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Maintenance manual CO2 pump
Nikhef number: Item number:
Date: 12/8/2011 * Page: 1 of 45
39300-MT-00018 AA3350 Status: In Work Revision: A.3
Project: LHCb VELO
Department: Mechanical Technology Top folder: CO2 cooling
Abstract: This document contains the maintenance manual for the CO2 pumps of the VTCS. In addition to this maintenance manual the Installation, operating & maintenance manual of the Diaphragm metering pump of Geveke Pompen is required. *Date of adding document to ENOVIA SmarTeam database
Created by: K. de Roo
Checked by:
Approved by:
Distribution list:
National Institute for Subatomic Physics Science Park 105, 1098 XG Amsterdam The Netherlands
LHCb Vertex Locator
EDMS No: 107 63 68
Date 19-01-2012
Documentation
MAINTENANCE MANUAL DIAPHRAGM METERING PUMPS
Krista de Roo, Bart Verlaat
Abstract: The annual maintenance of the pumps in the VELO Thermal Control System is described. Keywords: VELO, VTCS, Cooling, CO2, Maintenance, Pump, Manual, LEWA
Document Status Sheet
Version Date Pages Comments or Description of Changes
1
2
3
4
5
20-05-2010
03-10-2011
19-10-2011
05-12-1011
19-01-2012
39
43
44
45
45
-
Comments added (all pages)
Comments added (chapter 1)
Comments added following maintenance (all pages)
Comments added following maintenance (all pages)
In addition to this maintenance manual the Installation, operating & maintenance manual of the Diaphragm metering pump of Geveke Pompen is required.
Title
Serial no.
P.O. number
Location
Geveke ref. no.
Document no.
INSTALLATION, OPERATING & MAINTENANCE MANUAL
DIAPHRAGM METERING PUMP
475967-020.001
000 37 496
Amsterdam
106 557 53
LEWDOC124-0
3
Table of contents Table of contents ................................................................................................................. 3 1 Preparation for the maintenance (or repair) of the TL pump ...................................... 4
1.1 Disconnecting the pump from the electrical circuit ........................................... 13 2 Dismantling the pump insulation .............................................................................. 14 3 Pump maintenance .................................................................................................... 17
3.1 Withdraw hydraulic oil from the pump .............................................................. 17 3.2 Disconnecting the pump front ............................................................................ 18 3.3 Replacing the inlet and outlet valve of the pump ............................................... 21 3.4 Replacing the pump membrane & seal .............................................................. 24 3.5 Assembling the pump front ................................................................................ 27 3.6 Refreshing the hydraulic oil ............................................................................... 31
4 Pump motor maintenance ......................................................................................... 32 4.1 Withdraw traction oil from the pump ................................................................. 32 4.2 Refreshing the traction oil .................................................................................. 33 4.3 Replace gear shaped transmitter ......................................................................... 34
5 Preparing for commissioning of the pump ................................................................ 35 5.1 Connect the pump to the electrical circuit .......................................................... 35 5.2 Connect the pump to the CO2 system ................................................................ 36
5.2.1 Vent pump with CO2 ................................................................................... 36 6 Assembling the pump insulation ............................................................................... 40 Appendix I VCR Fitting Installation Instructions .......................................................... 43 Temperature sensors location ........................................................................................... 44 Appendix II List of replacement parts per pump ......................................................... 45
4
1 Preparation for the maintenance (or repair) of the TL pump Safety precautions:
Use gloves and wear a white LHCb-blouse when acting on components that originate from inside the cooling system.
All removed objects should be put in a labeled plastic bag, placed in the buffer zone and registered in the LHCb traceability database.
Keep a logbook with times and main actions in order to be able to correlate later with
PVSS.
Figure 1: Schematics of the CO2 plant The CO2 may not be vented directly to atmosphere, thus it must be collected in the accumulator and/or transferred to an external gas cylinder using the accumulator as intermediate storage and the recovery system. If for reasons of radio protection, first a sample of the CO2 needs to be taken and then follow the instructions in EDMS-report 1171878.
The work on the TL-pump can only start once practically all CO2 is stored in the accumulator and the gas pressure in the system is low (10 bar) , i.e. at step 17.
5
To store as much as possible CO2 in the accumulator and isolate the TL section, the accumulators need to be cooled. Cooling CO2 in the accumulator will condense the CO2 to liquid and as a consequence CO2 will be subtracted from the system into the accumulator. The procedure for subtracting the pumps from liquid is as follows:
1. Open the Operator main page on the touch screen 2. Press button “Expert Mode” 3. Log on with user “cooling” and the usual password
Figure 2: Operator main page
6
4. Expert main panel (Figure 3) will appear
Figure 3: Expert main panel
7
5. Press on button “Configuration” and the next panel will appear.
6. Press the red “STOP” button (and forget about the C-side for a while since we will keep it off for the moment)
7. In the configuration panel you have to put the following selection boxes in the
corresponding position: a. “CO2 TL (A-side)” to “manual” b. “TLR_PM101 (center pump)” to “manual” c. “Main Chiller (SA)” to “manual” d. “Backup Chiller (SB)” to “manual”
8. Press the “Back to previous screen” button to go back to the overview panel. 9. Press on the “Valves/Pumps” button and the next panel will appear.
