3d trasar boiler manual ver 4.2 11-10-10

7/25/2019 3D TRASAR Boiler Manual Ver 4.2 11-10-10

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Pen Flourometer Operation ManualOM0208

Nalco Global Equipment Solutions 1

33

Date 11-10-10Version 4.2

Nalco Global Equipment Solutions1601 West Diehl RoadNaperville, IL 60563-1198

3D TRASAR Boiler TechnologyInstallation and Operation Manual OM0211


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3D TRASAR Boiler Technology Installation and Operation Manual OM0211

2 Nalco Global Equipment Solutions


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3D TRASAR Boiler Technology Installation and Operation ManualOM0211_________________________________________________________________________


Table of Contents

1.0 Introduction...................................................................................................... 9

1.1 3D TRSAR Boiler Technology......................... .......................... .......................... ............... 91.2 3D TRASAR Boiler Models and Optional Component ...................................................... 111.3 About This Manual........................................................................................................... 121.4 Potential Applications ...................................................................................................... 12

1.4.1 Feedwater Treatment Programs............................................................................. 121.4.2 3D TRASAR Cycles Control ................................................................................... 131.4.3 Hardness Excursion Override................................................................................. 131.4.4 BT Phosphate / pH Product Line Control ................................................................ 131.4.5 Condensate Monitoring .......................................................................................... 13

1.5 Safety.............................................................................................................................. 141.5.1 Explanation of Symbols.............................. .......................... .......................... ........ 14

1.6 Installation, Assembly, Start-Up and Control Tuning Overview......................................... 15

2.0 System Installation ........................................................................................ 17

2.1 Unpack and Identify Parts................................................................................................ 172.1.1 Frames and Panels................................................................................................ 172.1.2 Items Requiring Assembly...................................................................................... 182.1.3 Additional Items Shipped Loose ............................................................................. 18

2.2 Mount the Panel (or Frame)............................................................................................. 192.2.1 General Installation Instructions ............................................................................. 192.2.2 Wall Mounting ....................................................................................................... 202.2.3 Frame Mount Dimensions ...................................................................................... 212.2.4 Installation Overview Diagrams .............................................................................. 22

2.2.4.1 TRASAR Fluorometer and NCSM Feedwater Systems..................................... 222.2.4.2 TRASAR Fluorometer Feedwater Systems ...................................................... 232.2.4.3 NCSM Feedwater Systems.............................................................................. 242.2.4.4 TRASAR Fluorometer Blowdown Systems....................................................... 25

2.2.4.5 Continuous Blowdown Conductivity Probe And Valves..................................... 262.2.4.6 Timed-Sample Blowdown Conductivity Probe And Valves ............................... 272.2.4.7 Condensate Monitor......................................................................................... 28

2.3 Plumb the System ........................................................................................................... 292.3.1 Plumbing Requirements ......................................................................................... 292.3.2 Plumbing Connections ........................................................................................... 302.3.3 Plumbing Notes...................................................................................................... 31

2.3.3.1 Sample Point ................................................................................................... 312.3.3.2 Sample Lines................................................................................................... 322.3.3.3 Discharge Line................................................................................................. 332.3.3.4 Cooling Water Lines......................................................................................... 332.3.3.5 Blowdown Conductivity Probe Assy, Control Valve & Flow Control Valves........ 34

2.3.3.6 Condensate Conductivity Probe Assy, Sample Take-Off, Control Valve & Flow

Control Valves ............................ .......................... .......................... ................. 372.3.3.7 Boiler NCM100 Probe Installation..................................................................... 38

3.0 Electrical Wiring and Connections............................................................... 39

3.1 Run Wires in the Control Box ......................................................................................... 39

3.2 Terminate Wires in the Control Box ................................................................................ 403.2.1 System Power Connections ................................................................................... 403.2.2 Internal Power Connection ..................................................................................... 403.2.3 Fuses..................................................................................................................... 40


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3.2.4 Control Relay Connections..................................................................................... 413.2.4.1 Control Relays Powered and Non-Powered Wiring.......................... .............. 413.2.4.2 Relay Connections Inside Controller................................................................. 423.2.4.3 Blowdown Valve Relay Box Connections..........................................................43

3.2.5 Alarm Relay Connections ....................................................................................... 44

3.2.6 Fluorometer Connections ....................................................................................... 443.2.7 Conductivity Probe Connections............................................................................. 45

3.2.7.1 Compensating vs. Non-Compensating Probes................................................ 453.2.7.2 Conductivity Probe Wiring............................................................................... 47

3.2.8 High Impedance (pH/ORP) Connections................................................................. 543.2.9 Nalco Corrosion Monitor (NCM100) .......................... ........................... .................. 553.2.10 Analog Inputs ........................ ........................... ........................... ........................... 553.2.11 Analog Input Module (Optional) ........................ ........................... ........................... 573.2.12 Analog Outputs ...................................................................................................... 593.2.13 Interlock ................................................................................................................. 593.2.14 Temperature (RTD) Inputs ..................................................................................... 603.2.15 Digital Inputs .......................................................................................................... 613.2.16 Modem/Phone Line Connections............................................................................62

3.2.17 Ethernet Connections .............................................................................................623.2.18 LAN Connections ................................................................................................... 633.2.19 USB....................................................................................................................... 633.2.20 SCADA (RS232/485/Ethernet)................................................................................ 633.2.21 3D TRASAR Boiler Controller Terminal Connection Diagram.................................. 653.2.22 3D TRASAR Boiler Controller Default Wiring .......................................................... 66

4.0 Final Assembly and Start-up.........................................................................67

4.1 Installation Check and Safety Check .............................................................................. 674.2 Shut all 3D TRASAR Boiler System Valves ................................................................... 674.3 Install and Connect the TRASAR Fluorometer................................................................ 684.4 Power Up Control System Without Sample or Cooling Water Flowing.............................69

4.4.1 TRASAR Fluorometer and NCSM System ..............................................................69

4.4.2 TRASAR Fluorometer Systems .............................................................................. 694.4.3 NCSM Systems...................................................................................................... 694.5 Configure System and Upload to 3D TRASAR Controller ................................................. 69

4.5.1 PC System Requirements ......................................................................................694.5.2 Installing the Software............................................................................................694.5.3 Configurator Support .............................................................................................. 70

4.6 Reboot the 3D TRASAR Controller .................................................................................. 704.7 Verify the Configuration Using the Controller Keypad/Screens ......................................... 704.8 Calibrate the Fluorometer ................................................................................................ 71

4.8.1 Fluorometer Calibration Procedure......................................................................... 714.8.2 Fluorometer Calibration Screen Instructions ........................................................... 71

4.8.2.1 Fluorometer 2-Point Calibration Screens Instructions (Successful Calibration).. 724.8.2.2 Fluorometer 2-Point Calibration Screens (Cancel Selected During Calibration). 724.8.2.3 Fluorometer 2-Point Calibration Screens (Calibration Fails)......................... ..... 72

4.9 NCSM Short Circuit Test.................................................................................................. 734.9.1 NCSM Short Circuit Test Procedure ....................................................................... 734.9.2 NCSM Short Circuit Test Screens Instructions........................................................ 73

4.10 Refurbish and Test the NCSM Reference Electrode......................................................... 744.10.1 NCSM Probes ........................................................................................................ 744.10.2 ORP/RTD Probes................................................................................................... 744.10.3 Reference Electrode............................................................................................... 754.10.4 NCSM Probe Cables .............................................................................................. 764.10.5 NCSM Probe Checkout .......................................................................................... 76


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4.10.6 Refurbishing the Reference Electrode .................................................................... 764.10.7 Reference Electrode Check.................................................................................... 794.10.8 Reference Electrode Check Screens...................................................................... 804.10.9 Install the Reference Electrode............................................................................... 80

