1.0 2.0 3.0 4.0 5.0 7.0 8.0 1.0 aillidiis [AALBORG SUNAOD OIL FIRED BOILER CONTENTS Instructions Drawings Boiler accessories Feed water system Feed water pumps Salinometer Chemical dosing station Sare parte CERTIFICATES (coov) AALBORG SUNRODauiels [AALBORG SUNROD We are devoted to supporting our AALBORG SUNROD products with commitment to a long term partnership. We aim to be where you need us the most. AALBORG SUNROD Gasvaerksvej 24 P.O, Box 844 9100 Aalborg Denmark Tel. +45 99 30 44 00 Tel, +45 40 16 66 86 (24 hrs.) Fax +45 98 10 22 33, AALBORG SUNROD AB Riddarplatsen 36 P.O. Box 907 $-175 29 Jarfalla Sweden Tal. +46 8 580 243 00 - +46 8 580 178 70 (24 hrs.) Fax +46 8 580 278 01 AALBORG SUNROD Rotterdam BV Glasblazerstraat 19 2984 BL Ridderkerk The Netherlands Tel, +31 180 461 462 Fax +31 180 461 602 Testbank Ship Repair & Boller Co Ltd Western Avenue Western Docks Southampton SO150HH gland ». +44 1703 78 78 78 “Fax +44 1703 78 78 26 AALBORG SUNROD Korea P.O. Box 598 9th floor, Nulwon Bldg. 825-3, Bumil-dong Dong-ku, Pusan Korea Tel. +82 51 636 5800 Fax +82 51 636 5887 AALBORG SUNROD K.K. 1-8, 7-chome, Isogami-dori Chuo-Ku, Kobe 651 Japan Tel. +81 78 271 5720 Fax +81 78 271 5741 AALBORG SUNROD (S) Pte Ltd 24 Mandai state Singapore 729915 Republic of Singapore Tol, +65 261 9898 Fax +65 266 1111 ‘Scandinavian Boiler Service Inc. 3200 8. Andrews Ave. Suite 204 Ft. Lauderdale, FL 33316 USA Tel, +1 954 763 7375 Fax +1 954 766 2624 AALBORG SUNROD AALBORG SUNROD Hong Kong Ltd. Room 2010, 20/F, C.C. Wu Bldg. 302-308 Hennessy Road, Wanchai Hong Kong Tel, +852 2836 3826 Fax +852 2834 8905 AALBORG SUNROD Hong Kong Ltd. ‘Shanghai Liaison Office Room 501, New Asia Hotel 422, Tian Tong Road ‘Shanghai 200085 People’s Republic of China Tel. 86 21 6306 6610 Fax +86 21 6356 5100 AALBORG SUNROD Dubai P. O, Box 53073, Al Jadat Dubai United Arab Emirates Tel. +971 4.341 061 Fax +971 4341 790 AALBORG BRASIL IND E COM LTDA Av. Vereador Isaias Prieto, 46 Rancho Grande - Itt - SP 13,304-780 Brazil Tel. +55 11 7824 0631 Fax +55 11 7824 0706 JBNidWversesocation 19JUN 971.0 INSTRUCTIONS 1.0 Boiler design data 2.0 AQ-9 oilfired boiler Generel description Principal function Ser tl 2 3. 4. Boiling out 5. Contamination 6. _Lighting-Up procedures 7. Cleaning the convection tube bank section 8. Stopping of boiler 9. Preservation of boiler during standstill 40° Maintenance 11. Plugging of boiler tubes 12, Application of castable refractorie 3.0 Instruction for feed and boller water 4.0 Instruction for safety valves 5.0 Instruction for water level gauge 6.0 Instruction for water level transmitter 7.0 Support of AQ-9 boilers AALBORG SUNROD auldBoiler Design Data Steam production Working pressure Design pressure Set pressure safety valve Feed water temperature imension Diameter excl, insulation Height oxol. of mountings, incl. uptake Total heating surface Water volume at normal water level Weight of boiler excl. of water Weight of boiler incl. of water Classificati Det Norske Veritas AALBORG SUNROD 8600 kg/h 4.2 Mpa 1.4 Mpa 1.0 Mpa 60 degr.C 2300 mm 5850 mm 90m 20.0 te 27.0 tscy Oe OM053i AQ-9 Oilfired Boiler General Description This oilfired boiler, illustrated on Figure | and Figure 2, is of all welded construc- tion. The fumace is surrounded by closely placed boiler tubes, which are welded at their lower ends tothe circular furnace header, and at their upper ends to the intermediate drum. In onder to achieve adequate circulation and thus avoid overheating of the furnace tubes, large bore downcomers are provided between the upper dram and the circular furnace header. eters In order to keep the boiler simmering at low pressure/temperature it is a good {idea to install heating coils in two of the downcomers, but please note that this is NOT included in our standard delivery. tenance One of the downcomers is provided with a heating coil which keeps the stand-by boiler simamering at low pressure. The furnace is provided with 2 furnace sight holes, ‘The upper drum and the intermediate drum as well are provided with manholes for acoess and inapection, The convection tube section is provided with three inspection doors for inspection and water washing of the tube bank. For the purpose of inspection and manual inside cleaning of the circular furnace header, six handholes are provided. ‘The arrangement of accessories on the oilfired boiler can be seen on the enclosed arrangement drawing, SSeUEERrene ene Unless anything else is specified the item nos. refered to in this chapter will be the nos, indicated on the enclosed “General arrangement”-drawing. nn 1 Note: Note: AALBORG SUNROD «ili, Page 1/27AQ-9 Oilfired boiler, sectional elevation > Upper drum ~~ (steam and water chamber) am “A i ira wane | J 3 inspection doors ve } 7 } pa oeem 4 ss} | ! LA Manhole ‘Uptake (not standard) ey: “Intermediate drum tat Ze 5} fe a Heating coil (not standard) Handhole Peischatt q fie == aaa Figure 1 pete AQ-9 Oilfired boiler (section A-A and B-B of Page 2/27 Figure 1), sect, plan eley. AALBORG SUNRODaf Oia Principal Function The oil burner is burning with « horizontal flame into the furnace, The exhaust gas passes fromthe furnace through the center uptake and into the convection tube bank, where the gas by means of baffle plates rotates one turn before leaving the boiler through the uptake In the furnace the temperature is as high as 1200°C. The high temperature and radiation cause that heat is transferred to the water filled furnace tubes and steam is produced. The steam is passing upwards through the intermediate drum and through the convection tubes, and is collected in the upper drum, When the exhaust 8 is passing the convection tube bank, heat is transferred to the convection tubes, resulting in steam raising, Owing to the high temperature in the furnace it is necessary to secure a sufficient water circulation through the fumace tubes to keep the temperature at an adequate level. Therefore the AQ-9 boiler is provided with large outside downcomers. Through the downcomers water circulates from the upper drum to the circular furace header, where the water is lead to the individual furnace tubes. The difference in specific density of water in the downcomers and the mixture of water and steam in the fumace tubes and convection tubes secure a natural circulation in the boiler. Service During normal service of the! regularly, e.g.: ® Alarms and shutdown systems @ Water level gauges (6) © Fouling of the fluegas side, see section 7 Feed and boiler water condition and water treatment system -rseveral things should be maintained and checked Condition and maintenance of the various valves connected to the boiler (and the associated systems) Whenever the various items are maintained and checked and it turns out that there is a fault, it should be reported and rectified at the first possible opportunity or immediately, if necessary, ie. if the faulty item is part of the safety system. 2 rr elt SAEED Should a fault occur in the boiler safety system, it must be rectified immedi- ately. If the boiler cannot be taken out of operation the boiler must only be operated under continuous manual supervision. st RENE During service the load changes should not be higher than 10% per minute, as that will have an unfortunate influence on the boiler water level and pressure, which in some cases may lead to a boiler shutdown. 2 3 Caution: AALBORG SUNROD i Page 3/27ler 4 Boiling Out ee Before putting the boiler into operation forthe first time, it should be boiled out to remove all protecting remedies and impurities in tubes and drums. The boiling out procedure is recommended to be carried out in the following way: Caution: Extreme care should be taken while handling the chemicals. The person: handling the chemicals/ solution should be properly dressed/protected. [Bl] Fin the boiler with a solution consisting of 4-5 kg trinatriumphosphate NasPOs per 1000 kg water. The chemicals can be added through the manhole. ‘Add feed water until the solution is visible in the water gauges above “lower water level” Close the feed water valve (3) (pump stopped). te Caution: Do never fill feed water into the boiler if the temperature difference between boiler and feed water exceeds 50°C. El Raise steam pressure slowly to working pressure according to the ighting-up curve shown on Figure 3, and keep the pressure for approx. 3-4 hours with closed main steam valve (2). El Scum untit water level is between “Normal water level” and “High ‘water level”. By this procedure grease and other impurities are removed from the internal surfaces of the boiler. {GQ Start skimming by opening the scum valve (5), and lower the water level to lower edge of “Normal water level” mark. Close the scum valve (5). nae [Ed Refitt the boiler with feed water and start skimming again in intervals of 30 minutes for a period of two hours. [Bd Stop the boiling out procedure by switching off the burner. Let the boiler water rest for about five minutes. (M0 Carry out a final skimming. Blow off the boiler water by opening the two blowdown valves (13). Remember to open the air escape valve (8), to avoid a vacuum in the boiler when the boiler pressure falls back to approx. unpressurized/at- mospheric pressure. Open the upper manhole in the steamdrum and let the boiler cool down to approx. 100 °C. Page 4/27 sil, AALBORG SUNRODThe boiler is to be flushed with clean water in upper and intermedi- ate drum, when the temperature has decreased, The flushing removes remaining impurities. E24 Upon completion of flushing, dismantle the handholes (27), and carry out flushing/mechanical cleaning of the circular header as all remaining impurities are settled in the bottom, ‘Take the two bottom blowdown valves (13), to pieces for cleaning and inspection because deposits/foreign substances will usually be ac- cumulated in these valves and cause leakings if not cleaned. BE] Inspeet the boiler and remove any remaining deposits and foreign sub- stances, Finally, new gaskets to be fitted in all hand- and manholes before refilling the boiler with water to upper edge of “Low water level”. ‘The boiler is now ready for lighting-up (see section 6) and to be put into service, Advice: During the first two weeks in operation we recommend to carry out frequently skimming and bottom blowdown to remove impurities entering the boiler from the pipe system. — eee Please use the ‘Boiling Out Scheme’ in Table 1 as a guideline and memory help. Boiling Out Scheme "ine Fae Fear 1 Use 4.5 kg Na3POs per ton of boiler water and fill up with feed water until upper edge of “Low water level” mack Light-up the boiler according to lighting-up curve, shown on Figure 3 in section 6.1, with closed main steam valve (2) Working pressure obtained Four (4) hours later the ist skimming is performed Half (4) an hour later the second skimming i performed Half (4) an hour later the third skimming is performed Hilf) an hour later the fourth skimming is performed lal (4) an hour later: stop the bumer Five (5) minutes later: perform a skimming but without refilling with feed water 10 ‘Blow down. Open the two bottom Blowdown valves (13) i ‘Open the airescape valve (8), when the boileris almost unpressurized 2 ‘Open upper manhole when the boiler is unpressurized B ‘When the boiter shell has been cooled down to approx. 100°C, perform al flushing wit clean water 14 (Cleaning of circular header and blowdowa valves (13) Ist Inspection of boiler ae eee ! is | ‘New gaskets fed for iand- and manholes 17 ‘The boiler is refilled with feed water and ready to be taken into operation Table [ AALBORG SUNROD Page 5/27Contamination Note: Ifthe boiler is contaminated with foreign substances like oil, chemicals, corrosion products, etc. itis very important to act immediately to avoid damages to the boiler. Layers of thin oil films, mud, etc. exposed to the heating surfaces causes a bad heat transfer in the boiler, leading to overheating followed by burned out pressure parts. In order to remove such contamination, a boiling out or acid cleaning have to be performed immediately. Corrosion products from the pipesystem or insufficient boiler water treatment may result in corrosion in the boiler itself. It is therefore important to observe that such circumstances do not occur in the system. Lighting-Up Procedures Caution: Note Every time the boiler has been stopped/off-line and has to be restarted, the lighting-up procedure described in this section has to be followed. Observe that the safety equipment is in good order before the lighting-up procedure takes place. | Before ghting-up, die pipe cuumections to the safety valves must be thor oughly cleaned for dirt and foreign bodies. 6.1 Principal Operation It is important to follow the lighting-up procedure described in this section to ensure that the boiler is not stressed beyond its allowable limits, and that the boiler is expanding in a smooth way. Whilst steam raising, maintain a steady firing rate until the boiler starts to take load. ‘When this occurs the firing rate should be kept in step with the steam flow, and at no titne should the boiler be put onto automatic control when the pressure is below the set value. ‘The rate at which to lighting up the boiler is shown on the “lighting-up curve” in Figure 3. As can be seen from the “lighting-up curve” the boiling point is reached (100 °C) in approx, 53 minutes. Page 6/27 wal, AALBORG SUNRODie g & g § i e OSes im) "Lighting-up curve" 280 200 +60 109) Pressure [barg] 50 Figure 3 apse Close the air escape valve (8), when all air has been expelled and steam is blowing. The lighting-up is to be continued until the service pressure is reached, In this example the service pressure of 8 barg is reached after approx. 85 minutes, and the boiler can be put onto automatic service. Please note in the following describtion that the valve positions may vary with the exact installation, as we are not aware of details in the yard’s pipe system layout, 6.1.1 Practical Lighting Up - Closed Main Steam Valve Below is given a brief description of the lighting-up procedure with a closed main steam valve (2). HY Close all valves on the boiler. Open the air escape valve (8). [Bl Open the valves for control and safety systems, (6)/(9V/(10)(14Y/(16) If the boiler water level is not corresponding to upper edge of “lowest water level”, fill or drain water until this level is reached. I Start the burner at absolute minimum firing rate and raise the boiler temperature/pressure according to the “Lighting-Up Curve” in Figure 3. Ie may in this respect be neccesary to start and stop the bummer at intervals, ‘When the boiler pressure has reached approx. 1.5 barg, the air escape valve (8) is closed until “cracked open” During lighting-up the water level will raise. [EH It could be neccesary to dr: EE Check the water level gauges (6), when the boiler pressure has reached. approx. 3 barg. some water during lighting-up. AALBORG SUNROD cil, Page 7/27Note: Caution: Tees It is advisable to check “low water level” cut-out function. Drain some of the boiler water and check that the burner is cut-out when the water level falls back below the “low water level” mark, [0 Ensure that the feed water system is ready for operation and open all the nessecary valves in the feed water line. At the same time ensure that the feed water treatment system is put into service. When the boiler service pressure is almost reached, the steam by-pass valve (15), is opened. By-passing the main steam valve, the steam flows out to the consumers and hereby warms up the steam pipe line slowly, which makes it possible to open the main steam valve (2). ‘The steam line is warmed up by leading steam into it and gradually raising the pressure by slowly opening the main steam valve (2) mune Ensure that the condensate and make up system is ready for operation. fanaa nn oe ety If the boiler pressure is reached before the steam line is warmed up, the burner should be stopped and may be put into automatic operation. If the boiler is steaming into a hot steam system in service, then: Slowly open the main steam valve (2), two turns, and then open fully. It should however be noted that the boiler load is not increasing more than 10% per minute ‘The boiler will automactically be “on line” when the boiler pressure corresponds the pressure in the steam line, IF the boiler automatic control, alarm and shutdown systems have to be checked in “warm condition’, it should be done before the service pressure is reached. ‘Slowly open the main steam valve (2) fully, and close the air valve (8), when the steam line has been warmed up. The boiler is now on line. Ensure that the follor is working proper! @ Boiler and burner alarms and shutdown functions # Feed water, condensate and make up water systems + Water treatment system 6.1.2 Practical Lighting-Up - Open Main Steam Valve Below is given a description of the lighting-up procedure with open main steam valve (2) and unpressurized main steam line. the boiler plant consists of more than one oilfired, and if another boilers steaming the procedure with closed main steam valve described in the previous section can be followed), as the boiler cannot produce steam into the main steam line until the steam pressures are equal for both the boiler and the main steam line. Close all valves on the boiler. Page 8/27 vil, AALBORG SUNRODCaution: Note: ‘Open the air escape valve (8), and the main steam valve (2). [El Open the valves for control and safety systems (6)/(9)/(10)((14)/(6). If the boiler water level is not corresponding to upper edge of “lowest water level”, fill or drain water until this level is reached, [Bd Start the burner at absolute minimum firing rate and run in manual mode. Raise the boiler temperature/pressure according to the “Lighting-Up Curve” in Figure 3 Tt may in this respect be neccesary to start and stop the bumer at intervals at the beginning, ‘When the boiler starts to produce steamn (at 100 °C), the firing rate should be kept in step with the steam flow, see the “lighting up curve" on Figure 3 Ensure that the feed water system is ready for operation and open all the nessecary valves in the feed water line. [Bh Start the feed water system. Ensure that the feed water treatment system is put into service at the same time as the feed water system Ensure that the condensate and make up systems is ready for operation. QQ the air escape valve (8) is closed uulil “cracked open”, when the boiler pressure has reached approx. 