Swas Penal Drawings PDF

STEAM & WATER
ANALYSIS SYSTEM
AS BUILT
DRAWINGS & DOCUMENTS
CLIENT : BHEL, TRICHY
PROJECT : BORL-BINA
YOUR REF : LOI DATED 29TH SEP, 2007
F.M. NO. : FM-JN-1007-041
O/A NO. : 1580003726

WHAT’S INSIDE
DESCRIPTION
1. P & I DIAGRAM OF SAMPLING SYSTEM
2. G.A. DIAGRAM OF WET PANEL
3. G.A. DIAGRAM OF DRY PANEL
4. FOUNDATION DETAILS
5. BILL OF MATERIAL
6. WIRING DIAGRAM
7. SPECIFICATION SHEETS
8. SIZING CALCULATION
9. TEST CERTIFICATES
10. SWAS MANUAL
i.exe
P & I DIAGRAM OF SAMPLING SYSTEM
G.A. DIAGRAM OF WET PANEL
G.A. DIAGRAM OF DRY PANEL
BILL OF MATERIALS
PROJECT : BORL Date : 19/03/2008
Page: 1/2
BILL OF MATERIAL FOR WET RACK
ITEM DESCRIPTION MAKE SPECIFICATION QTY PER QTY FOR

NO SHEET NO. UNIT 3 SETS
1a SAMPLE ISOLATION VALVE (HIGH TEMP) FORBES MARSHALL A4-11503-IBR 06 18
( IBR )
1b SAMPLE ISOLATION VALVE (LOW TEMP) FORBES MARSHALL A4-11509 02 06
2a SAMPLE COOLER – DHX-12 – IBR FORBES MARSHALL A4-11721A 02 06

2b SAMPLE COOLER – DHX-6- IBR A4-11721B 01 03
2c SAMPLE COOLER – DHX -18 –IBR A4-11721C 01 03
04 COOLANT FLOW INDICATOR FORBES MARSHALL A4-11550-3/4 04 12
5a COOLANT ISOLATION VALVE FORBES MARSHALL A4-11521 08 24
06 SAMPLE FILTER FORBES MARSHALL A4-11568 08 24
08 PRESSURE REGULATOR FORBES MARSHALL A4-11570 04 12
09 SAMPLE RELIEF VALVE FORBES MARSHALL A4-11581 04 12
9a SHELL RELIEF VALVE FORBES MARSHALL A4-11581-SH 04 12
10 TEMP. GAUGE( CAPILLARY TYPE ) GIC / H GURU A4-11615 04 12
11 PRESSURE GAUGE GIC / H GURU A4-11600 04 12
12 TEMPERATURE SWITCH SWITZER / INDFOSS A4-11635 04 12
14 SOLENOID VALVE ASCO / ROTEX A4-11671 04 12
PREPARED BY CHECKED BY APPROVED BY

Page: 2/2
BILL OF MATERIAL FOR WET RACK
ITEM DESCRIPTION MAKE SPECIFICATION QTY PER QTY FOR

NO SHEET NO. UNIT 3 SETS
15 REGULATING VALVE FORBES MARSHALL A4-11509-IV 20 60
16 ROTAMETER EUREKA A4-11700 08 24
17 TUNDISH FORBES MARSHALL ……. 04 12
19 CATION COLUMN (DUAL TYPE) FORBES MARSHALL A4-11730 02 06
22 BACK PRESSURE REGUALTOR FORBES MARSHALL A4-11720 04 12
23 THREE WAY BALL VALVE FORBES MARSHALL. A4-11710 04 12
COMPRESSION FITTINGS SWAGELOK/ PARKER …….. A.R. A.R.
CE CONDUCTIVITY CELL WITH 20m CABLE FORBES POLYMETRON A4-CT-SEN 03 09
pH FLOW THRU CHAMBER FORBES MARSHALL --- 02 06
PE pH ELECTRODES WITH 20m CABLE FORBES MARSHALL A4-PH-SEN 02 06
TUBE FITTINGS SWAGELOK / PARKER AR AR

WET RACK FORBES MARSHALL ------ 01 03
Page : 1/1

BILL OF MATERIAL FOR ANALYSER PANEL
ITEM DESCRIPTION MAKE SPEC.. QTY PER QTY PER

NO SHEET NO UNIT UNIT
CT CONDUCTIVITY ANALYSER MONEC 8964 FORBES POLYMETRON A4-8964 03 09
PT PH-ANALYSER MONEC 8965L FORBES POLYMETRON A4-8965L 02 06
SI SILICA ANALYSER MODEL : 9210 POLYMETRON / HACH ULTRA A4-09210 01 03

(3 CHANNEL) (**) - FRANCE
ANALYSER PANEL FORBES MARSHALL --- 01 03
NOTE : INSTRUMENT MAKED WITH (**) ARE ORDERED BY BHEL ON DIRECT IMPORT BASIS FROM OUR PRINCIPALS M/S HACH S.A. ( POLYMETRON, FRANCE.)

Page: 1/1
BILL OF MATERIAL OF CHEMICAL REAGENTS
ITEM DESCRIPTION GRADE QTY FOR EACH

NO ANALYSER FOR
12 MONTHS
1 REAGENTS FOR SILICA ANALYSER
• SODIUM MOLYBDATE POWDER ANALYTICAL GRADE 1.5 KG
• OXALIC ACID POWDER ANALYTICAL GRADE 0.5 KG
• AMMONIUM FERROUS SULPHATE ANALYTICAL GRADE 1.0 KG
• SULPHURIC ACID (98%) ANALYTICAL GRADE 1L
2 REAGENTS FOR pH ANALYSER NOT APPLICABLE ---------
3 CATION CONDUCTIVITY ANALYSER NOT APPLICABLE ---------
4 SPECIFIC CONDUCTIVITY ANASLYSER NOT APPLICABLE ---------

Page: 1/1
BILL OF MATERIAL FOR COMMISSIONING SPARES
ITEM DESCRIPTION MAKE QTY

NO
01 CONNECTORS (1/4” OD) FORBES MARSHALL 10
02 FERRULES (1/4” OD) FORBES MARSHALL 10
03 FITTINGS (1/4” OD) FORBES MARSHALL 10
04 FOR SILICA ANALYSER START UP KIT, INSTRUCTION MANUAL (*) -
(*) NOTE: THE START UP KIT / INSTRUCTION MANUAL COMES ALONG WITH THE ANALYSER.
THIS WILL NOT BE SUPPLIED ALONG WITH THE SYSTEM.

FOUNDATION DETAILS
WIRING DIAGRAM
SPECIFICATION SHEETS
DATA SHEET
ITEM : 1a SAMPLE ISOLATION VALVE (HIGH TEMP-IBR)

TYPE HIGH TEMPERATURE STOP (GLOBE) VALVE
PRESSURE CLASS 2500

TEMPERATURE 540 Deg. C. (MAX)
BODY BODY MATERIAL A182-F22
TRIM MATERIAL SS - 316
PACKING GRAPHOIL
HAND WHEEL MALLEABLE IRON
MOUNTING LINE
INLET 1/2” NB S/W

CONNECTION OUTLET 1/2” NB S/W
FLUID WATER / STEAM
PROCESS PRESSURE 250 Kg/Cm2
PARAMETERS TEMPERATURE 500 Deg. C.

FLOW 100 LPH
MAKE FORBES MARSHALL

MODEL : FM PART NO : F4W2015VKINM11
IBR – CERTIFIED VALVE
NOTE : PROCESS CONNECTION OF VALVES WERE WELDED WITH CONNECTOR TO SUIT ¼” OD SAMPLE
TUBING
PRP.BY TITLE :
CHK.BY SAMPLE ISO. VALVE (HT)
SLNO MODIFICATIONS APP.BY SPEC.SHT NO A4-11503-IBR
DATA SHEET
ITEM : 1b SAMPLE ISOLATION VALVE (LOW TEMP)

TYPE NEEDLE TYPE
PRESSURE 200 Kg/Cm2
TEMPERATURE 200 Deg. C.
BODY BODY MATERIAL SS-316
TRIM MATERIAL SS - 316
PACKING PTFE
HANDLE CARBON STEEL
MOUNTING PANEL
INLET 1/4” OD DOUBLE FERRULE COMPRESSION

FITTING
CONNECTION OUTLET 1/4” OD DOUBLE FERRULE COMPRESSION
FITTING
FLUID WATER/ STEAM
PROCESS PRESSURE 200 Kg Cm2

PARAMETERS TEMPERATURE 200 Deg. C.
FLOW 100 LPH
MAKE : FORBES MARSHALL

MODEL : F4W2011509
PRP.BY TITLE :
CHK.BY SAMPLE ISO. VLV (LT,1/4”OD)
SLNO MODIFICATIONS APP.BY SPEC.SHT NO A4-11509
DATA SHEET
ITEM : 2a SAMPLE COOLER

DESIGN TUBE COIL IN SHELL COUNTER FLOW
MOUNTING SURFACE
MATERIAL ASTM A312, TP-304
SHELL DESIGN PRESSURE 10 Kg/Cm2
TEST PRESSURE 15 Kg/Cm2
MAX. CW PRESSURE 6 - 7 Kg/Cm2
BAFFLE MATERIAL ASTM A312, TP-304
MATERIAL ASTM A213, TP-316 SEAMLESS (IBR)
TUBE OD X THICKNESS 1/4” OD, 20 SWG (1 MM)
COIL TEST PRESSURE 375 Kg/Cm2
MAX. SAMPLE PR. 250 Kg/Cm2
MAX. SAMPLE TEMP. 560 Deg.C.
PRESSURE 2 - 7 Kg/Cm2
COOLING WATER TEMPERATURE 30 ~ 40 Deg.C.
FLOW REFER COOLER SIZING CALCULATION
SAMPLE INLET 1/4” OD
CONNECTION SAMPLE OUTLET 1/4” OD

COOLING WATER ¾” / 1/2” NPT(F)

MODEL : DHX-12 _IBR
PRP.BY TITLE :
CHK.BY SAMPLE COOLER
SLNO MODIFICATIONS APP.BY SPEC.SHT NO A4-11721A
DATA SHEET
ITEM : 2b SAMPLE COOLER

MOUNTING SURFACE
CHILLED WATER TEMPERATURE 20-25 Deg.C.
FLOW REFER COOLER SIZING CALCULATION

COOLING WATER 1/2” NPT(F)

MODEL : DHX-6 _IBR
PRP.BY TITLE :
SLNO MODIFICATIONS APP.BY SPEC.SHT NO A4-11721B
DATA SHEET
ITEM : 2c SAMPLE COOLER

MOUNTING SURFACE
COOLING WATER TEMPERATURE 30 ~ 40 Deg.C.
FLOW REFER COOLING SIZING CALCULATIONS.

