Manual

Manual and maintenance

Note: Due to bulk content the complete guide isn’t displayed, only brief example

Based on technological project, the options are three fluids which are used during the anti-de/icing process:

• Softened water, temperature 60°C;
• ADF type I, temperature 60°C;
• ADF type IV, ambient temperature.

Based on the technological scheme of the process of storage and flowing of pure fluid, three reservoirs have been designed:

• Hot water tank (HW), volume 40 m³, overall dimensions Ø2.5 × 8.8 m
• ADF-I tank (ADF-I), volume 80 m³, overall dimensions Ø2.9 × 12.8 m
• ADF-IV tank (ADF-IV), volume 60 m³, overall dimensions Ø2.5 × 12.8 m

Tanks are made as horizontal ones without double layer placed in a bundwall inside the facility. Since hot water and ADF-I are heated to 60 ° C, the tanks are insulated with 50 mm mineral wool in aluminium formwork with supporting substructure for insulation. Tanks are equipped with:

• Fluid filling connector;
• Fluid extraction connector;
• Heating connectors;
• Complete discharge connector;
• Sight glass with two valves and possibility of drainage;
• Dial valve and its connector;
• Temperature probe connector;
• Two inspection panels (with measuring probe connectors) and steel ladders to enter the tank;
• Lifting equipment for the tank;
• Steel holder with supporting steel structure for fixing and anchoringthe tank.

Since the project task requires washing of the tank, they are equipped with two inspection panels. While the tank is being washed both panels are opened to allow air circulation inside the tank during the washing. There is a steel platform above the tank that is used forits service (washing, etc.).
The tanks are placed inside a bundwall with a drainage pit in its corner. If the fluid leaks, it is collected in this pit from where it continues to evacuate via drainage pumps.
A pump station is located on the front side of the bundwall. According to the technological scheme, the following pumps are installed:

1. ADF type I

- pump for discharging fluid from the cistern to tank
- two pumps (active and backup) to discharge fluid from the tank at two locations.

2. ADF type IV

- pump for discharging fluid from the cistern to tank
- two pumps (active and backup) to discharge fluid from the tank at two locations.

3. HW

- two pumps (active and backup) to discharge fluid from the tank at two locations.

The pumps are equipped with a by-pass tube so that the vehicle pump can be used on a cistern or ADF vehicle if the vehicle has its own pump. The delivery line has built-in flow meters. The connection of the ADF cistern is provided in the cabinet on the front side of the facility. Quick couplersof 2 “and 2½”dimensions are built in for the connection to the cistern.

The hot water tank is re-filled with water from the city supply system which is previously softened in a duplex softener. The softener is connected to the installation via ball valve taps which are located in front and behind and via by-pass tube to the valve.

ADF vehicles are supplied with fluids at two locations. There are sector valves in front of them which are processed in the electrical project. Manual valves are also provided in the cabinet behind the sector valves as safety in case of sector valves failure. The cabinets are equipped with quick connectors3 ” for hot water, ADF type I and ADF type IV.

A drainage valve is installed on the pipeline so that the drainage of the pipeline is possible.

The following parameters were considered when selecting the pump flow:

• Volume of ADF cistern 25 m³;
• Time of the ADF cistern discharge 60 min;
• Volume of the ADF tank, on the ADF vehicle, max. 5 m³;
• Time for filling ADF 10 min;
• Volume of the water tank, on the ADF vehicle, max. 4.1 m³;
• Time for filling the water, 10 min;
• Recommended speed in the pipeline 1-2 m/s.

Pump flows have been adopted in accordance with the above parameters. Pressure drops were calculated based on the geometry of the pipeline.

Centrifugal pumps are installed for the hot water transport while the “rotary lobe” pump type is installed for the transport of ADF. These pumps are type of volume pumps, occupy little space and achieve relatively low rpm.

It is possible to measure the level of liquid in the tank on all three reservoirs. The temperature is measured on the hot water and ADF type I reservoirs.

LS 202 Lower level meter

LS 203 Upper level meter

TE 204 Temperature meter

Automatics protects the pump from dry running and protects the tank from overflowing. It provides the tanks to be filled up to a maximum volume of 90%. Running of the pump for fluid intake is blocked above this level. Automatics also blocks the simultaneous running of the pump for both intake and discharge of the fluid.