4.11 Feedwater pH and Conductivity Probe Installation ........................................................... 81

4.12 pH Probe Calibration ....................................................................................................... 814.13 Conductivity Probe Calibration......................................................................................... 83

4.13.1 Recommended Conductivity Standards.................................................................. 834.13.2 2-Point Calibration.................................................................................................. 844.13.3 1-Point Calibration.................................................................................................. 86

4.13.3.1 Continuous Sample On/Off or PID Control .............................................. 864.13.3.2 Timed Sample Continuous On/Off Control .............................................. 864.13.3.3 Timed Sample Proportional Control......................................................... 87

4.13.4 Extracting a Conductivity Probe from the Blowdown Line of an Operating Boiler..... 884.13.5 Installing a Conductivity Probe into the Blowdown Line of an Operating Boiler ........ 894.13.6 Cleaning a Fouled Conductivity Probe............................... .......................... ........... 89

4.14 System Leak Test and Final Piping Insulation .................................................................. 894.15 Startup ............................................................................................................................ 90

4.15.1 NCSM & Fluorometer Models System Valve Identification ................................... 904.15.2 TRASAR Fluorometer and NCSM System Startup.................................................. 904.15.3 TRASAR Fluorometer Only System Startup............................................................ 924.15.4 NCSM Only System Startup (without Sample Conditioning System) ....................... 934.15.5 Condensate Monitor System .................................................................................. 93

4.16 Test Data Download to a USB Data Stick and Laptop Computer...................................... 954.17 Verify Operation of the Control Outputs ........................................................................... 954.18 Test High-Temperature Shutdown & Pressure Relief ....................................................... 954.19 Check Remote Communications...................................................................................... 96

4.19.1 3D TRASAR Boilers Nalco Global Gateway Setup.................................................. 964.19.2 3D TRASAR Boilers Phone Line Verification .......................................................... 98

5.0 Tasks to Perform Before Control Tuning.........................................102

5.1 Ensure an Interlock Is Connected or Shutdown Process Is Established.......................... 1025.2 Verify Chemical Pump Capability................................................................................... 1025.3 Check Pump Responses and Measure Lag Times......................................................... 1035.4 Control Selection........................................................................................................... 1045.5 NCSM Set Point Determination...................................................................................... 105

5.5.1 0-100% Scavenger Pump Test............................................................................. 1055.5.1.1 0-100% Pump Test by Manually changing the Output ................................. 1055.5.1.2 Pump Test Using the NCSM PID Tuning Program ...................................... 106

5.5.2 Comfort Control NCSM Setpoint........................................................................... 1065.5.3 Ideal Control NCSM Setpoint................................................................................ 107

5.6 TRASAR Setpoint.......................................................................................................... 1075.7 Intermittent Operation.................................................................................................... 107

5.7.1 General Considerations........................................................................................ 1075.7.1.1 Interlocks and Alarms .................................................................................... 1075.7.1.2 Control Options.............................................................................................. 1075.7.1.3 Control Expectations...................................................................................... 108

5.7.2 Special NCSM Considerations ............................................................................. 1085.7.2.1 General Considerations ................................................................................. 1085.7.2.2 Monitoring...................................................................................................... 1105.7.2.3 Manual Feed.................................................................................................. 1105.7.2.4 Control ........................................................................................................ 110

5.7.2.4.1 High & Low Temperature Interlock ................................................... 1115.7.2.4.2 No Flow Switch................................................................................ 112


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5.7.2.4.3 Slaved Control ................................................................................. 1135.7.2.4.4 ON/OFF Control............................................................................... 1135.7.2.4.5 PID Control ...................................................................................... 113

6.0 ON/OFF Relay Control .................................................................................114

6.1 ON/OFF Control Using the PID 4-20 Outputs.................................................................114

7.0 Proportional Control Configuration............................................................115

7.1 Blowdown Control (Cycle Control using 3D TRASAR Fluorometer) ................................ 1157.2 Feedwater Flow-Based Proportional Control .................................................................. 117

8.0 PID Configuration and Tuning ....................................................................119

8.1 Check PID Configuration................................................................................................ 1198.2 When to Auto Tune........................................................................................................ 1198.3 Before Starting Auto Tune.............................................................................................. 1198.4 Checklist for Auto Tune..................................................................................................1198.5 TRASAR PID Auto Tune................................................................................................1208.6 NCSM PID Tuning ......................................................................................................... 1228.7 Manual Tuning............................................................................................................... 1248.8 Set PID to ON/OFF Control (or Manual) if PID Auto Tune Cannot Be Completed .......... 1259.9 Monitor PID Control ....................................................................................................... 125

9.0 Blowdown Monitor and Control Setup .......................................................126

9.1 Conductivity Monitor & Blowdown Control Setup............................................................1269.1.1 Conductivity Control Mode Options....................................................................... 1269.1.2 Temperature Probe Assignment ...........................................................................1269.1.3 Conductivity Control Mode.................................................................................... 1279.1.4 Monitor Only Mode............................................................................................... 1299.1.5 PID Control Mode.................................................................................................1299.1.6 Continuous (ON/OFF) Control Mode..................................................................... 1319.1.7 Time Sample (ON/OFF) Control Mode.................................................................. 132

9.7.1.1 Time Sample Continuous Mode...................................................................1339.7.1.2 Time Sample Proportional Mode ................................................................. 134

9.1.8 Interval Details ..................................................................................................... 1359.1.9 Sample Schedule ................................................................................................. 1359.1.10 Setting Up Timed Sample Proportional Control .................................................. 1389.1.11 Troubleshooting and Adjusting Tips for Interval Control ........................................ 1419.1.12 Review Conductivity Control Setup....................................................................... 1419.1.13 Notes on Control Modes, Alerts and Alarms.......................................................... 142

9.2 Fluorometer-Based Blowdown Control Setup................................................................. 144

10.0 Condensate Monitor Control Setup .........................................................146

11.0 Controller Operation .................................................................................149

11.1 Display Panel Functions ................................................................................................ 14911.2 The Keys ...................................................................................................................... 149

11.2.1 Ethernet and USB Connections and Power Switch .......................... ..................... 14911.3 The Graphic Icons ......................................................................................................... 15011.4 Menu, Information, Actions and Alarms Keys Flow Diagram........................................... 15011.5 Menu Key...................................................................................................................... 15111.6 Control Setting Screens................................................................................................. 151

11.6.1 TRASAR Factors Screen......................................................................................15111.6.2 PID 1-8 Screens................................................................................................... 152


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11.6.3 Relays 1-5 Screens.............................................................................................. 15211.7 Alarm Setting Screens................................................................................................... 152

11.7.1 Alarm Settings...................................................................................................... 15211.7.2 Alarm Screens ..................................................................................................... 154

11.8 Network Screens ........................................................................................................... 154

11.9 Preference Screens....................................................................................................... 155 11.9.1 Units Screens ................................................................................................ 155

11.9.2 Date Screens................................................................................................. 15511.10 Input Types Screens................................................................................................... 155

11.10.1 pH/ORP Input Screen............................. .......................... .......................... .......... 15611.10.2 Analog Input Screen..................... .......................... .......................... .................... 15611.10.3 TRASAR Fluorometer Screen .............................................................................. 156

11.11 Shortcut Keys............................................................................................................. 15611.11.1 Calibrate .............................................................................................................. 15711.11.2 Manual Control................................ ............................. .......................... .............. 15711.11.3 Test Send ............................................................................................................ 15711.11.4 Reboot ................................................................................................................. 157

12.0 Communications and Data Management ................................................... 158

12.1 3D TRASAR Boiler Optimizer ........................................................................................ 15812.2 3D TRASAR Boiler Configurator .................................................................................... 15812.3 3D TRASAR Boiler Controller ........................................................................................ 15812.4 SCADA Systems ........................................................................................................... 15812.5 3D TRASAR Web.......................................................................................................... 159