1.5 barg, BB) Check the water level gauges (6), when the boiler pressure has reached approx. 3 barg. It is advisable to check the “low water level” cut-out function, [2 Drain some of the boiler water and check that the burner is cut-out when the water level falls back below the “low water level” sign. If the boiler automatic control, alarm and shutdown system have to be checked in “warm condition”, it could be done before the service pressure is reached, When the boiler steam pressure reaches the service pressure, the burner can be put into automatic operation and the air escape valve (8) closed. The boiler is now on line. Ensure that the following is working properly: * Boiler and burner alarms and shutdown functions © Feed water, condensate and make up water system © Water treatment system AALBORG SUNROD li, Page 9/27Outlet Gas Temp. [°C] Coie ane Cleaning the Convection Tube Bank Section Under normal circumstances with a correct combustion, fouling of the convection tube bank will be minimized. Therefore cleaning will only be required every second or third year, because the boiler design secures a relatively high gas velocity in the convection tube bank section. It is recommended to keep a consecutive record of the flue gas temperature or the flue gas pressure loss related to different boiler loads (clean boiler) ‘The otiginal data used as a comparison can be inserted in achart as shown on Figure 4 (an empty chart is enclosed in the paper manual for such purpose). In this way it is possible to monitor the fouling condition of the convection tube bank and determine when the boiler needs cleaning. Convection tube bank check scheme o = = — ute op 2 : & Diff, pessure g : a 0 10 20 30 40 50 60 70 80 90 100 Load % Figure 4 nto When looking at the temperature curve fouling starts with a “rapid” inerease in temperature and is then “fading”. This phenomenon is due tothe fact that the tubes inthe new boilerare without fouling when the boiler is started first time. After some time the growth in this fouling fades, which entails the curve to “fade”, ‘When the boiler needs cleaning, this should be done by water washing through the inspection doors (29) and the flue gas uptake. Before commencing the water washing, the bottom of the furnace must be covered e.g. with a tarpauling. This is done to avoid that water is splashing on the refractory atthe furnace bottom, since water can be very damaging to the refractory, when the boiler is heated up again, Water washing through the inspection doors will flush the deposit into the centre of the boiler and into the furnace from where it should be removed, either through the drain or by using a pump. Sea water could be used as the washing media, but in such a case the water washing must always be completed with a desalting by means of distillate, fresh water or perhaps alkaline water in order to avoid salt or acid corrosion, Page 10/27 s AALBORG SUNRODOa) ‘Heavy orsticky soot deposits should be soaked with a 10% soda-ash solution before water washing is commenced, in order to “loosen” the deposit and reduce the washing time, The solution should be spread in through the inspection doors (29), ‘When the water washing is finalized, the boiler should be closed as quickly as possible and lightened up in order to dry out the boiler. ‘The lighting-up should be done very slowly in order to avoid damages to the refractory. During the water washing the refractory will be contaminated with water, and if the lighting-up rate is too high, the water evaporates too quickly and may result in damaging the refractory by making fissures, which can lead to breaking off the refractory. The lighting-up time after water washing must take one (1) hour longer than the normal lighting-up time, and the burner must be operated as by the following during the first hour: © The burner should run in its absolute minimum firing rate © The first half hour the burner is “on” for one (1) minute and “off” for the next two (2) minutes; the sequence goes on continuously * The second half hour the burner is “on” for two (2) minutes and “off” for the next two (2) minutes; the sequence goes on continuously After the first hour of lighting-up has been completed as described above, the normal “Lighting-Up Curve” (Figure 3) is followed until the required service pressure is reached. Stopping of Boiler 8.1 Normal Stop Procedure ‘When the boiler is stopped or taken out of service, the following should be considered: Blow down the following: * water level gauges (6) © sensor lines for transmitter equipment © bottom blowdown of the boiler, blowdown valves (13) skimming of the boiler water surface using the scum valve (5) - should be done shortly after the burner has been stopped and no steam generation has taken place. Cheek the low water shutdown equipment. If the boiler is going to be taken out of service for only a few hours, nothing has to be taken care of, Ifthe boiler is going to be taken out of service forshorter or longer periods, it should be considered how to preserve the boiler (for details, see section 9) AALBORG SUNROD sili, Page 11/27any Page 12/27 Caution: Warning: SKS A a ee EN Please note when the boiler is connected to a feed water system, which is continuously running, the manual feed water valveshould be manually closed, as the automatic feed water control valve cannot be expected to be tight, In the event that ambient empe~ature falls below zero (0°C) empty the boiler and sensor lines in order to protect from frost, Alternatively keep the boiler simmering. 8.2 Emergency Stop If the boiler is suddenly stopped e.g. by one of the shutdown functions, the cause of the shutdown should be investigated and rectified. Subsequently the boiler can be restarted. ey Donever override a shutdown function in order to keep the boiler running, as it will result in serious consequences for engine staff and equipment. ge SESE SI The only overriding of functions, which is allowed is the intended manual mode of running the boiler/bumer. If the boiler is not required to be put into service again after an emergency stop, it should be considered how the items mentioned under the “Normal Stop Procedure” (section 8.1) can be performed. itand-by/Off Service 8.3 Stand-by/Off Service In stand-by periods and “of-service” for shorter periods the boiler is to be kept on a low pressure (simmering) at 2-3 barg e.g, by means of the heating coils (17) if provided. This arrangement preserves the boiler against corrosion caused by oxygen entering not tight gaskets. ———— ‘After stand-byloff-service periods the lighting-up procedure described in Section 6 must be followed. Lighting-up procedure begins at a simmering pressure of 2-3 barg, as mentioned above. ————— lt, AALBORG SUNRODPreservation of Boiler During Standstill Steam boilers taken out of operation for a short or long period of time should be preserved to avoid corrosion vamages on the water side and the exhaust gas side. 9.1 Corrosion Processes When iron and steel corrode under fairly neutral conditions, the chemical reaction will be: iron + oxygen + water = rust In general terms the reaction could be described as: metal + oxygen + water (moisture) = corrosive product Corrosion requires the above three elements to develope. If one of the elements is eliminated, the corrosion will stop. 9.2. Corrosion in the Atmosphere ‘When corrosion takes place uncer atmospheric conditions, the corrosion process is the same as described above, but it can be difficult to figure out where the water comes from. You should imagine that the corrosion occurs in a very thin moisture layer on the metal surface - a layer developed by moisture from the surrounding air. As the layer is very thin, the acoess of oxygen from the airis easy and therefore, it is the thickness of the moisture layer, its salt content and conductivity which influence the corrosion. The thickness of the moisture layer depends on the relative humidity of the surrounding air and the relative humidity thus gets a crusial affect on corrosion of metals such as steel, which does not form protective layers of corrosion products. 9.3 Acids Eee See eee eee eee eect The impact of acids in the air will be determined by extent and type. Generally strong acids will transform with the metal and develop hydrogen and metallic salt. ‘The metallic salts developed will at the same time with their absorbent capacities and conductivity contribution increase the “normal” atmospherical corrosion Contamination of the above mentioned type is for example SO2-pollution of air from sulphuric fuels, During operation the steel parts ofthe boiler will be exposed to the sulphuric acid in the exhaust gas, and iron sulphate is thus generated. These deposits will affect the corrosion rate during standstill. Investigations of the humidity conditions, during which corrosion can be 1e- duced/stopped, have shown that the corrosion will be insignificant ifthe humidity is kept below 40% relative humidity (RH), which can be achieved by dehydration, Corrosion can also be minimized more traditionally by keeping the boiler at an excess temperature above the ambient air temperature, Figure 5 shows curves of AALBORG SUNROD il, Page 13/27ete the necessary minimum excess temperature (designated critical boiler tempera- \/ ture,Te) as a function of the ambient air temperature and humidity. Determination of critical boiler temperature, Te T. PC] 5 » 8 © © 8 6 © Ambient Aix Temperature [°C] Figure 5 Weide As will appear from the above, the humidity of the air has a vital affect on the corrosion speed of steel to the effect that an increasing humidity of the air involves an increased risk of corrosion and thus higher corrosion speed. Consequently, it is possible to solve some corrosion problems by controlling the humidity of the air. Preservation of the Water Side of the Boiler ‘A major function of water treatment is to protect the boiler against corrosion. By ‘adding oxygen binding agents to the boiler water during operation the boiler water is kept free from oxygen and the oxydation process will not occur. During standstill oxygen will inevitably enter the boiler as it is cooled down and. the corrosion process will start ‘The surface of boiler tubes is normally covered by athin layer of magnetite (Fe30%) “The magnetite protects the steel against corrosion where the surface is thoroughly and effectively covered, Ifthe layer breaks, corrosion will start immediately. ‘As magnetite galvanically has at least the same capacities as copper against stecl, corrosion can be rather extensive and only limited by the contents of oxygen and the conductivity of the boiler water. ‘The corrosion attack will be in the form of pittings covered by a thin or thick layer of rust. The progress of corrosion in a pitting is shown on Figure 6. Page 14/27 vil, AALBORG SUNRODAlternatively, a small steam phase inhibitor is to be added to the boil Ora Corrosion in a pitting Boller Water Figure 6 coroscdr It should be noted that corrosion does not occur on the same location as oxygen reacts with the magnetite surface; it occurs at the bottom of the corrosion pit below. the rust. ‘The corrosion process comprises three main elements: metal, oxygen, and water For obvious reasons the metal in the boiler cannot be removed. Instead either the oxygen or the water must be eliminated. That is the basic principle of boiler preservation, The following describes the various preservation methods of the water side of the boiler. 9.4.1 Dry Preservation ‘When applying this method the boiler is totally emptied of water and dried out. Emptying the boiler of water is done by bottom blowing the boiler at 3-5 bar pressure, opening the boiler and draining it of remaining water. [EB] Manhote doors and handhole covers to be opened as long as the boiler is hot, and if there is water left in the bottom it has to be removed, e.g. by using a vacuum cleaner. BBM it the boiler is cold, drying of the boiler is done by either circulating dried air from a fan or by placing bags of silicagel in the boiler, Before closing manhole doors, place a tray with, burning charcoal to remove oxygen. As soon as you have placed the charcoal, close manhole doors with new gaskets. after cooling and careful draining, and the boiler can aftefwards be closed com- pletely 9.4.2 Wet Preservation While dry preservation is a question of draining off water to avoid corrosion, the principle of wet preservation is to prevent oxygen from entering the boiler. AALBORG SUNROD «lt, Page 15/27eG Note: BEES This method can be used for a short period of ‘lay-up’ (1-3 months). ‘The boiler is filled with treated boiler water and hydrazine is added until an excess of 100-200 ppm is obtained. The water should be circulated continuously or at least once per week to avoid corrosion from any peretration of oxygen, and it is necessary to check the hydrazine concentration and add the necessary amount to have an excess of 100-200 ppm. Other oxygen binding agents can be used, too, The pH-value should be 9.5-10.5 If there is any risk of temperature falling back below 0°C, this method should not be used to avoid frost damages. 9.4.3 Nitrogen Preservation ‘The boiler has to be drained, dried and sealed in the same way as mentioned above under Dry Preservation (section 9.4.1), ‘Make a connection to the bottom of the boiler and open air escape valve (8) in the top of the boiler. Connect cylinders with nitrogen to the bottom via a reduction valve and purge the boiler until you are sure that no oxygen is left. Close air escape valve (8). Leave a cylinder with nitrogen connected to the boiler via reduction valve and keep an overpressure of approx. 0.2 bar in the boiler. 9.5 Preservation of the Exhaust Gas Side of the Boiler ‘When the boiler is taken out of operation, the risk of corrosion on the exhaust gas side will always exist. ‘The soot deposited during operation will absorb moisture during standstill ‘The deposits contain ferrous sulphite which, combined with moisture, will be transformed to rust and free sulphuric acid attacking the boiler steel. ‘The following describe the various methods of preservation against acid corrosion on the exhaust gas side. 9.5.1 Dry Preservation ‘When this method is applied, a dehydration unit is installed blowing very dry air into the furnace (through the burner or another connection). The relative humidity of the air should be around 15-25% RH.to prevent corrosion, This humidity of the air balances with approx. 1% humidity in soot. To obiain a sufficiently low relative humidity the boiler must be closed tight so that the uncontrolled ventilation is as low as possible. The uncontrolled ventilation is the term used about the amount of moist air getting into the boiler from outside and ‘which among other things determines the dryness of air that the dehydration unit will maintain in the boiler. ‘When preserving the exhaust gas side, it is recommended to let the air blow through the chimney for the first 2-3 days of the drying out period and then close the chimney damper and start recirculation. Page 16/27 vil, AALBORG SUNRODA similar effect as that of a dehydration unit can be obtained by keeping the boiler warm. The temperature in the boiler can be kept high by means of the heating coil located in one of the downcomer tubes. 