Warora-Installation Operation and Maintenance Manual

7/31/2019 Warora-Installation Operation and Maintenance Manual

1/23

Catalogue

Major part of the device

1 General

2 Device components and its system

3 Working process

4 Handling and storage

5 Installation and adjustment

6 Application and operation

7 Maintenance

8 Frequent fault and troubleshooting

Electrical control

1 General

2 Function description

3 Installation, commissioning and operation

4 Maintenance and error processing


2/23

SHANGHAI ELECTRIC GROUP

CO. LTD.Zhenjiang East China Electric Power

Equipment Factory

:qilidian zenjiang jiagsu :212017 :86-511-85614193

:0511-85623761 :[email protected] :http://www.suyuan.com

1

Major part of the device

1 General

This chemical dosing device for water treatment consists of auto NH3 dosing device,

auto N2H4 dosing device and Na3PO4 dosing device which are used for two units. Three

devices are controlled by one control panel.

The main function of the chemical dosing device is that putting the prepared dilute

solution of chemicals(NH3, N2H4, Na3PO4) into the feedwater, condensation water ,boilerwater or closed-type cooling water system through the dosing pump to adjust the quality of

water vapor in the system to prevent metallic corrosion , to prevent calcium scale from

depositing in the boiler .

2 Device components and its system

No.

Description

Model/specification

Qty

Remarks

1

Ammonia dosing equipment H30-1 1

1.1Ammonia solution tank

1000L 1000mm 316SS 2

1.2Ammonia mixer

910rpm 1.1kw 2

1.3 Level guage

UHZ-10C00B

L=1300mm2

1.4 Ammonia metering pump for

feed water

RA060S024

58L/h 2.0Bar 316SS3 Milton Roy

1.5 Ammonia metering pump for

condensate water

RB090S067


1.6 Pulsation damper

NXQ-L/A 304SS 6

1.7 Relief valve

RV2-MF-6N-AS316

@1.6MPa3 HY-LOK

1.8 Relief valve

RV2-MF-6N-AS316

@3.2MPa3 HY-LOK

1.9 Y GLT-25 304SS 2


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No.

Description

Model/specification

Qty

Remarks

Y-type strainer

1.10 Ball valve DN15~DN25 1

1.11 Pressure guage

YA-100 0~2.5MPa 3

1.12 Pressure guage

YA-100 0~6MPa 3

1.13

Ammonia transfer pumpC786-36 92L/h 7Bar 1 Milton Roy

1.14Pipe & accessories

DN15~DN32 304SS 1

1.15 SkidCarbon steel 1

1.16ladder & platform

Carbon steel 1

2

Hydrazine dosing equipmentH30-1 1

2.1

Hydrazine solution tank1000L 1000mm 316SS 2

2.2

Hydrazine mixer

910 rpm 1.1 kw 2

2.3 Level guage

UHZ-10C00B

L=1300mm2

2.4 Hydrazine metering pump for

feed water

RA060S024


2.5 Hydrazine metering pump for

condensate water

RB090S067


2.6

Pulsation damper

NXQ-L/A 304SS 6

2.7 Relief valve

RV2-MF-6N-AS316

@1.6MPa3 HY-LOK

2.8 Relief valve

RV2-MF-6N-AS316

@3.2MPa3 HY-LOK

2.9Y Y-type strainer

GLT-25 304SS 2

2.10Ball valve

DN15~DN25 1

2.11 YA-100 0~2.5MPa 3


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No.

Description

Model/specification

Qty

Remarks

Pressure guage

2.12 Pressure guage YA-100 0~6MPa 3

2.13Pipe & accessories

DN15~DN32 304SS 1

2.14 Hydrazine transfer pump

C786-36 92L/h 7Bar 1 Milton Roy

2.15

SkidCarbon steel 1


Carbon steel 1

3

Phosphate dosing equipmentH30-1 1

3.1 Phosphate solution tank

1000L 1000mm 316SS 2

3.2 Phosphate mixer

910 rpm 1.1 kw 2

3.3 Level guage

UHZ-10C00B

L=1300mm2

3.4

Phosphate metering pump

MBH101-8MPF

47L/h 240Bar 316SS

4 Milton Roy

3.5Pulsation damper

NXQ 304SS 4

3.6 Relief valve

RV2-MF-6N-AS316

@19.5MPa4

3.7Y Y-type strainer

GLT-25 316SS 2

3.8

Ball valveDN15~DN32 1

3.9

Globe Valve

DN15 8

3.10

Pipe & accessoriesDN15~DN32 304SS 1

3.11 Pressure guage

Y-150 0~40MPa 4

3.12

SkidCarbon steel 1


Carbon steel 1


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No.

