O & M Manual - Pcil - 1

INDEX
VOLUME DESCRIPTION VOLUME DESCRIPTION

BOILER Pages Pages
1 (a) Boiler Operation and Maintenance PLANT AUXILIARIES
PLANT AUXILIARIES Compressor 137
3 (a)
BFP 56 Cooling tower 94
Deaerator 25 PLANT CONTROL AND INSTRUMENTATION
ARC Valve 16 Control valves and positioner 275
4 (a)
DM tank 12 Transformer 26
2 (a) Dosing pump 17 PLANT CONTROL AND INSTRUMENTATION
Butterfly valves 9 Electromagnetic flow meter 24
Safety valves 6 Flow Elements 33
Sample coolers 33 Gauges 3
WTP PLC 37
4 (b)
PLANT AUXILIARIES Pressure Switch 1
Silencer 13 RTD and thermocouple 77
HP and LP valves 16 UPS 117
Level Gauge 6 RF type level switch 17
RAVs 16 PLANT CONTROL & INSTRUMENTATION
Slide gates 5 4 (c) Transmitters 347
2 (b)
Manual Hoist 44
Fire Fighting System 14 PLANT CONTROL & INSTRUMENTATION
AC and Ventilation system 38 4 (d) VFD drives-1
EOT cranes 31 4 (d) VFD drives-2
Rapping mechanism 12 PLANT ELECTRICAL SYSTEM
PLANT AUXILIARIES 5 (a) HT switchgear 4
2 (c) Miscellaneous pumps 3 PLANT ELECTRICAL SYSTEM
PLANT AUXILIARIES 5 (b) LT switch gear 32
2 (d) Hot gas generator and auxiliaries -1 73 Battery charger 7
5 (c)
2 (d) Hot gas generator and auxiliaries -2 CGL Motor 16
BOILER OPERATION
AND
MAINTENANCE MANUAL
CONTENTS
SECTION DESCRIPTION PAGE NO.
A Overall Plant Description
1 Plant Introduction
2 Site Specific Design Data
3 Mechanical Equipment Description Summary
4 Electrical Equipment Description Summary
5 Control and Instrumentation Equipment Description Summary
6 Anticipated Performance Data Sheet
7 Control Philosophy
B Plant Startup and Shutdown Procedure
C Construction Features
D Recommended Water Quality
E Boiler and Auxiliary Control and Protection Concept
F Maintenance Practices
G( Boiler Preservation
H) Commissioning Procedure
* Lubrication Schedule
J+ Attachment
1 Boiler GA
2 Boiler P&ID
A.OVERALL PLANT DESCRIPTION
A.1 PLANT INTRODUCTION
In ever growing industrialization of developed and developing nations, electric power generation through Waste heat
Recovery boilers have played very important role over more than two decades now. Waste Heat Gases from Cement Plant
are being utilized for steam generation. Utilization of Waste heat gases from the Cement Plant contributes to Green
Power as this reduces the use of the Natural Resources and it contributes to save the earth and the reduce the growing
Pollution in the industries due to emission of SOx, NOx etc. This aspect has been attracting more and more attention of
governments as well as people and the main focus is now on generation of steam with environmentally friendly system of
firing in boilers, without the use of natural resources.
In Cement manufacturing (dry process), nearly 40% of the total input heat is rejected as the waste heat from the exit
gases of the pre-heater (PH) and Air quenching clinker cooler (AQC). This waste heat has various applications within the
cement plant such as drying of Raw materials/Fuel, preheating the combustion air to Kiln etc. Even after utilizing the heat
for above application, there is still waste heat available in the PH & AQC circuit which can be effectively utilized for power
generation.
Considering the potential of waste heat available from the exhaust gases of pre-heater & from the hot air available from
cooler vent, M/s Parasakti Cement Industries Ltd have installed a Waste Heat Recovery (WHR) based captive power plant
in their existing cement plant at Jetipalam Distt Guntur AP. And as there is no CPP within the premises of Plant, HAG
option have been added in the AQC Boiler heat input to get some additional power benefit.
"WHR Boiler" offers valuable solution to reduce ill effects of pollution. Salient advantages of this system are:
a) Effective utilization of the Waste Heat Gases from Cement plant.
b) Contribution to Green Power.
c) No Use of Natural Resources for Power Generation.
d) Increase in Life and efficiency of the pollution control equipment’s in Cement Plant.
The WHR boilers are user friendly and needs only the control of the Dampers for diversion of the gases into the steam
generators.
The advantages of WHR boiler are such as:

¾ Simple and reliable arrangement.
¾ Easy in Operation.
¾ Low Operating cost.
¾ No Fuel required
¾ Low Generation Cost
¾ Low Maintenance required
A.2 SITE SPECIFIC DESIGN DATA (PH & AQC)
2 No x WHRB Natural Recirculation, Water Tube, Single drum, Vertical Orientation with bottom Entry for AQC & Vertical
Orientation with top entry in case of PH.
Waste Heat Recovery Boiler on Cement Plant

UNIT VALUE
PARAMETERS
Total Boiler’s Rating [MCR] (PH & AQC) HP Steam Kg/hr 29200
HP Steam Pressure @ Super heater – 2 Outlet (AQC Boiler) Kg/cm²(g) 14.5
HP Steam Temperature @ Super heater -2 Outlet (AQC Boiler) °C 390±5
AQC Boiler LP steam quantity Kg/hr 1800
LP Steam Pressure @ LP Super heater Outlet (AQC Boiler) Kg/cm²(g) 2.5
LP Steam Temperature @ LP Super heater Outlet (AQC Boiler) °C 195
PH Boiler LP steam quantity Kg/hr 3200
LP Steam Pressure @ LP Super heater Outlet (PH Boiler) Kg/cm²(g) 2.5
LP Steam Temperature @ LP Super heater Outlet (AQC Boiler) °C 195
Design Code
Boiler Pressure Parts IBR
Boiler Piping ASME B31.1 approved by IBR
Flue Gas Data (For PH Boiler)

PARAMETERS UNITS VALUE
Flue gas flow Nm³/Hr 1,62,925

Inlet Temperature Deg C 320
Outlet Temperature Deg C 180 ± 5
Flue gas inlet pressure at Tapping point mmWC -590
Flue Gas Composition :-
CO2 % Volume 30.5
H2 O % Volume 0.8
N2 % Volume 64.7
O2 % Volume 4
Dust Loading gm/Nm3 103
Flue Gas Temperature Profile (PH- Boiler)
Sr. Component Deg C.

Boiler inlet 320
1
2 HP Super heater Outlet 308
3 HP Evaporator outlet 212
4 LP Super heater Outlet 200
5 LP Evaporator Outlet 180 + 5
Flue Gas Data (For AQC- Boiler)
Flue gas flow (Cooler Exhaust) Nm³/Hr 1,42,000
Flue Gas Temperature ( Cooler Exhaust) Deg C 305
Flue Gas Flow ( HAG Outlet) Nm³/Hr 1,53,200
AQC Boiler Inlet Temperature °C Deg C 440

Outlet Temperature °C Deg C 90 ± 5
Flue gas pressure at Tapping point (Cooler Exhaust) mmWC -20
Flue gas pressure at HAG Inlet (Deduster Outlet) mmWC -35
Flue gas pressure at AQC Boiler Inlet (HAG Outlet) mmWC -55
Flue Gas Composition :-

H2 O % Vol 0.00
N2 % Vol 79.00
O2 % Vol 21.00
Dust Loading gm/Nm3 30
Flue Gas Temperature Profile (AQC-Boiler)
Sr. Component Deg C
1 Boiler inlet 440
2 HP Super heater 2 Outlet 400

3 HP Super heater 1 Outlet 373
4 HP Evaporator outlet 212
5 LP Super heater outlet 211
6 Economizer outlet 171
7 LP Evaporator Outlet 151
8 Condensate Pre-heater outlet 90 ± 5
Flue gas Pressure profile

Sr. Component AQC PH
mmWc mmWc
1 Flue gas Pressure at Tapping point -20 -590
2 Flue gas Pressure at outlet Tapping -170 - 670
3 Pressure drop across I/L & O/L Tapping 150 80
Water & Steam Temperature profile for AQC & PH Boiler

Sr. Component Units AQC PH
1 Inlet of Condensate Pre-heater Deg C 48 Not Applicable
2 Outlet of Condensate Pre-heater Deg C 118 Not Applicable
3 Inlet of Economizer Deg C 126 Not Applicable
4 Outlet of Economizer Deg C 193 Not Applicable
5 HP Drum Temp Deg C 193 193
6 Inlet of Primary Super heater HP Deg C 201 201
7 Outlet of Primary Super heater HP Deg C 340 300
8 HP Steam Temperature at Mixing Header Deg C 320
9 Inlet of Final HP Super heater Deg C 320 Not Applicable
10 Outlet of Final HP Super heater Deg C 390 Not Applicable
11 LP Drum Temp Deg C 127 127
12 LP Super heater Outlet Temp Deg C 195 195
Water & Steam Pressure profile
Sr. Component (Pressure) AQC Boiler PH Boiler

Kg/cm² (g) Kg/cm² (g)
1 Inlet of Condensate Pre heater 5.0 Not Applicable

2 Outlet of Condensate Pre-heater 3.0 Not Applicable
3 Deaerator Operating Pressure 1.44
4 Economizer outlet 19 Not Applicable
5 HP Steam drum operating pressure

6 HP Super heater I inlet
7 HP Super heater I outlet 15.4 15.5
8 Mixing Header 15.5
9 HP Super heater II inlet 15.5 Not Applicable
10 HP Super heater II outlet (MSSV) 14.5 Not Applicable
11 LP Steam Drum Operating pressure
12 LP Super heater Inlet pressure
13 LP Super heater Outlet pressure 2.5 2.5
Electrical power
For LT motors (UPTO AND INCLUDING 200 KW)
Voltage V 415±10%
Frequency Hz 50+5%
For HT motors (above 200 KW)
Voltage V 11000
Frequency Hz 50
For Instrumentation (field switches, Level gauge illumination, solenoid valves etc.)
Voltage V 230±10%
Frequency Hz 50+%
For Control Instruments
Voltage V 110±10%
COOLING WATER FOR BOILER AUXILIARIES

PARAMETERS UNIT VALUE
Pressure Kg/cm²(g) 4
Temperature Deg C 42°C Max, 33°CMin
Quality Raw water
INSTRUMENT AIR
PARAMETERS UNIT VALUE
Pressure Kg/cm²(g) 6-7
Dew point Deg c -20
Quality — As per ISO 8573-1
CHEMICALS FOR DOSING

HP Dosing at Steam Drum (LP & HP Both) Tri Sodium Phosphate
DETAIL SPECIFICATION OF PRESSURE PARTS AND EQUIPMENTS FOR AQC BOILER
HP STEAM DRUM
S. No DESCRIPTION UNITS VALUE
1 Design code --- IBR 1950 with latest amendments
2 Design pressure kg/cm²(g) 17
3 Design temperature Deg C 208
4 Hydro test pressure kg/cm²(g) 25.5
5 Length mm 5000
6 Inner diameter mm 1200
7 Thickness mm 18
8 Type of Dished End --- Tori spherical
9 Thickness of Dished end mm 18
10 Material of construction --- SA 516 Gr. 70
11 Quantity --- One
12 Corrosion allowance --- IBR 1950 with latest amendments
13 Internals --- Demister Pad & Baffles

14 Quantity of safety valves --- 2
LP STEAM DRUM
5 Length mm 4000
7 Thickness mm 8
11 Quantity --- One

HP PRIMARY SUPER HEATER
5 Tube Type --- FINNED
6 Total Heat transfer area (Thermal) m² 119 – TUBES , 1017- FINS
7 Type configuration --- INLINE
8 Tube outer diameter mm 44.5
9 Tube thickness mm 3.25
10 No. of Tubes (Wide x Deep) --- 42 X 4
12 Effective Tube Length mm 8000
13 MOC of tubes --- SA 210 GR A1
14 MOC of headers --- SA 106 GR B
15 Type of Fin --- SPIRAL
16 Fin Dimensions (Height x Thk x Fins per m) mm x mm 12.7 X 1.3 X 156
HP FINAL SUPERHEATER
6 Total Heat transfer area (Thermal) m² 398 – TUBES , 2009- FINS
7 Type configuration --- INLINE
10 No. of Tubes (Wide x Deep) --- 42 X 4
HP EVAPORATOR
6 Total Heat transfer area (Thermal) m² 1108 – TUBE, 5102- FIN
7 Type configuration --- STAGGERED
9 Tube thickness mm STRAIGHT TUBES- 3.25, BENDS – 3.6
10 No. of Tubes (Wide x Deep) per Module --- 38 X 4
12 No. of Modules --- 2
ECONOMIZER
2 Design pressure kg/cm²(g) 32.5
6 Total Heat transfer area (Thermal) m² 541 – TUBES, 3045- FINS

14 MOC of tubes ---
17 Fin Dimensions (Height x Thick x Fins per m) mm x mm 12.7 X 1.3 X 156
CONDENSATE PREHEATER
1 Design code --- IBR 1950 WITH LATEST AMENDMENTS
6 Total Heat transfer area (Thermal) m² 775 – TUBES , 4350 FINS
7 Type configuration --- STAGGRED
LP EVAPORATOR
6 Total Heat transfer area (Thermal) m² 428 – TUBES ,2040- FINS
LP SUPERHEATER

6 Total Heat transfer area (Thermal) m² 41 – TUBES ,109- FINS
17 Fin Dimensions (Height x thk x Fins per m) mm x mm 12.7 X 1.3 X78
Safety Valves
DESCRIPTION
UNITS HP DRUM HP DRUM HP SH 1 OUTLET HP SH 2 OUTLET
/APPLICATION
Type --- Spring loaded Spring loaded Spring loaded Spring loaded
Make --- Fainger Lesser Fainger Lesser Fainger Lesser Fainger Lesser
Medium --- Saturated Steam Saturated Steam Superheated Steam Superheated Steam
WHRS-AQC2HP- WHRS-AQC2HP- WHRS-AQC2HP- WHRS-AQC2HP-

Tag No. -
MAS-SV-001 MAS-SV-002 MAS-SV-004 MAS-SV-003
Working Pressure Kg/cm² 15.3 15.3 15.1 14.5
SET PRESSURE Kg/cm² 18 19 17.5 17
Relieving Capacity TPH 7.62 8.02 3.9 36.47
QUANTITY --- One One One One
DESCRIPTION UNITS LP DRUM LP DRUM LP SH OUTLET ECO
Type --- Spring loaded Spring loaded Spring loaded Spring Loaded
Make --- Fainger Lesser Fainger Lesser Fainger Lesser Fainger Lesser
Medium --- Saturated Steam Saturated Steam Superheated Steam Feed Water
WHRS-AQC2LP- WHRS-AQC2LP- WHRS-AQC2LP- WHRS-AQC2HP-

Tag No. -
MAS-SV-001 MAS-SV-002 MAS-SV-003 FDW-SV-001
Working Pressure Kg/cm² 2.5 2.5 2.45 23
SET PRESSURE Kg/cm² 4 5 3.5 32
Relieving Capacity TPH 0.72 0.93 0.66 34.6
QUANTITY --- One One One One
LEVEL INDICATOR FOR STEAM DRUM

S. No DESCRIPTION UNITS DETAILS
1 Make --- V Automat & Inst. Ltd
2 Type --- Transparent Level gauge
3 Location --- Steam Drum
4 Operating pressure.(HP/LP) kg/cm²(g) 15.5 / 2.5
5 Design Pressure (HP/LP) kg/cm²(g) 19 / 5
6 C/C distance (HP/LP) mm 686 / 686
7 Operating temp. (HP/LP) Deg C 202 / 138
8 Design temp (HP/LP) Deg C 215 / 160
BLOW DOWN TANK
S. No DESCRIPTION DETAILS
1 Design code IBR 1950 with latest amendments
2 Design pressure 1.5 kg/cm²(g)
3 Design Metal Temperature 128 Deg C
4 Hydro test pressure 2.25 kg/cm²(g)
5 Shell Height 2000 mm
6 Shell ID 1200 mm
7 Shell thickness 8 mm
8 Type of ends TORISPHERICAL
9 Material of construction SA 516 GR 70
10 Type of Level gauge
LEVEL GAUGE FOR BLOW DOWN TANK

2 Type --- Tubular Type
3 Location --- Blow-down Tank
4 Operating pressure. kg/cm²(g) Atmospheric
5 Design Pressure kg/cm²(g) 1.5
7 C/C distance mm 1000
8 Operating temp. Deg C 100
9 Design temp Deg C 150
HP DOSING SYSTEM
1 Make -- Flow Control Pumps & Systems
2 Major parts --- Storage tank – 1 no (Common for AQC HP &

LP), Stirrer – 1 no., Dosing pumps – 2 nos.
Storage tank Details
1 Size of storage tank mm x mm x mm Dia.750 X 890 H X 3thk
2 Tank capacity liters 300
3 MOC of tank --- MSRL
Dosing pump Details
1 Pump make/Model --- FLOW CONTROL MAKE FCP 5011
2 Pump capacity lph 0-5

3 Pump discharge Pressure kg/cm²(g) 30
4 Pump type --- Positive Displacement
Agitator details
1 Type of operation --- Slow Speed Motorized AGI, Propeller Type
Motor details
1 Motor for Pump --- 0.5 hp/1440 rpm/415V/50Hz
2 Motor for Agitator --- 0.5 hp/ 1440 rpm/415V/50Hz
INSULATION & Al. CLADDING

S. No DESCRIPTION VALUE
1 Type LRB Mineral Wool
2 Density 100-150 kg/m³
3 AL Cladding 20 SWG
DETAIL SPECIFICATION OF PR. PARTS AND EQUIPMENTS FOR PH BOILER
1. STEAM DRUM
5 Length mm 5000
7 Thickness mm 18
11 Quantity --- One
2. SUPER HEATER
5 Tube Type --- Bare
6 Total Heat transfer area (Thermal) m² 921
7 Type configuration --- Inline
10 No. of Tubes (Wide x Deep) --- 58 x 6
3. EVAPORATOR
5 Tube Type --- Bare
6 Total Heat transfer area (Thermal) m² 8428
7 Type configuration --- Inline
10 No. of Tubes(Wide x Deep) for Module 1 to 4 --- 58 x 4
4. SAFETY VALVES
DESCRIPTION
UNITS HP DRUM HP DRUM HP SH 1 OUTLET
/APPLICATION
Type --- Spring loaded Spring loaded Spring loaded
Make --- Fainger Lesser Fainger Lesser Fainger Lesser
Medium --- Saturated Steam Saturated Steam Superheated Steam
Tag No. - WHRS-PH2HP-SV-001 WHRS-PH2HP-SV-002 WHRS-PH2HP-SV-003

Working Pressure Kg/cm² 15.9 15.9 15.7
SET PRESSURE Kg/cm² 18 19 17.5
Relieving Capacity TPH 7.62 8.0 2.56
QUANTITY --- One One One
5. LEVEL INDICATOR FOR STEAM DRUM

2 Type --- Transparent Level gauge

3 Location --- Steam Drum
4 Operating pressure. kg/cm²(g)
5 Design Pressure kg/cm²(g)
7 C/C distance mm
8 Operating temp. Deg C
9 Design temp Deg C
6. BLOW DOWN TANK

S. No DESCRIPTION VALUE
1 Design code IBR 1950 with latest amendments
2 Design pressure 1.5 kg/cm²(g)
3 Design Metal Temperature 135 Deg C
4 Hydro test pressure 2.25 kg/cm²(g)
5 Shell Height 2000 mm
6 Shell ID 1200 mm
7 Shell thickness 8 mm
8 Type of ends Tori spherical
9 Material of construction SA 516 GR 70
10 Type of Level gauge Transparent Type
7. LEVEL GAUGE FOR BLOW DOWN TANK

2 Type --- Tubular Type

3 Location --- PH Blow down tank
4 Operating pressure. kg/cm²(g) Atmospheric
5 Design Pressure kg/cm²(g) 1.5
7 C/C distance mm 1000
8 Operating temp. Deg C 100
9 Design temp Deg C 150
8. HP DOSING SYSTEM
1 Make -- Flow Control Make
2 Major parts --- Storage tank – 1 no (Common for AQC HP &

LP), Stirrer – 1 no., Dosing pumps – 2 nos.
Storage tank Details
1 Size of storage tank mm x mm x mm Dia.750 X 890 H X 3thk
2 Tank capacity liters 300
3 MOC of tank --- MSRL
Dosing pump Details
1 Pump make/Model --- FLOW CONTROL MAKE FCP 5011
2 Pump capacity LPH 0-5

3 Pump discharge Pressure kg/cm²(g) 30
4 Pump type --- Positive Displacement
Agitator details
1 Type of operation --- Slow Speed Motorized AGI, Propeller Type
Motor details
1 Motor for Pump --- 0.5 hp/1440 rpm/415V/50Hz
2 Motor for Agitator --- 0.5 hp/ 1440 rpm/415V/50Hz
9. Insulation
Sr. Description Value
1 Type LRB Mineral Wool
2 Density 100-150 kg/m³
3 Al. Cladding 20 SWG
Mechanical Equipment Description Summary

Technical data sheet:
A. Chain Conveyor – AQC Boiler
Location AQC BOILER

Quantity 05
Make TURBOVENT
Design Capacity 10 TPH
Width Single Strand DCC 250 X 500mm
Conveying speed 0.1077 m/sec
Control
Bulk Density (Clinker Dust) 1.1 T/m3
Input Coupling
Gear Box Geared Motor -1.1Kw 19rpm
A. Screw Conveyor – PH Boiler
Location PH BOILER
Quantity 01
Make TURBOVENT
Design Capacity 20 TPH
Width U-trough, horizontal, 450mm Dia
Conveying speed 26 rpm
Control
Bulk Density (Raw meal Dust) 0.85 T/m3
Input Coupling
Gear Box Geared Motor -3.7Kw 26 rpm
B. Boiler HP feed pump

Make KSB Pumps
Quantity 02 (01 W + 01 S)
Rated Flow 41.3 m3/hr
Rated differential head 290 m
Feed water temperature 126 Deg C
Bearing lubrication Antifriction Bearing & Plain Bearing
Coupling type Gear Type Spacer Coupling
Flow Control
C. Make-Up Water Deaerator & FW Storage Tank
Make EAS
Quantity One
Deaeration Capacity 38.8 TPH
Storage tank volume 8 m3
Storage tank usable volume (NWL to LLWL) 6.3 m3
Design pressure 3.5 kg/cm2 (g) & full vacuum
Design temperature 200 Deg C
D. DM water storage tank
Make Rostfrei Steels

Quantity one
Capacity 100m3
Storage tank volume 109.40 KL
Storage tank usable volume (NWL to LLWL) 87 KL
Design pressure Atmospheric
Design temperature Ambient
G. Silencer – Details & drawings enclosed
H. Boiler anticipated parameters –Enclosed
I. Rotary airlock valves - Drawings
J. Schedule of Valves (Format Attached below) – enclosed
Class
S.N. Valve Tag No. Type Size NB Opn. End. Conn. Body mtl. Qty. per Boiler
Rating
K. Schedule of electrical equipment (Format attached below) – enclosed load list

Motor Motor Voltage
Qty Operatio
Equipment Rating speed level Feeder Type Remark
n
W S (KW) (rpm) Volt
L. Hot gas generator data sheet. – enclosed
M. RAVs. – Details Enclosed
N. Cooling Water Make up pump

Make Mather & Platt - WIlo
Quantity 02 Nos (1W + 1S) TYPE – Vertical
Rated Flow 60 m3/hr
Feed water temperature Ambient
Bearing lubrication Anti friction bearings
Coupling type Pin & Bush Coupling
O. Raw water transfer pump

Make Kirloskar Brothers Ltd
Quantity 02 (1 W + 1S)
Rated Flow 6.5m3/hr
Rated differential head 55m WC
Feed water temperature Ambient
Bearing lubrication
Coupling type
P. Fire hydrant pumps

Make Mather & Platt (WILO)
Quantity 01 No’s Main Electric driven Pump / 01 No’s Jockey Pump / 01 No’s Diesel Engine driven pump
Rated Flow Main & Diesel driven – 171 m3/hr Jockey Pump – 10.8 m3/hr
Rated differential head Main & Diesel driven – 88m, Jockey Pump – 88m
Bearing lubrication
Coupling type Spacer Type Coupling
Q.DM Transfer pumps

Make Wilo – Vertical Pump
Quantity 02 No. (1W + 1S)
Rated Flow 4 m3/hr
Rated differential head 35m
Bearing lubrication Anti Friction Bearings
Coupling type
R. Cooling Tower. Details Enclosed

S.ACW Pumps
Make Mather & Platt – Wilo Brand
Quantity 02 No’s (1 W + 1S)
Rated Flow 200 m3/hr
Bearing lubrication Antifriction Bearings
Coupling type Spacer type coupling
T. MCW Pumps
Make Mather & Platt
Quantity 02 No.s (1W + 1S)
Rated Flow 2310 m3/hr
Bearing lubrication Anti Friction bearings
Coupling type Flexible Pin Bush type coupling
U.CT fans – Enclosed with cooling tower details
V. Side stream filter – Capacity 125m3/hr
A.3 CONTROL PHILOSOPHY
Instrumentation and control philosophy of WHR boiler incorporates control loops, which are mostly common with other
conventional boiler control systems. Broadly total scheme can be split into:
1. Boiler Protection
2. Boiler Interlock
3. Auto Control
BOILER PROTECTION
During cold or hot startup of the boiler as also normal operation of the unit, certain parameters e.g. drum level; final steam
temperature, Flue Gas temperature etc. are monitored on continuous basis and ensures that unit will be pulled out of service in
cases of deviations beyond set limits. The unit will be restarted only after normal values are established.
BOILER INTERLOCK
In order to start the boiler smoothly, safely and in a desired sequence, certain interlocks are provided. The contacts / sources to
achieve sequential start are drawn from MCC, transmitters, actuators etc. The unit can also be shut down safely as per desired
sequence and same contacts will mostly be useful in normal shut down sequence.
AUTO CONTROLS
The steam generator is normally expected to maintain operating parameters at desired levels from approximately 60% MCR to
100% MCR by tuning the standard control loops as described below:
THREE-ELEMENT CONTROL
The drum level control is executed as conventional three-element control system and designed to keep the level in the boiler
drum constant at all load conditions. For steam flow up to 30% of the MCR flow, drum level control is executed as a single
element control. For steam flow above 30% of the MCR flow, drum level control is executed as a three-element control.
The three elements of this control system are steam flow, drum level and feed water flow. Temperature correction is applied for
feed water flow; temperature & pressure compensation is applied for steam flow; pressure correction is applied for drum level.
Load changes, i.e. changes in steam flow rate as steam is drawn by the turbine, are feed forwarded to the boiler drum level
controller as disturbance variables.
The set point signal for the feed water flow control comes from the drum level controller. Feed water controller output then
adjusts the feed flow to maintain the desired drum level. When the desired drum level is maintained the feed water flow and
steam flow will generally match. But, feed water flow will be slightly higher because of continuous blow down.
Level transmitters generate following alarms: LOW-LOW, LOW, HIGH, and HIGH-HIGH. The maximum and minimum levels in the
boiler drum are monitored. As soon as water level in the drum drops below LOW-LOW level, boiler must be tripped. An emergency
blow down is provided in case the drum level goes to HIGH-HIGH for restoring the normal water level.
Three (3) drum level transmitters are used for drum level measurement. Drum level reading is obtained by taking median value of
readings for the respective transmitters on the drum. From three separate level transmitters high, high-high, low, low-low alarms
and trip signals are generated and 2 out of 3 Logic will be used for tripping of Boiler and High and Low Alarm.
FLUE GAS PRESSURE CONTROL
Three (3) pressure transmitters are used to measure the Flue Gas pressure (usually measured at a point at the tapping, Boiler
inlet & Outlet) with the inlet value being used for control. The three pressure inputs will be monitored to provide an alarm signal,
whereas Inlet Flue Gas pressure drop gives a trip signal to the boiler as the induced draught is very high at boiler inlet -650mmW
C. If flue gas pressure at PH boiler inlet beyond -700mmWC Boiler will trip.
Similar is the case in AQC boiler where the induced draught is maintained by the ID fan at the Clinker ESP Outlet. If flue gas
pressure at boiler inlet beyond -75 mmWC Boiler will trip.
If an excessive deviation occurs between the measured values of pressure and the desired value then the auto/manual station
will be taken to manual control, & Open Command to bypass damper will be given.
STEAM TEMPERATURE CONTROL

Final Super heater steam temperature is controlled by the modulation of spray water control valves to the two stages of
attemperation. Attemperator is located between Mixing Header & SH2 of AQC Boiler
SH2 outlet steam temperature is used as a measured value to SH2 outlet controller with desired value being manually set.
Output of this controller being the set point of SH2 inlet steam temperature controller via a high selector relay which compares
the output to the saturation temperature limit derived from the drum pressure signal.
SH2 inlet steam temperature is used as the measured value to the SH2 inlet steam temperature controller. The controller output
is supplied to the Attemperator spray valve.
As the load increases, the quantity of water spray also increases. In the event of only one spray nozzle, it is likely that at higher
water flow, atomization of water may not be proper, which may adversely affect on life of Attemperator. However, dual-spray
nozzle system incorporated in WHR boiler ensures fine spray of water, within specific limits through each nozzle, to achieve quick
evaporation.
FLUE GAS FLOW CONTROL

Flue gas flow inside the boiler is regulated by the By Pass Regulation Damper in both cases of PH & AQC Boiler.
If there is any deviation in boiler parameters as given in the trip list, It gives a command of boiler trip, which is actually opening of
the bypass damper for control of the flue gas flow in the boiler. If after opening of Bypass damper due to certain value parameters
such as Flue Gas temperature, Drum Level, Main Steam Temperature etc. normalizes, the Bypass Damper is again closed as per
requirement, normalizing the boiler operation.
In case of AQC Boiler HAG Operation has to be bypassed by the HAG Bypass Multi-louver damper in case of any abnormality/
variation in Kiln operation.
B. BOILER OPERATION
B. BOILER OPERATION
Section Overview
This section describes the start up, shut down procedures of the WHRB. WHRB operation logics, Maintenance practices & safety
are also described here.
Topics Covered
1. Pre-requisites to be Attended Before Start up
2. Boiler Start Up
3. Boiler Shutdown
4. Paralleling WHRB To The Plant steam Mains
5. Cooling of Shutdown WHRB & Its Preservation
6. Do’s and Don’ts
7. WHRB Log Sheet
8. Emergency Procedures
9. Alarms and Tripping
10. Operation Logic
11. Troubleshooting Chart
1. PRE-REQUISITES TO BE ATTENDED BEFORE START UP
¾ All pre-commissioning activities like Refractory dry out of AQC Boiler Inlet Duct, Alkali Boil Out, Hydro test of the complete
system, Safety Valve floating check and steam blowing of pipe lines should have been completed prior to startup of boiler
for continuous operation
¾ All instruments should be taken on line and checked for proper functioning. Switch on power supply to MCC and control
panel. Ensure all the safety interlocks are in operation and functioning. Necessary personal protection equipment and
field safety gear should be kept in place.
¾ Provide all manholes and hand-holes with proper gaskets. Use sealant for proper holding of gaskets.
¾ Flush all piping like feed water piping, drain lines, CBD piping etc with water to ensure no clogging in pipelines.
¾ Open isolation valves for level transmitters & level gauge for steam drum. Run the feed Water pump with minimum
opening of flow control valve. Fill the system with fresh boiler feed water up to common below normal water level. Close
the manual valve at pump discharge and stop the pump.
¾ Check system for any leaks or mal-functioning equipment.
¾ Reduce the water level by operating blow-down valve and check the operation of level low alarms from transmitter are
functioning properly. Also check readings on level transmitter and level gauges are matching.
¾ Keep water level 2 inches below the normal operating level.
¾ Adjust valves for boiler operation according to VALVE SETTINGS.
¾ Check electrical and pneumatic motorized operation of valves.
¾ Ensure flow and pressure of instrument air and cooling water is as per requirement.
Feed Water Supply

Primarily before allowing the flue gases to the Waste Heat Boiler, a thorough check should be made of all feed water supply
equipment to insure a continuous and adequate supply of treated and de-aerated feed water to the boiler.
The feed water quality should be maintained as per norms.
Refer concerned chapter for recommended water chemistry.
Valve Settings
Valves Line Up
As the boiler is to be operated mainly from the DCS from the control room (except for some venting / draining during filling /
charging etc. which are done locally) the valve line up has to be prepared accordingly on field.
Root valves of all Instruments (Pressure gauges, Pressure transmitters, Flow transmitters, DP transmitters etc.,) must be kept open
and their drains if any are to be kept closed. They are not separately listed:
Super Heater
¾ Open the vents on the inlet and outlet header of Super Heater and should be closed after the boiler pressure had reach
5 Kg/cm²
Economizers
¾ Keep the air vents open on the outlet headers of the Economizer these valves to be closed after water is filled up to the
vents.
¾ Keep the drain valves on the headers open for boiler water filling, these valves to be closed after boiler water filling.
Blow Down Tank

¾ Verify that the inlet cocks of level gauge are open and its drain valve is closed.
¾ Verify that the above valves to the blow down tank are open & closed.
Steam Drum
¾ Verify that Inlet valves of Level Transmitters, are opened and their drain valves closed.
¾ Verify that root valves of pressure transmitter’s pressure gauges are open.
¾ Open Air Vent valves.
¾ Verify that drains from level Indicator and level gauges closed.
¾ Verify that the valve on HP dosing to Drum are open.
¾ Verify the CBD regulating valve is closed.
¾ Verify that valves on sample line from CBD line to sample cooler are open.
¾ Open the valves on the saturated steam sample line to sample coolers
Steam Line from Super Heater Outlet to the Main steam header
¾ Verify that root valves of pressure gauges and pressure transmitters, are open.
¾ Verify that up-stream / down-stream isolating valves of steam flow transmitters are open.
¾ Drain valves from the steam line, is open.
¾ Verify from DCS that the pneumatically operated Start-up vent valves is open
¾ Keep close the MSSV.
Filling Water in Boiler

¾ For filling water in a cold boiler, cold water from the boiler filling line is preferred. The following procedure is for
filling from the boiler filling line.
¾ During this filling, for assurance of correct steam drum water level, post an attendant at the drum level to monitor
the local gauges and to communicate to the control room when a level of -150mm is reached
¾ Open the boiler filling line valve.
¾ Water rises to the steam drum through the Economizer. It may take about some minutes to fill water to the required
level. As level of water reaches – 150mm on (confirmation by the attendant), water filling can be discontinued by
Close filling water line valve.
Lineup the Feed Regulating Stations
Note
For line up a cold boiler, cold water from the boiler filling line, initial fill pumps be used for first fill. Regular boiler feeding may not be
required for some time after line up. Feed lines are lined up such that any of the Feed Regulating stations can be taken into service
from DCS.
¾ Verify that drain valves on feed line at boiler inlet are closed.
¾ Verify that the root valves of all the instruments are open.
¾ Isolation valve of the Pressure indicator is open.
¾ Isolation valve of the Flow element are open.
¾ Verify that both the 100% flow control valve is in the closed (0%) position in the DCS.
100% Feed Control Station

¾ Verify that the manually operated inlet isolating valve of the feed regulating station is open.
¾ Close the drain valves before the regulating valve control valve.
¾ Verify that the outlet manual isolating valve from the feed station, are open.
Attemperation Control Station
¾ Close the drain valves before the regulating valve control valve.
¾ Verify that the outlet manual isolating valve, are open.
Feed Line to Economizer

¾ Verify that the line drains are closed.
¾ Verify that valve (Economizer Bypass valve) is closed.
B 2.1.5.0 See the following valves are closed positively

¾ Feed water regulating & Attemperation control valves are closed and are in manual control.
¾ All blow-down and drain valves on boiler.
¾ Main steam stop valve.
¾ Drain valves for instruments.
Open the following valves:

¾ All steam drum vents
¾ Economizer vent valve.
¾ All instrument and control connection to the boiler Super heater header vents, drains, startup vent, and main steam line
drains.
Filling with Water

The filling line is provided to the steam drum with an isolation valve & an NRV. The valve is provided for the isolation at DM inlet.
Fill the boiler to about 2 inches below normal water level on the level gauge, thus allowing room for expansion of water with heating
and pressure rise. Only boiler quality feed water should be used for filling. It is desirable to fill the boiler with de-aerated feed
water. Filling with hot water is permissible provided water is added slowly and flow does not exceed capacity of de-aerating
heater. Strains set up in the waste heat recovery boiler from hot water filling are minor compared to strains induced from heating
cold water rapidly. When filling with water, drum vent should be opened to permit escape of steam or air. All the respective valves
on the startup vent piping are to be kept open.
Heating Up
Once the boiler has been filled with water, the flue gas may be taken into the boiler. The flue gas temperature and the steam drum
pressure are to be controlled as mentioned in the Start-up curve attached.
¾ Minimum 1/3rd of steam generation to be vented to assist circulation of boiler and to control superheated steam
temperature. At any point of time during startup the super heater steam temperature should not exceed the temperature
mentioned in the curve. Flue gas temperature at boiler inlet to be kept below 300 °C until the steam circulation in the
super heater is established. Prior to placing a super heater in service, the super heater headers vents and drum vents and
main steam line drain should be opened to clear all water, condensate and entrained air. These drain & vents should all
remain open until the steam pressure reaches about 4 to 5 Kg/cm2 g and a definite flow of steam through the super
heater have been noted. At this time, the steam drum vents should be closed.
¾ As the steam pressure reaches 60% of operating pressure open the main steam stop valve gradually and allow heating up of
steam piping approximately for 30-45 min till the Battery limit isolation valve to the main steam header. This will help
draining of condensate through the steam drain line and attaining operating temperature of piping. After attaining the
required temperature & pressure gradually open the main steam stop valve fully and close the startup vent valve.
¾ During all the above steps, maintain normal water level in the steam drum. Initially, the controls should be on manual mode
only and once the steam supply to the process is started, change the controls in auto mode and monitor continuously.
2. BOILER START UP
This chapter describes the boiler start up procedures as applicable for the following boiler conditions:
¾ Startup of a cold boiler
¾ Startup of a warm / Hot boiler
NOTE
1. Procedures explained in this chapter apply for startup of the boiler already commissioned Commissioning a new boiler
calls for several additional requirements.
It is assumed that operators are fully familiar with the design and construction features described in the earlier section.
2. Owner is encouraged to evolve standard operating procedures (SOP) based on the framework and recommendations
that are explained in the subsections below
¾ The SOPs have to be well understood by operating personnel for safe and reliable operation.
¾ The preparations for a boiler start up so far described can be summarized as below:
¾ Walk down checks of the boiler, economizer & all pipelines.
¾ System/ valves line up of the boiler & economizer, feed water system, steam line and drain lines.
¾ Filling the boiler with feed water and normalizing the drum level.
Cold Start up Procedure:

In general, super heaters are located in areas of high temperatures and as a result, the danger of oxidizing or burning the super
heater tubes always exists. Thus, like it is important to maintain the water in the boiler, it is equally important to maintain steam
flow through a super heater and at a rate sufficient to absorb and carry away the heat surrounding the super heater. The rate of
steam flow must compensate for the rate of heat input to the super heater. It is not only true during periods of normal operation
but also during startup and shutdown periods. Bearing these in mind, the following procedure is described for cold start up.
Allow the flue gases to pass through the Boiler for gradual heating up of the Boiler system. Initially the flue gas temperature at
the Boiler inlet shall be < 300 °C.
Flue gas temperature at boiler inlet to be kept below 300°C until the steam circulation in the super heater is established. Prior to
placing a super heater in service, the super heater headers vents and drum vents should be opened to clear all water, condensate
and entrained air. These vents and drains, should all remain open until the steam pressure reaches about 4 to 5 Kg/cm2 g and a
definite flow of steam through the super heater have been noted. At this time, the steam drum vents should be closed.
It is necessary to leave the super heater vent open until the unit is on line and a definite steam flow is obtained through the
super heater tubes. It is essential that steam should flow through the super heater at all times when it is subjected to high gas
temperature
Please follow the pressure rising curve for determining the rate of increasing the steam drum pressure.
Gradually reduce the water level in the drum during warming up period to normal water level by blowing down the boiler as
required to maintain the water level in the gauge glass. This is to drain the water level swelling during heating up.
While the boiler is heating up make frequent checks of the boiler expansion movements. In case of any abnormalities, stop flue
gas flow and carry out remedial action.
Check the boiler water concentration and constituents as frequently as required to maintain proper boiler water concentration by
blow down.
As the drum pressure increases, progressively throttle the final super heater outlet header startup vent. Do not close startup vent
completely until steam flow through the main steam line is established.
As the steam pressure reaches 60% of operating pressure crack open the main steam stop valve gradually and allow heating up of
steam piping approximately for 30-45 min. This will help attaining operating temperature of piping. After attaining the required
temperature & pressure gradually fully open the main steam stop valve and close the startup vent valve.
During all the above steps, maintain normal water level in the steam drum. Initially, the controls should be on manual mode only
and once the steam supply to the process is started, change the controls in auto mode and monitor continuously.
Note
It is advised to avoid frequent startup and stoppage, as this will lead to thermal cyclic loading of the boiler and premature
failures
Hot Startup Procedure:
Restarting the boiler after banked condition again requires controlled flue gas flow rate so as to prevent the super heater from
overheating. This procedure is applicable for starting of boiler after a short stop. The conditions should apply:
¾ Drum pressure must be > or equal to 8 Kg/cm2 (g). Drum water level should be at normal water level.
¾ The main steam stop valve will be in closed condition. Open the startup vent valve to minimum venting and monitor
super heater outlet steam temperature.
¾ Admit approximately 10% of the flue gas for a period of 30 minutes. Keep a close watch on the super heater outlet
steam temperature adjust start-up vent valve as required.
¾ Open main steam drain valves & removes condensate and crack open main steam stop valve and warm up the
steam line leading to turbine.
¾ Now gradually increase the flue gas flow and increase the steam drum pressure as per the pressure rising curve.
Adjust the flue gas quantity and / or start-up vent valve opening as required.
¾ As the steam pressure reaches operating parameter, fully open main steam stop valve & charge steam to turbine.
Gradually close the startup vent.
¾ Take all the controls on auto mode and check for stable operation.
Note
It is advised to avoid frequent startup and stoppage, as this will lead to thermal cyclic loading of the boiler and premature
failures.
5.4 Operator Action Required During Boiler Cold Start up

¾ Ensuring permissible rate of heat input to WHRB during start up
¾ Operator can also check the local exhaust gas and temperature indications
¾ Monitor Drum metal temperatures.
¾ Monitor the water level in the drum. As the temperature reaches about 90°C, a huge swelling of water level in the
drum takes place. The operator anticipates this and controls the level by opening the CBD valve
¾ Initially, checking the local level gauges makes a careful assessment of water level in the drum
¾ Observe the air vent on drum. Air gets expelled and steady steam starts coming out of the air vents
¾ Observe drum pressure at DCS by Pressure transmitter , as also local pressure gauges
¾ When drum pressure shows 2kg/cm², drum air vents can be closed when the steam pressure builds up to 3–5
kg/cm², super heater drain valves are to be closed.
¾ When the swelling phase of drum water level is over and the level shows a decreasing trend, the feed control can be
taken into service by opening isolating valves it can be positioned as required manually to maintain drum level.
¾ Ensure CBD, feed water and super-heated steam samples are flowing to the coolers and the pH, conductivity
meters are in operation. Verify pH and conductivity is within permissive values.
¾ Allow the WHRB steam pressure and temperature to build up to rated temperature and pressure by suitably
adjusting start up vent valve.
¾ When steady feeding is established through the feed control valve, the same can be taken on auto mode, by
switching into auto mode.
¾ If sluggish, continue manual operation of for some more time before trying again.
¾ Monitor the steam drum water level.
¾ Monitor the parameters, which can cause a WHRB trip.
3. BOILER SHUT DOWN
Normal Shutdown Procedure

The following procedure for normal shutdown is based on the assumption that the unit is operating at full load on automatic control
and the unit should be brought to zero pressure and cool the boiler completely.
Gradually reduce the load on the unit reducing the flue gas flow rate in line with decreasing steam flow Allow the pressure drop
with the reduction in load to accelerate cooling. Steam temperature control may be left on automatic until the point is reached
where better control can be obtained on manual.
Open the startup vent gradually and close the main steam stop valve.
Open the bye pass damper
This operation should be carefully done in order to prevent any stoppage of the cement kiln as draught is disturbed during
operation of bypass damper.
Close the boiler outlet duct isolation damper after getting the open limit feedback from the bypass damper. Then Close the boiler
inlet duct isolation damper after getting the close limit feedback from the outlet damper. Reduce the boiler steam pressure. As
the boiler pressure drops below 5 Kg/cm2, open steam drum vent. In Case of PH Boiler the Seal Air fans to be started in case any
maintenance to be taken with the Kiln in Operation to have 100% isolation for Man safe entry to the Boiler.
Immediately after the boiler is off line, after 5 kg/cm2 wide open the super heater vents and drains.
After the boiler is completely depressurized, then the cooling process can be initiated in order to permit entry into the unit for
maintenance, proceed as follows: Purge the unit cools the unit by opens the entire manhole. Maintain water level at normal.
Stop chemical dosing pumps.
During long shut down of the boiler, Feed water pump can be shut down only after stabilizing drum level.
If the boiler is to be emptied the boiler water temperature should be reduced to at least 70°C before draining.)
Open the manhole when the flue gas temperature is below 50°C.
Emergency Shutdown Procedure.

¾ Open the startup vent gradually and close the main steam stop valve.
¾ Open the bye pass damper in sequence as stated above of the cement kiln
¾ Close the Boiler Outlet Damper and after getting close feedback from the boiler outlet damper, close the Boiler inlet
damper.
¾ Sequence of the damper opening should be only as stated above as any mal-operation of sequence may lead to
boiler or duct imploding as high negative draught is there in the PH side.
¾ In case of AQC Boiler HAG operation has also to be bypassed and need to shut off the HAG by the philosophy as
indicated in HAG OEM Manual
During Black - Out Procedure Condition
¾ During the Blackout condition
¾ Close the MSSV and open the startup vent to minimum position just for protecting the super heater (ensure to
avoid overshooting of main steam temp).
¾ The BFP should start within 3-min with the help of emergency power supply and manually maintain the water level in
the steam drum.
¾ Emergency power supply has to be provided to the MSSV, Startup vent and by pass duct damper. The steam drum
pressure and the level have to be manually maintained.
4. PARELLALING WHRB TO PLANT STEAM MAINS

Paralleling WHRB to the Plant steam Mains
Paralleling WHRB to the steam mains of the plant is an important operation to be carefully done without affecting the
temperature of steam in the plant. In this case the sequence of introducing steam into turbine will be in the following sequence:-
First Line up AQC Boiler and start rolling the turbine with HP steam. Till then warm up vent of LP steam injection line at the turbine
is to be in open condition.
Once the Turbine attains full speed & the generator is synchronized with the Grid, introduce the LP steam through the LP Injection
line at Turbine inlet and close the warm up vent.
After this process Paralleling PH Boiler steam to the Mixing header at AQC Boiler Primary Super heater is an important activity for
which below pre-requisites are required
The pre requisites for this operation are:

¾ Building the steam pressure in PH Boiler to a pressure slightly more than AQC Boiler Primary HP Steam super
heater outlet pressure/mixing header pressure
¾ With the buildup of required steam pressure and temperature in PH Boiler O/L, the main steam stop valve can
be opened slowly heating up the line with the drains till AQC mixing header open.
¾ Once the Line is heated up and temperature at mixing header normalizes, Initiate a full open command for
MSSV, and allow the steam to completely go through the mixing header & close all the drains slowly.
¾ Reduce the opening of the startup vent valve to about 15%. This valve can be completely closed later (once
boiler is connected to plant completely.)
¾ Observe steam temperatures after SH. If main steam temperature at turbine inlet starts coming down then
open the Turbine inlet warm up vent for some time till the temperature normalizes.
¾ Observe the feed control station. When steam flow exceeds 25%, full load control station comes into service
(based on operator selection)
5. BOILER COOLING DOWN
Cooling down of boiler:
This chapter describes the methods of cooling a shutdown WHRB and the steps to be followed for the same.
System Description
WHRB after shut down has to be cooled carefully. If the cooling rate is accelerated, thermal stresses develop in the thick
components such as the steam drum, Economizer, Evaporator, Super Heater headers, etc.
A WHRB is shut down either for keeping it in reserve as a stand by unit or for maintenance and inspection. The purpose of the
shutdown determines the method of cooling to be adopted.
Natural Cooling
The WHRB after a shutdown is allowed to cool slowly in a ‘boxed up condition’. The following valves are also closed.
¾ MSSV valve
¾ HP dosing to Drum
¾ CBD from Drum
¾ Sample line of WHRB water, saturated steam & SH Steams to SWAS System
The WHRB cools slowly, loosing its heat by radiation to the environment. Till the steam drum pressure drops to 2 kg/cm² (g),
permissible water level is maintained in the drum (+150mm to – 250mm) by intermittent feeding. After the steam drum pressure
falls below 2 kg/cm² (g) maintaining water level in the drum is not essential.
When the steam drum pressure is less than 2 kg/cm2 (g), the access doors in the WHRB are kept open to create a natural draft
through the WHRB to the chimney. WHRB cools to an accessible level in about two-three days.
Forced Cooling
If the WHRB has to be made available for inspection or repair and the shut down time has to be reduced to a minimum, forced
cooling of the WHRB is done.
After the shutdown of the WHRB, the HP dosing, CBD and sample cooler valves are closed as for natural cooling. Water level in
the drum is also maintained between permissible levels till the steam drum pressure falls to 2kg/ cm2 (g) For 8 hours after the
shutdown, the WHRB is allowed to cool naturally in the boxed up condition.
After 8 hours, access doors on WHRB are opened to allow air flow through the WHRB to the stack.
Controlled opening of the startup valve also speeds up the de-pressurization of steam in the WHRB. De-pressurization rate is not
to exceed 10 kg/cm2 per hour.
6. DOS AND DON’TS
Do’s
¾ Startup of boilers should be done only after Kiln Operation is stable
¾ Drum level should be monitored and maintained accordingly.
¾ By pass damper open command should go immediately when the drum level is Low Low. Bypass damper should be
opened slowly in co-ordination with Cement plant Operation team without disturbing the cement plant operation.
¾ Cold filling of the Boiler with DM Water and maintain drum level –100mm before cold start.
¾ Ensure that the dust conveying system of Cement Plant is running.
¾ Opening of drum vent, super heater vent, startup vent, evaporator vent before startup of the boilers.
¾ Each Hammering system should be operated periodically/continuously based on flue gas parameters
¾ Receive permission from Cement Plant Kiln operation people before operating the boiler dampers
¾ Damper Opening & Closing Sequence should be as per the logic.
¾ Check for the Opening of slide gates below Boiler Hopper atleast once in shift, also ensure dust is getting conveyed
through the dust conveyors by visually checking through conveyor man hole. If no dust is found in the conveyors investigate
for the correctness of Hopper level switch. Opening of the Emergency slide gate on the Boiler Hopper can also be initiated
to check the dust level in the hopper
¾ Close drum vent when drum pressure reaches 2 kg/cm²
¾ During kiln operation if there is any urgency to open the bypass damper the logic of opening the bye pass damper should
be in co-ordination with cement plant operation team without disturbing the cement plant
¾ Bypass Damper opening should be done on fan draught behavior during operation and then decide the timing.
¾ If Kiln Main drive only stops and the ID fan doesn’t trip. We can continue the boiler operation for at least 30 minutes, if
cement plant operation team allows the same.
¾ This sometimes is not acceptable to kiln operation people as kiln starts cooling down which are not a healthy condition for
them during restart due to which boiler trip has to be incorporated with Kiln & ID fan tripping with some delay.
¾ Proper co-ordination has to be there between the kiln operation people and power plant operation people, both have to
understand well each other’s problems is the only key to run this waste heat recovery power plant.
¾ After the boiler comes into normal operation the complete boiler has to be checked for false air ingress if any which has to
be arrested especially in case of PH Boiler as high negative draught is there.
Don’ts
¾ Don’t close or open the bye pass damper immediately.
¾ Damper interlocks shall never be bypassed
¾ Don’t start the boiler without permission of the Kiln Operation People
¾ Don’t start the boiler without ensuring the water filling in the condensate pre heater of AQC boiler
Most Important is the sequence of dampers during boiler box up and boiler Lined up process Sequence should be as below:-
x During Boiler Lineup:
As Boiler Inlet & Outlet Dampers are ON/OFF type dampers, Open Limit of the Inlet & both HAG & Bypass damper
should only permit the opening of the Outlet damper & Open Limit for Inlet Damper, Outlet damper & HAG Bypass
damper should only permit the Bypass damper to be closed slowly which is a regulating type damper. Below 5%
feedback & closed limit of the Bypass damper should only indicate the full closing of the bypass damper. When the
Inlet, Outlet & HAG bypass damper are fully opened, by pass damper can be operated (Close/Open) if required for
cement plant operation.
Bypass damper physical verification should be done from inside while calibrating with the manual pointer provided by
the vendor outside the damper for intermittent calibrations to be done for feedback errors during operation.
x During boiler box up :
Vice versa sequence of Line up. Extreme care has to be taken while opening the bye pass damper. Bypass Damper
opening should be done in co-ordination with cement plant operation team with disturbing the cement plant Operation
& based on fan draught behavior during operation and then decide the timing. Also open limit should come at DCS only
above 95% opening of the damper. Then only permission shall go for closing the outlet damper and after that the inlet
damper. But permission interlocks shall be in the same manner. As said above. This is for the safety of the boiler & the
cement plant
Sometimes a condition comes when we want to box up the boiler, but kiln operation people don’t allow opening the
bypass damper. This only occurs when the kiln operation is not in proper conditions that time the induced draught of
the fan which is in DCS picture plays a major role and damper can be opened with proper co-ordination with Kiln
Operation desk.
7. EMERGENCY PROCEDURES
Emergency Procedures
This Section Describes the Causes and Action during emergency condition.
Low Water Level
Causes
¾ Feed water control system failure.

¾ BFP failure
¾ Tube leak
Action
Compare control room indication with gauge glass level. If the water level falls out of sight due to momentary failure of water
supply system, due to negligence of the operator, due to momentary fluctuations that might occur with extraordinary changes in
load, appropriate action should be taken at once. Any decision to continue to operate, even if only for a short time at a reduced
rating would have to be made by someone in authority who is thoroughly familiar with the circumstances that led to the
emergency and positively certain that the water level can be restored immediately without damaging the boiler.
In the absence of such a decision shut off steam flow and divert the gas from the bypass duct.
Simultaneously, if feed water has become available and the operator is assured that no pressure part has been damaged
¾ Take the feed water control system into manual mode.
¾ Allow the water flow to boiler gradually to normal water level. (Do not hurry up which may lead to sudden
quenching and tube leak) if pressure part damage is suspected
¾ Reduce the steam pressure gradually
¾ Open the drum air vent when the pressure drops below 2 kg/cm2
¾ Cool the boiler so as to examine the extent of damage
¾ Drain the boiler after cooling
¾ If any tube rupture and bulging is observed rectify the same
¾ After the repairs conduct Hydro test
¾ Determine the cause of low water level.
High Water Level

Causes
¾ Feed water control malfunction
¾ Operator error
¾ Instrument air supply failure
¾ Foaming
Action
¾ Take the drum level control loop into manual mode
¾ Reduce the water level immediately by operating the continuous blow down to maintain the drum level
¾ Reduce the steam discharge rate, if necessary
¾ Start the stand by compressor if required.
Tube Failure
Operating the boiler with a known tube leak is not recommended. Steam or water escaping from a small leak at
pressure can cut other tubes by impingement and set up a chain reaction of tube failures. Large leaks can be
dangerous. The boiler water may be lost, boiler casing can get damaged.
Small leaks can sometime be detected by the loss of water in the cycle or system. A loss of boiler water or by the noise
made by the leak if a leak is suspected the boiler should be shut down as soon as possible by following the normal
shutdown procedure.
After the exact location of the leak or leaks is located, the leaks may be repaired by replacing the failed tube or by
splicing in a new section of tube, conforming to relevant ASME code. An investigation of the tube failure is very
important so that the condition causing the tube failure can be eliminated and future failures can be prevented. This
investigation should include a careful visual inspection of the failed tube and in some cases a lab analysis. It is
recommended that every effort be made to find the cause of tube failures before operation is resumed.
ALARM & TRIP LIST
BOILER ALARM & TRIP LIST (PH Boiler)
PROJECT- 1 X 6.85 MW Cement WHRS Project
CUSTOMER-PARASAKTI CEMENT INDUSTRIES LTD. AP
Alarm*/Trip** Values
Sr.no. Description Low High Remarks
Low* High*
Low** High** Unit
(Alarm) (Alarm)
(Trip) (Trip)
1 Kiln Trip - - - - Both PH & AQC Boiler will Trip
2 PH Fan Trip - - - - Boiler Trip
Boiler Trip at High High & Low

Low and Alarm At High & Low
3 HP & LP Drum Level -200 -300 +100 +150 mmWC
Values ( 2 out of 3
Logic)
4 HP Drum Pressure 13 - 18 - kg/cm²(g) Alarm at Low and High

Alarm at Low and High &
5 Main Steam Temp 280 - 330 350 Deg C Boiler trip at High High (2 out
of 3 Logic)
6 HP Main steam pressure 14 - 17.5 - kg/cm² Alarm at Low and High
Cement plant dust transport Alarm & Boiler Conveyor Trip

7 - - - - -
trip ( After Boiler Conveyors) in sequence
8 Flue Gas Inlet temp 280 - 360 380 Deg C Boiler Trip at High High
9 Flue Gas Outlet Temp - - 220 - Deg C Alarm at High
10 Boiler Inlet Flue Gas Pressure -650 - - - mmWC Alarm at Low
11 DCF 1 Trip - - - - - Alarm & Boiler RAV’s Trip

DCF 1Zero Speed Switch
- - - - - Alarm
13 Alarm
DCF 2 Zero Speed Switch
- - - - - Alarm
14 Alarm
RAV # 1 Zero Speed Switch - - - - - Alarm & RAV-1 Trip
15 Alarm
RAV # 2 Zero Speed Switch - - - - - Alarm & RAV-2 Trip
16 Alarm
17 RAV # 1 Trip - - - - - Alarm
18 RAV # 2 Trip - - - - - Alarm
Boiler Dust Hopper # 1 Level
- - - - Level
19 HI Alarm & Boiler Trip Command
Boiler Dust Hopper # 2 Level after 15 Minutes Delay
- - - - Level
20 HI
26 BD tank level high - - - - mmWC Alarm
27 HP Dozing Tank Level Low - - - - Level Alarm

28 HP Dozing Tank Level Low Low - - - - Level HP Dozing Pump Trip
29 Hammering System # 1 - - - - - Alarm

33 MS line MSSV Open Torque - - - - - Alarm
34 MS line MSSV Close Torque - - - - - Alarm
PH steam Stop Valve Open
- - - - - Alarm
56 Torque
PH steam Stop Valve Close
- - - - - Alarm
57 Torque
Upstream isolation of PH
- - - - - Alarm
58 Main FCV Open Torque
Upstream isolation of PH
- - - - - Alarm
59 Main FCV Close Torque
Upstream isolation of PH - - - - - Alarm
60 bypass FCV Open Torque
Upstream isolation of PH - - - - - Alarm
61 bypass FCV Close Torque
Main Steam Line Drain Close
- - - - - Alarm
67 Torque
MS start up vent regulation
- - - - - Alarm
68 Open Torque
MS start up vent regulation
- - - - - Alarm
69 Close Torque
PH drum EBD regulation Open
- - - - - Alarm
70 Torque
PH drum EBD regulation
- - - - - Alarm
71 Close Torque
PH drum CBD regulation
- - - - - Alarm
72 Open Torque
PH drum CBD regulation
- - - - - Alarm
73 Close Torque
Inlet Flue Gas Damper Open
- - - - - Alarm
75 Torque
Inlet Flue Gas Damper Close
- - - - - Alarm
76 Torque
Outlet Flue Gas Damper Open
- - - - - Alarm
77 Torque
Outlet Flue Gas Damper Close
- - - - - Alarm
78 Torque
Bypass Flue Gas Damper
- - - - - Alarm
79 Open Torque
Bypass Flue Gas Damper
- - - - - Alarm
80 Close Torque
BOILER ALARM & TRIP LIST (AQC Boiler)
PROJECT- 1 X 6.85 MW Cement WHRS Project
CUSTOMER- PARASAKTI CEMENT INDUSTRIES LTD. AP
Alarm*/Trip** Values
Sr.no. Description Low High Remarks
Low* High*
Low** High** Unit
(Alarm) (Alarm)
(Trip) (Trip)
Boiler Trip at High high &
Low Low , Alarm at High
1 HP/LP Drum Level -200 -300 +100 +150 mmWC
& Low Values (2 out of 3
Logic)
Alarm Only at High and
2 HP / LP Drum Pressure 14 - 17.5 - kg/cm²(g)
Low
Main Steam Temp ( SH-2

3 350 - 410 - Deg C Alarm at Low and High
Outlet)
Main steam pressure ( SH-2 Alarm Only at High and

4 13 - 16.5 - Kg/cm²(g)
Outlet) Low
5 Clinker ESP Fan Trip - - - - Boiler Trip
Cement plant clinker dust

6 - - - -
transport trip Alarm
7 Flue Gas Inlet temp 375 - 460 480 Deg C Boiler Trip at High High
8 Flue Gas Outlet Temp - - 150 - Deg C Alarm at High
9 Boiler Inlet Flue Gas Pressure -60 -75 - - mmWC Boiler Trip at Low Low
10 DCF # 1 Trip - - - - Alarm
11 DCF # 2 Trip - - - - Alarm

DCF # 1 Zero Speed Switch
12 - - - - - Alarm
Alarm
Alarm
DCF # 2 Zero Speed Switch
13 - - - - -
Alarm
14 RAV # 1 Trip - - - - Alarm

RAV #1 Zero Speed Switch
- - - - - Alarm
19 Alarm
RAV # 2 Zero Speed Switch
- - - - - Alarm
20 Alarm
RAV # 3 Zero Speed Switch
- - - - - Alarm
21 Alarm
24 BD tank level mmWC Alarm
25 Boiler Dust Hopper # 1 Level Hi - - - - Level
Alarm at High & Boiler
26 Boiler Dust Hopper # 2 Level Hi - - - - Level trip with a delay of 15
min
Alarm at High
Boiler Dust Hopper # 5 Level & Boiler trip immediately
- - - - Level
29 Hi
30 HP Dozing Tank Level - - - - Level Alarm
31 HP Dozing Tank Level - - - - Level HP Dozing Pump Trip
Economizer Outlet
- - 200 - Deg C Alarm
32 Temperature
33 CPH Outlet Temperature - - 135 - Deg C Alarm
AQC-1 steam Stop Valve Open
- - - - - Alarm
34 Torque
AQC-1 steam Stop Valve Close
- - - - - Alarm
35 Torque
Upstream isolation of AQC
- - - - - Alarm
36 Boiler Main FCV Open Torque
- - - - - Alarm
37 Boiler Main FCV Close Torque
- - - - - Alarm
38 Boiler bypass FCV Open Torque
- - - - - Alarm
39 Boiler bypass FCV Close Torque
AQC Boiler Steam Line Drain
- - - - - Alarm
40 Open Torque
AQC Boiler Steam Line Drain
- - - - - Alarm
41 Close Torque
AQC Boiler steam startup vent
- - - - - Alarm
42 regulation Open Torque
AQC Boiler steam startup vent
- - - - - Alarm
43 regulation Close Torque
AQC Boiler drum EBD
- - - - - Alarm
AQC Boiler drum EBD
- - - - - Alarm
AQC Boiler drum CBD
- - - - - Alarm
AQC Boiler drum CBD
- - - - - Alarm
48 Mid Tap Damper Open Torque - - - - - Alarm
49 Mid Tap Damper Close Torque - - - - - Alarm
50 End Tap Damper Open Torque - - - - - Alarm
51 End Tap Damper Close Torque - - - - - Alarm
52 Inlet Damper Open Torque - - - - - Alarm
53 Inlet Damper Close Torque - - - - - Alarm
54 Outlet Damper Open Torque - - - - - Alarm
55 Outlet Damper Close Torque - - - - - Alarm
56 By Pass Damper Open Torque - - - - - Alarm
57 By Pass Damper Close Torque - - - - - Alarm
Attemperator spray water line
58 - - - - - Alarm
isolation Open Torque
Attemperator spray water line
59 - - - - - Alarm
isolation Close Torque
Near Attemperator Spray
60 - - - - - Alarm
Nozzle Open Torque
Near Attemperator Spray - - - - - Alarm
61 Nozzle Close Torque
Main Steam Line Drain Open - - - - - Alarm
62 Torque
OPERATION LOGIC
PH BOILER OPERATION LOGIC
HAMMERING SYSTEM START PERMISIVES

Rapping Hammer system Start permissive will be ok if all the following conditions are satisfied.
1. Drive Ready to start
2. CV 01 running
3. Field Stop ok
4. Remote selected
5. No Trip condition persists
6. In case of CV-02 tripping, CV-01 will trip and due to this RAV’s of both side hoppers will trip resulting in tripping of the
Hammering system (Grouping to be done accordingly.)
HAMMERING SYSTEM TRIP CONDITIONS

Rapping Hammer System will trip if any one of the following signal present
1. with a delay of 15 minutes after CV01 Tripping / RAV 1 & 2 tripping
2. Zero Speed activated
3. Drive not ready
4. Field stop not ok
5. Remote not selected
6. Sequence stop operated
7. RAV 1 OR 2 not running.
Note: Conveyors, RAV’s to be grouped for Hammering system operation
RAPPING HAMMER SYSTEMS START/STOP (REMOTE/SEQUENTIAL OPERATION)

Rapping Hammer system will start if the following conditions are satisfied.
1. Rapping Hammer system start permissive ok
2. NO Stop/Trip condition persists.
3. {(Remote selected AND Remote Start PB operated) OR (Sequence Start command From Sequence Logic)}
4. CV02, CV01, RAV 1 & 2 running
Rapping Hammer system will stop if any one of the following signal present
1. Remote Stop PB operated
2. No Trip condition persists
3. Rapping Hammer system fail to start/trip
SEQUENCE COMMAND FROM SEQUENCE LOGIC
When Boiler Dust Transportation system On, Rapping Hammer system Enable, Sequence selected and Sequence Start command
given and following things will happen
1. Sequence selected and Sequence Running Indication will be on
2. Hammering system Enable
3. First Row Rapping Hammer system 1 & 2 will be on 2sec after and remain on for 5 minutes
4.5 min. after 2nd Row Rapping Hammer system 3 & 4 will be on 2 sec after and remain on for 5 min. In the same
sequence 3rd row (5 & 6), 4th Row (7 & 8) & 5th Row (9 &10)
7. 1st row Hammering system again will be on 30 min after the complete hammering system completes its one cycle
operation.
Rapping Hammer system sequence will stop if

1. Boiler Dust Transportation system not on
2. Sequence Stop PB operated
3. Sequence tripping with CV-01
Note: All hammering systems are designed to run continuously/Intermittently in sequence as mentioned above if required based
on flue gas parameters & site conditions.
SKIPPING OF ANY RAPPING HAMMER OPERATION DURING SEQUENTIAL OPERATION
To skip any Rapping Hammer system operation that particular Rapping system is to be disabled. This can be done by operating
that Rapping Hammer Enable PB twice.
REMOTE/SEQUENCE SELECTION
Remote will be selected when Remote select PB is operated and reset when Sequence selects PB is operated.
Sequence will be selected when Sequence select PB is operated and reset when Remote select PB is operated.
BOILER READY TO START

Boiler will be ready to start if the following signals are
1. DCF running. Cement Plant Dust transport running
2. PH Fan running.
3. Kiln running
4. Drum Level not high
5. Drum level not low.
BOIER TRIP CONDITION
Boiler will trip if any one of the following signal present
1. DCF not running / Cement Plant Dust Transport trip.
2. PH Fan not running.
3. Kiln not running
4. Drum Level very high
5. Drum level very low.
BOILER INLET TANDEM DAMPER OPEN PERMISIVES
Inlet Damper open permissive will be ok if all the following conditions are satisfied.
2. No Fault signal present
3. Damper not closing
4. Field Stop ok
5. Remote selected. Provision for Manual Operation should also be there.
6. Boiler Ready to start
7. Damper not full open
8. Opening Torque not high
9. {(Remote selected AND Remote Start PB operated) OR (Sequence Start command from Sequence Logic)}
10. By Pass Damper open feedback persists.
11. Seal Air Fan of Inlet Tandem Damper not running.
BOILER INLET TANDEM DAMPER CLOSE PERMISIVES
Inlet Damper close permissive will be ok if all the following conditions are satisfied.
3. Damper not opening
4. Field Stop ok
5. Remote selected Provision for Manual Operation should also be there
6. Closing Torque not high
8. Close Feedback of outlet damper & open feedback of Bye pass damper persists.
9. Seal Air Fan of Boiler Inlet Tandem Damper not running. (Seal Air Fan to be started only after full close limit of Boiler
Inlet Tandem damper is attained).
INLET DAMPER OPEN/CLOSE (REMOTE/SEQUENTIAL OPERATION)
Inlet Damper will open if the following conditions are satisfied.

1. Inlet Damper open permissive ok
2. {(Remote selected AND Remote Open PB operated AND Boiler Ready to start) OR
(Sequence selected AND Sequence Open command from Sequence Logic)}
Inlet Damper will close if the following conditions are satisfied

1. Inlet Damper close permissive ok
2. {(Remote selected AND Remote Close PB operated AND Outlet Damper Full close) OR
(Sequence selected AND Sequence Close command from Sequence Logic)}
BOILER OUTLET TANDEM DAMPER OPEN PERMISIVES
Outlet Damper open permissive will be ok if all the following conditions are satisfied.
4. Field Stop ok
6. Boiler Inlet Damper Full open
9. {(Remote selected AND Remote Start PB operated) OR (Sequence Start command
From Sequence Logic)}
10. Inlet Damper open feedback persists.
11. Seal Air Fan for Boiler Outlet Tandem Damper not running.
BOILER OUTLET TANDEM DAMPER CLOSE PERMISIVES
Outlet Damper close permissive will be ok if all the following conditions are satisfied.
4. Field Stop ok
5. Remote selected Provision for Manual Operation should also be there.
7. Damper not full open.
8. By Pass Damper open feedback persists
9. Seal Air Fan of Boiler Outlet Tandem Damper not running. (Seal Air Fan to be started only after full close limit of Boiler
Outlet Tandem damper is attained).
OUTLET DAMPER OPEN/CLOSE (REMOTE/SEQUENTIAL OPERATION)
Outlet Damper will open if the following conditions are satisfied.

1. Outlet Damper open permissive ok
Outlet Damper will close if the following conditions are satisfied

1. Outlet Damper close permissive ok
2. {(Remote selected AND Remote Close PB operated AND Bypass Damper Full open) OR
BOILER BYPASS DAMPER OPEN PERMISIVES
Bypass Damper open permissive will be ok if all the following conditions are satisfied.
4. Field Stop ok
9. Inlet and Outlet damper open feedback persists
10. PH Fan Running
11. Flue Gas inlet temp high > 480°C
BOILER BYPASS DAMPER CLOSE PERMISIVES
Bypass Damper close permissive will be ok if all the following conditions are satisfied.
4. Field Stop ok
8. Inlet and Outlet damper open feedback persists.
BYPASS DAMPER OPEN/CLOSE (REMOTE/SEQUENTIAL OPERATION)
Bypass Damper will open if the following conditions are satisfied.

1. By Pass damper Open Permissive ok
2. {(Remote selected AND Remote Open PB operated) OR (Sequence selected AND Sequence
Open command from Sequence Logic)}
3. PH Fan Running Bypass Damper will close if the following conditions are satisfied
1. By Pass Damper close permissive ok.
2. {(Remote selected AND Remote Close PB operated AND Boiler Ready to start) OR
SEQUENTIAL OPERATION OF INLET/OUTLET DAMPER OPENING AND BYPASS DAMPER CLOSING FROM SEQUENCE LOGIC
When Damper Sequence selected AND No Boiler Trip signal present AND Damper Sequence Start PB (Opening) operated
following things will happen
1. Inlet Damper open command will be generated.
2. After getting .Inlet Damper full open feedback from Field Outlet Damper will start opening
3. After getting Outlet Damper full open feedback from Field Bypass Damper will start closing
Closing the Boiler Bypass damper during Boiler Cold Start should be done slowly and manually to protect the Boiler Pressure
parts.
SEQUENTIAL OPERATION OF INLET/OUTLET DAMPER CLOSING AND BYPASS DAMPER OPENING FROM SEQUENCE LOGIC
When Damper Sequence selected AND Damper Sequence Stop PB (Closing) operated OR Boiler Trip signal present following
things will happen
1. Bypass Damper will start opening
And % opening to be closely done in coordination with Cement Plant Operation team without disturbing the cement plant
operation & based on Boiler Start up conditions (Hot/Cold)
2. After getting bypass Damper full open feedback from Field Outlet Damper will start closing after getting Outlet Damper
full close feedback from Field Inlet Damper will start Closing.
RAV 1& 2 START/STOP LOGIC
RAV1 &2 will start if the following conditions are satisfied

1. RAV1&2 fail to start/trip signal not present.
2. Field Stop ok
3. Remote selected
4. Motor not Trip
6. Chain Feeder 1 running
7. MCC Ready to Start
8. Stop command not operated from DCS
9. Start command given from DCS
RAV1 & 2 will stop if any one of the following signals is present
1. RAV1 & 2 Fail to start/trip signal present.
2. Zero Speed Switch not okay
3. Field Stop not ok
5. Motor Trip
6. Chain Feeder 1 not running
7. MCC not Ready to Start
CHAIN FEEDER START/STOP LOGIC
Chain Feeder will start if the following conditions are satisfied

1. Chain Feeder Fail to start/trip signal not present.
2. Field Stop ok
3. Remote selected
4. Motor not Trip
6. Cement Plant Dust Conveyor (Raw Meal Silo Feed Elevator) running
Chain Feeder will stop if any one of the following signals is present
1. Chain Feeder Fail to start/trip signal present.
4. Motor Trip
5. Cement Plant Dust Conveyor (Raw Meal Silo Feed Elevator) not running
MOTORISED ISOLATION VALVE BEFORE MAIN/BYPASS FEED CONTROL VALVE OPEN/CLOSE LOGIC
Motorized Isolation valve will open if all the following conditions are satisfied.
3. Valve not closing
4. Field Stop ok
5. Remote selected
6. Main/Bypass Feed Control Valve full closed
7. Valve not full open
9. (Remote selected AND Remote Open PB operated)
Motorize Isolation Valve will close if all the following conditions are satisfied.
3. Valve not opening
4. Field Stop ok
5. Remote selected
9. (Remote selected AND Remote Close PB operated)
STEAM HEADER DRAIN VALVE OPEN/CLOSE LOGIC
Motorized Drain valve will open if all the following conditions are satisfied.
4. Field Stop ok
5. Remote selected
Motorize Drain Valve will close if all the following conditions are satisfied.
4. Field Stop ok
5. Remote selected
PH 1 STEAM STOP VALVE OPEN/CLOSE LOGIC
Motorized Stop valve will open if all the following conditions are satisfied.
4. Remote selected
7. Bypass valve full open
Motorize Stop Valve will close if all the following conditions are satisfied.
4. Remote selected
7. {(Remote selected AND Remote Close PB operated)
MAIN STEAM STOP VALVE OPEN/CLOSE LOGIC
4. Remote selected
Motorized Stop Valve will close if all the following conditions are satisfied.
4. Remote selected
EBD VALVE OPEN/CLOSE LOGIC

EBD valve will open if all the following conditions are satisfied.
4. Remote selected
EBD Valve will close if all the following conditions are satisfied.
4. Remote selected
CBD VALVE OPEN/CLOSE LOGIC
CBD valve will open if all the following conditions are satisfied.
4. Remote selected
CBD Valve will close if all the following conditions are satisfied.
4. Remote selected
START UP VENT VALVE OPEN/CLOSE LOGIC
Startup vent valve will open if all the following conditions are satisfied.
4. Remote selected
Startup vent Valve will close if all the following conditions are satisfied.
4. Remote selected
HP DOSING PUMP 1/2 START/STOP LOGIC
HP Dosing Pump 1/2 will start if the following conditions are satisfied
1. Pump 1/2 Fail to start/trip signal not present.
2. Field Stop ok
3. Remote selected
4. Motor not Trip
6. Level not Low
Pump 1/2 will stop if any one of the following signals is present
1. Pump 1/2 Fail to start/trip
4. Motor Trip
5. Level Very Low
7. Stop command operate from DCS
HP DOSING TANK STIRRER START/STOP LOGIC
HP Dosing Tank Stirrer will start if the following conditions are satisfied
1. Stirrer Fail to start/trip signal not present.
2. Field Stop ok
3. Remote selected
4. Motor not Trip
6. Level not Low
HP Dosing Tank Stirrer will stop if any one of the following signals is present
1. Stirrer Fail to start/trip.
4. Motor Trip
5. Level Very Low
7. Stop command operated from DCS
ATTEMPERATOR SPRAY NOZZEL VALVE OPEN/CLOSE LOGIC

Nozzle valve will open if all the following conditions are satisfied.
4. Field Stop ok
5. Remote selected
6. Spray Water Flow > 0.5T/HR
8. Block Valve Full Open
Nozzle Valve will close if all the following conditions are satisfied.
4. Field Stop ok
5. Remote selected
8. {(Remote selected AND Remote Close PB operated) OR (Turbine Tripped)}
ATTEMPERATOR SPRAY BLOCK VALVE OPEN/CLOSE LOGIC
Nozzle valve will open if all the following conditions are satisfied.
4. Field Stop ok
5. Remote selected
6. Steam Flow > 7T/HR
Nozzle Valve will close if all the following conditions are satisfied.
4. Field Stop ok
5. Remote selected
8. {(Remote selected AND Remote Close PB operated) OR (Turbine Tripped)}
FAULT SIGNAL LOGIC FOR BI-DIRECTIONAL MOTOR ON/OFF TYPE

Fault signal will be generated if any one of the following signal is present.
1. Motor Trip
3. Fail to Open
4. Fail to Close
FAULT SIGNAL LOGIC FOR BI-DIRECTIONAL MOTOR INCHING TYPE

1. Motor Trip
FAULT SIGNAL LOGIC FOR UNI-DIRECTIONAL MOTOR

Fault signal will be generated if any one of the following signal is present
1. Motor Fail to start/trip
4. Motor Trip
B 11.2.0.0 AQC BOILER OPERATION LOGIC
BOILER READY TO START

Boiler will be ready to start if the following signals are
1. DCF 1 & 2 running
2. ID Fan running.
3. Kiln running
4. Clinker ESP Fan running
5. Cement Clinker Dust Conveying System on
6. Drum Level not high
7. Drum level not low.
BOILER TRIP CONDITION

Boiler will trip if any one of the following signal present
1. DCF 2 not running
2. ID Fan not running.
3. Kiln not running
4. Clinker Dust Conveying System not running
5. Clinker ESP Fan not running
6. Drum Level very high
7. Drum level very low.
BOILER INLET DAMPER OPEN PERMISIVES

Inlet Damper open permissive will be ok if all the following conditions are satisfied.
4. Field Stop ok
5. Remote selected
6. Boiler Ready to start
9. {(Remote selected AND Remote Start PB operated) OR (Sequence Start command from
Sequence Logic)}
10. Open Feedback of bypass damper & close feedback of outlet damper persists.
BOILER INLET DAMPER CLOSE PERMISIVES

Inlet Damper close permissive will be ok if all the following conditions are satisfied.
4. Field Stop ok
5. Remote selected Provision for Manual Operation should be there.
8. Open Feedback of by Pass damper & close feedback of outlet damper persists
INLET DAMPER OPEN/CLOSE (REMOTE/SEQUENTIAL OPERATION)
Inlet Damper will open if the following conditions are satisfied.

1. Inlet Damper open permissive ok
Inlet Damper will close if the following conditions are satisfied

1. Inlet Damper close permissive ok
2. {(Remote selected AND Remote Close PB operated AND END TAP Damper full close) OR
BOILER OUTLET DAMPER OPEN PERMISIVES

Outlet Damper open permissive will be ok if all the following conditions are satisfied.
4. Field Stop ok
5. Remote selected Provision for Manual Operation should be there
6. Boiler Inlet Damper Full open
10. {(Remote selected AND Remote Start PB operated) OR (Sequence Start command From Sequence Logic)}
11. By pass damper full open
BOILER OUTLET DAMPER CLOSE PERMISIVES

Outlet Damper close permissive will be ok if all the following conditions are satisfied.
4. Field Stop ok
8. By pass damper full open
OUTLET DAMPER OPEN/CLOSE (REMOTE/SEQUENTIAL OPERATION)

Outlet Damper will open if the following conditions are satisfied.
1. Outlet Damper open permissive ok
Outlet Damper will close if the following conditions are satisfied

1. Outlet Damper close permissive ok
2. {(Remote selected AND Remote Close PB operated) OR (Sequence selected AND
Sequence Close command from Sequence Logic)}
BOILER BYPASS DAMPER OPEN PERMISIVES

Bypass Damper open permissive will be ok if all the following conditions are satisfied.
4. Field Stop ok
8. Outlet, Inlet Damper full open
BOILER BYPASS DAMPER CLOSE PERMISIVES

Bypass Damper close permissive will be ok if all the following conditions are satisfied.
4. Field Stop ok
5. Remote selected
8. Inlet & Outlet damper full open Feed Back Persists.
BYPASS DAMPER OPEN/CLOSE (REMOTE/SEQUENTIAL OPERATION)

Bypass Damper will open if the following conditions are satisfied.
1. By Pass Damper open permissive ok
2. {(Remote selected AND Remote Open PB operated) OR (Sequence selected AND Sequence open command from
Sequence Logic)}
Bypass Damper will close if the following conditions are satisfied

1. By Pass Damper close permissive ok
2. {(Remote selected AND Remote Close PB operated AND Boiler Ready to start) OR
SEQUENTIAL OPERATION OF /END TAP/HAG BYPASS/OUTLET DAMPER OPENING AND BYPASS DAMPER CLOSING FROM
SEQUENCE LOGIC
Boiler Line up Process

When Damper Sequence selected AND No Boiler Trip signal present AND Damper Sequence Start PB (Opening) operated
following things will happen
1. END TAP Damper open command will be generated
2. After getting END TAP Damper full open feedback from Field HAG BYPASS Damper will start Opening
3. After getting HAG BYPASS Damper full open feedback from Field OUTLET Damper will start Opening
4. After getting Outlet Damper full open feedback from Field Bypass Damper will start closing
This Operation should take sufficient time to take the boiler inline during cold startup, whereas during hot start it can be closed
within 30 minutes.
SEQUENTIAL OPERATION OF INLET/OUTLET DAMPER CLOSING AND BYPASS DAMPER OPENING FROM SEQUENCE LOGIC
BOILER BOX UP PROCEDURE
When Damper Sequence selected AND Damper Sequence Stop PB (Closing) operated OR Boiler Trip signal present following
things will happen
1. By pass Damper will start opening.
This Damper can be opened quickly in co-ordination with Cement Process as the negative draught is very less and does
not cause any disturbance to Cement Plant Operation
2. After getting .Bypass Damper full open feedback from Field Outlet Damper will start Closing
3. After getting .Outlet Damper full close feedback from Field END TAP Damper will start Closing
BY PASS DAMPER OPERATION WHEN BOILER INLET GAS TEMP >450 DEGC
When Boiler Inlet Gas Temperature >460 Deg C and <480 Deg C By Pass Damper will open up to 50% and when the Temperature
>480 Deg C By Pass Damper will open 100%.
By Pass Damper will start closing when Boiler Inlet Temperature is < 435 Deg C.
CHAIN FEEDER 1 START/STOP LOGIC

Chain Feeder 1 will start if the following conditions are satisfied
1. Chain Feeder 1 Fail to start/trip signal not present.
2. Field Stop ok
3. Remote selected
4. Motor not Trip
6. Chain Feeder 2 running
10. Zero Speed Switch Okay.
Chain Feeder 1 will stop if any one of the following signals is present
1. Chain Feeder Fail to start/trip signal present.
3. Remote not selected Remote should be selected after starting of the equipment manually.
4. Motor Trip
5. Chain Feeder 2 not running
8. Zero Speed Switch Not Okay / Alarm
CHAIN FEEDER 2 START/STOP LOGIC

Chain Feeder2 will start if the following conditions are satisfied
1. Chain Feeder 2 Fail to start/trip signal not present.
2. Field Stop ok
3. Remote selected Remote should be selected after starting of the equipment manually.
4. Motor not Trip
6. Cement Plant Clinker Dust Conveyor running
Chain Feeder 2 will stop if any one of the following signals is present
1. Chain Feeder 2 Fail to start/trip signal present.
3 Remote not selected Remote should be selected after starting of the equipment manually.
4. Motor Trip
5. Cement Plant Clinker Dust Transport not running
STEAM HEADER DRAIN VALVE OPEN/CLOSE LOGIC

Motorized Drain valve will open if all the following conditions are satisfied.
4. Field Stop ok
5. Remote selected
Motorize Drain Valve will close if all the following conditions are satisfied.
4. Field Stop ok
5. Remote selected
AQC BOILER STEAM STOP VALVE OPEN/CLOSE LOGIC

4. Remote selected
Motorize Stop Valve will close if all the following conditions are satisfied.
4. Remote selected
EBD VALVE OPEN/CLOSE LOGIC
EBD valve will open if all the following conditions are satisfied.
4. Remote selected
EBD Valve will close if all the following conditions are satisfied.
4. Remote selected
CBD VALVE OPEN/CLOSE LOGIC

CBD valve will open if all the following conditions are satisfied.
4. Remote selected
CBD Valve will close if all the following conditions are satisfied.
4. Remote selected
START UP VENT VALVE OPEN/CLOSE LOGIC
Start up vent valve will open if all the following conditions are satisfied.
4. Remote selected
Start up vent Valve will close if all the following conditions are satisfied.
4. Remote selected
HP DOSING PUMP 1/2 START/STOP LOGIC

HP Dosing Pump 1/2 will start if the following conditions are satisfied
1. Pump 1/2 Fail to start/trip signal not present.
2. Field Stop ok
3. Remote selected
4. Motor not Trip
6. Level not Low
Pump 1/2 will stop if any one of the following signals is present
1. Pump 1/2 Fail to start/trip
4. Motor Trip
5. Level Very Low
HP DOSING TANK STIRRER START/STOP LOGIC

HP Dosing Tank Stirrer will start if the following conditions are satisfied
1. Stirrer Fail to start/trip signal not present.
2. Field Stop ok
3. Remote selected
4. Motor not Trip
6. Level not Low
HP Dosing Tank Stirrer will stop if any one of the following signals is present
1. Stirrer Fail to start/trip.
4. Motor Trip
5. Level Very Low
7. Stop command operated from DCS
FAULT SIGNAL LOGIC FOR BI-DIRECTIONAL MOTOR ON/OFF TYPE

1. Motor Trip
3. Fail to Open
4. Fail to Close
FAULT SIGNAL LOGIC FOR BI-DIRECTIONAL MOTOR INCHING TYPE
1. Motor Trip
FAULT SIGNAL LOGIC FOR UNI-DIRECTIONAL MOTOR

Fault signal will be generated if any one of the following signal is present
1. Motor Fail to start/trip
4. Motor Trip
5. MCC not Ready to Start.
6. Stop command operate from DCS.
C.CONSTRUCTION FEATURES
TITLE: WATER & STEAM CIRCUIT
FEED WATER SYSTEM
The water and steam system covered in this chapter describes the components of the WHRB which transfer heat from the exhaust
gas of the Kiln to the feed water flowing from the feed water main to convert it to steam of 14.5 Kg/cm² (g) at a temperature of
390 °C in case of HP & 2.5 Kg/cm² (g) at a temperature of 195 °C in case of LP .The components in the serial order of water flow
of path are
¾ Condensate Pre-heater
¾ Deaerator
¾ Boiler feed water Pump (Common for LP & HP System both)
FOR HP STEAM
¾ Economizer module AQC
¾ HP Boiler Feed Control Station
¾ HP Evaporators and drum natural circulation of PH and AQC Boiler
¾ HP Super heater 1 of AQC and PH Boiler
¾ Mixing Header
¾ HP Super heater 2 of AQC Boiler
¾ Final HP steam to Turbine
FOR LP STEAM
¾ LP Boiler Feed Control Station (Tapping from existing HP Feed Water line with a PRV)
¾ LP Evaporators and drum natural circulation of PH & AQC Boiler
¾ LP Super heater of PH & AQC Boiler
¾ Final LP steam to Turbine LP Injection Point
CONDENSATE PRE HEATER (CPH)

Condensate Preheater (CPH) assembly is envisaged in AQC Boiler in last module assembly placed at the top in flue gas path
before Clinker ESP & stack. Condensate Preheater is envisaged to recover available heat from the flue gas before discharging to
the atmosphere. The recovered heat increases the temperature of Condensate entering the Deaerator, thus overall efficiency of
the boiler is increased.
The CPH modules consist of a top and bottom header and helically wound Solid Fins tubes.
The CPH assembly is fully drainable by the drain valve provided on the inlet header. To expel air from the CPH during charging and
while draining air vent valves are provided on the outlet header.
Condensate inlet piping to the CPH is provided with following:
¾ Temperature Element for remote temperature indication.
¾ Pressure gauge for local pressure indication.
¾ Temperature gauge for local temperature indication.
¾ Flow Nozzle is provided to measure and provide signal to control valve located at the inlet of Condensate Preheater to
open / close. The amount of flow passing through control valve is depended on amount of steam generated in the Boiler.
Condensate water outlet piping from CPH is provided with following:
¾ A Temperature indicator after the tapping of the recirculation line.
¾ Pressure transmitter is provided for remote pressure indication and a pressure gauge for local indication.
Condensate water system is also having the bypass arrangement.
DEAERATOR (Common for Plant)

Deaerator supplies de-aerated water to PH & AQC boilers. Hot condensate from AQC Boiler Condensate Pre-heater flows back
into the Deaerator and also there is make up water connection for catering the losses.
Deaeration removes the corrosive gases such as dissolved oxygen and free carbon dioxide from the condensate water. This
ensures protection of the feed water lines, steam lines, boiler tubes and other pressure parts of the boiler against corrosion and
pitting thus saves boiler re-tubing and expensive plant shutdowns. Further as the temperature of feed water is raised to Deaerator
operating temperature of 126°C and then fed to the economizer to increase overall boiler thermal efficiency.
Deaeration is done by heating the condensate with steam vigorously scrubbing the water with this steam removes the last traces
of dissolved oxygen2 and brings down well below the recommended level in feed water.
The Deaerator in which make up water & condensate is heated to its boiling temperature at the operating pressure by steam. At
boiling point all the dissolved gases such as Oxygen, Carbon Dioxide, Etc. are liberated as solubility of gases decreases with
increase in temperature.
Steam rises from the bottom of Storage Tank, heating the water and rises through the interconnection pipe. Oxygen, Carbon
dioxide and other dissolved gases are vented out along with vent steam through the vent nozzle. Vent pipe has a globe valve to
throttle or restrict the flow of venting steam.
The dissolved Oxygen level in the feed water by mechanical Deaeration can be brought to 0.007 ppm. If oxygen level is not
maintained in Deaerator, the dissolved oxygen can be further scavenged by the reaction with chemicals such as Hydrazine. By
chemical scavenging the dissolved Oxygen level can be maintained to 0.007 ppm. Chemical is dosed in the storage section of
the Deaerator through a header, which is connected to the dosing system through a pipe with an isolation valve. The dosing of the
particular chemical is done in predetermined quantity and concentration.
Storage tank is supported by two saddle supports. One saddle is fixed and another is sliding to take care of thermal expansion.
Platforms and ladders are provided for tank for O & M feasibility.
Feed Water Pumping Station

The de-aerated water from the Deaerator storage tank is pumped into the boiler through feed water pumps (BFWP). Two feed
water pumps are commonly provided for both for HP & LP system (1W + 1S). The feed water pumps (2 x 100%) are multistage
Centrifugal Pumps. Electrical motors drive the pumps. Feed water pumps associated system:
Suction piping Common suction header for both the pumps is connected from the Deaerator outlet piping, providing necessary
NPSH. Each pump on suction side is provided with an isolation valve, strainer & local pressure indication.
Differential pressure switch across the strainer is provided to generate the diff. pressure Hi & Hi-Hi alarm signal in the DCS.
•Discharge piping of each pump on discharge side is connected to discharge header, which supplies feed water to the 2 HP
boiler drums through the Economizers located in AQC Boiler. Whereas in case of LP system, the a tapping with a pressure
regulating valve from the common Feed water pump discharge header & directly supplies the feed water to the both LP drums in
PH & AQC Boiler at the required pressure.
•The pressure transmitter installed on the header generates the discharge pressure low alarm signal to enable / caution for
starting the stand by pump.
Note (Please refer vendor pump manual for safe operation & maintenance of the BFWP)
•Auto Re-circulation valve (ARC): The automatic pump recirculation valves protect centrifugal pumps from possible damages
caused by thermal and hydraulic overloads at low load operations by means of an automatic controlled bypass flow which
corresponds with the required minimum flow of the pump. This protects the pump from cavitation due to churning effect.
•The cooling system is provided for the common Boiler feed water pump bearings .
Refer P&ID for Deaerator & BFP system (PB-33376-1)
Feed Control Station

WHRB, when it is in operation, must be kept continuously supplied with feed water to maintain normal level in the drum.
Feed water is obtained at the inlet of feed water control station from the Economizer Outlet of AQC Boiler after the feed water
pump at a temperature of 193 ºC.
There are two feed control stations (2 x 100%) for both AQC & PH boiler (HP) & separate feed control stations (2 X 100%) for LP
systems in both PH & AQC Boiler, out of which at least one of each must be in service in each case when the related WHRB is
operational.
2x100% feed controls is used during startups and is capable of feeding the boiler only when the steam flows from WHRB. A
feature of above 100% level control valves is that it enables the regulation of feed water to the WHRB to be on auto mode from
the very start of WHRB.
The following are installed in the common inlet line from the Plant feed main to the two feed regulation Stations.
¾ Pressure indicator to indicate feed water pressure
¾ Flow nozzle with impulse connections with 2 out of 3 flow transmitter.
The flow transmitters provide feed flow signal to the feed Indicating controller.
There are separate feed control stations (2 X100 %) for both PH & AQC boiler (HP) & 2 X100% for LP Circuit applicable for both
PH & AQC Boiler. The feed regulating stations are now described.
100% valve of Feed Regulation Station

The 100% feed regulating valve is used during Startup of the WHRB.
The valve can be operated either on auto or manual made. The positioning of on auto is controlled only by the level signal from
the Drum, which is acceptable at loads
Valve is a globe type control valve pneumatically actuated by a spring opposed diaphragm actuator. The characteristic of the
valve is linear, with equal increase in flow for equal valve opening. On loss of control air, the valve opens full. There is no manual
override for controlling the valve.
The valve is arranged between a motorized operated inlet Isolating valve and a manually operated outlet Isolating valve. The valve
is normally kept open. In Inlet of the both the valves a drain connection is provided with isolation valve. The drains normally
remain closed and opened only to drain the line when control valve has to be opened for inspection/maintenance.
The valve can be positioned on manual mode from the DCS to provide the required quantity of water to maintain normal water
level. In the auto mode the level indicating controller positions the valve.
Level transmitters continuously monitor the steam drum water level. A signal from two out of three of these transmitters feed a
level signal to through a 2/3 drum level micro. These level signals are compensated for drum steam pressure. The set point of the
controller is 0 (i.e. normal level, 50%). When is switched on the auto mode, the controller compares the level signal with the set
point and generates an error signal if there is a deviation and positions the valve through the positioner to correct the deviation
and its automatic control are adequate during WHRB startups & low steam flows, when rapid changes of drum level (except
during swelling) is not envisaged. The operation of control valves can be sluggish and cannot respond to rapid water level
changes due to large load changes.
The inlet, outlet and drain arrangements are similar to the low load control valve described earlier.
Valve is a full load feed regulating valve for maintaining drum water level and is pneumatically operated by a spring opposed
diaphragm actuator. The valve opens full on loss of control air and has no manual over ride. The valve is positioned by the flow
indicating controller.
It is a three element controller, which takes into account not only the drum level, but also the steam flow from WHRB and the
current feed water flow, to correctly position the feed regulating valve.
The drum level signal, compensated for drum pressure, is received in controller. A linearized steam flow signal, compensated for
steam pressure is also received in.
The drum level which is a measured variable signal is computed with the anticipatory signal of steam flow in and a resultant error
signal is fed to feed indicating controller compares the level error signal with the feed flow signal it receives from flow
transmitters and computes a control current signal based on its set point (usually normal level) . The valve position is transmitted
to the DCS. On the DCS, current drum level, steam flow, feed flow & the feed control valve position can be monitored.
The three element control adopted for the 100% flow control valves takes into account the drum level, steam flow and feed water
flow for positioning of both the control valve
Attemperation line
Attemperation control station consists of globe type pneumatically actuated control valve to control spray water flow to the
Attemperator. The control valve is provided with isolation valves and a bypass control valve with the isolation valves to prevent
back flow of steam a NRV is provided in the line.
The main steam temperature signal is received from the measured process variable is compared with the fled set point (SP) in the
temperature controller block and a control signal is generated. The control output signal (CV) from the controller will position the
Attemperator control valves through a current-pneumatic converter. Action of the control valve is Air/ Signal fail to open.
Attemperation station is located in between Super heater 1 & Super heater 2 of AQC Boiler.
Boiler Pressure Part Description

Various pressure parts are grouped as follows:
Economizer (Common for both PH & AQC Boiler)
Steams drum (Both LP & HP)
Evaporator (LP & HP Circuit both)
Super heater (LP & HP Circuit both)
Economizer (Common for both PH & AQC Boiler)

The Economizer located on the third last stages of the exhaust gas path of the AQC Boiler.
Finned tube Economizer is located in the boiler to recover economically feasible heat from the flue gas before discharging to the
atmosphere. The recovered heat increases the temperature of feed water entering the steam drum. The direction of feed water
flow (inside the tubes) and flue gas (outside the tubes) are parallel flow to avoid steaming in Economizer. Flue gas flows vertically
through the Economizer. Feed water from the Boiler Feed Water Pump enters the Inlet header of the Economizer.
The coils are arranged between inlet and outlet headers. The economizers are fully drainable by the drain valves provided on the
inlet headers to expel air from the economizers during filling of the boiler, air vents with valves have been provided on the outlet
header. Manholes are provided on the in/out duct casing for cleaning and inspection of the Economizer surfaces.
There are two modules of Economizer; during operation, feed water from BFP outlet flows to the Economizer- inlet header and
through the coils absorbing heat from the flue gas to economizer-outlet header then it flows to the steam drum via the feed
control station.
Economizer is provided with air vent and drains. ECO is hung from the top by Rod Hangers and anchor support with provision for
downward thermal expansion.
The drain valves are used for draining the ECO tubes when the WHRB is not in service, if required for maintenance
Feed water, after picking up heat from the Economizer, enters the HP Drum of both PH & AQC Boilers through the feed control
stations.
Feed water from Eco outlet header of AQC Boiler, one branch of feed pipe is connected to AQC Boiler HP drum through the AQC
Boiler HP feed control station and another branch is connected to PH Boiler HP drum through PH Boiler feed control station.
Temperature Indication
¾ Temperature Indication is meant for indicating feed water temperatures before & after Economizer.
A temperature transmitter provides indication in DCS.
Pressure Indication
¾ Pressure Indication is meant for indicating feed water pressure after Economizer.
Steam Drum
The Steam Drum is a welded cylindrical vessel. For PH Boiler the LP & HP steam drum is supported by the main down comers and
the down comers are placed on the WHRB structure with slide bearing. The slide bearing will permit the horizontal thermal
expansion of the drum. For AQC Boiler the HP & LP steam drums are supported on two saddle supports, one is fixed to main
structure & the other support is bolted with slotted hole to permit the thermal expansion of the drum. The drum is insulated by
bonded mineral wool mats. Two manholes are provided at either end to access the drum. The drum is closed tight at either end
cover plates bolted against the manhole rim by two holding bars.
A gasket is fitted between the cover plate and the mating machined surfaces in the dished ends. The cover plates swing inside,
for convenience during opening.
Steam Drum is fitted with several components to perform important functions, which are listed below:
Steam Drum receives feed water from the Economizer outlet through feed pipes and distributes the feed water along the length of
the drum by a perforated pipe to maintain a near constant level (Normal water level) for continuous supply to the evaporators
through down comer pipes. While flowing through the evaporator panels, by absorbing heat from the cement kiln exhaust gas, the
hot water gets converted to water / steam mixture and flows back to the steam Drum through riser tubes.
Steam drum receives the water – steam mixture from the evaporator tubes through the riser tubes, the water – steam mixture in
the steam drum separated by Baffle plates which is a primary steam separator. Further saturated steam flows through the
Secondary steam separator Demister pad installed at the outlet of the steam drum to separate traces of water particles and to
ensure steam purity. Water which is heavier is separated from steam and trickle down to mix with the water in the steam drum.
Saturated dry steam collects at the top of the drum and distributed to the Super heater.
Conditioning of Boiler Water

Due to continuous evaporation of boiler water in the drum, minor impurities present in the feed water, concentrate to high
impermissible levels in the boiler water. Rise in hardness of water (conductivity), content of chlorides, silica etc., have to be kept
to a minimum to prevent scale formation or deposits, in the evaporator tubes and drum.
Sample of Boiler water is collected from the continuous blow down line through the sample coolers and are to be tested in
laboratory. If the analysis indicate high conductivity (chlorides, silica etc.,), small pre-determined amount of water is
continuously drained from the steam drum through the continuous Blow down valve. Motorized Blow down valve (Globe valve) is
provided for controlling the flow to reduce their concentration to permissible levels in the steam drum.
Tri-Sodium phosphate is dosed into steam in the boiler drum to maintain a phosphate concentration of maximum 34 ppm and
pH of 9.0 to 11.2. The Phosphate has the capacity to convert hardness producing insoluble calcium/ magnesium salts to soluble
sodium salts, which are drained through the blow down. A typical reaction can be as follows
3 CaSO4 + 2 Na3 PO4 →Ca3 (PO4)2↓ + 3Na2 SO4
The dozed phosphate also provides desired alkalinity to the boiler water. An alkaline pH minimizes the possibilities of corrosion.
Dosing of phosphate to the Boiler water is to be done in a manner that it quickly mixes with the whole of Boiler water. To enable
this, a perforated 25NB pipe has been laid along the length of the steam drum and connected to the HP chemical dosing system
through line with an isolation valve and a non-return valve.
The following facilities have been provided in the steam Drum for the above operations:
Level Gauges, Level Indicators, Level Transmitters Level Sensing Instruments
Level sensing instruments are tapped off from the front & rear sides of the steam drum near the hemispherical dished ends. Level
Indicators & LEVEL TRANSMITTERS:-Three level transmitters are installed on the steam drum. Signal from the two of these
transmitters & level indicator are taken for three element control and the level transmitters signal is used for drum level control
as process variable .
Maintaining the normal water level in the steam drum is one of the important parameters, to monitor and control this, elaborate
provisions for level instrumentation has been made on the Steam Drum.
¾ Pressure Indicators
¾ Pressure indicators are provided for local indication
¾ Pressure Transmitters
¾ Pressure transmitter is installed on the steam drum to provide remote indication of steam drum pressure.
The reading of the steam drum water level by the level transmitters is affected by the drum pressure. Transmitters through
isolating valves mounted on the steam drum, provide a pressure compensation signal to the drum level control macro, so that
drum level signals represent true level neutralizing variations due to pressure changes. They also provide steam drum pressure
signal to DCS.
Drum Safety Valves

To protect the boiler and the personnel against the consequences of abnormal pressure increase caused by sudden load
fluctuations, closure of steam valves etc., two spring loaded mechanical safety valves have been fitted on the steam drum. On
increase of the steam pressure beyond the set value of the Safety Valve’s the valves open automatically to relieve the steam to
atmosphere. There are silencers on each safety valve to reduce the noise levels within the specified levels. The safety valve closes
when the drum pressure falls to the reset pressure of the valve. The relieving capacity of all the Safety Valves together with safety
valve on steam super-heater outlet line is designed in such a manner that even at maximum fluctuating of the Boiler, the valves
are capable to relieve the total generation of steam thus safeguarding the boiler.
Do not operate the WHRB with safety valves gagged. Passing safety valves must be attended during the next planned shutdown.
Air Vent
An air vent, with one isolation valves is provided at the outlet line of the steam drum to vent out air during initial boiler filling &
cold start-up and while de- pressurization/ shutting down the boiler to prevent the drum from going into vacuum pressure due to
condensation. While boiler cold start up, the air vent is kept open till the steam drum pressure reaches 2 kg/cm2 (g) and similarly
it is opened when the drum pressure falls to 2 kg/cm2 (g) during shutdown
Dosing and Blow down Connections

A Continuous Blow down (CBD) connection and a Chemical Dosing connection are provided on the steam drum for conditioning
of the Boiler Water.
Continuous Blow Down

Due to continuous evaporation of boiler water in the drum, minor impurities present in the feed water concentrate to high
impermissible levels in the boiler water. Rise in hardness of water, phosphates, content of chlorides, silica etc., have to be kept
to a minimum to prevent scale formation or deposits in the boiler evaporation tubes, drums, super-heater, steam piping and the
downstream equipment. Sample of boiler water is collected through a sample cooler and the sample is analyzed by an online
conductivity analyzer. Based on measured value of conductivity, determined amount of water is continuously drained from the
boiler drum through the Continuous Blow down (CBD) line by a motorized CBD valve to reduce the concentration of impurities
and to maintain within the permissible levels.
A 25 NB pipe with its one end open is provided below the steam drum, this line is connected to blow down tank. Blow down tank
consist of Level transmitter which gives signals to level control valve provided at the outlet of Blow down tank to maintain the BD
tank levels.
Evaporators (for both HP & LP circuits)

The HP Evaporator is located after the super heater coils in the flue gas path for both PH & AQC Boilers. Finned tube evaporators
for AQC Boiler and bare tube evaporators for PH Boiler are provided. The latent heat required for converting saturated water to
saturated steam is taken from flue gasses and mixture of saturated steam and water will enters to the steam drum. The direction
of steam and water mixture (inside the tubes) and flue gas (outside the tubes) are parallel in AQC Boiler whereas cross flow in PH
Boiler. Flue gas flows vertically through the Evaporators in both PH & AQC boilers. Saturated Water from the drum enters to the
Inlet header of the Evaporators. The coils are arranged between inlet and outlet headers. The evaporators are drainable.
Manholes are provided on the in/out duct casing for cleaning and inspection of the HP evaporator surfaces.
There are four modules of HP evaporator & single module of LP evaporator in PH Boiler & single module each of HP & LP
evaporator in AQC Boiler; during operation, the saturated water from the drum is supplied to the evaporator coils through inlet
header where the water absorbs latent heat from the flue gases and again flows back to steam drum through outlet header. Or in
other words the Evaporators convert saturated boiler water received from the Drum through down comer pipes into a steam water
mixture, by absorption of latent heat from the Kiln exhaust gas.
The steam water mixture is led back to the drum from the evaporators through riser pipes. The Evaporators are hung from the top
in the flue path by rod hangers in AQC and PH boiler Evaporator is supported on boiler cage, with provision for thermal expansion
downward & in the sides.
In the steam drum, the steam water mixture flows through the separators where water & steam are separated and saturated
steam is collected in the steam header and flows to the Primary Super heater. Separated water mixes with boiler water to flow
through the Evaporator circuit again.
Super Heaters (Both HP & LP Circuit)

Saturated Steam collected at the outlet of PH HP steam drum flow through the Primary super heater section to convert saturated
steam into superheated steam by heat absorption from flue gasses. This superheated steam further collected in mixing header
located at the outlet of AQC boiler Primary Super heater.
Similarly saturated steam collected at the outlet of AQC Boiler HP Steam drum flow through the Primary super heater section to
convert saturated steam into superheated steam by adding degree of superheat.
Both AQC and PH Boiler Superheated steam collected at Mixing header and Total superheated steam further superheated in AQC
Boiler Final HP super heater through Attemperator control station. Attemperator control station is envisaged to maintain the final
super heater steam temperature going to Turbine.
Super heaters are made of modules, each consisting of an inlet header and an outlet header, with coils between the headers.
Super heater modules are hung from their top headers with provision for thermal expansion down wards.
The direction of steam (inside the tubes) and flue gas (outside the tubes) for both AQC and PH Boiler HP Super heater are counter
flow for optimum heat transfer.
Continuous and sufficient flow of the steam through the Super heater ensures the metal temperature of the coils does not exceed
the design value.
HP Final Super Heater inlet header (being the bottom most point in AQC) is provided with drain. Air vents is provided on the outlet
header of the HP final super heater. The air vents are opened before line up of the boiler. They are closed at a drum pressure of 2
to 5 Kg/cm²
Similarly saturated steam collected at the outlet of both PH & AQC Boiler LP Steam drum flow through the single LP super heater
section in both PH & AQC Boilers to convert saturated steam into superheated steam by adding degree of superheat and finally
injected in the Turbine through the LP injection point.
Attemperator
An Attemperator is provided after the mixing header of AQC boiler to maintain the final HP steam temperature. Spray is controlled
by quantity of feed water from the outlet of BFP header into the Attemperator through a pneumatic control globe valve which
controls the HP SH2 outlet temperature.
The spray water is taped from the feed water piping before the feed water control station at the BFP outlet header. Attemperation
control station consists of globe type pneumatically actuated control valve to control spray water to the Attemperator. The control
valve is provided with isolation valves and a bypass control valve with the isolation valves. To prevent back flow of steam a NRV is
provided in the line.
STEAM TEMPERATURE CONTROL LOOP

Steam temperature control is designed to maintain the Final HP steam temperature at 390° C. As the heat pickup in the Super
heater increases with load; the spray water quantity will increase.
The final steam temperature is measured and transmitted by the transmitter to the controller in DCS. The measured value is
compared to the fixed set point in the controller and a control output signal is generated, which is sent to position the
temperature control valve.
Main Steam Piping

The SH steam line connecting the outlet header of Super heater to the plant mainly comprising of:
• PRESSURE & TEMPERATURE MEASUREMENTS Pressure indicators with one isolation valves are provided for local pressure
indication.
Pressure transmitters installed on the steam line provide the main steam pressure signal to DCS. Pressure signals are taken as
the process variable for the pressure indicating controller. Steam pressure very high and Very low alarm is generated from the
signal and is indicated in DCS.
Temperature elements with transmitter are provided on the main steam line to measure and transmit the steam temperature to
DCS. Temperature signal is taken as the process variable for the temperature indicating controller.
ELECTRICALLY OPERATED MAIN STEAM STOP VALVE

This valve isolates the WHRB from the plant / Common steam header. Main steam stop valve is provided to isolate the boiler
from the plant during shutdown and during start-up until the operating parameters are attained. During regular operation of the
boiler, this valve is kept fully open supplying steam from the boiler to the plant mains. For line charging till TG Inlet
SAFETY VALVE,
This is a spring loaded, valve set at 15 Kg/cm²; pressure to protect the boiler against over pressures. The safety valve is similar to
Drum safety valves described earlier. The exhaust of the safety valve is piped to a silencer to reduce the noise levels when the safety
valve is operating. The silencer is mounted on a separate structure on top of the WHRB.
START UP VENT VALVE
Startup vent is an electrically operated regulating valve. The startup vent valve is to be kept open while start up. The valve is
normally set to open when there is load upset at a pressure higher than normal operating header pressure and below the super
heater safety valve set pressure. This valve is expected to relieve the excess pressure. For this purpose, pressure controller which
takes pressure impulses from the main line, commands start up vent valve to open the valve. The exhaust of is connected through
a silencer to reduce noise levels during its operation.
FLOW NOZZLE
Flow nozzle is installed on the steam line to provide impulse to upstream & downstream pressure readings to steam flow
transmitter. Flow nozzle is connected after the main steam stop valve.
Total 2 Flow nozzles provided in main steam line for AQC Boiler at HP Primary Super heater outlet and another flow nozzle at the
outlet of HP Final Super heater. Where, in PH Boiler, one Flow nozzle is provided at the outlet of HP Primary Super heater.
Similarly one flow nozzle is provided at the Outlet of LP super heater in both PH & AQC Boilers.
NRV As the plant steam supply is from more than one boiler, to prevent back flow of steam from the steam mains to the boiler,
when the boiler trips or when the boiler pressure is lower than that of the steam mains, a non-return valve has been provided before
the main steam stop valve.
STEAM LINE DRAIN

A motorized drain valve is provided at the inlet of MSSV. Other steam line drains consist of the manually operated valve .The
manually operated valve is kept opened during connecting to the main steam header.
SAMPLE CONNECTION
To analyze the super-heated steam quality, a sample line is taped off from the main steam line with an isolation valves and
connected to the Sample Coolers.
Operational Control
This section explains the major operational control points described in this chapter.
Steam Drum
Maintain feed water, boiler water quality, and chemical concentration as prescribed.
Maintain water level in the steam drum within permissible low and high levels. The protection system envisages boiler trip at very
low levels, which should not be bypassed.
Maintain drum level gauges in good working condition. Operators may verify the level transmitter reading with the level gauge once
a day.
THERMAL STRESSES IN DRUMS DURING START UP AND SHUT DOWN
Steam Drum is a large cylindrical shell. Before line up of a boiler, the inner and outer surfaces of the drum are at the same
temperature. When boiler is lined up, the inner surface gets heated up first by the water (and then by steam) and transmits heat
to the outer surface of drum. The heat transfer is by conduction and is a bit slow. For short time after line up, there can be
differences of temperature between steam and water surfaces of the drum. Such a difference can set up thermal stresses, which
are not desirable, and an alarm sounds gives at DCS. To minimize the thermal stresses, the operator must restrict the flue gas flow
rate when starting the WHRB by modulating the bypass control damper.
SWELLING
During WHRB startup, as the Boiler water temperature reaches 90°C, there is an increase of water level caused by increase in the
volume of hot water. Such swelling, if not controlled, can cause a High Level trip. To avoid this, initial filling is normally restricted to
low level (say – 100 to 150 mm) and the smart Operator anticipates a swell and uses the BD to drain and control the level.
Do not operate the WHRB with safety valves gagged.
Passing safety valves must be attended during the next planned shutdown.
Super Heaters
Super heaters must be drained after shut down and cooling of the boiler. They must also be kept open before a cold start up till 5
2
kg/cm pressure is built up. During hot charging they are opened for a few minutes.
Superheat steam temperatures at exit of Super Heater main steam temperatures must be monitored to see there is no excessive
heat pick up. Compare these figures with predicted performance values. High steam temperatures may mean high metal
temperatures.
General
2
Boiler water can be drained after a shut down only after depressurizing to 2 kg/cm and after cooling to 80 °C
Draining of Boiler water must preferably be done through the blow down tank.
If a tube failure is detected, it is advisable to plan for an early shut down. It may be possible to quickly repair the failed tube and
return to service. If the shutdown is in-ordinately delayed, there are possibilities of larger secondary damages, which may prolong
the shutdown, required for repairs.
Manually operated valves must be closed hand tight only. Use of levers on hand wheels is not desired.
Drum Metal Temperature Monitoring

When a WHRB is started after filling water to normal level, initially drum metal temperatures on the steam side and water side may
show considerable difference due to slow convective heat transfer across the drum metal and difference of heat inputs across the
water washed & steam washed parts of the drum. The temperature difference, if it exceeds 50°C, may set up abnormal thermal
stresses. Thermo well provision is given to measure the metal temperature in case of abnormal stresses occur.
Steam and Water System Technical Performance Data
WHRB Design Pressure: Maximum Working Pressure Kg/Cm² (g)
Set pressure and capacity of safety valves

Tag No Set Pressure kg/cm² (g)
WHRS-AQC2HP-MAS-SV-001 18
WHRS-AQC2HP-MAS-SV-004 17.5
WHRS-AQC2HP-FDW-SV-001 32
WHRS-AQC2LP-MAS-SV-001 4
WHRS-AQC2LP-MAS-SV-002 5
WHRS-AQC2LP-MAS-SV-003 3.5
WHRS-PH2HP-MAS-SV-001 18
WHRS- PH2HP-MAS-SV-002 19
WHRS- PH2HP-MAS-SV-003 17.5
Do not operate the WHRB with safety valves gagged.