9.5.2 Blowing in Additives The sulphur dioxide or sulphuric acid generated during combustion will in turn initiate generation of ferrous sulphate. During operation the generation of sulphur dioxide and sulphuric acid can be prevented/eliminated by ensuring that the temperature does not drop below the ) and carbondioxia (CU2), which may lead to corrosion in the boiler, steam and condensate system, —_—_ ees Itis of great importance that the feed and boller water are chemically treated in order to avoid corrosion from the above mentioned things. ee It is recommended that the operator contacts an established water treatment company and gets assistance to have a suitable water treatment system put into operation from the very beginning of the service of the boiler. Aalborg Sunrod il, Page 1/3ee Enews pie} 2 Feed and Boiler Water Characteristics ‘The requirements recommendations ofthe various values for feed and boiler water are listed in Table I below. ‘Requirements for feed and boiler water | Unit Feed Water Boiler Water “Appearance : Clear and free of mud Clear and free of mud Hardness: ppmCaCO3 0-05 il Cloride content ppmCr <5 100 “P” Alkalinity ppmCaCOs, 100-150 Total (T) Alkalinity ppm CaCOs <2x"P"- Alkalinity pH-value at 25°C_ : 85-95 Hydrazine excess ppm Nog Phosphate excess pm POs Specific density at 20°C kgin? Conductivity at 25°C Sic Oil content, = NL Table 1 If hydrazine (NzH) is not used, sodium sulphate (Ne2SOu) can be used instead, and the excess should be 30 - 60 ppm. In cases where other kinds of oxygen binding agents are used, itis recommended that an excess of oxygen hinding agents ean he measticed and indicate that no ‘oxygen has been dissolved in the boiler water. If it is requested to measure the content of dissolved oxygen directly, it is recommended to keep the value < 0,02 ppm. In addition to the above values, the various water treatment companies will add further demands, depending on the method used for treatment of feed and boiler water. However, the most important point is that the above values or their equivalents are observed and that a regular (daily) test of feed and boiler water is carried out (see next section). Page 2/3 wily, Aalborg Sunrodb) 5 Feed and Boiler Water Maintenance The following are recommended water maintenance instructions, More exact details concerning analyses and blowdowns should be set up together with the supplier of chemicals for water treatment. 3.1 Daily ee Analyses of feed and boiler water, 3.2 Weekly soos Skimming (surface blowdown) according to analyses, but at least once per week (2 minutes with fully open valve). Blowdown (bottom blowdown) according to analyses, but at least once per week (each blowdown valve I minute in low load condition), 3.3 Monthly ee Check of functions for salinity and oil detection systems. 3.4 Yearly Ce Check of the water side of the boiler and hotwell/deaerator for corrosion and scaling. Check the injection pump unit. Aalborg Sunrod ll, Page 3/3,a Safety Valves General In the following the measures required to achieve a safe and reliable maintenance of the safety valves will be described, together with adjustment and dismantling instructions, Anexample of an installation of the safety valve is shown on Figure 1 Mounting of safety valves, example fe att 2 Maintenance and Start-up of Boiler A regular inspection of the safety valve is recomended at least once a year. Some media and appliances require a more frequent inspection, this is according to the experience of the applier. Warning! Before handling and dismantling of the safety valve ensure that the system is NOT pressurized! Before lighting-up the boiler the pipe connections must be thoroughly cleaned for dirt and foreign bodies. AALBORG SUNROD atin Page 1/4eI RES Note: Note: Warning: IE the valve is not completely tight, which often happens after starting up the plant, \_/ this isusually caused by impurities between the seat and the cone. In order to remove these impurities the valve must be heavily blown out by means of the lifting device. If the valve is not tight after several blowings, it may be due to the fact that a hard foreign body has got stuck between the cone and the seat, and it will then be necessary to dismount the valve for overhaul. In case of a leaking safety valve the valve must be inspected and over-hauled at earliest possible opportunity. It must be ensured that the boiler is totally unpressurized before dismounting the valve. Before dismantling the safety valve in the workshop the position of the adjusting screw must be measured and noted which will facilitate the adjust- ment later when the valve is to be adjusted when in service. IF the facings between the cone and the seat have been damaged, they must be grinded Bl The cone can be grinded against a cast iron plate, using a _—_ fine grained carborundom stirred in kerosene. ‘The seat in the valve body can be grinded in the same way by using a cast iron punch of suitable size. Never use the cone itself when grinding the seat. ‘The spindle and the valve cone must always be secured against turning as the seat and the cone may thus be damaged. EE Before assembly the valve must be thoroughly cleaned, and all traces of grinding material and impurities must be removed. ‘When the valve has been mounted the boiler is commissioned, and the valve is then checked for leakages and adjusted to the set pressure. EY The adjustment screw is secured by means of its lock nut, and the valve is sealed. 2.1 Routine Check The following should be regarded as recommendations of routine checks on the safety valves, in order to keep a proper functioning. 2.4.1 Yearly ‘The safety valve should be tested in operation by raising the boiler pressure. Page 2/4 lil, AALBORG SUNRODi Expansion and exhaust pipe should be examined at the same time. 2.4.2 Monthly [EY Examine the safety valves for any leaking, such as: © Is water seeping from the drain plug at the valve body? ® Is the escape pipe hot due to seeping steam from the valve seat? (EQ Examine the drain and expansion device at the escape pipe. Examine the lifting gear device, i.c. clean up and grease all sliding parts. Adjustment and Dismantling Safety valves are delivered with the required spring setting and sealed against unautherized adjustment Adjustments are only allowed in the spring margins. Outside the margin a new spring is required. The pressure in a system should not exceed 90% of the set pressure, All item nos. mentioned in the following sections refer to Figure 2. 3.1 Dismantling of Lifting Device Safety valve with open cap HEB Remove bolt(39) Remove lift lever (41) 3.2 Set Pressure Change without Spring Change NF ETETETEEETETETETETFTETECECETCE Note: Pay attention to spring range sneer ier shh MB spindle (14) must be held fast by all alterations Loosen lock nut (21) Turn the adjusting screw (17) clockwise for higher and anticlockwise for low set pressures Secure the new setting with the lock nut (21) Reassemble lifting device 3.3 Spring Change BG Spindle (14) must be held fast by all alterations Remove pin (16) from spindle cap (39) AALBORG SUNROD sii, Page 3/4Loosen lock nut (21) and turn adjusting screw (17) anticlockwise, Peet then the spring (37) is not under tension Loosen the nuts (8) and remove the bonnet (42) Remove the upper spring plate (26) and spring (37) Remove the spindle (14) with disc (12), guide plate (4) and lower spring plate (26) [2 Clean the seat (2) and disc (12) Remount the spindle unit with the new spring and upper spring plate Assemble bonnet (42) and adjust to the spring range ED Secure the spring setting through the lock nut (21) Remount lifting device Assembling drawing of safety valye ara 29,40 2 Bonnet A tng toe z a Satin 39 Bolt wh 38 Screw Eee 37 Spring 9 2p i 27 Geter 2 99,47 be Spemele Butte 6 vane ss Non 21 Lack nt a SS 18 Bal i 17 Adj coe eS 9. 16 Soc pa a 15 Gaset et a 14 Spindle eS ie 13 Lieaie ei 12Dee H 10,25 1025 Spi cates Be = > Lit ian ng ees £ Stee nt 26 Fane 4 Spindle guide mS a 4 3 stue = 3 Dsest Z 1 Body 16 18 7 12 13 15,22 2 1 aE Figure2 net Page 4/4 lit, AALBORG SUNRODan ea ny ‘Water Level Gauge 1 Mounting on Boiler ‘This section describes how to mount the water level Bauge on the boiler side. Water level gauge on boiler side Ne o = Nut «Box heads S = Joint rings + Box heads “Tuber ~ Screws Screws + Cock plug 6 D- Drain cocks Ny G- Gauge body Y S. Cocks W. Cocks Figure 1 Ki Olecde Remove nuts (1) and lift off stuffing box head (2) from cock. Insert gaskets between cock flanges and boiler flanges and bolt up the cocks $ and W on to the boiler flanges. a Place the stuffing box heads (4) on the ené tubes (5) - insert joint rings (3) in the recess of each cock. AALBORG SUNROD Page 1/5Press the stuffing box heads (4) together with the gauge body (G) on the gauge cocks $ and W. [Gy Tighten units (1) to form a pressure tight seal. Turn the gauge body (G) to the required position and tighten the union nuts (4). [Ed Open the cocks. 2 Maintenance and Service Instructions 2.1 Maintenance ‘The item nos. mentioned in the following maintenance instructions refer to Figure 1 ‘When out of service with the gauge body in cool and unpressurized condition the hexagon screws (6) can be retightened. EG Start at the centre, working to opposite sides alternatety. Max torque: 60 Nm in cold and under working conditions. 2.1.1 Maintenance During Service Check-up [EQ Tighten the nuts (1). Bolts on boiler flanges. EM wnion nurs (4). Boltform screws (7) with cocks in open positions. Ifa leak cannot be stopped by tightening the bottom screws (7), the sealing surface, of the cock plug (8) may be damaged or corroded. Itcan also be necessary to change the packing (3). 2.2 Blowing Dow ‘The item nos. mentioned in this following blowing down procedures refer to Figure 1 ‘The gauge should be blown down before lighting up the boiler and just be- fore closing down the boiler. 2.2.4 Cleaning the Water Side: {2@ Shut the cock S and open the cock W. Open the drain cock D for a short time. This sucks the water out of the glass without, however, totally unpressurizing the gauge body. Shut the cock D and then water is forced upwards into the glass again. Repeat this procedure several times, opening and shutting the cock D. The water level in glass rises and falls. Page 2/5 ii. AALBORG SUNRODant Ee eEiO 2.2.2 Cleaning the Steam Side. HEB shut the cock W. Bi Open the cock S. [Bi] Blow through the steam side and gauge body by opening the drain cock D for 1-2 seconds. A steam blowing of longer duration is not advisable considering the service life of glass, Turn the cocks to operating position. 2.3 Dismantling. ‘The following dismantling instructions refer to Figure } and Figure 2, 6 Screws 9 - Wedge piece 10- Centre piece LD- Reflex 12- Sealing gasket 13+ Cushion gasket 14- Cover plate Figure 2 Si Seate Sectional view of the water level gauge TEE shut the cocks $ and W. 1B The drain cock D to be opened until the glass is completely emptied. Remove nuts (1) and lift off stuffing box heads (2) together with the gauge body from the cocks $ and W. IEG Stacken the union nuts (4) and pull off the stuffing box head (2). Place the gauge body (G) horizontally with the screws (6) turning up- wards and loosen the screws. EG Move the wedge piece (9) lengthwise and lift upwards, AALBORG SUNROD a Page 3/5Page 4/5 15. 16+ 17- 18- 19- Cas [El Litt off centre piece (10) reflex glass (11) and gaskets (12 and 13), [Ey Clean sealing surface of cover plate (14) and centre piece (10) and examine for through going scars 2.4 Assembling ‘The following assembling instructions refer to Figure 2. GE insert following items into the centre piece (10): sealing gasket (12) reflex glass (11) cushion gasket (13). Place cover plate (14) on top. Insert wedge piece (9) and move lengthwise forcorrect position. ‘Tighten screws (6) evenly starting at the centre, working to opposite alternately. Max torque: 60 Nm in cold and under working conditions, 2.5 Maintenance of the Straight-through Cock 2.5.1 Operation Principle and Maintenance. Screw Split ring Packing sleeve Plog Bottom screw Figure 3 woes ‘The following assembling instructions refer to Figure 3, Detail drawing of the straight - through cock ‘The cylindrical plog (18) is sealed with a resilient packing sleeve (17). Should leakage arise during service the packing sleeve must be further compressed by tightening the bottom scrow (19) until the leakage is stopped. This must only be done with the cock in open position. iil, AALBORG SUNRODa AALBORG SUNROD 2.5.2 Dismantling. Remove bottom screw (19). {BB Remove screw (15), washer and handle. Knock the plug (18) together with split ring (16) and packing sleeve (3) out of the cock body by means of a soft mandrel, Remove split ring and knock plug out of the packing sleeve, [Bh Clean all sealing surfaces carefully and lubricate threads with a high temperature grease before installation. 2.5.3 Assembly. [Hd Place the split ring (16) in the recess of the plug (18). {B Push new packing sleeve onto plug. Press the complete unit into cock body. Turn the packing sleeve until the ridge fits with the groove in the cock body. ‘The eyelets of the packing sleeve must neither protrude nor be tilted. Screw in bottom screw (19). Place the handle and washer on the plug and fit screw (15). ‘Tighten the bottom screw(19) and check if the plug is turnable. ali, Page 5/5Water Level Transmitter 1 Operation ‘The water level transmitter controls and supervises the water level in boiler and ‘operate on tie following principle: AA float and float rod carry a transmitting magnet which runs in a stainless stell transmitting tube. The transmitting magnet operates the extemally installed magnet switches. When the magnet switches have been triggered, they remain in that position. Devices with extemal float chambers, the one shown on Figure 1, are connected to the boiler sockets by two shut-off valves, Arrangement of water level transmitter = \a ee Drain valve Figure 1 ete AALBORG SUNROD ill, Page 1/3,Starting Operation ‘The starting operation is to be performed before raising steam and lighting up the boiler. HW Check for correct assembly and wiring. Shut drain valve and open shut-off valves slowly and gradually. Let water into the boiler or steam drum until normal level has been reached and adjust magnet switches to switching level. The magnet switches must rest against the transmitting tube. Execute a function test as described in the following subsection. 2.1 Function Test Al devices must be tested for correct function before they ate put into operation. ‘The purpose ofthe function testis to check whether the alarm functions are working properly. The test must be carried out when the boiler is steaming, During operation, this test should be carried out at least once a day as described below. [i Slowly close the upper shut-off valve, and allow the water level to rise, ‘When doing this it should be observed whether the alarm function “Stop of feed water pumps” is activated when “High water level” is reached. Fully close the lower shut-off valve and very slowly open the drain valve. As the water level falls check whether the alarm function “Start of stand-by pump” is activated when the water level reaches the “Low water level”-mark. Let water fall further, and check whether the alarm function “Stop of burner” is activated when the mark “Too low water level” is reached. Operation and Maintenance Important To ensure correct operation check each detector whenever an opportunity occurs by comparing the magnetic switch function with the level in the water gauge. A great difference in the water levels may indicate either blocked connections to the chamber or a water logged float. Therefore it is important to blow-through the devices and their connection pipes during each shift and at least once a day (see below). ‘This blowing-through procedure should preferably be performed just before closing down the boiler plant to prevent fossilized sludge deposits — ‘To prevent shocks to the float the valves must be operated slowly. i Page 2/3, al, AALBORG SUNROD‘When the boilers is not in operation, all devices including the shut-off valves should be tested for faultless conditions. 