HCP100A英文操作维护手册[B].doc

HCP100A ManualPALL CORPORATIONINSTALLATION, OPERATION ANDMAINTENANCE MANUALHCP100A SERIES Turbine oil Conditioning Purifier Pall Filter (Beijing) Co., Ltd.No. 12, Hongda Nanlu, Beijing Economic & Technological Development AreaPost Code:100176 Tel: (010) 67802266 Fax: (010) 67802319ForewordThis manual is provided to serve as the installation, operation and maintenance guide for the equipment supplied in accordance with the details given in the customers purchase order. The contents should be read before attempting anyphase of installation, operation and maintenance.The equipment and any optional items are packed individually for assembly bythe customer. Unpack carefully and check all items received against the invoice.This equipment has been tested and quality controlled in accordance with Pallstandard procedures and also in accordance with the tests specified in the contractwhen required ( i.e. for specially designed equipment). However, the equipment asshipped may have been opened or disassembled for draining, cleaning, etc., aftertesting. The customer should satisfy himself that no nuts, bolts, flanges, pipes,closures or any other component have worked loose during shipment; these should be tightened wherever necessary.A nameplate has been permanently attached to the equipment. When requesting information, service or spare parts, please refer to the information given on this plate.It is the users responsibility to check actual operating conditions to ensure that the filter elements, vessel and sealing materials are compatible with the application and are within local safety codes. MANUAL PART NUMBERISSUEDATE MAN HCP100A BJULY 2006ContentsAbstract3Part Number4Design Data5Alarm Conditions7Storage and installation11Storage11Pre-installation inspection11Connection of HCP to Fluid Supply12Connection of Electrical Power Supply15Operator interface17Introductions to interface17Main menu18Getting Started22Water removal circulationFiltration circulation 2223System drain24Maintenance25Routine maintenance schedule25Routine maintenance activities25Fault finding27Appendix29List of spare parts29Pall drawings HCP100A INST: 2 sheets in totalPall drawings H0473.E-A: 5 sheets in total llAbstractThis unit designed by Pall, is dedicated for filtration and water removal of turbine oil. It incorporates together the functions of fine filtration and high efficiency water removal of oil. It can effectively remove some solid particles and emulsion, free water in oil. After that, the oil cleanliness level is up to NAS Level 6, and the content of free water may be lower than 100 PPM.Functions of this unit:1. Filtration circulation: could be used as solid particle filtration equipment independently.2. Water removal circulation: could remove the emulsion and free water in turbine oil.Features of this unit:1. No-watch running: It can run smoothly during normal operation after debugging, while requiring nobody to watch it.2. Automatic emergency alarm: It can automatically alarm and prompt operation methods when abnormal condition occurs and maintenance is needed.3. Automatic emergency stop: It can automatically shut down the system when a serious emergency occurs.4. System status display: The human-computer interface can display current and previous operation data.5. Telemetry unit status display: Real time display of unit status.Theory of this unit:1. Filtration theory: High performance Pall Ultipor III filters incorporate state-of-the-art design technology, including a unique patented “helical wrap” pleat support system and composite element structure for unsurpassed strength, performance and service life. The result is a cost-effective solution clearly superior to traditional filter designs.2. Water removal theory: When oil enters the coalescer, firstly it enters coalescer element. Free water and emulsified water become larger drops of water after passing filter element due to the peculiar polarity molecules in coalescer element materials. Before Oil enters separator element above, relatively large water drops in oil have fallen to the water bag below due to gravity. There are still some relatively small water drops go up to separator element with oil due to inertia. Separator element is made up of special hydrophobe materials. When oil passes separator element, water drops are kept outside. Then oil enters separator element and go out from the outlet. Water drops gather and become larger and at last fall into the water bag due to gravity.PART NUMBERHCP100A turbine oil purifier part Number： HCP100A R 3 A C A B C D A： “K”means voltage 200V, 3Ph., 230Vac/24Vdc control circuit； “M”means voltage 220V, 3Ph. , 230Vac/24Vdc control circuit； “N”means voltage 230V, 3Ph. , 230Vac/24Vdc control circuit； “R”means voltage 380V, 3Ph. , 230Vac/24Vdc control circuit； “S”means voltage 400V, 3Ph. , 230Vac/24Vdc control circuit； “T”means voltage 415V, 3Ph. , 230Vac/24Vdc control circuit； “U”means voltage 440V, 3Ph. , 230Vac/24Vdc control circuit； “V”means voltage 460V, 3Ph. , 230Vac/24Vdc control circuit； “W”means voltage 480V, 3Ph. , 230Vac/24Vdc control circuit； B： “3”means frequency 50 HZ； “4”means frequency 60 HZ； C： “A”means standard element configuration，see table below； “K”means high efficiency element configuration，see table below； D： “C”means mobile； “S”means stable。 