HEATMAX. Mechanical Installation and Commissioning Instructions HEATMAX

Transcription

1 HEATMAX Mechanical Installation and Commissioning Instructions HEATMAX

2 1. General Safety Information 2. General Product Information 3. Installation 4. Commissioning 5. Maintenance General Safety Information Note: This document refers only to the mechanical installation and commissioning of the Heat Max System and should be used in conjunction with the relevant user manuals for the other system components. Warning This product is designed and constructed to withstand the forces Use of the product for any purpose other than as intended use could cause damage to the product and may cause injury as fatality to the personnel. Before installation or maintenance, always ensure that all primary steam and condensate return lines and water lines are isolated. Ensure any residual internal pressure in the system on connecting pipe work is carefully relieved. This system is designed and constructed to the specific parameters. To achieve the best results from this system ensure that the parameters are adhered to. Customer to provide Canopy/Roof to protect the Heat Max skid from the weather. Lifting The system must be lifted only with the help of a frame structure and not using any components of the system. The system must be placed in position and securely bolted to the floor. Sufficient space should be provided around the system to have better access for maintenance.

3 General Product Information General Information The Heat Max System is designed to generate hot water using low pressure steam. This system is designed and constructed always for specific parameters. 2.2 Operation The Heat Max System provides instantaneous temperature controlled hot Water using steam as the heating medium. The plate heat exchanger is used to heat the water using low pressure steam. The system also incorporates an overheat protection system for a safety. The overheat protection system consists of a PT-100 sensor and a normally closed solenoid valve fitted on the pressure reducing valve or pneumatically actuated on/off valve, which gets the signal from on/off controller. During over heating of water, in case of failure of primary temperature control loop, the overheat protection system is actuated and the steam supply to the plate heat exchanger is cut off. 2.4 Components of Heat Max System: The Heat Max System is available with two variations, as under, a. Heat Max System without bypass arrangement. b. Heat Max System designed with bypass arrangement. With reference to the above variations, the Heat Max System consists of the following items : Heat Max System consisting of: 1. Piston Type Isolation 2. Strainer 3. On Off valve 4. Safety valve (to be vented to a safe place) 5. Temperature control valve 6. Plate Type Heat Exchanger 7. Steam Operated Mechanical Pumping Trap 8. Water by bass valve Primary Temperature Control Loop: A pneumatically actuated steam flow control valve is used to modulate the steam flow to the plate heat exchanger using a PT-100 Temperature Sensor and a PID Controller for precise control. This loop consisting of:

4 1. Temperature control valve with Electro-Pneumatic Positioner having in-built I/P converter 2. PID Controller. 3. PT-100 Temperature Sensor. PT-100 Temperature Sensor senses the water temperature at the outlet of the PHE & gives signal to PID controller. PID Controller accepts signal from the Temperature Sensor & gives 4 20mA output to the E/P converter inbuilt in electro-pneumatic Positioner. E/P Converter based on the signal from controller gives signal to Actuator on Steam Control valve to controls the flow of steam to PHE Overheat Protection Loop: This loop comes in to action only when primary loop fails. This stops the steam supply to PHE if primary temperature control loop fails & temperature at the outlet of PHE exceeds set temperature in on-off controller & avoids overheating This loop consisting of : 1. Solenoid Valve fitted on ON/OFF valve or fitted on air supply line to Temperature Control valve before AFR. 2. ON-OFF Controller. 3. PT-100 Temperature Sensor. PT-100 Temperature Sensor senses the water temperature at the outlet of the PHE & gives signal to On/Off controller. On/Off Controller accepts signal from the Temperature Sensor & gives relay output to Solenoid Valve based on the set point. Solenoid valve accepts signal from on/off controller and stops the steam supply by either stopping air supply to actuator on normally closed valve or providing the air supply to actuator on normally open valve Condensate removal solution This loop consisting of : 1. Steam Operated Mechanical Pumping Trap Pumping trap combination used to remove condensate from the PHE under all conditions, even under stall condition. Condensate removal is essential, to keep the PHE heating area free from condensate. Thus steam consumption is less due to high heat transfer area and high thermal efficiency in a plate heat exchanger By-pass arrangement on the secondary side This consists of a accurately sized water flow stop valve and accurately sized flow diverting pipe line.

5 Installation Warning: Before proceeding with any installation or maintenance work read section 1, Safety information. 3.1 Steam and condensate connections It is important that the steam supply to the unit is supplied as dry and as clean as Possible, in accordance with good steam engineering practice. It should also be ensured that all connecting pipework is stress free and adequately supported. The steam supply should always be maintained at the specified design pressure and temperature for the unit. The unit must not operate above the maximum steam pressure and temperature indicated on the name-plate. The installation of an appropriately sized safety valve (if not provided by Forbes Marshall), to protect any lower pressured equipment on either the primary or secondary side of the heat exchanger, is strongly recommended. The installation of Strainer (if not provided by Forbes Marshall), with appropriate filtration element based on the Steam or Water quality is strongly recommended to avoiding choking of PHE or damage of the system component like Pumps etc. Forbes Marshall supply a range of traps, strainers, separators, safety valves and pressure reducing equipment. Connect the Steam Inlet Line, Condensate Outlet Line, Water Inlet Line & Outer Outlet Line as indicated in respective GA drawing for unit. 3.2 Air supply Connect a compressed air supply (4 to 5 bar(g) ) to the AFR mounted on the control valve. 3.3 Electrical Supply All electrical wiring and connections should be carried out in accordance with National regulations and Standards. Power supply to be given to Control Panel as indicated on the name-plate & as per the wiring diagram provided in Control Panel for unit.

6 Commissioning We recommend the service and support of a Forbes Marshall Commissioning Engineer. Details of this service can be found by contacting Forbes Marshall. Note: In most new installations, dirt collects in the steam line during construction of piping systems. It is essential to flush this out prior to commissioning. Commissioning procedure: - Check all electrical connections are secure and as per installation drawing. - Dry commissioning valve stroke check - An initial valve stroke check should be carried out to ensure free movement of the valve stem. - Shut steam inlet valve upstream of the & Open all condensate drain valves. - Switch off electrical power. - Open secondary isolating valves Upstream/downstream of the. - Start the main secondary water circulating pump(s) if fitted. - Check for secondary water circulation through the. - If the circulation is okay, switch on the power to the unit, first ensuring that the voltage and frequency are correct. - Check the PID controller & ON/OFF controllers for actual temperature & set point temperature. Note: ensure the temperature setting is suitable for the application. If this needs to be altered, refer to the PID & ON/OFF Controller Set-up Manuals. - Slowly open main steam inlet valve. - Check process temperature is within the acceptable limits of the set point. Important ON/0FF controller setting for Overheat Protection: - ON/0FF controller should be set at a suitable level to protect plant, process and personnel. Details of setting can be found in the ON/OFF Controller Set-up Manuals. Care should be taken to ensure sufficient difference between the process set point and the high limit set point, to avoid any unwanted high limit tripping. - Check temperature rises to set value and controls satisfactorily. - If necessary adjust or fine Tune PID settings, (see 'PID Controller Set-up Manuals). We would strongly recommend that only a suitably trained controls engineer adjust these parameters in PID & ON/OFF Controller - Check operation of condensate pump.

7 The unit is now ready for service Maintenance Warning: Before proceeding with any maintenance work read section 1, Safety information. For maintenance of the individual components of the system, please see the relevant operating manuals for the components concerned enclosed with this operating manual.