When the fluid reaches its maximum or minimum level the meter gives a signal to the relay to switch off the pump either in automatic or manual mode.

Re-filling of the hot water tank is both manual and automatic. In automatic mode the electro-valve opens when the water level in the tank falls below 50% as required by the investors. This valve is bypassed with a manual valve so it is possible to manually fill the tank at any time.

There’s an electrical connector on ADF vehicles that gives signals to the pumps when the tanks in the vehicle are full. These signals control the the pump and sector valves running. When one inlet location is activated the pump is driven by a frequency regulator (inverter) to 50% of the flow and a sector valve is opened for the given inlet. By connecting the ADF vehicle to another inlet location the signal is given to the other sector valve to be placed in the open position and the flow is adjusted by the frequency regulator at 100%.

Heating of the hot water tank volume 40 m3 and the fluid reservoir ADF type volume 80 m3 is carried out via pre-insulated hot water pipeline and 3 indirect heating substations with a total capacity of 1000 kW.

HEATING SUBSTATIONS

Three fully equipped heat substations have been installed within the heating substation room:
1. TP for heating the tank of thefluid ADF type1, volume 80 m3;
2. TP for heating a 40 m3 hot water tank
3. TP for heating rooms in a new facility

• The following equipment is installed on the primary part of the heating substation:
– heat exchanger with a capacity of 480 kW (fluid: water / ADF type I) – soldered type, plate material stainless steel (position 2)
– isolating valves – ball valves of diameter DN80;
– pressure and flow regulator «dp» (with motor drive) DN50 kVs = 32 m3 / h for regulation of the differential pressure on the primary part of the TP and for regulation of the desired water temperature in the ADF tank. The flow controller (motor valve) regulates the desired temperature of the tank by changing the flow in the primary network. Control is via DC controller ECL300;
- other equipment (dirt separator, draincock, pressure gauge, thermometer and connecting pipeline with fittings).
The TP package also includes the following electrical equipment located on the common frame: electronic temperature regulator, electronic controller and graphic display with the possibility of showing all essential parameters.

• On the secondary part of the heat substation the following equipment is installed:
– “Rotary lobe” type of pump to transport ADF from the tank to exchanger (position 7). These pumps are type of volume pumps, occupy little space and achieve relatively low rpm.

• The following equipment is installed on the primary part of the heating substation:
– heat exchanger capacity 480 kW (fluid:water/water) – soldered type, plate material stainless steel (position 1);
– isolating valves – ball valves of dimeter DN80;
– pressure and flow regulator «dp» (with motor drive) DN50 kVs = 25 m3 / h for regulating the differential pressure on the primary part of the TP and regulating the desired water temperature in the hot water tank. The flow controller (motor valve) regulates the desired temperature in the reservoir by changing the flow in the primary network. Control is via DC controller ECL300;
- other equipment (dirt separator, draincock, pressure gauge, thermometer and connecting pipeline with fittings).
The TP package also includes the following electrical equipment located on the common frame: electronic temperature regulator, electronic controller and graphic display with the possibility of showing all essential parameters.

• On the secondary part of the heat substation the following equipment is installed:
– circulator pumps to transport hot water from the tank to the alternator of the following technical characteristics (position 6):

Heating and ventilation

Heating in room with tanks 0.01 and preparation of samples 0.02 is constant heating of calorifier. The calorifiers are controlled by spatial thermostats – one block in the tank room and the other in the room where water is softened. The block thermostat is both a thermostat and a speed regulator for the motor of the calorifier. The desired temperature is set on the thermostat and the desired speed is set on the speed regulator. The heat capacity of the calorifier covers both transmission and ventilation losses.

They can run in automatic mode by switching on the thermostat or can also be switched on manually in the room -SA143 and -SA155 (the room where water is softened).

In the sample examination room 0.03 heaters are aluminum radiators. The pipe network is made of steel pipes. The temperature mode of the heating installation system is 60/40° C.

Modular containers have heating with electric radiators and electronic thermostat.