12.5.1 3D TRASAR Web Setup....................................................................................... 15912.5.1.1 Create/Edit Users ....................................................................................... 16012.5.1.2 Assign Controllers (Data Sources ............................................................... 16012.5.1.3 Manage Controller (Data Source) Setup Information ................................... 161

12.5.2 3D TRASAR Web Data ........................................................................................ 16112.5.3 3D TRASAR Web Reports ................................................................................... 16212.5.4 3D TRASAR Web Alarms..................................................................................... 163

12.6 3D TRASAR Wireless Gateway ..................................................................................... 16413.0 Shutdown and Maintenance ....................................................................... 165

13.1 Shutdown...................................................................................................................... 16513.1.1 Combination TRASAR Fluorometer and NCSM System Shutdown ....................... 16513.1.2 TRASAR Fluorometer Only System Shutdown ..................................................... 16513.1.3 NCSM Only System Shutdown (without Sample Conditioning System .................. 166

13.2 TRASAR Fluorometer Maintenance............................................................................... 16613.2.1 Clean TRASAR Fluorometer Flow Cell ................................................................. 16613.2.2 Calibrate TRASAR Fluorometer............................................................................ 16713.2.3 Check/Replace TRASAR Fluorometer Desiccant.................................................. 167

13.3 NCSM Maintenance ...................................................................................................... 16713.4 Sample Conditioning System Maintenance............................ .......................... .............. 167

13.5 Conductivity and pH Probe Maintenance ....................................................................... 16814.0 Troubleshooting........................................................................................... 169

14.1 General System Troubleshooting................................................................................... 16914.2 TRASAR Fluorometer Troubleshooting.......................................................................... 17614.3 Alarm Screen Troubleshooting....................................................................................... 17714.4 NCSM Troubleshooting ................................................................................................. 181

14.4.1 Factors That Affect Corrosion Stress and NCSM Control Ranges ......................... 18214.4.2 Replacement NCSM Probes................................................................................. 18314.4.3 Cables ................................................................................................................. 184


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14.4.4 ORP TB11 and NCSM 1024 mV Tests ..............................................................18514.4.5 REF Electrode...................................................................................................... 18514.4.6 ORP Probe Check................................................................................................187

14.5 PID Troubleshooting...................................................................................................... 18814.5.1 PID Troubleshooting Table ...................................................................................188

14.5.2 Interpreting & Troubleshooting Auto Tune Failure and Warning Messages............ 18914.5.2.1 Warning Messages ...........................................................................................18914.5.2.2 Failure Messages..............................................................................................193

14.6 Blowdown Control Troubleshooting................................................................................ 19714.7 Feedwater Conductivity Troubleshooting Flow Chart...................................................... 19914.8 Blowdown Conductivity Troubleshooting Flow Chart ......................................................200

15.0 Specifications..............................................................................................201

16.0 Replacement Parts and Accessories ........................................................207

17.0 Warranty ....................................................................................................211

18.0 Responsibility for Safe Delivery ................................................................211

APPENDICES

A. Scale Control using 3D TRASAR for Boilers...................... ........................... ..................... 212B. NCSM Probe Technology and Advanced Field Tests ........................................................ 224C. Pictorial Instructions of NCSM Reference Electrode Refurbishing...................................... 232D. Advanced PID Control Settings......................................................................................... 235E. Sample Conditioning System ............................................................................................237F. Notes On Control Modes, Interlocks, Control Overrides & Alarms...................................... 240G. Electrical Grounding Test Procedure for 3D TRASAR Controllers......................................245H. Panel and Frame System Dimensions...............................................................................248I. 3D TRASAR Boiler Systems Features Table..................................................................... 251J. Hardness Override Screens.............................................................................................. 254K. Coordinated Phosphate Screens.......................................................................................256L. Boiler Blowdown Survey ...................................................................................................261M. Boiler Saturated Steam Tables..........................................................................................263N. Modbus Communications Settings.................................................................................... 265O. Replaceable Battery Removal & Installation......................................................................268P. Connecting 2 3D TRASAR Boiler Controllers to 1 NGG (ver. 1.0)......................................270Q. Connecting a 3D TRASAR Cooling Controller and a 3D TRASAR Boiler Controller to

1 NGG (ver. 1.0) ............................................................................................................... 274R. 3D TRASAR Boiler Automation System Pre-Installation Checklist .....................................280


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1.0 Introduction

1.1 3D TRASAR Boiler Technology

3D TRASAR Boiler Technology is a complete boiler performance management system, intended to

maximize safety, reliability, and operating costs associated with boilers and steam generation .It continuously measures key system parameters and, when upsets occur, takes immediate correctiveaction, preventing operational problems and maximizing boiler performance. The 3D TRASAR Boilerequipment also has the ability to communicate with system users via the 3D TRASAR Web, textmessages or email, keeping the informed of changes or upsets.

Reliable production of steam

Steam availability - no unplanned outages

Minimize scale & corrosion

Safe production of steam

Food safety (FDA, NSF, Kosher)

Environmental / regulatory compliance

Minimize risk to plant personnel

Cost Performance

Maximize Equipment Life

Overall Lowest Total Cost of Operation

3D TRASAR Boiler System Capabilities

3D TRASAR Controller & Configurator Software

Communication for Remote Monitoring and Alarming

Web Reporting & Data Management

3D TRASAR Fluorometer for Scale Control

Corrosion Stress Monitor (NCSM) for Pre-boiler Corrosion Control

Conductivity-Based Blowdown Control

3D TRASAR Technology-based Blowdown Control

Feedwater pH & Conductivity Monitoring

Condensate Monitoring

for Boilers

Safety Reliability

for Boilersfor Boilers

Safety

TCO

Reliability


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Components

There are 6 primary components to 3D TRASAR Boiler Technology:

Boiler Controller- This is the central component to 3D TRASAR Boiler Technology that defines andcontrols system parameters. The Controller is setup and managed by interfacing (locally or remotely)with Nalcos advanced Boiler Configurator software.

Nalco Corrosion Stress Monitor (NSCM) - This is Nalcos innovative oxidation-reduction potentialtechnology that directly measures the systems corrosion stresses under actual high temperature and

pressure operating conditions. This measurement is made continuously and on-line so theappropriate adjustments and responses to changes in corrosion stresses can be made in real time.The actual measurement is often referred to as AT ORP and is expressed in mV.

3D TRASAR Fluorometer- This is a new solid-state fluorometer that can measure all NalcoTRASAR 3 products, including all NexGuard internal boiler treatments. The controller uses thesemeasurements to automatically respond to boiler system changes and maintain optimum treatmentlevels of highly effective scale and deposit inhibitors to keep boilers clean and free of scale anddeposits.

ControllerFluorometer

(TRASAR 3)

NCSM

Sample

Conditioning

System(SCS)

Feed Water

Monitoring Module

(pH & Conductivity)

Blowdown

Relay Box

3D TRASAR Boiler TechnologyBasic Components


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The patented 3D TRASAR on-line fluorometer consists of a flow cell and LED light source, filters,and detectors. The filters and detectors are tuned to specific light frequencies unique to Nalcoproducts and resultant process reactions. The LED light source is extremely bright at the appropriatefrequencies to reliably and precisely measure the chemical properties of the flowing water. This solid-state device provides years of trouble-free operation.

Sampling Conditioning System (SCS) This system is designed to safely cool and reduce thepressure of the side stream sample prior to entering the Nalco fluorometer. There are two models,one for low-pressure samples (< 50 psig / 3.4 bar) and one for high-pressure samples (50 -1500 psig/ 3.4 103 bar). This system is not intended for use on steam samples.