Figure 4: Configuration panel
8
10. Check that the electrical valves are in the following positions, if not change to the correct position, to let the CO2 circulate from the cooling plant via the transfer line to the VELO and back.
a. TLR_VL101 to port-2 (=left) (i.e. connect the TLR-pump section with the TL-part)
b. TL_VL102 open c. TL_VL103 to port 2 (=left) (i.e. cool via SA) d. TL_VL104 open e. TL_VL109 open f. TL_VL111 close
Figure 5: Valves and pumps of the CO2 system
9
11. Go back to the overview panel and press the “Valves/Compressor” button under the Main chiller column. The next panel will appear.
12. To cool the accumulator, the freon injection valve to the accumulator cooling spiral needs to be opened.
a. To do this the slider bar below the accumulator needs to be set to “%”. b. Then type 100 in the field of freon injection valve SA_VL119.
13. Once the valve indicator reads 100%, the compressor can be started by pressing
the “on” button. Put the compressor frequency at 40 or 42 Hz. Check whether the temperature of sensor 117 after injection valve SA_VL119 is decreasing.
14. When the selected chiller is operating correctly the CO2 pressure (TR_PT102) in
the accumulator should go down and the level (TR_LT101) should go up. To check this, go back to the overview panel and press on the button “Status” under the “CO2 System” column. The next panel will give the reading of these sensors.
Figure 6: Main chiller page (SA)
10
15. Monitor the accumulator pressure with pressure sensor TR_PT102. 16. Continue cooling the accumulators until the Tsat is much lower than the other
temperatures. Minimal achievable pressure is about 9 to 10 bar, which is reached after about 1 hour. At a certain moment SA will stop due to a liquid-in alarm. All the liquid will now be in the accumulator and the rest of the system will be filled with gas, but please check the temperature in the evaporator and throughout the TR-side of the cooling plant.
17. Close electrical valve TR_VL104 (in order to separate the liquid CO2 in the
accumulator from the rest of the system). Write down the gas pressures in the system.
Figure 7: Status overview of CO2 system
11
18. The pump must meet the following conditions before it is disconnected from the cooling system:
The pump saturation temperature (PT101_Tsat) must be lower than the lowest temperature of the pumps temperature sensors. (TT112, TT113, TT114 & TT115). In this case the pump is filled with gas and will not lose much CO2. The release of liquid CO2 will cool the pump down and thus attract moisture when opened.
The lowest temperature of the pumps temperature sensors (TT112, TT113, TT114 & TT115) must be above the dew point (~12ºC) to prevent condensation of water in the system. When the temperatures decrease to a temperature below the dew point during venting, the venting must be interrupted until the temperature is back to normal.
The temperature sensors can be read from the touch screen in Status overview of CO2 system panel:
19. Press Status button in the Expert main panel 20. The status overview of CO2 system will appear (Figure 7) 21. Check that temperatures TT112, TT113, TT114 & TT115 are above ~12ºC and
that PT101_Tsat smaller than the pump temperatures. 22. When the pump meets the conditions written above, close TL_VL106 and
TL_VL08; turn the knob from a vertical direction towards a horizontal direction (clockwise), perpendicular to the tube. (See Figure 8)
TR_VL106
TR_VL108
TLR_VL109
TLR_VL101
TL_VL106
TL_VL108
TR_VL107TL_VL107
TLR_VL107
TLR_VL114
TL_VL114 TR_VL114
Figure 8: Valve control location
12
23. On the configuration panel of the touch screen: a. “CO2 TL (A-side)” to “auto (screen)” b. “CO2 TR (C-side)” to “auto (screen)” c. “TLR_PM101 (center pump)” on “right (forced)” d. Set “Main chiller (SA)” on ”auto (screen)” e. Set “Backup Chiller (SB)” on “auto (screen)” f. Press the “STOP”-button g. Press the “start TL A-side” button h. Press the “start TR C-side” button
Make sure both sides start correctly and that they reach their setpoint. 24. Empty the TL-pump section by:
a. Check if there is a VCR-cap on valve TL_VL107, b. Open manual valve TL_VL107 c. Slowly turning the nut of the cap such that the gas releases gently d. Close both the valve and the VCR-cap again.
Check that valves TLR_VL101 & TLR_VL109 are in the correct position, that
TLR_PM101 is ON, that the (to be maintained pump) is OFF and that valves TL_VL106 & TL_VL108 are closed!
13
1.1 Disconnecting the pump from the electrical circuit
When the CO2 in the system is rerouted through the center pump, the temperature of the pump is above the dew temperature (approximately 12 °C) and valves VL106 & VL108 are closed, the pump can be disconnected from the electrical circuit. Disconnect cable HT102 and PM101 as shown in Figure 9 and Figure 10. Pay attention to the exact cable label for the pump that must be disconnected, the labels for each pump are given in Table 1. On the touch screen will appear an Alarm for the membrane of the pump, no action is needed as the alarm is a consequence of the disconnected cables. Table 1: Cable numbers for the left, center and right pump
Pump Cable label Cable label Left TL_HT102 TL_PM101
Center TLR_HT102 TLR_PM101 Right TR_HT102 TR_PM101
Figure 11: Connector panel
Figure 10: Cables disconnected from panel Figure 9: Connector panel with cables
TL_PM101
TL_HT102
14
2 Dismantling the pump insulation The thermal insulation of the pump consists of several layers. With the following steps the insulation is dismantled.