Passing safety valves must be attended during the next planned shutdown.
Boiler Blow down System

This section describes the WHRB blow down system for safe draining of high pressure / High temperature steam and water from
the boiler using the blow down tank.
System Description
The P & I. Diagram of the water and steam system shows the various drains from the WHRB. Large quantities of steam or high
pressure / temperature water are not to be drained through open canals for the following reasons:
a) Such draining will cause splashing of high volumes of steam, which can be a nuisance by the noise it creates, and also it
affects the visibility around the draining area.
b) High temperatures of these drains can cause Scalding injuries to workmen who may come in contact with it.
c) The force and temperature of these drains will erode the linings of the drain canals.
d) Low-pressure steam, which can be recovered, if required, is wasted.
HIGH PRESSURE / HIGH TEMPERATURE STEAM AND WATER DRAINS (HP & LP)
S. No. Source Valve Nos. Temp of drain °C Frequency of usage
1. Continuous blow CBD with isolation 193 °C (HP Steam) Continuous, quantity depending on
down valve 127 °C (LP Steam) quality of boiler water
2. Intermittent / IBD with isolation 193 °C (HP Steam) During high level in steam drum and
emergency blow valve 127 °C (LP Steam) quality of boiler water
down
CBD Drain
Continuous blow down (CBD) is connected to the blow down tank. A motorized operated inching type valve is provided on CBD
line. Isolation valves at upstream are provided.
IBD / EBD Drain

Intermittent blow down (IBD) is connected to the blow down tank. A motorized operated inching type valve is provided on IBD
line. Isolation valves at upstream are provided.
Other Drains
The drains indicated in the P & ID are connected to the blow down tank. The blow down tank is capable of separating steam from
the drain water. The drains are connected tangentially in the upper half of the drum, to direct the drain fluid circumferentially
around the inner wall of the tank, to aid separation of steam and water by their differences in densities. A vent line of the tank is
provided open to atmosphere.
It can be seen that drains have been provided in the feed water line and connected to the drain canal. As these drains are either
for operation to drain these lines after isolation or for short time during charging, their connections to the open canal is not
expected to pose a problem.
¾ All level control station drain
¾ All pressure control station drain
¾ Steam drum level indicator.
¾ Steam drum safety valve drains
¾ Sample coolers let off drain.
¾ All equipment / pressure part drains
Continuous & Intermittent Blow down Control
CBD & IBD control involves the following operations:
Obtain a sample of boiler water from the steam drum to the Sample Coolers.
Analyze the sample for conductivity, hardness, NaCL, Silica, Fe, etc., and working out a rate of draining of boiler water to
maintain the concentrations as suggested in Boiler water quality.
Motorized opening / closing positioning the CBD valve is to be decided depending on the water quality. Motorized opening /
closing positioning the IBD valve is to be decided depending on the Steam drum high level and water quality.
Repeating the sampling, analysis and repositioning the CBD & IBD valve after certain Interval is necessary to maintain the
required Boiler water quality. This system of motorized control requires the services of collection of samples from sample coolers,
a chemist and a laboratory round the clock.
The arrangements provided for CBD control is:
A perforated pipe, laid along the water space in the steam drum connects through a stub to the continuous blow down line.
CBD & IBD line from drum connects to the blow down tank.
A tap off from the CBD line is taken to the sample coolers for intermittent analysis of boiler water conductivity and also for a grab
sample sampling of CBD / Boiler water is done in sample coolers of the sampling package.
This sample coolers package provides analysis of the following samples to provide comprehensive information of quality of
steam and water of WHRB.
¾ Samples of boiler water (CBD) from the steam drum of WHRB.

¾ While all the samples above are analyzed for conductivity by separate analyzers, the CBD samples are analyzed in
addition for pH also.
¾ Care of other sample coolers is identical. Valve is normally kept open to maintain small continuous flow of boiler
water to the blow down tank. This is required to ensure the sample at any time to the sample coolers is truly
representative of the sample being analyzed. This continuous flow also ensures that these lines do not get chocked
for want of adequate flow.
An isolating valve to the sample coolers is kept open. The sample coolers are used for grab sampling for doing the analysis of the
boiler & Blow down water and maintaining the boiler water quality.
Tri-sodium phosphate dosing to Boiler water is to maintain its phosphate content at 35 to 40 PPM. The tri-sodium phosphate at
the suggested levels maintains the alkalinity of the boiler water (pH 9.0 to 10.5) and also converts the harmful, insoluble calcium
and magnesium salts which form the residual hardness of boiler water, to benign soluble, sodium salts, in the form of a soft
sludge, to be drained by the CBD.
Phosphate dosing, prevents corrosion of the water washed parts of the steam drum and the Evaporator tubes, by adjusting the
speed or the stroke of the pump provided as described below. Excess as well as reduced phosphate levels in Boiler water should
be avoided. (The phosphate dosing is also sometimes called as "HP dosing" as the pump used develops high pressure to dose
against the boiler drum pressure).
Chemical Dosing & Sampling System
HP Dosing System
The equipment, which are of stainless steel, provided for phosphate dosing (“HP dosing”), are shown in P & I diagram and consists
of:
¾ A common mixing tank of 300 liters for preparation of tri-sodium phosphate solution.
¾ Two dosing pumps (with one stand by) dedicatedly for both HP & LP Boiler systems
DM Water source for preparation of the phosphate solution as well as for flushing
Generally Tri sodium phosphate is dozed through HP Dozing system to take care of the ingress of hardness salts and to increase the
boiler water pH.
Mixing Tank
The Mixing tank of 300 liters is a MSRL covered cylindrical vessel, with a level indicating gauge glass , DM water inlet line (with a
manual isolating valve) , an over flow drain line. A drain line with a manual-isolating valve, a dissolving basket for placing
required quantity of tri-sodium phosphate powder for preparation of the solution is provided. A solution inlet connection to the
pumps with a manual isolating valves, a motor operated stirrer is also fitted for preparation of chemical solutions. The level of the
mixing tank is monitored by level switch. Availability of a minimum level is a required permissive condition for starting or
continued service of a dosing pump.
Sr. Requirement Dosing % Dosage Specific Flow rate Chemical Qty. at 100%
No. Concentration ppm gravity (lit/hr) conc. (kg/day)
1 AQC Boiler
Tri sodium 0.5-5% 28 -- 20 0.50
Phosphate
2 PH Boiler
Tri sodium 0.5-5% 28 -- 20 0.55
Phosphate
Phosphate Dosing Pump

Two phosphate dosing pumps 0-5LPH and 30kg/cm²(g) pressure for HP Boiler & 0-5 LPH and 12 kg/cm²(g) pressure for LP
Boiler have been provided, out of which one is for service at a time, and the other is a standby. The pumps are plunger operated
reciprocating, positive displacement type. The stroke of the plunger can be altered for manual adjustment of flow to suit feed
water requirement. The vendor manual of the pump and gearbox is provided for full information on construction and parts detail.
Each pump is connected to a common discharge line with the following valve arrangement:
An inlet, valve with a "Y" strainer, Y strainer traps dirt or other solid particles in its basket. The Y strainer is to be cleaned once a
month, after stopping the pump and closing its inlet and outlet isolating valves.
On the discharge side of the pump, a pressure gauge and an outlet isolating valve is fitted before the common discharge line. A
safety relief valve has also been fitted on the discharge line to relieve any over pressures in case of closure of valves on the
discharge line. The outlet of the relief valve is returned to the mixing tank. The relief valve must be tested for its operation at the
set pressure at least once a year. The pump must not be operated with the relief valve continuously operating. (Cause of relief
valve operation must be found and rectified).
The common discharge line is connected to the HP dosing line of the steam drum through an NRV and an isolating valve. The
isolating valve is verified open before boiler line up and normally remains open all the time. Phosphate dosing is through a
perforated pipe along the full length of the water space in the drum.
Availability of a minimum level in the mixing tank is a pre-condition for starting or running of the dosing pumps. Out of the two
pumps, one pump is selected for service and the other is in reserve (DCS macro, Local panel). The pumps are interlocked such
that when a working pump trips, the reserve pump starts automatically.
A phosphate pump is placed immediately in service after the WHRB start up in the following manner:
Boiler water sample is analyzed and phosphate content is determined.
The pump is prepared by opening the outlet valve from the mixing tank, opening the inlet and the two outlet valves of the pump.
Two minutes are allowed after opening the inlet valve for the pump to get filled with phosphate solution. The pump is started by
switching on the motor. The pressure gauge is observed. It should show a reading, higher than the steam drum pressure. A Safety
Valve is provided on the pump discharge line for safety as this is a positive displacement reciprocating pump.
Any abnormal noise from the pump, motor or gearbox is noted. The safety relief valve should not also be operating. If there are no
abnormalities the pump is allowed to run.
Every four hours, the phosphate content in the boiler water is checked by laboratory sample analysis and also by the pH meter.
The pump speed stroke is increased or decreased to maintain the phosphate content within 8 to 10 PPM by continuous pump
operation.
The phosphate solution level is observed in the mixing tank by the level gauge. If the level falls to 25% of the gauge glass level,
additional solution is prepared as stated above. Low level switches are also provided in the tank for safety of the pumps.
FLUSHING THE PHOSPHATE PUMP AND THE LINES WITH WATER DURING LONG STOPPAGE OF THE WHRB:
If the WHRB is to be stopped for more than a few days for servicing or maintenance, the phosphate pumps and the line are
flushed with water to keep them clean in the following manner. (Flushing) line is connected from the tank solution preparation
DM waterline to the inlet line of the pumps. The pump which was in service earlier is run, for about 30 minutes to one hour. DM
Water flushes the phosphate solution from the pump and the lines to the steam drum and cleans them. The pump is stopped. The
outlet valve from the mixing tank, is not opened till the boiler is again lined up and a phosphate pump is required in service. At
that time the isolating valve on the DM line is closed.
NOTE: Do not operate the Stirrer of the HP dosing pump when the HP tank is dry or not filled with water or the dosing solution.
The dry operation of the stirrer can lead to failure of the stirrer (misalignment of the stirrer).
LP dozing system is provided in the common Deaerator for Hydrazine to scavenge the last traces of the dissolved Oxygen in feed
water.
The vendor manual of both the systems is provided for full information on construction and parts detail.
Maintaining Quality of Steam

Good Quality steam is obtained if the following requirements are met:
Proper assembly of baffles, demister pad in the steam drum as per erection instructions (checked before commissioning of the
Boiler) Boiler feed water as per norms as suggested.
(Monitor the feed water conductivity & PH analyzers) and Control of Boiler water quality as suggested.
Monitor the saturation steam & main steam conductivity Increase of saturation steam conductivity may be a warning for check of
drum internals or maintaining high water levels in steam drum. It should be understood that if the quality of Boiler feed water
deteriorates; the steam quality is directly affected. After several years of service, during a boiler over haul, baffles and demister
are checked for damage or erosion holes, which may bypass steam from the separation devices. Steam which bypasses the
separation devices carry with it moisture, with it salt contaminants to steam.
Higher than permissible levels of Silica in boiler water will result in Silica carry over in steam.
Operational Control
The water chemistry for determining low levels of impurities in water calls for special instruments, special analytical procedures
and an experienced chemist. These should be available from the time of commissioning the boiler.
In a chemical process plant, in spite of the best available demineralization facilities the boiler feed water may occasionally get
contaminated by return condenses from the system. A procedure to systematically check the return condensates (particularly for
contamination by Fe, Chlorides and Oil) must be established and contaminated condensates must be discarded.
Phosphate & Hydrazine dosing must be adjusted for continuous operation.
List of points in the Sample coolers for both PH & AQC boilers is given in the page below
TITLE: FLUE GAS SYSTEM

FLUE GAS SYSTEM
This chapter describes the Cement kiln exhaust flow through the WHRB, insulation and casing of WHRB and the Stack, various
sealing air connections are also indicated.
System Description
The steam drum & WHRB pressure part panels are supported on column structures. Insulation & steel casing is applied enclosing
the coils to provide a gas tight passage for the exhaust gas from the Cement kiln. The casing is covered fully with insulation and
aluminum cladding. The insulation is held by strips and the screws as shown in the respective drawing. Exhaust gas from the
Cement kiln enters the WHRB through ducting. The following are the instruments in the flue gas system.
¾ Flue Gas Pressure & Temperature at the tapping Point
¾ Flue Gas Pressure & temperature at Deduster Outlet
¾ Flue Gas Pressure & temperature at Boiler Inlet
¾ Flue Gas pressure & Temperature at Boiler Outlet
¾ Flue Gas Temperature at various intermediate stages.
¾ Boiler /Deduster Hopper Dust Level switches.
¾ Zero speed switches on the dust conveying equipment’s such as Drag Chain & RAV
¾ Damper Actuators for operating various dampers.
Operational Control
The anticipated performance figures both steam / water and gas side has been given in following section. The operator shall
familiarize himself with these figures. Elaborate instrumentation has been provided to measure each of these factors. Alarms
also have been provided to alert the operator in case of deviations for several of these readings Operator attention is needed
particularly for the following - Kiln Exhaust Gas (Boiler inlet) temperature -Gas side temperature drop, pressure drop
Steam/Water side heat pick up across pressure parts like,
– Super heater 1 & 2
– Evaporator coils
– ECO
– CPH
Evaluating these figures the operator should decide the need for hammering in case of PH Boiler (Or other checks during
a shutdown).
– Healthiness of aviation warning lamps is to be check periodically.
Flue Gas Flow can be monitored by spot flue measurement methods at the locations provided in ducts for flue gas flow
measurement. For reference values, refer Boiler Data sheet mentioned above in this manual.
The accuracy of the flow measurement will be based on instrument error, measurement errors & the upstream and downstream
corrections at the measuring points.
HAMMERING SYSTEM FOR PH BOILER

The exhaust gases from the Pre-heater which are entering the PH boiler contain high dust concentration. Moreover the operating
conditions in the cement plants requires design of waste heat recovery boilers which should be able to withstand the problem of
heavy coating formation, as the raw meal dust tends to adhere to the heat exchanging surfaces, resulting in drastic reduction of
capacity. As such the characteristics of the dust in the waste gases with regard to particle size, stickiness, abrasiveness has to be
taken into account while designing the boiler heating surfaces.
Heating surfaces of PH boiler are exposed to sticky dust coming along with the incoming gases from the Pre-heater. This dust
settles on the heating surface and reduces the overall heat transfer coefficient. Hence the heat transfer reduces. So provision of
proper dust removal system becomes essential for the PH boilers. The PH boilers are designed with horizontal tubes arrangement
and these tubes are continuously or periodically cleaned by mechanical hammering / rapping.
A rapping device is a special facility provided for boiler cleaning. By rapping the fouled convection heating surfaces, the bank
tubes are subjected to vibrations so that the deposited dust falls off. For PH boilers the rapping system (01 No.s each side) is
provided on each pressure part bundles of the boiler to have hammering. The hammering systems are provided on both L H and R
H sides of each boiler pressure part bundle from top to bottom of the vertical PH Boiler so that effective cleaning of all the tubes
in the entire cross section of the boiler is possible.
The rapping system consists of the drive motor, helical gear box, chain & sprocket arrangement with chain, the hammers
installed on the horizontal shaft. The shaft is rotating at a speed of 2.3 rpm. When the shaft rotates, the hammers installed on the
shaft hit the ends of the bottom part which results in vibrations to the tubes which are interconnected to each other. Due to
vibrations the dust accumulated over the tubes is dislodged and falls down. Depending on the nature / characteristics of the dust
in the gas, the rapping system is to be operated continuously or periodically.
PROCESS & PLANT STRUCTURE
Plant consists of two WHR Boilers installed behind cement plant. AQC boiler consists of LP & HP sections and PH boiler also
consists of both HP & LP sections.
Flue Gas Circuit
PH Boiler Circuit
PH BOILER is located in the circuit in between the PH outlet string and the existing PH Fan. The PH Boiler is designed to cool the
flue gasses from 320°C to 180°C to maintain required Flue Gas temperature at the inlet of Raw Mill after the PH Fan.
There are 2 Isolation ON / OFF Tandem type damper is located at boiler entry and exit to facilitate PH Boiler operation and
maintenance. These dampers are provided with seal air fans for volumetric isolation of the boiler during maintenance with the
Cement Plant in operation.
One By Pass Multi louver Damper located in the PH down comer duct to regulate the Flue gas flow to PH Boiler.
During the operation hot flue gasses are diverted to PH Boiler by opening inlet & outlet damper and start closing the bypass
regulating damper slowly. By pass regulating damper is to divert the flue gases through the PH Boiler and also to maintain the
Cement plant in stable operating conditions. After Cement plant is in stable condition with PH Boiler in operation the Total Flue
Gas Draught required is maintained by existing PH Fan itself.
In case, if temperature required at outlet of PH Fan is high, which might be required when there is high moisture content in Raw
Meal during rainy season, open by pass damper slightly so that partial hot gasses from PH outlet string will mix with cold PH
Boiler outlet gasses and maintain required temperature at the outlet of the PH Fan, which is connected to the Inlet of the Raw
Mill.
The direction of flue gas flow is Vertical (Top to Bottom) in case of PH Boiler. Dedicated Hammering system is provided (2 No’s in
each bundle of pressure parts) to remove of the sticky dust which is carried with the flue gases and sticks to Boiler pressure parts
due to its nature during operation. These are supposed to be removed to have a proper heat transfer across the pressure parts
surfaces.
Please Refer PB-33381-2 (Flue Gas P & ID for PH Boiler) for better understanding.
AQC Boiler Circuit

AQC boiler is located in circuit in between the Clinker Air Quenching cooler and the clinker ESP. End Tapping is envisaged for
Maximum heat recovery from existing Waste gases with a coal fired Hot Air Generator in the circuit. The AQC Boiler is designed to
cool the gasses from 440°C to 90°C so that maximum heat recovery from flue gasses is possible. The Boiler exhaust gasses will
deliver to Chimney through clinker ESP & ESP Fan.
Isolation ON/OFF Butterfly dampers are located at Deduster inlet (End Tap), at the Inlet of HAG, whereas at the outlet of HAG
there is Guillotine type hoisting damper to facilitate HAG Operation and maintenance.
One No Bypass Multi Louver Damper is located between existing End Tap (Cooler Exhaust) and Clinker ESP to regulate flue gas
flow to AQC Boiler. Also there is a Multi-louver damper to bypass the Hot Air Generator/to regulate Dilution gases through Hot Air
Generator
The Pre dust collector is provided before the Hot Air Generator to remove higher particles of abrasive dust coming from Cooler
End tap ducting so that dust loading at HAG/AQC Boiler inlet can reduce.
During operation Hot Flue gases are diverted from Cooler Exhaust (End Tap) to AQC Boiler by opening De-duster inlet and HAG
Bypass & Boiler Outlet damper. After that close Bypass Regulating damper to divert hot flue gases to Boiler and also to maintain
the cement plant in stable operating condition. After lining up the Boiler Operation cycle for the HAG Starts as per the logic, once
the HAG is in line the governing point will be the HAG outlet Temperature which will regulate the dilution gases by the Pneumatic
Multi-louver damper at HAG Inlet. The dilution gases for the Hot Air Generator is nothing but the Cooler Exhaust gases, which is
routed through HAG to dilute the high temperature gases generated by coal firing and obtain the required Flue Gas parameters at
the AQC Boiler Inlet. After Cement plant is in stable condition with AQC Boiler in operation the total Flue Gas Draught required is
maintained by existing Clinker ESP Fan itself.
The Mechanical Design Flue gas temperature allowed through AQC End Tap is 450 °C, whereas process design temperature is
305 Deg C. The process temperature at the Outlet of HAG is 440°C. If Flue gas temperature is more than 440 °C the Dilution air
quantity is increased by opening the Pneumatic Multi-louver damper at the Inlet of HAG & if it is still more & when it goes more
than 450 °C then open the fresh air damper to allow the ambient air to dilute the Flue Gases and maintain the temperature
within limit.
Even if the inlet temperature is not reduced and goes above 475°C then open the bypass damper fully and box up the boiler to
safeguard the Boiler pressure Parts from high gas temperature.
The direction of flue gas flow is Vertical in AQC Boiler (Bottom entry & Top Exhaust)
Pre Dust Collector
One (1) No. of Integrated Pre-dust collector before AQC Boiler is envisaged. Pre-dust collector installed to remove the heavier
dust particles from the gases coming from Mid Tapping so that relatively clean gases pass through the AQC boiler. Baffles are
placed inside the pre dust collector for better gas distribution throughout the Pre dust collector so that higher particles of dust
can be retained in the dust collector due to gravity.
Following are the Properties of dust considered for design of Pre dust collector.
¾ Dust Concentration : 40 gm/ Nm³
¾ Bulk Density of dust : 1300 Kg/ Nm³3
¾ Temperature of dust : 305 deg c
¾ Diameter of particle size : μ 100 & μ 200
Following are the results at the hopper outlet of Pre dust collector.
Sr.no Particle Particle Inlet Dust Outlet Dust Diameter Distribution

Diameter(μ) distribution Mass flow Mass flow wise wise
rate(Kg/s) rate(Kg/s) separation separation
Efficiency (%) Efficiency (%)
1 100 0.8 0.84 50.29 40.23
1.67
2 200 0.2 1.41 84.33 16.87
3 Total Dust Separation Efficiency (%) 57.10
Please Refer PB-33380-2 (Flue Gas P & ID for AQC Boiler) for better understanding.
Feed Water, Evaporation, Superheated Steam and Condensate Circuit
Feed Water Circuit
Feed Water Circuit comprising of Deaerator cum Storage Tank, BFW Pumps (Same pumps Dedicated for both HP & LP Circuits),
and Common Economizer (Only in AQC Boiler) and Attemperator station.
Feed water from Deaerator outlet at 126 deg C is fed through HP BFW pumps to Common Economizer for HP Circuit, whereas in
case of LP Circuit feed water from Deaerator outlet at 126 Deg C is fed by taking a tapping from the HP BFP outlet header with a
pressure regulating valve directly to the LP drum (for both PH & AQC Boiler). HP Economizer for both AQC and PH Boiler located in
AQC Boiler to recover more heat from Flue gases and preheat Feed water from 126 deg C to 183 deg C and maintains proper
approach to avoid steaming in Economizer. Further feed water enters to AQC Boiler HP steam drum through AQC Boiler Feed
Control station to facilitate proper level in steam drum through 3 Element Drum level controls.
Feed water for PH Boiler is taken by tapping at the inlet of Feed control station. Further feed water enters to PH Boiler drum
through PH Boiler Feed control station to facilitate proper level in PH HP steam drum through 3 Element drum level control.
Fluctuations in the feed water circuit because of flue gas flow / temp fluctuations taken care by Feed control station through 3
Element drum level control.
Evaporation Circuit
Saturated Water from Steam drum enters to Evaporator through inlet headers and get converted into saturated steam by
absorbing required latent heat from Flue gases and return back to steam drum. We have provided two stage Steam separators
one is baffle plate arrangement which is primary steam separator and another Demister pad which is second stage steam
separator to ensure required 99.99% saturated steam purity coming out from the steam drum.
Independent Evaporator circuit is provided for AQC (LP & HP Evaporator & both Steam Drum) and PH Boiler (LP & HP Evaporator
& both Steam Drum).
Superheated Steam Circuit

Saturated Steam collected at the outlet of AQC steam drum flow through the primary HP super heater section to convert
saturated steam into superheated steam by heat absorption from flue gasses. This superheated steam further collected in mixing
header located at the outlet of in AQC boiler Primary Super heater.
Similarly saturated steam collected at the outlet of PH Boiler Steam drum flow through the Single super heater section to convert
saturated steam into superheated steam by adding degree of superheat.
Both AQC and PH Boiler HP Superheated steam collected at mixing header at the outlet of AQC Boiler Primary Super Heater and
Total superheated steam further superheated in AQC Boiler Final super heater through Attemperator control station.
Attemperator control station is envisaged to maintain the Final Super heater steam Temperature going to Turbine.
Where as in case of LP circuit the LP saturated steam collected from the PH & AQC LP drum is routed through LP super heater
sections of both PH & AQC Boilers (located at the outlet of HP Evaporator section in both PH & AQC Boiler flue gas path) directly
to Turbine LP Injection Point.
Auxiliary steam for Deaerator is taken from Main LP Steam Line to steam turbine.
Condensate Circuit (Common for PH & AQC Boilers)

Condensate after expansion in the Steam Turbine gets cooled by releasing latent heat to the cooling water in the water cooled
condenser and gets collected in the hot well at the bottom of Water cooled condenser.
The collected Condensate from the hot well pumped to Condensate Pre-heater located in AQC boiler through Condensate
Extraction pump to recover maximum available heat from flue gases and gets heated up to 118 deg C. Further the heated
Condensate gets collected in the Deaerator to remove dissolved oxygen. This is to facilitate maximum heat recovery and reduce
de-aeration steam consumption.
No separate Condensate Pre-heater is envisaged in PH Boiler.
For HAG operation kindly refer Vendor manual for HAG Operation & Maintenance
(M/s Fives Combustion)
D.WATER CHEMISTRY
D. WATER QUALITY RECOMENDATIONS
Water Quality Recommendations

This chapter describes the standards for the boiler feed water and boiler water for corrosion and scale free operation of the WHRB and
for obtaining pure steam. Methods of control of boiler water are also explained.
NOTE
This chapter must be read in conjunction with the following vendor manuals.
HP dosing system -
Suggested quality of boiler feed water (and Attemperator water) fed to the WHRB is given in following table:
FEEDWATER
S.NO. DESCRIPTION UNITS VALUE
1 General Appearance --- Clear & Colorless

2 PH at 25 Deg C --- 8.5 - 9.5
3 Total Iron as Fe ppm < 0.01ppm
4 Total Copper ppm < 0.003 ppm
5 Oxygen cc/ltr < 0.007
6 Conductivity at 25°C after cation exchanger and CO2 removal ms/cm < 0.5
7 Free CO2 Nil
8 Silica ppm < 0.02 ppm
9 Hardness as CaCO3 ppm Nil
10 Oil ppm Nil
11 KMnO4 Ppm Nil
12 Total Carbonic acid ppm Nil
NOTE
¾ Alkaline levels of feed water minimizes corrosion of steel
¾ Chlorides, Silica, Iron, Copper, Organic matter etc., present in the feed water concentrate further in Boiler water. Their
higher concentration calls for increased blow down (CBD) of boiler water causing loss of useful heat.
¾ Silica in boiler water vaporizes to SiO2 and escapes through steam
¾ Copper present in water, deposits on the inner surfaces of evaporator tubes and is harmful
¾ Chlorides in boiler water depress the pH level and render boiler water acidic and may cause accelerated corrosion.
¾ Oxygen in boiler water promotes corrosion of boiler tubes
¾ Oil present in feed water deposit on tubes and interferes with heat transfer.
DRUM WATER
S.NO. DESCRIPTION UNITS VALUE
1 pH --- 9.0 to 10.0
2 Total Dissolved solids / Conductivity ms/cm < 50
3 Silica ppm <1.2
4 “p” Value mval/kg 0.1
5 Sodium Phosphate as PO4 mg/kg 2-6
Minor permissible contaminants present in the WHRB feed water concentrate to high levels in boiler water due to continuous
evaporation in the Steam drum - evaporator circuits. Two controls are exercised on Boiler water to avoid corrosion of WHRB
tubes and the drum water - washed surfaces.
Tri-sodium phosphate dozing to convert the hardness producing insoluble calcium, magnesium salts to soluble sodium salts
which can be drained by CBD and to maintain the alkalinity levels of boiler water.
NOTE: The drum water quality should be continuously monitored and suitable adjustment in blow down to be made to maintain
the drum water as per above recommendations.
E. BOILER AND ITS AUXILIARY PROTECTION
AND INTERLOCK CONCEPTS
E. BOILER AND ITS AUXILIARY PROTECTION AND INTERLOCK CONCEPTS
Boiler Protection
This chapter lists out various protections provided in the WHRB.
As the system protections and interlocks have been described in the preceding chapters along with the description of equipment,
a listing of these protections will only be made with brief notes on their significance. Testing of these interlocks & protections is
to be done before the first startup of WHRB and at suitable intervals subsequently.
Safety Valve on Steam Drum & Super heater

To protect the boiler safety valves have been provided with set pressures and blow down capacities as indicated below.
Tag No Capacity (TPH) Set Pressure kg / cm² (g)
WHRS-AQC2HP-MAS-SV-001 18 7.6
WHRS-AQC2HP-MAS-SV-002 19 8
WHRS-AQC2HP-MAS-SV-004 17.5 3.9
WHRS-AQC2HP-MAS-SV-003 17 36.5
WHRS-AQC2HP-FDW-SV-001 32 34.6
WHRS-AQC2LP-MAS-SV-001 4 0.73
WHRS-AQC2LP-MAS-SV-002 5 0.94
WHRS-AQC2LP-MAS-SV-003 3.5 0.66
WHRS-PH2HP-MAS-SV-001 18 7.6
WHRS- PH2HP-MAS-SV-002 19 8
Interlocks
Interlocks provided for various systems ensure safe and sequential operation at any point of operation which includes start up,
shut down and emergency conditions. Kindly refer the Section A for the detailed description of the Alarms & Interlocks
Description.
Boiler Protection
Operational Control
The interlocks are to be tested before commissioning. Repeat tests are advised once a year. Any malfunction noted during
operation has to be attended early. (Kindly refer the Logic Write up section for details of interlocks)
Automatic Control
To describe the automatic controls provided for operation of the WHRB.
Drum Level Control
It includes:
¾ Three Element Control
¾ High and low level alarm
THREE ELEMENT CONTROL

In the three element control, the feed water control valves are positioned after comparing the steam flow and feed flow signals
suitably corrected for the drum level signal.
The operator can select feed control station to be on duty.
The controller receives the steam flow signal and compares it with the current feed flow signal. Any variation in these is compared
with the two out of three, pressure compensated, level signal from the steam drum and a final error signal is computed by the
controller from its operator selected set point. From the final error signal, a correction signal is sent to position the selected feed
control valves. Such a control is termed as a three element control and maintains the steam drum water level, taking into account
steam flow and water flow
The controller provides the following alarms for both HP & LP Drums:
¾ Drum level Low alarm (- 200 mmWC)
¾ Drum level Low Low alarm (TRIP) (- 300 mmWC)
¾ Drum level High alarm (+50 mmWC)
¾ Drum level Hi Hi alarm (+150 mmWC)
Automatic controls have been provided for smooth, strain free and high efficiency operation of the WHRB. These controllers are
set during commissioning. Any mal operations of these controllers must be corrected to keep the controllers on auto mode all the
time. Adjustments of controllers, checking of pressure, temperature and flow transmitters must be attended by a qualified
instrument Engineer or technician.
BOILER INLET
¾ Temperature transmitter for remote indication in DCS.
¾ These temperature transmitters measure the temperature of exhaust gas. This is provided to safeguard the Super heater
and Evaporator panels.
BOILER INLET & OUTLET PRESSURE

¾ Pressure transmitters at Boiler Inlet & Outlet for pressure drop across the WHRB.
BEFORE & AFTER SUPERHEATERS
¾ Temperature Element for DCS indication of the temperature of the flue gas at the inlet & Outlet of both super
heaters.
BEFORE & AFTER EVAPORATOR
¾ Temperature Element for DCS indication of the temperature of the flue gas at the inlet & Outlet of the
evaporator.
AFTER ECONOMISER
¾ Temperature Element for DCS indication of the temperature of the flue gas at the outlet of the Economizer.
AFTER CONDENSATE PREHEATER
¾ Temperature indicator for remote indication of temperature at inlet to the Bag House.
'F. MAINTENANCE PRACTICES
G. MAINTENANCE PRACTICES
Section Overview
This section describes the various maintenance practices, overhauling, and preservation techniques. Also discussed are failures
and repair techniques.
This section covers the following
1. Recommended maintenance practices
2. Preventive maintenance program
3. Condition based maintenance
4. Maintenance check list for daily, weekly, monthly and annual inspection
5. Shutdown and cooling the boiler
6. Inspection after cooling
1. Recommended Maintenance Practices

Systematic maintenance is essential to keep the boiler and its auxiliaries in good condition and to obtain reliable operation of
the boiler with high availability and plant load factor. Effective maintenance aims at timely inspection of parts to repair or replace
defective components and to prevent their failure when the boiler is in service.
Maintenance can be classified as -

¾ Preventive maintenance – mostly condition based
¾ Annual Boiler overhauls to clean and inspect pressure parts.
The shutdown period of the overhaul is also utilized to attend to systems and parts which cannot be attended during short
shutdowns or when the boiler is in operation
The vendor manuals of the fans, motors, control valves with their positioner and actuators, instruments and controls, power
cylinders etc., prescribe certain minimum maintenance requirements which are to be carried out in one of the above two
maintenance categories.
It is suggested to maintain a defect register in the control room to register all the items, which need maintenance.
2. Preventive Maintenance
The objective of the preventive maintenance program is to obtain trouble free service from the component till the next
maintenance.
Vendor manual for various equipments suggest inspection periods, checks to be done and recommended spares. The true
objective of the maintenance program can only be realized, if a master plan of maintenance of all the components is prepared as
per vendor instructions.
Full benefits of maintenance can be obtained only if proper parts are used. Mandatory spare part list covers most of the spares
required. It may be found that in the first two years of operation due to variations of site conditions, some additional spares not
included are also required. Action has to be initiated to procure such spares.
Some equipment has 100% reserve standby units. (Feed water pumps etc.). Maintenance of such equipment’s can be organized
even when the boiler is in service, although some minimum risk is involved. Equipment such as igniters, scanners have
replacement spares which can be utilized when the working equipment are to be maintained without affecting the boiler
operation. The prepared master plan for maintenance should be periodically reviewed during the first three years of the boiler
operation.
It may be found that due to varying site conditions, the frequencies and quantum of work scheduled as per vendor manuals are
either too much or too less. Based on site experience, the frequencies and work schedules can be modified.
A scientific method of preparation of the preventive maintenance schedules is to make them condition based. In condition based
maintenance, the equipment and components of the plant are inspected daily, weekly monthly etc., as per a suggested schedule
by the local operators and deteriorating conditions if any observed are reported. Suggested inspection program is given in this
section. Based on operator reports of such inspection, maintenance works are planned for the next available planned shutdown.
Mandatory inspections prescribed by the vendors are also taken care of, irrespective of the equipment condition.
Preventive Maintenance Program for Valve

A preventive maintenance program for valves once in two years can be done with one or more of the following works:
¾ Dismantle the bonnet, clean the trim and valve seat, lapping them if necessary.
¾ Cleaning the valve stem and re-lubrication of the operating threads
¾ Renewing the bonnet joint, and assembling the trim on the valve seat
¾ Renewing the gland packing
¾ Renewing the valve flange joint, if necessary
Preventive Maintenance Program for Spares

It may be found that in the first two years of operation due to variations of site conditions, some additional spares are also
required. Action has to initiate to procure such spares.
The prepared master plan for maintenance should be periodically reviewed during the first three years of the boiler operation.
It may be found that due to varying site conditions, the frequencies and quantum of work scheduled as per vendor manuals are
either too much or too less. Based on site experience, the frequencies and work schedules can be modified
A scientific method of preparation of the preventive maintenance schedule is to make them condition based.
In condition based maintenance, the equipment and components of the plant are inspected daily, weekly, monthly etc. as per
suggested schedule by the local operators and the deteriorating conditions if any observed are reported. Suggested inspection
program is given in this chapter. Based on operator reports of such inspection, maintenance works are planned for the next
available planned shutdown. Mandatory inspections prescribed by the vendors are also taken care of, irrespective of the
equipment condition.
3. Conditioned Based Maintenance

The schedule of daily, weekly and monthly inspections given in the following pages do not require a boiler shutdown and in fact
can only be done when the boiler is in service. Three and six monthly inspections are done utilizing an available planned
shutdown approximately in the specified time period.
Objective of these inspections is to ensure that:

¾ The components are in trouble free condition.
¾ To carry out any minor repairs or adjustments this can be done with the boiler in service.
¾ To plan for repair of such items, this cannot be attended when the boiler is in service, during the next available
shutdown.
¾ To collect a database to determine optimum service life of the systems and components before maintenance if
required.
¾ The schedule can be expanded, curtailed or modified based on experience in the first two years of operation.
4. Daily Checks
To be done once a day by the local operator during his walk down checks. Such walk down checks is to be encouraged to be done in
each shift by the local operators. Only those operational checks which require maintenance work for correction have been
included.
EQUIPMENT CHECK WORK TO BE DONE

Local level gauges on steam ¾ Check illumination is proper. ¾ Replace fused bulbs.
drum ¾ Leaking valve glands. ¾ Isolate level gauge and tighten
¾ leaking ports leaking glands.
¾ Blurred level ¾ Replace leaking ports.
¾ Steam wash mica as suggested
by vendor (not to be done
¾ too frequently)
Comparison of levels Compare the levels after verifying there are no ¾ If there are serious discrepancies
indicated by local level gauge leaks from valves, glands etc. of the level calibration of the remote level
with that of remote level gauge and indicators. Report discrepancies. indicators has to be planned
indicators in the control room immediately.
Traces of water, oil spots on Such spots are indicative of valve leaks, ¾ Maintenance to be planned to
boiler floor, buck stay beams, instrument tapping leaks etc., Trace the eliminate the source either
boiler cladding etc. source of leak. immediately or during next
planned shutdown (depending on the
source and quantity of leak) and
accessibility for maintenance.
Lubricating oil levels of Fans, & Check adequacy of oil level. ¾ Top up if required (immediately)
feed pumps bearings, dosing ¾ If leakage through oil seals,
pump gear box etc. gaskets drain plugs etc. Are noticed
plan for maintenance during next
planned shutdown.
Fans, BFW pumps dozing •Check bearing temperatures. ¾ If higher than normal bearing
pumps •Check for Vibration Levels temperatures are noticed check for
cause proper oil level, correct grade
and quality of oil or grease, abnormal
sound or vibration.
¾ If bearing temperatures are very high,
start the reserve equipment and plan
for a maintenance checks.
¾ If vibrations are above the
satisfactory limits. Check for
mechanical looseness and start the
reserve equipment and plan for a
Drum and super heater Check for passing of safety valves ¾ Hand pop the affected safety valve one
safety valves. (noise or wisp of steam through silencer) or two times to
clear any dirt sticking to
the valve seats
¾ Lightly tap on the stem of
the safety valves.
¾ If these measures do not
succeed, if request for check
of the safety valve during next
Purity of instrument air Check by visual observation that the ¾ Oil and moisture in the instrument air is
instrument air is oil and moisture free. likely to clog the positioner of
(Oil and moisture content can also be pneumatic controllers / solenoids
checked by laboratory examination as per and make their operation sluggish or
standards) unreliable.
¾ Open drain valves of air receivers for
short time to drain condensate if any.
¾ If these measures are not successful,
inform the Maintenance group.
Steam or water leakages from ¾ Loose valve gland ¾ Tighten the gland nuts.
valves and from flange joints ¾ Loosened bolts of flange joint If the leakage not gets arrested, plan
and / or failed gasket. for maintenance
during shut down.
¾ Tighten the bolts. If the
gasket failed then plan for the
maintenance during shut down
Boiler cladding, air duct or flue Check for hot spots ¾ Hot spots may be due to leakage of flue
gas duct. gas or hot air. Source of leakage has
to be located after selective removal of
insulation (to be planned for the next
planned shutdown)
Daily Maintenance
Maintenance Check List during Operation
¾ Check the correctness of HP & LP water level in the control desk with direct level glass
¾ Check the level indicators for proper illumination.
¾ Check for unusual noises for steam / water leakage.
¾ Check for unusual noises for from pumps.
¾ Check for vibration in rotary equipment’s.
¾ Check for unusual traces of water on floor, buck stays or casings
¾ Check for valve & gland leakages.
¾ Check for air / gas leakages from ducts and flue.
¾ Check for hot spots, bulging etc. on casings, ducts etc.
¾ Check the positions of dampers and cleanliness
¾ Check for safety valve steam leakages.
¾ Check the bearings for lubrication and cooling water systems.
¾ Check all alarm annunciations with respect to set points.
¾ Check for water, oil along with instrument air
¾ Check the field instruments for its proper indications.
¾ Check the stack for any unusual smoke conditions.
Monthly Checks
Fans, Dosing pumps, With the vibration analyzer record vibration, By monthly recording of data, establish a
sound levels and measure bearing data base for deciding the overhaul time of
temperature Note the pressure, flow of air, the equipment. An overhaul once in two or
suction damper opening, (Capacity of the three years may be adequate. Database will
FD Fan) pressure (seal air blowers, HP dosing help in deciding the time frame. Sharp
pump) increase in vibration levels bearing
temperatures or sound levels may call of
early scheduling of overhauls.
BFW pumps Check for coupling alignment between By monthly recording of data, establish a
motor and pump. Check the impeller is not database for deciding the overhaul time of
rubbing with pump body. Check operation the equipment. An overhaul once in two or
of NRV at pump discharge. three years may be adequate. Database will
help in deciding the time frame. Sharp
increase in vibration levels bearing
temperatures or sound levels may call of
early scheduling of overhauls.
Safety valve operation Increase the boiler pressure and check the If necessary do the adjustments.
operation of valves.
Feed water tank / internals Deposits of foreign particles Clean with normal water
Dosing system Cleanliness of dosing tank, operation of Clean dosing tank with normal water, Adjust
pressure relief valve, lubrication oil level in relief valve ,if required Fill lubrication oil , if
pump. required
D P Manometer Choking of impulse tubes Liquid level in Clean impulse tube with air Keep liquid level
manometer at zero
Level switch for steam drum Close the steam out let valve and gas by If switch or alarm is not working, do the
water level very low pass damper. Open blow down valve and rectification work.
check for level switch very low alarm.
Checks Every Six Months
During a planned shutdown of the boiler, the following checks can

be done.
Boiler safety interlocks, start Coinciding with a planned shutdown of Plan for maintenance or re-calibration
permissive, boiler trip protection. boiler, carry out the checks to identify of defective items if any noticed, during
malfunctioning or sluggish pressure, the shutdown period.
temperature switches, solenoid operated
valves, positioner, proximity switches, actuators
etc.,
Checks Every Year
(See also jobs listed under Boiler overhaul)

Pressure temperature, Flow level, Utilizing the boiler annual shut down for Carry out any maintenance
differential pressure controllers overhaul, recalibrate all pressure, temperature, replacement or adjustment needed to
flow, level and d/p controllers as per vendor secure initial calibration values as per
manuals commissioning records
Pressure gauges, temperature Recalibrate, Verify functioning of Repairs or adjustments as necessary
gauges, Pressure/temperature pressure/temperature switches as per design
Switches
Positioner, actuators Verify functioning of positioner and actuators Repairs or adjustments as necessary as
by feeding current inputs to positioner and per vendor manuals to obtain
measuring the air pressure output of the performance as per commissioning
positioner and opening closing of actuators records. Verify functioning of proximity
switches where provided. Clean filters
of air regulators. Check functioning of
air regulators. Verify tightness of air
connections.
Annual Maintenance Check Sheet
COMPONENT NAME INSPECTION REQD FOR
Drums (water side ) ¾ Corrosion
¾ Scale / deposits
¾ Pitting
¾ Metal reduction
¾ Manhole seat
¾ Process / instrument tapping’s
¾ Internal cleanliness
Feed water pipe in steam drum. ¾ Plugging
¾ Tightness
¾ Holes orientation
¾ Corrosion
¾ Piping
Chemical dosing ¾ Plugging
Pipe in steam drum ¾ Tightness

¾ Holes orientation
¾ Corrosion / Pitting
Continuous blow down ¾ Plugging
Pipe in steam Drum ¾ Tightness

¾ Hole orientation
¾ Corrosion / pitting
Boiler tubes (water side) ¾ Corrosion
¾ Scale
¾ Pitting
¾ Metal reduction
Boiler tubes (gas side) ¾ Corrosion
¾ Build up
¾ Blisters
¾ Sagging
¾ Over heating
¾ Erosion
¾ Sealing
¾ Supports
¾ Cracks
¾ Expansion clearance
¾ Steam impingement
¾ Insulation
Evaporator coils – flue gas side ¾ Erosion
¾ Corrosion
¾ Build up
¾ Blisters
¾ Sagging
¾ Over heating
¾ Sealing
¾ Cracks
Super heater (steam side) ¾ Corrosion
¾ Erosion
¾ Scale
¾ Pitting
¾ Metal reduction
¾ Flare cracking
¾ Deposits
Super heaters (gas side) ¾ Corrosion
¾ Build up
¾ Sagging
¾ Over heating
¾ Erosion
¾ Sealing
¾ Supports
¾ Cracks
¾ Exp clearance
¾ Insulation
Economizer ¾ Corrosion
(water side) ¾ Scale
¾ Pitting
Economizer ¾ Corrosion
(gas side) ¾ Build up
¾ Blisters
¾ Sagging
¾ Over heating
¾ Erosion
¾ Sealing
¾ Supports
¾ Cracks
¾ Tightness of access
¾ Doors
Refractory ¾ Looseness
¾ Missing pieces
¾ Erosion
¾ Sealing
¾ Refractory
¾ Flame impingement on refractory
¾ Refractory holding arrangements.
¾ Corrosion
¾ Damper operating
¾ Mechanisms
Dampers ¾ Flaps rigidity
¾ Open/ close positions
¾ Expansion clearance condition of flaps
¾ Erosion of flaps
¾ Bearing freeness
¾ Lubrications
¾ Damper linkages
¾ Interlock mechanisms.
Remote level gauges ¾ Cleanliness

¾ Leaks
¾ Visibility
¾ Illumination
¾ Gauge cocks status
¾ Internal deposits
¾ Insulation
¾ Liquid status (if any)
Dosing pumps ¾ As per manuals

Power cylinders ¾ As per manuals
Convection pass ¾ Erosion and material accumulation.
¾ Signs of gas channeling.
¾ Tubes for erosion patterns.
¾ Economizer support beams for erosion.
¾ Lower water wall headers for erosion / cracks.
¾ Seal at economizer and super heater
piping penetration.
¾ All penetration for erosion.
¾ Super heater supports
¾ Riser roof
¾ For penetrations
¾ Sealing and cracks.
¾ Walls for erosion at the top of the tube
¾ Thermocouples and pressure taps for erosion /
corrosion.
¾ Pressure taps for plugs
¾ All penetration for sealing and erosion.
¾ All penetration and plates for warpage or damage.
Casing ¾ Bent
¾ Bulging
¾ Gas leakages
¾ Access door tightness
¾ Corrosion
¾ Erosion
Water level gauges ¾ Cleanliness
¾ Leaks
¾ Visibility
¾ Illumination
¾ Reflectors
¾ Mirrors
¾ Gauge cocks status
¾ Internal deposits
¾ Insulation
¾ High/low water alarms/tripping
Valves ¾ Erosion
¾ Corrosion
¾ Leakages
¾ Spindle movement
¾ Handle rigidity
¾ Drive mechanisms
¾ Lubrications
Safety valves ¾ Valve nozzle conditions

¾ Disc seat conditions
¾ Corrosion of internals
¾ Pitting
¾ Cracks
¾ Valve spring status
¾ Spring stiffness
¾ Corrosion of spring
Silencer status ¾ Spring stiffness
¾ Drain line status
¾ Drain line rigidity
¾ Discharge pipe rigidity
¾ Expansion clearances
¾ Valve settings
Boiler Annual Maintenance and Overhaul
In addition to the check and inspections listed under preventive maintenance, the boiler requires an annual shut down of about
10 to 15 days for cleaning, inspection ad overhaul of boiler pressure parts. The shutdown period is restricted to a minimum by
deploying adequate resources. If required, engineering department of TKII can assist the customer in carrying out the boiler
overhaul.
The annual shutdown is utilized for cleaning and inspection of the pressure parts and to collect data on the wear pattern of boiler,
super heater and economizer pressure parts. The shutdown opportunity is also utilized for overhaul of safety valves, regulating
and isolating valves and components, which cannot be attended when the boiler is in service. (The valve overhauls need not be
done every year).
Planning Before Overhaul

¾ Prepare a list of jobs to be done during the overhaul based on earlier inspection reports and the jobs listed below.
¾ Ensure availability of spares required for the proposed jobs.
¾ Ensure tools, tackles, scaffolding materials required for the job.
¾ Ensure availability of manpower required for the job (Own sources, contract labor etc) supervision services of TKII is also
available for carrying out annual overhauls and inspections.
5. Shutdown and Cooling the Boiler

¾ Shutdown the boiler in a planned manner.
¾ Doesn’t force cool the boiler
¾ Open all access and inspection doors.
Inspection after Cooling

¾ Carry out a preliminary inspection after cooling to check cleanliness and sign of deposition on pressure parts and needs
any cleaning.
¾ Open the access doors of the either sides of the drum.
¾ Allow the drum to ventilate for about 8 hours. If necessary a fan cooler can be fitted over temporary stand to force air
through the drum.
¾ From the time the drum manholes are opened till they are closed after inspection, the area around the drum must be
cordoned to restrict entry only to specifically authorized personnel.
¾ The names of persons who are entering the drum for inspection, along with tools they carry must be entered in a register.
Persons coming out of the drum after inspection should be asked to account for the material they carried into the drum.
This precaution is to prevent accidental dropping of foreign material through the water wall tubes, which may block
water circulation through them and can cause tube failures.
¾ Carry out a preliminary inspection of the drum to check for deposits on the water side of the drum.
¾ Using nylon brushes, the deposits (which are normally soft) are cleaned, collected on trays and disposed of outside the
drum. Washing down the deposits to the boiler tubes is not recommended.
¾ In case of excessive deposits, the chemist is asked to analyze the nature of the deposits. In case of excessive deposits, a
review of phosphate concentrations (higher than 10ppm) and boiler water quality control (high conductivity) may be
made to reduce the deposit in the next year of operation.
After cleaning the following examinations can be made.

¾ Examine the boiler drum metal for scale, pitting, corrosion and metal wastage. (Drum thickness is measured at a few
selected spots using ultrasonic instruments and compared to design thickness).
¾ Inspect fastenings of the baffles, cyclones, and demisters to see that they are intact, without corrosion pitting or holes.
Eroded or corroded drum internals can be patched by welding. No welding however is permitted on the drum metal. The
cyclones and demisters can be examined in position. They need not be dismantled. Reasonable water tightness of the
baffles and cyclones are to be ensured.
¾ Examine that feed water pipe is intact with flange connections tight and discharge exit correctly oriented.
¾ Examine that the continuous blow down pipe and dosing pipes is not plugged or corroded their supports are normal;
their holes have been correctly oriented.
¾ Examine that there are no cracks in the stub welding s of the drum.
¾ After the inspection, clean the manhole seats and provide new gaskets. Sometimes the boiler inspector may like to
inspect the steam drum. After this inspection and after verifying that all men and material have been removed from the
drum, close the manholes and bolt them tight.
Expansion Joints
Examine the expansion joints. Eroded / corroded parts can be patched by welding. When severe erosion is noticed (after several
years of service) the expansion joints are to be replaced. Collapse or stretching of the expansion joints is usually due to forces
exerted by the connecting ducts. Readjustment of duct supports will solve the problem and will assist the expansion joints to
regain their original dimensions.
Insulation and Cladding

x Verify insulation as per drawings and correct wherever necessary.
x Inspect cladding for damages due pitting, hotspots, dislocation etc. Repaired as necessary.
Other Equipment
Overhaul of fans, pumps, fuel feeders, control valves, actuators etc., is scheduled as per vendor instructions and condition
monitoring described under preventive maintenance
FEED & BOILER WATER CONDITIONING
1. INTRODUCTION
The successful use of boiler is dependent on proper water conditioning and treatment. The quality of water must have accurate
for trouble free operation of boiler.
The water as available to industry is not suitable for boiler use. A complete pre-treatment and internal chemical treatment is
necessary to make raw water suitable for boiler feed.
The objective of the water treatment is:
¾ Eliminate scaling - deposition in boiler which cause tube over heating leading to accidents.
¾ Control corrosion of boiler system, which cause failure of boiler tubes, leading to unscheduled shutdowns.
¾ Reduce carryover of water with steam, which is the cause of deposition on super heater/turbine blades, leading to the
expensive failures.
¾ To maintain peak boiler efficiency by keeping complete boiler water system clean
In order to meet above objectives, it is necessary to maintain certain chemical conditions in boiler condense and feed water
systems. A brief review of important factors is given in this section to assist those taking charges of new boiler equipment. It is not
possible to cover the subject fully, therefore; it is recommended that the care and control of water quality be entrusted to water
treatment specialist.
2. NEED FOR WATER TREATMENT
A. CORROSSIVE CONTROL
Water is corrosive to boiler metal. Typically corrosion due to water will reduce thickness of tube @ 1 mm/year. Thus the life and
safety of boiler entirely depends on the rate of corrosion of boiler metal. In order to protect boiler from corrosion, pre-treatment is
done to remove excessive corrosion ions like chloride, sulphate etc. However, further chemical conditioning is required to protect
boiler and auxiliary systems from corrosion.
Tri sodium phosphate, caustic, ammonia and amines are used as corrosion inhibitors. These chemicals form a protective film
over metal surface and reduce corrosion. It is necessary to maintain prescribed concentration of these chemicals in boiler water
systems continuously.
B.OXYGEN CORROSION INHIBITOR:

Oxygen is present in dissolved form in water. At high temperature, oxygen reacts with metal to cause pitting corrosion. Thus
prevention of oxygen leads to pin holes in economizer, steam drums and steam tubes.
Most of the oxygen is removed externally by Deaerator and preheating of feed water. However, traces of residual oxygen must be
removed by chemical conditioning.
Sodium sulfite, hydrazine and amines are recommended for oxygen removal. These chemicals react with residual oxygen making
it inactive and protect metal against pitting corrosion. Catalyzed oxygen scavengers are used for quick reaction.
C.SCALE / DEPOSIT CONTROL:

Raw water contains dissolved solids, hardness salts and suspended matters.
External treatment is used to remove such impurities.
¾ Clarification - To remove suspended matters.
¾ Filtration - To remove residual turbidity
¾ Softening - To remove hardness salts
De-alkaliser - To remove hardness salts and excessive alkalinity

x Demineralization - To remove residual salts and silica
x Mixed bed - To remove residual salts and silica from DM water.
A combination of above equipments is used to remove undesirable impurities in raw water.
SCALE CONTROL
Hardness salts in feed water cause formation in boiler. Under temperature and pressure inside the boiler and due to
concentration, hardness salts precipitate in tubes as calcium carbonate, calcium sulphate and Ca/Mg silicate scales.External
treatment like softening, demineralization or de-alkalization removes most of the hardness salts from boiler feed water. However,
malfunctioning of this equipment, occasional bypassing of the softener/DM plant or contamination of condensate or feed water
with raw water often led to ingress of hardness in the boiler.
All hardness salt precipitate inside boiler leading to hard scale formation on tubes. Such scale has lower conductivity causing
increase in metal temperature, leading to bursting of tubes in extreme conditions.
Therefore, inspire of elaborate external treatment, internal chemical conditioning is always recommended as additional safety.
Following chemical methods are used for internal treatment.
PHOSPHATE CONDITIONING
Tri-sodium phosphate is commonly used. Hardness salts react with tri-sodium phosphate to form calcium phosphate precipitate.
This precipitates above pH of 9.5 colloidal in nature and therefore do not allow for form hard scale of carbonate and silicates. The
precipitated hardness salts are then removed through blow down as sludge and boiler tubes are kept scale free.
Tri-sodium phosphate, apart from acting as hardness conditioning agent, also is a good corrosion inhibitor.
The recommended concentration in boiler water is given in Vendor Manuals
Note 1: TSP will act as hardness conditioner, only when boiler pH is above 9.5. Below 9.5 pH TSP may cause hard scale formation
of Ca3 (PO) 2. Therefore, coordinated or congruent phosphate treatment is recommended. The water treatment experts can advise
you right treatment after studying your water quality and operation conditions.
E. TURBINE / SUPERHEATER DEPOSITION CONTROL:

The solids in boiler feed water get concentrated in boiler. The concentration of solids in boiler is decided blow down and feed
water quality. The carryover of boiler water with steam depends on;
Mechanical Factors:
¾ Boiler load - Higher the load, lower is the steam purity
¾ Water level in boiler - Higher the water level in drum, lower is steam purity.
¾ Load Variation - Sudden increase in load reduce steam purity for short time.
¾ Separation efficiency - Higher efficiency, better is steam purity.
Chemical Factors:
¾ TDS - Higher TDS in boiler, lower is steam purity.
¾ Total Alkalinity - Higher alkalinity as % of TDS lower is steam purity
¾ Organics - Higher the organic contamination, lower is steam purity.
¾ Foaming - Higher the foaming character of water, Lower is steam purity.
The water carried over with steam due to above reasons is exactly similar in quality to blow-down or boiler water. In super
heater or in turbines, water evaporates, leaving dissolved and suspended matter as scales or deposits.
Thus severity of scaling and fouling of super heater and turbine depends on boiler water quality and steam purity.
Maintaining boiler water quality as per norms and maximum steam purity is the only way to prevent deposition due to
carryover of water with steam.
F.SILICA DEPOSIT CONTROL:

Silica is volatile under high temperature and pressure inside boiler. In turbines, the evaporated silica precipitates during
pressure and temperature reduction and form hard scales.
Maximum allowable concentration of silica depends on water analysis. Expert’s best decide the maximum permissible
concentration after striding the operating parameters.
G. CONDENSATE CORROSION CONTROL:
The carbon dioxide is present in boiler feed water in dissolved and combined from as carbonate. Under boiler pressure and
temperature it is liberated and carried over with steam as CO2 gas. This gas re dissolves in steam condensate to form carbonic
acid.
CO2 + H2O = H2CO3
H. MAINTENANCE OF PEAK EFFICIENCY:

Corrosion, scaling, fouling carryover and condensate corrosion can cause unscheduled shutdown, accidents and deterioration of
system efficiency. Therefore for trouble free operation and maintenance peak operation efficiency, a combination of various
internal chemical treatments is essential along with a good control over boiler water quality.
Maintaining boiler water quality by using commodity chemicals likes TSP, Hydrazine, and Sodium sulphate. However, it is
recommended that the care and control of water chemistry be entrusted to specialist.
(G. BOILER PRESERVATION PROCEDURE
INTRODUCTION
Both the gas and waterside of a boiler should be protected against corrosion during out of service periods. It is known that many
of the corrosion problems of boiler and auxiliary equipment have their inception during storage. Rusting of tube surfaces, as
indicated by the formation of the red hematite (Fe2O3), not only cause a roughened tube surface but also results in attack of
parent metal. The advantages of efficient feed water and boiler water treatment during operation may be lost if the same
diligence is not applied to protect heat. Transfer surfaces during idle periods. Protection from corrosion during storage becomes
vitally important considering the number of times during the life of a boiler when it and its auxiliary equipment are idle.
To minimize the possibility of corrosion, boiler to be placed into storage must be carefully prepared for the idle period and closely
watched during the outage. There are two methods available for storing the unit dry storage and wet storage. Although the wet
storage procedures is preferred such factors as availability of good quality water, ambient weather conditions, length of storage
period, auxiliary supply of heat, etc may dictate that the dry storage procedure is more practical.
Definition of Water Quality

Some cleaning procedures, hydrostatic testing and storage require water of higher quality than others. For the purpose of
economy and convenience the lowest water quality consistent with requirements is specified in these various procedures. The
terms that identify the different water qualities along with their definitions are list below: Station service water - Water normally
used for drinking, fire protection, etc.
Softened water - Filtered, sodium zeolite softened water with total hardness less than 1 ppm.
Two- bed demineralized water - Water then has been passed through Cation and anion ion exchanges in series.
Mixed bed demineralized water - Water that has been passed through a mixed bed demineralizer. Water from an evaporator is
considered to be of equal quality.
Treated demineralized water - Mixed bed demineralized water that has 200 ppm of hydrazine and enough ammonia added to
give final concentration of 10 ppm (or a pH of 10.0). In this procedure, condensate is considered to be treated demineralized
water.
Dry Storage Preservation

When it is known that a boiler is to be idle for a considerable length of time and that a brief period will be allowed for preparation to
return it to service, the dry storage method is recommended.
In this method the unit is emptied, thoroughly cleaned internally and externally dried, and then closed up tight to exclude both
moisture and air. Trays of lime, silica gel, or other moisture absorbent may be placed in the drums to draw off the moisture in the
air trapped by the closing up of the boiler.
The following general procedure is recommended when placing a unit into dry storage.
1. Admit Flue Gas to the boiler according to the normal start-up procedure and establish up to 3.5-kg/cm² (g) drum pressure.
Stop firing. Secure the boiler and when the pressure decays to 1.3 kg/cm² (g), immediately drain the boiler and headers
under air. As soon as possible, open the drums to allow air to circulate for drying of all internal surfaces.
This step is included for a unit that has been in service and is to be placed into storage. For a unit that has never been in service,
start with Step 2.
3. If the unit is full of water and cold, drain the unit under air. All non-drainable boiler tubes should be blown with
compressed air. If an external source of heat is available such as a steam coil air heater, portable heaters, etc., operate
these heaters to assist in drying the internal boiler surfaces.
Install trays (of non-porous construction and capable of passing through the drum manhole) containing the
moisture absorbent (silica gel is preferred) into the drums. Insert the trays into the drum being certain that none of the
absorbent comes into contact with the metal surface of the drum. To insure against an overflow of corrosive liquid after
the moisture has been absorbed, the trays should not be more than ½ full of dry absorbent. The amount of absorbent
can vary but the recommended minimum is one Kg of absorbent per 1000 Kg per hour steam flow capacity of the unit.
Open the isolation valve for nitrogen connection, on the steam drum, close all other vents and drains and pressurize the
boiler to 0.3 to 0.6 kg/cm2(g) with nitrogen. The amount of nitrogen required will vary according to the volume of the
unit.
With the boiler pressurized, alternately open all boiler drains to purge air from the unit until pressure decays to zero. It may be
necessary to repeat this process several times to reduce the amount of oxygen left in the unit to a minimum.
The unit should now be stored under 0.3 to 0.6-kg/cm² (g) nitrogen pressure maintained at the steam drum. To maintain the
nitrogen pressure, all connections and valves should be blanked or tightly closed. Check gas pressure daily to ensure
protection.
We would recommend that periodic inspection of the unit be performed every 3 months to assure that no corrosive action is
taking place and to replenish the absorbent as required. Since air will enter the unit during this inspection, it will be necessary to
repeat Steps 3 & 4 to expel the air.
The unit should be properly tagged and the appropriate warning signs attached noting that the boiler is stored under nitrogen
pressure and that complete exhaustion of the nitrogen must occur before anyone enters the drum. Before entering drums test to
prove that the oxygen concentration is at least 19.5%.
The above procedure is intended to include the economizer.
Wet Storage Preservation
The advantage of employing the wet storage procedure is that the unit is stored completely wet with the recommended levels of
chemicals to eliminate a wet-dry interface where possible corrosion can occur. It is suggested that volatile chemicals be used to
avoid increasing the level of dissolved solids in the water to be used for storage.
In preparing a unit for wet storage, the following procedure is recommended.
1. The unit should be filled with deaerated, Demineralized water treated with 200 ppm hydrazine (N2H4) for oxygen removal
and sufficient ammonia (NH3) in order to attain a pH of 10 (for demineralized water, this will require approximately 10 ppm
ammonia).
2. We strongly recommend pre-mixing of the chemicals with the water to insure a uniform mixture entering the boiler. This can
be accomplished by the blend-fill method. The blend-fill method consists of blending the chemicals with the demineralized
water at a continuous rate such that a uniform mixture is entering the boiler. Simply introducing the chemicals through the
drum after establishing water level will not insure adequate dispersion of chemicals to all internal surfaces, unless sufficient
heat is delivered to the furnace (i.e. firing the boiler) to induce natural circulation throughout the boiler.
3. Fill the unit with the treated demineralized water to the normal centerline of the steam drum. Stop filling further.
4. Back-fill the with treated Demineralized water until a rise in steam drum level is noted.
Continue filling until water exits from the steam drum vents. After filling, all connections should be blanked or tightly closed.
A source of low-pressure nitrogen should be connected at the steam drum to maintain 0.3 to 0.6 Bar G to prevent air from
entering the unit during the storage period.
The unit should be properly tagged and the appropriate warning signs attached noting that the boiler is stored under
nitrogen pressure and that complete exhaustion of the nitrogen must occur before anyone enters the drum. Before entering
drums test to prove that the oxygen concentration is at least 19.5%.
If storage continues into winter, ambient temperatures below the freezing point of water create a real hazard to the boiler
pressure parts and it will be necessary to provide a means of keeping the unit warm to avoid damage.
At some later date when the unit is to be placed into service, the boiler can be drained to normal start-up water level and placed
into operation.
In some cases, an expansion tank or surge tank (such as a 55-gallon drum) above the steam drum elevation may be required to
accommodate volume changes due to temperature changes. This tank is equipped with a tight cover and sight glass and contains
properly treated water. The tank should be connected to an available opening, such as a vent line at the top of the steam drum in
order to create a hydrostatic head. This tank will provide a ready, visual check of water level or in leakage during lay up.
A source of low-pressure nitrogen should be connected to the surge tank to maintain 0.3 to 0.6 Bar G to prevent air from entering
the unit during the storage period.
The treated demineralized water should be analyzed weekly, and when necessary, sufficient chemicals should be added through
the chemical feed line, to establish the proper levels recommended. Samples of the treated water can be taken at the continuous
blow down line or any suitable drain connection.
No unit should be stored wet when there is any possibilities of a temperature drop to the freezing point unless sufficient heat can
be provided to the unit to eliminate the danger of water freezing and subsequent damage to pressure parts.
Nitrogen Blanket
Nitrogen can be introduced at the following locations
¾ Through the steam drum
¾ Through the main steam line
The nitrogen required to seal the drainable components may be supplied from a permanent nitrogen system or portable tanks
located near the vent elevations. Due to differences in plant layout, the owner should choose his own method of piping the
nitrogen, either from their permanent system or from portable tanks, to the vent (or drain) locations listed.
The unit should be properly tagged and the appropriate warning signs attached noting that the boiler is stored under nitrogen
pressure and that complete exhaustion of the nitrogen must occur before anyone enters the drum.
Before entering drums test to prove that the oxygen concentration is at least 19.5 %
Hot Draining
If the WHRB shut down is for a short period of less than seven days and during that period maintenance work on pressure parts
have to be undertaken, the WHRB can be preserved by hot draining
The shut down WHRB is allowed to depressurize up to 2kg/cm2 (g) pressure on the drum. Water level is maintained up to
prescribed levels till that time.
When the steam drum pressure drops to 1.5 kg/cm2 (g), the air vents of the steam drum, Super heaters, economizer are opened
and the WHRB is drained through the economizer, evaporator (or only the sections required) by opening the required drain valves.
When all the water is drained, the residual heat of the water wall, economizer, Super Heater and steam drum, Flash dries most of
the moisture present on the tube surfaces. As the pressure parts remain dry, corrosion is prevented. This method of preservation
however is not effective for more than a week.
Alkaline Water Dozed With Hydrazine

If a WHRB has to be preserved for long periods (two months or more) an effective method of preservation is to fill the WHRB,
Super Heater and economizer with water treated with ammonia to a pH of 10.5 and dozed with 200 PPM or more hydrazine.
This water is completely filled in the water and steam space of the WHRB and a pressure of 5 kg/cm2 (g) is maintained in the
drum by a pump.
This method is effective but requires additional equipment such as a tank, and a pump with a connection to one of the drain
headers.
All the possible methods of preservation of a shut down WHRB, the nitrogen blanketing method is simple and suitable for the
type of preservation, which may be ordinarily required.
Preservation of Pressure Parts of WHRB during Long shutdown
During WHRB shut downs exceeding a few days, the external surfaces of the pressure parts of especially in a chemical plant
environment, may come under corrosive attacks by moisture, SO2, SO3 vapors etc
Keeping inspection doors tightly closed (when no inspection is being planned) may minimize such corrosion.
Water lancing with hot water or mild alkaline water once a month may wash out the corrosive components from the external
surfaces of the pressure parts.
TYPE OF PROCEDURE
SHORT OUTAGES Maintain the same hydrazine and ammonia concentration as present during normal operation. Establish 0.3 to
4 DAYS OR LESS. UNIT NOT 0.6 kg/cm² (g) nitrogen cap on the steam drum
DRAINED
SHORT OUTAGES Drain and open only those sections which require repair. Isolate remainder of the unit under 0.3 to 0.6 Bar
4 DAYS OR LESS. UNIT IS nitrogen pressure where possible. Maintain the same nitrogen and ammonia concentration for water remaining in
DRAINED the cycle
LONG OUTAGES Fill the boiler with water having 200 ppm of hydrazine and 10 ppm of ammonia to maintain pH 10.
LONGER THAN 4 DAYS UPTO Establish nitrogen cap of 0.3 to 0.6 kg/cm² (g), over the steam drum.
15 DAYS. UNIT IS DRAINED
LONG OUTAGES Dry storage of boiler with nitrogen alone is preferred procedure. Nitrogen cap of 0.3 to 0.6 kg/cm² (g), to be
MORE THAN 15 DAYS - UNIT IS maintained on the steam drum. Installed silica gel tray in the steam drum to soak moisture if any present in the drum
DRAINED. atmosphere
Preservation of Rotating Equipments

Put the rotating equipment in service once in every 48 hours or at least once in a week
1. If the equipment is going to be under long shutdown
a. Fill bearing block full of oil to preserve the bearing and rotate the Fan/Pump Shaft by 90° once in every 48 hours (If
bearing housing is oil lubricated)
b. Rotate the fan / pump shaft by 90° once in 48 hours (for bearing housings with grease)
c. Cover the bearing block & uncovered portion of shaft with plastic sheets to prevent dust/water ingress
d. Ensure no dust/water accumulates on the rotating equipment.

Preservation of Instruments
1. Cover all field instruments with plastic sheets
2. Power up the panel instruments and check the operation
3. Keep the control room dust and moisture free
4. Operate control valves, power cylinders once a week and check operation.
5. Operate quick shutoff valves frequently (Twice a week)

)H. COMMISSIONING PROCEDURE
Alkali Boil Out Procedure
For
1 x 6.85 MW CEMENT WHRS PROJECT
At
PARASHAKTI CEMENT INDUSTRIES LTD,

ANDHRA PRADESH
thyssenkrupp Industries India Pvt. Ltd.

Pimpri, Pune – 411018.
Date : 17.04.2018
Project : 1 x6.85 MW Cement WHRS project
Client : Parashakti Cement Industries Limited, Andhra Pradesh
Document no : Rev::03
ALKALI BOIL OUT PROCEDURE
CONTENTS
SR. NO. DESCRIPTION
SECTIONS
1.
ABSTRACT
2. OBJECTIVES
3. PRE-REQUISTIES
4. CHECK LIST
5. REQUIRED CHEMICALS
6. SAFETY PRECAUTIONS
7. PROCEDURE
8. COMPLETION CRITERIA
9. ALKALI BOIL OUT SCHEDULE
10. HOT RINSING
Prepared By :
Checked By : Approved by:
Page 2 of 16 Boiler Commissioning – Project Management
Date : 17.04.2018
1. ABSTRACT
Alkali Boil out Procedure (ABO) is Common for AQC-HP, AQC-LP, PH-HP AND PH-LP circuit.
For PH Boiler LP Circuit boiling pressure & TSP Concentration need to be changed.
2. OBJECTIVE
The cleaning of internal surfaces of boiler water circuit is essential to ensure that during normal operation of
steam generation, steam is free from impurities/foreign particles such as lubricants, oil, rust, sand, metal
fragments and assorted debris which are harmful for steam consumers e.g. steam turbine. This is achieved by
boiling out/circulating alkaline solutions through water circuit of boiler.
1. PRE-REQUISITES
1. Duct refractory Drying out procedure is completed. (If applicable)
2. Deaerator commissioning is completed & should be filled with adequate quantity of feed water.
3. Feed water line flushing is completed.
4. BFP is commissioned and ready.(WHRS-DEA-FDW-BFP-001/002/003)
DM plant is ready and adequate amount of DM water must be available (min. three times filling
5.
required)
6. Initial filling pump ready and available.(WHRS-DMS-DM-IFP-001)
7.
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Date : 17.04.2018
Neutralizing pit is available along with adequate quantity of neutralizer.
Feed control station motorised and control valve is ready and operation checked from DCS.
Tag Details:
AQC-(Tag no. WHRS-AQC-FDW-MOV-001, WHRS-AQC-FDW-MOV-002, WHRS-AQC-FDW-FCV-001,

WHRS-AQC-FDW-FCV-002)
PH-1-HP-(Tag no. WHRS-PH1HP-FDW-MOV-001, WHRS- PH1HP –FDW-MOV-002, WHRS- PH1HP -

8. FDW-FCV-001, WHRS- PH1HP -FDW-FCV-002)
PH-1-LP-(Tag no. WHRS-PH1LP-FDW-MOV-001, WHRS- PH1LP –FDW-MOV-002, WHRS- PH1LP -

FDW-FCV-001, WHRS- PH1LP -FDW-FCV-002)
PH-2-HP-(Tag no. WHRS-PH2HP-FDW-MOV-001, WHRS- PH2HP –FDW-MOV-002, WHRS- PH1HP -

FDW-FCV-001, WHRS- PH2HP -FDW-FCV-002)
PH-2-LP-(Tag no. WHRS-PH2LP-FDW-MOV-001, WHRS- PH2LP –FDW-MOV-002, WHRS- PH2LP-

FDW-FCV-001, WHRS- PH2LP -FDW-FCV-002)
IBD tank pre-commissioning is completed and IBD tank to Blow down sump drain line must be
9.
completed.
10. Drum level gauge installation is completed along with drain line up to safe location.
Boiler insulation of pressure parts, Drum, penthouse, Risers, interconnecting piping, cross over
11.
duct, Economiser casing is completed.
12. Air and flue gas all temperature and pressure readings are available in DCS.
13. Boiler expansion indicators are installed.
14.
Water and steam circuit all temperature, pressure readings to be made available in DCS. During
Prepared By :
Date : 17.04.2018
Alkali Boil Out one number of drum level transmitter to be taken in line and made available in DCS.
15. Feed water line all spring support are floated and temporary supports removed.
Main steam line up to MSSV all supports is erected. All spring support floated and temporary
16.
supports removed.
17. In drum safety valve and MS line safety valves Hydrostatic plug is installed.
18. Temporary ducting installed for RDO removed along with dummy.
19. Inlet, Outlet and Bypass dampers ready to operate
Sampling point must be erected between water wall drain station and its outlet isolation valve to
20.
IBD tank.
Ensure plant laboratory is ready and below mentioned testing instruments and requisite chemicals
is available for testing.
x PH
21.
x Oil & grease
x Turbidity
x Phosphate ( upto 5000ppm)
x M alkalinity & P alkalinity
Prepared By :
Date : 17.04.2018
2. CHECK LIST BEFORE COMMENCEMENT OF ALKALI BOIL OUT
1. All temporary supports have been removed and boiler is free for expansion.
2. Alkali chemical available and shifted to drum level.
3. Drum one side manhole is boxed up and another side is open and boiler drum gasket is available.
4. Boiler water filling is completed (level below 150mm of drum centre line).
5. Start up vent valve and its isolation both valves must be in close condition.
6. All super heaters drains are in open condition.
EBD (Emergency blow down) & CBD (Continues blow down) valves in closed condition.
AQC HP-(Tag no. WHRS-AQC2-HP-FDW-MOV-001, WHRS-AQC2-HP-FDW-MOV-002, WHRS-AQC2-

HP-FDW-GT-009, WHRS-AQC2-HP-FDW-GT-010, WHRS-AQC2-HP-FDW-FCV-001A, WHRS-AQC2-
HP-FDW-FCV-001B)
AQC LP-(Tag no. WHRS-AQC2-LP-FDW-MOV-001, WHRS-AQC2-LP-FDW-MOV-002, WHRS-AQC2-

LP-FDW-GT-003, WHRS-AQC2-LP-FDW-GT-004, WHRS-AQC2-LP-FDW-FCV-001A, WHRS-AQC2-LP-
7.
FDW-FCV-001B)
PH-HP-(Tag no. WHRS-PH2-LP-FDW-MOV-001, WHRS-PH2-LP-FDW-MOV-002, WHRS-PH2-LP-

FDW-FCV-001A, WHRS-PH2-LP-FDW-FCV-001B, WHRS-PH2-LP-FDW-GT-002, WHRS-PH2-LP-FDW-
GT-003)
PH-LP-(Tag no. WHRS-LP2-LP-FDW-MOV-001, WHRS-LP2-LP-FDW-MOV-002, WHRS-LP2-LP-FDW-

FCV-001A, WHRS-LP2-LP-FDW-FCV-001B, WHRS-LP2-LP-FDW-GT-002, WHRS-LP2-LP-FDW-GT-
003)
Prepared By :
Date : 17.04.2018
8. Down comers drain valves in closed condition.
9. Pressure gauges on drum and main steam line are installed and taken in line.
Mixing drum (plastic) for chemical (size -200litrs quantity 2 numbers and bucket or container of
10.
capacity 5 litres must be available on drum level).
11. Fire extinguisher and Fire tender is available.
Drum vents must be in open condition.
AQC HP - (Tags no. WHRS-AQC2-HP-MAS-GB-005)

12.
AQC LP- (Tags no. WHRS-AQC2-LP-MAS-GB-005)
PH HP- (Tags no. WHRS-PH2-HP-MAS-GB-005)
PH LP- (Tags no. WHRS-PH2-LP-MAS-GB-005)
13. Stirrer for mixing of TSP in water is available.
Prepared By :
Date : 17.04.2018
3. REQUIRED CHEMICAL:
Boiler water holding capacity (upto drum centerline)-
x AQC HP Boiler- ~27 m3
x AQC LP Boiler- ~8 m3
x PH Boiler- ~93 m3
Sl.No Chemical Quantity Required
AQC HP Boiler- 135 kg

1. Crystalline Tri-sodium phosphate (Na3Po4,12H2O)
AQC LP Boiler- 4 kg
PH Boiler- 465 kg
2. Detergent Total 6 Kg and 2 kg each for each Boiler Drum
Adequate quantity of lime (Soda ash) for neutralizing is required.
Calculation of required Chemical quantity:
Total quantity of chemical required: (Water holding capacity (m3) × required ppm)/1000
Quantity of chemicals is decided to maintain initial phosphate concentration 5000 ppm in boiler along with
the chemical total 3 kg normal good quality detergent/Washing powder to be added in boiler drum for
foaming purpose only.
Water holding capacity (up to steam drum centre line) ~
Prepared By :
Date : 17.04.2018
4. SAFETY PRECAUTION
Before commencement of Alkali boil out please ensure below mentioned safety pre-cautions are available.
x Good quality rubber hand gloves for handling Tri-sodium phosphate.
x Safety goggles for eyes. ( for chemical handling)
x Emergency eye wash station at drum elevation and near drainage station.
x Fire fighting system is ready and adequate quantity of fire extinguisher is available.
x Adequate illumination is available.
x Neutralizing pit is ready and adequate quantity of lime (Soda ash) is available for neutralizing.
x Ensure while giving blow down bottom header area a properly cordoned off with warning tapes
Prepared By :
Date : 17.04.2018
5. PROCEDURE :
After ensuring the above said checklist, alkali boil out out can be started and according to start up procedure
mentioned below.
5.1 Boiler Filling

i) Start boiler initial filling pump and charge boiler initial filling line.
ii) Boiler initial filling to be done from initial filling provided at Boiler Feed water line
iii) Before initial filling the boiler ensure below mentioned valves are in closed condition
Sr. No. Description
1. EBD line valves
2. CBD line valves
3. Drainage station to IBD tank drain line valve
iv) LEVEL-water to be filled below 150mm below the bottom of drum. Level to be visually ensured from other side which
is open.
Prepared By :
Date : 17.04.2018
5.2 Boiler Light Up:

.
AQC
.
Fill the boiler tubes and headers with Fresh DM Water up till the level below the steam drum.
Open the steam drum man hole from one side.
Prepare for boiler light up; open the, Boiler Inlet and Outlet damper completely to 100 % and start warming up the
boiler till the water temperature reaches 60-70degc.
PH
Fill the boiler tubes and headers with Fresh DM Water up till the level below the steam drum.
Open the steam drum man hole from one side.
Prepare for boiler light up; open the, Boiler Inlet and Outlet damper completely to 100 % and start warming up the
boiler till the water temperature reaches 60-70degc.
5.3 Filling the chemical in boiler drum:
When drum water temperature reaches above 60-80 deg c .Take water from boiler drum into mixing drum and
dissolve required chemicals thoroughly into the solution tank. Mix the chemical properly in the tank by normal
stirrer and after mixing transfers the solution into the drum via manhole. Do not pour the solution in empty boiler
drum. Repeat the steps and by this method dose the total quantity of Na3Po4, 12H2O into boiler drum. After
mixing the chemical into boiler drum dosed the detergent into boiler drum and box up drum manhole.
5.4 Boiler Pressure raising :
Start closing the bypass damper (HA/LA-05-FLG-DMPR-001) slowly. Let the gases to pass through boiler and
heat up the boiler pressure parts.
By controlling the bypass damper take the system pressure to maximum 8-10 kg/cm² and for LP drum 1.5
Prepared By :
Date : 17.04.2018
kg/cm2 pressure to be maintained.

Sl.No Boiler Pressure raising during ABO
1. AQC HP Boiler 8 kg/cm2
2. AQC LP Boiler 1.5 kg/cm2
3. PH Boiler 8 kg/cm2
Keep the system stable for 4 hours, then start opening the drain valves one by one for few seconds.
Check the quality of the blow down water. After every 2 hours blow down shall be given from bottom ring headers.
No. of blow down will depend on blow down water quality which needs to be checked during every blow down.
When the oil & grease content comes below 5 ppm. Alkali Boil Out to be stopped and boiler should be boxed up
immediately and left for natural cooling.
Keep it replenished with DM water and keeps draining the system and samples to be taken and checked.
Continue with the hot rinsing and draining process. After rinsing when the blow down water quality is as same as
the feed water quality,
5.5 Blow down sampling:
After completion of blow down from each header, crack open all drain line valves and collect sample from sampling point
located at drain line from drainage station to IBD tank & tested for.
x Phosphate concentration
x Alkalinity (Both M-alkalinity and P-alkalinity)
x Oil & Grease
x Turbidity
x PH & Conductivity
Prepared By :
Date : 17.04.2018
5.6 Drum level:

During blow down drum level will drop .Make up drum level by BFP through Feed water line and
maintained water level in approx 3-4 ports of drum level gauge.
When oil and grease in blow down water will comes below 5 ppm HAG should be off and close both the I/L, O/L
dampers, left the boiler for natural cooling.
When pressure decreases around 6 kg/cm2 all drain lines including CBD and IBD valves shall be opened
simultaneously for hot blow down of boiler. During hot blow down process sample shall be collected and checked
of the parameters stated above.
7. ALKALI BOIL OUT SCHEDULE :
Sr. No. Temperature range Time

1. Boiler initial filling
2. Water rising upto 80- 90 deg C
3. Chemical mixing in boiler drum and drum box up 4 hours
4. Pressure rising up to 12 kg/cm2 3 hours
Holding time at 12 kg/cm2 4 hours
5. First blow down at 12 kg/cm2 After 4 hours of attaining 12
kg/cm2
Consecutive blow downs at 12 kg/cm2 At every 2 hours interval till oil and
6. grease decreases below 5 ppm in
blow down
7. Boiler hot blow down At 4 kg/cm2
Prepared By :
Date : 17.04.2018
8. HOT RINSING:
OBJECTIVE
It is essential to carry out hot rinsing process after alkali boil out to remove residue phosphate, oil and grease from
boiler and also to ensure boiler blow down water quality matches with feed DM water.
PRE-REQUISITES
1. Alkali Boil out completed.

2. Post alkali boil out hot draining completed.
3. Boiler is cooled after alkali boil out and below screen temperature is below 70 degc.
4. Sufficient quantity of DM water available.
5. DM transfer pump is ready and available.
6. Neutralizing pit is available along with adequate quantity of neutralizer.
CHECK LIST
14. Furnace temperature is below 70 degc.
15. Drum, superheater vent is in open condition

16. Drum level gauge glass indication is available.
17. DM lab is available with all required testing chemicals
18. Mainsteam stop valve and by-pass valve is in closed condition
19. All superheater drains are in close condition
20. EBD valves and CBD valves are in closed condition.
Prepared By :
Date : 17.04.2018
PROCEDURE:
After ensuring the above said checklist, hot rinsing process can be started
¾ Start boiler initial filling pump and charge boiler initial filling line up to boiler drain header inlet .
¾ Start boiler filling from boiler feed water line.
¾ Fill DM water up to drum centre line.
¾ After filling water up to drum centre line stop DM transfer pump/initial fill pump
¾ While filling boiler take DM water sample and test at lab for
a. PH
b. Oil and grease
c. Turbidity
d. Phosphate
e. M-alkalinity and P-alkalinity
¾ During blow down collect water sample and test below mentioned parameters at laboratory.
a. PH
b. Oil and grease
c. Turbidity
d. Phosphate
e. M-alkalinity and P-alkalinity
¾ Hot rinsing procedure will continue till boiler blow down water quality matches with feed DM water quality.
¾ After completion of Hot rinsing Process Header Cleaning and Flushing to be carried out. For Header Cleaning and
Flushing Header stubs along with Drain to be cut (List of headers to be provided at site) and Flushing with Normal
temperature DM water (Preferably from DM transfer pump) to be carried out.
Prepared By :
Date : 17.04.2018
SAFETY PRECAUTION
x Before commencement of Hot rinsing process please ensure blow down sump is properly barricaded with
proper caution tag.
x While collecting samples all required PPE’s must be worn.
Prepared By :
STEAM BLOWING PROCEDURE
For
1 x 6.85 MW CEMENT WHRS PROJECT
At
PARASAKTI CEMENT INDUSTRIES LTD, ANDHRA

PRADESH

Pimpri, Pune – 411018.
Date : 18.04.2018
Client : Parasakti Cement Industries Limited, Andhra Pradesh
SR. NO. DESCRIPTION
SECTIONS
1. OBJECTIVES
2. PRINCIPLE
3. PRE-REQUISTIES
4. STEAM BLOWING CHECK LIST
5. PROCEDURE
7. POST STEAM BLOWING ACTIVITY
Prepared By : Boiler Commissioning-Project

Page 2 of 10
Checked By : Approved by: Management
Date : 18.04.2018
1. OBJECTIVE
The purpose of the steam blowing is to clean the super heater circuits and main steam line of any foreign material, mill
scale ,loose weld, dirt etc which may otherwise lead to damage of turbine blades, valves etc.
2. PRINCIPLE
Steam blowing is carried out in which, boiler pressure is raised to 12 Kg/cm2 and released through a quick opening
valve and steam blowing done till the Drum pressure drops from 12 Kg/cm2 to 8 Kg/cm2.
During steam blowing steam drum metal temperature changes has to monitor on continuous basis. Maximum
allowable thermal shock for drum material is 40 °C.
If allowable thermal shock reaches 40 °C, then operator has to close temporary blowing valve. Generally the pressure
drop from 12 Kg/cm2 to 8 Kg/cm2 happens in between 3-5 minutes and with 4 kg/cm2 pressure drop Drum metal
temperature does not drops more than 40 °C.
Repetitive heating and cooling of steam pipes with the help of high momentum of expanding steam dislodge the
rust/scales from pipe work.
3. PRE-REQUISITES
A. Services Required
1. Availability of Power Supply (H.T/L.T/220 VDC/ 110 V AC), Instrument / Service Air etc.
2. Availability of Lab facility for boiler water parameters inspection. Boiler water samples to be collected from IBD
drain line as SWAS will not be taken in line during Steam Blowing. Charging of SWAS system during Steam Blow will
leads to choking of Cooler internal tubes, Strainers etc.
Boiler Water samples to be collected for Checking pH, Conductivity and Silica.
3. Ensure adequate amount of DM water and fuel must be available.

Page 3 of 10
Date : 18.04.2018
B. Safety Precautions
1. Required quantities of PPE’s such as helmets, Temperature resistant hand gloves, Ear Mufflers etc. are available.
First aid kit box available in control room
2. Service water shall be made available near the activity area.
3. Required stair cases or platform or approaches etc with hand rails to temporary valves are made available.
4. Required barricades to be made to prevent personnel from coming into contact with temporary piping.
5. Required number of sign boards (Mentioning PPE requirements) to be put into position at selected locations to
indicate the ongoing process of steam blowing. Steam Exit Area must be cleared from personnel (not required for
Steam Blow operation) before giving Blow.
C. Emergency Procedures
1. The group consisting of personnel, which is carrying out steam blowing should be aware of procedures to be
followed in case of accidents involving injury to personnel.
2. The group should be aware of operating procedures of portable fire extinguishers to be used for quenching minor
fires.
3. The group should be aware that if any abnormality is observed in the permanent and temporary system during the
steam blowing operation, the operation should be immediately terminated and appropriate action taken to
address the issue.
D. Readiness of The Following To Be Ensured
Sr Description Checked
no.
1 Alkali boil out and post boil out activities like Hot rinsing, Header flushing completed
2 Post Welding, Inspection of header stubs and hydro test completed
3 Temporary exhaust piping erection completed along with all supports

Page 4 of 10
Date : 18.04.2018
3 Target plate and its fixing device are ready
4 Ensure hydrostatic test of pipe work is completed
5 Pressure and temperature gauges in temporary pipe are installed
ESP air load test completed, Hopper heaters, insulation heaters, Rapping systems are
7
Commissioned
8 All oxygen analyzers and CO analyzer (if provided) commissioned and reading available in DCS
Hydrostatic plugs from safety valves removed and safety valves (WHRS-AQC2HP-MAS-SV-001,
9 WHRS-AQC2HP-MAS-SV-002, WHRS-AQC2HP-MAS-SV-003, WHRS-AQC2LP-MAS-SV-001,
WHRS-AQC2LP-MAS-SV-002, and WHRS-AQC2LP-MAS-SV-003) assembled.
Main steam line from boiler outlet to exhaust all supports erected and spring supports Cold
10
setting completed
11 HP dosing system is commissioned and ready
Feed water pipe, de-super-heater pipe and Deaerator pipe have been flushed by water.
12
Desuperheater and Deaerator system is ready.
13 All man holes are closed.
Ensure Deaerator (WHRS-DEA-FDW-DEA-001, WHRS-DEA-FDW-BFP-001, WHRS-DEA-FDW-BFP-

14 002) BFP and DM transfer pumps (WHRS-DMS-DM-DM-DMTP-001 and WHRS-DMS-DM-DM-
DMTP-002) are ready
15 HGG in ready condition (WHRS-AQC2-FLG-HGG-001)
Steam must be exhausted outside turbine hall area which is cordoned off and notice displayed
16
prominently.
17 Fire fighting system is ready and commissioned.

Page 5 of 10
Date : 18.04.2018
4. STEAM BLOWING CHECK LIST
Sr.
Description Checked
No.
Main Steam Stop valve (WHRS-AQC2HP-MAS-MOV-001WHRS-AQC2LP-MAS-MOV-001,),

1 MSSV bypass (WHRS-AQC2HP-MAS-MOV-001A, WHRS-AQC2LP-MAS-MOV-001A) operation
checked from DCS.
2 MS line from boiler O/L to exhaust all spring support checked.
3 Steam blowing line from temporary blowing valve to atmosphere erected with all supports.
4 Target plate fixing arrangement done and is accessible in all exhaust line to atmosphere.
6 Trial of Temporary Sacrificing MOV, Warm up vent MOV completed from DCS
Trial of Chain Conveyor and RAV (WHRS-AQC2-FLG-RAV-001, WHRS-AQC2-FLG-RAV-002,

7 WHRS-AQC2-FLG-RAV-003, WHRS-AQC2-FLG-RAV-004, WHRS-PH2-FLG-RAV-001, WHRS-
PH2-FLG-RAV-002) completed from DCS
Deaerator pegging Steam PRDS line not connected to deaerator and end kept open for
8
venting to atmosphere for flushing at Deaerator end
Drum level transmitter

(WHRS-AQC2HP-FDW-LT-001A, WHRS-AQC2HP-FDW-LT-001B, WHRS-AQC2HP-FDW-LT-
001C, WHRS-AQC2LP-FDW-LT-001A, WHRS-AQC2LP-FDW-LT-001B, WHRS-AQC2LP-FDW-
LT-001C, WHRS-PH2HP-FDW-LT-001A, WHRS-PH2HP-FDW-LT-001B, WHRS-PH2HP-FDW-LT-
001C, WHRS-PH2LP-FDW-LT-001A, WHRS-PH2LP-FDW-LT-001B, WHRS-PH2LP-FDW-LT-
9
001C)
Drum pressure transmitter
(WHRS-AQC2HP-MAS-PT-001, WHRS-AQC2HP-MAS-PT-002, WHRS-AQC2LP-MAS-PT-001,
WHRS-AQC2LP-MAS-PT-002, WHRS-PH2HP-MAS-PT-001A, and WHRS-PH2HP-MAS-PT-
001B) s are ready for commission.
10 Expansion indicators installed in boiler
11 Tri-Sodium phosphate dosing pump is available for HP Dosing.

Page 6 of 10
Date : 18.04.2018
12 All required pressure and temperature indications are available in DCS.
Start up vent (WHRS-AQC2HP-MAS-MOV-002, WHRS-AQC2HP-MAS-GT-001, WHRS-PH2HP-

13 MAS-MOV-002, WHRS-PH2LP-MAS-GT-001) commissioned and MS line temperature
readings are available in DCS and PTs are ready to commission.
All Steam traps of Main Steam line Drains are not installed before Steam Blowing as
14
accumulation of dirt, Scales at upstream of Trap will leads to damage trap internals
Note: steam blowing should be started after ensuring all the system readiness mentioned above.
SEQUENCE OF STEAM BLOWING:
For this plant structure steam blowing can be completed in two stages.
1) Steam Blowing of AQC Boiler (HP & LP Circuits at the same time) up to TG Inlet.
Temporary blowing line along with a temporary blowing sacrificing valve to be erected at TG inlet before ESV with all
permanent support and its inspection completed.
Blowing to be done up to TG inlet for both HP & LP circuits to be carried out at alternatively. First HP side blow to be given
after reaching desired temp and pressure (by puffing method). After HP side blow is completed, after 5 min, start LP side
blow (continuous method) for about 10-15 min (time of blow should be decide on the drum parameters at site only).

Page 7 of 10
Date : 18.04.2018
2) Steam Blowing of PH Boiler (Only HP Circuit) till AQC mixing header.
Temporary blowing line along with a temporary blowing sacrificing valve to be erected at AQC mixing header inlet at the PH
main steam line with all permanent support and inspection completed.
Blowing to be done up to Mixing header Inlet. After ensuring cleanliness of target plate, temporary line to be removed and
PH main steam line to be connected with AQC mixing header.