Feed Water Monitoring Module The pH and conductivity of the feed water can be continuouslymeasured using this module. The sensors are mounted on the piping connecting the SCS and thefluorometer. There are two models, one for high-purity samples (conductivities from 5-500 S/cm)and one for low-purity samples (conductivities over 500 S/cm).

Blowdown Relay Box Using the relay box the boiler controller can control up to four motorizedboiler blowdown valves. The relay box provides the 4 SPDT relays needed to operate these types ofvalves. This option can be ordered pre-installed on the control system or separately for in-fieldupgrades.

Note: A conductivity probe assembly must be installed on each boiler where blowdown will becontrolled based on conductivity.

1.2 3D TRASAR Boiler Models and Optional Components

The 3D TRASAR Boiler Systems are available in a variety of models. Talk to you Nalcorepresentative about which model is right for your application. In addition to ordering the 3D TRASAR

Boiler Control System you will need to order one or more of the following accessories:

NCSM Accessories Kit (# 60189090)

3D Boiler TRASAR Startup Kit (# 500-BTSRKIT.88)

Boiler Conductivity Probe Assembly (#060-BDP100.88)

Motorized Blowdown Valve and Flow Control Valve (See SPEC-427)

The complete list of system model numbers, accessories and spare parts are listed in Section 16 andAppendix I.


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1.3 About This Manual.

This manual provides step-by-step instructions to install and startup a 060-BL55XX.88 series system(3D TRASAR Fluorometer and Corrosion Stress Monitor) in the shortest amount of time. Skip anysections that are not applicable to the model ordered. The installation of optional sensors and

equipment is also included. Models supplied in some regions require 240 VAC, 50Hz, power insteadof 120 VAC, 60Hz (See Appendix I)

Note: Models designed for installation in hazardous areas have a slightly different panel layout andplumbing configuration. Therefore, the installation and startup/shutdown procedures aredifferent. The controller is the same. See Manual OM0228 for details.

A Nalco Technical Representative will configure the system. Dont hesitate to contact thatperson if you have a question or problem.

1.4 Potential Applications

1.4.1 Feedwater Treatment Program Control

The Nalco Corrosion Stress Monitor (NCSM) is highly sensitive and reliable REDOX monitor that canbe used in any aqueous system where corrosion stress is to be monitored or controlled. The NCSM isprimarily used to control the reductive and oxidative state of boiler feed water (controlling the feed o fan oxygen scavenger or metal passivator to the feed water or determining deaerator efficiency). Inaddition, corrosion stress can be monitored and controlled in regions of the condensate system.Illustrations of typical feed water installations are shown below.

Additional 4-20 mA signals can be connected to the Boiler Controller and used to control pumps usingthe same control options available for the 3D TRASAR Fluorometer and NCSM, including intermittentoperation. For example, a pH signal could be used for PID control an amine or caustic pump. Setup,configuration and control tuning of the 3D TRASAR Fluorometer and NCSM serve as examples of thesteps that should be followed to incorporate other signals into control loops.

High-pressure sample point installation Low-pressure sample point installation

Note: Boiler internal treatment chemicals must be fed downstream of any attemperator takeoff points.

Scavenger

Feed water

Pump

Deaerator

N223XX

PID

or

ON/OFF

PID

PID

or

ON/OFF

PREFERRED

Sample Point

PREFERRED

N223XX

Feed PointScavenger

N223XX

Feed water

Pump

Deaerator

Feed waterPump

PID

or

ON/OFF

PID

orON/OFF

PID

Sample Point

(minimum 10)pipe diameters

from product feedpoint)

PREFERREDN223XX

Feed Point


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1.4.2 3D TRASAR Cycles Control

With the addition of a second fluorometer, the 3D TRASAR Controller can now be used to control theboiler cycles using TRASAR. It is important to note that one must have good PID control of TRASARin the feedwater before starting cycles based control in the blowdown. The boiler cycles cannot becontrolled if the feedwater does not have a consistent TRASAR value. Additionally, the boiler cyclesshould be chosen as to not have any potential scaling problems in the boiler. For help in determiningthe correct cycles value for your system contact the Nalco TRASAR Help Desk. This type of controlcan be configured using either On/Off or Proportional Control. For more information on setting upthese control methods consult the help file in the Configurator.

Note: Currently, this type of control can only be used for TRASAR 3 products.

1.4.3 Hardness Excursion Control Override

The 3D TRASAR Controller can utilize the signal from an on-line hardness analyzer to increase thefeed of scale control product if the hardness concentration in the feedwater exceeds normal operatinglevels. Product feed can be increased to accommodate the hardness excursion via two methods:

Fixed pump output level

Multiple of recent pump output history (multiple of Smart Failsafe Output)

1.4.4 BT Phosphate / pH Product Line Control

There are four different phosphate/pH control approaches used in high pressure boiler systems withthe objective to prevent boiler corrosion. These approaches are:

Coordinated Phosphate Control

Congruent Sodium Phosphate Control

Phosphate-Low Hydroxide (Tri-AD) Control

Equilibrium Phosphate Control

The 3D TRASAR Controller enables use of any of these control approaches. On line pH and tracedphosphate (using the XE-2 fluorometer) measurements are needed to implement these controls. It isimperative to have good control over the boiler water pH.

1.4.5 Condensate Monitoring

There are now models of the 3D TRASAR Boiler System design to monitor condensate. Conductivityand pH are continuously monitored. If the condensate does not meet the user-specified conditions arelay is activated. This can be wired to a valve to dump the contaminated condensate and/or triggeran alarm. Optionally corrosion (Nalco Corrosion Monitor) can also be monitored.


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1.5 Safety

Always follow the safety practices listed below:

Never perform any installation procedures with electrical power engaged.

Never perform any repairs with electrical power engaged.

Never open the 3D TRASAR controller box or junction box with electrical power engaged.

Maximum water pressure to the 3D TRASAR Fluorometer should never exceed 90 psi (6.2 bar),unless equipped with a Nalco Sample Conditioning System.

Maximum water temperature should not exceed 110F (43C), unless equipped with a NalcoSample Conditioning System.

Always wear the appropriate Personal Protective Equipment (PPE) when working on a 3DTRASAR system (i.e. gloves, protective eyewear, protective shoes, wearing a mask, etc.).

Always observe local and facility safety practices beyond those listed in this manual.

The 3D TRASAR Boilers systems 060-BLxxxx.88 Models are designed for use in non-hazardousareas. Contact NGES Help Desk for other installations. (Use 060-BXxxxx.88 Series Models)

The NCSM probe assembly (probes plus stainless steel cross and fittings) has been designed to

handle water at 2800 psi (193 bar) and 500F (260C). Since measurements are made at theboiler feedwater pressure and temperature this probe assembly will be very hot and under highpressure. Extra care should be taken when servicing the system.

The NCSM reference probe is always installed vertically. So, the base of the reference electrodeis at ambient temperature regardless of the water temperature flowing through the cell. Thebase portion of the electrode is still at system pressure. Do not assume the sample line hasbeen closed and depressurized because the base of the reference electrode is not hot.

All piping should be insulated to maintain sample temperature and prevent accidental burns.

A lockable valve should be installed on the sample line to isolate the system for maintenanceand prevent unauthorized energizing of the system. Follow al l lock out, tag out requirements forservicing.

WARNING: Always turn off power before making any electrical connections, whichincludes all interconnecting cables, otherwise permanent damage may occur to systemcomponents.

SAFETY WARNING: The 3D TRASAR controller does not create sound above the 85db noise level. Follow plant hearing protection regulations.

1.5.1 Explanation of Symbols

WARNING: Risk of damage to equipment

CAUTION-DANGER: High temperature, high pressure or electrical safety risk.

SAFETY WARNING: Safety equipment is needed or plant safety procedures must befollowed.


