DSS DOSING STANDARD SKIDS. Data Book. Pre-designed, assembled and tested chemical dosing skid.

Transcription

1 DSS DOSING STANDARD SKIDS Data Book Pre-designed, assembled and tested chemical dosing skid.

2 CONTENTS 1. GENERAL DATA 1.1 General description 3 2. IDENTIFICATION 2.1 Type key Quick selection guide of pre-configured DSS DESIGN LAYOUT 3.1 Parts identification 8 4. COMPONENT FUNCTIONS 9 5. DIMENSIONS 5.1 DSS chair DSS cabinet SUPPLIER LIST PERFORMANCE RANGE PUMP DATA 8.1 DDA pump technical data DDI pump technical data PUMPED LIQUIDS GUIDE 9.1 Chemical compatibility list 18 Issued 2/09/2016 Page 2 of 18

3 1. GENERAL DATA DSS Cabinet DSS Chair 1.1 General description Hydramet has been manufacturing skid based, project engineered, chemical dosing pump systems for over 25 years. Used in water treatment plants, waste water treatment plants, industrial applications and mining process plants, they are custom designed to the project s needs. Half of all skids built were two pump, duty/stand, free standing skid based systems. 80% of those systems had the same materials and a similar layout. This led to a standard system being designed, with all the standard features, that end users require in preengineered, assembled and tested modular unit. Standard Features Free standing, 316 SS frame with PVC backing board in either an open chair design or fully enclosed cabinet with lift in doors. Digital duty/stand dosing pumps. Suction manifold in rigid piping with isolation valves for duty to stand selection, flush and drain. Dual suction strainers. Calibration cylinder. Discharge manifold in rigid piping with isolation valves for duty to stand selection, flush and drain. Pressure relief valves and a pressure loading valve. Pressure gauge with chemical barrier block Signal cables, Terminal box & 240V GPO s. Options available: dampers, check valves, flow meter and dilution water flow control. Precise and easy installation A predesigned system makes installation easy. Design drafting is complete. Foot print dimensions are available to be incorporated into the civil design of the plant. Entry and exit connection size and location are predetermined. Installation problems are eliminated. Designed to save costs In general the investment for a dosing system is low compared to the overall design of a plant. The chemical system is the last item to be installed, so is last to be designed. Last minute design changes cost time when time is precious. Predesigned systems save money as drafting, engineering, procurement and manufacturing does not occur on the run. By choosing a completed design, there is no time loss. No design approval period. No expensive delays. Built to EC & Australian standards /42/EC Machinery Directive - Compliant to AS RCM approval - OH&S guidelines Issued 2/09/2016 Page 3 of 18

4 2. IDENTIFICATION 2.1 Type key Example: DSS L2 P2 X 1 X 2 X DDA Type Range Pump Model DSS Extras Style X None 1 Duty pump 1 Chemical flow meter 2 Duty/stand 2 2 x Chemical Flow meter 3 Duty/Duty 3 Dilution/carrier water 4 2 x Dilution/carrier water Frame 5 FM + carrier water 1 Chair SS 6 2 x FM + carrier water 2 Chair PC 7 2 x FM + 2 x carrier water 3 Cabinet SS 4 Cabinet PC J/box, cables & GPO 1 1 x pump Material 2 2 x pumps 1 upvc/viton 2 upvc/epdm Pulsation damper 3 cpvc/viton X No Damper 1 1 x Damper 5 SS/Viton 2 2 x Dampers Pressure Valve type Gauge No 1 valve X Gauge 2 Diaphragm valve 1 1 x 10 bar (16 bar for DDA ) 2 2 x 10bar (16 bar for DDA ) Suction manifold Single strainer with Cal. L1 cylinder Check valve after pump L2 Double strainer with Cal. cylinder X No check valve 1 Single extra Check Pressure manifold 2 Two extra check valves Duty - Relief and Loading P1 valve Duty/Stand - 2x Relief, 1 x Loading P2 valve Duty/Duty - 2 x Relief and Loading P3 valve P6 P7 P8 Duty - RV, PV + Auto Degas valve Duty/stand - RV, PV + Auto Degas valve Duty/Duty - RV, PV + Auto Degas valve Issued 2/09/2016 Page 4 of 18