Description

Model/specification

Qty

Remarks

4

Control system

H30-1 1

4.1 Control panel

(800+600)x600x2200mm 1

4.2EAdjustbale frequency AC

draive

ATV312 7

4.3 PLC

Modicon 1

4.3.1Master station

4.3.1.1

+RW VWDQG\ FRQWUROOHU

PRGXOH

140CPU67160 2

4.3.1.2

3RZHUVXSSO\PRGXOH140CPS12420 4

4.3.1.36

VORWUDFN;%3 1

4.3.1.45,2

5,2+($'&53 1

4.3.1.5

.

.PHPRU\FDUG 76;0)33. 1

4.3.1.6

(WKHUQHWPRGXOH140NOE77101 2

4.3.2

6ODYHVWDWLRQ

4.3.2.1

3RZHUVXSSO\PRGXOH140CPS12420 1

4.3.2.2RIO RIO DROP

140CRA93200

4.3.2.3 $,PRGXOH

$&, 2

4.3.2.4

$2PRGXOH$&2 1

4.3.2.5

',PRGXOH'', 3

4.3.2.6

'2PRGXOH''2 1

4.3.2.7 10 ;%3 1


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No.

Description

Model/specification

Qty

Remarks

VORWUDFN

3 Working process3.1 Chemical solution preparation and chemical dosing proces

3.1.1 Ammoniadosing unit3.1.1.1 Chemical solution preparation

First step: the chemical outlet valve of the standby solution tank should be opened and at

the same time the chemical outlet valve of the solution tank in which the chemicals are

already used up should be off; the second step: according to the dosing concentration

requirement, the prepared strong ammonia water is deliveried to the solution tank; the third

step: the demineralized water inlet valve of the solution tank is opened, at the same time

the level of the solution tank should be observed, when the level reaches the high level

point (or the required level), the water inlet valve should be off; the fourth step: the

agitator of the solution tank should startup, the demineralized water and ammonia in thesolution tank shall be sufficiently soluted and mixed, then the mixer should be off to finish

the chemical dosing work. The solution tank is under standby condition.

This system has two ammonia solution tanks, which are interchangeabl

3.1.1.2 Chemical dosing process

EE

E

When the chemical dosing is required, the chemical outlet valve of the solution tank, the

inlet valve and the outlet valve of the metering pump (make sure all the valves on the pipes

which the chemical solution flow through are open.)should be opened, the metering pump

shall start up. The flow adjusting rotation button on the metering pump shall be adjusted to

enable the outlet flow to reach the required one; also the output frequency of the frequency

converter shall be directly adjusted to change the output flow of the metering pump. The

ammonia solution shall enter the metering pump through the inlet pipe of its pump and be

transmitted to the dosing point through the outlet pipe. The chemical dosing work is

realized.


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3.1.2 N2H4 dosing unit3.1.2.1 Chemical solution preparation

*

The first step: the chemical outlet valve of the standby solution tank should be opened at

the same the chemical outlet valve of the solution tank in which the chemicals are used up

should be off; the second step: according to the dosing concentration requirement, the

prepared strong N2H4 solution should be deliveried to the metering box which is on the top

of the solution tank; the third step: the chemical outlet valve of the metering box should be

opened to enable the N2H4 solution to enter the solution tank; the forth step: the

demineralized water inlet valve of the solution tank should be opened, at the same time the

level gauge of the solution tank should be observed, when the water level reaches high (or

the required level), the water inlet valve should be off; the fifth step: the agitator of the

solution tank should start up, the demineralized water and N2H4 in the solution tank shall

be sufficiently soluted and mixed, then the agitator should be off to finish the chemical

dosing work. The solution tank is under standby condition.

This system has two N2H4 solution tanks, which are interchangeable.