COOLING WATER 3/4” NPT(F)

MODEL : DHX-18_IBR
PRP.BY TITLE :
SLNO MODIFICATIONS APP.BY SPEC.SHT NO A4-11721C
DATA SHEET
ITEM : 04 COOLANT FLOW INDICATOR FOR PRIMARY PANEL

GENERAL SERVICE COOLING WATER LINE
TYPE FLOW THROUGH

BODY MATERIAL SS 304
WINDOW TOUGHNED GLASS
BODY RING CARBON STEEL
END CONNECTION 3/4” NPT (F)
PROCESS TEMPERATURE 80 Deg. C. (max)

PARAMETERS FLUID WATER

FM PART NO : F4W2011550-3/4”
PRP.BY TITLE :
CHK.BY COOLANT FLOW INDICATOR
SLNO MODIFICATIONS APP.BY SPEC.SHT NO A4-11550-3/4”
DATA SHEET
ITEM : 5a COOLANT ISOLATION VALVE

GENERAL SERVICE COOLING WATER LINE
TYPE BALL VALVE

PRESSURE 10 Kg/Cm2
TEMPERATURE 100 Deg. C.
BODY BODY MATERIAL SS 304
BALL MATERIAL STAINLESS STEEL
MOUNTING LINE
PACKING PTFE
INLET 3/4” NPT (F)
CONNECTION OUTLET 3/4” NPT (F)
FLUID WATER
PROCESS PRESSURE 3 - 6 Kg Cm2

PARAMETERS TEMPERATURE 35 - 100 Deg. C.
FLOW 2500 LPH

FM PART NO : F4W2011521
PRP.BY TITLE :
CHK.BY ISOLATION VALVE (3/4”NPT(F)
DATA SHEET
ITEM : 06 SAMPLE FILTER

WORKING PRESSURE 250 Kg/Cm2
WORKING TEMP. 100 Deg. C
FILTER ELEMENT PR. DIFFERENTIAL LESS THAN 2 Kg/Cm2
ACROSS THE FILTER
AT 60 LPH
MICRON RATING 40 MICRON
MTL OF CONSTRUCTION SS-316
SHAPE CYLINDRICAL
WORKING PRESSURE 250 Kg/Cm2

FILTER HOUSING SEATING MATERIAL STAINLESS STEEL AISI-316
UNIT TEMP. RATING 100 Deg.C.
END CONNECTIONS 1/4” NPT (F)
SHAPE “T” TYPE CONSTRUCTION

PRP.BY TITLE :
CHK.BY SAMPLE FILTER
DATA SHEET
ITEM : 08 PRESSURE REGULATOR

FUNCTION REGULATION
LINE SIZE 1/4” OD
GENERAL MOUNTING LINE
CONTROL WITH A SOCKET SET SCREW WITH LOCK NUT
TEST PRESSURE 1.5 TIMES OF OPERATING PRESSURE

BODY SS-316
MATERIAL DIAPHRAGM PTFE

SEAT TEFZEL
INLET 1/4” OD
CONNECTION OUTLET 1/4” OD
FLUID WATER
INLET PRESSURE 250 Kg/Cm2 (MAX.)

OUTLET PRESSURE 0-6 Kg/Cm2(MAX.)
PROCESS SET PRESSURE 15 Kg/Cm2
PARAMETER TEMPERATURE 80 Deg.C.
FLOW 100 LPH MAX.

PRP.BY TITLE :
CHK.BY PRESSURE REGULATOR
DATA SHEET
ITEM : 09 SAMPLE PRESSURE RELIEF VALVE

GENERAL TYPE SPRING LOADED RELIEF VALVE
BODY SS-316
SEAT DISC. SS - 316
MATERIAL SPRING SS - 316
SPINDLE SS- 316
MOUNTING ON LINE
FLUID WATER
PROCESS OPERATING PRESSURE AS REQD UPTO 6 Kg/Cm2

PARAMETERS OPERATING TEMP. 80 Deg. C.
SET PRESSURE 1.1 X OPERATING PRESSURE
ADJUSTING SPRINGRANGE 10%

PRP.BY TITLE :
CHK.BY SAMPLE PR. RELIEF VLV
DATA SHEET
ITEM : 9a SHELL PRESSURE RELIEF VALVE
GENERAL TYPE SPRING LOADED RELIEF VALVE
MOUNTING IN LINE WITH COOLER SHELL ITEM 2b/2c
BODY SS-316
SEAT DISC. SS-316
MATERIAL SPRING SS-316
SPINDLE SS-316
MOUNTING ON LINE

FLUID WATER
OPERATING PRESSURE AS REQD UPTO 6 Kg/Cm2
SERVICE OPERATING TEMP. 80 Deg. C. MAX

SET PRESSURE 3.3 Kg/cm2

FM PART NO : F4W2011581-SH
PRP.BY TITLE :
CHK.BY SAMPLE PR. RELIEF VLV
SL. NO MODIFICATIONS APP.BY SPEC.SHT NO A4-11581-SH
DATA SHEET
ITEM : 10 TEMPERATURE GAUGE (CAPILLARY TYPE)

TYPE Hg FILLED BACK CONNECTION
MOUNTING PANEL
DIAL SIZE 100 MM
SCALE 0 - 100 DEG. C.
CASE MATERIAL STAINLESS STEEL-304
RANGE 0 - 100 Deg. C
ACCURACY + 1% OF FULL SCALE
BULB MATERIAL SS-316
STEM DIAMETER 8 mm
GENERAL STEM MATERIAL SS-316
PROCESS CONNECTION 1/2” NPT M)

WINDOW 100 mm SHATTER PROOF GLASS
DIAL ALUMINIUM
CAPILLARY MATERIAL STAINLESS STEEL-316

CAPILLARY LENGTH 2 METRES
POINTER M.S. BLACK PAINTED
OVER RANGE PROTECTION 125%

PROTECTION CLASS IP-65
MATERIAL SS-316
PROCESS CONNECTION 1/2” NPT(M)

THERMOWELL LENGTH 125 mm
MAKE : GIC / H GURU

F.M. PART NO.: F4W2011615
PRP.BY TITLE :
CHK.BY TEMPERATURE GAUGE
SL.NO MODIFICATIONS APP.BY SPEC.SHT NO A4-11615
DATA SHEET
ITEM : 11 PRESSURE GAUGE

TYPE DIRECT READING
MOUNTING PANEL MOUNTING
PRESS. ELEMENT BOURDON, SS-316

RANGE 0 - 6 Kg/Cm2
ACCURACY GLASS + 1% BETWEEN 10% & 90% FSD
GENERAL PROCESS CONNECTION 1/2” NPT (M)
DIAL SIZE 100 MM
OVER RANGE PROTECTION 125%
BLOWOUT DISC NEOPRENE

MEDIA WATER
ENCLOSURE STAINLESS STEEL
ENCLOSURE PROTECTION CLASS IP-65

WINDOW SHATTER PROOF GLASS
MATERIAL MEASURING ELEMENT SS-316
MOVEMENT SS-304
ENTRY REAR
MAKE :GIC / H GURU

F. M. PART NO. : F4W2011600
PRP.BY TITLE :
CHK.BY PRESSURE GUAGE
SL. NO MODIFICATIONS APP.BY SPEC.SHT NO A4-11600
DATA SHEET
ITEM : 12 TEMPERATURE SWITCH

ENCLOSURE MATERIAL DOUGH MOULDING COMPOUND
ENCLOSURE IP-66
GENERAL MOUNTING SURFACE
POWER SUPPLY 240V AC, 50Hz
MATERIAL TIN PLATED COPPER WITH SS ARMOURING
CAPILLARY LENGTH 3 METRES

ELEMENT RANGE 25 - 90 DEG. C.
MAX. WORKING TEMP. 105 Deg. C.
SETTING ADJUSTABLE
RANGE (INDICATION) 25 - 90 DEG.C.

RESET DIFF. MINIMUM
SWITCH SWITCH TYPE SNAP ACTION

CONTACT 2 N/O.& 2N/C (SPDT)
CONTACT RATING 250V, 5A,AC/250V,0.25 A DC
CABLE ENTRY 1/2” NPT

MATERIAL SS-316
THERMOWELL PROCESS CONNECTION 3/8” NPT (M)
DESIGN PRESS.TEMP. 6 Kg/Cm2

ACCURACY +/- 1% FULL SCALE

PERFORMANCE REPEATABILITY +/- 1% FULL SCALE
PROCESS TEMPERATURE 40-50 Deg.C.

PARAMETERS FLUID WATER
MAKE : INDFOSS / SWITZER

FM PART NO.: F4W2011643
PRP.BY TITLE :
CHK.BY TEMPERATURE SWITCH(DPDT)

SLNO MODIFICATIONS APP.BY SPEC.SHT NO A4- 11643
DATA SHEET
ITEM : 14 SOLENOID VALVE

TYPE 3/2 WAY DIRECT ACTING UNIVERSAL TYPE
CONNECTION 1/4” NPT(F)

MATERIAL - BODY STAINLESS STEEL
VALVE BODY MATERIAL - SEAT EPDM

OPERATION DIRECT/PILOT DIRECT
ORIFICE SIZE Nw = 2.4 MM

ENCLOSURE FOR COIL IP-65
POWER SUPPLY 240 V AC
SOLENOID COIL STYLE OF COIL EMBEDDED SCREW
COIL GLASS H
DUTY CONTINUOUS
FLUID WATER
PROCESS FLOW 100 LPH

PARAMETERS TEMP. NOR / MAX 45 Deg.C / 85 Deg.C
MAKE : ASCO / ROTEX
PRP.BY TITLE :
CHK.BY SOLENOID VALVE(3 WAY,)
DATA SHEET
ITEM : 15 REGULATING VALVE

TYPE NEEDLE TYPE
PRESSURE 10 Kg/Cm2
TEMPERATURE 100 Deg.C.

