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GEA BGR ENERGY SYSTEM INDIA LIMITED

OPERATION & MAINTENANCE MANUAL



FOR

DEBRIS FILTER









GEA DOC. NO.GI 3097 200 09 054 Rev.A







KORADI TPS EXPANSION PROJECT
UNITS 8, 9 & 10 - 3 x 660 MW








PROJECT NO. GBX/3097/2011



























































OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 1




C O N T E N T S

SECTION I INTRODUCTION ................................................................................................................... 4
1.1 DEBRIS IN C.W. SYSTEM........................................................................................................................... 5
1.1.1 MECHANISM ............................................................................................................................................................... 5
1.1.2 SOURCE OF LODGED OBSTRUCTIONS ................................................................................................................ 5
1.2 GEA BGR DEBRIS FILTER ......................................................................................................................... 6
1.2.1 DESCRIPTION ............................................................................................................................................................. 6
1.2.2 SPARE PARTS .............................................................................................................................................................. 7
1.3 SOLUTION ..................................................................................................................................................... 8
SECTION II DESCRIPTION OF COMOPONENTS ............................................................................. 9
2.1 DEBRIS FILTER (C11 / C12) ...................................................................................................................... 10
2.1.1 D.P. MEASURING SYSTEM ..................................................................................................................................... 10
2.1.2 CONTROL PANEL .................................................................................................................................................... 10
SECTION III LEADING PARTICULARS .............................................................................................. 11
3.1 GENERAL INFORMATION ..................................................................................................................... 12
3.2 DEBRIS FILTER C11 ............................................................................................................................... 12
3.4 WORM PLANETARY GEAR B21 ........................................................................................................... 13
3.4 GEARED MOTOR DRIVE T21 ............................................................................................................... 13
3.5 BALL VALVES ............................................................................................................................................. 15
3.6 BUTTERFLY VALVE M31 ...................................................................................................................... 16
3.7 ACTUATOR FOR BUTTERFLY VALVE T31 ......................................................................................... 16
3.8 D.P. TRANSMITTER D01....................................................................................................................... 18
3.9 DP INDICATING SWITCH D03 ............................................................................................................ 19
3.10 D.P. INDICATOR E01, E02, E03, E04 ................................................................................................... 20
3.11 INTERCONNECTING PIPING ................................................................................................................ 21
3.12 CONTROL PANEL S01 .......................................................................................................................... 21
SECTION IV PRECONDITION ............................................................................................................... 22
4.1 STORAGE/PRESERVATION ................................................................................................................... 23
4.1.1 EQUIPMENT & ACCESSORIES .............................................................................................................................. 23
4.1.2 ELECTRICAL & ELECTRONIC ITEMS .................................................................................................................. 23
4.2 SAFETY INSTRUCTIONS......................................................................................................................... 24
4.2.1 GENERAL ................................................................................................................................................................... 24
4.2.2 ELECTRCITY .............................................................................................................................................................. 24
4.2.3 PRESSURE ................................................................................................................................................................... 25
4.2.4 TEMPERATURE ......................................................................................................................................................... 25
4.3 GENERAL INSTRUCTIONS .................................................................................................................... 26
4.3.1 OPTIMISATION OF THE WATER CIRCULATION ............................................................................................. 26
SECTION V REQUIRED TOOLS AND MATERIALS ........................................................................ 27
5.1 REQUIRED TOOLS AND TACKLES ..................................................................................................... 28
OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 2
SECTION VI INSTALLATION INSTRUCTION ................................................................................. 29
6.1 DEBRIS FILTER ........................................................................................................................................... 30
6.2 DEBRIS DISCHARGE LINE ..................................................................................................................... 30
6.3 BALL VALVES ............................................................................................................................................. 30
6.4 D.P. MEASURING SYSTEM ..................................................................................................................... 30
6.5 ISOLATION VALVES ................................................................................................................................ 31
6.6 CONTROL PANEL...................................................................................................................................... 31
6.7 CABLING ...................................................................................................................................................... 31
6.8 PRESERVATION MEASURES BEFORE COMMISSIONING .......................................................... 32
SECTION VII SUPERVISION AND FINAL ASSEMBLY .................................................................. 33
7.1 COMPONENTS ........................................................................................................................................... 34
7.1.1 DEBRIS FILTER, WORM PLANETARY GEAR AND GEARED MOTOR DRIVE .......................................................... 34
7.1.2 DEBRIS DISCHARGE VALVE WITH ACTUATOR .............................................................................................. 34
7.1.3 DEBRIS DISCHARGE PIPE ...................................................................................................................................... 35
7.2 D.P. MEASURING SYSTEM ..................................................................................................................... 35
7.2.1 D.P. TRANSMITTER ................................................................................................................................................. 35
7.2.2 D.P. INDICATOR ....................................................................................................................................................... 35
7.2.3 D.P. ISOLATION VALVES (BALL VALVES) ......................................................................................................... 36
7.3 CONTROL PANEL...................................................................................................................................... 36
7.4 TIMER SETTING ........................................................................................................................................ 36
SECTION VIII COMMISSIONING........................................................................................................ 37
8.1 GENERAL INSTRUCTION ....................................................................................................................... 38
8.2 FILLING THE SYSTEM WITH WATER ................................................................................................. 39
8.3 TRIAL OPERATION IN AUTOMATIC MODE ................................................................................... 40
8.3.1 DIFFERENTIAL PRESSURE MEASURING SYSTEM ........................................................................................... 40
8.4 TRIAL OPERATION IN AUTOMATIC MODE (SHUT DOWN) ..................................................... 41
SECTION IX OPERATIONS ..................................................................................................................... 42
9.1 SYSTEM OPERATION .............................................................................................................................. 43
9.1.1 SALIENT FEATURES ................................................................................................................................................. 43
9.1.3 MANUAL MODE ...................................................................................................................................................... 44
9.1.4 AUTOMATIC MODE ................................................................................................................................................. 44
9.1.5 SETTINGS OF TIMERS (PLC INTERNAL TIMERS) ............................................................................................ 46
9.1.7 CAUSES FOR FAIL .................................................................................................................................................... 46
SECTION X SERVICE & MAINTENANCE .......................................................................................... 48
10.1 GENERAL MAINTENANCE .................................................................................................................... 49
10.2 MAINTENANCE OF DEBRIS FILTER ................................................................................................... 49
SECTION XI LUBRICATION ................................................................................................................... 51
11.1 PLANETARY WORM GEAR BOX ........................................................................................................... 52
11.2 GEARED MOTOR DRIVE ........................................................................................................................ 53
11.3 ACTUATOR FOR DEBRIS DISCHARGE VALVE .............................................................................. 54

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 3
SECTION XII TROUBLESHOOTING .................................................................................................... 55
12.1 DEBRIS FILTER ........................................................................................................................................... 56
12.2 BLOCKED TUBES ....................................................................................................................................... 57
12.3 D.P. TRANSMITTER .................................................................................................................................. 58
SECTION XIII DOCUMENTATION ...................................................................................................... 59
13.1 BALL VALVES ............................................................................................................................................. 60
13.1.1 PRIOR TO INSTALLATION ................................................................................................................................ 61
13.1.2 INSTALLATION ................................................................................................................................................... 61
13.1.3 OPERATION AND MAINTENANCE ............................................................................................................... 62
13.1.4 DIS-ASSEMBLY ..................................................................................................................................................... 62
13.1.5 REASSEMBLY ........................................................................................................................................................ 63
13.2 ACTUATOR FOR DEBRIS DISCHARGE VALVE (SG 07.1) ............................................................. 64
13.2.1 TECHNICAL DATA ............................................................................................................................................. 65
13.2.2 ADDITIONAL INFORMATION TO THE WIRING DIAGRAM .................................................................... 68
13.2.3 STORAGE ............................................................................................................................................................... 69
13.2.4 TYPE OF DUTY / MOUNTING POSITION ...................................................................................................... 69
13.2.5 MOUNTING OF HANDWHEEL / MANUAL OPERATION ........................................................................ 70
13.2.6 MOUNTING TO THE VALVE ............................................................................................................................ 70
13.2.7 ELECTRIC CONNECTION ................................................................................................................................. 71
13.2.8 SETTING OF END STOPS FOR PART-TURN ACTUATORS ON BUTTERFLY VALVES ......................... 73
13.2.9 CHANGING THE SWING ANGLE.................................................................................................................... 73
13.2.10 OPENING THE SWITCH COMPARTMENT .................................................................................................... 75
13.2.11 SETTING THE LIMIT SWITCHING ................................................................................................................... 75
13.2.12 SETTING THE TORQUE SWITCHING ............................................................................................................. 76
13.2.13 TEST RUN .............................................................................................................................................................. 77
13.2.14 SETTING THE ELECTRONIC POSITION TRANSMITTER (RWG) .............................................................. 78
13.2.15 SETTING OF MECHANICAL POSITION INDICATOR ................................................................................ 79
13.2.16 CLOSING THE SWITCH COMPARTMENT..................................................................................................... 80
13.2.17 SETTING THE OPERATING TIME ................................................................................................................... 80
13.2.18 ACTUATOR CONTROLS AUMA MATIC ........................................................................................................ 81
13.2.19 ELECTRONIC POSITIONER (OPTION) ............................................................................................................ 83
13.2.20 MAINTENANCE .................................................................................................................................................. 91
13.2.21 LUBRICATION ...................................................................................................................................................... 91
13.2.22 SPARE PARTS ...................................................................................................................................................... 92
13.2.23 SPARE PARTS LIST CONTROLS ....................................................................................................................... 94
13.3 DP TRANSMITTER .................................................................................................................................... 96
13.3.1 INSTALLATION ................................................................................................................................................... 97
13.3.2 LOCATION ............................................................................................................................................................ 97
13.3.3 SOURCES OF ERROR ........................................................................................................................................... 98
13.3.4 MOUNTING .......................................................................................................................................................... 98
13.3.5 WIRING .................................................................................................................................................................. 99
13.3.6 CALIBRATION .................................................................................................................................................... 100
13.3.7 SETTING OF JUMPERS ...................................................................................................................................... 101
SECTION XIV CATALOGUES .............................................................................................................. 103
SECTION XV DRAWINGS ..................................................................................................................... 123


NOTE: KKS NUMBERS MENTIONED IN THE MANUAL ARE FOR
UNIT 8 ONLY. FOR UNITS 9 & 10, FIRST TWO DIGITS OF THE
KKS NUMBER ARE TO BE READ AS 09 AND 10
RESPECTIVELY.

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 4






















SECTION I

INTRODUCTION
OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 5
1.1 DEBRIS IN C.W. SYSTEM

The Problem

Debris, such as shells, sticks, stones and plastics are common cause of failure in Condenser
and Plate Heat Exchangers. Localised attack (erosion - corrosion) leading to rapid failure in
the consequence. It has been reported that this is the major cause of failures at coastal
locations.

The Solution

Improvements in the primary screening would only lead to a partial solution. It would not
solve the problem of debris from within the C.W. System itself. Similarly, chlorination can
be used to kill mussels etc. but will not prevent the shells entering into the Condenser /
Plate Heat Exchanger. Recognition of these problems and the severe consequences of debris
trapped in the Plate Heat Exchanger/Condenser tubes are meant that some form of
secondary screening, located as close as possible to the inlet line, is now regarded as
essential. GEA-BGR offers a range of Debris Filters, which fulfill these requirements.

1.1.1 Mechanism

When water flows through Plate Heat Exchangers/Condenser Tubes, a shear stress is
produced in the wall surface, which is dependent on the C.W. velocity. For each alloy there
is a critical shear stress (Corresponding to a critical C.W. velocity) above which erosion -
corrosion will occur.

The free cross-sectional area at a lodged obstruction is reduced and this leads to a
corresponding increase in the C.W. Velocity locally (to maintain volume flow). This
increase may then be sufficient for the critical shear stress to be exceeded and for erosion -
corrosion to take place. Erosion - Corrosion is particularly a rapid form of attack. The
protective oxide film is removed and attack of the plate material can therefore proceed
virtually unimpeded. Plate penetration in a few thousand hours is common.

Where an extremely large area is blocked by debris, it is possible that the C.W. velocity in
the remaining area will be sufficiently high to cause film breakdown and subsequent
erosion - corrosion.

1.1.2 Source of lodged obstructions

The troublesome debris can come from one or two possible sources:

It penetrates the primary screening by way of gaps in the primary screening, allowing
debris to get through, there is carry-over on the travelling band screens, the debris is
fibrous and simply penetrates the screens or the prescreening system is overloaded and the
pressure - release flap is opened.

It originates from within the C.W. system. This could typically be pieces of concrete or
stones from the C.W. culverts, packing material from within the cooling tower or bio-
species which have grown to maturity in the C.W. System. Mussels, barnacles etc. can
easily penetrate the primary screening in the larval state and grow rapidly under the very
favourable conditions (warmth, ready supply of nutrients and oxygen) pertaining in the
OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 6
C.W. intake system. Sooner or later, the mussels etc. get detached and the shells enter the
plate causing blockages.

1.2 GEA BGR DEBRIS FILTER

1.2.1 DESCRIPTION

Equipment for continuously removing debris, such as mussels, fish, grass, leaves, pieces of
wood, plastics from circulating water (C.W.) system.

The Standard

Strainer Wedge Wire Screen size 5 x 8mm is chosen to meet the actual site condition.

Flushing cycle activated by differential pressure and time relay for normal flushing cycle of
3 minutes [Adjustable].

Fully automatic operation with an option of manual operation, if desired.

Filter Type "V"

The Strainer is characterized by its compactness, the housing diameter being equal to the
diameter of the C.W. inlet. It can be supplied in elbow design or as short straight length.

The DEBRIS EXTRACTOR is box shaped and located inside of the Strainer Basket,
extending along the whole length of the basket wall. The gap between the extractor and
the basket wall is 30-60 mm.

In this design, the strainer basket is fixed and the Debris Extractor is rotated around it
during cleaning. The CW enters the housing and cone shaped strainer basket axially. The
debris discharge pipe guides the debris to the Outlet Pipe.

The compact design of the "V"-type STRAINER means that the ratio of the free cross-
section of the strainer to the C.W. inlet cross-section.

Requirement

The operation of GEA-BGR Cleaning System(s) in connection with GEA-BGR Debris
Filter(s) should lead to a smooth-running, trouble-free operation with the best possible
efficiency of the condenser.
OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 7
1.2.2 SPARE PARTS

S. No. Description
Part
No
Qty. /
System
Recommended
Qty./System
Shell
1 Manhole - O Ring 51109 2 1
Gear Sealing Assembly
2 Sleeve 21331 1 1
3 Rear Bearing & Flange
21332,
21365
1 each 1 each
4 Front Bearing Disc 21334 1 1
5 Worm Gear Box 21335 1 1
6 O-ring
21336,
21351
1 each 1 each
7 U-Seal 21338 2 1
8 Shaft Seal 21340 2 1
Screen Basket
9 Screen Basket Bearing 21508 1 1
10 Disc 21509 1 1
Drive Shaft
11 Drive Shaft 21701 1 1
12 Protection Muff 21702 2 1
13 Coupling 21713 1 1
14 O Ring 21724 1 1
15 Gear Motor Drive 21737 1 1
16 Double Angular Contact Bearing 21738 1 1
17 Deflector Disc 21740 1 1
18 Internal Circlip 21741 1 1
19 Oil Seal 21742 1 1
20 External Circlip 21744 1 1
Debris Outlet & Debris Outlet Support
21 Butterfly Valve (300 NB) -- 1 1
22 Actuator for Butterfly Valve (SG 10.1-16) -- 1 1
23 Debris Outlet Gasket 21811 1 1
24 Bearing Sleeve 21823 1 1
25 V-Ring 21824 1 1
26 Turn Buckle Assembly Set (Debris Outlet Support) Sets 4 Sets 2 Sets
Valves & Accessories
27 Ball Valve (DN 25) -- 4 2
28 Seat Ball Valve (DN 25) -- 4 2
29 Gland Ball Valve (DN 25) -- 4 2
30 Gasket Ball Valve (DN 25) -- 8 4
31 DP Transmitter -- 1 1
32 DP Indicating Switch -- 1 1
OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 8
1.3 SOLUTION

Supplier Provides Customer Provides
A detailed operating manual containing
sufficient information of all components
to ensure satisfactory operation and
when necessary, enable repairs to be
carried out.
Operation of the GEA-BGR DEBRIS FILTER
according to the operating instructions.
Operating instructions, i.e. an extract
from the operating manual for
operating personnel.
Maintenance and repair work as specified in
the detailed operating manual.
Final assembly check. Nomination of personnel to be trained in
operation and maintenance activities.
Commissioning of the system
Instruction to the operating personnel.
Advice on and/or carrying out
servicing and repair work.

Detailed training of the operating
personnel by means of operating
instructions.


Erection, Commissioning work and other modifications to the system(s) are to be carried out. We
can take no responsibility for breakdowns and damage caused by failure to comply with the
OPERATING INSTRUCTIONS. Repairs if any should always be carried out in co-operation with
our FIELD ENGINEERING DEPARTMENT.



For advice please contact :

GEA-BGR ENERGY SYSTEM INDIA LIMITED
443, 1st FLOOR, GUNA BUILDINGS,
ANNA SALAI, TEYNAMPET
CHENNAI - 600 018. INDIA.
TEL - 00 91 - 44 - 2433 5958
FAX - 00 91 - 44 - 2434 3374
E-Mail - fedsv@geabgrenergy.com

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 9






















SECTION II

DESCRIPTION OF COMOPONENTS
OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 10
The description of various components which form part of Debris Filter is given below :

2.1 DEBRIS FILTER (C11 / C12)

The Debris Filter is of shell type construction with flanged ends. The Debris Filter consists
of a screen basket, Extraction arm assembly with rotation motor drive and a Debris
Discharge Unit.

The basket prevents the Debris from entering the main Inlet line. The cleaning action is
activated by the rotation motor. The accumulated debris is collected in the pipe and
discharged through the discharge unit.

The discharge unit comprises of a pipeline running through the central axis of the separator
and an Actuator operated valve that drains the Debris out.


2.1.1 D.P. MEASURING SYSTEM

The D.P. Measuring System constantly monitors the Differential Pressure across the Debris
Filter. This is done to avoid any damage to the screen basket. When the Differential
Pressure exceeds a preset value, the extraction arm assembly activated by the rotation
motor drive, cleans the basket. The above system consists of :

D.P. Transmitter [D01 / (08PAF21CP181 / 08PAF21CP182)] senses the Differential
Pressure and transforms this into an electrical output.

Isolation Valves [N36, N37 / (08PAF21AA301, 08PAF21AA302 / 08PAF21AA305,
08PAF21AA306)] isolate the D.P. Transmitter (D01) from the Cooling Water in case of
Service requirements.

Isolation Valves [N38, N39 / (08PAF21AA303, 08PAF21AA304 / 08PAF21AA307,
08PAF21AA308)] isolate the D.P. Indicating Switch [D03 / (08PAF21CP251 /
08PAF21CP252)] from the Cooling Water in case of Service requirements.



2.1.2 CONTROL PANEL

The Control Panel (S02) is of PLC based, which enables Automatic and Manual Operation
of the System. The Panel is provided with a Mimic Diagram that explains the system
functioning. Necessary Audio Visual annunciation is provided in the Mimic for easy
operation and for fault tracing.





OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 11























SECTION III

LEADING PARTICULARS

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 12
S. NO. DESCRIPTION DATA / PARAMETERS

3.1 GENERAL INFORMATION

i) No. of Strainers / Filter required 6 Nos.

ii) Liquid handled Clarified water

iii) Size of Debris Filter ID-2350 NB x 14mm tk

iv) Filter type / duty Online / Continuous

v) Location Condenser Inlet

vi) Design Data
- Operating Pressure < 5 Kg/cm
2
(g)
- Design Pressure 5.0 Kg/Cm
2
(g) and Full Vacuum
- Design Temperature 60
o
C
- Flow rate through filter
- Normal 38700 cu.m/hr
- Maximum 41910 cu.m/hr

v) Type of suspended matter likely to enter the filter Typical debris encountered in closed
circuit CW system with Cooling tower
< 30mm

vi) Differential pressure at Clean condition 50 mbar

vii) Differential pressure measuring system
set pressure for initiating flushing/
backwashing for alarm / annunciation 80 mbar

3.2 DEBRIS FILTER C11
(08PAF21AT001 / 08PAF21AT002)

i) Make GEA BGR India

ii) Quantity 6 Nos.

iii) Design Data
- Design code ASME Sec.VIII Div.I 2010
- Design temperature 60
o
C
- Operating pressure < 5.0 Kg/Cm2(g)
- Design pressure 5.0 Kg/Cm
2
(g) and Full Vacuum
- Test pressure 7.5 Kg/Cm
2
(g)
- Normal water flow 38,700 Cu.M/Hr.
- Maximum water flow 41,910 Cu.M/Hr.
- Installation position Vertical
- Fluid handled Clarified Water
- Empty weight 7,500 Kg.
- Operating weight 23,360 Kg.
OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 13

iv) Dimension
- Shell ID x Thk 2350mm x 14mm
- Shell length (face to face) 2600 mm
- Manhole Size 500 NB

v) Material of construction
- Shell Carbon Steel IS 2062 Gr. B
(Epoxy Coated)
- Main flange Carbon Steel IS 2062 Gr. B / A105 /
A148 Gr. 80-50W
(Epoxy Coated)
- Internals SS316


3.4 WORM PLANETARY GEAR B21
(08PAF21AT001-M01 / 08PAF21AT002-M01)

i) Make Bonfiglioli

ii) Model 3 / VF 05L3 227 HC HS AF

iii) Quantity 6 Nos.

iv) Design temperature 60
o
C

v) Total reduction ratio 227 : 1

vi) Input speed 195 rpm

vii) Input torque 16 Nm

viii) Output speed 0.86 rpm

ix) Output torque 2542 Nm


3.4 GEARED MOTOR DRIVE T21
(08PAF21AT001-M02 / 08PAF21AT002-M02)

i) General
- Manufacturer & Country of Origin Bonfiglioli , Italy
- Model VF49 F1 7 P71 B14 B6 + BN71 B4 B14
- Equipment driven by motor Gear
- motor type Squirrel cage induction motor, TEFC

ii) Quantity 6 Nos.

iii) Design Ambient Temperature 50C


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 14
iv) Design & Performance Data
- Frame Size BN 71B
- Type of duty S1
- Type of Enclosure and method of cooling TEFC
- Degree of protection IP 55
- Applicable standard to which motor
generally conforms IS 325 / IEC 34-1
- Type of mounting Horizontal Foot Mounted
- Direction of rotation as viewed from De End Bi-Direction
- Motor rating 0.37 kW
- Rated voltage 415 V AC
- Permissible variation of
a) Voltage + 10%
b) Frequency + 5 %
c) Combined voltage and frequency 10% Absolute
- Minimum permissible Starting voltage 304 V AC
- Rated speed 1370 rpm
- Full load current at Rated voltage & freq. 1.04 A
- Power factor at 100% load 0.77
- Efficiency at rated volt.&freq.-100% load 67%
- Starting torque at Minimum permissible voltage 5.2 Nm
- Rated torque 2.6 Nm
- Vibration As per IS:12065 / IEC 34-14
- Noise level (dB) As per IS:12075 / IEC 34-9

v) Bearings
- Type Life lubricated radial ball bearings
- Recommended lubricant Life lubricated
- Guaranteed life in hours 40,000 Hours

vi) Constructional features
- Stator winding - insulation class Class F with temperature raise limited
to Class B.
- Temperature rise by resistance method
above the ambient of 50
o
C 70
o
C (maximum)
- Method of temperature measurement Resistance method
- Stator winding connection Delta
- Number of terminals brought out 6
- Type of terminal box for Stator leads Air insulated
- Location for main terminal box Top
- Total weight of motor 8.1 Kg.

vii) GEAR BOX DETAILS

- Model VF 49 F1 7 P71 B14 B6
- Type Planetary Gear Box
- Total Reduction ratio 7:1
- Input speed 1370 rpm
- Output speed 196 rpm
- Input torque 2.6 Nm
- Output torque 15.1 Nm
OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 15
3.5 BALL VALVES

i) Make Weir BDK

ii) a. Size DN25
b. Tag Nos. N36, N37, N38, N39
(08PAF21AA301, 08PAF21AA302, 08PAF21AA303, 08PAF21AA304, 08PAF21AA305,
08PAF21AA306, 08PAF21AA307, 08PAF21AA308)
c. Type Manually Operated Full bore
d. Quantity 24 Nos.

iv) Liquid Handled Clarified Water

v) Design temperature 60
o
C

vi) Design Pressure 5.0 Kg/cm2 (g) & Full Vacuum

vii) Face to dimension 127 mm

viii) Manufacturing Standard EN-ISO-17292 / BS - 5351 /
ANSI B16.34 / API 598

ix) Testing Standard BS-EN-12266 / BS 6755 Part-I / API 598

x) Material of construction
a) Body &Tail Piece ASTM A 351 Gr.CF8M
b) Ball ASTM A 276 Typ 316
c) Stem ASTM A 276 Typ 316
d) Seat PTFE

xi) Type of end connection Flanged

xii) Flange / Drilling Standard ANSI B16.5 Cl.150 , RF



OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 16
3.6 BUTTERFLY VALVE M31
(08PAF21AA049 / 08PAF21AA050)

i) Make Intervalve

ii) a. Size DN 300
b. Type Actuator Operated
c. Quantity 6 Nos.

iii) Liquid Handled Clarified Water

iv) Design temperature 60
o
C

v) Design Pressure 5.0 Kg/cm2 (g) & Full Vacuum

vi) Test Standard BS-EN-12266 / BS 6755 Part-I / API 598

vii) Material of construction
- Body ASTM A 216 Gr.WCB
- Disc ASTM A 351 Gr. CF8 (SS 304)
- Shaft ASTM A 479 TYP 304
- Seat EPDM

viii) Flange / Drilling Standard Wafer type for sandwich between
Flanges as per ANSI B16.5 Cl.150.


3.7 ACTUATOR FOR BUTTERFLY VALVE T31
(08PAF21AA503 / 08PAF21AA504)

i) Make Auma, Germany

ii) Quantity for 6 Systems 6 Nos.

iii) Model No. SG 10.1-16 secs. / AM 01.1

iv) Application Valve Operation

v) Type Part turn actuator

vi) Torque range 250 - 600 Nm

vii) Type of duty S2 - 15 Minutes

viii) Enclosure IP 67

ix) Design ambient temperature 50
0
C

x) Torque limit switch 2 Nos.
(1 each in open and close position)

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 17
xi) End-of travel limit switch 4 Nos.
(2 each in open and close position)

xii) No. of N.O. + N.C contacts provided for
each limit switch 2 NO + 2NC contacts

xiii) Switch Contact Rating
a) at 240 V A.C 5 Amps
b) at 220 V D.C 0.5 Amps

xiv) Nominal output 0.16 kW

xv) Rated voltage 415 V AC

xvi) Rated frequency 50 Hz

xvii) No of phases 3 Ph

xviii) Admissible voltage fluctuation 10%

xix) Admissible frequency fluctuation 5%

xx) Admissible combined voltage and
frequency fluctuation (absolute sum) 10%

xx) Nominal current 0.60 A

xxi) Motor Speed 2800 rpm

xxii) Starting current 1.7 A

xxiii) Current at maximum torque 0.9 A

xxiv) Insulation class Class "F" with temp. rise limited to
Class "B"

xxv) Power factor 0.67

xxvi) Space heater Voltage Power 24 V DC, 5 - 20 Watts



OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 18
3.8 D.P. TRANSMITTER D01
(08PAF21CP181 / 08PAF21CP182)

i) Type Remote Seal, HART Protocol
Compatible

ii) Make Emerson Process Management

iii) Model 3051CD-2-A-2-2-A-1-A-S2-B4-M5-Q4 +
1199DDB10ARFW21DAA1HJ

iv) Quantity 6 Nos.

v) Liquid Handled Clarified Water

vi) Design temperature 50
o
C

vii) Design Pressure 5.0 Kg/cm
2
(g) & Full Vacuum

viii) Power Supply 16-48 V DC + 10%

ix) Transmitter measurement Differential pressure across debris filter

x) Measuring range 0 to 200 mbar

xi) Transmitter output 4 - 20 mA DC signal

xii) No. of wire 2 Nos.

xiii) Housing material Polyurethane - covered Aluminium

xiv) Material
- Upper & Lower Housing SS 316
- Diaphragm (Remote Seal) SS 316L
- Drain / Vent SS 316

xv) Mounting Surface Mounting

xvi) Meter Digital meter, 0 to 200mbar

xvii) Process connection 1" Flange as per ANSI B16.5 Cl.150

xviii) Zero and Span Drift + 0.015 % per deg C at maximum span
and 0.11 % per deg C at minimum
span.

xix) Load limit (at 24 V DC) 500 Ohms


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 19
xx) Performance data
- Accuracy + 0.075% of URL
- Static and overpressure limits 254 Kg/cm
2

- Stability + 0.125% of URL for 5 Years
-Turn down ratio 100:1

xxi) Diagnostics Self indicating features provided

xxii) Capillary Length 3 m

xxiii) Electrical Connection Screw type terminals

xxiv) Protection Class IP67

xxv) Cable Gland / Size Provided / 1/2" NPT


3.9 DP INDICATING SWITCH D03
(08PAF21CP251 / 08PAF21CP252)

i) Make General Instruments

ii) Model IDPS-S-150-S4-S6-B-15-NT-M-18M-
0to200mbar-B

ii) Medium Clarified Water

iii) Quantity for 6 Systems 6 Nos.

iv) Type Bellows

v) Sensing Element material SS 316

vi) Casing Stainless Steel

vi) Enclosure IP 66

viii) Range 0 to 200 mbar

ix) Switch Type Snap Action

x) Set points 1 Set point at 80 mbar (Adjustable)

xi) Contact rating 5 Amps, 240 V AC, 220V DC, 0.5 AMP

xii) Repeatability + 1% Span

xiii) Accuracy +1.5% FSD

xiv) Electrical Connection Screw Type Terminals

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 20
xv) Cable glands Provided / 1/2" NPT

xvi) No. of Contacts 1 NO + 1 NC



3.10 D.P. INDICATOR E01, E02, E03, E04
(Common for Tube Cleaning System & Debris Filter)

i) Make Shinko, Japan

ii) Model JIR 301 - M

iii) Quantity 12 Nos.

iv) Type Analog to Digital

v) Power supply 230V AC / 50 Hz

vi) Measuring Range 0 to 100 mbar (TCS)
0 to 200 mbar (DF)

vii) Installation type Flush Panel mounted

viii) Measuring input 4 - 20 mA DC

ix) Panel cutout dimension 92mm x 45mm

x) Output signal
- Type Digital
- Number of control points Two (TCS), One (DF)

xi) Control set at 40 mbar / 60 mbar (TCS)
80 mbar (DF)

xii) Design ambient temperature 50
0
C



OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 21
3.11 INTERCONNECTING PIPING

i) Make GEA BGR

ii) Sizes 300 NB

iii) Design temperature 60
o
C

iv) Design pressure 5.0 Kg/cm
2
(g) & Full Vacuum

v) Test pressure 7.5 Kg/cm
2
(g)

vi) Material of Construction
- Pipe Carbon Steel, IS 3589
- Flange Carbon Steel, A105
- Fittings Carbon Steel, A234 Gr. WPB

vii) Connections
- Type Flanged
- Drilling standard ANSI B16.5 Cl.150 lbs., RF


3.12 CONTROL PANEL S01
(08PAH21GS001)
(Common for Tube Cleaning System & Debris Filter)

i) Type PLC Based

ii) Quantity 3 Nos.

iii) Make of PLC ABB

iv) Supply Voltage 2 x 240 V AC, 50 Hz (UPS)
1 x 240 V AC, 50 Hz (Non-UPS)

v) Control Voltage 24V DC

vi) Cables (Power & Control) PVC

vii) Installation Position Vertical, Floor Mounted

viii) Location Indoor

ix) Protection Class IP 54

x) Cable Entry Bottom

xi) Paint Shade Inside : Brilliant White
Outside : RAL 7032


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 22






















SECTION IV

PRECONDITION


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 23
4.1 STORAGE/PRESERVATION

4.1.1 EQUIPMENT & ACCESSORIES

The equipments, pipes and rods are to be kept on wood plank without touching the mud.

All pipes shall be preserved by a coat of preservative or paint.

Plates shall be preserved by positioning vertically with proper supports in such a way they
shall not get sagged or bent permanently.

All machined surfaces shall be preserved by rust preventive coating and covered by
Polythene Sheet. Machined surfaces shall not be kept in such a way that damages can
occur.

The equipment should be kept away from the flammable items.

Cover the finished goods with Tarpaulin/Polythene sheet to keep away from dust and
rain. Then they should be packed in wooden box and stored in a group with tag nos. for
easy identification. Cannibalization should be avoided.

4.1.2 ELECTRICAL & ELECTRONIC ITEMS

All Motors and actuators shall be away from areas where water or water droplet are likely
to fall.

Electrical and Electronic goods are to be covered with 3 types of packing like thermo coal,
air bubbled sheet and polythene sheet, as applicable.


INSTRUCTIONS DURING SHUTDOWN FOR MORE THAN 48 HOURS

Drain out the Circulating Water of Debris Filter.

Flush the Debris Filter with Fresh Water.

Ensure that the Debris Filter is clean and dry.


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 24
4.2 SAFETY INSTRUCTIONS

4.2.1 GENERAL

Purpose
To meet the accident free and also to achieve all the erection activities as per the guidance
of safety instructions.

Scope
This is applicable to staff, skilled and unskilled manpower deputed during execution of
erection & commissioning of on load condenser tube cleaning system.

Responsibilities
It is every one responsibility to follow the safety instructions during erection work in order
to meet the accident free day.

Procedure
Obtain the line clearance (Permit) from the engineer incharge before starting up the
erection activities in case of retrofit.

During erection of heavy activities, isolate the area of erection before starting up the work.

Use the proper scaffolding and ladder whenever required to work in elevated locations.

Use the safety belts to the manpower deputed to carry out the work in elevated locations.

Follow the use if helmets, safety shoes in day-to-day activities inside the plant premises.

Ensure that all the flammables and wastages are kept away from the working area.

Ensure that the welders use appropriate shielding glass during welding activity.

Ensure that the grinders use the goggles and apron during the grinding works.

Ensure that the masks are worn during painting activity.

Ensure that the load is lifted within the safe working load of the crane, rope, chain,
D-shackle etc.

The lifting angle of the rope or chain shall be within the safety limit.


4.2.2 ELECTRCITY

Check all the wire connections to prevent from looseness

Leave all electrical connection to trained and qualified electrician

Always use proper Lockout/Tagout procedures

Always check your tools before use
OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 25

All tools must be inspected & tagged by a qualified electrician

The joints of the cable ends have to be properly insulated

The power take up points of cables provided with proper socket pin arrangement.

Do not use appliance with defective parts

Always switch off the power supply after using electrical equipment.

Replace/ report any defective electrical cords or equipment.

Electrical cords must not create a tripping hazard.

Investigate and report any unusual odors coming from electrical equipment or appliances.

Turn off and unplug any electrical device before attempting to service or repair it.

Do not overload electrical circuits.


4.2.3 PRESSURE

Our equipment is designed to the Design Pressure of 4 bar (g) and is safe for the given
operating pressure condition.

4.2.4 TEMPERATURE

Our equipment can be safely operated up to the maximum temperature of 60C.

SUPPLIERS SCOPE CUSTOMERS SCOPE
Delivery of GEA-BGR component
based on the design agreed in the
contract and manufacture to an agreed
quality programme.
Adequate pre-cleaning of the cooling water
using bar screens, fine screens or similar type
of Screens.
Detailed INSTALLATION PLAN (Drg.
No.GI 3097 200 03 045) for installing the
GEA-BGR components.
Correct installation of the GEA-BGR
components
Proposals for the optimisation of the
cooling water system.

Instructions for installing the GEA-
BGR components.

Final inspection of the assembly

For guidance, the supplier provides the customer with INSTALLATION PLAN (DRG. NO.
GI 3097 200 03 045), contains detailed proposals and directives.

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 26
4.3 GENERAL INSTRUCTIONS

4.3.1 OPTIMISATION OF THE WATER CIRCULATION

Pre-Screening

The pre-screening must be sufficient, i.e., there must be no coarse debris larger than 10 mm which
can enter the Debris Filter via the cooling water system. When the pre-screening in inadequate,
partial blockage of the Debris Filter can occur and consequently result in unscheduled shutdown
of the DEBRIS FILTER for manual cleaning.


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 27























SECTION V

REQUIRED TOOLS AND MATERIALS


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 28
5.1 REQUIRED TOOLS AND TACKLES


CHAIN PULLEY BLOCK 5 TON 2 NOS.
ROPES 1 SET. FOR INTERNALS SHIFTING
CHAIN PULLEY BLOCKS 3 TON 2 NOS.
WINCH HOOK 1 NO.
WIRE ROPES & D SHACKELS 2 SES.
PNUMATIC BOLT LOOSENING / TIGHTENING 1 SET.
WITH THE REQUIRED SIZE SOCKETS
SLEDGING RING SPANNER 2 SETS.
[KNOCKING SPANNER]
SLEDGE HAMMER 2 NOS.
GAS CUTTING SET 1 SET.
WELDING MACHINE 1 SET. WITH CABLE & ACCESSORIES.
TIG WELDING SET 1 SET.
DOUBLE END & RING SPANNER 2 SETS [10MM TO 30x32]
ALLEN KEY SET [3MM TO 20MM] 1 SET.
CIRCLIP PLIER [6] [INNER & OUTER] 1 SET.
SCREW DRIVER [8 & 12] 1 SET.
FEELER GAUGE [6 Long] 1 SET
VERNIER CALIPER 1 NO.
PORTABLE HYDRAULIC JACK 2 NOS. [1 TON & 2 TON]
HAMMER 2LB / 4LB 1 NO. EACH
BRASS ROD x 10 1 NO.
CENTER PUNCH 1 NO.
SS WIRE BRUSH 2 NOS.
GQ4 & FF2 GRINDING MACHINE 1 SET EACH.
TAP SET M4 M20 WITH HANDLE 1 SET EACH
HACK SAW FRAME 1 NO.
HACK SAW FRAME WITH SPARE BLADE 1 SET.
[FOR SS BOLT CUTTING]
24V DC TRANSFORMER & HAND LAMPS 1 SET
EXHAUST FAN 1 NO.


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 29





















SECTION VI

INSTALLATION INSTRUCTION


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 30
6.1 DEBRIS FILTER

Installation is according to the P&I DIAGRAM (GI 3097 200 01 044) & Installation Plan
(GI 3097 200 03 045)

Any actuators used should only be attached after the general assembly, shortly before
Commissioning. Adjustment of the limit switch depends on momentum and path is to be
carried out according to the separate operating instructions for actuators.