EE

E

When the chemical dosing is required, the chemical outlet valve of the solution tank, the

inlet valve and the outlet valve of the metering pump (make sure all the valves on the pipes

which the chemical solution flow through are open.) should be opened, the metering pump

shall start up. The flow adjusting rotation button on the metering pump shall be adjusted to

enable the outlet flow to reach the required one; also the output frequency of the frequency

converter shall be directly adjusted to change the output flow of the metering pump. The

hydrazine solution shall enter the metering pump through the inlet pipe of its pump and be

transmitted to the dosing point through the outlet pipe. The chemical dosing work is

realized.

3.1.3 Na3PO4 dosing unit3.1.3.1 Chemical solution preparation


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The first step: the chemical outlet valve of the standby solution tank should be opened

at the same the chemical outlet valve of the solution tank in which the chemicals are used

up should be off; the second step:the prepared Na3PO4 cystal shall be put into the solution

basket from the material opening of the upper part of the solution tank; the third step: the

demineralized water inlet valve of the solution tank should be opened, at the same time the

level gauge of the solution tank should be observed, when the water level reaches high (or

the required level), the water inlet valve should be off; the fourth step: the agitator of the

solution tank should start up to enable the solid chemical to be soluted sufficiently then the

agitator should be off to finish the chemical dosing work. The solution tank is under

standby condition.

This system has two Na3PO4 solution tanks, which are interchangeable.


EE

E

When the chemical dosing is required, the chemical outlet valve of the solution tank,

the inlet valve and the outlet valve of the metering pump (make sure all the valves on the

pipes which the chemical solution flow through are open.)should be opened, the metering

pump shall start up. The flow adjusting rotation button on the metering pump shall be

adjusted to enable the outlet flow to reach the required one; also the output frequency of

the frequency converter shall be directly adjusted to change the output flow of the

metering pump. The phosphate solution shall enter the metering pump through the inlet

pipe of its pump and be transmitted to the dosing point through the outlet pipe. The

chemical dosing work is realized.

3.2 Operation3.2.1 Each metering pump shall feed the correspondent chemical dosing point.

4~20mAEE

For the metering pump with automatic adjusting flow device, the processed water quality

measuring signal 4~20mA shall be transmitted to the frequency converter, which shall

be used to adjust the motor frequency of the metering pump and its piston stroke so as to


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realize the adjustment of the output flow of the metering pump.

+

For the metering pump with manual adjusting flow, the manual adjusting screw of themetering pump shall be performed to adjust the output flow of the metering pump as per

the instruction manual of metering pump.

When a pump operates abnormally, the auxiliary pump shall be put into operation

manually. The system is equipped with the automatic adjusting device which can adjust the

output flow of the metering pump, so the control signal shall be switched to the control

device of the auxiliary pump at that time.

3.2.2

During the operation, normally only one solution tank provides chemical solution while

the other is under standby condition. When the level of the operating solution tank reduces

to the low level, the auxiliary tank shall be put into use manually.

3.2.3

x

4~20mA

Every solution tank is equipped with a magnetic floater level gauge so that the tank levelcan be site observed. And the solution tank is also provided with the level sensor which

function is that the operation panel can automatically alarm when the tank level reduces to

the low level or increases to the high level, or the metering pump shall automatically stop

operation when the level reduces to the low-low level. These alarm signal shall be transmit

to other system as per the requirement. The solution tank with the level transmitter shall

send 4~20mA anolog signal to the control system so that the present level of the tank can

be remote monitored.

4 Handling and storage4.1

The device and control cubicle shall be packaged and handled separately. Handling shall

be smooth and horizontal without rotation and the device shall not be damaged during the

handling.

4.2 /The device shall be storaged suitably and shall not be placed with exposure and be free of

rain and moisture

4.3


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During the storage, the connection shall be sealed well, and all the flange surface shall be

blocked by the blind plate and be free from foreign matter so as to prevent the affect on the

operation of the chemical dosing device.

5 Installation and adjustment5.1

8

The components of the whole device shall be put into place as per the arrangement

drawing, and the base shall be adjusted horizontally. After the adjustment, the anchor bolt

shall be tightened or the base and pre-embedded parts shall be welded, and the operation

platform and the base shall be tack welded.

5.2

Before the installation, the temporary blind plate of the pipe opening shall be dismounted

first and the foreign matters in the solution tank and the pipe shall be removed, then the

demineralized water pipe, the dirt discharge pipe, the inlet pipe and outlet pipe for

connection of the chemical solution for every device shall be connected.