TRIM MATERIAL SS-316
PACKING PTFE
HANDLE METAL
MOUNTING PANEL
INLET 1/4”OD
FLUID WATER / STEAM
PROCESS PRESSURE 3 Kg/Cm2 (OPERATING)

PARAMETERS TEMPERATURE 80 Deg.C.
FLOW 60 LPH

MODEL : F4W2011509
PRP.BY TITLE :
CHK.BY REGULATING VALVE
SLNO MODIFICATIONS APP.BY SPEC.SHT NO A4-11509 IV
DATA SHEET
ITEM : 16 ROTAMETER
FUNCTION INDICATION AND REGULATION
MOUNTING PANEL
FLOAT MATERIAL STAINLESS STEEL - 316

GENERAL MEASURING CONE BOROSILICATE GLASS
FLOAT MATERIAL SS-316 (A SHAPE)
SCALE LENGTH 80 mm
SCALE RANGE 2.9 LPH TO 29 LPH

SCALE LPH
METER ACCURACY + / - 3% OF FULL FLOW
WETTED PARTS SS-316
GLAND PACKING NEOPRENE

GLANDS ALUMINIUM
ACCESSORIES END CONNECTIONS 1/4” NPT (F)
DIRECTION OF REAR
CONNECTION
NEEDLE VALVE IN-BUILT AT INLET DIRECTION
PROCESS MEDIA WATER
FLUID DATA OPERATING PRESSURE 3 Kg/Cm2 (OPERATING)

OPERATING TEMP. 80 Deg.C.
MAKE : EUREKA
MODEL : MG-8
PRP.BY TITLE :
CHK.BY ROTAMETER
DATA SHEET
ITEM : 19 CATION COLUMN(DUPLEX TYPE)

DIAMETER 50 mm OD
GENERAL HEIGHT 500 mm
MATERIAL OF CONSTN ACRYLIC
RESIN TYPE CATION EXCHANGER

RESINS QTY OF RESIN 900 ML
SHELF LIFE OF RESIN 1 YEAR (IN MOIST CONDITION)
END CONNECTIONS 1/4” OD
CONNECTION NEEDLE VALVE (2 NOS) SS-316, 1/4” NPT(F)

MOUNTING CLAMPS M.S.
CONNECTORS (2 NOS) SS-316, 1/4” NPT(M) X 1.4” OD
PRESSURE 3 Kg/Cm2 (OPERATING)
PROCESS TEMPERATURE 80 Deg. C.

PARAMETERS FLOW RATE 30 LPH

FM PART NO : F4W2011730 FOR CATION COLUMN
FM PART NO : F4W2011731 FOR CATION RESIN
PRP.BY TITLE :
CHK.BY CATION COLUMN
SLNO MODIFICATIONS APP.BY SPEC.SHT NO A4-11730/731
DATA SHEET
ITEM : 22 BACK PRESSURE REGULATOR

FUNCTION REGULATION
LINE SIZE 1/4” OD
GENERAL MOUNTING LINE
CONTROL WITH A SOCKET SET SCREW LOCK NUT
BODY SS-316
MATERIAL DIAPHRAGM PTFE
SEAT TEFZEL
INLET 1/4” OD
FLUID WATER
PROCESS INLET PRESSURE 3Kg/Cm2 (REGULATED)

PARAMETERS SET PRESSURE 2.5 Kg/Cm2
TEMPEATURE 60 Deg.C.
FLOW 100 LPH MAX.

PRP.BY TITLE :
CHK.BY BACK PRESSIRE REG. (1/4” OD)
DATA SHEET
ITEM : 23 3 WAY BALL VALVE

TYPE BALL VALVE
PRESSURE 10 Kg/Cm2
TEMPERATURE 150 Deg.C.
TRIM MATERIAL SS-316
PACKING PTFE
HANDLE BAKELITE
MOUNTING PANEL
INLET 1/4” OD

DRAIN 1/4” OD
FLUID WATER
PROCESS PRESSURE 3 Kg/Cm2 (OPERATING)

PARAMETERS TEMPERATURE 80 Deg.C.
MAKE : HYDAIR
MODEL : F4W2011710
PRP.BY TITLE :
CHK.BY 3 WAY VALVE
DATA SHEET
ITEM PH ANALYSER
MANUFACTURERS FORBES MARSHALL
TRANSMITTER MODEL NUMBER 8965L
INSTRUMENT RANGE 0-14 PH, PROGRAMMABLE SPAN
SENSORS
ELECTRODE MAKE FORBES MARSHALL
MODEL NO FM1104
COMBINED PH ELECTRODE GLASS (MEASURING + REFERENCE)
TYPE COMBINATION, 3 CERAMIC DIAPHRAGM GLASS ELECTRODE,

REFILLABLE REFERENCE
CONNECTION 5 M CABLE NOISE SHIELDED COAX CABLE
IMMERSION LENGTH 120 MM
TEMPERATURE RATING 0 - 60 DEG C
TRANSMITTER
TYPE INDICATING 3 -1/2 DIGIT 14 MM HEIGHT LCD DISPLAY, 2
WIRE MICROPROCESSOR BASED
MOUNTING WALL
INPUT FROM PH SENSOR
OUTPUT 4-20MA, DC
AUTO TEMPERATURE COMPENSATION YES, AUTO & MANUAL

CALIBRATION 1 OR 2 POINTS – ZERO & SLOPE CHEMICALLY
ZERO & SPAN ADJUSTMENT YES, FROM FRONT PANEL KEYBOARD
DIAGNOSTICS INCORRECT – PROGRAMMING, ASYMMETRY POTENTIAL,
SLOPE POTENTIAL, TEMPERATURE SENSOR OPEN/SHORT
ENCLOSURE MATERIAL DIE-CAST ALUMINIUM
ENCLOSURE PROTECTION IP65 TO DIN 40050 IS:2147-1962 CI 7,1 (NEMA4) FOR WALL
MOUNTING
CABLE GLANDS ½” NPT DOUBLE COMPRESSION TYPE,
DIMENSIONS 165MM X 165 MM
ACCURACY +/- 0.2% FSD
STABILITY 0.02 PH PER WEEK
REPEATABILITY 0.02 PH PER WEEK
POWER SUPPLY 24 V DC
PRP.BY TITLE :
REV 2 INCORPORATED CHK.BY PH TRANSMITTER
SL. NO MODIFICATIONS APP.BY SPEC.SHT NO A4-8965H
DATA SHEET
ITEM : PHSEN pH SENSOR
MODEL FM1104
TYPE THREE DIAPHRAGM
SERVICE PH MEASUREMENT IN PUER OR ULTRAPURE
WATER
RANGE 0-14
TEMPERATURE 0 – 60 DEG C.
PRESSURE RATING 6 Kg/cm2

PH SENSOR SHAFT MATERIAL GALASS
DIAPHRAGM CERAMIC
REFERENCE ELECTRODE/ AgCl / KCl (3M)
REF. ELECTROLYTE
SENSOR LENGTH 120 MM
SCREW CAP HEAD S7
SUITABLE HOUSING FLOW THROUGH CHAMBER SS316

F. M. PART NO. : F4W20PH-SEN
PRP.BY TITLE :
CHK.BY pH SENSOR
SL. NO MODIFICATIONS APP.BY SPEC.SHT NO A4-PH-SEN
DATA SHEET
ITEM CONDUCTIVITY ANALYSER
MANUFACTURERS FORBES MARSHALL
MODEL NUMBER TRANSMITTER : 8964
INSTRUMENT RANGE FOR K=0.01 => 0.1µS/CM...10 µS/CM

(FREELY PROGRAMMABLE FOR K=0.1 => 0.1µS/CM...100 µS/CM
FOR ALL CELL CONSTANTS) FOR K=1 => 1µS/CM...1000 µS/CM
SENSORS
TYPE 2 ELECTRODE KOHLRAUSCH CELL
ELECTRODE MATERIAL SS 316 L/ UPPER BODY SS 316L
CONNECTION IP 65 GLASS POLYESTER CONNECTOR LOW NOISE CABLE
TEMPERATURE RATING T MAX = 125ºC
PRESSURE RATING P MAX = 10 KG/CM2
TEMPERATURE SENSOR BUILT IN PT 100
SAMPLE FLOW RATE 3-5 LPH
TRANSMITTER
TYPE 2 WIRE MICROPROCESSOR
DISPLAY BASED INDICATING 3-1/2 DIGIT 14 MM HEIGHT LCD DISPLAY,
MOUNTING WALL
INPUT FROM CONDUCTIVITY SENSOR
OUTPUT 4-20MA, DC ISOLATED OUTPUT
AUTO TEMPERATURE COMPENSATION YES, AUTO & MANUAL
CALIBRATION 2 POINT –ZERO & SLOPE - CHEMICALLY OR
ELECTRONICALLY
ZERO AND SPAN ADJUSTMENT YES, FROM FRONT PANEL KEYBOARD
DIAGNOSTICS ERROR INDICATION : DATA RECORDING, A/D CONVERSION,
CALIBRATION ERRORS, TEMP SENSOR OPEN OR SHORT
ENCLOSURE MATERIAL DIECAST ALUMINIUM
ENCLOSURE PROTECTION IP65
CABLE GLANDS ½’ NPT CABLE GLAND
DIMENSIONS 165MM X 165MM X 93 D MM
ACCURACY +/- 1% OF CALIBRATION SPAN
STABILITY 1% OF FULL SCALE
REPEATABILITY 0.3% OF SPAN
RESPONSE TIME 90% IN 20 SEC
POWER SUPPLY 24 VDC (2 WIRE)
PRP.BY TITLE :
REV 2 INCORPORATED CHK.BY CONDUCTIVITY TRANSMITTER
DATA SHEET
ITEM : CTSEN CONDUCTIVITY SENSOR
MODEL FM83 SERIES
TYPE THREADED CONNECTION
SERVICE CONDUCTIVITY MEASUREMENT IN PURE OR
ULTRAPURE WATER
RANGE +/-1%
TEMPERATURE 0 – 60 DEG C.
CONDUCTIVITY PRESSURE RATING 15 Kg/cm2

SENSOR BODY MATERIAL SS316
INTERNAL / EXTERNAL SS316L
ELECTRODE
CONNECTOR POLYESTER/IP65
MOUNTING CONNECTION ¾” NPT M
SUITABLE HOUSING FLOW THROUGH CHAMBER SS316
CELL MODEL / CONSTANT FM8310 - K=0.01…10µS/cm, 100KΏcm…100MΏcm
FM8311 - K=0.1…100µS/cm, 10KΏcm…10MΏcm
FM8312 - K=1.0 µS/cm…1M S/cm, 1 KΏcm…1 MΏcm