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1.6 Installation, Assembly, Startup and Tuning Overview

There are 3 major steps to getting the system up and running: Installation, Assembly and Startup,and PID Tuning. The Installation can be performed by Nalco service technicians, a localcontractor or by plant personnel. Nalco service technicians must perform Assembly and Startup.PID Tuning will be completed after the system has been monitored long enough to understandthe boiler system dynamics and operation. Nalco service technicians will tune the system.

The complete process includes the following tasks:

Boiler feedwater system, sample point and feed point survey

Boiler blowdown piping and operation survey

1. Installation

Unpack system and identify parts

Mount panel (install frame)

Plumb the feedwater sampling system- Sample lines- Pressure test sample lines- Double-insulate the sample lines- Drain line- Sample cooler line

Flush the sample line for 30 minutes

Run wires to control box- Power- 4-20 mA control wires- Nalco Corrosion Stress Monitor (NCSM) wires (remote mount only)- Interlock (steam flow)- Phone line (optional)- Ethernet line (optional)- Optional analog and/or digital inputs

Install boiler blowdown equipment (optional)- Plumb conductivity probe assembly- Plumb blowdown flow control valve and motorized valve- Run probe wires to 3D TRASAR Controller- Run motorized valve wires to Relay Box

2. Assembly and Startup

Installation check and site safety check

Shut all 3D TRASAR Boiler System valves

Terminate wires in the control box

Install and connect TRASAR Fluorometer

Power up control system without sample or cooling water flowing

Configure system and upload to 3D TRASAR Controller- Customer information- Boiler information- Probes- 4-20 mA inputs- Digital inputs- Relays- 4-20 mA outputs- Communications

Reboot 3D TRASAR Controller

Verify configuration using controller keypad/screens


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Calibrate TRASAR Fluorometer Nalco Corrosion Stress Monitor (NCSM) short circuit test Refurbish and test reference electrode (NCSM) Install reference electrode (NCSM)

System leak test and final piping insulation (NCSM) Test data download to USB and laptop computer Check remote communications LAN modem Wireless Gateway Check Sample Conditioning System high-temperature shutdown Calibrate boiler conductivity probes (optional) Install and calibrate feed water pH and conductivity probes (optional) Verify operation of control relays Verify pump installation

- Power and 4-20 mA wiring- Capability- Check pump and treatment level responses to 4-20 mA changes

Measure system lag time Ensure interlock connected or shutdown process established

Perform 0-100% oxygen scavenger pump test Determine control set points (Sales Representative) Manually open the blowdown control valve/relay and verify the blowdown conductivity set

point can be reached as expected.

3. PID Tuning (second site visit minimum 2 weeks monitoring required)

Check PID setup Complete PID tuning (each loop) Monitor PID control Set PID to ON/OFF control if PID tuning cannot be completed (or leave in manual control).


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2.0 System Installation

2.1 Unpack and Identify Parts

2.1.1 Frames and Panels

Wall mount: Configured for wall attachment. Select when floor space is restricted.

Frame mount: Configured for floor-mounted installation. Select when all space isrestricted.

NCSM Module: Enables installation of a second NCSM sensor.

Enclosed NCSM: Provides weather resistant protection. Select for outdoor installations andwet environments.

HP Sample ConditioningSystem

Provides sample conditioning ahead of the fluorometer for samples up to

1500 psi (103 bar) and 500 F (260 C).

LP Sample ConditioningSystem

Provides sample conditioning ahead of the fluorometer for samples up to

50 psi (3.4 bar) and 250 F (122 C). Select when sampling from deaerator

storage tank or before the boiler feedwater pump.

Nalco Global Gateway: Enables wireless communication of important information such as alarmsand performance indicators.

Fluorometer: Packed separately to prevent damage during shipping

NCSM Reference Probe Packed separately to prevent damage during shipping

Blowdown Relay Box Provides SPDT relays needed to operate motorized ball valves

Feed water pH andconductivity probes

Packed separately to prevent damage during shipping. Install on pipingmodule between SCS and fluorometer

Blowdown conductivityprobe assemblies

Packed separately to prevent damage during shipping. Install on boiler

blowdown piping. Rated for 250 psi (17.2 bar) and 392F (200C).


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2.1.2 Items Requiring Assembly

Fluorometer Fluorometer Outlet Fluorometer Inlet Valve Pigtail 16/3 SJOWQty. (1) Assembly and Tubing Connector Qty. (5)Part # Qty. (1) Qty. (1) Part # 991-05053481.88

060-BT3220.88(Scale Control Models)

Ethernet Crossover Cable (8 ft., orange) Service (Power) Cord 12/3 SJOW Additional Items

Qty. (1) Qty. (1) Fuses (4), Part #991-50473718

Part # 991-05047661.88 Part # 991-01928722.88 Installation Manual, Part # 521-OM0211.88

ORP/RTD Cable (6ft) Qty (1) Reference Probe (NCSM) Qty. (1)Part # 6026390 Part# 991-05058543.88

ORP/RTD Cable with pre-amp (6ft) Qty (1) remote installations only Fluorometer Cable Qty(1) Part # 6031277 Part# 060-TR5221.88

2.1.3 Additional Items Shipped Loose

060-TLM100.88 Tank Level Monitor

991-05058543.88 NCSM Reference probe

6026028 Insulation wrap, 50 ft roll (2 each)

6018909 * NCSM Accessory Kit - includes the parts listed below

6018911 10 cc plastic syringe

6018912 Special 14 SS hypodermic needle6018913 Electrode, cell, with BNC, for calibration

6018914 High-vacuum grease, 5.3 oz tube

6018930 0.1 N KCl Solution, 250 ml bottle

6018931 3.8 M KCl, Solution, 250 ml bottle

6031275 BNC BA80 Adapter

6031276 Cotton Tip Grease Applicators (10/pkg)

Literature Installation DVD, Blowdown DVD, NCSM DVD, Installation Checklist,Spec B-950

Feedwater pH andconductivity sensors(Optional)


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500-BTSRKIT.88 * 3D TRASAR Boiler Startup Kit includes the parts listed below

460-S0980.75 TRASAR 3 Calibration Solution, 1L Bottle

460-S0726.75 Hydrochloric Acid, 1:1, 1L bottle

500-P2817.88 Flow cell brush, 16

500-P0116.88 Beaker, 800 ml, plastic (3 each)

500-P2147.88 Syringe, 60cc, plastic (2 each)

500-BTSRKITLA.88 * 3D TRASAR Boiler Startup Kit, less acid includes parts listed below

460-S0980.75 TRASAR 3 Calibration Solution, 1L Bottle

500-P2817.88 Flow cell brush, 16

500-P0116.88 Beaker, 800 ml, plastic (3 each)

500-P2147.88 Syringe, 60cc, plastic (2 each)

* Note: Must be ordered separately

2.2 Mount the Panel

2.2.1 General Installation Instructions

1. Avoid installing the 3D TRASAR controller close (within 10 ft) to any high voltage source(s),large motors, or any known generator of electrical noise. Boiler feedwater pumps are not aproblem.

2. The mounting location should be well lit and dry.3. If mounting outside, provisions must be made to protect the controller from direct sunlight and

driving rain. The enclosed NCSM model must be used.4. In cold weather climates, provision must be made to prevent any cooling water piping (for

sample cooling coil) from freezing.5. The mounting location should be accessible to sample water (250-500 ml/min) and an

electrical power source (20 amp circuit at 85-250 VAC).6. If installing a model that includes a Sample Conditioning System mount the system wherethere is access to cooling water, typically 0.5-2.0 gpm (2-7.6 LPM).

7. Chemical feed pumps should also be located conveniently to the 3D TRASAR controller andchemical feed tanks.

8. Mount the controller as close as possible to the feedwater sample point to minimize lag time.A maximum distance of 100 ft (30 m) is desirable.