Disconnect the membrane crack sensor cable by releasing the bolt by hand (Figure 12 and Figure 13). Lightly push the connector towards the pressure gauge and then carefully pull loose the cable from its position.
Manually unbolt the two wing nuts (Figure 14) on the circular metal panel. Carefully remove the metal panel. Gently remove the insulation cube (Figure 15) below the pump by a small rotation
followed by carefully pulling the cube loose. The rotation direction is indicated on the insulation cube.
Insulation cubeInsulation
cube
Figure 15: View insulation cube
Figure 13: Membrane crack sensor cable nut bolt
Cable nut
Figure 12: Membrane crack sensor cable
Figure 14: Front of an isolated pump
Membrane crack sensor cable
Wing nut
Wing nut
Pressure sensor Insulation cube
15
Remove the left halve of the outer
insulation layer (Figure 16) en next carefully remove the right half.
Remove left half of the inner insulation layer (Figure 17) and next the right half of the inner insulation layer.
Figure 18: Removed left half of the inner insulation layer
Figure 17: Inner insulation layer
Right Left
Figure 16: Insulation layer behind the metal panel
Left
Right
16
On the side of the pump, an insulation part must carefully be removed (Figure 19 and Figure 20). The insulation part is located between the first and second seam from the front of the pump (Figure 20).
Remove the cylinder shaped insulation material above the pump, as indicated in Figure 22. Mind that this part is glued to the insulation of the pump.
Figure 22: Cylinder shaped insulation material
Figure 21: Removed insulation part
Figure 20: Insulation part between the first and second seam
First seam
Second seam
Insulation part
Figure 19: View of the insulated pump
17
3 Pump maintenance
3.1 Withdraw hydraulic oil from the pump
More information about withdrawing the hydraulic oil from the hydraulic oil reservoir can be found in ‘Membraanpompkoppen type M910 en M911 B2.2910 nl 6.3.2 Hydraulische vloeistof aftappen (blz 8)’.
Remove the black plug (Figure 23) Clean the black plug with a clean and dry towel. Withdraw the oil with the lube-oil extractor (Figure
24). Place the transparent tube in the opening of the pump and start pumping with the
vacuum pump. Pumping with the vacuum pump is only necessary to create an oil flow. At a slurping noise, the transparent tube must be placed back beneath the oil level.
The last smattering of oil can be removed by moving the tube over the bottom of the oil reservoir.
When all the oil is withdrawn from the reservoir, the transparent tube can be taken from the reservoir.
Clean the surface of the pump with a clean and dry towel. Place back the black plug on the hydraulic oil reservoir. The pump surface is
cleaned again with a clean and dry towel.
Transport the oil to the dedicated waste deposal! A cupboard with an oil drum for waste oil is located behind the workshop.
Figure 24: Lube-oil extractor
Black plug
Figure 23: Hydraulic oil reservoir
Equipment: Slotted (flat)
screwdriver Lube-oil
extractor Clean and dry
(paper) towels
18
3.2 Disconnecting the pump front
The procedure disconnecting the pump front can also be found in ‘Membraanpompkoppen type M910 en M911 B2.2910 nl: 6.3.3 Sandwich-membraan (blz 8)’. When the hydraulic oil is withdrawn from the pump, the VCR connection on top of the pump (Figure 25) and the VCR connection beside the pump (Figure 26) must be disconnected. The VCR connections can be unbolted with wrenches 5/8” or 16 and 3/4” or 19. For the bolt between the first and second seam a customized wrench 19 (Figure 59, page 29) is used.
Disconnect the PT100 cable by cutting the cable tie around the cable connector. Mind the pins of the connector, they may fall out. Secure the pins with tape.
Remove the threads (for the wing nuts) by hand, to make room for the socket
wrench.
Figure 28: Thread on the pump front
Thread
Figure 27: Cutting the cable tie round the cable connector
Figure 26: Tube on the side of the pump that must be disconnected
Figure 25: Tube on top of the pump that must be disconnected
Equipment: VCR Caps Nippers (kniptang) Socket wrench 24 Syringe (spuit) Transparent tube Wrench 10 Wrench 3/4” or 16 Wrench 19 (customized) Wrench 5/8” or 19
19
In practice there will be no alcohol left inside the membrane. Despite this, follow the next steps:
Check that the pressure within the membrane is doesn’t exceed 1 bar (Figure 14). In case the pressure is larger, contact Eddy Jans of Nikhef and report a membrane failure.
To withdraw the alcohol from the membrane, the transparent tube must be connected to the syringe and next the tube must be connected to the lower tube nipple, see Figure 29. Open both tube nipples with wrench 10. Usually the alcohol is evaporated and thus no alcohol can be withdrawn.
While opening the upper tube nipple listen carefully if there is a hissing sound coming from the nipple. When a hissing sound is coming from the nipple and the pressure sensor indicates a pressure of approximately 1 bar, the functioning of the pressure sensor must be checked. Once the membrane is loose, it must be checked for an oil leak into the system.
When both tube nipples are open the end of the syringe can be pulled back and the alcohol will flow into the syringe. When all the alcohol is withdrawn (pressure indication 1 bar) from the membrane, the transparent tube can be disconnected from the lower tube nipple.