5 Note: The previous identification type key is provided to understand the description of the product. Hydramet has pre-configured the most common use range as standard coded products ready for 2 week manufacturing times. Pre-configured DSS units are listed in the quick guide following. For units with descriptions not listed in the quick guide contact Hydramet for estimated lead times. Issued 2/09/2016 Page 5 of 18

6 2.2 Quick selection guide of pre-configured DSS Chem. group Frame Pumps Configuration Material -size Valve type Description 1 Chair PC DDA Duty/Stand upvc/v - DSS L2 P2 X 1 X 2 X DDA Chair PC DDA Duty/Stand upvc/v - DSS L2 P2 X 1 X 2 X DDA Chair PC DDA 30-4 Duty/Stand upvc/v - DSS L2 P2 X 1 X 2 X DDA Chair PC DDI Duty/Stand upvc/v - DSS L2 P2 X 1 X 2 X DDI AF 60-10AF 74 1 Chair PC DDI Duty/Stand upvc/v DSS L2 P2 X 1 X 2 X AF DN20 DDI150-4AF 75 1 Cabinet DDA Duty/Stand upvc/v - DSS L2 P2 X 1 X 2 X PC DDA Cabinet DDA Duty/Stand upvc/v - DSS L2 P2 X 1 X 2 X PC DDA Cabinet DDA 30-4 Duty/Stand upvc/v - DSS L2 P2 X 1 X 2 X PC DDA Cabinet DDI Duty/Stand upvc/v - DSS L2 P2 X 1 X 2 X DDI PC AF 60-10AF 79 1 Cabinet DDI Duty/Stand upvc/v DSS L2 P2 X 1 X 2 X PC AF DN20 DDI150-4AF 80 2 Chair SS DDA Duty/Stand upvc/e - DSS L2 P2 X 1 X 2 X DDA DDA Duty/Stand upvc/e - DSS L2 P2 X 1 X 2 X Chair SS DDA DDA 30-4 Duty/Stand upvc/e - DSS L2 P2 X 1 X 2 X Chair SS DDA DDI Duty/Stand upvc/e - DSS L2 P2 X 1 X 2 X DDI Chair SS AF 60-10AF 83 2 DDI Duty/Stand upvc/e DSS L2 P2 X 1 X 2 X Chair SS AF DN20 DDI150-4AF 84 2 Cabinet DDA Duty/Stand upvc/e - DSS L2 P2 X 1 X 2 X SS DDA Cabinet DDA Duty/Stand upvc/e - DSS L2 P2 X 1 X 2 X SS DDA Cabinet DDA 30-4 Duty/Stand upvc/e - DSS L2 P2 X 1 X 2 X SS DDA Cabinet DDI Duty/Stand upvc/e - DSS L2 P2 X 1 X 2 X DDI SS AF 60-10AF 87 2 Cabinet DDI Duty/Stand upvc/e DSS L2 P2 X 1 X 2 X SS AF DN20 DDI150-4AF 88 3 Chair SS DDA Duty/Stand upvc/e - DSS L2 P2 X 1 X 2 X DDA Chair SS DDA Duty/Stand upvc/e - DSS L2 P2 X 1 X 2 X DDA Chair SS DDA 30-4 Duty/Stand upvc/e - DSS L2 P2 X 1 X 2 X DDA Chair SS DDI Duty/Stand upvc/e - DSS L2 P2 X 1 X 2 X DDI AF 60-10AF 92 3 Chair SS DDI Duty/Stand upvc/e DSS L2 P2 X 1 X 2 X AF DN20 DDI150-4AF 93 3 Cabinet DDA Duty/Stand upvc/e - DSS L2 P2 X 1 X 2 X SS DDA Cabinet DDA Duty/Stand upvc/e - DSS L2 P2 X 1 X 2 X Code Issued 2/09/2016 Page 6 of 18