3.1 Blowing-through Procedure ‘The blowing-through procedure should be performed as describe below when the boiler plant is in operation. The job should be done at least once each 24 hours. HB Fully close the lower shut-off valve. Slowly open drain valve to fully open position, and allow the chamber to blow-through for about 30 seconds. ‘Then close the drain valve and open the closed shut-off valve. Fully close the upper shut-off valve Slowly open drain valve to fully open p to blow-through for about 30 seconds. ‘Then close the drain valve and open the closed shut-off valve. tion, and allow the chamber 3.2 Cleaning . The transmnitting magnet and the transmitting tube should be cleaned from dirt each three month, and the cleaning procedure is the following: 1 Slowly open drain valve, IB Slowly close the two shut-off valves. Remove top flange of the chamber, The float and floatrod with transmitting magnet is loosened from the top flange. [Eh The transmitter magnet and tthe transmitting tube is to be cleaned Bl The Moat chamber is cleaned for any fossilized mud Check that the float is not water logged. When the cleaning procedure is finished the transmitter is to be assembled as follows. The transmitting magnet is fitted in the top flange. Wy the top flange is fitted on the float chamber [1 Finaily a function test as described in section 2.1 is to be carried out. AALBORG SUNROD li, Page 3/3AALBORG SUNROD Support of AQ-9 Boilers Because of the height and weight of the boiler and the rather high position of the centre of gravity it is very important that the boiler will be supported at top to relieve the Pressure on the foundation flange. This support is to be arranged both longitudinally as well as transversally. in order to be able to lift and transport the boiler it is provided with two lifting irons on the top plate and two lifting irons on the shell plate. the two lifting irons on the shell plate can be used for some of the support, if the Position makes it possible. The position of these lifting irons to be decided by ACI and cannot be changed. Beyond the lifting irons we weld onto the boiler the number of irons which might be necessary for fixing to boiler. When fixing the boiler it 1s very important that the beans used are provided with links in each end and the beams are mounted as horizontally as possible so that the boiler has the possibility of free expansion because of the heat expansion. The position of the fixings and also the beams is in each case decided by the construction of the ship, but as a general cule at least one beam is to be mounted longitudinally and one transversely. Further, the beams are to be as short as possible so that the distance from the boiler to the nearest fix bulkhead will decide whether the longitudinal support is to be placed on the fore or aft edge of the boiler and whether the transverse support is to be placed in SB or BB side. Tf the transverse support cannot be placed directly transversally it might be advantageously to use two transverse beams to secure the boiler, see fig. 1. At double boiler installation it is important not to link the boilers to each other, see fig. 3. The following shows examples of possible positions of fixing irons Instruction K.7121.0 AALBORG SUNRODfig. 4‘AALBORG SUNROD 2.0 DRAWINGS Drwg. No.B44:001822d Drwg. No.B44:001856b Drwg. No. K11:001849b Drwg. No.B4:001851b Drwg. No. AQ9:74177c Drwg. No.B44:001693 Data sheet K.1117.1 Data sheet K.1038 Drwg. No. X1:136027 Arrangement of sockets List of mountings Gauge board Base Insulation Pipe for scavenging air Standard lifting eye Counter flanges Flow diagram for boiler installation AALBORG SUNRODSER | NOLWINSNT=SNTHS eure 60V BROT AIR SR TBS TON Oa svawiog Gyoqioo J ugT108 SHLNO_Gad73M_ 38 INKS NOYINOLL INS NI WWE? NOLL INSNI WUrg HLIM O3IVINSNI 3G GINOHS YIVOR SHI N3IG3" S3SPSASYd NUSFSONINTTOSI Ws, ONRIZIOS! TIE Z GIN SBYITOSI N3IGIM a BPE CE EN BECO a BB RO BOT omg Runisg 04) pa wiompaS upuad @ 50d" watea! Bin39| In TF ae ssung001T T Allowable H R dy de te Shackle load kg tons e000 7 2 aan 74 = 7 16000 190 2 aa 783 Cy 7 25,000 192 i m2 wore 5 ae 31 600 ze 106 eas 43 3 = 20000 200 28 wa 182 8 so 50000 an 10 2a 1526 % % x 2 0 se vs 1 75 - Standard lifting eye Data Sheet ET) for boilers with 75 & 100 mm insulation Pei tet SUNAOD Page tof 1ost | \ ' pes =| ' 1 + ak 00 Dimensions mm | | I Boit on | at D b k ht s | 2 Mires [45 [ors Toe 16 os | a 32 | 44 | 4/Mi2x50 20 | 269 | 105 | 18 7 | 40 32 14 | 47Miexs0 je 2s | 37 | 146 18 8 0 45 14 4/MI2x55_| 2 jaa | 140 | te [io | a | as | 48 | arwiexes 4o_| 43 7 i509 [ie | to | as 45 18 41.16 x55 50 60.3 165 20 125 4a | 45 18 4/16 x 60 65 | 761 | 195 | 22 | 145 | 52 so | 18. |_e/Mioxes 1 S| 989 | 200 | 24 [ie | 3 | 80 | 18 | a/miexes too | 1143 { 205 | 24 | 190 | 65 58 22 8/20 x 70 _125_| 199.7 [270 | 26 | 220 [68] 68 | 25 Te 7mpe xs0_| ‘s0_{ 1683 | soo | 23 | 250 | 7 | 74 | 26 | e/moaxeo 200 | 2101 | 360 | 30 | 310 | e0 | 80 | 26 | t2/Moaxe0 | Materia: c22.6 | Note: The thickness “sis inlarged in accordance with DIN 2634 | Data Sheet K.1038.1 Counter Flanges i Page 1 of sAikonsennes PN 25, (DIN 2634)Zz09E14x | jo/u0 + ‘pow uo}jo)NBas wajsks OV XE v0 Of owes Gfa 3.0 BOILER ACCESSORIES Data Sheets: Ref. to list of mountings, drwg. B44:001856b K.1131.1 - Safety valve, type 25.912 K.1000.2 - Stop valve, - straight way form K.1001.1 - Stop valve, - straight way form, non return K.1002.2 - Stop valve, - angle form K.1003.1 - Stop valve, - angle form, non return K.1010.1 - Needle and gauge valve K.1013.2 - Water level transmitter, RBA 21 K.1020.1 - Reflective water level gauge K.1040.0 - Needle valve K.1061.2 - Check valve K.1165.0 - Stop valve DN 8, PN 160 K.1168.0 - DP-unit K.1174.0 - Manometer 0160, 0 - 2.5 Mpa AALBORG SUNROD)Application: Construction: to blow off steam or neutral ‘gases and vapours, closed bonnet with open lifting device, Inlet nominal size DN25 till DN100, Flanges according to DIN 28607 / 28605, Flange thickness see table, Figur2s.s12 closed bonnet, with open disc liting device Denomination atrial 1 Body eaG-408 0708 2 Bonnet GeGa03 07088 3 cap GGG403 0704 4 Seat Xeoorts 1.4021 6 Dise, hardoned XOSCIMOT7 1.4122 8 Guidepiate xeoors 14001 © 7 Spring 3.1200-6, 1.8158,548iCr 6 3 dusting serow XeoGris 1.4021 ° Spindle xeoGris 1.4021 ae) ok 35 11 | Hoxagon nat cas [32 | Ling dovion 665408 O708 ‘Working tamperatiro © to w+ 350 (1 Guidepiate DN 65-100, @6G 40.3 /1.4122 AALBORG ‘SUNROD. Safety Valve Type 25.912 Data Sheet K.1131.4 Page tof 3Figur 25.912 ourrbartem | 2x40 | aexso | 40x05 | soxeo | esrim | wovias Tums i aeeeecea am atten Pe Ugg te CCE ae Petar ree nee ot | yee reer Pegged Bnet ees yep ye tata i » |» | a | 2 |» |» | , w | » | » | » | » | 2 | » : wo fom [ons | ow | wo fw | wo 1h ws | ons | we | ao | om | we | om _ wo | wo | ow | as | oe | oo | ow l et presser a « Heder eee Ces Coogee CEE PEERS [ora i Bue fae Weight (kg) { at worsee | e [oss [oe | « | we ] «© |» a gauge pressure Dimensions in mn Flanges according to DIN-standard Flange surface according to DIN 2526 Form © Date Sheet AALBORG Safety valve 4131.1 pr Page 201 3 Type 25.912Dismantling and Gagging Instructions Dismantling ENSURE THAT THE PRESSURE VESSEL IS COMPLETELY DEPRESSURIZED BEFORE DISMANTLING THE SAFETY VALVE a 1. Break seal and remove (15) 2. Remove pin (13) and lifting) lever (12) 3. Loosen screw (4) 4. Unscrew cap (1) and remove spindle cap (10) 5, Note the adjusting screw height (8) "6. Loosen the lock nut (14) and unscrew the adjusting screw (8) until the spring tension is reduced (7) i i 7. Loosen the nuts (11) and remove the bonnet (2) 8, Remove the spindle (2) with spring plates (3), spring (7), spindle guide (6), and disc (5) * Attention: Spindle must not be turned, danger of seat and disc surtace damage. Assembly: The assembly occurs in reverse order. Clean all parts thoroughly and replace gasket. The valve should be tested and sealed before taken back into service, Gagging When testing boilers and pressure vessels, at pressures exceeding the set pressure of the safely valve, itis necessary to mount a gag to prevent the valve from opening Gags are usually of the clamp type and are fitted to the valve after removal of the cap and iting lever. Gags must only be fitted hand tight to prevent damage to the spindle and seat surface. ‘AALBORG Safety valve SOD assuuie Type 25.912 Data Sheet K1131.4 Page 3 of 3Type: Straightway form Pressure class: py 25, Dimensions: Face to face DIN 3202, row Fi, anges DIN PN 25 Figur 23,008 T T ow { © | 0 | ax faxes] se 1H | srote | weieme as | saa | 95 | 65 | axe] a0 | too | 0 | a0 30_[ 150] 10s} 76 | ote | 20 | ia] ef a 35 | 160 [is es | oe] 140 | 190] ve" se a [190 [ 100 | too | ante [a0 [sp we[ 200 | 160 | vio | ore | 60 | 28 at so | 230 165 125 | aie] 160 | 235 w | ae a [ aio | res | ied | ore | 00 | Zes |e aaa 30 | a10_| 200) 160 ‘axis | 200 | 280 | a2] eas tou [350 | 235 | 100 aaa | 25 | os | 38 | 36 vas} 400 | 370 | 230 ea6 [250 | 375 | 5 | 150_|aeo_{ s00_| 250° | as | soo | «es | s6 | 8] 7s aaa om ail au SS over 8 | Hexagon ts ice 1.050 EEE eee Stop Valve — Data Sheet iildllli; AALBORG Straight way form K.1000.2 sess Page 1 of 1OsStraightway form sure class:PN 25 x Dimensions: Face to face DIN 9202, ow F1, flanges OIN PN26 a) Ele “e] E15) 7 ‘ Figur 23.006 R on | u | so | ok [nxea 20 | [svete | weiom as_[1a0 [os Tes Taxi] 120 [tao | 9 | 38 | 20 | 160 [05 [75 [axa | 120 | 100 [9 [as 25 [wo | 1s | es [axsa] 140 | 100 | 5 | 5 22 [190 [140 [00 Paxre | sao] 100 | is 49 [eo [50 | i0_| exis | 160 | gas asf a 50 | 290 | 185 | v8 | ante | 100 | 20s] 19 | 28 es [os | 185 | 148 [eve [100 | 268 | 2p | 1004 go {sto | “200 | 160 ['exve | 200 | 200 | ee | as 400 | 950" | “235 [190 | enze | ~zes| ses] as [08 125 | 400 | 270_| 220 [ex26 | 250 | a7s_| se | 6 s0_| eo [900 [280 [ @x26 | s0o_| 40s | s8 | 70 75 | ss0_[ 390] 250 [12251 400” | e658 co | 128 Pan | Denomination Msteriat Matera no. 7 Bos SeewS o708s z Bonnet (666 403 07049 3 Body seating x20659 1.4021.08 4 Die [xe r3 1.402105 s ‘Stem 1 X20 C13. 1.4024 € Handvbeel 6G 25 05025 7 Packing Aicgrphite @ Suce oK3 Tei 2 Hexagon nis cas, 1.0501 10 Gasket Alcgrapita wih Gr Nisa int mater i X12 CN 177 14510 Stop valve Data Sheet aatsona | Straight way form K.1001.1 sunroD | Non return Page to! +Type: Angle form Pressure class: PN 25 Dimensions: Side length DIN 3202, row Ft, flanges O1N PN 25 ox {| t | ee | ex [axea] eo | an | tee, [acne | | | «| aul |i} of « EO 25_[ too] 1a | 5 | amie | ico | ves [aa] ss we [ 108 | 40_[ T00_[ mate | 190 | 168} a] 8 ao_[ 118 |150"| vio [ ewsa | 60] 200| ar] a st_| vas [ves [vas | ait | 160 | ato | en [vas [ae [vas | ante | seo | 208 | a8] 0 ao_| 18 [ e00 | v60_| ove | 200 | 20s | se | an as _[200_[ a0 | m20 [eae | aso] aos ae] ar 130 | 228 | 300 | 280] eee | 300 [ao [es [ae Tat | Bessichnong Werks ‘worse Pan_| Benomnaton men Mateost nos Genduce 7 ae coo | eroes 2. | Begetaeckel 606 403 oro Staring ed a 3 | Booy seat ring ee fe «| Roast wien s4oanos Spindel wtaenote’ |, 6 | Se x20 ona RasePOMe Tonos Handrad 6 | Rana esas ees 7 | Sioptouenerschna | tangaouvancoeonn Stopou ingest ntereshite Sischrauben - @ { Sites oxes a1 8 |Reoonnus | 635 oso ve | Benin Tangashi wi Gc Santen Enage Sesiar aseashie wits Ge Meet iput eats! ¥ Fedor 12 Ct NIT 143 + | Ease nzernii77 «a0 Stop Valve Dats Sheet AALBORG Angle form K.1002.2 SUNOS Page 1 of 1Sroke “ype Angle form z Pressure class: pw 95 Dimensions: Side length DIN 3202, row FI flanges OIN PN 25 f T ioe [eonient ox | + [eo | ex [nsee] oc | om | ste, [Semct | % | | «| am | we] wo] oj a zo 95] v05 | 75 | ana] ve0_| 180] 9] as a Ea | 18 | ¥80_| 1907 | acta | 160 | 200 [a] ae so] 425 | 165 | 12s | axié | 100 | ao | ie | ate ee [tases [vas | are | a0 | ae | ze] ar wo [155 | 200360 [ate | 200 | 20s | 38] Ze vas [700 | aro | 220 | exes | aso | os [ee [a] 350] 226 | 300 | 250 | 6x26 | 300 | a0 | se | oe 73H Werssann an mstecnner | + [seme eeeeea 07083 2 | Sagelsecer coe s0a 0708 Sizing ae, S| Body seat ring isoibalit ae «| Reset eons 1408105 [5 | Senger Eee ig ragenolet |g | Sens x20cna Pasesole | eoz2 05 | enero seas aes 7 | BogpueserckonaT nemaraontvaraonte Siechreuben : ina e| Sssteween oxas 78 Sechstarinatern Tbk Hexagon nuts, ttt ae Dienives Reiorana nk Gon SanlonenEniage Gastar isgrahte wit Ge Nese anata Feder asi toe xigorwinr? ao Stop Valve Data Sheet AALBORG Angle form K.1003.1 ‘Stunoo Non return Page 1 of 7NAF 402730 T Dimensions esietance| Seat pt 0%. att, love Best seat | 4p Pert No efefel uf ela Geatcton| Seek | Wet zeny Be ie 402720 | 10 | 34°] 15 | 2" ‘a’| 5 | 20] 75| 64] ss] 800 %"] 3) 18] 2s} se] ss} te | as | 04 3s | osz Valves sre how-pressed in gunmetal 85-5-5-5. Inside screw, rising stem, one-piece body-bonnet, disc integral with stem. Bonnetless construction eliminates the disadvantages associated with bonnet-to-bady connec: sions — valve top cannot unscrew when stem backs against bonnet. This integral construction also main. shins correct stem aligment, with exact mating of disc and seat surfaces essential co positive shut-off nd long service life. Pitch of stem thread and contours of dise and seat orifice are balanced to provide optinum flow characteristics for manual regulation on throttling ser: vice. Precision finish of valve stem reduces friction on packing material to a minimum. Precompressed 62 var at desec Sunmeret | ao PIFE 402730 25 var at 226¢C | 10-15 | Male-Union with Test Flange | asses" | imeregnate Data Sheet K.1010.4 AALBORG ‘SUNROD, Needle and Gauge Valve Page 1 of 1TOV WRB 84-311 ‘TUS WRB 84-30 BV 759 / 1364 AE /DT2 ME/BT Pressure range PN 25 Max, allowable working pressure (bar) 20 Max. allowable working temperature (°C) 214 Working pressure max. 120 °C (bar) 2 Field of application: Water level limiter as per TAD 401, 402, 602. Adjustable control range W = 100 mm Switch current max. at 6 - 250 VAC 1.0, DcosA Protection of switch housing IP §4 as per DIN 40050 PN Motori | Measures, roe i a im Catt 7 7 conection fonge rain connect 2 | ore | 628 | 100 | 7 | 170 | omasasoNzo Rae Water level switch RBA 21 panne AALBORG DN 20 K.1013.2 ‘SUNAOD Page 1 of 1VY"10: See “List of mountings ‘The connexion between the gauge and the two gauge cocks iz lormed by endtubes: ©. 16 mm for connexion to 0 paupe cocks. ‘The seal fs made by a stulfingB0x in the gauge Cock and a jane ‘ing onthe Gauge, The gauge may be rotated thvough 300 ‘s10U0d Its axis fo ary desea position, S combined K ce End connexion with D gauge cocks (see Mlstation ‘esse! connexion by tange “Torque fot gauge bolts 60 Nr, cold or warm, ‘The auge Is titles with a KLINGER type A boreetcale retan lass. L. [ Overall and connexion dimensions (mm) e a me se ore tae ueneke | aengie [ amgne | GEESE PN 40 82 bar, 296° C saturated steam size x 5 @ xe. ui 200 | 8 so | 15.10, 3 oss [aie e0_| 15.80 xv 408 | 978 5@0 [17-30] 2a 466 [as 220 | I8-50] 2xvi 528 250_| 70-70 | 2x vi 588 [200 21-10 zavil | os. | ~seo | 22-90 2x 708 34024330. Savi 723 280__| 27.40, xvi 283 200_| 78.00. ‘xvi | 700s a0] 30-70 Sx 108 1028 340 | 37.80} Data Sheet aatsors | Reflective water level gauge, complete K.1020.1 ‘SUNROD + Page 1 of 1Type: Angle form Pressure class: PN 25 Dimensions: Side length DIN 202, row Ft flenges DIN PN 25, ow { t [ ee | em faxeel se | Ht | srcte | weignt sz | 250 | 230 [200 [1225] ao | «09 | oo | 181 200 [275 | 360] 210 | tas] aco | sis | 7a | 160 2s0_| ses | 2s | so | vac] seo | e10 [80 | 268 30e_| ars | es { «30 | veao| s20 | ars [vio | arr a60_| «28 | s5s_| e090 | veas | exo | 760 | 116 | S10 ‘a00_| 47s | 20 | $80_| 1685 | cao | 750 | ie | 700 soo [ses [730 | 660 | ace] 640 | oro | ver | 1098 | Part | Denomination Materia Material No. + | soay 68-C25N 1.0618.01 7 ‘DN =50=C2N 0407 Sonnet Onzs0:Gs-c2sn__| 1.0819.01 3 | soay seat ring xa0003, 1.4021,05 7 DN S200, x20G113 | 1.402105 Dise ON > 200, Hi/xeceri 18 | 1.0426/1.6502 5 | stem x206n3 1.4021.05 Siar sc2s aos 7 | Packing Allgraphive ® | sues ok 38 1181 S| Hexagon nuts ae ial HOE | tasty ‘Alegrapdive with Cr Niesteel input material 11 | pushing ‘cuzn 36 Poa 20404 ieee M2 CENT 1.4310 Stop Valve Data Sheet AALBORG Angle form K.1029.1 ‘SUNROD Page 1 of 4Resistance] oon] cana mg [oreo] Arron see] om, |eeffeont| eat | sunce mrongng |" Bgp" | Wht | part : Zz i Thread kg to | 4 438" BsP) 180 4 Procompressed Fomal 0.32 | 2573307 its | etre | esberazasce | oma PEPE oe [oe | om | cae | esse - iH Valves are hot-pressed in gunmetal 85-5-5-5, Inside screw, rising stem, one-piece body-bonnet, disc integral with stem, Bonnetiess construction eliminates the disadvantages associated with bonnet-to-body connections - valve top cannot unscrew when stem backs against bonnet. This integral construction also maintains Correct stem aligment, with exact mating of dise and seat surfaces essential to Posttive shut-off and long service life. Pitch of stem thread and contours of disc and seat orifice are balanced to provide optimum flow characteristics for manual Fegulation on throttling service, Precision finish of valve stem reduces friction on packing material to a minimum, Data Sheet 1040.0 AALBORG Needle Vaive eae Page tof 1Gs—e > 7 ie 7 = Dimension table t Dn 125 |150 | 200 { 250} 300 L a9 | as 29 29 33 A 100 [120 | 155] 200] 232 Denzs} 185 |226 | 286 | 343] 403 Weight 3.0 |4,8 {11,0 }15,0 } 25,0 Material, pressure and temperature ae Material Internal |g 3 | Max moreang an oe ec & tr 7 Body parts é g [ROERIng tenper lege. aloft EBs | $20%s120® fovea [root frase? |raoa® [toe |oeooe Steel oa 25 28/239] 22 | 21 | 17 | as | aa c2z 22 AALBORG, ‘SUNROD Check valve PN25 Data Sheet K.1061.2 Page 1 of 195 ! | I I 1 t w12 [a2 M20x1.5 90 Connection: Inlet: 1/2" BSP DIN 19207, form R s—n@utlet forsteel tubs o 12 Construction: Drop forged vaive body 00 20300 a Working temperature ba 3 ao & xo 2 ao 5 wo Bo Screw bonnet is locked with locking screw Surface: Black phosphatized DIN-Werkstoff Body: 1.04604 Bonnet: 1.0501 Body seatring: 1.4021 Dise 1.4122V - Stem 1.4104 Packing All-graphite Data Sheet ‘StNBOD Stop valve DN 8 PN 160 K.1165.0 V2" xo12 Page 1 of 1Reference tubeto be filled with water before start up, = wy 120 + eo oD) € 2 5 e & 2 a g 6 3 8 Flange EP oc DN 25 PN 40 ou DIN2685 2 G] drain vaived °| 3/8" BSP. K a Tubes 12 a Loose suppy or a yard fitting, x To be supported if neccessary. is 1 | u a Bo in} ce nce] 180 220 Three valve manifold with flange for direct mounting Drain valves of pressure transmitter. 