9. NCSM modules (no controller) can be mounted up to 1000 ft (305 m). (3 twisted pair,shielded 22 AWG cable required)

10. Do not mount on vibrating walls or surfaces. Damage to critical components can occur.

IMPORTANT: The 3D TRASAR controller is designedto meet NEMA 4X standards for weather resistance. Itis recommended that the unit be installed in a shelteredarea to minimize the chance of water or debris enteringthe enclosure when the cover is opened for wiring andmaintenance.

If the NCSM will not be installed in an indoor, protectedarea the Enclosed Model must be used.

In order to maintain the NEMA 4X rating:

Unused cord grips must remain plugged

Enclosure cover must be tightly closed at all times.


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Note: Sample points should be chosen based on many considerations:

- Sampled after the product has been applied to the system and has been mixed- Water sample should be characteristic of that seen by as many boilers as possible- The sample lag time must be minimized

- Existing customer sample spigots- Cooling water availability

The preferred sample point is after the Feedwater pumps where the product has been mixedthoroughly (See Section 1.4 and Appendix XX for additional information).

2.2.2 Wall Mounting

Panels should be mounted on a flat wall so that the controller is at eye level. All SCS panels must bemounted 1-1/2 below the controller and sensor panel.

Wall Mount Controller & Sensor Panel

Dimensions: 12 D x 33 W x 42 H (31 cm x 84 cm x 107 cm)

Material: PVC back panelMounting Holes: 7/16 diameter

Sample Conditioning System

Dimensions: 8 D x 33 W x 22 H (21 cm x 84 cm x 56 cm)Material: PVC back panelMounting Holes: 7/16 diameter


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2.2.3 Frame Mount Dimensions

Frame Mounted System

Dimensions: 29 D x 33 W x 66 H (74 cm x 84 cm x 168 cm)

Material: PVC back panel on SS frame


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2.2.4 Installation Overview Diagrams

Refer to the drawing in this section for general installation overviews

2.2.4.1 TRASAR Fluorometer and NCSM Feedwater Systems

1/4"SStubing

(100ftmax)

Mustbe2Xinsulated!

Feedwaterheadersample:250-500cc/minat1500psi(103bar),500deg.F(260deg.C)max.

Lockable

valve

1/4"MNPTconnection

(1/4"or1/2"tubingto

unpressurizeddrain)

Power120VAC,60Hz,20A-

MUSTBEGROUNDED!

Boilerinterlock-dryconta

ct

1/2"FNPTcooling

waterconnections

psi

Pressure

gauge

Cooling

water

supply

line

(approx.0.5-2gpm)

Piping

isolation

valve

NexGuardpump-4-20mA

Scavengerpump-4-20m

A

}22AWG

shieldedcable

minimum

1/4"Tubing

connection

Installcheck

valveifthereis

achanceof

backflow

Coolin

gwater

todrain

SSfilterpurgelinetodrain

FrameMountedSystem

(29"D

x33"Wx

66"H)

}

Power120VAC,60Hz,10A

(OptionalBlowdownRelayBox)

N/O+N/C+Neutralto

Mo

torizedValves

Reliefvalvedischargetodrain

NOTE:

060-B

LMxx.88,060-BLLCxx.88and

060

-BLPCxx.88Modelsrequire

240VAC,50Hz,10Apower


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2.2.4.2 TRASAR Fluorometer Feedwater Systems

Lockable

valve

1/4"SStubing

(100ftmax)

Mustbe2X

insulated!

1/4"MNPTconnection

(1/4"or1/2"tubingto

unpressurizeddrain)

Power120VAC,60Hz,20A-MUSTBEGROUNDED!

Boilerinterlock-drycontact

1/2"FNPTcooling

waterconnections

psi

Pressure

gauge

Coolingwater

supplyline

(approx.0.5-2gpm)

Coolingwater

todrainP

iping

isolationvalve

NexGuardpum

p-4-20mA

Scavengerpump

-4-20mA

}22AWG

shieldedcable

minimum

1/4"Tubing

con

nection

Installcheck

valv

eifthereis

a

chanceof

backflow

SSfilterpurgelinetodrain

F

rameMountedSystem

(29"Dx33"Wx

66"H)


}N/O+N/C+Neutralto

MotorizedValves


(OptionalBlowdownRelayBo

x)

Feedwaterheadersample:250-500cc/minat1

500psi(103bar),500deg.F(26

0deg.C)max.

NOTE:

060-BLMxx.88,060-BLLCxx.88

and

060-BLPCxx.88Modelsrequire



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2.2.4.3 NCSM Feedwater Systems

Feedwater

headersample:250-500cc/min

at2000psi(137bar),500deg.F(260deg.C)max.

Lockable

valve

1/4"SStubing

(100ftmax)

Mustbe2X

insulated!

Discharge

(1/4"tubing)


Boilerinterlock

-drycontact

psi

Pressure

gauge

Piping

isolation

valve

Scavengerpump-4-20mA

}22AWG

shieldedcable

minimum

1/4"tubing

connection

W

allMountedSystem

(

8"Dx33"Wx

42"H)

NOTE:

Wh

eninstallingremoteATORP

module

s

sig

nalwiresmustberunfromthejunctio

n

boxtothe3DTRASARController.

Ife

quippedwithanSCStheRTD(4-wire)

and

solenoidvalve(H/N/G)wiresmustbe

run

fromtheSCSjunctionboxtothe3D

TRASARControllerinseparateconduit.

ATORP/REF

(2-wires)

RTD

(4-wires)

}

NOTE:

S

amplewithSCS:250-500cc/minat15

00

psi(103bar),500deg.F(260deg.C)max.

NOTE:

060-BLMxx.88,060-BLLCxx.88and




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2.2.4.4 TRASAR Fluorometer Blowdown Systems

Lockable

valve

1/4"SStubing

(100ftmax)

1/4"MNPTconnection

(1/4"or1/2"tubingto

unpressurizeddrain)

Power120VAC,60Hz

,20A-MUSTBEGROUNDED!

1/2"FNPT

coolingwater

connection

psi

Pressure

gauge

Coolingwater

supplyline

(approx.0.5-2gpm)

Coolingwa

ter

todrain

Piping

isolation

valve

ModulatingBlow

down

Valve(4-20m

A)

(22AWGshielded

cableminimum)

1/4"Tubing

connection

Ins

tallcheck

valv

eifthereis

achanceof

b

ackflow

SS

filterpurgelinetodrain

Fra

meMountedSystem

(2

9"Dx33"Wx

66"H)


N/O+N/C+NeutraltoMotorizedValves


(BlowdownRelayBox)

NOTE:

060-BLMxx.88,060-BLLCxx.88and



Blowdownsample:250-500cc/minat1500psi(103bar),500deg.F(260de

g.C)max.

1/2"FNPT

coolingwater

connection

N

OTE:

Samplelinefromboilermustbe

plumbed

followingthe

"ContinuousB

lowdown"diagram

(sampletakeoffwhereconductivity

probeislocatedondiagram)


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2.2.4.5 Continuous Blowdown Conductivity Probe and Valves

Notes:

1. The gate valve upstream from the conductivity probe should be fully open when the boiler is running (to prevent

flashing at the probe).

2. Flow control valves downstream of the conductivity probe must be throttled back to create backpressure to

prevent flashing at the probe and/or control valve).

3. If a fluorometer will be used to control blowdown the sample takeoff point should be located where the

conductivity probe is shown in the diagram.


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2.2.4.6 Timed-Sample Blowdown Conductivity Probe and Valves

Notes:

1. The gate valve upstream from the conductivity probe should be fully open when the boiler is running (to

prevent flashing at the probe).

2. Flow control valves downstream of the conductivity probe must be throttled back to create backpressure

to prevent flashing at the probe and/or control valve).