Page 8 of 10
Date : 18.04.2018
5. PROCEDURE
Start up procedure for steam blowing
Take air compressors & ACW system in line, start the HP BFP and LP BFP and charge the line up to Feed Control Station
(FCS).
Follow below mentioned start up procedure of boiler for steam blowing;
a. Fill the HP & LP Drum (In Case of AQC Boiler) & HP Drum (In Case of PH Boiler) maintaining level at (-100mmWC), with
initial filling line. Open by Flue gas by pass damper, then inlet and outlet damper.
b. Start Closing the Flue Gas By-pass damper to regulate the Flue gases through the boiler slowly increasing the drum
pressure.
c. Close the Drum vent after 2 kg/cm2 (g) pressure is attained in the drum. When drum pressure reach 5 kg/cm2 (g),
close the super heater drains and MS line drain.
d. Watch the Drum level and line up the BFP and Feed control station
e. Slowly increase the steam pressure by closing the Flue Gas by-pass damper and charge the Main steam line up to
sacrificing valve by opening the Boiler MSSV slowly after steam pressure reaches 8 kg/cm2 (g). Open the start-up vent
valve and adjust opening to increase the Main Steam temperature as per requirement. Before charging the main steam
line till TG inlet ensure that all line drains and warm up vent before TG Inlet is opened.
f. When required steam temperature (above 225 °C for AQC Boiler (HP) and above 200 °C for PH Boiler) and pressure
of about (12-14) kg/cm2 (g) is attained before the Sacrificing valve, close the Warm up vent ,start up vent and the
line drains , FCV. Open the Flue Gas Bypass damper of the Boiler and give an open command to the sacrificing valve
and blow off the steam from the temporary blow off line till the steam pressure drops down to 4 kg/cm2 (g) -5 kg/cm2
( puffing method).
g. After Closing the Sacrificing valve Immediately open feed control valve and start taking feed water into Boiler, and
close feed control valve at drum level (-100mmWC).
h. After HP side blow is completed and water is taken in Boiler. Wait for 10 min to normalize and start giving LP side blow
continuously when pressure is 1.5 -2.5 kg/cm2 (g) for 10-15 min. (Blowing time should be decide on site based on the
drum level parameter) Flue gas flow rate to be regulated to maintain the pressure during blow ( continuous method).
I. After completion of blowing, check all the Main Steam line supports in field. If found normal give blows by
Following the same procedure keeping minimum 1.5 - 2 hour gap between 2 consecutive Blows, Continue the
Same procedure of HP and LP blow till target plate is cleared.
j. The steam blowing process should continue until target plate is declared cleared by TG OEM.
k. ESV flange up to turbine inlet which is not blown out in steam blowing to be acid pickled. (Depends upon
arrangement)

Page 9 of 10
Date : 18.04.2018
The steam blowing can be declared complete only after ensuring cleanliness of target plates mounted in the temporary
exhaust pipe. It is recommended to install the target plate after completing few blows in each stage. Since the highest
velocity of the steam is at the centre, the effectiveness of steam blowing is identified by knowing the absolute pitting on
the target plate in the central zone, i.e. the area covered by ¾ th of the diameter.
Note: For acceptance criteria of steam blowing Turbine OEM recommended acceptable limits to be followed.
7. POST STEAM BLOWING ACTIVITY

1. Removal of temporary blowing piping
2. Installation of Main steam Flow nozzles
3. Final walk down Checking for all Main steam piping supports
4. Termination of Deaerator pegging steam PRDS piping to deaerator
5. Parallelity checking for Main steam piping with STG ESV
6. Fixing of Steam traps at Main steam drain line.
7. Boiler Drum and Main steam safety valve floating and setting.

Page 10 of 10
*.LUBRICATION SCHEDULE
LUBRICATION SCHEDULE
WHR BASED POWER PLANT
PARASAKTI CEMENT INDUSTRIES LTD.
2M.0040
Grade of Quantity per TOTAL

Equipment KW Part to be Equipment Code / Lubrication Interval Lubricant Lubricants Name
Equipment Tag Number Lubricant Equipment QUANTITY Remarks
rating / Pole Lubricated Qty. Standards Hours Type & Makes
(Make) (Kg/Liters) (Kg/Liters)
HGG
OIL
WHRS-AQC2HP-HGG-P-001 Fluid to be Continues when pump under

NA BEARING 2 - Self lubricating Fluid to be pumped - - Bearing is lubricated by the fluid to be pumped
WHRS-AQC2HP-HGG-P-002 pumped operation
GREASE
WHRS-AQC2HP-HGG-M-001 /
0.75KW BEARING 2 NA NA Greased for life NA NA Greased for life NA No need to lubricate Greased for life
WHRS-AQC2HP-HGG-M-002
NA - BEARING 13 EP-3 NA Once every 3months Grease As Standard available at site ̴ 200grm 2.5kg
1. Initial Filling 300 grm/Bearing

NA - BEARING 2 EP-2 or EP-3 NA 300 grm/bearing Grease MOBIL: HXP 222. 300 grm 600 grm 2. After 1600 hrs Refilling 40 grm/Bearing
3. Replacement after 10000 hrs
30KW BEARING 2 NA NA Greased for life NA NA Greased for life NA No need to lubricate Greased for life
NA - DE & NDE Bearing 1 LGEP-2 NA Every 900 Hrs Grease Standard 10grm 20grm
1.5KW (DC) WHRS-AQC2HP-HGG-M-005 BEARING 1 NA NA Greased for life NA NA Greased for life NA No need to lubricate Greased for life
First fill for 240 hrs

WHRS-AQC2HP-HGG-RB-001 Blowers are supplied with NO Oil .
NA Gear case 2 SP-320 NA Then Oil Indian Oil 650ml every time 1300 ml
WHRS-AQC2HP-HGG-RB-002 Please fill Oil before 1st Start
Every 1440 Hrs replacement
18.5KW BEARING 2 NA NA Greased for life NA NA Greased for life NA No need to lubricate Greased for life
NA - Shaft Bearing 1 EP-3 NA Once Every Month Grease Standard 15-20 grm 15-20 grm
NA - NA 1 NA NA Greased for life NA NA Greased for life NA No need to lubricate Greased for life
1. Castrol Hipress or Alpha617

2. BP : CABOL75 or AMOCAM
NA - Gearbox 1 NA NA Every 10000 hrs refilling Oil 3 Ltr 3 Ltr
3.ESSO: Enclo120 or Gervil EP-3
4. IOC : Servomesh40 or Servosystem533
1. Castrol : Spherol Gr.Ap-3

2. BP : Mobilux Gr.3
NA - Motor 1 NA NA Every 10000 hrs refilling Grease 50 grm 50 grm Only 2/3 of rearing area to be filled to avoid Overheating
3. ESSO : Multipurpose Gr-2
4. IOC : Alvania Gr-3

NA - Pulleys 1 NA NA Every 2 weeks Grease 300 grm 300 grm Full completely with additional packing

Belt tensioning and Oil weekly on ends 2. BP : Mobilux Gr.3
NA - 1 NA NA Grease 150 grm 150 grm Full completely with additional packing
Steering Device Grease every 2 weeks 3. ESSO : Multipurpose Gr-2
NA - Belt steering Idler 1 NA NA Every 2 weeks Grease 300 grm 300 grm Full completely with additional packing
NA - Tension Spindles 1 NA NA Every 6 Month Grease 300 grm 300 grm Clean the spindles from Dirt and ready the grease
Open threads of 2. BP : Mobilux Gr.3
NA - 1 NA NA Every 6 Month Grease 100 grm 100 grm
fasteners 3. ESSO : Multipurpose Gr-2
NA - Gear box 1 NA NA Replace after Every 1,00,000 hrs Oil Servomesh 40 or Servosystem 553 2.5 Ltr 2.5 Ltr
NA - Damper shaft 5 EP-2 or EP-3 NA Check Every 2 weeks Grease Standard 10-15 grm / shaft 50 grm
WTP
GREASE
After 40000 hrs we

15 KW/2 EFSSPL-TKII-P-10.8-88-03 Bearing 1 NA NA 40000 NA NA have change the NA
bearing
After 40000 hrs we

75/2 EFSSPL-TKII-P-171-88-02 Bearing 1 NA NA 40000 NA NA have change the NA
bearing
After 40000 hrs we

102 HP/1800 EFSSPL-TKII-P-171-88-01 Bearing 1 NA NA 40000 NA NA have change the NA
bearing
EOT CRANE
OIL
MAIN HOIST GEAR

3.7 kw/8 pole 1 NO SP, 220/320 SPLASH TYPE CASTROL ALHA,SP, 220,320 50 LTS 50 LTS
BOX HR-500+150
AUXILLARY HOIST
11 kw/6 pole 1 NO SP, 220/320 SPLASH TYPE CASTROL ALHA,SP, 220,320 15 LTS 15 LTS
GEAR BOX HB-400
CROSS TRAVAL
0.75 kw/6 pole 1 NO SP, 220/320 SPLASH TYPE CASTROL ALHA,SP, 220,320 4 LTS 4 LTS
GEAR BOX VC-320
LONG TRAVAL
0.75 kw/6 pole 2 NO SP, 220/320 SPLASH TYPE CASTROL ALHA,SP, 220,320 15 LTS (EACH) 30 LTS
GEAR BOX HC-350
D i S
Dosing System'
t '
0.5LPH , 30 After 450 hours of operation or Indroll Lubricants / Caltex Alpha ZN 817/ Indion Oil 250 GRMS/PER
2003-B-00930 Pump internal parts 4 nos Gear Oil 460 460 Gear Oil 1000 GRM
Kg/cm2 every 3 months wichever is earlier Corporation Servomesh 50 PUMP
0.5 LPH , 30 After 450 hours of operation or Indroll Lubricants / Caltex Alpha ZN 817/ Indion Oil 250 GRMS/PER
0-10 LPH, 6 After 450 hours of operation or Indroll Lubricants / Caltex Alpha ZN 817/ Indion Oil 250 GRMS/PER
Miscellaneous Pumps
GREASE
After 40000 hrs we

1250 KW/6 WHRS-CWS-MCW-MCWP-001/002 Bearing 2 NA NA 40000 NA NA have to change the NA
bearing
After 40000 hrs we

37/4 WHRS-CWS-ACW-ACWP-001/002 Bearing 2 NA NA 40000 NA NA have to change the NA
bearing
After 40000 hrs we

18.5/2 WHRS-CWS-ACW-ACWP-001/002 Bearing 2 NA NA 40000 NA NA have to change the NA
bearing
After 40000 hrs we

15 KW/2 Bearing 1 NA NA 40000 NA NA have to change the NA
bearing
After 40000 hrs we

1.1 KW/2 Bearing 2 NA NA 40000 NA NA have to change the NA
bearing
Compressor
OIL
Sigma Fluid S- 40 litre for 2 No

25 KW Air Screw Element 2 6000 Oil 20 Litre/compressor
570 Compressor
GREASE
Anti-friction
800 Gram for 2
25 KW Motor Bearing 2 bearing grease 2000 Grease 400 Gram/Motor
Motors
Unirex N3 4
Cooling Tower
OIL
ISO VG-100; Change oil after 6 months or after

Hydraulic
GEAR BOX 3 IOLSERVO 3000 hours of operation whichever Oil 1 Litre/unit 3 Liters
Mineral Oil
SYSTEM 100 is earlier.
ISO VG-100;
Hoist 1 Hydraulic Oil IOLSERVO After 4 months Oil 1 Litre/unit 1 Liter
SYSTEM 100
Hammering System
OIL
after 24 months
ISO
GEAR BOX 14 Mineral Oil from date of Oil Shell/Kluber 4.5 Litre/unit 63 Liters
VG 220
supply
2500 to 3000
Chain & Sprocket 14 Mineral Oil SAE 30 Oil Servo/Castrol/Mobil 1.25 Litre/unit 17.5 Liters
hours of operation
RAV
OIL
Indian Oil/HP ISO

GEAR BOX 4 5000-8000hrs Oil Indian Oil/HP 1.25 Litre/unit 5 Liters
Grade 220 VG 220
Indian Oil/HP ISO

GEAR BOX 3 5000-8000hrs Oil Indian Oil/HP 3.75 Litre/unit 11.25 Liters
Grade 220 VG 220
GREASE
Indian Oil/HP
Bearing 8 EP-3, Grease 2000-2500hrs Grease Indian Oil/HP 0.05 kg/unit 0.4 kg
Grade 220
Indian Oil/HP
Bearing 6 EP-3, Grease 2000-2500hrs Grease Indian Oil/HP 0.075 kg/unit 0.45 kg
Grade 220
Slide Gates
GREASE
Threaded portion after 4000-5000

12 Indian Oil/HP EP-3, Grease Grease Indian Oil/HP 0.3 kg/unit 3.6 kg
for MSG Screw Rod hrs from first fill
++J. ATTACHMENTS
BOILER GA DIAGRAM


 




BOILER P&ID
SILENCER
RAV
VALVE SCHEDULE
Project : 1 x 6MW/7MW WHRS Project Doc. No. 2003-B-00944-0 Rev.2
Client : PARASAKTI CEMENT INDUSTRIES LTD., AP BOILER VALVE SCHEDULE Date: 03-11-2017
WO No. : 2M.0040
Mech. Mech.
Operating Operating Operating
Type of Design Design Body Total Special Requirement /
Sr.No. Item/Location Piping NB mm Pressure Temp Flow H / M End Conn. Class** IBR (Yes/No) Tag Numbers BW Schedule
Valve Pressure Temp MOC Qty Remark
(kg/cm2 (g)) deg. C (TPH)
(kg/cm2 (g)) deg. C
GATE VALVES
P&ID FOR DEAERATOR & BFP (PB-33376-1 Rev.A)
1 Upstream Isloation for PCV on Deaerator Aux. Steam Line Deaerator Steam Piping GATE 100 3 190 3 190 0.5 H BW 150 WCB 1 YES WHRS-DEA-AUX-GT-001 SCH.40
2 Downstream Isloation for PCV on Deaerator Steam Line Deaerator Steam Piping GATE 100 3 190 2.8 190 0.5 H BW 150 WCB 1 YES WHRS-DEA-AUX-GT-002 SCH.40
3 Isolation in steam line at Deaerator inlet Deaerator Steam Piping GATE 100 3 190 2.8 190 0.5 H BW 150 WCB 1 YES WHRS-DEA-AUX-GT-003 SCH.40
4 Intial Warm Up Line for Deaerator Storage Tank Deaerator Steam Piping GATE 80 3 190 M BW 150 WCB 1 YES WHRS-DEA-AUX-MOV-001 SCH.40
5 Condensate from GSC Condensate Piping GATE 80 15 80 10 60 35 H BW 150 WCB 1 YES WHRS-DEA-CDS-GT-001 SCH.40
6 Condensate from GSC to AQC-CPH inlet Header Condensate Piping GATE 80 15 80 10 60 35 H BW 150 WCB 1 YES WHRS-DEA-CDS-GT-002 SCH.40
7 CPH Bypass Valve Condensate Piping GATE 80 15 150 10 120 35 H BW 300 WCB 1 YES WHRS-DEA-CDS-GT-004 SCH.40
8 Isolation valve in condensate line near Deaerator Condensate Piping GATE 80 15 150 10 120 35 H BW 300 WCB 1 YES WHRS-DEA-CDS-GT-005 SCH.40
9 Deaerator outlet Line isolation (Locked Open) Feed Water Piping GATE 150 4 150 2 126 35 H BW 150 WCB 1 YES Locked Open Valve WHRS-DEA-01-FDW-GT-001 SCH.40
10 BFP-1 suction side isolation Feed Water Piping GATE 150 4 150 2 126 35 H BW 150 WCB 1 YES With Limit Swithces WHRS-DEA-01-FDW-GT-002 SCH.40
11 BFP-1 - Discharge side Isolation Valve Feed Water Piping GATE 80 35 150 28 126 35 M BW 300 WCB 1 YES WHRS-DEA-FDW-MOV-001 SCH.40
12 BFP-1 - Isolation for Minimum Recirculation Line near ARC Valve Feed Water Piping GATE 40 35 150 H SW 800 A105 1 YES Locked Open Valve WHRS-DEA-FDW-GT-004
13 BFP-1 - Isolation for Minimum Recirculation Line near Deaerator Feed Water Piping GATE 40 35 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GT-007
14 BFP-2 suction side isolation Feed Water Piping GATE 150 4 150 2 126 35 H BW 150 WCB 1 YES With Limit Swithces WHRS-DEA-FDW-GT-003 SCH.40
15 BFP-2 - Discharge side Isolation Valve Feed Water Piping GATE 80 35 150 28 126 35 M BW 300 WCB 1 YES WHRS-DEA-FDW-MOV-002 SCH.40
16 BFP-2 - Isolation for Minimum Recirculation Line near ARC Valve Feed Water Piping GATE 40 35 150 H SW 800 A105 1 YES Locked Open Valve WHRS-DEA-FDW-GT-005
17 BFP-2 - Isolation for Minimum Recirculation Line near Deaerator Feed Water Piping GATE 40 35 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GT-006
P&ID FOR WATER & STEAM (AQC) (PB-33377-1 Rev.A)

BFP Outlet to AQC - Feed Water isolation Valve upstream of attemperator
18 HP Feed Water Piping GATE 80 35 150 28 126 35 H BW 300 WCB 1 YES WHRS-AQC2HP-FDW-GT-001 SCH.40
tapping
19 Initial filling Line to HP Feed Water Line DM Water Piping GATE 40 10 50 H SW 800 A105 1 NO WHRS-AQC2HP-FDW-GT-002
20 Feedwater tapping to PH LP Section LP Feed Water Piping GATE 40 35 150 28 126 3.2 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GT-003
21 Feedwater tapping to AQC LP Section LP Feed Water Piping GATE 40 35 150 28 126 1.8 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GT-004
Feedwater Line to AQC - isolation Valve downstream of Attemperator
22 HP Feed Water Piping GATE 80 35 150 28 126 29.2 H BW 300 WCB 1 YES WHRS-AQC2HP-FDW-GT-005 SCH.40
tapping
23 AQC ECO bypass to HP drum of PH line isolation HP Feed Water Piping GATE 50 35 150 28 126 11.8 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GT-007
24 Isolation for Feed Water to PH Boiler (Economiser outlet) HP Feed Water Piping GATE 50 35 200 28 190 11.8 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GT-008
25 Upstream Isolation for HP side Main FCV (0-100%) HP Feed Water Piping GATE 80 35 200 28 190 17.4 M BW 300 WCB 1 YES WHRS-AQC2HP-FDW-MOV-001 SCH.40
26 Upstream Isolation for HP side Bypass FCV (0-100%) HP Feed Water Piping GATE 80 35 200 28 190 17.4 M BW 300 WCB 1 YES WHRS-AQC2HP-FDW-MOV-002 SCH.40
27 Downstream Isolation for HP side Main FCV (0-100%) HP Feed Water Piping GATE 80 35 200 28 190 17.4 H BW 300 WCB 1 YES WHRS-AQC2HP-FDW-GT-009 SCH.40
28 Downstream Isolation for HP side Bypass FCV (0-100%) HP Feed Water Piping GATE 80 35 200 28 190 17.4 H BW 300 WCB 1 YES WHRS-AQC2HP-FDW-GT-010 SCH.40
29 Isolation valve in feed water line at HP steam drum inlet HP Feed Water Piping GATE 80 35 200 28 190 17.4 H BW 300 WCB 1 YES WHRS-AQC2HP-FDW-GT-011 SCH.40
30 Hydrotest Connection to HP Steam Drum of AQC DM Water Piping GATE 25 35 50 H SW 800 A105 1 NO WHRS-AQC2HP-FDW-GT-010
31 Upstream Isolation of Emergency Blow Down Valve Blow Down Piping GATE 40 18 210 H SW 800 A105 1 YES WHRS-AQC2HP-BDS-GT-002
32 Upstream Isolation of Continuous Blow Down Valve Blow Down Piping GATE 25 18 210 H SW 800 A105 1 YES WHRS-AQC2HP-BDS-GT-001
33 Main attemperator line isolation Spray Water Piping GATE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GT-006
34 Upstream isolation for Attemperator TCV Spray Water Piping GATE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GT-013
35 Downstream isolation for Attemperator TCV Spray Water Piping GATE 25 18 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GT-014
36 HP Main Steam Startup vent isolation HP Main Steam piping GATE 100 18 400 H BW 300 WCB 1 YES WHRS-AQC2HP-MAS-GT-001 SCH.40
37 PH HP Steam - HP FSH Bypass Isolation HP Main Steam piping GATE 150 18 310 H BW 300 WCB 1 YES WHRS-AQC2HP-MAS-GT-002 SCH.40
With integral motorized
38 HP Main Steam Stop Valve HP Main Steam piping GATE 300 18 400 14.5 390 29.2 M BW 300 WCB 1 YES bypass valve (Inching WHRS-AQC2HP-MAS-MOV-001 SCH.40
type)
39 Initial filling Line to Feed Water Line of AQC LP Steam drum DM Water Piping GATE 25 8.5 50 H SW 800 A105 1 NO WHRS-AQC2LP-FDW-GT-001
40 Upstream Isolation for LP side Main FCV (0-100%) LP Feed Water Piping GATE 40 35 150 28 126 1.8 M SW 800 A105 1 YES WHRS-AQC2LP-FDW-MOV-001
41 Upstream Isolation for LP side Bypass FCV (0-100%) LP Feed Water Piping GATE 40 35 150 28 126 1.8 M SW 800 A105 1 YES WHRS-AQC2LP-FDW-MOV-002
42 Downstream Isolation for LP side Main FCV (0-100%) LP Feed Water Piping GATE 40 7 150 3.5 126 1.8 H SW 800 A105 1 YES WHRS-AQC2LP-FDW-GT-002
43 Downstream Isolation for LP side Bypass FCV (0-100%) LP Feed Water Piping GATE 40 7 150 3.5 126 1.8 H SW 800 A105 1 YES WHRS-AQC2LP-FDW-GT-003
44 Isolation valve in feed water line at LP steam drum inlet LP Feed Water Piping GATE 40 7 150 3.5 126 1.8 H SW 800 A105 1 YES WHRS-AQC2LP-FDW-GT-004
Page 2 of 13
WO No. : 2M.0040
Mech. Mech.
(kg/cm2 (g)) deg. C
45 Hydrotest Connection to LP Steam Drum of AQC DM Water Piping GATE 25 8.5 50 H SW 800 A105 1 NO WHRS-AQC2LP-FDW-GT-005
46 Upstream Isolation of Emergency Blow Down Valve-LP Drum Blow Down Piping GATE 40 4 150 H SW 800 A105 1 YES WHRS-AQC2LP-BDS-GT-002
47 Upstream Isolation of Continuous Blow Down Valve-LP drum Blow Down Piping GATE 25 4 150 H SW 800 A105 1 YES WHRS-AQC2LP-BDS-GT-001
48 LP Main Steam Startup vent isolation LP Main Steam piping GATE 50 5 210 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GT-001
49 LP Main Steam Stop Valve LP Main Steam piping GATE 150 5 210 2.5 195 1.8 M BW 150 WCB 1 YES bypass valve (Inching WHRS-AQC2LP-MAS-MOV-001 SCH.40
type)
P&ID FOR WATER & STEAM (PH) (PB-33378-1 Rev.A)
50 Initial filling Line to PH HP Feed Water Line DM Water Piping GATE 50 8.5 50 8.5 50 H SW 800 A105 1 NO WHRS-PH2HP-FDW-GT-001
51 Feedwater to PH HP drum- Upstream Isolation for Main FCV (0-100%) PH Boiler Feed water GATE 50 35 200 28 190 11.8 M SW 800 A105 1 YES WHRS-PH2HP-FDW-MOV-001
52 Feedwater to PH HP drum- Upstream Isolation for Bypass FCV (0-100%) PH Boiler Feed water GATE 50 35 200 28 190 11.8 M SW 800 A105 1 YES WHRS-PH2HP-FDW-MOV-002
53 Feedwater to PH HP drum- Downstream Isolation for Main FCV (0-100%) PH Boiler Feed water GATE 50 35 200 28 190 11.8 H SW 800 A105 1 YES WHRS-PH2HP-FDW-GT-002
54 FW to PH HP drum- Downstream Isolation for Bypass FCV (0-100%) PH Boiler Feed water GATE 50 35 200 28 190 11.8 H SW 800 A105 1 YES WHRS-PH2HP-FDW-GT-003
55 Isolation valve on Feedwater Line at inlet of PH HP Drum PH Boiler Feed water GATE 50 35 200 28 190 11.8 H SW 800 A105 1 YES WHRS-PH2HP-FDW-GT-004
56 Hydrotest Connection to PH HP Steam Drum DM Water Piping GATE 25 35 50 H SW 800 A105 1 NO WHRS-PH2HP-FDW-GT-005
57 Upstream Isolation of Emergency Blow Down Valve - PH HP Drum Blow Down Piping GATE 40 18 210 H SW 800 A105 1 YES WHRS-PH2HP-BDS-GT-002
58 Upstream Isolation of Continuous Blow Down Valve - PH HP Drum Blow Down Piping GATE 25 18 210 H SW 800 A105 1 YES WHRS-PH2HP-BDS-GT-001
59 PH HP Main Steam Startup vent isolation PH Main Steam piping GATE 65 18 310 H BW 300 WCB 1 YES WHRS-PH2HP-MAS-GT-001 SCH.40
60 PH HP Main Steam Stop Valve PH Main Steam piping GATE 150 18 310 15.4 300 11.8 M BW 300 WCB 1 YES bypass valve (Inching WHRS-PH2HP-MAS-MOV-001 SCH.40
type)
61 Initial filling Line to PH LP Feed Water Line DM Water Piping GATE 50 8.5 50 H SW 800 A105 1 NO WHRS-PH2LP-FDW-GT-001
62 Feedwater to PH LP drum- Upstream Isolation for Main FCV (0-100%) PH Boiler Feed water GATE 40 35 150 28 126 3.2 M SW 800 A105 1 YES WHRS-PH2LP-FDW-MOV-001
63 Feedwater to PH LP drum- Upstream Isolation for Bypass FCV (0-100%) PH Boiler Feed water GATE 40 35 150 28 126 3.2 M SW 800 A105 1 YES WHRS-PH2LP-FDW-MOV-002
64 Feedwater to PH LP drum- Downstream Isolation for Main FCV (0-100%) PH Boiler Feed water GATE 40 7 150 3.5 126 3.2 H SW 800 A105 1 YES WHRS-PH2LP-FDW-GT-002
65 FW to PH LP drum- Downstream Isolation for Bypass FCV (0-100%) PH Boiler Feed water GATE 40 7 150 3.5 126 3.2 H SW 800 A105 1 YES WHRS-PH2LP-FDW-GT-003
66 Isolation valve on Feedwater Line at inlet of PH LP Drum PH Boiler Feed water GATE 40 7 150 3.5 126 3.2 H SW 800 A105 1 YES WHRS-PH2LP-FDW-GT-004
67 Hydrotest Connection to PH LP Steam Drum DM Water Piping GATE 25 7 150 H SW 800 A105 1 NO WHRS-PH2LP-FDW-GT-005
68 Upstream Isolation of Emergency Blow Down Valve - PH LP Drum Blow Down Piping GATE 40 7 150 H SW 800 A105 1 YES WHRS-PH2LP-BDS-GT-002
69 Upstream Isolation of Continuous Blow Down Valve - PH LP Drum Blow Down Piping GATE 25 7 150 H SW 800 A105 1 YES WHRS-PH2LP-BDS-GT-001
70 PH LP Main Steam Startup vent isolation PH Main Steam piping GATE 80 5 210 H BW 300 WCB 1 YES WHRS-PH2LP-MAS-GT-001 SCH.40
71 PH LP Main Steam Stop Valve PH Main Steam piping GATE 150 5 210 2.5 195 3.1 M BW 300 WCB 1 YES bypass valve (Inching WHRS-PH2LP-MAS-MOV-001 SCH.40
type)
P&ID FOR PLANT STEAM SYSTEM (PB-33379-2 Rev.A)
72 HP Main Steam - isolation for Tapping to Ejector HP Main Steam piping GATE 50 16 400 H SW 800 A105 1 YES WHRS-PSSHP-MAS-GT-002
73 HP Main Steam - isolation for Tapping to Gland Sealing HP Main Steam piping GATE 40 16 400 H SW 800 A105 1 YES WHRS-PSSHP-MAS-GT-001
74 HP Main Steam - isolation for Steam Blowing vent Vent Piping GATE 300 16 400 M BW 300 WCB 1 YES WHRS-PSSHP-MAS-MOV-002 SCH.40
75 Upstream isolation for warmup vent -HP steam line Vent Piping GATE 80 16 400 H BW 300 WCB 1 YES WHRS-PSSHP-MAS-GT-003 SCH.40
76 LP Main Steam - isolation for Tapping to Dearator LP Main Steam piping GATE 100 4.5 210 H BW 150 WCB 1 YES WHRS-PSSLP-MAS-GT-002 SCH.40
77 LP Main Steam - isolation for Steam Blowing vent Vent Piping GATE 200 16 400 M BW 300 WCB 1 YES WHRS-PSSLP-MAS-MOV-002 SCH.40
78 Upstream isolation for warmup vent -LP steam line Vent Piping GATE 80 16 400 H BW 300 WCB 1 YES WHRS-PSSLP-MAS-GT-003 SCH.40
P&ID FOR DM WATER SYSTEM (PB-33383-2 Rev.A)

79 Drain valve for DM water Tank DM Water Tank GATE 80 2 50 H FE 150 WCB 1 NO WHRS-DMS-DM-GT-010
80 DM water Tank outlet isolation valve DM Water Piping GATE 100 2 50 H FE 150 WCB 1 NO WHRS-DMS-DM-GT-001
Page 3 of 13
WO No. : 2M.0040
Mech. Mech.
(kg/cm2 (g)) deg. C
WHRS-DMS-DM-GT-002,
81 DM water Transfer pumps - 1 & 2 - Upstream isolation DM Water Piping GATE 50 2 50 H SW 800 A105 2 NO
WHRS-DMS-DM-GT-003
WHRS-DMS-DM-GT-004,
82 DM water Transfer pumps - 1 & 2 - Downstream isolation DM Water Piping GATE 40 5 50 H SW 800 A105 2 NO
WHRS-DMS-DM-GT-005
WHRS-DMS-DM-GT-006,
83 DM water to Hotwell - upstream & Downstream isolation for LCV DM Water Piping GATE 40 5 50 H SW 800 A105 2 NO
WHRS-DMS-DM-GT-007
84 Initial Fill pump - Upstream isolation Initial Fill Piping GATE 100 2 50 H FE 150 WCB 1 NO WHRS-DMS-DM-GT-008
85 Initial Fill pump - downstream isolation Initial Fill Piping GATE 80 11 50 H FE 150 WCB 1 NO WHRS-DMS-DM-GT-010
Total 88
GLOBE VALVES
P&ID FOR DEAERATOR & BFP (PB-33376-1 Rev.A)
86 Bypass valve for PCV on Deaerator Steam Line Deaerator Steam Piping GLOBE 100 3 190 2.5 195 0.5 H BW 150 WCB 1 YES WHRS-DEA-AUX-GB-013 SCH.40
WHRS-DEA-AUX-GB-001,
87 Upstream Drain for PCV on DeA Steam Line (Main & Bypass) Drain Piping GLOBE 25 3 190 H SW 800 A105 2 YES
WHRS-DEA-AUX-GB-003
88 Downstream Drain for PCV on DeA Steam Line Drain Piping GLOBE 25 3 190 H SW 800 A105 2 YES
WHRS-DEA-AUX-GB-004
89 Isolation for PG & PT on DeA Steam Line dowstream of Desuperheater Deaerator Steam Piping GLOBE 25 3 190 H SW 800 A105 2 YES
WHRS-DEA-AUX-GB-007
90 Isolation for FT on DeA Steam Line dowstream of Desuperheater Deaerator Steam Piping GLOBE 15 3 190 H SW 800 A105 2 YES
WHRS-DEA-AUX-GB-009
Ustream, Downstream & Bypass Isolations for Steam Trap on DeA
91 Deaerator Steam Piping GLOBE 25 3 190 H SW 800 A105 3 YES WHRS-DEA-AUX-GB-011,
Steam Line
WHRS-DEA-AUX-GB-012
92 Upstream Isolation on Initial Fill Line to Dearator Initial Filling Piping GLOBE 50 10 50 M SW 800 A105 1 NO WHRS-DEA-DMS-MOV-001
93 Isolation valves for Pressure gauge on Deaerator Storage Tank Deaerator Storage Tank GLOBE 25 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-001
WHRS-DEA-FDW-GB-002,
94 Isolation valves for Pressure transmitter on Deaerator Storage Tank Deaerator Storage Tank GLOBE 25 4 150 H SW 800 A105 2 YES
WHRS-DEA-FDW-GB-003
95 Drain valve in Condensate line from GSC to AQC-CPH inlet Header Drain Piping GLOBE 25 15 80 H SW 800 A105 1 YES WHRS-DEA-CDS-GB-001
Condensate from GSC to AQC-CPH inlet Header - Isolation for pressure
96 Condensate Piping GLOBE 25 15 80 H SW 800 A105 1 YES WHRS-DEA-CDS-GB-002
gauge
97 Vent Isolation on AQC-CPH inlet Header Condensate Piping GLOBE 25 15 80 H SW 800 A105 1 YES WHRS-DEA-CDS-GB-003
98 Drain Isolation on Outlet Header of AQC-CPH Condensate Piping GLOBE 25 15 150 H SW 800 A105 1 YES WHRS-DEA-CDS-GB-004
99 Isolation for PT in AQC-CPH outlet to Deaerator line Condensate Piping GLOBE 25 15 150 H SW 800 A105 1 YES WHRS-DEA-CDS-GB-005
100 Isolation valve at AQC-CPH outlet Condensate Piping GLOBE 80 15 150 H BW 300 WCB 1 YES WHRS-DEA-CDS-GB-006 SCH.40
101 Deaerator Drain Line - to Flash Tank Deaerator Drain GLOBE 50 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-029
Drain isolation valves-upstream & down stream of Solenoid Valve in DeA WHRS-DEA-FDW-GB-027,
102 Deaerator Overflow GLOBE 25 4 150 H SW 800 A105 2 YES
over flow line WHRS-DEA-FDW-GB-028
103 Deaerator storage tank open drain valve Drain Piping GLOBE 50 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-026
104 Deaerator Line to BFP Suction Header- Isolation for Sample Cooler Feed Water Piping GLOBE 20 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-030
105 BFP-1 - Isolation for DP on Strainer Feed Water Piping GLOBE 25 4 150 H SW 800 A105 2 YES
WHRS-DEA-FDW-GB-032
106 BFP-1 - Drain Valve on suction side Drain Piping GLOBE 25 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-033
107 BFP-1 - Suction Side PG Isolation Drain Piping GLOBE 25 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-034
108 BFP-1 - Discharge Side PG Isolation Drain Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-035
109 BFP-1 - Discharge Side PSLL Isolation Drain Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-036
110 BFP-2 - Isolation for DP on Strainer Feed Water Piping GLOBE 25 4 150 H SW 800 A105 2 YES
WHRS-DEA-FDW-GB-038
111 BFP-2 - Drain Valve on suction side Drain Piping GLOBE 25 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-039
112 BFP-2 - Suction Side PG Isolation Drain Piping GLOBE 25 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-040
113 BFP-2 - Discharge Side PG Isolation Drain Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-041
114 BFP-2 - Discharge Side PSLL Isolation Drain Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-042
115 BFP Common Suction Header Drain Drain Piping GLOBE 25 4 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-043
116 BFP Common Discharge Header Drain Drain Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-044
117 BFP Common Discharge Header- PT isolation Feed Water Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-045
118 BFP-1 - Isolation for PG in Balance Leak-off Line Feed Water Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-046
119 BFP-2 - Isolation for PG in Balance Leak-off Line Feed Water Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-047
120 BFP-1 - Isolation for PG in Min. recirculation Line Feed Water Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-048
121 BFP-2 - Isolation for PG in Min. recirculation Line Feed Water Piping GLOBE 25 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-049
Page 4 of 13
WO No. : 2M.0040
Mech. Mech.
(kg/cm2 (g)) deg. C
122 BFP-1 - Isolation for Balancing Leakoff Line near Deaerator Feed Water Piping GLOBE 40 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-051
123 BFP-2 - Isolation for Balancing Leakoff Line near Deaerator Feed Water Piping GLOBE 40 25 150 H SW 800 A105 1 YES WHRS-DEA-FDW-GB-050
124 Isolation for Level Transmitters on Deaerator Deaerator GLOBE 25 4 150 H SW 800 A105 4 YES
WHRS-DEA-FDW-GB-021
125 BFP Outlet to AQC - Drain upstream of Main Attemperator Line Drain Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-001
126 Vent on Economiser inlet Header Vent Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-002
127 Drain on Economiser outlet Header Drain Piping GLOBE 25 35 200 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-003
128 Isolation for PT downstream of ECO. HP Feed Water Piping GLOBE 25 35 200 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-004
WHRS-AQC2HP-FDW-GB-005,
129 Isolation for FT upstream of FCS for AQC HP section. HP Feed Water Piping GLOBE 15 35 200 H SW 800 A105 4 YES
WHRS-AQC2HP-FDW-GB-008
130 Drain valves for FCS of AQC HP section. Drain Piping GLOBE 25 35 200 H SW 800 A105 4 YES
131 FCS to HP Steam Drum - isolation for PG HP Feed Water Piping GLOBE 25 35 200 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-013
132 Root Valves for level gauge on HP Steam Drum Feed Water Piping GLOBE 25 20 210 H SW 800 A105 4 YES
133 Drain Valves for level gauge on HP Steam Drum Feed Water Piping GLOBE 15 20 210 H SW 800 A105 2 YES
134 Root Valves for level transmitter on HP Steam Drum Feed Water Piping GLOBE 25 20 210 H SW 800 A105 6 YES
135 Root Valves for pressure gauge on HP Steam Drum Feed Water Piping GLOBE 25 20 210 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-003
WHRS-AQC2HP-MAS-GB-001,
136 Root Valves for pressure transmitter on HP Steam Drum Feed Water Piping GLOBE 25 20 210 H SW 800 A105 2 YES
WHRS-AQC2HP-MAS-GB-002
137 N2 Capping Line for HP steam Drum N2 Capping GLOBE 25 20 210 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-004
138 Emergency Blowdown Valve - HP Side Blow Down Piping GLOBE 40 20 210 M* SW 800 A105 1 YES Inching Duty WHRS-AQC2HP-BDS-MOV-002
139 Emergency Blowdown Bypass Valve - HP Side Blow Down Piping GLOBE 40 20 210 H SW 800 A105 1 YES WHRS-AQC2HP-BDS-GB-004
140 Downstream Isolation of Emergency Blow Down Valve - HP Side Blow Down Piping GLOBE 40 20 210 H SW 800 A105 1 YES WHRS-AQC2HP-BDS-GB-005
141 Continuous Blowdown Sample cooler Tapping - HP Side Blow Down Piping GLOBE 20 20 210 H SW 800 A105 1 YES WHRS-AQC2HP-BDS-GB-001
142 Continuous Blowdown Valve - HP Side Blow Down Piping GLOBE 25 20 210 M* SW 800 A105 1 YES Inching Duty WHRS-AQC2HP-BDS-MOV-001
143 Continuous Blowdown Bypass Valve - HP Side Blow Down Piping GLOBE 25 20 210 H SW 800 A105 1 YES WHRS-AQC2HP-BDS-GB-002
144 Downstream Isolation of Continuous Blow Down Valve - HP Side Blow Down Piping GLOBE 25 20 210 H SW 800 A105 1 YES WHRS-AQC2HP-BDS-GB-003
145 Isolation in for PG in spray water line attemperator Spray Water Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-026
146 Drain in spray water line to attemperator Drain Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-027
147 Upstream Drain for Attemperator TCV (Main & Bypass) Spray Water Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-029
148 Attemperator TCV line bypass valve Spray Water Piping GLOBE 40 35 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-034
149 Downstream of Attemperator TCV - PG isolation Spray Water Piping GLOBE 25 20 150 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-030
150 Downstream of Attemperator TCV - FT isolation Spray Water Piping GLOBE 15 20 150 H SW 800 A105 2 YES
151 Motorised valve in spray water line at attemperator inlet Spray Water Piping GLOBE 40 20 150 M SW 800 A105 1 YES WHRS-AQC2HP-FDW-MOV-003
152 Vent on HP Saturated Steam Line HP Steam piping GLOBE 25 18 210 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-005
153 HP Saturated Steam Sample Cooler Tapping HP Steam piping GLOBE 20 18 210 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-006
154 Drain Valve on HP Evap Inlet Header Drain Piping GLOBE 25 20 210 H SW 800 A105 1 YES WHRS-AQC2HP-FDW-GB-033
155 Vent Valve on HP PSH Inlet Header Vent Piping GLOBE 25 18 210 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-007
156 Drain Valve on HP PSH Outlet Header Drain Piping GLOBE 25 16.5 350 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-008
157 Isolation Valves for Pressure gauge downstream of HP PSH outlet header HP Steam piping GLOBE 25 16.5 350 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-009
Isolation Valves for Pressure transmitter downstream of HP PSH outlet
158 HP Steam piping GLOBE 25 16.5 350 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-010
header
Page 5 of 13
WO No. : 2M.0040
Mech. Mech.
(kg/cm2 (g)) deg. C
158A Drain & Vent valves on SH Mixing Header HP Steam piping GLOBE 25 16.5 350 H SW 800 A105 2 YES
159 Vent Valve on HP FSH Inlet Header Vent Piping GLOBE 25 16.5 350 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-011
160 Drain Valve on HP FSH Outlet Header Drain Piping GLOBE 25 16 400 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-012
161 Vent Valve on HP Main Steam Line HP Main Steam Piping GLOBE 25 16 400 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-013
162 Isolation Valves for Pressure gauge on HP Main Steam Line HP Main Steam Piping GLOBE 25 16 400 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-014
163 Isolation Valves for Pressure transmitter on HP Main Steam Line HP Main Steam Piping GLOBE 25 16 400 H SW 800 A105 2 YES
164 Drain Valve on HP Main Steam Line Drain Piping GLOBE 25 16 400 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-017
165 HP Main Steam Sample Cooler Tapping isolation HP Main Steam Piping GLOBE 20 16 400 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-018
Inching Duty
166 HP Main Steam Startup vent isolation HP Main Steam piping GLOBE 100 16 400 M* BW 300 WCB 1 YES (Operating Time <15 WHRS-AQC2HP-MAS-MOV-002 SCH.40
Sec)
167 Isolation Valves for Flow transmitter on HP Main Steam Line HP Main Steam Piping GLOBE 15 16 400 H SW 800 A105 4 YES
168 HP steam from PH2 boiler to AQC PH Outlet - Vent Valve Vent Piping GLOBE 25 18 310 H SW 800 A105 1 YES WHRS-AQC2HP-MAS-GB-023
169 HP steam from PH2 boiler to AQC PH Outlet HP Main Steam Piping GLOBE 150 18 310 H BW 300 WCB 1 YES WHRS-AQC2HP-MAS-GB-024 SCH.40
WHRS-AQC2LP-FDW-GB-001,
170 FW to AQC LP Drum - FT isolation LP Feed Water Piping GLOBE 15 35 150 H SW 800 A105 4 YES
WHRS-AQC2LP-FDW-GB-004
171 FW to AQC LP Drum - PG isolation LP Feed Water Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2LP-FDW-GB-023
172 Drain valves for FCS of AQC LP section. LP Feed Water Piping GLOBE 25 35 150 H SW 800 A105 4 YES
173 FW to AQC LP Drum downstream of FCS - PG isolation LP Feed Water Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-AQC2LP-FDW-GB-022
174 Root Valves for level gauge on LP Steam Drum LP Steam Drum GLOBE 25 6 150 H SW 800 A105 4 YES
175 Drain valves for level gauge on LP Steam Drum LP Steam Drum GLOBE 15 6 150 H SW 800 A105 2 YES
176 Root Valves for level transmitter on LP Steam Drum LP Steam Drum GLOBE 25 6 150 H SW 800 A105 6 YES
WHRS-AQC2LP-FDW-GB-015, WHRS-
AQC2LP-FDW-GB-016,
177 Root Valves for pressure gauge on LP Steam Drum LP Steam Drum GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-003
WHRS-AQC2LP-MAS-GB-001,
178 Root Valves for pressure transmitter on LP Steam Drum LP Steam Drum GLOBE 25 6 150 H SW 800 A105 2 YES
179 N2 Capping Line for LP steam Drum N2 Capping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-004
180 Emergency Blowdown Valve - LP Side Blow Down Piping GLOBE 40 6 150 M* SW 800 A105 1 YES Inching Duty WHRS-AQC2LP-BDS-MOV-002
181 Emergency Blowdown Bypass Valve - LP Side Blow Down Piping GLOBE 40 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-BDS-GB-004
182 Downstream Isolation of Emergency Blow Down Valve - LP Side Blow Down Piping GLOBE 40 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-BDS-GB-005
183 Continuous Blowdown Sample cooler Tapping - LP Side Blow Down Piping GLOBE 20 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-BDS-GB-001
184 Continuous Blowdown Valve - LP Side Blow Down Piping GLOBE 25 6 150 M* SW 800 A105 1 YES Inching Duty WHRS-AQC2LP-BDS-MOV-001
185 Continuous Blowdown Bypass Valve - LP Side Blow Down Piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-BDS-GB-002
186 Downstream Isolation of Continuous Blow Down Valve - LP Side Blow Down Piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-BDS-GB-003
187 Vent on LP Saturated Steam Line LP Steam piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-005
188 LP Saturated Steam Sample Cooler Tapping LP Steam piping GLOBE 20 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-006
189 Drain Valve on LP Evap Inlet Header Drain Piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-021
190 Vent Valve on LP SH Inlet Header Vent Piping GLOBE 25 4.5 150 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-007
191 Drain Valve on LP SH Outlet Header Drain Piping GLOBE 25 4.5 210 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-008
192 Vent Valve on LP Main Steam Line to Turbine Vent Piping GLOBE 25 4.5 210 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-009
Page 6 of 13
WO No. : 2M.0040
Mech. Mech.
(kg/cm2 (g)) deg. C
193 Isolation Valves for Pressure measurement on LP Main Steam Line LP Main Steam Piping GLOBE 25 4.5 210 H SW 800 A105 3 YES WHRS-AQC2LP-MAS-GB-011,
WHRS-AQC2LP-MAS-GB-012
194 Drain Valve on LP Main Steam Line Drain Piping GLOBE 25 4.5 200 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-013
195 LP Main Steam Sample Cooler Tapping isolation LP Main Steam Piping GLOBE 20 4.5 210 H SW 800 A105 1 YES WHRS-AQC2LP-MAS-GB-014
Inching Duty
196 LP Main Steam Startup vent isolation LP Main Steam piping GLOBE 50 4.5 210 M* SW 800 A105 1 YES (Operating Time <15 WHRS-AQC2LP-MAS-MOV-002
Sec)
197 Isolation Valves for Flow transmitter on LP Main Steam Line LP Main Steam Piping GLOBE 15 4.5 210 H SW 800 A105 4 YES
WHRS-AQC2LP-MAS-GB-018
WHRS-AQC2-BDS-GB-001,
198 Root Valves for LG isolation on BD Tank - AQC Blowdown Piping GLOBE 25 1 110 H SW 800 A105 2 YES
WHRS-AQC2-BDS-GB-002
199 BD Tank Outlet valve - AQC Blowdown Piping GLOBE 50 1 110 H SW 800 A105 1 YES WHRS-AQC2-BDS-GB-003
P&ID FOR WATER & STEAM (PH) (PB-31669-2 Rev.B)
200 Isolation for PG on Feedwater line to PH HP FCS Drain Piping GLOBE 25 35 200 H SW 800 A105 1 YES WHRS-PH2HP-FDW-GB-024
201 Drain valve on PH HP Feed Water Line Drain Piping GLOBE 25 35 200 H SW 800 A105 1 YES WHRS-PH2HP-FDW-GB-001
WHRS-PH2HP-FDW-GB-002,
202 Feedwater to PH HP drum - FT isolation PH Boiler Feed water GLOBE 15 35 200 H SW 800 A105 4 YES
WHRS-PH2HP-FDW-GB-005
Upstream & downstream Drain valves for FCS for Feedwater to PH HP WHRS-PH2HP-FDW-GB-007
203 Drain Piping GLOBE 25 35 200 H SW 800 A105 4 YES
drum WHRS-PH2HP-FDW-GB-008,
204 Isolation for PG downstream of PH HP FCS Drain Piping GLOBE 25 35 200 H SW 800 A105 1 YES WHRS-PH2HP-FDW-GB-023
205 Root Valves for level gauge on PH HP Steam Drum PH Steam Drum GLOBE 25 18 210 H SW 800 A105 4 YES
206 Drain Valves for level gauge on PH HP Steam Drum Drain piping GLOBE 15 18 210 H SW 800 A105 2 YES
207 Root Valves & drains for level transmitter on PH HP Steam Drum PH Steam Drum GLOBE 25 18 210 H SW 800 A105 6 YES
208 Root Valves for pressure gauge on PH HP Steam Drum PH Steam Drum GLOBE 25 18 210 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-003
WHRS-PH2HP-MAS-GB-001,
209 Root Valves pressure transmitters on PH HP Steam Drum PH Steam Drum GLOBE 25 18 210 H SW 800 A105 2 YES
WHRS-PH2HP-MAS-GB-002
210 N2 Capping Line for PH HP Steam Drum N2 Capping GLOBE 25 18 210 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-004
211 Emergency Blowdown Valve - PH HP Drum Blow Down Piping GLOBE 40 18 210 M* SW 800 A105 1 YES Inching Duty WHRS-PH2HP-BDS-MOV-002
212 Emergency Blowdown Bypass Valve - PH HP Drum Blow Down Piping GLOBE 40 18 210 H SW 800 A105 1 YES WHRS-PH2HP-BDS-GB-004
213 Downstream Isolation of Emergency Blow Down Valve - PH HP Drum Blow Down Piping GLOBE 40 18 210 H SW 800 A105 1 YES WHRS-PH2HP-BDS-GB-005
214 Isolation for blowdown Sample cooler of PH HP Drum Blow Down Piping GLOBE 20 18 210 H SW 800 A105 1 YES WHRS-PH2HP-BDS-GB-001
215 Continuous Blowdown Valve - PH HP Drum Blow Down Piping GLOBE 25 18 210 M* SW 800 A105 1 YES Inching Duty WHRS-PH2HP-BDS-MOV-001
216 Continuous Blowdown Bypass Valve - PH HP Drum Blow Down Piping GLOBE 25 18 210 H SW 800 A105 1 YES WHRS-PH2HP-BDS-GB-002
217 Downstream Isolation of Continuous Blow Down Valve - PH HP Drum Blow Down Piping GLOBE 25 18 210 H SW 800 A105 1 YES WHRS-PH2HP-BDS-GB-003
218 Vent on PH HP Saturated Steam Line PH Steam piping GLOBE 25 18 210 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-005
219 PH HP Saturated Steam Sample Cooler line PH Steam piping GLOBE 20 18 210 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-006
220 Drain Valve on PH HP Superheater Inlet Header Drain Piping GLOBE 25 18 210 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-007
221 Vent Valve on PH HP Superheater Outlet Header Vent Piping GLOBE 25 16 310 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-008
222 Vent Valve on PH HP Main Steam Line to Turbine Vent Piping GLOBE 25 16 310 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-009
223 Isolation Valves for Pressure gauge on PH HP Main Steam Line PH Main Steam Piping GLOBE 25 16 310 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-010
224 Isolation Valves for Pressure transmitter on PH HP Main Steam Line PH Main Steam Piping GLOBE 25 16 310 H SW 800 A105 2 YES
225 Drain Valve on PH HP Main Steam Line Drain Piping GLOBE 25 16 310 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-013
226 PH HP Main Steam Sample Cooler Tapping isolation PH Main Steam Piping GLOBE 20 16 310 H SW 800 A105 1 YES WHRS-PH2HP-MAS-GB-014
Page 7 of 13
WO No. : 2M.0040
Mech. Mech.
(kg/cm2 (g)) deg. C
Inching Duty
227 PH HP Main Steam Startup vent isolation PH Main Steam Piping GLOBE 65 16 310 M* BW 300 WCB 1 YES (Operating Time <15 WHRS-PH2HP-MAS-MOV-002 SCH.40
Sec)
228 Isolation Valves for Flow transmitter on PH HP Main Steam Line PH Main Steam Piping GLOBE 15 16 310 H SW 800 A105 4 YES
229 Drain Valve on PH HP Evap Inlet Header Drain Piping GLOBE 50 18 200 H SW 800 A105 2 YES
WHRS-PH2HP-FDW-GB-0XX
WHRS-PH2HP-BDS-GB-001,
230 Root Valves for LG isolation on BD Tank -PH HP Blowdown Tank GLOBE 25 2.5 120 H SW 800 A105 2 YES
WHRS-PH2HP-BDS-GB-002
231 BD Tank Outlet valve - PH Blowdown Piping GLOBE 50 2.5 120 H SW 800 A105 1 YES WHRS-PH2HP-BDS-GB-006
232 Isolation for PG on Feedwater line to PH LP FCS Drain Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-PH2LP-FDW-GB-024
233 Drain valve on PH LP Feed Water Line Drain Piping GLOBE 25 35 150 H SW 800 A105 1 YES WHRS-PH2LP-FDW-GB-001
WHRS-PH2LP-FDW-GB-002,
234 Feedwater to PH LP drum - FT isolation PH Boiler Feed water GLOBE 15 35 150 H SW 800 A105 4 YES
WHRS-PH2LP-FDW-GB-005
Upstream & downstream Drain valves for FCS for Feedwater to PH LP WHRS-PH2LP-FDW-GB-007
drum WHRS-PH2LP-FDW-GB-008,
236 Isolation for PG downstream of PH LP FCS Drain Piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-PH2LP-FDW-GB-023
237 Root Valves for level gauge on PH LP Steam Drum PH Steam Drum GLOBE 25 6 150 H SW 800 A105 4 YES
238 Drain Valves for level gauge on PH LP Steam Drum Drain piping GLOBE 15 6 150 H SW 800 A105 2 YES
239 Root Valves for level transmitter on PH LP Steam Drum PH Steam Drum GLOBE 25 6 150 H SW 800 A105 6 YES
240 Root Valves for pressure gauge on PH LP Steam Drum PH Steam Drum GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-003
WHRS-PH2LP-MAS-GB-001,
241 Root Valves pressure transmitters on PH LP Steam Drum PH Steam Drum GLOBE 25 6 150 H SW 800 A105 2 YES
WHRS-PH2LP-MAS-GB-002
242 N2 Capping Line for PH LP Steam Drum N2 Capping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-004
243 Emergency Blowdown Valve - PH LP Drum Blow Down Piping GLOBE 40 6 150 M* SW 800 A105 1 YES Inching Duty WHRS-PH2LP-BDS-MOV-002
244 Emergency Blowdown Bypass Valve - PH LP Drum Blow Down Piping GLOBE 40 6 150 H SW 800 A105 1 YES WHRS-PH2LP-BDS-GB-004
245 Downstream Isolation of Emergency Blow Down Valve - PH LP Drum Blow Down Piping GLOBE 40 6 150 H SW 800 A105 1 YES WHRS-PH2LP-BDS-GB-005
246 Isolation for blowdown Sample cooler of PH LP Drum Blow Down Piping GLOBE 20 6 150 H SW 800 A105 1 YES WHRS-PH2LP-BDS-GB-001
247 Continuous Blowdown Valve - PH LP Drum Blow Down Piping GLOBE 25 6 150 M* SW 800 A105 1 YES Inching Duty WHRS-PH2LP-BDS-MOV-001
248 Continuous Blowdown Bypass Valve - PH LP Drum Blow Down Piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-PH2LP-BDS-GB-002
249 Downstream Isolation of Continuous Blow Down Valve - PH LP Drum Blow Down Piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-PH2LP-BDS-GB-003
250 Vent on PH LP Saturated Steam Line PH Steam piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-005
251 PH LP Saturated Steam Sample Cooler line PH Steam piping GLOBE 20 6 150 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-006
252 Drain Valve on PH LP Superheater Inlet Header Drain Piping GLOBE 25 6 150 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-007
253 Vent Valve on PH LP Superheater Outlet Header Vent Piping GLOBE 25 4.5 210 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-008
254 Vent Valve on PH LP Main Steam Line to Turbine Vent Piping GLOBE 25 4.5 210 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-009
255 Isolation Valves for Pressure gauge on PH LP Main Steam Line PH Main Steam Piping GLOBE 25 4.5 210 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-010
256 Isolation Valves for Pressure transmitter on PH LP Main Steam Line PH Main Steam Piping GLOBE 25 4.5 210 H SW 800 A105 2 YES
257 Drain Valve on PH LP Main Steam Line Drain Piping GLOBE 25 4.5 210 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-013
258 PH LP Main Steam Sample Cooler Tapping isolation PH Main Steam Piping GLOBE 20 4.5 210 H SW 800 A105 1 YES WHRS-PH2LP-MAS-GB-014
Inching Duty
259 PH LP Main Steam Startup vent isolation PH Main Steam Piping GLOBE 80 4.5 210 M* BW 300 WCB 1 YES (Operating Time <15 WHRS-PH2LP-MAS-MOV-002 SCH.40
Sec)
Page 8 of 13
WO No. : 2M.0040
Mech. Mech.
(kg/cm2 (g)) deg. C
260 Isolation Valves for Flow transmitter on PH LP Main Steam Line PH Main Steam Piping GLOBE 15 4.5 210 H SW 800 A105 4 YES
261 Drain Valve on PH LP Evap Inlet Header Drain Piping GLOBE 50 6 150 H SW 800 A105 2 YES
WHRS-PH2LP-FDW-GB-0XX
P&ID FOR PLANT STEAM SYSTEM (PB-31670-2 Rev.B)
262 Vent Valve on HP Main Steam Line to Turbine Vent Piping GLOBE 25 16 400 H SW 800 A105 1 YES WHRS-PSSHP-MAS-GB-001
WHRS-PSSHP-MAS-GB-002,
263 Drain Valve on HP Main Steam Line to Turbine Drain Piping GLOBE 25 16 400 H SW 800 A105 2 YES
WHRS-PSSHP-MAS-GB-003
Upstream and downstream Isolation valves for steam trap in HP main WHRS-PSSHP-MAS-GB-004,
steam line drain near Turbine (Drain-8) WHRS-PSSHP-MAS-GB-005
265 Bypass Isolation valve for steam trap in HP main steam line near T Drain Piping GLOBE 25 16 400 H SW 800 A105 1 YES WHRS-PSSHP-MAS-GB-006
266 Warmup vent valve -HP steam line Vent Piping GLOBE 80 16 400 M* BW 300 WCB 1 YES Inching Duty WHRS-PSSHP-MAS-MOV-001 SCH.40
267 Drain for Warmup vent in HP Steam line at Turbine inlet Drain Piping GLOBE 25 16 400 H SW 800 A105 1 YES WHRS-PSSHP-MAS-GB-007
268 Vent Valve on LP Main Steam Line to Turbine Vent Piping GLOBE 25 4.5 210 H SW 800 A105 1 YES WHRS-PSSLP-MAS-GB-001
WHRS-PSSLP-MAS-GB-002,
269 Drain Valve on LP Main Steam Line to Turbine Drain Piping GLOBE 25 4.5 210 H SW 800 A105 2 YES
WHRS-PSSLP-MAS-GB-005
270 Warmup vent in LP Steam line at Turbine inlet Vent Piping GLOBE 80 4.5 210 M* BW 150 WCB 1 YES Inching Duty WHRS-PSSLP-MAS-MOV-001 SCH.40
271 Drain for Warmup vent in LP Steam line at Turbine inlet Drain Piping GLOBE 25 4.5 210 H SW 800 A105 1 YES WHRS-PSSLP-MAS-GB-006
P&ID FOR RAW WATER SYSTEM (PB-31673-3 Rev.B)
WHRS-RWS-RW-GB-001,
272 Isolation for Flow Transmitter on WTP Inlet C.T. Makeup Piping GLOBE 15 8 50 H SW 800 A105 2 NO
WHRS-RWS-RW-GB-002
WHRS-RWS-RW-GB-003,
273 Isolation for Flow Transmitter on WTP Outlet C.T. Makeup Piping GLOBE 15 8 50 H SW 800 A105 2 NO
WHRS-RWS-RW-GB-004
P&ID FOR DM WATER SYSTEM (PB-31674-2 Rev.B)
WHRS-DMS-DM-GB-001,
274 DM water Transfer pumps - 1 & 2 - Isolation for PG on discharge side DM Water Piping GLOBE 25 5 50 H SW 800 A105 2 NO
WHRS-DMS-DM-GB-002
275 DM water Discharge Line - Isolation for PSL DM Water Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-003
276 DM water Discharge Line - Isolation for PT DM Water Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-004
277 DM water Minimum recirculation line - Upstream of RO DM Water Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-005
278 DM water Minimum recirculation line - Isolation valve near Tank DM Water Piping GLOBE 25 3 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-0XX
279 DM water isolation for HP Dosing of AQC & PH Boiler DM Water Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-006
WHRS-DMS-DM-GB-007,
280 DM water to Hotwell - LCV upsteam & Downstream drain valves DM Water Piping GLOBE 25 5 50 H SW 800 A105 2 NO
WHRS-DMS-DM-GB-008
281 DM water to Hotwell - LCV bypass Valve DM Water Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-014
282 DM water isolation for LP Dosing DM Water Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-009
283 Initial Fill Pump - Isolation for PG on discharge side Initial Filling Piping GLOBE 25 11 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-010
284 Initial Fill Pump - Isolation for PSL on discharge side Initial Filling Piping GLOBE 25 11 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-011
285 Initial Fill Line - isolation for AQC WHRB Initial Filling Piping GLOBE 50 11 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-012
286 Initial Fill Line - isolation for PH WHRB Initial Filling Piping GLOBE 50 11 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-013
287 Initial Fill Line - isolation for Deaerator Initial Filling Piping GLOBE 50 11 50 H SW 800 A105 1 NO WHRS-DMS-DM-GB-015
P&ID FOR COOLING WATER SYSTEM (PB-31675-1 Rev.B)
WHRS-RWS-RW-GB-005,
288 Isolation valves FT on Raw water line to CT Forebay Raw Water Piping GLOBE 15 8 50 H SW 800 A105 2 NO
WHRS-RWS-RW-GB-006
WHRS-RWS-RW-GB-001,
289 Upstream & Downstream Drains for CT Make-up LCV Raw Water Piping GLOBE 25 8 50 H SW 800 A105 2 NO
WHRS-RWS-RW-GB-002
290 Bypass valve for CT Make-up LCV Raw Water Piping GLOBE 125 8 50 H FE 150 WCB 1 NO WHRS-RWS-RW-GB-003
WHRS-CWS-MCW-GB-001,
291 MCW Pump A & B - Upstream drains Drain Piping GLOBE 25 2 50 H SW 800 A105 2 NO
WHRS-CWS-MCW-GB-007
292 MCW Pump A & B - Isolation Valves for DP Across Suction Strainer MCW Piping GLOBE 25 2 50 H SW 800 A105 4 NO
WHRS-CWS-MCW-GB-009
293 MCW Pump A & B - Isolation Valves for Suction side PG MCW Piping GLOBE 25 2 50 H SW 800 A105 2 NO
WHRS-CWS-MCW-GB-010
294 MCW Pump A & B - Isolation Valves for Discharge side PSL MCW Piping GLOBE 25 5 50 H SW 800 A105 2 NO
WHRS-CWS-MCW-GB-011
295 MCW Pump A & B - Discharge side vent valves Vent Piping GLOBE 25 5 50 H SW 800 A105 2 NO
WHRS-CWS-MCW-GB-012
Page 9 of 13
WO No. : 2M.0040
Mech. Mech.
(kg/cm2 (g)) deg. C
296 MCW Pump A & B - Isolation for PG on Discharge Header MCW Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-CWS-MCW-GB-014
297 MCW Pump A & B - Isolation for PSL on Discharge Header MCW Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-CWS-MCW-GB-013
WHRS-CWS-ACW-GB-001,
298 ACW Pump A & B - Upstream drains Drain Piping GLOBE 25 2 50 H SW 800 A105 2 NO
WHRS-CWS-ACW-GB-007
299 ACW Pump A & B - Isolation Valves for DP Across Suction Strainer ACW Piping GLOBE 25 2 50 H SW 800 A105 4 NO
WHRS-CWS-ACW-GB-009
300 ACW Pump A & B - Isolation Valves for Suction side PG ACW Piping GLOBE 25 2 50 H SW 800 A105 2 NO
WHRS-CWS-ACW-GB-010
301 ACW Pump A & B - Isolation Valves for Discharge side PSL ACW Piping GLOBE 25 7 50 H SW 800 A105 2 NO
WHRS-CWS-ACW-GB-011
302 ACW Pump A & B - Discharge side vent valves Vent Piping GLOBE 25 7 50 H SW 800 A105 2 NO
WHRS-CWS-ACW-GB-012
303 ACW Pump A & B - Isolation for PG on Discharge Header ACW Piping GLOBE 25 7 50 H SW 800 A105 1 NO WHRS-CWS-ACW-GB-014
304 ACW Pump A & B - Isolation for PSL on Discharge Header ACW Piping GLOBE 25 7 50 H SW 800 A105 1 NO WHRS-CWS-ACW-GB-013
305 ACW Pump A & B - Drain Valve on Discharge Header Drain Piping GLOBE 25 7 50 H SW 800 A105 1 NO WHRS-CWS-ACW-GB-015
306 MCW Line to CW Supply Header - PT isolation MCW Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-CWS-MCW-GB-015
307 MCW Supply Header - PG isolation MCW Supply Header GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-CWS-MCW-GB-022
308 Isolation valves for DPT between MCW Supply & Return Lines MCW Piping GLOBE 25 5 50 H SW 800 A105 4 NO
WHRS-CWS-MCW-GB-021
309 MCW Return Header - PG isolation MCW Return Header GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-CWS-MCW-GB-023
310 MCW Line to MCW Return Line - FT isolation MCW Piping GLOBE 15 5 50 H SW 800 A105 2 NO
WHRS-CWS-MCW-GB-017
311 MCW Return Line Drain Drain Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-CWS-MCW-GB-024
312 MCW Return Line Vent Vent Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-CWS-MCW-GB-025
313 MCW Return Line - PT Isolation MCW Return Piping GLOBE 25 5 50 H SW 800 A105 1 NO WHRS-CWS-MCW-GB-026
314 ACW Supply Line - Isolation for FT ACW Piping GLOBE 15 7 50 H SW 800 A105 2 NO
WHRS-CWS-ACW-GB-017
315 ACW Supply Line - Upstream Isolation for BFP 1 & 2 ACW Piping GLOBE 50 7 50 H SW 800 A105 3 NO WHRS-CWS-ACW-GB-020,
WHRS-CWS-ACW-GB-021
316 ACW Supply Line - Upstream Isolation for BFPs - PG isolation ACW Piping GLOBE 25 7 50 H SW 800 A105 1 NO WHRS-CWS-ACW-GB-019
317 ACW Return Line - Downstream Isolation for BFP 1 & 2 ACW Piping GLOBE 50 7 50 H SW 800 A105 3 NO WHRS-CWS-ACW-GB-023,
WHRS-CWS-ACW-GB-024
318 PG isolation for supply & return lines of Sample coolers ACW Piping GLOBE 25 7 50 H SW 800 A105 2 NO
WHRS-CWS-ACW-GB-027
319 Isolation for AQC & PH BD tank quenching line ACW Piping GLOBE 25 7 50 H SW 800 A105 1 NO WHRS-CWS-ACW-GB-029
Total 368
NON-RETURN VALVES
P&ID FOR DEAERATOR & BFP (PB-31667-1 Rev.B)
320 Upstream of Deaerator on DeA Steam Line DeA Steam Piping NRV 100 3 190 2.5 195 0.5 - BW 150 WCB 1 YES WHRS-DEA-AUX-NR-001 SCH.40
321 NRV in Intial Warm Up Line for Deaerator Storage Tank DeA Steam Piping NRV 80 3 190 - BW 150 WCB 1 YES WHRS-DEA-AUX-NR-002 SCH.40
322 NRV on Initial Fill Line to Dearator DM Water Piping NRV 50 10 50 - SW 800 A105 1 NO WHRS-DEA-DMS-NR-001
323 AQC-CPH outlet to Deaerator inlet Condensate Piping NRV 80 15 150 10 120 35 - BW 300 WCB 1 YES WHRS-DEA-CDS-NR-001 SCH.40
324 BFP-1 - Discharge side NRV Feed Water Piping NRV 80 35 150 28 126 35 - BW 300 WCB 1 YES WHRS-DEA-FDW-NR-002 SCH.40
325 BFP-1 - NRV on Minimum Recirculation Line near Deaerator Feed Water Piping NRV 40 25 150 - SW 800 A105 1 YES WHRS-DEA-FDW-NR-007
326 BFP-2 - Discharge side NRV Feed Water Piping NRV 80 35 150 28 126 35 - BW 300 WCB 1 YES WHRS-DEA-FDW-NR-003 SCH.40
327 BFP-2 - NRV on Minimum Recirculation Line near Deaerator Feed Water Piping NRV 40 25 150 - SW 800 A105 1 YES WHRS-DEA-FDW-NR-006
328 BFP-1 - NRV on Balancing Leakoff Line near Deaerator Feed Water Piping NRV 40 25 150 - SW 800 A105 1 YES WHRS-DEA-FDW-NR-004
329 BFP-2 - NRV on Balancing Leakoff Line near Deaerator Feed Water Piping NRV 40 25 150 - SW 800 A105 1 YES WHRS-DEA-FDW-NR-005
330 BFP Outlet to AQC - NRV upstream of Main Attemperator Line HP Feed Water Piping NRV 80 35 150 28 126 29.2 - BW 300 WCB 1 YES WHRS-AQC2HP-FDW-NR-001 SCH.40
331 Initial filling Line to HP Feed Water Line DM Water Piping NRV 40 8.5 50 - SW 800 A105 1 NO WHRS-AQC2HP-FDW-NR-002
Page 10 of 13
WO No. : 2M.0040
Mech. Mech.
(kg/cm2 (g)) deg. C
332 FCS to HP Steam Drum - NRV on feedwater Line HP Feed Water Piping NRV 80 35 200 28 190 29.2 - BW 800 WCB 1 YES WHRS-AQC2HP-FDW-NR-003 SCH.40
333 Hydrotest Connection to HP Steam Drum of AQC DM Water Piping NRV 25 35 200 - SW 800 A105 1 NO WHRS-AQC2HP-FDW-NR-004
334 NRV in spray water line (at tapping) Spray Water Piping NRV 40 35 150 - SW 800 A105 1 YES WHRS-AQC2HP-FDW-NR-005
335 NRV in spray water line (downstreamof TCV) Spray Water Piping NRV 40 18 150 - SW 800 A105 1 YES WHRS-AQC2HP-FDW-NR-006
335 A NRV downstream of HP PSH outlet to Mixing header AQC Steam piping NRV 200 18 350 15.4 340 17.4 - BW 300 WCB 1 YES WHRS-AQC2HP-MAS-NR-003 SCH.40
336 HP Main Steam NRV Downstream of Main Steam Stop Valve HP Main Steam piping NRV 300 16 400 14.5 390 29.2 - BW 300 WCB 1 YES WHRS-AQC2HP-MAS-NR-001 SCH.40
337 FW to AQC LP Drum - Feed Water NRV LP Feed Water Piping NRV 40 35 150 28 126 1.8 - SW 800 A105 1 YES WHRS-AQC2LP-FDW-NR-004
338 Initial filling Line to LP Feed Water Line DM Water Piping NRV 25 8.5 50 - SW 800 A105 1 NO WHRS-AQC2LP-FDW-NR-001
339 FCS to LP Steam Drum - NRV on feedwater Line LP Feed Water Piping NRV 40 7 150 3.5 126 1.8 - SW 800 A105 1 YES WHRS-AQC2LP-FDW-NR-002
340 Hydrotest Connection to LP Steam Drum of AQC DM Water Piping NRV 25 9 150 - SW 800 A105 1 NO WHRS-AQC2LP-FDW-NR-003
341 LP Main Steam NRV Downstream of Main Steam Stop Valve LP Main Steam piping NRV 150 4.5 210 2.5 195 1.8 - BW 150 WCB 1 YES WHRS-AQC2LP-MAS-NR-001 SCH.40
342 HP Main Steam from PH to steam Mixing Header in AQC boiler PH Main Steam piping NRV 150 18 300 15.4 300 11.8 - BW 300 WCB 1 YES WHRS-AQC2HP-MAS-NR-002 SCH.40
P&ID FOR WATER & STEAM (PH) (PB-31669-2 Rev.B)

343 Initial filling Line to PH HP Feed Water Line DM Water Piping NRV 50 8.5 50 - SW 800 A105 1 NO WHRS-PH2HP-FDW-NR-001
344 FCS to PH HP Steam Drum- NRV on feedwater Line PH Boiler Feed water NRV 50 35 200 28 190 11.8 - SW 800 A105 1 YES WHRS-PH2HP-FDW-NR-002
345 Hydrotest Connection to PH HP Steam Drum DM Water Piping NRV 25 35 200 - SW 800 A105 1 NO WHRS-PH2HP-FDW-NR-003
346 PH LP Main Steam NRV Downstream of Main Steam Stop Valve PH Main Steam piping NRV 150 16 300 14.5 300 11.8 - BW 300 WCB 1 YES WHRS-PH2HP-MAS-NR-001 SCH.40
347 Initial filling Line to PH LP Feed Water Line DM Water Piping NRV 50 8.5 50 - SW 800 A105 1 NO WHRS-PH2LP-FDW-NR-001
348 FCS to PH LP Steam Drum- NRV on feedwater Line PH Boiler Feed water NRV 40 7 150 3.5 126 3.2 - SW 800 A105 1 YES WHRS-PH2LP-FDW-NR-002
349 Hydrotest Connection to PH LP Steam Drum DM Water Piping NRV 25 9 150 - SW 800 A105 1 NO WHRS-PH2LP-FDW-NR-003
350 PH LP Main Steam NRV Downstream of Main Steam Stop Valve PH Main Steam piping NRV 150 4.5 210 2.5 195 3.2 - BW 300 WCB 1 YES WHRS-PH2LP-MAS-NR-001 SCH.40
P&ID FOR DM WATER SYSTEM (PB-31674-2 Rev.B)

WHRS-DMS-DM-NR-001,
351 DM water Transfer pumps - 1 & 2 - Downstream NRVs DM Water Piping NRV 40 5 50 - SW 800 A105 2 NO
WHRS-DMS-DM-NR-002
352 Initial Fill Pump Downstream NRV Initial Filling Piping NRV 80 11 50 - FE 150 WCB 1 NO WHRS-DMS-DM-NR-003
P&ID FOR COOLING WATER SYSTEM (PB-31675-1 Rev.B)
C.I. IS.-
WHRS-CWS-MCW-NR-001,
353 MCW Pump A & B - Discharge side NRVs MCW Piping NRV OD 616 5 50 - FE 150 210 FG 0 NO Wafer Type
WHRS-CWS-MCW-NR-002
260
C.I. IS.-
WHRS-CWS-ACW-NR-001,
354 ACW Pump A & B - Discharge side NRVs ACW Piping NRV 200 7 50 - FE 150 210 FG 0 NO Wafer Type
WHRS-CWS-ACW-NR-002
260
P&ID FOR INSTRUMENT AIR SYSTEM (PB-31676-3 Rev.B)
WHRS-CMP-IST-NR-001,
355 Instrument Air Line - NRVs downstream of Fine Filter Instrument Air Piping NRV 40 9 50 - SW 800 A105 2 NO
WHRS-CMP-IST-NR-002
Total 37
Grand Total 493
Notes
1 All motorised valves are with integral actuator
2 IBR certificate is required for all IBR valves as mentioned in above list
Prepared
DRJ
By:
Checked BOILER VALVE SCHEDULE
RNN
By:
Page 11 of 13
Project : 1 x 6MW/7MW WHRS Project Doc. No.
Client : PARASAKTI CEMENT INDUSTRIES LTD., AP COMMISSIONING SPARES LIST Date: 18-05-2016
WO No. : 2M0037 P&ID Ref:
Design Design
Type of Body Qty. per Special Requirement /
Sr.No. Item/Location Fluid Piping NB mm Pressure Temp H / M End Conn. Class** IBR Tag Numbers
Valve MOC Boiler Remark
(ATA) deg. C
GATE VALVES
1 Commissioning spares GATE 25 H SW 800 A105 2 Yes Commissioning spares
4 Commissioning spares GATE 80 H BW 300 WCB 2 Yes Commissioning spares
5 Commissioning spares GATE 150 H FE 150 WCB 0 Yes Commissioning spares
Total 9
GLOBE VALVES
1 Commissioning spares GLOBE 15 H SW 800 A105 1 No Commissioning spares
2 Commissioning spares GLOBE 15 H SW 800 A105 5 Yes Commissioning spares
Total 45
NON-RETURN VALVES
1 Commissioning spares NRV 25 - SW 800 A105 1 Yes Commissioning spares
2 Commissioning spares NRV 25 - SW 800 A105 1 No Commissioning spares
3 Commissioning spares NRV 40 - SW 800 A105 1 Yes Commissioning spares
4 Commissioning spares NRV 40 - SW 800 A105 1 No Commissioning spares
Total 4
BALL VALVES
1 Commissioning spares BALL 25 H SW 800 A105 0 No Commissioning spares
2 Commissioning spares BALL 40 H SW 800 A105 0 No Commissioning spares
Total 0
Grand Total 58
Notes
1
Prepared By: DRJ

COMMISSIONING SPARES LIST
Checked By: RNN Approved By:
ELECTRICAL LOAD LIST
Client: Parasakti Cements Ltd, Telangana ELECTRICAL LOAD LIST - R3 Doc. No:
Project: 1x7MW WHRS Project Date: April 18,2017
Client : Parasakti Cement Industries Ltd, AP

ELECTRICAL LOAD LIST Doc No: 2003-E-0147-0, Rev-02
Project : 1 X 6.875 Mw WHRS Project
thyssenkrupp Industries India Pvt.Ltd Date : 10-01-2018
Intermitte Total Total Total Remark

No. of
Rating in Connected Load Standby Type of
RPM nt Load in Continuous Standby Intermittent Scope P-Priliminary Remark
Sl. kW Load in kW Factor Load in kW Working Starter
Load Description Total Working Standby kW Load in kW Load in kW F- Finalized
No. Load in kW
9 = (5 - 7 - 8)
1 2 3 4 5=1*4 6 7=3*4 8 10 11 12
*6
I. Boiler
IA. Boiler MCC- AQC -2
1 RAV 4 4 0 0.750 3.00 0.90 0.00 0.00 2.70 0.00 0.00 DOL TKII Vendor F WHRS-AQC2-FLG-RAV-001, 002, 003 AND 004
2 HP Dosing Pump for HP AQC 2 1 1 0.370 1440 0.74 0.90 0.37 0.00 0.33 0.33 0.00 DOL TKII Vendor F
3 HP Dosing Pump for LP AQC 2 1 1 0.370 1440 0.74 0.90 0.37 0.00 0.33 0.33 0.00 DOL TKII Vendor F
4 Stirrers 1 0 1 0.370 1440 0.37 0.90 0.37 0.00 0.00 0.00 0.33 DOL TKII Vendor F
5 Drag Chain Conveyor 1A, 2, 3, 4 4 4 0 1.100 4.40 0.90 0.00 0.00 3.96 0.00 0.99 DOL Client F
Based on Confirmation from Client
6 Drag Chain Conveyor -1 1 1 0 1.500 1.50 0.90 0.00 0.00 1.35 0.00 1.35 DOL Client F
Actuators for Valves-HP

Tag : WHRS-AQC2HP-MAS-MOV-001
7 Main steam Stop Valve 1 1 0 3.3 3.30 0.90 0.00 3.30 0.00 0.00 2.97 RDOL(NI) TKII Vendor F
Act. No. K300F14A
Tag : WHRS-AQC2HP-MAS-MOV-001A
7A Integral Bypass for Main steam Stop Valve 1 1 0 0.08 0.08 0.90 0.00 0.08 0.00 0.00 0.07 RDOL(I) TKII Vendor F
Act. No. KM30F10A
Tag : WHRS-AQC2HP-MAS-MOV-002
8 Steam start up vent valve 1 1 0 1.8 1.80 0.90 0.00 1.80 0.00 0.00 1.62 RDOL(I) TKII Vendor F
Act. No. KM150F10A
Tag : WHRS-AQC2HP-FDW-MOV-001 / 002
9 FCV upstream isolation valves 2 1 1 0.18 0.36 0.90 0.18 0.16 0.00 0.16 0.16 RDOL(NI) TKII Vendor F
Act. No. K30F10A
Tag : WHRS-AQC2HP-BDS-MOV-002
10 EBD regulation 1 1 0 0.08 0.08 0.90 0.00 0.08 0.00 0.00 0.07 RDOL(I) TKII Vendor F
Act. No. KM30F10A
Tag : WHRS-AQC2HP-BDS-MOV-001
11 CBD regulation 1 1 0 0.08 0.08 0.90 0.00 0.08 0.00 0.00 0.07 RDOL(I) TKII Vendor F
Act. No. KM30F10A
Tag : WHRS-AQC2HP-FDW-MOV-001
12 Attemperator Spray Nozzle 1 1 0 0.18 0.18 0.90 0.00 0.18 0.00 0.00 0.16 RDOL(NI) TKII Vendor F
Act. No. K30F10A
Actuators for Valves-LP
Tag : WHRS-AQC2LP-MAS-MOV-001
Act. No. K30F10A
Tag : WHRS-AQC2LP-MAS-MOV-001A
Act. No. KM30F10A
Tag : WHRS-AQC2LP-MAS-MOV-002
Act. No. KM30F10A
Tag : WHRS-AQC2LP-FDW-MOV-001 / 002
Act. No. K30F10A
Tag : WHRS-AQC2LP-BDS-MOV-002
Act. No. KM30F10A
Tag : WHRS-AQC2LP-BDS-MOV-001
Act. No. KM30F10A
Actuators for Dampers

18 Isolation Damper at boiler inlet (End tap) (Butterfly 1 1 0 1.100 1.10 0.90 0.00 1.10 0.00 0.00 0.99 RDOL(NI) Client F
19 Isolation Damper at boiler outlet (Butterfly damper) 1 1 0 0.550 0.55 0.90 0.00 0.55 0.00 0.00 0.50 RDOL(NI) Client F Based on confirmation from Client
20 Fresh air damper at Cooler inlet (Multi louvre type) 1 1 0 0.120 0.12 0.90 0.00 0.12 0.00 0.00 0.11 RDOL(I) Client F
By pass Regulating Dampers (Modulating with inching)
21 1 1 0 1.100 1.10 0.90 0.00 1.10 0.00 0.00 0.99 RDOL(I) Client F Emergency power required
for AQC Boiler (Multi louvre type)
22 Isolation Damper at deduster inlet 0 0 0 0.000 0.00 0.90 0.00 0.00 0.00 0.00 0.00 RDOL(NI) Client F
23 HAG Inlet Damper (Butterfly damper) 1 1 0 1.100 1.10 0.90 0.00 1.10 0.00 0.00 0.99 RDOL(NI) Client F Based on confirmation from Client
24 HAG Bypass Damper (Multi louvre type) 1 1 0 1.100 1.10 0.90 0.00 1.10 0.00 0.00 0.99 RDOL(I) Client F
25 HAG Outlet Damper (Hoisting Damper) 1 1 0 1.100 1.10 0.90 0.00 1.10 0.00 0.00 0.99 RDOL(NI) tkII Vendor P
26 Coffee Pot Damper 1 1 0 0.550 0.55 0.90 0.00 0.00 0.50 0.00 0.00 RDOL(NI) tkII Vendor P
IB. Boiler MCC- PH 2

1 RAV 2 2 0 1.500 3.00 0.90 0.00 0.00 2.70 0.00 0.00 DOL TKII Vendor F
2 HP Dosing Pump 2 1 1 0.370 1440 0.74 0.90 0.37 0.00 0.33 0.33 0.00 DOL TKII Vendor F
3 Stirrers 1 0 1 0.370 1440 0.37 0.90 0.37 0.00 0.00 0.00 0.33 DOL TKII Vendor F
4 Screw Conveyor 1 1 0 3.700 3.70 0.90 0.00 0.00 3.33 0.00 3.33 DOL Client F
Actuators for Valves- HP

Tag : WHRS-PH2HP-MAS-MOV-001
Act. No. K60F10A
Tag : WHRS-PH2HP-MAS-MOV-001A
Act. No. KM30F10A
Tag : WHRS-PH2HP-MAS-MOV-002
Act. No. KM60F10A
Tag : WHRS-PH2HP-FDW-MOV-001 / 002
Act. No. K30F10A
Tag : WHRS-PH2HP-BDS-MOV-002
Act. No. KM30F10A
Tag : WHRS-PH2HP-BDS-MOV-001
Act. No. KM30F10A
Actuators for Valves-LP
Sheet 1 of 4

No. of
No. Load in kW
9 = (5 - 7 - 8)
1 2 3 4 5=1*4 6 7=3*4 8 10 11 12
*6
Tag : WHRS-PH2LP-MAS-MOV-001
Act. No. K60F10A
Tag : WHRS-PH2LP-MAS-MOV-001A
Act. No. KM30F10A
Tag : WHRS-PH2LP-MAS-MOV-002
Act. No. KM60F10A
Tag : WHRS-PH2LP-FDW-MOV-001
Act. No. K30F10A
Tag : WHRS-PH2LP-BDS-MOV-002
Act. No. KM30F10A
Tag : WHRS-PH2LP-BDS-MOV-001
Act. No. KM30F10A
Actuators for Dampers

9 IsolationTandem Dampers at inlet for PH Boiler 1 1 0 1.1 1.10 0.90 0.00 1.10 0.00 0.00 0.99 RDOL(NI) Client F
10 Isolation Tandem Dampers at outlet for PH Boiler 1 1 0 1.1 1.10 0.90 0.00 1.10 0.00 0.00 0.99 RDOL(NI) Client F Based on Client Confirmation
Seal Air fan for Tandem damper at inlet and outlet of
11 2 0 2 3.7 7.40 0.90 7.40 7.40 0.00 6.66 6.66 RDOL(NI) Client F
PH Boiler
By pass Regulating Dampers (Modulating with inching)
12 1 1 0 1.10 1.10 0.90 0.00 1.10 0.00 0.00 0.99 RDOL(I) Client F Emergency power required
for PH Boiler (Multi louvre type)
13 Motors for Hammering Unit 14 14 0 1.5 21.00 0.90 0.00 0.00 18.90 0.00 0.00 DOL TKII F
II STG MCC
IIA Plant Steam Valves
1 MS line to TG inlet drain - HP 0 0 0 0 0.00 0.90 0.00 0.00 0.00 0.00 0.00 RDOL(NI) TKII Vendor P
2 MS line to TG inlet drain - LP 0 0 0 0 0.00 0.90 0.00 0.00 0.00 0.00 0.00 RDOL(NI) TKII Vendor P
Tag : WHRS-PSSHP-MAS-MOV-001
3 warm up vent - HP 1 1 0 0.25 0.25 0.90 0.00 0.25 0.00 0.00 0.23 RDOL(I) TKII Vendor F
Act. No. KM60F10A
Tag : WHRS-PSSLP-MAS-MOV-001
4 warm up vent - LP 1 1 0 0.08 0.08 0.90 0.00 0.08 0.00 0.00 0.07 RDOL(I) TKII Vendor F
Act. No. KM30F10A
Tag : WHRS-PSSHP-MAS-MOV-002
5 Sacrificing valve for HP MS line 1 1 0 3.3 3.30 0.90 0.00 3.30 0.00 0.00 2.97 RDOL(NI) TKII Vendor F
Act. No. K300F14A
Tag : WHRS-PSSLP-MAS-MOV-002
6 Sacrificing valve for LP MS line 1 1 0 1.7 1.70 0.90 0.00 1.70 0.00 0.00 1.53 RDOL(NI) TKII Vendor F
Act. No. K300F14A
Tag : WHRS-DEA-FDW-MOV-001 / 002
7 HP BFP outlet isolation 2 1 1 0.18 0.36 0.90 0.18 0.16 0.00 0.16 0.16 RDOL(NI) TKII Vendor F
Act. No. K30F10A
Tag : WHRS-DEA-AUX-MOV-001
8 Initial warm up line / pegging steam line 1 1 0 0.18 0.18 0.90 0.00 0.18 0.00 0.00 0.16 RDOL(NI) TKII Vendor F
Act. No. K30F10A
Tag : WHRS-DEA-DMS-MOV-001
9 Isolation valve for Initial filling line to Dea Tank inlet 1 1 0 0.09 0.09 0.90 0.00 0.09 0.00 0.00 0.08 RDOL(NI) TKII Vendor F
Act. No. K30F10A
10 Boiler feed pumps -HP 2 1 0 55 2980 110.00 0.90 0.00 0.00 99.00 0.00 0.00 Supply TKII F VFD
11 LP Dosing Pump 2 1 1 0.370 0.74 0.90 0.37 0.00 0.33 0.33 0.00 DOL TKII Vendor F
12 Stirrers 1 1 0 0.370 0.37 0.90 0.00 0.00 0.33 0.00 0.00 DOL TKII Vendor F
IIB STG Auxiliaries

1 Condensate Extraction pump 2 1 1 37.0 74.00 0.80 37.00 0.00 29.60 29.60 0.00 DOL Client F WHRS-STG-TGD-MT-001 / 002
2 Main Oil pump 0 0 0 0.0 0 0.00 0.80 0.00 0.00 0.00 0.00 0.00 DOL Client P Shaft Driven
3 Auxiliary Oil pump 1 1 0 11.0 11.00 0.80 0.00 11.00 0.00 0.00 8.80 DOL Client F WHRS-STG-LOC-MT-001
4 Oil Vapour Extraction Pump Oil Mist Seperator 2 1 1 0.7 2800 1.40 0.80 0.70 0.70 0.00 0.56 0.56 DOL Client F WHRS-STG-LOC-MT-002 / 003
Soft Starter Panel
5 Barring Gear Motor 1 1 0 15 15.00 0.80 0.00 15.00 0.00 0.00 12.00 DOL Client F
WHRS-STG-LOC-MT-004
6 GVC Blower Motor 2 1 1 2.2 2876 4.40 0.88 2.20 2.20 0.00 1.94 1.94 DOL Client F WHRS-STG-AUX-MT-001 / 002
7 Control oil Pump 2 1 1 7.5 1467 15.00 0.80 7.50 0.00 6.00 6.00 0.00 DOL Client F WHRS-STG-COC-MT-001 / 002
8 Lube oil purifier / Centrifuge 1 1 0 0.75 0.75 0.70 0.00 0.00 0.53 0.00 0.00 Client F
Supply
9 Lube Oil Purifier heater 2 2 0 12.0 24.00 1.00 0.00 0.00 24.00 0.00 0.00 Client P
10 Lube oil tank heaters 4 4 0 3.0 12.00 1.00 0.00 0.00 12.00 0.00 0.00 DOL Client P
11 Generator space heaters (230 V, 1 phase) 2 2 0 1.0 2.00 1.00 0.00 0.00 2.00 0.00 0.00 Supply Client F 16A DP MCB with power contactor from TG MCC panel
12 Exiter space heaters (230 V, 1 phase) 1 1 0 0.2 0.20 1.00 0.00 0.00 0.20 0.00 0.00 Supply Client F with generator Breaker On interlock for auto start/stop.
13 Spare 1 Supply Client
14 Spare feeder for AOP 1 1 0 11 11.00 0.80 0.00 0.00 0.00 0.00 0.00 DOL Client P
15 Spare feeder for OVE 1 1 0 1.3 1.30 0.80 0.00 0.00 0.00 0.00 0.00 DOL Client P
16 Spare for Barring gear motor 1 1 0 15 15.00 0.80 0.00 0.00 0.00 0.00 0.00 DOL Client P
16A Main steam line to STG isloation 1 1 0 4 4.00 0.80 0.00 0.00 0.00 0.00 0.00 RDOL Client F WHRS-STG-MAS-MOV-001
16B Main steam line to STG isloation - Bypass 1 1 0 0.06 0.06 0.80 0.00 0.00 0.00 0.00 0.00 RDOL Client F WHRS-STG-MAS-MOV-001A
16C Injection line to STG isloation 1 1 0 1 1.10 0.80 0.00 0.00 0.00 0.00 0.00 RDOL Client F WHRS-STG-MAS-MOV-002
16D Injection line to STG isloation - Bypass 1 1 0 0.06 0.06 0.80 0.00 0.00 0.00 0.00 0.00 RDOL Client F WHRS-STG-MAS-MOV-002A
230V (AC SUPPLY) Panel Auxilliary Supply

IIC
requirements
1 Generator relay & metering panel 1 1 0 1.500 1.50 0.00 0.00 0.00 0.00 0.00 SUPPLY Client F
2 Generator Synchronizing panel 1 1 0 1.500 1.50 0.00 0.00 0.00 0.00 0.00 SUPPLY Client F
3 Generator LASCPT Panel 1 1 0 1.500 1.50 0.00 0.00 0.00 0.00 0.00 SUPPLY Client F
4 Generator NGR Panel 1 1 0 1.500 1.50 0.00 0.00 0.00 0.00 0.00 SUPPLY Client F
5 Generator AVR Panel 1 1 0 1.500 1.50 0.00 0.00 0.00 0.00 0.00 SUPPLY Client F
6 Turbine Supervisory panel 1 1 0 1.500 1.50 0.00 0.00 0.00 0.00 0.00 SUPPLY Client F
Sheet 2 of 4

No. of
No. Load in kW
9 = (5 - 7 - 8)
1 2 3 4 5=1*4 6 7=3*4 8 10 11 12
*6
7 Generator water leakage detector 1 1 0 1.500 1.50 0.00 0.00 0.00 0.00 0.00 SUPPLY Client F
8 Barring Gear Starter panel 1 1 0 1.500 1.50 0.00 0.00 0.00 0.00 0.00 SUPPLY Client P
9 DC starter panel 1 1 0 1.500 1.50 0.00 1.50 0.00 0.00 0.00 SUPPLY Client F
10 Spare feeder 1 1 1 0 1.500 1.50 0.00 1.50 0.00 0.00 0.00 SUPPLY P
13 Turbine Gauge Panel 1 1 0 1.500 1.50 0.00 1.50 0.00 0.00 0.00 SUPPLY F
IID 110V DC SUPPLY

1 Emergency Oil Pump (DC) 1 1 0 2.200 1500 2.20 0.80 0.00 2.20 0.00 0.00 1.76 DC Starter Client F Emergency power required
2 Panel auxilliary supply requirements
3 Generator relay & metering panel 1.000
4 Generator Synchronizing panel 1.000
5 Generator AVR Panel 1.000
6 Turbine Supervisory panel 1.000
16 Amp DP MCB
6A NGR Panel 1.000
7 Spare feeder 1 1.000
IIE 230V (AC UPS POWER SUPPLY)

1 Continuous wattage 1 1 0 1.237 1.24 0.80 0.00 0.00 0.99 0.00 0.00 SUPPLY Client P
2 wattage for 60 min 1 1 0 1.243 1.24 1.80 0.00 1.00 0.44 0.00 1.80 SUPPLY Client P
3 wattage for 1 min 1 1 0 1.267 1.27 2.80 0.00 1.00 0.75 0.00 2.80 SUPPLY Client P
4 Panel auxilliary supply requirements
5 Generator relay & metering panel 0.500
6 Generator Synchronizing panel 0.500
7 Turbine Supervisory panel 0.750
16 Amp DP MCB
0.750
IIF EMERGENCY POWER (415 V)
1 DC System 1 1 0 10.0 10.00 0.90 0.00 10.00 0.00 0.00 9.00 Supply TKII Vendor P
2 UPS system 1 1 0 10.0 10.00 0.90 0.00 10.00 0.00 0.00 9.00 Supply TKII Vendor P E&I to confirm
3 Emergency lighting 1 1 0 5.0 5.00 0.90 0.00 5.00 0.00 0.00 4.50 Supply TKII Vendor P
III AC & Ventilation MCC

1 Packaged AC Unit fot Control Room & MCC Room 4 3 1 25.500 102.00 0.95 25.50 0.00 72.68 24.23 0.00 Supply TKII Vendor P
2 Split A/C unit - WTP 3 3 0 4.500 13.50 0.88 0.00 0.00 11.88 0.00 0.00 Supply TKII Vendor P
3 Air Washer - supply air fans 2 2 0 11.000 22.00 0.85 0.00 0.00 18.79 0.00 0.00 S/D TKII Vendor P
4 Air Washer pumps 2 1 1 0.750 1.50 0.44 0.75 0.00 0.33 0.33 0.00 DOL TKII Vendor P
5 AVF Motor 4 4 0 0.180 1.00 0.88 0.00 0.00 0.88 0.00 0.00 DOL TKII Vendor P
6 Exhaust fans - Cable Cellar 3 3 0 1.100 3.30 0.49 0.00 0.00 1.60 0.00 0.00 DOL TKII Vendor P
7 Exhaust fans - Compressor Room 1 1 0 0.370 0.37 0.25 0.00 0.00 0.09 0.00 0.00 DOL TKII Vendor P
8 Exhaust fans - BFP area 1 1 0 0.370 0.37 0.25 0.00 0.00 0.09 0.00 0.00 DOL TKII Vendor P
9 Exhaust fans - Battery Room 1 1 0 0.050 0.05 1.00 0.00 0.00 0.05 0.00 0.00 DOL TKII Vendor P Single Phase
10 Exhaust fans - WTP Room 2 2 0 0.750 1.50 0.34 0.00 0.00 0.51 0.00 0.00 DOL TKII Vendor P
IV EOT
1 EOT Crane 1 1 0 15.000 15 0.90 0.00 15 0 0.00 32.00 SUPPLY TKII Vendor P
V Cooling Tower & DM water

1 CT Fans 3 2 1 37.000 111.0 0.84 37.00 0.00 62.16 31.08 0.00 SUPPLY TKII F VFD suitable drive
2 ACW Pumps 2 1 1 45.000 90.0 0.90 45.00 0.00 40.50 40.50 0.00 DOL TKII F
3 MCW Pumps 2 1 1 250.000 500.0 0.90 250.00 0.00 225.00 225.00 0.00 SUPPLY TKII F VFD
4 DM Water transfer pumps 2 1 1 1.100 2.2 0.90 1.10 0.00 0.99 0.99 0.00 DOL TKII F
5 CT make up pumps 2 1 1 18.500 37.0 0.90 18.50 0.00 16.65 16.65 0.00 DOL TKII F
Tag : WHRS-CWS-MCW-BF-003 / 004
6 MCW oump discharge butterfly valves 2 1 1 0.550 1.1 0.90 0.55 0.55 0.00 0.50 0.50 RDOL(I) TKII Vendor F
Act. No. SA6E90 + GS100.2
Tag : WHRS-CWS-ACW-BF-003 / 004
7 ACW oump discharge butterfly valves 2 1 1 0.060 0.1 0.90 0.06 0.06 0.00 0.05 0.05 RDOL(I) TKII Vendor F
Act. No. SA3E22 + GS63.2
8 Boiler Initial filling pumps 1 1 0 15.000 15 0.90 0.00 0 13.5 0.00 0.00 DOL TKII F
VI Compressor
1 Instrument air compressor+Dryer 2 1 1 25.000 50 1.08 0.00 25.000 27.1 0.00 27.10 SUPPLY TKII Vendor F Service factor 1.08
VII Water Treatment Plant

1 Raw Water Pumps 2 1 1 3.7 7.4 0.85 3.70 0 3.145 3.15 0.00 DOL TKII Vendor F
2 MB Blower 2 1 1 1.5 3 0.85 1.50 0 1.275 1.28 0.00 DOL TKII Vendor F
3 UF Backwash Pump 2 1 1 2.2 4.4 0.85 2.20 0 1.87 1.87 0.00 DOL TKII Vendor F
4 RO Feed Pump 2 1 1 1.1 2.2 0.85 1.10 0 0.935 0.94 0.00 DOL TKII Vendor F
5 RO HPP 2 1 1 3.7 7.4 0.85 3.70 0 3.145 3.15 0.00 DOL TKII Vendor F
6 Blower for Degasser 2 1 1 0.37 0.74 0.85 0.37 0 0.3145 0.31 0.00 DOL TKII Vendor F
Sheet 3 of 4

No. of
No. Load in kW
9 = (5 - 7 - 8)
1 2 3 4 5=1*4 6 7=3*4 8 10 11 12
*6
7 DG Water transfer Pump (DM Feed Pump) 2 1 1 1.1 2.2 0.85 1.10 0 0.935 0.94 0.00 DOL TKII Vendor F
8 SSF Feed Pump 1 1 0 11 11 0.85 0.00 0 9.35 0.00 0.00 DOL TKII Vendor F
9 Blower for SSF 1 1 0 10 10 0.85 0.00 0 8.5 0.00 0.00 DOL TKII Vendor F
10 RO CIP Pimp 1 1 0 2.2 2.2 0.85 0.00 1.5 0.595 0.00 1.28 SUPPLY TKII Vendor F
11 ALUM DOSING TANK Aggitator 1 1 0 0.37 0.37 1.00 0.00 0 0.37 0.00 0.00 SUPPLY TKII Vendor F Single Phase
12 ALAKLI DOSING TANK Aggitator 1 1 0 0.37 0.37 1.00 0.00 0 0.37 0.00 0.00 SUPPLY TKII Vendor F Single Phase
13 ALAKLI DOSING TANK Aggitator (2) 1 1 0 0.37 0.37 1.00 0.00 0 0.37 0.00 0.00 SUPPLY TKII Vendor F Single Phase
14 NaOCl Dosing Pumps 2 1 1 0.1 0.2 1.00 0.10 0 0.1 0.10 0.00 SUPPLY TKII Vendor F Single Phase
15 Alum Dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase
16 Actuator for UF Valves (6) 5 5 0 0 0 1.00 0.00 0 0 0.00 0.00 SUPPLY TKII Vendor P 24 V Supply from PLC
17 UF dosing pumps (1) 2 1 1 0.1 0.2 1.00 0.10 0 0.1 0.10 0.00 SUPPLY TKII Vendor F Single Phase
18 UF dosing pumps (2) 2 1 1 0.1 0.2 1.00 0.10 0 0.1 0.10 0.00 SUPPLY TKII Vendor F Single Phase
19 Acid dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase
20 SMBS Dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase
21 Antiscalent dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase
22 RO Dump Valve actuator 1 1 0 0 0 1.00 0.00 0 0 0.00 0.00 SUPPLY TKII Vendor P
24 V Supply from PLC
23 RO flushing valve actuator 1 1 0 0 0 1.00 0.00 0 0 0.00 0.00 SUPPLY TKII Vendor P
24 PH dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor P Single Phase
25 H2S04 Dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase
26 Corrosion inhibitor Dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase
27 Disperent dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase
28 Scale inhibitor dosing pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase
29 NaoCL Dosing Pumps 2 1 1 0.04 0.08 1.00 0.04 0 0.04 0.04 0.00 SUPPLY TKII Vendor F Single Phase
VIII Fire Fightening System (Raw Water Tank Area)

1 Electrical Motor driven Main Hydrant Pump 1 1 0 90 90 0.72 0.00 90.00 0.00 0.00 64.80 SUPPLY TKII Vendor P
2 Electrical Motor driven Jockey Pump 1 1 0 7.5 7.50 0.68 0.00 7.50 0.00 0.00 5.10 SUPPLY TKII Vendor P
IX Hot Gas Generator MCC- for AQC Boiler

1 Combustion Air Fan 2 1 1 30.000 60.00 0.80 30.00 0.00 24.00 24.00 0.00 VFD TKII Vendor F VFD by tkII
2 Coal Conveying Air Fan 2 1 1 18.500 37.00 0.80 18.50 0.00 14.80 14.80 0.00 DOL TKII Vendor F
3 Emergency Cooling Air Fan 1 1 0 1.500 1.50 0.80 0.00 0.00 1.20 0.00 1.20 DOL TKII Vendor F Emergency power req
4 Coal Conveying system 1 1 0 5.500 5.50 0.80 0.00 0.00 4.40 0.00 4.40 VFD TKII Vendor F VFD by tkII
5 Solenoid Valves 8 8 0 0.018 0.14 0.80 0.00 0.14 0.00 0.00 0.01 DOL TKII Vendor F
6 RAV 1 1 0 0.750 0.75 0.80 0.00 0.00 0.60 0.00 0.60 RDOL TKII Vendor F
7 LDO oil pumps 2 1 1 0.750 1.50 0.80 0.75 0.00 0.60 0.60 0.60 DOL TKII Vendor F
8 Local Control Panel 1.000 SUPPLY F
9 For 1 No. HEI 0.500 SUPPLY P
10 For 1 No flame Scanner 20 VA SUPPLY P
11 For 1 No. Flow meter 10VA SUPPLY P
Actuators for Dampers in HAG

12 Isolation damper at burner inlet in coal conveying line 0 0 0 0 0.00 0.80 0.00 0.00 0.00 0.00 0.00 RDOL(NI) TKII Vendor P
13 Isolation damper at Comb Air fan outlet 0 0 0 0 0.00 0.80 0.00 0.00 0.00 0.00 0.00 RDOL(NI) TKII Vendor P
14 Isolation damper at Dilution Air fan inlet & outlet 2 2 0 0 0.00 0.80 0.00 0.00 0.00 0.00 0.00 RDOL(I) TKII Vendor P Emergency power required
15 Isolation damper at Emergency cooling fan outlet 0 0 0 0 0.00 0.80 0.00 0.00 0.00 0.00 0.00 RDOL(NI) TKII Vendor P
Isolation damper at Hot Air Generator outlet - hoisting
16 0 0 0 0 0.00 0.80 0.00 0.00 0.00 0.00 0.00 RDOL(NI) TKII Vendor P
damper
Isolation damper at Hot Air Generator outlet -coffee pot
17 0 0 0 0 0.00 0.80 0.00 0.00 0.00 0.00 0.00 RDOL(NI) TKII Vendor P CONSIDERED IN ACTUATORS FOR DAMPERS
damper
18 Electromagnet for coffee pot damper 1 1 0 0.2 0.20 0.80 0.00 0.20 0.00 0.00 0.16 RDOL(NI) TKII Vendor F
780.87
Notes on Starter Scheme:
1. Inching / Non-Inching starter requirement for motorised valves will be confirmed during drawing review stage.
F : Motor Ratings are final
Note : Reference for Electrical Load List of WTP, HAG & STG enclosed along with this load list
P : Motor Ratings are Preliminary
DOL - DIRECT ON LINE STARTER

DOL(**) - DIRECT ON LINE STARTER FOR SINGLE PHASE 220V SUPPLY
SUPPLY - SUPPLY FEEDER
RDOL - REVERSIBLE DIRECT ON LINE STARTER
RDOL(I) - REVERSIBLE DIRECT ON LINE STARTER (Inching Duty)
RDOL(NI) - REVERSIBLE DIRECT ON LINE STARTER (Non-Inching Duty)
O/G - SIMPLE FUSE / OUTGOING FEEDER
2. Above mentioned load list is tentative.
3. All motorised actuators are with integral starters
4. The above Electrical load list is Preliminary & is updated/revised based on vendor inputs.
Sheet 4 of 4
BURNER DATA SHEET
BURNER DATA SHEET DOCUMENT NO. FCS-BDS-01
Company Name FIVES COMBUSTION SYSTEM PVT LTD
Project Name Project Engineer HARDIK SONI (HS)
ThyssenKrupp Industries
Purchaser FCS Project No. 2017.3610
India Pvt. Ltd.,
End User A/c PARASHAKTI CEMENT Rev No. 0
P10117217/JB1001 Dated
Purchase Order No. Date 24.08.2017
25.01.2017
0 24.08.17 Initial Issue NM HS DP

Rev. No. Date Description Prepared By Checked By Approved BY
1/4
CLIENT DOC NO. FCS-BDS-01
India Pvt. Ltd.,
PROJECT REV NO. 0
FCS JOB 2017.3610 DATE 24.08.2017
A HOT GAS GENERATOR