3/8" BSP DIN19213-83 Data sheet Aataona DP-Unit ree SuNROD Page 1 of 1KaN78.eo1 3ofoss cee (EN i 196. Measuring range : 0-16 bar Weight 1 appr. 0.8 kg Connection 3/8" BSP Execution: Moisture tiaht. resistant tn hases, saline celutiono, cl, grease, diiuley aukis, etc. Measuring System: Bourdon tube tin-bronze Material: Case steel - surface, black polyamid Screw cap : light metal - surface, black polyamig Socket: brass - mat nickel-plated Data Sheet Manometer o 160 K.1179.0 [AALEORG SUNROD Page 1 of t& AALBORG SUNROD 808 4.0 FEED WATER SYSTEM electrical-pneumatical feed water regulation (Drwg. No. X1:134686) Data Sheets: OM6510.0a - Instruction K.1041.1 - Pneumatic control valve K.1177.0 - Filter regulator K.1168.0 - DP-unit AALBORG SUNRODny Feed Water System 1 General Description 1.1 Water Level Control ‘The feed water supply to the boiler is handled by a one-element control system, ic the addition of feed water is controlled according to the water level only. ‘The control system is designed to maintain the water level in the boiler as well as to provide the required alarm and safety shut-down functions related to the water level. The water level transmitter is mounted on the boiler as indicated on the arrangement ty drawing in Figure | Level transmitter arrangement From feedwater line Reference impulse leg 2 1 - Filling valve 2/3 - Stop valve 4/5- Drain valve 6 - Manifold 7 - Differential pressure transmitter | oh NX Figure 1 6510. .CDR cy Page 1/6 AALBORG SUNROD ll,Page 2/6 ny All item nos. in brackets mentioned in this chapter refer to Figure 1, if nothing else is stated. ‘The level control basically works as follows: » The differential pressure transmitter converts the detected water level impulse into a 4-20 mA DC signal used as input for the level controller. » The level controller, located in the boiler control panel, will in response also give a 4-20 mA DC ouiput signal to the pneumatic control valve. ‘© The level controller has a built-in level indicator device. © The valve is equipped with an electro-pneumatic valve positioner for conversion of the current input to a pneumatic signal and for control of the valve stroke accoding to the input signal, © The differential pressure transmitter signal is also used for remote level indication in the engine control room. 1.2 Alarm System The alarm system consists of two independant automatic means of shutting off the ‘il supply at too low water level (as required by the classification society) and a ‘number of other alarms: +» Separate low water level float switch for shut-off of the fuel oil supply at too low water level (see arrangement of sockets/ list of boiler mountings). ‘# Limit switches (located in boiler control panel) connected to the differential pressure transmitter output signal comprised of: — shut-off of the oil supply at too low water level — low level alan — high level alarm — stop of feed water pumps at too high water level Extent of alarms is shown on the wiring diagrams for the boiler control panel (see separate instructions). 1.3 Feed Water Control Valves The pneumatical control valve is equipped with a electro-pneumatic valve posi- tioner for control of the valve stroke according to the input control signal from the computer. The valve is “normal closed”, ie. it will be closed in case of power and/or ccontfol air failure. By fault in the differential pressure transmitter signal the control valve will be closed as well. A handwheel enables manual operation of the valve. ae AALBORG SUNRODos oy Installation ‘The following general installation recommendations should be observed. 2.1 Feed Water Control Valve Ht EY Install the valve at an easy accessible location with sufficient mainte nance space, Install the valve in vertical position with actuator upwards. If impos- sible the valve may be tilted down to horizontal position (but never the inverted position). [EB Avoid strains on the valve from pipes and never use the valve as fix- ing point for the pipe line. Clean the pipes thoroughly to clear out any dirt, welding pearls, ete before installing the valve. (A strain on the valve inlet side can be recommended for the initial service period). 2.2 Impulse Piping ‘The impulse pipes must be carefully designed to ensure correct measurements Install the pipes with continous fall (at least 5°) from the boiler connections to the transmitter to prevent trapping of air, Use carbon steel pipes with a nominal size of not less than DNIS (14" ID). Make impulse piping as short as possible and do not insulate, 2.3 Differential Pressure Transmitter ‘The differential pressure transmitter, maintenance valves and mud vessels are most conveniently mounted on a panel at an easy accessible location, Install the transmitter with the process connection upwards to prevent trap- ping of air. Connect the reference impulse leg (upper boiler connection) to the low pres- sure connection (L), and the variable impulse leg to the high pressure connection (HD), Install the valves for maintenance close to the transmitter for easy operation. Install the mud vessels and drain valve close to the transmitter for easy blow- down of the the impulse legs. (lite ay a an) AALBORG SUNROD iba Page 3/6Calibration and Set Point Proposals VY Note: Before starting the boiler the reference impulse leg must be totally filled with water. 0 The span and zero elevation should be checked and, if necessary, calibrated to obtain a 20 mA output signal when the water level is at the upper boiler connection and a4 mA output when the level is at the lower connection, 2 | Calibration of differential pressure transmitter : : | Spanbetween )-_-—Differential calibration | “Transmitter Water level connection, mm, pressure,mmWC | output, mA ‘Lower connection ae 521 4 fread Upper connection 20 Table 1 (28 The damping adjustment should be set at maximum. 3.2 Level Indicator Controller (PID-type) ‘The set point should correspond to the normal water level mark on the boiler, ic. the controller is set on NW, ‘The control action should be reversed, i. increasing output at decreasing input. Proportional band, integral and derivative action time (PID-values) should be set according to operation experiences of the actual boiler plant. 3.3 Electronic Limit Switches {in control panel) Item Heeight above lower boiler connection, mim Shuroffof ol supply at toolow waerient 145 8.4 Low level alarm 195 7) : ‘igh evel alarm 400 16.2 Stop of feed water pump at 100 igh water level Table 2 *) This figure is calculated as follows: ‘height above lower connection \. 1. ma] \U height benveenconnections ue Page 4/6 wl AALBORG SUNRODThe positioner action should be direct, ic. increasing output (air pressure) at increasing input (current signal), corresponding to the control action of the level controller. The valve must be stroked, so that it is completely closed at 20 mA input and completely open at 4 mA input. Calibration / Set Point Record ‘The actual performed calibration and setting of the various components should be recorded in the tables below to provide valuable information for operation and maintenance. Readjustments should always be written down also. Span adjustment, mmWC Zero elevation, mamWC Damping, degrees irom min, pos. Notes: Table 3 oo Jevel indicator controller Gn boiler control panel). ‘Setpoint, mimWC Proportional band, Xp % Inegral action time, Ty in. Derivative action ime, Ty mia, Notes: Table 4 AALBORG SUNROD lls Page 5/6‘Shut-off of oil supply aL too low water level, mA. Lowlevelalarm, mA. High level alarm, mA ‘Stop of feed water pump attoo igh ‘water level (if provided), mA Notes: Table 5 Ee “Reed water control valve Proportional band adjustment Xp, Number of bums trom closed position Volugeagusinen, Se cost pestin Tos Table 6 “Air reducing set | Outpurpressure, bar Notes: eee eee eRe EEE EEE EEE EEE EEE EEE Table7 Page 6/6 AALBORG SUNRODTECHNICAL sPecsFrcaTioN ALE PRESSURE CLASS [in pas iz TNCOULAR CAST TRON 8007 MATERIAL eee Tan TERIAL STAINLESS STEEL PTFE V-RING WAIT eee {-10°C TO +220°¢) Fai GamSTERE EBA PERCENTARE POSITIONING Aa Teor ACTUATOR Tee aTaE oe |_| Bae DIAPHRAGH AREA (cm) 2s0_| 290 | eco FILLING WOLIRE (Wc) 422337 PAK AIG PRESSIRE 1660) er hand 95% TiN DEVICE = “eri Ho eID 1/P-POSITIONER aaa a DIMENSIONS (me) 15 4.8 4130 Ss 6s 2 #3 is 20 8.3 DP32 450 405° 35 250 250 225 aL 50 40 230 165 125, £25 3 ele Gei=|«|o| eaters OP33 4 520 300_] 290 300 60, &0 1: ‘DPS4 310 al hd i } 625 | 405 420 | 400 cn CONVERSION FACTOR FOR FLOW COEFFICIENT: ev = 1.17 kv AALBORG ‘SUNROD. Pneumatic Control Valve Data Sheet Type 23.440 DP K.1041.1 With /P ~ Positioner rarer; Hata Ro Part Designation re sore eae cassoa / 7043 2 | Mounting bomet | Seating Ker / tears 4 | Pog X20.6r18 1 1021.05 3 | Sendo 200618 1 140B.05 6 | Sting box PTREVsing uh sprgtredos 7] Gulang bush ting bxtoutng) 20.019 / 4025.05 -haroned | Sade Severin @ | Hexagon nas 35 11.0501 to | Gasket rhe 14 | seowiont KIzGrNS tes 7108 18 | _ Spring-Type Straight pin 555SI7 11.0970 _| a2 | _Botona uit Kio crNiT 169 / 1480 24_ | Bolows hous 668-409 707048 25 | Spacer ing Ving uni XS.rN 109 7 14901 [ 27__| Seng XRCrNITT7 71.4310 zs | bush Rehlred PTFE 20 | Gasiat Sotiron wo | Seaper Rehored PTFE | Sp SS520K | so7ar » Hanioned so | Aster oP 51_ | Skettopnoumate Postonorype 3763 Paset Pneumatic Control Valve Ses Type 23.440 DP SUNROD With UP - Positioner Data Sheet K1041.4 Page 2of 2ry ‘ ‘LET PRESSURE 7 tor : Be Crit Bs > : 7 2 att fs | ‘faa ; SEE ‘SEER SH iia Technical Data: Mediums... cerevessees Compressed alr only Maximum inlet pressure:.....2..2. 17 bar ‘Operating temperature: ses 720°C to+ 65°C Fiiter element: s+ Sum Recommended regulating press: ... 0.14-7 bar Gauge ports:........ 118" BSP Connections ports a" BSP Pressure gauge: ....... 0- 10 bar Weight: . Bete + 04kg _= | KANT7, 01, 0203.4 Filter Regulator with Automatic Drain AALBORG SUNROD Data Sheet K.1177.0 Page 1 of fReference tubeto be filled with water before start up. ° a Flangé x DN 25 PN 40 DIN 2635 Sy eaaie aod Three valve 180 400 | 61 Drain valves manifold with flange for direct mounting 250 of pressure transmitter. DIN 19213-B3. J Dim"! 525 mm 800 mm Data Sheet AALBORG DP-Unit K.1168.0 SuNKOS Page 1 of 188 ‘AALBORG SUNROD 5.0 FEED WATER PUMPS Data list 0M3010.0 - Instruction AALBORG SUNROD[AALBORG SUNROD BOILER FEED WATER PUMPS Pump Type Medium Capacity Delivery head Motor Motor rating Voltage Speed Full load current Starting current Protection class Insulation class Temperature class : CR 16 - 100 Water at max.120 °C 13 m/h 195 m WC 15 kW 3x 440 V- 60 Hz 3500 RPM (25.6 A) (143 A) IP 44 F B AALBORG SUNRODa eo Feed Water Pumps i Note. Warning: General ‘The multistage in-line centrifugal pumps are usable for pumping feed and boiler water in the boiler plant. ‘To havea proper functioning of the centrifugal pumps itis essential that the pumped liguid does not contain any solid particles or fibres. Further the liquid must not attack the pump material chemically, 1.1 Technical Data a © Ambient temperature: Max. 40°C. © Liquid temperature: -15°C to 120°C. © Minimum flowrate (independent of liquid temperature): 0.4 m3/h. * Maximum inlet pressure: 15 bar, however, the actual inlet pressure + pressure when the pump is running against a closed valve must always be ower than the “maximum permissible operating pressure". © Electrical data: See motor nameplate. * Noise level: 71 dB(A). Further technical data can be found on the Data Sheet related to the pumps. ‘The pump is not allowed to run against a clased discharge valve as this will ‘cause an increase in temperature/formation of steam in the pump which may cause damage to the pump. IE there is any danger of the pump running against a closed discharge valve, a minimum liquid flow through the pump should be ensured by connecting abypass/a drain to the discharge pipe. ‘The drain can for instance be connected to a tank. Start-Up Do not start the pump until ithas been filled with liquid. | Do not start the pump until it has been primed and vented, AALBORG SUNROD ail, Page 1/5Note: Note: Note: 24 Priming i _ ‘The following does only apply to systems where the liquid level is above the pump inlet [BB Close the discharge isolating valve and loosen the vent screw in the: pump head, see Figure 1 eset nS ASRS Pay attention to the direction of the vent hole and take care to ensure that the escaping water does not cause injury to persons or damage to the motor or other components. In hot water installations, special attention should be paid to the risk of injury caused by scalding hot water. _ eta RS TNS Slowly open the isolating valve in the suotion pipe until asteady stream of liquid runs out the vent hole. ‘Tighten the vent screw and completely open the isolating valve(s). Tllustration of the centrifugal pump Hlustration of the centrifugal pump Vent Screw/ Priming Plug Drain Plug/ Bypass Valve ==> Flow direction Eee EEE eee eee cere eee cee ee Figure 1 cut 2.2 Checking Direction of Rotation Do not start the pump to check direction of rotation until it has been filled with liquid. sre so i SS SP SSS ‘The direction of rotation should not be checked with the motor alone, as an adjustment of the shaft position is required when the coupling has been removed. Page 2/5 AALBORG SUNRODSC seaaenm eM) The correct direction of rotation is shown by arrows on the pump head and/or on the motor fan cover. When seen from the fan, the pump should rotate counter-clock. wise, 2.3 Starting = Before starting the pump, 1G completely open the isolating valve on the suction side of the pump and leave the discharge isolating valve almost closed. By Start the pump. Vent the pump during starting by loosening the vent screw in the pump head until a steady stream of liquid runs out the vent hole, sec Figure 1, susan rr rs tsa sR Pay attention to the direction of the vent hole and take care to ensure that the escaping water does not cause injury to persons or damage to the motor or other components. In hot water installations, special attention should be paid to the risk of injury caused by scalding hot water. ean SE 7S ERE ‘When the piping system has been filled with liquid, slowly open the discharge isolating valve until it is completely open. ‘When pumping liquids containing air, itis advisable to vent the pump regularly. To vent the pump, loosen the vent screw in the pump head during operation. 2.3.1 Frequency of Starts and Stops Motors smaller than 4 kW should not start more than 100 times per hour. Other motors should not start more than 20 times per hour. Maintenance Serna SS RET HANTS Before starting work on the pump, make sure that no power is supplied to the pump and that it cannot be accidentally switched on. sete iii SS NE seasseteimaraaS Before removing the cover of the electrical terminal box and before any removal/dismantling of the pump, make sure that the electricity supply has been switched off. tment EOS re SNE Pump bearings and shaft seal are maintenance-free, Warning: 3 ‘Caution: Caution: AALBORG SUNROD sil, Page 3/5If the pump is to be drained for a long period of inactivity then, ce Remove one of the coupling guards to inject a few drops of silicone oil on the shaft between the pump head and the coupling. ‘This will prevent the shaft seal faces from sticking. ‘When fitting the coupling guards, make sure that they are centred vertically in the recesses in the pump head. 3.1 Motor Bearings ‘Motors which are not fitted with grease nipples are maintenance-free. Motors fitted with grease nipples should be lubricated with a high-temperature 1ithinm-based grease. In the case of seasonal operation (motoris idle for more than 6 months of the year), it is recommended to grease the motor when the pump is taken out of operation. 4 Frost Protection _ Pumps which are not being used during periods of frost should be drained to avoid damage. [Hi] Drain the pump by loosening the vent screw in the pump head and by removing the drain plug from the base. _ eres tT ESTES TEES Warning: Caremust be taken to ensure that the escaping water does not cause injury to persons or damage to the motor or other components. lit lot water installa- tions, special attention should be paid to the risk of injury caused by scalding hot water. Donot tighten the vent screw and replace the drain plug until the pump is to be used VY Before replacing the drain plug in the base, screw the bypass valve out against the stop, see Figure 1. it the drain plug by tightening the large union nut followed by the bypass valve. 