5.3 The electrical device installation refers to Section 2 electrical system

6 Application and operation6.1 Preparation and check before the application6.1.1 Check the instrument such as the pressure guage, level guage.

6.1.2 Check the sealing of the pipe connection and tighten the bolt and nut.6.1.3 Check the cleanness of the solution tank, metering tank, valve and pipe.

6.1.4 Preparation and checking before the operation of the metering pump (please refer to the

operation and maintanence manual of the metering pump)

1 2mm

Check the oil level which shall be in around 2mm of the oil level guage center line.

2

Regulate the piston stroke of the metering pump to zero.

3

Manually turn the rotating section of the pump and check whether exists jamming or

unbalance.

4

Check whether the rotation direction of the motor accords with the indication.

5

Check whether the valves on the intake and outlet pipe of the pump is opened.

6


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Check whether the foundation bolt of the pump is loose or not.

6.1.5 Checking before the operation of the mixer

1

Check whether the lubricant on the transmission part of the mixer is suitable.2

Manually turn the rotation shaft, check whether exists jamming or unbalance.

3

Check whether the rotation direction of the motor accords with the indication.

4

Check whether the foundation bolt and louver bolt is loose.

6.1.6

Checking of the control cubicle and electrical section refers to Section 2 electrical control

system.

6.2 Operation6.2.1 Preparation of various chemical solution

6.2.2 Open the relevant inlet or outlet pipe valve of the pump.

6.2.3 Press the sta button to start up the operating pump.

6.2.4 The operation of electrical section for the whole device refer to Section 2 electrical control

system.6.2.5 The abnormal condition during the operation of the whole device shall be timely checked

and eliminated.

6.3 Shut down

/

When the chemical dosing device stops operation, the relevant pipe valve and pressure

guage valve shall be off. During the long time shut down of the unit, the chemical solution

in the pump and pipe shall be discharged and shall be rushed by water. If it is cold, the

necessary anti-frozen measures must be taken.

7 Maintanence7.1 The whole device shall be kept clean and dry.

7.2 The oil level shall be suitable for the transmission part of the chemical dosing pump, and

the lubricant shall be replaced regularly as per the instruction manual of the pump.

7.3 Installation, dismounting and assembly of the pump shall be in accordance with the


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instruction manual of the pump.

7.4 The instrument, valve shall be checked periodically and be regulated, repaired or replaced

under abnormal conditions.7.5 The bearing of the mixer shall be oiled periodically, the louver shall be checked regularly

to avoid being loose.

7.6 The filter shall be cleaned periodically to prevent block.

8 Frequent failure and troubleshooting8.1 Inadequate or no output flow

Causes Methods

Broken of the pump intake pipe

Replace with the new intake pipe to ensure

the tightness of the pipe

Block of the pipe

Clean the pipe or replace with the new one,

check the filter and dismount the filter net to

clean

Unfreely operation of the pump valve

Check, clean or replace

Solid cystal appearance or the solidimpurities

Increase the output flow or restrain theconcentration or clean

The safety valve not reaching the setting

pressure to unload.

Check, adjust, clean or replace the safety

valve

Leakage of the connection of the outlet

pipe

Check to ensure the tightness

Jamming of the check valve

Slightly knock the check valve to make the

valve core looseE E

Low output frequency of the frequency

converter

E E

Increase the output frequency of the

frequency converter

Inadequate liquid pressure oil

Increase the liquid pressure oil

Broken of the diaphragm of the metering

pump

Replace the diaphragm of the metering pump

+


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Leakage of the relief valve of the

metering pump

As per the instruction of the metering pump,

regulate the relief valve of the metering pump

8.2

Overheat of the pump body (the motor) Causes Methods

1. The pump body exceeding the max.

allowed pressure results in overload

Reduce the output pressure

2. Low oil level

Fill the oil to the required level

3. ELong term operation in the low frequency

condition

E

Manual adjust to reduce the stroke of the

metering pump or to reduce the concentrationof the chemical solution to improve the