Ventilation of the tank room is artificial (duct fan V) and provides air change. The air inlet is via the FZ fixed louver in the lower zone. The manual lid enables the closing of this vent in the coldest part of the year. In other areas ventilation is natural, through the window.

Electric motor drive and central monitoring and control system

Power supply limits are clamps of the EMP and CSNU cabinets.

The final limits of the project are:
• Electric loads: pumps, fan and calorifiers listed in the first part of the manual;
• Equipment in the process field.

The project of electric motor drive and central monitoring and control system is conceptually divided into three technological units.

The first technological unit – The storage of ADF and softened hot water

The first unit refers to the ADF type I, ADF type IV and softened water storage. They are stored in the following tanks:
• Softened water tank (HW), volume 40 m³;
• ADF Type I tank (ADF-I), volume 80 m³;
• ADF Type IV tank (ADF-IV), volume 60 m³.

One continuous measurement of fluid level and two threshold levels (minimum and maximum level) are installed in each tank. For the continuous measurement of the level – a radar gauge is installed while the vibrating forks are installed for threshold monitoring. The amount of fluid in the tanks can be read on the central system at any time.

Pumps that transport these fluids into and out of the tanks also belong to this unit.

ADF type I and ADF type IV are delivered to the tanks in storage through the injection pumps at two inlet locations. The maximum limit level meter automatically blocks (the blockage is achieved in the relay technique) the pump injections and prevents overfilling of the tank and uncontrolled leakage of the liquid. The water tank is filled by pressure from the water supply system with water which is previously softened. At the entrance to the water reservoir is a motor drive valve.

Discharge from the tank and delivery of liquids in the ADF vehicle is carried out via 3x pumps (one active and one backup). The prevention from dry running is performed in the relay technique (the minimum tank level sensor).

Power supply of electric motor loads for this part is performed in relay technique and status and operation signals are transferred to the central monitoring and control system. Loads are provided with a choice of control modes via optional switches A-0-R (automatic – off – manual).

Second technological unit – a heating substation

The second unit refers to the heating substation of the object.

The installation of basic circulator pumps (one active one backup) is done at the entrance of the heating system in the heat substation.

There are three fully equipped heating substations within the heating substation room:
1. TP for heating the tank of the fluid ADF type1, volume 80 m3;
2. TP for heating a 40 m3 hot water tank;
3. TP for heating rooms in a new facility

Circulator pumps 3x are used on the secondary part of all three mentioned heat substations (one active one backup).

Within each TP there is also the following electrical equipment located on the common frame: electronic temperature regulator, electronic controller and a graphic display with the possibility of showing all essential parameters.

Third technological unit – Collector tanks

The third unit refers to collector tanks in which fluid from the platform is collected. The liquid is deposited in four wastewater tanks. Within the project measurements of wastewater liquid levels is also processed (minimum and maximum level as well as the continuous measurement) and leakage control from these tanks.

Distribution cabinets

Two distribution cabinets were made:
• Distribution cabinet + RO-EMP (processes technological units 1 and 3) – located in the hot water and ADF storage;
• Distribution cabinet + RO-TP (processes the technological unit 2) – located in the heat substation.

A modular automation station (DDC) is planned for the cabinet + RO-EMP with the necessary number of I / O modules and communication modules, which is used for automatic operation of installations and data transmission.
Electronic regulators of fully equipped heat substations are connected through the communication cable (ModBus protocol) with an automation station in the distribution cabinet + RO-EMP.
There’s a specified workstation for the management and control of all technological units located in the facility next to the plant which serves for the accommodation of employees.
One continuous measurement of fluid level and two threshold levels (minimum and maximum) is done for each tank. For the continuous measurement of the level a radar gauge is installed while the vibrating forks are installed for threshold monitoring. The amount of fluid in the tanks can be read on the central system at any time.
Pumps which transport these fluids into and out of the tanks also belong to this unit.

ADF type I and ADF type IV are delivered to the tanks in storage through the injection pumps at two inlet locations. The maximum limit level meter automatically blocks (in the relay technique) the pump injections and prevents overfilling of the tank and uncontrolled leakage of the liquid. The water tank is filled by pressure from the water supply system with previously softened water. At the entrance to the water reservoir is a motor drive valve.