5 Fault Finding Chart Before removing the terminal box cover and before any removal/dismantling of the pump, make sure that the electricity supply has been switched off. Page 4/5 fi. AALBORG SUNRODoman CETTE eae Fault Cause @) Supply failure bases blown, ae tared| ©) Motor starter overload has tripped out. 1 Motordoes notrun when stated) ¢)y4ain contacts in motor starter are not makingcontact or the ols faulty. e)Control circuit fuses are defective, £) Motor is defective, a) One fiseis blown, +b) Contacts in motor starterovertoad are faulty. jiMoier starter overload trips out | 2) csbie connection isis o fal. Sageaely when supply is |G) Motor winding isceretive eviction Pump mechanically blocked ‘5 Overioad seting 100 low. 3.Motor starter overload trips out | 2) Overload seing ootow. aecasionall b)Low voltage at peate umes. 4. Motor starter has not tr Salosscnaasaim’ [ocmeia mance, ry 2) Pump inlet pressure is too low. 5.Pumpeapacity notconstant. | b) Suction pipefpump partly blocked by impurities ) Pump draws nai, 2) Suction pipefpamp blocked byimpurities 8) Potar dab lat vabe bck clsedpstin 6.Pumpruns bat gives nowater, | c)Leakagein suction pipe. 4) Airin suction pipe or pump. )Motorroiates inthe wrong direction 2) Leakage in suction pip. 7. Pumpruns backwards when | b) Foot of non-retum valve defective. Switched of ©) Foot valve blocked in open ar partly openpesition <6) Non-return valve leaks or is blocked in parly open pesttion. aid 8) Pump shaft position is incorrect. 8. Leakage in shaft sea t)Shatseal i detec. €) Cavitation occurs in the pump. Y.NoIse ) Pump does not rotate freely iricional resistance) because of incorrect pump shaft position, ©) Frequency converter operation: Resonance in the installation, Table 1 6 Service _ Note: If a pump has been used for a liquid which is injurious to health or toxic, the pump will be classified as contaminated. _=e ete rg Any application for service (no matter to whom itmay be made) mustinclude details about the pumped liquid if the pump has been used fo: liquids which are injurious to health or toxic AALBORG SUNROD il, Page 5/5~ ‘savBORG SUNROD 6.0 SALINOMETER Data Sheets OM885#01.0 - Salinity alarm equipment i K.1089 - Conductive electrode, ERL 16-1 - Conductivity controller LRS 1- 5b AALBORG SUNRODGC)Cy Salinity Alarm Equipment Conductivity Limit Switches, LRS 1-5b 1.1 Purpose and Application Continuous monitoring of the conductivity of liquids with the conductivity elec- trode ERL 16, Signalling of preselected conductivity limit value Application in steam boiler plants for feedwater and condensate monitoring 1.2 Design EC ee eS ee eeSEeeeeeseereereeeeee EEE eeeeeeeeeEe Plug-in unit plastic case for installation in control cabinets. The terminals in the case are accesible after looseing two screws and unplugging the unit from its base. The avoid confusion with other plug-in units inserts are fitted in the bases so that only the correct unit may be plugged into each base. The plug-in units may be snapped onto a 35 mm supporting rail or screwed into position on a mounting panel. 1.3 Technical Data ‘The dimensions of the LRS 1-5b electrode are shown on Figure | Dimensions of LRS 1-5b conductivity limit switch Figure 1 since AALBORG SUNROD vila, Page 1/7* Function: Measuring transducer with switch contact for conductivity used with the conductivity electrode type ERL 16, manual temperature compensation at operating point * Input: 4 connections for the conductivity electrode ERL. * Output: | potential-free relay contact; — max contact rating: 250 V, 500 W, 3 A ohmic with alife of 4x 10° switch- ing cycles or 0.35 A inductive witha life of 2x 10° cycles, — contact material silver, hard-gold plated * Limit value: Continuously adjustable within the respective range — 04...10 mS/em or 0.4...1 mS/em for LRS 1-Sb Seeation between the wo ranges by switch on font panel, values refered to ‘Temperature influence can be compensated with the aid of adjustor up to max 250°C on reaching service temperature initial position calibrated to 25°C. © Switching hystrerises: 1% © Indicators, 2 LEDs: — green for o > limit value — ted foro > limit value * Cell constant of conductivity electrode: C = 1.0 L/em * Electrode supply voltage: Delta voltage 0.5 Vp/1000 Hz for LRS 1-5b. © Main supply: 220 V / 60 Hz, 3.5 VA. * Protection: IP 40 © Permissible ambient temperature: 0...55°C © Case materials: — Base: ABS plastic, black — Cover: ABS plastic, stone-grey © Approx. weight: 0.5 kg * Cable requiged for wiring to the electrode: Screened cable, e.g. 4x0.5 mm’, cable length see Table 1. * Associated Conductivity Electrodes: Type ERL 16-...., PN 40 1.4 Installation and Service Instructions 1.4.1 Installation with Mounting Clip [By Snap unit onto 35 mm supporting rail. 1.4.2 Installation without Mounting Clip | [BW Loosen cover serews and unplug unit from its base. Unscrew mounting clip. Drill the holes in the base marked 6 4.3 mm, Fasten base with two screws M 4 onto mounting panel, AALBORG SUNROD Page 2/7Musee 1.4.3 Wiring Wiring should be carried out in accordance with wiring diagram (see diagram on Figure 2 or inside cover of plug-in unit). The mains voltage is indicated on the name plate. Wiring Diagram ectrode vor. For wiring to the clectrode screened cable, e.g, 4 x 0.5 mm? is required, length see Table 1. If other cables with a higher self-capacitance are used, for the same cable Jength the initial non-linear range is increased (see Table 1 below). The screen should only be connected to terminal 12 of the conductivity limit switch, but not to the terminal « of the electrode or to earth of the control cabinet. HH To introduce cable, remove cable entries in the base. BD After wiring replace cover and tighten screws. Influence of cable capacity on linearity in the initial measuring range can be seen in Table 1, (basis: cable capacity 200 pF/m). Shorter cables than listed in Table 1, | reduce the initial, non-linear measuring range. = LRS 1-56 | Nominal measuring range 04..10mS¥em (0.04.1 mS/em Linear inthe range 1..l0mS/em O.1.LmS/om Cable length : 50m | Cable capacity 3 1000F 108 Line resistance per condvetor 2308 a Table t AALBORG SUNROD sll, Page 3/7OM885i01.0) 1.4.4 Commissioning Selection of measuring range With the aid of the switch provided on the front panel. Calibration The conductivity limit switch is not provided with an automatic temperature compensation. The temperature influence on the conductivity has therefore to be compensated at service temperature, ‘Take sample of liquid to be monitored via sample cooler and determine conductivity with a conductivity meter. [Bil Set switchpoint adjustor o on value found. [Bh With the tiquid at service temperature turn adjustor Cal to the left until the lamps switch from red to green, Set 5 During operation the actual conductivity value can easily be found by tuming switchpoint adjustor o until the lamps switch from green to red or vice-versa, In the case of boiler water the density is normally measured in “Bé, A relationship between °BE and conductivity c can approximately be established as follows: 1 °Bé corresponds to a salt content of 7000 ppm. 1000 ppm NaCl produce a conductivity of 2000 uSfem at 25°C. ‘The following equation can be deived: @ [mS/cm] . [°BE] measured x 14 tch point adjustor o on required limit value. Example: If 0.4 “BE are measured, this corresponds to a condvetivity © = 5.6 mS/om in accordance with the above equation. This value has to be preset ‘Then turn adjustor Cal until the lamps switch over. 1.4.5 Performance Test Short-circuit of terminals 3 and 1 of the electrode or terminals 9 and 12 of the conductivity limit switch: The red lamp should light up independently of the position of the switch point adjustor. 1.4.6 Maintenance Deposits on the electrode tip produce an error in measurement which becomes apparent by a continual decrease of the measured value. Ifthe electrode is used in fluids prone to form deposits, also in the case of entrained oil traces, it is tecom- mended to clean the electrode tip every six months, To clean wipe tip with abrasive cloth and then wash teflon sleeve with trichloroethylene or similar. AALBORG SUNROD wl, Page 4/71.4.7 Relay Arc Suppression for Inductive Loads ‘When switching of inductive loads voltage peaks are produced that may reach several times the mains voltage. The result is: * The operation of control and measuring systems may be impaired by in- terference caused by the voltage peaks, * The life of the relay contacts is reduced by the electric arcs formed We therefore recommend that inductive loads are provided with commercial arc suppressor RC combinations (e.g, 0.1 1/100 ©), Conductive Electrodes, ERL 16 2.1 Purpose and Application Monitoring of Conductivity Continuous monitoring of boiler water for increase in density with the conductivity limit switch type LRS. Monitoring of the condensate retumed to the boiler to detect any penetration of acids, alkalis, etc. Continuous Blowdown Control Automatically controlled continuous blowdown to reduce blowdown wastage and increase the operating safety with the continuous blowdown controller type LRR L-.. and the continuous blowdown valve type BAE. Automatic closing of blow- down line during boiler shut-down, 2.2 Design eee ere eee Theconductivity electrodes are provided with an electrode rod completely insulated by @ PTFE tubing with the exception of the measuring surface. A pressure-tight sealing between electrode rod and body is ensured by a Teflon tube. The electric connection is carried out by a four-pole connector. The design of the installed conductivity electrode type ERL 16-1 with screwed connection 3/4” BSP, preferably for installation into a measuring pot. An example of an installation in a measuring pot is shown on Figure 3 AALBORG SUNROD sil, Page 5/7ciate Example of installation of electrode into a measuring pot d 3 Fi igure 3 Louie 2.3 Operation For monitoring the boiler water its, conductivity is used, The conductivity produces ‘ proportioual current if measuring surface and voltage supply remain constant 2.4 Technical Data * Max service pressure: 32 barg. at saturation temperature 238°C (higher Pressures on request). * Connection: BRL 16-1; Screwed 3/4" BSP. * Length supplied: ERL 16-1 (3/4" BSP): 99 mm, see also Figure 4, where the dimension of the ERL 16-1 are shown. * Materials: — Body ERL 16-..... USt37-2 (DIN No 1,0036) — Electrode rod: X6 CtNiMoTi 17 122 (1.4571) — Electrode tip: 1.4571 — Insulating tubing: PTFE — Terminal box: Plastics © Permissible conductivity range. from 1 Siem * Max permissible ambint temperature at terminal box: 60°C * Electric connection: Four-pole connector with screw terminals cable strain relief and cable gland Pg 11 * Approx. weight: 1.6 kg with max length L — Electro demounting flange: 1.4 kg AALBORG SUNROD will, Page 6/7oy Dimensions of ERL 16-1 Electrode ox | | a emt ly Leo Figure 4 Aden 2.5 Important Notes Cable required for wiring: Screened cable e.g. 4x 0.5 mm? for cable length see data sheet of electronic control unit used with the electrode. The conductivity electrode may be installed vertically, horizontally or radially inclined. The electrode tip must be constantly submerged by at least 100 mm, When mounting the electrode into steam or pressurized hot water boilers the relevant regulations must be considered, AALBORG SUNROD Page 7/7Patt ~max. 100°C Scrowed ai" BSP 99 Max. service pressure: 82 barg (465 psig) at saturation tempera- ture 238 °C (higher pressures on request) Materials: Body: U St, 37-2 (DIN No. 1.0036) Electrode rod: X 5 CrNi 18 9 (1.4301) Electrode tip: X 10 CiNiMoTi 18 10 (1. 4571) Insulating tubing: PTFE Terminal box: Plastics Permissible conductivity range: from 10 Siem, Max. permissible ambient temperature at terminal box: 100°C Electric connection: Four-pole connector with screw terminals, cable strain relief and cable gland Pg 11 Approx. weight: ERL 16-1: 1.6 kg Data Sheet Conductive Electrode K.1089.0 ERL 16-1 Page tof 1Conductivity Limit Switches LRS 1-5b, LRS 1-6) Purpose and Application Continuous monitoring of ne eenductivityofiq- bids with the GESTRA conavetivity eleciroce types EAL 16, LAG 17 oF LRG 18, Signaling of preselected conductivity fmt vaue pplication in steam boiler plants for leecwa- ter and condensate monitoring: for conden: ‘sate monitoring incistrict eating plants. in the apes anc pulp industry ana in eatering kite fens: fer conductivity monitoring in’ water treatment plants; tor manitoring of coating Towers: for dyebatn monitering in dye works, er Design Plug-in unit in plastic case for instalation in coniroi cabinets. The terminals in the case are accessible after loosening two serews angune plugging the unit from its base, The avoid cone fusion with other plug-in units of the GESTAA range, inserts are fitted in the bases so that ‘only the correct unit may be plugged into each bese, ‘The plugin unite may be snapped onto @ 35 mm supporting railorserewedinto position ‘on a mounting panel. Field enclosures for several plug-in units are evallable on request. ee Technical Data Function ‘Mecourhuy ranscucer vath switen contact for conductivity usec with te conduetivisy electrode types EAL 16,LAG17 or LAG 19, ‘manual temperature ‘compensation 3! ‘operating point Input 4 connections for one conductivity elece ltode ERL or LAG. Output 1 potentii-rse relay contact: ‘max. contact rating: 280 V. S00 W. 3. Conmie with life of 4x 16 switching eyetes © 0.35 Aincuetive with @ le of 2 x 108 cycles: ‘contact material sliver narc-gotd plated Umit vaive Continuously adjustable within the respec tive range 0.4..30 mem or 0.08..3 Siem for tS 1-56, 4.300 uS/em oF 0.6.10 Slee fer LAS 1-85 selection between the two ranges by Switch on tront panel, values relerted te 25°C ‘emperature intuence can be compen saled with the aig of adjustor up to max, 250°C on reaching service temperature, initia position callbrateato 25°C Switching nysterises 1% Incicators 2LEDs: green tor 9 < limit valve ec lor D> hrs value Call constant of conduct Ce 1.0 (rem) elecvoce Issue Date: 186 Blectiode supply vortage Deke votiage 0.5 V3/1000 H2 for LAS 1-56 oita voltage 1.34767 He for LAS 1-60 ‘Maing supply 320 Vi60 Hz, 220 V/50 Hz, 220 VISO He, 35vA [please state votage when ordering) Protection Pag Peimissiie ambient temperature 0..85°C Case materas Bast: ABS plastic, black Covers ABS plastic, etone-grey Approx. weight O5ig ee Important Notes Gable require for witing to ne electrode: ‘Screened cable, e.g. 4x 0.5 men, cable length ‘Seetablouncer instalation and Sovice stu: ons", ee Order and Enquiry Specifications GESTRA concuetivty limit switeh 2s measure ing transduce’ with switch contact used with the GESTRA conductivity electrode types EAL orkAc: Conductivity iit switen type LAS 1 plug-in unit in plastic case for installation in control cabinets Mains supply. — Associated Conductivity Electrodes Conductivity electrode types ERL 16... PN 0 LRG I7-1, NES or LRG 16-3; PN 60, Concetivity limit switch LAS 1-50, LASBe ‘AALBORG SUNROD 7.0 CHEMICAL DOSING STATION K.7452.0 - Instruction for dosing pump K.1093.0- Dosing pump AALBORG SUNRODae ‘ABLBORG SUNROD a INSTRUCTION FOR DOSING PUMP ~ Instruction K.7452.0 ry AALBORG SUNROD>ProMinent® g am ma/ 4 Instruction Manual Pr. Minent®instruction Hanual gamma/4-W and ganma/4-I Table of contents Legend of symbols on opera tor panel Summary instructions Sectional drawing and legend General description Installation J commissionin: Operating instructions, ganma/4-W internal control, manual setting of stroking rate ternal rol, pacing by pulse signals Fault annunctations and fault reset Operatin ions, gamma/g-1 antennal control, manual setting of stroking rate External gontrol, pacing by pulse signals External control, pacing by analog signals wit annuneiations and fault reset Additional information Operating conditions Electria connection Suetion Lift Motoring eacuracy Conmecting metering pump in lel with induetive loads Minow faults, causes and remedies Replacing diaphragm P mp Selection guide Adjusting flow output chnisal data Capacity and te: Terminal plan Typical Saoa 12 2 4 15 16 16 16 7 7 18 19 a 22 23-36 a7 98-42Legend of symbols on operator panel Stroke length adjustment Level of enclosure IF 65 Pilot and stroke indicating Light Fault indication Power supply Connector for external control sable Float switch connector Connector for flow monitor HQORO—H PA > Relay output for peripheral eystens Summary instructions, gamma/é A folding card with summary operatin below will be supplied with every 4 base. instruatio mp, inserted inta the pump Model gam Hodel gamma/s-1Sectional drawing and legend 1100 readout 2 Stroke length adjusting knob 3 Programm selector key 4 Up/Doun keys § Stop/Start key 8 Stroke indicating light ? Fault/Lack-of-chemieal indication 8 Power supply % Connector for external control oa 10 Float Switch connector 11 Connector for flow monitor 12 Cable gland thread (Fa 9) for relay output 13 Fower end housing 14 Short-stroke ‘solenoid drive 15 Liquid end with suetion and discharge connectors 16 Bleed valve, coarse adjustment iéa Bleed valve, fine adjustment 17 Hose no: bleed valve 18 Hose ni suetion conneator 19 Grip ring 20 Pump diaphragm with steel core and FIFE facing 21 Intermediate disk with safety leak hole ble tronie circuit board with miecroproces card with summary operating instructionsView of ap 19 18 17 Wo 6 87912Co General description FroHinent ganma/4 solenoid-driven diaphragn-type metering pumps for liquid media consist of the following main nommenenen Rowen end with housing (13), solenoid (14) and elestronia eireuit