Sr. No. Description Unit Value
A1 Qty. of HGG No(s). One
A2 Application To generate hot gases to generate steam WHRU Boiler
A3 HGG orientation Vertical
A4 Type of Burner - GRC Burner :Coal Fired with LDO/HSD for startup
A5 Fuel Fired
A5.1 Main Pulverized Coal
A5.2 For Startup LDO/HSD
A6 Register Draft Loss mmWC <250
A7 Turn Down For Pulversised Coal - 1:3
A8 Turn Down Ratio Oil 1:3
A9 Heat Release Rate per HGG Mkcal/hr 8.4 (With Coal)
A10 HGG Outlet Temperature deg.C 440 - 450
Kindly note dilution air ports pressure drop is calculated based

A11 Hot Air Pressure at HGG Outlet mm WC on 20 mmwc.The HAG outlet pressure shall be maintained to
have negative draft in your system.
A12 HGG Outlet Hot Gas Flow at 440-450 Deg Cel Kg/hr 198000
A13 Coal Flow Rate Kg/hr 1500

A14 Gross calorifice Value of Coal Kcal/kg 5600
A15 Coal particle size Micron <100
A16 Firing capacity with LDO fuel Mkcal/hr 2.52
A17 Gross Calorific Value of LDO/HSD Kcal/kg 10000
A18 Combustion Air Flow Rate Kg/hr 15500
A19 Combustion Air Temp Deg C 40
Dilution air req. flow per burner from Cooler Vent to

A20 Kg/hr 181100
HGG
A21 Dilution Air Temp from Cooler Deg C 305
Dilution Air Pressure @ inlet of HGG dilution air

A22 mmWC (-20)
nozzle from cooler from Cooler Vent to HGG
A23 Coal Conveying Air required per burner Kg/hr 970

A24 Emergency Cooling Air Flow Rate Kg/hr 4700
A25 Emergency Cooling at Pressure mmWC 50
B For LDO/HSD
B1 Temperature of fuel at burner inlet Deg C 40
B2 Viscosity of @ 40 Deg cel cSt 2.5-15.7
B3 Specific gravity @ 15 Deg Cel 0.88
B4 density Kg/m3 880
B5 Pressure at Burner Inlet Kg/cm2(g) ~10
B6 Oil Flow Rate at Burner Kg/hr 252
B7 Oil Pressure at Piperack Inlet Kg/cm2(g) ~12
B8 Oil Flow Rate at Pump Outlet Kg/hr 302
B9 Oil Pressure at Pump Outlet Kg/cm2(g) 15
2/4
India Pvt. Ltd.,
PROJECT REV NO. 0
FCS JOB 2017.3610 DATE 24.08.2017
C Atomising Air @ Pipe Rack Inlet
C1 Pressure Kg/cm2(g) 4
C2 Temp. Deg.C 40
C3 Flow Rate Kg/hr 50
D Instrument Air @ Pipe Rack Inlet
D1 Pressure Kg/cm2(g) 6-7
D2 Temp. Deg.C 40
D3 Flow Rate Kg/hr 65
E Pilot Type
E1 Type of Ignition System - High Energy Igniter (HEI)
F Power Supply
F1 Instrument / Panel Power VAC 220
F2 Solenoid Voltage VAC 220
F3 Motor Supply VAC 415
F4 Non UPS Utilty Suuply VAC 230
F5 Variation In Volatge +/- 10%
F6 Variation In Frequency +/- 5 %
G Coal Composition
Pulverized Coal % RAW COAL
G1 Ultimate Analysis Wt%
G1.1 Carbon % 57.75
G1.2 Hydrogen % 3.96
G1.3 Nitrogen % 1.12
G1.4 Sulphur % 0.08
G1.5 Oxygen % 12.09
G1.6 Moisture % 1.5
G1.7 Ash % 23.5
G2 Proximate Analysis %
G2.1 Fixed Carbon % 40-50
G2.2 Volatile Matter % 25-35
G2.3 Coal Ash % 15-25
G2.4 Coal Moisture % 7-12- Raw Coal 1.5-5 - Fine coal
3/4
India Pvt. Ltd.,
PROJECT REV NO. 0
FCS JOB 2017.3610 DATE 24.08.2017
H SITE DATA
H1 Ambient temperature
H1.1 Maximum dry bulb temperature °C 50
H1.2 Minimum dry bulb temperature °C 20
H1.3 Mean dry bulb temperature °C 32
H1.4 Wet bulb temperature °C 28

H2 Plan design temperature °C 35
H3 Electrical equipment design temperature °C 50
H4 Wind Speed m/s 44
H5 Relative Humidity (Performance) % 70
H6 Area Classification Safe and Non Hazardous
H7 Area classification of LDO tank area (tank instruments Hazardous, IIA / IIB, T3
H8 Maximum noise level dBA <85 @ 1.0 mtrs distance
H9 Seismic Zone Zone - II
H10 Site elevation 106 mtrs above MSL
H11 Average Rainfall mm 850
H12 Plant Location Jetti palem, Rentachintala, Guntur Dt., Andhra Pradesh, India
I PERFORMANCE GUARANTEE ARAMETER

I1 Performance Parameter Value
I1.1 Hot gas generator heat release capacity < 8.4 Mkcal/hr – with Coal
I1.2 Hot gas generator outlet temperature 440-450 °C + 1%
I1.3 Fuel flow rate each hot gas generator 1500 kg/hr
I1.4 Turndown 1:3
I2 Note
I2.1 1. Measurement / instrument error of 1% shall be allowed.
HGG outlet temperature guaranteed above is average temperature during performance test duration if equipment is operated at
I2.2 design capacity and combustion air and cooler air is regulated as required to achieve this temperature. The temperature shall be
measured further away from HGG, preferably at the inlet of mill, so that temperature measured is more stable.
For capacity measurement, fuel flow rate will be measured. The fuel calorific value (LHV) considered by us for this capacity rating
I2.3 is 5600 kcal/kg during performance testing of HGG, you/your client shall provide us with calorific value details/ ultimate analysis of
fuel for our reference.
4/4
COOLING TOWER
PLANT AUXILIARIES
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#
DEAERATOR
ARC VALVE
Series TDM
Installation- and
maintenance instructions
Content
1. Dangers and safety precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1 Danger to persons and materials . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Avoid dangers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Packing and marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Assembly and disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.1 Installation at the jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2. Disassembly of the TDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Assembly of the TDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Disassembly of the bypass section . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.5 Assembly of the bypass sections. . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. Commissioning of the TDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6. Maintenance instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7. Warranty conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8. Instructions in case of damages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9. Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10. Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10.1 Sectional drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10.2 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
10.3 Datasheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2
1. Dangers and safety precautions
Minimum flow valves have the same potential danger as pressure vessels. Therefore
planning, installation, operation and maintenace shall be done according the necessary
safety precautions.
1.1 Danger to persons and materials

The minimum flow valves should only be operated within their limits of design and
layout
No changes are to be made without our approval. Only use original spare parts
Safety regulations, site regulations and installation safety precautions are to be

followed
Please follow the instructions as given in this installation-, maintenance and assembly
instructions
1.2 Avoid dangers

Maintenance of the Automatic Recirculation Valve shall only be done by trained
personnel
Before disassembly, the installation has to be shut off and the valve pressureless and
cooled down
Please make sure that these safety precautions can only be cancelled after ending the
assembly of the valve
Please be aware that also in a pressureless valve there might still be medium
Wear protective clothing
3
2. Description
The SCHROEDAHL Automatic Recirculation Valve model TDM is applied in centrifugal
pump systems in order to provide an automatic leak-off flow in case of low load condi-
tions.
The application range of the series TDM with a multistage pressure let-down section is,
independent of the temperature, for the operating pressures from 64 bar (a) to 250 bar
(a) (900 psig to 3600 psig). The valve consists of an upper and a lower housing, each
provided with a flange. The bypass housing, and as an option also the start-up housing,
are located horizontally at the side of the valve. The valve trim comprises a check valve
as also a control- and throttle section.
The valve protects centrifugal pumps, especially boiler feed pumps, against overheating,
by maintaining, automatically, a minimum flow. At flows, lower than the required mini-
mum flow the check valve activates, by means of a lever, a vortex plug. When lifted of its
seat, the vortex plug allows a flow throuh the pressure reduction section to the suction
tank (or condensate tank). The opening characteristic is linear; the bypass flow increases
when the check valve moves from its switch point further into its closing position. Becau-
se of the modulation bypass control, the total of process flow and minimum flow remains
approximately constant.
The check valve, shaped like a differential control piston and spring loaded, has such
a high own frequency, that waterhammering is avoided. The check valve dampens
pulsations because of its throttling effecton the mainflow and stabilises unstable pump
characteristics in the partial load range.
The housing is made from forged steel and is provided with a chromium steel liner in the
check valve area. All moving parts and guides consist of alloy steel which are compatible.
Alternative materials are available as options (see drawing and parts lists).
4
3. Packing and marking
The Automatic Recirculation Valve is shipped, depending on size, in an aluminium box
(reusable), skid-carton or in a wooden crate.
The standard factory conservation is sufficient to protect the valve for a period of approx.
6 month (the stocking area should be dry and ventilated).
If special packing or conservation is required, this should be stated with the order. The
valve nameplate is attached to every valve housing. Specific valve data are indicated on
the valve nameplate as per sample below.
Fax:02265/9927927
If spare parts are required, the following valve data should be provided with the inquiry
(order):
production number K ........ (stamped in valve body), valve model number and part
number (check parts list).
5
4. Assembly and disassembly
The Automatic Recirculation Valve type TDM is usually installed vertically, with the
mainflow upward, and directly on the pump discharge flange. The bypass housing is
connected to the bypass piping (and the piping consequently to the feedwater tank or
other tank), so that a recirculation flow will be possible. Other installation positions of
the valve (horizontal, upside-down) are possible, if so ordered only! No special tools are
required for the installation, assembly or disassembly of the valve.
4.1 Installation at the jobsite

In order to prevent damage to the flange finish and / or the bolts the complete valve
should be installed in the piping free of tension / stress. Before tightening the bolts
with a torque wrench (torques as recommended by the factory!), please ensure that the
machined flange surfaces and packing rings are clean.
4.2. Disassembly of the TDM

Remove the TDM from the piping system
Disassemble the bypass housing (pos. 09). Pull the bypass trim „M“ out of the
assembly (careful!)
Apply a screwdriver between the collar of the control head (pos. 11) and the valve
body (pos.01)
Remove the upper body (pos.02) from the lower body (pos.01) by loosening the
hexagon nuts (pos. 28)
The check valve (pos.07) and spring (pos.06) can now be removedfrom the lower
body (pos.01)
Clean all parts and check for any damages
In case of damaged seats (check valve seat or bypass seat), this should be repaired
by lapping the respective parts on the seats. Replace ring (pos.30) if required
6
4.3 Assembly of the TDM
Replace the check valve (pos.07) with the spring (pos.06) in the lower body (pos.01)
Now the upper body (pos.02) is placed on the lower body (pos.01) and the hexagon nuts
(pos. 28) are tightened (check cross sectional drawing!)
Carefully insert the bypass section „M“ in the valve body and ensure that the lever (pos. 13)
fits (slides) in the slot in the check valve (pos.07)
The bypass housing (pos.09) with the bypass orifice (pos. 23, 31, 36-38) is now carefully
replaced and tightened to the housing (pos.01) with the hexagon nuts (pos. 29)
4.4 Disassembly of the bypass section

Occasionally, and because of contamination of the fluid, a complete disassembly of the bypass
trim may be required. At each inspection the bypass should be checked for proper operation.
In case of damages, the bypass section should be removed, disassembled and the damaged
parts replaced.
Inspection:
Check the seating of the vortex plug (pos. 12) and the vortex bushing (pos.10) for any
damages
When damaged the vortex plug and vortex bushing should be replaced as an unit
Check glyd-rings pos. 33.1, 34.1 and 35.1 for any damages
Note:
In case of doubt the complete bypass assembly (pos. 10-16, 21, 23, 31-36) may be
replaced and the disassembled bypass may be send to the factory for repair
Replace the complete seal set
7
4.5 Assembly of the bypass sections
Proceed in the reverse order as per disassembly instruction above.
5. Commissioning of the TDM

The valve is commissioned together with the pump. When the mainshut-off valve in the
pump discharge piping (to the boiler or process) the specified bypass flow is maintained
through the bypass section (and to the piping of the bypass system). By closing or ope-
ning the main shut-off valve, the opening and closing of the bypass can be checked.
The switch point of the valve can be established acoustically (use a technical stetho-
scope or even a screwdriver to the ear will do). In case a manual start-up connection is
provided on the valve, the minimum flow is achieved through this section.The automatic
bypass is closed during commissioning and the manualstart-up is opened. The automatic
bypass section is spared (protected) during commissioning in this way, as the fluid might
still be contaminated and/ or carry solids!
6. Maintenance instructions
The TDM has been designed in a special way so that no special maintenance is required.
Maintenance is restricted to cleaning the trim together with the pumpat regular intervals.
After disassembly of the valve, all seals should be replaced(by new seals) before re-
assembly of the valve.
7. Warranty conditions
If no special conditions have been agreed upon the order, the warranty is limited to 24
months after shipment or 8000 hours of operation. The warranty does not include dama-
ges caused by improper handling,dirt in the system or normal wear.
8
8. Instructions in case of damages
In order to judge the damages (and the cause), the following information is required:
1) The production number of the valve

i.e. K..-.... (Year of manufacturing / production no.)
2) Valve model type and size e.g. TDM DN..., PN...
3) A description of the system in which the valve is installed
4) Please use the datasheet, page 14, for communication of loaddata information
9. Customer service
In case information is required, or in case of breakdown, the following organisation
can be addressed:
SCHROEDAHL-Arapp SCHROEDAHL International Corp.
Spezialarmaturen GmbH & Co. KG 2400 Augusta Dr., Suite 285
Sales international dept. Houston, Texas 77057
Schoenenbacher Str. 4 USA
51580 Reichshof-Mittelagger
Germany Phone: 001-713-975-8351
Fax: 001-713-780-0421
Phone: +49 2265 9927-0
Fax: +49 2265 9927-927
9
SCHROEDAHL offers advise, delivery, installation, commissioning, maintenance, repair
and modification. Our customers are offered an extensive customer service, which is
worldwide available, 24 hours a day.
Quality assurance of SCHROEDAHL valves is made according to the high quality require-
ments of German and international quality authorities.
We fulfill all requirements acc. DIN, UVV, VdTÜV, ADStandards, TRD and all international
standards as ASME as well as DIN ISO 9001/EN29001.
Besides the Automatic Recirculation Valves we also have the following products
in our programme:
Control valves for powerplants and industrial applications
Desuperheaters
Strainers
Adjustable pressure regulating valves for pressure reduction
Flow actuated control valves for various applications
10
10. Attachments
10.1 Sectional drawing

P = pump end
R = pipeline end
B = by-pass end
Installation P- R vertical
R 02
03 40
26 04
28 41
06 08
30
34 33 35
07.1 34.1 25 33.1 35.1 12 10 36 23 09
07
07.2
01
42
B
03.1
13 14 11 16 15 21 31 32 29 27
11
10.2 Parts list
Housing
Material Recommended
Pos. Description Spare parts
CS SS
01 Lower body 1.0460 1.4404
02 Upper body 1.0460 1.4404
03 Valve stemguide 1.4552 1.4552
03.1 Valve stemguide 1.4552 4) 1.4552 4)
04 Guide bolt 1.4021 1.4021
06 Spring 1.4310 1.4310 X
07 Check valve (assy.) 1.4404 1.4404 X
07.1 Check valve 1.4404 1.4404
07.2 Stem 1.4404 1.4404
08 Liner 1.4301 1.4301
09 Bypass branch 1.0460 1.4404
25 Guide pin 1.4305 1.4305
26 Bolt 1) 1)
27 Bolt 1) 1)
28 Hexagon nut 2) 2)
29 Hexagon nut 2) 2)
30 O-Ring 3) 3) X
40 Damper 4) 4)
41 Guide-Ring PTFE/ Carbon 4) PTFE/ Carbon 4) X
42 Guide-Ring PTFE/ Carbon 4) PTFE/ Carbon 4) X
1) 8.8 to DN 150 PN 40, DIN 1.7709 from PN 63 and from DN 200 PN 10

2) 8 to DN 150 PN 40, W-Nr. 1.7258 from PN 63 and from DN 200 PN 10
3) EPDM, BUNA, VITON, FLUORAZ, CHEMRAZ, PTFE
4) Design with damper / standard from DN 150
12
Bypass
Pos. Description Material Recommended

Spare parts
10 Vortex bushing 1.4122 1.4122 X
11 Control head 1.4122 1.4122 X
12 Vortex plug 1.4122 1.4122 X
13 Lever 1.4313 1.4313 X
14 Pivot pin 1.4021 1.4021 X
15 Bushing 1.4122 1.4122 X
16 Piston 1.4122 1.4122 X
21 Disc 1.4122 1.4122 X
23 Bypass orifice 1.4122 1.4122 X
31 O-Ring 3) 3) X
32 O-Ring 3) 3) X
33 O-Ring 3) 3) X
33.1 Glyd-Ring PTEF/ Carbon PTEF/ Carbon X
34 O-Ring 3) 3) X
35 O-Ring 3) 3) X
36 O-Ring 3) 3) X
1) 8.8 to DN 150 PN 40, DIN 1.7709 from PN 63 and from DN 200 PN 10

2) 8 to DN 150 PN 40, W-Nr. 1.7258 from PN 63 and from DN 200 PN 10
3) EPDM, BUNA, VITON, FLUORAZ, CHEMRAZ, PTFE
4) Design with damper / standard from DN 150
13
10.3 Datasheet
Automatic Recirculation Valve

Technical Data
Customer: Datasheet:
Enquiry no.:
Prior reference: Quantity:
Order no.:
Project:
Automatic Recirculation Valve type:
Valve inlet [in.] DN PN Acc.:

Valve outlet [in.] DN PN Installation: vertical horizontal
Bypass outlet [in.] DN PN Paint:
Start-up [in.] DN PN Start-up above below checkvalve
Mat.-/test certificates:
Materials
Housing: Internals: Seals:
Medium Operating temp. [°C]:

S.G. [kg/m³]: Design temp. [°C]:
H0 = m
QM = m³/h HM = m Suction pr. pv bar
Q100 = m³/h H100 = m Differential pr. (p1-pn) bar
Qmax = m³/h HQmax = m Backpress pN bar
QA = m³/h HA = m Backpress pA bar
Notes:
Revision Date Description Name Signature
14
©2008 XYQOM GmbH — www.xyqom.net
SCHROEDAHL-ARAPP
Spezialarmaturen GmbH & Co. KG
Schoenenbacher Str. 4
51580 Reichshof-Mittelagger
Germany
Phone +49 2265 9927-0
Fax +49 2265 9927-927
www.schroedahl.com
info@schroedahl.com
Schroedahl International Corporation

2400 Augusta Dr. Suite 285
Houston, Texas 77057
United States of America
Phone +1 713 9758351
Fax +1 713 7800421
sic@schroedahl.com
DM TANK
Operation and Maintenance Manual 5267)5(,67((/6,1&
ROSTFREI STORAGE TANK- SAFETY PRECAUTION
/ OPERATION &MAINTENANCE MANUAL

Table of Contents Page No.
1. INTRODUCTION …............................................................................... 1
2. INSTALLATIONS …………………………………………………….. 2
3. PRECAUTIONS………………………………………………………... 2
4. SAFETY………………………………………………………………… 4
5. OPERATIONS …………………………………………………………. 5
6. PREVENTIVE MAINTENANCE……………………………………… 6
7. LINER MAINTENANCE……………………………………………… 7
8. WARRANTY…………………………………………………………… 7
9. RECOMMONDATIONS………………………………………………. 8
10. CONTACT DETAILS………………………………………………… 9
1 INTRODUCTION
Every RSPL water/waste water storage tank is designed to provide many years of service
when properly installed and maintained. The following are guidelines to protect your
investment and comply with tank warranty requirements. Please perform the following
maintenance observations and corrections as periodically recommended or as required
below. RSPL or their agents can inspect the tanks and perform some maintenance tasks
with little or no extra cost. However, some tasks should be handled by the tank
manufacturer or their authorized agents only.
ROSTFREI STEELS PVT. LTD. Page 1 of 9

2 INSTALLATIONS
Tank installation shall be in supervision of Rostfrei steels representative or by a RSPL
authorised contractor or with the help of Installation Manual of RSPL.
3 PRECAUTIONS
Precaution at the time of connection of Pipe Lines
¾ Each nozzle and connecting pipeline should be supported from
bottom/ground level, so that no extra load can be put on it.
¾ Any supports of pipe or external equipment should not fixed with tank without our
information & technician suggestions
¾ Do not weld the pipe line directly with flanges; it should be always nut-bolting
with connecting flange.
¾ RSPL recommends to use rubber bellows for connectivity between pipeline and
big size nozzles (above 200 NB) to avoid leakage from nozzle due to vibration or
stress.
¾ The connecting flange of tank nozzle must match and aligned with Plumbing
piping flange. The pipe/flange must not be pulled to match flange faces.


Precaution after handover/commissioning of tank:
• Do not enter in tank when it is filled up with liquid.

• Please do civil copping at time of testing or just after testing as per below
drawing
• Any person entering inside the tank should use the wall or roof manhole and
should go down with the help of internal ladder.
• It should be noted that person entering inside the tank should use rubber
gumshoe without heel or should be naked feet. Any sharp thing or equipments
should not be used inside the tank during the service time.


• At the time of cleaning we should use cotton base fiber brush and after
brushing the peeled off insoluble dust particle should be cleaned with the use
of wet cotton cloth.
• Avoid using any sharp objects during liner cleaning.
• If leakages observe in the tank it should be rectified immediately, as the

regular leakages can corrode the sheets/ flanges/ nut-bolts and tank can
damage. In such case please contact manufacturer ASAP.
• Please provide a railing/ Fencing surrounded the tank so that the Truck, Hydra,
and Crane OR any other movable equipment doesn’t strike/smash with the
tank. As shown on below pics:
If Tanks are installed underground:
• The tank should be buried from river sand only when the tank was fully loaded
with water/waste water.
• Do not try to bury the tanks while it is empty at the time of Installation
process.
• Do not use concrete mixture, stones, soil etc. for back fill area surrounding the
tank. Always use low density river sand.
4 SAFETY
Safety and long life of these tanks required only little attention as explained below. All
unqualified/untrained persons are to stay out of the work area at all times. A person who
has not read this manual and does not understands all operating and safety instructions is
not qualified to operate this equipment.


¾ If there is delay in water/waste water testing by any reason, please make sure all
the flanges should be duly covered by dummy/blind flanges etc.- because the
foreign particles or small animals can enter in the tank and can damage the liner
¾ No continuous vibration above Seismic Zone-4 should be near about tank, it will
create unnecessary motion on Nut & bolts to be loose.
¾ Vegetation and soil, which can trap moisture against concrete and steel, should be
cleared from the outside base of the tank. Similarly, tree limbs and bushes should
be trimmed from the tank shell to prevent scratches in the steel coating. (Scratches
are not only unsightly but precursors to premature coating failure and corrosion.)
¾ Do not put/hang the rusted material over the tank structure, and in connected with
structure. This will sacrifice Zincalume coating on steel.
¾ Whenever any small corrosion found, such area should be paint immediately, to
avoid further rusting.
5 OPERATIONS
A RSPL tank is a water/waste water storage vessel that does not require any operations as
long as the tank is located on a proper foundation and there are no leaks of liquid from the
flexible membrane liner inside of the tank. The equipment installed either inside of the
storage tank or exterior to the storage tank to treat, fill or remove water/waste water
should be covered by a separate operations and maintenance program.
On an annual basis the following items should be checked:
1. The foundation should not exhibit any cracks or slippage.
2. There should not be any voids under or within 3 feet of the tank foundation.
3. There should be no water/waste water running from the tank walls. However,
dampness may occur around the tank wall due to interior or exterior
condensation.


4. There should not be any areas of rust on the tank structure.
5. There should not be any missing nuts/bolts from the tank structure.
6. All piping should be inspected for leaks.
6 Preventive Maintenance
Rostfrei Steel Tanks are designed in such a way that it needs very minimum preventive
maintenance after commissioning. If somehow any problem is observed, then Rostfrei
Steels is always there to solve it. Some of the following points need to be considered for
safe and satisfactory usage of the Rostfrei Steels Water/waste water Storage Tanks.
• Check for nut-bolts looseness.

• Check for Rust on nut-bolts & tanks.
• Tank should be inspected 1 time in month for any rusting externally & 1 time in a
year internally by loosens liner from the top.
• Tank should not have any leakage which can damage steel sheets. Leakage should
be arrested in max 1 to 3 weeks.
• Tank should be painted internally & externally wherever any rusting observed. (It
depends on external environment as Zinc Aluminum Steel is tested for 20 years
without rust life by TATA Blue Scope).
• *To get best life, please check steel tank condition from inside also
by entering between loose liner & steel sheet, once a year. If any
rusting visible, it may require painting or changing panel. This
process require (free of cost) Rostfrei supervisor. Please call us for
services.
7 Liner Maintenance
• Any puncture found in the liner, can be rectified by using a small cut piece of liner and
with the help of butyl tape.
• First clean the surface of the liner at punctured location, and blow heat slightly to
warm the surface of the cut piece patch and put the butyl tape on it and again warm it
with hot gun and fix it on the puncture in the liner.
• The use of hot gun should be done cautiously. High heat of the hot gun can also
damage the liner.
• For Leakage repair you can use Adhesive with liner small patch, before applying the
same clean the area properly as shown on process.

Special Instructions
1. Only a trained person will perform the rectification of puncture task.

2. Always be cautioned for use of Hot-Gun. The high heat can be damage the liner so
use of Hot Gun as per required heat. The trainee should use Hot-Gun with the
presence of trained and skilled man.
3. Avoid using any sharp objective during liner maintenance.
4. Always enter in tanks bare footed (without shoes)
5. Please contact manufacturer in such cases.
8 WARRANTY
¾ Warranty will be applicable as per our Offer.
¾ If any mishap occur due to maintenance flaws, RSPL will not be responsible for
that.
¾ The warranty is applicable only on maintained tanks. Any mishap due natural
calamities does not cover in warranty.


9 RECOMMENDATIONS:
** RSPL recommends covering the tanks under insurance for all types of risks after
successful commissioning.
Anode protection is used to enhance the life of sheet metal from corrosion, rust etc. It is
recommended to all clients that if you feel that the atmosphere is corrosive or water/waste
water contact, sheet starts rusting. Then request you to buy more anode protection to
protect Tank/Sheet from Corrosion/Rusting. We send standard number of anode
protection at the time of installation.
A drawing is sketched below showing the installation manual of anode.
Kindly call us for kind of assistance needed, again thanks for chosen Rostfrei storage
tanks.

10 CONTACT DETAILS
For Any further details please contact as here under:
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ǣ൅ͻͳǦͳͳǦͶ͸͸ͳͳͲͲͲሺͳͲͲሻ
ǣ൅ͻͳǦͳͳǦͶ͸͸ͳͳͲͳͳ
ǣ̷ǤሺǤሻ
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ǣǤǤ

DOSING PUMP
BUTTERFLY VALVE
INSTALLATION, OPERATION & MAINTENANCE MANUAL
DelVal Flow Controls Private limited

(A DIVISION OF DelTech CONTROLS LLC, USA)
DelVal Series –
50/52, 5A/5B
Butterfly Valves
INSTALLATION,
OPERATION AND
MAINTENANCE MANUAL
ENGINEERING DATA SHEET
E.D.S. NO – EDS 055
ISSUE DATE : NOVEMBER 2006
REVISION No:- 01
REVISION DATE :-24-04-2007
( Please read the entire instructions carefully before installation or servicing. )
Guarantee :
“Our liability, with respect to any defect or failure of the goods supplied or for any loss, injury or
damage attributable onward, is limited to replacement or repair of the defects which under proper use
appear therein and arise solely from faulty materials and workmanship. This guarantee is for a period of
18 calendar months after the original goods were first shipped or within 12 calendar months from the
date of installation, whichever is earlier, provided that such defective parts are returned without charge to
our factory for examination. No other warranty is either expressed or implied.”
TABLE OF CONTENTS
Item Description Page no
1. Introduction 2
2. Technical Data 2
3. Safety Precautions 2
4. Transportation, Receiving and Storage 3
5. Installation 3
6. Operation of the Valve 5
7. Maintenance 5
8. Disassembly & Assembly Instructions 6
9. Recommended Spare Parts 7
10. Exploded View 8
11 Troubleshooting 9
EDD-FT-007 Page 1 of 9
1 Introduction 3 Safety Precautions.
1.1 Scope of the Manual. 3.1 Do not exceed the valve pressure /
The purpose of this manual is to ensure that the valves temperature rating limitations!
supplied are properly installed and maintained to give x Exceeding the pressure/temperature rating limitations
trouble free performance. marked on the valve may result in major damage or
Personal injury. Users of these valves should ensure
This manual covers DelVal single piece body butterfly that the valve pressure / temperature is less than or
valves from 2” to 24” in both wafer and lug designs. equal to the rated pressure/temperatures. If required,
end user should incorporate appropriate
1.2 Marking. limiting/monitoring devices in the system for the safe
Specifications of the valve are marked on the body or on operation of the valve.
name plate or both, prior to shipment. The identification
3.2 Use the valve for specified application only!
marking generally consists of size of valve, pressure
rating, body material, trim material and the date of x User to ensure that the valve is used only for the
manufacturing. ( Ref to fig 1.1 ) specified application as agreed between the
manufacturer and the purchaser.
3.3 Follow the safety rules and regulations!
x User of the valve must be aware of all the safety rules
and regulations related to a particular environment in
which the valve is to be used.
DelVal
3.4 Do not disassemble the valve or remove it from

the pipeline while the valve is pressurized!
x Disassembling or removing a pressurized valve will
result in uncontrolled pressure release. Always isolate
the relevant part of the pipeline, release the pressure
from the valve and remove the media before
dismantling the valve.
x Be aware of the type of media involved. Protect people
and the environment from any harmful or poisonous
substances.
x Make sure that no dust, dirt can enter the pipeline
during the valve maintenance.
3.5 When handling the valve or the valve package,
bear in mind its weight!
x Never lift the valve or valve package by the handle, gear
operator, actuator or hand wheel. Place the rope
Fig 1.1 Valve Marking
securely around the valve body while handling the
valve. Refer to Fig No. 1.2
2 Technical data
2.1 Pressure Rating
Construction :
Single piece body both in wafer and lug design.
Pressure Rating :
Valve Size Rating
2” - 12” 175 PSI / 12 BAR.
2” - 24” 150 PSI / 10 BAR (PN10).
2” – 24” 50 PSI / 3.5 BAR.
2” - 12” 230 PSI / 16 BAR (PN 16).
Seat Temperature Range.
Seat type Temperature Range
EPDM -130 F (-250 C) TO 2480 F (1200 C)

BUNA-N / Nitrile -130 F (-250 C) TO 2120 F (1000 C)
Viton / FKM -230 F (-50 C) TO 3920 F (2000 C)
Silicone -580F (-500 C) TO 3560 F (1800 C) Fig 1.2 Lifting of the Valve
5 Installation
4 Transportation, Receiving and
5.1 When removing the valve from storage a careful check
Storage. should be made to ensure that the valve has not been
4.1 Valves are being packed in cartons, boxes or pallets damaged during the storage period.
while shipping to the customer. Care should be 5.2 Valve open or close position is indicated on the notch
taken to store them in a suitable place. We plate for lever operated valves or on the top of the gear
recommend storing the valves indoors in a dry and operator for gear operator operated valves.
dust free atmosphere (Refer to figure 2.1). While
unpacking the valves, check that the valves and any 5.3 Center valve, span body with bolts, but do not tighten.
other accessories have not been damaged during Slowly open disc to ensure that it clears adjacent pipe
transportation. ID and leave at full open position. Tighten bolts in
cris cross pattern refer fig 3.5.
Fig 2.1 Storing the Valve.

Fig 3.1 Lug Valve Installation.
x Caution:
Placing the valves directly on the ground or on a 5.4 For flange welding center valve with disc 100 open
concrete floor should be avoided! between flanges, span bolts, align this assembly in pipe
and tack weld flanges to pipe. After tack welding,
4.2 All wrapping and protection on the valves should not remove valve and finish welding.
be removed until the valve is ready for installation.
All valves are delivered with disc in 100 open position
(Refer to figure 2.2).
W E L D IN G
Fig 2.2 Disc in 100 open position
4.3 If the valves are stored for a long time, then all the Fig 3.2
valves should be cleaned and hydro / pneumatic 5.5 Valve should be checked for identification purpose and
tested before installation. Refer to General ensure that characteristics of valve matches to those
Arrangement drawing, which lists the appropriate specified for piping specifications, for the line where that
testing standards, or consult the nearest branch is to be mounted. Nameplate instructions will give the
office / factory for more information. necessary information.
4.4 Valves are bi-directional and can be installed in
either direction.
4.5 Lever or hand wheel of gear operator for respective
valves are packed loosely and kept in the same box,
in which the valve is packed (wherever applicable).
When handling the valve either by hand or by
mechanical means, special care should be taken not
to damage the lever or gear operator. Lift the valve
only as shown in fig 1.2. Lifting the valve from any
other location may damage the valve components.
Fig 3.3 Valve Alignment.
Note:
It is recommended to use ASTM A193 Gr.B7 fasteners for flange bolting.
Fig 3.4 : Installation of valve into pipe line.
Note: a) Do not attempt to correct the line misalignment by means of flange bolting Ref to fig 3.3.
b) Do not use flange gaskets Ref to fig 3.4.
5.6 Recommended Bolt Tightening Sequence:
Place the valve between the flanges, centre it and then span the valve body with all flange bolts, but do not
tighten the bolts. Carefully open the disc to the full open position, making sure the disc does not hit the
adjacent pipe I.D. Now systematically remove jack bolts or other flange spreaders, and hand-tighten the flange
bolts as shown in fig.3.5 Very slowly close the valve disc to ensure disc edge clearance from adjacent pipe
flange I.D. Now open the disc to full open and tighten all flanges bolts as per specification as shown in fig.
Finally, repeat a full close to full open rotation of the disc to ensure proper clearance.
Fig 3.5: Initial Centering & Flanging of Valve
7 Maintenance.
6 Operation of the Valve. Note:

Observe the safety precautions as outlined in section 3
before performing maintenance.
6.1 For lever operated valves, the hand lever is either
assembled with the valve or shipped loose
depending upon the size of valve / hand lever.
7.1 Preventive Maintenance.
6.2 For gear operated valves, THE GEAR OPERATOR 7.1.1 In order to avoid valve failure during operation, all
OPEN / CLOSE ADJUSTMENT HAS BEEN DONE valves in a process plant should be periodically
PRIOR TO SHIPMENT AND MUST NOT BE inspected thoroughly to detect the wear of disc,
CHANGED. Rotation of hand wheel in the clockwise seats, seals and even body. It is recommended that
direction closes the valve and counter clockwise on such occasions seats, seals and bushings
rotation opens it. (Looking from hand wheel end) The should be replaced.
details of gear operator are shown in the fig. 4.1. The
internal details/construction of gear operator may
vary as per manufacturers standard. 7.1.2 The type of process, fluids involved, working
conditions and location of the valves in the process
plants, will determine the frequency of periodic
inspection / maintenance which in fact will be made
at the time of partial or total shutdown of the plant.
Preventive maintenance is absolutely essential as
the failure due to lack of the same may cause an
emergency shut down of the plant.
7.1.3 Section 8 describes the procedure for disassembly,

repair and assembly of the valve. The procedure
will be the same for a valve failing during operation
due to lack of preventive maintenance.
Fig 4.1 : Details of gear operator. 7.1.4 Once a valve is repaired, it should undergo a
complete set of tests to make sure that the valve is
adequate for the original working conditions.
Hydro/Pneumatic tests should be carried out as per
6.3 DelTech Butterfly valve always close in a clockwise the specifications relevant to the valve (Refer
direction. Valve should always be rotated through General Arrangement Drawing).
90º to the fully opened or fully closed position.
6.4 Valve should be opened and closed slowly to avoid 7.2 Lubrication of Worm Gear operator.
hammering effect on the valve and pipeline.
7.2.1 Worm gear operators are packed with grease.

6.5 Once the flushing is complete, valve should be Normally the grease is suitable for -20oC (-40F) to
operated 3-4 times and then kept in the fully open 80oC (1760F). For other applications, consult the
position. nearest branch office / factory.
6.6 If the valve is not operating to fully open or fully

closed position, and/or leaking, do not apply 7.2.2 Grease should be changed as following. If operated
excessive force to operate the valve. This can frequently, after approx. 3 years. If operated rarely,
damage the seats or stem. after approx. 5 years.
Caution:
7.2.3 Recommended Greases-
x Apply gradual force on the handwheel of the gear
operator and do not give impacts. Servogem EP2 (Extreme Pressure),
Mobilux EP2,
x Do not apply extra leverage (using pipe/bar), when Valvoline EP2,
the end stops of the gear operator are reached. Chevron EP2.
!
WARNING
Pipeline pressure can propel the loose flange bolts & flanges, and can cause personal injury
or equipment damage. Relieve pipeline pressure before removing flange bolts and flanges.
WARNING
! Moving Parts from accidental operation of powered (Pneumatically / Electrically) actuator can
cause personal injury or equipment damage. Disconnect and lock power to actuator before
servicing.
8.1.3 Remove the notch plate bolts (10,11,12) and
8 Disassembly and Assembly
remove the notch plate (9).
Instructions :
8.1 Disassembly Instructions: 8.1.4 Remove the circlip (8) (fig 8.1) and pull the stem out
( Refer to exploded view No. 10.1) with stem retainer ring (7).
Before disassembling, please ensure that all spare parts 8.1.5 Pull the disc (3) from the body (1) as shown in fig
as detailed in Table 1 of Section 9, are available. For 8.2
below mentioned procedure, the numbers in the bracket 8.1.6 Remove the stem bushing (6) and U cup stem seal
refer to the part numbers of the components as indicated (5) from the body (4).
in exploded view (fig no 10.1). 8.1.7 Compress the seat as shown and pull it out from
x In case the valve is in operation, release the the body (Refer to the fig 8.3).
pressure from the line. Note: After the complete disassembly of the valve, all the
x Rotate the valve stem (04) manually to keep the components should be stored in a clean place to avoid
Valve in the half-open position. This will remove damage.
pressure in the pipeline.
x Always fully close valve before removing from line to 8.2 Repair of Components.
avoid damage to disc 8.2.1 The metallic parts should be cleaned.
x Valve can be repaired by removing the entire valve 8.2.2 To clean the seats and seals use a dry clean cloth.
from pipeline. Use mounting holes to lift the valve
8.2.3 After cleaning components examine for damaged
(Wherever applicable).
parts. Ensure that there are no scoring marks on
8.1.1 Unscrew the lever lock bolt (13). Lift the lever the metallic sealing surfaces. Check the seals for
(14) by pressing the latch of the lever out of the scratches / wear.
stem (4) in case of hand lever operated valve. 8.2.4 Replace the damaged parts. The parts such as
8.1.2 Lift the gear operator (15) out of the stem (4) by seal, bushings are recommended to be replaced
removing the bolts in case of gear operated with new ones whenever the valve is dis-
valve. assembled: refer to Table 1 of Section – 9 for
further details.
1
1 P ress
Pull
3
2
C irclip
8 P ull
Fig 8.1 Fig 8.2 Fig 8.3
Disassembly of the Stem, Disc and Seat.

Note: When the gear operator or hand lever or actuator is re-assembled on the valve, it may be necessary to adjust
gear operator or hand lever or actuator travel stops to ensure proper setting of the butterfly in the open and closed
position
8.3 Assembly Instructions. 8.3.1.4 Insert U cup seal (5), bushing (6) refer fig no 8.6.
( Refer to exploded view No. 10.1) 8.3.1.5 For 2”-12”(series 50/52) and 2”-8” (series 5A/5B)
8.3.1 VALVES OPERATING WITH LEVER. Insert the stem (4) in to the body ensuring that
8.3.1.1 Place the body (1) on a clean work surface. double D of stem aligns with double D of the disc.
Insert the retaining ring (7) in to the stem and then
8.3.1.2 Start assembly by pressing the seat as shown & install the retaining circlip (8) refer fig no 8.6.
pushing it into the valve body with seat stem
holes aligned to the body stem holes as shown 8.3.1.6 For 14” -24”(series 50/52)and 10”-14”(series 5A/5B)
in the fig (8.4) and work the seat into the groove Insert the stem (4) in to the body ensuring that
provided on the body. double D of stem aligns with double D of the disc.
Install the stem retaining circlip (17) in to the stem,
8.3.1.3 Position the disc (2) as shown in fig (8.5) taking insert the retaining ring (7) in to the stem (4) and
care that double D is at the bottom of the valve then install the retaining circlip (8) refer fig no 8.6.
body. Special care must be taken not to damage
the seat surface.
8.3.1.7 Fit the notch plate (9) on the mounting flange with
the notches in the first quadrant of the valve top
plate with the stop tabs at the 12 ‘O’ clock and 3
‘O’ clock position (fig 8.7).
8.3.1.8 Fit the lever (14) so that the lever fully engages in 1
the notches when the lever latch is released and
tighten the handle lock bolt (13). P re s s
8.3.1.9 Press the handle lever latch and position the disc
so that the valve is in the fully closed position.
Align the last notch on the notch plate at the 3-o
clock position with the handle lever and tighten P ush
the notch plate screws (10,11,12).
2
8.3.1.10 Press the handle lever latch and position
the disc so that the valve is in the fully open
position and release the lever. The lever should F ig 8 .4
line up with the last notch on the notch plate at
the 12-o clock position.
1
8.3.2 VALVES OPERATING WITH GEAR
OPERATOR.
(Refer Table 1 of Section –9 & Exploded View No. 10.1) P ush
8.3.2.1 Follow the points from 8.3.1.1 to 8.3.1.6.
8.3.2.2 Rotate the valve disc to the fully open position. 3
8.3.2.3 Rotate the gear operator to the fully open
position.
8.3.2.4 Line the valve stem with gear operator bore and D o u b l e 'D '
slide the gear operator (15) onto the valve with
the hand wheel (16) to the right of the valve name F ig 8 . 5
plate. C ir c lip 8
8.3.2.5 Position the gear operator so that the tapped R e t a in in g 7
holes in the bottom of the gear operator line up r in g
with the valve top mounting holes and install the C ir c lip 17
mounting bolts. S te m 4
8.3.2.6 Loosen the gear operator travel stops and rotate 6
B ush
the handwheel until the valve is in the fully closed
Double 'D'
position. Tighten the travel stop on the right hand ' U 's e a l 5
side of the gear operator.
8.3.2.7 Rotate the hand wheel until the valve is in fully
open position. Tighten the travel stop on the left-
hand side of the gear operator.
8.3.2.8 Make 2-3 cycles of the valve from fully open
position to the fully closed position to make sure
that the stops are set correctly. F ig 8 .6
9 Recommended Spares Kit.
Before the start of the repair operations, we recommend
that one set of spares as given in the table below should
be available.
For normal operation (2 years), we recommend one INDIA
set of spares be available at site.

9.1 List of Recommended Spare Parts
Table no 1.
Part Name Part No. Qty. (Nos.)
Seat 2 01
Bushing 6 01
U cup seal 5 01
Circlip 8 01 Fig 8.7 Notch plate position.
10. Exploded View
Exploded View Fig No: 10.1
14 16
13
10
11
9 12
15
FO R LE VE R O P ER ATED VALVE FO R G EAR O PER ATED VALVE
7
S r.N o . D E S C R IP T IO N Q TY. 17
1 BODY 1
2 SEAT 1
6
3 D IS C 1
4 STEM 1
5
5 S T E M S E A L ( D O U B L E 'U ' C U P ) 1
6 S T E M B U S H IN G 1
7 R E T A IN IN G R IN G 1
8 R E T A IN IN G C IR C L IP 1
4
9 N O TC H P LA TE 1
10 HEX. HEADED SCREW 2
11 P L A IN W A S H E R 2
12 HEX. NUT 2
13 H A N D L E V E R L O C K IN G S C R E W 1
14 H AN D LEVER 1
15 G EAR O PER ATOR 1
16 HANDW HEEL 1
S T E M R E T A IN IN G C IR C L IP
17 F o r 1 4 " -2 4 " (S e rie s 5 0 /5 2 ) 1 1
a n d 1 0 " -1 4 " (S e rie s 5 A /5 B )
Troubleshooting:
Symptom Cause Corrective Action

Replace stem sealing as described
Stem Leaks Stem seal in seat is leaking
in disassembly & assembly.
Replace seat as described in
Seat is worn or damaged
Valve leaks at disassembly & assembly.
closed position Disc edge is worn or Consult factory for potential
damaged. application problem.
SAFETY VALVE
12 1
Products at a glance
Type 441 Type 237

Flanged standard pressure For all smaller capacity
series suitable for steam, gas applications of steam,
and liquid service. They have gases and liquids.
proven themselves as a universal IBR approved.
safety valve for many applications. Type 441, 237 & 549
IBR & CCoE approved.
Type 549 Type 459 IC

Safety valve for gas, liquid or steam. Safety valve for gas, liquid or steam.
Also for thermal relief application. Also for thermal relief application.
Available in screwed and flanged Available in screwd and flanged
connection for all utility applications. connection for all utility applications.
CCoE approved. Can be supplied with "UV" stamp.
IBR approved.
Type 526 IC
Flanged safety relief valves with
"UV" stamp, Designed as per
API 526, Now available from LESER India.
How to contact LESER India
Head Office - Mumbai

136/137, Sanjay Bldg. 3, Mittal estate
Marol, Andheri Kurla Road,
Andheri (E), Mumbai-400 059, India.
Telephone: +91-2853 2200
Email: info@leser.co.in
Website: www.leser.co.in
Manufacturing Facility - Paithan

D-3, M.I.D.C. Paithan,
Dist. Aurangabad,
Maharashtra-431 148, India.
Email: sales@leser.co.in
Edition April 2015
The-Safety-Valve.com The-Safety-Valve.com
2 3
Operating Instructions Operating Instructions
1 Introduction LESER products in configuration

1.1 About LESER their application – in all industrial for Indian requirements Safety valves can also be equipped with
With more than 800 employees LESER applications. • Indian approvals (IBR, CCoE), bursting discs, pneumatic
is the biggest manufacturer of safety International (ASME Sec. VIII, UV supplementary loading, bellows and
valves in Europe and one of the leading Above all that we do stand our Stamp) upstream changeover valves.
companies In this branch worldwide. LESER values: • Materials for the Indian market Certain regulations and standards apply
• LESER safety valves are used by • Short and reliable delivery times depending on the system and medium.
Precise. Committed. Efficient. These regulations and standards must
leading companies in industries such as through local manufacturing
Our modern manufacturing and testing be observed.
chemical, petrochemical, industrial • Competitive price level
facilities ensure high quality safety In addition to the information in this
gases, oil and gas production, and • Global LESER design concept for
valves and a large central stock user's guide, the generally appliable
machine building, as well as the food reliable valve function
guarantees short delivery times for safety and work safety regulations must
and pharmaceutical.
valves and spare parts. To date, the • Manufactured to global quality and also be observed. In lke manner, the
• LESER offers spring-loaded and more than 2,00,000 safety valves process standards
pilot-operated safety valves for all environmental protection regulations
installed underline the trust the must be adhered to.
industrial applications according to PED customers have in LESER India.
and ASME VIII as application-based 1.3 About this User Guide
Our safety valves are being used by
solutions for special requirements. This user's guide covers the folliwing
customers across all major industries
• LESER safety valves are developed like oil & gas, petrochemicals, types of safety valves and peripheral
for the international market at our chemicals, pharmaceuticals, and devices in summeary form:
headquarters in Hamburg / Germany Original Equipment Manufacturers • spring-loaded safety valves (A),
and manufactured at our modern (OEMs).
factory in Hohenwestedt / Germany.
LESER India has all the detailed
• LESER India produces safety knowledge and modern technology
valves for the local market. required for producing high quality
• Eight subsidiaries in Europe, safety valves. Our safety valves are
America, the Middle East, and Asia, as manufactured in the Paithan factory,
well as authorized and trained which has an annual capacity of 24,000
representatives in over 80 countries valves. In the past two years, LESER
guarantee competent consulting and India has invested in new processes and
quick, reliable delivery technologies. The facilities have been
equipped with modern CNC and drilling
1.2. About LESER India machines.
LESER India is a progressing safety
valve company for a progressing
country. LESER produces globally
proven safety valves with German
technology and LESER quality in a
configuration especially for Indian
requirements. This ensures that the
customers receive the best solution for
4 5
2. General Notes 4.2 Draining of Condensate 4.3 Mounting Brackets

Pressure Relief Valves are high quality break off and enter the valve causing it To prevent dirt and all kinds of impurities For pressure relief valves with mounting
devices which should be handled with to leak. from the pressure relief valve the brackets a fastening provision for the
great care. To ensure the correct If valves with open bonnets and/or drainage of discharge pipe and pressure brackets should be made to withstand
performance of a pressure relief valve all levers are to be re-painted after dispatch relief valve must be done via discharge the forces of reaction when valve blows
parts are made with exact precision. from the factory, care must be taken to pipe. Therefore, LESER India pressure off. The brackets are provided with holes
Only this precision ensures the correct protect the sliding parts. Otherwise the relief valves are not normally provided for all these sizes.
functioning of the pressure relief valves. correct operation of the pressure relief with drain holes. According to rules, a
Careless handling of the finished valve in valve may be affected. drain hole of sufficient size must be 4.4 Insulation
workshops, stores, during incorporated at the lowest point of pipe In case insulation is provided for the
transportation or installation could work. In all cases the discharge pipe pressure relief valve, the bonnet must be
cause leakage or possibly permanent 3. Transport Protection must first slope in a downwards kept free to avoid unacceptable heating
damage. The inlet and outlet of the pressure relief direction and fitted with a suitable size up of the spring.
The seating surfaces have been valves are protected during drain hole before any bends are
machined, lapped and polished with transportation with plastic caps. These connected (refer to sketch below). 4.5 Inlet Pipe
high precision to ensure the required caps should only be removed just before The inlet pipe for pressure relief valves
tightness. Even though the surfaces are installing the valve. Exception: should be as short as possible and should
extremely hard, the seat can still be The lifting lever of spring loaded In special cases an optional drain hole be so arranged, that when the valve is in
damaged. By all means, one must take pressure relief valves is secured with a may be recommended in the valve body its fully open position the pressure drop
care to prevent dust, foreign particles wire to the bonnet. This wire should be as it may be that pipe work drainage must not exceed 3% of set pressure. If the
etc. from entering the valve during removed only after installation. For cannot be guaranteed at a lower point calculation results in a pressure drop
transportation, installation and testing the set pressure or tightness of than the valve. The standard drain hole higher than 3% of set pressure, then the
operation. the pressure relief valve remove also this which will then be supplied by the inlet pipe size must be enlarged.
All the pressure relief valves are wire and take care that the lever is not factory is 1/4" BSP or 1/2” BSP
thoroughly tested and sealed. The engaged with the spindle cap. depending on the valve size. 4.6 Discharge Pipes/Back Pressure
purpose of sealing is to ensure that the The discharge piping on vapors and
alignment and pressure setting is not 4. Installation/Assembly gases should be installed in an
disturbed due to unauthorized/external 4.1 General Notes ascending direction, on liquids in an
tampering. For the new installations, if Spring loaded pressure relief valves inclined direction. The discharge
there is any performance related issues, should be installed with the bonnet Add, drain pipe
pipework of all pressure relief valves
it should be immediately reported to us in case of should be so arranged that the back
VERTICALLY UPWARDS. prepared drain hole
or our nearest representative so that we pressure, which is built up during blow
Furthermore, pressure relief valves off, does not exceed a max. 15% of set
can either advise for the immediate All drainage pipes that have been
should be mounted in such a way that pressure. In case of higher back
solution or depute our service person. It connected must be free of restriction
no inadmissible static, dynamic or pressure, pressure relief valves with
is highly recommended that the seal is and the ends easily seen. Care must be
thermal loads can be transmitted to the pressure compensating metal bellows
kept intact. taken when discharging any drainage to
valve due to up and downstream pipe (balanced type) shall be used. In case
When installing pressure relief valves work. prevent injury to personnel. For example
with threaded connections use only the back pressure is >0.15 times set
on steam, connect a suitable steam
gaskets or metal seal washers. Sealing pressure, the capacity of the pressure
trap.
materials such as PTFE tape should not relief valves must be recalculated.
be used as this type of material can
6 7
4.7 Pressure Relief Valves with 6. Dismantling and assembly

bellows It is important to ensure that the lifting instructions (For Valve Type
Pressure relief valves with metal bellows lever does not engage the spindle cap 237 with Cap H2)
have a vent hole in the bonnet. This hole after the lift operation. The lever must be 1. Remove lead seal (85 & 86).
is protected by a plastic plug. This deflected towards the center line of the
bonnet until the lifting fork is 2. Unscrew and remove cap, H2 (40).
plastic plug has to be removed at the
disengaged. 3. Slacken locknut (19).
time of installation and necessary care
must be taken to prevent moisture from 4. Turn adjusting screw (18) to the
entering the bonnet. If the fluid escapes The pressure relief valves represent the required set pressure.
from the vent hole indicates that the last step in the line of protection for the 5. Check admissible pressure range
bellows have failed. Repair is required. level, and they should be able to prevent of the spring!!
When pressure relief valves with bellows excess pressure when all other 6. Clockwise turning of adjusting
are used with toxic or inflammable automatic or pilot operated checking screw increases the spring
fluids, care must be taken to fit a suitable instruments have failed. To guarantee tension, obtaining a higher set
vent pipe to provide safe venting. For this function pressure relief valves pressure.
this purpose, the vent hole is having require, like all other technical 7. Turning anticlockwise of adjusting
threaded 1/4" BSP female connection. equipment, regular service. How often a screw reduces the spring tension,
valve must be checked, depends on the obtaining a lower set pressure.
actual operating conditions, so, no 8. Reassemble in reverse order and
5. Mode of Operation/Maintenance general indications can be given. lock at the set pressure.
The working pressure of the plant Usually pressure relief valves operating
should be at least 5% below the blow in a corrosive or on laden fluids require
down pressure of the valve to enable a service more often than valves Dismantling and assembly
correct reseat. When a slight leakage operating for clean conditions. This also instructions
occurs, due to deposits between the applies if the pressure relief valve
sealing surfaces, surfaces can be
(For Valve Type 237 with pull
operates frequently causing a higher
cleaned by operating the lifting lever button lifting device.)
wear out to the seat and disc.
causing the valve to blow off. 1. Remove lead seal.
The valve should be closed by sudden 2. Remove pin (74 A).
CAUTION!!
release of the lever. If this procedure 3. Pull knob (43) from lever cover
does not stop the leakage, the valve (40).
seats are probably damaged. Repairs 4. Unscrew and remove lever cover
should be carried out at our workshop or Note: Care should
(40).
by a qualified person. It is be taken to ensure
valve spindle is 5. Remove parallel Pin (74 B).
recommended to lift manually the valve
lifting lever from time to time in order to not rotated. 6. Remove spindle cap (46) from
prevent accumulation of deposits that spindle (12).
will affect valve operation. For steam 7. Slacken lock nut (19) of adjusting
service valves with IBR certification, the screw(18).
requirements are established in the IBR
regulations-1950.
8 9
7. Dismantling and assembly

Spring replacement 18. Screw the inlet body (1) in to outlet instructions spring plate (17) to locate on split
8. Turn adjusting screw (18) body (2). (For valve type 441 and 549 with ring (14).
anticlockwise to reduce spring 19. Load the spring (54) to obtain the packed Lever, H4 ) 15. Replace spring (54).
tension. While doing so, secure required set pressure. 1. Loosen the existing lead seal. 16. Slip on the upper spring plate (16)
spindle (12) against rotation by Clockwise rotation of adjusting onto the spindle (12).
2. Press the lever (43) towards the
using splint pin. screw (18) increases pressure. 17. Align adjusting screw (18), and
middle until it reaches the stop so
9. Unscrew Inlet Body (1) from the Anticlockwise rotation of adjusting bonnet (9), over the spindle (12)
that the lifting fork (44) no longer
Outlet Body (2). screw (18) reduces pressure. and refit.
holds the spindle cap (46).
10. Remove pre-assembled disc- 20. Secure the spindle (12) against 18. Fit and tighten the hexagonal nuts
3. Loosen and remove the lever
spindle unit from the outlet body. rotation by using splint pin. (56). For Type 549, screw on the
cover (40).
11. Remove upper spring plate (16). 21. Secure the adjusting screw (18) bonnet (9).
4. Loosen the spindle cap (46) from
with the lock nut (19). 19. Load the spring (54) to obtain the
12. Lift off the spring (54). the spindle (12), remove the
22. Refit spindle cap (46) on the securing ring (91) and the pin (74). required set pressure. Clockwise
13. Carefully clean seat (1) and disc
spindle (12). rotation of adjusting screw (18)
(7), and if required body internals. 5. Loosen the lock nut (19) of the
23. Drive in parallel pin (74). adjusting screw (18). increases pressure. Anticlockwise
14. Replace spring (54).
24. Screw on lever cover (40). rotation of adjusting screw (18)
15. Slip on upper spring plate (16) to 6. Turn the adjusting screw (18)
25. Refit knob (43). reduces pressure.
the spindle (12). anticlockwise to remove the spring
26. Drive in pin (74) and lock it by tension. 20. Tighten the lock nut (19) onto the
16. Insert pre-assembled disc-spindle adjusting screw (18).
unit into the outlet body. securing ring (91). 7. Remove the hexagonal nuts (56)
27. Seal the valve (85 & 86). from the flange of the bonnet (9). 21. Refit and secure spindle cap (46)
17. Lift the spindle with the help of by pin (74) and securing ring (91).
Incase of Type 549, loosen and
splint pin and loosen the adjusting
remove the bonnet (9). 22. Screw-on the lever cover (40).
screw slightly.
8. Lift off the bonnet (9). 23. Pull the lever (43) towards the
9. Remove the upper spring plate middle so that the lifting fork (44)
(16). is pushed under the spindle cap
(46).
10. Lift off the spring (54) and remove
lower spring plate (17) and split 24. Test spindle will lift correctly by
ring (14). pulling lever.
11. Remove spindle (12) with guide (8) 25. Seal the valve.
and disc (7).
12. Carefully clean seat (5) and disc
(7), and if required body internals.
13. Refit spindle (12) with guide (8)
and disc (7).
14. Fit the split ring (14) into spindle
groove and retain with the
securing ring (59); slip on lower
10 11
Exploded View Valve Type 441 Valve Type 549
ITEM NO. DESCRIPTION ITEM NO. DESCRIPTION

1 BODY 1 INLET BODY
5 NOZZLE 2 OUTLET CHAMBER
7 DISC + LIFTING AID 7 DISC
8 SPINDLE GUIDE + INSERT + 8 GUIGE T549
SECURING RING 9 BONNET T549 CLOSED
9 BONNET 12 SPINDLE-549 DO=8, 12.5
12 SPINDLE 14 SPLIT RING
14 SPLIT RING 16 SPRING PLATE
17 SPRING PATE 18 ADJUSTING SCREW
18 ADJUSTING SCREW 19 LOCK NUT
19 LOCK NUT 40 LIFTING CAP ‘H4'
40 LIFTING CAP ‘H4' 43 LEVER
43 LEVER 44 LIFTING FORK
44 LIFTING FORK 45 LEVER-SHAFT
45 LEVER-SHARFT 46 COUPLING H4 SIZE 1. TYPE 549
46 SPINDLE CAP 48 FLANGE
54 SPRING 54 SPRING
55 STUD 57 ROLL PIN
56 NUT 59 SECURING RING (SPLIT RING)
57 ROLL PIN 60 GASKET Ø42.5xØ34.5x1
59 SECURING RING FOR SPLIT 61 BALL
RING 74 PIN
60 GASKET FOR GUIDE 75 GASKET Ø45xØ33.2x1
61 BALL 76 GASKET Ø36xØ29.5x1
74 PIN FOR SPINDLE CAP 80 GLAND
75 GASKET FOR CAP 82 NUT
76 GASKET FOR NOZZLE 85 LEAD SEAL
80 GLAND 86 SEAL WIRE
82 HEX NUT 91 SECURING RING
91 SECURING RING FOR SPINDLE
CAP
SAMPLE COOLER
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WƌĞƐƐƵƌĞʹϭϱ͘ϵŬŐͬĐŵϮ
dĞŵƉĞƌĂƚƵƌĞʹϮϬϯĞŐ͘
ϮͿ ^ĂƚƵƌĂƚĞĚ^ƚĞĂŵ
WƌĞƐƐƵƌĞʹϭϱ͘ϵŬŐͬĐŵϮ
ϯͿ ^ƵƉĞƌŚĞĂƚĞĚ^ƚĞĂŵ
WƌĞƐƐƵƌĞʹϭϱ͘ϳŬŐͬĐŵϮ
dĞŵƉĞƌĂƚƵƌĞʹϯϬϬĞŐ͘
ϰͿ ůŽǁĚŽǁŶtĂƚĞƌ
WƌĞƐƐƵƌĞʹϮ͘ϴŬŐͬĐŵϮ
dĞŵƉĞƌĂƚƵƌĞʹϭϰϮĞŐ͘
ϱͿ ^ĂƚƵƌĂƚĞĚ^ƚĞĂŵ
WƌĞƐƐƵƌĞʹϮ͘ϴŬŐͬĐŵϮ
dĞŵƉĞƌĂƚƵƌĞʹϭϰϮĞŐ͘
ϲͿ ^ƵƉĞƌŚĞĂƚĞĚ^ƚĞĂŵ
WƌĞƐƐƵƌĞʹϮ͘ϲŬŐͬĐŵϮ
dĞŵƉĞƌĂƚƵƌĞʹϭϵϱĞŐ͘

ϳͿ ůŽǁĚŽǁŶtĂƚĞƌ
WƌĞƐƐƵƌĞʹϭϱ͘ϱŬŐͬĐŵϮ

ϴͿ ^ĂƚƵƌĂƚĞĚ^ƚĞĂŵ
WƌĞƐƐƵƌĞʹϭϱ͘ϱŬŐͬĐŵϮ

ϵͿ ^ƵƉĞƌŚĞĂƚĞĚ^ƚĞĂŵ
WƌĞƐƐƵƌĞʹϭϰ͘ϱŬŐͬĐŵϮ
dĞŵƉĞƌĂƚƵƌĞʹϯϵϬĞŐ͘

ϭϬͿ ůŽǁĚŽǁŶ^ƚĞĂŵ
WƌĞƐƐƵƌĞʹϮ͘ϱŬŐͬĐŵϮ
dĞŵƉĞƌĂƚƵƌĞʹϭϯϵĞŐ͘

ϭϭͿ ^ĂƚƵƌĂƚĞĚ^ƚĞĂŵ
dĞŵƉĞƌĂƚƵƌĞʹϭϯϵĞŐ͘

ϭϮͿ ^ƵƉĞƌŚĞĂƚĞĚ^ƚĞĂŵ
dĞŵƉĞƌĂƚƵƌĞʹϭϵϱĞŐ͘

^d/KE
/E^d>>d/KE/E^dZhd/KE^
KEdEd^

ϭ͘ /EdZKhd/KE

Ϯ͘ &KhEdKEWZWZd/KEEW>DEd

ϯ͘ hd/>/d/^KEEd/KE^

ϯ͘ϭŽŽůŝŶŐtĂƚĞƌ
ϯ͘Ϯ^ĂŵƉůĞ>ŝŶĞŽŶŶĞĐƚŝŽŶƐ
ϯ͘ϯ/ŶƚĞƌͲĐŽŶŶĞĐƚŝŽŶƐĂŵƉůĞƉŝƉĞǁŽƌŬ

ϭ͘ /EdZKhd/KE͗

dŚŝƐ ĚŽĐƵŵĞŶƚ ŝĚĞŶƚŝĨŝĞƐ ƚŚĞ ƌĞĐƚŝŽŶ ĂŶĚ /ŶƐƚĂůůĂƚŝŽŶ ƉƌŽĐĞĚƵƌĞƐ ƚŚĂƚ ĂƌĞ
ŶĞĐĞƐƐĂƌǇƚŽďĞĐŽŵƉůĞƚĞĚďĞĨŽƌĞƚŚĞĐŽŵŵŝƐƐŝŽŶŝŶŐŽĨƚŚĞ^ĂŵƉůŝŶŐĂŶĚĐŽŶĚŝƚŝŽŶŝŶŐ
ĞƋƵŝƉŵĞŶƚĐĂŶƉƌŽĐĞĞĚƐĂƚŝƐĨĂĐƚŽƌŝůǇ͘dŚĞƌĞĐƚŝŽŶĂŶĚ/ŶƐƚĂůůĂƚŝŽŶƉƌŽĐĞĚƵƌĞĐŽǀĞƌƐƚŚĞ
ŝŶƐƚĂůůĂƚŝŽŶĂŶĚƉŽƐŝƚŝŽŶŝŶŐŽĨƚŚĞ^ĂŵƉůĞƌĂĐŬ͘
Ϯ͘ &KhEd/KEWZWZd/KEEW>DEd͗

• ĨůĂƚĨůŽŽƌŽƌƉůŝŶƚŚŝƐƌĞƋƵŝƌĞĚĂƐĨŽƵŶĚĂƚŝŽŶĨŽƌƚŚĞĞƋƵŝƉŵĞŶƚ͘ ^ƵŝƚĂďůĞĨŽƵŶĚĂƚŝŽŶ
ďŽůƚƐĂƌĞƌĞƋƵŝƌĞĚĨŽƌĨůŽŽƌŝŶŐĨŝǆŝŶŐ͘
• ĞƚĞƌŵŝŶĞ ƚŚĞ ƉƌĞĐŝƐĞ ůŽĐĂƚŝŽŶ ƌĞƋƵŝƚĞĚ ĨŽƌ ƚŚĞ ĐŽŵƉůĞƚĞĚ ĨƌĂŵĞ ĂŶĚ ĂƐ ĐůŽƐĞůǇ ĂƐ
ƉŽƐƐŝďůĞ͕ŵĂƌŬŽƵƚĂŶĚĚƌŝůůƚŚĞĨůŽŽƌƚŽƌĞĐĞŝǀĞƚŚĞĨůŽŽƌďŽůƚƐ͘
• DĂŶĞƵǀĞƌƚŚĞĨƌĂŵĞŝŶƚŽƉŽƐŝƚŝŽŶ͕ĂůŝŐŶŝŶŐƚŚĞďŽůƚŚŽůĞƐĂƐĐůŽƐĞůǇĂƐƉŽƐƐŝďůĞǁŝƚŚƚŚĞ
ĨŝǆŝŶŐƐŝŶƚŚĞĨůŽŽƌ͘
• ŚĞĐŬƚŚĂƚĂůŝŐŶŵĞŶƚĐĂŶďĞĂĐŚŝĞǀĞĚǁŝƚŚĂůůĨůŽŽƌĨŝǆŝŶŐƐƐŝŵƵůƚĂŶĞŽƵƐůǇ͘
• &ĂƐƚĞŶĂůůĨůŽŽƌƐƚŝŐŚƚůǇ͘
• ĨƚĞƌĨŽůůŽǁŝŶŐƚŚĞĂďŽǀĞƉƌŽĐĞĚƵƌĞ͕ƚŚĞĞŶƚŝƌĞĂƐƐĞŵďůǇƐŚŽƵůĚƐƚĂŶĚĨŝƌŵůǇĨŝǆĞĚƚŽƚŚĞ
ĨůŽŽƌ͘

ϯ͘ hd/>/d/^KEEd/KE^͗
KK>/E'tdZ
tŚĞŶĐŽŶŶĞĐƚŝŶŐƚŚĞƐĞƌǀŝĐĞƉŝƉĞǁŽƌŬĞŶƐƵƌĞƐƚŚĂƚŝƚŝƐĂĚĞƋƵĂƚĞůǇƐƵƉƉŽƌƚĞĚ͕
ĚŽŶŽƚƵƐĞƚŚĞĐŽŽůĞƌŽƌĐŽŽůĞƌǀĂůǀĞƐĂƐĂŶĂŶĐŚŽƌƉŽŝŶƚ͘WƌŽǀŝƐŝŽŶƐŚŽƵůĚďĞŵĂĚĞ
ǁŚĞŶĨŝƚƚŝŶŐƚŚĞƉŝƉĞǁŽƌŬƚŽĂůůŽǁĨŽƌƚŚĞƉŽƐƐŝďůĞĞǆƉĂŶƐŝŽŶĂŶĚĐŽŶƚƌĂĐƚŝŽŶůŝŬĞůǇƚŽ
ŽĐĐƵƌĚƵƌŝŶŐŽƉĞƌĂƚŝŽŶŽĨƚŚĞƉůĂŶƚ͘ŽŽůŝŶŐǁĂƚĞƌĐŽŶŶĞĐƚŝŽŶƐĂƌĞĨůĂŶŐĞĚϮ͟EE^/
ϭϲ͘ϱϭϱϬηƌĞƐƉĞĐƚŝǀĞůǇ͘

^DW>>/EKEEd/KE^͗
ůůƐĂŵƉůĞŝŶůĞƚĐŽŶŶĞĐƚŝŽŶƐĂƌĞďǇƐƚĂŝŶůĞƐƐƐƚĞĞůƚƵďŝŶŐƚŽƚŚĞŝŶůĞƚǀĂůǀĞ͕Ъ͟E^^Ͳ
ϯϭϲƚƵďŝŶŐ͕ƐŽĐŬĞƚǁĞůĚĂĚĂƉƚŽƌƐĂƌĞƉƌŽǀŝĚĞĚĨŽƌĐŽŶŶĞĐƚŝŽŶďǇŽƚŚĞƌƐ͘

>KtKtE,ZKEEd/KE͗
dŚŝƐ ĐŽŶŶĞĐƚŝŽŶ ŝƐ Ă ϭͬϰ͟ K ƚƵďĞ ƐŝƚƵĂƚĞĚ Ăƚ ŽŶĞ ĞŶĚ ĂŶĚ Ăƚ Ă ůŽǁĞƌ ůĞǀĞů ŽĨ ƚŚĞ
ƐĂŵƉůŝŶŐƌĂĐŬ͘

^d/KE

KDD/^^/KE/E'WZKhZ
ϭ͘ K:d
Ϯ͘ Z,
ϯ͘ 'EZ>^Z/Wd/KE
ϰ͘ WW>/>KhDEd^
ϱ͘ ^hZ/dzE,>d,
ϲ͘ EEyhZ/͗,<>/^d&KZ^dZdͲhW

ϭ͘ K:d
dŚĞƉƵƌƉŽƐĞŽĨƚŚŝƐĚŽĐƵŵĞŶƚŝƐƚŽĚĞƐĐƌŝďĞƚŚĞ^dZdhWƉƌŽĐĞĚƵƌĞƐ͘

Ϯ͘ Z,
dŚĞ ƐĐŽƉĞ ŝƐ ƚŚĞ ĚĞƐĐƌŝƉƚŝŽŶ ŽĨ ƚŚĞ ƐƚĞƉƐ ĨŽƌ ĐŚĞĐŬŝŶŐ ĞƋƵŝƉŵĞŶƚ ĂŶĚ ĂĐĐĞƐƐŽƌŝĞƐ
ŵŽƵŶƚĞĚŽŶƚŚĞĚŝĨĨĞƌĞŶƚĐŽŶĚŝƚŝŽŶŝŶŐĂŶĚĂŶĂůǇƐŝƐƉĂŶĞůƐ͘dŚĞƐĞƚĞƐƚƐǀĞƌŝĨǇƚŚĂƚƚŚĞ
ƐǇƐƚĞŵǁŽƌŬƐĂĐĐŽƌĚŝŶŐƚŽƚŚĞƐƉĞĐŝĨŝĐĂƚŝŽŶƐŽĨƚŚŝƐƉƌŽũĞĐƚ͘

dŚĞ ĞŶĚ ĐƵƐƚŽŵĞƌ͕ WĂƌĂƐŚĂŬƚŝ ĞŵĞŶƚ /ŶĚƵƐƚƌŝĞƐ >ŝŵŝƚĞĚ ŵƵƐƚ ƉƌŽǀŝĚĞ ĂƐƐŝƐƚĂŶĐĞ
ĚƵƌŝŶŐƚŚĞƐƚĂƌƚͲƵƉ͘^ĂŝĚĂƐƐŝƐƚĂŶĐĞǁŝůůŶŽƚďĞůŝŵŝƚĞĚƚŽƚŚĞƉƌŽǀŝƐŝŽŶŽĨŵĂƚĞƌŝĂůƐĂŶĚ
ĞƋƵŝƉŵĞŶƚ͕ďƵƚǁŝůůĂůƐŽŝŶĐůƵĚĞůĂďŽƌ͕ƐĐĂĨĨŽůĚŝŶŐ͕ĞƚĐ͘

ϯ͘ 'EZ>^Z/Wd/KE
dŚŝƐ ĚŽĐƵŵĞŶƚ ƐŚŽǁƐ ĚŝĨĨĞƌĞŶƚ ƐĞĐƚŝŽŶƐ͕ ƌĞǀŝƐŝŽŶƐ ƚŽ ďĞ ŵĂĚĞ ĚƵƌŝŶŐ ƚŚĞ ƐƚĂƌƚͲƵƉ Ăƚ
ĚĞƐƚŝŶĂƚŝŽŶ͘
/Ŷ ĞĂĐŚ ŽĨ ƚŚĞ ďůŽĐŬƐ͕ ƚŚĞ ĂĐƚŝŽŶƐ ƚŽ ďĞ ĐĂƌƌŝĞĚ ŽƵƚ ĂƌĞ ĚĞƐĐƌŝďĞĚ͕ ĂƐ ǁĞůů ĂƐ ƚŚĞ
ƌĞĨĞƌĞŶĐĞĚŽĐƵŵĞŶƚƐĂŶĚƐƉĂĐĞĨŽƌƚŚĞƌĞůĞǀĂŶƚĂŶŶŽƚĂƚŝŽŶƐ͘

ϯ͘ϭ,<^^D>z

ĞƐĐƌŝƉƚŝŽŶ͗

• ŚĞĐŬǁŝƚŚƚŚĞWΘ/ĂŶĚǁŝƚŚƚŚĞ'ĞŶĞƌĂůƌƌĂŶŐĞŵĞŶƚ͕ĨŽƌƚŚĞĐŽƌƌĞĐƚƉůĂĐĞŵĞŶƚ
ŽĨƚŚĞĂĐĐĞƐƐŽƌŝĞƐ͕ǀĂůǀĞƐ͘
• >ŝŬĞǁŝƐĞ͕ ŵĞƚŝĐƵůŽƵƐ ĂŶĐŚŽƌŝŶŐ ŽĨ ƚŚĞ ĐŽŶƚĂŝŶĞƌ ƚŽ ƚŚĞ ŐƌŽƵŶĚ ƐůĂď ƐŚŽƵůĚ ďĞ
ĐŚĞĐŬĞĚ͘

ĐƚŝŽŶƐ͗
• sŝƐƵĂůŝŶƐƉĞĐƚŝŽŶƚŚĂƚĂůůĞƋƵŝƉŵĞŶƚŝƐŝŶŝƚƐĐŽƌƌĞĐƚƉůĂĐĞĂŶĚŝŶŐŽŽĚĐŽŶĚŝƚŝŽŶ͘
• sŝƐƵĂůŝŶƐƉĞĐƚŝŽŶŽĨƚŚĞĂŶĐŚŽƌŝŶŐĞůĞŵĞŶƚƐŽĨƚŚĞĐŽŶƚĂŝŶĞƌƚŽƚŚĞŐƌŽƵŶĚ͘
ϯ͘Ϯ KWZd/KEK&s>s^
ŚĞĐŬĨŽƌƚŚĞĐŽƌƌĞĐƚĂĚũƵƐƚŵĞŶƚŽĨƚŚĞŽƉĞŶŝŶŐͬĐůŽƐŝŶŐǀĂůǀĞƐ͘
ĐƚŝŽŶƐ͗
• KƉĞŶĂŶĚĐůŽƐĞĨƌŽŵϬйƚŽϭϬϬйƚŚĞŵĂŶƵĂůǀĂůǀĞƐŽĨƚŚĞƐǇƐƚĞŵ͘
• KƉĞŶĂŶĚĐůŽƐĞĨƌŽŵϬйƚŽϭϬϬйƐŽůĞŶŽŝĚǀĂůǀĞƐŝŶƚŚĞƐǇƐƚĞŵ͘
ϯ͘ϯ ><d^d
dŚĞĂŝŵŝƐƚŽǀĞƌŝĨǇƚŚĞĂďƐĞŶĐĞŽĨůĞĂŬƐŝŶƚŚĞƉƌŽĐĞƐƐůŝŶĞƐ͘
ĐƚŝŽŶƐ͗
dŚĞƉƌĞƐĞŶĐĞŽƌĂďƐĞŶĐĞŽĨůĞĂŬƐǁŝůůďĞĚĞƚĞĐƚĞĚǀŝƐƵĂůůǇŝŶƚŚĞƚĞƐƚƐŽĨƚŚĞĨƵŶĐƚŝŽŶŝŶŐ
ŽĨƚŚĞĞƋƵŝƉŵĞŶƚǁŝƚŚůŽĂĚ͘sŝƐƵĂůĐŚĞĐŬ͘
ϰ͘ WW>/>KhDEd^
^t^^ǇƐƚĞŵƌĂǁŝŶŐΘĂƚĂ^ŚĞĞƚ
ϭͿ WΘ/^ĂŵƉůŝŶŐƐǇƐƚĞŵ
ϮͿ 'ĞŶĞƌĂůƌƌĂŶŐĞŵĞŶƚĚƌĂǁŝŶŐ
ϯͿ &ŽƵŶĚĂƚŝŽŶĞƚĂŝůƐ
ϲ͘ϭ'ĞŶĞƌĂůĂĐĐĞƉƚĂŶĐĞĐƌŝƚĞƌŝĂ
KWE/E'ͬ>K^/E's>s^͘
/ŶƚŚĞĐĂƐĞŽĨĨŝŶĚŝŶŐĞǀŝĚĞŶĐĞƚŚĂƚƚŚĞǀĂůǀĞƐĚŽŶŽƚŽƉĞŶŽƌĐůŽƐĞĐŽƌƌĞĐƚůǇĂƚƚŚĞŝƌ
ůŝŵŝƚ;ϬйͲϭϬϬйͿ͕ƚŚĞƐĞǁŝůůďĞƌĞǀŝĞǁĞĚĂŶĚĂƐĞĐŽŶĚƚĞƐƚǁŝůůďĞĐĂƌƌŝĞĚŽƵƚůĂƚĞƌ͘
>K>/d/KEK&><^͘
/ŶƚŚĞĐĂƐĞŽĨůĞĂŬƐ͕ƚŚĞŚǇĚƌĂƵůŝĐƚĞƐƚŝŶƚŚĂƚƉŝƉĞůŝŶĞǁŝůůŶŽƚďĞĂĐĐĞƉƚĞĚ͘ƐĞĐŽŶĚ
ƚŝŐŚƚŶĞƐƐƚĞƐƚǁŝůůďĞĐĂƌƌŝĞĚŽƵƚĂĨƚĞƌƌĞǀŝĞǁŽĨƉŽƐƐŝďůĞĚĞĨĞĐƚƐ͘
^d/KE

W>Ed/dDKWZd/E'/E^dZhd/KE^

KEdEd^

ϭ͘ 'EZ>KWZd/E'ZYh/ZDEd^

Ϯ͘ Yh/WDEdΘZKhd/E,<^

Ϯ͘ϭKWZd/E'ΘD/EdEE>/dZdhZ

ϯ͘ dZKh>^,KKd/E'

tZE/E'͗K^Zs>>Z>sEd^&dzZh>^

ϭ͘ 'EZ>KWZd/E'ZYh/ZDEd^

dŚĞ ĞƋƵŝƉŵĞŶƚ ŝƐ ƉĂƌƚ ŽĨ ƚŚĞ &ĞĞĚ ĂŶĚ ^ƚĞĂŵ ŶĂůǇƐŝƐ ^ǇƐƚĞŵ͘ KƉĞƌĂƚŝŽŶ ŽĨ ƚŚĞ
ĞƋƵŝƉŵĞŶƚ ŝƐ ĚŝĐƚĂƚĞĚ ďǇ ƚŚĞ ƌĞƋƵŝƌĞŵĞŶƚƐ ŽĨ ƚŚĞ &ĞĞĚ ĂŶĚ ^ƚĞĂŵ ŶĂůǇƐŝƐ ^ǇƐƚĞŵ͘ ƵƌŝŶŐ
ŶŽƌŵĂůŽƉĞƌĂƚŝŽŶ͕ƚŚĞĞƋƵŝƉŵĞŶƚƐŚŽƵůĚƌƵŶĨŽƌƉƌŽůŽŶŐĞĚƉĞƌŝŽĚƐǁŝƚŚůŝƚƚůĞŽƌŶŽĂƚƚĞŶƚŝŽŶ͘
,ŽǁĞǀĞƌƌŽƵƚŝŶĞĐŚĞĐŬƐ͕ŵĂĚĞŽŶĐĞĚĂŝůǇŽƌĂƐĞǆƉĞƌŝĞŶĐĞƐƵŐŐĞƐƚ͕ǁŝůůŚĞůƉƚŽƉƌĞƐĞƌǀĞƚƌŽƵďůĞ
ĨƌĞĞĂŶĚĞĨĨŝĐŝĞŶƚŽƉĞƌĂƚŝŽŶŽĨƚŚĞƐǇƐƚĞŵ͘

Ϯ͘ Yh/WDEdEZKhd/E,<^͘

Ϯ͘ϭ͘ϭ^DW>KE/d/KE/E'DKh>^͗

• ŚĞĐŬ ƚŚĂƚ ƚŚĞ ƐĂŵƉůĞ ĨůŽǁ ƌĂƚĞƐ ĂƌĞ Ăƚ ƚŚĞ ƌĞƋƵŝƌĞĚ ůĞǀĞůƐ͕ ĂĚũƵƐƚŝŶŐ ƚŚĞ ĐŽŶƚƌŽů ǀĂůǀĞƐ ĂƐ
ŶĞĐĞƐƐĂƌǇ͘
• ŚĞĐŬ ƚŚĂƚ ƚŚĞƐĂŵƉůĞƚĞŵƉĞƌĂƚƵƌĞ ŽŶ ĞĂĐŚůŝŶĞŝƐŝŶƚŚĞƌĂŶŐĞŽĨϰϱĚĞŐ͕͘͘ ĂĚũƵƐƚŝŶŐƚŚĞͬ
ĐŽŽůŝŶŐǁĂƚĞƌĨůŽǁĐŽŶƚƌŽůǀĂůǀĞŝĨŶĞĐĞƐƐĂƌǇ͘
• dŽŬĞĞƉƚŚĞƐĂŵƉůĞĨŝůƚĞƌƐƌĞĂƐŽŶĂďůǇĐůĞĂƌŽĨĚĞďƌŝƐ͕ƚŚĞĨŝůƚĞƌĞůĞŵĞŶƚƐŚŽƵůĚďĞƌĞŵŽǀĞĚĂŶĚ
ĐůĞĂŶĞĚŽŶĂƌĞŐƵůĂƌďĂƐŝƐ͘dŚŝƐƉĞƌŝŽĚǁŝůůďĞĚĞƚĞƌŵŝŶĞĚǁŝƚŚĞǆƉĞƌŝĞŶĐĞ͕ǁŚĞŶƚŚĞĐŽŶĚŝƚŝŽŶ
ŽĨƚŚĞƌĞŵŽǀĞĚĨŝůƚĞƌĞůĞŵĞŶƚŝƐĞǆĂŵŝŶĞĚ͘

Ϯ͘ϭ͘Ϯ^DW>/E>d/^K>d/KEs>s^

KWZd/KE͗

sĂůǀĞƐƌĞƋƵŝƌĞĚĐŚĞĐŬŝŶŐďĞĨŽƌĞďĞŝŶŐƉƵƚŝŶƚŽŽƉĞƌĂƚŝŽŶ͘/ŶĂĚĚŝƚŝŽŶ͕ƌĞŐƵůĂƌŝŶƐƉĞĐƚŝŽŶŝƐĂůƐŽ
ŶĞĐĞƐƐĂƌǇĚƵƌŝŶŐŽƉĞƌĂƚŝŽŶĂŶĚƉƌŽŵƉƚĂƚƚĞŶƚŝŽŶŐŝǀĞŶŝĨƚƌŽƵďůĞĂƌŝƐĞƐ͘ƐĂŐĞŶĞƌĂůƌƵůĞ͕ǀĂůǀĞƐ
ƐŚŽƵůĚďĞƐƵďũĞĐƚĞĚƚŽƐĐŚĞĚƵůĞĚŵĂŝŶƚĞŶĂŶĐĞŝŶƚŚĞŵĂŶŶĞƌŶŽƌŵĂůƚŽĂůůƌƵŶŶŝŶŐŵĂĐŚŝŶĞƌǇ͘
WĂƌƚŝĐƵůĂƌĂƚƚĞŶƚŝŽŶŝƐĚƌĂǁŶƚŽƚŚĞĨŽůůŽǁŝŶŐŝŵƉŽƌƚĂŶƚŝŶƐƚƌƵĐƚŝŽŶƐ͘

>hZ/d/KE͗

dŚĞƐĞ ǀĂůǀĞƐ ĚŽ ŶŽƚ ŶŽƌŵĂůůǇ ƌĞƋƵŝƌĞ ůƵďƌŝĐĂƚŝŽŶ ďĞƚǁĞĞŶ ƚŚĞ ƐƉŝŶĚůĞ ĂŶĚ ǇŽŬĞ ďƵƐŚ͘ Ŷ
ĞǆĐĞƉƚŝŽŶƚŽƚŚŝƐŵŝŐŚƚ ďĞǁŚĞŶƚŚĞǀĂůǀĞŝƐƐƵďũĞĐƚĞĚƚŽĞǆĐĞƉƚŝŽŶĂůůǇŚŝŐŚƚĞŵƉĞƌĂƚƵƌĞƐ͕Žƌ
ǁŚĞŶƚŚĞǀĂůǀĞƌĞŵĂŝŶƐŽƉĞŶŽƌĐůŽƐĞĚĨŽƌůŽŶŐƉĞƌŝŽĚƐ͘/ŶƚŚŝƐŝŶƐƚĂŶĐĞ͕ŝƚŵĂǇďĞŚĞůƉĨƵůƚŽ
ŝŶƐĞƌƚƐƵŝƚĂďůĞŚŝŐŚƚĞŵƉĞƌĂƚƵƌĞŐƌĞĂƐĞ͕ƐƵĐŚĂƐZKKED,d͕ŽŶƚŚĞƚŚƌĞĂĚĨĂĐĞƐ͘tŚĞŶĂǀĂůǀĞ
ŝƐ ŶŽƚ ŽƉĞƌĂƚĞĚ ĨŽƌ ůŽŶŐ ƉĞƌŝŽĚƐ͕ Ă ƉĂƌƚŝĂů ǁŽƌŬŝŶŐ ŽĨ ƚŚĞ ƐƉŝŶĚůĞ ĂďŽƵƚ ŽŶĐĞ ƉĞƌ ŵŽŶƚŚ ŝƐ
ƌĞĐŽŵŵĞŶĚĞĚ͘

^dd/',dE^^͗

ǀĞŶĂŶĞǁǀĂůǀĞ͕ǁŝƚŚƐĞĂƚŝŶŐĨĂĐĞƐůĂƉƉĞĚƚŽƉĞƌĨĞĐƚŝŽŶ͕ĂŶĚǁŝƚŚƐĞĂƚͬĚŝƐĐĐŽŶƚĂĐƚƚŚƌŽƵŐŚŽƵƚ
ƚŚĞĞŶƚŝƌĞĐŝƌĐƵŵĨĞƌĞŶĐĞ͕ǁŝůůďĞƉƌĞƐƐƵƌĞͲƚŝŐŚƚŽŶůǇǁŚĞŶƐƵĨĨŝĐŝĞŶƚƐƚĞĂŵůŽĂĚŝƐĂƉƉůŝĞĚ͘dŚĞ
ŚĂŶĚǁŚĞĞůƐ͕ŚŽǁĞǀĞƌ͕ĂƌĞƐŝǌĞĚŝŶŽƌĚĞƌƚŚĂƚƚŚĞƌĞƋƵŝƌĞĚƚŽƌƋƵĞĐĂŶďĞĞǆĞƌƚĞĚŵĂŶƵĂůůǇ͘dŚĞ
ƵƐĞŽĨƐƚĞĂŵŬĞǇƐŽƌŽƚŚĞƌǁƌĞŶĐŚĞƐƐŚŽƵůĚŶŽƚďĞŶĞĐĞƐƐĂƌǇ͕ĂŶĚĐĂŶůĞĂĚƚŽƐĞƌŝŽƵƐĚĂŵĂŐĞ
ƚŽƚŚĞǀĂůǀĞ͘

ŐĞŶĞƌĂůƌƵůĞ͕ĂƉƉůŝĐĂďůĞƚŽƐŵĂůůǀĂůǀĞƐ͕ŝƐƚŚĂƚƚŝŐŚƚƐĞĂƚŝŶŐĐĂŶďĞĂĐŚŝĞǀĞĚǁŝƚŚƵƉƚŽĂƋƵĂƌƚĞƌ
ŽĨĂƚƵƌŶŽĨƚŚĞŚĂŶĚǁŚĞĞůĂĨƚĞƌĐŽŶƚĂĐƚŝƐŵĂĚĞďĞƚǁĞĞŶƚŚĞƐĞĂƚŝŶŐƐƵƌĨĂĐĞƐ͘ůŽƐŝŶŐƚŚĞǀĂůǀĞ
ĂŐĂŝŶƐƚĨŽƌĞŝŐŶ ŵĂƚƚĞƌ ůŽĚŐĞĚŽŶ ƚŚĞƐĞĂƚĐĂŶƌĞƐƵůƚŝŶŐƌŽŽǀĞƐŽƌ Ɖŝƚ ŵĂƌŬƐ͕ ƉƌĞǀĞŶƚŝŶŐƚŝŐŚƚ
ƐŚƵƚͲŽĨĨ͕ĂŶĚĐĂŶůĞĂĚƚŽ͚ǁŝƌĞͲĚƌĂǁŝŶŐ͛ĂŶĚƚŚĞĚĞƐƚƌƵĐƚŝŽŶŽĨƚŚĞƐĞĂƚŝŶŐĨĂĐĞƐ͘

/ĨůĞĂŬĂŐĞŝƐĚĞƚĞĐƚĞĚŽŶĐůŽƐŝŶŐƚŚĞǀĂůǀĞ͕ĚŽŶŽƚĂƉƉůǇŝŶĐƌĞĂƐĞĚƚŽƌƋƵĞƚŽƚŚĞŚĂŶĚǁŚĞĞůŝŶĂŶ
ĞĨĨŽƌƚƚŽŽďƚĂŝŶůĞĂŬʹĨƌĞĞĐůŽƐŝŶŐ͘ZĞͲŽƉĞŶƚŚĞǀĂůǀĞĂŶĚĂůůŽǁƚŚĞĨůŽǁƚŽĐůĞĂŶĨŽƌĞŝŐŶŵĂƚƚĞƌ
ĨƌŽŵƚŚĞƐĞĂƚŝŶŐĨĂĐĞƐ͕ƌĞƉĞĂƚŝŶŐŵŽƌĞƚŚĂŶŽŶĐĞŝĨŶĞĐĞƐƐĂƌǇ͘

W</E',DZd/',dE^^͗

WĂĐŬŝŶŐ ƌŝŶŐƐ ƵƐĞĚ ŝŶ ŚŝŐŚ ƚĞŵƉĞƌĂƚƵƌĞ ƐĞƌǀŝĐĞ ĂƐ ƌĞĐĞŝǀĞĚ ĨƌŽŵ ƉĂĐŬŝŶŐ ŵĂŶƵĨĂĐƚƵƌĞƌƐ ĂƌĞ
ƉŽƌŽƵƐĂŶĚƐŚŽƵůĚŝŶŝƚŝĂůůǇďĞĐŽŵƉƌĞƐƐĞĚĂƐŵƵĐŚĂƐƉŽƐƐŝďůĞƚŽƉƌŽǀŝĚĞĂŐŽŽĚƐĞĂů͘hŶůĞƐƐ
ŽƚŚĞƌǁŝƐĞƌĞƋƵĞƐƚĞĚ͕ǀĂůǀĞƐǁŝůůŶŽƌŵĂůůǇďĞƉĂĐŬĞĚǁŝƚŚ'ZW,K/>ƉĂĐŬŝŶŐƌŝŶŐƐ͘
,ǇĚƌŽƐƚĂƚŝĐƚĞƐƚƉƌĞƐƐƵƌĞǁŝůůĐŽŶĚŝƚŝŽŶƚŚĞƌŝŶŐƐ͕ĞƐƉĞĐŝĂůůǇƚŚĞƚǁŽŽƌƚŚƌĞĞůŽǁĞƌŽŶĞƐ͘'ůĂŶĚ
ŽůƚƐƐŚŽƵůĚďĞƌĞͲƚŝŐŚƚĞŶĞĚĂĨƚĞƌƚĞƐƚƚŽŵĂŝŶƚĂŝŶƚŝŐŚƚŶĞƐƐ͘dŚĞŐůĂŶĚďŽůƚƐƐŚŽƵůĚĂůƐŽďĞƌĞͲ
ƚŝŐŚƚĞŶĞĚĂĨƚĞƌƚŚĞŝŶŝƚŝĂůϱͲϳĐǇĐůĞƐ͘

Ϯ͘ϭ͘ϯ^DW>KEdZK>s>s^

^Z/Wd/KE͗

EĞĞĚůĞsĂůǀĞƐĂƌĞƌƵŐŐĞĚůǇĐŽŶƐƚƌƵĐƚĞĚĨƌŽŵďĂƌƐƚŽĐŬŵĂƚĞƌŝĂů͘dŚĞǀĂůǀĞƐŚĂǀĞĂĐůĂƐƐϮϱϬϬ
ƌĂƚŝŶŐĂŶĚ
ĞƐŝŐŶŝŶĐŽƌƉŽƌĂƚĞƐĨƵůůďĂĐŬƐĞĂƚŝŶŐĂŶĚĂŶƚŝͲďůŽǁŽƵƚƐƚĞŵ͘

DĂŝŶƚĞŶĂŶĐĞ͗

dŚĞƌĞŝƐŶŽƌĞĐŽŵŵĞŶĚĞĚŵĂŝŶƚĞŶĂŶĐĞĨŽƌƚŚŝƐƐĞƌŝĞƐŽĨǀĂůǀĞƐ͕ŽŶůǇƚŽĞŶƐƵƌĞƚŚĞŐůĂŶĚƉĂĐŬŝŶŐ
ĚŽĞƐŶŽƚůĞĂŬ͕ďƵƚĚƵĞƚŽƚŚĞĚĞƐŝŐŶƚŚŝƐŝƐŚŝŐŚůǇƵŶůŝŬĞůǇ͘/ŶƚŚĞĞǀĞŶƚŽĨĂǀĂůǀĞŵĂůĨƵŶĐƚŝŽŶ
ƚŚĞĐŽŵƉůĞƚĞǀĂůǀĞƐŚŽƵůĚďĞƌĞƉůĂĐĞĚ͘

Ϯ͘ϭ͘ϰKK>Ed/^K>d/KE>>s>s^

^Z/Wd/KE͗

^ŵĂůůƐƚĂŝŶůĞƐƐƐƚĞĞůďĂůůǀĂůǀĞƐĂƌĞƵƐĞĚĨŽƌƚŚĞŝƐŽůĂƚŝŽŶŽĨƚŚĞƐĂŵƉůĞƐĂŶĚƐŵĂůůŐƵŶŵĞƚĂůͬ
ĐĂƌďŽŶƐƚĞĞůďĂůůǀĂůǀĞƐĨŽƌƚŚĞĐŽŽůĂŶƚƐƵƉƉůŝĞƐ͘

dŚĞďĂůůǀĂůǀĞƐĂƌĞŵŽƐƚƵŶůŝŬĞůǇƚŽƌĞƋƵŝƌĞĂƚƚĞŶƚŝŽŶ͕ĂŶĚŶŽŵĂŝŶƚĞŶĂŶĐĞŝƐƚŚĞƌĞĨŽƌĞŶĞĞĚĞĚ͘
/ŶƚŚĞĞǀĞŶƚŽĨƚƌŽƵďůĞĂƌŝƐŝŶŐǁŝƚŚƚŚĞǀĂůǀĞƐ͕ƚŚĞǇƐŚŽƵůĚďĞƚƌĞĂƚĞĚĂƐĚŝƐƉŽƐĂďůĞŝƚĞŵƐĂŶĚ
ƌĞƉůĂĐĞĚ͘

dŚĞǀĂůǀĞƐĂƌĞŝŶƚŚĞŽƉĞŶƉŽƐŝƚŝŽŶǁŝƚŚƚŚĞŚĂŶĚůĞƉĂƌĂůůĞůƚŽƚŚĞǀĂůǀĞďŽĚǇ͕ĂŶĚĐůŽƐĞĚǁŝƚŚ
ƚŚĞŚĂŶĚůĞĂƚƌŝŐŚƚĂŶŐůĞƐ͘dŚĞǀĂůǀĞƐĚŽŶŽƚŚĂǀĞƚŚĞƉƌŽǀŝƐŝŽŶĨŽƌǀĞŶƚŝŶŐƚŽĂƚŵŽƐƉŚĞƌĞŝŶĂŶǇ
ƉŽƐŝƚŝŽŶ͘

Ϯ͘ϭ͘ϱ^DW>/^K>d/KEϯtz>>s>s^͗

^Z/Wd/KE͗

^ŵĂůůƐƚĂŝŶůĞƐƐƐƚĞĞůďĂůůǀĂůǀĞƐĂƌĞƵƐĞĚĨŽƌŝƐŽůĂƚŝŽŶŽĨƚŚĞƐĂŵƉůĞ͕ĐŽŵƉƌŝƐĞĂĐĂƐƚƐƚĞĞůďŽĚǇ
ǁŝƚŚƌĞŵŽǀĂďůĞƐƚĞŵ͕ǀĂůǀĞƐĞĂƚĂŶĚĞŶĚĐŽŶŶĞĐƚŽƌƐ͘

dŚĞǀĂůǀĞƐĚŽŶŽƚŚĂǀĞƚŚĞƉƌŽǀŝƐŝŽŶĨŽƌǀĞŶƚŝŶŐƚŽĂƚŵŽƐƉŚĞƌĞŝŶĂŶǇƉŽƐŝƚŝŽŶ͘

D/EdEE͗

• dŚĞsĂůǀĞƐĂƌĞŵŽƐƚƵŶůŝŬĞůǇƚŽƌĞƋƵŝƌĞĂƚƚĞŶƚŝŽŶďƵƚŝŶƚŚĞƵŶůŝŬĞůǇĞǀĞŶƚĂƐƉĂƌĞƐŬŝƚŝƐ
ĂǀĂŝůĂďůĞ͘ dŚŝƐ ŝŶĐůƵĚĞƐ ƌĞƉůĂĐĞŵĞŶƚ ͚K͛ ƌŝŶŐƐ͕ ǀĂůǀĞ ƐĞĂƚƐ͕ ƉĂĐŬŝŶŐ ǁĂƐŚĞƌƐ ĂŶĚ
ŝŶƐƚƌƵĐƚŝŽŶƐ͘
• ZĞŵŽǀĞ ƚŚĞ ŚĂŶĚ ǁŚĞĞů ďǇ ƵƐŝŶŐ ĂŶ ůůĞŶ ŬĞǇ ŝŶ ƚŚĞ ƐŽĐŬĞƚ ƐĞƚ ƐĐƌĞǁ ĂŶĚ ƚƵƌŶŝŶŐ
ĂŶƚŝĐůŽĐŬǁŝƐĞ͘
• ZĞŵŽǀĞƚŚĞǀĂůǀĞďŽĚǇĨƌŽŵŝƚƐŵŽƵŶƚŝŶŐƉĂŶĞůŽƌďƌĂĐŬĞƚďǇƌĞůĞĂƐŝŶŐƚŚĞƉĂŶĞůŶƵƚ͘
• ŝƐĐŽŶŶĞĐƚĨƌŽŵƚŚĞƐĂŵƉůĞƉŝƉĞǁŽƌŬ͘
• ZĞŵŽǀĞƚŚĞŐůĂŶĚͲƉĂĐŬŝŶŐŶƵƚďǇƚƵƌŶŝŶŐĂŶƚŝͲĐůŽĐŬǁŝƐĞ͘
• ZĞŵŽǀĞ ƚŚĞ ƐƚĞŵ ĂƐƐĞŵďůǇ ĨƌŽŵ ƚŚĞ ďŽĚǇ͕ ƌĞƉůĂĐĞ ƐƚĞŵ ͚K͛ ƌŝŶŐƐ ĂŶĚ ƐƚĞŵ ƉĂĐŬŝŶŐ
ǁĂƐŚĞƌƐ͘E͘͘ŽŶŽƚĚŝƐĐĂƌĚŐůĂŶĚƉĂĐŬŝŶŐʹƚŚŝƐŝƐƚŽďĞƌĞͲƵƐĞĚ͘
• dŽĂĐĐĞƐƐƚŚĞǀĂůǀĞƐĞĂƚƐ͕ƐĞĐƵƌĞƚŚĞďŽĚǇƵƐŝŶŐĂƐƵŝƚĂďůĞǁƌĞŶĐŚĂŶĚƌĞŵŽǀĞƚŚĞĞŶĚ
ĐŽŶŶĞĐƚŽƌƐ͘
• ĂƌĞŵƵƐƚďĞĞǆĞƌĐŝƐĞĚǁŚĞŶƌĞŵŽǀŝŶŐǀĂůǀĞƐĞĂƚƐĂŶĚ͚K͛ƌŝŶŐƐĨƌŽŵƚŚĞďŽĚǇ͘&ŝƚŶĞǁ
ƐĞĂƚƐĂŶĚ͚K͛ƌŝŶŐƐ͘
• ZĞͲĂƐƐĞŵďůǇŝƐƚŚĞƌĞǀĞƌƐĂůŽĨƚŚĞƌĞŵŽǀĂůƉƌŽĐĞĚƵƌĞƚĂŬŝŶŐĐĂƌĞŶŽƚƚŽĂůůŽǁƚŚĞŝŶŐƌĞƐƐ
ŽĨĚŝƌƚͬĐŽŶƚĂŵŝŶĂƚŝŽŶŝŶƚŽƚŚĞǀĂůǀĞ͘

^^D>zK&KDWZ^^/KE&/dd/E'^͗

• dŚĞƐĞ ŝŶƐƚƌƵĐƚŝŽŶƐ ĂƌĞ ĂƉƉůŝĐĂďůĞ ƚŽ Ăůů ƚǁŝŶͲƌŝŶŐ ŚŝŐŚ ƉƌĞƐƐƵƌĞ ƚƵďĞ ĐŽŵƉƌĞƐƐŝŽŶ
ĐŽƵƉůŝŶŐƐŝŶƚŚĞƐŝǌĞƌĂŶŐĞЬ͟K͘
• dŚĞĐŽŵƉƌĞƐƐŝŽŶĨŝƚƚŝŶŐƐĂƌĞƐƵƉƉůŝĞĚƌĞĂĚǇĂƐƐĞŵďůĞĚ͕ĨŝŶŐĞƌͲƚŝŐŚƚ͕ǁŝƚŚƚŚĞƐĞĂůŝŶŐƌŝŶŐƐ
ŝŶƚŚĞĐŽƌƌĞĐƚŽƌĚĞƌ͘/ƚŝƐŶĞŝƚŚĞƌŶĞĐĞƐƐĂƌǇŶŽƌĚĞƐŝƌĂďůĞƚŽĚŝƐŵĂŶƚůĞƚŚĞĨŝƚƚŝŶŐ͘/ŶƚŚĞ
ĞǀĞŶƚŽĨƚŚĞĨŝƚƚŝŶŐďĞĐŽŵŝŶŐĚŝƐͲĂƐƐĞŵďůĞĚ͕ƚŚĞƉĂƌƚƐŵƵƐƚďĞƌĞͲĂƐƐĞŵďůĞĚŝŶƚŚĞŽƌĚĞƌ
ĂŶĚŽƌŝĞŶƚĂƚŝŽŶƐŚŽǁŶŝŶƚŚĞĚƌĂǁŝŶŐ͕ƐůŝƉƉŝŶŐĞĂĐŚĐŽŵƉŽŶĞŶƚŽǀĞƌĂƐŚŽƌƚƉŝĞĐĞŽĨƚƵďĞ
ŽĨƚŚĞĐŽƌƌĞĐƚƐŝǌĞƚŽĞŶƐƵƌĞĂůŝŐŶŵĞŶƚ͕ĂŶĚƚŝŐŚƚĞŶŝŶŐƚŽĨŝŶŐĞƌͲƚŝŐŚƚ͘
• ŶƐƵƌĞƚŚĂƚƚŚĞĐŽƌƌĞĐƚƐŝǌĞŽĨĐŽŵƉƌĞƐƐŝŽŶĨŝƚƚŝŶŐŚĂƐďĞĞŶƐĞůĞĐƚĞĚĨŽƌƚŚĞƚƵďĞƚŽďĞ
ĞŵƉůŽǇĞĚ͘dŚĞƚƵďĞƐŚŽƵůĚďĞĂĐůŽƐĞƐůŝĚŝŶŐĨŝƚŝŶƚŚĞŶƵƚ͕ƌŝŶŐƐĂŶĚďŽĚǇ͘
• ŶƐƵƌĞƚŚĂƚƚŚĞƚƵďŝŶŐƚŽďĞƵƐĞĚŝƐŶŽƚƐĐŽƌĞĚ͕ĨůĂƚƚĞŶĞĚŽƌŽƚŚĞƌǁŝƐĞĚĂŵĂŐĞĚ͘ƵƚƚŚĞ
ĞŶĚŽĨƚŚĞƚƵďĞƐƋƵĂƌĞĂŶĚĐĂƌĞĨƵůůǇĚĞďƵƌŝŶƐŝĚĞĂŶĚŽƵƚƐŝĚĞ͘
• /ŶƐĞƌƚƚŚĞƚƵďĞŝŶƚŽƚŚĞĨŝƚƚŝŶŐ͕ĞŶƐƵƌŝŶŐƚŚĂƚŝƚƉĂƐƐĞƐƌŝŐŚƚƚŚƌŽƵŐŚƚŚĞŶƵƚĂŶĚďŽƚŚƌŝŶŐƐ
ƚŽƌĞƐƚĨŝƌŵůǇŽŶƚŚĞŝŶƚĞƌŶĂůƐŚŽƵůĚĞƌŽĨƚŚĞďŽĚǇ͘
• ^ĞůĞĐƚĂƐƉĂŶŶĞƌǁŚŝĐŚŝƐĂĐůŽƐĞĨŝƚŽŶƚŚĞďŽĚǇŽĨƚŚĞĨŝƚƚŝŶŐ͕ŽƌĂůƚĞƌŶĂƚŝǀĞůǇŚŽůĚƚŚĞ
ďŽĚǇŽĨƚŚĞĨŝƚƚŝŶŐŝŶĂǀŝĐĞ͘
• hƐŝŶŐĂƐƉĂŶŶĞƌŽĨƚŚĞĐŽƌƌĞĐƚƐŝǌĞ͕ŐĞŶƚůǇƚŝŐŚƚĞŶƚŚĞŶƵƚƵŶƚŝůƚŚĞƚƵďŝŶŐǁŝůůũƵƐƚŶŽƚ
ƚƵƌŶďǇŚĂŶĚ͘
• ^ĐƌŝďĞĂŵĂƌŬŽŶƚŚĞŶƵƚ͘
• hƐŝŶŐƚŚŝƐŵĂƌŬĂƐĂƌĞĨĞƌĞŶĐĞ͕ƚŝŐŚƚĞŶƚŚĞŶƵƚĂĨƵƌƚŚĞƌϭ͘ϭͬϰƚƵƌŶƐ͘
• dŚĞ ĨŝƚƚŝŶŐ ŝƐ ŶŽǁ ƌĞĂĚǇ ĨŽƌ ƵƐĞ Ăƚ ŵĂǆŝŵƵŵ ƉƌĞƐƐƵƌĞ͘ /ƚ ŵĂǇ ďĞ ĚŝƐŵĂŶƚůĞĚ ĂŶĚ ƌĞͲ
ĂƐƐĞŵďůĞĚ ŵĂŶǇ ƚŝŵĞƐ͘ KŶ ƌĞͲĂƐƐĞŵďůǇ͕ ƚŚĞ ŶƵƚ ƐŚŽƵůĚ ďĞ ƚŝŐŚƚĞŶĞĚ ƚŽ ƚŚĞ ĂďŽǀĞ
ƉŽƐŝƚŝŽŶĂŶĚƚŚĞŶƐůŝŐŚƚĂĚĚŝƚŝŽŶĂůƐĞĂƚŝŶŐƉƌĞƐƐƵƌĞĂƉƉůŝĞĚǁŝƚŚƚŚĞƐƉĂŶŶĞƌ͘
Ϯ͘ϭ͘ϲ^DW>KK>Z^