7 SS DDA Cabinet DDA 30-4 Duty/Stand upvc/e - DSS L2 P2 X 1 X 2 X SS DDA Cabinet DDI Duty/Stand upvc/e - DSS L2 P2 X 1 X 2 X DDI SS AF 60-10AF 97 3 Cabinet DDI Duty/Stand upvc/e DSS L2 P2 X 1 X 2 X SS AF DN20 DDI150-4AF 98 4 Chair PC DDA Duty/Stand upvc/v - DSS L2 P2 X 1 X 2 X DDA Chair PC DDA Duty/Stand upvc/v - DSS L2 P2 X 1 X 2 X DDA Chair PC DDA 30-4 Duty/Stand upvc/v - DSS L2 P2 X 1 X 2 X DDA Chair PC DDI Duty/Stand upvc/v - DSS L2 P2 X 1 X 2 X DDI AF 60-10AF 02 4 Chair PC DDI Duty/Stand upvc/v DSS L2 P2 X 1 X 2 X AF DN20 DDI150-4AF 03 4 Cabinet DDA Duty/Stand upvc/v - DSS L2 P2 X 1 X 2 X PC DDA Cabinet DDA Duty/Stand upvc/v - DSS L2 P2 X 1 X 2 X PC DDA Cabinet DDA 30-4 Duty/Stand upvc/v - DSS L2 P2 X 1 X 2 X PC DDA Cabinet DDI Duty/Stand upvc/v - DSS L2 P2 X 1 X 2 X DDI PC AF 60-10AF 07 4 Cabinet DDI Duty/Stand upvc/v DSS L2 P2 X 1 X 2 X PC AF DN20 DDI150-4AF 08 Chemical Groups 1 Sodium Hypochlorite. All acids to 96% solution, Ferric & Ferrous solutions. General chemicals. 2 Ammonia, Alum, Antiscalant, SMBS 3 Sodium Hydroxide, Soda ash, Copper sulphate 4 Calcium Hypochlorite, Sodium Hypochlorite, Acids to 96%. Issued 2/09/2016 Page 7 of 18

8 3. DESIGN LAYOUT 3.1 Parts Identification Pos. Key Specification 1 Free-standing open Chair frame or Cabinet enclosure with bolt down feet & lifting lugs. 2 Doors. Clear upvc. Lift-in type. (For Cabinet frame only) 3 Grundfos Digital Diaphragm dosing pump/s DDA -, DDI - AF series 4 Pressure Relief Valve/s, hard plumbed into the discharge manifold 5 Pressure loading valve 6 Suction manifold with suction strainer/s and selection/isolating valves 7 Calibration cylinder. (Always with Diaphragm valve for slow release.) 8 Flush valves with camlock connection. 9 Drain valves with camlock connection. 10 Pressure gauge & chemical barrier block 11 Signal junction box. SS (Plus input signal cable, Alarm output cable, 4-20mA output cable) 12 IP66 AU/NZ 1-phase GPO 13 Emergency Shut down button Documentation: 3D CAD as built P&ID drawing. Operation manual. Performance test certificates Wooden packing crate Possible options: Pulsation Damper. (Not required for digital dosing pumps running below 105l/h) External chemical flow meter Dilution or carrier water flow control system Issued 2/09/2016 Page 8 of 18