Remove the pressure sensor completely (Figure 32). Mind loose parts! Secure the nut on top of the pump with a cable tie, so that the bolt on top of the
pump is free (Figure 34).
Figure 32: Unbolted pressure sensor Figure 31: Disconnecting the pressure sensor
Connective
Upper tube nipple
Figure 30: Loosening the upper tube nipple Figure 29: Withdrawing the alcohol from the membrane
Syringe
Transparent tube
Lower tube nipple
20
Loosen the bolts on the front of the pump cross wise with socked wrench 24. When all the bolts are loose the pump front can be removed safely by grabbing
the sides of the pump front and pulling the pump front slowly back. Mind the weight of the pump front.
When the pump front is taken off, cover the two open tube ends with caps. Close the open ends of the system VCR seals and caps. To prevent moist
condensing in the cold system.
The grooved lines on the back of the pump front may not be damaged. Therefore
the grooved lines should not be touched under any circumstance. The grooved lines must be checked for any damages. In case of damage to the grooved lines, take up contact with Eddy Jans of Nikhef
Figure 35: Unbolting the pump front
Figure 34: Cable tie to secure the nut on top of the pump
Figure 33: Nut on top of the pump
21
3.3 Replacing the inlet and outlet valve of the pump
The type of spring, metal ball and seat ring can be found in documentation ‘Membraanpompkoppen type M910 en M911 B2.2910 nl’ in the part list of the technical drawings. Take off the tube section from the inlet side of the pump front. Protect the tube ends with plastic caps. For the next step a vise is required. The surface of the pump front may not be damaged thus use vise jaw protectors! Clench the pump front between the jaws so that the grooved lines won’t get damaged (Figure 36 and Figure 37). Position the pump front so that the inlet valve is under and still accessible.
Unscrew the inlet valve with wrench 36 and carefully take the whole out and place the parts on a clean surface. Mind loose parts!
Figure 39: Pump front without tube
Removed insulation
Tube bolt
Inlet bolt
Figure 38: Unbolting the tube from the pump front
Figure 36: Pump front placed in a vise front Figure 37: Pump front placed in a vise back
Equipment: Acetone Clean and dry
(paper) towels 2 caps 2 Seat rings Spring 2 Metal balls Torque wrench 36 Vise Vise jaw protectors Wrench 36 Wrench 3/4” or 16 Wrench 5/8” or 19
22
Position the pump front so that the outlet valve is under and still accessible. Take off the square insulation material around the valve (Figure 40) Unscrew the valve with wrench 36 Carefully take the whole out, mind the loose parts and spring! Place the parts on a clean surface
The loose parts for the outlet valve consist of a seat ring, a spring, a metal ball and
a shell. The loose parts for the inlet valve are a shell, a metal ball and a seat ring.
Remove the insulation from the pump front Clean the surface of the pump front with a dry and clean towel Clean the opening for the inlet and outlet valves
Figure 40: Bolt that must be unscrewed Figure 41: Unscrewing the bolt
Outlet bolt and parts
Inlet bolt and parts
Figure 42: Respectively outlet and inlet valve of the pump front
23
Place the insulation back around the pump front. The silver coloured layer of the insulation must be placed to the back (with the grooved lines) of the pump front. The lower side of the insulation is the flat side covered with a silver coloured layer. The pressure gauge connection is up.
Check if there is no insulation material left in the valve openings and clean the seats in the openings with acetone.
Place the pump front in the vise jaws with the flat side of the insulation covered with a silver coloured layer down.
Mount the inlet valve back to the pump front. Therefore a new metal ball and seat ring is necessary (Figure 42).
Clean the seats of the seat ring and the shell. Place the metal ball in the shell and then put the seat ring with the dot directed to
the metal ball on the shell. Check that the inlet hole of the pump front is clean from insulation. Place the whole with the seat ring down in the valve. Close the hole with kapton tape and place a VCR cap on the inlet valve.
Mount the outlet valve back to the pump front. Therefore a new metal ball, spring
and seat ring is necessary. Clean the seats of the seat ring and the shell. Check that the outlet hole of the pump front is clean from insulation. Place the shell in the valve with the open side up, next place the spring through
the shell in the valve. On top of the spring place the metal ball and the seat with the dot face towards the metal ball.
Close the hole with kapton tape and place a VCR cap on the outlet valve.
Next both valves must be bolted with 120 Nm by means of torque wrench 36. Place the square insulation part back on top of the pump front. Before installation of the pump front remove the kapton tape!
Outlet bolt and parts
Inlet bolt and parts
Figure 44: Respectively outlet and inlet valve of the pump front and components
Figure 43: Removed insulation from the pump front
24
3.4 Replacing the pump membrane & seal
The procedure of replacing the membrane can also be found in ‘Membraanpompkoppen type M910 en M911 B2.2910 nl: 6.3.3 Sandwich-membraan (blz 8)’. Remove the white seal around the pump surface as shown in Figure 45. Next remove the seal glue by hand.
The hydraulic oil is withdrawn from the hydraulic oil reservoir in the pump. Some oil remained in the pump front behind the membrane of the pump. A leak bucket is used to catch to oil while unscrewing the membrane. Position the leak bucket on the pump by placing the bolts in the leak bucket through the pipes and next fasten the bolts as shown in Figure 46.
