003 Subnet 255.255.255.000 Gateway 192.168.001.001 If you need to make a change press the edit key & make changes as stated above. Reboot the controller & verify settings again. Controller # 2 Verify the IP settings on the controller. Press the Menu key on the control panel. Enter password. Select Network 2 by using the up & down arrows on the keypad to verify the settings below. DHCP is Disabled IP Address 192.168.001.004 Subnet 255.255.255.000 Gateway 192.168.001.001 If you need to make a change press the edit key & make changes as stated above. Reboot the controller & verify settings again.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ How to direct connect to a 3DT boiler water controller This will work for controller #1 and controller #2. No change has been done to the network Ethernet #1 setting Connect a crossover cable to the connection port on the left side of the 3D TRASAR controller. Using the 3D TRASAR Boiler Configurator and select the following: Import Configuration directly from a controller.
Use Direct Ethernet Cable from the drop down window The default IP Address for Ethernet # 1 will appear in the IP address window. This should only need to be changed if Ethernet #1 IP address has been changed in the controller network settings screen. Click on connect
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 Connecting remotely to a 3D TRASAR Boiler Controller that has a port number Using the 3D TRASAR Boiler Configurator select: Import configuration directly from controller OK
Select Wireless AT&T from the drop down To connect to the first controller Enter 1 and the NGG phone number and leave the Port # 80 Click on connect
To connect to the 2nd controller Enter 1 and the NGG number Enter the Port number in the Port number field The last number in the IP address is how to determine the port forward address. Contollers IP address = 192.168.001.003 = :3080 = NGG number 15001234567:3080 Contollers IP address = 192.168.001.004 = :4080 = NGG number 15001234567:4080 Click connect
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ Change the 3DTB controller phone number to show the port number While connected to the controller Select Communication Settings
Enter the connect Port # for the controller Click OK
For assistance call 630-305-CHEM (2436) Press #1 for the NGES Help Desk
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APPENDIX Q
Connecting a 3D TRASAR Cooling Controller and a 3D TRASAR Boiler Controller to 1 NGG ver 1.0
The 3DT cooling water controller requires 2 CAT5E cables The 3DT boiler water controller requires 1 CAT5E cables Only 2 CAT5E cables are supplied with the NGG these should be used for the 3DTC controller Extra materials required for the installation. To be used for the 3DT boiler water controller. • 1 CAT5E LAN cables that will reach from the NGG to the 3D TRASAR units. • 2 cord grips: One for the NGG and one for the 3D TRASAR unit. Install the NGG The NGG must be powered and have 3 to 4 yellow signal bars and a cellular link light. The cooling water controller CAT5E cable connections The 3D TRASAR Cooling Controller will require 2 CAT5E LAN cables (supplied with the NGG). See photo below for controller connections.
The boiler water controller CAT5E cable connections The 3D TRASAR Boiler Controller will require 1 CAT5E LAN cable. Connect the CAT5E cable to Ethernet port # 2 inside the controller. See photo below for controller connections. The CAT5E cable for this controller will also need to be connected to the NGG port switch.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ Use the controller keypad to set the network settings on both controllers The 3D TRASAR Cooling Controller network settings Controller #1 Verify the IP settings on the controller. Press the Menu key on the control panel. Enter password. Select Network by using the up & down arrows on the keypad to verify the settings below. o DHCP is Disabled o IP Address 192.168.001.002 o Subnet 255.255.255.000 o Gateway 192.168.001.001 If you need to make a change press the edit key & make changes as stated above. Reboot the controller & verify settings again. The 3D TRASAR Boiler Controller network settings Controller # 2 Verify the IP settings on the controller. Press the Menu key on the control panel. Enter password. Select Network 2 by using the up & down arrows on the keypad to verify the settings below. DHCP is Disabled IP Address 192.168.001.004 Subnet 255.255.255.000 Gateway 192.168.001.001 If you need to make a change press the edit key & make changes as stated above. Reboot the controller & verify settings again.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 How to direct connect to the controllers Controller #1 (3D TRASAR Cooling Controller) Verify the controller IP address. Press the Menu key on the control panel. Enter password. Select Network settings by using the up & down arrows on the keypad to verify the IP address. Contoller number 1 = IP Address 192.168.001.002 Connect a crossover cable to your PC and the connection port on the left side of the 3D TRASAR Cooling Controller. Using the 3D TRASAR Cooling Configurator and select the following: Import settings from existing controller