^Z/Wd/KE͗

dŚĞƐĂŵƉůĞĐŽŽůĞƌƐĂƌĞĂƌĂŶŐĞŽĨŚŝŐŚůǇĞĨĨŝĐŝĞŶƚƵŶŝƚƐĚĞƐŝŐŶĞĚĨŽƌƚŚĞƌĂƉŝĚĐŽŽůŝŶŐŽĨƐĂŵƉůĞƐ
ŽĨďŽŝůĞƌǁĂƚĞƌĂŶĚƐƚĞĂŵŽǀĞƌƚŚĞƌĂŶŐĞŽĨƚĞŵƉĞƌĂƚƵƌĞƐĞŶĐŽƵŶƚĞƌĞĚǁŝƚŚŝŶƚŚĞƉŽǁĞƌƉůĂŶƚ͘
dŚĞĐŽŽůĞƌƐĚŝĨĨĞƌŝŶƚŚĞůĞŶŐƚŚ͕ĚŝĂŵĞƚĞƌĂŶĚ ŵĂƚĞƌŝĂůŽĨƚŚĞĐŽŽůŝŶŐĞůĞŵĞŶƚ;ĂŶĚŚĞŶĐĞƚŚĞ
ůĞŶŐƚŚŽĨƚŚĞƐŚĞůůͿƌĞƋƵŝƌĞĚĨŽƌƚŚĞĚŝĨĨĞƌĞŶƚƚŚĞƌŵĂůĚƵƚŝĞƐ͕ĂŶĚĂůůƌĞƉůĂĐĞŵĞŶƚƉĂƌƚƐĞǆĐĞƉƚ
ƚŚĞĐŽŽůŝŶŐĐŽŝů͕ĂƐƐŽĐŝĂƚĞĚƐƚƵĚĐŽƵƉůŝŶŐƐ;ƵƐĞĚĨŽƌƐĞĐƵƌŝŶŐƚŚĞĐŽŝůƚŽƚŚĞĐŽŽůĞƌůŝĚͿ͕ĂŶĚƐŚĞůů
ĂƌĞŝŶƚĞƌĐŚĂŶŐĞĂďůĞďĞƚǁĞĞŶƚŚĞĚŝĨĨĞƌĞŶƚĐŽŽůĞƌƐ͘

dŚĞĐŽŽůĞƌŝƐƉĂƌƚŝƚŝŽŶĞĚŝŶƚŽƚŚƌĞĞĐŽŶĐĞŶƚƌŝĐĐŚĂŵďĞƌƐďǇŵĞĂŶƐŽĨƚǁŽĂǆŝĂůƚƵďƵůĂƌďĂĨĨůĞƐ͘
dŚĞĐŽŽůŝŶŐǁĂƚĞƌĨůŽǁƐŝŶƚŽƚŚĞƚŽƉŽĨƚŚĞŝŶŶĞƌĐŚĂŵďĞƌ͕ĂŶĚƚŚĞŶƉĂƐƐĞƐƚŽƚŚĞŽƵƚĞƌĐŚĂŵďĞƌ͕
ƌĞƚƵƌŶŝŶŐƵƉǁĂƌĚƐƚŽƚŚĞŽƵƚůĞƚƉŽƌƚ͘
/E^d>>d/KE͗

dŚĞĞƋƵŝƉŵĞŶƚƐŚŽƵůĚŶŽƚďĞĚƌŽƉƉĞĚ͕ĚƌĂŐŐĞĚŽƌŽƚŚĞƌǁŝƐĞƚƌĞĂƚĞĚƌŽƵŐŚůǇ͘^ĂŵƉůĞŽƌĐŽŽůŝŶŐ
ǁĂƚĞƌƉŝƉĞǁŽƌŬŵƵƐƚEKdďĞƵƐĞĚĨŽƌůŝĨƚŝŶŐƉƵƌƉŽƐĞƐ͘ĂƌĞŵƵƐƚďĞƚĂŬĞŶƚŽĞŶƐƵƌĞƚŚĂƚƚŚĞ
ũŽŝŶƚĨĂĐĞƐĂƌĞŶŽƚďƌƵŝƐĞĚĂŶĚĞƋƵŝƉŵĞŶƚŝƐŶŽƚĚĂŵĂŐĞĚŝŶĂŶǇǁĂǇ͘

EŽǁĂƚĞƌƐŚŽƵůĚďĞĂůůŽǁĞĚƚŽƌĞŵĂŝŶŝŶƚŚĞĐŽŽůĞƌƐŚĞůůŽƌƐĂŵƉůĞƉŝƉĞǁŽƌŬŝĨĨƌĞĞǌŝŶŐŝƐůŝŬĞůǇ
ƚŽŽĐĐƵƌ͘

ŽŽůĞƌĂƐƐĞŵďůŝĞƐƐŚŽƵůĚďĞĨŝƌŵůǇŵŽƵŶƚĞĚŝŶĂǀĞƌƚŝĐĂůƉŽƐŝƚŝŽŶŝŶĂƐĂĨĞͬƐĞĐƵƌĞďƵƚĂĐĐĞƐƐŝďůĞ
ƉŽƐŝƚŝŽŶ͘;EŽƚĞƚŚĞĐůĞĂƌĂŶĐĞƌĞƋƵŝƌĞĚĨŽƌƚŚĞƌĞŵŽǀĂůŽĨƚŚĞĐŽŽůĞƌƐŚĞůůĨŽƌĐŽŝůĐůĞĂŶŝŶŐͿ͘

dŚĞƐĂŵƉůĞƉŝƉĞǁŽƌŬƐŚŽƵůĚďĞƌŽƵƚĞĚŝŶĂƐĂĨĞŵĂŶŶĞƌƉƌŽƚĞĐƚŝŶŐƉĞƌƐŽŶŶĞůĂŐĂŝŶƐƚĐŽŶƚĂĐƚ
ǁŝƚŚŚŽƚƉŝƉĞƐďǇŝŶƐƵůĂƚŝŶŐǁŚĞƌĞŶĞĐĞƐƐĂƌǇ͘

ŶƐƵƌĞĂŶĂĚĞƋƵĂƚĞƐƵƉƉůǇŽĨĐŽŽůŝŶŐǁĂƚĞƌŝƐĂǀĂŝůĂďůĞĂŶĚĐŽŶŶĞĐƚĞĚ͘
KŶĐŽŵƉůĞƚŝŽŶŽĨŝŶƐƚĂůůĂƚŝŽŶ͕ƉƌĞƐƐƵƌĞƚĞƐƚĂůůƉŝƉĞǁŽƌŬĂŶĚĐŚĞĐŬĨŽƌůĞĂŬƐ͘

'EZ>KWZd/E'WZhd/KE^͗

tŚĞŶ ŽƉĞƌĂƚŝŶŐ ƚŚŝƐ ĞƋƵŝƉŵĞŶƚ͕ ŝƚ ŵƵƐƚ ĂůǁĂǇƐ ďĞ ƌĞŵĞŵďĞƌĞĚ ƚŚĂƚ ƚŚĞ ƐĂŵƉůĞ ŝƐ Ăƚ ŚŝŐŚ
ƚĞŵƉĞƌĂƚƵƌĞĂŶĚƉƌĞƐƐƵƌĞ͕ĂŶĚĨŽƌƚŚŝƐƌĞĂƐŽŶĐĂƌĞŵƵƐƚďĞƚĂŬĞŶƚŽĞŶƐƵƌĞƚŚĂƚ͗Ͳ

WĞƌƐŽŶĂůĐŽŶƚĂĐƚǁŝƚŚŚŽƚƐĂŵƉůĞŝŶůĞƚƉŝƉĞǁŽƌŬĞƚĐ͘ŝƐĂǀŽŝĚĞĚ͘
ůŽǁŝŶŐĚŽǁŶŽĨƐĂŵƉůĞůŝŶĞƐŝƐƵŶĚĞƌƚĂŬĞŶǁŝƚŚĐĂƵƚŝŽŶ͕ƚŽĂǀŽŝĚƚŚĞƉŽƐƐŝďŝůŝƚǇŽĨƐĐĂůĚŝŶŐ͘
EŽĞƋƵŝƉŵĞŶƚŝƐĐŽŶŶĞĐƚĞĚƚŽƚŚĞƐĂŵƉůĞŽƵƚůĞƚ͕ǁŚŝĐŚŝƐŝŶĐĂƉĂďůĞŽĨǁŝƚŚƐƚĂŶĚŝŶŐƚŚĞĚĞƐŝŐŶ
ƉĂƌĂŵĞƚĞƌƐ͘
ůůǀĂůǀĞƐŵƵƐƚďĞŽƉĞƌĂƚĞĚƐůŽǁůǇ͘

KWZd/KE͗

WZͲ^dZdZYh/ZDEdÊWZhd/KE^͗

• ŚĞĐŬƚŚĂƚƚŚĞŝŶƐƚĂůůĂƚŝŽŶŚĂƐďĞĞŶĐĂƌƌŝĞĚŽƵƚŝŶĂĐĐŽƌĚĂŶĐĞǁŝƚŚĐŽƌƌĞĐƚƉƌŽĐĞĚƵƌĞƐ͘
KƉĞŶ ƚŚĞ ĐŽŽůĂŶƚ ŝŶůĞƚ ĂŶĚ ŽƵƚůĞƚ ǀĂůǀĞƐ ƚŽ ƚŚĞ ĐŽŽůĞƌ ĨƵůůǇ͘ ŚĞĐŬ ƚŚĂƚ ƚŚĞ ĐŽŽůĂŶƚ ŝƐ
ĨůŽǁŝŶŐǀŝŐŽƌŽƵƐůǇĂŶĚĂůůŽǁƚŚĞĐŽŽůĂŶƚƚŽĨůŽǁƵŶƚŝůĂůůƚŚĞĂŝƌŝƐĞůŝŵŝŶĂƚĞĚĨƌŽŵƚŚĞ
ƐǇƐƚĞŵ;ŶŽĂŝƌďƵďďůĞƐĂƌĞŝŶǀŝĞǁŝŶƚŚĞƐŝŐŚƚŐůĂƐƐͿŝĨĨŝƚƚĞĚ͘
• ŚĞĐŬƚŚĂƚĂůůƐĂŵƉůĞǀĂůǀĞƐĂƌĞĐůŽƐĞĚ͘ĂƌĞĨƵůůǇŽƉĞŶƚŚĞƐĂŵƉůĞŝŶůĞƚǀĂůǀĞƵŶƚŝůĨƵůůǇ
ŽƉĞŶ͕ĨŽůůŽǁĞĚďǇĂƋƵĂƌƚĞƌͲƚƵƌŶŝŶƚŚĞŽƉƉŽƐŝƚĞĚŝƌĞĐƚŝŽŶ;ƚŽƉƌĞǀĞŶƚƚŚĞǀĂůǀĞƐƚŝĐŬŝŶŐ
ŽŶƚŚĞďĂĐŬʹƐĞĂƚŝŶƚŚĞŽƉĞŶƉŽƐŝƚŝŽŶͿ͘ŚĞĐŬĨŽƌůĞĂŬƐ͘
• ĂƵƚŝŽƵƐůǇŽƉĞŶƚŚĞƐĂŵƉůĞŽƵƚůĞƚǀĂůǀĞƵŶƚŝůƚŚĞƐĂŵƉůĞďĞŐŝŶƐƚŽĨůŽǁ͘ůůŽǁƚŚĞƐĂŵƉůĞ
ƚŽĨůŽǁĂƚƚŚĞƌĂƚĞŽĨϮͲϯůŝƚƌĞƐͬŵŝŶƵƚĞƵŶƚŝůƚŚĞŝƐƐƵŝŶŐƐĂŵƉůĞďĞĐŽŵĞƐĐůĞĂƌĂŶĚĨƌĞĞ
ĨƌŽŵĚĞďƌŝƐ͘

tZE/E'͗
/ĨĞŝƚŚĞƌƚŚĞƐĂŵƉůĞŽƌĐŽŽůĂŶƚƚĞŵƉĞƌĂƚƵƌĞƐďĞĐŽŵĞƚŽŽŚŽƚ͕ĐůŽƐĞƚŚĞƐĂŵƉůĞŝŶůĞƚǀĂůǀĞĂŶĚ
ĂůůŽǁƚŚĞĐŽŽůĂŶƚƐǇƐƚĞŵƚŽƌĞĐŽǀĞƌƚŚĞŶĐŽŶƚŝŶƵĞŝŶƐƚĂŐĞƐ͘

ĚũƵƐƚƚŚĞƐĂŵƉůĞŽƵƚůĞƚǀĂůǀĞĂŶĚƌƵŶƚŚĞƐĂŵƉůĞĂƐϭůŝƚĞƌͬŵŝŶƵƚĞ͕ĂůůŽǁƚŚĞƐǇƐƚĞŵƚŽƐĞƚƚůĞ
ĚŽǁŶ ďǇ ƌƵŶŶŝŶŐ ĨŽƌ ĂƉƉƌŽǆ͘ ϱ ŵŝŶƵƚĞƐ ĂŶĚ ĐŚĞĐŬ ƚŚĂƚ ƚŚĞ ĐŽŽůĂŶƚ ŽƵƚůĞƚ ƉŝƉĞǁŽƌŬ ĚŽĞƐ ŶŽƚ
ďĞĐŽŵĞŚŽƚ͘/ĨŝƚĚŽĞƐ͕ƚŚĞŶƚŚĞƚĞŵƉĞƌĂƚƵƌĞŝƐƚŽŽŚŝŐŚĂŶĚĂŶŝŶĐƌĞĂƐĞŝŶƚŚĞĐŽŽůĂŶƚĨůŽǁŝƐ
ŶĞĐĞƐƐĂƌǇ͘

^dZdhWWZKhZ͗

• ĨƚĞƌĨŽůůŽǁŝŶŐƚŚĞĂďŽǀĞƉƌŽĐĞĚƵƌĞ͕ƚŚĞĐŽŽůĞƌƐŵĂǇďĞůĞĨƚƌƵŶŶŝŶŐĐŽŶƚŝŶƵŽƵƐůǇĂƚƚŚĞ
ĚĞƐŝŐŶĨůŽǁƌĂƚĞ͘

• /Ĩ ŝƚ ŝƐ ĚĞĐŝĚĞĚ ƚŽ ƐŚƵƚ ĚŽǁŶ ďĞƚǁĞĞŶ ŝŶƚĞƌŵŝƚƚĞŶƚ ƐĂŵƉůĞƐ͕ ƚŚĞŶ ƚŚĞ ĂďŽǀĞ ƉƌĞͲƐƚĂƌƚ
ƉƌŽĐĞĚƵƌĞŵƵƐƚďĞŽďƐĞƌǀĞĚ͘
EKd͗

tŝƚŚŝŶƚĞƌŵŝƚƚĞŶƚƐĂŵƉůŝŶŐ͕ƐƵĨĨŝĐŝĞŶƚƚŝŵĞƐŚŽƵůĚďĞĂůůŽǁĞĚƚŽƉƵƌŐĞƚŚĞƵƉƐƚƌĞĂŵƐĂŵƉůĞůŝŶĞ
ŽĨƐƚĂŐŶĂŶƚƐĂŵƉůĞ͘dŚĞƚŝŵĞƌĞƋƵŝƌĞĚǁŝůůĚĞƉĞŶĚŽŶƚŚĞƐŝǌĞĂŶĚůĞŶŐƚŚŽĨƚŚĞůŝŶĞ͘ƉƌĂĐƚŝĐĂů
ŝŶĚŝĐĂƚŝŽŶŽĨǁŚĞƚŚĞƌƚŚĞůŝŶĞŚĂƐďĞĞŶƉƵƌŐĞĚŵĂǇďĞŽďƚĂŝŶĞĚďǇĐŚĞĐŬŝŶŐƚŚĞƚĞŵƉĞƌĂƚƵƌĞŽĨ
ƚŚĞ ƐĂŵƉůĞŝŶůĞƚƉŝƉĞ͕Ă ŚŝŐŚƚĞŵƉĞƌĂƚƵƌĞŝŶĚŝĐĂƚŝŶŐƚŚĞƉƌĞƐĞŶĐĞŽĨĨƌĞƐŚ ƐĂŵƉůĞ͘,ŽǁĞǀĞƌ͕
ĐĂƌĞŵƵƐƚďĞƚĂŬĞŶƚŽĂǀŽŝĚŝŶũƵƌǇƚŽƉĞƌƐŽŶŶĞů͘

^,hdKtEWZKhZ͗

/ŶƚŚĞĨŽůůŽǁŝŶŐŽƌĚĞƌ͗
ůŽƐĞƚŚĞƐĂŵƉůĞŝŶůĞƚǀĂůǀĞ͘
ůŽƐĞƚŚĞƐĂŵƉůĞŽƵƚůĞƚǀĂůǀĞ͘
ůŽƐĞƚŚĞĐŽŽůĂŶƚŝŶůĞƚĂŶĚŽƵƚůĞƚǀĂůǀĞƐ͘

t/EdZ/^d/KE͗

dŽƉƌŽƚĞĐƚĂŐĂŝŶƐƚĨƌĞĞǌŝŶŐĚƵƌŝŶŐďŽŝůĞƌƐŚƵƚĚŽǁŶƐ͗Ͳ

• ŶƐƵƌĞƚŚĂƚĐŽŽůĂŶƚŝƐŽůĂƚŝŽŶǀĂůǀĞƐĂƌĞĐůŽƐĞĚ͘
• ZĞŵŽǀĞ ƚŚĞ ĚƌĂŝŶ ƉůƵŐͬƌĞůŝĞĨ ǀĂůǀĞ Ăƚ ƚŚĞ ďŽƚƚŽŵ ŽĨ ƚŚĞ ĐŽŽůĞƌ ĂŶĚ ĂůůŽǁ ƚŚĞ ƐŚĞůů ƚŽ
ĞŵƉƚǇĐŽŵƉůĞƚĞůǇ͘
• /ƚƐŚŽƵůĚďĞĂƐĐĞƌƚĂŝŶĞĚƚŚĂƚǁĂƚĞƌǁŝůůŶŽƚƐƵďƐĞƋƵĞŶƚůǇĞŶƚĞƌƚŚĞƐŚĞůůďĞĨŽƌĞƌĞƉůĂĐŝŶŐ
ƚŚĞĚƌĂŝŶƉůƵŐůŽŽƐĞůǇ͘
• tŝƚŚƚŚĞƐĂŵƉůĞŝŶůĞƚ͖ĂŶĚŽƵƚůĞƚǀĂůǀĞƐĐůŽƐĞĚ͘
• KƉĞŶĨƵůůǇƚŚĞƐĂŵƉůĞŽƵƚůĞƚǀĂůǀĞ͕ĚŝƐĐŽŶŶĞĐƚƚŚĞĐŽŝůĂƚƚŚĞĐŽŶŶĞĐƚŽƌƐ;ŝĨĨŝƚƚĞĚͿĂŶĚ
ďůŽǁ ƚŚĞ ĐŽŝů ƚŚƌŽƵŐŚ ǁŝƚŚ ĐŽŵƉƌĞƐƐĞĚ Ăŝƌ Žƌ ŶŝƚƌŽŐĞŶ͕ ďĞĨŽƌĞ ĐŽŵŵĞŶĐŝŶŐ ƚŚŝƐ
ƉƌŽĐĞĚƵƌĞ͕ĂůůƉĞŽƉůĞŝŶƚŚĞŝŵŵĞĚŝĂƚĞǀŝĐŝŶŝƚǇĂƌĞƚŽďĞǁĂƌŶĞĚĂŶĚƚŚĞĞŶŐŝŶĞĞƌŶŽƚŝĨŝĞĚ
ŽĨƚŚĞ ŝŶƚĞŶƚŝŽŶƚŽ ĂƉƉůǇĐŽŵƉƌĞƐƐĞĚĂŝƌ ŽƌŶŝƚƌŽŐĞŶ͘'ƌĞĂƚĐĂƌĞŵƵƐƚ ďĞ ƚĂŬĞŶ ǁŚĞŶ
ƵƐŝŶŐ ŶŝƚƌŽŐĞŶ ƚŽ ĂǀŽŝĚ ĞŶĐůŽƐĞĚ ƐƉĂĐĞƐ ĂŶĚ ŽƉĞƌĂƚŽƌƐ ŵƵƐƚ ŬĞĞƉ ĐůĞĂƌ ŽĨ ĞǆŚĂƵƐƚŝŶŐ
EŝƚƌŽŐĞŶ'ĂƐ͘

tZE/E'͗KďƐĞƌǀĞĂůůƌĞůĞǀĂŶƚƐŝƚĞƐĂĨĞƚǇƌƵůĞƐ͕ƌĞĐŽŶŶĞĐƚƵŶƚŝůƌĞƋƵŝƌĞĚĨŽƌŶŽƌŵĂůŽƉĞƌĂƚŝŽŶ
ĂŐĂŝŶ͘ĞĨŽƌĞƌĞͲƵƐŝŶŐĞŶƐƵƌĞƚŚĂƚƚŚĞĐŽŶŶĞĐƚŽƌƐĂŶĚĚƌĂŝŶƉůƵŐĂƌĞĨƵůůǇƌĞƚŝŐŚƚĞŶĞĚĂŶĚƚŚĞŶ
ĐĂƌƌǇŽƵƚƚŚĞƉƌĞͲƐƚĂƌƚƉƌŽĐĞĚƵƌĞ͘

• dŽƉƌŽƚĞĐƚĂŐĂŝŶƐƚĨƌĞĞǌŝŶŐǁŝƚŚƚŚĞďŽŝůĞƌŽƉĞƌĂƚŝŶŐ͕ĂůůŽǁƚŚĞĐŽŽůĞƌƚŽƌƵŶĐŽŶƚŝŶƵŽƵƐůǇ
ǁŝƚŚĂƐĂŵƉůĞĨůŽǁƌĂƚĞŽĨϯϬŬŐͬŚƌ͘ǁŝƚŚĐŽŽůĂŶƚĨůŽǁŝŶŐŶŽƌŵĂůůǇ͘

D/EdEE͗

• dŚĞĐŽŝůƐŚŽƵůĚďĞĞǆĂŵŝŶĞĚĨŽƌĐŽŶĚŝƚŝŽŶĞǀĞƌǇϲŵŽŶƚŚƐŽƌƐŽŽŶĞƌĂƐĐŽŶĚŝƚŝŽŶƐĚŝĐƚĂƚĞ͘

dK/^DEd>KK>Z/E^/dh&KZK/>yD/Ed/KE͗

• ŶƐƵƌĞƚŚĂƚƚŚĞƐĂŵƉůĞͲŝƐŽůĂƚŝŶŐǀĂůǀĞĂƚƚŚĞƐĂŵƉůŝŶŐƉŽŝŶƚŽƌƉƌŽďĞŽŶƚŚĞŵĂŝŶƉůĂŶƚ
ŝƐ>K^ĂŶĚ>K<͘ůŽƐĞĂŶĚůŽĐŬŽĨĨĂůůƐĂŵƉůĞŝƐŽůĂƚŝŽŶǀĂůǀĞƐŽŶƚŚĞĐŽŽůĞƌĂŶĚ
ďŽƚŚƚŚĞŝŶůĞƚĂŶĚŽƵƚůĞƚĐŽŽůĂŶƚŝƐŽůĂƚŝŽŶǀĂůǀĞƐ͘KƉĞŶƚŚĞƐĂŵƉůĞŽƵƚůĞƚǀĂůǀĞŽŶƚŚĞ
ĐŽŽůĞƌƚŽĞŶƐƵƌĞƚŚĂƚƚŚĞƐĂŵƉůĞƉŝƉĞǁŽƌŬŝƐĚĞͲƉƌĞƐƐƵƌŝǌĞĚ͘
• ZĞŵŽǀĞƚŚĞĚƌĂŝŶƉůƵŐͬƌĞůŝĞĨǀĂůǀĞĂƚƚŚĞďŽƚƚŽŵŽĨƚŚĞĐŽŽůĞƌĂŶĚĚƌĂŝŶƚŚĞǁĂƚĞƌĨƌŽŵ
ƚŚĞƐŚĞůů͘
• ZĞŵŽǀĞƚŚĞϰďŽůƚƐĂŶĚďƵƚƐƐĞĐƵƌŝŶŐƚŚĞďŽĚǇŽĨƚŚĞůŝĚ͘
• ĂƌĞĨƵůůǇůŽǁĞƌƚŚĞƐŚĞůůĂǁĂǇĨƌŽŵƚŚĞůŝĚ͘
• ǆĂŵŝŶĞƚŚĞĐŽŝů͕ƉĂƌƚŝĐƵůĂƌůǇŝŶƚŚĞǀŝĐŝŶŝƚǇŽĨƚŚĞƐĂŵƉůĞŝŶůĞƚ͕ĨŽƌƐŝŐŶƐŽĨƉŝƚƚŝŶŐ͘

dKZ^^D>d,KK>Z/E^/dh&K>>Kt/E'K/>yD/Ed/KE͗

• &ŝƚĂŶĞǁŐĂƐŬĞƚŝŶƉŽƐŝƚŝŽŶŽŶƚŚĞƐŚĞůůĐůĂŵƉƌŝŶŐ͘
• ĂƌĞĨƵůůǇƐůŝĚĞƚŚĞƐŚĞůůŽǀĞƌƚŚĞĐŽŽůŝŶŐĐŽŝůŝŶƚŽƉŽƐŝƚŝŽŶ͘
• &ŝƚĂŶĚƚŝŐŚƚĞŶĚŝĂŐŽŶĂůůǇƚŚĞϰůŝĚƐĞĐƵƌŝŶŐďŽůƚƐĂŶĚŶƵƚƐƚŽĂƚŽƌƋƵĞŽĨϯϬED

^^D>/E'd,KK>Z͗

• &ŝƚĂŶĞǁŐĂƐŬĞƚŝŶƉŽƐŝƚŝŽŶŽŶƚŚĞƐŚĞůůĐůĂŵƉƌŝŶŐ͘
• ĂƌĞĨƵůůǇƐůŝĚĞƚŚĞƐŚĞůůŽǀĞƌƚŚĞĐŽŽůŝŶŐĐŽŝůŝŶƚŽƉŽƐŝƚŝŽŶ͘
• &ŝƚĂŶĚƚŝŐŚƚĞŶĚŝĂŐŽŶĂůůǇƚŚĞϰůŝĚƐĞĐƵƌŝŶŐďŽůƚƐĂŶĚŶƵƚƐƚŽĂƚŽƌƋƵĞŽĨϯϬED͘
• ZĞƉůĂĐĞƚŚĞĚƌĂŝŶƉůƵŐͬƌĞůŝĞĨǀĂůǀĞŝŶƚŚĞďŽƚƚŽŵŽĨƚŚĞĐŽŽůĞƌ͘

ZdhZE/E'd,KK>ZdK^Zs/͘
ϭͿ ^ƵƉƉŽƌƚƚŚĞĐŽŽůĞƌŝŶƉŽƐŝƚŝŽŶ͕ĨŝƚĂŶĚƚŝŐŚƚĞŶƚŚĞƚǁŽƐĞĐƵƌŝŶŐŶƵƚƐ͘
ϮͿ ZĞͲĐŽŶŶĞĐƚƚŚĞĐŽŽůĂŶƚƉŝƉĞǁŽƌŬ͘
ϯͿ /ĨƚŚĞƐĂŵƉůĞůŝŶĞƐŚĂǀĞĐŽŵƉƌĞƐƐŝŽŶĨŝƚƚŝŶŐƐ͕ƌĞͲĐŽŶŶĞĐƚƚŚĞƐĂŵƉůĞƉŝƉĞͲ
ǁŽƌŬ ǁŝƚŚ ƚŚĞ ŝŶůĞƚ ĂŶĚ ŽƵƚůĞƚ ƉŝƉĞƐ ŝŶ ƚŚĞ ŽƌŝŐŝŶĂů ƉŽƐŝƚŝŽŶ ƵƐŝŶŐ ŶĞǁ
ĐŽŵƉƌĞƐƐŝŽŶƌŝŶŐƐ͕ƚŚĞŽƌŝŐŝŶĂůŶƵƚƐƐŚŽƵůĚďĞƌĞͲƵƐĂďůĞ͘
ϰͿ dĞƐƚ Ăůů ũŽŝŶƚƐ ĂŶĚ ǀĂůǀĞ ƐƚĞŵ ƐĞĂůƐ ĨŽƌ ƉƌĞƐƐƵƌĞ ƚŝŐŚƚŶĞƐƐ ŝŶ ĂĐĐŽƌĚĂŶĐĞ
ǁŝƚŚůŽĐĂůƐĂĨĞƚǇƉƌŝĐĞƐ͘

ZKDDEd^dWZ^^hZ^͗
^ĂŵƉůĞƐŝĚĞʹϭ͘ϱǆǁŽƌŬŝŶŐƉƌĞƐƐƵƌĞ͘
ŽŽůŝŶŐǁĂƚĞƌƐŝĚĞͲϭ͘ϱǆǁŽƌŬŝŶŐƉƌĞƐƐƵƌĞ͘
Ϯ͘ϭ͘ϳ^DW>&/>dZ^
^Z/Wd/KE͗

,ŝŐŚͲƉƌĞƐƐƵƌĞ ĨŝůƚĞƌƐ ĂƌĞ ƵƐĞĚ ƚŽ ƉƌĞǀĞŶƚ ĚĞďƌŝƐ ĨƌŽŵ ƌĞĂĐŚŝŶŐ ƚŚĞ ĞƋƵŝƉŵĞŶƚ
ĚŽǁŶƐƚƌĞĂŵ͘
dŚĞĨŝůƚĞƌŚĂƐĂĨŽƌŐĞĚďŽĚǇŽĨ^^ͲϯϭϲĂŶĚĂĐůŽƐĞůǇĨŝƚƚŝŶŐƉĞƌĨŽƌĂƚĞĚƐƚ͘ƐĐƌĞĞŶ͘

/E^d>>d/KE͗

• ŶƐƵƌĞƚŚĂƚƚŚĞĨŝůƚĞƌŝƐƐƵŝƚĂďůĞĨŽƌƚŚĞƌĞƋƵŝƌĞŵĞŶƚƐĞƌǀŝĐĞďǇĐŚĞĐŬŝŶŐƚŚĞƚĂŐŵĂƌŬŝŶŐ
ĂŶĚƚŚĞƌĂƚŝŶŐĐĂƐƚŽŶƚŚĞďŽĚǇ͘
• ĞĨŽƌĞŝŶƐƚĂůůĂƚŝŽŶ͕ĐĂƌĞĨƵůůǇŝŶƐƉĞĐƚƚŚĞƐƚƌĂŝŶĞƌĨŽƌƉŽƐƐŝďůĞĚĂŵĂŐĞĚƵƌŝŶŐƚƌĂŶƐƉŽƌƚŽƌ
ŚĂŶĚůŝŶŐ͘
• ^ƚƌĂŝŶĞƌƐƐŚŽƵůĚďĞŝŶƐƚĂůůĞĚĂƐĐůŽƐĞĂƐƉŽƐƐŝďůĞƚŽŵĂĐŚŝŶĞƌǇŽƌǀĂůǀĞƚŽďĞƉƌŽƚĞĐƚĞĚ͘
dŚĞĂƌƌŽǁĐĂƐƚŵĂƌŬĞĚŽŶƚŚĞƐƚƌĂŝŶĞƌďŽĚǇŵƵƐƚƉŽŝŶƚŝŶƚŚĞĚŝƌĞĐƚŝŽŶŽĨƚŚĞĨůŽǁ͘
• /ŶƐƚĂůů ƚŚĞ ƐƚƌĂŝŶĞƌ ŝŶ ƚŚĞ ƉŝƉĞůŝŶĞ ƵƐŝŶŐ ĐŽƵŶƚĞƌ ĨůĂŶŐĞƐ͕ ŐĂƐŬĞƚƐ ĂŶĚ ĨĂƐƚĞŶĞƌƐ
ĐŽƌƌĞƐƉŽŶĚŝŶŐǁŝƚŚƚŚĞƐƚƌĂŝŶĞƌĞŶĚƐĂŶĚƐƵŝƚĂďůĞĨŽƌƚŚĞĨůƵŝĚƚŽďĞĨŝůƚĞƌĞĚ͘
• DĂŬĞƐƵƌĞƚŚĂƚĂůůďŽůƚƐĂŶĚƉůƵŐĂƌĞƉƌŽƉĞƌůǇƚŝŐŚƚĞŶĞĚ͘
• /ƚŝƐƌĞĐŽŵŵĞŶĚĞĚƚŚĂƚĂƋƵŝĐŬĐůĞĂŶƵƉŽĨƚŚĞƐƚƌĂŝŶĞƌŝƐŵĂĚĞĂĨĞǁŚŽƵƌƐĂĨƚĞƌƐƚĂƌƚƵƉ
ďǇŽƉĞƌĂƚŝŶŐƚŚĞĚƌĂŝŶƉůƵŐ͘

/ĨƚŚĞƉƌĞƐƐƵƌĞ ĚƌŽƉďĞĨŽƵŶĚŝŶĞǆĐĞƐƐŽĨƚŚĞ ŶŽƌŵĂůĨŝŐƵƌĞƐ͕ĂĐŽŵƉůĞƚĞŵĂŝŶƚĞŶĂŶĐĞĐŚĞĐŬ
ƐŚŽƵůĚďĞƉĞƌĨŽƌŵĞĚ͘

D/EdEE
Ă͘ ŽŵƉůĞƚĞŵĂŝŶƚĞŶĂŶĐĞƐŚŽƵůĚďĞĐĂƌƌŝĞĚŽƵƚĂƚůĞĂƐƚŽŶĐĞĂǇĞĂƌ͕ŽƌǁŚĞŶĞǀĞƌƚŚĞƉƌĞƐƐƵƌĞ
ĚƌŽƉŝƐĨŽƵŶĚƚŽďĞŝŶĞǆĐĞƐƐŽĨƚŚĞŶŽƌŵĂůĨŝŐƵƌĞƐ͘
ď͘ &ŽƌĐŽŵƉůĞƚĞŵĂŝŶƚĞŶĂŶĐĞ͕ĨŽůůŽǁƚŚĞƐƚĞƉƐďĞůŽǁ͗Ͳ
ŝ͘ ŶƐƵƌĞƚŚĂƚƚŚĞůŝŶĞŚĂƐďĞĞŶƐŚƵƚͲŽĨĨĂŶĚĚĞͲƉƌĞƐƐƵƌŝǌĞĚ͘
ŝŝ͘ >ŽŽƐĞŶĐŽǀĞƌďŽůƚƐĂŶĚďƵƚƐĂŶĚƌĞŵŽǀĞĐŽǀĞƌĂŶĚŐĂƐŬĞƚ͘
ŝŝŝ͘ tŝƚŚĚƌĂǁĂƐŬĞƚͬ^ĐƌĞĞŶĂŶĚĐĂƌĞĨƵůůǇŝŶƐƉĞĐƚĨŽƌĚĂŵĂŐĞ͘/ĨĂŶǇŚŽůĞŝŶƚŚĞƐĐƌĞĞŶŝƐ
ĨŽƵŶĚŽďƐƚƌƵĐƚĞĚ͕ĐůĞĂŶŝƚ ǁŝƚŚĐŽŵƉƌĞƐƐĞĚ ĂŝƌĂŶĚͬŽƌ ĂŶǇ ƐƵŝƚĂďůĞƚŽŽů͘/ĨƚŚĞƐĐƌĞĞŶŝƐ
ďƌŽŬĞŶŽƌĚŝƐƚŽƌƚĞĚ͕ƌĞƉůĂĐĞŝƚ͘

EĞǀĞƌƌĞŝŶƐƚĂůůĂďƌŽŬĞŶŽƌĚŝƐƚŽƌƚĞĚƐĐƌĞĞŶ͊
ŝǀ͘ ĂƌĞĨƵůůǇĐůĞĂŶƚŚĞŝŶƐŝĚĞŽĨƚŚĞĨŝůƚĞƌďŽĚǇ͘
ǀ͘ &ŝƚĂŶĞǁŐĂƐŬĞƚ͘
ǀŝ͘ /ŶƐƚĂůůƚŚĞŶĞǁƐĐƌĞĞŶŽƌƚŚĞŽůĚĐůĞĂŶĞĚƐĐƌĞĞŶ͘
ŶƐƵƌĞƚŚĂƚƚŚĞĂƐŬĞƚͬ^ĐƌĞĞŶŝƐƐĞĂƚĞĚĐŽƌƌĞĐƚůǇ͘
ǀŝŝ͘ ZĞƉůĂĐĞĐŽǀĞƌĂŶĚƚŝŐŚƚĞŶďŽůƚƐĂŶĚŶƵƚƐ͘
ǀŝŝŝ͘ ^ůŽǁůǇƉƌĞƐƐƵƌŝǌĞƚŚĞůŝŶĞ͕ĐŚĞĐŬŝŶŐĨŽƌůĞĂŬƐ͘
ŝǆ͘ tƌŝƚĞŽŶƚŚĞĨŝůƚĞƌďŽĚǇŽƌƚĂŐƚŚĞĚĂƚĞŽĨƚŚĞŵĂŝŶƚĞŶĂŶĐĞŽƉĞƌĂƚŝŽŶ͘

Ϯ͘ϭ͘ϵ^DW>WZ^^hZZ>/&s>s

^Z/Wd/KE͗

dŚĞƌĞůŝĞĨǀĂůǀĞŝƐŽŶĞŽĨĂƐĞƌŝĞƐŽĨĂĚũƵƐƚĂďůĞŝŶͲůŝŶĞǀĂůǀĞƐĐŽŶƐƚƌƵĐƚĞĚĨƌŽŵƐƚ͘Ɛƚ͘ϯϭϲǁŝƚŚĂ
ƐŽĨƚsŝƚŽŶ͚K͛ƌŝŶŐƚŽĞŶƐƵƌĞĂůĞĂŬƚŝŐŚƚƐĞĂů͘KŶĐĞƐĞƚƚŽƚŚĞƌĞƋƵŝƌĞĚƉƌĞƐƐƵƌĞ͕ƚŚĞǀĂůǀĞƐŚŽƵůĚ
ƌĞƋƵŝƌĞŶŽĨƵƌƚŚĞƌĂƚƚĞŶƚŝŽŶƵŶůĞƐƐŝƚĨĂŝůƐƚŽƐŚƵƚŽĨĨƚŝŐŚƚůǇ͘

:h^d/E'd,^dWZ^^hZ͗

dŽĂĚũƵƐƚƚŚĞƌĞůŝĞĨǀĂůǀĞ͕ŝŶƐĞƌƚĂƐƚĂŶĚĂƌĚƐĐƌĞǁĚƌŝǀĞƌŝŶƚŽƚŚĞůŽĐŬŝŶŐƐĐƌĞǁ͕
hŶůŽĐŬ ƚŚĞ ůŽĐŬŝŶŐ ƐĐƌĞǁ ďǇ ƚƵƌŶŝŶŐ ŝƚ ĂŶƚŝͲĐůŽĐŬǁŝƐĞ ƵŶƚŝů ƚŚĞ ŚĞǆĂŐŽŶĂů ŬĞǇ ƐůŝĚĞƐ ŝŶƚŽ ƚŚĞ
ĂĚũƵƐƚŝŶŐƐĐƌĞǁ͘
dƵƌŶďŽƚŚƐĐƌĞǁƐƚŽƚŚĞĚĞƐŝƌĞĚĐƌĂĐŬŝŶŐƉƌĞƐƐƵƌĞ͘;ůŽĐŬǁŝƐĞŝŶĐƌĞĂƐĞƐƚŚĞŽƉĞŶŝŶŐƉƌĞƐƐƵƌĞ͕
ĂŶƚŝͲĐůŽĐŬǁŝƐĞĚĞĐƌĞĂƐĞƐƚŚĞƉƌĞƐƐƵƌĞͿ͘
ZĞƚƌĂĐƚƚŚĞƐĐƌĞǁĚƌŝǀĞƌŬĞǇŝŶƚŽƚŚĞůŽĐŬŝŶŐƐĐƌĞǁ͘
>ŽĐŬƚŚĞůŽĐŬŝŶŐƐĐƌĞǁĂŐĂŝŶƐƚƚŚĞĂĚũƵƐƚŝŶŐƐĐƌĞǁďǇƚƵƌŶŝŶŐƚŚĞůŽĐŬŝŶŐƐĐƌĞǁĐůŽĐŬǁŝƐĞ͘

ZW>DEdK&WZd^

dŚĞƐǇƐƚĞŵŵƵƐƚďĞŝƐŽůĂƚĞĚĂŶĚĚĞƉƌĞƐƐƵƌŝǌĞĚďĞĨŽƌĞƌĞŵŽǀŝŶŐƚŚĞǀĂůǀĞ͘
dŽ ĚŝƐŵĂŶƚůĞ ƚŚĞ ǀĂůǀĞ ƚŚĞ ĂĚũƵƐƚŝŶŐ ĂŶĚ ůŽĐŬ ƐĐƌĞǁƐ ŵƵƐƚ ďĞ ƌĞŵŽǀĞĚ ƚŽ ƌĞůŝĞǀĞ ƚŚĞ ƐƉƌŝŶŐ
ƉƌĞƐƐƵƌĞ͘
dŚĞŝŶƐĞƌƚůŽĐŬƐĐƌĞǁĂŶĚƚŚĞŝŶƐĞƌƚƉƌŽƉƉĞƚĐĂŶƚŚĞŶďĞƌĞŵŽǀĞĚ͘
dŚĞ͚K͛ƌŝŶŐƐŚŽƵůĚďĞĞǆĂŵŝŶĞĚĂŶĚŝĨĚĂŵĂŐĞĚƌĞƉůĂĐĞĚ͘
ůůƉĂƌƚƐƐŚŽƵůĚƚŚĞŶďĞĐůĞĂŶĞĚ͕ƌĞƉůĂĐĞĚŝĨŶĞĐĞƐƐĂƌǇĂŶĚƚŚĞŶƌĞĂƐƐĞŵďůĞĚŝŶƌĞǀĞƌƐĞŽƌĚĞƌŽĨ
ĂďŽǀĞ͘

dDWZdhZ'h'

ϭ͘ 'EZ>͗

ĂĐŚŝŶƐƚƌƵŵĞŶƚŚĂƐĂƐĞĂůĞĚƐǇƐƚĞŵĐŽŶƐŝƐƚŝŶŐŽĨDĞƌĐƵƌǇĨŝůůĞĚĞůĞŵĞŶƚ͘dŚŝƐŝŶƚƵƌŶŽƉĞƌĂƚĞƐ
ƚŚĞƉŽŝŶƚĞƌŽĨƚŚĞŝŶƐƚƌƵŵĞŶƚƚŽŝŶĚŝĐĂƚĞƚŚĞƚĞŵƉĞƌĂƚƵƌĞŽĨƚŚĞƐƵƌĨĂĐĞƚŽǁŚŝĐŚŝƚŝƐĂƚƚĂĐŚĞĚ͘
dŚĞŐĂƵŐĞŝƐĨĂƐƚĞŶĞĚƚŽƚŚĞƉŝƉĞǁŽƌŬǀŝĂĂĐŽůůĞĐƚĂŶĚƐƉƌŝŶŐĂƌƌĂŶŐĞŵĞŶƚ͘

Ϯ͘ D/EdEE͗

EŽ ŵĂŝŶƚĞŶĂŶĐĞ ŝƐ ƌĞƋƵŝƌĞĚ͘ /Ĩ ĐĂƌĞĨƵůůǇ ŝŶƐƚĂůůĞĚ͕ ƚŚĞ ŝŶƐƚƌƵŵĞŶƚƐ ǁŝůů ĨƵŶĐƚŝŽŶ ĐŽƌƌĞĐƚůǇ ĨŽƌ
ŵĂŶǇ ǇĞĂƌƐ͘ dŚĞ ŽƉĞƌĂƚŽƌ ŝƐ ĂĚǀŝƐĞĚ ƚŽ ĐŚĞĐŬ Θ ĐĂůŝďƌĂƚĞ ƚŚĞ ŝŶƐƚƌƵŵĞŶƚƐ ŽĐĐĂƐŝŽŶĂůůǇ ŝĨ
ĐŽŶĚŝƚŝŽŶƐĂƌĞŶŽƚŝĚĞĂů

Ϯ͘ϭ͘ϭϬd,ZDKt>>^

dŚĞƌŵŽǁĞůůƐĂƌĞƵƐĞĚǁŚĞƌĞƚŚĞƌŵŽŵĞƚĞƌƐŵĂǇďĞƐƵďũĞĐƚĞĚƚŽŚŝŐŚƉƌĞƐƐƵƌĞŽƌĐŽƌƌŽƐŝŽŶ͘dŚĞǇ
ĂƌĞĂůƐŽƌĞƋƵŝƌĞĚǁŚĞƌĞƚŚĞƌŵŽŵĞƚĞƌƐĂƌĞƚŽďĞƌĞŵŽǀĞĚǁŝƚŚŽƵƚĚƌĂŝŶŝŶŐƚŚĞƐǇƐƚĞŵ͘

ůƚŚŽƵŐŚƌĞƐƉŽŶƐĞƚŝŵĞŝƐŐƌĞĂƚĞƌƚŚĂŶǁŚĞƌĞŶŽƚŚĞƌŵŽǁĞůůŝƐƵƐĞĚ͕ĂĐĐƵƌĂĐǇŝƐŶŽƚĂĨĨĞĐƚĞĚ͘
dŚĞƚŚĞƌŵŽǁĞůůŝƐŵĂĐŚŝŶĞĚĨƌŽŵƐŽůŝĚďƌĂƐƐďĂƌĂŶĚǁŝůůĂĐĐĞƉƚĂƚŚĞƌŵŽŵĞƚĞƌƐƚĞŵǁŝƚŚĂЪ͟
ŵĂůĞĐŽŶŶĞĐƚŝŽŶƚŚƌĞĂĚ͘

Ϯ͘ϭ͘ϭϭ^DW>WZ^^hZ'h'^

WZ^^hZ'h'

'EZ>͗

'ĂƵŐĞƐĂƌĞĨŝƚƚĞĚƚŽĐŚĞĐŬƚŚĞƐĂŵƉůĞůŝŶĞƉƌĞƐƐƵƌĞĂŶĚƚŽĂƐƐŝƐƚŝŶƚŚĞƐĞƚƚŝŶŐŽĨĂŶǇƉƌĞƐƐƵƌĞ
ƌĞĚƵĐŝŶŐĚĞǀŝĐĞ͘

KWZd/KE͗
tKZ</E'WZ^^hZ͗

/ĨƚŚĞǁŽƌŬŝŶŐƉƌĞƐƐƵƌĞŝƐƐƚĞĂĚǇ͕ƚŚĞŐĂƵŐĞƐƐŚŽƵůĚEKdďĞŽƉĞƌĂƚĞĚKEd/EhKh^>zďĞǇŽŶĚ
ϳϱйŽĨƚŚĞŵĂǆŝŵƵŵŐƌĂĚƵĂƚŝŽŶ͘/ĨƚŚĞƉƌĞƐƐƵƌĞŝƐĨůƵĐƚƵĂƚŝŶŐ͕ŶĞǀĞƌƵƐĞĂŐĂƵŐĞĐŽŶƚŝŶƵŽƵƐůǇ
ďĞǇŽŶĚϲϬйŽĨƚŚĞŵĂǆŝŵƵŵŐƌĂĚƵĂƚŝŽŶ͘

Dy/DhDWZ^^hZ͗

dŚĞŐĂƵŐĞƐŵƵƐƚŶĞǀĞƌďĞǁŽƌŬĞĚďĞǇŽŶĚƚŚĞĞŶĚŽĨƚŚĞƐĐĂůĞ͕ĂŶĚŽƌŶŽƚĚĞƐŝŐŶĞĚƚŽǁŝƚŚƐƚĂŶĚ
ŽǀĞƌůŽĂĚƐ͘

D/EdEE͗
^ŚŽƵůĚ ĂŶǇĨĂƵůƚŝŶƚŚĞƌĞĂĚŝŶŐďĞƐƵƐƉĞĐƚĞĚƚŚĞŶ ƚŚĞŐĂƵŐĞƐŚŽƵůĚďĞŝƐŽůĂƚĞĚĂŶĚƌĞŵŽǀĞĚ
ĨƌŽŵŝƚƐůŽĐĂƚŝŽŶ͘dŚĞŐĂƵŐĞƌĞĂĚŝŶŐƐŚŽƵůĚƚŚĞŶďĞĐŚĞĐŬĞĚĂůŽŶŐƐŝĚĞĂĐĂůŝďƌĂƚĞĚŐĂƵŐĞĂŶĚŝĨ
ƚŚĞĞƌƌŽƌŝƐĐŽŶĨŝƌŵĞĚŝƚǁŽƵůĚďĞƌĞƚƵƌŶĞĚƚŽƚŚĞŵĂŶƵĨĂĐƚƵƌĞƌĨŽƌƌĞƉĂŝƌ͘

Ϯ͘ϭ͘ϭϯ>>s>s^

^Z/Wd/KE͗

^ŵĂůůƐƚĂŝŶůĞƐƐƐƚĞĞůďĂůůǀĂůǀĞƐĂƌĞƵƐĞĚĨŽƌƚŚĞŝƐŽůĂƚŝŽŶŽĨƚŚĞƐĂŵƉůĞƐĂŶĚƐŵĂůůďƌĂƐƐͬĐĂƌďŽŶ
ƐƚĞĞůďĂůůǀĂůǀĞƐĨŽƌƚŚĞĐŽŽůĂŶƚƐƵƉƉůŝĞƐ͘

dŚĞďĂůůǀĂůǀĞƐĂƌĞŵŽƐƚƵŶůŝŬĞůǇƚŽƌĞƋƵŝƌĞĂƚƚĞŶƚŝŽŶ͕ĂŶĚŶŽŵĂŝŶƚĞŶĂŶĐĞŝƐƚŚĞƌĞĨŽƌĞŶĞĞĚĞĚ͘
/ŶƚŚĞĞǀĞŶƚŽĨƚƌŽƵďůĞĂƌŝƐŝŶŐǁŝƚŚƚŚĞǀĂůǀĞƐ͕ƚŚĞǇƐŚŽƵůĚďĞƚƌĞĂƚĞĚĂƐĚŝƐƉŽƐĂďůĞŝƚĞŵƐĂŶĚ
ƌĞƉůĂĐĞĚ͘

dŚĞǀĂůǀĞƐĂƌĞŝŶƚŚĞŽƉĞŶƉŽƐŝƚŝŽŶǁŝƚŚƚŚĞŚĂŶĚůĞƉĂƌĂůůĞůƚŽƚŚĞǀĂůǀĞďŽĚǇ͕ĂŶĚĐůŽƐĞĚǁŝƚŚ
ƚŚĞŚĂŶĚůĞĂƚƌŝŐŚƚĂŶŐůĞƐ͘dŚĞǀĂůǀĞƐĚŽŶŽƚŚĂǀĞƚŚĞƉƌŽǀŝƐŝŽŶĨŽƌǀĞŶƚŝŶŐƚŽĂƚŵŽƐƉŚĞƌĞŝŶ
ĂŶǇƉŽƐŝƚŝŽŶ͘

Ϯ͘ϭ͘ϭϰKK>Ed&>Kt/E/dKZ^

^Z/Wd/KE͗

dŚĞĨůŽǁŝŶĚŝĐĂƚŽƌŝƐĂĚĞǀŝĐĞŝŶĐŽƌƉŽƌĂƚŝŶŐĨůŽǁĨŝŶŐĞƌƐŝŶĚŝĐĂƚŽƌ͘/ƚŝƐŽĨǀĞƌǇƌŽďƵƐƚĐŽŶƐƚƌƵĐƚŝŽŶ
ĂŶĚǁŝůůǁŝƚŚƐƚĂŶĚŚŝŐŚƚĞŵƉĞƌĂƚƵƌĞĂŶĚƉƌĞƐƐƵƌĞ͘

&ŽƵƌƚŝĞͲďŽůƚƐƉĂƐƐŝŶŐƚŚƌŽƵŐŚƌĞƚĂŝŶŝŶŐĨůĂŶŐĞƐŚŽůĚƚŚĞƚǁŽƚŚŝĐŬŐůĂƐƐĚŝƐĐ͚ǁŝŶĚŽǁƐ͛ŝŶĐŽŶƚĂĐƚ
ǁŝƚŚũŽŝŶƚƐŽŶĞŝƚŚĞƌƐŝĚĞŽĨƚŚĞďŽĚǇ͘dŚĞĨŝŶŐĞƌƐĂƌĞĐĂƉƚŝǀĞŝŶƚŚĞďŽĚǇďǇŵĞĂŶƐŽĨĂƐƉŝŶĚůĞ
ƐĞĐƵƌĞĚŝŶƚŽĂǁĞďŝŶƚŚĞďŽĚǇĐĂƐƚŝŶŐ͘

ZED/EdEE͗

dŚĞĨůŽǁŝŶĚŝĐĂƚŽƌƐŚŽƵůĚďĞŝŶƐƉĞĐƚĞĚƉĞƌŝŽĚŝĐĂůůǇƚŽĞŶƐƵƌĞƚŚĂƚƚŚĞŐůĂƐƐĚŝƐĐƐĂƌĞĐůĞĂŶĂŶĚ
ĨƌĞĞĨƌŽŵĞƌŽƐŝŽŶƚŽƚŚĞŝŶŶĞƌĨĂĐĞĂŶĚƐĐƌĂƚĐŚĞƐĞƚĐ͘ŽŶƚŚĞŽƵƚĞƌĨĂĐĞ͕ĂůƐŽƚŚĂƚƚŚĞƐƉŝŶŶĞƌ
ŵŽǀĞƐĨƌĞĞůǇǁŚĞŶƚŚĞĐŽŽůŝŶŐǁĂƚĞƌŝƐĨůŽǁŝŶŐ͘

WĞƌŝŽĚŝĐƌĞŵŽǀĂůŽĨƚŚĞĚŝƐĐƐŵĂǇďĞŶĞĐĞƐƐĂƌǇĨŽƌĐůĞĂŶŝŶŐ͕ĂŶĚĨŽƌƚŚŝƐƉƵƌƉŽƐĞƚŚĞĐ͘ǁƉŝƉĞ
ǁŽƌŬƐŚŽƵůĚďĞŝƐŽůĂƚĞĚĂŶĚĚƌĂŝŶĞĚĚŽǁŶƚŽĂƚůĞĂƐƚďĞůŽǁƚŚĞůĞǀĞůŽĨƚŚĞŝŶĚŝĐĂƚŽƌ͘

dĂŬŝŶŐĐĂƌĞƚŽŵĂŝŶƚĂŝŶƌĞĂƐŽŶĂďůǇƵŶŝĨŽƌŵƉƌĞƐƐƵƌĞŽŶĂůůďŽůƚƐ͕ĂƐƚŚĞǇĂƌĞƵŶĚŽŶĞ͕ůŽŽƐĞŶĂŶĚ
ƌĞŵŽǀĞƚŚĞĨŽƵƌƌĞƚĂŝŶŝŶŐďŽůƚƐƚŽŐĞƚŚĞƌǁŝƚŚƚŚĞĨůĂŶŐĞƐĂŶĚŐůĂƐƐĚŝƐĐƐ͘ŚĞĐŬƚŚĂƚƚŚĞĨŝŶŐĞƌƐ
ŵŽǀĞĨƌĞĞůǇ͘ /ĨƚŚĞǇ ĚŽ ŶŽƚŵŽǀĞĨƌĞĞůǇ͕ƌĞŵŽǀĞ ƚŚĞƐƚĂŝŶůĞƐƐƐƚĞĞůƐƉŝŶĚůĞ͕ ƵƐŝŶŐ ĂƐŵĂůůƉŝŶ
ƉƵŶĐŚ͕ĂŶĚĐůĞĂŶƚŚĞĨŝŶŐĞƌƐĂŶĚƐƉŝŶĚůĞŝŶƐŽĂƉǇǁĂƚĞƌ͘ZĞƉůĂĐĞĂŶĚĞŶƐƵƌĞƚŚĂƚŵŽǀĞŵĞŶƚŝƐ
ĨƌĞĞ͕ĂůƚĞƌŶĂƚŝŶŐƚŚĞĨŝŶŐĞƌƐƐŽƚŚĂƚƚŚĞǇŐŝǀĞĂŶŝŶĚŝĐĂƚŝŽŶŽĨĨůŽǁ͘

ůĞĂŶƚŚĞŐůĂƐƐĞƐŝŶƐŽĂƉǇǁĂƚĞƌ͕ŽƌŝĨĚĂŵĂŐĞĚ͕ĚŝƐĐĂƌĚĂŶĚƌĞƉůĂĐĞǁŝƚŚŶĞǁ͘

ĞĨŽƌĞĨŝƚƚŝŶŐĂŶǇŐůĂƐƐĚŝƐĐ͕ĂƚƚĂĐŚĂƐŝŶŐůĞƚŚŝĐŬŶĞƐƐŽĨĂĚŚĞƐŝǀĞƚĂƉĞƚŽƚŚĞŽƵƚĞƌĐŝƌĐƵŵĨĞƌĞŶĐĞ
ĂŶĚƚŽƚŚĞŶŽŶͲũŽŝŶƚĨĂĐĞŽŶůǇŽĨƚŚĞĚŝƐĐ͕ƚŽƉƌĞǀĞŶƚĚŝƌĞĐƚĐŽŶƚĂĐƚŽĨƚŚĞŐůĂƐƐǁŝƚŚŵĞƚĂůƉĂƌƚƐ͕
ƚŽĂǀŽŝĚĂĐĐŝĚĞŶƚĂůĐƌĂĐŬŝŶŐ͘ŶƐƵƌĞƚŚĂƚƚŚĞƌĞŝƐŶŽƚĂƉĞĂĚŚĞƌŝŶŐƚŽƚŚĞŝŶŶĞƌũŽŝŶƚĨĂĐĞ͘

ůĞĂŶƚŚĞĨĂĐĞƐŽŶƚŚĞŝŶĚŝĐĂƚŽƌďŽĚǇ͕ĂŶĚĨŝƚŶĞǁŐĂƐŬĞƚƐ͘ZĞͲĂƐƐĞŵďůĞ͕ƚĂŬŝŶŐĐĂƌĞƚŽƉƌĞƐĞƌǀĞ
ĞǀĞŶƉƌĞƐƐƵƌĞŽŶĂůůďŽůƚƐ͕ĂǀŽŝĚŝŶŐĞǆĐĞƐƐŝǀĞƚŽƌƋƵĞ͘dƌŝŵĂǁĂǇĂŶǇĞǆĐĞƐƐƚĂƉĞ͕ƚĂŬŝŶŐĐĂƌĞŶŽƚ
ƚŽƐĐƌĂƚĐŚƚŚĞŐůĂƐƐ͘

/ĨĂĐŽŵƉůĞƚĞƌĞƉůĂĐĞŵĞŶƚƵŶŝƚŝƐƚŽďĞĨŝƚƚĞĚ͕ĚŽŶŽƚƵƐĞĞǆĐĞƐƐŝǀĞƚŽƌƋƵĞŝŶŵĂŬŝŶŐƉŝƉĞũŽŝŶƚƐ͕
ĂƐƚŚŝƐĐĂŶĚĂŵĂŐĞƚŚĞďƌŽŶǌĞďŽĚǇ͘

7528%/(6+227,1*
^DW>KE/d/KE/E'WE>͗
^zDWdK
WK^^/>h^ d/KE
D
ŚĞĐŬƚŚĂƚƚŚĞƉƌŽďĞŝƐŽůĂƚŝŽŶǀĂůǀĞƐĂƌĞĨƵůůǇŽƉĞŶ͘
/ƐŽůĂƚŝŽŶǀĂůǀĞƐĐůŽƐĞĚ ŚĞĐŬƚŚĂƚƚŚĞƐĂŵƉůĞŝŶůĞƚǀĂůǀĞŝƐĨƵůůǇŽƉĞŶ͘
ŚĞĐŬƚŚĂƚƚŚĞƐĂŵƉůĞŽƵƚůĞƚǀĂůǀĞŝƐĨƵůůǇŽƉĞŶ͘
ŚĂŶŐĞƚŚĞƉŽƐŝƚŝŽŶŽĨϯͲǁĂǇďĂůůǀĂůǀĞƚŽĚƌĂŝŶĂŶĚƌŽƚĂƚĞƚŚĞ
&h>dϭ
WƌĞƐƐƵƌĞƌĞĚƵĐŝŶŐǀĂůǀĞŝƐ ŬŶŽď ƉƌŽǀŝĚĞĚ ŝŶ ĂŶƚŝͲĐůŽĐŬ ĚŝƌĞĐƚŝŽŶ͘ dŚĞ ƐĂŵƉůĞ ǁŝůů ŐĞƚ
>ŽƐƐŽĨ
ďůŽĐŬĞĚǁŝƚŚĚĞďƌŝƐ͘ ĨůƵƐŚĞĚǁŝƚŚŝƚƐŽǁŶƉƌĞƐƐƵƌĞ͘ĨƚĞƌĨĞǁŵŝŶƵƚĞƐ͕ZĞͲĂƉƉůǇƚŚĞ
ƐĂŵƉůĞ
ƉƌĞƐƐƵƌĞĂŶĚĐŚĂŶŐĞƚŚĞϯͲǁĂǇďĂůůƉŽƐŝƚŝŽŶƚŽƐĂŵƉůŝŶŐŵŽĚĞ͘
&ŝůƚĞƌďůŽĐŬĞĚ ZĞŵŽǀĞĂŶĚƌĞƉůĂĐĞƚŚĞĨŝůƚĞƌ͘
ƌŽŬĞŶŽƌůĞĂŬŝŶŐƐĂŵƉůĞ ŚĞĐŬƚŚĞƐĂŵƉůĞůŝŶĞ͕ŝŶĐůƵĚŝŶŐƚŚĞĐŽŽůĞƌĐŽŝůĂŶĚƌĞĐƚŝĨǇĂƐ
ůŝŶĞ ŶĞĐĞƐƐĂƌǇ͘
KƉĞŶĐŽŽůĂŶƚŝƐŽůĂƚŝŽŶǀĂůǀĞĨƵůůǇ͘
ŚĞĐŬƚŚĂƚƚŚĞĨůŽǁŝŶĚŝĐĂƚŽƌƐŚŽǁƐĂŐŽŽĚĨůŽǁ͘
ŚĞĐŬƚŚĂƚƚŚĞĐŽŽůĂŶƚůŝŶĞƐĂƌĞŶŽƚďůŽĐŬĞĚǁŝƚŚĚĞďƌŝƐ͘
/ŶƐƵĨĨŝĐŝĞŶƚĐŽŽůĂŶƚ ŚĞĐŬƚŚĂƚƚŚĞƉƌĞƐƐƵƌĞĚŝĨĨĞƌĞŶƚŝĂůďĞƚǁĞĞŶƚŚĞĐŽŽůĂŶƚĨůŽǁ
ĨůŽǁŝŶŐ ĂŶĚ ƌĞƚƵƌŶ ŝƐ ĐŽƌƌĞĐƚ͘ ; ůŽǁ ĚŝĨĨĞƌĞŶƚŝĂů ǁŝůů ĐĂƵƐĞ ĂůůŽǁ
&h>dϮ
ĐŽŽůĂŶƚĨůŽǁͿ͘
^ĂŵƉůĞ ŚĞĐŬ ƚŚĂƚ ƚŚĞ ĐŽŽůĂŶƚ ƌĞůŝĞĨ ǀĂůǀĞ ;ŝĨ ĨŝƚƚĞĚͿ ŝƐ ŶŽƚ ƉĂƐƐŝŶŐ
ƌƵŶŶŝŶŐ ĐŽŽůĂŶƚ͘
ŚŽƚ ^ĂŵƉůĞ ĨůŽǁ ƌĂƚĞ ŝƐ ƚŽŽ ĞĐƌĞĂƐĞƚŚĞƐĂŵƉůĞĨůŽǁƌĂƚĞƚŽƚŚĞĐŽƌƌĞĐƚůĞǀĞů
ŚŝŐŚ ŚĞĐŬƚŚĂƚƚŚĞƐĂŵƉůĞƌĞůŝĞĨǀĂůǀĞŝƐŶŽƚƉĂƐƐŝŶŐƚŚĞƐĂŵƉůĞ͘
ƵǆŝůŝĂƌǇ ĐŽŽůĂŶƚ ŽƵƚůĞƚ /ŶĐƌĞĂƐĞƚŚĞĐŽŽůĂŶƚĨůŽǁƌĂƚĞ

ƚĞŵƉĞƌĂƚƵƌĞŝƐƚŽŽŚŝŐŚ ĞĐƌĞĂƐĞƚŚĞĐŽŽůĂŶƚƚĞŵƉĞƌĂƚƵƌĞ
ĞĐƌĞĂƐĞƚŚĞƐĂŵƉůĞĨůŽǁƌĂƚĞ͘
^zDWdKD WK^^/>h^ d/KE
>ĂĐŬ ŽĨ ƉƌŽĐĞƐƐ ǁĂŝƚƚŚĞƌĞƚƵƌŶƚŽŶŽƌŵĂůŽƉĞƌĂƚŝŽŶ

ƉƌĞƐƐƵƌĞͬĨůŽǁ
&h>dϯ ůŽǁ ĚŽǁŶ ǀĂůǀĞ Žƌ ůŽƐĞŽƌƌĞƐĞĂƚƚŚĞǀĂůǀĞ
^ĂŵƉůĞĂƚ ƌĞůŝĞĨǀĂůǀĞƉĂƐƐŝŶŐ
ůŽǁ /ƐŽůĂƚŝŽŶ ǀĂůǀĞƐ ŶŽƚ KƉĞŶǀĂůǀĞƐĨƵůůǇ
ƉƌĞƐƐƵƌĞ ĨƵůůǇŽƉĞŶ
WƌĞƐƐƵƌĞ ƌĞĚƵĐŝŶŐ ZĞƐĞƚ ƚŚĞ ƉƌĞƐƐƵƌĞͲƌĞĚƵĐŝŶŐ ǀĂůǀĞ͘ ^ĞĞ ƐƉĞĐŝĨŝĐ
ǀĂůǀĞƐĞƚƚŽŽůŽǁ ŝŶƐƚƌƵĐƚŝŽŶƐ
ůŽƐĞĚŽǁŶƚŚĞƐĂŵƉůŝŶŐƐǇƐƚĞŵ
&h>dϰ ŚĂŶŐĞƚŚĞƌĞůŝĞĨǀĂůǀĞ͘
ĞďƌŝƐƚƌĂƉƉĞĚ
^ĂŵƉůĞ ZĞŵŽǀĞƚŚĞĨĂƵůƚǇƌĞůŝĞĨǀĂůǀĞƚŽƚŚĞǁŽƌŬƐŚŽƉ
ďĞƚǁĞĞŶƚŚĞůŝĚĂŶĚ
ƌĞůŝĞĨǀĂůǀĞ ZĞƐƚĂƌƚƚŚĞƐǇƐƚĞŵ͘
ƐĞĂƚ
ůĞĂŬ ^ĞĞ ƐƉĞĐŝĨŝĐ ƌĞůŝĞĨ ǀĂůǀĞ ŝŶƐƚƌƵĐƚŝŽŶƐ ĨŽƌ ƌĞͲĨƵƌďŝƐŚŝŶŐ
ŝŶĨŽƌŵĂƚŝŽŶ
ŚĞĐŬĐŽŽůŝŶŐǁĂƚĞƌĨůŽǁĂƚƚŚĞĐŽŽůĂŶƚĨůŽǁŝŶĚŝĐĂƚŽƌ
ŚĞĐŬ ƚŚĞ ĐŽŽůĂŶƚ ĨůŽǁ ŝŶĚŝĐĂƚŽƌ͕ ŝĨ ďůŽĐŬĞĚ ĐůĞĂŶ Žƌ
ƌĞƉĂŝƌĂƐŶĞĐĞƐƐĂƌǇ
&h>dϱ ŽŽůĂŶƚƐƵƉƉůǇĨĂŝůƵƌĞ
ŚĞĐŬƚŚĂƚƚŚĞŝƐŽůĂƚŝŶŐǀĂůǀĞƐĂƌĞĨƵůůǇŽƉĞŶ͘
EŽĨůŽǁŝŶ
ŚĞĐŬ ĐŽŽůĂŶƚ ƉŝƉĞ ǁŽƌŬ ĂŶĚ ĐŽŽůĞƌ ĨŽƌ ďůŽĐŬĂŐĞƐ͕
ƚŚĞƐĂŵƉůĞ
ŝŶĐůƵĚŝŶŐďĞĨŽƌĞĂŶĚĂĨƚĞƌƚŚĞŝƐŽůĂƚŝŽŶǀĂůǀĞƐ͘
ŝŶůĞƚĂƚ
dŚĞĐŽŽůĂŶƚ ŚĞĐŬƚŚĞĐŽŽůŝŶŐǁĂƚĞƌƐƵƉƉůǇƚŽƚŚĞƐĂŵƉůŝŶŐŝŶƌĂĐŬʹ
ZŽƚĂŵĞƚĞƌ
ƚĞŵƉĞƌĂƚƵƌĞŝƐƚŽŽ ŝƚƐŚŽƵůĚďĞϱǑ
ͬ'ƌĂď
ŚŝŐŚ
ƐĂŵƉůĞ͘
^ĂŵƉůĞ ĨůŽǁ ƌĂƚĞ ƚŽŽ ZĞĚƵĐĞƚŚĞƐĂŵƉůĞĨůŽǁƌĂƚĞ͘
ŚŝŐŚ
WATER TREATMENT PLANT
TECHNICAL HAND BOOK
FOR
1X6.85MW POWER PLANT

WATER TREATMENT PLANT
OPERATION MANUAL
PARASAKTHI CEMENT INDUSTRIES LIMITED

JETTIPALEM VILLAGE, RENTACHINTALA MANDAL
GUNTUR Dt., ANDHRA PREDESH
A HANDBOOK
FOR
WATER TREATMENT PLANT OPERATOR

JPR NEER ENVIRO TECH
PLOT NO.20A, DOOR NO.135,
NATESAN NAGAR, ATHIPET
CHENNAI-58
Tel No. 91-44-26546157
Email: jpr_net@rediffmail.com
TABLE OF CONTENTS
1. INTRODUCTION
2. RAW WATER QUALITY
3. PROCESS WATER SYSTEM
4. TECHNICAL SPECIFICATION FOR PROCESS
5. REVERSE OSMOSIS SYSTEM
6. SPECIAL MONITORING & TROUBLE SHOOTING
7. SAFETY INTERLOCKING
8. PREVENTIVE MAINTANENCE
9. CALIBRATION PROCEDURE FOR INSTRUMENTS
. $77$&+0(176
JPR NEER ENVIRO TECH CHENNAI 2

INTRODUCTION
Very few water supplies are suitable in their natural condition for drinking or industrial
purposes and most of them require some form of treatment before use.
Water from some bore wells and mountain springs may be physically pure and from
chemical point of view, they may need conditioning. In majority of cases water may contain
hardness and occasionally suspended impurities and turbid matter.
To purify the water to meet out the boiler feed parameter and cooling tower feed
parameter different type of combined systems like, chemical coagulation, clarification,
filtration, ultra-filtration, Reverse osmosis De mineralization by two bed system and mixed
bed system for boiler feed and systems like RO, De alkalized and softener for cooling tower
feed.
JPR NEER ENVIRO TECH offered / provided wide range of standard plants and
custom built plants to suit individual requirements in water and waste water treatment.
JPR Neer Enviro Tech is specialist in water and waste water treatment for
industries and domestic.
JPR Neer Enviro Tech will provide consultancy, Environmental audit, and
solution for existing issues and provide all type of Water and waste water treatment
systems and equipments.

RAW WATER QUALITY
pH - 8.2
Turbidity - 0.1 NTU
TDS - 370 ppm
Total hardness as CaCO3 - 180 ppm
Chlorides as Cl - 66 ppm
Sulphate as SO4 - 55 ppm
Nitrate as NO3 - 0.05 ppm
Carbonate as CO3 - 18 ppm
Bi Carbonate as HCO3 - 140ppm
Iron as Fe - < 0.1ppm
Silica as SiO2 - 8.08 ppm
Colloidal silica - Nil
Fluorides as F - 0.7 ppm

PLANT TREATED WATER QUALITY PARAMETER:
1. Multi Grade Filter:

Turbidity : < 1.0 NTU
Suspended solid : <2 ppm
Ph : Equal to raw water
TDS : Equal to raw water
2. UF system:
Suspended solid : <0.5 ppm
SDI : <3.5
Ph : Equal to raw water
TDS : Equal to raw water
3. RO System:
Suspended solid : Nil
Ph : 6.4 to 6.8
TDS : <30ppm
4. SAC out water:
pH : <3
Total hardness : Nil
5. SBA outlet water:

PH : 6.3 to 8.1
Conductivity : <10 micron Siemens /cm
TDS : <4 ppm
Chloride ; Nil
Silica : <0.6 ppm
6. MB outlet water:
pH : 6 to 7.3
Conductivity : <0.5 micro Siemens/ cm
Silica : <0.02 ppm
7. DM Water after pH correction:

pH : 8 to 9.2
Conductivity : <10 micro Siemens/cm
Silica : <0.02 ppm

WATER BALANCE DIAGRAM FOR
HOT WATER TREATMENT SYSTEM:
JPR NEER ENVIRO TECH CHENNAI

WATER BALANCE DIAGRAM FOR HOT WATER TREATMENT SYSTEM:

STANDARD OPERATING PROCEDURE (SOP)
UF system operation:
UF System consists of following equipments.
1. Raw water tank with low level switch (LLS-001)
2. Raw water transfer pump is called MGF/UF feed pump ( RWP-001&002)
3. Raw water chlorine dosing system 1 nos100 liter LDPE tank (DT-001) and 2 Nos
7LPH pump (DP-001&002) available in the system for raw water disinfection. One
low level switch (LLS-002)provided in the tank to inform chemical low
4. Raw water coagulation (Alum) Dosing system-1 nos100 Liter LDPE tank (DT002)and
2 Nos-7LPH pump (DP-003&004) available in the system with one 0.5HP agitator (
AG-001) One low level switch (LLS-003)provided in the tank to inform chemical low
5. Multi Grade Filter (MGF-001) of capacity 4.5 M3/hr with respective service and back
wash valves.
6. One Differential Pressure Switch (DPS001) provided in the MGF to monitor the MGF
inlet and outlet pressure difference.
7. UF system of cap 4.5 m3/hr have 2 Nos of 50 sq. meter surface area membrane and
auto operation service inlet valve (AV001) Service outlet valve (AV-002), Back wash
inlet Valve (AV003), Back wash outlet Top (AV004) Back wash outlet (AV-005).
And also it have 2 Nos manual CIP inlet valve (CIPMV-001), CIP outlet valve
(CIPMV-002) One Bag filter (PF-001) with 7”x 20” long 20 micron bag in PP available
in the system. To operate the auto pneumatic valve instrument air monitoring system
like pre filter regular and manifold available in the system. One Differential pressure
switch (DPS-002) provided in the system to monitor pressure difference between
membrane inlet and product outlet.
8. Enhanced Chemical injection systems Hypo/ Caustic and Acid available in the UF
system with 1 Nos60 liter LDPE tank and17 liter capacity pump -2 Nos for

Hypo/caustic and 1 nos 60 liter LDPE tank and 17liter/hr capacity pump-2 Nos for
Acid.
9. UF product water tank of capacity 5.0KL in FRP with low level switch LLS-004 and
HLS-001 available in the system. One level gauge float and board (LI-001) also
available in the tank. Accessories like over flow drain and ladder provision available
in the tank.
Raw Water Pump:

1. No of pump-2 Nos in that One working and other stand by.
2. These pumps are called MGF/UF feed pump.
3. Pump Tag No. UFFP001A &B
4. Pumps are energized from raw water tank pump room panel.
5. That feeder is controlled by remote WTP PLC
6. Pumps have suction and discharge valves and NRV
7. One pressure switch (Tag No.PS001) is connected in the discharge line to conform
pumps water pumping.
8. One level Switch (Tag No. LLS-001) provided in the raw water tank to inform the
tank low level.
9. This pump suppose to be control and run 100% by PLC
Operating Procedure:
1. Select the pump any one of pump-to remote
2. Open respective pump Suction and discharge valve.
3. Ensure water available in the pump by priming
4. Now selected pump can operate by PLC Manual/ Auto
5. Switch on the Pump by manual mode first for MGF filter back wash
6. If switch on pump is not pumping water, discharge Low pressure switch (PS-001)
switch off the pump.(Trip)

7. Respective fault information will display in the PLC operation monitor SCADA
Screen.
8. Fill the pump with water and re start.
9. The above same fault information will come if mistakenly selection one pump and
respective valve open other pump.
10. Re ensue selected pumps valves are open before switch on the pump.
11. If you put it Auto mode with respective UF cycle information from PLC this selected
pump will run automatically.
12. If system is running continuously every 8 to 10 Hours once change the pump
selection from working to standby and ensure water available in the pump and
respective piping by priming.
Chemical dosing system:

1. Raw water is required chlorination for dis infection the water
2. Chlorine doing pumps (Tag No. DP-001A/001B) with 100 liter LDPE chlorine dosing
tank (Tag No. DT-001) available before MGF.
3. Low level switch (Tag No. LLS002) available in the tank to inform chemical level low
in the tank.
4. Manual/ remote selection available in the panel. If we put in manual mode we can
operate the pump by manual. If we put in remote mode we can operate through
SCADA.
5. In remote mode it is linked with UF auto cycle. We UF is in auto cycle mode
whenever the UF feed pump is running selected chlorine dosing pump will
automatically.
6. Chlorine level around 1 to 1.5ppm to be maintain by adjusting the dosing pump
dosing control knob
7. . Raw water is required coagulant to convert colloidal particle as suspended and
removed from filter. Alum is used as coagulant

8. Coagulant doing pumps (Tag No. DP-002A/002B) with 100 liter LDPE chlorine
dosing tank (Tag No. DT-002) available before MGF.
9. Low level switch (Tag No. LLS003) available in the tank to inform chemical level low
in the tank.
10. One 0.5HP agitator (Tag No. AG-001) provided in the tank for chemical mixing.
11. Agitator operation is purely manual. Whenever chemical is prepared that time only
agitator will run
12. Around 5% concentration alum solution is prepared by adding 5kg of alum in 100
liter of water.
13. If water is very high turbidity (More than 10NTU) only alum dosing is required. If not
required we can switch of pump in both mode of operation
14. Manual/ remote selection available in the panel. If we put in manual mode we can
operate the pump by manual. If we put in remote mode we can operate through
SCADA.
15. In remote mode it is linked with UF auto cycle. We UF is in auto cycle mode
whenever the UF feed pump is running selected chlorine dosing pump will
automatically.
16. Alum level around 15 to 25ppm to be maintain by adjusting the dosing pump dosing
control knob

Multi Grade Filter:
1. Multi grade filter have service inlet valve FV-001, service outlet valve FV-002, back
wash inlet FV-003, back wash outlet- FV-004, Rinse valve FV-005, air release valve-
FV-006, Air scoring inlet valve- FV007
2. Multi Grade filter have one Differential pressure switch (Tag No.DPS001) to monitor
filter bed head loss and inform to operator for back wash.
3. While charging the MGF first two or three time back wash to be done to remove all
foreign particle present in the filter sand.
4. Put UF control system in manual mode to do the back wash of filter etc
5. After proper back filter to be lineup for service by opening service inlet valveFV-001
and Service outlet valve FV-002
6. Now filter is ready for service.
7. When UF is in auto mode. UF feed pump water pass through MGF before enter UF
membrane.
8. In the regular interval or base on the DPS-001 information filter to be back washed to
remove the deposited foreign particle like slit and dust
Bag filter:
1. Bag filer (Tag No. BF-001) will be available in the UF system before UF membrane.
2. Bag filter will remove more than 50 micron particle if any coming out from sand filter.
3. If the pressure difference increase more than 0.4kg/cm2 the filter back to be
replaced.

UF System:
1. UF system consist of 2 Nos of 50sq m. Membrane.
2. UF system water flow will be controlled by Service inlet valve AV-001, Service outlet
Valve AV-002, Back wash inlet valve AV-003, Back wash top outlet valve AV-004
and back wash bottom outlet valve AV-005. In addition to that CIP Inlet valve UFV-
001 and CIP outlet valve UFV-002 provided.
3. UF frequent fouling tendency of UF membrane UF operation will be designed 100%
automation.
4. UF have the following process in the PLC control auto operation.
5. UF selected feed pump will on and respective selected dosing pumps will on and
MGF filtered the water and feed to UF
6. Up rinse is the first process to that time AV-001 and AV-004 will be open for few sec
(45 sec). In this process Filtered raw water pass through the membrane and product
side collected water will be drained some time to remove line foreign particle. Then
set value time over this process will be stopped means AV-004 will close. Before that
AV-002 will open to avoid line jerking.
7. Service is the UF water collection process in that time AV-001 and AV-002 is in open
condition. This process will continue for 45 to 60 min. This time UF treated water is
collected in the UF product water tank. UFPT-001.
8. Back wash top is the process to clean the UF membrane in the reverse flow of water
to remove the membrane surface deposited particle. That time the effluent is coming
out from the UF system top outlet header. This process will be happen 45 sec.
Separate UF back wash pump (tag No, UFBW-001A&001B) is used to feed the UF
product water to UF membrane for Back wash
9. Back wash bottom. Once back wash top process is over the AV-005 will open and
AV- 004 will be closed. Now AV-003 and AV-005 will be in open condition. This also
called back wash process. In this process effluent will be drain through bottom

header. So this process is called back wash bottom. One the time over UFBW pump
will off than the valve AV-003 and AV-005 will close.
10. Final rinse process will start. In that process valve AV-001 and AV-004 will open and
Selected UF feed pump (UFFP-001A&001B) will on. Now Filtered raw water enter
and pass through the UF membrane to drain. Once pre sated time over. Valve AV-
002 will open and AV-004 will close. Now service cycle start.
11. Likewise the above process cycle will repeatedly going.
12. Enhanced chemical cleaning Caustic/ Hypo and Acid system available in the UF
system for periodic chemical cleaning of UF Membrane,
13. As per predefined cycle completion 1st caustic/hypo cleaning will done
14. And as predefined cycle completion 2nd acid cleaning will be done.
15. Caustic solution will be maintained 1% caustic with 0.5% hypo in the dosing tank.
16. Acid solution will be maintaining 1% solution in the dosing tank.
RO System”:
1. RO system have Feed 5 micron rating micron filter (Tag No. MF-001) one No.
2. RO feed water is chemically treated to avoid or reduce RO membrane fouling and
damage.
3. Anti scalant chemical is dosing thorough doing pump (Tag No. DP-005A &005B) to
control scaling tendency of concentrate water. One 100 dosing tank (Tag No.DT-
005) used for this. Solution will be prepared 1% and dosage will be maintain around
4 to 6ppm.
4. SMBS chemical is dosing through dosing pump (Tag No. DP-006A&006B) to de
activated free chlorine present in the feed water. One 100 liter dosing tank (Tag No.
DP-006) used for this. Solution will be prepared around 5% and dosage will be
maintain 4 to 8 ppm. One ORP monitor the dosage. SMBS dosing reduce and
maintain the ORP value below 200mV. If ORP value is more than that Dump Valve
AV-006 will open and drain the water and not allow this water to RO membrane.

5. Acid is dosing through dosing pump (Tag No. DP-007A&007B) to main the feed
water pH to avoid carbonate scaling. One 100 liter tank is (Tag No. DP-007) used for
this. This dosing is required only water temporary hardness is more than 200ppm.
Otherwise this dosing is not required.
6. RO system have 2 Nos high pressure pump (Tag No.HPP-001A & 001B).
7. RO high pressure pump boosting the water pressure to over cum the osmotic
pressure and collect the product water.
8. RO system 4 membrane of 8” in two tube. That is 1:1 array configuration.
9. Nearly 75% of feed water is recover as product -3.0M3/hr 1.0M3/hr to 1.2M3/hr
water is drained as reject. Nearly 2.5M3/hr water is circulated as recirculation to
maintain membrane min brine flow.
10. Auto flush valve (Tag No. AV-007) available in the system for safe auto operation.
11. System can operate manual and auto.
12. CIP system inbuilt with RO. The UFCIP tank and pump used for this
.
RO System operating procedure:
1. Ensure RO High pressure pump suction and discharge valve and reject control valve
open.
2. Switch on Selected RO feed pump (Tag No.ROFP-001A&001B)
3. Before that respective pump suction valve are in open condition.
4. Gradually open discharge valve to avoid line jerking.
5. Switch on All selected dosing pump. Before that prepare and keep required quantity
of chemical with advisable concentration.
6. Set the dosing pump flow of dosage.
7. Now UF product water from UF product tank pumped by RO feed pump and mixed
with required quantity of chemicals and pass through micron filter, RO High pressure
pump and go to RO pressure tube,
8. RO membrane system have 2 out path one called product and other is called reject.

9. Now RO system feed water major portion coming through reject path and min portion
coming through product path.
10. Allow this process for some time 3 to 5 min to ensure all air removed from RO
system piping and membrane.
11. Then switch on Selected RO High pressure pump. One Low pressure switch (Tag
No. LPS-001, LPS-002 will control the high pressure pump ON. If High pressure
pump suction side pressure lower than set pressure, High pressure pump will not
switch on. Ensure the all pre filter and pump valves are in proper open condition to
main the min high pressure pump suction pressure.
12. Suction side pressure is OK, high pressure pump will run and develop membrane
side pressure.
13. Gradually open high pressure pump discharge valve to meet required RO product
flow (3.0M3/hr) Reject flow (1.2M3/hr) Reject recirculation flow (2.5M3/hr).
14. Now RO is running.
15. Record all pressure, flow in hourly basic.
16. Record feed water quality and product water quality in the above same interval.
17. If the pressure is increased more than 0.kg/cm2 to meet required product and reject
flow from commission time report is clear indication about membrane fouling. We
need chemical cleaning.
18. RO product water pass through Degasser tower (Tag No. DGT-001) and collected in
the De gassed water tank (Tag No. DGWT-001)
19. De gasser tower remove free carbon di oxide from the RO product water.
20. Nearly 95% salt removed water is collected as RO product and collected in the
DGWT.
21. At the time of RO water collection De Gasser Blower should run.
22. First collect the RO water in the UF CIP Tank.
23. Every day while shut down the system. UF and RO system should flush with CIP
tank RO water to avoid scaling fouling of UF and RO membrane

DM plant:
1. DM stream consist of DM feed pumps (Tag No. DMFP-001A&001B), Strong Acid
Cation (Tag No. SAC-001) Strong Base Anion (Tag No.SBA-001), Mixed Bed (Tag
No.MB-001), MB blowers (Tag No. MBB-001A&001B) and PH boosting system consist
of Dosing pump (Tag No. DP008A & 008B) with 100 liter dosing Tank (DT-008). In
addition to that Acid measuring tank for SAC and MB 100 liter tank (Tag No. AMT-001
and AMT-002), Caustic Dilution Tank 100 liter (Tag No.CDT-001 and CDT-002) with
suitable motorized agitators (Tag No. AG-002 and AG-003)
2. De Gassed water pumped and pass through SAC, SBA, and MB and collected in DM
water tank (DMWT-001). The addition of pH boosting chemical through selected
dosing pump to maintain 8.5 to 9 pH in the DM water tank
3. DM plant operating flow rate is 3.0M3/hr and approximate OBR is around 300M3.
4. SAC have Service inlet valve B-001 Service outlet valve-B-002, power water valve B-
003, Bottom drain valve-B-004, Ejection suction valve- B-005 and top rinse valve B-006
5. . SBA have Service inlet valve C-001 Service outlet valve-C-002, power water valve C-
003, Bottom drain valve-C-004, Ejection suction valve- C-005 and top rinse valve C-
006
6. MB have Service inlet valve D-001 Service outlet valve-D-002, Back wash inlet
valveD-003, Back wash outlet valve- D-004, Caustic power water valve D-005, Caustic
drain valve D-006, Caustic suction valve- D-007, Acid power water valveD-008, Acid
cum drain valve D-009,
7. Acid suction Valve- D-010, Air release valve –D-011, Air scoring inlet valve- D-012, Air
drain valve D-013
8. SAC service is UP flow and regeneration is down flow,
9. SBA service is UP flow and regeneration is down flow
10. MB service is down flow and regeneration is down flow.
11. In service SAC give 2 to 3 pH with Nil Hardness treated water

12. In service SBA give 6.8 to 8 pH with nil chloride and less than 5 TDS water. Silica will
be less than 05ppm
13. In service MB will give 6.3 to 7.3 pH with Less than 0.5 TDS and less than 0.02ppm of
silica water
14. After pH boosting DM water tank water will be 8.5 to 9PH, conductivity less than
10millisemense/cm and silica will be less than 0.02ppm
15. DM regeneration given in the process description

HOT WATER TREATMENT SYSTEM (BOILER)
PROCESS DISCRIPTION:
Krishna river/ Mine sump water is chlorinated for disinfection of microbe and oxidize
the heavy metal and iron. Then that water pass through Multi Grade Filter to remove
suspended solid and colloidal particles. Then the filtered water pass through Bag filter to
Ultra Filter system, where all the fine colloidal particles and colloidal silica removed.
UF treated water is collected in the UF product water tank. Frequent fouling will
happen in the UF membrane due to deposit of fine colloidal particles in the surface of UF
membrane. It induces frequent back wash to clean the membrane surface.
PLC control auto operation is introduced in the UF system to do the frequent back
wash and continuous services. UF treated water is free from colloids. So fouling tendency of
post treatment like RO is drastically reduced and gives better performance and life of RO
membrane.
Enhanced Chemical cleaning system and periodic chemical cleaning system in built
with UF system to keep the UF membrane in fresh condition.
Then UF treated water pumped to RO system through polish micron filter. The RO
system removes nearly 96% of dissolved salts from the feed water. Portion of feed water
nearly 25% of feed quantity is drained with removed salt. Remaining 75% of salt removed
water is collected as RO Product and pass through Degasser Tower to remove free CO2
and collected in the Degassed water tank/ RO Water tank.
Then the RO water is pumped to 2 Bed DM Plant and Mixed bed DM plant to remove
the remaining minerals present in the RO water. In two bed DM plant cation unit Exchange
cation present in the water by H+ ion. So Cation outlet hardness should be nil and pH will
around 2 to 4
Then 2 Bed cation water is feed to 2 Bed Anion unit, There anion potion in the water
is exchanged by OH- ion and all salt are convert to water. In Anion Type-1 resin are used.
That resin adsorbed reactive silica.
The treated water at 2 Bed outlet will be 5.8 to 7.5 PH and hardness- Nil, chloride – nil and
silica less than 0.5 ppm
Than the water feed the Mixed bed unit where both cation and anion resin are mixed
in nature. Due to that remaining residual salt both cation and anion is exchanged
simultaneously. It also adsorbed remaining silica. The treated water at the outlet of MB will
be conductivity less than 0.5 micro Siemens/cm and silica less than 0.02 ppm
Then MB outlet water pH is boosted to 8.5 to 9 by dosing Morpoline and collected in the DM
water tank.

UF MULTI GRADE FILTER
Chlorinated water pass through UF Multi Grade Filter to remove suspended matter
and colloidal particles the filter is designed in such a way to remove the suspended and
colloidal particles. Properly sieved graded pebbles and quartz sand are used in the filter.
The filter is designed the filtering medium almost universally employed for this purpose
consists of silica sand, in accordance with pre-determined standards.
The Chlorinated Raw water enters the filter through inlet valve and gets uniformly distributed
through the filtering media passing through the sand bed below, leaving behind suspended
impurities on and in the bed. The clear water then drains through the gravel layers and gets
collected through the header and lateral systems finally discharging through the filtered
water outlet.
The precipitated impurities from the partially settled water which are retained by the FILTER
MEDIA. Is accumulate. After some time to such an extent that they obstruct further passage
of water through the filter and percolation is very much reduced. The dirt collected over the
filter is then removed by back washing the filter.
It is general practice to backwash the filtration plant before taking it on to service cycle.
Hence before start of service cycle, the following procedure shall be followed:-
Before taken to the service, filter to be back washed as per the following procedure.

SAND FILTER BACK WASH PROCEDURE
BACKWASH (STEP-I)
Open Backwash Inlet Valve slowly and Backwash Outlet valve fully. Slowly water trickles
down in the drain and keeps open Back wash Inlet valve in control and outlet valve fully, until
the effluent in the drain becomes clear. Then close both backwash Inlet & Outlet valves.
Adjust backwash inlet valve to get required flow.
BACK WASH FLOW RATE : 9.0 M3/HR

DURATION : 10 MIN.
AIR REMOVAL (STEP-II)

Open valve service inlet valve slowly and then Air Release valve thoroughly to remove the
air entrenched in the filter bed. Once water is drained from Air Release valve without any air
then close Air Release valve.
DURATION : 5 MIN.
RINSE & SERVICE CYCLE (STEP-III)

As the filter media is fluidized during backwash, to settle it again rinse cycle is followed.
Open Service Inlet Valve & Rinse Valve slowly and simultaneously until Effluent is clear.
Then close Rinse Valve and open Service Outlet Valve
RINSE FLOW RATE : 6 M3/HR

DURATION : 5 MIN.

MAINTENANCE
It is advisable to lower the water on the filter to the level of the sand bed periodically, say
once in three months and examine the bed, immediately after backwash. The sand should
be clean and the bed is smooth and in level. There should be no cracks (or) balls of mud
formed with bed. If the sand bed is hard, and has formed lumps, it should be carefully
broken and back washed properly. If the sand is not clear and appears to have a floating of
mud on it, the backwash operation is not effective. Use more water till the sand regains its
normal state, and backwash the plant frequently to ensure normal clear state. To avoid
micro-biological problem, periodic chlorine sanitation at 100 ppm is required.
UF SYSTEM:
UF is fine filtration. UF membrane removes fine colloidal particles from the water. UF
membrane is made of poly-sulfone it made in such way to create very fine pores in that. The
pore size is below 0.05 micron.
In general UF system is designed in auto operation. UF membrane removes very fine
particles. So fouling will be very high. Colloidal deposit in the membrane surface should be
remove frequently to avoid depth fouling. UF system auto operation will be control PLC.
UF each membrane housing have 3 port. In that 2 ports are in feed side of hollow fibre
membrane and remaining 1 ports are in the product side.

To meet the proper operation cycles that system is designed in the following way.
It has six auto valve and two manual valve to control operation
Auto operation sequence:
1. Service inlet- Bottom – AV1
2. Product out let- Top-AV2
3. Back wash inlet – Bottom- AV3
4. Back wash drain- Bottom – AV4
5. Back wash drain- Top- AV5
System operation:
1 Switch on the respective pumps feeder and put the selection respective pump
2 Switch on the cycle start in the electrical panel.
3 Auto valve AV1 and AV5 open.
4 After few sec Selected UF feed pump will switch on.
5 Few sec membrane rinse ( top rinse) will continue for30sec
6 Then AV2 will open and AV5 will be closed.
7 Now service cycle started and continue for 60 min
8 Once service cycle over UF feed pump will switch off and after few sec Valve AV1
and AV2 will close.
9 Then back wash top process will start.
10 In that process Valve AV3 and AV5 will open.
11 After few sec Back flush pump will switch on and permit the UF water for back the
membrane. This process will continue for 45 sec.
12 Then Valve AV4 will open and AV5 will close. Now Back wash bottom process
continue for 45 sec. Back wash pump will run continuously.
13 After pre defined sec the B/W pump will switch of and close the respective valves
14 Then open the valve AV1 and AV5 and on the UF feed pump for final rinse.
15 After few sec Valve AV3 open and close VA5 to collect the UF product
16 After 60 min of service the cleaning process will repeat.
17 Auto enhanced CIP is inbuilt in the system.
18 Every 60 cycles once Caustic/ hypo dosing system will switch on with the system in
back wash mode.
19 Additional 2 to 5 min chocking time given in the cycles.
20 And every 120 cycles one Acid dosing will be activated for cleaning in the back wash
cycle
21 Additional 2 to 5 min chocking time given in the cycle.

Recommended Dosing for chemicals for enhanced back wash;
1. Caustic 500 ppm
2. Hypo chlorite 100 ppm
3. Citric Acid 500 ppm
Chemical preparation:
1 25 liter caustic diluted in 25 liter water and 2.5 liter sodium hypochlorite in one tank.
2 10 kg in 100 liter water.
CHEMICAL CLEANING PROCEDURE (MANUALLY);
Depend upon membrane fouling different type of chemical cleaning is required for UF. In
general advice at least monthly once chemical cleaning is required for UF systems.
Separate chemical preparation tank is available in the UF system. One back flush pump is
exclusive used for CIP circulation.
A. CAUSTIC HYPO CLEANING:
It is required for colloidal fouling and bio fouling.
1. Take 500 liter of UF/RO water in the UF CIP tank.

2. Prepare 1% caustic solution by adding 10 liter of caustic lye.
3. Maintain 100ppm of chlorine by adding 1 liter of hypo chloride
4. Open CIP inlet and outlet valves.
5. Before switch on the B/F pump which is exclusively assigned for CIP close UF
tank to this pump suction valve and open CIP tank outlet valve.
6. On the CIP pump and control CIP outlet valve in such a way to maintain the flow
around 15 M3/hr.
7. Circulate 20 min then switch of the pump.
8. Give chocking for 20 Min and run the pump again.
9. Like this repeat the process 4 time.
10. Then drain the chemicals from the CIP tank.
11. Open the UF tank valve and run the CIP pump with the flow of around 20 to 25
M3/hr for 10 to 20 min still the effluent chemical residual level is nil.

B. CITRIC ACID CLEANING:
It is required for colloidal fouling and bio fouling.
1. Take 500 liter of UF/RO water in the UF CIP tank.

2. Prepare 1% caustic solution by adding 5 kg of Citric acid.
3. Open CIP inlet and outlet valves.
4. Before switch on the B/F pump which is exclusively assigned for CIP close UF
tank to this pump suction valve and open CIP tank outlet valve.
5. On the CIP pump and control CIP outlet valve in such a way to maintain the flow
around 15 M3/hr.
6. Circulate 20 min then switch of the pump.
7. Give chocking for 20 Min and run the pump again.
8. Like this repeat the process 4 time.
9. Then drain the chemicals from the CIP tank.
10. Open the UF tank valve and run the CIP pump with the flow of around 20 to 25
M3/hr for 10 to 20 min still the effluent chemical residual level is nil.
HOW REVERSE OSMOSIS WORKS:
The phenomenon of osmosis occurs when pure water flows from a dilute saline solution
through a membrane into a higher concentrated saline solution.
A semi-permeable membrane is placed between two compartments. “Semi-permeable”
means that the membrane is permeable to some species, and not permeable to others.
Assume that this membrane is permeable to water, but not to salt. Then, place a salt
solution in one compartment and pure water in the other compartment. The membrane will
allow water to permeate through it to either side. But salt cannot pass through the
membrane.
As a fundamental rule of nature, this system will try to reach equilibrium. That is, it will try to
reach the same concentration on both sides of the membrane. The only possible way to
reach equilibrium is for water to pass from the pure water compartment to the salt-containing
compartment, to dilute the salt solution.
Osmosis can cause a raise in the height of the salt solution. This height will increase until
the pressure of the column of water (salt solution) is so high that the force of this water

column stops the water flow. The equilibrium point of this water column height in terms of
water pressure against the membrane is called osmotic pressure.
If a force is applied to this column of water, the direction of water flow through the membrane
can be reversed. This is the basis of the term reverse osmosis. Note that his reversed flow
produces a pure water from the salt solution, since the membrane is not permeable to salt.
PRE-TREATMENT
To increase the efficiency and life of a reverse osmosis system, effective pre-treatment of
the feed water is required. Selection of the proper pre-treatment will maximize efficiency and
membrane life by minimizing:
• Fouling
• Scaling
• Membrane degradation
The net result of the above will be the optimization of:

• Product flow
• Salt rejection
• Product recovery
• Operating costs
For the purpose of this manual, “fouling” will refer to the entrapment of particulates such as
iron floc or silt, whereas “scaling” will refer to the precipitation and deposition within the
system of sparingly soluble salts such as calcium sulphate (CaSO4) or barium sulphate
(BaSO4).
Pre-treatment of feed water must involve a total system approach for continuous and reliable
operation. For example, an improperly designed and/or operated clarifier will result in
loading the sand or multimedia. Filter beyond its operating limits. Such inadequate pre-
treatment often necessitates frequent cleaning of the elements to restore productivity and

salt rejection. The cost of cleaning, downtime, and lost system performance can be
significant.
The proper treatment scheme for the feed water will depend on:
• Feed water source
• Feed water composition
• Application
The type and extent of a pre-treatment system will depend to a large extent on whether the
feed water source is well water or surface water. In general, well water is a consistent feed
source which has a low Silt Density Index (SDI) (typically < 2) and low bacteria count. Well
water typically requires a very simple pre-treatment scheme such as acid addition, inhibitor
addition, and a 5 μm cartridge filter.
Surface water, on the other hand, is a variable feed water source which is affected by
seasonal factors. It is also characterized by a high SDI and can have a high bacteria count.
Pre-treatment for surface water is more elaborate than pre-treatment for well water.
Additional pre-treatment steps often include polymer addition, clarification, and multimedia.
Filtration.
Once the feed water source has been determined, a complete and accurate analysis
of the feed water should be made. The importance of this feed water analysis cannot be
over emphasized. It is critical in determining the proper pre-treatment and RO system
design.
Finally, the application often determines the type or extent of reverse osmosis pre-treatment.
For example, pre-treatment in an electronics application might be much more sophisticated
than for a municipal system due to the different product water quality requirements.