board with mikroprocessor (21), and Liduia end with suction and discharge connectors (45), pump diaphragm (20) and intermediate disk (at). The pump output has a pulsating flow profile Every pulse Generated by the electronic cirauit exeites the solenoid’ Uhicr Anauem attracts the movably supported armature. The pump “aren phragm connected to the armature displaces the median tn “the Jiauid end, expelling it through the discharge valve and closing fhe balls of the suction valve. The maximum stroke length 2 tone the Sgt Model ganma/4 2000 only 0.63 mm). hen the pulse decays, ihe solenoid becomes de-energized and the armature with the pump diaptwagm is spring-returned into its original position, hae ses the suction stroke to be performed, new media is drave into the liquid end, the balls of the discharge valve alose. By means of the stroke length adjusting knob the flow output per stroke can be infinitely varied between 100 and 40%. thie Pajustment should be made only while the pump is operating, when the adjustment bolt is temporarily relieved. in the internally controlled, or manual, mode the stroking rate can be varied by means of the two keys (4) from 1 to 120 strokes per minute in steps of one. The settings ore repeatable with Quartz-like accuracy, The output flow is proportional to the stroking rate,a Installation and Fasten pump on chemical tank or bracket by meana of 5 mm dia. more sama washers. To ensure a proper performance, the "valoos must Qiways be arranged in a vertical position, ‘Connect’ the caer ty ime to the suction connector below by passing the Eguerely aut hose through union nut and grip ring and sliding tt over the hose nozzle to a stop. onmissioning Savéion: Use only union nuts and grip rings of a size appropriate fo the hose dianeter. Otherwise the stability of the joint is not safeguarded, Now, tighten union nut to obtain secure fastening. To improve the Sfobility of the joint, especially when using 12 mm dia. hose. give the fastened line a short pull and tighten the union nut once nore, {hen Stainless steel connectors and pipes are used, pass pipe Shuough union nut, slide grip ring over the pipe end'to a ston. and tighten union nut. then Joining FE or PIFE tubing to stainless steel connectors, Place a stainless steel ferrule inta end of tubing, chorten the suction line so that the foot valve subsequently to be fitted just clears the tank bottom. Allow for a clearance of at least 50 nm if media contains matter tending to settle to. the bottom Ce Medels qamma/4 1000...0408 PF are equipped with 2 bypass-type bleed valve (16), Fasten a 4 mm id. (mans & my ieds) higoe cathe bypass hose nozzle (17) and run it back into the chemical tanke Ose the cgtasion and connect the discharge line to discharge fonnectar and injection valve. Open bleed valve by giving the protruding part about one turns in an anticlockwise direstion, This opens the coarse passage of the bleed valve for the purpase of priming. in case of liquid ends without bleed valve, connect discharge line to discharge conneator only, not to injection valve. Flug power cord into mains socket and set stroke volume.to 100% Fress Stop key (5) to avoid uncontrolled pumping, Start automatic quick-priming by pressing the Up and Down keys (4) simultaneous. ly, Keep keys pressed until media fills the liquid end completely and comes out of the liquid end with every pump stroie. Close bleed valve or connect discharge line to injestion valve, respectively,Cy tith media tending to emit fumes and vapors, fine bleeding san be Gaploved continuously if the liquid end is equipped wich e bleed yalve. Loosen screw (ida) inside the bleed vstoe by giving it about turn in an antoclockwise direction. Thee 2 Wises a gonstant slip-stream to be returned into the chemical tank. The Siphogtream should have a flow rate of about 20% of the total CHEPYE flow. If the return line to the tank is made to ony above ere, tiquid level, the bleed valve acts also ass cangue breaker ghat prevents the chenical tank from being dravn enpty should a vacuum occur in the discharge line. fennect, if any, float switch, external control sable or cable bf flow monitor after having removed the protestive sare, Set desired flow output, using the respective nomograph (see fechnival data). Select ‘desired electrania function ae per following deseription: Operating instruc ions, ganmas4-W Modes of operation: “Manual” or internal sontrol qhe Bump operates at a constant stroking rate, which aan he fet to 1. ..120 strokes per minute by means of the Us and Doon keys, When set to 0 strokes per minute, the pump will he aroperative. The actual stroking rate in’strakes per minute Will be displayed on the LCD readout, ¢9.38strokesimin. Contact =) Honual Hin iawn Contoct, 1919-1 The pump can be stopped by pressing the “Start/stop" key, when the readout will display the letters "SP", Press {Stop/Start* key to re-start the pump at the stroking rate last employed "Contact" or external control The pump is capable of being controlled by external pulse Signals from mechanical contact elosure or semiconductor on open collector circuits having a residual voltage of less than 350 mV. The minimum pulee duration vequired is 20 : milliseconds. Every pulse received causes only one stroke to be performed, Maximum stroke frequency is 120 strokes/min, .oO On continuous sonta a only one stroke will be performed, As. stroke requires the contact to be opened first and then to be te-closed. Every pulse received WELL flash the arrow symbol next ‘to “Gontact" an the left-hand side of the readout. aus System switches automatically inte the external control mode and the LCD readout displays the letter the 6~pole conneator of the eentrol cable is in the socket marked ) a8 soon a adueed into Connecting the external sontrel cable Raise perspex cover and pull float-switch connector, if any Flug Gentral cable connector lightly inte the left-hand socket co that the guide ledge fits into the groove, Sarew down soupling slecos without edging it, “Dos. Control" = Flow moniter (optional) Install the flow sensor of the flow monitor next to t sonnector and plug cable inte the socket marked ne discharge gpa nrGleed the pump or to cheek its proper functioning press Sup" and "Down" keys simultaneously for st least 3 seconds. The pump will operate at the maximum “stroking pate as long as the keys are pressed, Teeetiteh into the manual mode, that is, operation at a constant, internally controlled stroking rate, remove the external control cable (mandatory) and, by pressing the "Up" key, change stroking rate from 0 to the desired value. Adding the flow monitor (Dos, Control") function Fress “Stop/Start" key and “Up" key simultaneously. an arrow pointing to "Dos.control" shows that the flow monitor ic activated. Then, if flow fails for 8 strokes in succession, the Punp will be stopped, the red fault indicating lamp will light up and the readout will flash error "F 5", Press the “Stop/start* key to reset fault anunaiation and resume operation. Dropping the flow monitor ("Dos, Control" function Press "Stop/Start" and "Down" keys simultaneously, The arrow pointing to "Dos, Control" disappears and the pump continues to operated without flaw monitor.Om Possible readings of the LCD readout (Model gamma/4-W) yi20..,0" = Manual made. Arrow points to "Manual". Reading indicates stroking rate in strokes per sincte, Yellow LED goes out while a stroke is performed CE" > (Not with Model ganmaré-1) External mode, External control cable is Plugged in. Arrow points fo "Contact". Yellow LED goes out while a steone is performed, bey, 7 PUMP IB Switched Off, Re~start by means of “Stop/Stanty key, Fault annuneiations and fault y set "F 2" Overtemperature qemperature sensor (optional) stops pump on account of excessive eo eeotd, temperature. After solenoid has weet ey down to Bdwissible working temperature, re-start by pressing the “Stop/Start" key, "F 3" Lack of chemical Hate up chemical tank. Fault annunciation and fault reset are delayed by about 3 seconds “F &" Flow failure (optional) The flow monitor has registered no fficient, flow for 6 consecutive strokes, Remedy defect tap/Start" kay SSS —=gamma/4-W (©) =) Fa Ste so1032Operating instructions, gamna/4-T The operator panel of the different modes and funetions "Stop/Star "Up" and "Dow oo] eee ) "Manual “Contact” "Analog" aa" "20..,0 ma" "20.0.4 mam Model gam a/o-T has 4 keys for selecting For starting and stopping the pump. When the pump is stopped the readout diplays "Sr" For changing stroking rate or functions Programming key, for going into the seleation mode (press for 3 seconds until indicating arrow flashes) and for entering the selected function The following funetions, which ane identified on the readout hy 14 indicating arrows, can be selected: Manual setting of strokitia rate between 1 and 120 strokes per minute, When set to oO strokes per minute, the pump will be inoperative, The agtual stroking rate in strokes per minute will be displayed on the LED readout. External control by voltaag-free contacts, Semiconduster contacts or open-colleator circuits having a residual voltage of less than 350 mV. @ pulse duration of at least 20 milliseconds is required, Contact load about 12 mA, Stroking rate control by standard process signals. The stroking rate will be displayed on the LCD readout in strokes per minute Analog signal of 0,..20 mf relates to 0...120 strokes per minute. Analog signal of 4...20 ma relates to ©...120 strokes per minute, @n alarm will be given if signal drops below 4 ma, LED readout displays error "F 4", Analog signal of 20...0 mA relates to 0.,.120 strokes per minute. Analog signal of 20...4 mA relates to 9...120 strokes per minute, An alarm will be given if signal drops below 4 mA. LED readout displays error "F 4", at“yeas Pulse step-down: 1...1999 pulses received generate 1 pump stroke, "n" is constantly displayed on the Led readout, ne Fulsa step-up: 1 pulse received generates 1s. :1999 pump strokes. "n" is constantly displayed on the Led readon “Select” Fredetermining counter far 1...1999 strokes. The LCD readout displays the Muanber of pump strokes yet to be performed. "Kemory* Buffer memory for pulses received in excess oF maximum stroking rate, In the “Contact” mode the buffer memory function ean be added to the step-up "Lin", step-down "ni1" nd “Select” functions, “Dos. Control" Aativates flow moniter (if optional flow sensor is used). Can be added to all funetions “Minimum Tank level monitor (if optional float switch is used), “Contagt" Indication of pulses received. Selecting funstiens The factory setting of aauma/4 will be for "Manual" operation at minus Pally controlled maximum stroking wate mf 120 eteohes per minute ares ehid variation of the stroking rate setting cen be obtained by constantly pressing the "Up" or "pasue key. The selene OninG rate cannot be exceeded irrespestive of fmatinn selected, “Contact” — External pacing by pulses stepped up 1:1; without buffer memory. 1 pulse received ganerates 1 pump stroke. Note: The maximum stroking rate in the “Contaa cvs mode is the stroking rate last selected, Tf required, first shange setting in the "Manual” moda to desired maximum stroking rate pe ghey, for about 3 seconds until the arrow pointing ta 1" flashes, Shift arrow to “Cont by means of the "Down “RN Key once more. One or two arrows appear, pointing to "nL", Select" on "Memory", Eress "Up" or “Oown* key several times until there is only one arrow left, pointing to "tin", Pr FP" key to enter function,ganna / A= Pa igiga Fress "Up" key, The readout display the figure 1, If the readout displays a figure greater than 1 (resulting from an eariion setting), correct it to 1, using the "Down key", If a different ived generates 4 e Uo" key @.g. 1:6 C1 pulse ane of the teaeuiler memory function “Memory” is tobe adied,pross the “P key fr aboul’ seconds unt the arrow pointing 16 (Contact Hashes, than press “P” once more. Press "Up" or “Down” key several times untl two arows appear at “1:n" and "Memory", Press "P" to enter function. step-up Patio is desired Pump strokes), set figura 4 by m Troms Pulses received in exaess will be stored and worked off at ihe maximum stroking rate set last in the “Manunl" made.) Tes SReRpup ratio, in this “example figure 4, will be disploved Att the tine The “Memory” function can be dropped by pressing the "P* key for 3 sacands, press "P" key once more and release tho arrow at "Memory" by pressing the "Up" of "Down" key several times. Entor function with"P* key, Tf pulses areto be stepped down -in the ratio of ") e.a, 204. 20 QULSES Pareived ga pum yeroKe = pi key “until ow pointing to "Con. Flashes, Fress "F" key once more or “Memory” until arrows peintin yin appear es until there is only one FB" hey to enter funtion. tio, in this Fress "Up" or "Gown" key several ti arrow left, pointing to "n:1", Fress Sek figure 20 by means of the "Up" key, The step-up ra Guauple figure 20 will be displayed all the tine. To add’ *Henory Bibed above, function proseed a: ( = gamma/4=] (©) Contoct anual Hintnan Contact os. Conte. Analog Henory 0,,.208 Select 4. 20m8 20...0ak in 7 20. dn mit 1918.4a "Select" ~ Fredetermining counter moda: Step-up function with a display of number of punp strokes yet to be performed, Example: 180 punp strokes per pulse received or por manual starting pulse: Preee iby key until the arrow pointing to “contact” flashes. Tpees “b* key once more. one or two arrows appear, pointing to “1 TL", Select" or "Memory". Brees "ups or "Down" key several times until there is only one arrow left, pointing to "Select", Press “ps key key to enter funetion, Set figure 150 by means of "Up* ihe 180 pump strokes can be started by an eaternal pulse or by teas Ok the " key. When the pump is idle, the readout displa ore umber of pump strokes selected, if it is working, the nunken of Pump strokes yet to be performed. To add "Memory" function Proceed a5 described above see eeontetete Stored data in the "Select" mode plus “Memory Tunetion if fhe pulses stored in the buffer meméry are no lonaer required ko be worked off, delete stored data by going into the "anunt= node or by pulling the power plug for a short monent, fnalog" ~ Straking rate is direstly or inversely propartional to 4 0. .20 ma or 4...20 standard process signal, Example: 4...20 ma fess 'ptrkey until indicating arrow flashes. Shift indicating array to "Analog" by means of "Up" or "Down" key. Press "F* hey gree more. Another arrow will appear within the area ranging from neg tO mA phe 204-4 ah Sek arrow to 4...20 ma", Enter by pressing "P" key Note: If no signal source is connected to the external control “ows gable, or the signal is lower than 4 mA, error "F 4" will be onnunciated at once, Connect signal source, ‘start pump by pressing "Stop/Start" key. The stroking rate will now be proportional to the analog signal, 4.