Table of part Number and element configuration:ModelCoalescerSeparatorProtectionCirculationCNQTY.CNQTY.CNQTY.CNQTY.HCP100A1202845(standard)5120165211200339(standard)1120033711202846(high efficiency)1200335(high efficiency)Design Data1. IdentificationName of equipment:Pall turbine oil purifierModel type:HCP100A 2. Design Operating ConditionsFluid:Turbine oilFluid temperature range:+40 +70 （104158）Maximum fluid viscosity:=-0.045 MPaInlet pump P01 flow rate:100 L/minPump relief valve RV01 setting:0.8 MPaInlet strainer FL01 rating:250mProtection filter FL02 rating: 5(c)=1000（high efficiency） 12(c)=1000（standard）Circulation filter FL03 rating: 7(c)=1000Outlet strainer FL04 rating：250mCoalescer element rating： 10m（standard） 1m（high efficiency）Vacuum switch SP01 setting: -0.08 MpaPressure switch SP02 setting: 0.7MpaDifferential pressure indicator SDP01 setting： 0.24 MpaDifferential pressure indicator SDP02 setting： 0.30 MpaDifferential pressure indicator SDP03 setting： 0.24 Mpa 4. Materials of ConstructionBase frame:Corrosion protected carbon steelVessel:304 stainless steelThreaded fittings and fastener:Corrosion protected carbon steel Control panel box:Corrosion protected carbon steel5. Sealing material Nitrile 6. InterfacesFluid inlet port:M642 male port(for 604 welding connector)Fluid outlet port:M522 male port(for504 welding connector) 7. Electrical SystemPower supply: See unit nameplateTotal motor power: 3 kW （50Hz）Connected load: See nameplate for full current detailsPower supply protection rating: To suit full load current shown on unit nameplate. Maximum 32 A8. INSTRUMENTATIONPLC display with keypad（located on control panel）Start pushbutton（located on control panel）Stop pushbutton（located on control panel）Emergency stop pushbutton（located on control panel）Power on lamp（located on control panel）Discharge lamp（located on control panel）Isolator （located on control panel）Control reset button（located on control panel）Amber flashing beacon（located on top of control panel）Inlet vacuum gauge VG01（right to control panel）Temperature gauge TG01（right to control panel）Inlet vacuum switch SP01（located on pump inlet pipe）Outlet pressure switch SP02（located on outlet pipe）Pressure gauge PG01, PG02, PG03（right to control panel） Differential pressure indicator SDP01 （located on filter FL02）Differential pressure indicator SDP02 （located on differential pressure module） Differential pressure indicator SDP03（located on filter FL03）Drip tray float switch SL01 （located in fluid drip tray） Water level sensor BLW01 （located under the water bag）Water level switch SWL01 （located on drain pipe）Alarm Conditions Alarm and Warning Messages The oil purifier is provided with a number of interlocks and switches to ensure that it operates correctly and safely. The table below lists all alarm conditions for the unit. The active mode refers to times at which the alarm may be invoked. The action shows the result of each alarm.CONDITIONINDICATIONACTIONACTIVE MODESFUNCTIONSP017BARHIGH OUTLET PRESSUREPressure switch SP02 detected an outlet pressure greater then the maximum specified running limit of 7bar.Press RESET to return.ShutdownRunningPrevention of high outlet pressures, which can cause other faults.SDP012.4BAR(SDP01=PG02-PG01)FILTER FL02 BLOCKED!Unless this is a cold start condition, the filter FL02 element must be changed before differential pressure reaches 2.4 bar; otherwise, unit will shut down after 120 minutes.Remaining time for shut-down: XXX minutesAfter replacing the element, Press RESET to return.WarningRunningElimination of unnecessary shutdowns.CONDITIONINDICATIONACTIONACTIVE MODESFUNCTIONSDP012.4BAR(SDP01=PG02-PG01)FILTER FL02 BLOCKED!Filter FL02 element must be changed;Failure to differential pressure indicator SDP01, please check it and replace/repair.Press RESET to return.Shutdown RunningPrevention of running with defective switchSDP023BAR(SDP02=PG03-PG02)FILTER VE01 BLOCKED!Unless this is a cold start condition, the filter VE01 must be changed before differential pressure reaches 3 bar; otherwise, unit will shut down after 120 minutes.Remaining time for shut-down: XXX minutesAfter replacing the element, Press RESET to return.WarningRunningElimination of unnecessary shutdowns.SDP023BAR(SDP02=PG03-PG02)FILTER VE01 BLOCKED!Filter VE01 element must be changed;Failure to differential pressure indicator SDP02, please check it and replace/repair.Press RESET to return.Shutdown RunningPrevention of running with defective switchSDP032.4BAR(SDP03=PG03-PG01)FILTER FL03 BLOCKED!Unless this is a cold start condition, the filter FL03 element must be changed before differential pressure reaches 2.4 bar; otherwise, unit will shut down after 120 minutes.Remaining time for shut-down: XXX minutesAfter replacing the element, Press RESET to return.WarningRunningElimination of unnecessary shutdowns.CONDITIONINDICATIONACTIONACTIVE MODESFUNCTIONSDP032.4BAR(SDP03=PG03-PG01)FILTER FL03 BLOCKED!Filter FL03 element must be changed;Failure to differential pressure indicator SDP03, please check it and replace/repair.Press RESET to return.Shutdown RunningPrevention of running with defective switchThe solenoid valve YV01 faultTHE SOLENOID VALVE YV01 FAULTPlease repair or replace