F. M. PART NO. : F4W20CT-SEN
PRP.BY TITLE :
CHK.BY SENSOR FOR CONDUCTIVITY
SL. NO MODIFICATIONS APP.BY SPEC.SHT NO A4-CT-SEN
DATA SHEET
ITEM SILICA ANALYSER ( 3 CHANNEL)
MANUFACTURER POLYMETRON S.A – FRANCE
MODEL NO. 09210=A=1003

METHOD PHOTOMETRIC SILICO MOLYBDENE BLUE COLOR
LIGHT SOURCE SINGLE BEAM INFRARED LED AT 820 NM AND REFERENCE

BEAM
RANGE 0-1000 PPB, FREELY PROGRAMMABLE
ACCURACY +/- 2% OR +/-0.5, ppb
CALIBRATION 2 POINT – ZERO & SLOPE, WITH TWO SOLUTIONS OF KNOWN

CONCENTRATION. MANUAL/AUTOMATIC
CALIBRATION CYCLE UPTO 168 HRS PROGRAMMABLE
REPETABILITY +/- 2% OR +/- 0.5 ppb
FLOW CELL ACRYLIC UNIT, CONICAL DESIGN BUBBLE EXPELLING
NO OF CHANNELS ONE * 2 THROUGH PLC BASED SEQUENCER WITH HOLD

FACILITY OF LAST READ VALUE
SAMPLE CONDITION
TEMPERATURE +5.....+50 DEG C
PRESSURE 0.2..... 6 BAR
FLOW RATE 10-20 LPH PER CHANEL
SAMPLING PUMP SINGLE MULTICHANNEL PUMP
PUMP TUBES POLYEURTHENE TUBE
TRANSMITTER TYPE MICROPROCESSOR BASED
DISPLAY TYPE INDICATING BACKLIT LCD
DISPLAY DETAILS CONC., CURRENT OUTPUT. ON LCD CALIBRATION, FLUSH

MODE, STANDBY MODE, RELAY STATUS BY LEDS.
DIAGNOSTICS LACK OF SAMPLE, PHOTOMETER FAULT & CALIBRATION
ERROR
MOUNTING DIMENSIONS 485 W X 890 H X 290 D MM
OUTPUT 4-20mA, DC, GALVANICALLY ISOLATED, 800Ω MAX LOAD FOR
EACH STREAM
ENCLOSURE MATERIAL ABS
ENCLOSURE PROTECTION IP 54, TRANSMITTER IP 65
RELAY OUTPUTS SYSTEM ALARAM – COMMON, ONE ALARM / CHANNEL 30V
DC 0.5A MAX.
POWER SUPPLY 100 – 240 VAC 50 Hz
PRP.BY TITLE :
CHK.BY SILICA ANALYSER
SIZING CALCULATIONS
4WSHS_2K07_1007_041-BHEL TRICHI BORL Sample cooler sizing calculations
Cooler sizing
Customer: BHEL Trichy

Project: BORL - 1,2,3
Sample I/L Sample Sample Enthalpy Sample Sample EnthalpyO Total C.W. C.W. C.W.
Sr. Sample Cooler
Service temp I/L Pr Flow Inlet O/L temp O/L Pr utlet Enthalpy I/L O/L reqd.
No. Model
(degC) (Kg/Cm2) (LPH) (KCal/Kg) (degC) (Kg/Cm2) (KCal/Kg) Kcal/Hr Temp Temp (LPH)
A B C D E F G (D-G)*C=H I J K=H/(J-I)
SAMPLING RACK # 1
1 Feed Water 115 137.5 50 115 43 137 43 3600 38 48 360 DHx-6
2 Drum Water 332 133 50 332 43 132.5 43 14450 38 48 1445 DHx-12
3 Main Steam 515 118 40 811 43 117.5 43 30720 38 48 3072 DHx-18
4 Saturated Steam 332 133 20 631 43 132.5 43 11760 38 48 1176 DHx-12
Total cooling water reqd. for wet rack#1 6053
SAMPLING RACK # 2
1 Feed Water 115 137.5 50 115 43 137 43 3600 38 48 360 DHx-6
2 Drum Water 332 133 50 332 43 132.5 43 14450 38 48 1445 DHx-12
3 Main Steam 515 118 40 811 43 117.5 43 30720 38 48 3072 DHx-18
Total cooling water reqd. for wet rack# 2 6053
SAMPLING RACK # 3
1 Feed Water 115 137.5 50 115 43 137 43 3600 38 48 360 DHx-6
2 Drum Water 332 133 50 332 43 132.5 43 14450 38 48 1445 DHx-12
3 Main Steam 515 118 40 811 43 117.5 43 30720 38 48 3072 DHx-18
Total cooling water reqd. for wet rack# 3 6053
Note :
1.0 The sample cooler will be protected by a safety relief valve.
2.0 The Chloride content in the cooling water must be less than 35 ppm.
3.0 The above mentioned sizing calculations are applicable for Steam / Water only.
4.0 Differencial pressure of 1.5 Kg/cm2 is required across Inlet and outlet Cooling water Header.
5.0 wet Racks are field mounted
PPD BY CHECKED BY APPD BY

COOLER SIZING.xls Sample Flow
Sr. No. Sample Line Details pH Ks Kc Si Grab Total flow for Line
SAMPLING RACK # 1
1 Feed Water 10 10 10 20 50
2 Drum Water 10 10 10 20 50
3 Main Steam 10 10 20 40
4 Saturated Steam 20 20
Total Flow 160
SAMPLING RACK # 2
1 Feed Water 10 10 10 20 50
2 Drum Water 10 10 10 20 50
3 Main Steam 10 10 20 40
Total Flow 160
SAMPLING RACK # 3
1 Feed Water 10 10 10 20 50
2 Drum Water 10 10 10 20 50
3 Main Steam 10 10 20 40
Total Flow 160
Ks: Specific Conductivity Analyzer 3 Nos

Kc: Cation Conductivity Analyzer 6 Nos.
pH: pH Analyzer 6 Nos.
Si: Silica Analyzer 3 Nos 3 Channel
Grab: Grab Sampling
PPD BY CHECKED BY APPD BY

OPERATING & MAINTENANCE INSTRUCTIONS
FOR
SAMPLE HANDLING SYSTEM
CONTENTS
SECTION A - EQUPMENT DESCRIPTION
SECTION B - INSTALLATION INSTRUCTIONS
SECTION C - COMMISSIONING PROCEDURE
SECTION D - PLANT ITEM OPERATING INSTRUCTIONS

SECTION A
EQUIPMENT DESCRIPTION
EQUPMENT DESCRIPTION
CONTENTS
1. INTRODUCTION
2. CONDITIONING EQUIPMENT
2.1 CONTINUOUS SAMPLE MONITORING

2.2 ANALYSER MONITORING
INTRODUCTION
1.0 The equipment is designed and assembled to enable conditioning of samples,

of boiler water and steam, by reducing the temperature and pressure to a
suitable state whereby a continuous sample may be presented on to on-line
analyzer(s), and a manual sample may be drawn off as required.
2.0 CONDITIONING EQUIPMENT
2.0 CONTINUOUS SAMPLE MONITORING
2.0.1 This equipment is used for the temperature and pressure reduction of
all samples. The equipment is mounted on a treated and painted mild
steel rack complete with sample counter. All items being easily
accessible for maintenance purposes.
2.0.2 The sample circuit comprises of sample inlet isolation and blow down
valves, sample coolers, filter, pressure reducing valve and relief valve.
There is a High Temperature control system for all lines. This
comprises a temperature indicator, Temperature switch, solenoid
valve and a control box. Temperature switch is having 2 SPDT
contacts. One is used to indicate high - temperature alarm & other
activates the solenoid valve. Individual sample flow indicators are
provided to cater sample for individual analysers. Back pressure
regulators are installed on the outlet of grab sample for all lines. This
maintains the constant flow & pressure to the analyzers. All the
individual sample coolers are having cooling water isolation valves;
shell pressure relief valves.
2.0.3 To enable operators to take a manual sample we have incorporated a

manual sample grab facility.
2.0.4 The sample coolers operate in a counter current mode with the
sample flowing in the opposite direction to the cooling water, this is to
ensure that the sample outlet temperature will be at its lowest, i.e.
approaching the coolant inlet temperature.
2.2 ANALYSER MOUNTING
2.2.1 Transmitters & Analyzers are mounted on a separate panel. Called as

Dry panel. Signal cables & Power cables are terminated in a separate
TB’s inside the Dry panel.
SECTION B
INSTALLATION INSTRUCTIONS
CONTENTS
1. INTRODUCTION
2. STORAGE & HANDLING
3. FOUNDAITON PREPARATION AND PLACEMENT
4. UTILITIES CONNECTIONS
4.1 COOLING WATER

4.2 SAMPLE LINE CONNECTIONS
4.3 INTER-CONNECTION SAMPLE PIPE WORK
4.4 POWER AND SIGNAL CONNECTIONS.
1. INTRODUCTION:
This document identifies the Erection and Installation procedures that are necessary to be
completed before the commissioning of the Sampling and conditioning equipment can
proceed satisfactorily. The Erection and Installation procedures cover the installation and
positioning of the Sample Racks and Analyzer Panels.
2. STORAGE AND HANDLING:
2.1.1 The equipment should not be dropped, dragged or otherwise treated roughly.
Slinging and hoisting must be by means of the lifting eyes on the mainframe;
sample or cooling water pipe work must not be used for this purpose. For the
lifting weight of the equipment refer to the relevant drawing. Care should be
taken to ensure that joint faces are not bruised, and that valve spindles are not
bent. Due care should be exercised to protect the equipment from damage.
Apart from these commonsense considerations, the assembly may be
regarded as rugged instrumentation and handled accordingly.
2.2 No water should be allowed to stand in the shell or sample pipe work if
freezing is likely to occur. Water containing more than 35 ppm chlorides must
not be allowed in the coolers at any time, whether operating or not.
3. FOUNDATION PREPARATION AND PLACEMENT:
3.1 A flat floor or plinth is required as foundation for the equipment. Suitable
foundation bolts are required for flooring fixing.
3.2 Determine the precise location requited for the completed frame and as closely
as possible, mark out and drill the floor to receive the floor bolts.
3.3 Maneuver the frame into position, aligning the boltholes as closely as possible
with the fixings in the floor.
3.4 Check that alignment can be achieved with all floor fixings simultaneously.
3.5 Fasten all floor fixing tightly.
3.6 After following the above procedure, the entire assembly should stand firmly
fixed to the floor.
4. UTILITIES CONNECTIONS:
4.1 COOLING WATER.