operation frequency

8.3 Overwhirling of the indicator of the pressure guage under normal working pressure

Causes Methods

1. 8 Unsuitable pre-charge pressure or the gas

leakage of the accumulator

,

Check the charge pressure and charge to the

required value

2. Broken of the accumulator peltry

Replace the accumulator3. The chemical solution entering the

accumulator

Dismount the valve of the accumulator and

pour out its inner solution

Electrical control system

1 General

4~20mA

The electrical control system of the automatic chemical dosing device for water treatment

consists of electrical control and thermal control. The electrical control is used to perform

the start-up and stop control of the electrical device and various protection inside the

device. The thermal control is used to receive 4~20mA to control the stroke of metering

pump or the motor rotation of the metering pump so as to change the dosing and to satisfy

the dosing requirement of different water quality, and to alarm for the fault of the metering

pump, the mixer or the level. The main technical parameters are as follows:


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1.1 50HZ415V

35KA

0~99minElectrical control

Working source: AC 50HZ415V

Limited breaking capacity of the main switch35KA

Timing range of the mixer0~99min

1.2 50HZ230V

4~20mADC

Thermal control

Working source:AC 50HZ230V

Input signal :4~20mADC

1.3 IP55

5~40

10~75%

Others

Motor protection degree of the metering pump: IP55

Working condition: ambient temperature: 5~40Relative humidity: 10~75%

No polluted or corrosive gas

No violent vibration

1.4P

Color meaning

The green light indicates stop, the red light indicates operation

The green button indicates stop, the red button indicates start up

2 Function introduction2.1 Control method and type

Three dosing devices are equipped with one set of control panel to distribute the

electricity, and the chemical dosing control system is independent. The inner unit does

not need re-wiring upon the device at on site.

2.2 Dynamic control loop


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E

E

The dynamic control loop (motor control) consists of the high breaking capacity air circuit

breaker, AC contactor, thermal relay and the on or stop button and indicating light on the

control panel etc.(the auto control system also includes the frequency converter etc.). The

button and the light can realize the start-up or stop and the status of the motor. The thermal

relay or the frequency convertor can realize such functions as the overload, shortcircuit

and phase loss protection of the metering pump and the mixter and the alarm control. The

detailed on and stop operation see the sketch panel nameplate. The following are the

introduction of the thermal control function and instruction for the dynamic loop of the

metering pump etc.

2.2.1 Control loop of the metering pump

The motor operation of the metering pump shall be locked by the low-low level signal of

the solution tank (the switch chosen from the panel), i.e. when the liquid level of the

selected solution tank is lower than the low-low level setting value, the motor shall not be

able to start or automatically stop operation.

2.2.2 Automatic control function E

This function is realized by the frequency converter.

The chemical dosing control of the metering pump uses manual adjustment, which is to

directly manual adjust the screw (the stroke)of the metering pump to change the dosing

amount

2.2.2 Control loop of the mixer

0~99

5

The motor control loop of the mixer is equipped with the timer which can be adjusted

continuously for 0~99 min. When the operation time equals to the setting time, the mixer

shall automatically stop. The ex-factory setting time of the timer is 5 min.

3 Installation, commissioning and operation3.1 Installation of the device

The chemical dosing device adopts the unit assembly method, and three devices are


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equipped one control pannel. The cable (via the cable tray)from the control cubicle to the

electrical component of the device is installed by the manufacturer without the site

construction, so the workload reduces greatly. The site main installtion work is as follows:

3.1.1 Check the component and material list of the chemical dosing sytem.3.1.2 c Identify the inlet and outlet wiring of the control panel and the wiring of the terminal

blocks.

3.1.3 The connection of the outside power source, the cable of the control system and the

earthing wire.

The construction unit shall install and wiring as per the component arrangement drawing

and the electrical arrangement drawing and the wiring diagram of the terminal blocks for

the chemical dosing room.

3.2 Commissioning3.2.1 Preparation before the commissioning1

Check whether the wiring inside the cubicle is right, or the terminal is virtual connected

or is lost, or the unit component is loose or not.

2

Check the cable connection between the electrical cubicle and the powered device, and the

earthing conditions.

3

Check the wiring from the outside power cable, the outside signal cable to the control

cubicle is correct, and check the polar of the signal cable leads.

4+

Check the spec., the model, quantity of the components in the cubicle complies with the

information provided by the manufacturer.

5

Under the off state of the disconnector, check the mechanical part of the air circuit breaker,

contactor, relay, timer, button and rotation button have turned well, and have no jam.