6.2 DEBRIS DISCHARGE LINE

Piping arrangement and installation of debris discharge valve according to P&I DIAGRAM
(GI 3097 200 01 044) & Installation Plan (GI 3097 200 03 045).

Pipework should slope down to outlet.

Bowed and syphonic piping arrangements should be avoided

Connecting pipes should not be under stress.

Make sure that there are sufficient pipe supports.

While welding avoid excessive weld root penetration.


6.3 BALL VALVES

Position of installation according to P&I DIAGRAM (GI 3097 200 01 044) & Installation Plan
(GI 3097 200 03 045).


6.4 D.P. MEASURING SYSTEM

Assembly according to P&I DIAGRAM (GI 3097 200 01 044) & Installation Plan (GI 3097
200 03 045).

Arrangement of measuring unit is recommended in the immediate vicinity of filter or in an
easily accessible place.

Pipework to DP Transmitter should slope upwards.

Do not mix positive and negative terminals.

Note : Once the system has been assembled the Isolation Valves should be closed.


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 31
6.5 ISOLATION VALVES

Position of installation according to P&I DIAGRAM (GI 3097 200 01 044) & Installation Plan
(GI 3097 200 03 045).

Locate in dry area protected from dripping water.

Locate wherever possible, close to the system.


6.6 CONTROL PANEL

GENERAL

Arrangement as per Control Panel Wiring Diagram

Protect from direct sunlight when installed outdoors.


6.7 CABLING

The requirement of laying of power cables is to drive the motors and the requirement of
laying control cables are for signal transmission and control power extension to various
devices installed at field.

Cables shall be supplied in cable drums. Before cutting the cables detailed measurements
shall be taken in the field as per the field route convenience and as directed by the
installation engineer. Cutting the cable for different length shall be such that wastage is
minimum.

Cables are to be routed as per routing given in the cable schedule. Whenever routing is not
given in the drawing, cable shall be routed as per direction of erection engineer. The cable
shall be routed away from oil and fire hazard area.

Cable laid in cable trays shall be clamped at the interval of 1 meter by suitable clamps.

Cable tag (Cable No/ Equipment destination / Description of the cable) should be clamped
at both sides of the cables i.e. control panel end and Field end.


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 32
6.8 PRESERVATION MEASURES BEFORE COMMISSIONING

Once the installation is over as per the P&I DIAGRAM (GI 3097 200 01 044) & Installation
Plan (GI 3097 200 03 045) the following checks have to be carried out as a preventive
measure for the entire system before commissioning.

- Ensure that all the fasteners of equipments such as Debris Filter & Inter Connecting
Piping have been fully tightened.
- Make sure that the gaskets in between the flanges have been placed properly prior to
tightening of the fasteners.
- The instruments such as Pressure Gauges & DP Transmitters should be covered
suitably to avoid any water dipping on them.
- Make sure that cables of all the electrical drives such as Motors, Actuators have been
terminated properly on both field and panel end.
- There should not be any moisture ingress to be allowed in the panel and the electrical
drives as it may lead to reduction in resistance value.
- If the commissioning is not planned immediately all the drives to be properly covered
so that the equipments are protected from dust, water and other pollutions.


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 33
























SECTION VII

SUPERVISION AND FINAL ASSEMBLY



OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 34
7.1 COMPONENTS

7.1.1 Debris Filter, Worm Planetary Gear and Geared Motor Drive

Test Name Requirement Activity Result
1 Assembly Must be carried out according to
P&I Diagram (GI 3097 200 01 044)
& Installation Plan (GI 3097 200 03
045)
Check
2 Name Plate Must be complete Check
3 Geared Motor
- Wiring
Motor must be connected according
to the circuit diagram
Check
- Current setting Must be adjusted to the rated
current according to the name plate
Check Adjustment
with-in the
range
specified
- direction of rotation Must be clockwise viewed from the
flow direction
Check by
starting &
stopping
the rotation
Motor


7.1.2 Debris Discharge Valve with Actuator

Test Name Requirement Activity Result
1 Assembly Must be carried out according to
P&I Diagram (GI 3097 200 01 044)
& Installation Plan (GI 3097 200 03
045)
Check
2 Actuator
- Wiring
Both motor and control signalling
equipment must be connected
according to the circuit diagram.
Check
- Current setting Must be adjusted to the rated
current according to the name plate
of the actuator
Check Adjustment
with-in the
range
specified
- end position
indicator (Control
Cabinet)
In the position OPEN the
corresponding lamp must light up.
Check
In the position CLOSE the
corresponding lamp must light up.
Check


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 35
7.1.3 Debris Discharge Pipe

Test Name Requirement Activity Result
1 Assembly Must be carried out according to
P&I Diagram (GI 3097 200 01 044)
& Installation Plan (GI 3097 200 03
045)
Check

7.2 D.P. MEASURING SYSTEM

7.2.1 D.P. TRANSMITTER

Test Name Requirement Activity Result
1 Assembly Must be carried out according to
P&I Diagram (GI 3097 200 01 044)
& Installation Plan (GI 3097 200 03
045)
Check
2 Connection of
positive and negative
pipelines

Must be correct Check
3 Installation
Perpendicular to the instrument
Check

Avoid Zero shift
Lowest level possible in respect to
the Tube Cleaning System
4 Wiring Terminal & Loops for proper
wiring
5 Voltage & Polarity 24V at the Terminals of the
Transmitter & Indicator (loop-
wired)


7.2.2 D.P. INDICATOR

TEST DESCRIPTION REQUIREMENT ACTIVITY RESULT
1 Power Supply 220 240V DC at the Terminals
Visual
Check

2 Input 4 20 mA output from D.P.
Transmitter
3 Wiring 24V DC positive to D.P.
Transmitter positive.
D.P. Transmitter negative to D.P.
Indicator positive.
24V DC negative to D.P.
Transmitter negative.
4 Set Value 80 mbar

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 36
7.2.3 D.P. Isolation Valves (Ball Valves)

Test Name Requirement Activity Result
1 Assembly Must be carried out according to
P&I Diagram (GI 3097 200 01 044)
& Installation Plan (GI 3097 200 03
045)
Check
2 Operation

Must function without an excessive
torque.
Check


7.3 CONTROL PANEL

Test Description Requirement Activity Result
1 Assembly Must be according to Control
Panel Wiring Diagram
Check
2 Wiring (Supply lines
from field to panel
and from panel to
field)
Must be done according to the
Cable Routing and Cable Schedule
Check
3 Incoming Supply
Switch
Switch on
Illuminated Push
Button :
Lamp Test
All lamps must light up Press and
Check

4 MPCB (Motor
Protection Circuit
Breaker)
Range Setting is proper Check



7.4 TIMER SETTING

Tag
No.
Name Requirement Activity Result
Flushing Timer 3 Min. (PLC Internal Timer)

Check
System Cycle Timer 4 Hours (PLC Internal Timer)

Check
DP High Sequence
Lead Timer
30 Sec. (PLC Internal Timer)

Check
DP Fail Timer 10 Min. (PLC Internal Timer)

Check


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 37






















SECTION VIII

COMMISSIONING



OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 38
8.1 GENERAL INSTRUCTION

Before commissioning of the system the following controls of the electric installation are to
be undertaken.

o Comparison of the electrical connections in the Control Panel, to the motor(s), and if
available, the monitoring system with the circuit diagram.

o Testing of the Motor overload relays.

o Check adjustment of the time relays.

Check whether the assembly of GEA BGR components and the laying of the pipes for
Debris Discharge and Flush water have been carried out according to the documents /
drawings.

Check the direction of rotation of extraction arm by starting the geared motor drive. The
rotary arms can run when dry.

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 39
8.2 FILLING THE SYSTEM WITH WATER

Pre-requirement :

- All isolation valves are to be closed
- Debris Discharge valve closed

Refer P&I DIAGRAM for Item Tag Nos.
Item Name Operation Effect
S01 Control Panel Is energized
- main switch
Illuminated Push
Button : Lamp Test
Switch ON
press
All lamps should glow, if not change
the defective Lamps
AUTOMATIC STOP Lamp AUTOMATICSTOP : ON
AUTOMATIC START : OFF
B21, T21 Gear Motor Drive Lamp OFF : ON
ON : OFF
M31, T31

Debris Discharge
Valve
Lamp CLOSE : ON
Lamp OPEN : OFF
OPEN THE MAIN INLET
Pre requirement for further operations :
- the min. / max. quantity of cooling water does not fall below or exceed that given in the data
sheet
N36, N37,
N38, N39
D.P. Isolation Valves Open by hand D.P. Line is filled with water
THE TOTAL SYSTEM IS COMPLETELY FILLED WITH WATER

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 40
8.3 TRIAL OPERATION IN AUTOMATIC MODE

Pre-requirement :

- Isolation valves are open
- The system is ready for Automatic Mode

Refer P&I DIAGRAM for Tag / KKS Nos.
Item Name Operation Effect
S01 Control Panel
Push Button
AUTOMATIC START

Press

Lamp AUTOMATIC START : OFF
M31, T31 Debris Discharge
Valve
Opens Lamp CLOSE : OFF
Lamp OPEN : ON
B21, T21 Geared Motor Drive Starts to rotate
after the
Debris
Discharge
Valve is fully
opened
Lamp ON : ON
OFF : OFF
Flushing Timer picks up. When the timing is elapsed the closing operation is done
M31, T31

Debris Discharge
Valve
Closes Lamp OPEN : OFF
Lamp CLOSE : ON
B21, T21 Geared Motor Drive Stops Lamp ON : OFF
OFF : ON

System stays in AUTOMATIC mode.
Flushing can be introduced by PLC
timer or DP Signal

8.3.1 DIFFERENTIAL PRESSURE MEASURING SYSTEM

Comment

The fouling of the Filter is measured and displayed using the D.P. Measuring system.
When the Filter is clean, the display must show less than 80 mbar. Turbulences caused by
the operation can lead to different values being shown. In this case resetting to the relative
80 mbar positions must be undertaken. This is to be carried out according to the
"Descriptions of Components" and should only be done by our Service Department.

The sequence of operations can also be initiated in two other Auto Modes of operations

i) By the Timer, whenever its set time is elapsed.
ii) Whenever the DP across the Debris Filter goes above the set value.


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 41
8.4 TRIAL OPERATION IN AUTOMATIC MODE (SHUT DOWN)

Pre-requirement :

- System is in AUTOMATIC ON position as specified under 8.2 (Before the flushing
timer is elapsed)

Refer P&I DIAGRAM for Tag Nos.
Item Name Operation Effect
S01 Control Panel
Push Button
AUTOMATIC
STOP

Press
Lamp AUTOMATIC START : OFF
AUTOMATIC STOP : ON
M31, T31

Debris Discharge
Valve
Closes Lamp OPEN : OFF
Lamp CLOSE : ON
B21, T21 Geared Motor
Drive
Stops Lamp OFF : ON
ON : OFF
SYSTEM IS OUT OF SERVICE
CAUTION :

System must be in operation when main cooling water is running.

For complete SHUT-DOWN close DP isolation valves N36, N37, N38, N39

Turn MAIN SWITCH at Control Panel to position OFF.

When the system is to be kept OUT OF SERVICE for a longer time the Cooling Water must
be drained off from all the equipments.




OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 42






















SECTION IX

OPERATIONS

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 43
9.1 SYSTEM OPERATION

This write up covers the sequence of operations for Debris Filter in the AUTO mode and
MANUAL mode.

9.1.1 SALIENT FEATURES

i) The Control logic is set out to cater to the operational requirements of Debris Filter under
all conditions.

ii) Debris Filter functions in two modes.

a. LOCAL AUTO MODE - Operation in LOCAL AUTO can be selected by turning the
function selector switch in the Control Panel to LOCAL AUTO.
b. MANUAL MODE - Operation in MANUAL can be selected by turning the function
selector switch in the Control panel to MANUAL.

iii) Electric actuators are provided with end travel limit and collective fault switches.

iv) Indication and audible alarm, in the form of feedback signal, has been provided in the
panel for all failure signals.

v) 4-20mA Analog Signal from the Differential Pressure Transmitter (08PAF21CP181) is used
for DP measurement across Debris Filter. And DP Indicator with switch (08PAF21CP251) is
used as backup for the DP set point.

vi) Ready to start lamp has to illuminate only when all the electrical drives are in HEALTHY
condition. The HEALTHY condition is defined as a condition when all FAIL, DP
high and DP fail indications are in OFF condition. These conditions and the
availability of the START PERMISSIVE (Any one of the main CW pumps on feedback
AND 'Supply and return line MOV (08PAB21AA003 and 08PAB21AA006 or
08PAB21AA004 and 08PAB21AA005) open feedback signals from the DCS and DP
minimum set signal from DPT across the Debris Filter) signal will lead to switch ON the
READY TO START indication. In case the START PERMIT signal is cut off during
normal operation of DF, the system is brought to stop condition as detailed under
NORMAL AUTOMATIC STOP.

vii) Summary failure indication is for failures in the power circuitry and individual drives.
Sequence failure indication is for run time failure of actuators during the operation of the
system.

viii) When the system is in AUTOMATIC Mode it will not respond for any manual pressing
of individual Illuminated Push Button.

ix) The illuminated pushbutton will blink when the electric actuator operated valves move
from one status to another status. The corresponding illuminated pushbutton will glow
steadily when end travel limit switch is reached.

x) If Power fails, in any stage of the logic sequence - all equipment will come to initial position
when power is restored, and manual interference is required for restarting.

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 44
9.1.3 MANUAL MODE

The system can be operated by activating individual drives once the Selector Switch is
turned to MANUAL. This mode is used predominantly for testing & commissioning
purposes.

Note : Please note down there will be no interlocking of equipments in manual mode
and any equipment can be operated at any stage.

9.1.4 AUTOMATIC MODE

INITIAL CONDITIONS

i) DEBRIS DISCHARGE VALVE ACTUATOR (08PAF21AA502) should be in CLOSE
position.
ii) GEARED MOTOR DRIVE (08PAF21AT001-M02) should be in OFF position
iii) All FAIL indication in Control panel should be in OFF position.
iv) Any one of the main CW pumps (2x50%) on feedback AND 'Supply and return line MOV
(08PAB21AA003 and 08PAB21AA006 or 08PAB21AA004 and 08PAB21AA005) open
feedback signals' and DP minimum set signal (START PERMISSIVE) signal should be
available.
v) Manual valves 08PAF21AA301, 08PAF21AA302, 08PAF21AA303 & 08PAF21AA304 should
be in open position.
vi) If the INITIAL CONDITIONS are satisfied, the operation of the system can be executed in
the following sequence. In case the initial conditions are not met, then the relevant
equipment has to be brought manually to the required state to meet the INITIAL
CONDITIONS (provided there are no FAIL indications)
vii) Select AUTO/MANUAL function to LOCAL AUTO position.
viii) SYSTEM AUTOMATIC STOP indication will be illuminated
ix) READY TO START Indication should be illuminated
x) Press the "SYSTEM AUTOMATIC START" illuminated pushbutton in MIMIC to start the
system in "AUTO" mode.

AUTO START SEQUENCE

i) Press the AUTO START illuminated pushbutton the following operations take place in
sequence. AUTO START illuminated pushbutton will start to blink and the illuminated
push button AUTO STOP will be switched OFF.
ii) DEBRIS DISCHARGE VALVE ACTUATOR (08PAF21AA502) will open.
iii) GEARED MOTOR DRIVE (08PAF21AT001-M02) will be switched ON.
iv) Now the system is in operation position and FLUSHING TIMER will pick up for 3
minutes (PLC internal timer)
v) Once the flushing time of 3 minutes is elapsed, Flushing Operation will be stopped.
vi) GEARED MOTOR DRIVE (08PAF21AT001-M02) will be switched OFF.
vii) DEBRIS DISCHARGE VALVE ACTUATOR (08PAF21AA502) will be CLOSED.
viii) System cycle timer will be energized.
ix) The system will restart for next cleaning as per the above sequence after the preset system
cycle timer elapses.


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 45
DEBRIS FILTER OPERATION BY D.P. MODE

When the differential pressure across the Filter exceeds 80 mBar (Adjustable depending on the site
condition), the DP HIGH SEQUENCE LEAD TIMER (30 seconds) will be energized to ensure that
the increase in differential pressure is not due to any momentary surge.

After a time delay of 30 seconds, if the DP is still higher than 80 mBar, the flushing sequence will
commence. System Cycle timer will be de-energized and the flushing sequence will be started as
indicated below. During the flushing time if the DP is reduced the sequence will not be disturbed
up to the end of the sequence of operation.

i) D.P. HIGH Indication will be illuminated.
ii) DEBRIS DISCHARGE VALVE ACTUATOR (08PAF21AA502) will be opened.
iii) GEARED MOTOR DRIVE (08PAF21AT001-M02) will be switched ON.
iv) Now the system is in operation condition and FLUSHING TIMER will pick up for 3
minutes (PLC- internal timer).
v) Once the flushing time of 3 minutes is elapsed, check the differential pressure across the
Filter.
vi) If DP is above 80 mBar, then DP FAIL TIMER will pick up for 10 minutes (PLC internal
timer) and the Flushing operation will be continued.
vii) Once the DP fail time of 10 minutes is elapsed, Check the differential pressure across the
Filter is still above 80 mBar.
viii) If DP is still higher than 80 mBar, the flushing operation continues, the DP FAIL indication
will blink, HOOTER will be actuated.
Press the FAULT ACCEPT Push Button to switch OFF hooter and DP FAILURE
indication will be illuminated steadily.
Now the manual intervention is required to ascertain the cause and rectify manually. Once
DP is reduced to less than 80 mBar press the FAULT RESET Push Button DP FAILURE
indication will be switched OFF.
ix) If the DP is lesser than 80 mBar, system cycle timer will be started. And GEARED MOTOR
DRIVE (08PAF21AT001-M02) is switched OFF. DEBRIS DISCHARGE VALVE ACTUATOR
(08PAF21AA502) will be CLOSED.

DEBRIS FILTER OPERATION IN TIMER MODE

When the system is in AUTO mode and immediately after the completion of flushing cycle, the
system cycle time is energized for 4 hours (System Cycle Timer PLC internal timer). Once the
SYSTEM CYCLE TIMER is elapsed, the debris flushing sequence starts with the following
sequence of operations:

i) DEBRIS DISCHARGE VALVE ACTUATOR (08PAF21AA502) will be opened.
ii) GEARED MOTOR DRIVE (08PAF21AT001-M02) will be switched ON.
iii) Now the system is in operation position and FLUSHING TIMER will pick up for 3 minutes
(PLC- internal timer).
iv) Once the flushing time of 3 minutes is elapsed, Flushing Operation will be stopped.
v) GEARED MOTOR DRIVE (08PAF21AT001-M02) is switched OFF.
vi) DEBRIS DISCHARGE VALVE ACTUATOR (08PAF21AA502) will be CLOSED.
vii) System cycle timer will be started for 4 hours.



OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 46
AUTOMATIC STOP SEQUENCE

This will take place only if the system is in AUTO MODE and the system in flushing operation.
This is initiated when the AUTO STOP illuminated Push Button is pressed or Flushing timer
elapses or START PERMISSIVE feedback cut off or any fail comes, the following sequence of
operation will take place.

i) GEARED MOTOR DRIVE (08PAF21AT001-M02) is switched OFF.
ii) DEBRIS DISCHARGE VALVE ACTUATOR (08PAF21AA502) will be CLOSED.
iii) Auto start indication will be switched off and Auto Stop indication will be illuminated.


