SAMPLE COOLER INSTALLATION AND MAINTANANCE INSTRUCTIONS
1. SAFETY INFORMATION
Safe operation of these products can only be guaranteed if they are properly installed, commissioned, used and maintained by qualified personnel (see Section 1.11) in compliance with the operating instructions. General installation and safety instructions for pipeline and plant construction, as well as the proper use of tools and safety equipment must also be complied with.
1.1 Intended use
Referring to the Installation and Maintenance Instructions, name-plate and Technical Information Sheet, check that the product is suitable for the intended use/application. The products comply with the requirements of the European Pressure Equipment Directive 97/23/EC and fall within category ‘SEP’. It should be noted that products within this category are required by the directive not to carry the mark.
i) The products have been specifically designed for use on steam and water, which are in Group 2 of the above-mentioned Pressure Equipment Directive. The products’ use on other fluids may be possible but, if this is contemplated, ARS should be contacted to confirm the suitability of the product for the application being considered.
ii) Check material suitability, pressure and temperature and their maximum and minimum values. If the maximum operating limits of the product are lower than those of the system in which it is being fitted, or if malfunction of the product could result in a dangerous overpressure or overtemperature occurrence, ensure a safety device is included in the system to prevent such over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) ARS products are not intended to withstand external stresses that may be induced by any system to which they are fitted. It is the responsibility of the installer to consider these stresses and take adequate precautions to minimize them.
v) Remove protection covers from all connections and protective film from all name-plates, where appropriate, before installation on steam or other high temperature applications.
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded) before attempting to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some previous time. Consider: flammable materials, substances hazardous to health, extremes of temperature.
1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.
1.6 The system
Consider the effect on the complete system of the work proposed. Will any proposed action (e.g. closing isolation valves, electrical isolation) put any other part of the system or any personnel at risk? Dangers might include isolation of vents or protective devices or the rendering ineffective of controls or alarms. Ensure isolation valves are turned on and off in a gradual way to avoid system shocks.
1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume that the system has depressurised even when the pressure gauge indicates zero.
1.8 Temperature
To avoid burns, it is essential that cooling water is flowing before opening the sample inlet valve. Always close the sample inlet valve before turning off the cooling water.
1.9 Tools and consumables
Before starting work ensure that you have suitable tools and /or consumables available. Use only genuine ARS replacement parts.
1.10 Protective clothing
Consider whether you and /or others in the vicinity require any protective clothing to protect against the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling objects, and dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person. Installation and operating personnel should be trained in the correct use of the product according to the Installation and Maintenance Instructions. Where a formal ‘permit to work’ system is in force it must be complied with. Where there is no such system, it is recommended that a responsible person should know what work is going on and, where necessary, arrange to have an assistant whose primary responsibility is safety. Post ‘warning notices’ if necessary.
1.12 Handling
Manual handling of large and/or heavy products may present a risk of injury. Lifting, pushing, pulling, carrying or supporting a load by bodily force can cause injury particularly to the back. You are advised to assess the risks taking into account the task, the individual, the load and the working environment and use the appropriate handling method depending on the circumstances of the work being done.
1.13 Residual hazards
In normal use, the external surface of the product may be very hot. If used at the maximum permitted operating conditions the surface temperature of some products may reach temperatures of 350°C (662°F). Many products are not self-draining. Take due care when dismantling or removing the product from an installation (refer to ‘Maintenance instructions’).
1.14 Freezing
Provision must be made to protect products which are not self-draining against frost damage in environments where they may be exposed to temperatures below freezing point.
1.15 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, this product is recyclable and no ecological hazard is anticipated with its disposal providing due care is taken.
1.16 Returning products
Customers and stockists are reminded that under EC Health, Safety and Environment Law, when returning products to ARS they must provide information on any hazards and the precautions to be taken due to contamination residues or mechanical damage which may present a health, safety or environmental risk. This information must be provided in writing including Health and Safety data sheets relating to any substances identified as hazardous or potentially hazardous.
ARS sample coolers are used in with hot fluid processes at desired points in quickly and effectively measurement.
The cooling system is designed for on line measurement devices; especially designed high temperature fluids are to quickly bring the required temperature for optimal measurement. Our customers can get solutions to different needs and requirements with modular design. We are able to provide mounted on the wall and also can be supplied in stainless steel on the skid.
2 Operation WARNING
To avoid the risk of scalding, it is essential that a full flow of cooling water is present before opening the sample inlet valve. Always close the sample inlet valve before turning off the cooling water. Sample pipework becomes very hot under normal working conditions, and will cause burns if touched. Follow this procedure for safe operation and accurate sampling:
– Open the cooling water inlet valve first and ensure that a full flow can be seen at the cooling water outlet.
– Gradually open the sample inlet valve and regulate the flow to achieve a cooled sample at about 25°C (77°F).
– Allow the sample to run for a while before collection. This will ensure that a true sample is collected for analysis.
– When enough liquid has been collected close the sample inlet first, and then the cooling water inlet valve.
– After closing the sample inlet valve the sample OUT connection may drip for a few minutes while the coil drains.
3 Maintenance
No routine maintenance is required
pH ANALYZER
pH: The steam which goes to turbines has to be ultra pure. The pH value of the feed water gives direct indication of alkalinity or acidity of these water. The ultra pure water has pH value of 7. In a steam circuit; it is a normal practice to keep the ph value of feed water at slighly alkaline levels. This helps in preventing the corrosion of pipe work and other equipment. Typically dedicated pH analyzers are recomended at following locations in a steam circuit: high pressure heaters, DM make-up mater, candensate extraction pump discharge.
Your Benefits
• Complete system for Simple and Fast operation
• The ultimate in pH/ORP measurement accuracy
• Self-Pressurising Electrodes
• Easy setup and Maintenance
CONDUCTIVITY
Conductivity is an important an parameter for detecting any contamination of steam in the boiler. Conductivity of pure water is almost zero (1-2 mSiemens). Ingress of any kind of dissolved impurity will raise conductivity instantly. Thus conductivity is an important parametrer fort he detection of leakages. Typical points in the steam circuit where conductivity could be monitored are: superheated steam, drum water, hşgh pressure heaters, low pressure heaters, conderser, plant effluent, D.M. plant, make up water to D.M. plant
SILICA
The presence of Silica in the steam and water circuits of a power generation plant is associated with a number of problems both in the super heater and turbine sections. The solubility of silica in steam increases with pressure. Hence there are chances of silica carryover. The presence of silica in steam can lead to deposition in superheated tubes and on the turbine blades which may lead to loss of efficiency and turbine blade failure. For proper working of turbines, continuous monitoring of silica is highly recommended. Similarly, the monitoring of anion and mixed bed ion exchanges safeguards and optimizes the operation of the demineralization plant. Thus the typical points in steam circuits where silica analysis is required are low level Silica measurement in: high pressure and low pressure turbines, steam, drum (saturated) steam, CEP discharge, make-up water, D.M. make-up water and high level Silica measurement in drum water.
DISSOLVED OXYGEN
At elevated temperature, dissolved oxygen causes corrosion which may cause puncturing and failure of piping and components respectively. Dissolved oxygen also promotes electrolytic action between dissimilar metals causing corrosion and leakage at joints and gaskets. Mechanical deaeration and chemicals scavenger additives are used to remove the dissolved oxygen. An analytical check of process efficiency, therefore, is essential. Dissolved oxygen monitoring is imperative in power stations using neutral or combined operating conditions (pH 7,0 – 7,5 or 8,0 – 8,5). The typical points in steam circuit where dissolved oxygen monitoring is required are deaerator inlet and outlet.