9 4. COMPONENT FUNCTIONS Chair frame: Main supporting structure. Designed to offer clear viewing and open access to all components from the front and side of the skid. Cabinet enclosure: Offers maximum protection to operating personal and surrounding equipment from exposure to sudden leaks of toxic chemicals. With easy access through the lift-out opening clear panel door and ample room to complete operational tasks and maintenance. Powder coated vs. SS frames: All DSS frames are made from 316 stainless steel. Where chemicals that corrode SS are dosed, powder coating provides essential barrier protection. Dosing pumps: Control and deliver the correct dose rate of chemical using industry standard control modes such as manual adjustment, pulse contact and analogue (0/4-20mA) flow pacing. Refer to the appropriate pump data book for details. The Grundfos digital dosing pumps offered will measure the output flow of the chemical and provide a 4-20mA output signal for connection to the plant PLC Discharge manifold: Constructed from rigid solvent welded piping for excellent chemical resistance the simple layout of the valving allows functional system changes such as duty/stand pump selection, pressure release, flush and drain within easy reach. Selection valves - vs. Diaphragm: Quarter turn ball valves are quick acting so have an operational safety advantage. valves have more seals and seat with the potential to wear and leak. valves lock fluid internally between the ball and body, where gaseous liquids can expand and fracture the valve. Diaphragm valves are slower to operate. The diaphragm is the only internal seal. The diaphragm cannot trap chemical within the mechanism so no danger of trapped gases. Pressure relief valve: Releases over-pressure back to the suction side of the dosing pump. Protects the pressure side of the system from high pressure failure. Pressure loading valve: Maintains a consistent back pressure of 3 bar on the dosing pump. Ensures accuracy of the dose rate. Prevents chemical siphoning through system. Suction manifold: Rigid solvent weld construction for excellent chemical resistance and secure mounting. The valve layout allows selection changes to control the flow path and flushing connection for clean up or service. Dual in-line strainers: Clean the in-flow chemical of foreign particulate matter and protect the integrity of the dosing pump/s and valves. One can be cleaned while the other is in service. Calibration cylinder: Used to test the accuracy of the dosing pump settings Diaphragm valve cal cylinder control: Slow release prevents over filling and surging. Pressure gauge: Visual indication of system operating pressure. Signal cable terminal box: On board termination point for all signal cable wiring. Signal cables: Connect pump signal functions to terminal box. Electrics: AU/NZ IP66 240V GPO protects against electric shock in the event of a chemical leak. Pressing the emergency shut down button stops electricity going to the pumps or other electrical components on the skid. Connections: Union type chemical entry and exit points. Labelling: All major components, E.g. pumps, valves, strainers, etc., labelled code and system description to match the operation manual. Options: Pulsation dampers: Reduces pulsing and vibration in discharge line. (Only for DDI 150 above 70% discharge rate.) External flow meter: Provides independent chemical delivery measurement to the plant PLC. Modular connection manifold: Connects 2, 3 or 4 units suction systems together. Issued 2/09/2016 Page 9 of 18

10 5. DIMENSIONS 5.1 DSS Chair DN 15 Issued 2/09/2016 Page 10 of 18

11 DN 20 Weight: 92 95kg Issued 2/09/2016 Page 11 of 18

12 5.2 DSS Cabinet DN 15 Issued 2/09/2016 Page 12 of 18

13 DN 20 Weight: Kg Issued 2/09/2016 Page 13 of 18

14 6. SUPPLIER LIST Supplier list Product manufacturer 15mm 20mm Skid frame Hydramet X X Suction manifold, suction strainer, selection/isolating valves, fittings & George Fischer X X pipe. Material: Pipe Sched. 80, upvc UV resist Grey. Calibration cylinder Koflo X X Digital Diaphragm dosing pumps Grundfos X X Pressure manifold, drain/flush valves, fittings and pipe. George Fischer X X Material: Pipe Sched. 80 upvc, UV resistant Grey. Pressure Relief Valve Grundfos/Stubbe X X Pressure loading valve Grundfos X X Pulsation Damper Hidracar/Grundfos X X Junction box Grundfos X X GPO & E-stop Clipsal/ABB X X Signal cables & terminal junction box Grundfos X X Documentation: 3d CAD as built P&ID drawing. Operation manual. Performance test certificates Hydramet X X Issued 2/09/2016 Page 14 of 18

15 7. PERFORMANCE RANGE P [bar] 16 DDA (Future development) 10 DME DDA DDI DDA DME DDA 30-4 DDI Q [l/h] Fig. 1 Pump performance range Issued 2/09/2016 Page 15 of 18

16 8. PUMP TECHNICAL DATA 8.1 DDA pump technical data Issued 2/09/2016 Page 16 of 18

17 8.2 DDI pump technical data Issued 2/09/2016 Page 17 of 18

18 9. PUMPED LIQUIDS GUIDE 9.1 Chemical capability list Issued 2/09/2016 Page 18 of 18