When connecting the service pipe work ensures that it is adequately
supported, do not use the cooler or cooler valves as an anchor point.
Provision should be made when fitting the pipe work to allow for the possible
expansion and contraction likely to occur during operation of the plant.
4.2 INTER CONNECTION SAMPLE PIPE WORK

All inter-connecting pipe work between root valve, wet panel and analyzer
panels must be flushed and tested as “Debris Free” prior to connections at the
inner bulkhead locations by others.
All inter-connecting pipe work must be capable of withstanding an operating

pressure of 3-5 kg / cm2 (G) as a maximum condition to be compatible with
that installed in the units.
4.3 POWER CONNECTIONS:

Power supply 230 V AC, 50 Hz UPS & Non UPS have to be connected to the
respective TB’S located inside the Panel
SECTION C
COMMISSIONING PROCEDURE
COMMISSIONING PROCEDURES
CONTENTS
1. INTRODUCTION
2. TEST PREPARATION AND SERVICES
3. CONDITIONING MODULE
3.1 GENERAL
3.2 FOR EACH INDIVIDUAL LINE
4. ANALYSERS
COMMISSIONING PROCEDURES:
1. INTRODUCTION:
The equipment is designed and assembled to enable the conditioning of samples

of Boiler Water and Steam by reducing the Temperature and Pressure to a
suitable state to enable the chemical parameters of the sample to be monitored.
2. TEST PREPARATION AND SERVICES :
2.1 Test Equipment for the Sampling Conditioning Equipment
Multimeter
Insulation tester
2.2 Permanent Services :
230/1/50 V AC Power Supply
2.3 Test Preparation:
2.3.1 Visually inspect all equipment for damage and close all valves.
2.3.2 Check that the equipment is secured to the floor.
2.3.3 Check that all drains are connected.
2.3.4 Check that all sample and coolant lines are connected. In particular that inter-
connection pipe work between the conditioning and analyzer panels has been
made in the sequence as indicated by the tags provided at the inner bulkhead
connections.
2.3.5 Ensure that all services are available.
2.3.6 Carry out insulation resistance checks on power supplies. DO NOT APPLY
MEGGER INSULATION TESTS ON THE ANALYSERS.
2.3.7 Carry out earth system continuity checks.
2.3.8 Check all fuses and ratings.
2.3.9 Check that all lights are operational. (Where fitted).
2.3.10 Check that the boilers are on line and up to pressure.
2.3.11 Refer the Analyser manufacturer’s instructions for the Analyser Preparation.
2.3.12 Check that the process is available for samples to run continuously through
each line.
2.3.13 Ensure that all power is available and switched on.
2.3.14 Prior to commissioning of the analysers, an Instrumentation Engineer /
Analyser specialist must complete the installation of the analyzer probes,
resins and prepare buffers and chemicals in conjunction with the chemists as
necessary.
Refer to paragraph (a) for installation of dissolved oxygen probe and (b) for
installation of pH probe. Refer to manufacturers instructions for installations of
remaining probes
3. CONDITIONING MODULE
3.1.1 GENERAL.
3.1.2 Check that all the sample valves are closed.
3.1.3 Check that the services are connected including the tundish drain and
that they are free from leaks.
3.1.4 Open fully the blow down isolation valves and allow the sample to run
for one half (1/2) hour in each line.
3.1.5 After the initial blow down period close the blow down isolation valve.
3.1.6 Open the aux. COOLANT inlet valves fully
3.1.7 Check that the aux. Coolant is flowing and allow to flow for approx.
one half (1/2) hour until all the air is eliminated from the system.
3.1.8 Check that the power is on to all modules.
3.2 FOR EACH INDIVIDUAL LINE.
3.2.1 Operate the 3-way ball valve to enable a grab sample to be obtained.
3.2.2 Slowly open the sample inlet valve allowing the sample to flow through
the grab valve to drain, until a clean sample is obtained.
3.2.3 Operate the 3-way ball valve to close the grab sample and divert flow
to the tundish.
3.2.4 Check for any leaks and rectify as necessary.
3.2.5 Open & adjust the flow control valve on the sample flow indicators.
3.2.6 Allow any air in the system to be removed.
3.2.7 The sample pressure gauge should read below 1 bar when the sample
is flowing and 2 bar when isolated.
3.2.8 Check for leaks and rectify as necessary.
3.2.9 Close the sample inlet valve.
3.2.10 Proceed to the Analysers after commissioning all sample lines.
3 TRANSMITTER / ANALYSER :
Refer to the analyzer Manufacturers Document for each particular analyzer.

SECTION D
PLANT ITEM OPERATING INSTRUCTIONS

CONTENTS
1. GENERAL OPERATING REQUIREMENTS
2 EQUIPMENT & ROUTINE CHECKS

1.1 SAMPLE CONDITIONING PANEL
1.2 ANALYSERS
3 OPERATING & MAINTENANCE LITERATURE
4 TROUBLE SHOOTING
1.1 SAMPLE CONDITIONING PANEL
1. GENERAL OPERATING REQUIREMENTS
WARNING: OBSERVE ALL RELEVANT SAFETY RULES
The equipment is part of the Feed and Steam Chemical Analysis System. Operation of the
equipment is dictated by the requirements of the Feed and Steam Chemical Analysis System.
During normal operation, the equipment should run for prolonged periods with little or no
attention. However routine checks, made once daily or as experience suggest, will help to
preserve trouble free and efficient operation of the system.
2. EQUIPMENT AND ROUTINE CHECKS.
2.1 SAMPLE CONDITIONING MODULES:
2.1.1 Check that the sample flow rates are at the required levels, adjusting the flow
indicator control valves as necessary.
2.1.2 Check that the sample temperature on each line is in the range of 45deg. C,
adjusting the chilled water / cooling water flow control valve 5a if necessary.
2.1.3 To keep the sample filters reasonably clear of debris, the filter element should be
removed and cleaned on a regular basis. This period will be determined with
experience, when the condition of the removed filter element is examined.
2.2 ANALYSERS.
Refer to Analyser Manufacturers Literature.

3. OPERATING & MAINTENANCE LITERATURE
DRG. ITEM NO DESCRIPTION

1a Sample Isolation Valve (HT)
1b Sample Isolation Valve ( LT)
2a Sample Cooler [ DHX-12 ]
2b Sample Cooler [ DHX-6 ]
2c Sample Cooler [ DHX-18 ]
04 Coolant Flow Indicator
5a Cooling Water isolation valve
06 Sample filter
08 Pressure Regulator
09 Sample Pressure Relief Valve
10 Temperature gauge
11 Pressure Gauge
12 Temperature switch
14 3 Way Solenoid Valve
15 PG – Isolation valve
16 Rotameter with built-in-needle valve
17 Tundish
22 Back pressure regulator
23 3 way grab sample valve
24a Flow Switch With Indicator
27 Bulkhead union
ph Ph Analyser cum Indicator
Cond. Specific and Cation Cond. Analyser
Si. Silica Analyser
DO2 Dissolved Oxygen Analyser
HYD Hydrazine Analyser
PHOS Phosphate Analyser
NA Sodium Analyser with Sequencer
SAMPLE CONTROL VALVES
1. Description:
Needle Valves are ruggedly constructed from Bar stock material. The valves have a
class 2500 rating and design incorporates full back seating and anti-blowout stem.
2. Maintenance:
There is no recommended maintenance for this series of valves, only to ensure the
gland packing does not leak, but due to the design this is highly unlikely. In the event
of a valve malfunction the complete valve should be replaced.
BALL VALVES
COOLANT ISOLATION BALL VALVES
1. DESCRIPTION:
Small stainless steel ball valves are used for the isolation of the samples and small
gunmetal / carbon steel ball valves for the coolant supplies.
The ball valves are most unlikely to require attention, and no maintenance is
therefore needed. In the event of trouble arising with the valves, they should be
treated as disposable items and replaced.
The valves are in the open position with the handle parallel to the valve body, and
closed with the handle at right angles. The valves do not have the provision for
venting to atmosphere in any position.
BALL VALVES
SAMPLE ISOLATION 3 WAY BALL VALVES:
1. DESCRIPTION:
Small stainless steel ball valves are used for isolation of the sample, comprise a cast
st. st. body with removable stem, valve seat and end connectors.
The valves do not have the provision for venting to atmosphere in any position.
2. MAINTENANCE:
The Valves are most unlikely to require attention but in the unlikely event a spares kit is
available. This includes replacement ‘O’ rings, valve seats, packing washers and
instructions.
Remove the hand wheel by using an Allen key in the socket set screw and turning
anticlockwise.
Remove the valve body from its mounting panel or bracket by releasing the panel nut.
Disconnect from the sample pipe work.
Remove the gland-packing nut by turning anti-clockwise.
Remove the stem assembly from the body, replace stem ‘O’ rings and stem packing
washers. N.B. Do not discard gland packing – this is to be re-used.
To access the valve seats, secure the body using a suitable wrench and remove the
end connectors.
Care must be exercised when removing valve seats and ‘O’ rings from the body. Fit
new seats and ‘O’ rings.
Re-assembly is the reversal of the removal procedure taking care not to allow the
ingress of dirt / contamination into the valve.
ASSEMBLY OF COMPRESSION FITTINGS:
These instructions are applicable to all twin-ring high pressure tube compression couplings in
the size range 6 mm OD to 25 mm OD. (1/4 inch OD to 1 inch OD).
1. The compression fittings are supplied ready assembled, finger-tight, with the sealing
rings in the correct order. It is neither necessary nor desirable to dismantle the fitting.
In the event of the fitting becoming dis-assembled, the parts must be re-assembled in
the order and orientation shown in the drawing, slipping each component over a short
piece of tube of the correct size to ensure alignment, and tightening to finger-tight.
2. Ensure that the correct size of compression fitting has been selected for the tube to be
employed. The tube should be a close sliding fit in the nut, rings and body.
3. Ensure that the tubing to be used is not scored, flattened or otherwise damaged. Cut
the end of the tube square and carefully deburr inside and outside.
4. Insert the tube into the fitting, ensuring that it passes right through the nut and both
rings to rest firmly on the internal shoulder of the body.
5. Select a spanner which is a close fit on the body of the fitting, or alternatively hold the
body of the fitting in a vice.
6. Using a spanner of the correct size, gently tighten the nut until the tubing will just not
turn by hand.
7. Scribe a mark on the nut.
8. Using this mark as a reference, tighten the nut a further 1.1/4 turns.
9. The fitting is now ready for use at maximum pressure. It may be dismantled and re-
assembled many times. On re-assembly, the nut should be tightened to the above
position and then slight additional seating pressure applied with the spanner.
SAMPLE COOLERS
DHx SERIES COOLERS
1. DESCRIPTION:
The DHx series of sample coolers is a range of highly efficient units designed for the
rapid cooling of samples of boiler water and steam over the range of temperatures
encountered within the power plant. The coolers differ in the length, diameter and
material of the cooling element (and hence the length of the shell) required for the
different thermal duties, and all replacement parts except the cooling coil, associated
stud couplings (used for securing the coil to the cooler lid), and shell are
interchangeable between the different coolers.
The cooler is partitioned into three concentric chambers by means of two axial tubular
baffles. The cooling water flows into the top of the inner chamber, and then passes to
the outer chamber, returning upwards to the outlet port.
2. INSTALLATION:
The equipment should not be dropped, dragged or otherwise treated roughly. Sample
or cooling water pipe work must NOT be used for lifting purposes. Care must be taken
to ensure that the joint faces are not bruised and equipment is not damaged in any
way.
No water should be allowed to remain in the cooler shell or sample pipe work if
freezing is likely to occur.
Cooler assemblies should be firmly mounted in a vertical position in a safe / secure but
accessible position. (Note the clearance required for the removal of the cooler shell for
coil cleaning).
The sample pipe work should be routed in a safe manner protecting personnel against
contact with hot pipes by insulating where necessary.
Ensure an adequate supply of cooling water is available and connected.
On completion of installation, pressure test all pipe work and check for leaks.
3 GENERAL OPERATING PRECAUTIONS:
When operating this equipment, it must always be remembered that the sample is at
high temperature and pressure, and for this reason care must be taken to ensure that:-
a) Personal contact with hot sample inlet pipe work etc. is avoided.
b) Blowing down of sample lines is undertaken with caution, to avoid the
possibility of scalding.
c) No equipment is connected to the sample outlet, which is incapable of
withstanding the design parameters.
d) All valves must be operated slowly.
1. OPERATION:
1.1 PRE-START REQUIREMENTS AND PRECAUTIONS:
Check that the installation has been carried out in accordance with correct
procedures. Open the coolant inlet and outlet valves to the cooler fully. Check
that the coolant is flowing vigorously and allow the coolant to flow until all the
air is eliminated from the system (no air bubbles are in view in the sight glass)
if fitted.
Check that all sample valves are closed. Carefully open the sample inlet valve
until fully open, followed by a quarter-turn in the opposite direction (to prevent
the valve sticking on the back – seat in the open position). Check for leaks.
Cautiously open the sample outlet valve until the sample begins to flow. Allow
the sample to flow at the rate of 2-3 liters / minute until the issuing sample
becomes clear and free from debris.
WARNING: If either the sample or coolant temperatures become too hot, close the sample
inlet valve and allow the coolant system to recover then continue in stages.
Adjust the sample outlet valve and run the sample as 1 liter / minute, allow the
system to settle down by running for approx. 5 minutes and check that the
coolant outlet pipe work does not become hot. If it does then the temperature
is too high and an increase in the coolant flow is necessary.
1.2 START UP PROCEDURE:

After following the above procedure, the coolers may be left running
continuously at the design flow rate.
If it is decided to shut down between intermittent samples, then the above pre-
start procedure must be observed.
NOTE: With intermittent sampling, sufficient time should be allowed to

purge the upstream sample line of stagnant sample. The time
required will depend on the size and length of the line. A
practical indication of whether the line has been purged may
be obtained by checking the temperature of the sample inlet
pipe, a high temperature indicating the presence of fresh
sample. However, care must be taken to avoid injury to
personnel.
1.3 SHUTDOWN PROCEDURE:

In the following order:
1) Close the sample inlet valve.
2) Close the sample outlet valve.
3) Close the coolant inlet and outlet valves.
1.4 WINTERISATION:
To protect against freezing during boiler shutdowns:-

1) Ensure that coolant isolation valves are closed.
2) Remove the drain plug/relief valve at the bottom of the cooler and
allow the shell to empty completely.
It should be ascertained that water will not subsequently enter the
shell before replacing the drain plug loosely.
With the sample inlet and outlet valves closed.
3) Open fully the sample outlet valve, disconnect the coil at the
connectors (if fitted) and blow the coil through with compressed air or
nitrogen, (before commencing this procedure, all people in the
immediate vicinity are to be warned and the engineering notified of the
intention to apply compressed air or nitrogen. Great care must be
taken when using nitrogen to avoid enclosed spaces and operators
must keep clear of exhausting Nitrogen Gas.
WARNING: Observe all relevant site safety rules) loosely reconnect until required for normal
operation again. Before re-using ensure that the connectors and drain plug are fully
retightened and then carry out the pre-start procedure.
To protect against freezing with the boiler operating, allow the cooler to run continuously with a
sample flow rate of 30 kg/hr with coolant flowing normally,
5 MAINTENANCE:
The coil should be examined for condition every 6 months or sooner as conditions
Dictate.
5.1 TO DISMANTLE COOLER IN SITU FOR COIL EXAMINATION:
1) Ensure that the sample-isolating valve at the sampling point or probe on the
main plant is CLOSED and LOCKED. Close and lock off all sample isolation
valves on the cooler and both the inlet and outlet coolant isolation valves.
Open the sample outlet valve on the cooler to ensure that the sample pipe
work is de-pressurized.
2) Remove the drain plug/relief valve at the bottom of the cooler and drain the
water from the shell.
3) Remove the 4 bolts and buts securing the body of the lid.
4) Carefully lower the shell away from the lid.
5) Examine the coil, particularly in the vicinity of the sample inlet, for signs of
pitting.
5.2 TO REASSEMBLE THE COOLER IN SITU FOLLOWING COIL EXAMINATION:
1) Fit a new gasket in position on the shell clamp ring.
2) Carefully slide the shell over the cooling coil into position.
3) Fit and tighten diagonally the 4 lid securing bolts and nuts to a torque of 30 NM
4) Replace the drain plug/ relief valve in the bottom of the cooler.
6.0 SAMPLE COOLER COIL REPLACEMENT:
6.1 REMOVING THE COOLER FROM SERVICE.

1) Ensure that the sample-isolating valve at the sampling point or probe
on the main plant is CLOSED and LOCKED. Close and lock off all
sample isolation valves on the cooler and both the inlet and outlet
coolant isolation valves. Open the sample outlet valve on the cooler
to ensure that the sample pipe work is de-pressurized.
2) Remove the drain plug at the bottom of the cooler, and drain the water
from the shell.
3) Disconnect the coolant pipe work to the cooler. If the sample lines are
welded, saw through the sample inlet and outlet pipes reasonably
close to the cooler, in a position convenient for re-welding later. If the
sample lines have compression connection, disconnect these
compressions fittings.
4) Support the cooler, unscrew and remove the two nuts retaining the
cooler, and remove the cooler to the workshop.
6.2 REMOVING THE COOLING COIL:
1) Remove the 4 bolts and nuts securing the lid in place.
2) Carefully lower the shell away from the lid.
3) Measure and note the distance from the bottom of the coil to the lid.
4) Measure and note the overall length of the coil and the lengths of
straight pipe, and the relative positions of bends on the sample pipe
work.
5) Cut through the coil inlet and outlet pipes just below the cooler lid.
6) Unscrew both the compression union nuts from the stud couplings in
the lid, and remove the inlet and outlet pipe work.
7) Remove the stud couplings from the cooler lid.

6.3 FITTING THE NEW COOLING COIL:
1) Ensure that all parts of the cooler are de-scaled and clean.
2) Blow through the new coil to ensure that it is not blocked, and is free
from debris.
3) Mark off on the new cooling coil with the dimensions noted in 6.2.3
and 2.4 above.
4) Fit the lid correctly on the inlet and outlet pipes in relation to the
measurements taken in 6.2.3 above.
5) Secure the coil in this position using new compression olives, and if
necessary new stud coupling bodies and / or compression nuts.
6) Bend the cut the inlet and outlet pipes to match those removed as
noted in 6.2.4 above.
6.4 ASSEMBLING THE COOLER:
1) Fit a new gasket in position on the shell clamp ring.
2) Carefully slide the shell over the cooling coil into position.
3) Fit and tighten diagonally the 4 lid securing bolts and nuts to a torque
of 30 NM.
4) Replace the drain plug / relief valve in the bottom of the cooler.
6.5 RETURNING THE COOLER TO SERVICE.
1) Support the cooler in position, fit and tighten the two securing nuts.
2) Re-connect the coolant pipe work.
3) If the sample lines have compression fittings, re-connect the sample

pipe-work with the inlet and outlet pipes in the original position using
new compression rings, the original nuts should be re-usable
4) Test all joints and valve stem seals for pressure tightness in
accordance with local safety practices.
6.6 RECOMMENDED TEST PRESSURES:
Sample side – 1.5 x working pressure.