Use direct/Ethernet Connection
Click on Advanced and enter the correct IP address and password (default password is 12345). Click OK Click on Connect
Controller #2 (3D TRASAR Boiler Controller) No change has been done to Ethernet #1 network setting so direct connect as normal.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ Connecting remotely to controller that has a port number Controller #1 (3D TRASAR Cooling Controller) Using 3D TRASAR Cooling Configurator select: Connection method select: Use Wireless Gateway Enter 1 and NGG number 15001234567 Note if a port forwarding address is used it will need to be entered after the NGG number
To connect to the 2nd controller (3D TRASAR Boiler Controller) Using the 3D TRASAR Boiler Configurator select: Import configuration directly from controller Click OK
Enter 1 and the NGG phone number Enter the Port number in the Port number field leave the 80 The last number in the IP address is how to determine the port forward address. Contollers IP address = 192.168.001.004 = :4080 = NGG number 15001234567:4080 Click connect
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 Change the 3D TRASAR Cooling Controller phone number to show the port number While logged on to the controller Select Email Settings
Enter 1 and the NGG phone number and the correct port number.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ Change the 3D TRASAR Boiler Controller phone number to show the port number While connected to the controller Select Communication Settings
Enter the connect Port # for the controller Click OK
For assistance call 630-305-CHEM (2436) Press #1 for the NGES Help Desk
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APPENDIX R
3D TRASAR Boiler Automation System Pre-Installation Checklist
Customer Name: __________________ Location:________________________ Nalco Rep.:_______________________3DT Boiler Model #:________________ Installation can be performed by Nalco service technicians, a local contractor or by plant personnel, however, final assembly and startup can only be performed by Certified Nalco service technicians. Certified Nalco service technicians will return to tune the system’s control loops after operating conditions have been monitored long enough to characterize system dynamics. To insure you are aware of system installation requirements, a Certified Nalco service technician will schedule a preinstallation site walk-through visit using this checklist, identifying and addressing any questions or issues that might arise. It is our expectation that a copy of this checklist, with all applicable sections completed, will be provided to the customer and whoever will be doing the installation work.
3D TRASAR Boiler Control System Location The 3D TRASAR Boiler control system should be located where it won’t interfere with plant or mill floor traffic patterns. Based on the model ordered, you must insure that adequate floor or wall space is available in the selected location to properly install and securely anchored the system. Wall-mount systems should be anchored at a height that places the 3D TRASAR Boiler controller display at eye level. Always keep safety considerations foremost in mind. Remember, these units will be connected to a sample line containing hot, pressurized boiler feedwater. Additional considerations include: The control system must be oriented so that it can be easily accessed. Ideally, it should also be located as close as possible to the feedwater sample take-off point. If high (500 cc/min) sample flow rates can be sustained, the system can be installed farther away, however, maximum sample line run length should never exceed 100 ft (30 m). Space requirements:
•
Wall Mount Controller & Sensor Panel Dimensions: 12” D x 33” W x 42” H (31 cm x 84 cm x 107 cm)
•
Sample Conditioning System (SCS) Dimensions: 8” D x 33” W x 22” H (21 cm x 84 cm x 56 cm)
•
Frame Mounted System Dimensions: 29” D x 33” W x 66” H (74 cm x 84 cm x 168 cm)
NOTE:
Separate SCS panels, e.g., those supplied with wall mount units, will need to be mounted 1-1/2” below the controller panel so be sure to factor this into your size calculations.