9.1.5 SETTINGS OF TIMERS (PLC Internal Timers)

i) Flushing Timer : 3 Minutes (PLC Internal Timer)
ii) System cycle Timer : 4 Hours (PLC Internal Timer)
iii) DP high Sequence lead timer : 30 Sec. (PLC Internal Timer)
iv) DP fail timer : 10 Minutes (PLC Internal Timer)


9.1.7 CAUSES FOR FAIL

a. BY MPCB FAILURE

If Motors/Valves are overloaded, the corresponding MPCB will trip and FAIL Indication will
come in Control panel MIMIC. Press FAULT ACCEPT Push Button so that lamp will glow
steadily.

After the equipment is checked for the healthiness, reset the MPCB. Press FAULT RESET Push
Button, so that FAIL Indication goes OFF.

b. BY COLLECTIVE FAULT SWITCH

If collective fault switch is engaged in either position of the Actuator, corresponding Actuator
FAIL Indication will come in Control panel MIMIC and the Power Contactor will de-energize.
Press FAULT ACCEPT Push Button, Indication will glow steadily.

After actuator comes to free movement, press FAULT RESET Push Button FAIL indication goes
OFF.

c. RUN TIME ERROR

During running period, if time taken by the Actuator is over headed, respective Power Contactor
will be de-energized by PLC Internal Timer called runtime error timer and corresponding FAIL
Indication will blink.
ACTUAL SETTING
RUNNING PERIOD FOR FAIL
1. Debris Discharge valve Actuator 16 Sec. 20 Sec.

Press FAULT ACCEPT Push Button, FAIL Indication will glow steadily and after the end travel
limit received, Press FAULT RESET Push Button, FAIL Indication goes OFF.
OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER

KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 47

d. OPERATION DURING FAIL OF ANY ONE OF THE EQUIPMENT

If individual equipment fails to operate during the operation of the sequence logic all the
equipments except the failed one will go to initial position and operator must restart the system
after resolving the problem of failed equipment.

e. SUMMARY FAILURE INDICATION

During operation of the equipment, if problem in the Power Circuit i.e. problem in Over Load
Relay and Main Circuit Breaker, supply to the particular equipment will cut off. The
corresponding FAIL Indication will glow along with the SUMMARY FAILURE Indication.

f. SEQUENCE FAILURE INDICATION

During operation of the equipment, if problem in the Control Circuit i.e. runtime error, supply to
the particular equipment will cut off. The corresponding FAIL Indication will glow along with the
SEQUENCE FAILURE indication.

g. RED, YELLOW, BLUE LAMP INDICATION

If the Main incoming source available the RED, YELLOW and BLUE incoming indications lamps
will glow.

h. LAMP TEST PUSH BUTTON

If the lamp test is Push Button is pressed all lamps in the control panel will glow to check their
healthiness.

i. FAULT ACCEPT AND FAULT RESET PUSH BUTTON

The SEQUENCE / SUMMARY FAIL Indication will blink along with the equipment FAIL
Indication for fault condition, Alarm will be switched ON.

Press FAULT ACCEPT Push Button, SEQUENCE / SUMMARY FAIL and corresponding
equipment FAIL Indication will glow steadily and Alarm will be switched OFF.

After rectification of the fault, press FAULT RESET Push Button, SEQUENCE / SUMMARY FAIL
Indication and corresponding equipment FAIL Indication goes OFF.
OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 48























SECTION X

SERVICE & MAINTENANCE

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 49
10.1 GENERAL MAINTENANCE

Activity Frequency
Check the tightness of all fixing bolts of filter internals Yearly
Check alignment of gear sealing, rotating arms and debris outlet pipe Yearly
Check condition of sacrificial anodes and if found corroded excessively
arrange for replacement (if provided)
Yearly
Lubricate gear box Yearly
Check condition of mechanical seal of water pumps and replace if
required
Half Yearly & Yearly
Check and replace all rubber items and seals inside the filter Yearly
Grease Drive shaft coupling Yearly
Check condition of pump rubber coupling and replace if found
cracked
Quarterly, Half Yearly
and Yearly
Check condition of valve seats and replace if found leaking Half Yearly and Yearly
Check and replace Panel indicating lamp bulbs if found blow off Half Yearly and Yearly

10.2 MAINTENANCE OF DEBRIS FILTER

Item Name Check Maintenance
C11 Debris Filter
including flange
connection
Visually Check
outside for leakiness
from time to time
None
B21, T21 Geared Drive
with Motor
None After approx. two hundred
(200) operating Hrs. check that
the fastening bolts fastened
properly and tighten if
necessary, change grease after 3
- 5 years.
M31, T31

Debris Discharge
Valve
Visually check outside
for tightness from
time to time
None
- actuator with normal use of actuator, the
grease in mechanical lock
adjustment device and the
moving parts like Valve
adaptor and the coupling are
lubricated for every 3 years.
When subjected to heavier
services (duty) the intervals
between changes should be
correspondingly shorter.
OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 50
Item Name Check Maintenance
N36, N37,
N38, N39
DP Isolation
Valves
Visually check outside
for leak tightness from
time to time
None
D01

D.P. Measuring
System
Visually check outside
for leak tightness from
time to time
None
S01
Control Panel
- button : Lamp
Test
Press from time to
time
all lamps must light up, replace
those which do not
Operations are automatically
monitored and
displayed.
None
- Faults are automatically
monitored and
displayed.
None
- Current Setting Check from time to
time that it functions




OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 51






















SECTION XI

LUBRICATION

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 52
11.1 PLANETARY WORM GEAR BOX

MAKE BONFIGLIOLI, ITALY
TYPE 3 / VF 05 L3 227 HC HS AF
TYPE OF LUBRICATION SYNTHETIC OIL
LUBRICATION MAKE SHELL / MOBIL
GRADE TIVELA S 220 / SHC XMP 220
TEMPERATURE -20C TO +60C
INITIAL CHARGE QUANTITY Factory Filled
REFILLING PERIOD
Initial oil change after 150 200 hours.
Subsequent oil change after every 2000 - 3000
hours operation. Alternatively change oil once
a year.
REFILLING QUANTITY
Planetary Gear - 2.10 LITRES
Worm Gear - 0.43 (Life Lubricated)


SYNTHETIC & MINERAL LUBRICANTS SHOULD NOT BE MIXED

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 53

11.2 GEARED MOTOR DRIVE

MAKE BONFIGLIOLI, ITALY
TYPE VF 49 F1 7 P71 B14 B6 + BN71 B4 B14
TYPE OF LUBRICATION SYNTHETIC OIL
LUBRICATION MAKE SHELL / MOBIL
GRADE TIVELA S 320 / GLYGOYLE 320
TEMPERATURE -20C TO +60C
INITIAL CHARGE QUANTITY 0.12 Lit (Factory Filled - Life Lubricated)
REFILLING PERIOD SELDOM REQUIRED
REFILLING QUANTITY SELDOM REQUIRED


SYNTHETIC & MINERAL LUBRICANTS SHOULD NOT BE MIXED
OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 54
11.3 ACTUATOR FOR DEBRIS DISCHARGE VALVE


MAKE AUMA, GERMANY
TYPE SG 07.1-16 secs
TYPE OF LUBRICATION GREASE
LUBRICATION MAKE SHELL / MOBIL / IOCL
GRADE
ALVANIA EP(LF) 00/ MOBILPLEX EP0/
Servogem EP0
TEMPERATURE -25 Deg.C TO +80 Deg.C
INITIAL CHARGE QUANTITY FACTORY FILLED
REFILLING PERIOD SELDOM REQUIRED
REFILLING QUANTITY SELDOM REQUIRED


USE ONLY SUITABLE GREASE ! DO NOT MIX DIFFERENT GREASES !

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 55






















SECTION XII

TROUBLESHOOTING


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 56
12.1 DEBRIS FILTER


Item Name Operation Effect
T21 Geared drive for rotary
system
Control Panel
- ROTATION MOTOR
- overload relay



Press
Not working

Hooter alarms
lamp FAIL : ON
has sprung out
Push Button : FAULT
ACCEPT
Press ALARM OFF
Press ALARM OFF
Rectify Fault
Push Button : FAULT
RESET
Press LAMP FAIL : OFF
LAMP SUMMARY FAIL : OFF
FAULTFINDING :
Item Fault Cause Repair
T21 Motor Overload (trips
overload relay)
motor overload
relay is set too low
Adjust to rated current
Motor is blocked Checked the gear drive
Move freely : correct


Item Name Operation Effect
T31 Actuator for Debris Outlet
Valve
Not working
Control Cabinet
- Debris Outlet Valve
Hooter alarms
Lamp Fail : ON
- Overload Relay Has sprung out
Push Button : FAULT
ACCEPT
Press ALARM OFF
Rectify fault
Push Button : FAULT
RESET
Press LAMP FAIL : OFF

LAMP SUMMARY FAIL : OFF
FAULTFINDING :
Item Fault Cause Repair
T31 Motor Overload motor overload
relay is set too low
Adjust to rated current
Motor is blocked Checked the
- actuator
Move freely : correct possible
faults as per special operating
instructions


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 57
Item Name Operation Effect
S01 Control Panel Hooter alarms
D.P. Debris Filter Lamp
DP FAIL HIGH : ON
Push Button : FAULT
ACCEPT
Press AUDIO ALARM : OFF
Push Button : RESET
DP FAIL
Press Lamp
DP FAIL HIGH : ON
Push Button : FAULT
RESET
Press LAMP FAIL : OFF

LAMP SUMMARY FAIL : OFF
FAULT FINDING :
Item Fault Cause Repair
E02 /
E04
Filter overload Limit value is set
too low
Adjust to related value
C11 Filter basket of debris filter
has not been cleaned in
spite of flushing
Too much debris
enters the filter or
coarse debris has
caused clogging in
debris discharge
line
Let filter flush several times
under supervising delta-p
display

12.2 BLOCKED TUBES

Item Name Operation Effect
D.P. Measuring System
Impulse lines (Both
Positive & Negative)
is Blocked

is Blocked
Transducer and Measuring lines are Flushed and their operation again checked
If the failure indicator again lights up carry out
FAULT FINDING :
Item Fault Cause Repair
Negative or Positive lines
Blocked
Fouling Manual Cleaning of Blocked
pipes
Isolating Valve is
closed
Open


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 58
12.3 D.P. TRANSMITTER

FAILURE REMEDY
Transmitter milliamp reading is
zero
Verify power is applied to signal terminals
Check power wires for reversed polarity
Verify terminal voltage is 10.5 to 42.4 V dc
Check for open diode across test terminal
Transmitter Not Communicating
with HART Communicator
Verify the output is between 4 and 20 mA or saturation
levels
Verify clean DC Power to transmitter (Max AC noise
0.2 volts peak to peak)
Check loop resistance, 250 minimum (PS voltage -
transmitter voltage/loop current)
Check if unit is addressed properly
Transmitter milliamp reading is low
or high
Verify applied pressure
Verify 4 and 20 mA range points
Verify output is not in alarm condition
Verify if 4 20 mA output trim is required
Transmitter will not respond to
changes in applied pressure
Check test equipment
Check impulse piping or manifold for blockage
Verify applied pressure is between the 4 and 20 mA set
points
Verify output is not in alarm condition
Verify transmitter is not in Loop Test mode
Digital Pressure Variable reading is
low or high
Check test equipment (verify accuracy)
Check impulse piping for blockage or low fill in wet leg
Verify transmitter is calibrated properly
Verify pressure calculations for application
Digital Pressure Variable reading is
erratic
Check application for faulty equipment in pressure line
Verify transmitter is not reacting directly to equipment
turning on/off
Verify damping is set properly for application
Milliamp reading is erratic
Verify power source to transmitter has adequate
voltage and current
Check for external electrical interference
Verify transmitter is properly grounded
Verify shield for twisted pair is only grounded at one
end

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 59





















SECTION XIII

DOCUMENTATION




OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 60





















13.1 BALL VALVES

This write up contains instructions for installation, operation and maintenance of Ball Valves.


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 61
13.1.1 PRIOR TO INSTALLATION

a) The valve and its accessories are to be checked for any damage during transportation.

b) Any wrapping and protection applied should be left in place until the valve is installed.

c) If the valves are left exposed they should be protected against entry of foreign material in
the valve parts.

d) If the valves are stored for a long time, then before installing all valves should be cleaned
with lubricants. It is advised to store the valve in full open position.

e) The pipe should be flushed clean, before mounting the valve. Impurities such as sand and
parts of welding electrodes could damage the ball surface and the seats.

f) Valves stored for long time should be hydraulic tested before installation.

g) If drain tapping or by passing is to be done, body should be drilled on the bosses provided.

13.1.2 INSTALLATION

a) The flange gaskets & fasteners must be suitable for the operating conditions.

b) The Standard Valves can be mounted in any convenient position, preferably with access to
packing gland nuts, actuators etc. The mounting of the valve with the stem downwards
must be avoided because in case of possible leakage in the packing the flowing fluid would
run over the actuator. Mounting of valve with the stem horizontal is normally preferred.

c) The pipe misalignment should not be corrected by means of flange bolts.

d) Valves should not carry the weight of pipeline to avoid distortion and jamming.

e) Valve Supporting :

It is normal to have valve supported simply by its connections and proper supporting of
the pipe line. This minimizes strain on the valve caused by stress in the pipeline. The valve
can be supported by its body with pipe clamps and supports. The supporting structure
should not be fastened to flange bolts or actuators.

f) The gland packing should be tightened uniformly before installing and after the trial
operation of the valve.

g) Proper gasket should be inserted between the mating flanges. The flange bolt holes should
be aligned and held in place.

h) The nuts on back side of the valve flange should be held first and then the bolts should be
inserted.

i) All the bolts should be finger tightened first.


OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 62

j) Torque wrench must be used to tighten the bolts.

k) The stem packing may leak after a long storing time. The packing must be tightened
uniformly before installing the valve.

l) The pipe line must be flushed carefully once more when the valve are mounted to remove
all the possible impurities. Before flushing the valve should be kept open fully.

m) The packing should be re-tightened if necessary until all leakage has stopped.

13.1.3 OPERATION AND MAINTENANCE

a) Valves should be opened and closed slowly to avoid hammering effect on the valve and
pipeline.

b) Valve should be "fully opened" or "fully closed" so that wire drawing effect can be reduced.

c) It is advisable to use the valves only for on-off services. The use of valve for throttling
services should be avoided.

d) If the valve leaks, extra leverage or extra force should not be used on the stem. The valve
must be removed and inspected to locate the cause of leak.

e) After a long service life, the seats can be interchanged if required.

f) Normally the ball valve needs no regular maintenance. In case if leak occurs the stem
packing should be tightened.

g) When replacing the packing, the valve should not be under pressure. Actuator need to be
removed. After loosening the gland nut and lifting up the gland the packing can be
removed.

h) The body end cover studs and nuts should not be over tightened to avoid the body seal
leak. Instead body seal should be removed and replaced by new one.

13.1.4 DIS-ASSEMBLY

It may be necessary to disassemble the valve for maintenance because of following reasons:

o Valve leaks in close condition.
o Ball is stuck.
o Inside of valve needs cleaning.

DIS-ASSEMBLY FROM PIPE LINE

o The line should be depressurised and the system fluid must be drained. The valve
should be cycled several times to relieve any pressure inside the valves.

o The valve should be kept in open position, unfastened and placed on a level surface.

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 63
DIS-ASSEMBLING THE VALVE

o The valve must be flushed to remove the residuals in the valve.

o The valve must be supported on a platform.

o The adaptor should be removed and split nut screw is unscrewed.

o The check nut, gland and bracket must be removed if the valves are driven by actuator.

o The lever nut, lever, gland nut, gland must be removed if the valves are manually
operated.

o The body end connection should be unscrewed and the body should be separated from
the end pieces.

o The body tailpiece connection should be unscrewed and the tail piece should be
separated from the body.

o The disassembled parts must be placed on clean wood or cardboard. The ball should
not be kept on cement or metal surfaces.

o The seat rings and body seal should be taken out. Body seal may be replaced during re-
assembly.

o The valve should be kept closed and the ball must be removed.

o The stem is then pushed into the body cavity and removed through the end port. The
stem washer and stem seal can now be removed.

o All dirty parts are to be cleaned carefully. If necessary suitable solvents should be used.

o The sealing surface of the ball or the seat is to be checked for any damage. If only the
seats are damaged, the seats must be replaced. Minor scratches or flashes on the ball
surface or in the seats can be smoothened with fine grinding cloth.

o The condition of the stem seals and the stem washer should be checked.

13.1.5 REASSEMBLY

Reassembly can be done exactly in the reverse order of dis-assembly.




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13.2 ACTUATOR FOR DEBRIS DISCHARGE VALVE (SG 07.1)

This write up contains the general operation instructions of the Actuator for Ball Valve.