Figure 45: Removing seal
Figure 46: Positioning the leak bucket
Equipment: Acetone Clean and dry (paper)
towels Wrench 36 Leak bucket and supplies Membrane Acetone Clean and dry (paper)
towels Seal
25
Gently peel the membrane loose from the pump surface. Make sure that the membrane is loosened from the pump surface. Carefully place the index finger and middle finger behind the membrane and place the thumb on the membrane. Slowly turn the membrane left as indicated in Figure 47 and Figure 48. While unscrewing the membrane, oil will leak from the pump.
Check the used membrane for damages, no damages means no oil leakage into the cooling system. Carefully remove the leak bucket, with the hydraulic oil, from the pump by unbolting the bolts. Clean the leak bucket.
Carefully clean the surface, the grooved lines and the blue line of the pump with acetone.
! When mounting the new membrane one should carefully handle the membrane as the layers may not be deformed!
Mount the membrane by turning it clockwise until you feel that the membrane touching the housing. From this point add one half to three quarters of a turn. Till the membrane is clearly mounted to the housing.
Figure 49: Screwing down the new membrane
Figure 48: Unscrewing the membrane Figure 47: Holding the membrane
26
Peel a small part of the new seal and stick this on the blue line around the pump as shown in Figure 50 and Figure 51.
When the blue line is covered, cut the seal at length close to the start of the seal, no overlay.
Figure 51: Stick on the new seal on the pump Figure 50: Pealing the new seal
27
3.5 Assembling the pump front
Information about assembling the pump front on the pump can also be found in ‘Membraanpompkoppen type M910 en M911 B2.2910 nl: 6.4 Montage (v.a. blz. 11) Information about making VCR connections can be found in Appendix I ‘VCR Fitting Installation Instructions’ of this document. Remove the caps from the inlet valve and place the tube section back. Mind to make this connection carefully as it cannot be checked for leak tightness! The valve is positioned towards the front of the pump front (Figure 52). Tighten the connection bolt with wrench 5/8” or 16 and wrench 3/4” or 19. Place back the insulation part to cover this connection.
Place a gasket with retainer ring and position this on the tube connection on the side of the pump as shown in Figure 54.
Figure 52: Tube with tap connected to the pump front
Equipment: Acetone Alcohol Cable tie Clean and dry
(paper) towels Gasket with retainer
ring Pincers Socket wrench 24 Syringe (spuit) Transparent tube Wrench 10 Wrench 3/4” or 16 Wrench 17 Wrench 5/8” or 19 Wrench 19
(customized)
28
Remove the cap on the outlet valve of the pump front. Clean the grooved lines on the pump front with acetone. Carefully place back the pump front so that tube connections fit and fix by hand
two bolts in the front of the pump.
Cut loose the cable tie round the tube connection on top of the pump (Figure 34)
and place a gasket. Fasten the two VCR connections by hand.
Fix the remaining bolts equally by hand in the
front of the pump. Mind that the two bolts with the threads are positioned on the third opening on the right from the top and on the second opening on the left from the top (Figure 55).
Increase the momentum of the bolts in steps and crosswise (order shown in Figure 57). The steps are 8.5 Nm (6 ft∙lb), 17 Nm (13 ft∙lb), 42 Nm (31 ft∙lb ) and 85 Nm (63 ft∙lb). The recommend torque for the centerpump is 95 Nm.
Figure 56: Screw down the bolts with socket wrench 24
Figure 55: Front bolts
Threat bolt
Threat bolt
First bolt
Figure 54: Gasket placed on the tube connection on the side of the pump
Figure 53: Gasket with clasps
Figure 57: Screw down the bolts cross wise
29
Close the VCR connection on the side of the pump in Figure 58. This connection is difficult to reach, therefore use the modified wrench 19 (Figure 59) and try to reach the connection from the other side of the cooling system. When there is not enough space to reach the connection, temporarily remove the pump motor according to chapter 4. Fasten the tube connection on top of the pump (Figure 58) with wrench 16 and 19.
Place back the pressure sensor with the tube nipple radial directed away from the center of the pump front (Figure 61). Fasten the pressure sensor such that the pressure indication panel is set horizontal.
Open the tube nipples (Figure 61) with wrench 10. Connect transparent tubes to the upper and lower nipple. Place the tube from the upper nipple into a jar with alcohol. Make sure that the end of the tube is below the alcohol level.
Figure 60: Pressure sensor is being placed back in the pump front
Figure 58: Side and top connection
Side connection Top
connection
Figure 59: Modified wrench 19
Figure 61: Pressure sensor fastened in the pump front
Upper tube nipple
Lower tube nipple
30
Fill the syringe with alcohol and connect the syringe to the tube of the lower nipple.
Hold the syringe above the nipple height and with the end of the syringe up (Figure 62). Empty the syringe by pushing the end of the syringe, next pull back the end of the syringe.
After the first filling with the syringe it may be necessary to refill the syringe. In this case the tube of the lower tube nipple must be held high while removing the syringe from the tube. Refill the syringe with alcohol and connect the syringe to the lower nipple tube. Mind that the tube must be held high to prevent air from entering the membrane.
Again empty the syringe by pushing the end of the syringe, next pull back the end of the syringe.
Repeat this a few times until no longer air bubbles appear from the membrane.
Close the upper nipple followed by closing the lower nipple. Remove the tubes from the nipples. The alcohol is kept in the membrane of the
pump.