FACTORS / INFLUENCING REVERSE OSMOSIS PERFORMANCE:
Permeate `Flux’ and salt rejection are the key performance parameters of a reverse osmosis
process. They are mainly influenced by variable parameters which are as follows:
• Pressure
• Temperature
• Recovery
• Feed water salt concentration
PRESSURE
With increasing effective feed pressure, the permeate TDS will decrease while the permeate
flux will increase.
TEMPERATURE
If the temperature increases and all other parameters are kept constant, the permeate flux
and the salt passage will increase.
RECOVERY
The recovery is the ratio of permeate flow to feed flow. In the case of increasing recovery,
the permeate flux will decrease and stop if the salt concentration reaches a value where the
osmotic pressure of the concentrate is as high as the applied feed pressure. The salt
rejection will drop with increasing recovery.
FEED WATER SALT CONCENTRATION

The impact of the feed water salt concentration on the permeate flux and the salt rejection.
SCALE CONTROL
Scaling of a reverse osmosis membrane may occur when sparingly soluble salts are
concentrated within the element beyond their solubility limit. For example, if a reverse
osmosis plant is operated at 50% recovery, the concentration in the concentrate stream will
be double the concentration in the feed stream. As the recovery of a plant is increased, so is

the risk of scaling. Therefore, care must be taken not to exceed the solubility limits of slightly
soluble salts, or precipitation and scaling may occur.
In a reverse osmosis system the most common sparingly soluble salts encountered are
CaSO4, CaCO3 and silica. Other salts creating a potential scaling problem are CaF2,
BaSO4 and SrSO4.
In order to prevent scaling of a reverse osmosis membrane the following design practices
are possible.
ACID ADDITION
Most natural surface and ground waters are almost saturated with respect to CaCO3. The
solubility of CaCO3 depends on the pH, as can be seen from the following equation:
Ca ++ + HCO 3 – H+ + CaCO3
Accordingly, by adding H + as acid, the equilibrium can be shifted to the left side in order to
keep calcium carbonate dissolved. The acid used should be of food grade quality.
Sulfuric acid is easier to handle and in many countries more readily available than
hydrochloric acid, but on the other hand, additional sulphate is added to the feed stream.
This might be critical with respect to sulphate scaling.
In order to avoid calcium carbonate scaling, CaCO3 should tend to dissolve in the
concentrate stream rather than to precipitate. This tendency can be expressed by the
Langelier Saturation Index (LSI) for brackish waters and the Stiff & Davis Stability Index
(S&DSI) for sea waters. At the pH of saturation (pH S), the water is in equilibrium with
CaCO3.
The definitions of LSI IS:
LSI = pH - pH S (TDS <10,000 mg/l)
To control calcium carbonate scaling by acid addition alone, the LSI in the concentrate
stream must be negative. If a high quality scale inhibitor is used, the LSI in the concentrate

stream can be < 1.5. This will reduce or eliminate the acid consumption. Many inhibitors
allow operation up to an LSI of < 1.8 in the concentrate.
SCALE INHIBITOR ADDITION

Scale inhibitors (anti-scalants) can be used to control carbonate scaling, sulphate scaling
and calcium fluoride scaling.
Scale inhibitors have a “threshold effect”, which means that minor amounts adsorb
specifically to the surface of micro crystals thereby preventing further growth and
precipitation of the crystals.
Polymeric organic scale inhibitors are more effective than SHMP. However, precipitation
reactions may occur with cationic poly-electrolytes or multivalent cations, e.g. aluminium or
iron. The resulting gum like products are very difficult to remove from the membrane
elements. Overdosing of Antiscalants should be avoided.
The anti-scalants have been tested for at least 1,000 hours in contact with an element at
typical operating conditions without any negative effect on the membrane.
They can be considered compatible with FILMTEC membranes up to 50 ppm, concentration

in the concentrate (unless otherwise stated). The efficacy of these products has not been
tested.
RO permeate should be used when diluting the anti-scalant Calcium present in
untreated water may form a precipitate with the anti-scalant at high anti-scalant
concentrations. Precautions must also be taken so that there is no microbiological growth in
the anti-scalant dilution tank.
In order for the biocide present in the anti-scalant to be effective, the anti-scalant must not
be diluted. Cationic polymers (e.g. poly-electrolytes) may co-precipitate with negatively
charges anti-scalants and foul the membrane. Make certain that no significant amounts of
cationic polymers are present when adding an anionic anti-scalant.

CLEANING AND DIS-INFECTION
The surface of RO membrane is subject to fouling by foreign materials which may be
present in the feed water such as hydrates of metal oxides, calcium precipitates, organics
and biological matter. (The term “fouling” here includes the build-up of all kinds of layers on
the membrane surface, including scaling).
Occasionally, fouling of the membrane surfaces is caused by
• Inadequate pre-treatment system

• Pre-treatment upset conditions
• Improper materials selection (pumps, piping, etc.)
• Failure of chemical dosing systems
• Inadequate flushing following shutdown
• Improper operation control
• Slow build-up of precipitates over extended periods (barium, silica)
• Change in feed water composition
• Biological contamination of feed water
The fouling of membrane surfaces manifests itself in a performance decline, lower permeate
flow rate and/or higher solute passage. Increased pressure drop between the feed and
concentrate side can be a side effect of fouling.
Cleaning can be accomplished very effectively because of the membrane’s combination of
pH stability and temperature resistance.
If the time of cleaning is delayed too long however, it is difficult to remove the foulants
completely from the membrane surface. The cleaning will be more effective the better it is
tailored to the specific fouling problem. Sometimes, a wrong choice of cleaning
chemicals can even worsen the situation. Therefore, the type of foulants on the
membrane surface should be determined prior to cleaning.
Elements should be cleaned whenever:

The normalized permeate flow drops by 10 percent
The normalized salt content of the product water increased by 15%
The inlet pressure P increases by 15% from the reference conditions (initial
performance established during the first 24 to 48 hours of operation)
It should be noted that it is important to normalize flow and salt content of the permeate
according to the normalization procedure.
In using any chemicals mentioned in this section, follow accepted safety practices. Always
wear eye protection as a minimum. In the case of handling corrosive chemicals (e.g. sulfuric
acid) wear full face cover and protective clothing. Consult the relevant Material Safety Data
Sheets as supplied by the manufacturer of the chemicals.
Check the materials of construction used in the cleaning system is adequate and compatible
with the cleaning chemicals to be used. Never use aluminium as material in contact with
the cleaning solution.
RO CLEANING PROCEDURE
There are seven steps in the cleaning of reverse osmosis modules:
1. Prepare and mix the appropriate cleaning solution, and check pH of the solution. Ensure
that all chemicals are dissolved and well-mixed before circulating the solution to the
elements. Any cleaning solution must be clear.
2. Recycle. After the process water is displaced, cleaning solution will be present in the
concentrate stream. Then recycle the concentrate to the cleaning solution tank and allow
the temperature to stabilize. Observe the turbidity of alkaline or detergent solutions to
judge efficiency. If the cleaning solution colors or becomes turbid, restart with a freshly
pre-pared cleaning solution. Check the pH during acid cleaning. The acid is consumed
when it dissolves inorganic precipitates. So if the pH increases more than 0.5 pH units,
add more acid.
3. Soak. Turn the pump off and allow the elements to soak. Sometimes a soak period of
about 1 hour is sufficient. For difficult fouling an extended soak period is beneficial; soak
the elements overnight for 10-15 hours.

4. The high flow rate flushes out the foulants removed from the membrane surface by the
cleaning. If the elements are heavily fouled, which should never happen, may aid
cleaning. At higher flow rates excessive pressure drop may be a problem. The maximum
recommended drops are (Delta P) 1.4 bar (20 PSI) per element or 4.1 bar (60 PSI) per
multi-element vessel, whichever value is more limiting. For 8" elements, the direction of
flow during cleaning must be the same as during normal operation to avoid telescoping
of the elements.
5. Drain the spent cleaning solution out of the system. Recommendation: Take a sample of
the spent and of the fresh cleaning solution. From the results of a chemical analysis, you
can determine the amount of substances removed from the membrane elements.
6. Flush out. RO permeate or good quality water (filtered, SDI < 3, free of bacteria and
chlorine, conductivity < 10,000 μS/cm) is used for flushing out the residual cleaning
solution. To prevent precipitation, the minimum flush out temperature is 20°C. Before
starting up the plant with normal operating pressures and flows, the bulk of the cleaning
solution must be flushed from the elements.
7. Rinse out. The RO plant is started up again resuming nor-mal operating conditions. As
cleaning chemicals will be pre-sent on the permeate side after cleaning, the permeate
must be discharged to drain for at least 10 minutes (or until the required permeate
quality is obtained) when starting up after cleaning. When another cleaning cycle with
another cleaning chemical is to follow, make sure that the permeate side of the module
is rinsed out as well. Otherwise a chemical reaction with the following cleaning chemical
may happen.
During the rinse out step, the operating parameters should be noted to judge the cleaning
efficiency and to decide if another cleaning is required.
If the system has to be shut down after cleaning for longer than 24 hours, the elements
should be stored in a preservation solution.

TABLE 2: SAMPLE CLEANING SOLUTIONS FOR RO MEMBRANE
0.1% (W) 0.1%

NaOH STP and
0.1% (W) and pH 1.0
NaOH and pH 12.00 30 Na4EDT
Cleaner 12.00 30 Deg Deg C A or 0.2% 0.5% 2.0% 0.2% 1.0%
Foulant C max. or 1% max. or 0.1% (W) (W) (W) (W) (W)
(W) and 0.025% TSP and HCL H2PO4 Citric NH2S Na2S2
Na4EDTA and and Na 1.0% acid O3H O4
pH 12. 30 Deg DDS and TSP and
C max. pH 12. 1.0%
30 Deg C Na4EDT
max. A
Inorganic salts Best OK OK OK
Metal oxides good OK good
Inorganic good
Colloids
Silica OK
Biofilms Best good good
Organic Good Good
(W) Denotes weight percent of active ingredient
Cleaning chemical symbols, in order used: NaOH is Sodium Hydroxide: Na-EDTA is the
sodium salt of ethylene Dia.mine tetra acetic acid: Na-DDS is sodium salt of dodecylsulfate:
STP is Sodium triphosphate (Na5P3O10): TSP is tri-sodium phosphate.
(Na3PO4x12 H2)): HCl is Hydrochloric acid: H3PO4 is phosphoric acid : Citric acid is
C3H4(OH)(CO2H3): NH2SO3H is sulfamic aicd : Na2S2O4 is sodium hydrosulfite.
DISINFECTING RO SYSTEMS
If the plant has been infected by bacteria or mold, a disinfection must be carried out after the
cleaning. The procedure is the same as for cleaning, except that the high flow pumping step
can be skipped.

FORMALDEHYDE
Formaldehyde can be used as a disinfectant with 0.5 to 3.0% concentrations. Care should
be taken in handling this chemical and in flushing the system after use.
Hydrogen Peroxide and Peracetic Acid
Hydrogen peroxide or hydrogen peroxide/peracetic acid solutions can be used at

concentrations up to 0.2%. The biocidal efficacy of peracetic acid is much higher than that of
hydrogen peroxide, but as most peracetic acid solutions also contain hydrogen peroxide,
care must be exercised not to exceed the 0.2% concentration as a sum of both compounds.
Continuous exposure at this concentration may eventually damage the membrane. Instead,
periodic use is recommended.
When hydrogen peroxide is applied, the pH of the solution must be lower than 4. A pH of 3 is
recommended. This will ensure optimal biocidal results and longer membrane lifetime. If no
acid is added to the hydrogen peroxide solution, the chemical attack on the membrane will
be much faster. When a mixture with peracetic acid is used, pH adjustment is usually not
required.
If an alkaline cleaning has preceded disinfection, the alkalinity has to be carefully rinsed out
also from the permeate side (check pH!) before peroxide/peracetic acid is applied.
Otherwise the membrane might become oxidized.
Two other factors greatly influence the rate of hydrogen peroxide attack on the membrane:
temperature and iron.
The disinfecting solution must not exceed 25°C. Membrane samples tested with 0.5%
hydrogen peroxide at 34°C showed a very high salt passage after several hours. At 24°C
however, membrane samples demonstrated compatibility with 0.5% hydrogen peroxide after
96 hours.

Iron or other transition metals must not be present, because they catalyze membrane
degradation in the presence of hydrogen peroxide solutions. RO samples were tested using
a 0.15% solution of hydrogen peroxide and tap water containing iron. After 150 hours, the
salt passage of the membrane began to increase dramatically.
Following procedure for disinfection with hydrogen peroxide solutions:

1. Any type of deposit on the membrane or other parts of the system should be removed
with an alkaline cleaner before disinfecting. Removal of these deposits, which harbor micro-
organisms, will maximize the degree of disinfection. After alkaline cleaning, flush the system
with RO permeate.
2. Clean the RO system with acid, e.g. 0.1% by volume hydrochloric acid or 0.4% by volume
phosphoric acid, to remove any iron from the membrane surface. Flush the unit with RO
permeate.
3. Circulate a solution of 0.2% hydrogen peroxide (preferably containing peracetic acid)
diluted with RO permeate and pH adjusted to 3-4 with HCl at a temperature below 25°C for
20 minutes.
4. Allow the elements to soak in the disinfecting solution for 2 hours.
Flush out the disinfecting solution. Rinse the system.

Other Disinfectants
Iodine, quaternary germicides, and phenolic compounds cause flux losses and are not
recommended for use as disinfectants.
70% ethanol can be used for disinfection. Brand name biocides have also been tested for
effects on the membrane performance. There are fully compatible and limited compatible
biocides.
Those biocides which have limited compatibility can be in contact with the membrane
for two hours a week for at least 3 years without any significant effect on the membrane

performance. However, in continuous contact, a change in membrane performance might be
detectable after a few weeks.
Biocides with full compatibility can be in contact with the membrane continuously for at least
one year without significant loss of salt rejection and permeate flux (cleaning may be
required, however, after long term disinfection). Those biocides can also be used for
preservation.
BEFORE GOING TO THE CHEMICAL CLEANING PROCESS WE ADVICE YOU TO

CONTACT JPR MASSU CONTROL SYSTEMS AND DO THE CLEANING PROCESS
BASED ON THEIR ADVICE.
RO PLANT OPERATING PROCEDURE
1. Switch on RO feed pump.

2. Open pump delivery valves
3. Open PSF inlet valve and air release valve to remove air from the filter. Once water
continuously coming from the air release close air release and open rinse valve.
4. Allow, five minutes sand filter in the rinse process then check the turbidity and SDI.
Once turbidity < 0.2 NTU and SDI < 4, close rinse outlet valve and open PSF outlet
valve.
5. Before switch on the high pressure pump following details to be recorded:
a. Micron filter inlet pressure (It should be 2 – 3 kg/cm2)
b. High pressure pump suction pressure (It should be 2 kg/cm2)
c. High pressure pump discharge (It should be 8-9 kg/cm2)
d. RO membrane reject pressure (It should be7-8kg/cm2)
6. Ensure reject control valve is in opened conditions
7. Switch on high pressure pump- 1 or 2. Permit the water through the reject for few
minutes. Gradually pressurizing the system by controlling by respective system reject

control valve. System should be in the following operating conditions based on the
first 24 hours operation conditions::
a. Micron filter inlet pressure (It should be 2.6 kg/cm2)
b. High pressure pump suction pressure (It should be 2.1 kg/cm2)
c. High pressure pump discharge (It should be 7.9 kg/cm2)
d. RO membrane second array inlet pressure (It should be
7.0 kg/cm2)
e. RO Reject pressure [ It should be 6.5 kg/cm2]
f. Feed pH meter reading 8.2 (It will vary according to the treated water pH)
g. Product pH meter reading 6.5
(It will vary according to acid Dosage)
h. Inlet flow 4.0 CuM/hr
i. Product flow 3.0 CuM/hr
j. Reject flow 1.0 Cum/hr
k. Reject recirculation flow 2.5M3/hr
l. Treated water Conductivity < 35 micro Siemens/cm
m. ORP < 250 mill volt
8. Collect the product water in the CIP tank by opening product header circulation valve
for cleaning purpose simultaneously to transfer the product water to Degasser tower
to collect in the Degassed water tank.
9. Before transfer to RO Product water to DGT switch on the DGT Blower
10. Cleaning of membrane by the product water collected in the chemical tank is to be
carried out once in every day.
11. While cleaning with the product water, switch on CIP pump. Open the delivery valve
and system recirculation inlet and outlet valve. Also open product water circulation
valve.
12. Cleaning process to be carried out for min. 10 minutes. Open the reject control valve
and allow the water to drain.

13. Starting and end of the cleaning process check the CIP tank water conductivity, pH
and record it.
14. Operating parameters should be constant in working condition.
15. If major variation in the operating parameters by 15% inform the supplier to get
corrective action.
16. pH, conductivity and ORP meter to be calibrated regularly.
17. Pressure gauge calibration is required at least once in two months.
18. Sensor for all the measuring instruments should be changed once in 6 months
SPECIAL MONITORING
CHEMICAL DOSING
1. LR grade Sulphuric acid (98%) should be used.
2. Acid dosing level to be adjusted according to the feed pH.
3. Anti-scalant (JPR APPROVED) should be used.
4. Anti-scalant dosing quantity to be monitored for every two hours. Dosing rate will be vary
based on the feed water quality If any change in the raw water consult with the supplier
for dosage.
MICRON FILTER
1. Inlet and outlet pressure to be monitored regularly.
2. Inlet, outlet pressure difference exceeds 1.0 kg/cm2 cartridge should be replaced.
3. Once in a week the position of cartridge should be checked.
4. Once in a week cartridge should be sanitized.
HIGH PRESSURE PUMP

Discharge and suction pressure to be monitored regularly
Pump noise and temperature to be monitored regularly
Pump load current should be monitored regularly

RO MEMBRANE
1. Product water quality like pH, Conductivity, TDS, M. alk., total hardness to be checked
twice in a shift.
2. Reject water quality like, pH, conductivity, TDS, M. alk., total hardness to be checked
once in a shift.
3. Weekly once Silica, iron, heavy metals tests to be carried out in feed, Product and reject
water.
4. System each inlet array pressure should be monitored and record it. If pressure variation
exceeds 1 kg/cm2 to meet the regular product flow which indicates the system fouling.
While commissioning high pressure pump discharge pressure, each arrays reject
pressure at - 7.5CuM/hr flow of product in Unit-I is 7.9 kg/cm2, 7.0kg/cm2,
6.5kg/cm2 respectively
5. Reject flow to be maintained around 2.5 m3/hr

DM PLANT OPERATIONG PROCEDURE:
JPR NEER ENVIRO TECH given 2 bed DM followed by MB unit to meet the Boiler feed
water quality. Ion exchange resin is used to remove the salt present in the water by
exchange of ion.
Two type of resins are used in the DM plant. One is called Strong Acid Cation and other
called Strong Base Anion.
STRONG ACID CATION (SAC):

Strong acid cation unit designed to meet the committed OBR. The cation resin is charged
with HCl to charge H+ ion in the resin. While service time the resin elutes H+ ion and
exchange Cation present in the water. The exchange process as follows.
NaCl + RH+ Æ HCl + RNa+
Ca(HCO3)2 + RH+ Æ H2O + CO2 + RCa+
Mg(OH)2 + RH+ Æ H2O + RMg.
Like the above way all the cations present in the water is exchange by the H+ ion. Due to
continuous elution of H+ ion the H+ ion concentration in the resin is reduced and it goes to
exhaustion stage. In the Cation service process all the carbonate alkalinity is converted as
CO2. RO water is feed to DM plant. So present of CO2 is very less only
Then the resin is re charged by HCL in the process of regeneration. In the
regeneration process the chemical exchange take place in the following way.
RNa + HCL Æ RH+ + Nacl
RCa + HCl Æ RH+ + CaCl2
RMg + HCl Æ RH+ + MgCl2
Now resin is fully charged with H+ ion and ready for service. Regeneration procedure will be
given below. After cation exchange process completed anion exchange process followed.

STRONG BASE ANION (SBA):
Strong acid Anion unit designed to meet the committed OBR. The Anion resin is charged
with NaOH to charge OH- ion in the resin. While service time the resin elutes OH- ion and
exchange Anion present in the water. The exchange process as follows.
HCl + ROH- Æ H2O + RCl-
H2SO4 + ROH- Æ H2O + RSO4-
In addition to that Anion Adsorbed CO2 and reactive Silica present in the water.
Like the above way all the Anions present in the water is exchange by the OH- ion. Due to
continuous elution of OH- ion the OH- ion concentration in the resin is reduced and it goes to
exhaustion stage.
Then the resin is re charged by NaOH in the process of regeneration. In the
regeneration process the chemical exchange take place in the following way.
RCl + NaOH Æ ROH- + Nacl
RSO4 + NaOH Æ ROH- + Na2SO4
Now resin is fully charged with OH- ion and ready for service. Regeneration procedure will
be given below.
Mixed Bed:
The above SAC and SBA service process in happening in the mixed bed
simultaneously. In the MB Unit the cation and anion resin are mixed in nature. The specific
gravity of cation resin is higher than Anion Resin. While regeneration the cation and anion
resin are separated by back wash.
REGENERATION PROCESS:
After exhaust the 2 Bed DM ie SBA outlet conductivity exit 10 Micro Siemens/cm both cation
and anion to be regenerated

STRONG ACID CATION REGENERATION:
Per regeneration we need 41 liter of HCl 30% commercial grade. Pour/ transfer the acid 41
liter from main HCL Tank to Acid Measuring Tank -1
Step-I Back wash.
To loosen the resin bed back wash is must. Back wash to be done by opening back wash
inlet and out let valve.
Back wash flow 1.2 M3/hr
Back wash duration 5 min
Step-II Injection.
After air release all valve should be closed and then open ejector power water valve partially
and open drain middle collector outlet valve fully. Acid injection is upward flow process. Acid
solution enter from the top of resin bed and the effluent elute from the bottom strainer plate.
Counter current regeneration will give better regeneration and performance of the resin bed.
Once effluent is coming from bottom smoothly open ejector suction valve to inject the acid to
the bed. Adjust ejector power water valve and acid suction valve in such a way to maintain
the injection time. .After injection give chocking for some time to get better exchange of
resin. Once the Injection tank is empty close all he valves.
Acid Injection flow 1.0 M3/hr
Injection duration 15 min
Chocking duration 5 min
Step-III Slow rinse.
In the injection direction at injection flow resin to washed with feed water. In this time only
max amount of exchange will happen in the resin. Open Power water valve fully and open
partially Middle collector drain valve. And also open slightly the inlet valve to maintain
counter flow to avoid resin fluidize. After recommended time close all the valves.
Slow rinse flow 1.0M3/hr

Step-IV Fast rinse.
Open service inlet valve and Top drain valve and maintain 80 to 100% service flow. After
recommended time check the Total hardness and PH.If total hardness is nil and pH is above
2. Close the drain valve and open th service outlet valve. Now plant is ready for service.
Fast rinse flow 2.5 to 3.0 M3/hr
Back wash duration 10 to 15 min
STRONG BASE ANION REGENERATION:

Per regeneration we need 31.5 liter of Caustic lye 45%commercial grade. Pour/ transfer the
caustic lye 31.5 liter and add from main Caustic Tank to Caustic Dilution Tank -. And add 15
Lt of MB water to maintain 30% solution in the Dilution tank
Step-I Back wash.
To loosen the resin bed back wash is must. Back wash to be done by opening back wash
inlet and out let valve.
Step-II Injection.
After air release all valve should be closed and then open ejector power water valve partially
and open bottom drain outlet valve fully. Acid injection is upward flow process. Caustic
solution enter from the top of resin bed and the effluent elute from the bottom strainer plate.
Counter current regeneration will give better regeneration and performance of the resin bed.
Once effluent is coming from bottom drain smoothly open ejector suction valve to inject the
Caustic to the bed. Adjust ejector power water valve and acid suction valve in such a way to
maintain the injection time. .After injection give chocking for some time to get better
exchange of resin. Once the Injection tank is empty close all he valves.

Step-III Slow rinse.
partially bottom drain outlet valve. And also open slightly the inlet valve to maintain counter
flow to avoid resin fluidize. After recommended time close all the valves.
Step-IV Fast rinse.
Open service inlet valve and bottom drain valve and maintain 80 to 100% service flow. After
recommended time check the chloride by sliver nitrate and pH. If total chloride is nil and pH
is around 7.5 to 8.5. Close the drain valve and open the service outlet valve. Now plant is
ready for service.
Fast rinse flow 6 to 7.5 M3/hr
MIXED BED REGENERATION:

Acid preparation:
Per regeneration we need 25 liter of HCl 30% commercial grade. Pour/ transfer the acid 25
liter from main HCL Tank to Acid Measuring Tank -2. Add 25 liter of water and maintain
around 15% solution strength.
Caustic preparation:
Per regeneration we need 38 liter caustic lye 45% commercial grade. Pour/ transfer the
caustic 38 liter from main Caustic lye tank to Caustic dilution tank-2. Add DM water 60 liter to
maintain 15% solution.
Step-I Back wash.
To separate the cation and anion resin back wash is very vital process. Due to specific
gravity difference Anion resin gradually getting up and cation settled in the bottom. Back

wash to be done by opening back wash inlet and out let valve. Conform the resin separation
in the view glass before close the valves
Step-II Air release and settlement
To ensure resin bed column free from air enrich air release process to be done by opening
back wash inlet and air release valve. After air is thoroughly removed from the bed close the
valves. And keep the system for some time ideal to settle all the floating resin.
Back wash duration 2.0 min
Step-III Acid Injection.
After air release all valve should be closed and then open Acid ejector power water valve
partially and open drain middle collector outlet valve fully. Acid injection is upward flow
process. Acid solution enters from the bottom of resin bed and the effluent elute from the
middle collector. Counter current regeneration will give better regeneration and performance
of the resin bed. Once effluent is coming from middle collector smoothly open ejector
suction valve to inject the acid to the bed. Adjust ejector power water valve and acid suction
valve in such a way to maintain the injection time. Slightly open inlet valve to maintain
balance flow to avoid resin fluidize. After injection give chocking for some time to get better
exchange of resin. Once the Injection tank is empty close all he valves.
Step-IV Slow rinse.
partially Middle collector outlet valve. And also open slightly the inlet valve to maintain

Step-V Caustic Injection.
After Acid slow rinse all valve should be closed and then open caustic ejector power water
valve partially and open drain middle collector outlet valve fully. Acid injection is upward flow
process. Once effluent is coming from middle collector smoothly open ejector suction valve
to inject the acid to the bed. Adjust ejector power water valve and acid suction valve in such
a way to maintain the injection time. Slightly open inlet valve to maintain balance flow to
avoid resin fluidize. After injection give chocking for some time to get better exchange of
resin. Once the Injection tank is empty close all he valves.
Step-VI Caustic Slow rinse.
partially Middle collector outlet valve. And also open slightly the inlet valve to maintain
Step-VII Air Scoring.
After injection and slow rinse both cation and anion resin to be mixed properly. Air scoring
process is adapted in the system for mixing the resin. Open air release valve and drain the
water in the mixed bed column just 100 mm above the resin level by open the bottom drain
valve. Once the water level in the bed below caustic distributor then close the drain valve.
Maintain air release in open condition. Before switch on the blower conform the air drain
valve is in open condition. Then switch on the air blower. Now air is coming from air drain.
Then gradually close the air drain and open air inlet vale. Now air scoring starts. Blowing air

mix cation and anion resin and come out from air release. After 5 min check the water ph
which is coming along with air. It is around neutral and less conductivity close air inlet valve
and open air drain valve. Then switch o the blower Allow few min to settling all floating resin
Air scoring air flow 10.0 M3/hr
Air scoring duration 10 min to 15 min
Settled down duration 5 min
Step-V Fast rinse.
Open service inlet valve and bottom drain valve and maintain 80 to 100% service flow. After
recommended time check the ph and conductivity. If conductivity is less than 0.5 and pH is
around 6 to 7.5. Close the drain valve and open the service outlet valve. Now plant is ready
for service.
Fast rinse flow 6 to 7.54 M3/hr
Duration 10 to 15 min
TECHNICAL SPECIFICATION
x Hot water Treatment system
FILTER FEED PUMP

Qty. : Two Nos. (1W+1S)
Supplied by : JPR NEER ENVIRO TECH
Capacity of the pump : 6 M3/HR AT 3.0 KG/CM2
Make / Model : Kirloskar-KDT568
Type : Centrifugal mono bloc
MOC : CI
Power : 5 HP / 2900rpm
Accessories : 1 Nos pressure gauge at each pump discharge
1 Nos pressure switch at delivery line

CHLORINE DOSING SYSTEM – DP001&DP002 and DT001
Qty. : Two No. (1W+1S)
Tag No : DP001 and DP002
Capacity of the pump : 7.6 LPH
Head : 3.5 kg/cm2
Chemical to be dosed : NaOCL
Make / Model : Roytronic/Milton Roy
MOC : PVC
Model : P+036-7381
Dosing tank : 100 liter in LDPE
Tag No : DT001
Accessories : 1 Nos Low level switch
ALUM DOSING SYSTEM Tag No. (DP00X & DP00Y and DT00X
Qty. : Two No. (1W+1S)
Tag No : DP-00X and DP-00Y
Capacity of the pump : 7.6 LPH
Head : 3.5 kg/cm2
Chemical to be dosed : NaOCL
Make / Model : Roytronic/Milton Roy
MOC : PVC
Model : P+036-7381
Dosing tank : 100 liter/ LDPE – DT00X
Accessories : 0.5 Hp/230v/AC mixer
1 Nos- Low level switch

UF- MULTI GRADE FILTER
Qty. : One
Size : 700 Dia. x 2250 hos
Service flow rate : 6.0 M3/hr
Back wash flow rate : 9.0 M3/hr
Working pressure : 3.5 kg/cm2
MOC : MSEP
Top distribution : Bell Mouth
Bottom collection : Header and laterals
Accessories : 2 Nos pressure gauges 0-7kg/cm2-4”Dia.l
1 No sample cock-15 NB
1 Nos Differential pressure switch
UF- BAG FILTER

Qty. : One
Housing Size : 180 Dia. x 600 hos
MOC of housing : PP
Flow rate : 4.5 M3/hr
Bag filter : 4”x 20” long-20 micron -1 Nos

UF- SYSTEM-4.5 M3/HR
Qty. : One Set
Back wash flow rate : 17 M3/hr
Feed water quality : <5 NTU
Product water quality : <0.5 NTU
Product SDI : <3.5
No of UF membrane : 2 Nos
Total Surface area : 50 x2 =100 m2
Model :
MOC : Modified PES
Type : Multi pore hollow fiber
Molecular cutoff : 100 K Dolton
Make : Membrane Hitec
End connection : 50 NB Victaulic
Mode of operation ; Auto PLC control
Piping : SS304
Accessories : pressure switch-1 for air pr monitor
Differential pr switch 1 for membrane
One Rota meter at inlet- 1.0 to 5.0 M3/hr
2 Nos pressure gauges 0-7kg/cm2-4”Dia.l

ENHANCED ACID DOSING SYSTEM-UF
Qty. : One
Capacity of the pump : 17 LPH at 3.5 Kg/cm2
Chemical to be dosed : Citric Acid
Make / Model : Milton Roy / B-12
MOC : PVC
ENHANCED CAUSTIC/HYPO DOSING SYSTEM - UF

Qty. : One
Capacity of the pump : 17 LPH at 3.5 Kg/cm2
Chemical to be dosed : Caustic hypo solution 20%
Make / Model : Milton Roy / B-12
MOC : PVC
CIP TANK - UF
Qty. : One
Capacity : 600 LITER
MOC : FRP

UF BACK WASH PUMP
Capacity of the pump : 18M3/hr at 2.5 Kg/cm2
Make / Model : Kirloskar-KSMB-328
MOC : SS304
Power : 3.0HP/415V/50Hz
UF PRODUCT WATER TANK:

Qty. : One
Capacity : 3.0 KL
Size : 1600Dia. x 2750 Hos
Type : Vertical, Cylindrical
MOC : FRP
RO FEED PUMP
Capacity of the pump : 5.4M3/hr at 2.4 Kg/cm2
Make / Model : Kirloskar – KSMB-129
MOC : SS304
Power : 1.0HP/415V/50Hz

ANTISCALANT DOSING SYSTEM
Qty. : 2 Nos (1W+1S)
Capacity of the pump : 7.6 LPH@ 3.5 KG/CM2
Chemical to be dosed : Antiscalant
Make / Model : Milton Roy- Roytranic-P+063-738N1
MOC : PVC
SODIUM METABISULPHITE DOSING SYSTEM

Capacity : 7.6 LPH
Working pressure : Sodium Meta bi-sulphate
Make / Model : Roytronic / Milton roy/P+036-7381
MOC : PVC
ACID DOSING SYSTEM

Capacity : 7.6 LPH
Working pressure : HCl-1% Solution
Make / Model : Roytronic/Milton roy/P+036-7381
MOC : PVC

MICRON FILTER:
Qty.. : Two Nos
MOC : PP
No. of elements : 2 Nos 4.0”x20” long
Type : PP Depth Cartridges
MAKE : JPR Neer Enviro Tech
HIGH PRESSURE PUMP:

Qty. : 2 Nos
Capacity : 6.0 cum/hr @ 100 MWC
MOC : SS 304
Make : Kirloskar
Model : KSIL-5-20
Power : 4.0HP/2900rpm/415V/50Hz
RO MODULE:
No. of Stream/Unit : 1 Units
No. of Pressure tube : 2 Nos
Tube size : 8” x 2 Elements
Array : 1:1
No. of membranes : 4 Nos
Membrane Model : GE-8040
Feed flow : 4.0 CuM/hr
Product flow : 3.0 CuM/hr
Reject flow : 1.00 CuM/hr
Reject recirculation : 2.5 CuM/hr
Over all system recovery : 75 %

Instrument : One No pH meter – to monitor feed
Water pH
One No. ORP meter – with sensor
& dump valve.
One Nos. conductivity meter at the
Product water.
Pressure gauge- 3 Nos.
3 Nos Rotameter to measure
Product. Reject, Reject recirculation
DEGASSER TOWER:
Qty. : One
Size : 350 Dia. x 2750
Flow Rate : 3.0 cum/hr
MOC : FRP
Packing media. : Pall rings- 38 mm-1200 Nos
Bottom and top tray : FRP
DEGASSER BLOWER
Qty. : 2 Nos
Supplied : JPR NEER ENVIRO TECH
Capacity : 10 cum/MIN
MOC : MSEP
Make : RSK
Power/RPM : 1.0 HP/1450 RPM

DEGASSED WATER TANK:
Qty. : One
Capacity : 2.5 M3
MOC of SAC : FRP
Accessories : 1 Nos Level switch
1 No gauge
DM FEED PUMP:
Qty. : 2 Nos (1W_1S)
Supplied : JPR NEER ENVIRO TECH
Capacity : 3.5Cum/hr
Head : 3.5 kg/cm2
MOC : SS 304
Power : 1.0 HP
Make : Kirloskar
Model : KSMB-129
STRONG ACID CATIION:

Qty. : One
Working Pressure : 3.5kg/cm2
Service flow : Up flow
Regeneration : down flow counter current
Ionic load : 30 ppm

Resin quantity : 180 liter
OBR : 90 M3
Regeneration chemical : 30% HCl
Reg chemical quantity : 42 liter
Service Hours : 30 Hos
MOC of SAC : MSRL
Acid measuring tank : 100 liter in FRP
Top distribution : Strainer plant with strainer
Bottom collection : strainer plate with strainer
1 No PH indicator
STRONG BASE ANION:

Qty. : One
Ionic load : 30 ppm
Resin quantity : 170 liter
OBR : 90 M3
Regeneration chemical : 48% Caustic lye
Reg chemical quantity : 31 liter
MOC of SAC : MSRL
Acid measuring tank : 100 liter in LDPE
Top distribution : Strainer plate with strainer

Bottom collector : strainer plate with strainer
Service flow : Up flow
Regeneration flow : Down flow / counter current.
1 No conductivity Meter
MIXED BED:
Qty. : One
Ionic load : 10 ppm
Resin quantity : 60 liter- Cation
: 100 liter Anion Type-1
Resin Make : TERMAX
OBR : 180 M3
Regeneration chemical : 30% HCl for cation
48% Caustic lye for Anion
Reg chemical quantity : 14 liter-30% HCl for cation
18 Liter- 48% caustic lye for Anion
MOC of SAC : MSRL
Acid measuring tank : 100 liter in LDPE
Caustic Dilution Tank : 100 liter in LDPE
Top distribution : SS316 Header with strainer
Middle collector : SS316 Header with strainer

Service flow : Down flow
Regeneration flow : Cation-Down flow
Anion- down flow.
1 No conductivity meter
MB BLOWER:
Qty. : 2 Nos
Capacity : 10CUM/HR@0.4KG/CM2
Make/ Model : Kay international- AC35
Power : 1HP/1450RPM/415V
Motor make : BB
PH CORRECTION DOSING SYSTEM:

Qty. : 2 Nos
Capacity : 7.6 LPH at 3.5 kg/cm2
Make/ Model : Milton roy/Roytranic-P+063-738N1
Accessories : 1 Nos PH meter
DM WATER SOTRAGE TANK: - by client
DM WATER TRANFER PUMP: - By client

DOSING CALCULATION
1. Raw water chlorination:
Chlorination required disinfecting the water. Chlorine kill microbes, and digest
organic present in the water.
Chlorination also oxidizes the heavy metal ion and covert as precipitate. Depend on
water contamination chlorine dosage is fixed to maintain min of 0.5 ppm residual
chlorine at the user end.
Calculation:
Flow rate of system = Q M3/hr
Chlorine maintain in water = P ppm
Concentration of solution = C%
Chlorine solution required/hr = V liter/hr
V=Q x P x 100 / 1000x C
Example:
Filter flow rate = 5 M3/hr
Chlorine required in water = 2 ppm
Concentration of solution = 5 (Sodium hypo solution)
Chlorine solution required/hr = 5 x 2 x 100 / 1000 x 5
= 0.2 liter/hr.
2. Raw water Alum dosing:
If raw water have high turbidity we need to add coagulant to convert all colloidal
particle to suspended. Suspended particles will be removed by post treatment like
MGF, BF etc. Alum chemical is used as coagulant before MGF for coagulation.
Calculation:

V=Q x P x 100 / 1000x C
Example:
Filter flow rate = 5 M3/hr
Alum required in water = 20 ppm
Concentration of solution = 5 (Sodium hypo solution)
Chlorine solution required/hr = 5 x 20 x 100 / 1000 x 5
= 2.0 liter/hr.
3. AntiScalent required for RO:

Antiscalent is dosed in the RO feed water to control the scaling tendency of water.
Due to threshold behavior of antiscalent chemical avoid salt crystallization and keep
the colloidal and salt in suspended. Due to that effect the colloids and salt crystals
will not settle on membrane surface. The suspended stage of colloids and salt
washed out with reject water. Because of that RO membrane fouling is drastically
reduced
Calculation:

V=Q x P x 100 / 1000x C
Our RO Plant antiscalent usage

RO feed flow rate = 4.0 M3/hr
Antiscalent required = 3 ppm
Concentration of solution = 1% (1liter of chemical dilute in 99 liter
of water)
Antiscalent solution required/hr = 4 x 3 x 100 / 1000 x 1
= 1.2 liter/hr.
4. SMBS required for RO:
In the RO pretreatment like sand filter and UF system required chlorine to eliminate
Bio fouling. Due to that we are using chlorine in the feed water. After UF treatment
some amount of residual chlorine will be present in the RO feed water. Presently RO
membrane made from thin film polyamide polymer. Any oxidizing agent present in
the feed water RO membrane bonding will brake gradually and that pore size will
increase. Gradually treated water quality will affect. So we should ensure RO feed
water should be free from oxidizing element. Chlorine is one of oxidizing agent. So it
should be removed from the RO feed water. If you dose suitable quantity of reducing
agent, oxidizing agent will nullify. SMBS (Sodium Meta Bi sulfate) is the reducing
agent. So dosing of SMBS will nullify the free chlorine present the RO feed water. In
practice to remove 1 ppm of chlorine 4 ppm of SMBS is required.
Calculation:

V=Q x P x 100 / 1000x C
Our RO Plant SMBS usage

RO feed flow rate = 4.0 M3/hr
SMBS required = 10 ppm (safer side)
Concentration of solution = 5% (5kgs of chemical dilute in 100 liter of
water)
SMBS solution required/hr = 4.0 x 10 x 100 / 1000 x 20
= 0.2 liter/hr.

LIST OF INSTRUMENTS WITH LOCATION AND FUNCTION
LEVEL SWITCH:
1. LLS-001 purpose- Raw water tank low level switch
Location- Raw water tank
Setting- 500 mm from bottom
Type- float switch
2. LLS-002 purpose- Dosing tank (DT001) low level switch
Location- chlorine dosing tank
Type- side mount-
Model LB-2, Balmar
3. LLS-003 purpose- Dosing tank (DT002) low level switch
Location- Alum dosing tank
Type- Side mount
Model LB-2, Balmar
4. LLS-004 purpose- UF product tank low level switch
Type- Float switch
5. HLS-001 purpose- UF product tank High level switch
Type Float switch
6. LLS-005 purpose- RO dosing tank
Location- RO-SMBS dosing tank
Model- LB-2 Balmar

7. LLS-006 purpose- RO dosing tank low level switch
Location- Anti scalent dosing tank
Model- LB-2 Balmar
8. LLS-007 purpose- RO dosing tank low level switch
Location- RO acid dosing tank
9. LLS-008 purpose- DGWT low level switch
Location- De gassed water tank
Type Float switch
10. HLS-002 purpose- DGWT High level switch
Type- float switch
11. LLS-009 purpose- pH boosting tank low level switch
Location- DM water pH boosting
12. LLS-010 purpose- Sulfuric acid tank low level
Location- CT acid dosing tank low
Type- LB-2, Balmar
13. LLS-011 purpose- Corrosion inhibitor low level switch
Location- CT corrosion inhibitor water tank
14. LLS-012 purpose- Dispersant low level switch
Location- CT dispersant dosing tank

15. LLS-013 purpose- Scale inhibitor tank low level switch
Location- CT scale inhibitor dosing tank
16. LLS-014 purpose- Hypo dosing tank
Location- CT hypo dosing tank
LEVEL SWITCH:
1. PS-001 purpose- Raw water pump discharge pressure
Location- Raw water pump discharge header
Setting- 2.5kg/cm2
2. DPS-001 purpose- MGF differential pressure
Location- Between Inlet and outlet of MGF
Setting- 0.5kg/cm2
3. PS-002 purpose- Air pressure low in UF
Location- UF pneumatic valve air pressure
Setting- 5.0kg/cm2
4. DPS-002 purpose- UF inlet& outlet pressure difference

Location- Between UF inlet and outlet
Setting- 1.0kg/cm2
5. PS-003 purpose- UF back wash pump discharge
Location- UF back wash pump discharge
Setting- 1.5kg/cm2
6. PS-004 purpose- RO feed pump discharge pressure
Location- RO feed pump discharge header
Setting- 1.5kg/cm2

7. LPS-001 purpose- RO HPP -1 suction pressure low
Location- RO HPP-1 suction line
Setting- 1.0kg/cm2
8. LPS-002 purpose- RO HPP-2 suction pressure low
Location- RO HPP-2 suction line
Setting- 1.0kg/cm2
9. PS-005 purpose- DM feed pump discharge pressure
Location- DM feed pump discharge header
Setting- 2.5kg/cm2
10. PS-006 purpose- SSF feed pump pressure
Location- SSF feed pump discharge header
Setting- 2.5kg/cm2

MONITORING INSTRUMENT:
1. RO Conductivity meter:
Purpose -RO outlet quality measure
Location - RO product header
Setting - Greater than 50 – warning
Make/mode : Aster/ CT450
Range : 100 to 2000
Cell constant :1
2. SBA-Conductivity meter:
Purpose - SBA outlet water quality
Location -SBA outlet
Setting -<5 micro Siemens/cm – warning
3. MB-Conductivity meter:
Purpose - MB outlet water quality
Location - MB outlet
Setting - < 0.5 –micro Siemens/cm warning
4. RO PH meter:
Purpose - RO feed pH measure
Location -RO feed inlet header
Setting -6 to 7.4 recommended range
5. SBA outlet pH meter:
Purpose - SBA outlet water pH value measure
Location - SBA outlet header
Setting - 6.8 to 7.8
6. MB outlet pH meter:
Purpose - pH value of DM water after ph correction
Location -DM tank inlet
Setting -8.2 to 9.0

7. ORP meter:
Purpose - RO inlet ORP value
Location -RO inlet line
Setting -less than 200 mV/cm
8. UF feed Rota meter:
Purpose -UF service flow measurement
Location -UF inlet
Type -On line
Make -Aster
Range 500 to 5000LPH
9. UF Back wash Rota meter:
Purpose - UF back wash flow measurement
Location -UF back wash pump discharge
Type -On line
Make -Aster
Range -1200 to 20000LPH
10. RO product Rota meter:
Purpose - RO product flow measurement
Location -RO product outlet line
Type -On line panel mounted
Make -Aster
Range -500 to 5000LPH
11. RO reject Rota meter:
Purpose - RO reject flow measurement
Location -UF inlet
Type- -On line panel mounted
Make -Aster
Range -500 to 5000 LPH

12. RO reject recirculation Rota meter:
Purpose - RO recirculation flow measurement
Location - RO reject to feed line
Type - Online, Panel mount
Make - Aster
Range -500 to 5000 LPH
13. DM feed Rota meter:
Purpose - DM service flow measurement
Location - DM plant feed pump discharge header
Type - On line, panel mount
Make - Aster
Range - 500 to 5000 LPH

SPARES AND CONSUMABLE
List of Operation and maintenance spares and consumable
Operational chemicals considering 20 Hours operation
1. Chlorine ( sodium Hypo chloride) 3.5 liter/day
2. Alum( Aluminum sulphate power 0.5kg/day
3. SMBS power 0.6kg/day
4. Anti scalent Permatreat-190 or equ 0.4 liter/day
5. Hydro chloric acid 33% commercial 13.0 liter/day
6. Caustic lye 45% concentration 13.0 liter/day
7. Morpoline PH boosting chemical 0.45kg/day.
8. RO cleaning chemical alkaline 0.01 liter/day
9. RO Cleaning chemical Acid 0.015 liter/day
Operational consumable monthly

1. 4” x 20” long 50 micron bag filter 2.0 Nos
2. 4” x 20” long jambo micron cartridge 2.0 Nos
General maintenance spares
1. MGF Filter media. -2 Years one- 1200 kg.
2. UF membrane -3 to 4 year once- 1 Nos.
3. RO membrane 3 to 4 years- 4 Nos.
4. DM cation resin 10% makeup every year- 50 liter/year
5. DM anion resin 10% makeup every year -50 liter/year
6. Pump mechanical seal- 4 set/year
7. Gear oil for Blower and gearbox – 3 liter/ year
8. 230V solenoid coil for valve- 2Nos.
9. UPVC pipe sch40- 90,72,60,50,40,32 and 20mm-12 meter/each
UPVC pipe sch40- Elbow, Tee, Union, Valves solvent type-90, 72, 60,40,32,20 mm- 6 Nos
each

"55"CHME/5S4

CONDUCTIVITY METER
PRESSURE GAUGE
AND
PRESSURE SWITCH
ORP METER
AND
pH METER
TURBINE FLOW TRANSMITTER
PUMP CATALOGUE
AND
PERFORMANCE CURVECURVE
30)0(6&
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PLANT AUXILIARIES
SILENCER
OPERATING AND MAINTENANCE MANUAL
FOR
STEAM DISCHARGE SILENCERS
LOCATION:
PARASAKTI CEMENT INDUSTRIES LIMITED
AP, INDIA
CLIENT:
THYSSENKRUPP INDUSTRIES INDIA PVT LTD
PUNE, INDIA.
SUPPLIED BY
M/S.SHARNATH EQUIP PVT LTD..,

PLOT NO:127, PERUNGUDI INDUSTRIAL ESTATE,
PERUNGUD,
CHENNAI-600096.
PH: +91 44 43593782
YEAR OF MANUFACTURE -2017

CONTENTS
SL.NO. DESCRIPTION CHAPTER
1 TECHNICAL DATA 1
2 DATA SHEET 2
3 SYSTEM DESCRIPTION 3
4 DRAWING ATTACHED 4
TECHNICAL DATA
CHAPTER-1
TYPE - Expanded Acoustic absorption
DESIGN CODE - ASME SEC VIII DIV-1,
NOISE MEASUREMENT - As per ISO 1680
MOUNTING - Vertical
ACCOUSTIC LINER - Glass wool packed fill
NOISE LEVEL AT SILENCER O/L - 85 dBa at 1M distance having

specified flow & pressure.
DRAIN SIZE - 2 Nos 20 NB with Plug
LOCATION - Outdoor
COMPANION FLANGE,
GASKETS - Provided
HARDWARERAINHOOD
WITH BIRD SCREEN - Provided
PAINTING - Heat Resistant AL Paint to

withstand 400°C
JOINT EFFICIENCY - 0.7
PERFORATED SHEETS - SS-304, IS2062 Gr.B
SHELL PLATES MOC - IS2062 Gr.B
INLET PIPE MOC - SA 106 Gr.B,
FLANGE MOC - IS2062 Gr.B, SA105

DATA SHEET
CHAPTER-2
SR.NO. DESCRIPTION UNIT AQC HP Drum SV1+ AQC HPPSH SV

Drum SV1 O/L
1. Qty. offered No(s) One(1) One(1)
2. Process Media - SAT.STEAM SH.STEAM
3. Mounding/ - Vertical Vertical

Orientation
4. Silencer Design Pr. Kg/cm2 (g) 19.0 19.0
5. Silencer Design Deg. C 214 355

Temp.
6. Relieving TPH 7.626 8.025 3.909

Capacity
7. Guaranteed Noise
Level at Outlet of
Silencer@ 1m dBA 85 85
distance
8. Silencer Inlet Line mm 100NB Sch 100NB 100NB Sch 40

Size (NB) 40 Sch 40
9. Min. Corrosion mm 3.0 3.0

Allowance for CS
Parts
10. Size Dia, C1,C2 mmxmm Dia-800, C1-1250 & C2- Dia 800x1400
1150
11. Weight Kg 1050 950
12. Acoustic Packing MoC GlassWool GlassWool
13. Bottom Plate with MoC IS2062 Gr.B IS2062 Gr.B

Drain.
14. Bird Screen MoC GLAVANISED MS GLAVANISED

&Whether Cowl.
15. Lifting Lugs - 2Nos. 2No.

16. Supports Brackets - 4Nos. 4Nos.
17. Flanges with Size std. MoC 100NB 100NB 100NB ANSI-CL150
Counter-Flanges Type ANSI- ANSI- IS2062 Gr.B RF
CL150 CL150
IS2062 IS2062
Gr.B RF Gr.B RF
18. Hardware MoC HT HT
19. Gasket MoC Spiral wound SS- Spiral wound SS-

304/Equivalent 304/Equivalent
20. Diffuser Pipe Size MoC SA 106 Gr.B SA 106 Gr.B
21. Pr.drop.across Kg/Cm2 1.27 1.27 1.27

Silencer
SR.NO. DESCRIPTION UNIT AQC HP FINAL SH AQC LP DRUM

SV+ START-UP SV1+DRUM SV2
VENT
2. Process Media - SH.STEAM SAT.STEAM

Orientation
5. Silencer Design Deg. C 405+5 152.5

Temp.
6. Relieving TPH 36.468 8.8 0.779 0.934

Capacity
7. Guaranteed Noise 85
Level at Outlet of
Silencer@ 1m dBA 85
distance
8. Silencer Inlet Line mm 200NB Sch 200NB 80NB 80NB

Size (NB) 40 Sch 40 Sch40 Sch40

Allowance for CS
Parts
10. Size Dia, C1,C2 mmxmm Dia-800, C1-1250 & C2- Dia-800, C1-1250 &
1150 C2-1150
11. Weight Kg 1075 1050

Drain.
14. Bird Screen MoC GLAVANISED GLAVANISED

&Whether Cowl.
15. Lifting Lugs - 2Nos. 2Nos.
17. Flanges with Size std. MoC 200NB 150NB 80NB 80NB
Counter-Flanges Type ANSI ANSI ANSI CL- ANSI CL-
CL150 CL150 150 150 IS2062
SA105 RF SA105 IS2062 Gr.B RF
RF Gr.B RF

20. Diffuser Pipe Size MoC SA106 Gr.B SA106 Gr.B
21. Pr.drop.across Kg/Cm2 1.27 1.27 0.55 0.55

Silencer
SR.NO. DESCRIPTION UNIT AQC LP FINAL SH SV PH LP DRUM SV1+

+ START-UP DRUM SV2

Orientation

5. Silencer Design Deg. C 215 152.4
Temp.
6. Relieving TPH 0.66 0.5 2.016 2.417

Capacity
7. Guaranteed Noise
Level at Outlet of
Silencer@ 1m dBA 85
distance
8. Silencer Inlet Line mm 80NB Sch 80NB Sch 100NB 100NB

Size (NB) 40 40 Sch 40 Sch 40

Allowance for CS
Parts
10. Size Dia, C1,C2 mmxmm Dia-800, C1-1250 & C2- Dia-800, C1-1250 & C2-
1150 1150
11. Weight Kg 1050 1050

Drain.

&Whether Cowl.
17. Flanges with Size std. 80NB 80NB 100NB 100NB

Counter-Flanges MoC ANSI CL- ANSI CL- ANSI CL- ANSI CL-
Type 150 IS2062 150 IS2062 150 150
Gr.B RF Gr.B RF IS2062 IS2062
Gr.B RF Gr.B RF

20. Diffuser Pipe Size MoC Sa106 Gr.B Sa106 Gr.B

Silencer
SR.NO. DESCRIPTION UNIT PH LP FINAL SH SV+ PH HP DRUM SV1+
START-UP DRUM SV2

Orientation
5. Silencer Design Deg. C 215 215

Temp.
6. Relieving TPH 0.66 1 7.624 8.025

Capacity
7. Guaranteed Noise
Level at Outlet of
distance
8. Silencer Inlet Line mm 80NB Sch 100NB 100NB 100NB

Size (NB) 40 Sch 40 Sch 40 Sch 40

Allowance for CS
Parts
10. Size Dia, C1,C2 mmxmm Dia-800, C1-1250 & C2- Dia-800, C1-1250 & C2-
1150 1150
11. Weight Kg 1050 1050

Drain.

&Whether Cowl.
17. Flanges with Size std. 80NB 100NB 100NB 100NB

Counter-Flanges MoC ANSI CL- ANSI CL- ANSI CL- ANSI CL-
Type 150 IS2062 150 IS2062 150 150
Gr.B RF Gr.B RF IS2062 IS2062
Gr.B RF Gr.B RF

20. Diffuser Pipe Size MoC Sa106 Gr.B Sa106 Gr.B

Silencer
SR.NO. DESCRIPTION UNIT PH HP FINAL SH SV+ PSS HP WARM-UP

START-UP VENT
2. Process Media - SH.STEAM SH.STEAM

Orientation
5. Silencer Design Deg. C 340+5 405+5

Temp.
6. Relieving TPH 2.563 3.5 5.8

Capacity
7. Guaranteed Noise
Level at Outlet of
distance
8. Silencer Inlet Line mm 80NB Sch 80NB Sch 80NB Sch 40

Size (NB) 40 40

Allowance for CS
Parts
10. Size Dia, C1,C2 mmxmm Dia-800, C1-1250 & C2- Dia-800 x 1400
1150
11. Weight Kg 1050 950

Drain.

&Whether Cowl.
17. Flanges with Size std. 80NB 80NB 80NB ANSI CL-150
Counter-Flanges MoC ANSI CL- ANSI CL- SA105 RF
Type 150 IS2062 150 IS2062
Gr.B RF Gr.B RF

20. Diffuser Pipe Size MoC SA106 Gr.B SA106 Gr.B
21. Pr.drop.across Kg/Cm2 0.89 0.89 1.27

Silencer
SR.NO. DESCRIPTION UNIT PSS LP WARM-UP

VENT
1. Qty. offered No(s) One(1)
2. Process Media - SH.STEAM
3. Mounding/ - Vertical
Orientation
4. Silencer Design Pr. Kg/cm2 (g) 5.0
5. Silencer Design Deg. C 205+5

Temp.
6. Relieving TPH 1.0

Capacity
7. Guaranteed Noise
Level at Outlet of
Silencer@ 1m dBA 85
distance
8. Silencer Inlet Line mm 80NB Sch 40

Size (NB)
9. Min. Corrosion mm 3.0

Allowance for CS
Parts
10. Size Dia, C1,C2 mmxmm Dia-600 x 1150
11. Weight Kg 750
12. Acoustic Packing MoC GlassWool
13. Bottom Plate with MoC IS2062 Gr.B

Drain.
14. Bird Screen MoC GLAVANISED

&Whether Cowl.
15. Lifting Lugs - 2Nos.
16. Supports Brackets - 4Nos.
17. Flanges with Size std. 80NB ANSI CL-150

Counter-Flanges MoC IS2062 Gr.B RF
Type
18. Hardware MoC HT
19. Gasket MoC Spiral wound SS-

304/Equivalent
20. Diffuser Pipe Size MoC SA106 Gr.B
21. Pr.drop.across Kg/Cm2 0.70

Silencer
SYSTEM DESCRIPTION
CHAPTER - 3
The expanded acoustic absorption silencer comprises of two main components, the diffuser forming
perforated extension to the exhaust pipe surrounded by various concentric perforated shells, and an
acoustically lined casing.
The various perforated shells divide the discharge flow into a multi tube of small jets which together with
attenuating the transmitted noise, also modifies the noise regenerated at the atmospheric outlet. The
acoustically lined casings further attenuate the noise present within the silencer.
The silencer is provided with sealing arrangement at the inlet to allow for the thermal expansion of the
exhaust pipe. The silencer is provided with 2nos drain with plug should be removed after installation and
the drain should be left open at a safer area.
The silencer described here is for application where steam is discharged to atmosphere such as safety
valves, start-up vent discharges, They are designed for outdoor duty in order to reduce annoying
neighborhood noise and supplied for
x Drum Safety Valve Exhaust,
x Super Heater Safety Valve Exhaust,
x Warm-up and Start-up Vent Valve Silencer,
.
CHAPTER - 4
DRAWING ATTACHED : REF SEPL/TKIIPL/5545,5546,5548 R-00 & 5547,5549 R-02
------------ END PAGE ---------

HP AND LP VALVES
LEVEL GAUGES
RAV
23(5$7,21 0$,17(1$1&(0$18$/
)25
527$5<$,5/2&.)(('(5
PROJECT: 1 X 6.875 MW WASTE HEAT RECOVERY CPP

CLIENT: PARASAKTI CEMENT INDUSTRIES LTD,AP
1
TABLE OF CONTENTS FOR ROTARY AIR LOCK / FEEDERS
SECTION DESCRIPTION PAGE NO.
I GENERAL INFORMATION 3
II APPLICATION 4
III PRE INSTALLATION PREPARATION 5
IV INSTALLATION 8
V OPERATION 9
VI SAFETY 11
VII DONT'S FOR HANDLING 11
VIII MAINTENANCE 12
IX RECOMMENDED LUBRICANTS 15
X RECOMMENDED SPARES 16
XI G.A.DRAWINGS 17
2
Rotary Air Lock / Feeder
General Information
These instructions have been prepared in an effort to acquaint you with the fundamentals
of this Rotary Air Lock / Feeder. It is important that these instructions be read carefully
and that the procedure outlined be understood and followed.
It has been our experience that in most instances Rotary Air Lock / Feeder can be
properly erected and operated by field personnel if care is taken initially to the steps
covered in this Manual.
A Rotary Air Lock / Feeder is often only one of many pieces of equipment in a material
handling system and its proper operation is contingent upon the correct operation of the
other pieces of equipment.
This Rotary Air Lock / Feeder will give you many years of satisfactory service, but in order
to do so, maintenance is of vital importance. There are few normal wearing parts in this
equipment which will require periodic replacement. It is our effort to make available
spares which require periodic replacement. It is our effort to make available from stock as
many replacement parts as possible but there are cases where this is not feasible. For
that reason we included a section covering recommended spare parts. We urge you to
give serious consideration to the early purchase of these items to avoid lengthy and costly
shutdowns due to not having these on hand when needed.
3
Applications
A Rotary Air Lock / Feeder are used in pneumatic conveying system, dust control
equipment and as volumetric feeders to maintain an even flow of material in processing
systems.
The basic use of Rotary Air Lock / Feeder is sealing pressurized systems against loss of
air or gas while maintaining a flow of material between equipment’s of differential
pressures. These units are also widely used as volumetric feeders for metering materials
at precise flow rates from bins, hoppers or silos.
For most of the applications drop through type of air locks are used and for
relatively non abrasive materials blow through air locks are recommended
where the rotor pockets discharge directly into the pneumatic conveying system.
For granules and palliated materials where product damage is not desired while
handling in a rotary valve / feeder by getting in between the rotor tip and casing,
tangential or side entry air locks are used.
4
PRE-INSTALLATION PREPARATION
INSPECTING AND UNCRATING AFTER DELIVERY
1. Inspect the airlock shaft while the airlock is still secured to the shipping pallet.
To inspect the airlock shaft:
A) If damaged, remove the shaft cover located on the non-drive end of the shaft and the
chain guard (see Figure1).
B) Check both ends of the shaft to see if they have been bent or damaged. If this is
the case, file a claim with the freight company for damages and contact our customer
service department.
C) Replace the shaft cover and the chain guard.
D) Be sure that the cover is firmly in place.
CAUTION: The shaft cover must be in place at all times. If the cover is
lost in shipment or lost during airlock operation, contact our customer
service department for a replacement at no charge.
Figure 1
2. Remove the airlock from the shipping pallet.
5
Uncrate the airlock in the following manner:
A. Remove the shipping bolts securing the airlock to the shipping pallet
(see Figure 1) .
B. Lift the airlock from the pallet using a tool truck or forklift.
C. Set the airlock on a smooth level surface.
D. Check all the bolts to be sure they are installed securely.
3. Inspect the rotor.
¾ To inspect the rotor:

A. Locate and read all safety decals (see Figure 1).
B. Remove the protective shipping cover (see Figure 1).
CAUTION: When the protective shipping cover is removed from the airlock, do
not place hands in the airlock or attempt to turn the rotor by hand. Personal
injury could occur.
C. Using a soft probe, check the rotor and the interior of the airlock for foreign material.
¾ For airlocks without the drive motor attached:
D. Using a soft (brass or wood) probe, turn the rotor (see Figure 2). If the
rotor turns freely, the inspection is complete.
Figure 2
6
For airlocks with the drive motor attached:
E. Connect the airlock motor to the power source. If the rotor turns freely, disconnect the
power source; the inspection is complete.
DANGER: Do not place hands or feet in the airlock while the power
Source is connected to the motor.
WARNING: Always wear proper eye protection
CAUTION: If the motor or speed reducer produces an unusual noise,

disconnect the power and lockout. Then check rotation to be sure motor is not
wired backwards.
4. Inspect the motor.
¾ Inspect the airlock motor in the following manner:
A. Read all the materials supplied with the airlock concerning the motor.
B. Be sure that the motor is securely mounted to the airlock.
5. Inspect the speed reducer.
¾ Inspect the speed reducer in the following manner:
A. Read all the materials supplied with the airlock concerning the speed
reducer.
B. Determine whether the speed reducer is grease lubricated (Turbovent

standard) or oil lubricated.
C. If the reducer is grease lubricated, do nothing. It has been filled with

grease at the factory and is ready for use.
D. If the reducer is oil lubricated, add the appropriate oil as specified by the
manufacturer.
7
Installation
1. Prior to installation check for any foreign material inside the rotor by rotating
the rotor shaft by hand.
2. After checking we recommend that the inlet and outlet flanges be covered
until the valve is put in position.
3. Rotary Valves must be installed with the top and bottom flanges parallel to the mating
system flanges and adequately supported to prevent distortion. Asbestos rope or
neoprene gaskets should be fitted between the top and bottom mating system
flanges as per the temperature requirement.
4. Install the rotary air lock valve with the arrow pointing down.
5. Check the bearing and seal glands for lubrication. In case the air lock / feeder is kept
in stock for a longer duration, clean out the pre-packed grease and lubricate again
with fresh lubricant.
6. Check the adjustable blades for proper tightening and clearances.
7. Mount the drive in place and check for alignment of the drive and driven sprockets and
fix the chain. Lubricate the chain with grease before put into operation.
8. Fix the guard in position.
9. After the valve is put in position, make sure all ping is in place and the air purge / relief
vents are connected, whenever required.
10. Fix the speed monitor switch in position as per manufacturer’s recommendation
wherever provided (Optional).
11. Wherever applicable air purge connection at the gland packing i.e. over the lantern
ring should be given by client to provide a pressure more than the differential
pressure in the air lock.
8
Operation
1. Prior to Start up of the valve check for rotation of drive as per the arrow direction.
Serious damage may result due to reverse operation.
2. Start the drive by switching (ON-OFF) and observe for any unusual sound or vibration.
3. Check the amperage of the motor, to be within the limits of the manufacturer’s
recommendation.
4. Run the rotary valve / feeder for 4-6 hours and afterwards drain the oil totally from the
Geared motor and refill with the recommended grade of oil to the level as per the
manufacturers recommendation.
5. Check for any leakage of air at the mating flanges and glands and if noticed check for
tightness of fasters and whether the gland packing / gaskets are put in position.
6. After the initial operation period, we recommend that the plant personnel monitor the
functioning of the valve on a planned schedule.
9
High Temperature Applications
1. The air lock is assembled at shop floor with extra clearance between the rotor and the
housing.
2. The Air lock to be put in operation for 8 hours and checked for expansion on the rotor
by measuring the clearance between the rotor and housing.
3. On cooling, the adjustable blades are to be adjusted as per the recommended

clearance and tightened accordingly.
4. The air lock is provided with bush bearing and if the same seizes due to the expansion
of the shaft, the bush should be removed and machined to increase the clearance on
the shaft. This could be required as the clearances are designed as per theoretical
calculations for thermal expansion and may differ from the practical expansion.
5. The air lock should be put into operation and if it seizes again repeat Step4.
10
Safety
a. Never run the rotary air lock / feeder in a manner where rotor is exposed.
b. Do not open unit or attempt any form of inspections until the following are done.
I. Unit has stopped all motions on its own.
II. Do not attempt to stop the motion by mechanical device or otherwise.
III. Electrical disconnect has been placed in Open Position and locked
open with a key lock.
c. Do not attempt to clean the rotor pockets while in motion.
d. Do not attempt to adjust the adjustable blades while the rotor is in motion.
D O N’T’S FOR HANDLING
1. Do not sling the wire rope on the drive or on shaft of Rotary Air Lock for lifting
2. Do not remove the inlet packing unit the equipment is ready for installation.
3. Do not use hammer for removing any part as it would damage the casting body.
11
Maintenance
The feeder should be electrically locked out of service prior to any maintenance or repair
1. Bearings
a. Remove the bearing covers and clean the lubricant completely.

b. Check the clearance of the bearings (if found damaged replace the bearings)
c. Re-Lubricate the bearing and fix it as per the standard engineering practice.
Packing Glands
The packing can be replaced in Rotary Air Lock / Feeder without removing the feeder
from the installation.
a. Remove male packing gland stud nuts.
b. Pull male packing gland back
c. Remove packing with packing hook
d. Install new packing glands
e. Push packing gland into position and fix the nuts
f. Replace the carefully tighten gland stud nuts to compress packing, but not to the extent
that excessive drag is forced on the shaft.
12
Air Purge
Lantern rings with air purge connection on the end plates is provided as a standard
feature.
The air purge should be connected to a airline to create a pressure more than the
differential pressure in the air lock ONLY WHEN HANDLING ABRASIVE MATERIALS IN.
OPEN ROTORS to avoid frequent wear of gland packing resulting in material and air
leakage.
4. Adjustable Blades
a. It is very important to check for the wear of the blades through the inspection door
periodically.
b. To remove the inspection door use the jacking bolts provided on it.
c. Re-adjust the clearance through inspection doors and tighten the fixing bolts, otherwise
it will result in excessive air leakage due to wear.
d. After proper adjustment of the blades put back the inspection door in position.
5. Replacement of Adjustable Blades
a. Remove the chain guard and remove the chain from the sprockets.
b. Unlock and remove the bearing locknut at the non drive end.
c. Unbolt the drive side end plate and pull the entire assembly along with the rotor.
d. Remove the old adjustable blade and after brushing of loose material from the tip of the
rotor, fit in the new wear blade with the chamfer towards the direction of rotation i.e.
anti clockwise.
e. The blades should be loosely fitted in level with the rotor diameter.
f. Re-install the rotor and fix the end plate of the drive side and then the bearing to be
locked in position.
g. Then the driven side bearing locknut to be put in position and fix the bearing cover.
13
h. Adjust all the wear blades to the recommended clearance and tighten the bolts.
6. Rotor Replacement:
a. Repeat steps a, b, c of Serial No.5
b. Remove the sprocket and drive end side end plate from the rotor assembly.
c. Fix the new wear blades on the new rotor loosely in level with the rotor diameter.
d. Assemble the drive side end plate and drive sprocket on the new rotor assembly.
e. Then repeat steps f, g, h of Serial No.5
7. Chain
The roller chain furnished with all the feeders is pre-lubricated at the factory. The chain
should be greased periodically based on the operation with the recommended lubricant.
8. Clean out opening
The material trapped in between the rotor and the end plate should be periodically
cleaned through the clean out opening provided at the bottom side of end plate by
compressed air.
9. Air Relief Holes
The material trapped in the rotor and the same should be periodically cleaned through the
Air relief holes opening provided at the face of the housing surface by compressed air.
Even inspection opening can be used for cleaning of the material trapped in the rotor by
compressed air or manually.
IMPORTANT
Frequent cleaning of the trapped material would avoid jamming of rotor assembly
14
Recommended Lubricants
a. Recommended Grease : For Ambient Temperature
60° C 120° C
Bearings Suruogen – 2 BP-Energrease RRB-2
Glands - DO - - DO -
Chain - DO - - DO -
b. Recommended Grease for high temperature
Kopal Compound
This is a copper lead based anti size compound. Withstands high temperature up to
1100°C. The same may be procured from M/s Anand Engineers Pvt. Limited (Lubricants
Division), 66, MIDC, Road No.13, Andheri (East), Mumbai – 400093, Phone: 8368711 /
8372641.
The grease should be pumped through the grease nipples provided on the bearing
housings. Over greasing will result in some grease leakage eventually finding its way into
bearing race and this will increase the viscosity of lubricant resulting in over heating of the
bearing.
The lubricants given are put forward in association with the manufacturers and
commission of any equivalent make does not mean that cannot be used.
The particular suppliers must however accept full responsibility that grades outside this
list are fully equivalent.
15
Recommended Spares
Spares should be ordered in advance of requirement. To expedite delivery particularly in

an emergency, the information given below should accompany the order so that parts can
be readily identified.
1. Serial number and size of Air Lock given on the name plate of the machine.
2. Item number and description of the part and quantity required.
3. Recommended spares per Air Lock.
a. Rotor with shaft : 2 Set
b. Adjustable Tips : 1 set
c. Bearings : 2 No.
d. Packing Rope : 4 Sets
16
SLIDE GATE
SLIDE GATE
INSTALLATION
&
OPERATION MANUAL
PROJECT: 1 X 6.875 MW WASTE HEAT RECOVERY CPP

CLIENT: PARASAKTI CEMENT INDUSTRIES LTD,AP
-1-
CONTENTS
S.NO DESCRIPTION PAGE NO
I GENERAL INFORMATION 3
II PRE INSTALLATION CHECKUP 4
III OPERATION 4
IV MAINTENANCE 4
V RECOMMENDATIONS 5
VI RECOMMENDED SPARES 5
-2-
GENERAL INFORMATION
These instructions have been prepared in an effort to acquaint you with the
fundamentals of this slide gates. It is important that instructions be read carefully and
that the procedure outline be understood and followed.
It has been our experience that in most instances slide gate can be properly erected
and operated by field personnel if care is taken initially to the steps covered in this
manual.
This slide gates has been designed for your requirements, but proper attention is
necessary to ensure peak operating efficiency.
It is strongly suggested that if you encounter unexplainable difficulties during initial

start up of operation, you may please contact us:
TURBVOENT INDUSTRIES PVT.LIMITED

8-3-214/21, Srinivasa Nagar Colony (West)
Hyderabad - 500 038,
Phone: - +91 40 44119100.
E-mail: info@turbovent.com
Our field personnel are usually availably for supervisory assistance.
A Slide gate is often only one of many pieces of equipment in a material handling
system and its proper operation is contingent upon the correct operation of the other
pieces equipment.
These Slide Gates will give you many years of satisfactory service, but in order to do
so, maintenance is of vital importance. There are very few number of normal wearing
parts is this slide gate which will require periodic replacement.
It is our effort to have available from stock as many replacements part as possible but
there are cases where this is not feasible. For that reason we have included a section
covering recommended spare parts. We urge you to give serious consideration to the
early purchase of these to avoid lengthy and costly shutdowns due to not having these
on hand when needed.
-3-
PRE INSTALLATION CHECKUP
1. Prior to installation the following are to be checked:
a. Check for receipt of all the materials as per part list.
b. Check for any damage of body/Arms if any, to be rectified bore installation.
c. Check matching Flanges are as per our drawing.
2. All the loose parts to be put in position as per the match marking and assembled.
3. The gates should be aligned and leveled completely and the assembly bolts to be
tightened.
OPERATION & MAINTENANCE
Once the slide gates are put in operation, observe for wear and tear of the slide plate.
1. Replace the roller before it is fully worn-out.
2. Check periodically for any wear of slide plates and repair/replace accordingly.
OPERATION AND MAINTENANCE OF PNUEUMATICALLY OPERATED SLIDE

GATES:
1. DESCRIPTION:
This is a quick Shut off Gate of -1- mm and -2- mm square and Slide Gate
sizes -3- Nos. The Gate is fabricated from IS: 2062 material with Slide Plate.
1 2 3
A 700 7300 1No
-4-
2. OPERATION:
Gates are operated pneumatically by the double ended Pneumatic Cylinder

coupled to the plate of the gate. The operation of the Cylinder is through a 5/2
single solenoid valve. The valve is energized when the gate is to be opened. On
De- Energisation of the solenoid valve, the gate will close automatically.
3. SPECIAL INSTRUCTIONS:
Confirm correct supply voltage before connecting power supply to the system.
Ensure clean & lubricated air supply to the valve operating Pneumatic Cylinder.
Gate should be cleaned from time to time to avoid its sticking.
4. RECOMMENDATIONS:
It is strongly recommended that a good quality FRL is used on the incoming Air line
to the valve. This ensure high life for solenoid valve as well as cylinder.
5. RECOMMENDED SPARES:
Following Spares are recommended: -
Rollers - 1 Set.
Seal kit for Pneumatic Cylinder - 2 Sets.
-5-
MANUAL HOIST
FIRE FIGHTING SYSTEM
O & M Manual for Fire Protection System Client: Parasakti Cement.
MANUAL FOR FIRE PROTECTION

SYSTEM
at
PARASAKTI CEMENT - 1x6.85MW

WHRBPP, AP.
Prepared By
EFFICIENT FIRE & SECURITY SOLUTIONS PVT. LTD.
SURVEY NO 144, GANESH NAGAR INDUSTRIAL

AREA, OPP. HINDUSTAN LEVER LTD.
A/P : PHURSUNGI DIST : PUNE -412 308.
MAHARASHTRA. INDIA
Ph. +91-20-60502050/60,09822008747
Email : anandgadekar@hotmail.com
1
General: PARASAKTI CEMENT - 1x6.85MW WHRBPP, AP. has setup a complete integrated
Waste Heat Recovery Based Power Plant. It comprising one number of Preheater
boilers (PH-2) and one number of AQC boiler, turbine generator along with necessary
utilities. Hence plant is qualified as ORDINARY HAZARD OCCUPANCY as per the
TAC guidelines. The fire protection system designed is as per the TAC guidelines for
fire protection.
Following is the installed fire fighting system,
SR. NO AREA DESCRIPTION PROTECTION
Fire Hydrant System, Wet Riser, Fire

1 AQC BOILER AREA Extinguisher and Addressable Fire Alarm
System.

2 STG AREA Extinguisher and Addressable Fire Alarm
System.

3 WTP AND DM TANK AREA Extinguisher and Addressable Fire Alarm
System.
4 PH2 BOILER AREA Extinguisher and Addressable Fire Alarm
System.
5 COOLING TOWER AREA Fire Hydrant System.
1. FIRE HYDRANT SYSTEM

Plant Buildings are provided with Pressurized fire hydrant system along the plant. The
hydrant points are strategically located as per approved drawing. The distance between
2 consecutive hydrant points does not exceed 45 meter as per guidelines. Hydrant
system consists of fire pump house, water mains and hydrant valves with associated
branch pipes, nozzles and hoses with couplings, water monitor etc. The water for fire
hydrant is taken from the water storage tanks and is connected via pipe line to Fire
Pump house.
The System is designed such that the system will be under pressure at all times. Any
water pressure losses in system will be taken care of by Jockey Pump. If Jockey Pump
2
cannot maintain adequate set pressure, Main Electrical Pump will start. In case, main
pump fails to start/not able to maintain pressure, Diesel Engine Driven Pump will start
and water will be made available for fire fighting.
PUMPS SPECIFICATION
Sr. Pump Specifications Flow Pressure
No.
1. Jockey Electrical Pump 10.8 m3/hr 88 MWC
2. Main Electrical Pump 171 m3/hr 88 MWC
3. Standby Diesel Engine Driven Pump 171 m3/hr 88 MWC
SET POINTS FOR PUMPS FOR ITS AUTO OPERATION

Sr. Pumps Pump AUTO PUMP OFF set
No. ON set Pressure in Bar
Pressure in Bar
1. Jockey Electrical Pump 7 8
2. Main Electrical Pump 5 Manual
3. Standby Diesel Engine Driven Pump 3 Manual
The system can be kept in MANUAL as well as AUTO mode through selector switch
provided on the Fire MCC panel at Pump House.
Diesel Engine can also be started with local control panel provided with the diesel
engine set. The starter mechanism with battery charger is provided for this purpose.
The system is hydraulically designed such that minimum pressure of 3.5 bars is
available at top of building floor when 2 hydrant points are opened simultaneously.
2. ADDRESSABLE FIRE ALARM SYSTEM

The addressable fire alarm system is provided at STG and WTP buildings, and manual
call points are installed at various locations as mentioned in the fire alarm GA drawing.
.
Main fire alarm panel is placed in STG control room. All other devises are installed as
per below table.
3
2.1 BOQ of proposed fire alarm system @ WHR Based Captive Power Plant,
2.2 Schematic diagram of proposed fire alarm system @ WHR Based Captive Power
Plant,
2.3 SENSORS ADDRESS AND LOCATION TABLE FOR ADDRESSABLE FIRE ALARM SYSTEM
4
FASAddressList
Device Address Loop Zone

ZoneDescription Location
Description No. No. No.
MSD 1 1 1 MCC&ControlRoom AboveFalseCeiling
MSD 12 1 1 MCC&ControlRoom BelowFalseCeiling
5
MSD 25 1 2 CABLECELLARROOM AtCeiling
MSD 33 1 3 BATTERYROOM AtCeiling
MSD 34 2 4 WTPBUILDINGAREA PLCROOM
MSD 35 2 4 WTPBUILDINGAREA CHEMICALROOM
MSD 36 2 4 WTPBUILDINGAREA POWERROOM
MCP 101 1 1 MCC&ControlRoom ATMAINENTERANCE
Hooter 102 1 1 MCC&ControlRoom ATMAINENTERANCE
MCP 103 1 1 MCC&ControlRoom ATEASTENTERANCE
Hooter 104 1 1 MCC&ControlRoom ATEASTENTERANCE
MCP 105 1 2 CABLECELLARROOM ATENTERANCE
Hooter 106 1 2 CABLECELLARROOM ATENTERANCE
MCP 107 1 3 BATTERYROOM ATENTERANCE

Hooter 108 1 3 BATTERYROOM ATENTERANCE
6
MCP 109 2 4 WTPBUILDINGAREA ATENTERANCE
Hooter 110 2 4 WTPBUILDINGAREA ATENTERANCE
MCP 111 2 5 PHͲ2Boiler AT0.0MtrLevel

MCP 112 2 6 AQCBoiler AT0.0MtrLevel
MM 115 2 2 CABLECELLARROOM FIREATLHS
Note:Aboveaddresslististentativecanbechangeduringcommissioningtosuitatsite
MFAP – MAIN FIRE ALARM PANEL

MSD – MULTI SENSOR DETECTOR
MCP – MANUAL CALL POINT
HT – HOOTER
MM – MONITOR MODULE
FI – FAULT ISOLATOR
3. PORTABLE FIRE EXTINGUISHERS
The fire extinguishers and sand buckets provided throughout the plant at strategic
locations as mentioned in approved drawings.
SAND
ABCͲ ABCͲ DCPͲ MFͲ COͲ2
SR.NO DESCRIPTION MfͲ50Ltr. BUCKETS
4Kg 6Kg 5Kg 22Ltr. 4.5Kg.
1 AQCBOILER 1 1 0 0 0 0 0
2 HAGAREA 1 1 0 0 0 0 0
3 LDOTANK 0 0 0 0 2 0 0
4 WTP 1 1 0 0 0 1 0
5 STGBUILDING 3 3 0 0 0 4 0
6 TRANSFORMER 2 2 1 0 0 1 2
7 MAINLUBEOILTANK 0 0 0 1 0 0 0
TOTAL 08 08 01 01 02 06 02
7
4. MAINTENANCE
4.1 PUMPS
A trained pump man shall be available on all shifts and at all hours of the day and night
to operate the pumps as and when required. Pump sets shall be run for at least five
minutes every day. The level of water in the priming tank shall be checked daily by
observing water level indicator to ensure that the foot valve of the pump is not leaking.
All pump glands shall be maintained in efficient working condition and the packing
renewed as required to maintain efficiency. Suction and delivery valves shall be
examined once every six months, particularly where sand or other objectionable matter
is liable to be drawn through the pump suction. All working parts shall be kept clean and
lightly oiled as cleanliness greatly adds to efficiency. Any necessary repairs shall be put
in hand and carried out immediately. Electrically driven pumps bearing grease cup shall
be checked once every week and refilled with fresh grease, if necessary. Starter
contacts shall be cleaned once every week. Insulation resistance of pump motor circuit
shall be examined once every six months and record of results shall be maintained.
4.2 HYDRANT MAINS

Hydrant mains shall be tested once a fortnight with a pump delivering at its maximum
pressure, with all hydrant valves closed and, thereafter, a running test with two or more
hose lines each 30 m long operating shall be carried out. This checks the efficiency of
the pump as well as the tightness of the hydrant mains.
All cut-off valves shall be operated and oiled, if necessary, once a month.
Cut-off valves shall be thoroughly overhauled annually to remove sludge and other
foreign matter collected in the valve seating.
4.3 HYDRANTS
All hydrants shall be examined systematically once a week to ensure that valves and
spring catches are maintained in good condition and all Brass/SS parts polished. Spare
washers shall be kept for hydrant valve seats. It is recommended that the painting of
standpoints and above ground piping be carried out annually.
4.4 HOSE PIPES AND NOZZLES

All hose boxes/hose stations shall be inspected externally once every week to ensure
that the equipment installed therein is intact. Further, the hose boxes/hose stations shall
be cleaned internally and externally once a month. When the hose gets worn out at the
tail end of the coupling(s), it is permissible to cut the end(s) of the hose. However
should the lengths of the hose after cutting(s) fall below 90 percent of its original, i.e. 15
8
m or 7.5 m the hose shall be discarded. A Hose Register shall be kept showing the
history of each length. Information such as date purchased, date brought into use, date
cut (if reduced in length), is useful and a column shall be provided for remarks by the
Committee’s Inspectors to whose inspection the Hose Register shall be open. Any hose
becoming inefficient through use, neglect or from any other cause, shall be discarded.
Fire protection hose shall not be used for purposes other than fire protection and drill.
All concerns are advised to keep a supply of cheap hose for watering paths, washing
out or filling boilers, etc. Such hose shall not be mixed with fire protection hose but
kept in an entirely separate place. It is recommended that hose couplings and branch
pipes be polished once a fortnight. Considerable diversity of practice has been noticed
in the attention paid to the drying and storing of hose and the following suggestions in
this connection shall be carried out. After use, hose to be thoroughly washed in clean
water and then thoroughly dried. A rack or some similar contrivance at least 10 m high
to be provided so that, after cleaning, hose may be suspended to drain and dry
evenly. This is to be done in the shade and not in the sunshine so that the hose is
evenly dried inside and out. Care to be exercised that it is not removed until it is
thoroughly dry in all places. The hose to be then thoroughly brushed with a hard bristle
or wire brush, and re-rolled, care being taken to choose a dry and clean place where on
to roll it; and replace in the boxes or hose stations. Care to be taken after washing that
the hose does not touch the ground, where it might be soiled.
Hose to be rolled up evenly and carefully, the female or spring coupling end being in the
centre. In this manner the spring clips, when grasped one in each hand, form a `reel’
and the hose can be quickly run out in the event of fire.
OR ALTERNATIVELY
The hose to be doubled in the centre of its length and rolled up evenly from the fold
Both the Male and Female couplings will then be on the outside of the roll. This permits
the nozzle being attached to the hose while being stored in readiness for use, and the
hose runs out without twisting.
4.5 MEASURES TO BE TAKEN WHERE THE INSTALLATION IS FOR ANY

REASON TEMPORARILY INOPERATIVE
9
Where the installation is expected to remain inoperative for a period exceeding 24

hours, prior sanction shall be obtained from the Committee. If any component of the
hydrant system is to be replaced for any reason whatsoever, the entire system shall not
be rendered inoperative but the particular section only shall be isolated by closing the
necessary cut-off valves. If, however, it is not possible to complete the replacement
before nightfall, the cut-off valves shall not be left closed overnight. Instead, blank
flanges shall be provided at the point where the component has been removed so that
the entire system, other than the component, which has been removed, would remain
operative through the night. Only one compartment of the reservoir shall be emptied out
at a time of cleaning or repair work. If the foot valve of the suction line is removed for
cleaning/repairs, it shall, as far as practicable, be replaced before nightfall. If the pump
is expected to be inoperative for more than 72 hours, every effort shall be made to
connect the service water supply to the hydrant system for the duration the pump is
inoperative. If the hydrant service is to be extended, the extended portion shall be first
laid and, thereafter, the connection between the existing system and the extension shall
be carried out expeditiously, so that the entire system is not left inoperative overnight.
4.6 MAINTENANCE SCHEDULE FOR FIRE PUMP & FIRE HYDRANT SYSTEM:
Sr. Inspection Parameter Frequency Condition
No. inspection
Ok Not Ok Not
Applicable/Remarks
1. System in AUTO Mode Daily
2. Water Level in Priming Daily
Tank
3. 5 Minute operation of Daily
pumps
a Main Pump
b Jockey Pump
c Diesel Engine Pump
4. Pump Bearing Grease Weekly
Cups
5. Starter Contact Cleaning Weekly
6. Hydrant Valve and its Weekly
spring latch operation
10
7. Inspection of hose box, Weekly

hose station, hose reel
externally
8. Hose Coupling and Fortnightly
branch pipe cleaning
9. Hydrant Mains Tightness Fortnightly

10. 2 Hydrant valve flow test Fortnightly
11. Inspection of hose box, Monthly
hose station, hose reel
internally
12. Cut off isolation valve Monthly
operation and oiling
13. Cut off isolation valve Monthly
operation and oiling
14. Suction and delivery Monthly
valve cleaning and
greasing
15. Insulation resistance of 6 Monthly

pump motors
16. Suction and delivery 6 monthly
valve thorough cleaning
11
4.7 MAINTENANCE SCHEDULE FOR FIRE EXTINGUISHER:
CONDITION
S. N. INSPECTION PARAMETER FREQUENCY
INSPECTION
OK NOT OK N A /
REMARK
S
1 Fire Extinguisher Condition Daily
2 Fire Extinguisher Pressure Monthly
Gauge
3 Fire Extinguisher HPT Quarterly
4 Fire Extinguisher Last Refill Quarterly
12
4.8 MAINTENANCE SCHEDULE FOR ADDRESSABLE FIRE ALARM SYSTEM
FREQUENCY
S. N. INSPECTION PARAMETER CONDITION
INSPECTION
NOT N A /
OK
OK REMARKS
1 Panel Healthy Condition Daily
2 Physical Damage to Fortnightly
smoke/heat/MSD Devices
3 Cleaning of smoke/heat/MSD Quarterly
devices
4 Physical damage to Manual Quarterly
Call Point
5 Operation of Hooter Monthly
6 Inspection of smoke/heat/ Quarterly
MSD devices/MCP/Hooter
4.0 LIMITED WARRANTY
13
THIS IS TO CERTIFY THAT FIRE HYDRANT SYSTEM SUPPLIED, AND COMMISSIONED BY

EFFICIENT FIRE SERVICES. IS WARRANTED FOR ANY MANUFACTURING DEFECTS FOR
18 MONTHS FROM THE DATE OF SUPPLY OR 12 MONTHS FROM THE DATE OF
COMMISSIONING, WHICH EVER IS EARLIER.
PRODUCTS OR COMPONENTS SUPPLIED OR USED BY EFFICIENT FIRE SERVICES. ARE
WARRANTED ONLY TO THE EXTENT OF THE MANUFACTURE’S WARRANTY. NO
WARRANTY IS GIVEN FOR PRODUCTS OR COMPONENTS WHICH HAVE BEEN SUBJECT
TO MISUSE, UNAUTHROISED REPAIR, ALTRATION OR UN-MAINTAINED.
EFFICIENT FIRE SERVICES. WILL REPAIR OR REPLACE DEFECTIVE PARTS FREE OF
CHARGE, PROVIDED AFTER OUR INSPECTION THAT THE MATERIAL IS DEFECTIVE AT
THE TIME OF INSTALLATION OR COMMISSIONING.
EFFICIENT FIRE SERVICES. WILL NOT BE LIABLE FOR ANY INCIDENTAL OR
CONSEQUENTIAL LOSS, DAMAGE OR EXPENSES ARISING DIRECTLY OR INDIRECTLY
FROM THE USE OF THE PRODUCT INCLUDING DAMAGEA FOR INJURY TO PERSON,
DAMAGE TO PROPERTY AND PENALTIES RESULTING FROM ANY SYSTEM SUPPLIED
BY EFFICIENT FIRE SERVICES. IN NO EVENT EFFICIENT FIRE LIABLITY EXCEED AN
AMOUNT EQUAL TO THE SALE PRICE OF THAT PARTICULAR PRODUCT.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES
AND REPRESENTATIONS WEATHER EXPRESSED, IMPLIED, ORAL OR WRITTEN.
For M/s EFFICIENT FIRE & SECURITY SOLUTIONS PVT. LTD.
Authorized Signatory
14
AC AND VENTILATION SYSTEM
Operation & Maintenance
instructions manual
for
Air Conditioning systems -

6.85MW Waste Heat Recovery Project,
Guntur, A.P
With best complements

Advance Ventilation Pvt. Ltd.
101. HSIDC INDUSTRIAL ESTATE, KUNDLI- 131 028,
Distt.: SONEPAT (Haryana).
Phones : (0130) 2219092-96
Telefax : (0130) 2219093
MOBILE : 98111 62584, 98112 29022, 92121 65586
E-mail : sales@advanceventilation.com
Regd. Office : Q-26, MODEL TOWN-1, DELHI-110 009.

PHONES : (011) 27114022 , 27658707 , 27415909
Delhi Office : 610, P.P. Towers, C-1,2,&3 Netaji Subhash Place, Delhi-110 034.
PHONES : (011) 27355795, 27355796
CONTENTS
01. Project Order details.
02. Specifications of the systems.
03. Installation; Operation and Maintenance instructions.
04. Motor Maintenance Information.
05. Equipments catalogues.
06. Electrical control panel drawing
07. Equipment general arrangement and duct layout drawings

31th March, 2018 M8/DEL-048.TKIIPL P. 1
Project Order details
Name of the project Air-conditioning systems for Control

Room In TG Building
Name of customer ThyssenKrupp Industries India Pvt. Ltd.
Name of User Parasakti Cement Industries Limited
P.O. No. & Date 2500012357 Dated 11-12-2017.
Type of Air-conditioning Hiper Ceiling Suspended Ductable Air

systems.
Conditioning System,Mega Split Air
Conditioners
Installation; Operation
and Maintenance
Instructions.
MAINTENANCE MANUAL
PARASAKTI CEMENT INDUSTRIES LIMITED
INTRODUCTION : This order comprises of Air conditioning of the Control

Rooms and various other areas of the power plant
building ., a detailed area-wise list is attached in the
manual.
Air Conditioning : The system includes floor mounted ductable Package (Hi-
per) AC’s and High wall split Air conditioners of Blue
Star Limited make. Cool air is supplied through supply air
ductings which has been thermally insulated. Each room
have been provided with supply air ducting and diffusers
for proper distribution of the cool air. Return air is being
taken for re-circulation through the return air grilles.
Condensing units are installed on the outer side of the building, which have
been connected to the Indoor units with copper refrigerant piping of heavier
gauge for the re-circulation of the refrigerant for condensation via condensing
units.
Operation of AC’s
All the AC’s are provided independent automatic microprocessor based control
panels / remote controls which have been installed/placed in each air
conditioned space.
MAIN COMPONENTS / ASSEMBLIES :
[1] Air Conditioners (Packaged Air cooled)
(a) Indoor units complete with cooling coil, expansion valve, integrated
copper tubing, expansion valve, blower with motor, filters and HP/LP
switches etc.
(b) Outdoor units with Compressors, condensing coil, integrated copper
tubing and condenser fan motor.
(c) Microprocessor based control panels/ remote controls.
Contd…2
(d) Piping :
(i) Drain piping (pvc pipes I 1” & ½”)
(ii) Copper refrigerant piping
(e) Supply air ducting with :

(i) Thermal Insulation
(ii) Grilles / Diffusers
(iii) Flexible canvas connections.
(f) Cabling and Earthing complete with cable trays & supports / clamps.
MAINTENANCE SCHEDULE
INDOOR UNIT:
(a) Centrifugal Fan : Periodical check up of Mounting

nuts, bolts etc. Maintenance crew to
tabulate the work schedule.
(b) Pre filters : Periodical check up and cleaning of

the filter using clean & dry
compressed air (preferably nitrogen).
(c) Electrical : Check for any loose / hanging wire

of motor terminal / control panel.
Tighten if required.
OUTDOOR UNIT :
(a) Condenser Coil : Periodically clean the condenser coil

for clogging & dust deposition.
(b) Condenser fan & : Periodically check the normal working

motor of the condenser fan & its drive motor.
Contd...3
TROUBLE SHOOTING :
[1] INDOOR UNIT:
Trouble Action
(i) Excessive Vibration / Noise - Check mounting bolts for its
Tightness. Tighten if required.
- If still vibrate report to the
manufacturer.
[2] REDUCED AIR SUPPLY :
Possible Troubles Action to be taken
(i) Chocked filters : - Clean the filters with the clean

compressed air, away from the
machine.
(ii) Loose belts - Tighten belts for required tension
(iii) Close damper position - Check and open the damper for right
position.
(iv) Reverse direction of rotation - Change the direction as per arrow

of impeller of fan marking by interchanges the motor
phase / connection.
(v) Unequal air supply to the - Balance the air supply using volume
conditioned space. control damper of grilles.
[3] Low cooling - Close all the doors & other opening of
the conditioned space.
- Check for the clogging of the
condenser coil, it should be clean for
proper condensation.
- Leak in the ducting to be sealed if
found.
- Clogged filters, these should be
cleaned on regular basis.
Contd…4
Specifications of the
Air Conditioning
System
Areawise details of the AC units installed :
Ceiling Suspended Ductable Package (Hi-per) AC :
Models : DSAP-2042 R2 (17TR)
S. No. Location Unit Cap Quantity

01. Control Room 17 TR Three (3)
Mega Split Air-conditioner :
Models : MHW301RC (2.5 TR)
S. No. Location Unit Cap Quantity

01. PLC Room in WTP Building 2.5 TR Two (2)
Maintenance
instructions
for
Electric Motor
GENERAL : Maintenance of Induction Motors”

be followed. Motors should be
Siemens/ABB/BBL/Kirloskar Motors installed in well ventilated areas.
have been designed, manufactured Drip –Proof Motors should be run
and tested to a high standard of in clean dry surroundings. If
excellence. Motors conform to protecting shields or guards are
relevant Indian Standards as given used, they must not obstruct the
on the name plate. free flow of air around the motor.
Precautions should be taken to see
These motors are sound in design that the hot air does not re-
and robust in construction and will circulate or blow into another motor
give satisfactory service with correct nearby.
installation and normal routine
maintenance.
FOUNDATION :
INSPECTION :
Motors on receipt should be The foundation of the motor,

checked for any damage during preferably of concrete, or structural
transit. Any damage should be steel, must be sufficiently rigid to
reported to us as well as to the minimize vibration and to maintain
carrier. alignment between the motor and
the load. Normally, a mixture of
four parts of stone and two parts of
STORAGE :
sand and one part of cement by
volume is suitable.
During storage, the motor is PINIONS, PULLEYS &

exposed to many hazards. Rain &
condensation can rust steel parts COUPLINGS:
cause pitting on the bearing and
seriously reduce the insulation
resistance. Dust, dirt and debris
These should be bored to the
encountered especially in a new
standard diameter and fitted on to
enough to clog motor ventilating
the shaft with a screwing motion
passages. All these factors make it
and never be driven on as this will
essential to store the motors carry
create undue stress on the
out regular maintenance during
bearings. In cases where motors
storage. It is preferable to store the
are direct coupled, like fans,
motors indoor and with special
pumps etc., we recommend the
treatment if the atmosphere is
use of flexible couplings as this
corrosive. Rotate the shaft
reduces stresses due to slight
periodically to avoid the grease
misalignment, which otherwise will
setting down.
whip and break the shaft in case of
belt drives, it is preferable to
INSTALLATION : arrange the slack side of the belt to
be on top and the belt should run
While installing a motor, we as close to the bearing as possible.
recommend that IS:1965, “Code
of practice for installation &
ELECTRICAL CONNECTIONS AND individually designed to suit the

INSULATION RESISTANCE : particular application giving due
considerations to starting torque and
A diagram of connections is provided starting current. Motors upto 3 HP
on the name plate. This should be would have 3 leads brought out
used alongwith the starter diagram. suitable for DOL starting only while
Check phase sequence of incoming above 3 HP would have a leads
supply and the direction of rotation. brought out suitable for star delta
To change direction of rotation, starting. Slipring motors can be
interchange any two of the line leads. started by inserting external
resistance in the rotor circuit (across
On all new motors or where an sliprings). Starting torque and
existing motor has been stored for a current values on the choice of the
length of time in a damp situation, the rotor resistance.
insulation resistance of the windings,
both between phases and to earth, MAINTENANCE :
should be taken by means of a 500
volt megger, BEFORE THE MOTOR KEEP CLEAN : Motor should be
IS PUT INTO SERVICE. The kept clean and free from oil, dust
insulation resistance should not be and moisture, care should be taken
lower than one megaohm when the to see that vent passages are not
motor is cold. If it is lower due to blocked. Especially, in case of textile
moisture, it should be dried before motors, the cotton fluff should be
starting the motors. it is removed periodically.
recommended that the procedure of
drying out of windings given in IS 900 The earthing conductor should be
be followed. regularly inspected and checked for
continuity. The insulation resistance
OPERATION : of stator and rotor windings should
be checked regularly, between
Clean up the motor and fan enclosure respective terminals and the frame.
if necessary. Turn the shaft by hand
to see that it rotates freely. Check In case of slip –ring motors, carbon
connection to see that the are tight dust should be blown out regularly
and clean. Connect the motor to load from slip – rints and brushes. The
and check for satisfactory operation. pressure on brushes should be
checked.
STARTING METHODS &
PERFORMANCE : BEARINGS :
Squirrel Cage Motors are generally Grease lubricated Ball Bearings are
started Direct –On-Line (DOL). charged with right quality and
Normally each motor is quantity of grease at the time of
despatch and will run for a long
period without much attention
when replenishing it is only necessary using a tubular driff to ensure correct

to remove the bearing covers on the alignment during fitting.
end shield and fill as much grease in
as possible but avoid overfilling. After NOTE :
3 or 4 regreasings the grease should
be changed completely. For In the case of non – standard motors
replenishing, fresh grease of lithium wherever necessary special
base, should be used. MIXING OF instructions will be provided.
DIFFERENT BASE GREASE
SHOULD BE AVOIDED AS THE MOTOR PROTECTION :
ESSENTIAL LUBRICATING
PROPERTIES MAY BE LOST. While selecting control gears for
motors it is essential to see that the
Bharat Petroleum grease ‘MP2’ is motors are properly protected
recommended for better bearing against faulty operating conditions.
performance no other grease should The general recommendations being
be mixed while regreasing. It ‘MP2’ a provision for overload setting,
grease is not available. single phasing preventor and under
voltage relay. For proper protection
Indian Oil Corpn’s MOBILUX II’ be fuses should be renewed
used after thoroughly cleaning periodically. A fuse rating selection
bearing and parts. chart is given below :
Bearings are an interference fit on the SPARE PARTS :

motor shaft and for removal without
damage, properly designed draw – off While ordering Spare Parts, always
tackle is necessary. Bearings should quote Machine Number which will be
be refitted by taping on to the shaft found on the Name Plate.
* * * * *
Drawing
for
Control Panel
Drawing
List of
recommended
Spares
Equipment’s
General Arrangement
Drawings.
Manual of
Operation & Maintenance
instructions
For
Fan + Filter Units and other
Ventilation system components-
6.85MW Waste Heat Recovery Project, Guntur, A.P .
With best compliments

Advance Ventilation Pvt. Ltd.
101. HSIIDC INDUSTRIAL ESTATE, KUNDLI- 131 028,
Distt.: SONEPAT (Haryana).
Phones : (0130) 2219092-96
MOBILE : 98111 62584 (SKC),9811229022(AKC)
Telefax : (0130) 2219096
E-mail :skc@advanceventilation.com, sales@advanceventilation.com
Project Office : 8th Floor, NDM-2 Building

D-1,2 & 3, Netaji Subhash Place
Pitampura, New Delhi – 110 034
Regd. Office : 610,P.P.Towers
C-1,2 & 3,Netaji Subhash Place,Pitampura –New delhi-1100
27th March, 2018 M18/DEL-048.TKIIPL P.1
CONTENTS
01. Project Order details.
02. Installation; Operation and Maintenance instructions.
03. Specifications of the Ventilation systems.
04. Motor Maintenance Information.
05. Maintenance Instructions for the Air Filter Cells.
06. Equipment general arrangement Drawings.

Project Order details
USER (Customer) Parasakti Cement Limited Jett, Rentachintala
Mandal,Guntur,A.P
BUYER JACHAK DIGVIJAY
P.O. No. & date 2500012357 & 11-12-2017
Equipments and its application Dry Ventilation system

Fan + Filter Units
Exhaust Air Fan
Air Intake louvers
SUPPLIER (Manufacturer) Advance Ventilation (P) Limited
Plot No. 101, HSIIDC Industrial Estate,
KUNDLI- 131 028,
Distt.: Sonepat,
Haryana.
AVPL Job Reference M118/DEL-048.TKIIP

Installation; Operation
and Maintenance
Instructions.

GENERAL:
The purpose of providing these ventilation equipments/system is to ventilate the

indoor spaces of the Cement plant by using the principle of dilution ventilation.
The area that are provided with the ventilation systems are:
Air Compressor Room
The below stated areas are provided with only Exhaust Air Systems:
Battery Room
Cable Cellar Room
Chemical Room
TG hall Operating floor
WTP Hall
WTP/Switchgear & Panel Room
DatasheetoftheExhaustFansinstalledatvariouslocations
1.) Location : Battery Room
Application Ventilation (exhaust) system
No. of exhaust fans 1
Model No./Size 450mm Sweep diameter
Type of the fan Propeller Type
Air quantity ; CMH 1870
Static Pressure ; mmWc 7.5
Fan speed ; RPM 900
Power Input (Watts) 132
2.) Location: Chemical Room
Static Pressure ; mmWc 7.5
Fan speed ; RPM 900
Contd…2

3.) Location: Cable Cellar

Static Pressure ; mmWc 10
Fan speed ; RPM 1400
4.) Location: WTP / SwitchGear & Panel Room
5.) Location: WTP Hall
Contd…3
The equipments are designed, and implemented to force supply the fresh and
filtered air at the required indoor space of the building; and to exhaust the stale
air from the indoor space; wherever required. The supplied air pressurized the
indoor space and therefore prevents the ingress of the dust into the space thus
making it a dust free space.
Here in this application, the ventilation (supply) air is distributed uniformly all
around the selected places using a well-designed supply air ducts network.
EQUIPMENTS:
The ventilation (supply) air equipments for the complete Cement plant building
are accommodated into the civil-masonry plant room constructed at site as per
the general arrangement drawings.
The ventilation (supply) air handling systems are sized for handling different
airflow rates for the different Sub-Station Buildings. The principal system
components / equipments and accessories are as per below: -
(i) Fresh air intake louvers.

(ii) Air pre filter cells.
The fresh and filtered ventilation (supply) air so available from this
equipment; shall be forced supply into the indoor space through the supply
air grilles provided with adjustable louver/damper assembly.
The specification / principal technical parameters of the ventilation (supply)

air equipment are given in the tables / data sheets provided in the section
of ‘Specifications of the Ventilation Systems’.
INSTALLATION:
The ventilation (supply) air equipments are supplied in completely
assembled condition; and grouted/mounted on its respective locations; as
per the general arrangement details, and guidelines given in the drawings:
Sl. No Location Drawing no.

Supply Air Fans in Air
01. AVPL-2M18-040-48-09
Compressor Room
04. All Exhaust Air Fans AVPL-2M18-040-48-05,09
The power supply requirement is of 415 volts, 3 phase, 50 Hz.
OPERATION:
It is recommended to continuously operate the ventilation air equipments, so

as to not to allow the rising of the indoor temperature of the sub-stations and
also to maintain a positive pressure in the plant. However, it may also be
switched OFF if the outdoor atmospheric temperature conditions are favorable.
Contd…4
The operation of these ventilation equipments is just very simple; after

completing the installation checks written here below:
01. All the system components are mounted in its proper orientation,
leveled properly; and fastened / anchored or grouted.
02. All the leakage / openings in the plant room are sealed.
03. The adjustable Grilles louvers blades shall be set for the required
direction of
air flow.
Now, the ventilation (supply) air system is ready for startup. So take an inching
start for the fan check for its direction. If everything is fine put the system in
full operation.
RUNNING MAINTENANCE:
1. Check for vibration and tightness of all the fasteners .