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13.2.1 TECHNICAL DATA

Fe a t ur e s a nd f unc t i ons
Type of duty 1)
SG: Short time duty S2 - 15 min
SGR: Intermittent duty S4 - 25 %
Motors Standard: 3-ph AC asynchronous motor, type IM B9 according to
IEC 34 (SG and SGR)
Options: 1-phase AC motor (SG only)
DC shunt motor (SG only)
Insulation class Standard: F, tropicalized
Option: H, tropicalized (3-phase AC motors only)
Motor protection Standard: Thermoswitches (NC)
(DC motors without motor protection)
Option: PTC thermistors (according to DIN 44082)
Self-locking Yes
Swing angle Standard: 80 to 110 adjustable between min. and max. value.
Options: 3040, 4055, 5580, 110160, 160 230 or 230 320
Limit switching Counter gear mechanism for end positions CLOSED and OPEN
Standard: Single switch (1 NC and 1 NO) for each end position
Options: Tandem switch (2 NC and 2 NO) for each end position,
switches galvanically isolated
Triple switch (3 NC and 3 NO) for each end position,
switches galvanically isolated
Intermediate position switch (DUO limit switching),
available for any intermediate position
Torque switching Infinitely adjustable torque switching for direction OPEN and CLOSE
Standard: Single switch (1 NC and 1 NO) for each direction
Options: Tandem switch (2 NC and 2 NO) for each direction, switches
galvanically isolated
Position feedback signal,
analogue (options)
Potentiometer or 0/4 20 mA (RWG)
For further details, see separate data sheet
Mechanical position indicator
Continuous indication, adjustable indicator disc with symbols OPEN and
CLOSED
Running indication (option) Blinker transmitter
Heater in switch compartment Standard: Resistance type heater with 5 W, 24 V DC
Options: Self-regulating PTC heater, 5 20 W
24 48 V AC/DC, 110 250 V AC/DC or 380 400 V AC
Motor heater (option) 12.5 W
Manual operation Manual drive for setting and emergency operation, handwheel does not
rotate during electrical operation.
Option: Handwheel lockable
Connection to controls AUMA plug/ socket connector with screw type connection
Splined coupling for connection to the
valve shaft
Standard: Coupling without bore
Options: Machined coupling with bore and keyway, square bore or
bore with two-flats according to EN ISO 5211
Valve attachment Dimensions according to EN ISO 5211
Voltage supply Refer to name plate of actuator controls
External supply of the electronics 24 V DC + 20 % / 15 %,
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(option) Current consumption: Basic version approx. 200 mA, with options up to
500 Ma
Switchgear Standard: Reversing contactors
2)
(mechanically and electrically
interlocked) for motor power up to 1.5 kW
Options: Thyristor unit (recommended for modulating actuators) for
motor power up to 1.5 kW, 500 V AC with internal fuses
Control Standard: Control inputs 24 V DC, OPEN - STOP - CLOSE (via opto-
isolator, with one common), current consumption: approx.
10 mA per input
Observe min. duration of impulse for modulating actuators
Option: Control inputs 220 V AC, OPEN - STOP - CLOSE (via opto-
isolator, with one common), current consumption: approx.
15 mA per input
Output signals Standard: 5 output relays with gold-plated contacts:
4 potential-free NO contacts with one common:
max. 250 V AC, 0.5 A (resistive load)
Standard configuration:
End position OPEN, end position CLOSED, selector switch
REMOTE, selector switch LOCAL
1 potential-free change-over contact, max. 250 V AC, 0.5A
(resistive load) for collective fault signal
Standard configuration:
Torque fault, phase failure, motor protection tripped

Option: Signals in connection with positioner:
End position OPEN, end position CLOSED (requires
tandem switch within actuator)
Selector switch REMOTE, selector switch LOCAL via
selector switch 2nd level
1 potential-free change-over contact, max. 250 V AC, 0.5A
(resistive load) for collective fault signal
Standard configuration:
Torque fault, phase failure, motor protection tripped
Voltage output Standard: Auxiliary voltage 24 V DC, max. 50 mA for supply of the
control inputs, galvanically isolated from internal voltage
supply
Option: Auxiliary voltage 115 V AC, max. 30 mA for supply of the
control inputs,
3)
galvanically isolated from internal voltage
supply
Local controls Standard: Selector switch LOCAL - OFF - REMOTE (lockable in all
three positions)
Push buttons OPEN - STOP - CLOSE


3 indication lights:
End position CLOSED (yellow), collective fault signal (red),
end position OPEN (green)
Option: Protection cover, lockable
Functions Standard: Switch-off mode adjustable
Limit or torque seating for end position OPEN and end
position CLOSED
Overload protection against excessive torques over the
whole travel
Excessive torque (torque fault) can be excluded
by collective fault signal
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Phase failure monitoring with automatic phase correction
Push-to-run operation or self-retaining in REMOTE
Push-to-run operation or self-retaining in LOCAL
Blinker transmitter signal can be switched on or off by
actuator (option)
Options: Positioner
4)

Nominal position value via analogue input E1 = 0/4 20 mA
Adjustable behaviour on loss of signal
Adjustable sensitivity (dead band) and pause time
Split Range operation
Motor protection evaluation Standard: Monitoring of the motor temperature in combination with
thermoswitches in the actuator motor
Options:
Additional thermal overload relay in the controls
PTC tripping device in combination with PTC thermistors in
the actuator motor
Electrical connection Standard: AUMA plug/ socket connector with screw type connection
Threads for cable glands Standard:
Options:
Metric threads
Pg-threads, NPT-threads, G-threads
Wiring diagram Wiring diagram according to commission number included in delivery
Further options for version with RWG in the actuator
Position feedback
(Option)
Analogue output E2 = 0/4 20 mA (load max. 500 )
Service conditions
Enclosure protection according to
EN 60 529
5)

Standard: IP 67
Options: IP 68
IP 67-DS (Double Sealed)
IP 68-DS (Double Sealed)
(Double Sealed: electrical connection compartment additionally sealed
against interior)
Corrosion protection Standard: KN Suitable for installation in industrial units, in water or
power plants with a low pollutant concentration

Options: KS Suitable for installation in occasionally or
permanently aggressive atmosphere with a moderate
pollutant concentration (e.g. in wastewater treatment
plants, chemical industry)
KX Suitable for installation in extremely aggressive
atmospherewith high humidity and high pollutant
concentration
KX-G same as KX, however aluminium-free version (outer
parts)
Finish coating Standard: Two-component iron-mica combination
Standard colour Standard: Grey (DB 702, similar to RAL 9007)
Option: Other colours are possible on request
Ambient temperature Standard SG: 25 C to + 70 C
Standard SGR: 25 C to + 60 C (with 3-phase AC motor)
Options: 40 C to + 60 C, low temperature incl. heating system
50 C to + 60 C, extreme low temperature incl. heating
system (SG with 3-phase AC current only)
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Lifetime SG 05.1/ SG 07.1: 20,000 operating cycles (OPEN - CLOSE - OPEN) for 90
SG 10.1: 15,000 operating cycles (OPEN - CLOSE - OPEN) for 90
SG 12.1: 10,000 operating cycles (OPEN - CLOSE - OPEN) for 90
SGR 05.1 12.1
6)
: min. 2.5 million operations (control steps)
Accessories
Wall bracket
(7)
AUMA MATIC mounted separately from the actuator, including plug/
socket connector.
Connecting cables on request.
Recommended for high ambient temperatures, difficult access, or in case of
heavy vibrations during service.
Other information
EU Directives Electromagnetic Compatibility (EMC): (89/336/EEC)
Low Voltage Directive: (73/23/EEC)
Machinery Directive: (98/37/EC)
Reference documents Product description

Electric part-turn actuators SG


Product description,

Actuator controls AUMA MATIC


Dimension sheets SG/ SGR

with integral controls AUMA MATIC


Technical data SG/ SGR
Technical data AM 01.1
Electrical data SG/ SGR
1) Based on 20 C ambient temperature and at an average load with running torque according to Technical data SG or SGR
2) The lifetime guaranteed by the manufacturer amounts to min. 2 million cycles. If a higher number of switching cycles is to be
expected, thyristor units with virtually unlimited lifetime should be used
3) Not possible in combination with PTC tripping device
4) Requires position transmitter in actuator
5) For 3-phase asynchronous motors in enclosure protection IP 68, higher corrosion protection KS or KX is strongly recommended.
Additionally, for enclosure protection IP 68, we recommend to use the double sealed terminal compartment DS. For special
motors, the enclosure protection according to the name plate applies
6) The lifetime depends on the load and the number of starts. A high starting frequency will rarely improve the modulating
accuracy. To reach the longest possible maintenance and fault-free operation time, the number of starts per hour chosen should
be as low as permissible for the process
7) Cable length between actuator and AUMA MATIC max. 100 m. Not suitable for version with potentiometer in the actuator.
Instead of the potentiometer, an RWG has to be used in the actuator

13.2.2 ADDITIONAL INFORMATION TO THE WIRING DIAGRAM

Information A A running indication is possible if blinker transmitter (S5) is installed
(opening and closing of contacts).
Direction CLOSE: Connections XK 6 - XK 7
Direction OPEN: Connections XK 6 - XK 8
Contacts remain closed in end position.
When connected to an external PLC, the blinking signal can be switched off
via the DIP-switches (table 6)

Information B The type of seating in the end positions is determined by the valve
manufacturer. The setting is done at the programming switches S1-2 and
S3-2. The tripping of a torque switch in an intermediate position switches off
the actuator and causes a fault signal.
The limit switches serve for signalisation when switching off by torque
seating. They need to be set so that the appropriate switch is tripped shortly
before reaching the end position. If the torque switch trips before the limit
switch, the actuator is switched off and a fault signal is generated. For
further programming possibilities, e.g. self-retaining in operation mode
REMOTE, see table 6.
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Information D The following faults are registered and can be transmitted to the control
room as a potential-free collective fault signal:
Power failure
Phase failure
Motor protection tripped
Torque switch tripped in mid-travel.
This signal can be switched off on the logic board, see table 6.

Information E Input signals according to DIN 19 240.
The nominal operation current of inputs XK 2, XK 3, and XK 4 amounts to 10
15 mA. If the internal voltage 24 V DC is used for remote control, it must
only be connected via potential-free contacts.


Information F In case of wrong phase sequence, the running direction is automatically
adjusted. In case of a phase failure, the actuator stops. The fault is indicated at
LED V14 on the interface board. For collective fault signal, see information
D.

Information G Potential-free contacts are available for signals. The internal control voltage
(XK 11 / + 24 V and XK 5 / 24V) must not be used for external lamps, relays
etc.

13.2.3 STORAGE

In order to avoid damages due to unappropriate storage, following points should be observed :

Store in well ventilated, dry rooms
Protect against humidity from the ground by storage on wooden frame, in shelf etc.
Cover actuator with foil for protection against dust, dirt etc.
Protect machined surfaces at mounting flange (5.0) coupling (14) and coupling housing by
applying an appropriate corrosion protection, e.g. non-acid grease.

13.2.4 TYPE OF DUTY / MOUNTING POSITION

AUMA part-turn actuators in standard-version are suitable for operation at ambient temperatures
from -25C upto +80C. They are designed for short-time duty S2-15 min. (according to VDE 0530).

AUMA part-turn actuators can be mounted and operated in any position.

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13.2.5 MOUNTING OF HANDWHEEL / MANUAL OPERATION


MOUNTING OF HANDWHEEL

Apply grease to handwheel shaft.
Place handwheel (40) on handwheel shaft.
Mount compression spring with washer and cheese head screw (40.043).
Check whether handwheel can be easily pulled out on the handwheel shaft and is pushed
back by spring action after releasing.
Place cap (40.043) into handwheel hub.

MANUAL OPERATION

Part turn actuator has a handwheel lock and for releasing the lock pull the handwheel out.
Rotation must start only after releasing the handwheel lock.

13.2.6 MOUNTING TO THE VALVE

For butterfly valves, the recommended mounting position is end position CLOSED (Prior
to mounting, bring the part-turn actuator to the mechanical end stop CLOSED by turning
the handwheel clockwise.).
For ball valves, the recommended mounting position is end position OPEN (Prior to
mounting, bring the part-turn actuator to the mechanical end stop OPEN by turning the
handwheel counterclockwise.).
Thoroughly degrease mounting faces of part-turn actuator and valve.
Apply a small quantity of grease to the valve shaft.
Place coupling sleeve onto valve shaft and secure (refer to figure, detail A or B), ensure that
dimensions X, Y, and Z are observed (refer to table 1).
Apply non-acidic grease at splines of coupling.
Fit actuator so that fixing holes in actuator and valve mounting flange are in alignment.
If necessary, move actuator up or down one tooth on the coupling. If required, turn
handwheel/ crank a little in direction OPEN or CLOSE until holes align to the threads.
Ensure that the spigot (if provided) mates uniformly in the recess and that the mounting
faces are in complete contact.
Fasten the actuator with bolts of minimum quality 8.8 using lock washers. Fasten bolts
evenly crosswise to the appropriate torque according to table 1.


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13.2.7 ELECTRIC CONNECTION

CONNECTION WITH AUMA PLUG/ SOCKET CONNECTOR

Work on the electrical system or equipment must only be carried out by a skilled electrician
himself or by specially instructed personnel under the control and supervision of such an
electrician and in accordance with the applicable electrical engineering rules.

Check whether type of current, supply voltage, and frequency correspond to control and motor
data (refer to name plates at part-turn actuator and controls).
Loosen bolts (50.01) (see figure) and remove plug cover.
Loosen screws (51.01) and remove socket carrier (51.0) from
plug cover (50.0).
Insert cable glands suitable for connecting cables (The
enclosure protection stated on the name plate is only ensured if suit-
able cable glands are used.).
Seal cable entries which are not used with suitable plugs.
Connect cables according to order-related terminal plan.
Refer GEA wiring diagram for the terminal plan pertaining to
the part-turn actuator.


Table 1: Dimensions for couplings/ fastening torques for bolts
Ty p e X ma x . Y ma x .
Z
ma x .
8 . 8 TA [ Nm]
SG(R) 05.1-F05 5 3 60 4 x M 6 11
SG(R) 05.1-F07 5 3 60 4 x M 8 25
SG(R) 07.1-F07 7 3 60 4 x M 8 25
SG(R) 07.1-F10 7 3 60 4 x M 10 51
SG(R) 10.1-F10 10 3 77 4 x M 10 51
SG(R) 10.1-F12 10 3 77 4 x M 12 87
SG(R) 12.1-F12 10 6 100 4 x M 12 87
SG(R) 12.1-F14 10 6 100 4 x M 12 87
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Table 2: Technical data AUMA plug/ socket connector
Technical data Power terminals
1
) Protective earth Control terminals
No. of contacts max. 6 (3 are used) 1 (leading contact) 50 pins/ sockets
Marking U1, V1, W1, U2, V2, W2

1 to 50
Connecting voltage max. 750 V 250 V
Current max. 25 A 16 A
Type of customer connection Screws Screw for ring lug Screws
Cross section max. 6 mm
2
6 mm
2
2.5 mm
2

Material: Pin/ socket carrier
Contacts
Polyamide Polyamide Polyamide
Brass (Ms) Brass (Ms)
Brass, tin plated or gold plated
(option)
1) Suitable for copper wires. For aluminium wires, please contact AUMA

AUMA MATIC ON THE WALL BRACKET

The AUMA MATIC can also be mounted separately
from the actuator on a wall bracket.
For the connection of actuator and AUMA MATIC on
wall bracket, use suitable flexible and screened connecting
cables (Connecting cables are available on request.).
Permissible cable distance between actuator and
AUMA MATIC amounts to a max. of 100 m.
Versions with potentiometer in the actuator are not
suitable. Instead of the potentiometer, an RWG has to be used
in the actuator.
Connect the wires to the actuator in correct phase
sequence.
Check the direction of rotation before switching on.

FITTING THE COVER

After connection,
Insert the socket carrier (51.0) into the plug cover (50.0) and fasten it with screws (51.01).
Clean sealing faces at the plug cover and the housing.
Check whether O-ring is in good condition.
Apply a thin film of non-acidic grease (e.g. Vaseline) to the sealing faces.
Replace plug cover (50.0) and fasten bolts (50.01) evenly crosswise.
Fasten cable glands with the specified torque to ensure the required enclosure protection.


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13.2.8 SETTING OF END STOPS FOR PART-TURN ACTUATORS ON BUTTERFLY VALVES

The settings can only be performed if the valve has not yet been mounted in a pipeline.

SETTING ENDSTOP CLOSED

If hex. bolts (03) are fastened, loosen by approx. 3 turns.
Turn handwheel counterclockwise (closing direction), until valve is closed (end position
CLOSED).
Check whether end stop (10) has rotated, otherwise turn end stop (10) clockwise up to the
stop.

In case end position CLOSED has been passed, reverse several turns at the handwheel and
approach end position CLOSED again.
Turn end stop (10) by 1/8 turn counterclockwise (Protective cap (16) must not be loosened
in the process).
Fasten hex. bolts (03) crosswise with torque 25 Nm

SETTING ENDSTOP OPEN

The swing angle has been set in the factory. Therefore, the end stop OPEN need not be set.

SETTING LIMIT SWITCH CLOSED

After setting the end stop CLOSED, the limit switching for end position CLOSED can be set
immediately. For this, the switch compartment has to be opened and the indicator disc has to be
removed.

13.2.9 CHANGING THE SWING ANGLE

The swing angle only has to be changed if the swing range for setting the end stops is not
sufficient.
Unless ordered otherwise, the swing angle is set to 90.
In the standard version, the swing angle can be adjusted within the range of 80 to 110.
Optional swing angle ranges can also be availed as in Technical Data.

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INCREASING THE SWING ANGLE


Unscrew protective cap (16).
While holding end stop nut (2.4) in position with open end wrench
(19 mm), remove grub screw (2.02).
Turn end stop nut (2.4) counterclockwise. Do not exceed dimension A max. (table 3).
Move valve manually to the desired end position OPEN.
Turn end stop nut (2.4) clockwise until it is tight up to the stop nut (7).
Degrease face of grub screw (2.02).
Hold end stop nut in position (2.4) with open end wrench (19 mm) and fasten grub screw
(2.02) with torque 85 Nm.
Check O-ring (016) and replace if damaged.
Replace protective cap (16).

REDUCING THE SWING ANGLE

Unscrew protective cap (16).
While holding end stop nut (2.4) in position with open end wrench (19 mm), remove grub
screw (2.02).
Move valve into the desired end position OPEN.
Turn end stop nut (2.4) clockwise until it is tight up to the stop nut (7) and do not fall below
dimension A min. (Table 3)
Degrease face of grub screw (2.02).
Hold end stop nut in position (2.4) with open end wrench (19mm) and fasten grub screw
(2.02) with torque 85 Nm.
Check O-ring (016) and replace if damaged.
Replace protective cap (16).
Table 3
Type A min. [mm] A max. [mm]
SG 05.1/ SGR 05.1 10 22
SG 07.1/ SGR 07.1 10 22
SG 10.1/ SGR 10.1 8 17
SG 12.1/ SGR 12.1 12 23

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13.2.10 OPENING THE SWITCH COMPARTMENT



Remove 4 bolts and take off the cover at the switch compartment
Pulling off the indicator disc. Open end wrench (approx. 14 mm) may be used as lever.

13.2.11 SETTING THE LIMIT SWITCHING

SETTING END POSITION CLOSED (BLACK)

Turn handwheel clockwise until valve is closed.
To prevent that the end stop is reached (due to overrun) before the limit switch has tripped,
turn handwheel 4 turns (overrun) in counterclockwise direction. During test run check
overrun and, if necessary, correct setting of the limit switching.
Press down and turn setting spindle A with screw driver (5 mm) in direction of arrow,
thereby observe pointer B.
While a ratchet is felt and heard, the pointer B moves 90 every time. When pointer B is 90
from mark C, continue turning slowly.
When pointer B has reached the mark C, stop turning and release setting spindle. If you
override the tripping point inadvertently (ratchet is heard after the pointer has snapped),
continue turning the setting spindle in the same direction and repeat setting process.




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SETTING END POSITION OPEN (WHITE SECTION)

Turn handwheel counterclockwise until valve is open.
To prevent that the end stop is reached (due to overrun) before the limit switch has tripped,
turn handwheel 4 turns (overrun) in clockwise direction. During test run check overrun
and, if necessary, correct setting of the limit switching.
Press down and turn setting spindle D with screw driver (5 mm) in direction of arrow,
thereby observe pointer E. While a ratchet is felt and heard, the pointer E moves 90 every
time. When pointer E is 90 from mark F, continue turning slowly. When pointer E has
reached the mark F, stop turning and release setting spindle. If you override the tripping
point inadvertently (ratchet is heard after the pointer has snapped), continue turning the
setting spindle in the same direction and repeat setting process.

CHECKING THE LIMIT SWITCHES

The red test buttons T and P are used for manual operation of the limit switches.
Turning T in direction of the arrow LSC (WSR) triggers limit switch CLOSED.
Turning P in direction of the arrow LSO (WL) triggers limit switch OPEN.
After checking the switches, the fault (red indication light) has to be reset using the OPEN
or CLOSE push buttons of the local controls for operation in the opposite direction.

13.2.12 SETTING THE TORQUE SWITCHING
The set torque must suit the valve!
This setting must only be changed with the consent of the valve manufacturer!


Loosen both lock screws O at the torque dial
Turn torque dial P to set it to the required torque (1 da Nm = 10 Nm). Example:
the above figure shows the following setting:
11.5 da Nm = 115 Nm for direction CLOSE
12.5 da Nm = 125 Nm for direction OPEN
Tighten lock screws O again
The torque switches can also be operated in manual operation.
The torque switching acts as overload protection over full travel, also when stopping in the
end positions by limit switching.

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CHECKING THE TORQUE SWITCHES

The red test buttons T and P are used for manual operation of the torque switches:
Turning T in direction of the arrow TSC (DSR) triggers torque switch CLOSED.
Turning P in direction of the arrow TSO (DOEL) triggers torque switch OPEN.
If a DUO limit switching (optional) is installed in the actuator, the intermediate position
switches will be operated at the same time.
After checking the switches, the fault (red indication light) has to be reset using the OPEN
or CLOSE push buttons of the local controls for operation in the opposite direction.