Is the system installed far enough away (over 10 ft or 3m) from any high voltage source(s), e.g., large motors or any known generator of electrical noise? (Boiler feedwater pump motors may be excluded from this restriction.) The mounting location should be well lit and dry. When the system is to be installed outdoors, provisions will need to be made to protect the controller from direct sunlight and driving rain. An enclosed NCSM, rather than the standard Lexan plastic shielded version, must also be ordered for use in these type installations. In cold weather climates, provisions must be made to protect the cooling water and sample lines from freezing temperatures.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________ The identified 3D TRASAR Boiler automation system installation location should be near an electrical panelboard capable of supplying the system with up to 30 amps of grounded AC power at 85-250 VAC. If installing a model that includes a Sample Conditioning System, insure you have access to a reliable, continuously operating cooling water source. If you will be remotely-locating an NCSM (one without its own 3D TRASAR controller module), check to insure it will not be located more than 1000 ft (305 m) from the main controller. NOTE:
Do not mount control systems or devices on walls or surfaces where they will be subjected to vibration. Damage to critical components can occur that might cause spurious alarms or premature hardware failure.
Suitable Feedwater Sample Point Selection A single feedwater sample point is needed to supply a suitable sample to the 3D TRASAR Boiler automation system. This sample point should conform to all of the following criteria: 1. The preferred sample point location is on the discharge side of the feedwater pump/s where a representative sample of the feedwater supply to all boilers being controlled can be collected. This location must be downstream of the NexGuard and oxygen scavenger injection points. If you are unable to locate the sample tap at this location, continue to step 2, otherwise proceed to step 3 below. 2. Is the sampling point located downstream of and at a point where adequate mixing of the NexGuard and oxygen scavenger has occurred? In general, the sample point should be at least 10 pipe diameters downstream of the chemical injection point, preferably after at least one pipe bend. 3. A stainless steel sample quill that is long enough to collect a sample from a point approximately 2” from the inside wall of the pipe. The pipe must be installed through the side of the feedwater supply line. Be sure and select a quill insertion point that is fully flooded, i.e., at a point where no trapped air could interfere with collection of the sample. To minimize the potential for quill fouling, never sample from the bottom of a horizontal piping run. Also, since the deaerator drop leg supplying the feedwater pump/s is typically fully flooded, it is usually acceptable to locate the sample point in this run, otherwise, we recommend that you avoid locating taps in vertical pipe runs unless you are sure flow is upward, guaranteeing that the pipe is fully flooded where the sample is being collected. Further, insure an approved lockable valve is installed where the sample line connects to the quill (for lock out, tag out purposes). 4. If this is a utility boiler, contact the 3D TRASAR Help Desk (sample points must be thoroughly reviewed). 5. The selected sample point should be as close to the 3D TRASAR Boiler automation system location as possible. For best NCSM measurement results, the sample temperature must be as close as possible to the temperature of the water at the point it enters the feedwater sample quill, therefore, short sample line length is important. Short lines minimize both temperature loss and lag time - an important consideration when tuning system control loops.
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Sample Line Specifications A continuous sample line must be run from the shutoff valve at the feedwater sample quill to the NCSM inlet connection point on the 3D TRASAR Boiler automation system. Specific items to check include: If you plan to use existing sample piping runs, insure they are no larger than ¼” O.D. in size. Larger diameter tubing or piping of any size greater than 1/8” IPS steel will greatly increase sample lag time and adversely affect the performance of your new control system. Copper and other similar (non-ferrous) materials should never be used in construction of the sample line or for in-line components. If you will be installing a new sample line, we recommend that the sample line be constructed of ¼” O.D., Type 316 stainless steel tubing, with a nominal wall thickness of 0.035”. A secondary isolation valve should be installed at the end of the sample line, i.e., where it connects to the 3D TRASAR control system. It is also recommended that a bleed valve be installed at this location, connected in the line between this secondary valve and the block valve on the #D TRASAR Boiler automation system. This will enable service personnel to safety bleed pressure from the line as well as facilitating periodic flushing of the line. Insure that a pressure gauge is installed on the sample line between the lockable valve on the quill and the secondary isolation valve at the control system so the pressure in the line can be checked prior to maintenance. The sample line must be kept as short as possible. Ideally, the maximum run length should never exceed 40 feet (12 m), however, if sample flow rates of up to 500 cc/min can be sustained, e.g., when the system is installed on larger boilers, the maximum sample line length can be extended to 100 feet (30 m). NOTE:
During system operation, the sample flow rate and temperature must be kept constant to ensure accurate measurements and promote optimal dosage control. This will also help when troubleshooting problems that might arise during system operation.