+.20 mA corresponding to 1,,.120 strokes per mitute, Any new setting must be entered by means of the “PY key, The pump vill return into the original mode unless the new setting is entered within 25 seconds 4, Stroke frequencyFaure annunciations and fault reset 2 ase of a fault one of the following foult annunciations will be displayed flashing on the LeD readout, the pump Will be paptehed OFF, the red LED will light up and the Copeiopaly alarm relay op oye op 3H BE qm “Fo Be pull in Overflow of buffer memory "Memory", The storage capacity of 65,535 pals. the data have bean deleted, Restart by means of "Stop/Start" key has been exceeded and Overtemperature png teePerature sensor (optional) has stopped pump on Aggune of excessive solenaid tenperature. after solonotd LBs old down to admissible working temperature, nevetone by pressing the "Stop/Start" key, If ¢y ambient Tgmperature is too high, reduce maximum stroking rate” (roe “Operating conditions). Lack of chemical Hoke up chemical tank or, to bridge gap until then, pull flaat switch connector from pump. bevel of liquid left before air is drawn; About 15 mm. Fault ennunsiation and fault reset are delayed by about 3 seconds Signal current in the analog mode (4...20 ma, 20...4 mf) is less than 4 ma Renove e soure! Re-start hy means of "Stop/Start” key, defective cable, defective signal Flow failure The flow sensor (optional) has registered no, or ine sufficient, flow for @ consecutive strokes. Remedy cause. Fossible couse Entrapped air or gas in the liquid end (bleed Liquid end). back of shemiaal (if no float switch is used) (make up tank and bleed suction line and liquid end, see page 7). Blockage of foot, suction, discharge or injection valve (clean, see page ig + ump diaphragm is defective (replace, see page 2 ). Thveespole cable from flow sensor is not properly conneated (aheak and remedy), Making flow monitor inaetive: First press "Stap/Start" key, then simultaneously key. Down Activating flow monitor Press "Stap/Start" key and "Up" key simultaneously, Re-start by pressing "Stop/Start" key, 16Cy “F 6" System fault (microprocessor) ihe electronia control circuit is self-monitoring. If there isa fault, the system will be switched off, Return pump or complete electronic circuit to supplier for repair ar replacement, Trveguiar stroking serefing rate and solenoid eperation are quarte-controlled. Synchronization is effected when the mains voltage pasese through zero. This ma sionally couse audible irregular stroking, (he maxinum adwissible ambient temperature ranges from -10 eC to Tee pal 2282, Of higher temperatures reduce the meviage fireking rate by about 3 strokes per minute per 1 @C, At mehione Eenperatures of up to 50 OC the pump aan be operated at manigun stroking rate for periods of up to 1 hour, Relative humidity: 10...98%, not condensing jon: Frofinent ganna/é metering pumps must not be used for flammable or explosive media Electric connestion The pump is connected to the mains power supply by means of the aktached power cord and plug. The design range of tha. pores Supply is 210...250 V, 50,..60 H=, the tolerable range 495.0 Vv, 48.62 He TRE RUMP is switched on ond off by switshing the power supply. The pump can be stopped any time, and re-started with the previous settings, by means of the "Stop/Start” key Even when disconnected from the paver supply for years, the pump aan be brought back to operation in the mode last selested. Remote switching is only possible via float switch connector (10) by means of a voltage-free contact or an open-collestor cincuit. The contact lead is about 0.8 mA at 5 Uytion lift Depending on the pump type, the ma amna/s with the Liquid end Fill pce “Feetnical data"), The suction lift with the Liquid “eng anpty depends on the stroke volume and is lover hen the strone volume is small. The pump cannot prime against a head ximum suction 1ift of the d owith media is 1.8.,,5m Wc If the pump feeds into a pressurized syst id has areidentally gram some air, the air will be just compressed within the Liquia gra pnd wo media will be discharged. In this case disconnect tne Sera tne from the injection valve and quick-prine the pune by pressing the "Up" and "down" keys sinultaneously until "Cre rou tine and the liquid end are completely filled ond free cr bubbles Hedels ganma/é 1000, 2001, 1201, 0803, 1002 and 0408 PF eNpehed with a bleed valve. Gir bleeding can be accomplished without disconnecting the discharge line by giving. the biesd salve on the liquid end ane turn maxinum and causing the pump te auketrprine until the suction line and the liquid. end are campletely filled, © If a float switeh is used, the ump Will be switehed off to keep it from drawin air as soon as the minimum tank level is reached” Netering y aecura aun given are the result of flow measurements with water of 2 kemparature of 20° 8C. When conditions remain unchanged and a stroke length setting of not less than 30% is enployed “the flan repeatability is ¢ +/- 2% of nated aapasity, fgcurate metering is not possible unless the discharge press: is constant to some extent and not lower than t har, valve te an eee sngdie is to be discharged against atmospheric preseu (openmended diseharge line?, a loading or back-preseure should be fitted to the discharge valve in order to om artificial back pressure of about 1.5 bar eng Ghemieal tank level is located above the metering pump (Flooded jon), the back pressure should be sa high that» differential pressure of at least about 1,5 bar exists, Otnerwice @ bagk-pressure valve or a spring-loaded injection valve with an appropriate opening pressure should he used. Note: A hack-pressure or antisiphaning valve gannot be “considered as being a tightly closing isolating valve. Tf required, install an isolating valve, which is closed when the pump is idle, in the suetion ling The suetion line should be as short as possible and be routed with 2 continuously rising slope to prevent air bubbles frow collecting fn output flow, once set and possibly confirmed by ealibration, gan be reproduced exactly by setting the stroking rate to the eriginal value since the stroking rate is stristly linens sed exactly repeatable. Thus, an excellent flow repeatability ts ensured,Sonnecting metering pump in parellel with induetive loads if the pump is to be connested in parallel with dead, such as a solenoid valve on an elesenta motor, tranereni@ cineuit of the pump is liable to be damaged by feansient peak voltages when the parallel, load is cvitemes off. peg his reason the pump and the parallel lead aust be fecloee4 Auge each other at the moment of switching. therefore, the Pung ust have its own separate switch contacts: isolation by aris of ® multimpole conta tor or switen (14 the inductive load Pyy is (= 20 W the pump PH and the load HY could have a Somuon control cantast) Isolation by means of an iliery contactor u u H Mv PM PM ay 190014 18004 Supply veltage Slenoid valve, motor or similar load = ProMinent® metering pump Varistor (The varistor is d equipment of the metering pump. If necessary, an additional varistar (Part No 71,09.07.7) could be connected externally in parallel with the pump. 1.Minow faults causes and ‘renedies Fump does not prime in spite of Ff. Ll stroke length and proper air bleeding Crystalline deposits due to dry valves: Lift sustion nose femporarily end flush liquid end well. If unsuccessful, diss desenble and clean valves, The valve insert san be driven out by neans of a 3 am puneh Pump does not work, yellow LED is extin om the LED readout: t, no foult arnuneistion Cheek mains yaltage Have fuse checked by authorized se if blown. vise parsonnel, and replaced Caution: s shown on lable only 0.25 A super slow Part No, 71.20.35,5 9.5 A super slow "71.20.3704 1.25 A super slow “ 71.20.38.9 2.25 A super slow = * "9413013917 If fault cannot be remedied by replacing the electronie ciravit ar whole pump sli ed in the fa No flow output, although the yellow indicating light is flashing The stroke length is set to zero, or too short, Increase stroke length by means of stroke adjusting knoh (9) Air might possibly be entrapped in the liquid end. @leed as described in Section "Installation and conmissionina” Red fault indicating light goes on Take note of fault annuneistion, on the LOD readout, More infarmation on remedying electronia f. page sits will be given on Float switch does not stop the pump although tank is empty Float is blocked, Remove deposits and elean flost, a9.Media leaks from intermediate disk Diaphragm leaks. Tighten bolts of liquid end epossuise and contueas Gheration. Tf this proves unsuccessful, the diaphragn te ruptured and must be replaced, anf diaphragm Replacing the Develo, SPE Skroke Length to zero white pump is working. Flush Liquid end fhoroughly if “hazardous media was handled, Squirt water von’ e peeergeny into the ‘suction eonnector hy ‘means of a squeeze bottle, Tf necessary, turn punp upside down to bring sauesc® connector to the top. cee eeneHs Of Tiquid end, pull then out for about § am, but Seathbgeve them in the Liquid end. Unscrew disahnagm fon aypature by turning the complete liquid end anticlockuise with s slight jerk, Care Mee diaphragn into the intermediate disk and replace liquid eng so that the suction connector is next to the drain hole in tre Untermediate disk. Stick fastening sarews through and turn fhe whole assembly clockwise until the diaphragm fe ca rely fined. Let the pump work, set stroke length to 100% and tune ent whole assembly clockwise until the ion connector paints right foun. With pump still working, tighten serews crosswise, Wier phauid ends made of PF, except’ Model 0216, the bleed sive’ te docated near the top next to the discharge Valve, and the bypass, norzle laterally near the bottom next to the suation valve, To enable you to remedy smaller faults at any time we recommend you to have a spare pants Kit available (see spare Parts Lice)Pump selection guide wa] De] 5 sre] Sa st te) i eee =| sa sxe ssi] 21 | ooze|secrz] toa)” {4 zzrz | ors) 44 9120 Ba} pa) s Sse] Se | (605) i . =| $3] sro) sst} 21 | ooze fess] o9cal 2° szort| avec) 828 4a a0s0 ToT al 0a} $ 5 ueing Sa] Sea S20) (sou) i «| 08 -uesng} + | 8] 8] ssi] zd oozfeaeso] iste) 8°) eval cuz} “SS? 44 2001 an] su) xs sx “sxa 3 xd a (es) i . i + | Pd 9] ssi] 21] coed coved ste] "| evsolore é e090 somieie ws oat ee s (ua (vet) i rors ” . . Sst] 2 zd avz'o sere] 9 | zerojoore| Tt 4s 1021 oe aay at +s ow ‘xg “gx $ oo ms) bs set) (oz) i 29" “ ” ves} wx9 | ssi} zt} oozd| zet‘o} s6'd al | s60'd a9% 02 dd L002 oe Lopb"t Lesb"t] BL] 87] we Cw tory-t] — tzge-i} “Sea} S39 § eo x}uP33] Bald] bea) x9 kstze (su) i va Ayer say| dé} x9} x9] ssi} 2 | ooze|geo‘o| 92'd § | ezotd ozo) oO dd O00L . caEtaee 237 fam) g last) mean (54) 8) Ss] ip [sels 2 fdeE [rw | 9 |toeq| as] vy S88 ty sodomy 1-¥/8]H-9/8) as pL rey cE adhe sanssaad Bunssaad ee i Lele PEfred atesane| — yaeq ‘ew | p/oums,suomose ON F4ed fon 3ue3f ‘Stemaaey| ? She xareedea] ye Agtsedep ee ere Cy SPING uoF;DeTes Gung eno -TwH9aL¥I7S00 LW3NIHOUS CAdjusting flow output Determine the correction coeff back pressure in the discharge on one of the following pagos. cient KF relating to th etual ing, using the respective diagram Divide desired output flow by correction sorrected output flow, efficient KE to find Etter corrected output flow on senter scale “Flow rate’ in 1/h or ai/nin, Place a straight edge through value entered an ficy rate Fgeke: In order to obtain reasonable stroke length snd) stron et pate jtettings, the straight edge should run mone of ratd ferizontally, Select the next highest round figure on the stroee dength seale, connect with valye on flow rate snale and projec eee tt eeroking rate seals, Read off stroking eat intersection on stroking rate scale For high viseosity media and media tending to emit vapors and Eines Select 9 Larger stroke Length with a correspondingty loons pereking vate. for a good mixing effect choose a shorter eter length with a correspondingly higher stroking ra Set metering pump ac pump is working. ordingly. Adjust stroke length only when the If the output flow is to meet hi the actual output Flow a ner demands of accuracy, measure sorrect the settings ascordingly.ganmas4 2002 capacity a back oressuir stroking rave Hin. stvaking rate (Internal controls Stroke length adjusting range Fower supply Average power eonsumecion Control va) tage Hindmum duravian of paeina (ickernial eentrols Lontact load Leval of engiosure Suction dine PR, T versions 5 version varge Line FP, T version 3 versian Net/Gross uetant ueight, S version Maxima suetion 1i fe pacity and technical data of Model qamma/s 2001 metering pump 0.69 I/h; 0.096 mi/stroke 20 bar 7200 soh; 420 spm sm Yo 80,..60 Me IP $5 Hose 6 mm Pipe 6 mm Hose 6 mm Pioe 6 + mm tea, x 4 wm id, pins 0.9 ka about 3 m Wg,ProMinent*gamma/4 2001 KorrekturFaktor 100 90 80, 70 60 . 50 as 40 +> 6 8 £ tu 8 ~ ed z Zee on = 2a < foe sae. = 28 Bs e § Bz £23 gee ieee Teseg gif y Bae ass e333 a g oe cea g ae gre az 3 age bre wtih & bbs oe +s 38 ForderLeistung in Abh’ngigkeit von Gegendruck Rating in relation to back pressure 5 Débit Fonction de La contre-pression 5 1S 4 8 . 4 ee 4 ga! 4 He Bo bos a 0 1S 4 6 8 it) 12 14 16 18 20 bar Nomograph for determining flow output of Model aamma/4 2001 and diagram for determining correction coefficient for flow output relative to back pressure Hiaximum capacity against 10 bar 0.95 1/h = 0.132 misstroke Maximum aapacity against 20 ba 0.69 L/h = 0.096 mi/strokeTerminal plan gamma/é beEsaEaaad 2 © a i -§ Hubmagnet iz iH stroke mognet electro-cinent eee i ry braun A oe — Netz Q Fe FQ) ES power 0 gelb/gron at ,aag c 5 oe 2 ” t F 2 aL braun Relais ‘option Tomperatur= Ee be | ee. retoy sensor tin] Eh? E96? Les 9 teayercturcenear . avertlssew de taap ar Adererbeniecoloursicoulers des conduis braun/orownforon CY 4 4 blav/blue/bleu sebiyelon/eune weiB/white/blanc 4] Je sshwar iar =| Tie al le g | {é al al gl &] [s - Dosiertberwachung ra Extern/Analog Few senitor NiveauschaLter control. dosage Level switch external/anatog controle de niveau ‘externe/onalogi que Kentokt. geschlossen-Leerenzeige contest closed-enpty ind, 20, Ferme-ind,ERSATZTEILE Bezeichnung Bestel Inummer 100-127 v 25. Steuerung gamma/4-1 Steverung ganma/4-W Sicherung 81.90.87.8 91.90, 81.90.93.6 8190.98.46 a1.9% 81.90.94. 71.20.37.1 71.20.38.9 71l20¢29.7 ‘Typical installations ‘Metering pump ‘Chemical tank Foot valve with strainer and check valve Injection valve, spring-loaded Injection valve, enhanced spring load Loading valve Loading valve Loading valve Pulsallon dampener Solenoid valve 11 Drain valve 12 Bleed valve 13 Isolating valve BSeervoasons 1.) Standard installotion 2. Atmospheric discharge, low head i = sao a reserje head 3a) Flooded suction, e valve large discharge head a a Sree hares al 10 16B4i6 ad)low discharge head 5) With Long suction Sal dvemneryel pined = \ \ 4 4 \ \ ase ‘ a i) e054 oO « HT} Beg nt 196a/4 4b) Installation to prevent siphoning of hazardous media Bee ) sea 18714 <0.| 6a) Puluation-free discharge into 2 pressurized systen a wu ene Wa }— 1004 Cc 60) without overfeeding eon $s 9 lid ld J ™it 1 a 7)Frotection against excess pressure oo reser 40 6b) into an atmospheric system 6 82 on ve / yl ogo iar ot 8)Discharge into 2 vacuum 993148)With media tending to emit 10) Multiple batching fumes and vapors ; (an 1 aaa 8 re9si4 Formula for determining back-pressure valve imum head of liquid on top of . Poe 148 Hae 6 = em) gxa where Nyge: Max. head Gn) Pp Fressure setting of back~pressure valve (bar) g: Gravity constant (0 m/sA2y Qi Density of media (kg/duna) 11jCorreat installation of back-pressure valve 90008Faulty installations 12) Suction lift too high 199608 14)Media will be gravity-fed through pump SS 998 18) Suction line cannot be air-ble AL seo 18) Fulsation dampener ineffective co 2. so99re186 min. 500 600 26, || SS 2 ig SS —— I 8 i |_._80. 90 6 1-9 # 4 ? Dosing pump. : 601 chemical tank, 3 I} Foot valve with strainer 7 and non return valve. Dosing valve, Springloades, 1/4 inch BSP nippel. : 6/4 PE hose, Feed pump. Feed line, 410 AALBORG ‘SUNROD, Dosing Pump Gamma 4W/200) PP Instruction K.1093.2 pana 1 of 3tae este nage rere eS bron ® 2, or , 2 son Tenpsratur= 7 eno doe oe [=a i (Aetarenti eceunieaes des condi: : «Siu sabjabonaine 3(ED): owbreentor serene ® -shirraBckt F 2 ali a ae fee motte Extern/Anatog leet ete Technical Data | Raingear fatngs st ate mactace | nomic | | . . presse Dresure B) le leelfs| <3 #3) 2/83/25[28) fg! |] 2 zul8zles| 283] 2 |. | Pome [cose Lae |e | ents aur | um FUE) HG] 2 fe bye mter teen] Jace 8/33/83] 33 rt i ! : | [ana 7 20 ; i cernie [ion 200 °F) 92.21.35. dt byes loon | 20, 05a a fae | 94] ane |e Steel | rE rT Instruction AALBORG Dosing Pump Gamma 4W/2001 pp K.1095.2 SUNROD Page 2 of 3@ 3 tye 8 > ee Be i a4 ow 3 HE oo » 4 eat « a4 sage Aon a aE ve 8 a 2 a ha Br st od 05 = ae : oot ot E oe oo i oor Te x : om 0s L aap 3 z ia 3 i 00 Eo be 3 ete ee le a i & oF oa at B baat i s € ating In retoien to beck pressure sy 4 eh Sti Basd ‘ ‘ 48 8 ee | te Nowogresh for deterwining flov output of Hodel souare 2001 and ho relative to back pressure Hoxsum espsetty epainst 10 da Noximun Ssoeaiey againce 20 bar Max rot ing ax back pressure lax stroke rete Rin. stroke Frequency(nanvel control only) Adjustable stroke-lengen sett ing Supply voltage Nominal power consumption Control voltage Protection class Suction connection types PP, Suction connection types § Pressure connection types PP, T Pressure connection types & Contact duration required for externally controlled pumps Contact Lose Dinensions(length width height} Not weioht/ship-weight/type's Max suction Lift for determining correction doeffictent for flew ovepet 0.95 17h » 0.152 a1/stroke 069 Isnt Glaze mivatrene 0.69 1/m, 9.09 mts! 46 ber 5000 stokes/n 120 stokes/min 60 strokes/n t strokes/min. 10 = 1o0s, 220%, 30/60 Hz, 0,54 €0 20 ide 2av IP es. tubing: 0/5 s6xanm Pipe: 9/3 of nm tubing: 9. eéatam pipe: 0. 86 nm 20 as 12 aa 2e7x800106 2,5/2,1/plus 0,8 kg Approx. 5 ae Instruction ‘AALBORG Dosing Pump Gamma 4¥/200) pp K.1093.2 SUNROD Page 3 of 5- Prous 8.0 SPARE PARTS AALBORG SUNRODNo. q | Part a Object Sketch Intended for ‘Type Rar 1 | Spring Safely vane | 25.912 2 | Glass Water level gauge | 2x IV 4 | Gasket A Water level gauge | 2x IV 6 | Gland ring (+ Water level gauge 2163709 160 1 | Pressure gauge a8 Boller fleet a2" 24 | Tupe plug 5 Boiler tube {ens me) 6494105 Manhole Klinger - sit C 4 | Gasket 425 x 825 x15 4500 2158320 Hanutote Novepress 8 | Gasket 9 125 Multi 2163142, eee Pe | | +00 Fumace | 10 | Sendoomic teen Plistio 14 | erteee6 : | Data Sheet Spare Parts List Page 1 of 1 ‘RALEORG SUNROO AQ-9 Boiler958100: 996 22109 99m) J0}0m o21UHA| 6bv9) 988100: 998 | _s zzeL0o're + ON Buymosp 995 ‘sI9990S 4 Bulo>ld oe s6nct LS oy — Ia we oer az oye poe BUT wo coi febTeeOOTFaBSUtUY: Tro ea Si CEI an deli A adf Burziwoyo dno Asnjoy ices lenin 70 ed Burziwico woayg ajoy uonoadsul 7 vrais a¥oud a : Jajiog qn: s2%0m Joon. Jeuing bby | uowueuig —— SAN O®© ®@ \ “smasos PUD SdUUDjD YyIM | b 8ypi|dueaoo uoljojnsul UO painoas aq oO} é henog ane s 4ip buibuaanos 40} adid syL —— "AISI SV JONNOLLV3IQNI 734 | TOMLNOD UAL’ @ 3s) TVILWWNENe- WILT 4 e a junow Aij2Bup $2: 2) DK 340 nOjeG pa ‘sua e ‘ o eT -@