13.2.13 TEST RUN

CHECKING THE DIRECTION AND ROTATION

Place indicator disc on shaft.

The direction of rotation of the indicator disc (see figure) indicates the direction of rotation
of the output drive.


Move actuator manually to intermediate position or to sufficient distance from end
position.
Set selector switch to local control (I)
Switch on the power supply.
Press push button CLOSE and observe the direction of rotation: If the indicator disc turns
clockwise, the direction of rotation is correct.
If the direction of rotation is wrong, switch off immediately. Afterwards correct phase
sequence in the connecting cable from the wall bracket to the actuator and repeat test run
Push button CLOSED Push button STOP
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CHECKING THE LIMIT SWITCHING
Set selector switch to position OFF (0).
Move actuator manually into both end
positions of the valve.
Check whether limit switching is set
correctly. Hereby observe that the appropriate
switch is tripped in each end position and released
again after the direction of rotation is changed. If
this is not the case, the limit switching must first be
set, as described earlier.

When limit switching is set correctly:
Set selector switch to local control (I) (figure 15).
Perform test run at the local controls via push buttons OPEN - STOP - CLOSE.
Close switch compartment

13.2.14 SETTING THE ELECTRONIC POSITION TRANSMITTER (RWG)
For remote indication or external control

After mounting the part-turn actuator to the valve, check setting by measuring the output current
and re-adjust, if necessary.


The position transmitter board is located under the cover plate


SETTING 3- / 4- WIRE SYSTEM 4 20 mA

Connect voltage to electronic position transmitter.
Move valve to end position CLOSED.
Pull off indicator disc.


Table 4: Technical data RWG 4020
Terminal plans

KMS TP_ _ 4 / _ _ _
3- or 4- wire system
KMS TP _ 4 _ / _ _ _
KMS TP _ 5 _ / _ _ _
2-wire system
Output current Ia 0 20 mA, 4 20 mA 4 20 mA
Power supply Uv
24 V DC, 15 %
smoothed
14 V DC + (I x RB),
max. 30 V
Max. input
current
I
24 mA at 20 mA
output current
20 mA
Max. load RB
600

(Uv - 14 V) / 20 mA
Positioner Board
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Connect ammeter for 0 20 mA to measuring points.
The circuit (external load) must be connected (observe max. load RB), or the appropriate
poles at the terminals (refer to wiring diagram) must be linked, otherwise no value can
be measured.
Turn potentiometer (E2) counterclockwise until stop is felt.
Turn potentiometer (E2) slightly back.
Turn potentiometer 0 clockwise until output current starts to increase.
Turn back potentiometer 0 until a residual current of approx. 0.1 mA is reached.
Move valve to end position OPEN.
Set potentiometer max. to end value 16 mA.
Move valve to end position CLOSED.
Set potentiometer 0 from 0.1 mA to initial value 4 mA.
This results in a simultaneous shift of the end value by 4 mA, so that the range is now
4 - 20 mA.
Approach both end positions anew and check setting. If necessary, correct the setting.

If the maximum value cannot be reached, the selection of the reduction gearing must be checked.

13.2.15 SETTING OF MECHANICAL POSITION INDICATOR

Place indicator disc on shaft.
Move valve to end position CLOSED.
Turn lower indicator disc until symbol CLOSED is in alignment with the mark on the
cover.
Move actuator to end position OPEN.
Hold lower indicator disc in position and turn upper disc with symbol OPEN until it is
in alignment with the mark on the cover.
The indicator disc turns approx. 180 for a swing angle of 90.





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13.2.16 CLOSING THE SWITCH COMPARTMENT

Clean sealing faces of housing and cover
Check whether O-ring is in good condition.
Apply a thin film of non-acidic grease to the sealing faces.
Replace cover on switch compartment and fasten bolts evenly crosswise.


13.2.17 SETTING THE OPERATING TIME


Remove motor cover.
Set required operating time with potentiometer.
Clean sealing faces of housing and motor cover.
Check whether O-ring is in good condition.
Apply a thin film of non-acidic grease to the sealing faces.
Fit and fasten motor cover (for enclosure protection IP 68, the motor cover is additionally
sealed with thread sealing material.)


Table 5: Operating times for 90
SG 05.1 5.6 to 45 seconds
SG 07.1 11 to 90 seconds
SG 10.1 11 to 90 seconds
SG 12.1 22 to 180 seconds
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13.2.18 ACTUATOR CONTROLS AUMA MATIC

Functions of the diagnosis LEDs on the interface board (standard vision)

V14 is illuminated: Phase failure and/ or motor protection tripped.
In combination with motor protection (PTC thermistor):
Reset by selector switch position I I I at local controls

V15 is illuminated: Torque fault: Torque switch operated in mid-travel

The LEDs STOP, CLOSE, OPEN indicate the available control commands (only in selector switch
position REMOTE).


Positions of the boards within controls
Cover Plate on interface board
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Programming the logic board

The type of seating limit or torque seating (switch S1-2 and switch S3-2) must be determined by
the valve manufacturer.


Set desired programming according to table 6 at the switch S2-2.

Tabl e 6
DI P s wi t c h S2 - 2
Pr og r a mmi ng
(ON = pressed)
Direction CLOSE Direction OPEN
Self-retaining REMOTE

Push-to-run operation REMOTE

Self-retaining LOCAL

Push-to-run operation LOCAL

Blinker transmitter (option)
activated deactivated

Torque fault: Torque switch tripping (in mid-
travel) contained in collective fault signal
Included not included


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EMERGENCY-OPEN and EMERGENCY-CLOSE signal (option)

(5
th
digit in wiring diagram MSP C, D, or P)

When an EMERGENCY run command is given the actuator operates the valve to the
predetermined end position (effective in all three selector switch positions: LOCAL, OFF,
REMOTE).

The input at terminal XK 1 (refer to wiring diagram) must be connected to an NC contact
(closed circuit principle) at + 24 V DC.
If EMERGENCY- OPEN or EMERGENCY CLOSE signal is generally not desired:

Take off cover plate and disconnect links B1 (for EMERGENCY - CLOSE) and B2 (for
EMERGENCY - OPEN).

13.2.19 ELECTRONIC POSITIONER (OPTION)

Technical data

Table 7: Technical data for positioner
Command signal (input signal E1, set value) 0/4 20 mA (Option: 0 5 V)
Feedback (input signal E2, actual value) 0/4 20 mA (Option: 0 5 V)
Sensitivity (dead band) E (P9) 0.5 % 2.5 %
Fine tuning

Sens

(P7)
(useful for output speeds <16 rpm only)
min. 0.25 %
Pause time

t-off

(P10) 0.5 10 s
Input resistance 250 Ohm
Modulating duty with stepping mode (not required for modulating setting):
Running time

t-on (P8)
effective until error is 25 %; then set value is
automatically reduced by 3.
0.5 15 s

Cover plate for EMERGENCY- OPEN or EMERGENCY- CLOSE option
Links: B1 (EMERGENCY - CLOSE)
B2 (EMERGENCY - OPEN)
LED FOR
EMERGENCY run command
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Setting

The positioner in the actuator controls AUMA MATIC is programmed according to the purchase
order details and is set together with the actuator prior to delivery.

Due to peculiarities of the regulating system not known beforehand, a readjustment may become
necessary. Before adjusting the positioner, the programming of the positioner should be checked.

Check programming of the logic board

The self-retaining REMOTE function (see table 6) must be switched off in conjunction with the
positioner.

Take off cover plate and carry out required programming at positioner board according to table 8
and 9.

Prior to setting, it must be ensured that the circuit for the position feedback E2 (see wiring
diagram) is closed (measuring device or link). In case of missing signal E2, the LED (V10) E1/E2
< 4 mA is illuminated and the positioner shows no reaction.

Cover Plate Positioner
Positioner Board A7
Label with signal indication
(in our example: E1 = 4 20 mA, E2 = 4 20 mA)
E1{
E2{
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Setting type of signal

The signal type (current/ voltage signal) of nominal value E1 and actual value E2 is set in the
factory and marked with a label on the cover plate of the positioner.

If the setting is subject to a subsequent change, the marking also has to be changed. Furthermore
the wiring diagram indicated on the name plate of the actuator controls also changes.

Table 8: Possible settings
Command signal
Setpoint E1
Feedback
Actual value E
1
)
Pr ogr a mmi ng
via DIP switch S1-7
4 20 mA
0 20 mA
4 20 mA
0 20 mA

4 20 mA
0 20 mA
0 5 V

0 5 V
4 20 mA
0 20 mA

0 5 V 0 5 V

0 10 V
4 20 mA
0 20 mA

0 10 V 0 5 V


In case of a loss of signal of nominal value E1 or actual value E2, the reaction of the actuator can be
programmed via the switch S2-7. The complete range of choices, however, is only available with
signals 4 20 mA.

The following reactions are possible:

Fail as is : Actuator stops immediately and remains in this position.
Fail close : Actuator moves the valve to the end position CLOSED.
Fail open : Actuator moves the valve to the end position OPEN.

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1) During loss of signal, signals from 0 20 mA and 0 5 V may be misinterpreted since E1 or E2 (without any
fault) can also be 4 mA (end position CLOSED = 0 mA or 0 V) when working properly.
2) Signals for internal feedback:
0/4 20 mA from electronic position transmitter or 0 5 V from precision potentiometer 5

Positioner adjustment end position CLOSED (standard version)

Before beginning the setting of the positioner, it has to be ensured that the limit and torque
switching of the actuator as well as the feedback have been set.
Set selector switch (local controls) to position LOCAL.
Move multi-turn actuator by pressing push button to end position CLOSED.
Supply nominal value E1 of 0 or 4 mA (see wiring diagram).
Turn potentiometer

t-off

(P10) counterclockwise to the stop


Positioner Board A7

Missing signals E1/ E2 or wrong polarity are indicated by LED (V10)

E1/E2 < 4 mA"


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Connect voltmeter to measuring points MP3 and MP4 for measuring the nominal value
(0 5 V).
For a nominal value E1 of 0 mA, the voltmeter shows 0 V.
For a nominal value E1 of 4 mA, the voltmeter shows 1 V.
In case nominal value (0 V or 1 V) is not correct: Correct nominal value signal in control
room.
Connect voltmeter to measuring points MP2 and MP1 for measuring the actual value
signal.
For an actual value E2 of 0 mA, the voltmeter shows 0 V.
For an actual value E2 of 4 mA, the voltmeter shows 1 V.
If measured value is not correct:
Adjust position feedback and repeat

positioner adjustment

.

Tabl e 10
I
f

Possible LED display:
T
h
e
n

Required setting in end position CLOSED:
the LEDs are not illuminated
Turn potentiometer 0 (P3) slightly clockwise until
LED (V27 yellow) is illuminated
LED (V28 green) is illuminated
Turn potentiometer 0 (P3) slightly clockwise until
LED (V28 green) is no longer illuminated and
LED (V27 yellow) is illuminated
LED (V27 yellow) is illuminated
Turn potentiometer 0 (P3) counterclockwise until
LED (V27 yellow) is no longer illuminated.
Then turn potentiometer 0 (P3) slightly to clockwise until
LED (V27 yellow) is illuminated

Positioner adjustment end position OPEN (standard version)

Run multi-turn actuator by pressing push button (local controls) to end position OPEN.
Connect voltmeter to measuring points MP2 and MP1 for measuring the actual value E2:
When position feedback is set correctly, the voltmeter shows 5 V. If measured value is not
correct:
Adjust position feedback and repeat positioner adjustment.
Connect max. command signal (nominal value E1) = 20 mA.
Connect voltmeter to measuring points MP3 and MP4 for measuring the nominal value E1:
For a nominal value of 20 mA, the voltmeter shows 5 V.
If measured value is not 5 V:
Check the externally supplied command signal E1.

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Table 11
I
f

LED display:
T
h
e
n

Required setting in end position OPEN:
the LEDs are not illuminated
Turn potentiometer

max. (P4) slightly counterclockwise until


LED (V28 green) is illuminated
LED (V28 green) is illuminated
Turn potentiometer

max

(P4) clockwise until LED (V28


green) is no longer illuminated
Then turn potentiometer

max

(P4) slightly counterclockwise


until LED (V28 green) is illuminated.
LED (V27 yellow) is illuminated
Turn potentiometer

max

(P4) slightly counterclockwise until


LED (V27 yellow) is no longer illuminated and
LED (V28 green) is illuminated

Setting the sensitivity

Set selector switch at the local controls to position REMOTE.
Set command signal E1 according to label on cover plate (see figure). The sensitivity (E /
dead band) is set to maximum value (2.5 %) in the factory.
With the potentiometer E (P9) the dead band can be increased by turning clockwise. Left
stop = small dead band (= high sensitivity). For a precise setting of the dead band, a set
point device with setting options in the 0.1 mA range is required.
A better sensitivity Emin = 0.25 %) can be achieved by turning the potentiometer P7 (sens)
clockwise.

When setting E, the following must be observed:
If the number of starts is too high, this will lead to unnecessary wear at the valve and actuator.
Therefore the maximum possible dead band acceptable for the process must be set.

To prevent exceeding the max. permissible number of starts (refer to Technical data sheets for
modulating actuators) in extreme cases, a pause time between 0.5 s (left stop) and 10s (right stop)
may be set with the potentiometer t-off (P10).

Cover Plate for Positioner


Label with signal indication
(in our example: E1 = 4 20 mA, E2 = 4 20 mA)
V28 (green)
V27 yellow
V8 red
V10 red
P10
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Cover Plate for Positioner A7

Positioner adjustment end position OPEN (inverse operation)

In standard version the maximum input signal (E1 = 20 mA) results in operation to end position
OPEN.
By switching the code switch S3-7 to position 1 an inversion of this signal definition
(inverse operation) can be achieved.
In case an RWG (option) is installed, the connections 7 (red) and 5 (black) on the positioner
board of the actuator have to be exchanged.
In case a potentiometer is installed, (option) the connections 21 (red) and 22 (black) at the
potentiometer must be interchanged.

Before beginning the setting of the positioner, it has to be ensured that the limit and torque
switching of the actuator as well as the feedback have been set.

Set selector switch (local controls) to position LOCAL.
Run actuator with push button to End position OPEN
Supply nominal value E1 of 0 or 4 mA (see wiring diagram).
Turn potentiometer

t-off

(P10) counterclockwise to the stop


Missing signals E1/ E2 or wrong polarity are indicated by LED (V10) E1/E2 4 < mA"
Connect voltmeter to measuring points MP3 and MP4 for measuring the nominal value
(0 5 V).
For a nominal value E1 of 0 mA, the voltmeter shows 0 V.
For a nominal value E1 of 4 mA, the voltmeter shows 1 V.
In case nominal value (0 V or 1 V) is not correct, Correct nominal value signal in control
room.

Connect voltmeter to measuring points MP2 and MP1 for measuring the actual value
signal.
E1{
E2{
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For an actual value E2 of 0 mA, the voltmeter shows 0 V.
For an actual value E2 of 4 mA, the voltmeter shows 1 V.
Adjust position feedback and repeat

positioner adjustment

.


Positioner Board A7


Table 12
I
f

Possible LED display:
T
h
e
n

Required setting in end position OPEN:
the LEDs are not illuminated
Turn potentiometer 0 (P3) slightly clockwise until
LED (V28 green) is illuminated
LED (V27 yellow) is illuminated
Turn potentiometer 0 (P3) slightly clockwise until
LED (V27 yellow) is no longer illuminated and
LED (V28 green) is illuminated
LED (V28 green) is illuminated
Turn potentiometer 0 (P3) counterclockwise until
LED (V28 green) is no longer illuminated.
Then turn potentiometer 0 (P3) slightly clockwise until
LED (V27 yellow) is illuminated

Positioner adjustment end position CLOSED (inverse operation)

Run actuator with push button (local controls) to end position CLOSED.
Connect voltmeter to measuring points MP2 and MP1 for measuring the actual value E2:
When position feedback is set correctly the voltmeter shows 5 V. If measured value is not
correct:
Adjust position feedback and repeat positioner adjustment.
Connect max. command signal (nominal value E1) = 20 mA.
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Connect voltmeter to measuring points MP3 and MP4 for measuring the nominal value E1:
For a nominal value of 20 mA, the voltmeter shows 5 V.
If measured value is not 5 V:
Check the externally supplied command signal E1.

Table 13
LED display: Required setting in end position CLOSED:
the LEDs are not illuminated
Turn potentiometer

max

(P4) slightly counterclockwise until


LED (V27 yellow) is illuminated

LED (V27 yellow) is
illuminated

Turn potentiometer

max

(P4) clockwise until LED (V27


yellow) is no longer illuminated.
Then turn potentiometer

max

(P4) slightly counterclockwise until


LED (V27 yellow) is illuminated.

LED (V28 green) is
illuminated

Turn potentiometer

max

(P4) slightly counterclockwise until the


LED (V28 green) is no longer illuminated and
the LED (V27 yellow) is illuminated.

13.2.20 MAINTENANCE

After maintenance, check part-turn actuator for damage to paint finish. If damage to paint-
finish has occurred after mounting, it has to be touched up to avoid corrosion. Original
paint in small quantities can be supplied by AUMA.
AUMA part-turn actuators require very little maintenance. Precondition for reliable service
is correct commissioning.
Seals made of elastomers are subject to ageing and must therefore regularly be checked
and, if necessary, be exchanged.
It is also very important that the O-rings at the covers are placed correctly and cable glands
fastened firmly to prevent ingress of dirt or water.
If rarely operated, perform a test run about every 6 months. This ensures that the actuator
is always ready to operate.
Approximately six months after commissioning and then every year check bolts between
part-turn actuator and valve/gearbox for tightness. If required, tighten applying the
torques given in table 1.

13.2.21 LUBRICATION

AUMA part-turn actuators are filled with grease for lifetime. A change of grease or re-lubrication
is not necessary.
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13.2.22 SPARE PARTS


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No. Type Description No. Type Designation
1 E Housing 36.5 B Mechanical position indicator
2.0 B Worm shaft assly.
36.6
*
B
Blinker transmitter including pins at wires
(without impulse disc and insulation
plate)
2.4 E
End stop nut (included in sub-
assembly 2.0)
3.0 B Manual drive worm assly. 36.10 E Cover plate
4.0 B Worm wheel 38.0 B Pin carrier (without pins)
5.0 B Mounting flange assly. 38.2.2 B Pin for motor
10.0 B Limit stop housing assly. 38.2.3 B Pin for controls
14 E Coupling 38.2.4 B Wire for protective earth
16 E Cap 39.0 B Plug cover assly.
17.0 B Torque finger assly.
39.2 B
Socket carrier
(complete with sockets)
21.0 B Limit drive finger assly.
29.0 B Manual drive bearing assly.
39.2.2 B
Socket for motor
(included in sub-assembly 39.2)
32.0 B Planetary gearing assly.
34.0 B Motor assly.
39.2.3 B
Socket for control
(included in sub-assembly 39.2) 34.22 B
Motor plug pin carrier (without
pins)
39.2.4 B
Socket for protective earth
(included in sub-assembly 39.2)
34.23 B Pin for motor
40 B Handwheel assly.
34.24 B Pin for thermoswitch
34.7 B Motor brake 40.043 E Cap assly.
34.8 B Motor electronic board
40.43 B Ball handle assly.
41 B Motor plug, socket assly.
34.9 B Cover plate
35.0 B Cover assly. 152.1
*
B Potentiometer (without slip clutch)
36.0 B
Control unit assly. (without
switches)
152.2
*
B Slip clutch for potentiometer
36.1 B Torque switching head 153.0
*
B Electronic position transmitter (RWG)
36.2 B Heater 153.1 * B
Potentiometer for RWG (without slip
clutch)
36.3.1 B Stud bolt for switches 153.2
*
B Slip clutch for RWG
36.3.2 B
Switch for limit/ torque switching
(including pins at wires)
153.3
*
B Electronic board RWG
S 1 S Seal kit (small)
36.3.4 E Spacer S 2 S Seal kit (large)

* not included in basic equipment

Note:
Please state type and commission no. of the actuator (see name plate) when ordering spare parts.
Delivered spare parts may slightly vary from the representation in these instructions.
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13.2.23 SPARE PARTS LIST CONTROLS







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No . Description No . Designation
001.0 Housing 008.1 Interface board
002.0 Local controls 009.0 Logic board
003.0 Local controls board 013.0 Adapter board
003.1 Primary fuse 500.0-1 Cover
003.2 Cover for fuse 501.0 Socket carrier (complete with sockets)
004.0 Switchgear 502.0 Pin carrier (without pins)
004.2 Carrier for contactors 503.0 Socket for control
004.3 Socket carrier (complete with sockets) 504.0 Socket for motor
006.0 Power supply unit including mounting plate 505.0 Pin for controls
006.1 Mounting plate for power supply unit 506.0 Pin for motor
006.2 Power supply unit 507.0 Plug cover
006.2-1 Secondary fuse F3 508.1 Reversing contactors
006.2-2 Secondary fuse F3 509.1 Padlock
008.0 Interface board S1 Seal kit


Note:

Please state type and commission no. of the device (see name plate) when ordering spare parts. Delivered spare
parts may slightly vary from the representation in these instructions.