Maintenance
instructions
for
Electric Motor

GENERAL : Maintenance of Induction Motors”
be followed. Motors should be
installed in well ventilated areas.
Siemens/ABB/BBL/Kirloskar/CG
Drip –Proof Motors should be run
Motors have been designed,
manufactured and tested to a high in clean dry surroundings. If
standard of excellence. Motors protecting shields or guards are
conform to relevant Indian used, they must not obstruct the
Standards as given on the name free flow of air around the motor.
plate. Precautions should be taken to
see that the hot air does not
These motors are sound in design re-circulate or blow into another
and robust in construction and will motor nearby.
give satisfactory service with
FOUNDATION :
correct installation and normal
routine maintenance.
The foundation of the motor,
preferably of concrete, or
INSPECTION : structural steel, must be
sufficiently rigid to minimize
Motors on receipt should be vibration and to maintain
checked for any damage during alignment between the motor and
transit. Any damage should be the load. Normally, a mixture of
reported to us as well as to the four parts of stone and two parts
of sand and one part of cement by
carrier.
volume is suitable.
STORAGE :
PINIONS, PULLEYS &
During storage, the motor is
COUPLINGS:
exposed to many hazards. Rain &
condensation can rust steel parts
These should be bored to the
cause pitting on the bearing and
standard diameter and fitted on to
seriously reduce the insulation
the shaft with a screwing motion
resistance. Dust, dirt and debris
and never be driven on as this will
encountered especially in a new
create undue stress on the
enough to clog motor ventilating
bearings. In cases where motors
passages. All these factors make
are direct coupled, like fans,
it essential to store the motors
pumps etc., we recommend the
carry out regular maintenance
use of flexible couplings as this
during storage. It is preferable to
reduces stresses due to slight
store the motors indoor and with
misalignment, which otherwise
special treatment if the
will whip and break the shaft in
atmosphere is corrosive. Rotate
case of belt drives, it is preferable
the shaft periodically to avoid the
to arrange the slack side of the
grease setting down.
belt to be on top and the belt
should run as close to the bearing
as possible.
INSTALLATION :
While installing a motor, we

recommend that IS:1965, “Code
of practice for installation &
ELECTRICAL CONNECTIONS AND Individually designed to suit the
INSULATION RESISTANCE : particular application giving due
considerations to starting torque
A diagram of connections is provided and starting current. Motors upto 3
on the name plate. This should be HP would have 3 leads brought out
used alongwith the starter diagram. suitable for DOL starting only while
Check phase sequence of incoming above 3 HP would have a leads
supply and the direction of rotation. brought out suitable for star delta
To change direction of rotation, starting. Slipring motors can be
interchange any two of the line started by inserting external
leads. resistance in the rotor circuit
(across sliprings). Starting torque
and current values on the choice of
On all new motors or where an the rotor resistance.
existing motor has been stored for a
length of time in a damp situation,
the insulation resistance of the MAINTENANCE :
windings, both between phases and
to earth, should be taken by means
of a 500 volt megger, BEFORE THE
MOTOR IS PUT INTO SERVICE. The KEEP CLEAN : Motor should be kept
insulation resistance should not be clean and free from oil, dust and
lower than one megaohm when the moisture, care should be taken to
motor is cold. If it is lower due to see that vent passages are not
moisture, it should be dried before blocked. Especially, in case of
starting the motors. it is textile motors, the cotton fluff
recommended that the procedure of should be removed periodically.
drying out of windings given in IS
900 be followed.
The earthing conductor should be
regularly inspected and checked for
continuity. The insulation resistance
of stator and rotor windings should
be checked regularly, between
respective terminals and the frame.
OPERATION :
Clean up the motor and fan In case of slip –ring motors, carbon
enclosure if necessary. Turn the dust should be blown out regularly
shaft by hand to see that it rotates from slip – rints and brushes. The
freely. Check connection to see that pressure on brushes should be
the are tight and clean. Connect the checked.
motor to load and check for
satisfactory operation.
BEARINGS :
STARTING METHODS &

PERFORMANCE :
Grease lubricated Ball Bearings are
charged with right quality and
Squirrel Cage Motors are generally quantity of grease at the time of
started Direct –On-Line (DOL). despatch and will run for a long
Normally each motor is period without much attention
when replenishing it is only using a tubular driff to ensure
necessary to remove the bearing correct alignment during fitting.
covers on the end shield and fill as
much grease in as possible but avoid NOTE :
overfilling. After 3 or 4 regreasings
the grease should be changed In the case of non – standard
completely. For replenishing, fresh motors wherever necessary special
grease of lithium base, should be instructions will be provided.
used. MIXING OF DIFFERENT BASE
GREASE SHOULD BE AVOIDED AS
THE ESSENTIAL LUBRICATING MOTOR PROTECTION :
PROPERTIES MAY BE LOST.
Bharat Petroleum grease ‘MP2’ is While selecting control gears for

recommended for better bearing motors it is essential to see that the
performance no other grease should motors are properly protected
be mixed while regreasing. It ‘MP2’ against faulty operating conditions.
grease is not available. The general recommendations
being a provision for overload
setting, single phasing preventor
Indian Oil Corpn’s MOBILUX II’ be and under voltage relay. For proper
used after thoroughly cleaning protection fuses should be renewed
bearing and parts. periodically. A fuse rating selection
chart is given below :
Bearings are an interference fit on

the motor shaft and for removal SPARE PARTS :
without damage, properly designed
draw – off tackle is necessary. While ordering Spare Parts, always
Bearings should be refitted by quote Machine Number which will
taping on to the shaft be found on the Name Plate.

Maintenance
instructions
for
Air Filter Cells


Maintenance of the Air Filter Cells
The cleaning frequency (time) is subject to the dust concentration level in

the outside atmospheric air. Generally it could be 20-25 days; subject
however to the nature of the industry, and surrounding atmospheric
conditions. The cleaning is a must when the pressure drop across the filter
cells is increasing beyond 15 mmWG.
FILTER CLEANING:
Cleaning of air filter cells (dislodging of the accumulated dust)

is recommended for offsite. No cleaning operations should be
done with filter cells in position. Put off the ventilation (supply)
air fans, and remove the filter cells from its position.
It is also recommended to keep a set of air filter cells spare, so

that instant replacement of the cleaned up filter cells is done.
The dirty filter cells are taken to the mechanical workshop /
maintenance shop for cleaning exercise, and keeping this set of
filter cells ready for use in the next cleanup requirement.
The dirty filter cells shall be reversed; and gently tapped from
clean air side of the filter cell for dislodging of loose dust. Now,
low pressure air (0.5-1.oKg/cm2) shall be blown in reverse
(clean air face to dirty end) direction to free all the pores of the
filter media of the accumulated dust particles.
Caution: Do not use high pressure air as it may damage

the filtering media/cause local cavities
allowing passage of dust through these air
filter cells in normal operation.

List of
recommended
Spares

List of recommended Spare Parts
In this ventilation equipments/systems no much inventory
of spares is required to be maintained at the plant site;
excepting the followings :
01. Air pre filter cells : 1 set of each size.
*****

Equipment’s
General Arrangement
& Duct Layout
Drawings.
EOT CRANE
INSTRUCTIONS FOR
OPERATION & MAINTENANCE
MANUAL
OF
DOUBLE GIRDER E.O.T.CRANE
GRIP ENGINEERS PVT. LTD.,

KISTAPUR ROAD, MEDCHAL – 501 401, R.R. DISTRICT
(TELANGANA)
PHONE : 9247020031 TO 35
Mail: sales.hyd@gripengineers.com visit us : www.gripengineers.com
1.0 INTRODUCTION
GRIP is a leading Indian Company has the Unique status of being a manufacturer
of Cranes and Equipments.
Machine Building Division of the Company has sophisticated manufacturing

facilities. Apart from manufacture of Equipments for Steel Plant, Cement Plants
and Process Plant, the division specializes in manufacture of various types of
special purpose and workshop duty cranes.
The Division has designed and supplied Cranes to the Core Industries such as,
Steel Plant, Power Plant, Cement Plant and Chemical Plants.
The Division has been accredited with ISO 9001-2015.

2.0 GENERAL DESCRIPTION
2.1 Types of Crane
2.1.1 Electric Overhead Travelling (EOT) Cranes:
EOT Cranes travel on a pair of Gantry Rails mounted on Gantry Girders, which in
turn are supported on columns on two sides of the bay. The Crane consists of
Bridge Girders, End Carriages, Platforms, Trolley Assembly and long travel drive
machinery. Machineries for hoisting motion and trolley travel (traverse motion) are
mounted on the trolley. The trolley moves on rails fixed on the top of bridge
girders.
These cranes find their application in wide range of industry. Depending upon the
need specified by the customer in inquiry, the cranes are supplied with special
features such as:-
- 2 or 3 trollies running on common pair of bridge girders (paper industry).)

- 2 Trollies running on 2 separate pair of bridge girders (4 girder ladle
cranes in Steel Plant.
- Creep / Inching speed for various motion
- Planetary gear box with 2 motor drive for hoist motion (ladle cranes).
- Thyristor / Variable Voltage Variable Frequency Controls for various
drives.
- Hoist arrangement with 4 independent rope suspension (ladle crane).
- Hoist motion with anti-swinging arrangement for wire rope (Stockyard
Cranes).
- Trolley running on the top of one bridge girder (Mono box cranes)
- Permanent / detachable attachments such as Grab Bucket, Magnet, lifting
beam, rotating beam, slab/coil tong, sheet pack lifter, `C’ Hook, etc.
- Two part trolley with rotation drive for upper trolley part (rotating trolley
cranes)
- Flame-Proof design.
- Insulated Hook Block
- Remote control either Radio or infra red.
- Travelling type operator’s cabin.
- PLC operation.
2.1.2 Underslung Cranes
These Cranes are used in places where adequate space is not available between
top of gantry girder and bottom of roof truss. These cranes run on the inner
flanges on gantry girder I-Beams.
2.1.3 Goliath / Semi Goliath Cranes
Unlike EOT Cranes, Goliath cranes run on gantry rails mounted on floor level. The
bridge girders are supported on a pair of legs which are supported on end
carriages.
Semi Goliath cranes operated on rails mounted on shop gantry girder on one side
and on shop floor on the other side.
2.1.4 Moving type Cantilever Crane
These cranes commonly find their application in large steel plants. These cranes
run only on one Gantry rail. Reaction rollers are provided to balance the moment
arising out of cantilever loads. These cranes are mainly used for maintenance
operation in Steel Plants.
2.2 Major parts of EOT Crane
The major parts of EOT Crane are:-
- Trolley assembly
- Bridge Girders
- End Carriages
- Long Travel drive mechanism
- Platforms
- Trolley power supply arrangement
- Operator’s cabin
2.2.1 Trolley assembly
The trolley assembly consists of hoist drive mechanism, trolley travel mechanism
and the trolley frame. Typically the trolley frame is supported by 4 wheels which
runs on rails mounted on bridge girder. For the safety of maintenance personnel
the following is provided on the trolley:
- The top of trolley frame is covered with chequered plate / antiskid plate.
- Toe guards/kick plates are provided around opening and
- Hand rails and access ladder are provided.
2.2.2 Bridge Girder
The bridge girders are fabricated using tested weldable quality steel plates. The
bridge girders are stiffened with the help of vertical / longitudinal stiffeners
according to the design requirement. The girders are cambered upwards.
The bridge girder transmits the lifted load and the loads arising out of weight of
trolley, LT drive mechanism, platforms, electrical panels, operator’s cabin and its
self weight to the gantry girder through end carriages and long travel wheels.
2.2.3 End Carriages
The end carriages are fabricated from tested weldable quality plates / rolled
members. The end carriages are rigidly connected to the girders through
machined bolts. The end carriages along with bridge girders form a rigid frame
which resists skewing forces. The end carriages houses long travel wheels.
2.2.4 Long Travel Drive Mechanism
Depending on crane span, duty classification and long travel speed, either single,
twin or four units of long travel drives are provided on each crane.
Long travel drive consists of Sq. cage / Slipring motor, reduction gear box, brake,
couplings, floating / line shafts and long travel wheels.
The selection of type of motors, gear boxes and brake is governed by design
requirements and the specifications of the customer.
2.2.5 Platforms
Access platforms are provided for easy access to operator’s cabin wherever as
ked for, electrical panels and for maintenance of long travel machinery.
Toe guards/kick plates and hand rails are provided on the platform for safety of
operating personnel. The platform also supports fixtures for under bridge lights.
Generally, separate platforms are provided for supporting foot mounted long travel
drive mechanism to minimize transmissions of vibration of LT mechanism to main
platforms. Access ladders are provided for safe access to different levels of
platform and from girder/end carriage to platform.
2.2.6 Trolley power supply arrangement
The power supply to the trolley is through festoon cable arrangement. The
arrangement typically consists of fabricated brackets supported from girder /
platform brackets, I beam and cable supporting trollies. Fabricated cable collector
arm is provided on crane trolley for bringing cables from cable trollies to crane
trolley. Steel chain is provided between cable trollies to eliminate pull (tension) on
cable during movement of crane trolley along the span.
2.2.7 Operator’s Cabin
Open / closed cabin is provided for the operation of crane as per the requirement
of the customer. If so, specified by customer, pendent push button station /
Remote control is provided for controlling crane operation with or without cabin
control.
The cabin is of fabricated construction. It houses crane controllers, chair for

operator, ventilation fan and bell. The front portion of the cabin is made compact
to improve the visibility of operator.
Toughened glass and door for entry are provided for closed cabin.
Depending on availability of space of crane, a staircase or a ladder is provided for

access to crane platform from cabin.
3.0 INSTRUCTIONS FOR STORAGE & HANDLING
Crane parts after shop assembly and inspection are dismantled for ease of
transportation. The various sub-assemblies / components of the crane are
dispatched to customer’s site by Road / Rail / Sea route depending upon
destination.
Large bulky components such as bridge girders, end carriages, trolley assembly,
grab buckets, etc. are dispatched in unpacked condition. To ensure safety in
transit, adequate commercial quality packing is provided for electrical components
such as electrical panels, master controller, etc. Consignment destined to foreign
countries are packed in seaworthy packing as agreed with the customer.
Proper storage of crane components is important for achieving guaranteed

performance after commissioning.
To minimize commissioning time and to obtain best results, we recommend the

customer to take of the following points:-
3.1 To avoid multiple handling which can result in avoidable damage, heavy
consignments such as bridge girders, end carriage, trolley assembly and bulky
structural parts should be unloaded in the bay where the crane is to be erected
near the erection area.
3.2 Expensive electrical items such as panels, cables, etc. should be stored in
protected area to avoid pilferage and to avoid deterioration due to climatic
condition. Care must be taken to avoid direct exposure of electrical components
to rain.
3.3 The site must be made ready in all respect well in advance to receive the crane
and to avoid the delay in erection / commissioning of crane.
3.4 The girder should be stored vertically with trolley rail on the top side. The girder
should be supported on the bottom flange. The girder should not be stored resting
on its web.
3.5 The end carriages should be stored vertically. A minimum of two supports should
be provided.
3.6 The trolley should be stored in a covered area. When this is not possible due to
site restriction, the electrical machineries mounted on trolley and the long travel
drive machinery mounted on the platform / end carriage should be covered by
thick plastic sheet and the complete trolley should be covered by tarpaulin.
3.7 Mechanical components such as bottom black, wire ropes, shafts, etc. should be
stored in covered storage area. All fasteners including machined bolts should be
kept properly.
3.8 Electrical items like panels, resistance boxes, cables, master controllers, etc.
should be stored in closed area. These items must not be stored in open yard.
4.0 STANDARD ERECTION PROCEDURE FOR EOT CRANE
The instruction given below for site assembly and erection of crane should be
carefully read and followed. Proper erection of crane is important for long and
trouble free service.
Material sent to site is packed according to the requirement and based on

experience gained in transporting such material. The material received at site
should be verified against the packing list.
Any loss or damage to the material during transit should be checked immediately
on receipt of material at site. Please intimate to us regarding any shortages /
damages for lodging claims with insurance company. Incase the consignment is
covered under customer’s insurance policy then such claims should be lodged
directly by the customer with a copy to us. Minor damage to the structural parts
can be repaired at site.
4.1 Preparation for erection.
4.1.1 The space where the crane is to be erected is free from any obstruction. Ensure
that enough head room and facility for taking anchorage is available.
4.1.2 Erection equipment such as mobile crane, derrick, pulley block, winch, slings,
tools, etc are available at site.
4.1.3 The following service are available at site:-
- Electrical power: 415V, 3 Ph, A.C

- Welding transformer
- Gas and cutting set.
4.1.4 The power supply to Down Shop Leads (Power angle) is effectively cut off and is
not started inadvertently/accidentally when the erection crew is at work.
4.2 Steps for Erection
4.2.1 Decide upon the method of erection to be adopted from available standard
procedure such as,
- By derrick
- By using mobile crane of adequate capacity and boom length
4.2.2 Lift the end carriage ensuring the positional correctness by referring the G.A.
drawing.
4.2.3 Lock them in position by requisite wooden packing and by tying wire rope.
4.2.4 Both end carriages should be vertical, parallel and in one line with respect to each
other.
4.2.5 Fix platforms on girder as per drawing and match marking. If adequate lifting
capacity is not available, then platforms can be erected after girder erection.
4.2.6 Place the mobile crane / derrick and place the girder across the bay. Check match
marks on girder and end carriages to ensure correct erection.
4.2.7 Put slings at the center and balance the girder
4.2.8 Tie manila ropes at both the ends of the girder for maneuvering the girder position
while lifting.
4.2.9 Lift the girder and after reaching required height lower it at the correct position on
end carriages.
4.2.10 Insert Drift pins at four corners of End carriage/Girder joint for location and them
put machined bolts in the remaining holes. Bolts should not be fully tightened
unless the second girder is erected.
4.2.11 Remove the packing and ties and push the assembly to a suitable position for
lifting of 2nd girder.
4.2.12 Repeat steps 4.2.5 to 4.2.8 for the other girder. Lift the girder and after reaching
sufficient height push the End carriage in position and lower the girder over end
carriage.
4.2.13 Repeat the step given at 4.2.10. Check the diagonals and span. Then tighten the
bolts. Replace the drift pins with machined bolts and tighten them also.
4.2.14 Erect the trolley keeping the crane at center.
4.2.15 Lift miscellaneous items like hand railings, current collector, ladders, cable trolley
beam, Trolley cable collector arm, etc. and fit them in proper position with correct
fasteners.
4.2.15 Lift the panels, Resistance boxes, etc. and lay them as per drawing.
4.2.16 Lay the cable trays / troughs as per drawing and site condition.
4.2.17 Fit other miscellaneous electrical equipment as per drawing.
4.2.18 Lay the trolley trailing cables on cable trolley moving on I-Beam.
4.2.19 Fit MCC/Main switch, limit switch for CT & LT. Fix the actuators for limit switches
at proper places after checking the hook approaches as per drawing.
4.2.20 Complete wiring on bridge, crab as per wiring diagram using necessary
accessories like glands, lugs, number ferrules, sleeves for resistance boxes, etc.
4.2.21 Complete two point earthing on bridge, crab, etc.
4.2.22 Properly clamp the cables and dress up.
4.2.23 Complete reeving of wire rope and clamp the rope on the drum.
4.2.24 Complete lubrication piping as per the drawing.
4.2.25 Complete touching (painting) of the crane wherever required.
4.2.26 Remove all loose material laying on the Trolley / Crane platform which is likely to
fall down when the crane is in motion.
5.0 PROCEEDURE FOR COMMISSIONING OF THE CRANE.
5.1 Checks to be made before commissioning.
Before commissioning the crane carry out the following checks to ensure that the
crane is ready for operation.
5.1.1 Check physical dimensions / tolerances such as span, diagonal, skew, etc. of the
crane and ensure that they are within acceptable limits.
5.1.2 Fill up oil in gear boxes as per the marking on the dipstick.
5.1.2 Grease various points using lubrication system / Grease gum. Grease thrust
bearing provided in the hook block.
5.1.3 Apply lubricant to the wire rope
5.1.4 Fill up brake oil in the thruster brakes
5.1.5 Give supply to control transformer, check all sequences of control panel.
5.1.6 Give power to the crane and carry out power test on panels.
5.1.7 Set all limit switches and brakes.
5.1.8 Install buffer, buffer stoppers and actuators for limit switches.
5.1.9 Check setting of times for smooth operation.

5.2 Trial Operation and Commissioning:
5.2.1 Arrange test load, cradle for placing the load and slings as required below the
crane hook for load testing of the crane. (These should be arranged by the client
even if responsibility for crane erection and commissioning is given to Grip
Engineers Pvt. Ltd. in terms and contract).
5.2.2 Operate all mechanism of the crane on NO LOAD one by one. Check the
performance of each mechanism and that of safety devices. Ensure that all the
safety devices are operating properly and there is no abnormal noise from the
mechanisms.
5.2.3 Operate hoist mechanism with 50% load and check brake settings.
5.2.4 Operate hoist mechanism with 100% load (SWL). Initially lift the load slightly and
stop the hoist motion. Ensure that the brakes are holding the load effectively.
Then start operation of all the mechanisms with 100% SWL one after another. Lift
and lower the load several time and then record the performance of the crane with
respect to :
- Actual Speeds
- Motor currents
- Girder deflection
- Hook approach, height of lift and other physical clearances
The permissible value / tolerances are as follows:-
ITEM TOLERENCE
For Speeds
- For all motions except lowering motion + / - 10%
Of hoist drive
- For lowering motion of hoist drive +25% / -10%
For Girder deflection with Safe Working Load Span in mm/900
For Hook approach + / - 100 mm
For Head Room + / - 5%
For End Clearance + 50 mm
For End Approach + / - 100 mm
5.3 Over head Test
5.3.1 After successful completion of load test, the crane should be subjected to overload
test with 125% of the rated load to ascertain :
- That the crane mechanisms and the structural are capable of withstanding
overload.
5.3.2 During overload test, performance parameters such as speeds and Girder
deflection are not to be recorded.
5.3.3 Before taking reading for “Permanent Test” of the girder, Hoist and Lower load
equivalent to 125% of SWL several times, Then place the trolley at one end of the
girder and measure the girder level under NO LOAD conditions. Bring the trolley
at center and sling the load (125% of SWL) to crane hook and hoist the load very
slowly by about one meter. Hold the load for about 2 minutes and lower the load
gradually to floor. Mover the trolley at the girder end. Measure the girder level
after about 30 minutes to confirm that there is no permanent set in the girder.
5.3.4 Similarly operate all the motions of the crane with 125% of SWL to confirm that the
crane mechanisms are capable of withstanding the overload.
5.3.5 Only after completion of above mentioned tests and attending to the plug points
the crane should be handed over for regular operation.
6.0 INSTRUCTIONS FOR SAFE OPERATION OF OVERHEAD TRAVELLING

CRANES.
Safety of personnel operating at shop floor, equipment installed on shop floor and
crane itself depends on safe operation of crane. Therefore, it is imperative that
only competent, physically fit and properly trained crane operators are given the
responsibility for crane operation. For safe operation of crane, recommendations
given below should be understood and followed.
6.1 General Instructions
6.1.1 The crane should not be loaded beyond the maximum safe working load specified
on the crane name plate. For Cranes having more than one hoisting mechanisms
with single or multiple trolleys, special attentions should be paid to ensure that the
total lifted load by all the mechanism does not exceed the specified safe working
load and the load on each hoisting mechanism does not exceed the safe working
load of the individual hoisting mechanism.
6.1.2 It must be ensured that the trolley and the hoisting mechanisms are loaded only in
the vertical direction for the safe operation of the crane. Side pulling of the loads,
shunting of rail cars or other vehicles by means of crane hook is prohibited.
6.1.3 It is also prohibited to use the crane for tearing of jammed loads. Sharp or jerky
starting, stopping and lowering of loads is not allowed.
6.1.4 The wire rope should not be allowed to uncoil from the rope drum completely. At
least two dead turns of the wire rope should be left on the rope drum when hook
block is at the bottom most position.
6.1.5 Wire rope loops should be avoided at all the times since this may cause breakage
of the wire rope and lead to accidents.
6.1.6 Various safety devices such as limit switches, corner switches, buffer stoppers,
etc. are provided on the crane as per the requirement of codes / customer’s
specifications. These devices are meant to provide safety to the operating
personnel as well as are essential for the safety of the crane itself. Special
attention should be given to ensure that these safety devices remain functional at
all the times and their settings are not tempered with. The limit switches are the
emergency switches. These should not be used for the normal operation of the
crane.
6.1.7 Creep speeds are meant for spotting the loads at exact location. Creep speed
should be used only for a short duration for this purpose. The crane should be not
be operated for long period with creep speed.
6.1.8 Prior to leaving the crane, the main switch / main circuit breaker should be kept in
the OFF position.
6.2 Instructions for Crane Operator
Before the crane operator starts his work, he will first ensure that:
- The Hoist brake is not loose
- When the hook reaches its highest safe position, the power to the motor is
shut off through the actuation of the limit switch.
Incase any of these conditions are not fulfilled or if the operator is in doubt, he
should not operate the crane, but report to his supervisor.
The following points should be noted by all the crane operators:-
6.2.1 Always use the ladder / entry platform to get to and from the crane.
6.2.2 Crane operators should not pass from one crane to another except by means of
ladders.
6.2.3 General inspection and lubrication of cranes should be carried out at regular
intervals during working days.
6.2.4 For cranes not subjected to full load frequently, the hoist brakes should be
checked before lifting load to its limit. Make a trial lift by raising the load for a short
height from the floor, then lower and apply brakes. If the brakes do not hold, do
not continue to work the crane until the brakes have been adjusted.
6.2.5 The over hoisting limit switch is a safety device which is installed to operate only
under EMERGENCY condition and does not relieve the crane operator of the
responsibility for accidents resulting from running the hoist block too high. When
the hoist block is approaching the limit switch, the speed of hoist should be
extremely slow. Crane operators must not use the limit switch deliberately to stop
upward lifts. The limit switch must not be put out of action in order to obtain
greater lifting height.
6.2.6 The crane operator shall be responsible for the load from the time it has been
raised until he receives the signal from the SLINGER to lower. Do not move any
load without the appropriate signal from the slinger in charge.
Do not carry a load over the heads of persons on the shop floor. Always use
alarm bell / warning signal before moving the load from one place to another. If it
is necessary to make a temporary stop when traveling, avoid suspension of load
over gangway.
6.2.7 When approaching a load which is to be lifted, place the crane hook centrally over
the load, otherwise the load will swing when lifted. Do not lift the load at an angle
or try to tow the load.
6.2.8 Commence lifting slowly. Do not lower too rapidly. Do not stop load suddenly
when lowering as this will lead to over-stressing of the slings and the wire rope
and reduce their service life.
6.2.8 Always move the controller handles carefully.
6.2.9 Two persons must not be in crane cabin at the same time as this will distract the
attention of the operator.
6.2.10 Turn the controller handle by slow steps through the “ON” positions but return
quickly to the “OFF“position.
6.2.11 Always let your motors stop before reversing.

6.2.12 Reduce the traveling speed as the crab nears the end of the bridge and as the
crane nears the end of the gantry.
6.2.13 Before the crane operator leaves the crane, all the controller handles must be
placed in the OFF position and the MAIN SWITCH should be put in OFF position.
6.2.14 While resuming duty, do not switch on the MAIN SWITCH until absolutely certain
that no one is on the crane platform.
6.2.15 Carrying of persons on the crane hooks is a dangerous practice and is strictly
prohibited.
6.2.16 The block should never be lowered to a point where less than two full turns of the
wire rope are on the drum.
6.2.17 When two cranes are operating independently on the same track, they should
maintain a safe distance between then. When two cranes are used to lift the same
load, the work should be supervised by a responsible engineer.
6.2.18 The operator should not allow the crane / trolley to bump against wheels stops.
6.2.19 When any person is working on or near the rail track of an overhead crane,
effective measures should be taken to ensure that the crane does not approach
within 6 meters of the place where the person is working.
6.2.20 Take utmost care to ensure that no part of load or crane comes in contact with
power supply angles.
6.2.21 When the crane fails to respond correctly to the controls, the crane operator
should immediately stop the crane operation and report the matter to his
supervisor. No attempts should made to overcome the problem by repeated
operations of the controllers.
6.2.22 When the crane is in motion, the crane driver should always keep his hands on the
controllers.
7.0 PROCEDURE TO START THE CRANE
Before starting the crane operation observe the following:-
7.1 Check crane and crane way for any obstructions.
7.2 Release all locking devices

7.3 Check that parts needing lubrication have required quantity of lubricants
7.4 Ensure that no item is lying loose on the crane and the trolley
7.5 Check for neutral position of all control gears.
7.6 Switch on the crane protective gear
7.7 Check brakes and limit switches for their proper functioning.
NOW THE CRANE IS READY FOR OPERATION.
8.0 PROCEDURE TO STOP THE CRANE
The following procedure should be observed while leaving the operator’s cabin
and the crane.
8.1 Run empty hook and the trolley to the specified resting position.
8.2 Run crane to the access point.
8.3 Press the OFF push button provided in the cabin / pendent
8.4 Switch off the isolating switches.
8.5 Actuate locking devices, if any.
NOW THE CRANE IS OUT OF OPERATION.
9.0 Replacement of wire rope
Observe the condition of the wire rope periodically for the following defects and
change the rope if necessary.
9.1 Replace the wire rope if the outer wire of the rope have become loose.
9.2 Observe the wear of the wire rope. Replace the wire rope if the reduction in rope
diameter is more than 5%.
9.3 Replace the wire rope if it is subjected to severe overload or shock load.
9.4 Replace the wire rope when the total number of visible broken wires exceeds 10%
of total number of wires in the rope, at any place, in a length of eight times the
rope diameter.
9.5 Replace the wire rope when there is evidence of severe corrosion or if the core of
the wire rope has collapsed.
9.6 Replace the wire rope when it has been subjected to localized distortion, damage
or kinks.
9.7 Storage of Wire Ropes
Observe the following while storing the wire ropes.
9.7.1 Store the ropes in well ventilated and covered shed. As far as possible the store
should be free from moisture, dust and fumes.
9.7.2 Lubricate the outer layer of wire rope every three month. Rotate the reel
containing the rope through 180 degrees every three month.
9.7.3 Store the wooden reel only on a cemented flow.
9.7.4 Handling of wire rope
Wire ropes should be carefully unwound from the drum to avoid formation of kinks
which will lead to rejection of new wire rope. Care should be taken to avoid
contamination of dirt with rope.
10.0 INSTRUCTIONS FOR LUBRICATION
10.1 Periodic lubrication of rotating parts is essential for trouble free and safe operation
of crane. General guide lines are outlined below for lubrication schedule that
should be followed. Lubrication intervals shorter than recommend below may be
followed depending upon actual environmental conditions and the frequency of
usage of the crane. Service life and operational safety of the equipment depend
to a large extent on maintenance and lubrication. All driving parts are to be
regularly examined for faultless operation. In the event of unusual sounds or
undue heating, the cause is to be investigated and the fault eliminated.
10. 2 INSTRUCTION FOR LUBRICATION
______________________________________________________________________________
Part of Method of Frequency of Remarks Lub.

Crane Lubrication Lubrication Brand
Wheel Bearing CRP/NIGI/NIGG weekly Clean bearing and fill Type 1

New grease every year
Input Geared CRP/NIGI/NIGG weekly Clean bearing and fill Type 1

Coupling New grease every year
Motor Bearing NIGI weekly Clean bearing and fill Type 2

Hook Bearing NIGI Weekly Clean bearing and fill Type 1

Pulley Bearing CAP/NIGI/NIGG Weekly Clean bearing and fill Type 1

Enclosed Gears SPLASH weekly Drop oil every week Type 4

Change oil initially after
200 Hrs. & then after
every 1500 Hrs.
Output Geared NIGI Monthly Clean coupling and fill Type 1

Coupling new grease every year
Line shaft CRP/NIGI/NIGG Monthly Clean bearing and fill Type 1

Bearing new grease every year
Rope drum CRP/NIGI/NIGG Monthly Clean bearing and fill Type 1

Pedestal new grease every year
Bearing
Wire Rope HAND Monthly Type 3
Gear Box NIGI Monthly Type 1

Rope Drum
Joint
Cable Trolley NIGI Monthly Type 1

Bearings
Brake lever pin NIGI Monthly Type 1

____________________________________________________________________________________
11.0 INSTRUCTIONS FOR MAINTENANCE OF ELECTRICAL MACHINERY
____________________________________________________________
11.1 General
In order to maintain electrical machinery in good working condition, prevent

accidents and make their lift long, it is most essential to carry out routine and
periodical inspection and maintenance.
Depending upon the environmental and operating conditions the rate of

deterioration of electrical machinery varies. Thus, it is difficult to establish uniform
standards for inspection of electrical machinery.
11.2 General Considerations on Maintenance & Inspection:
With any crane in use for a long time, the crane and its electrical machinery
gradually deteriorates. Such natural degradation should be distinguished from that
of the trouble caused by the constructional or functional defect. The essential
purpose of inspection and maintenance is to prevent such trouble from occurring.
Different electrical machineries have different rates of deterioration. In making the

maintenance plan, it is important to understand which part has the high rate of
wear and the degree of functional importance of that part.
11.2.1 The following parts have high rate of wear and hence should be considered as
expendable.
1. Contact piece of reversible master controller
2. Contact piece of magnetic contactor for main circuit
3. Auxiliary contact piece
4. Carbon brush
5. Brake lining
11.2.2 The following parts have moderate rate of wear:
1. Bearing of motors
2. Mechanical movable parts of magnetic contactor (pin, lever, spring, etc.).
The parts listed at 11.2.1 and 11.2.2 are natural expendables and should
be replaced with new products when damaged beyond the operating limit.
11.2.3 The following items are detrimental to the proper functioning of electrical
machinery and requires the proper attention:
1. Abnormal decrease in insulation resistance.
2. Entry of water into the machinery
3. Accumulation of carbon powder, dust or dirt in the machinery having a

possibility to cause moisture absorption, deterioration of insulation or
interference with ventilation.
4. Badly imbalanced air gap of A.C. Motor or collision of insulation or

interference with ventilation.
5. Loosening of lead or terminals
6. Abnormal drop of supply voltage / frequency.
11.2.4 The following parts may cause trouble due to carelessness in use or due to poor
maintenance, hence these parts should be repaired or replaced:
1. Fused contact piece
2. Burnt out magnetic coil
3. Slipring face damaged by flash over
4. Winding burnt out by overloading
5. Winding short-circuited between layers due to deteriorated insulation or

burnt out by grounding.
The parts listed under 11.2.1 require frequent inspection and those covered under
112.2 should be inspected from time to time.
The scope and frequency of inspection depends on the conditions applicable to

each machine, but the minimum recommended requirements are as follows:
11.3 Scope and Number of Times of Maintenance and Inspection :
11.3.1 Round-about inspection should be done by the crane operator two times daily,
before and after the work. In addition, if any abnormality is noticed during
operation, the crane must be stopped at once and inspect the suspected part.
During inspection, at least the parts covered under 11.2.1 should be checked.
Additionally, it is recommended that the person in charge of maintenance should

make the round-about inspection at least once a week.
11.3.2 Periodical Inspection
Once a year disassemble important operating parts for inspection. This inspection
should be done irrespective of the fact that any trouble of abnormality is
encountered or not. It occasionally happens that the defect in the part is noticed
for the first time after it is disassembled.
11.4 Planning for Maintenance:
Abnormality or trouble notice during daily or periodical inspection should be

removed immediately. If the repair of damaged part is not possible, replacement
with new part should be made. It is essential to keep spares in stock to provide for
unexpected trouble so that the stoppage of operation is kept to the minimum.
11.5 Precautions on use of Crane
Even correctly manufactured electrical equipment may become inoperative and

can cause serious trouble if they are not used properly. Therefore, the operator
must be made aware of the following points:-
1. Make sure of the operation of safety devices beforehand
2. Do not load beyond the safe working load
3. Do not use crane beyond its designed duty cycle
4. Do not use crane in lower notches of master controller for long period.
5. Do not use creep speed for continuous / long operation. The creep speed
is only for spotting the load.
6. Avoid quick deceleration
7. At the end of the shift inspect the crane and prepare for the next shift.
11.6 The following paragraphs describes the procedures for maintenance, inspection
and precautions to be taken for important parts of crane.
11.6.1 Power Source
As the characteristics of motor and its performance depends on the voltage

variation, crane should be taken to prevent voltage variation beyond 10%
- Ensure that the voltage drop within the cable does not exceed 3%
- Power feeding point to the DSL should be positioned as close as possible
to the center to minimize the voltage drop.
11.6.2 Main Collector:
Check weekly that collector’s line-up correctly with main conductors. Wear on the
collector shoes should be examined monthly. Collector shoes should be replaced
when their thickness is reduced by 50% of original thickness.
11.6.3 Motors
11.6.3.1 Insulation Resistance
Insulation resistance of motor shows reasonably high value when the motor is
new. With the time of use it gradually decreases due to deterioration of insulating
material, moisture absorption or accumulation of dust or dirt. The rate and degree
of such decrease in insulation resistance depend upon environmental and
operating conditions.
Insulation resistance of the windings both between phases and to earth should be
taken by means of a 1000 V meggar BEFORE THE MOTOR IS PUT INTO
SERVICE. The insulating resistance should not be lower than 2 mega ohms when
the motor is cold. If it is lower due to moisture, it should be dried before full
voltage is applied to the motor terminals.
11.6.3.2 Slipring and Brush Gear
Sliprings and brush gear of slipring motors require careful inspection and attention.
Sliprings should be checked with specific attention to the following points:
- Check slipring for pin holes on contact surface. If excessive pin holes are
observed then remove them by machining or replace the slipring.
- Sparking at the slipring is harmful. Due to distortion of slipring or shaft,

slipring rotates eccentrically, which leads to sparking. In such an event
the slipring surface should be machined.
The reduction in slip ring diameter should not be more than 5mm with respect to
original diameter.
Brushes of slipring motors should be checked periodically for wear and

smoothness. Brushes should not be allowed to wear below 12mm. Brushes
should press evenly and radially on to the sliprings. Recommended brush
pressure is 0.13 to 0.20 kg/cm sq. The sliprings and the brushes should be free
from oil and dust. The slipring covers should be opened every month and any
carbon dust accumulated should be blown out to avoid flashover.
11.6.3.3 Terminal Box and Lead Terminal
Screwed / bolted part of terminal box and lead terminal is liable to get loosened
due to mechanical vibration. Check it periodically and tighten if necessary.
11.6.3.4 Bearing
All motors are fitted with antifriction bearings in bearing housings and are charged
with grease. Grease the bearings periodically. Also disassemble the bearing
annually and after washing, refill it with high quality grease.
11.6.4 Brakes.
Maintenance of Electromechanical brakes is vital for safe operation of crane.
Hence, utmost attention must be paid to ensure that brakes are in proper working
condition at all times.
Fail safe brakes are used on cranes to ensure application of brake in the event of
power failure. When the power is supplied to the fail safe brakes, spring is
compressed due to the actuation of electro Hydraulic thruster / magnet and the
brake is opened. When power supply to thruster / magnet is stopped the brake
closes under the force of spring.
Heavy duty, self aligning cast iron shoes are provided on brakes for gripping the
break drums when the brakes are applied. Brake shoes are provided with treated
fabric lining.
To minimize down time in replacement of shoe lining, complete brake shoes with
shoe lining should be kept in stock. To adjust the brake torque, the length of
brake spring should be adjusted suitably.
11.6.4.1 Electro Hydraulic Thruster Brakes:
The thruster consists of motor driven centrifugal oil pump. Before installing the
brake wipe out dirt around oil filter plug. To charge oil in thruster, remove oil filter
plug and level plug and fill oil slowly. Operate thruster several times till it operates
smoothly.
Change thruster oil periodically after 2 years. Top up the oil if the oil level is below
the requirement. When thruster is dismantled, take precaution to ensure that dirt
does not enter inside the thruster.
11.6.4.2 Electromagnetic DC Brakes
Incase of electromagnetic DC Brake the release of brake takes place through

actuation of magnet. The torque of the brake can be adjusted by turning torque
adjuster nut. To increase the torque rotate the nut clockwise and to reduce
rotation in anticlockwise.
When the brake is properly adjusted for stroke, the torque adjuster washer face
stands clear of armature surface. As the lining wears this clearance decreases. If
the adjustment is neglected, the brake operation becomes sluggish and when the
torque adjuster washer touches armature surface, the torque drops rapidly
reaching zero when the clearance is used up.
The clearance dimension is not a measurable value but depends upon proper
adjustment of individual brake.
After replacement of shoe lining readjust the brake. The brake should also be
readjusted to compensate for lining wear when the sounding pin depresses more
than 0.4mm below the surface of armature.
To adjust the brake, tighten the pull rod nut until the sounding pin in the outer
armature flushes with the surface of armature, when pressed in de-energised
condition.
11.6.5 Master Controller
Master controller is housed in sheet steel enclosure and is provided with easily
removable cover for ease of maintenance. Before opening the master controller,
isolate the main power supply.
Contacts should be checked periodically for the wear and should be replaced
where the wear is found to be more than 30%.
Apply a thin film of grease at pivot points of roller and on cam shaft ends every
sixth month.
11.6.6 Control Panels
Maintenance of equipment in the control panels has the greatest effect on the
efficient operation of the crane.
Contactors and relays should be protected from dust and heat. Inspect
and clean them frequently to prevent leakage.
Contact pressure, stroke and gap of contacts should be maintained properly.
Examine wear of contacts periodically and replace the contacts when excessive
wear is observed.
11.6.7 Limit switches:
Limit switches, though not normally used in regular operation of crane are
important for safety of crane.
Functioning of limit switches should be checked periodically to ensure that they

remain operational all the time.
11.6.8 Contactors
Before inspection, switch off the contactor and upstream fuse switch. Inspect
contactor terminal first after two months of installation and then after every six
month.
Alteration of contact arrangement (NO to NC and vice versa) adversely affect the
contactor performance. Also removal of unutilized contacts from contactors
affects performance of remaining contacts. Hence, this should be avoided.
Do not get perturbed over tarnished, blackened or slightly pitted contactors.

These are normal phenomenon.
Contacts can be cleaned by carbon tetra chloride. Do not use abrasives to clean
the contacts. Hard deposits on contact tips can be removed by blunt knife,
however, deposits on contact bridges need not be removed.
Do not apply grease or petroleum jelly on contacts. If contacts are slightly welded,
they can be separated by a screw driver. If they are not easily separable by above
procedure, replace them.
Replace contacts when only 30% of original contact tip remains balance. Contacts
should be replaced in pairs of moving and fixed contacts. After replacement,
operate contactor a few times before putting it back in operation.
Tighten arc chambers screw periodically. Do not use broken / damaged / cracked
arc chambers and coil. Replace it. Do not clean magnet with sharp/pointed
object/file or sand paper as it upsets mating of magnet faces. Clean magnet with
lubricant / chamois lather.
The only parts that can be replaced in a contactor are contacts, arc chambers and
coils. Other parts of the contactor are designed for lift. Finally use only genuine
spare parts to ensure safety.
11.6.9 Time Delay Relay (Timer)
The relay can be converted from ÒN DELAY’ to ÒFF DELAY’ and vice versa. To
do this, remove two screws that hold the magnet coil frame and rotate the
assembly through 180. Base plate marking indicates which function tie timer is set
for. In RTPNI type remove the top instantaneous contact assembly before the coil
assembly is rotated.
The relay has timing range of 0.05 to 1 min. or 0.05 to 3 min. to increase the timing
period, turn the adjusting screw in the clockwise direction. To decrease the timing
period turn the adjusting screw in the counter clockwise direction.
Do not lubricate any part of time delay relay. No special maintenance of the relay
is required.
Always use the relay in vertical position. Time relay contacts should be at the
bottom.
Normally open and normally closed contacts of the same pole must be used on
the same polarity.
Ensure that the timing head is not operated by unauthorized persons.
11.6.10 Moulded Cage Circuit Breaker (MCCB)
Inspection and Maintenance are to be carried out when the system is under de-
energised condition.
Check and tighten the cable terminations periodically. Never operate MCCB
without arc chutes. MCCB with U/V release can be made ON only with
energisation of it.
Check position of contacts and their simultaneous movement by making the
contact (fixed and moving) to touch.
Arc chutes should be replaced along with the contacts. Arc chutes can be taken
out by removing the fixing screw. After taking out the old arc chutes, clean the
cover from inside thoroughly and fix the arc chute in position.
11.6.11 Magnetic Overload Relay
Isolate equipment before inspection.
Current settings are marked in amperes on calibration plate. To change the

setting, raise or lower the dashpot until top edge is in line with calibration mark
required.
Time lag is controlled by the rate at which oil is allowed to pass from top to
underside of piston. There are three holes on the disc, one small, one medium
and the other large. When long delayed operation is desired the small hole is set
corresponding to the hole on the plunger. The medium hole and large hole are
meant for further quicker operations respectively.
Before filling the dashpot oil ensure the dashpots are clean. Change the dashpot
oil periodically to get the best results. Oil is to be filled up to the brass insert
(inside portion of the dashpot).
12.0 SPARES AND SERVICES
12.1 Spares
GRIP Engineers Pvt. Ltd. undertakes Supply of Spares for equipments

manufactured by them.
Customer attention is drawn to the fact that Spurious/Poor quality spares procured
from other sources may lead to more down time of equipment and this may also
affect the performance of connected components as well. For example the quality
of wheel assembly will have bearing on life of gearboxes, coupling and motors as
well.
We therefore strongly recommend that the customer pay utmost attention to the
source and quality of spares being procured by them.
12.2 Services
12.2.1 Grip Engineers offers services for Erection and Commissioning of Cranes and
equipments for Core industries. These services are provided not only for the
equipments supplied by Grip but also for the equipments procured by client
through other sources (including imported equipments).
12.2.2 Grip Engineers also offers to undertake comprehensive annual maintenance of

cranes installed in India under separate contract.
The maintenance contract can include supply of spares and guaranteed

availability of crane is so desired by the customer.
****
Item Description Checks & Counter Measures
D W M HY Y
C T RAILS
Wear of C T rail tread Rail tread should be minimum 90% of original *
size
C T rail joints Joints to be checked for alignment. Remove *
sharp edges if any. The gap between rail ends
should be less than 2mm and difference in rail
level should be less than 1 mm.
WIRE ROPES
Inspect the rope for defects in Replace the rope if necessary. Refer to *
strands and wires “Instruction for replacement of wire ropes”
Inspect rope clamps Keep tight and locked. Check for tightness on *
the way following the change of wire rope
ROPE DRUMS
Inspect the crests between the If sharp edges are formed, grind to give smooth *
grooves radii
Inspect grooves and ensure that If any, eliminate by grinding *

there is no excessive scoring by
wire rope on grooves
Drum shell thickness at the bottom Drum thickness should be minimum 80% of the *
of the groove original thickness. If the wear is excessive,
replace the drum
ROPE SHEAVES
Inspect grooves and ensure that If any, eliminate by grinding *
there is no excessive scoring by
wire rope on grooves
Wear at the bottom of the groove < = 25% of diameter of the rope or 30% of *
original thickness of sheave flange whichever is
smaller.
Ensure that the edges of the groove If sharp edges are formed, grind to give smooth *
are not sharp due to wear radii.
Inspect for hair cracks Replace sheave *
GEAR BOXES
Examine the sound of gearing If unusually noisy, check wear of gear teeth, *
during idle running & under load tightness of clamping bolts, lubrication &
bearings
Examine oil level in gear boxes Should be as specified on dip stick *
Check oil leakage If excessive, check clamping bolts. Replace *
worn-out / broken oil seals. Avoid overfilling of
lubricant
Is there any abnormal sign of teeth Check quality and cleanliness of lubricant. *
pitting or scoring Check, whether pitting tends to grow. If yes,
then replace the part
GEAR COUPLINGS
Examine the noise of coupling If unusually high check the gear teeth for wear. *
during the starting & stopping Check lubrication
Examine grease leakage Check coupling alignment & the tightness of *
clamping bolts. Replace ‘O’ rings if these are

damaged
Coupling alignment at input Misalignment of flexible coupling at input should *
be within 0.2 MM
Coupling alignment at output Misalignment of line shaft should be within 1.5 *

MM
BEARINGS
Examining sound of bearings and If unusually high, check lubrication & bearing *
bearing temperature by feel of hand alignment. Replace the bearing if worn out
Bearing lubrication
Grease lubrication Suitable charge of grease between 1/3rd to 2/3rd *
of bearing clearance. Avoid excessive grease
feeding
Oil lubrication Top the oil as required. Pay special attention to *

cleanliness of lubricant
MISCELLANEOUS CHECKS
Check machinery bolts for tightness Machinery bolts such bolts between stools and *
gearbox, motor, brake, drum pedestal etc.
should be checked for tightness. Tighten these
bolts if found loose.
Welded snugs Welded snugs provided on machinery stools for *
gearboxes, brakes, drum pedestals, equilising
pulley etc., should be checked for their physical
contact with respective machineries.
Adjustable stoppers for motors Adjustable stopper provided on motor stools *
should always remain in contact with respective
motors
Electrical Machinery
MOTOR
Check bearing temperature If very hot then check quantity & quality of *
lubricant and alignment of drive machinery.
Bearing vibration / abnormal noise If excessive then check bearing fitment in *
housing, wear of bearing and for accumulation
of dust in the bearing. Clean or replace the
bearing if necessary
Motor does not start Check voltage on each phase, Check control *
gear for open circuits and condition of carbon
brushes.
Motor overheats while running Motor may have one phase open, ensure that *
all the leads are properly connected. Also
check for foreign material in the air gap and
remove the same
.
Motor vibration Check drive alignment, bearing condition and *
balancing of the rotor and take corrective action.
BRAKES
*
Lining wear Check wear of brake lining. Lining should be
replaced when the thickness of the lining is 50%
of original. Rivet head should not rub against
the drum
Slip of load Check that the drum surface is free from oil / *
grease. Adjust the brake for lining wear. Check
and maintain the gap in DC brakes.
Oil of Thruster brake Check oil level in the thruster brake. Replace oil * *
every year
Brake Drums Check for wear. Replace the drum when the *
diameter is reduced by 2 MM from the original
diameter
RESISTANCE BOXES
Racks Inspect resistor racks and ensure that they are *
supported rigidly
Terminal bolts Inspect terminal bolts and ensure that they are *
tight
Cleanliness Clean the dust accumulated on the resistor *
especially on the insulators
LIMIT SWITCHES
Operation of hoist limit switches Check operation for satisfactory performance *
Condition of contacts Examine wear of contacts and if found rough *

then file to make it smooth. Ensure that the
contacts and the mechanism is free from dust.
CONTACTORS
Condition of Contracts Examine wear of contacts periodically. Replace *
contact when 30% of original contact tip
remains balance. Do not apply grease or
petroleum jelly on contacts.
GENERAL
Connecting bolts Check connecting bolts for tightness *
Welding on load bearing structurals Avoid notches and welding on bottom flanges &
lower portion of webs of girder, end carriage
balancer body and crab structure
Painting of structurals Repaint the structures after 10% of painted

surface becomes rusty or blistered.
RAPPING MECHANISM
Document No: EPE/OPM/2K18/001 Date- 22.05.2018
Client: Thyssenkrupp Industries (I) Pvt. Ltd.
End User: Parasakti Cement Industries Ltd. ,Jett,AP.
OPERATION & MAINTENANCE MANUAL

FOR
RAPPING MECHANISM
Manufacturer
ESTEEM POWER EQUIPMENTS (I) PVT LTD.
marketing@esteemindia.com
vivek.karyakarte@esteemindia.com
www.esteemindia.com
Office / Factory Address: Plot No.12, Gat No. 1452/1, Bhimashankar Co-Op. Industrial Estate,
A/P: Pargaon Peth. Pune-Nashik Highway, Tal: Ambegaon, Dist: Pune. Pin.-410512. ,Maharashtra, India.
Page 1 of 12
INDEX
Chapter
Title Page No.
No.
01. General 3-4
02. Initial Start Up 5
03. Regular Start Up 6
04. Regular Shut Down & Emergency Shut Down 6
05. Operating Instructions 7
06. Regular Do’s & Don’ts 8
07. Periodic Maintenance 9
08. Annual Maintenance 10
About Company 11-12
Page 2 of 12
Chapter No. 01
General
Coil rapping mechanism is new development to remove soot from coil surface which is
exposed to flue gases. This is a very new technique and no steam is required to blow soot like
regular soot blowers. Coil Rapping Mechanism is a system in which soot is removed by
Mechanical means.
Rapping Mechanism consists of following main sub-assemblies.
1. Motor Mounting Structure with Geared Motor

Motor mounting structure is structural frame on which geared motor is mounted. Driving
shaft is mounted on frame with self-aligned spherical roller bearing at both ends and split
bearing in between for ease of maintenance. Simplex chain sprocket is mounted on motor
shaft and driving shaft respectively and simplex chain is used to transfer the motion.
Number of teeth on driving and driven sprocket are selected based on output speed
required at driven shaft. Cranks are mounted on driven shaft. Number of cranks on
respective shaft depends upon number of coils and coil hanging arrangement inside casing.
Base plates of Motor mounting structure are welded to the platform at the respective
elevation level. Alignment of mounting structure is very important from operation point of
view.
2. Hammer Block Assembly

Hammer Block Assembly consists of bunch of hammer plates which acts as a dead weight.
These hammer plates are assembled at one end of levers which are pivoted at crank.
Number of hammer plates are kept adjustable in order to adjust dead weight. Dead weight is
decided based on number of coils to which its impact load is going to transferred. Hammer
plates are hardened. Hammer plate profile is designed in such a way that all four edges can
be used. Dimensions of hammer block assembly are kept such that it’s impact must be at
the center of string rod end cap. Alignment and selected weight of hammer block assembly
are very important.
Page 3 of 12
3. Striking Rod Guide Box Assembly

Striking rod guide box assembly consists of striking rod and it’s guide arrangement. Striking
rod end cap is hardened. Holding part of the Striking Rod Guide Box Assembly i.e. Reducer is
welded to the casing. Alignment of Striking Rod is of immense important. Flanges are
provided with ceramic rope gasket and striking rod is provided with seal boot in order to
avoid in grace of atmospheric air inside the casing. Metallurgy of striking rod is important as
the end of the striking rod is exposed to the hot zone inside casing. Impact load of hammer
block assembly is applied on striking rod end cap. This load is transferred to inner shaft
which is attached to the coils inside casing.
4. Inner Shaft Attachment

It is very important to have proper coil holding arrangement for efficient working of rapping
mechanism. Impact load of the hammer is transferred to Inner shaft through striking rod.
This impact load creates vibrations to the coil. Soot is removed due to these vibrations. It is
very important that inner shaft must be collinear to striking rod assembly which gives the
better results.
Page 4 of 12
Chapter No. 2
Initial Start Up
1. Ensure that all Mounting Structures are erected at respective elevation levels.
2. Ensure that all temporary supports welded or connected to equipment for fabrication and
erection purpose are removed and they do not become obstruction.
3. Ensure that elevation level and alignment of striking rod assembly is correct as per
drawing.
4. Ensure that elevation level and alignment of inner shaft is correct as per drawing.
5. Ensure that striking rod and inner shaft are collinear which is very important.
6. Ensure that impact of hammer block assembly is exactly at the Centre of striking rod end
cap and there is no misalignment in vertical as well as horizontal plane.
7. Ensure that centre to centre distance between adjacent striking rod and respective hammer
block assembly is equal and must be as per approved drawing.
8. Ensure that proper gap is maintained between end of the striking rod and inner shaft end
plate.
9. Ensure the direction of rotation of geared motor.
10. Ensure the current drawn by geared motor is as expected.
11. Ensure that oil is filled in gear box of geared motor.
12. Ensure that all parts are assembled properly.
13. Ensure all site weld joints are free from defects.
14. Ensure that all flanged joints are properly sealed with gaskets.
Start Up Sequence.
Start Rapping Mechanisms mounted on same platform in the sequence.

Start Rapping Mechanism at the frequency based on site conditions.
Page 5 of 12
Chapter No. 3
Regular Start Up
1. Ensure that all motors are in healthy condition.
2. Ensure that all hammers are in good condition.
3. Ensure that all striking rods end caps are in good condition.
4. Start Rapping Mechanism one by one as per sequence.
5. Ensure that there is no obstruction between hammer block assembly and striking rod.
6. Ensure all cranks and hammer blocks are at their original positions.
Chapter No.- 4
Regular shut down
During planned shutdown ensure following sequence.
1. Ensure that all motors are covered in order to protect them from any damage.
2. Ensure that all striking rods as well as hammer blocks are at safe positions to avoid accident
to maintenance personnel.
3. Carry out oiling and greasing of Bearings, Sprocket & Chain, Crank Pin and Striking Rod
guide bush.
Emergency shut down.

1. If emergency shut down is because of site requirement, follow the procedure as like normal
shut down.
Page 6 of 12
Chapter No. 5
Operating Instructions
Following are important parameters and due attention to be given to satisfy operating
conditions.
1. Alignment of striking rod , hammer block assembly is proper.
2. Alignment of geared motor is proper.
3. Motor must be in healthy condition.
4. Gear box is filled with lubrication oil recommended by manufacturer. Required oil level is
maintained as indicated.
5. Ensure that all parts are in good condition.
6. Alignment of driving and driven shaft is proper.
7. Chain is properly tightened. Chain guard is in its place.
8. Hammer plate weight is as per manufacturer’s instruction. Do not add or remove the hammer
plate without manufacturer’s instruction.
9. All flanged joints are in proper condition.
10. All nut and bolts are at place.
11. Frequency of rapping system must be selected based on amount of soot deposited on tubes.
12. As it is a mechanical system it’s periodic maintenance is very important.
Page 7 of 12
Chapter No. 6.
Regular Do’s & Don’ts
Regular Do’s.
1. Change the geared motor lubricant after every 3 months.
2. Ensure that geared motor is in healthy condition.
3. Do oiling and greasing at Bearings, Crank Pin, Chain, Striking Rod Guide bush after every
15 days interval.
4. Check the tightness of the chain at regular intervals.
5. Check the tightness of flanged joint at regular intervals.
6. Check the alignment of hammer assembly with respect to striking rod assembly after every
15 days.
7. Check the current drawn by motor at regular intervals and ensure that it is within acceptable
range.
8. Check the weld joints where the base plate is welded to platform at regular intervals.
Regular Don’ts
1. Do not change the hammer plate weight without approval from manufacturer.
2. Do not run the geared motor without lubricants.
3. Do not run the mechanism if the alignment is improper.
Page 8 of 12
Chapter No. 7
Periodic Maintenance.
Following periodic maintenance program are recommended.
1. Make maintenance log sheet for each rapping system.

2. All geared motors are to be maintained as per recommendation of supplier.
3. Follow the lubrication schedule as per below table.
Lubrication Schedule For Rapping Mechanism

Lubrication
Description Of
Sr.No. Lubricant Make Qty. Schedule /
Part
Frequency
1 Geared Motor SAE 80 W Oil Castrol / Equivalent 1200 ml. 3 Months.
Castrol / SKF/
2 Bearing Grease 50 gms. 15 Days.
Equivalent
Castrol / SKF/
3 Sprocket & Chain Grease 30 gms. 15 Days.
Equivalent
Striking Rod
4 SAE 40 W Oil Castrol / Equivalent 40 ml. 15 Days.
Guide Bush
5 Crank Pin SAE 40 W Oil Castrol / Equivalent 15 ml. 15 Days.
Page 9 of 12
Chapter No. 8.
Annual Maintenance
During annual maintenance following operations to be done.

1. Replace the lubrication oil in the geared motor.
2. Replace the damaged parts if any.
3. See the condition of hammer plates and striking rod end cap and take the corrective
action.
4. Check the critical weld joints for it’s soundness i.e. weld joint at base plate to platform
and weld joint at casing where striking rod guide assembly is welded.
5. Carry out oiling and greasing at bearings, sprocket , chain, striking rod guide bush,
crank pin, etc.
6. Check all flanged joints for bolt tightness and take corrective action if any.
Page 10 of 12
About Company
Esteem Power Equipments (I) Pvt. Ltd., Pune, is an engineering organization engaged in
design &manufacturing of waste heat recovery systems, all kind of heat transfer equipments and
heavy engineering fabrication jobs and started from 1st Jan 2008.
DNA of Company
Customer care, Innovation and Joy of work with highest safety.
Vision of Company
Want to become leader in “Waste Heat Recovery” system as designer and supplier.
Mission of Company
Design and supply heat transfer equipments for right specification, to appropriate cost
Business Focus
The company is having expertise in boiler designing, waste heat recovery systems & various
heat transfer equipments.
The company focus is on design & manufacturing various types of heat transfer equipments
like steam generators, waste heat recovery systems and heat exchangers, economizers (Plain tube,
finned tube & C. I. gilled tube), air pre-heaters and execution of turn-key projects associated with it.
The company is also focusing on business of modernization of old boilers (like change of
technology from FBC to stoker firing or other way, gas/ liq fuel firing to solid fuel firing etc.)
debottlenecking (like increasing rating of boiler for flow, temperature etc.), Hot Air Generators (HAG)
and Hot Gas Generators (HGG) upto 750⁰C and other Products with proven technology etc.
The company is also focusing on business of various boiler and power plant auxiliaries, like
steam blow of silencers, deaerators, HP & LP dosing systems, LP heaters, HP heaters, Rapping
Mechanism etc.
Team
The team consists of stake holder and paid directors expert in Design, Execution and Finance
along with qualified and experienced managers, Engineers and workers.
Page 11 of 12
Details of Company
Works:
Plot No. 12, Gat No. 1452/1,
Bhimashankar Co-op. Industrial Estate,
At Post Peth, Pargaon, Tal. Ambegaon,
Dist. Pune 410512. Maharashtra
Email.: marketing@esteemindia.com
vivek.karyakarte@esteemindia.com
GST DETAILS.
Company Name: Esteem Power Equipments (I). Pvt. Ltd.

State: Maharashtra
GST Application Ref. No.: AA2703170992802
GST Provisional ID : 27AABCE9168K1Z5
PAN : AABCE9168K
Thanking you,
For Esteem Power Equipments (I) Pvt. Ltd., Pune.
Vivek Karyakarte
Managing Director
+91-9822242750
Page 12 of 12
PLANT AUXILIARIES
MISCELLANEOUS PUMPS
Wilo Mather and Platt – MISO/ PISO (ISO 2858) pumps
en Installation and operating instructions

Wilo Mather and Platt_MISO_20131004_01
Disclaimer
Wilo Mather and Platt is very grateful for your interest in its products. The basic objective of
this document is to provide instructions for maintaining and operating Wilo Mather and Platt
MISO / PISO pumps. Instructions are complied for the person having a working knowledge of
Ring section pumps and the pumps shall be installed under expert supervision and guidance.
With this document Wilo Mather and Platt does not accept any liability for inaccurate
installation, operation or maintenance of the product at site. The authorities that install and
maintain the pump shall be responsible for hassle free installation operation or maintenance
of the product.
This document is prepared with at most care to ensure correct and accurate information,
enabling the user to have trouble free installation and operational support. However, there
can be few areas for improvement to make this document error free.
We welcome your valuable suggestions to make this document complete in all respects.
Mather and Platt pumps Ltd.

(Part of Wilo SE Germany)
Mumbai-Pune Road, Chinchwad,
Pune- 411 019, Maharashtra (India)
Tel: +91 20 27442100/1/2/3/4,
Toll Fee Service: 1-800-266-8866
Fax: +91 2027442111
service@matherplatt.com
www.matherplatt.com
Installation and operating instructions Wilo Mather and Platt –MISO / PISO Pumps 2
Fig.1: Pump Handling [3.1]
Fig.2: Engine driven pump [6.1.2]
Equal Clearance to be maintained on

all sides on the periphery for coupling
alignment
Fig.3: Pump Foundation [7.2.1]
Fig.4: Leveling of Base-plate [7.2.2]
Fig.5: Coupling assembly [7.2.3]
Fig.6: Forces and Moments [7.2.4]
Fig.7: Suction line- Bad [7.2.5]
Bad Suction Layout which will cause air pockets and failure to pump
Fig.8: Suction line- Good [7.2.5]
Good suction layout
Fig.9:
Fig.10: Suction line [7.2.5]
Fig.11: Stuffing box packing [7.2.7]


1 General information .................................................................................................................................... 7
2 Safety .................................................................................................... .............................................. 7
2.1 Designation of information in the operating instructions .................................................................. 7
2.2 Personnel qualifications .............................................................................................................................. 7
2.3 Danger in event of non-observance of the safety instructions ............................................................. 7
2.4 Safety consciousness on the job ................................................................................................................ 7
2.5 Safety instructions for the operator .......................................................................................................... 7
2.6 Safety instructions for installation and maintenance work .................................................................... 8
2.7 Unauthorized modification and manufacture of spare parts .................................................................. 8
2.8 Improper use ................................................................................................................................................. 8
2.9 Safety & control devices ............................................................................................................................ 8
3 Transport and interim storage .................................................................................................................... 8
3.1 Handling ......................................................................................................................................................... 8
3.2 Delivery ......................................................................................................................................................... 9
3.3 Storage .......................................................................................................................................................... 9
3.4 Pump returning back to the supplier .................................................................................................. 9
4 Intended use .................................................................................................... ................................... 9
5 Product information ............................................................................................................................ 10
5.1 Data plate .......................................................................................................................................... 10
5.2 Type key .................................................................................................... .......................................... 10
5.3 General description .............................................................................................................................. 10
5.4 Scope of delivery ................................................................................................... ............................. 11
5.5 Accessories...................................................................................................... ..................................... 11
6 Description and function ..................................................................................................................... 11
6.1 Description of the product .................................................................................................................. 11
7 Installation and electrical connection (Motor / pump coupling system) ............................................. 14
7.1 Installation of bare shaft pump ........................................................................................................... 14
7.2 Installation of the complete pump set ............................................................................................... 15
8 Commissioning .................................................................................................... ................................ 19
8.1 Cleaning prior to start .................................................................................................... ...................... 19
8.2 Filling and venting ................................................................................................................................ 20
8.3 Starting the pump .................................................................................................... ........................... 20
9 Maintenance .......................................................................................................... .............................. 23
9.1 Routine maintenance and frequency of inspection ........................................................................... 23
9.2 Overhaul maintenance ......................................................................................................................... 23
9.3 Disassembling the pump ...................................................................................................................... 25
9.4 Reassembling the pump ..................................................................................................................... 26
9.5 Recommended spare parts .................................................................................................................. 26
10 Faults, causes and remedies ............................................................................................................... 29

11 Decommissioning and recycling .......................................................................................................... 29
12 Annexure ............................................................................................................................................ 30
1 General information WARNING!
The user can suffer (serious) injuries. “Warning”
About this document implies that (serious) injury to persons is
The language of the original operating probable if this information is disregarded.
instructions is English. All other languages of CAUTION!
these instructions are translations of the original There is a risk of damaging the pump/installa-
tion. “Caution” implies that damage to the pro-
operating instructions.
duct is likely if the information is disregarded.
These installation and operating instructions are
NOTE:
an integral part of the product. They must be kept Useful information on using the product. It also
readily available at the place where the product is draws attention to possible problems.
installed. Strict adherence to these instructions is
a precondition for the proper use and correct
operation of the product.
2.2 Personnel qualifications
The installation personnel must have the
These installation and operating instructions appropriate qualification for this work.
correspond to the relevant version of the product
and the underlying safety standards valid at the
2.3 Danger in event of non-observance
time of going to print. Supplied pump will operate
trouble free and satisfactorily on the condition of the safety instructions
that, it is installed with due care and maintained Non-observance of the safety instructions can
properly. result in risk of injury to persons and damage to
For hassle free operating life, it is recommended product/installation. Non-observance of the
that the pump should operate under specified safety instructions can result in the loss of any
“Operating conditions”. Pump operating claims to damages.
conditions are mentioned on the “Nameplate” In detail, non-observance can, for example, result
affixed to the pump. in the following risks:
If operating parameters deviate from the  Failure of important product/installation
specified parameters as on the “Nameplate”, functions
please contact manufacturer.”  Failure of required maintenance and repair
procedures
 Danger to persons from electrical, mechanical
2 Safety and bacteriological influences
These operating instructions contain basic  Property damage
information which must be adhered to during
installation and operation. For this reason, these 2.4 Safety consciousness on the job
operating instructions must, without fail, be read The safety instructions included in these
by the service technician and the responsible installation and operating instructions, the
operator before installation and commissioning. existing national regulations for accident
The machine operator list must be filled out prevention together with any internal working,
completely. By signing this list, all persons operating and safety regulations of the operator
working on or with the product confirms that are to be complied with.
they have received, read and understood this
operating & maintenance manual. 2.5 Safety instructions for the operator
It is not only the general safety instructions listed This appliance is not intended for use by persons
under the main point "safety" that must be (including children) with reduced physical,
adhered to but also the special safety instructions sensory or mental capabilities, or lack of
with danger symbols included under the following experience and knowledge, unless they have
main points. been given supervision or instruction concerning
use of the appliance by a person responsible for
2.1 Designation of information in the their safety. Children should be supervised to
operating instructions ensure that they do not play with the appliance.
Symbols:  If hot or cold components on the product/the
General danger symbol unit lead to hazards, local measures must be
taken to guard them against touching.
Danger due to electrical voltage  Guards protecting against touching moving
components (such as the coupling) must not
NOTE: ... be removed whilst the product is in operation.
Signal words: DANGER!  Leakages (e.g. from the shaft seals) of
Acutely dangerous situation. hazardous fluids (which are explosive, toxic or
Non-observance results in death or the most hot) must be led away so that no danger to
serious of injuries. persons or to the environment arises. National
statutory provisions are to be complied with.
 Highly flammable materials are always to be
2.9 Safety & control devices
kept at a safe distance from the product. Direct controls are applicable when the pump is
supplied along with motor/panels. When motor/
 Danger from electrical current must be panel is in end user’s scope of supply, it is advised
eliminated. Local directives or general to go for CE approved motors /panels.
directives [e.g. IEC, VDE etc.] and local power Environmental safety
supply companies must be adhered to. Disposal of any unwanted/scrap material should
 Depending on the type, size and capacity (kW), be disposed in appropriate way so as not to cause
the products produce a sound pressure up to any harm to the environment. No hazardous
75 dB (A) to 110 dB (A). material is used in Wilo Mather and Platt MISO /
 The actual sound pressure, however, depends PISO pumps.
on several factors. These include, for example,
type of prime mover, installation type; NOTE
fastening of accessories and pipeline, operating To avoid ambiguity in the use of the word
site condition, background noise, etc. „replace” the words „replace” and „renew” are
used in this manual in the following context:
 Once the product has been installed, We
Replace - To put back, in its existing state, a part
recommend that the operator makes additional
or component that has previously been removed.
measurements under all operating conditions.
Renew - To substitute a new part of component
CAUTION!
for a worn or damaged one.
In accordance with the laws in effect,
guidelines, standards and regulations, ear
protection must be worn if the sound 3 Transport and interim storage
pressure is greater than 80dB (A). The Immediately check the pump and transport
operator is responsible for ensuring that this is packaging for damage in transit upon receipt.
observed! Take the necessary steps within the period’s
defined by the transport company in the event
2.6 Safety instructions for installation of damage in transit.
and maintenance work DANGER! Risk of getting crushed!
The operator must ensure that all installation and The installation or removal of the product must
maintenance work is carried out by authorized not be performed by one person alone.
and qualified personnel, who are sufficiently Measures should be taken to bar persons from
informed from their own detailed study of the standing beneath a suspended load. Further-
operating instructions. more, it is also prohibited to move suspended
Work on the product/unit must only be carried loads over exposed workplaces where people
out when at a standstill. It is mandatory that the are present. The fastening devices should be
procedure described in the installation and adapted to the conditions at hand (weather,
operating instructions for shutting down the hooking system, load, etc.) Use suitable faste-
product/unit be complied with. ning devices to handle the weight of the pro-
Immediately on conclusion of the work, all safety duct.
and protective devices must be put back in CAUTION! Risk of damage to the pump!
position and/or re-commissioned.
Risk of damage due to improper handling
during transport and storage.
2.7 Unauthorized modification and
The pump should be protected against
manufacture of spare parts humidity, frost and mechanical damage during
Unauthorized modification and manufacture of transport and interim storage.
spare parts will impair the safety of the product/
personnel and will make void the manufacturer's
3.1 Handling
declarations regarding safety. CAUTION! Risk of damage to the pump! Risk of
Modifications to the product are only permissible falling!
after consultation with the manufacturer. Pumps should never be lifted with slings enga-
Original spare parts and accessories authorized ged below the bearing housing. Eyebolts on
by the manufacturer ensure safety. The use of pump top casing are only for lifting top casing
other parts will absolve us of liability for during maintenance. Do not lift complete pump
consequential events. with the eyebolts. Safe working load of wire
ropes reduces with increase in included angle.
2.8 Improper use Never put down or pick up the product when it
The operating safety of the supplied product only is not secured. Tilting of the product should be
guaranteed for conventional use in accordance avoided at all costs.
with Section 4 of the operating instructions. The Only suitable lifting gear and load carrying equip-
limits values must on no account fall under or ment with valid test certificates and adequate
exceed those specified in the catalogue/data lifting capacity for the loads involved (such as
sheet. belts/ wire ropes/slings) should be used for lifting &
transporting the product. If chains are used, they
3.3.2 Long-term storage (more than 3 month)
should be secured against slipping along with
If the equipment will be subject to extended storage
protective cover to prevent damage to the
condition prior to installation, then the
product, paint and/or injury to personnel.
manufacturer must be informed about storage
When lifting the pump in combination with the
duration, so that special protection can be
bedplate, the lifting tackle should be attached to
recommended.
the lifting lugs provided on the base plate side
 Place the MISO / PISO pumps horizontally on firm
member. To lift the pump the lifting slings should
foundation and secure it against falling.
pass beneath the pump body at suction and
delivery flanges (see lifting diagrams - see also  The machine must be protected from direct
general safety Information, chapter 2). These sunlight, heat, dust, and frost.
must have sufficient load bearing capacity to  The rotors or propellers must be turned at
ensure that the product can be transported regular intervals. This prevents the bearing
safely. Refer figure 1 and 2 from locking and the film of lubricant on the
mechanical shaft seal is renewed.
3.2 Delivery  For mechanical seal, we recommend: relative air
On arrival, the delivered items must be inspected humidity below 65%, temperature between
for damage and a check made that all parts are 15°C and 25°C. Direct exposure of the
present. If any parts are damaged or missing, the mechanical seal to heat (sun, heating) as well as
to ozone, present or produced by ultraviolet
transport company or the manufacturer must be
informed on the day of delivery. Any claim made light (halogen or fluorescent lamps), must be
at a later date will be deemed invalid. Damage to avoided because of the risk of embrittlement
parts must be noted on the delivery or freight of elastomeric materials.
documentation.
3.4 Pump returning back to the supplier

3.3 Storage Products, which are delivered back to the plant,
must be clean and correctly packaged. In this
context, clean means that impurities have been
3.3.1 Short-term storage (less than 3 month)
removed and decontaminated if it has been used
The equipments as shipped have adequate
with materials, which are hazardous to health.
protection for short-term storage in a covered,
The packaging must protect the product against
dry and ventilated location at the job site prior to
damage.
installation.
CAUTION! Guarantee not applicable!
If the pump is not installed immediately after
delivery, it must be stored in a dry and clean place Products, which are not suitably packaged for
with sufficient ventilation, no vibration, no delivery back, are no longer covered by guaran-
freezing and the temperature variations must be tee!
smooth. Bearings and couplings must be
protected against sand, dust and foreign bodies.
To avoid corrosion and jamming, please lubricate 4 Intended uses
the pump and make turn the rotating elements The pump supplied is intended for specific fluid.
for several turns at least once a week. Pre-packed Refer pump data sheet and order confirmation.
desiccants may be used to absorb moisture & For any change in pumped fluid refer Wilo Mather
keep the pump dry. It must be removed before and Platt beforehand. MISO / PISO pumps are used
putting the pump on operation. in water supply, water-circulating systems and
process, injection water, spray pond, air-
conditioning, water treatment, Sprinkler & drip
irrigation, fire fighting, etc. If the operating
conditions are different of the specifications
given in the order, (i.e. type of liquid, temperature
or duty point), the end user must ask a written
agreement to Wilo Mather and Platt on the new
operating conditions before starting the pump.
5 Product information 5.2 Type key
5.1 Data plate MISO 150-500

MISO/PISO Name of the range
150 Delivery nozzle diameter
500 Max. Impeller diameter
5.3 General description

Limits of usage of the standard range
The technical features of the product have been
described in the offer made for this product,
especially the fluid compatibility. Please refer to
this:
Property Value Remarks
Speed 2900, 1450 1/min Model dependent

Discharge nominal diameters DN 32 up to 200
Flange standard PN 16/25
Limit of fluid temperature (min. /max.)
- Mechanical seal version [°C] -20 up to +120

-Gland packing version [°C] -20 up to +80
Limits of ambient temperature (min. /max.) -16 up to +40 other on request
[°C]
Ambient humidity < 90 % other on request
Max. operating pressure 16 bar, generally 10 bar for some models
Motor insulation class F other on request
Motor protection level IP 55
Electrical protection for motor – required in place (in accord-
ance with local regulation)
Acoustic pressure level, (In accordance with Refer to the data plate on
motor performances) the motor on in technical
leaflets
Electrical connections 3~230V, 50Hz (≤4kW) Other frequency, voltages,
3~400V, 50Hz (≥5,5kW) please contact manufacturer
5.4 Scope of delivery 6.1.1 Shaft Seal
Pump can be delivered Depending on the application, different shaft sealing
 As a complete pump set including electrical motor, executions are offered
base plate, coupling and coupling guard;
It is advised to use the stuffing box version in the
 Either without motor or
 As bare shaft pump without base plate. following installation configurations:
 If the pump draws from a suction line,

5.5 Accessories
 If the pump has a feed line with a pressure of less
 Companion Flange than 0.5 bar.
 Foundation bolts  If the pumped liquid is at or near its boiling point.
 Shims
6.1.2 Engine driven pump
An engine driven pump set is the unitization of a bare
6 Description and function shaft pump and a Diesel engine on the same base
plate. Refer to the engine installation manual. The
6.1 Description of the product engine driven pump set is supplied with the
MISO / PISO pumps are horizontal, single foundation bolts for grounding. Use the one supplied
stage volute casing pumps with nominal or equivalent of bigger size. Ensure a correct electrical
outputs and flange dimensions meeting ANSI earth connection between engine, base plate and main
B16.1 CLASS 125 FF (FOR CAST IRON earth. (Figure 2)
FLANGES) / ANSI B16.5 CLASS 150 RF (FOR
STEEL FLANGES). Their back pull out NOTE:
construction enables the disassembly of the
complete bearing unit towards the drive side Before starting the pump please cross check the
without removing the pump casing from the alignment of pump and engine on the base plate,
pipe work. MISO / PISO pumps are preferably coupling bush fitment, clearness on the periphery of
used when pure or turbid liquids, not the coupling. If any difference in the centre height is
containing solid particles, are handled. observed please use shims of suitable thickness to
overcome the misalignment.
Connection Details
No. Pump 1P2 6B1 8B1 Pump 1P2 6B1 8B1 11L 11D
1 MISO 32-125 1/4" 1/2" 1/2" PISO 32-125 1/4" 1/2" 1/2" 1/4" 1/4"
2 MISO 32-160 1/4" 1/2" 1/2" PISO 32-160 1/4" 1/2" 1/2" 1/4" 1/4"
3 MISO 32-200 1/4" 1/2" 1/2" PISO 32-200 1/4" 1/2" 1/2" 1/4" 1/4"
4 MISO 32-250 3/8" 1/2" 1/2" PISO 32-250 3/8" 1/2" 1/2" 1/4" 3/8"
5 MISO 50-125 1/4" 1/2" 1/2" PISO 50-125 1/4" 1/2" 1/2" 1/4" 1/4"
6 MISO 50-160 1/4" 1/2" 1/2" PISO 50-160 1/4" 1/2" 1/2" 1/4" 1/4"
7 MISO 40-200 1/4" 1/2" 1/2" PISO 40-200 3/8" 1/2" 1/2" 1/4" 1/4"
8 MISO 40-250 3/8" 1/2" 1/2" PISO 40-250 3/8" 1/2" 1/2" 1/4" 3/8"
9 MISO 40-315 3/8" 1/2" 1/2" PISO 40-315 1/4" 1/2" 1/2" 1/4" 3/8"
10 MISO 65-125 1/4" 1/2" 1/2" PISO 65-125 1/4" 1/2" 1/2" 1/4" 1/4"
11 MISO 65-160 1/4" 1/2" 1/2" PISO 65-160 1/4" 1/2" 1/2" 1/4" 1/4"
12 MISO 50-200 1/4" 1/2" 1/2" PISO 50-200 1/4" 1/2" 1/2" 1/4" 1/4"
13 MISO 50-250 3/8" 1/2" 1/2" PISO 50-250 3/8" 1/2" 1/2" 1/4" 3/8"
14 MISO 50-315 3/8" 1/2" 1/2" PISO 50-315 3/8" 1/2" 1/2" 1/4" 3/8"
15 MISO 65-200 3/8" 1/2" 1/2" PISO 65-200 3/8" 1/2" 1/2" 1/4" 3/8"
16 MISO 65-250 3/8" 1/2" 1/2" PISO 65-250 3/8" 1/2" 1/2" 1/4" 3/8"
17 MISO 65-315 3/8" 1/2" 1/2" PISO 65-315 3/8" 1/2" 1/2" 1/4" 3/8"
18 MISO 80-250 3/8" 1/2" 1/2" PISO 80-250 3/8" 1/2" 1/2" 1/4" 3/8"
19 MISO 100-200 3/8" 3/8" 1/2" PISO 100-200 3/8" 3/8" 1/2" 1/4" 3/8"
20 MISO 100-250 3/8" 1/2" 1/2" PISO 100-250 3/8" 1/2" 1/2" 1/4" 3/8"
21 MISO 100-315 3/8" 3/4" 1/2" PISO 100-315 3/8" 3/4" 1/2" 1/4" 3/8"
22 MISO 100-400 3/8" 3/4" 1/2" PISO 100-400 3/8" 3/4" 1/2" 1/4" 3/8"
23 MISO 100-500 3/8" 3/4" 3/4" PISO 100-500 3/8" 3/4" 3/4" 1/4" 1/2"
24 MISO 150-200 3/8" 3/4" 1/2" PISO 150-200 3/8" 3/4" 1/2" 1/4" 3/8"
25 MISO 125-250 3/8" 3/4" 1/2" PISO 125-250 3/8" 3/4" 1/2" 1/4" 3/8"
26 MISO 125-315 3/8" 3/4" 1/2" PISO 125-315 3/8" 3/4" 1/2" 1/4" 3/8"
27 MISO 125-400 3/8" 3/4" 1/2" PISO 125-400 3/8" 3/4" 1/2" 1/4" 3/8"
28 MISO 125-500 3/8" 3/4" 3/4" PISO 125-500 3/8" 3/4" 3/4" 1/4" 1/2"
29 MISO 150-250 3/8" 3/4" 1/2" PISO 150-250 3/8" 3/4" 1/2" 1/4" 3/8"
30 MISO 150-315 3/8" 3/4" 3/4" PISO 150-315 3/8" 3/4" 3/4" 1/4" 1/2"
31 MISO 150-400 3/8" 3/4" 3/4" PISO 150-400 3/8" 3/4" 3/4" 1/4" 1/2"
32 MISO 150-500 3/8" 3/4" 3/4" PISO 150-500 3/8" 3/4" 3/4" 1/4" 1/2"
33 MISO 200-315 3/8" 3/4" 3/4" PISO 150-315 3/8" 3/4" 3/4" 1/4" 1/2"
1P2: Pressure Gauge; 6B1: Casing Drain; 8B1: GlandDrain; 11L: Constant level oiler; 11D: Oil Drain
6.1.3 Sealing system

To prevent leakage along the shaft at the point
of emergence from the pump casing, gland Mechanical Seal
packing or mechanical seals may be fitted in the During running, a slight leakage may occur. If the
stuffing box situated at each end of the casing. pump is equipped with an external flush, quench
Gland Pack or heating, the flush, quench or heating supply
For correct operation of the pack gland as light has to be switched on before the pump is started.
leakage (20-40 drops per minute) is essential. If The mechanical seal must be allowed to cool
the leakage is reduced too much by re- before the next restart.
tightening the packing, the packing rings will be
destroyed.
6.1.4 Rotating element
The rotating element of MISO pump consist
of following parts
For gland pack version pumps
No. Part description No. Part description

1700 Impeller nut 2310 Gland
1501 Impeller 2070 Thrust collar
2111 Spacer sleeve 2600 Bearing
2300 Log ring 3200 Impeller key
2410 Gland packing 1800 Shaft
4250 O-ring 3250 Coupling key
2100 Shaft sleeve 2902 Cir-clip
7 Installation and electrical connection The existing accident prevention regulations
(Motor / pump coupling system) must be observed.
DANGER! Risk of getting crushed! WARNING! Danger of electric shock!

The installation or removal of the product must Any hazards from electrical current should be
not be performed by one person alone. ruled out.
Measures should be taken to bar persons from
Any instructions from local or general
standing beneath a suspended load. Further-
directives [e.g. IEC, VDE etc.] or directives of
more, it is also prohibited to move suspended
the local electricity supply companies must be
loads over exposed workplaces where people
observed.
are present. The fastening devices should be
adapted to the conditions at hand (weather,
7.1 Installation of bare shaft pump
hooking system, load, etc.) Use suitable
It is strongly recommended to use component
fastening devices to handle the weight of the such as coupling, guards, motors, base plates
product. supplied by Wilo Mather and Platt to install a bare
WARNING! Danger of personal injury! shaft pump on a base plate.
The installation and electrical connection It is mandatory that those components should be
should be performed only by qualified CE certified and the coupling guard must comply
personnel in compliance with local regulations. with the regulation EN 953.
This section provides instructions on the
recommended methods of installing pumping 7.1.1 Electrical motor selection
sets on to concrete foundations. Careful Select an electrical motor with sufficient power
attention must be paid to the customer and margin regarding the motor rating. The table
contractor’s installation drawings during the bellow will guide you in this selection.
installation procedures to ensure that the
pumping set is accurately positioned on the
correct datum levels.
Shaft power P2 ≤ 4 KW 4 kW < P2 ≤ 10 kW 10 kW < P2 ≤ 40 kW 40 kW ≤ P2

Recommended power 25 % 20 % 15 % 10 %
margin
Example: 7.1.3 Selection of a base plate

• Duty point: 100 m3/h – 35 m – pump efficiency Select a base plate in accordance with the local
78 % regulations, sufficiently large and strong to
• Pump shaft power: 12.5 kW support the pump and motor.
• Electrical motor rating (including margin):
12.5 * 1.15 = 14.3 kW 7.1.4 Pump set assembling
• IEC motor power rating available: 15 kW Fix the pump and motor equipped with their half
coupling on the base plate and make the align-
Use a foot mounted motor B3 (IM 1001) ment of those elements. It is recommended to
which comply with the IEC34-1 standard. fit the coupling guard supplied as accessories by
Wilo Mather and Platt.
7.1.2 Coupling selection
Use a semi-flexible coupling to link the pump to Note:
the driver.
If coupling guard is supplied loose, then kindly
Select the size of the coupling in accordance drill and fit it on the base plate at proper
with the recommendation of the coupling location.
manufacturer. Strictly follow the coupling
And if pump is supplied with coupling and motor
manufacturer’s instructions for the fitting of mounted on the base-plate, please ensure
the coupling between the pump and the motor. proper alignment of pump motor and coupling.
(The coupling must comply with the standard
EN349). The alignment of the pumps and the
motor must be checked after the installation of
the pump set on its foundation and when the
piping is connected. In addition an alignment
control must take place when the system works
at its nominal temperature. The coupling guard
must comply with the EN 953 standards in order
to avoid any contact with rotating parts during
operations.
7.2 Installation of the complete pump set
 Before any installation work is carried out, the CAUTION! Risk of material damage!
machine should be inspected for damage that may Do not hold the pump by the motor/module when
have occurred during handling, transport & storage. tightening the screwed connections. Apply the
 Installation within a building: install the pump in a dry, wrench surfaces to the suction/pressure port
well ventilated and frost-resistant room. inserted.
 Pumping machinery should have adequate access and  It is insufficient to check level on the machined pads
working room for maintenance operations. Adequate of base plate with a spirit level because it is possible
overhead space for lifting devices and working that some types of errors will not be revealed or will
clearance must be provided. be accepted as being within acceptable limits. These
 Installation outside a building (outdoor installation): distortions as showed in figure 4. Therefore it is
 Install the pump with a suitable protection to avoid necessary to use I-beam straight edge along with
rainfalls strong wind and particles which can damage engineer’s master level.
the pump or motor.
 Avoid exposure of the pump to direct sunlight. 7.2.2 Leveling and installing the base plate
 An appropriate solution to avoid frost must be CAUTION! Risk of material damage!
implemented. Pumps and drivers that are received with both
CAUTION! Risk of material damage! machines mounted on a common base plate are
Ensure sufficient ventilation/heating if the ambient checked for alignment before shipment.
temperature exceeds/falls below the permitted However during shipment, storage it may get
limit values. disturbed.
• Carry out all welding and soldering work prior to the  Use I-beam straight edge and an engineer’s master
installation of the pump. level (with accuracy of 0.02 mm / meter) for leveling
CAUTION! Risk of material damage! the base plate. I-beam should rest on the machined
Dirt from the pipe system can destroy the pump surfaces of the base plate, or on the leveling pads if
during operation. Flush the pipe system prior to the provided. These machined surfaces where level is being
installation of the pump. checked must be clean and free from paint, burrs etc.
• Provide shut-off valves in front of and behind the
 Check datum position of base frame as given in G.A.
pump.
Adjust the level of the base plate by inserting shims
between the bed plate and the packer plate until the
7.2.1 Foundations bed plate is leveled and supported on all the packing
The foundation should be sufficiently substantial to plates at the height required for the connection of
absorb any vibration and to form a permanent, rigid suction and discharge branches. For checking the
support for the base plate. The foundation must get levels across two pads, I-beam type straight edge
large dimensions. should be used extensively in conjunctions with
Generally, the weight of the foundation is around engineer’s master level. Level should be achieved
2 to 3 time the pump set weight. This is important in within 0.05 mm per 250 mm.
maintaining the alignment of a direct connected unit. In
 When the base plate is leveled, grout the foundation
building the foundation, the top of the foundation
bolts only. Care should be taken so as not to disturb
should be left approximately one inch low to allow for
the verticality of foundation bolts. For grouting use
grouting. Foundation bolts of the proper size should be
rich mix of 1: 1:2 of cement, sand and gravel below 12
embedded in the concrete, located by template (refer
mm. Alternatively quick setting grout mix can be used.
figure 3).
 When the grout has set, gently but firmly tighten the
foundation bolts. Care must be taken not to distort the
Foundation bolt base plate or loosen the foundation bolts in the grout
by excessive tightening.
1 Erection packers  When the grout has set, gently but firmly tighten the
2 Finish grout foundation bolts. Care must be taken not to distort the
3 Concrete base plate or loosen the foundation bolts in the grout
by excessive tightening.
NOTE:
Leave top of foundation rough! Do
not finish with trowel.
 A pipe sleeve about 2 ½ diameters large than
the bolt should be used to allow movement for
the final positioning of the bolts. For
installations where a low level of noise is
expected, built the foundation in a pit lined
with appropriate insulation material in order to
avoid vibration transmission to the ground.
7.2.3 Coupling assembly
Install the coupling avoiding hard blows; if Coupling should be loosely coupled and the halves must
necessary warm them for an easier fitting. be free to move relative to each other, Otherwise gauge
Arrange the pump and motor on a level base. Indicators can be incorrect. Where, tightly fitting pins or
The shaft ends must be perfectly concentric. spring prevent loose the springs or pins should be
The distance between each half of the RB removed and a line scribed across both half couplings and
(RATHI) coupling must be 2 - 3 mm. For readings taken only when the two marks are aligned.
spacer couplings, the distance between
shaft is mentioned in &10-2 – value “X” Radial alignment
(100 / 140 / 180mm.)  Clamp a dial gauge on one of the couplings or to the
If other manufacturer couplings are used,
shaft as shown in figure 5 with the plunger resting on
follow the manufacturer’s instructions. After
installation on the foundation and the rim of the other half coupling. Set the dial zero.
connecting the pipe work, the coupling Rotate the coupling and note the reading at each
alignment must be checked and realigned, if quarter revolution. Any variation in the readings
necessary. Moreover, after reaching the indicates the deviation from alignment and the position
operating temperature the alignment of the of one of the units must be adjusted until the readings
coupling must be checked again. The at each quarter revolution are identical or within the
coupling requires a guard that meets tolerances given below. Refer figure 5b
DIN31001 in order to avoid accidental
contact during operation. Alignment Tolerances
In any event, the operating instructions of
the coupling manufacturer must be
Speed (rpm) Parallel Angular
followed, since the coupling is a component
incorporated by Wilo Mather & Platt. tolerance tolerance
<1000 0.15 mm TIR 0.15 mm TIR
From 1000 to 1800 0.15 mm TIR 0.10 mm TIR
From 1800 to 3600 0.10 mm TIR 0.05 mm TIR
TIR: Total Indicated reading
Alignment of the pumps and its driving units

 When the base plate is leveled and the CAUTION! Risk of material damage!
satisfactory alignment is completed, proceed All the alignments (angular as well as radial) have to be
with connection of suction & delivery piping. carried out by using 3 dial indicators, simultaneously.
Recheck the alignment after piping and run
the final grout beneath the base plate. Allow Angular alignment
minimum seven days time for curing. Grout After isolating the driven unit from its power supply,
mix in the proportion specified earlier for clamp two dial indicators at diametrically opposite points
foundation bolt grouting should be used. It is on one half coupling or to the shaft behind it with the
further recommend that all hollow pockets in plunger resting on the back of the other half of the
the base plate shall be filled after curing of coupling. Rotate the coupling unit. The gauges are to be
earlier grout. in line vertically and set the dial to read zero. Rotate the
The following procedures outline coupling by 180 and record the readings on each gauge.
recommended practice given in BS-3170 in The readings should be identical, though not necessarily
1972 (Appendix A) for checking shaft zero. Either positive or negative readings are acceptable
alignment. This method is independent of the provided they are equally positive or negative. Adjust the
trueness of the coupling or shaft and is, position of one of the units if necessary. Rotate the
therefore, not affected by canted coupling coupling unit. The gauges are to be in the line horizontally
faces or eccentricity of the outside diameter and adjust the dial to zero. Repeat the operation outlined
of coupling, the coupling. Before commencing above by rotating the coupling by 180
the alignment, rotate each shaft
independently to check that the bearings run
freely and that the shaft is true to 0.1mm or
better. Check that no damage can be caused
when the shaft of the driven unit is turned.
7.2.4 Pipe work
No stress must be imposed on the pump casing by

the pipe work; neither by the weight of the pipes nor
by the tightening of badly fitting pipes (Figure 6). All
pipe worked attached to the pump must be fully
supported and the mating faces of the pipe flanges
must be parallel and all bolt holes coinciding with
each other. (See table of maximum forces on flanges) Avoid stress on the pump casing a: pump flange; b:
It is important, therefore, that alignment of the pump pipe work
and motor should be rechecked after the pipes are
finally fitted. Resetting or supporting the pipes must For difficult pumping on the suction side, to stabilize
correct any deviation in the alignment. the flow, a pipe length 15 times the diameter of the
suction branch should be installed before the suction
branch.
• The flow rate in the suction line or inflow line must
not exceed 2 - 3 m/s.
• Pipe velocity may need to be reduced further to
satisfy pump NPSH requirements and to control
suction pipe losses.
MAXIMUM ALLOWABLE FORCES & MOMENTS ON MISO PUMPS, FLANGES IN CAST

IRON Forces [N] and moments [Nm]
Nominal Sizes of Flanges
Flange size 50 65 80 100 125 150 200 250

[mm]
Fx 710 890 1070 1420 1955 2490 3780 5340

Each side
Forces (N) Fy 890 1130 1330 1780 2490 3110 4890 6670
Fz 580 710 890 1160 1600 2050 3110 4450
Mx 460 690 950 1330 1760 2300 3530 5020

Each nozzle
Moments (Nm) My 230 435 470 680 1020 1180 1760 2440
Mz 350 530 720 1000 1360 1760 2580 3800
*For casing in Stainless Steel use multiplying factor of 1.5 with above values
7.2.5 Suction line 7.2.6 Discharge line
See the sketches figure 8 for the optimum layout CAUTION! Damage to the pump
of pump installation for flow and suction lift ope- Pump casings have sometimes been cracked by
ration. Ensure that air pockets cannot be created. pressure surges imposed on them through the
Unequal nominal widths of the suction branch absence of a non-return valve. A back flow can
and suction line must be compensated by serisouly damage the bearings and the
eccentric transition pieces (refer figure 8). mechanical seal.
 It is recommended that a strainer is installed in For flow regulation, a valve must be installed
front of the suction pipe with a filter surface of behind the pump. If non-return valves are used,
at least 3 times the pipe cross section they should close smoothly. Pressure shocks must
(approx.100 meshes/cm²). be avoided.
 The suction opening of the suction line should be
well below the liquid level, and a strainer should
be used. 7.2.7 Stuffing box packing (figure 11)
 The strainer must be far enough from the bottom CAUTION! Risk of quick wear or leakages
to avoid excessive inlet losses, which could packing should be handled with care and it
impair pumping performance. It is advisable to
should not be allowed to pick up the dust or
check that there is no leakage.
abrasive matter by coming into contact with
 A shut-off valve should be installed in the feed
floors or dirty benches. It is bad practice to
line. It must be closed for maintenance work. It
hammer packing to facilitate the insertion.
should be installed in order to avoid air pockets
Pumps are dispatched from our works with the
forming in the spindle cap, i.e. with the spindle in
stuffing boxes unpacked; otherwise packing will
a horizontal position or pointing vertically
be aged. The packing is packed with greaseproof
downward.
paper and dispatched with the pump. The softest
possible packing i.e. plaited cotton impregnated
with oil and colloidal graphite is recommended for
most duties. Required number of and lengths of
packing should be cut off so that each length will
pass once round the shaft sleeve line and meet to
end. The ends of packing must be cut at 45 °.
After cleaning the stuffing box and shaft sleeves
the packing should be inserted into the stuffing
box. Each ring should be pushed into position
individually using the glands joint of each ring
must be positioned 180˚ from joints of its
neighbor. A logging ring included in the
arrangement; should be inserted into the stuffing
box at the appropriate time during the packing
Layout of pump installation sequence so that it is aligned with the cooling
water connection. The gland should now be fitted
1) Eccentric reducer (suction) or concentric square with the pump casing and the nut should
reducer (discharge) be screwed up to little more than finger
2) Isolating valve tightness.
3) Suction line
4) Bend
7.2.8 Mechanical seal
5) Foot valve with strainer
CAUTION! Damage to the pump
6) Isolating valve
Never start the pump without liquid inside
7) Regulating valve
otherwise the mechanical seal will be damaged
instantaneously.
No real operation is required during the setup
of the pump. Only filling and venting the pump
are mandatory before switching on the main.
7.2.9 Pressure gauge connections

CAUTION! Risk of leakage of the fluid!
Never connect a pressure gauge onto the pump
when the system is under pressure.
Pressure gauge connections are available on the
pump casing close to the flanges. Then pressure
gauge can be connected on suction and
discharge side.
7.2.10 Electrical connection 7.2.11 Operation with frequency converter
 The rotation speed can be adjusted in the operating
WARNING! Danger of electric shock limits of the pump given in the technical data. The
The electrical connection should be established electrical motors can be driven by a frequency
by an electrician approved by the local electri- converter in order to adapt the pump performances
city supply company in compliance with the the duty point required. Please contact Wilo Mather
applicable local regulations [e.g. VDE regulati- and Platt before connecting the frequency converter
ons]. to the motor to make sure that the electrical motor is
 The current type and voltage of the mains con- compatible with this driver. In any case, please
nection must correspond to the specifications on inform Wilo Mather and Platt at the quotation stage
the name plate. if the pump set will by driven by a frequency
 Refer to the motor and panels instruction manual converter this might influence the motor selection.
at the time of installation and connection. Motors  The converter should never generate voltages peaks
or electrical control panels are operated with to the motor connection higher than 850V and
alternating or industrial high-voltage current. deliver voltages variations ΔU/Δt greater than 2500
 The electrical connection is established via a V/μs.
fixed mains connection line.  If the above conditions cannot be fulfilled, an
 The local regulations must be adhered to. appropriate filter should be place between the
 Ensure that there is a provision for isolation of all frequency converter and the motor. Please contact
energy sources and locking. If the machine has the frequency converter manufacturer for guidance
been switched off by, a protective device, it must in the selection of this filter.
not be switched on again until the error has been  Strictly follow the Frequency converter manufacturer
corrected. instructions.
 The electrical system (machine including  The minimum rotation speed of the pump should
protective devices and operating position) must never go below 40% of the nominal speed.
always be grounded. Refer pump GA drawing &
respective manuals of motor/electrical control
panel for connecting earthing suitable as per
8 Commissioning
motor rating and relevant regulations and
standards including proper earthing lug size and WARNING! Danger of injury
fasteners. The devices whether on pump/motor/electrical
 Under no circumstances may any connecting panels must never be dismantled or disabled. They
cables touch the pipeline or the pump or motor must be checked by an authorized technician for
housing. proper functioning before, start-up. Refer to motor
 If there is a possibility that people can come into & electrical panel instruction manuals for electrical
contact with the machine and the pumped liquid safety & control devices information.
(e.g. at construction sites), the grounded
connection must be additionally equipped with a WARNING! Danger of pump damage!
fault current protection device. Do not operate the pump away from specified
 To ensure drip water protection and strain relief operating range. Operating beyond duty point may
of the cable connections, use cables with an not pose a risk to the operator but will reduce the
appropriate outer diameter and screw the cable efficiency of the pump or damage the pump itself.
glands tight. Furthermore any cables nearby Operation more than 5 minutes, at close valve
screwed connections for outlet loops should be condition is not recommended. For hot liquids this
bent in order to divert any accumulating drip is not recommended at all. Ensure that always site
water. Close any unassigned cable glands with NPSH-A is more than NPSH-R.
the existing sealing discs and screw them tight.
8.1 Cleaning prior to start
8.1.1 Pipe work flushing

Before the pumps are brought into service, either
on initial commissioning or on re-commissioning
after overhaul, the pipe work associated with the
pumps must be flushed through. This will clear
deposits or scales which may have accumulated
in the pipes, and which could damage the internal
components of the pumps.
8.2 Filling and venting
Fill and vent the system correctly, through air 8.2.3 Pumps operating on hot liquids
cock. Brief dry running will damage the pump. Pumps operating on hot liquids are usually so
Please also note that these pumps are not self- arranged that the liquid flow into the pump is
priming, which means that the impeller & casing under pressure. If the saturation pressure of such
must always be fully filled with fluid to be liquids is above atmospheric pressure, any
handled before putting in operation attempt to prime the pump will result in the liquid
WARNING! Danger of injury! "flashing" from the air cocks. For these reasons,
There is a risk of burns if the pump is touched! the air cocks at the top of the pump casing
The entire pump may become very hot, depen- should be left slightly open when priming boiler
ding on the operating state of the pump or circulating pumps until air has been driven out of
system (fluid temperature). the casing completely.
CAUTION! Danger sealing system damage! The cooling water services of a pump handling
Any attempt to run the pump dry or partially hot liquids should be turned on before the pump
full may result in seizure of the rotating is primed. These services may supply cooling
internal components. water to the bearings and / or stuffing boxes.
Where the services are functioning, open the inlet
valves and start warming the pump throughout.
8.2.1 Pumps operating on flooded suction head Never cut off the water services while the pump is
When these pumps operate on a flooded open
"on temperature". Where bearings are water-
the air release valve situated on top of the pump
cooled, adjust the cooling water supply until the
casing, open the pump inlet isolating valve and
bearings have a running heat. Over-cooling may
vent the air out of the casing. When the liquid
lead to condensation of moisture from the
issues from the air vent, free of air, the pump is
atmosphere inside the bearing with consequent
properly primed. The air vent must be closed
contamination of the oil. The suction valve, if
after priming and before the pumping set is
provided, must be fully open and the delivery
started.
valve must be closed.
8.2.2 Pumps operating on negative suction head