You need to insure that the temperature of the feedwater sample reaching the NCSM probe is as hot as possible and representative of the temperature at the point the sample enters the sample collection quill. The NCSM measurements are made directly on the uncooled sample and are not temperature compensated, therefore, the sample line will need to be insulated from the take-off point all the way to the point where it connects to the sample conditioning system on the 3D TRASAR Boiler control system. Rolled insulation material is provided with the system and will be used to double wrap the sample line. For longer sample lines, additional rolls of insulation might be required - insure sufficient quantities have been ordered to complete the double wrap requirement. Note: The insulation wrap also serves a second purpose – it protects personnel from burns that could be caused if someone accidently touched the hot sample line. The sample line will need to be purged for 15 to 20 minutes immediately prior to connecting it to the 3D TRASAR Boiler System. This is done to blow potential contaminants/foulants from the line which is particularly important during the initial system startup, the time when the incoming sample is most likely to contain solids, e.g., dirt, oxides of iron, grease, installation debris, etc.,that could plug the filters and small orifices on your new control system. Insure everyone understands the need for flushing and that this will be repeated immediately prior to startup.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________
Sample Outlet Line The feedwater sample exits on the right side of the 3D TRASAR Boiler automation skid and should be piped to an open drain. If you plan to reuse this water, you can also route it to a suitable containment vessel and pump it back to the system, e.g., to an unpressurized condensate receiver. The following guidelines will help you install this line properly: To prevent siphoning and/or backflow, eliminate the potential for backpressure on the Fluorometer internals, as well as provide a place where a “grab sample” can be captured during system maintenance, insure that an air gap exists between the end of the sample discharge line and the open drain or containment vessel connection. Outlet line pipe rises greater than 10 feet [3m] should be avoided. If the discharge must be located above the system, a check valve must be installed in the discharge line to prevent backflow. IMPORTANT: You must insure that boiler water does not siphon back through the 3D TRASAR Boiler automation control system when there is no feedwater flow, e.g., when the FW pump/s is/are turned off. Siphoning could cause a high temperature alarm, suspend control action/s and shut down flow through the system, even if the Sample Conditioning System (SCS) is operating properly. Check to insure that the sample discharge flow will be unrestricted between the connection point to the control system and the open drain or containment vessel connection. Do not combine the discharge lines from multiple controllers into a common header upstream of the open drain or containment vessel. On NCSM models without sample coolers, the sample discharge line must also be insulated to protect personnel from the hot tubing. CAUTION! DANGER! The discharge from a NCSM not equipped with a Sample Conditioning System must be cooled and depressurized unless the system receiving the discharge can safely accept up to 500 cc/min of 2800 psi (193 bar) maximum, 500°F (260°C) boiler water.
Sample Cooling Water Requirements Cooling water (chilled water) must be provided if your new 3D TRASAR Boiler automation control system is equipped with a sample conditioning system. The sample conditioning system is designed to cool the incoming boiler feedwater sample to a temperature of less than 110°F (43°C) and to reduce its pressure to 50 psig or less. This is done to protect the control system and safeguard workers. Check that adequate quantities of chilled water will be available at or near the location selected for the controller. Typical flow rates of from 0.5 to 2 gallons per minute (2-7.6 lpm) will be required, depending on the cooling water temperature and sample flow rates. Nalco’s Sample Cooler Cooling Water Flow Requirement Estimator , version 1.0, can be used to help you more accurately determine how much cooling water flow will be needed. To prevent fouling, the cooling water supplied to the system must be free of suspended solids and miscellaneous debris. It must also flow continuously and at constant pressure. The supply side of this chilled water loop will need to be piped to the sample cooler water inlet connection that is located at the bottom of the sample cooler situated on the left side of the control system.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211 The cooling water discharge should be piped from the connection point at the top of the sample cooler to a nearby open drain or returned to the chilled water circuit for reuse, as appropriate. We recommend that the cooling water inlet and outlet lines, where connected to the sample cooler, be fitted with a tee and two valves. This will allow the cooling water to be drained and facilitate periodic maintenance of the cooler. Stainless steel valves should be used in case future descaling requirements necessitate acid flushing of the cooler assembly.