Screw down the threads by hand (Figure 63). Reconnect the PT100 cable and secure the connection with a cable tie.
Figure 63: Bolt down the threads
Thread
Thread
Figure 64: PT100 connection secured by a cable tie
Figure 62: Refreshing the alcohol layer in the membrane
31
3.6 Refreshing the hydraulic oil
The procedure refreshing the hydraulic oil can also be found in ‘Membraanpompkoppen type M910 en M911 B2.2910 nl: 6.1 Onderhoud (blz 7) and 6.4 Montage (blz 11)’. Remove the black plug of the hydraulic reservoir as described in paragraph 3.1. Remove the vent valve, located near the black plug beneath the square piece of insulation. Fill the liter dose bottle with Morlina 5 oil, Figure 66, by placing a funnel in the bottle and next pouring the Morlina 5 oil in the bottle up to 11 cm above the bottle bottom. Place the funnel in the opening for the hydraulic oil, Figure 65. Pour the Morlina 5 oil in the pump. Refill the liter dose bottle up to 11 cm and pour it in the pump until the oil level is approximately 50 mm beneath the opening. Place back the vent valve and o-ring and fasten with a torque of 45 Nm. Clean the surface of the pump and place back the black plug.
Figure 65: Hydraulic oil opening Figure 66: Shell Morlina oil 5
Equipment: Clean and dry
(paper) towels Dose bottle Measure tape Shell Morlina Oil
5 Slotted (flat)
screwdriver Socket wrench 24
32
4 Pump motor maintenance
4.1 Withdraw traction oil from the pump
More information about withdrawing the traction oil from the traction oil reservoir can be found in ‘Drijfwerk type LDC met handmatige slagafstelling, motor vertical B1.721.1 nl, 6.1.2.1 Synthetische olie (blz 5)’. The traction oil in the traction oil reservoir of the pump is withdrawn with the lube-oil extractor (Figure 24).
Remove the orange plug of the pump and remove the oil from the dipstick with a clean and dry (paper) towel.
Place the end of the transparent tube of the lube-oil extractor in the traction oil reservoir of the pump and start pumping with the vacuum pump on top of the sphere. Pumping with the vacuum pump is only necessary to create an oil flow. At a slurping noise, the transparent tube must be placed back beneath the oil level. The last smattering of oil must be removed by slowly moving the tube over the bottom of the oil reservoir. When all the oil is withdrawn from the oil reservoir, the transparent tube can be taken out of the reservoir.
Clean the opening of the pump and the o-ring with a clean and dry (paper) towel.
Transport the oil to the dedicated waste deposal! A cupboard with an oil drum for waste oil is located behind the workshop.
Figure 69: Transparent tube placed in the oil reservoir
Figure 68: Orange lid
Oil level in reservoir
Figure 67: Orange lid of the traction oil reservoir
Equipment: Clean and dry
(paper) towels Lube-oil
extractor
33
4.2 Refreshing the traction oil
Information about refreshing the traction oil can be found in ‘Drijfwerk type LDC met handmatige slagafstelling, motor vertical B 1.721.1 nl: 6.1.2.1 Synthetische olie (blz. 5)’. The procedure of measuring the oil level in traction oil reservoir can be found in ‘Drijfwerk type LDC met handmatige slagafstelling, motor vertical B 1.721.1 nl: 6.1.1 Controle-intervallen (blz. 4)’.
A funnel is placed in the opening of the traction oil reservoir of the pump and the fresh oil is poured into the oil reservoir. The oil level in the oil reservoir should have a height such that, while the orange plug is fastened in the opening, 1/3 of the dotted marking on the dipstick is covered with oil as indicated in Figure 68.
Three half funnels of Shell Tivela Oil S220 (Figure 70) is poured in a small jerry can, shown in Figure 71.
Figure 72: Funnel placed in the traction oil reservoir of the pump
Figure 73: Pouring fresh traction oil in the traction oil reservoir
Figure 70: Shell Tivela Oil S220
Figure 71: Small jerry can for the traction oil
Equipment: Clean and dry
(paper) towels Funnel Light Shell Tivela
Oil S220 Small jerry can
34
4.3 Replace gear shaped transmitter
The procedure of replacing the gear shaped transmitter (tandkrans) is also given in ‘Drijfwerk type LDC met handmatige slagafstelling, motor verticaal B 1.721.1 nl: 6.1.2.2 De tandkrans voor de koppeling (blz. 5)’ and a view of the tandkrans is given in ‘Torsie-elastische klauwkoppeling B1.950 nl: 3.2 Constructie en werking (blz. 3)’. Remove the four bolts from the cylindrical flange which secure the motor to the pump. Carefully lift the motor from the neck of the pump and lay it down in front of the pump with the cables up. Pay close attention that the correct bolts are removed!
Remove the gear shaped transmitter (tandkrans) and replace it with a new one. Place the motor back on the neck of the pump and mount the four bolts. When further work must be done while the motor is taken from the pump, the neck of the pump must be covered.