Coolant side - 1.5 x working pressure.
SAMPLE FILTERS
1.0 DESCRIPTION:
High-pressure filters are used to prevent debris from reaching the equipment
downstream.
The filter has a forged body of 316 st. st. and a closely fitting perforated st. st.
screen.
2.0 INSTALLATION:
2.1 Ensure hat the filter is suitable for the requirement service by checking the
tag marking and the rating cast on the body.
2.2 Before installation, carefully inspect the strainer for possible damage
during transport or handling.
2.3 Strainers should be installed as close as possible to machinery or valve to

be protected. The arrow cast marked on the strainer body must point in
the direction of the flow.
2.4 Install the strainer in the pipeline using counter flanges, gaskets and
fasteners corresponding with the strainer ends and suitable for the fluid to
be filtered.
2.5 Make sure that all bolts and plug are properly tightened.
2.6 Slowly pressurize the line, checking for leaks.
2.7 It is recommended that a quick clean up of the strainer is made a few

hours after startup by operating the drain plug.
Should the pressure drop be found in excess of the normal figures, a complete maintenance
check should be performed.
2.1 MAINTENANCE;
2.2 Complete maintenance should be carried out at least once a year, or

whenever the pressure drop is found to be in excess of the normal figures.
2.3 For complete maintenance, follow the steps below:-
2.3.1 Ensure that the line has been shut-off and de-pressurized.
2.3.2 Loosen cover bolts and buts and remove cover and gasket.
2.3.3 Withdraw Basket/Screen and carefully inspect for damage. If any hole
in the screen is found obstructed, clean it with compressed air and / or
any suitable tool.
If the screen is broken or distorted, replace it.
Never reinstall a broken or distorted screen!
2.3.4 Carefully clean the inside of the filter body.
2.3.5 Fit a new gasket.
2.3.6 Install the new screen or the old cleaned screen.

Ensure that the Basket / Screen is seated correctly.
2.3.7 Replace cover and tighten bolts and nuts.
2.3.8 Slowly pressurize the line, checking for leaks.
2.3.9 Write on the filter body or tag the date of the maintenance operation.
SAMPLE PRESSURE REDUCING VALVE
1. GENERAL :
The Pressure Regulator is a self contained, spring-loaded pressure-reducing regulator.

This unit is designed for use in high purity water systems ; the only materials in contact
with the flow media are 316 stainless steel and Teflon.
The regulator utilizes a soft seat main valve for bubble right shut off in dead –end
applications and a metal diaphragm sensing element for good pressure control
sensitivity.
2. MATERIALS
Standard materials of construction contacting fluid media are as follows:
Regulator Body 316 st. st

Diaphragm 316 st. st
Seat TEFLON
Remaining Parts 316 st. st
3. OPERATION
Controlled outlet pressure settings are obtained on the pressure regulator by adjusting
the control knob. Rotating the knob clockwise raises the outlet pressure while an
anticlockwise rotation coupled with venting of the downstream side of the regulator
pipe work lowers the outlet pressure.
Final adjustment should be made in the direction of increasing the pressure to obtain
the most accurate set points.
4. DISASSEMBLY:
The following steps outline the disassembly of the regulator for maintenance and
repair.
4.1 Clamp the regulator in a vice by the flats on the bottom of the body.
4.2 Adjust the hand knob full anticlockwise.
4.3 Using a spanner, loosen the bonnet
4.4 Remove the bonnet assembly, spring button, load spring, back-up plate and
diaphragm.
4.5 The main valve assembly can be disassembled by using a screwdriver to turn
the seat retainer anticlockwise until it is free of the regulator body. Valve stem
and seat spring can now be lifted from the body. The friction sleeves can be
removed from the body by either just inverting the body (if they are loose), or
by carefully easing them out with a long, thin instrument inserted in the center
holes.
4.6 Valve seat maybe removed from the seat retainer using a sharp instrument.
5. RE-ASEMBLY
The regulator is reassembled in the reverse order of disassembly, observing the

following precautions.
5.1 Inspect all parts and replace those worn or damaged with Forbes Marshall
replacement parts.
5.2 ALL PARTS SHOULD BE CLEANED TO THE CLEANLINESS LEVEL

REQUIRED FOR SAFE OPERATION WITH THE MEDIA USED.
All parts in the flow stream must be free of particles, which could prevent the
proper seating of the main valve.
5.3 Apply a thin, uniform coating of a flour carbon grease to the indentation of the
spring button the threaded portion of the adjusting screw and the entire
threaded area of the bonnet inside diameter
5.4 Valve seat must be installed with it’s chamfered side towards the valve stem
5.5 The body and bonnet are best joined by holding the bonnet assembly open
end up and dropping items into the bonnet one at a time in the proper
orientation. The diaphragm (item 6) can then be centered on the lubricated
conical seating surface before the body assembly is inverted and screwed into
the bonnet firmly hand tight. The regular can then be placed in a vice for the
torquing of the bonnet.
To achieve a proper metal to metal seal between the bonnet and the body, the
bonnet must be torqued to the 75 ft.-lbs value a minimum of 3 times.
Subsequent to reassembly, the regulator should be connected to a pressure

source with a media compatible with the use of the regulator and pressurized
to check for internal and external leakage and operating characteristics.
6. SETTING LIMIT ON THE MAXIMUM OUTLET PRESSURE:
The hand knob of the regulator can be adjusted to limit the maximum outlet pressure
attainable to any value between 50 and 100% of the rated outlet pressure range. To
set this limit, connect the regulator to a pressure source and a gauge to indicate the
regulator outlet pressure.
Apply an inlet pressure to the regulator equal to the maximum inlet pressure expected
in service.
Remove the plug and loosen the nut using a ½” socket.
Using a screwdriver, turn the adjusting screw clockwise until the indicated outlet
pressure is 5 to 10% higher than the pressure at which the limit is desired.
Spin the hand know clockwise until it stops against the top of the bonnet; turn it back
about 1/8 turn anticlockwise and hold it in this position with one hand; tighten the nut
against the hand knob with 40-50 in.-lbs torque. Re-insert the screwdriver into the
adjusting screw and twist the hand knob and adjusting screw anticlockwise
simultaneously until they are no longer jammed against the top of the bonnet.
Turn the adjusting hand knob clockwise to ensure that it stops when the outlet
pressure reaches the desired maximum pressure.
7. FAULT FINDING
7.1 FAULT 1:
The regulated pressure continues to increase after lock-up without a change in

the control knob position.
POSSIBLE CAUSE:
Valve seat needs replacement.
ACTION:
Follow instructions in Maintenance section.
7.2 FAULT 2
Media leakage through or around the edge of the bonnet.
POSSIBLE CAUSE:
Insufficient torque on the bonnet (item 1)
ACTION:
Re-torque the bonnet to 75 – 100 ft. –lbs.
If leakage persists, disassemble the regulator as instructions in the

Disassembly section and inspect for nicks and scratches on the radius where
the diaphragm seats against the body.
Replace the body if nicked.
Replace the diaphragm and reassemble the regulator.

7.3 FAULT 3
Regulated pressure drops off sharply even when the flow is within the
regulator capabilities.
CAUSE
Clogged inlet filter
ACTION
Remove the old filter with a sharp instrument and press in a new one with
hand pressure on a blunt instrument.
7.4 FAULT 4
Leakage via vent port in valve bonnet.
CAUSE :
1) Fractured diaphragm
2) Dirt / debris preventing correct seating of the diaphragm.
ACTION
1) Replace the diaphragm and valve seat and re-assemble the regulator.
2) Carefully clean the diaphragm sealing surfaces and inspect for any
damage. If there is any sign of damage then new parts must be fitted.
SAMPLE / COOLING WATER PRESSURE RELIEF VALVE
1. DESCRIPTION:
The relief valve is one of a series of adjustable in-line valves constructed from st. st.
316 with a soft Viton ‘O’ ring to ensure a leak tight seal. Once set to the required
pressure, the valve should require no further attention unless it fails to shut off tightly.
2. MAINTENANCE:
The valve comprises the following parts:
One piece body st. st. 316

Poppet insert st. st. 316
Insert lock screw st. st. 316
‘O’ Ring seal Viton.
Spring st. st. 302
Adjusting and lock screws st. st. 316
2.1 ADJUSTING THE SET PRESSURE:
To adjust the relief valve, insert a standard screwdriver into the locking screw,
Unlock the locking screw by turning it anti-clockwise until the hexagonal key
slides into the adjusting screw.
Turn both screws to the desired cracking pressure. (Clockwise increases the
opening pressure, anti-clockwise decreases the pressure).
Retract the screwdriver key into the locking screw.
Lock the locking screw against the adjusting screw by turning the locking
screw clockwise.
2.2 REPLACEMENT OF PARTS
The system must be isolated and depressurized before removing the valve.
To dismantle the valve the adjusting and lock screws must be removed to
relieve the spring pressure.
The insert lock screw and the insert proppet can then be removed.
The ‘O’ ring should be examined and if damaged replaced.
All parts should then be cleaned, replaced if necessary and then reassembled
in reverse order of above.
TEMPERATURE GUAGE
1. GENERAL:
Each instrument has a sealed system consisting of Mercury filled element. This in turn
operates the pointer of the instrument to indicate the temperature of the surface to
which it is attached. The gauge is fastened to the pipe work via a collect and spring
arrangement.
2. MAINTENANCE:
No maintenance is required. If carefully installed, the instruments will function correctly

for many years. The operator is advised to check & calibrate the instruments
occasionally if conditions are not ideal.
THERMOWELLS
Thermo wells are used where thermometers maybe subjected to high pressure or corrosion.
They are also required where thermometers are to be removed without draining the system.
Although response time is greater than where no thermo well is used, accuracy is not affected.
The thermo well is machined from solid brass bar and will accept a thermometer stem with a ½”
male connection thread.
SAMPLE PRESSURE GUAGES
1) GENERAL:
Gauges are fitted to check the sample line pressure and to assist in the setting of any
pressure reducing device.
2) OPERATION:
2.1 WORKING PRESSURE:
If the working pressure is steady, the gauges should NOT be operated