Chemical Feed Points & Chemical Pumps General: If selecting a new feed pump location, select a site that will facilitate interconnection with the 3D TRASAR Boiler control system, i.e., one that supports the necessary control and power wiring connections, yet is close enough to the chemical storage tanks to promote reliable pump operation. Internal Treatment (i.e. NexGuard) – For optimal control, this chemical should be fed into the drop leg of the Deaerator. A stainless steel injection quill long enough to inject the chemical near the centerline of the pipe should be installed at this feedpoint. If the injection point will be located in the Deaerator, insure its location won’t cause excessive (over 15 minutes) lag times as this could make automated control impossible. Insure the injection quill is located at least 10 pipe diameters ahead of a bend or elbow. Do not feed concentrated unmixed product immediately ahead of a bend to avoid FAC or erosionrelated corrosion. A correctly sized variable speed pump will be needed to feed the TRASAR internal treatment and/or pH (amine or caustic) adjustment chemical/s. This pump will need to be able to accept a 4-20 mA, 24 VDC control signal output by the 3D TRASAR Boiler automation system to vary the speed of the pump motor. If you plan to use an existing deaerator feedpoint, insure it is sited someplace other than in the dome or where high levels of dissolved oxygen are present. Oxygen scavenger (i.e. Nalco 1720, 1700, or ELIMINOX) – Best practices require use of a separate injection quill for this product, i.e., do not, if at all possible, inject it using the same quill as the internal treatment chemical. A correctly sized variable speed pump for Corrosion Stress (NCSM) control will be needed to feed the oxygen scavenger. This pump will also need to be able to accept a 4-20 mA, 24 VDC control signal output by the 3D TRASAR Boiler automation system to vary the speed of the pump motor.
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3D TRASAR Boiler Technology Installation and Operation Manual OM0211_________________________________________________________________________
Electrical Power One 120 VAC, 30 A, 60 Hz or, alternatively, one 120 VAC, 20 A, 60 Hz and one 120 VAC, 15 A, 60 Hz grounded and overcurrent protected branch circuit/s are required to power the 3D TRASAR Boiler control system (some models, destined for use outside the US, require 240 VAC, 15 amp power sources). Four separate AC power connections may be needed, depending on which system options have been ordered. If possible, a 120 VAC 4x4 outlet box, containing two grounded 120 VAC, 15 A and two grounded 120 VAC, 20 A receptacles, should be installed near the skid to power the system and its associated peripheral devices. If required by Code, component electrical connections might need to be run in EMT, rigid or Sealtite conduit and hard wired to each respective control system component. IMPORTANT NOTE:
The 3D TRASAR Boiler automation system MUST BE PROPERLY GROUNDED! Erratic instrument readings could result if the unit is poorly or ineffectively grounded.
NOTE: Separate 120 VAC power wiring should be run to each of the following control system components. Route the conductors into each box but be sure the installer is aware that we DO NOT want them terminated at this time. Have him label each set of conductors and leave each circuit de-energized, following applicable lock out, tag out guidelines. The Nalco Certified service technician who performs system assembly and startup tasks will be responsible for correctly connecting these conductors. Power Connection Specifications: 3D TRASAR Controller: 120 VAC, 20 amp, 60 Hz (240 VAC, 10 amp, 50-60 Hz) Blowdown Relay Box: 120 VAC, 10 amp, 60 Hz (240 VAC, 5 amp, 50-60 Hz) Analog Input Module: 120 VAC, < 1 amp, 60 Hz (240 VAC, ½ amp, 50-60 Hz) – comes equipped with a 6-ft long, 3-prong (15A) power cord Nalco Global Gateway: 120 VAC,