Figure 76: Gear shaped transmitter protector in the neck of the pump
Figure 75: Unbolting the motor from the pump Figure 74: Motor of the pump
Bolt motor and pump connection
Bolt motor and pump connection
Bolt motor and pump connection
Equipment: Wrench 13 New tandkrans Coverage for
the pump neck
35
5 Preparing for commissioning of the pump
5.1 Connect the pump to the electrical circuit
Connect the electrical circuit by connecting cable HT102 and PM101 as shown in Figure 77 . Pay attention to the exact cable label for the pump that must be connected, the labels for each pump are given in Table 2. Reset the alarms in the touch screen. Table 2: Cable numbers for the left, center and right pump
Pump Cable label Cable label Left TL_HT102 TL_PM101
Center TLR_HT102 TLR_PM101 Right TR_HT102 TR_PM101
Figure 79: Connector panel
Figure 78: Cables disconnected from panel Figure 77: Connector panel with cables
TL_PM101
TL_HT102
36
5.2 Connect the pump to the CO2 system
When a section has been emptied the O-rings of all the corresponding relief valves must be replaced. Replace the o-ring of relief valve TL_BD105. O-ring type: Fluorocarbon FKM Seal kit for R3A series VI-R3A-K2 (01-12-2011)
Figure 80: Relief valve
5.2.1 Vent pump with CO2 Information about making VCR connections can be found in Appendix I ‘VCR Fitting Installation Instructions’ of this document. To clear the pump from air it will be vented with CO2. The Open ended valve VL114 on the side of the pump is the CO2 connection and open ended valve VL107 on the valve panel is used as a venting valve (Figure 81). Table 3: Venting valve numbers
Pump Valve number Valve number Left TL_VL107 TL_VL114
Center TLR_VL107 TLR_VL114 Right TR_VL107 TR_VL114
Equipment: Bottle with clean CO2 Cylinder connection tube Suds and brush (zeep en
kwast) Tab head (Figure 83) Wrench 3/4” or 16 Wrench 5/8” or 19 Wrench 18
37
Make sure that valve VL106 and VL108 are still closed and that VL107 is closed. Remove the cap from valve VL107 with wrench 3/4” or 19 as shown in Figure 82.
Remove the cap from VL114 while holding the valve house with wrench 18 (Figure 83). Take a cylinder with clean CO2 and connect it to VL114 with the dedicated stainless steel flexible hose, mind to hold the valve house (Figure 83)! Use the special handle (Figure 83) to open VL114 by turning it in line with the tubing.
TR_VL106
TR_VL108
TLR_VL109
TLR_VL101
TL_VL106
TL_VL108
TR_VL107TL_VL107
TLR_VL107
TLR_VL114
TL_VL114 TR_VL114
Figure 81: Valve control location (2)
Figure 82: Remove cap from valve VL107
38
Open the CO2 cylinder, the volume in the pump is now under pressure. Check if all the connections, that have been opened, are closed properly by rubbing the connections with suds. When bubbles appear, a leak is present and the connection must be closed again.
Remember to check the tube fitting of the relief valve! The connection on the inlet side of the pump cannot be tested. Check if the membrane pressure is equal to 1 bar? For venting the pump volume follow this procedure:
Close valve VL114 Open valve VL107 Wait for the volume to empty Close valve VL107 Open VL114 Wait for the volume to fill
Repeat this filling and venting at least five times. Do not vent the last filling! Leave it in the pump. This will be given to the system and compensate for the loss of released fluid. Close the CO2 cylinder. Make sure that valves VL107 and VL114 are closed. Carefully disconnect the CO2 cylinder, as the tube is under high pressure. Open the VCR connector a bit and let the pressure escape by holding the valve house with wrench 18 and open the connection a bit with wrench 3/4” or 19. When the hissing stops the tube can fully be disconnected. Close the open ends of valves VL107 and VL114 with VCR caps and new seals.
Figure 83: CO2 bottle tube connection
39
Follow the steps to connect the pump to the CO2 cooling system: Check that valve VL107 and VL114 are closed Open valve VL106 and VL108
Table 4: Valve numbers for the left, center and right pump
Pump Valve number Valve number Left TL_VL106 TL_VL108
Center TLR_VL101 TLR_VL109 Right TR_VL106 TR_VL108
Press the red “STOP” button
Check that the selection boxes, on the configuration page, are in the specified positions, if not change to the correct position.
o “CO2 TL (A-side)” on “auto (screen)” o “CO2 TR (C-side)” on “auto (screen)” o TLR_PM101 (center pump)” on “auto/default” o “Main Chiller (SA)” on “auto (screen)” o “Backup Chiller (SB)” on “auto(screen)”
Press the “start TL A-side” and start TR C-side” buttons. Verify that electrical valve TR_VL108 stays in position port-2 and the cooling starts correctly and finishes by sending the Cooling Ready A and C signals. This can be seen on the user screen under the status fields labeled “CO2 status” for the A and C side, respectively as well as on the “Interlocks” page.
40
6 Assembling the pump insulation
Place the removed insulation part back over the connection on the side of the pump. Don’t use glue.
Place the removed cylinder shaped insulation part on top of the pump front. This part can be glued for good insulation.
Place back the right en left inner layer halves and next place back the right and left insulation halves.
Figure 86: Location insulation on top of the pump
Figure 87: Both inner layer halves
Figure 85: Removed insulation part between the first and second seam
Insulation part
Figure 84: View of the insulated pump
41
Figure 93: Front of an isolated pump Figure 92: Circular metal panel
Figure 88: Removed left half of the inner insulation layer
Figure 89: Inner insulation layer
Right Left
Figure 90: The removed insulation halves Figure 91: Insulation layer behind the two insulation halves
42
Place back the circular metal panel and screw down the wing nuts. Now the insulation cube can be placed back over the valve. Reconnect the membrane crack sensor cable.