6 500V 0.5

Measure the terminal connection of the motor to ground insulation resistor by means of


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500V M meter, and the resistance shall not be less than 0.5 MThe control cable

shall not be measured.

7

After the checking, the jobsite shall be timely cleaned and the measuring wire shall be

removed to restore previous condition of the device. Close the front and back cubicle door

and the cover of the cable tray. The main switch shall be in off status

3.2.2 Site commissioning1 c

Carefully read the operation instructions of the metering pump, the operating machine

and adjustor of the motor etc. and understand the working principle of the electrical system

and meaning of the nameplate on the cubicle control panel.

2 5 x 10%

The relevant device in the cubicle shall be set as per the operation requirement: the acting

value of the timer (5 min), the flow of the metering pump (10%), the adjustment of the low

level, low-low level probe location. (Notes:the setting value set by the manufacturer before

ex-factory of the device is indicated in the bracket.)

3

E

Notify the electrician to energize the chemical dosing device and to turn on the mainswitch. The volage in the front of the cubicle has the correct indication. Then turn on the

air circuit breaker one by one, and the red light on the panel for stop condition is on. When

no fault is found, turn on the control power switch in the thermal control cubicle, the

power source light of the frequency converter etc. is on.

4.

Inject 1/2 solution of the whole volume to the tank according to the mechanical operation

sequency (the concrete solution preparation shall be as per the operation requirement of the

power plant). The red float column level inside the level gauge is the level of the solution

tank.

5

Short-time start up the motor and check the rotation direction of the motor. Before the

trial-runing of the motor, check the rotation of the motor shall be in accordance with the

symbol on the shell. If not correct, change the power phase sequence timely.

6Static commissioning

a. Manual metering pump


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Open the inlet and outlet valve of the pump, start the chemical dosing metering pump, usehand wheel to regulate the dosing of metering pump, then the change of the pump piston

stroke that is the dosing shall be observed. Close the inlet valve on the top and bottom of

the level gauge, open the dirt discharge valve at the bottom, when the level of the tank

reduces to the low-low level probe location, the alarming light is on. When the level of the

tank reduces below the low-low level probe location, each pump shall automatically stop.

The alarm test for the high level refers to that of the low level.

b. Automatic metering pumpE E E

E E E 50HZ15HZ

EEE

The rotation of the metering pump shall be controlled by the frequency convertor, and the

panel of frequency convertor shall be set on output status. The output frequency shall be

regulated by the frequency to control the rotation of the pump motor. The upper and lower

limit of the output frequency of the frequency converter shall be 50HZ and 15HZ. The

frequency converter shall not be allowed to work long time under low frequency. The

detailed operation of the frequency converter refer to the operation instruction.

c. The mixer

Start up the mixer of the solution tank one by one, when the setting time is over, the mixer

shall automatically stop, meanwhile the setting value of the time relay shall be checked.

3.2.3 Dynamic commissioning

Dynamic commissioning means the trial running of the complete chemical dosingdevice

before put into operation. This shall be done coordinated with the electrical and boiler

professions so as to prevent the happening of the accident.

1.

Open the inlet and outlet valve of the pump and relevant valve as per the mechanical

operation sequence.

2

4-20mA

Measure the input signal (i.e.the signal of electric conductivity) between the input

terminals of the adjuster by means of the universal meter set on the DC voltage level, the

input signal should be 4-20mA which proves the outside commissioning signal has been

transmitted.

3


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Start up the metering pump, observe the pump rotation.

4

After the adjustment, the device shall be put into operation.

3.3 Trial-operation of the device3.3.1 Necessary inspection shall be done before the trial-operation of the device. When no fault

has been found, the operator shall start up the chemical dosing device.

3.3.2 When the metering pump automatically regulate the dosing amount, it is on the remote

control status.

3.3.3 After the start-up, the cubicle door shall be closed timely and the required operating

records shall be filled.

3.3.4 - Observation of the following items during the operation

1

Control cubicle (panel indicating light, voltage meter etc.)

2

Operation condition of the pump motor

3E

Indication condition of the frequency converter

4

Check of the components (temperature rise of the cable, heating of the terminal,wearing of the contactor)

3.3.5 Check of the following items during the interval of the continous operation

1

Switchover test of the metering pump

2

Switchover test of the solution tank

3

Close-loop disturbance test of the adjusting loop

-

The finish of the above items means the site commissioning work of this device has been

made.