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2.2.4.7 Condensate Monitor

Lockable

valve

1/4"SStubing

(100ftmax)

Mustbe2Xinsulated!

1/4"MNPTconnection

(1/4"or1/2"tubingto

unpressurizeddrain)


1/2"FNPTcooling

waterconnections

psi

Pressure

gauge

Coolingwatersup

plyline

(approx.0.5-2gpm)

Coolingwater

todrain

Piping

isolation

valve

1/4"Tub

ingconnection

FrameMountedSystem

(29

"Dx33"Wx

66"H)

R

eliefvalvedischargetodrain

Condensatesample:250-500cc/minatlessthan50psi(3bar),250deg.F(12

1deg.C)max.

N/O+N/C+Neutralto

MotorizedValves

Pow

er120VAC,60Hz,10A

(B

lowdownRelayBox)

Installcheck

valveifthereis

achanceof

bac

kflow


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2.3 Plumb the System

2.3.1 Plumbing Requirements

The 3D TRASAR Boilers Systems have the following plumbing requirements, depending on the

components included in the specific model ordered.

Feedwater or Fluorometer-Based Systems

PlumbingRequirement

Models with SampleConditioning Systems

NCSM Models without SampleConditioning Systems

Sample line SS tubing, rate for 1500 psi(103 bar), 500F (260C) minimum.

SS tubing, rate for 2800 psi (193bar), 500F (260C) minimum.

Pressure tested Pressure tested

Flushed prior to system connection Flushed prior to system connection

Double insulated up to system Double insulated up to system

Lockable valve at take off point Lockable valve at take off point

Pressure gauge at take off point Pressure gauge at take off point

Discharge line tubing or pipe run tounpressurized drain or flash tank

SS tubing, rate for 2800 psi (193bar), 500F (260C) minimum.

NA Pressure tested

NA Plumbed to system able to accept 500cc/min sample at 2800 psi (193 bar),500F (260C) minimum.

Cooling water line tubing or pipe NA

PlumbingRequirement

Blowdown or Condensate Conductivity Probe Assembly

Sample Piping reduced to at assembly cross. Rated for 250 psi (17.3 bar) at392F (200C) maximum.*

Note:A Sampling Conditioning System will be needed if the sample pressure and temperatureexceeds the conductivity probe limits.

PlumbingRequirement

Condensate Monitor

Sample line SS tubing, rate for 50 psi (3 bar), 250F (121C) minimum.

Pressure tested

Flushed prior to system connection

Insulated up to system

Lockable valve at take off point

Pressure gauge at take off point

Discharge line tubing or pipe run to unpressurized drain or flash tank

Cooling water line tubing or pipe


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2.3.2 Plumbing Connections

The 3D TRASAR Boilers Systems have the following plumbing connections, depending on thecomponents included in the specific model ordered.

Feedwater System Components Connection Type

NCSM Fluorometer

SampleConditioning

System Sample Inlet Sample OutletCooling WaterInlet & Outlet

X X X Tube Fitting FNPT FNPT

X X Tube Fitting MNPT FNPT

X Tube Fitting Tube Fitting NA

X X Tube Fitting FNPT FNPT

Condensate System Components Connection Type

pH &Conductivity NCM100 Sample Inlet Sample Outlet

Cooling WaterInlet & Outlet

X Tube Fitting FNPT FNPT

X X Tube Fitting FNPT FNPT


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2.3.3 Plumbing Notes

2.3.3.1 Sample Point

The feedwater sampling point must be located where adequate mixing of the NexGuard and

oxygen scavenger has occurred. A sample point downstream of the feedwater pump ispreferred. If a sample tap cannot be installed at this location the sample point should be locatedat least 10 pipe diameters from the chemical injection point, preferably after at least one pipebend.

The condensate sample point should be located downstream of potential contaminationsources where the condensate line will be full. Condensate receiver tanks offer a convenientsample location.

It is extremely important to eliminate entrapped air or particulates in the feed water line. Thiscan be accomplished by sampling from pipe approximately 2 from the internal pipe wall using astainless steel sample quill inserted through the side of the pipe (see Replacement Partsand Accessories).

Be sure to select a sample point where the feedwater pipe will be fully flooded. Avoid verticalpipe runs for sample points unless the flow is upwards. It is usually acceptable to use thedeaerator drop leg for a sample point. Since it is typically flooded.

Never sample from the bottom of a horizontal pipe run. Particulates be carried into the sampleline and clog filters and/or valves

Install an approved lockable valve on the sample line at the sample point (for lock out, tag out).A secondary isolation valve is installed at the sensor assembly to facilitate maintenance.

The NCSM sample point for utility boilers should be prior to the deaerator. Probe locations willvary according to plant type and configuration. Conduct a full plant feedwater audit to identify

NCSM sample locations where the measurement of reduction-oxidation (REDOX) stress willprovide the most benefit. Contact the 3D TRASAR Help Desk.

Guidance for Selection of Suitable Sample Points:1. Select point that provides best opportunity for a reliable sample2. Minimize potential for vapor in sample3. Avoid locations that could introduce excessive suspended solids4. Vertical piping OK if it is the deaerator dropleg since no bubbles present5. Use a SS sample quill that extends approx. of the radius (2 maximum) into the pipe.

SamplePoint

SamplePoint

Horizontal pipe Vertical pipe Vertical pipe

2

1

3

1

4

5

5


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2.3.3.2 Sample Lines

Sample water flow of 250-500 ml/min is typically required. If the flow drops below 200 ml/minthe control will cease and the unit will alarm.

Use OD 316 stainless steel tubing for all sample lines. Larger diameter tubing or the use of

piping will greatly increase sample lag time and adversely affect control.

Pitch the sample line downward at least 10 towards the sample outlet.

Minimize the number of valves, fittings and elbows. Bend tubing rather than installing a fitting.Avoid traps or pockets where fluid or sludge can collect.

Throttle the sample flow at the Sample Conditioning System rotameter or NCSM discharge(NCSM only models).

The NCSM probe should ideally be located within 40 ft (12.2 m) of the sample take-off point. Adistance of 100 ft (30 m) is tolerable (total piping length). Long distances create temperaturelosses, which affect probe performance.

The NCSM measurements are made directly on the un-cooled sample and are not temperature

compensated. All sample lines must be well insulated (2X wrapped) to ensure that thetemperature of the water reaching the probe is as hot as possible and has a constanttemperature. Insulation is also needed to protect personnel from the hot tubing.

The sample flow rate must be kept constant to ensure accurate measurements and obtain gooddosage control. Keeping a constant temperature and flow rate will also help troubleshoot anyquestionable NCSM values.

Insulating should be performed after it has been ascertained that there are no leaks. Be sure toinsulate the NCSM probe as described in this manual.

A pressure gauge must be installed on the sample line downstream from the lockable valve.So, the pressure in the line can be checked prior to any maintenance.

It is recommended that a valve be installed on the end of the sample line. This will allow the

control panel to be completely isolated. A Nalco Corrosion Monitor (NCM100) probe can be installed on the 3D TRASAR System inlet

plumbing providing the sample temperature is under 250F (121C) and under 1000 psi (69bar). The probe must be installed in the special 1 x 3/8 tee such that the probe tips arepointing down into the sample flow. The discharge from the tee must be upward (dischargeform 3/8 side port) to ensure the tee remains flooded.

Strip insulation should be double and triple wrapped to minimizeheat loss from the sample line and NCSM probe. The NCSM cell(cross) should be insulated last with a small piece of insulationthat can easily be removed when the probes need to berefurbished or checked. Be sure to leave access to the SS fittingson the probes (that connect the probes to the cross). Do notinsulate the ORP/RTD and Reference probes. The picture showsthe cross after insulation has been applied.