Figure 94: Removed insulation cube
43
Appendix I VCR Fitting Installation Instructions
44
Temperature sensors location The location of the temperature sensors (TTxxx), valves (VLxxx), etc. can be found in the tertiary CO2 schematics, Figure 95.
Figure 95: Tertiary CO2 schematics
TR
_AC
101
TR
_PM
101
Tert
iary
VTC
S R
ight
Det
ecto
r (T
R)
TR
_PT
101
TR
_PT
104
TR
_PT
102
TR
_VL
101
TR
_VL
103
TR
_VL
104
TR
_VL
105
TR
_VL
106TR
_VL
107
TR
_VL
108
TR
_VL
109 T
R_V
L11
0
TR
_VL
111
TR
_VL
113
TR
_LT
101 T
R_B
D10
3
SA_H
X10
5 /
TR
_HX
101
SB_H
X10
5 /
TR
_HX
102
SA_H
X10
8 /
TR
_HX
103
TL
_HT
103
TR
_HT
104
SB_H
X10
8 /
TR
_HX
104
TR
_HT
101
TR
_VL
102
TR
_PT
103
TR
_HT
102
TR
_BD
101
TR
_BD
102
TR
_BD
104
TR
_BD
106
TR
_BD
107
TL
R_V
L10
1
TL
R_P
M10
1
TL
R_V
L10
7
TL
R_V
L10
9
TL
R_V
L11
0
TL
R_V
L11
1
Liqu
id to
co
ncen
tric
tube
Vapo
r mix
ture
from
co
ncen
tric
tube
Vapo
r mix
ture
from
co
ncen
tric
tube
Liqu
id to
co
ncen
tric
tube
TL
_AC
101
TL
_PM
101
Tert
iary
VTC
S Le
ft D
etec
tor
(TL)
TL
_PT
101
TL
_PT
104
TL
_PT
102
TL
_VL
101
TL
_VL
103
TL
_VL
104
TL
_VL
105
TL
_VL
106
TL
_VL
107TL
_VL
108
TL
_VL
109
TL
_VL
110
TL
_VL
111
TL
_VL
113
TL
_LT
101
TL
_BD
103
SA_H
X10
3 /
TL
_HX
101
SB_H
X10
3 /
TL
_HX
102
SA_H
X10
7 /
TL
_HX
103
TL
_HT
103
TL
_HT
104
SB_H
X10
7 /
TL
_HX
104
TL
_HT
101
TL
_VL
115
TL
_VL
102
TL
_PT
103
TL
_HT
102
TL
_BD
101
TL
_BD
102
TL
_BD
104
TL
_BD
106
TL
_BD
107
TL
R_P
T10
3
TL
R_H
T10
2
(101
)
(103
)(1
04)
(106
)
(105
)
(112
)
(115
)
(116
)
(117
)
(118
)
(121
)
(123
)
(122
)(1
14)
(113
)
(120
)
(107
)
(102
)(1
19)
(110
)
(108
)
(109
)
(101
)
(103
)(1
04)
(106
)(1
05)
(111
)
(112
)
(115
)
(116
)
(117
)(1
18)
(121
)
(123
)
(122
)(1
14)
(113
)
(120
)
(107
)
(110
)
(108
)
(109
)
(124
)(1
24)
(112
)
(115
)
(122
)
(114
)
(113
)
TL
_VL
112
TR
_VL
112
TL
_HT
105
(125
)
TR
_HT
105
(125
)
TR
_FL
101
TL
_FL
102
TR
_FL
102
TL
_FL
101
TR
_HX
105
(102
)(1
19)
Tam
bie
nt
TL
_VL
114
TL
R_V
L11
5
TR
_VL
115 T
R_V
L11
4
TL
R_V
L11
4
TL_S
.01
S.02
S.04
S.05
S.03
S.15
S.16
S.17
S.19
S.18
.01
S.18
.02
S.09
.29
S.20
S.21
S.22
TLR_
S.20
TLR_
S.01
TR_S
.01
S.02
S.05
S.04
S.03
S.15
S.16
S.17
S.18
.01
S.18
.02
S.19
S.22
S.20
S.21
S.12
.29
S.09
.29
S.12
.29
TL
_VL
116
TR
_VL
116
TR
_PT
101
TR
_FL
103
45
Appendix II List of replacement parts per pump Part Type Amount Maintenance intervalHydraulic oil Shell Morlina Oil 5 ? Annual Traction oil Shell Tivela oil S220 0.5 liter Annual Gear shaped transmitter 95/98 Sh A (red) 1 Annual (8 800 H) Gasket with clasps Swagelok SS-4-VCR-2-GR 1 Annual Alcohol - 0.1 liter - Seat ring DN10 HK-H 25DX9 2 Annual Metal ball 14D DIN 5401 2 Annual Spring DN10 HK_H 0.6 BAR ST 1 Annual Seal D1/3 3X1, 5X25 1 Annual Membrane LEWA BD64 M900 Liquid 1 Annual Small cable ties - 5 - Cylinder with clean CO2 ? 1 -