Discharge from the tank and delivery of liquids to the ADF vehicle is carried out via 3x pump (one active one backup). The prevention from dry running is performed in the relay technique (the minimum tank level sensor).

Power supply of electric motor loads for this part is performed in relay technique and status and operation signals are transferred to the central monitoring and control system. Loads are provided with a choice of control modes via optional switches A-0-R (automatic – off – manual).

An emergency shutdown

In case of emergency shutdown two safety buttons of the yellow case are used with a red mushroom head push button which does not reset upon release:
- SB-EMP is located at the entrance of the plant with tanks and it switches off the main switch in the cabinets of the electric motor drive + RO-EMP and + RO-TP,
- SB-TP is located at the entrance of the heat substation and it switches off the main switch in the cabinet of the electric motor drive + RO-TP.

Switches and signal lamps on the cabinet

Switch of the intake pump ADF type I – SA35

The switch can be set in three modes: automatic operation, off and manual. When set to the automatic operation mode the pump is activated by the sauter controller and operates all the way until the maximum level meter is activated, when the level of the fluid reaches the meter – a signal is sent via relay and it switches off the intake pump ADF type I.
In manual mode the pump is switched on regardless of the sauter controller and it operates until it reaches the maximum level or if we don’t switch it off.
There are two signal lights placed above the switch on the cabinet door: green indicating regular operation and red indicating that the pump is defective. Automatics is performed in relay technique.

ADF type I- discharge pump switches –SA63 and –SA65

The -SA63 switch is used to select the mode, automatic, off or manual. If we select the automatic mode, the command is given via the sauter controller. If we put the switch in the manual mode, then we switch on the pump regardless of the controller.
The -SA65 switch is used to select the pump depending on whether we will use an active one or a backup pump to discharge. Position 1 – active pump, position 2 – backup pump.
The pumps will run until the switch is off or until the level of liquid doesn’t reach the minimum level meter when the protection against dry running is activated. Protection is performed in the relay technique. When the minimum level is reached the -KA62 relay separates the contacts and the connection between the first and the second switch is cut.
There are two signal lights placed above the switch on the cabinet door: green indicating regular operation and red indicating that the pump is defective. Automatics is performed in relay technique.

Fan switch –SA166

The -SA166 switch is used to turn on the fan.

0 – off

1 - on

Switch to open the valve for filling the water tank –SA175

The switch has got three modes:
1 - automatic
0 – off
2 – manual

When set to the automatic mode, the valve is opened by the sauter controller and remains open until the maximum level sensor LS103 is activated; when the level of the liquid reaches the meter – a signal is sent via the KA171 relay to close the valve for filling the tank with water.

In manual mode the valve is opened regardless of the sauter controller and it stays in this mode until the water reaches the maximum level or if we don’t turn the switch off.

Sector valve switches – inlet locations, water intake in ADF Vehicle –SA185 and –SA186

The switch -SA185 has got three modes:
1 - automatic
0 – off
2 – manual

When set to the automatic mode the valve is opened and closed by the sauter controller and no other switch is used.

When the -SA185 switch is set to position 2 – manual mode – then we control the valve by the -SA186 switch.

The switch -SA186 has two settings:
1 - opening
2 – closing

The valve switch on the delivery line for collector tanks –SA245

The -SA245 switch has got three modes:
1 - automatic
0 – off
2 – manual

When set to the automatic mode the valve is opened by the sauter controller.
When the switch is in the manual mode the valve opens regardless of the controller.
The valve is opened to collect the liquids into collector tanks.

Button for testing the door lights –SB261

Pressing the -SB261 button turns on all the signal lights on the door thus checking the proper work of signaling.

Switches –QS310 and –QS315

The -QS310 switch has got two modes:
0 – off
1 – on

When switched on, we release the voltage by the switch QS315, but also by the UPS input.

With switch -QS315 we have a choice of power supply from the UPS or from the grid.

1 - automatic
0 – off
2 – manual

If the -QS310 switch is off, we cannot use UPS nor switch -QS315.

Phone

+381 11 319 02 47
+381 11 319 02 48

Email

office@sofelektro.rs
info@sofelektro.rs

Address

Zelena Gora 46/5, 36000 Kraljevo