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NOTE: During initial startup, the sample is likely to contain solids (such as oxides of iron, grease,dirt, etc.) that settle in the sample tubing. It is very important that these solids be flushedout to avoid plugging of the system. The incoming sample line should be purged for 15 to20 minutes prior to connecting it to the sample conditioning system

CAUTION-DANGER: The discharge from the line will be flashing steam. It must bedirected to a drain capable of accepting water at the systems operating temperature andpressure. Maximum for NCSM is 2800 psi (193 bar0, 500F (260C).

2.3.3.3 Discharge Line

Sample discharge should flow unrestricted to a free-falling drain/vessel with no backpressurethat can damage the fluorometer.

Pipe rises greater than 10 feet [3m] should be avoided. If the discharge must be located abovethe system install a check valve on the discharge line.

NOTE: Ensure that if there is no feedwater flow (FW pumps turned off) boiler water does notsiphon back through the 3D TRASAR skid. There should be FW check valves in place to

prevent this from occurring (do not assume that they exist or are working they need to bechecked). This siphoning could cause a high temperature alarm and control suspensionand skid-flow shut down even if the SCS is in operation.

Do not combine the discharge from other controllers.

CAUTION-DANGER: Do not combine the fluorometer or NCSM sample discharge with theSS filter purge line, pressure relief vent, or NCSM pressure bleedvent into a single manifold. This will prevent the safety devices fromfunctioning properly.

The sample water outlet flow can be plumbed into a containment vessel and pumped to an un-pressurized condensate receiver to minimize waste.

On NCSM models without sample coolers, the sample discharge line must be insulated toprotect personnel from the hot tubing.

CAUTION-DANGER: The discharge from a NCSM not equipped with a SampleConditioning System must be cooled and depressurized unless thesystem receiving the discharge can safely accept 500 cc/min at 2800psi (193 bar), 500F (260C).

2.3.3.4 Cooling Water Lines

Chilled water should be used.

The cooling water inlet is at the bottom of the sample cooler and cooling water outlet is at thetop.

The purpose of the sample conditioning system is to cool the sample below 110F (43C) anddepressurize the sample to below 50 psig. So, it is safe for workers and the instrumentation.Typical cooling water flow rate will be in the 0.5 to 2 gallons per minute range.

It is recommended that both the cooling water inlet and outlet lines be fitted with a tee and twovalves. This will to allow the cooling water to be drained and cooler shell to be flushed with acidto remove any scale.

Cooling water to be used should be of good quality, free from suspended solids andmiscellaneous debris. Cooling water must flow continuously and at a constant pressure.


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2.3.3.5 Blowdown Conductivity Probe Assembly, Control Valve and Flow ControlValve

A conductivity probe, control valve (motorized ball valve) and flow control valve must be installed oneach boiler where blowdown will be controlled using conductivity. All are ordered separately. Theplumbing arrangement is dependent on the blowdown requirements. The diagrams below illustrate

the installation for continuous sampling; recommended for systems blowing down > 5000 lbs/hr(2273 kg/hr) and intermittent sampling; recommended for systems blowing down < 5000 lbs/hr(2273 kg/hr).


35/290



IMPORTANT NOTES:

1. The maximum temperature and pressure the conductivity probe can handle is 392F (200C)and 250 psig (17.2 bar). If the boiler operates above these conditions a sample conditioningsystem must be installed upstream of the conductivity probe to reduce the temperature andpressure.

CAUTION-DANGER: DO NOT install the conductivity in a boiler above 392F(200C) and 250 psig (17.2 bar). Probe failure and serious

personal injury will result.

2. Both flow control valves downstream of the conductivity probe must be throttled backto maintain backpressure in the lines. The valves cannot be in the wide-open position.Otherwise, flashing in the line will occur if the line discharges to atmospheric pressure.

WARNING: Flashing will damage the conductivity probe and valve seals.

3. Restrictions in the piping upstream of the conductivity probe can cause a pressure drop andflashing. This will result in erratic readings and damage the probe and valve seals. Allupstream isolation valves should be full-port and set to fully open.


36/290



4. The motorized ball valve and flow control valve must be installed downstream from theconductivity probe.

DO NOT install the conductivity probe between the valves. Flashing will occur.

5. The flow control valve must be installed downstream from the motorized ball valve to prevent

flashing. Mount within 12-18 (0.3-0.5 m) of the motorized ball valve to avoid water hammer.DO NOT exceed 18 (0.5 m) or flashing may still occur inside the ball valve.

6. To ensure the piping remains full at the conductivity probe run a segment of pipingdownstream of the probe above the level of the probe cross (see diagram).

7. Likewise, wide spots (small diameter piping bushed up to larger piping) upstream of theprobe will cause flashing. Larger diameter piping from the boiler should transition down to the cross and probe without reverting to pipe segments of increased diameter. In addition,larger diameter piping should not be installed immediately downstream the cross.

8. Ensure the flush valve installed on the bottom of the cross and probe closes properly.Leaking will cause flashing at the probe or improper flooding of the conductivity probe.

9. The conductivity probe must be installed so the flow-through hole in the probe is in line withthe sample flow. The K-factor is stamped on the probe and is aligned with the hole (see

photo).

10. Mount the probe cross in a horizontal pipe run at least 2 ft (0.6 m) downstream of anyelbows or fittings that may cause turbulence.

DO NOT mount the probe on a vertical pipe run.

11. Piping can be reduced to diameter downstream of the conductivity probes on boilers withblowdown rates under 5000 lbs/hr (2273 kg/hr). So, a motorized ball valve and flowcontrol valve can be used.

12. Mount the motorized ball valve away from the boiler. So, it does not overheat the electronics.

13. Follow pipe length guidelines shown on the diagrams. Piping that is too lengthy will requirelonger flush times for the piping and probe to reach boiler water temperatures (required foraccurate measurements). On smaller boiler systems this may result in excessive boiler

blowdown.


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2.3.3.6 Condensate Conductivity Probe Assembly/Sample Take-Off, Control Valveand Flow Control Valve

Condensate lines can be monitored using a conductivity probe assembly installed directly into thecondensate line. Alternately, a sample line can be run to the 3D TRASAR Condensate Monitor where

pH, conductivity and corrosion (via NCM100) are monitored. In either case a flow control valve mustbe installed on the sample line to ensure the probe sample lines are full. A 3-way motorized controlvalve can be installed on the condensate line to dump contaminated condensate.

Notes:

1. The condensate probe assembly (P/N 060-BCP100.88) is similar to the blowdown probe

assembly except it is designed for measuring lower levels of conductivity (up to 500 S/cm)and includes an RTD for temperature compensation. Follow the probe plumbing guidelines inSection 2.3.3.5.

CAUTION-DANGER: DO NOT install the conductivity probe in a condensate lineabove 392F (200C) and 250 psig (17.2 bar). Probe failureand serious personal injury will result.

2. Use SS tuning for the sample take-off for the 3D TRASAR Condensate Monitor. Follow thesample line guidelines outlined in Section 2.3.3.2.

CAUTION-DANGER: Samples supplied to the 3D TRASAR Condensate Monitormust have a pressure below 50 psi (3.4 bar). If theCondensate Monitor is equipped with the optional NCM100the sample temperature must also be below 250F (121C).

CondensateReceiver Tank

Condensate

Storage Tank

Throttling

Valve

Conductivity

Probe or Sample

Take-Off

Condensate

Pump

3-Way Valve

Condensate

Dump


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2.3.3.7 Boiler NCM100 Probe Installation

The high-temperature, high-pressure NCM100 probe must be used for boiler feedwater applications(Nalco P/N 400-NCCMP6.88). A NPT compression fitting is included with the probe. There are twoways of installing the boiler probe assembly.

Into

3d trasar boiler manual ver 4.2 11-10-10

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