CONTINUOUSLY beyond 75% of the maximum graduation. If the pressure is
fluctuating, never use a gauge continuously beyond 60% of the maximum
graduation.
2.2 MAXIMUM PRESSURE:
The gauges must never be worked beyond the end of the scale, and or not
designed to withstand overloads.
3) MAINTENANCE:
Should any fault in the reading be suspected then the gauge should be isolated and
removed from it’s location. The gauge reading should then be checked alongside a
calibrated gauge and if the error is confirmed it would be returned to the manufacturer
for repair.
SAMPLE SOLENOID VALVES
1. DESCRIPTION:
The 3-way stainless steel solenoid valve in which the valve changes configuration only
while the operating coil is energized. A further small spring is provided for exerting
pressure on the soft seat. Liquid flows through the valve from ABOVE the seat. So
that the applied upstream pressure tends to close one port. This should be observed
when installing a new valve.
The seat assembly contains a replaceable soft rubber seat, ensuring leak – tight shut-
off. The construction is very simple and the valve my easily be dismantled for
maintenance, should the need arise.
2. MAINTENANCE :
No routine maintenance is necessary, but should the valve fail to operate satisfactorily,
proceed as follows.
2.1 ELECTRICAL:
Disconnect from the supply and check the solenoid coil for continuity. The
110/220 AC coil rating is 8 VA.
2.2 MECHANICAL:
Disconnect the electrical supply and remove the coil by undoing the central
retaining nut. Lift the coil away from the valve. Holding the valve body with a
large spanner or vice, undo the plunger assembly and remove it. Carefully lift
out the mechanism and examine for signs of debris or damage as follows:
2.2.1 Check that the valve seat (in the body) is not damaged. If there is
pitting or mechanical damage (which is most unlikely), then the valve
must be replaced.
2.2.2 Slide the plunger out of the flange tube and check that the spring is in
good condition. Replace if necessary. Clean the flange tube and
piston.
2.2.3 Check that the return spring is in good condition. If this is broken or
distorted it should be replaced. Clean all parts and re-assemble.
2.2.4 Check that the seat disc is in good condition. If not, rise out the old
disc and after cleaning the seat and disc housing, insert a new disc,
ensuring that it is evenly bedded in. This is made easier if the disc is
slightly moistened with water first.
2.2.5 Replace the plunger into the flange tube and replace the mechanism.
Tighten the plunger assembly holding the valve body with a spanner
or a vice.
2.2.6 Replace the solenoid coil and tighten the retaining nut. Re-connect
the electrical supply.
SAMPLE FLOW METERS
1. GENERAL:
The sample flow meter is suitable for unsupported mounting in pipe work. The rigid
box frame prevents the transmission of pipe stresses to the indicator tube and affords
complete protection against random damage likely to occur on industrial plant
installations.
2. OPERATION:
Flow indication is automatic on commencement of sample flow, and the float should
‘hang’ symmetrical, spinning gently. It should rise and fall freely in the metering tube,
which is tapered with the larger end at the top. The height reached by the float is
determined by the area of gap between the float and the tube at which the upward
force from the fluid flow and the weight of the float are equalized. The flow rate is read
from the position of the topmost surface of the float against the scale on the metering
tube.
3. MAINTENANCE:
The metering tube, float and seals maybe removed without disturbing the flow meter
body, or the interconnecting pipe work. This enables cleaning or replacement of parts
to be carried out with considerably ease.
BALL VALVES
SAMPLE AND COOLANT ISOLATION BALL VALVES:
1. DESCRIPTION:
Small stainless steel ball valves are used for the isolation of the samples and small
brass / carbon steel ball valves for the coolant supplies.
The ball valves are most unlikely to require attention, and no maintenance is therefore
needed. In the event of trouble arising with the valves, they should be treated as
disposable items and replaced.
The valves are in the open position with the handle parallel to the valve body, and
closed with the handle at right angles. The valves do not have the provision for
venting to atmosphere in any position.
TROUBLE SHOOTING
SAMPLE CONDITIONING PANEL:
FAULTS, POSSIBLE CAUSES.
SYMPTOM POSSIBLE CAUSE ACTION
FAULT 1
Loss of sample Isolation valves closed Check that the probe isolation
valves are fully open.
Check that the sample inlet valve

is fully open.
Check that the sample outlet

valve is fully open.
Pressure reducing valve is Disassemble the pressure

blocked with debris. reducing valve – See Section
3.14
Remove the valve seat and

check, that the hole is clear.
Filter blocked Remove and replace the

complete filter
Broken or leaking sample line Check the sample line, including

the cooler coil and rectify as
necessary.
TROUBLE SHOOTING
FAULT 2
Sample running hot 1. Insufficient coolant Open coolant isolation valve fully.
flowing
Check that the flow indicator shows a
good flow.
Check that the coolant lines are not

blocked with debris.
Check that the pressure differential

between the coolant flow and return is
correct. (A low differential will cause
allow coolant flow).
Check that the coolant relief valve (if

fitted) is not passing coolant.
Sample flow rate is too high Decrease the sample flow rate to the
correct level
Check that the sample relief valve is not

passing the sample.
Auxiliary coolant outlet Increase the coolant flow rate
temperature is too high
Decrease the coolant temperature
Decrease the sample flow rate.

TROUBLE SHOOTING
FAULT 3
Sample at low Lack of process pressure / flow Await the return to normal operation
pressure Blow down valve or relief valve Close or reseat the valve
passing
Isolation valves not fully open Open valves fully
Pressure reducing valve set too Reset the pressure-reducing valve.
low See specific instructions. See
section 3.14.
FAULT 4
Sample relief valve Debris trapped between the lid Close down the sampling system
leaking and seat
Change the relief valve.
Remove the faulty relief valve to the

workshop
Restart the system.
See specific relief valve instructions

for re-furbishing information. See
section 3.15
Worn pressure reducing valve Close down the sample system.
lid/seat, allowing too much
sample to pass. See specific reducing valve
instructions for the refurbishing
information. See section 3.14.
Refurbish the valve.
Restart the sample system.

TROUBLE SHOOTING
FAULT 5
High Temperature Coolant supply failure Check both coolant supplies are
cut off activated on circulating throughout the circuit.
all lines
Check both coolant valves for
blockages.
.
The coolant temperature is too Check the Coolant water supply to
high the sampling rack – it should be 30-
35ºC @ 4000 L/hr
TROUBLE SHOOTING
FAULT 6
High Temperature Power supply failure Check relay and replace if faulty
cut off activated on
a single line Check wiring for faulty connection.
Coolant failure on line Check that the isolating valves are

fully open.
Check the coolant flow indicator, if

blocked clean or repair as necessary.
Check coolant pipe work and cooler

for blockages, including before and
after the isolation valves.
Insufficient coolant supply Open the coolant isolating valves

fully.
Sample flow rate too high Reduce the sample flow rate.
Coolant temperature too high Adjust the cooling water temperature
ANALYSER:
Refer to appropriate manufacturers instruction manual for details of faults and corrective
procedures for each individual analyzer / transmitter.

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STEAM & WATER

CLIENT : BHEL, TRICHY

YOUR REF : LOI DATED 29TH SEP, 2007

F.M. NO. : FM-JN-1007-041

O/A NO. : 1580003726

1. P & I DIAGRAM OF SAMPLING SYSTEM

2. G.A. DIAGRAM OF WET PANEL

3. G.A. DIAGRAM OF DRY PANEL

10. SWAS MANUAL

BILL OF MATERIAL FOR WET RACK

ITEM DESCRIPTION MAKE SPECIFICATION QTY PER QTY FOR

2a SAMPLE COOLER – DHX-12 – IBR FORBES MARSHALL A4-11721A 02 06

04 COOLANT FLOW INDICATOR FORBES MARSHALL A4-11550-3/4 04 12

5a COOLANT ISOLATION VALVE FORBES MARSHALL A4-11521 08 24

06 SAMPLE FILTER FORBES MARSHALL A4-11568 08 24

08 PRESSURE REGULATOR FORBES MARSHALL A4-11570 04 12

09 SAMPLE RELIEF VALVE FORBES MARSHALL A4-11581 04 12

9a SHELL RELIEF VALVE FORBES MARSHALL A4-11581-SH 04 12

10 TEMP. GAUGE( CAPILLARY TYPE ) GIC / H GURU A4-11615 04 12

11 PRESSURE GAUGE GIC / H GURU A4-11600 04 12

12 TEMPERATURE SWITCH SWITZER / INDFOSS A4-11635 04 12

14 SOLENOID VALVE ASCO / ROTEX A4-11671 04 12

PREPARED BY CHECKED BY APPROVED BY

BILL OF MATERIAL FOR WET RACK

ITEM DESCRIPTION MAKE SPECIFICATION QTY PER QTY FOR

16 ROTAMETER EUREKA A4-11700 08 24

17 TUNDISH FORBES MARSHALL ……. 04 12

19 CATION COLUMN (DUAL TYPE) FORBES MARSHALL A4-11730 02 06

22 BACK PRESSURE REGUALTOR FORBES MARSHALL A4-11720 04 12

23 THREE WAY BALL VALVE FORBES MARSHALL. A4-11710 04 12

COMPRESSION FITTINGS SWAGELOK/ PARKER …….. A.R. A.R.

CE CONDUCTIVITY CELL WITH 20m CABLE FORBES POLYMETRON A4-CT-SEN 03 09

pH FLOW THRU CHAMBER FORBES MARSHALL --- 02 06

PE pH ELECTRODES WITH 20m CABLE FORBES MARSHALL A4-PH-SEN 02 06

TUBE FITTINGS SWAGELOK / PARKER AR AR

PREPARED BY CHECKED BY APPROVED BY

ITEM DESCRIPTION MAKE SPEC.. QTY PER QTY PER

PT PH-ANALYSER MONEC 8965L FORBES POLYMETRON A4-8965L 02 06

SI SILICA ANALYSER MODEL : 9210 POLYMETRON / HACH ULTRA A4-09210 01 03

ANALYSER PANEL FORBES MARSHALL --- 01 03

PREPARED BY CHECKED BY APPROVED BY

ITEM DESCRIPTION GRADE QTY FOR EACH

2 REAGENTS FOR pH ANALYSER NOT APPLICABLE ---------

3 CATION CONDUCTIVITY ANALYSER NOT APPLICABLE ---------

4 SPECIFIC CONDUCTIVITY ANASLYSER NOT APPLICABLE ---------

PREPARED BY CHECKED BY APPROVED BY

BILL OF MATERIAL FOR COMMISSIONING SPARES

ITEM DESCRIPTION MAKE QTY

02 FERRULES (1/4” OD) FORBES MARSHALL 10

03 FITTINGS (1/4” OD) FORBES MARSHALL 10

04 FOR SILICA ANALYSER START UP KIT, INSTRUCTION MANUAL (*) -

PREPARED BY CHECKED BY APPROVED BY

ITEM : 1a SAMPLE ISOLATION VALVE (HIGH TEMP-IBR)

PRESSURE CLASS 2500

INLET 1/2” NB S/W

FLUID WATER / STEAM

PROCESS PRESSURE 250 Kg/Cm2

PARAMETERS TEMPERATURE 500 Deg. C.

MAKE FORBES MARSHALL

ITEM : 1b SAMPLE ISOLATION VALVE (LOW TEMP)

INLET 1/4” OD DOUBLE FERRULE COMPRESSION

FLUID WATER/ STEAM

PROCESS PRESSURE 200 Kg Cm2