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13.3 DP TRANSMITTER

This write up contains the installation operation and maintenance details of DP Transmitter.



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13.3.1 INSTALLATION

The Rosemount Differential Pressure Transmitters may be used for accurate measurement of
differential pressure of flow.

Measurement accuracy depends upon proper installation of the transmitter and impulse piping.
Mount the transmitter close to the process and use a minimum of piping to achieve best accuracy.
Keep in mind the need for easy access, personnel safety, practical field calibration, and a suitable
transmitter environment. Install the transmitter to minimize vibration, shock, and temperature
fluctuation.

Differential Pressure transmitters are often installed in harsh environments due to process and
economic considerations. The transmitter should, however, be located to minimize the effects of
temperature gradients and fluctuations, and to avoid vibration and shock.

13.3.2 LOCATION

The best location for the transmitter in relation to the process pipe depends on the process itself.
Use the following guidelines to determine transmitter location and placement of impulse piping:
Keep impulse piping as short as possible.
Slope the impulse piping at least 1inch per foot (8 cm per m) upward from the transmitter
toward the process connection.
Avoid high points in liquid lines.
Make sure both impulse legs are the same temperature.
Use impulse piping large enough to avoid friction effects and blockage.
Vent all gas from liquid piping legs.
When using a sealing fluid, fill both piping legs to the same level.
When purging, make the purge connection close to the process taps and purge through
equal lengths of the same size pipe. Avoid purging through the transmitter.
BLOCK DIAGRAM OF OPERATION
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Keep corrosive or hot (above 250F [121C]) process material out of direct contact with the
sensor module and flanges.
Prevent sediment deposits in the impulse piping.
Keep the liquid head balanced on both legs of the impulse piping.
Avoid conditions that might allow process fluid to freeze within the process flange.

13.3.3 SOURCES OF ERROR

The piping between the process and the transmitter must accurately transfer the pressure to obtain
accurate measurements. There are five possible sources of error: pressure transfer, leaks, friction
loss (particularly if purging is used), trapped gas in a liquid line, liquid in a gas line, and density
variations between the legs.

13.3.4 MOUNTING

The DP Transmitter is mounted with the use of a mounting bracket to a two inch pipe.

Model 3051 process connections on the transmitter flange are 1/418 NPT. Flange adapter unions
with 1/214 NPT connections must be ordered using the DF option. The threads are Class 2; use
your plant-approved lubricant or sealant when making the process connections. The process
connections on the transmitter flange are on 2 1/8-inch (54mm) centers to allow direct mounting to
a three-valve or five-valve manifold. Rotate one or both of the flange adapters to attain connection
centers of 2 inches (51mm), 2 1/8 inches (54mm), or 2 inches (57mm).

Install and tighten all four flange bolts before applying pressure, or process leakage will result.
When properly installed, the flange bolts will protrude through the top of the module housing. Do
not attempt to loosen or remove the flange bolts while the transmitter is in service.

The transmitter is calibrated in a horizontal or vertical position at the factory. Mounting the
transmitter in a position other than factory calibration position will cause the zero point to shift by
an amount equivalent to the liquid head. The transmitter should be rezeroed to cancel the liquid
head effect caused by the process connection height differences.

Only use bolts supplied with the Model 3051 or sold by Rosemount Inc. as spare parts for the
Model 3051 transmitter. To ensure a tight flange, adapter, or manifold seal

Finger-tighten the bolts.
Torque the bolts to the initial torque value using a crossing pattern as per the table.
Torque the bolts to the final torque value using the same crossing pattern as per the table.

Bolt Material Initial Torque Value Final Torque Value
CS-ASTM-A445 Standard 300 in.-lb (34 N-m) 650 in.-lb (73 N-m)
316 SSTOption L4 150 in.-lb (17 N-m) 300 in.-lb (34 N-m)
ASTM-A-193-B7MOption L5 300 in.-lb (34 N-m) 650 in.-lb (73 N-m)
MonelOption L6 300 in.-lb (34 N-m) 650 in.-lb (73 N-m)

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13.3.5 WIRING

The transmitter terminal block is in the compartment of the electronics housing labeled FIELD
TERMINALS. The other compartment contains the transmitter electronics module. Connections
for the HART-based communicator are attached beneath the terminal screws on the terminal
block. You can connect the Rosemount Model 282 Loop Validator at the signal terminals to
provide power to the transmitter temporarily for calibration or diagnostic purposes. Or you can
attach it to the test connections on the terminal block of the transmitter for indication purposes.

Use shielded twisted pairs to yield best results. In order to ensure proper communication, use
24 AWG or larger wire, and do not exceed 5000 feet (1500 meters). Installed signal wiring should
not be run together and should not be in the same cable tray as AC power wiring.

Connect the lead that originates at the positive side of the power supply to the terminal marked
+ and the lead that originates from the negative side of the power supply to the terminal marked
. Avoid contact with the leads and terminals. Do not connect the powered signal wiring to the
test terminals. Power could damage the test diode in the test connection.

CAUTION

If the test diode is accidentally destroyed, the transmitter can still be operated without local
indication by jumping the test terminals.

Plug and seal unused conduit connections on the transmitter housing to avoid moisture
accumulation in the terminal side of the housing. If you do not seal the unused connections, mount
the transmitter with the electrical housing positioned downward for drainage. Install wiring with a
drip loop. Arrange the drip loop so the bottom is lower than the conduit connections and the
transmitter housing.

Do not run signal wiring in conduit or open trays with power wiring, or near heavy electrical
equipment. You may ground the signal wiring at any one point on the signal loop, or leave it
ungrounded. The negative terminal of the power supply is a recommended grounding point.
Device must be properly grounded or earthed according to local electric codes.

WIRING DIAGRAM
OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 100
Do not remove the transmitter covers in explosive environments when the circuit is live.
Transmitter covers must be fully engaged to meet Explosion-Proof requirements. Before
connecting a communicator in an explosive atmosphere, make sure the instruments in the loop are
installed in accordance with intrinsically safe or nonincendive field wiring practices. Avoid contact
with the leads and terminals. High voltage that may be present on leads can cause electrical shock.

For 420 mA transmitters, you will need a power supply capable of providing 10.5 to 55 V dc at the
transmitter, and a meter to measure output current. To enable communication, a resistance of at
least 250 ohms must be present between the communicator or AMS loop connection and the power
supply. The dc power supply should provide power with less than 2 percent ripple. The total
resistance load is the sum of the resistance of the signal leads and the load resistance of the
controller, indicator, and related pieces. Note that the resistance of intrinsic safety barriers, if used,
must be included.

13.3.6 CALIBRATION

Calibration process is done in three steps with a smart transmitter:
Rerange sets the 4 and 20 mA points at the desired pressures;
Sensor Trimadjusts the position of the factory characterization curve to optimize the
transmitter performance over a specified pressure range or to adjust for mounting effects
Analog Output Trimadjusts the analog output to match the plant standard or the control loop.

The Range Values command sets the 4 and 20 mA points (lower and upper range values). Setting
the range values to the limits of expected readings maximizes transmitter performance. In practice,
you may reset the transmitter range values as often as necessary to reflect changing process
conditions.

The transmitters can be reranged in any one of the three modes :
1. Rerange with a communicator only
2. Rerange with a Pressure Input Source and a Communicator
3. Rerange with a Pressure Input Source and the Local Zero and Span Buttons

Reranging using only the communicator is the easiest and most popular way to rerange the
transmitter. This method changes the values of the analog 4 and 20 mA points independently
without a pressure input.

Reranging using the communicator and a pressure source or process pressure is a way of
reranging the transmitter when specific 4 and 20 mA points are not known. This method changes
the values of the analog 4 and 20 mA points.

Reranging using the local zero and span adjustments and a pressure source is a way of reranging
the transmitter when specific 4 and 20 mA points are not known and a communicator is not
available.

You can trim the sensor using either the full trim or the zero trim function. The trim functions vary
in complexity, and their use is application-dependent. Both trim functions alter the transmitters
interpretation of the input signal.

The Analog Output Trim commands allow you to adjust the transmitters current output at the 4
and 20 mA points to match the plant standards. This command adjusts the digital to analog signal
conversion.
OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 101
13.3.7 SETTING OF JUMPERS

Security (Write Protect)

There are three security methods with the Model 3051 transmitter:

1. Security Jumper: prevents all writes to transmitter configuration.
2. Local Keys (Local Zero and Span) Software Lock Out: prevents changes to transmitter
range points via local zero and span adjustment keys. With local keys security enabled,
changes to configuration are possible via HART.
3. Physical Removal of Local Keys (Local Zero and Span) Magnetic Buttons: removes
ability to use local keys to make transmitter range point adjustments. With local keys
security enabled, changes to configuration are possible via HART.

NOTE
If the security jumper is not installed, the transmitter will continue to operate in the security OFF
configuration.

You can prevent changes to the transmitter configuration data with the write protection jumper.
Security is controlled by the security (write protect) jumper located on the electronics board or
display face. Position the jumper on the transmitter circuit board in the ON position to prevent
accidental or deliberate change of configuration data.

If the transmitter write protection jumper is in the ON position, the transmitter will not accept
any writes to its memory. Configuration changes, such as digital trim and reranging, cannot take
place when the transmitter security is on.

Configuring Transmitter Alarm and Security Jumper Procedure

To reposition the jumpers, follow the procedure described below :

If the transmitter is installed, secure the loop and remove power.
Remove the housing cover opposite the field terminal side. Do not remove the transmitter
covers in explosive atmospheres when the circuit is live.
Reposition the jumpers as desired. (Refer Figure for jumper positions and the transmitters with
optional LCD display)
Reattach the transmitter cover. Transmitter covers must be fully engaged to meet Explosion-
Proof requirements.

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 102
NOTE
Security jumper not installed = Not Write Protected
Alarm jumper not installed = High Alarm


NOTE
Security jumper not installed = Not Write Protected
Alarm jumper not installed = High Alarm




ELECTRONIC BOARD
OPTIONAL LCD DISPLAY

OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 103























SECTION XIV

CATALOGUES
VF 49...P(IEC)
VF 49_
BN_2D
M M1 M2 N N1 N2 N3 N4 LB AC
VF 49 P63 B5 11 12.8 4 140 115 95 10.5 9.5
3.0
63 184 121
VF 49 P71 B5 14 16.3 5 160 130 110 10.5 9.5 71 219 138
VF 49 P80 B5 19 21.8 6 200 165 130 10 11.5 80 234 156
VF 49 P63 B14 11 12.8 4 90 75 60 7 6 63 184 121
VF 49 P71 B14 14 16.3 5 105 85 70 10.5 6.5 71 219 138
VF 49 P80 B14 19 21.8 6 120 100 80 10 7 80 234 156
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9
0
1
1
5
F
D
0
8
2
5
0

7
0
0
8
6
5
1
4
5
F
A
0
8
2
5
0
7
0
0
8
5
0
1
4
4
2
2
B
N
1
8
0
L
4
1
4
6
5
1
4
3
8
9
0
.
8
2
4
5
6
.
5
2
.
5
2
.
5
1
2
5
0
1
3
5
F
D
0
9
3
0
0

4
0
0
1
4
5
0
1
7
5
3
0
B
N
2
0
0
L
4
1
4
6
5
1
9
6
9
0
0
.
8
3
5
8
7
.
1
2
.
7
2
.
8
1
6
5
0
1
5
7
F
D
0
9
4
0
0

3
0
0
1
8
5
0
1
9
7
5
0
H
z
NOTE :These values refer to the rear shaft end.
APPD
DT
CHKD
DT
DRN
DT
VHD
INTERVALVE INDIA LTD
17/12/2011
GEA BGR ENERGY SYSTEMS INDIA
MOD NO REV DATE SIGN
Customer
Po No 1100006960 Date
Project
IF IN DOUBT
ASK
Size A B C D E F G H J K L M WT Kgs Qty Tag
300NB (12" 30 6 * 300 78 237 270 14 125 8 42 4 30 48 3
29/12/2011
SCALE
N.T.S.
TQ No :
1141763 IV No :
IVGKB BUTTERFLY VALVE WITH BARE
SHAFT
DRG No : 1/1141763/GKB006-1
Valve Dimensions
KORADI - DF PROJ ECT
Valve Rating
Mfg Std
Test Std
HYD Test
Flange Drilling Std
Body
Seat
Notes
1) DO NOT USE FLANGE GASKETS DURING VLV INSTALLATION.
ALL DIMS.ARE INDICATIVE EXCEPT FACE TO FACE DIM.B
SEAT LEAKAGE-TIGHT SHUT OFF
2)
3)
4)
5)
ALL DIMENSIONS ARE IN MM.
FLOW DIRECTION-BI-DIRECTIONAL
ANSI B16.5(#150)
PN 10
API 609
API 598/BS6755 PART I
15 KG/CM2
11 KG/CM2
Pos Qty Moc Ga Drg Text
1 1 A216 GR.WCB+EPOXY+EPDM BONDED BODY SEAT
2 1 A351 CF8M DISC
3 1 A276/479 SS316 ST HARD SHAFT
4 2 STEEL + PTFE GLACIER BEARING
5 1 EPDM O RING THRUST PAD
6 1 EPDM O RING SHAFT
7 2 A276/479 SS 316 TAPER PIN
8 1 MILD STEEL+EPOXY BOTTOM COVER
9 1 B148 AL BRONZE C95800 THRUST PAD
10 1 POLYACETAL TOP BUSH
11 1 IS1570 C45/BS970 EN8 PARALLEL KEY
Technical data AUMA part-turn actuators SG 05.1 - SG 12.1
Issue 1.98
DO 02.02.006GB
We reserve the right to alter data according to improvement made. Previous data sheets become invalid with the issue of this data sheet.
Notes:
AUMA motors are provided with thermoswitches to protect the windings
(refer to terminal plans KMS). Our warranty will lapse if those thermoswitches are
not connected in the control circuit.
Motor data are approximate. Due to usual manufacturing tolerances there may be
deviations from the values given.
Application:
Valve attachment:
Electrical operation of valves (e.g. butterfly valves and ball valves).
Dimensions according to ISO 5211.
Coupling: unbored splined coupling for connection to the valve shaft, part-turn actuator can be
repositioned 4 x 90on coupling
Self-locking: yes
Type of duty: short-time duty S 2 - 15 min
1)
Swing angle: standard: 80to 110adjustable between min. and max. value
options: 25- 40, 40- 55, 55- 80, 110- 160, 160- 230or 230- 320
Limit switching: counter gear mechanism for end positions CLOSED / OPEN
Torque switching: adjustable torque switching for closing and opening direction
Operating time: for 1-phase AC special motors adjustable (see below),
for 3-phase AC motors in steps (see next page)
Position indicator: mechanical, continuous
Heater in switch compartment: 5 - 20 W, self-regulating
110 - 250 V AC / DC (standard)
24 - 48 V (when with AUMA MATIC)
Motors: 3-phase AC motor or 1-phase AC special motor
Insulation class: F, tropicalized
Motor protection: thermoswitches
Electrical connection:
Terminal plan:
AUMA multi-pin plug, internal wiring of motor and controls on plug/socket connector
KMS TP 100/001 (basic version)
Manual operation: Manual drive for setting and emergency operation, handwheel does not rotate during
electric operation.
Ambient temperature: standard: 25 C to + 70 C
2)
option: 40 C to + 60 C (low temperature L)
Enclosure: IP 67 according to EN 60 529, dust and water tight
Corrosion protection: standard: KN, suitable for installation in industrial units, in water- or power plants
3)
option: KS, recommended for installation in aggressive atmospheres, e.g.
maritime climate or aggressive chemical substances, as present in
certain sections of waste water treatment plants
Finish coating: standard: two-component iron-mica combination
Standard colour: silvergrey (DB 701, similar to RAL 9007)
Reference documents: brochure SG 05.1 - SG 12.1
dimension sheet SG 05.1 - SG 12.1
with 1-phase AC motors
Tripping
torque
4)
both directions
Valve
mounting
flange
ISO 5211
Valve
shaft
AUMA part-turn
actuator type
220 - 240 V; 50/60 Hz
(at 110 - 120 V double current
values)
M
o
t
o
r
p
o
w
e
r
5
)
N
o
m
i
n
a
l
c
u
r
r
e
n
t
C
u
r
r
e
n
t
a
t
m
a
x
.
t
o
r
q
u
e
a
n
d
s
h
o
r
t
e
s
t
o
p
e
r
a
t
i
n
g
t
i
m
e
S
t
a
r
t
i
n
g
c
u
r
r
e
n
t
H
a
n
d
w
h
e
e
l
d
i
a
m
e
t
e
r
T
u
r
n
s
f
o
r
9
0