3.3.6 - Attention during the operation1

Be sure the level of the chemical solution shall be at least at 1/2 of the effective level

of the level guage before the start-up of the mixer.

2E

If there is any fault for the frequency converter, it shall be checked. If necessary


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inform the manufacturer to handle.

3

If the auxiliary metering pump is required to put into operation, attention shall bepaid to switch the start and stop signal, the outside control signal from the operating

pump to the auxiliary one.

4

The cubicle door shall be timely closed to prevent the entering of the dust and dirty water.

4 Maintenance and fault processing4.1 Maintenance4.1.1 Periocally clean the dust deposited in the cubicle, keep the cleanness of the electrical

device and its nearby.

4.1.2

Periocally check the contactor condition of the air circuit breaker, the AC contactor, the

relay and the level guage probe.If not contact well, check it timely.

4.1.3 Check the wiring of the motor terminal box, the terminal box of the chemical dosing unit

and the terminal blocks inside the cubicle.

4.1.4 The following repair shall be made during the overhaul of the device.

1Dismantle of the mixer motor

2+

Inspection of the pump motor (see the attached document)

3E+E

Inspection the frequency converter performance (refer to the operation instruction of

the frequency converter)

4.1.5

Periodically check the marking tube of the wire and the marking plate of the cubicle panel

etc.. The damaged and lost one shall be added or replaced.

4.1.6 Adjust necessarily the parameter as per the operation requirement of the power plant.

4.2

Fault phenomenon

Causes

Processing method


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Unable to startup

of the motor

1. Not energizing of the

power source

Check the air circuit breaker, the AC

contactor in the control circuit have beenturned on

2. Action of the thermal

relay

Check the overload, shortcircuit, phase

lose conditions, after eliminating the fault

reset the relay and start up, if still acts, the

overload current setting value shall be

adjusted again.

3. Fault of the control

loop

X

XCheck the wiring and fuse, if the fuse is

broken, replace with the same spec. fuse.

4. Inner fault of the motor

Dismantle and repair the motor

5. Much lower level of

the tank

Add some chemical solution to be higher

than the low low level

6. E Action of the frequency

converter

Disconnect the air circuit breaker to

re-energize

Unable to adjust

the dosing amount

1. No outside control

signal

4~20mA

Measure 4~20mA DC power between the

terminals of the signal blocks. If not

detected, check whether the control

system has the output signal and whether

the power source wiring is correct

2. E

The frequency

converter not receive

the outside signal

+E E Refer to the operation instruction of the

frequency converter, set the relevant

parameter of the frequency converter to

enable it to receive the outside signal


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Not alarm in the

low level

1. Not energizing of the

power source

XCheck the alarm power works well,

including the switch of the power , thewiring and the fusec

2. Fault of the liquid level

sensor

Replace after confirm, if the float column

of the level guage has no magnet, replace

the level guage

Not stop operation

of the pump in

low-low level

1.

The level of the

chemical not reduce to

the low low level probe

location

Not processing

2. Damage of the liquid

guage

Check the probe of the level guage, the

magnetic floater etc.

3. Control loop

Check the operation loop of the pump

motero inside the control cubicle

Big vibration after

the startup of the

mixer

1. Uncorrect rotation of

the motor

Adjust the power phase sequence

2. Distortion of the mixer

shaft

Align or replace the mixer shaft

E

Fault code occurs

in the frequency

converter

+E

Check the fault as per

the operation

instruction of the

frequency converter

E

Check the existence of the fault,

re-enegenize the frequency converter after

disconnect it

E E

Under long time

low frequency

operation of the

frequency

converter

Long stroke or more

concentration of the

chemical solution

Reduce the stroke or reduce the

concentration of the solution


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E

EUnder the full

frequencyoperation of the

frequencyconverter

Short stroke or lowerconcentration

Increase the stroke or the concentration ofthe solution

E E

The frequency of

the converter not

vary with the

change of the

current signal

E

Uncorrect wiring or

uncorrect parameter

setting of the frequency

converter

+E

Check the wiring, set the parameter as per

the operation instruction of the frequency

converter

Documents

Warora-Installation Operation and Maintenance Manual