it.Press RESET to return.ShutdownRunningPrevention of running with defective solenoid valveThe solenoid valve YV02 faultTHE SOLENOID VALVE YV02 FAULTPlease repair or replace it.Press RESET to return.ShutdownRunningPrevention of running with defective solenoid valveSL01=OPENDRIP TRAY FLOODED!Float switch SL01 shows that the drip tray is flooded.Please drain and re-start unit.Press RESET to return.ShutdownStandby & runningPrevention of fluid spillage.PR01 = OpenSUPPLY FAULT!A phase fault or under voltage fault has been detected by relay PR01. The fault is associated with the phase rotation or the voltage is less than 90% of the nominal marked on the nameplate.Trace fault, then press RESET to restart.ShutdownStandby & runningPrevention of reverse operation of motors or under-voltage.QM01 = OpenFLUID PUMP OVERCURRENT!Motor circuit breaker QM01 has tripped.Press RESET to return.ShutdownStandby & runningProtection from over current.CONDITIONINDICATIONACTIONACTIVE MODESFUNCTIONWater level lowWATER LEVEL LOWWater level sensor BLW01 has detected a low level condition in the water bag.Press RESET to return.ShutdownRunningPrevention of fluid loss.Water level highWATER LEVEL HIGHWater level sensor BLW01 has detected a high level condition in the water bag.Press RESET to return.ShutdownRunningDetection of high water levelTime for water level to fall from SWL03 to SWL02 too long.WATER LEVEL TOOK TOO LONG TO FALL FROM SWL03 TO SWL02!Press RESET to return.ShutdownRunningDetection of outlet flow inefficiency.PLC module faultANALOG QUANTITY MODULE FAULTPower failure to this module, please check it. Please consult Pall service personnel if module fault.Press “Reset” button to return.Shutdown RunningPrevention of running with defective PLCPLC module faultLOW SIGNAL OF ANALOG QUANTITY Failure to input signal line, please check it.Failure to BLW01, please check it.Press “Reset” button to return.Shutdown RunningPrevention of running with defective PLCPLC module faultHIGH SIGNAL OF ANALOG QUANTITYHigh water level, press “Reset” button to discharge water.Failure to BLW01, please check it.Press “Reset” button to return.Shutdown RunningPrevention of running with defective PLCStorage and InstallationNote: The efficacy and reliability of this fluid purifier will be affected greatly by the quality of the installation. Every effort should be made to adhere to the guidelines described herein in respect of the commissioning of the equipment. Its recommended to use the service provided by Pall or its approved agents to install and maintain this unit, to avoid low efficiency and/or operating troubles due to improper installation.StorageIf the Oil Purifier is not to be installed immediately: Store the Oil Purifier in clean, dry and cool conditions and wherever practical in the packaging supplied. Use desiccant sachets in electrical enclosure if storage is to be for more than one month, or in humidity of greater than 85%RH. DO NOT remove packaging until ready to install. To prevent accidental internal contamination retain the port blanking plugs in position until ready to connect to the system.Pre-installation InspectionPrior to installation check that the purifier is suitable for use on the intended system. Such factors as pressures, flow rate and seal materials should be considered.Note: Its recommended to connect this unit with the bypass of the system oil tank. Dont directly connect it online with the system. Please contact Pall or its authorized agents for any questions. Remove all protective shipping framework, covers and shipping packaging. Inspect the unit upon arrival for possible damage incurred during shipment. In the event that damage has occurred, immediately enter a claim with the carrier. If necessary Pall (Beijing) Filter Co., Ltd. or its representative may be consulted. It is recommended that all of the blanking plugs are left in place, until connection is made to the system pipework, to prevent the ingress of local contaminants. The unit has been inspected and tested to a high standard prior to leaving the factory. Ensure that no nuts, bolts or other components have come loose in transit. All components must be inspected by the customer, before putting the unit on stream, to ensure that it is sufficiently clean for use. Connection of HCP to Fluid SupplyCaution: The following drawing shows common installation errors which MUST be avoided if the unit is to operate efficiently. Please read the accompanying text thoroughly to ensure a correct installation. The following points relate to the diagrammatic representation of a typical poor purifier installation shown above. The points are referenced numerically on the diagram.1. Inlet Line Design / SizingThe purifier inlet line must be sized and designed so as to avoid excessively low pressures in the inlet line. Low pressures in the inlet line can cause problems associated with the following:- Increased likelihood of leakage. It should be noted that, where a suction exists in the inlet line, air will be drawn in through a leak, rather than fluid being lost. Expansion of air out of solution forming bubbles. Loss of inlet pump efficiency. All of these conditions will lead to a reduction in the inlet pump flow rate and, consequently, a loss of treatment efficiency.The graph