W
e
i
g
h
t
6
)
m
i
n
.
N
m
m
a
x
.
N
m
S
t
a
n
d
a
r
d
S
p
e
c
i
a
l

m
a
x
.
m
m
S
q
u
a
r
e
m
a
x
.
m
m
T
w
o
-
f
l
a
t
m
a
x
.
m
m
O
p
e
r
a
t
i
n
g
t
i
m
e
f
o
r
9
0

a
d
j
u
s
t
a
b
l
e
kW A appr. A appr. A mm
appr.
kg
90 150 F 05 F 07 25,4 22 22 SG 05.1 5,6 s 45 s 0,115 1,5 3 3 160 58 19
120 300 F 07 F 10 25,4 22 22 SG 07.1 11 s 90 s 0,115 1,5 3 3 160 58 19
250 600 F 10 F 12 38 30 27 SG 10.1 11 s 90 s 0,230 2 4 4 160 107 25
500 1200 F 12 F 14 50 36 41 SG 12.1 22 s 180 s 0,230 2 4 4 160 110 29
Continuation see next page
1-phase AC (standard voltages and frequencies)
Volt 110 - 120 220 - 240
Hz 50 / 60 50 / 60
1) Based on 20 C ambient temperature and on an
average load equal to approx. 50 % of max torque
2) Version AUMA NORM with 3-phase AC motor up to + 80 C
3) If permanently or occasionally exposed to aggressive
substances, a higher corrosion protection KS
or KX must be chosen.
4) adjustable between min. and max. values
5) at shortest operating time
6) with unbored coupling
SG 05.1 - SG 12.1
Issue 1.98
DO 02.02.006GB
1) adjustable between min. and max. values
2) at 50 Hz
3) with unbored coupling
Notes:
AUMA motors are provided with thermoswitches to protect the windings
(refer to terminal plans KMS). Our warranty will lapse if those thermoswitches are
not connected in the control circuit.
Motor data are approximate. Due to usual manufacturing tolerances there may be
deviations from the values given.
Permissible fluctuation of nominal voltage: 5 %. If voltage drops below there may
be a reduction of nominal output torque.
We reserve the right to alter data according to improvement made. Previous data sheets become invalid with the issue of this data sheet.
Technical data AUMA part-turn actuators
3-phase AC (standard voltages and frequencies)
Volt 220 230 240 380 400 415 440 460 500
Hz 50 50 50 50 50 50 60 60 50
with 3-phase AC motors
Tripping
torque
1)
both directions
Valve
mounting
flange
ISO 5211
Valve shaft AUMA part-turn
actuator type
400 V 50 Hz
M
o
t
o
r
p
o
w
e
r
M
o
t
o
r
s
p
e
e
d
2
)
N
o
m
i
n
a
l
c
u
r
r
e
n
t
C
u
r
r
e
n
t
a
t
m
a
x
.
t
o
r
q
u
e
S
t
a
r
t
i
n
g
c
u
r
r
e
n
t
P
o
w
e
r
f
a
c
t
o
r
H
a
n
d
w
h
e
e
l
d
i
a
m
e
t
e
r
T
u
r
n
s
f
o
r
9
0

W
e
i
g
h
t
3
)
m
i
n
.
N
m
m
a
x
.
N
m
S
t
a
n
d
a
r
d
S
p
e
c
i
a
l

m
a
x
.
m
m
S
q
u
a
r
e
m
a
x
.
m
m
T
w
o
-
f
l
a
t
m
a
x
.
m
m
O
p
e
r
a
t
i
n
g
t
i
m
e
f
o
r
9
0

i
n
s
e
c
o
n
d
s
2
)
kW 1/min A appr. A appr. A cos mm
appr.
kg
90 150 F 05 F 07 25,4 22 22
SG 05.1 4 0,160 2800 0,60 0,8 1,7 0,67
160 58 18
SG 05.1 5,6 0,160 2800 0,60 0,7 1,7 0,67
SG 05.1 8 0,090 2800 0,50 0,6 1,0 0,58
SG 05.1 11 0,080 1400 0,55 0,6 0,9 0,60
SG 05.1 16 0,045 1400 0,35 0,4 0,5 0,60
SG 05.1 22 0,045 1400 0,35 0,4 0,5 0,60
120
210
F 07 F 10 25,4 22 22
SG 07.1 5,6 0,160 2800 0,60 0,8 1,7 0,67
160 58 18
300
SG 07.1 8 0,160 2800 0,60 0,8 1,7 0,67
SG 07.1 11 0,160 2800 0,60 0,7 1,7 0,67
SG 07.1 16 0,090 2800 0,50 0,6 1,0 0,58
SG 07.1 22 0,080 1400 0,55 0,6 0,9 0,60
SG 07.1 32 0,080 1400 0,55 0,6 0,9 0,60
250
420
F 10 F 12 38 30 27
SG 10.1 11 0,160 2800 0,60 0,9 1,7 0,67
160 107 24
600
SG 10.1 16 0,160 2800 0,60 0,9 1,7 0,67
SG 10.1 22 0,160 2800 0,60 0,8 1,7 0,67
SG 10.1 32 0,090 2800 0,50 0,7 1,0 0,58
SG 10.1 45 0,080 1400 0,55 0,6 0,9 0,60
SG 10.1 63 0,080 1400 0,55 0,6 0,9 0,60
500
840
F 12 F 14 50 36 41
SG 12.1 22 0,160 2800 0,60 0,9 1,7 0,67
160 110 28
1200 SG 12.1 32 0,160 2800 0,60 0,9 1,7 0,67
840 SG 12.1 45 0,080 1400 0,55 0,7 0,9 0,60
1200 SG 12.1 63 0,080 1400 0,55 0,7 0,9 0,60
Dimensions
EN ISO
5211
A A3 A4 AA
min.
B1 B2 B3
1)
B4
2)
C
4)
D D1 D2 D3 E F G H J
SG 05.1/AM F05
40 159 199 30 101 137 190 274 337 105 160 40 20 115 115 128 275 50
SG 07.1/AM F07
SG 10.1/AM F10 63 159 199 30 111 172 190 274 347 105 160 40 20 115 150 153 291 56
SG 12.1/AM F12 80 159 199 30 111 172 190 274 347 105 160 40 20 115 150 170 313 70
Dimensions
J1 K L
max.
L1 M N P1
3)
P2
3)
P3
3)
R T U Z d1 d2 d3 d4 h h1
SG 05.1/AM
150 170 60 63 235 171 M25x1.5 M20x1.5 M32x1.5 232 45 150 32 90
50 M6 9.5
SG 07.1/AM 55 70 M8 3 13
SG 10.1/AM 150 170 80 63 235 171 M25x1.5 M20x1.5 M32x1.5 242 55 150 32 125 70 102 M10 3 17
SG 12.1/AM 150 192 100 63 235 171 M25x1.5 M20x1.5 M32x1.5 242 55 150 32 150 85 125 M12 3 20
SG 05.1 SG 12.1
SGR 05.1 SGR 12.1
AM 01.1
Issue 2.09
We reserve the right to alter data according to improvements made. Previous documents become invalid with the issue of this document.
1/2
Y003.513/002/en
DimensionsPart-turnactuatorswithintegral controlsAUMAMATIC
A
A

D
2
d2
d3
d1
C

D
E
A
A
M
N
J1
P2
P1
A
3

D
3

D
1
4)
A
4
P3
Space required for removal
Valve attachment according to EN ISO 5211
Dimensions of couplings see next page
Space required for removal
1)
3ph AC-Motor
2)
Special 1ph AC-motor and DC motor (Both not suitable for SGR modulating proposes!)
3)
Standard, other threads on request
4)
Precise dimension, depending on the AUMA MATIC version
MS01/MS02 20516013
GI/3097/TCS/OS/ACTBU
BUTTERFLY VALVE ACTUATOR WIRING DIAGRAM
23034063
23034063



ITEM DETAIL
Description
3051CD2A22A1AS2B4M5Q4
Differential Pressure Transmitter
3051CD Transmitter Type: Differential Pressure Transmitter
2 Pressure Range: -250 to 250 inH2O/2.5 inH2O (-623 to 623 mbar/6.2 mbar)
A Transmitter Output: 4-20 mA with Digital Signal Based on HART Protocol
2 Flange Type Flange Material Drain/Vent Flange Adapters: Coplanar, SST, SST
2 Isolating Diaphragm: 316L SST
A O-Ring: Glass-filled PTFE
1 Sensor Fill Fluid: Silicone
A Housing Material Conduit Entry Size: Polyurethane-covered Aluminum, 1/2-14 NPT
S2 Diaphragm Seal Assemblies: Two Remote Seals (Direct Mount or Capillary Connection Type)
B4 Mounting Bracket: Coplanar Flange Brack\et for 2-in. Pipe or Panel Mounting,all SST
M5 Display Type: LCD Display for Aluminum Housing (Housing Codes A, B, C, and D only)
Q4 Calibration Data Certification: Calibration Certificate

1199DDB10ARFW21DAA1HJ
Flanged Remote Seals
1199 Type: Remote Seals
D Seal Location/Capillary Connection Type: Same Seal on Both High and Low Pressure Sides of
Transmitter, Welded
D Fill FluidTemp. Limits: D.C. 200
B Inside Diameter inches (mm)Material: 0.028 in. (0.71 mm), 316 SST Armored Sleeving, 0.028
10 Capillary Connection Length: 10 feet (3.0 meters)
A Industry Standard: ANSI (American National Standards Institute)
RFW Process Connection Style: Flanged Remote Seal
2 Process Connection Size: 1-in. (ANSI) 25A (JIS)
1 Flange Pressure Rating: Class 150 (ANSI)
DA Diaphragm MaterialUpper Housing MaterialMounting Flange Material: 316L SST, 316L SST, 316 SST
A Flushing Connection Ring Material (lower housing): 316 SST
1 Flushing Option: One 1/4-in. Flushing Connection
H Non-Sanitary,Flushing Plug; Sanitary,Ra Finish: SST Drain/Vent in Flushing Connections
J Gasket for Lower Housing: Teflon Gasket for Lower Housing















Back Entry, Panel Mounting
Y Yoke Mounting (2 pipe mounting)
P
MOUNTING
BottomEntry, Surface Mounting S
MOVEMENT
Brass
CASE
SS304
SS316 S6
S4
Die-cast Aluminium AL
SS316 S6
DIAPHRAGM / BELLOW
15 - 150 mm
DIAL
Ordering Information
TYPE : IDPS
Please Specify
RANGE
A
B
C
D
E
kg/cm (g)
Bar (g)
PSI
KPa
mmHg
UNIT
Size Code Rating Code Facing Code
150#
300#
600#
900#
1500#
2500#
RF
FF
RTJ
LT
LG

1
1
2
3
A
B
C
D
E
F
RF
FF
RTJ
LT
LG
15
20
25
40
50
80
F - FLANGED PROCESS CONNECTION **
CONNECTION
SIZE MALE / FEMALE
Male
Female 10
6
15
25
20
32
F
M
METRIC THREADS
18 M - M 18 x 1.5
20 M - M 20 x 1.5
24 M - M 24 x 1.5
27 M - M 27 x 2
33 M - M 33 x 2
X X - Any other
40
1/4
3/8
1/2
3/4
1
1.1/4
1.1/2
TYPE
BP
NT
BT
GS
PF
NS
NPT
BSP
BSPT
PF
Gas
NPSM
www.general-gauges.com 46
The recommendations made in this catalogue are to be used as intended guide. No guarantee of material can be undertaken since other
factors may affect the performance. We reserve the right to change the specifications mentioned in this catalogue without any notice as
improvements & development is a continuous process at General. Responsibility of typographical errors is specifically disclaimed.
Please Specify
Static Pressure
Chemical Seal Unit-Refer
Catalogue CSU
U
Accessory - Refer
Catalogue ACC
X
D
L
O
N
P
Dual Scale
NACE-MR-01-75
O Cleaning
2
2" Pipe Mounting Bracket
Nil
OPTION
B 2SPDT
A 1SPDT
E External zero Adjustment
CE CE Certificate
Digital Indicator
JIR-301 Series
Standard Features: Multi-Input,
Retransmission and 3 Alarms
Model JIR
1/8 DIN (96mm x 48mm)
-320 to 2500F
-199.9 to 750.0F
-320 to 1800F
0 to 3200F
0 to 3200F
0 to 3300F
-320 to 1500F
-199.9 to 750.0F
-320 to 2300F
0 to 2500F
0 to 4200F
-200 to 1370C
-199.9 to 400.0C
-200 to 1000C
0 to 1760C
0 to 1760C
0 to 1820C
-200 to 800C
-199.9 to 400.0C
-200 to 1300C
0 to 1390C
0 to 2315C
K
J
R
S
B
E
T
N
PL-II
C (W/Re5-26)
4 to 20mA DC
0 to 20mA DC
0 to 1V DC
0 to 10V DC
1 to 5V DC
0 to 5V DC
Input Type Scale
-1999.9 to 9999, -199.9 to 999.9
-19.99 to 99.99, -1.999 to 9.999
Thermocouple
DC
For DC current input a shunt resistor (sold separately) (50) is required.
Structure
Unit available in standard DIN size (1/8 DIN).
NEMA 4X protective construction.
Black enclosure.
Programmable Alarms
Unit features standard three alarm outputs.
True Multi-Input
Unit features true multi-input capabilities:
10 thermocouple types, 2 RTD types,
2 current inputs, and 4 voltage inputs.
Retransmission
Unit features standard 4-20mA process variable
retransmission.
Optional outputs available.
Large LED Display
All units feature dual display. PV red 4 digits,
Alarm SV green 4 digits.
Approvals
UL, cUL and CE Safety Approvals.
Warranty
All units manufactured to strict ISO standards
and offer full 3 year manufacturers warranty.
Low Cost
Most advanced price/performance package available.
Standard Features Input Range Table
-199.9 to 999.9F
-300 to 1500F
-199.9 to 850.0C
-200 to 850C
Pt100 RTD
High Performance
Temperature & Recording
Instrumentation
Terminal Wiring
Panel Cutout
TA or TV
Shinko is an
ISO 9001
facility
Display
PV.........Red 4-digit Character Size: 16.0 x 7.2 mm (H x W)
SV........Green 4-digit Character Size: 10.0 x 4.8 mm (H x W)
Input
Thermocouple ----- K, J, R, S, B, E, T, N, PL-II C (W/Re5-26) External resistance: 100 or less
(However, for B input: 40 or less)
RTD ------------------ Pt100, 3-wire system
(Resistance per wire: 10 or less)
DC current ---------- 0 to 20mA DC, 4 to 20mA DC Input impedance: 50
(Connect shunt resistor 50 between input terminals.)
Allowable input current: 50mA or less
(When shunt resistor 50 is used.)
DC voltage ---------- 0 to 1V DC Input impedance: 1M or greater
Allowable input voltage: 5V or less
Allowable signal source resistance: 2k or less
0 to 5V DC, 1 to 5V DC, 0 to 10V DC Input impedance: 100k or greater
Allowable input voltage: 15V or less
Allowable signal source resistance: 100 or less
Thermocouple -------------------- Within 0.2% 1digit of each input span 1 digit or 2C (4F) whichever is greater
However, R or S input 0 to 200C (0 to 400F): Within 6C (12F)
B input 0 to 300C (0 to 600F): Accuracy is not guaranteed.
RTD --------------------------------- Within 0.1% of each input span, or 1C (2F) whichever is greater
DC current and DC voltage ----- Within 0.2% 1digit of each input span
Alarm 1 (A1)
Alarm 2 (A2)
Alarm 3 (A3)
Alarm action and Energized/De-energized can be selected by key operation.
The same as the indicating accuracy.
ON/OFF action
Thermocouple and RTD: 0.1 to 100.0C (F)
DC current and DC voltage: 1 to 1000
(The placement of the decimal point follows the selection)
Relay contact 3A 250V AC (Resistive load), Electric life: 100,000 times
Setting accuracy
Action
Hysteresis
Output
Accuracy
(Setting Indicating)
Input Sampling
Rate
0.25 seconds
Retransmission
General Specifications
The input value is converted in analog every 0.25 seconds, and it is outputted in DC current.
Resolution: 1/12000
DC current: 4 to 20mA DC (load resistance, Max 550 )
Output accuracy: Within 0.3% of output span
Supply Voltage
100 to 240V AC 50/60Hz, 24V AC/DC 50/60Hz
Allowable voltage fluctuation: 85 to 264V AC, 20 to 28V AC/DC Power consumption approximately 10VA
Isolation
Resistance
500V DC 10M or greater
Dielectric
Strength
Between Input terminal and Ground terminal, Input terminal and Power terminal ------------ 1.5kV AC for 1 minute
Between Power terminal and Ground terminal ---------------------------------------------------- 1.5KV AC for 1 minute
Between Output terminal and Ground terminal, Output terminal and Power terminal -------- 1.5KV AC for 1 minute
(Output terminal comprised A1, A2 and A3 output terminals transmission output terminal and communication terminal)
Material Color Material: Flame resistant resin. Color: Black
Environment Ambient temperature: -10 to 50C Ambient humidity: 35 to 85%RH (No condensation)
Setting Method Sheet key input
Dimensions 96mm x 48mm x 100mm (W x H x D) Weight: Approximately 300g
Mounting Method Screw type mounting bracket
Attached
Function
Sensor correction, Setting value lock, Power failure countermeasure, Self-diagnosis, automatic cold junction
temperature compensation (thermocouple type only), Sensor burnout alarm, Input burnout, Warm-up indication, Dust-
proof/Drip-proof IP66, Hold function.
Specified
(TA or TV)
Retransmission
The input value is converted in analog every 0.25 seconds, and is outputted in DC current or DC voltage.
If this option is applied, the standard transmission output (4 to 20mA) becomes ineffective.
Resoulution: 1/12000
DC current (TA): 0 to 20mA DC (load resistance, max 500)
DC voltage (TV): 0 to 1V DC (load reistance, min. 100k), 0 to 5V DC (load resistance, min. 500k)
1 to 5V DC (load resistance, min. 500k), 0 to 10V DC (load resistance, min. 1M)
Output accuracy: Within 0.3% of output span
Operates various setting value changes, setting value readings and settings from external computer.
If this option is added, Hold function is not available.
Code form --------------------------------- ASCII
Connectable units ------------------------ A maximum of 31 units per host computer
Data transfer rate ------------------------ 9600 bps (2400/4800/19200 bps changeable by key operation)
Communication system ------------------ Half-duplex start stop synchronous
Error detection ---------------------------- Parity check, checksum
Serial
Communication
(C5)
Transmitter
Power Supply
(P24)
24V DC from terminals 9 and 10, and this becomes the power source for a 2-wire transmitter.
If this option is added, Alarm 2 (A2) output is not available.
Output voltage: 24V 3V DC (when load current is 30mA)
Ripple voltage: 200mV (when load current is 30mA)
Max. load current: 30mA
Options
Input
Thermocouple: K, J, R, S, B, E, T, C (W/Re5-26), N, PL-II
Standard Specifications
Input Switching 6-point push button switch (Push button head: Black)
Material, Color Material: Flame resistant resin, Color: Light gray
Mounting
Flush, Mounting bracket: One-touch type (Panel thickness: Within 1 to 3 mm), Weight: Approx. 250g
INPUT CODE
Multi-range T/C, RTD, DC M
SUPPLY VOLTAGE CODE
24 V/DC 24V
100 - 240V AC ---
JIR-301-M ___ ___
Model Number Configuration
OPTIONS* CODE
Retransmission
DC current 0 to 20mA DC TA
DC voltage 0 to 1V DC,0 to 5V DC TV
1 to 5V DC, 0 to 10V DC
Transmitter Power Supply 24V DC P24
RS-485 C5
When the option P24 is added, Alarm 2 output is not available.
When the option C5 is added, Hold function is not available.
Terminal Arrangement
Selector Switch (Model FS-106-E)
Panel Cutout
OPERATION & MAINTENANCE MANUAL
FOR DEBRIS FILTER
KORADI TPS EXPANSION PROJECT GI 3097 200 09 054 Rev.A
GBX/3097/2011 Sheet 123























SECTION XV

DRAWINGS





KEY BENEFITS OF GEA BGR
TUBE CLEANING SYSTEM & DEBRIS FILTER

Increase in the Heat Transfer Rate
Optimum Turbine Back Pressure
Optimum Power Generation
Avoidance of Corrosion/Erosion of Condenser Tubes
Life Enhancement of Condenser Tubes
No Shutdown for Manual Cleaning
Economy in Fuel Cost
Low Chemical cost for Water Treatment
Typical payback period of 12-18 months on investment




































CONTACT :

GEA BGR ENERGY SYSTEM INDIA LIMITED
443, ANNA SALAI, TEYNAMPET, CHENNAI - 600 018. INDIA.
TEL: (+91 44) 2433 5958 FAX : (+91 44) 2434 3374
E-Mail : ed@geabgrenergy.com Website : www.bgrcorp.com