There are two methods of priming pumps that
8.3 Starting the pump
draw their liquid from an elevation lower than the
pump inlet branch: 8.3.1 Direction of rotation
 If the inlet pipe work is fitted with a non-return Disconnect the drive coupling and run the motor
foot valve, the pump casing and inlet pipe work to check its direction of rotation. A directional
can be filled with liquid from an external source arrow is provided on the pump unit.
under pressure. The pressure imposed on the
pump by this method must not exceed that for
which the pump is designed. In certain cases pri-
ming can be achieved by flooding back from the
delivery side of the pump.
 By extracting air or gas from the pump casing. To
enable this method to be used, the gland
arrangement must be sufficiently air-tight or it
should be liquid sealed from an external supply.
For operation details of gas exhausts reference
should be made to the manufacturer’s
instructions. Some form of priming indicator is
usually fitted to indicate when the priming
operation is complete.
 Check that suction and delivery pressure gauges are
8.3.2 Pre-starting checks
connected. Test and make available any alarm, signals,
 Check that the inlet isolating valve is open and
interlock systems and any of the protective devices
that the delivery valve is closed.
incorporated in the auxiliary and main pumping
 Check that there is no blockage in the strainer at control system.
the end of the suction line.
 Ensure that all electrical checks on motor, relay setting
 Check for free rotation of the unit when coupled. in panel etc have been carried out in accordance with
the instructions of motor manufacturer.
 Ensure that stuffing box sealing water seal connection
is provided as shown in GA Drawing.
Pre-start Check up
Activities Checked on Remarks
1 Alignment with and without piping
2 Flushing of pipe lines and ensures no leakages
3 Availability of sufficient liquid in sump/suction as per
specifications
4 Installation of all instruments
• Suction and delivery pressure gauges
• Pressure switches
• Temperature gauges
• Any other as supplied/specified
5 Operation of suction, delivery and inline valves
6 Proper supports for piping and other allied equipments
7 Availability of flushing/sealing liquid for stuffing box
8 Availability of sufficient cooling liquid for bearings as specified
9 Free rotation of pump and drive shafts
10 Lubrication of bearings
11 Checking of insulation resistance of motor
12 Proper cable termination
13 Motor protection relay settings
14 Check all interlocks as specified/provided
15 No load trial operation of drive
• Direction of rotation is ok
• Noise and vibration within limits
• Bearing temperatures and winding temperatures are
within limits
• Overall operation is satisfactory
16 Coupling of pump and drive and free rotation of shafts in
coupled condition
17 Suction valve is fully opened
18 Pump is fully primed and all air is vented
19 Delivery valve is closed (if required)
20 Emergency shutdown is possible
8.3.3 Normal starting and running checks  If applicable, ensure that the stuffing box is not
 When all the foregoing pre-start checks are overheating and that there is slight leakage from the
satisfactory, start the pump and check the gland (about 1 drop per second). There may be at
direction of rotation (indicated by a direction first a tendency for the stuffing boxes to run warm
arrow on the pump casing) otherwise stop the because of the high viscosity lubricant in the
pump immediately for correction of direction of packing. During the first few minutes of running with
rotation. Then run the pump at its rated speed. new packing, a small quantity of very viscous fluid
 Check the ammeter reading to ensure that the will be extruded, but the flow should reduce when
motor is not being overloaded. the packing has settled down.
 Check the mechanical seal for leak. In the start 8.3.4 Sealing system
phase (and also after downtimes) slight leakage Gland packing
can be expected. Visual leakage checks are CAUTION! Risk of damaging the pump!
however required from time to time. Distinctly If the gland plate is too tight, the packing stuff
visible leakage will require an exchange of the
will be immediately damage.
seal. Wilo Mather and Platt offers a repair set
At the beginning of the operation, the leak at the
containing all parts required for an exchange.
gland packing should be important. It should
 Check that the bearing is not overheating. Bea- reduce progressively after several hours by a
rings will normally run at a temperature of 30 ˚C- balanced and reasonable tightening the gland
35 ˚C above ambient temperature. The ideal plate. The gland packing must operate without
running temperature of bearings is 40 ˚C to 60 ˚C excessive temperature. The correct setting of the
for ball bearings and 40 ˚C to 55 ˚C for bush gland packing let a permanent leak around 1 or 2
bearings. The temperature should never exceed drops per seconds.
82 ˚C for ball bearings and 75 ˚C for bush If this leak is too much and cannot be adjusted
bearings. If the bearings are overheating its cause with the gland plate, the packing stuffing’s are
should be investigated immediately. worn and must be replaced.
 If the foregoing checks are satisfactory, open the Mechanical seal
delivery valve slowly and bring the pump
CAUTION! Risk of damaging the pump!
gradually up to its rated parameters indicated in
A mechanical seal must never operate without
the data sheet/name plate and based on pressure
fluid and lubrication even for a short period of
gauge and ammeter readings. Unless the pump is
time.
fitted with a special leak-off device, it should not Insure that the pump is completely full of water
be run for a long period against a closed delivery and vented before starting the pump. Small
valve. Check that the driving unit is not being leakages can occur during the period of running-
overloaded during valve opening. Overloading in, they should disappear after several hours of
may occur if the pump is discharging into an operation. If the leakages don’t stop, shut down
empty system. If the pumping unit fails to the pump disassemble the mechanical seal and
generate at least its rated delivery pressure it control their condition.
must be stopped immediately, the cause
ascertained,
 Check vibration of pump set and ensure that
8.3.5 Normal shutdown
vibration level is within limits specified. Check WARNING! Risk of Burns!
that noise level is within stipulated limits. If the fluid temperature and system pressure is
high, close the isolation valves upstream and
 The pumps may be run for 8 hours trial operation
downstream of the pump. Initially let the pump
and all the parameters like delivery pressure,
cool.
current, bearing temperature, etc. Be recorded
periodically.  Close the delivery valve to reduce the load on
the driving unit.
 Make the following checks at regular intervals. It
is recommended that they be made at every  Stop the driver of the pump.
change of shift.  When the pump has come to rest, close the
 Check the suction and discharge pressure gauge suction-isolating valve.
for normal operating pressure, if there is signifi-  Isolate any ancillary supplies.
cant drop in the suction or discharge pressure the
pump may have lost its supply. In the event of 8.3.6 Emergency Shutdown
this fault occurring, the pump must be stopped In the event of any malfunction of the
immediately and the cause of liquid loss equipment, switch off the pump set. When the
eliminated. pump has come to rest, close the suction &
 Check the mechanical seal or stuffing box discharge valves, isolate the driving unit power
assembly for overheating. supply & rectify the fault.
tine maintenance checks for this purpose are as under:
9 Maintenance
 To keep daily logbook records of working parameters like
Maintenance and repair work should be carried out suction and discharge pressure, flow rate, current drawn,
by qualified personnel only. bearing temperature, etc. These parameters should be
WARNING! Danger of electric shock! recorded twice a shift. Any sudden change should be a
signal for investigation. Refer Section Maintenance &
Any danger from electrical current should be ruled
Inspection log.
out.
 Check bearings for normal temperature. See 8.3.3
• The pump should be electrically isolated and
secured against unauthorized switch-on prior to  Vibration & sound level readings should be taken once in
any maintenance or repair work. a fortnight and values compared with that of previous
• Any damage to the connection cable should records.
always be rectified by a qualified electrician only.  Check that there is sufficient leakage from the gland
WARNING! Risk of scalding! packing to ensure proper cooling and lubrication. (if
At high fluid temperatures and system pressures, applicable) For mechanical seal, check that there is no
allow the pump to cool down first and then visible leakage.
depressurise the system.  For any abnormality observed from the visual/ manual
inspection and through maintenance & inspection logs,
9.1 Routine maintenance and stop the pump and investigate.
frequency of inspection  Fault finding - Many of the common faults which occur
on centrifugal pumps and which can be diagnosed by
Centrifugal pump requires very little routine
observations are given in the chart under section 10
maintenance; however, serious troubles can be
Faults, causes and remedies.
often avoided by regular observation and analysis
of various working parameters. Some of the rou
Routine maintenance
Parts Action Period Remarks
Mechanical Seal Check for Leakage Daily 5.6 gm/hr per pair of seal face
Gland Packing Check for Leakage Daily 10 to 120 drops/min
Check for Leakage Half yearly If required replace with new pickings
Bearings Check temperature Weekly Bearings are greased for life and are
maintenance free
Suction Pressure Check Pressure Daily
Discharge Pressure Check Pressure Daily
Flushing Check Flow Weekly Flow through the Flushing pipes must be
clear and continuous
Vibration Vibration Weekly
Voltage and Current Check for the rated values Weekly
Rotating element Check the rotating for wear Yearly
Clearances Check the clearances Yearly If value of clearance is more, neck ring
between neck ring and should be replaced
Total Dynamic Head impeller
Check Suction and Discharge Yearly
TDH
Alignment Check the alignment of pump Half yearly For reference use pump motor GA Drawing
with motor
NOTE:
9.2 Overhaul maintenance
The figures given in the table above are only valid if
the wear rings and the impeller are made with in the
9.2.1 General information same materials of low galling tendencies. For
After a long period of service, wear will occur in materials with higher galling tendencies (AISI 304/
parts of the pump, necessitating the renewal of a
316 etc...), higher clearance is provided (0.125 mm
few components. Logbook records will indicate
to be added to given values).
wear as gradual deterioration of performance is
Information regarding original design dimensions
noticed. Once this is known, pumps should be
and clearances is furnished in data sheet. Any other
taken for overhaul. It is recommended that yearly
information, if needed, can be requested from
stripping & checking of wear & tear and
Service Department, Wilo Mather and Platt. Such
clearances should be done and overhauling where
request must quote name plate number and type of
required.
the pump in question.
If related pair of components show a marked
degree of wear in relation to the rest of the unit, The parts most likely to be affected are:
then it may be sufficient to renew only the  Impeller
heavily worn components. If the wear is uniform  Mechanical seal
throughout the pump, then all wearable  Neck Rings
components may require renewal.  Sleeves
Measurements should be taken and recorded of  Stuffing Box Bush
all wearable components at the first, and every  Bearings
subsequent overhaul period. Reference to these  Coupling Bushes/ membrane set
records will enable an accurate assessment of the
rate of wear to be made, and a reasonably Before commencing dismantling operations,
accurate forecast regarding when a particular ensure that the following tools and tackles are
component may require renewal can be made. available:
 A crane / chain pulley block suitable for
handling the weight of pumping unit.
Internal nominal Nominal gap at the
 A selection of ring and open-ended
diameter of the wear diameter in (mm)
spanners in
ring in (mm)
British and Metric sizes.
65 0.38  Eyebolts in British and Metric sizes.
100 0.46  Cotton rope, wire rope and slings.
150 0.58 - 0.55  Hardwood and metal packing blocks.
 Miscellaneous tools including a set of Allen
200 0.62
keys, drills, pin drivers, files etc.
250 0.68
 Extractor / puller for bearing and coupling.
300 0.74 The torque value to be set for a particular size
350 0.84 - 0.80 of screw is dependent upon:
 Material of screw
 Parent metal
 Whether the screw is untreated or plated
 Whether the screw is dry or lubricated
 The depth of the thread
Tightening torques – Untreated Screw (black finish); Coefficient of Friction 0.14

Property Torque Nominal diameter – Coarse thread
class
M6 M8 M10 M12 M14 M16 M20
8.8 Nm 9.2 22 44 76 122 190 300
Ft. lb 6.8 16.2 32.5 56 90 140 221
9.3 Disassembling the pump
Exploded view of MISO pump (Gland pack version)
Gland pack version
No. Description No. Description
1000 Casing 2600 Bearing

1185 Back cover 2752 Bearing end cover (NDE)
1192 Support foot 2753 Bearing end cover (DE)
1501 Impeller 2760 Bearing housing
1700 Impeller nut 2902 Internal circlip
1800 Shaft 2902-1 External circlip
2070 Water deflector 3200 Key (impeller)
2100 Shaft sleeve 3250 Key (coupling)
2111 Spacer sleeve 4250 O ring for sleeve
2300 Logging ring 4250-1 O ring for casing
2310 Gland 4031 Lip seal
2410 Gland packing
 Strip the coupling and remove the spacer if

fitted. lubricant, the bearing running temperature and
 Unfasten nuts holding frame adaptor to pump the noise level during the operation.
casing and lift off rotating element with bearing
housing. For PISO pumps
Note: Where coupling without spacer is fitted, it  First drain out the oil completely
will be necessary to move driving unit away from  Rest procedure for dismantling of pump is same
the pump before this operation can be carried as of ET pumps
out. 
 Impeller can be drawn off after removing impeller
nut.
 Remove gland & back cover.
• Draw shaft sleeve off the shaft
Note: Unnecessary removal of the bearings
should be avoided because frequent removal of
the bearings can damage it and cause
deterioration of the interference fit. Bearings
should be removed Only, if they need close
inspection. Symptoms which will act as a guide
are the condition of the
9.4 Reassembling the pump 9.5 Recommended spare parts
In case of standard operation, we recommend the
 Press Drive End bearing onto shaft, pushing following list of spare part regarding the period of
on inner ring functioning.
 Fit external cir-clip For 2 years of normal operation:
 Vacuum and blow out all cavities of bearing  Mechanical seal or Packing, ball bearings and
Housing the different gasket required for the
 Mount the bearing housing onto the shaft dismounting of the pump.
 Press Non Drive End bearing on shaft For 3 years of normal operation:
 Fasten outer bearing cover assembly  Mechanical seal or Packing, ball bearings and
 Secure inner bearing cover assembly the different gasket required for the
 Fit deflector & coupling key dismounting of the pump, wear rings and their
 Place back cover on bench. Insert the packing nuts. For the pumps equipped with Gland
/ Logging ring set into the stuffing box packing, include the gland plate and lubrication
 Fit gland into stuffing box spacer.
 Hold gland with nuts finger tight
For 5 years of normal operation:
 Fasten back cover assembly to frame adaptor
The maintenance of the MISO / PISO pumps is
 Fit the sleeve & rotate shaft- check for
rubbing easier than other pump types. Then in order to
 Fit impeller key tightly, fit the gasket on front facilitate this operation we strongly
and back side of the impeller and tap Impeller recommended purchasing a batch of part with
lightly into place the pump in order to reduce the shut down
 Tighten impeller nut, steady shaft at coupling timing.
end It is strongly recommended to purchase the
 Check operating gap 0.5-1.5 mm in between original spares parts from WILO Mather and
back cover & impeller Platt. In order to avoid any mistake we invite
 Lightly grease ‘O’ ring and fit you to supply with any spare parts demand, the
 Stand casing on suction flange information mentioned on the data plate of
 Vacuum and blow out all cavities the pump and / or motor.
 Grease seal ring area all around
 Lower rotating element assembly into casing
take care of ‘O’ ring (Place the bearing
housing in vertical position for ease of
assembly)
 Fit all stud & nut
 Check free rotation of shaft
 Bolt on support foot finger tight
 Adjust support foot and tighten bolt
 Fit casing plug
For PISO pumps
 Press the coupling end bearing first
 Then slide in the oil thrower
 Now place the impeller end bearing
 Rest procedure is same as that of MISO
pumps
 After completion of reassembly of pump, fill
the bearing hosing with oil of proper grade
and quantity
Recommended spare parts (Gland pack version)
No. Description Quantity Recommended Spare Parts
For MISO pumps
1 Bearing housing 1
2 Back cover 1
3 Support foot 1
4 Gland 1 +
5 Casing 1
6 Impeller 1
7 Neck ring 1 +
8 Logging ring 1 +
9 Shaft 1
10 Key (coupling) 1 +
11 Gland packing 6 +
12 Key (impeller) 1 +
13 Shaft sleeve 1
14 Spacer sleeve 1
15 Bearing end cover 2
16 Impeller nut 1
17 Internal circlip 1
18 External circlip 1
19 Bearing (impeller end) 1
20 Lip seal 2 +
21 Water deflector 2
22 O ring for casing 1 +
23 Impeller wearing ring 1 +
24 Bearing (coupling end) 1 +
25 O ring for sleeve 1 +
For PISO pumps (additional to above parts)
1Oil thrower 1
2 Constant oil leveler 1
3Breather plug 1
Recommended spare parts (Mechanical seal version)

No. Description Quantity Recommended Spare Parts
For MISO pumps
1 Bearing housing 1
2 Back cover 1
3 Support foot 1
4 Casing 1
5 Impeller 1
6 Neck ring 1 +
7 Shaft 1
8 Key (coupling) 1
9 Key (impeller) 1 +
10 Shaft sleeve 1
11 Spacer sleeve 1
12 Bearing end cover 2
13 Impeller nut 1
14 External circlip 1 +
15 Bearing (impeller end) 1 +
16 Mechanical seal 1 +
17 Lip seal 2
18 Water deflector 2
19 O ring for casing 1 +
20 Impeller wearing ring 1 +
21 Bearing (coupling end) 1 +
22 O ring for sleeve 1 +
For PISO pumps (additional to above parts)
1Oil thrower 1
2Constant oil leveler 1
3Breather plug 1
10 Faults, Causes and Remedies
Symptoms Possible cause of trouble and remedies

(Each number is defined in the table below)
-- Output too low 1,2,3,4,5
-- Pump does not prime or only intermittently 6,7,8
-- Pump leaks 9,10
-- Temperature of the pump increases 7,11,13
-- Noisy pump 10,11,14,15
-- The motor contactor trips 8,10,16,17
Causes Remedies
1 Back pressure too high
Regulate a new the operating point
2 Pump or pipe work ,not Vent and fill the pump as well as the suction or in flow line
3 completely filledhigh or positive Check the liquid level; open the shut off valves on the suction side.
Suction lift too
suction head too low Clean the filters / strainers
4 Impeller sealing gap too large
Replace worn parts
5 Wrong direction of rotation Change the motor connection
6 Pump casing ,shaft seal, foot Replace the casing seal. Check the shaft seal. Check the flange connections
7 valve or lift
Suction suction line leaks
too high or positive Check the liquid level; open the shut off valves on the suction side.
suction head too low Clean the filters on the suction side
8 Loose or jammed parts in the Open and clean the pump
9 pump bolts not correctly
Casing Check the tightening torque of the casing bolts
10 tightened
Mechanical seal leaks Check the seal surfaces and rubber material of the mechanical seal.
In case of damages exchange mechanical seal
11 Pump or pipe work not Vent and fill the pump as well as the suction line or in flow line
12 completely filledagainst closed
Pump is running Open the shut off valve on discharge side
13 valve
Pump or pipe work not Purge of air the pump and the pipe work
14 completely
Pump is notfilled
properly leveled or Check the pump leveling and alignment
15 is distorted
Foreign material in the pump Dismantle and clean the pump
16 Earth fault Check the earth connection.
Check the potential causes such as damaged wirings or cables,
leakages on electrical parts
17 Operating conditions outside Refer to pump operating conditions stated in technical data
of performance range of pump
11 Decommissioning and recycling

The disposal of all material or debris must be done in order to protect the
environment.
The Wilo Mather and Platt’s pumps do not contain any dangerous
substances. The major part of the pump is recyclable. The disposal and
recycling of the pump sets must be done in accordance with the local in
force regulations.
The dismounting must be done by qualified personal.
Clean and decontamination must be achieved before any
transportation or recycling
Annexure
Cross sectional Drawing of MISO Gland pack pump (Grease lubricated)
No. Part No. Part Name No. Part No. Part Name
1 1000 Casing 14 2600 Bearing
2 1181 Neck ring 15 2752 Bearing end cover (NDE)
3 1185 Back cover 16 2753 Bearing end cover (DE)
4 1192 Support foot 17 2760 Bearing housing
5 1501 Impeller 18 2902 Internal circlip
6 1700 Impeller nut 19 2902-1 External circlip
7 1800 Shaft 20 3200 Key (impeller)
8 2070 Water deflector 21 3250 Key (coupling)
9 2100 Shaft sleeve 22 4250 O ring for sleeve
10 2111 Spacer sleeve 23 4250-1 O ring for casing
11 2300 Logging ring 24 4250-2 O ring for Brg. Hsg.
12 2310 Gland 25 4260 Breather plug
13 2410 Gland packing
Cross sectional Drawing of MISO Mechanical seal pump (Grease lubricated)
1 1000 Casing 13 2752 Bearing end cover (NDE)
2 1181 Neck ring 14 2753 Bearing end cover (DE)
3 1185 Back cover 15 2760 Bearing housing
4 1192 Support foot 16 2902 Internal circlip
5 1501 Impeller 17 2902-1 External circlip
6 1700 Impeller nut 18 3200 Key (impeller)
7 1800 Shaft 19 3250 Key (coupling)
8 2070 Water deflector 20 4250 O ring for sleeve
9 2100 Shaft sleeve 21 4250-1 O ring for casing
10 2111 Spacer sleeve 22 4250-2 O ring for Brg. Hsg.
11 2420 Mechanical seal 23 4260 Breather plug
12 2600 Bearing
Cross sectional Drawing of PISO Gland pack pump (Oil lubricated)
1 1000 Casing 15 2600 Bearing
2 1181 Neck ring 16 2752 Bearing end cover (NDE)
3 1185 Back cover 17 2753 Bearing end cover (DE)
4 1192 Support foot 18 2760 Bearing housing
5 1501 Impeller 19 2902 Internal circlip
6 1700 Impeller nut 20 2902-1 External circlip
7 1800 Shaft 21 3200 Key (impeller)
8 1950 Oil thrower 22 3250 Key (coupling)
9 2070 Water deflector 23 4250 O' ring for sleeve
10 2100 Shaft sleeve 24 4250-1 O ring for casing
11 2111 Spacer sleeve 25 4250-2 O ring for Brg. Hsg.
12 2300 Logging ring 26 4260 Breather plug
13 2310 Gland 27 4700 Oil level indicater
14 2410 Gland packing
Cross sectional Drawing of PISO Mechanical seal pump (Oil lubricated)
1 1000 Casing 14 2752 Bearing end cover (NDE)
2 1181 Neck ring 15 2753 Bearing end cover (DE)
3 1185 Back cover 16 2760 Bearing housing
4 1192 Support foot 17 2902 Internal circlip
5 1501 Impeller 18 2902 External circlip
6 1700 Impeller nut 19 3200 Key (impeller)
7 1800 Shaft 20 3250 Key (coupling)
8 1950 Oil thrower 21 4250 O ring for sleeve
9 2070 Water deflector 22 4250-1 O ring for casing
10 2100 Shaft sleeve 23 4250-2 O ring for Brg. Hsg.
11 2111 Spacer sleeve 26 4260 Breather plug
12 2420 Mechanical seal 27 4700 Oil level indicater
13 2600 Bearing
Exploded View
No. Part Name No. Part Name

1A Bare shaft pump 9A Washer
2A Coupling 10A Lock nut
3A Motor 11A Hex nut
4A Base frame 12A Coupling guard
5A Spacer C plate 13A Non losable fixing
set
6A Key (pump shaft) 14A Hex head Screw
7A Key (motor shaft) 15A Washer
18A Hex Head Screw
Oil details for PISO pumps (ISO Grade 46 oil)
Pre-Stating Checks for Pump set
Sl Activities Checked on Remarks

No
1 Alignment with and without piping
2 Flushing of pipe lines and ensure no
leakages
3 Availability of sufficient liquid in sump /
suction as per specifications.
Suction and delivery pressure gauges
Pressure switches
Temperature gauges
Any other as supplied / specified.
5 Operation of suction, delivery and inline
valves
6 Proper supports for piping and other
allied equipments.
7 Availability of flushing / sealing liquid
for stuffing box.
8 Availability of sufficient cooling liquid
for bearings as specified
11 Checking of insulation resistance of
motor
13 Motor protection relay settings
14 Check all interlocks as specified /
provided
Direction of rotation is ok
Noise and vibration within limits
Bearing temperatures and winding
temperatures are within limits
Overall operation is satisfactory
16 Coupling of pump and drive and free
rotation of shafts in coupled condition
17 Suction valve is fully opened
18 Pump is fully primed and all air is vented
19 Delivery valve is closed (if required)
20 Emergency shutdown is possible.
Wilo-SCP
en Installation and operating instructions

Wilo_SCP_ OIM_20 140311_ 03
Disclaimer
Wilo Mather and Platt is very grateful for your interest in its products. The basic objective of this
document is to provide instructions for maintaining and operating Wilo Mather and Platt Horizontal
Split Case pumps. Instructions are complied for the person having a working knowledge of
Horizontal Split case pumps and the pumps shall be installed under expert supervision and
guidance.
With this document Wilo Mather and Platt does not accept any liability for inaccurate installation,
operation or maintenance of the product at site. The authorities that install and maintain the pump
shall be responsible for hassle free installation operation or maintenance of the product.
This document is prepared with at most care to ensure correct and accurate information, enabling
the user to have trouble free installation and operational support. However, there can be few areas
for improvement to make this document error free.

Tel: +91 20 27442100/1/2/3/4,
Fax: +91 2027442111
www.matherplatt.com
Fig.1:
Fig.2:
Fig.3:
Fig.4:
Fig.5:
Fig.6:
F zs Fzd
Mzs Mzd
Fyd
M yd
Fxd
M xd
M ys
Fys
Fxs
M xs
Fig.7:
Fig.8.1:
Fig.8.2:
Fig.8.3:
D
Fig.8.4:
Ø 4xØ
D
Fig.8.5:
D
Fi g.9:
Fig.10:
20
18
16 5 3
21
11
14 25
23
10
7
2 1
8 9
12 13
22 15
19
4 6 17
24
26
1 General information ..................................................................................................................... 8
2 Safety ...................................................................................................................................................8
2.1 Designation of in fo rm at ion in the operating i nstructions ......................................................................8
2.2 Personnel qualificati ons ........................................................................................................................ 8
2.3 Danger in event of non-observance of the safety instructions ............................................................ 8
2.4 Safety consciousness on the job ......................................................................................................... .. 8
2.5 Safety instructi ons fo r the operator ................................................................................................... .. 8
2.6 Safety instructi ons fo r installation and maintenance work ................................................................... 9
2.7 Una uth o rized modi fication and manufacture of spare parts .................................................................9
2.8 Imp ro per use .......................................................................................................... ............................... 9
2.9 Safety & control devices ...................................................................................................................... 9
3 Transport and interim storage (fig. 1) ............................................................................................ 9

3.1 Handling .............................................................................................................................................. 9
3.2 Deli very ............................................................................................................................................... 10
3.3 Storage ................................................................................................................... ............................ 10
3.4 Pump return ing back to the supplier .................................................................................................. 10
4 Intended use .................................................................................................................................... 10

5 Product information ................................................................................................. ...................... 11
5.1 Data plate ........................................................................................................................................ 11
5.2 Typ e key ................................................................................................................. ........................... 11
5.3 Gen eral descripti on ........................................................................................................................... 11
5.4 Scope of deli very ................................................................................................... ............................ 12
5.5 Accessories ............................................................................................................ ........................... 12
6 Description and function ................................................................................................................ 12

6.1 Descripti on of the product ......................................................................................... ........................ 12
7 Installation and electrical connection (Motor / pump coupling system) ................................. 16

7.1 Install ati on of bare shaft pump ............................................................................ ............................. 16
7.2 Install ati on of the complete pu mp set ..................................................................... .......................... 17
8 Com missioning ................................................................................................................................ 21

8.1 Clean ing prio r to start ........................................................................................................................ 21
8.2 Filling and venting ............................................................................................................................. 22
8.3 Starting the pump ...................................................................................................... ....................... 22
9 Maintenance ................................................................................................................................... 25
9.1 R outine maintenance and frequency of inspection .......................................................................... 25
9.2 Ov erh aul maintenance ................................................................................................ ...................... 25
9.3 Disassembling the pump .................................................................................................................... 29
9.4 Ex a min ati on of Int erna l Components ............................................................................................... 30
9.5 Reassembling the pump ................................................................................................................... 32
9.6 Recommended s pare parts ................................................................................................................ 35
10 Faults, causes and remedies ........................................................................................................ 37
11 Decommissioning and recycling ................................................................................................. 38
Installation and operating instructions Wilo-SCP

1 Gen eral informati on CAUTION!
There is a ris k of damaging the pump/installa-
About this document tion. “Caution” implies that damage to the pro-
The language of the original operating instruc- duct is likely if the info rma ti o n is disregarded.
tions is Engli s h. All other languages of these inst- NOTE:
ructions are translations of the original operating Useful information on using the product. It also
inst ructions. draws attention to possible problems .
These installation and operating instructions are
an integral part of the product. They must be kept 2.2 Personnel qualifications
readily available at the place where the product is The installation personnel must have the approp-
installed. Strict adherence t o thes e inst ructions is ri ate quali fi cation for this work.
a precondition for the proper use and correct ope-
ration of the product. 2.3 Danger in event of non-observance of the
These installation and operating instructions cor- safety instructions
respond to the relevant version of t he product and Non-observance of the safety instructions can
the underlying safety standards valid at the time result in risk of inj ury to persons and damage to
of going to pri nt . product/installation. Non-observance of the
EC declaration of conformity safety instructions can result in the loss of any
A copy of the EC declaration of conformity is a cl aims to damages.
component of these operating instructions. In det ail, non-observance can, for example, result
If a technical modification is made on t he designs in the following risks:
named there without our agreement, this declara- • F ail ure of important product/installation func-
tion loses its validity. tions
• Fail ure of required maintenance and repair proce-
dures
2 Sa fety • Danger to persons from electrical, mechanical and
These operating instructions contain basic infor- bacteriological influences
mation which must be adhered to during installa- • Property damage
tion and operation. For this reason, thes e
operating instructions must, without fai l, be read 2.4 S afety consciousness on the job
by the serv i ce techni ci an and the responsible op e- The safety inst ructions included in thes e installa-
rator before installation and commissioning . The tion and operating instructions, the existing nati-
machine operator list must be filled out comple- onal regulations for accident prevention together
tely. By signing this list, all pers ons working on or with any internal working, operating and safety
wi th the product confirms t hat they have recei- regulations of the operator are to be complied
ved, read and understood this operating & main- with.
tenance manual.
It is not only the general safety instructions listed 2.5 S afety instructions for the operator
under the main point "safety" that must be adhe- This appliance is not intended for use by persons
red to but also the special safety instructions with (i n cl udi ng children) with reduced phys i cal , sensory
danger symbols included under the foll owi ng main or mental capabilities, or lack of experience and
points. knowledge, unless they have been given supervi-
sion or instruction concerning use of the appliance
2.1 Designation of information in the operating by a person responsible for their safety. Children
instructions should be supervised to ensure that they do not
play with the appliance.
S ymbols: • if hot or cold components on the product/the unit
Gen eral danger sym bol lead to hazards, local measures must be taken to
guard them against touching.
Danger due to electrical voltage • Guards protecting agai nst touching m ov ing com-
ponents (such as the coupling) must not be remo-
NOTE: ... ved whil st the product is in operation.
• L eakages (e.g. from the shaft seals) of hazardous
fl uids (which are explosive, toxi c or hot) must be
Signal words : led away so that no danger to persons or to the
DANGER! environment ari ses . National statutory provisions
Acutely dangerous situation. are to be complied with.
Non-observance results in death or the most
serious of injuries.
WARN ING!
The user can suffer (serious) injuries. “Warni ng”
implies that (serious) injury to pers ons is proba-
ble if this information is disregarded.
8
• Highl y flammable materials are always to be kept 2.9 S afety & control devices
at a safe distance from the product. Direct controls are applicable when the pump is
• Danger from el ectrical current must be eliminated. supplied along with motor/panels. When motor/
Local directives or general directives [e.g. IEC , VDE panel is in end user’s scope of supply, it is advised
etc.] and lo cal power supply companies must be to go for CE approved motors /panels.
adhered to. Environmental s afety
x Depending on the type, size and capacity (kW), Dis pos al of any unwanted/s crap material should
the products produce a sound pressure up to 75 be disposed in appropriate way so as not to cause
dB (A) to 110 dB (A) up to 1 meter distance. any harm to the envi ronment. No hazardous
x The actual sound pressure, however, depends on material is used in Wil o SCP pumps.
several factors. These include, for example, type
of prime mover, installation type; fastening of NOTE
accessories and pipeline, operating site To avoid ambiguity in t he use of the word
condition, background noise, etc. „replace” the words „replace” and „renew ” are
x Once the product has been installed, We used in this manual in t he foll o wing context:
recommend that the operator makes additional Replace - To put back, in its existing state, a part
measurements under all operating conditions. or component that has previously been removed.
Renew - To substitut e a new part of component
2.6 S afety instructions for installation and for a worn or damaged one.
maintenance work
The operator must ensure that all installation and
maintenance work is carried out by authorised and 3 T ranspo rt and int erim storage (fig. 1)
qualifi ed personnel, who are sufficiently informed Immediately check the pump and transport
from their own detailed study of the operating packaging for damage in transit upon receipt.
inst ructions. Take the necessary steps within the periods defi-
Wo rk on the product/unit must onl y be carried out ned by the transport company in the event of
when at a standstill. It is mandatory that the pro- damage in transit.
cedure described in the installation and operating DANGER! Ris k of getting crushed!
instructions for shutting down the product/unit The installation or removal of the produ ct must
be compli ed with. not be performed by one pe rs on alone.
Im m ediately on conclusion of the work, all safety Measures should be taken to bar persons from
and protective devices must be put back in posi- standing beneath a suspended load. Further-
tion and/or recommissioned. more, it is also prohibited to move suspended
loads over exposed workplaces where people
2.7 Unauthorised modification and manufactu re of are present. The fastening devices should be
spare parts adapted to the conditions at hand (weather,
Unauthorised modi fication and manufacture of hooking system, load, etc.) Use suitable faste -
spare parts will impair the safety of the product/ ning devices to handle the weight of the pro-
personnel and will make void the manufacturer's duct.
declarations regarding s afety. CAUTI ON! Ris k of damage to the pump!
Mo di fications to the product are only permissibl e Ris k of damage due to i mproper handling duri ng
after consultation with t he manufacturer. Ori gi nal transport and storage.
spare parts and accessories authorised by the The p um p should be prote cte d against humidity,
manufacturer ensure safety. The use of other frost and mechanical da mage duri ng transport
parts will absolve us of liabilit y for consequenti al and interim storage.
events.
3.1 Handli ng
2.8 Impro pe r use CAUTI ON! Ris k of damage to the pump! Ris k of
The operating safety of the supplied product only falling!
guaranteed for conventional use in accordance Pumps should never be lifted with sli ngs enga-
with Section 4 of the operating instructions . The ged below the bearing housing. Eye bolts on
limit values must on no account fall under or pump top casing a re only for lifting top casing
exceed those speci fied in the catalogue/dat a duri ng maintenance. Do not lift complete pump
sheet. with the eyebolts. S afe working load of wire
rope s re duce s with i ncrease in included angle.
Ne ver put down o r pi ck up the product when it is
not secured. Til ti ng of the product should be
avoided at all costs.
Onl y suitable lifting gear and load carrying equip-
ment with vali d t est certifi cat es and adequate lif-
ting capacity for the loads involved (such as belts/
wire ropes /sli n gs) should be used for lifting &
transporting the product. If chains are used, they
Installation and operating instructions Wilo-SCP 9

should be secured against slipping along w ith pro- 3.3.2 Lon g-term storage (more than 3 month)
tective cover to prevent damage to the product, If the equipment will be subject to ext ended sto-
paint and/or inj ury to personnel. rage condition prior to in stallation, then the
When lifting the pump in combination with the manufacturer must be informed about storage
bedplate, the lifting tackle should be attached to duration, so that special protection can be recom-
the lifting lugs provided on the base plate side mended.
member. The angle of the lifting ropes should not • Place the SCP pumps horizontally on firm founda-
exceed 8° if shackles are used and 24° if hooks are tion and secure it against falling.
used. To lift the pump the lifting slings should • The machine must be protect ed from direct sun-
pass beneat h the pump body at suction and deli- light, heat, dust, and frost.
very flanges (s ee lifting diagrams - see also gene- • The rotors or propellers must be turned at regular
ral safety Inform ation, chapter 2). These must intervals. This prevents the bearing from locking
have sufficient load bearing capacity to ensure and the film of lubricant on t he mechanical shaft
that the product can be transported safely. Refer seal is renew ed.
figure 1 and 2 • For mechanical seal, we recommend : relative air
humidity below 65%, temperature bet ween 15°C
3.2 Delivery and 25°C. Di rect exposure of the mechanical seal
On arri v al , the delivered items must be inspected to heat (sun, heating) as well as to ozone, present
for damage and a check made that all parts are or produced by ultravi olet light (halogen or fl uore-
present. If any parts are damaged or missi ng, the scent lamps), must be avoided because of the risk
transport company or the manufacturer must be of embrittlement of elastomeric materi al s .
informed on the day of del ivery. Any cl aim made at
a later date will be deemed i nvali d. Damage to
parts must be noted on the delivery or freight 3.4 Pum p retur ni ng back to the supplier
document ation. Products, which are delivered back to the plant,
must be clean and correctl y packaged. In this con-
text, clean means that impurities have been
3.3 Storage removed and decont aminat ed if it has been used
wit h mat erials , which are hazardous to health.
3.3.1 S hort-term storage (less than 3 month) The packaging must protect the product against
The equipments as shipped have adequate pro- damage.
tection for short-term storage in a covered, dry CAUTI ON! G uarantee not applicable!
and ventilated location at the job site prior to ins- Products, which are not suitably packaged for
tallation. delivery back, are no longer covered by guara n-
If the pump is not installed immediatel y after deli- tee!
very, it must be stored in a dry and clean place with
sufficient ventilation, no vibration, no freezing
and the temperature variations must be smooth. 4 I ntended use
B eari ngs and couplings must be protected against The pump supplied is intended for speci fi c flu i d.
sand, dust and foreign bodies. To avoid corrosion R efer pump data sheet and order confirmation. For
and jamming, please lubricate the pump and make any change in pumped fl uid refer Wi lo beforehand.
turn t he rotating elements for several turns at Horizontal split Case pumps are used in water sup-
least once a week. Pre-packed desiccants may be ply, water- ci rculating systems, injection water,
used to absorb moisture & keep the pump dry. It spray pond, air-conditioning, w ater treat ment,
must be removed before putting the pump on Sprinkler & drip irrigation, fi re fighting, juices etc.
operation. If the operating conditions are different of the
specifications given in t he order, (i.e. type of
liquid, temperature or duty point), the end us er
must ask a written agreement to Wilo on t he new
operating conditions before starting t he pump.
10
5 P rod u ct inform a tion 5.2 Type key
5.1 Data plate SCP200/320H A-110/4/T4-R1/ E0

SCP Name of the range
200 Discharge flange nominal diameter
in mm
320 Nominal diameter of the impeller in mm
HA Type of Hy draul i c :
- HA = Standard type version A
- HB = Standard type version B
- HS = Single suction impeller
- DV = Double volute
- DS = Double st age
110 M otor power rating in kW
4 Number of poles
T4 Voltage Three phases 400V
R1 M aterial configuration : Casing in cast
iron, Bronze impeller, Stainless st eel
shaft (RoHS compliant)
E0 M echanical seal material configuration
Carbon / SiC EP DM type AQ1EGG
5.3 General description

Li mi ts of usage of the standard range
The techni cal features of the product have been
described i n t he offer made for this product, espe-
ci all y the fluid compati bilit y. Please refer to this :
Property Value Remarks
Speed 2900, 1450, 980 1/mi n M odel dependent

Discharge nominal diameters DN 50 up to 400
Flange standard PN 16/25 ISO 7005-2, as needed
Li mit of fluid temperature (min./max.)
- M echanical s eal version [°C] -8 up to +120

-Gland packing version [°C] -8 up to +105
Li mit s of ambient temperature (min./max.) [°C] -16 up to +40 other on request
Ambient humidity < 90 % other on request
M ax. operating pressure 16 bar, generally 25 for some models
M otor insulation class F other on request
M otor protection level IP 55
El ect ri cal protection for motor – required i n place (in accord-
ance with local regulation)
Acoustic pressure level, (In accordance with Refer to the data plate on the
motor performances) motor on in technical leaflets
Standard fluid allowed Central heating liquid in accordance Standard vers ion
with VDI 2035, cooling water.
Cold w ater
M ixture water/glycol up to 40 % of Standard vers ion

volume. Temp ≤ 40 °C for concentra-
tions between 20% and 40% vol.
Contact WILO for all other fluids Onl y for special version
El ect ri cal connections 3~230V, 50Hz (≤4kW) Other frequency, voltages,
3~400V, 50Hz (≥5,5kW) please contact WILO

5.4 S cope of delivery 6.1.1 Casing
Pump can be delivered The pump casing is of volute form, cast in halves,
• as a complete pump set including electrical motor, which are bolted toget her along the pump axis.
base plate, coupling and coupling guard; Gasket paper is provided bet ween the split flanges
• either w ithout motor or of top and bottom casing. For accurate location
• as bare s haft pump without base plat e. casing halves, bearing housings / brackets etc. are
located with dowel pins.
5.5 Accessories The suction and del ivery branches of the pump are
• Companion Flange cast integral with bottom half casing, which also
• Foundation bolts incorporate the mounting feet. Holes are tapped
• Shims on suction and delivery branches for connecting
the pressure gauges and providing casing drain.
Bores of bottom half casing are grooved t o provide
6 Descri ption and f unction location for stuffing box bushes. The top half
casing carries connections for liquid seal for both
6.1 Description of the product sides. Air vent cock is fitted on the top and also
Split casing pumps are either single or two stages. priming hole is also provided on the top of casing.
They are of relatively simple construction, the
casing being split along the pump axis so that nor-
mal maintenance work can be carried out without
disturbing the position of either the pumping set
or pipe work.
12
Connection Details
No. Pump CG PG PM AC CDS CDD CD GD VG TG
1 SCP 50-220 HA 1/4 1/4 1/4 1/4 1/4 1/4 – 1/4 M8 –
2 SCP 50-180 HA 1/4 1/4 3/8 3/8 1/4 1/4 – 3/4 M8 –
3 SCP 50-340 HA 3/8 3/8 1/2 3/8 1/2 1/2 – 3/4 M8 –
4 SCP 50-340 DS 3/8 3/8 1/2 3/8 3/8 3/8 3/8 3/4 M8 –
5 SCP 65-390 HS 3/8 3/8 1/2 3/8 1/2 1/2 – 3/4 M8 –
6 SCP 80-230 HA 3/8 3/8 1/2 3/8 1/2 1/2 – 3/4 M8 –
7 SCP 80-200 HA 3/8 3/8 1/2 3/8 1/2 1/2 – 3/4 M8 –
8 SCP 80-380 DS 3/8 3/8 1/2 3/8 3/8 3/8 1/2 3/4 M8 –
9 SCP 80-340 HA 3/8 3/8 1/2 3/8 1/2 1/2 – 3/4 M8 –
10 SCP 80-360 DS 3/8 3/8 3/4 3/8 1/2 1/2 – 1/2 M8 –
11 SCP 100-270 HA 3/8 3/8 1/2 3/8 1/2 1/2 – 3/4 M8 M8
12 SCP 100-280 HA 3/8 3/8 1/2 3/8 1/2 1/2 – 3/4 M8 M8
13 SCP 100-360 HA 3/8 3/8 1/2 3/8 1/2 1/2 – 3/4 M8 M8
14 SCP 100-400 HA 3/8 3/8 1/2 3/8 1/2 1/2 – 3/4 M8 M8
15 SCP 100-410 DS 3/8 3/8 3/4 3/8 1/2 1/2 1/2 1/2 M8 M8
16 SCP 125-290 HA 3/8 3/8 1/2 3/8 1/2 1/2 – 3/4 M8 M8
17 SCP 125-330 HA 3/8 3/8 1/2 3/8 1/2 1/2 – 3/4 M8 M8
18 SCP 125-440 HA 3/8 3/8 1/2 3/8 1/2 1/2 – 3/4 M8 M8
19 SCP 125-470 HA 3/8 3/8 3/4 3/8 3/4 3/4 – 3/4 M8 M8
20 SCP 125-460 DS 3/8 3/8 3/4 3/8 1/2 1/2 – 3/4 M8 M8
21 SCP 150-290 HA 3/8 3/8 1 3/8 1/2 1/2 – 3/4 M8 M8
22 SCP 150-390 HA 3/8 3/8 1/2 3/8 3/4 3/4 – 3/4 M8 M8
23 SCP 150-350 HA 3/8 3/8 3/4 3/8 3/4 3/4 – 3/4 M8 M8
24 SCP 150-450 HA 3/8 3/8 1/2 3/8 3/4 3/4 – 3/4 M8 M8
25 SCP 150-580 HA 3/8 3/8 1 3/8 1/2 1/2 – 3/4 M8 M8
26 SCP 150-530 HA 3/8 3/8 1 3/8 3/4 3/4 – 3/4 M8 M8
27 SCP 150-460 DS 1/2 1/2 3/4 3/8 1/2 1/2 1/2 1/2 M8 M8
28 SCP 200-310 HA 3/8 3/8 1/2 3/8 3/4 3/4 – 3/4 M8 M8
29 SCP 200-320 HA 3/8 3/8 3/4 3/8 3/4 3/4 – 3/4 M8 M8
30 SCP 200-370 HA 3/8 3/8 3/4 3/8 3/4 3/4 – 3/4 M8 M8
31 SCP 200-360 HB 3/8 3/8 3/4 3/8 3/4 3/4 – 3/4 M8 M8
32 SCP 200-390 HA 3/8 3/8 1 3/8 3/4 3/4 – 3/4 M8 M8
33 SCP 200-440 HA 3/8 3/8 1 3/8 3/4 3/4 – 3/4 M8 M8
34 SCP 200-460 HA 3/8 3/8 1 3/8 3/4 3/4 – 3/4 M8 M8
35 SCP 200-550 HA 3/8 3/8 1 3/8 1/2 1/2 – 3/4 M8 M8
36 SCP 200-480 HA 3/8 3/8 1 3/8 1/2 1/2 – 3/4 M8 M8
37 SCP 200-560 HA 3/8 3/8 1 3/8 1/2 1/2 – 3/4 M8 M8
38 SCP 200-660 DV 3/8 3/8 1 3/8 1 1 – 1 M8 M8
39 SCP 250-250 HA 3/8 3/8 1/2 3/8 1/2 1/2 – 3/4 M8 M8
40 SCP 250-390 HA 3/8 3/8 1 3/8 3/4 3/4 – 3/4 M8 M8
41 SCP 250-360 HA 3/8 3/8 1 3/8 3/4 3/4 – 3/4 M8 M8
42 SCP 250-450 HA 3/8 3/8 1 3/8 1/2 1/2 – 1 M8 M8
43 SCP 250-570 HA 3/8 3/8 1 3/8 1/2 1/2 – 1 M8 M8
44 SCP 250-700 DV 3/8 3/8 1 3/8 1 1 – 1- 1 /4 M8 M8
45 SCP 250-740 DV 3/8 3/8 1 3/8 1 1 – 1- 1 /4 M8 M8
46 SCP 300-330 HB 3/8 3/8 1 3/8 3/4 3/4 – 3/4 M8 M8
47 SCP 300-380 HA 3/8 3/8 1 3/8 1 1 – 3/4 M8 M8
48 SCP 300-400 HA 3/8 3/8 1 3/8 3/4 3/4 – 3/4 M8 M8
49 SCP 300-490 HA 3/8 3/8 1 3/8 1 1 – 1 M8 M8
50 SCP 300-570 HA 3/8 3/8 1 3/8 1 1 – 1 M8 M8
51 SCP 300-660 DV 3/8 3/8 1-1/2 3/8 1 1 – 1 M8 M8
52 SCP 350-500 HA 3/8 3/8 1 3/8 1 1 – 1 M8 M8
53 SCP 350-470 HA 3/8 3/8 1 3/8 1 1 – 1 M8 M8
54 SCP 400-540 HA 3/8 3/8 1 3/8 1 1 – 1 M8 M8
55 SCP 400-480 HA 3/8 3/8 1 3/8 1 1 – 1 M8 M8
56 SCP 400-550 HA 3/8 3/8 1 3/8 1 1 – 1 M8 M8
57 SCP 400-710 HA 3/8 3/8 1 3/8 1 1 – 1-1/4 M8 M8
58 SCP 400-660 DV 1/2 1/2 1 3/8 1 1 – 1 M8 M8
C G: Compound Ground; P G: P ressure Gauge; PM : P ri ming ; A C : A ir Co ck ; C DS : C asing D ra in (S u ct io n ); CD D: Casing Drain (Delivery);
C D: Ca sing D ra in; GD : G lan d D rain; V G: V i b rat i on Gauge; T G: Te mper ature G auge

6.1.2 Neck ring emergence from the pump casing, gland packing
To prevent the entry of pump liqui d from delivery or mechanical seals may be fitted in the stuffing
side of impeller to suction side, neck ring is provi- box situat ed at each end of t he casi ng.
ded. Fine running clearence is provided between
neck ring and impeller neck. Periodic restoration Gland Pack
of this clearence is necessary for satisfact ory per- For SCP pumps plaited cotton impregnat ed with
formance of the pump. For two stage pumps thes e oil and coll oi dal graphite is used.
neckrings are located in the bottom half of the
casing by half-spigot (tung and groove) and its Mec hani cal Seal
rotation is restri cted by flat face of the top casing. For SCP pumps Burgmann made M G1 or M 7
For rest of the single stage pumps plain neck rings mechanical seals are used.
with neck ring pins in bottom casing for locking
are used. The neck ring pin is press fitted in the 6.1.4 Rotating element
neck ring. The rotating element of SCP pump consist of fol-
lowing parts
6.1.3 Sealing system
To prevent leakage along the shaft at the point of
For gland pack version pumps
No. Part description No . Part description
1 Shaft 13 O-ring
2 Impeller 14 Bearing end cover (D.E.)
3 Impeller key 15 Bearing (D.E.)
4 Sleeve 16 Bearing housing (D.E.)
5 Neck ring 17 Bearing end cover (N.D.E.)
6 Sleeve nut 18 Bearing (N.D.E.)
7 Spacer Sl eeve 19 Lock w asher
8 Stuffing box bush 20 Lock nut
9 Logging ring 21 Bearing housing (N.D.E.)
10 Gland 22 Coupling key
11 Gland packing 23 Water throw er
12 Thrust collar 24 Neck ring pin
14
For mechanical seal version pumps
No. Part description No. Part description
1 Imp ell er 13 Bearing end cover (D.E.)

2 Shaft 14 Bearing (D.E.)
3 Neck ri ng 15 Bearing housing (D.E.)
4 Imp ell er key 16 Thrust collar
5 Sleeve 17 Bearing end cover (N.D.E.)
6 O-ring 18 Bearing (N.D.E.)
7 Spacer Sl eeve 19 Lock w asher
8 Sleeve nut 20 Lock nut
9 Stuffing box bush 21 Bearing housing (N.D.E.)
10 M echanical seal 22 Coupling key
11 Graub screw 23 Water thrower
12 Gland plate 24 Neck ring pin
The rotating element consist of a shaft on to The pump rotor is supported ondeep groove ball
which an impeller is placed and arrested at its bearings on either side of the shaft. Bearings are
position with a key to avoid free rotation with res- located i n the bearing housing, which are attached
pective of rotation of the shaft . Renewable shaft to the end of the pump casing. Stuffing box
sleeves are provided on both side to protect the bushes are provided on eit her side of t he s haft on
shaft from corrosion and erosion. The impeller is the sleeve and is located in the bottom half of the
locked at its position by sleeve and cowl nuts, casing in half-spigot. The purpose of stuffing box
which have threads left/right handed as per the bush i s to guide the l i q ui d toward the impeller eye.
direction of rotation of shaft. Whereas the back face of the stuffing box provi-
des support to gland packing. Water thrower is
placed after gland plate on both side of shaft.

7 I nstall ati on and electrical conn ecti on The existing accident pre vention regulations
(Moto r / pu mp coupling s ystem) must be observe d.
DANGER! Ri s k of getting crushe d! WARNI NG! Danger of electric shock!

The installation or removal of the product must Any hazards fro m electrical current should be
not be performed by one pers on alone. ruled out.
Measures should be taken to bar persons from Any instructions from local or general directives
standing beneath a suspended load. Further- [e.g. IEC, VDE etc.] or di recti ves of the local elec-
more, it is also prohibited to move suspended tricity supply companies must be observed.
loads over exposed work places where people
are present. The fastening devices should be 7.1 Installation of bare shaft pump
adapted to the conditions at hand (weather, It is strongly recommended to us e component
hooking system, load, etc.) Use suitable fas te- such as coupling, guards, motors , base plates sup-
ning devices to handle the weight of the pro- plied by Wilo to install a bare shaft pump on a base
duct. plate.
WARNING! Dang er of personal injury! It is mandatory that thos e components should be
The installation and electrical connection should CE certified and the coupling guard must comply
be performed only by qualified pe rsonnel in wit h the regulation EN 953.
compliance with local regulations. This section
provi des instructions on the recommen de d 7.1.1 Electri cal moto r selection
methods of installing pumpi ng sets on to con- Select an electrical motor with sufficient power
crete foundations. Careful attention must be margin regarding the motor rati ng. The table bel-
pai d to the customer and contra ctor’s i nstalla- low will guide you in thi s selection.
tion drawi ngs duri ng the installation procedures
to ensure that the pumpi ng set is accurately
positioned on the correct datum le vels.
Shaft power P2 ≤ 4 KW 4 kW < P2 ≤ 10 kW 10 kW < P2 ≤ 40 kW 40 kW ≤ P2

Recommended power 25 % 20 % 15 % 10 %
margi n
Example: 7.1.3 Selection of a base plate

• Duty point: 100 m3/h – 35 m – pump efficiency Select a base plate in accordance with the local
78 % regulations , sufficiently large and strong to sup-
• Pump shaft power : 12,5 kW port the pump and motor.
• El ect ri cal motor rating (including margin) :
12,5 * 1,15 = 14,3 kW 7.1.4 Pumpset assembling
• IEC motor power rating available : 15 kW Fix the pump and motor equipped with their half
coupling on the base plate and make the align-
Use a foot mounted motor B3 (IM 1001) which ment of those elements. It is recommended to fit
comply to the IEC34-1 standard. the coupling guard supplied as accessories by
Wilo.
7.1.2 Coupli ng selection
Use a semi-fl exi bl e coupling to li nk t he pump to NOTE:
the driver.
Select the size of the coupling in accordance with If pum p is suppli ed with coupling and mot or mount ed on
the recommendation of the coupling manufactu- the base-pl ate, pleas e ensure proper alignm ent of pump
rer. Strictly follow the coupling manufacturer’s
motor and coupling.
instructions for the fitting of the coupling bet-
ween the pump and the motor. (The coupling
must comply with the standard EN349). The align-
ment of the pumps and the motor must be che-
cked after the instal l at ion of the pump set on its
foundation and when the piping is connected. In
addition an alignment control must take place
when the system works at its nominal tempera-
ture. The coupling guard must comply with the EN
953 standard in order to avoid any contact with
rotating parts during operations.
16
7.2 Installation of the complete pump set NOTE:
• Before any installation work is carried out, the Leave top of foundation rough! Do not finish with
machine should be inspected for damage that may trowel.
have occurred during handling, transport & sto- • A pipe sleeve about 2 ½ diameters large than the
rage. bolt should be used to allow movement for the
• Inst all ati on wit hin a buil di ng: install the pump in a fi nal positioning of t he bolts. For installations
dry, well ventilated and frost-res istant room. where a low level of noise is expected, built the
• Pumping machinery should have adequat e access foundation in a pit lined with appropriate insula-
and working room for m aint enance operations. tion material in order to avoid vi b ration trans mis-
Adequate overhead space for lifting devices and sion to the ground.
working clearance must be prov ided. CAUTI ON! Ris k of materi al damage!
• Inst all ati on outside a b u il di ng (outdoor installa- Do not hold the pump by the motor/module
tion): when tightening the screwed connections.
• Install the pump with a suitable protect ion to Appl y the wrench surfaces to the suction/pres-
avoid rainfalls strong wind and particles which sure port inserte d.
can damage t he pump or motor. • It is insufficient to check level on t he machined
• Av oid exposure of the pump to direct sunlight. pads of base plate with a spi rit level because it is
• An appropriate solution to avoid frost must be possible that some types of errors will not be
implemented. revealed or will be accepted as being within
CAUTI ON! Ris k of materi al damage! acceptable limits. These distortions as showed i n
E nsu re sufficient ventilation/heating if the figure 4. Therefore it is necessary to use I-beam
ambient temperature exceeds/falls below the straight edge along with engineers mast er level.
permitted limit values.
• C arry out all welding and soldering work prior to 7.2.2 Le velling and installing the base plate
the installation of the pump. CAUTI ON! Ris k of materi al damage!
CAUTI ON! Ris k of materi al damage! Pumps and dri vers that are received with both
Di rt from the pipe system can destroy the pump machines mounted on a common base plate are
duri ng operation. Fl us h the pipe system pri or to checked for alignment before shipment. Howe-
the installation of the pump. ver during shipment, storage it may get distur-
• Provide shut-off valves in front of and behind the bed.
pump. • Use I-beam straight edge and an engineer’s mas-
ter level (with accuracy of 0.02 mm / meter) for
7.2.1 Foundations (figures 2, 3) levelli ng the base plate. I-beam should rest on the
The foundation should be sufficiently substantial machined surfaces of the base plate, or on the
to absorb any vibration and to form a permanent, levelli ng pads if provided. These machined sur-
ri gi d support for the base plate. The foundation faces where level is being checked must be clean
must get large dimensions. and free from paint, burrs etc.
Generally, the weight of the foundation is around • Check datum position of base frame as given in
2 to 3 time the pump set weight. Thi s is important G.A. Adjust the level of the bas e plate by inserting
in maintaining the alignment of a direct connec- shims between the bed plate and the packer plate
ted unit. In building t he foundation, the top of the until the bed plate is levelled and supported on all
foundation shoul d be left approximately one inch the packing plates at the height required for the
low to allow for grouting. Foundation bolts of the connection of suction and discharge branches. For
proper size should be embedded in the concrete, checking the levels across two pads, I-beam type
located by template (refer figure 3). straight edge should be used ext ensi vel y in con-
junctions with engi neer’s master level. Level
should be achieved within 0.05 mm per 250 mm.
• When the base plate is levelled, grout t he founda-
tion bolts only. Care should be taken so as not to
disturb the verticality of foundation bolts. For
grouting use ri ch mi x of 1: 1:2 of cement, sand and
gravel below 12 mm. Alternatively quick setting
grout mix can be us ed.
• When the grout has set, gently but firmly tight en
the foundation bolts. Care must be taken not to
distort the base plate or loosen the foundation
Foundation bolt bolts in the grout by ex cessive tightening.
• When the grout has set, gently but firmly tight en
the foundation bolts. Care must be taken not to
1 Erection packers
distort the base plate or loosen the foundation
2 Fi ni sh grout
bolts in the grout by ex cessive tightening.
3 Concrete

7.2.3 Alignment of the pumps and its dri vi ng units Radial alignment
• When the base plate is levelled and the satisfac- • Cl am p a dial gauge on one of the couplings or to
tory-alignment is com p l eted, proceed with con- the s haft as shown i n figure 5 with t he plunger
nection of suction & delivery piping. Recheck the resting on the rim of t he other half coupling. Set
alignment after piping and run the final grout the di al zero. Rotate the coupling and note the
beneath the base plat e. All o w minimum seven reading at each quarter revolution. Any variation in
days time for curing. Grout mix in the proportion the readings indicates t he deviation from align-
specified earlier for foundation bolt grouting ment and the position of one of the units must be
should be used. It is further recommend that all adjusted until the readings at each quart er revol u-
hollow pockets in the base plate s hal l be filled tion are identical or wit hi n the tolerances given
after curing of earlier grout . below. Refer figure 5b
• The following procedures outline recommended
practice given in BS-3170 in 1972 (Appendi x A) Alignment Tol erance s
for checking shaft alignment. Thi s method is inde-
pendent of t he trueness of the coupling or shaft Pump speed Angular Radial
and is, therefore, not affected by cant ed coupling alignment alignment
faces or eccentri ci t y of the outside diameter of
the coupling. Before commencing the al ignment , A < 1000 rpm 0.15 mm TIR 0.15 mm TIR
rotate each shaft indep endently to check that the B > 1000 rpm t o 0.1 mm TIR 0.15 mm TIR
bearings run freely and that the shaft is true to 1800 rpm
0.1mm or better. Check that no damage can be C 1800 rpm to 0.05 mm TIR 0.1 mm TIR
caused when the shaft of the driven unit is turned. 3000 rpm
C o upli ng should be loosely coupled and the halves
TIR = Total In di c ate d R e a ding
must be free to move relative to each other,
otherwise gauge Indicators can be incorrect .
Distance between coupling halves for S CP
Where, tightly fitting pins or spring prev ent loose
pu mps
coupling, the springs or pins should be removed
and a line scribed across both half couplings and
readings taken only when the two marks are al ig-
ned.
CAUTI ON! Ris k of materi al damage!

All the alignments (angul ar as well as radi al )
have to be carri ed out by using 3 di al indicators,
simultaneously.
Angul ar alignment
• Aft er isolating the driven unit from its power sup-
ply, clamp two dial i ndicators at diametrically Rotational speed Ga p
opposite points on one half coupling or to the [mm]
shaft behind it with the plunger resting on the
back of the other half coupling (See figure 5). 990 rpm 1450 rpm 2900 rpm
Rotat e the coupling unit. The gauges are to be in – 3-55 kW 3-55 kW 2-4
line verti call y and set the dial to read zero. Rotate 90-120 kW 75-250 kW 75-560 kW 2-6
the coupling by 180 and record the readings on > 120 kW > 250 kW > 560 kW 3-8
each gauge. The readings should be identical ,
though not necessarily zero. Either positive or
negative readings are acceptable provided they
are equal ly positive or negative. Adjust the posi-
tion of one of the units if necessary. Rotate the
coupling unit. The gauges are to be in t he li ne
horizontally and adjust the di al to zero. Repeat the
operation outlined above by rotating the coupling
by 180°.
18
7.2.4 Pipe work
No stress must be imposed on the pump casing by
the pipe work; neither by the wei ght of the pipes
nor by the tight ening of badly fitting pipes
(figure 6). All pipe worked attached to the pump
must be fully supported and the mating faces of
the pipe flanges must be parallel and all bolt holes
coincidi ng with each other. (see tabl e of maximum
forces on flanges) It is important ,therefore, that
alignment of the pump and motor should be re-
checked after the pipes are fi nall y fitted. R eset- Avoid stress on the pump casing
a: pump flange; b: pipe work
ting or supporting the pipes must correct any
deviation in the al i gnment.
For difficult pumping on the suction side, to stabi-
lise the flow, a pipe length 15 times the diameter
of the suction branch should be installed before
the suction branch.
• The flow rate i n t he suction line or inflow line must
not exceed 2 - 3 m/s.
• Pipe velocity may need to be reduced further to
satisfy pump NPSH requi rements and to control
suction pipe losses (refer figure 6).
MAXI MUM ALLOWABLE FORCES & MOMENTS ON SCP PUMPS, FLANGES IN CAST I RON
Forces [N] an d moments [Nm]
No mi nal S izes of Flanges
Forces (N) an d Moments (Nm)
Flange size 50 65 80 100 150 200 250 300 350 400 450 500
[mm]
nozzle Fy 890 1130 1330 1780 3110 4890 6670 8000 8900 10230 1115 7780
Fz 580 710 890 1160 2050 3110 4450 5340 5780 6670 7335 7890
Fr 1280 1640 1920 2560 4480 9620 9630 11700 12780 14850 16230 17650
My 230 435 470 680 1180 1760 2440 2980 3120 3660 3905 4175
Mz 350 530 720 1000 1760 2580 3800 4610 4750 5420 5725 6060
Mr 620 970 1280 1800 3130 4710 6750 8210 8540 9820 10235 10775

7.2.5 S uction line 7.2.6 Discharge line
See the sket ches figure 7 for the optimum layout CAUTI ON! Damage to the pump
of pump installation for flow and suction lift ope- Pump casings have sometimes been cracked by
ration. Ensure that air pockets cannot be created. pressure surges imposed on them through the
Unequal nominal widths of the suction branch and absence of a non-return valve. A back flow can
suction line must be compens ated by eccentric serisouly damage the bearings and the mechani-
transition pieces (refer figure 8). cal seal.
• It is recommended that a strainer is installed in For flow regulation, a valve must be installed
front of the suction pipe wit h a filter surface of at behind the pump. If non-return valves are used,
least 3 times the pipe cross section (approx.100 they should close s moothly . P ressure shocks must
meshes/cm²). be avoided.
• The suction opening of the suction line should be
well below the li qui d l evel , and a strainer should be
used. 7.2.7 S tuffing box packing (fig. 9)
• The strainer must be far enough from the bottom CAUTI ON! Ris k of qui ck wear or leakages
to avoid excessive inlet losses, which could impair Packing should be handled with care and it
pumping performance. It is advisable to check that should not be allowed to pick up the dus t or
there is no leakage. abrasive matter by coming into contact with
• A s hut-off valve should be installed in the feed floors or di rty benches. It is bad practice to ham-
line. It must be closed for maint enance work. It mer packing to facilitate the insertion.
should be installed in order to avoid air pockets Pumps are dispatched from our works with the
forming i n t he spindle cap, i.e. with the spindle in stuffing boxes unpacked; otherwise packing will
a horizontal position or pointing vertically down- be aged. The packing is packed with greaseproof
ward. paper and dispatched with the pump. The softest
possible packing i.e. plaited cotton impregnated
with oil and co ll oi dal graphite is recommended for
most duties. Required number of and lengths of
packing should be cut off so that each length will
pass once round the shaft sleeve line and meet to
end. The ends of packing must be cut at 45 °. After
cleaning the stuffing box and shaft sleeves the
packing should be ins erted into the stuffing box.
Each ri ng should be pushed into position individu-
all y using the glands joi nt of each ring must be
positioned 180˚ from joints of its neighbour. A
loggi ng ring i ncluded i n the arrangement; should
be inserted into the stuffing box at the appropri-
ate time during the packing sequence so that it is
Layout of pump installation aligned with the cooli ng w ater connection. The
gland should now be fitted square with the pump
1) Eccentric reducer (suction) or concentric casing and t he nut should be screwed up to little
reducer (di s charge) more than finger t ightness.
2) Isolating valve
3) Suction line 7.2.8 Mechani cal seal
4) Bend CAUTI ON! Damage to the pump
5) Foot valve with strainer Never start the pum p without liqui d inside
6) Isolating valve otherwise the mechanical seal will be damaged
7) Regulating valve instantaneously.
No real operation is required during the setup of
the pump. Only filli ng and venting the pump are
mandatory before switching on the main.
7.2.9 Pressure gauge connections

CAUTI ON! Ris k of leakage of the fluid!
Never connect a pressure gauge onto the pump
when the system is under pressure.
Pressure gauge connections are available on the
pump casing close to the flanges. Then pressure
gauge can be connected on suction and discharge
side.
20
7.2.10 El ectri cal connection 7.2.11 Ope ration with frequency con verter
WARNI NG! Danger of electric shock The rotation speed can be adjusted in the opera-
The electrical connection should be established ting limits of the pump given in the t echni cal data.
by an electrician approved by the local electri - The electrical motors can be driven by a frequency
city supply company in compliance with the converter in order t o adapt the pump performan-
applicable local regulations [e.g. VDE regulati- ces the duty point requi red. Please contact Wilo
ons]. before connecting the frequency converter to the
• The current type and voltage of the mains con- motor to make sure that the electrical motor i s
nection must correspond to the specifications on compatible with this driver. In any case, please
the name plate. inform Wil o at the quotation stage if the pump set
• R efer to the motor and panels instruction manual will by driven by a frequency converter this m i ght
at the time of ins tall ation and connection. M otors influence the motor s election.
or electrical control panels are operated with • The converter should never generat e volt ages
alternating or industrial high-voltage current. peaks to the motor connection higher than 850V
• The electrical connection is established vi a a fixed and deliver voltages variations ΔU/ Δt greater than
mains connection line. 2500 V/μs.
• The lo cal regulations must be adhered to. • If the above conditions cannot be fulfill ed, an
• Ensure that there is a provision for isolation of all appropriate filter should be place between the
energy sources and locking. If the machine has frequency converter and the motor. Please con-
been switched off by, a protective device, it must tact the frequency converter manufacturer for
not be switched on again until the error has been guidance in the selection of this filter.
corrected. • Strictly follow the Frequency converter manufac-
• The electrical system (machine including prot ec- turer instructions.
tive devices and operating position) must always • The minimum rotation speed of the pump should
be grounded. R efer pump GA drawing & respective never go bellow 40% of the nomi nal speed.
manuals of motor/electrical control panel for con-
necting earthing suitable as per motor rating and
relevant regulations and st andards including pro- 8 Commissioning
per earthing lug size and fasteners . WARNI NG! Danger of injury
• Under no circumstances may any connecting The devices whether on pump/motor/electrical
cables touch the pipeline or the pump or motor panels must never be dismantled or disabled.
housing. They must be checked by an authorized techni-
• If there is a possi bility that people can come into cian for proper functioning before, start-up.
contact with the machine and the pumped liquid Refer to motor & electrical panel instruction
(e.g. at construction sit es), the grounded connec- manuals for electrical safety & control devices
tion must be additionally equipped with a fault information.
current protection device. WARNI NG! Danger of pump damage!
• To ensure drip water protection and strain relief of Do not operate the pump away from specified
the cable connections, use cables with an approp- operating range. Operating beyond duty point
riate outer diameter and screw the cable glands may not pose a ri s k to the operator but will
ti ght. Furthermore any cables nearby screwed re duce the efficiency of the pump or damage the
connections for outl et loops should be bent in pu mp i tself. Operati on more than 5 minutes, at
order to di vert any accumulating drip water. Close close valve condition is not recommende d. For
any unassigned cable glands with the existing hot liqui ds this is not recommended at all.
sealing discs and screw them ti ght. Ens ure that always site NPSH-A is more than
NPS H-R.
8.1 Cl eani ng prior to start
8.1.1 Pipe work flushing

Before the pumps are brought into service, either
on in iti al commissioning or on re-commissioning
after overhaul, the pipe work associated with the
pumps must be flushed through. This will clear
deposits or scales which may have accumulated in
the pipes, and which could damage the i nt ernal
components of the pumps.

8.1.2 Cl ea ni ng of bearings 8.2.2 Pumps operating on negative suction he ad
SCP pumps are fitted with pre-lubricated, sealed There are two methods of priming pumps that
bearings which do not require ext ernal lubrication draw their liqui d from an elevation lo wer than the
for life. For Ball bearings which require external pump inlet branch:
greasing and i f the unit has been in store for a long • If the inlet pipe work is fitted wit h a non- return
period before commissioning, the bearings should foot valve, the pump casing and inlet pipe work
be cleaned and flushed out with clean white spirit can be filled with li qui d from an external source
or good quality paraffin. Waste oil/paraffin & used under pressure. The pressure imposed on the
cotton clot h should not be used for this purpose, pump by this method must not exceed that for
as particles of foreign matter may be left behind which the pump is designed. In certain cases pri-
which would caus e damage when the bearing is in ming can be achieved by flooding back from t he
service. B eari ngs should be then fi ll ed with recom- delivery side of the pump.
mended grade and quality of fresh lubricant t o the • By extracting ai r or gas from the pump casing. To
level. Refer list of lubricants at the end of this enable this method to be used, t he gl and arrange-
manual . ment must be sufficiently ai r-tight or it should be
liqui d sealed from an external supply. For opera-
8.2 Fil li ng and venting tion details of gas exhausts reference should be
Fill and vent t he system correctly, through air made t o t he manufacturer’s instructions. Some
cock. B ri ef dry running will damage the pump. Ple- form of pri ming indicator is usually fitt ed to ind i-
ase also note that these pumps are not self-pri- cate when the priming operation is complet e.
ming, which means that the i m pell er & casing
must always be full y filled with fl ui d to be handled 8.2.3 Pumps operating on hot liquids
before putting in operation Pumps operating on hot liquids are usually so
WARNI NG! Danger of injury! arranged that the liquid flow into the pump is
There is a ri s k of burns if the pum p is touched! under pressure. If the sat uration pressure of such
The entire pump may become very hot, depen- liquids is above at mospheric pressure, any att-
ding on the operating state of the pump or sys- empt to prime the pump will result in the liquid
tem (fluid temperature). "flashing" from the air cocks. For these reasons,
CAUTI ON! Danger sealing system damage! the ai r cocks at the top of the pump casing should
Any attempt to run the pum p dry or parti all y full be left slightly open when priming boiler circula-
may result in seizure of the rotating internal ting pumps until air has been driven out of the
components. casing completely.
The cooling water services of a pump handling hot
8.2.1 Pumps operating on flooded suction head liquids should be turned on before t he pump is pri-
When these pumps operate on a flooded open the med. These services may supply cooling water to
air release valve situated on top of the pump the bearings and / or stuffing boxes. Where the
casing, open the pump inlet isolating valve and services are functioning, open the inl et valves and
vent the air out of the casing. When the liquid start warming the pump throughout. Nev er cut off
issues from the air vent, free of air, the pump is the water services while the pump is "on tempera-
properly primed. The air vent must be closed aft er ture". Where bearings are wat er- cool ed, adjust the
priming and before the pumping set is started.. cooling wat er supply until the bearings have a
running heat. Over-cooling may lead to conden-
sation of moisture from the at mosphere inside t he
bearing wit h consequent contamination of the oil.
The suction valve, if provided, must be ful ly open
and the delivery valve must be clos ed.
8.3 S tarting the pump
8.3.1 Direction of rotation

Di s connect the drive coupling and run the motor
to check its direction of rotation. A directional
arrow is provided on the pump unit.
22
8.3.2 Pre-starting checks tive devices incorporated in the au xili ary and main
• Check that the inlet isolating valve is open and pumping control system.
that the delivery valve is cl osed. • En s ure that all electrical checks on motor, relay
• Check that there is no blockage in t he strainer at setting in panel etc have been carried out i n
the end of the suction line. accordance with the instructions of motor manu-
• Check for free rotation of the unit when coupled. facturer.
• Check that suction and deli very pressure gauges • Ensure that stuffing box sealing water seal con-
are connected. Test and make available any alarm, nection is provided as shown in GA Drawing.
signal s , int erl ock syst ems and any of the protec-
Pre-start Check up
Activities Checked on Remarks

1 Ali gn m ent with and without piping
2 Flushing of pipe lines and ensure no leakages
3 Avail abilit y of sufficient liquid in sump/suction as per specifica-
tions
• Suction and delivery pressure gauges
• Pressure switches
• Temperature gauges
• Any other as supplied/specified
5 Operation of suction, delivery and inline valves
6 Proper supports for piping and other allied equip ments
7 Avali abilit y of flushing/sealing li qui d for stuffing box
8 Avail abilit y of sufficient cooling li qzi d for bearings as speci fi ed
11 Checking of insulation resistance of motor
13 M otor protection relay s ettings
14 Check all interlocks as specified/provided
• Direction of rotation is ok
• Nois e and vibration within limits
• Bearing temperatures and winding temperatures are within
limits
• Overall operation is s atisfact ory
16 Coupling of pump and drive and free rotation of shafts in coupled
condition
17 Suction valve is full y opened
18 Pump is full y primed and all air is vented
19 Del ivery valve is closed (i f requi red)
20 Emergency shutdown is possibl e
8.3.3 Normal starting and run ni ng checks • If applicable, ensure that the stuffing box is not
• When all t he foregoing pre-start checks are s atis- overheating and that there is s light leakage from
factory, start the pump and check the direction of the gland (about 1 drop per second). There may be
rotation (indicated by a direction arrow on the at first a tendency for the stuffing boxes to run
pump casing) otherwise stop the pump immedia- warm because of the high viscosity lubricant in
tel y for correction of direction of rotation. Then the packing. During the first few minutes of run-
run the pump at its rated speed. ning with new packing, a small quantity of very
• Check the ammeter reading t o ens ure that the viscous fluid will be extruded, but the flow should
motor is not being overloaded. reduce when the packing has settled down.

• Check the mechanical seal for leak. In the start 8.3.4 Sealing system
phase (and also after downtimes) slight leakage Gland packing
can be expected. Vis u al leakage checks are howe- CAUTI ON! Ris k of damaging the pump!
ver required from time t o time. Distinctly visible If the gland plate is too tight, the packing stuff
leakage will require an exchange of the seal. Wil o will be immediately dama ge.
offers a repair s et containing all p arts required for At the beginning of the operation, the leak at the
an exchange. gland packing should be important. It should
• Check t hat the bearing is not overheating. Bea- reduce progressively after several hours by a
rings will normally run at a temperature of 30 ˚C- balanced and reasonable ti ght ening the gland
35 ˚C above ambient temperature. The ideal run- plate. The gland packing must operate without
ning t emperature of bearings is 40 ˚C to 60 ˚C for excessive temperature. The correct setting of the
ball bearings and 40 ˚C to 55 ˚C for bush bearings. gland packing let a permanent leak around 1 or 2
The temperature should never exceed 82 ˚C for drops per seconds.
ball bearings and 75 ˚C for bush bearings. If the If this leak is too much and cannot be adjusted
bearings are overheating its cause should be with the gland plate, the packing stuff are worn
investigated i m mediately. and must be replaced.
• If the foregoing checks are satisfactory, open the Mec hani cal seal
deli very val ve sl owl y and bring the pump gradually CAUTI ON! Ris k of damaging the pump!
up -to its rated paramet ers indi cat ed in the data A mechanical seal must never operate without
sheet/name plate and based on pressure gauge fluid and l ubri cati on even fo r a short period of
and ammeter readings. Unless the pump is fitted time.
with a special leak-off device, it should not be run Insure that the pump is completely full of water
for a long period against a closed delivery valve. and vented before starting the pump. S m all leaka-
Check that the drivi ng unit is not being overloaded ges can occur during the period of running-in,
during valve opening. Overloading may occur if they should disappear aft er several hours of ope-
the pump is discharging into an empty system. If ration. If the leakages don’t stop, shut down the
the pumping unit fai ls to generate at least its rated pump disassemble the mechanical seal and con-
delivery pressure it must be stopped immediately, trol thei r conditi on.
the cause as cert ained,
• Check vibration of pump set and ensure that vib- 8.3.5 Normal shutdown
ration level is within limits specified. Check that WARNING! Ris k of Burns!
noise level is within stipulated limits. If the fluid temperature and system pressure is
• the pumps may be run for 8 hours trial operation high, close the isolation val ves upstream and
and all the parameters like delivery pressure, cur- downstream of the pump. I ni ti all y let the pump
rent, bearing temperature, et c. B e recorded perio- cool .
dically. • Close the delivery valve to reduce the load on the
M ake the fol lowi ng checks at regular intervals. It is driving unit.
recommended that they be made at every change • Stop the driver of the pump.
of shift. • When the pump has come to rest, close the suc-
• Check t he suction and discharge pressure gauge tion-isolating valve.
for normal operating pressure, if there is signifi- • Is olate any ancil l ary supplies .
cant drop in the suction or discharge pressure the
pump may have lost its s up pl y. In the event of this 8.3.6 Emergency S hutdown
fault occurring, the pump must be stopped imme- In the event of any malfunction of the equipment,
diately and the cause of liquid loss eli m inated. switch off the pump set. When the pump has
• Check the mechanical seal or stuffing box as sem- come to rest, close the suction & discharge valves,
bly for overheati ng. isolate the driving unit power supply & rectify the
fault.
24
9 Ma in ten ance tine maintenance checks for this purpose are as
under:
Maintenance and repai r work should be carried • To keep dail y logbook records of worki ng parame-
out by qualified personnel only. ters like suction and discharge pressure, flow rate,
WARNI NG! Danger of electric shock! current drawn, beari ng temperature, etc. These
Any danger from ele ctrical current should be parameters should be recorded twice a shift. Any
rul ed out. sudden change should be a signal for investiga-
• The pum p should be electrically isolated and tion. Refer Section M aintenance & Insp ection log.
secured against unauthori se d s witch-on prio r to • Check bearings for normal temperature. See 8.3.3
any maintenance or repai r work. • Vibration & sound level readings should be taken
• Any damage to the connection cable should once in a fortnight and values compared with that
always be rectified by a qua lified electrician of previous records.
only. • Check that t here is sufficient leakage from the
WARNING! Ris k of scalding! gland packing to ensure proper cooli ng and lubri-
At high fluid temperatures and system pressu- cation. (i f applicable) For mechanical seal , check
res, allow the pum p to cool down first and then that there is no visible leakage.
depressurise the syste m. • For any abnormality observed from the visual/
manual inspection and through maintenance &
9.1 Routine maintenance and frequency of inspection logs, stop the pump and investigate.
inspection • Fault finding - M any of the common faul ts which
Centrifugal pump requires very little routine occur on centrifugal pumps and which can be dia-
maint enance, However, serious troubles can be gnosed by observations are given i n the chart
often avoided by regular observation and analysis under section 10 Faults, causes and remedies.
of various working parameters . Some of the rou-
Routine maintenance

M echanical Seal Check for Leakage Daily
Gland Packing Check for Leakage Daily 10 to 120 drops/min
Check for Leakage Hal f yearly If required replace with new pickings
Bearings Check temperature Weekly Bearings are greased for life and are main-
taince free
Su ction P ressure Check P ressure Daily
Discharge P ress ure Check Pressure Daily
Flushing Check Flow Weekly Flow through the Flushing pipes must be
Clearances Check the clearances bet- Yearly If value of clearance is more, neck ring
ween neck ring and impeller should be replaced
Total Dynami c Head Check Suctio n and Discharge Yearly
TDH
Alignment Check the ali g nment of pump Hal f yearly For reference use pump motor GA Drawing
with motor
NOTE:
In case fault can not be diagnosed, please fill up
the form in section the Issue/Feed back and send
it to service depart ment at Wilo.

9.2 Overhaul mai ntenance NOTE:
The figures given in t he table above are only valid
9.2.1 General information if the wear rings and the impeller are made with in
After a long period of service, wear will occur in the same materials of low galling t endenci es . For
parts of the pump, necessitating t he renewal of a materials with higher g all i ng t endencies (AISI 304/
few components. Logbook records will indicate 316 etc...), higher clearance i s provided (0.125 mm
wear as gradual deterioration of performance is to be added to given values).
noticed. Once this is known, pumps should be Information regarding ori ginal des ign dimensions
taken for overhaul. It is recommended that yearly and cl earances is furnished in data sheet. Any
stripping & checking of wear & tear and clearances other information, if needed, can be requested
should be done and overhauli ng where requi red. from Service Department, WILO SE. Such request
If related pair of components show a marked must quote name plate number and type of the
degree of wear in relation to the rest of the unit, pump in question.
then it may be sufficient to renew only the heavily The parts most likely to be affected are:
worn components. If the wear is uniform throug- • Impel l er
hout the pump, then all wearable components • Mechanical seal
may require renewal. • Neck Rings
M easurements should be taken and recorded of all • Sleeves
wearable components at the first, and every sub- • Stuffing B ox Bush
sequent overhaul period. Reference to these • Bearings
records will enable an accurate assess ment of the • Coupling Bushes/ membrane s et
rate of wear to be made, and a reasonably accurate
forecast regarding when a particular component Before commencing dismantling operations,
may require renewal can be made. ensure that the following tools and tackles are
avail abl e:
I nternal nominal Nomi nal gap at the • A crane / chain pulley block suitable for handling
diameter of the wear diameter in (mm) the weight of pumping unit .
ring in (mm) • A s election of ri ng and op en-ended spanners in
Briti sh and M etri c sizes.
65 0.38 • Eyebolts in B riti s h and M etric sizes.
100 0.46 • Cotton rope, wire rope and slings.
150 0.58 - 0.55 • Hardwood and metal packing blocks.
• M iscellaneous tools i ncluding a set of Allen keys,
200 0.62
drills , pin drivers, files etc.
250 0.68 • Ex t ract or / puller for bearing and coupli ng.
300 0.74
350 0.84 - 0.80 The torque value to be set for a parti cu l ar size of
screw is dependent upon:
• Material of screw
• Parent metal
• Whether the screw is untreated or plated
• Whether the screw is dry or lubri cated
• The depth of the thread
Tightening torques – Untreated S crew (black fini s h); Coefficient of Fri cti on 0.14
Property Torque Nomi nal diameter – Coarse thread
class
M6 M8 M10 M12 M14 M16 M20 M22 M24 M27 M30 M33 M36
8.8 Nm 9.2 22 44 76 122 190 300 350 500 600 1450 1970 2530
Ft. lb 6.8 16.2 32.5 56 90 140 221 258 369 443 1069 1452 1865
26
9.3 Disassembling the pump
Ex ploded view of SC P pump ( Gl and pack version)
Glan d pack ve rsion

No. De scription No. De scription
1 C asing top half 20 Bearing end cover (Non Drive En d)
2 C asing bottom half 21 Stud for bearing end cover
3 Impeller 22 Bearing (Non Drive End)
4 Shaft 23 Lock washe r
5 Neck ring ( We ar ring) 24 Lock n ut
6 Impeller key 25 Be aring housing (Non Drive End)
7 Shaft sleeve 26 Hex plug
8 O-ring 27 Air cock
9 Spacer Sleeve 28 Hex screw for jacking
10 Sleeve nut 29 Studs for splitflange
11 Stuffing box bush 30 Coupling key
12 Gland packing 31 Gaske t
13 Logging ring 32 Water thrower
14 Gland 33 Steady pin
15 Stud for gland 34 Stud coupling
16 Bearing end cover (Drive End) 35 Sealing connection (Flushing Pipe)
17 Bearing (Drive End) 36 Hex screw for bearing housing
18 Bearing housing (Drive End) 37 4 way valve

Ex ploded view of S CP (M ech ani cal seal version)
Mechani cal se al ve rsion

No. De scription No. De scription
1 C asing top half 20 Bearing end cover (Non Drive En d)
2 C asing bottom half 21 Stud for bearing end cover
3 Impeller 22 Bearing (Non Drive End)
4 Shaft 23 Lock washe r
5 Neck ring ( We ar ring) 24 Lock n ut
6 Impeller key 25 Be aring housing (Non Drive End)
7 Shaft sleeve 26 Hex plug
8 O-ring 27 Air cock
9 Spacer Sleeve 28 Hex screw for jacking
10 Sleeve nut 29 Studs for splitflange
11 Stuffing box bush 30 Coupling key
12 Mechanical seal 31 Gaske t
13 Grab screw 32 Water thrower
14 Gland plate 33 Steady pin
15 Stud for gland 34 Stud coupling
16 Bearing end cover (Drive End) 35 Sealing connection (Flushing Pipe)
17 Bearing (Drive End) 36 Hex screw for bearing housing
18 Bearing housing (Drive End) 37 4 way valve
28
9.3.1 Disassembling the top casing 9.3.3 Dis ma ntli ng the rotating element (Mechani cal
• Isolate the pump system by closing sucti on and seal version pump)
delivery valve. The onl y difference between disassembly of gland
• Drai n the pump and open the upper air vent (27). pack and mechanical seat version pump is the
• R em ove two steady pins(33) and the split flange disassembly of the mechani cal seal
nuts . The procedure up to water thrower removal i s
• For gland packi ng: same as per gland pack version.
• R em ove nuts of split gland(15) from both ends Disassembly of mechanical seal is as follows:
and slide away the gland(14). Remove gland • Sli de out the gland plate carefully over the shaft.
packing(12) as well as logging ring (13) • Now mark the position of mechanical seal(12) on
• For mechanical seal: the shaft(4) to ease the position while reassemb-
• Disconnect the flushing tubes(35), loos en the ling
nuts of the gland plate(14) and slide them away on • Unscrew the grub screw of the seal adjusting ring
the shaft(4). • Pull the mechanical seal carefully over the shaft
• R em ove al l studs(29) joining top & bottom followed by removal of adjusting ri ng
casing(1&2). Connect suitable lifting tackles to • Rest procedure i s same as explained for gland pack
the eye bolts(37) provided on top half casing(1). version pump
Remove the casing gasket(31)
• R em ove the paper gasket(31) placed in between 9.4 Exami nati on of I nternal Com pon ents
the two casing halves With the disassembled rotating element , the
internal components and clearances can be che-
9.3.2 Dis ma ntli ng the rotating element (Gland pack cked
version pump)
• R em ove the coupling s crew /nut of t he coupling 9.4.1 Casi ng neck ring
• R em ove the screw of the bearing end cover (16 & Use an internal micromet er to measure the bore of
20) casing ring, taking measurements at intervals
• R em ove the steady pin (33) and hex screw (36) of around the circumference to check for uneven
bearing housing (18 & 25) wear. A comparison between thi s dimension and
• Li ft the rotor element that of the impeller neck will indicate the amount
• R em ove the coupling and coupling key(30) of diametrical clearance between the casing neck
• R em ove bearing housings of both drivi ng and non ring and the impeller neck. If this clearance is
driving ends (18 & 25) 150% or more than the original design clearance,
• Now remove the lock nut (24) and lock washer or if the det erioration in hydraulic performances
(23) from the shaft free end has been such that no furt her deterioration can be
• R em ove the both dri ving and non driving bearings tolerated duri ng the next operation period, the
(17 & 22) using puller (Never try to extract the neck ring should be replaced.
bearing by applying force to the outer race) The impeller-wearing ring t o casing neck ri ng
• Now remove the thrust collar(19) from the non clearance must be restored to the original design
driving end of the s haft value by fitting small- in-bore neck rings, bored
• R em ove the water thrower(32) from both sides of out to suit the diameter of the impeller.
the shaft(4)
• R em ove the gland(14) and gland packing(12) from 9.4.2 Shaft S leeves
the shaft along with logging ring(13) The shaft sleeve should be examined to see if it is
• Remove the stuffing box bush(11) from bot h side grooved or generally worn. The outside diameter
• No w unscrew and remove the sleeve nuts(10) and of the sleeve should be measured and a compari-
spacer sleeves(9) on both side son made with the bore of the stuffing box bush
• C arefull y extract the o-ring(8) from the sleeve(7) through which the sleeve passes. The amount of
with suitable tool without damaging it clearance between the two can thus be checked
• Now remove the neck rings(5) from the impel- to determine whether or not it is within accepta-
ler(3) ble limits.
• In order to remove the sleeves effortlessl y, apply
some mol ly cream or grease on the shaft and slide
the sleeves over it(Als o first clean the shaft prior
to the removal of the sleeves). M ark the position
of impeller(3) on the shaft(4) to ease the reposi-
tion it while reass embli ng.
• Now remove the impeller(3) carefully avoiding
damage to the impeller key(6)
• If difficulty is observed in removal of the impeller,
apply heat uniformly over t he impeller shrouds
inwards towards the hub

9.4.3 I mpel l er circumference to check the uneven wear. Diffe-
Inspect the impeller as follows: rences between the neck OD and t he neck ring ID
• Exam i ne the impeller for damage. measured will give us the clearance between the
• For corrosive /erosion pitting. two. Clearance t hus obtained should not be more
• Cavitations pitting. than 150% of maximum designed cl earance.
• Bent or cracked vanes, inlet and out let vane end
wear. 9.4.4 Shaft & keys
If damage is extensive, impeller may need replace- Sh aft should be checked for the trueness, or any
ment. other mechanical damage and corrosi on. If the
Further information should be sought from Wil o shaft i s not true wit hi n 0.1 mm TIR (Tot al Indicated
before any decision on repair work is undertaken. Reading), it should be replaced/repaired. Exami ne
• Around the eye, wearing rings protects the impel- the shaft keys and keyways. Remove damaged or
ler. Examine around t he eye at neck portion for worn out keys.
grooving in alignment with spindle axis ; slight
grooving is acceptable but deep or profuse groo- 9.4.5 Beari ngs
ving must be remedied by machining the impeller The ball bearings fi tted on the SCP range are gre-
by taking a polish cut on wearing ring. Spare wear ased for life. Then no maintenance is required.
rings are supplied with excess outside di amet er to Check that bearing rotates freely and smoothl y,
facilitate machining after fitti ng. The wear rings veri fy that the outer ring presents no abrasions or
are shrink fitted on impeller neck and are screwed. discoloration. If there is any doubt regarding the
NOTE: serviceabilit y of the bearing it should be replaced.
Impeller wearing rings are an optional feature to As exceptions, the (*) marked models of SCP
enhance the protection for impeller eye. In st an- receive bearing which need re-greasing.
dard case pump is supplied with neck ring only. The re-filling must take place each 1000 hours of
• To check wear around the impeller neck, us e pre- operation and the grease fully replaced every
cision instruments such as outside micrometer to 3000 hours or earlier if the local prescription
accurately measure the outside diameter. M easu- requires it.
rements should be taken at intervals around t he
BALL BEARI NGS
Pumps DRIVE END EXISTING NDE

Designation Size Size
SCP 50-220 HA 6204 2z 6302 2z

SCP 50-180 HA 6304 2z 6304 2z
SCP 50-340 HA 6304 2z 6304 2z
SCP 50-340 D S 6305 2z 6305 2z
SCP 65-390 H S 6305 2z 6305 2z
SCP 80-230 HA 6305 2z 6305 2z
SCP 80-200 HA 6305 2z 6305 2z
SCP 80-380 D S* N206 6305 2z
SCP 80-340 HA 6305 2z 6305 2z
SCP 80-360 D S 6306 2z 6306 2z
SCP 100-270 HA 6305 2z 6305 2z
SCP 100-280 HA 6305 2z 6305 2z
SCP 100-360 HA 6305 2z 6305 2z
SCP 100-400 HA 6305 2z 6305 2z
SCP 100-410 DS 6307 2z 6307 2z
SCP 125-290 HA 6306 2z 6306 2z
SCP 125-330 HA 6306 2z 6306 2z
SCP 125-440 HA 6306 2z 6306 2z
SCP 125-470 HA 6308 2Z 6308 2Z
SCP 125-460 DS 6309 2z 6309 2z
SCP 150-290 HA 6306 2Z 6306 2Z
SCP 150-390 HA 6308 2z 6308 2z
SCP-150-350 HA 6308 2z 6308 2z
30
BALL BEARI NGS
Pumps DRIVE END EXISTING NDE
SCP 150-440 HA 6308 2z 6308 2z
SCP 150-580 HA 6311 2z 6311 2z
SCP 150-530 HA 6311 2z 6311 2z
SCP 150-460 DS 6309 2z 6309 2z
SCP 200-310 HA 6308 2z 6308 2z
SCP 200-320 HA 6308 2z 6308 2z
SCP 200-370 HA 6308 2Z 6308 2Z
SCP 200-360 HB 6308 2z 6308 2z
SCP 200-390 HA 6311 2z 6311 2z
SCP 200-440 HA 6311 2z 6311 2z
SCP 200-460 HA 6311 2z 6311 2z
SCP 200-550 HA 6311 2z 6311 2z
SCP 200-480 HA 6311 2z 6311 2z
SCP 200-560 HA 6314 2z 6314 2z
SCP 200-660 DV 6314 2z 6314 2z
SCP 250-250 HA 6306 2z 6306 2z
SCP 250-390 HA 6311 2Z 6311 2Z
SCP 250-360 HA 6311 2z 6311 2z
SCP 250-450 HA 6314 2z 6314 2z
SCP 250-570 HA 6314 2z 6314 2z
SCP 250-700 DV* 6316 2z 3316
SCP 250-740 DV* 6316 2z 3316
SCP 300-330 HB 6311 2z 6311 2z
SCP 300-380 HA 6311 2Z 6311 2Z
SCP 300-400 HA 6311 2z 6311 2z
SCP 300-490 HA 6314 2z 6314 2z
SCP 300-570 HA 6314 2z 6314 2z
SCP 300-660 DV 6318 2Z 6318 2Z
SCP 350-500 HA 6314 2z 6314 2z
SCP 350-470 HA 6314 2z 6314 2z
SCP 400-540 HA 6314 2Z 6314 2Z
SCP 400-480 HA 6314 2z 6314 2z
SCP 400-550 HA 6316 2z 6316 2z
SCP 400-710 HA 6316 2z 6316 2z
SCP 400-660 DV* 6316 2z 3319
9.4.6 S tuffing box bush

Check bore of stuffing box bush and compare with
sleeve diameter. If "cl earance is excessive, the
bush should be renew ed.
9.4.7 Mechani cal seal

Ensure that the sliding face do not pres ent any
scratches or abnormal wear. Verify that the driving
collar is well screwed on the shaft at the right
place. Check that no material block the spring
action.

9.5 Reas s em bli ng the pump 9.5.2 Re-assembly of the pump (Gland pack version
pump)
9.5.1 Reasse mbl y of rotating element (Gland • Ensure that casing is clean, dry and free from
pack version pump) forei gn matter. Cl ean casing neck ring and st uf-
• Place the impeller key(6) at its seat on the s haft(4) fing box bush seating thoroughly and ensure
• Now slide the imp ell er(3) at its position on the they have no burrs.
shaft(4), matching the marked position done • Now lift the rotor assembly and place it on the
while dis ass embl y bottom half casing (2)
• Place the neck ring(5) on the impeller eye • Put a gasket(31) from 0.25 mm thick black joint
• Sli de the sleeve(7) on both side of t he impeller paper or simil ar gasket material and locate on
over the shaft split flange of bottom half casing.
• Ins ert the O-ring(8) in between t he shaft(4) and • M ake sure the neck ring pin(38) provided t o the
sleeve(7) neck ring (5) and stuffing box bush(11) sits pro-
• Now place the spacer sleeve(9);ensuring proper perly in their respective sit
positioning of the O-ring(8) • Now screw the bearing end cover(16 & 20) to
• Screw the sleeve nut(10);but don’t tight it now, the bearing housing (18 & 25) and bearing
keep it loos e housing to the bottom casing(2)
• Now slide in the stuffing box bush(11) over the • Pull the water thrower(32), gland(14) and log-
shaft on both sides ging ring(13) towards the bearings(17 & 22) on
• Place the logging ri ng (13) next to the stuffing box both side
bush(11) • Now check the position of impeller; if adjust-
• Side in the gland (14), followed by water thrower ment is required, do it by loosing / tightening the
(32) n both side sleeve nut(10) on either side of the impeller
• Now slide the bearing inner cover(16 & 20) on eit- • After proper positioning of the impeller, tight
her side of the shaft(4) the sleeve nut(10)
• Now place the thrust coll ar (19) followed by thrust • Place all the studs for split flange(29) at their
end bearing (22). To place the bearing at its posi- respective positions
tion using proper mounting aid • Now place the top half casing(1)
• Now place the lock washer (23) and lock nut(24). • Insert the steady pins(33) of casing(1 & 2) and
• Tight the lock nut completely with proper tighte- bearing housing(18 & 25) at respective their
ning tool and lock it with the lock washer (23). For position
ti ght ening sequence refer figure 10 • Tighten the bolts with a torsion bar wit h the
• No w place the bearing(17) at the drivi ng end using proper sequence
proper mounting aid • C heck for the proper position of neck ri ng(5) and
• Press the bearing housing(18 & 25) over t he bea- stuffing box bush(11)
rings(17 & 22) using a mallet • Now stuff i n the stuffing box with the number of
gland pack rings. For proper cutting procedure
of packing rings refer figure 9.
• Press in the logging ring and stuff in remaining
gland pack rings
• Now place the gland at its position and hand
tight its studs(15)
• Check for free rotation of the shaft
Tabl e for Gland Packing Details For SCP pumps
Pump Gland Packing ri ng Pump Gland Packing ri ng

pa cking quantity pa cki ng quantity
size size
mm 2 mm 2
SCP 50-220 HA 12 2 SCP 200-390 HA 20 3
SCP 50-180 HA 14 3 SCP 200-440 HA 20 3
SCP 50-340 HA 10 5 SCP 200-460 HA 20 3
SCP 50-340 D S 9 3 SCP 200-550 HA 20 3
SCP 65-390 H S 14 3 SCP 200-480 HA 20 3
SCP 80-230 HA 14 3 SCP 200-560 HA 22 3
SCP 80-200 HA 14 3 SCP 200-660 DV 22 3
SCP 80-380 D S 10 3 SCP 250-250 HA 16 3
SCP 80-340 HA 14 3 SCP 250-390 HA 20 3
32
Tabl e for Gland Packing Details For SCP pumps
SCP 80-360 D S 10 4 SCP 250-360 HA 20 3

SCP 100-270 HA 14 3 SCP 250-450 HA 22 3
SCP 100-280 HA 14 3 SCP 250-570 HA 22 3
SCP 100-360 HA 14 3 SCP 250-700 DV 20 4
SCP 100-400 HA 14 3 SCP 250-740 DV 20 4
SCP 100-410 DS 10 6 SCP 300-330 HB 20 3
SCP 125-290 HA 16 3 SCP 300-380 HA 20 3
SCP 125-330 HA 16 3 SCP 300-400 HA 20 3
SCP 125-440 HA 16 3 SCP 300-490 HA 22 3
SCP 125-470 HA 17.5 3 SCP 300-570 HA 22 3
SCP 125-460 DS 12 5 SCP 300-660 DV 20 4
SCP 150-290 HA 16 3 SCP 350-500 HA 22 3
SCP 150-390 HA 17.5 3 SCP 350-470 HA 22 3
SCP 150-350 HA 17.5 3 SCP 400-540 HA 22 3
SCP 150-440 HA 17.5 3 SCP 400-480 HA 22 3
SCP 150-580 HA 20 3 SCP 400-550 HA 20 4
SCP 150-530 HA 20 3 SCP 400-710 HA 20 4
SCP 150-460 DS 12 3 SCP 400-660 DV 20 5
SCP 200-310 HA 17.5 3
SCP 200-320 HA 17.5 3
SCP 200-370 HA 17.5 3
SCP 200-360 HB 17.5 3
9.5.3 Reassembly of rotating element (Mechani cal

seal version pump)
Procedure for rotor assembly for mechanical seal
pump is simil ar up to assembly of stuffing box
bush(11)
Reassembly of mechanical seal is as follows:
• Extreme cl eanli ness must be observed during ins-
tallation, and damage to the seal faces and moun-
ting rings must be avoided
• Place t he adjusting ring of mechanical seal at its
pre marked position
• Place the grab screw(13) at its position on the
adjusting ring, but tight it yet
• The O-rings may be oiled to reduce friction, during
installation of the seal. EP-rubber O-rings should
Location of mechanical seal of shaft
not come into contact wit h oil or grease; In this
case lubrication with glycerine or water is recom-
1) Pump casing
mended.
2) Stationary seat
• Never cover the sliding faces with a lubricant as
3) Stationary seat
they must be assembled completely dry, clean and
4) Gl and plate
dust-free.
5) O-ring
• When pressing in stationery seals, make sure that
6) Shaft
the pressure distribution is uniform. The O- ring
X. M echanical seal
must be fitted using water or alcohol only.
1.6 Abut ment ring
• Crowned drive pins must be replaced whenever
1.7 Abut ment ring fixing s crew
the seal is dismantled. During ins erti on of the st a-
tionary seats, especially those of special carbon,
care must be taken to exert pressure evenly.
• Now check the distance of seal as shown in the
figure and adjust its value as per val ues given table
• For rest parts foll ow the above explained proce-
dure as per gland pack version pump

Tabl e for Mec hani cal S eal Adjustment
Pump Me ch.s eal Distance on the shaft Pump Me ch.s eal Distance on the shaft
Di am. (L) Di am. (L)
(Ø dw) MG1 M 74 (Ø dw) MG1 M 74
SCP 50-220 HA 28 mm 16.5 mm 26 mm SCP 200-390 HA 75 mm 30 mm 37 mm
SCP 50-180 HA 32 mm 17.5 mm 26 mm SCP 200-440 HA 75 mm 30 mm 37 mm
SCP 50-340 HA 32 mmq 17.5 mm 26 mm SCP 200-460 HA 75 mm 30 mm 37 mm
SCP 50-340 DS 38 mm 20 mm 26 mm SCP 200-550 HA 75 mm 30 mm 37 mm
SCP 65-390 HS 38 mm 20 mm 26 mm SCP 200-480 HA 75 mm 30 mm 37 mm
SCP 80-230 HA 38 mm 20 mm 26 mm SCP 200-560 HA 95 mm 36 mm 42.8 mm
SCP 80-200 HA 38 mm 28 mm 26 mm SCP 200-660 DV 95 mm 36 mm 42.8 mm
SCP 80-380 D S 42 mm 20 mm N.A. SCP 250-250 HA 50 mm 20.5 mm 42.8 mm
SCP 80-340 HA 38 mm 20 mm 26 mm SCP 250-390 HA 75 mm 30 mm 37 mm
SCP 80-360 D S 48 mm 20 mm 26 mm SCP 250-360 HA 75 mm 30 mm 37 mm
SCP 100-410 DS 55 mm 35 mm N.A SCP 300-330 HB 75 mm 30 mm 37 mm
SCP 125-290 HA 50 mm 20.5 mm 27.5 mm SCP 300-380 HA 75 mm 30 mm 37 mm
SCP 125-330 HA 38 mm 20 mm 26 mm SCP 300-400 HA 75 mm 30 mm 37 mm
SCP 125-470 HA 60 mm 28 mm 32.5 mm SCP 300-570 HA 95 mm 36 mm 42.8 mm
SCP 125-460 DS 65 mm 40 mm N.A SCP 300-660 DV 115 mm N.A. 42 mm
SCP 150-290 HA 50 mm 20.5 mm 27.5 mm SCP 350-500 HA 95 mm 36 mm 42.8 mm
SCP 150-460 DS 60 mm 28 mm 32.5 mm SCP 400-660 DV 130 mm N.A. 42 mm
SCP 200-310 HA 60 mm 28 mm 32.5 mm
SCP 200-320 HA 60 mm 28 mm 32.5 mm
SCP 200-370 HA 60 mm 28 mm 32.5 mm
SCP 200-360 HB 60 mm 28 mm 32.5 mm
9.5.4 Re-assembly of the pump (Mechanical seal NOTE:

version pump) Whil e assembling stainless steel component,
For assembling mechanical seal version pump fol- molybdenum-disulphide paste should be applied
low the same procedure as done for gland pack to prevent galling / s eizure and also to facilitate
version pump. Difference in assembly of mechani- easy removal in future.
cal seal pump is as follows: NOTE:
Reassembly of mechanical seal is as follows: Change the gasket each time when t he pump is
• After placing the top half casing(1) at its position opened.
and tightening the studs(29)
• Sli de i n the gland plate(15) at its position and tight
its studs
• Now fix the flushing tubes(35) to the mechanical
seal gland plate(15)
• Rest procedure is same as explained above for
gland pack version pump
34
9.6 Recommended spare parts • Take the same lot of part as for 3 years and add the
In case of standard operation, we recommend the shaft and impeller.
following list of spare part regarding t he period of The maintenance of the split case pumps is easier
functi oning. than other pump types. Then in order to facilitate
• For 2 years of normal operation: this operation we strongl y recommended pur-
• M ech ani cal seal or Packing, ball bearings and the chasing a batch of part with the pump in order to
different gasket required for the dismounti ng of reduce the shut down timing.
the pump. It is strongly recommended to purchase t he origi-
• For 3 years of normal operation : nal spares parts from <WILO> . In order to avoid
• M ech ani cal seal or Packing, ball bearings and the any mistake we invit e you to suppl y with any spare
different gasket required for the dismounti n g of parts demand, the information mentioned on the
the pump, wear rings and their nuts. For the data plate of the pump and / or motor.
pumps equipped with Gl and packing, include the
gland plate and lubrication spacer.
• For 5 years of normal operation:
Recommended spare parts (Gland pack version)

No. Des cri pti on Quantity Recommended S pare
Parts
1 Casing top half 1
2 Casing bottom half 1
3 Impeller 1
4 Sh aft 1
5 Neck ring (Wear ring) 2 ‡
6 Impeller key 1
7 Sh aft sl eeve 2
8 O-ring 2
9 Spacer sleeve 2
10 Sleeve nut 4
11 Stuffing box bush 2
12 Gland packing Set ‡
13 Logging ring 2
14 Gland 2
15 Stud for gland 2
16 Bearing end cover (Dri ve End) 1
17 B earing (Dri ve End) 1 ‡
18 Bearing housing (Dri ve End) 1
19 Thrust collar 1
20 Bearing end cover (Non Drive End) 1
21 Stud for bearing end cover 1
22 Bearing (Non Dri ve End) 1 ‡
23 Lock w asher 1 ‡
24 Lock nut 1 ‡
25 Bearing housing (Non Dri ve End) 1
26 Hex plug –
27 Air cock 1 ‡
28 Hex screw for jacking 2
29 Studs for splitflange –
30 Coupling key 1
31 Gasket 1 ‡
32 Water thrower 1
33 Steady pin –
34 Stud coupling 4
35 Sealing connection (Fl us hi ng Pipe) 2 ‡
36 Hex screw for bearing housing 8
37 4 way vlve 2 ‡
38 Neck ring pin 2 ‡
Coupling guard 1 ‡

Recommended spare parts (mechanical seal version)
No. Des cri pti on Quantity Recommended S pare
Parts
1 Casing top half 1
2 Casing bottom half 1
3 Impeller 1
4 Sh aft 1
5 Neck ring (Wear ring) 2 ‡
6 Impeller key 1
7 Sh aft Sl eeve 2
8 O-ring 2
9 Spacer Sl eev e 2
10 Sleeve nut 4
11 Stuffing box bush 2
12 M echanical s eal 1 ‡
13 Grab screw 2 ‡
14 Gland plate 2 ‡
15 Stud for gland 2
16 Bearing end cover (Dri ve End) 1
17 B earing (Dri ve End) 1 ‡
18 Bearing housing (Dri ve End) 1
19 Thrust collar 1
20 Bearing end cover (Non Drive End) 1
21 Stud for bearing end cover 1
22 Bearing (Non Dri ve End) 1 ‡
23 Lock w asher 1 ‡
24 Lock nut 1 ‡
25 Bearing housing (Non Dri ve End) 1
26 Hex plug –
27 Air cock 1 ‡
28 Hex screw for jacking 2
29 Studs for splitflange –
30 Coupling key 1
31 Gasket 1 ‡
32 Water thrower 1
33 Steady pin –
34 Stud coupling 4
35 Sealing connection (flushing pipe) 2 ‡
36 Hex screw for B earin g Housing 8
37 4 way valve 2 ‡
38 Neck ring pin 2 ‡
Coupling guard 1 ‡
36
10 F au lts, causes and remedies
S ymptoms Possible cause of trouble and remedies

(Each n umbe r is defined in the table below)
-- Pump does not deliver water. 1,2,3,4,6,11,14,16,17,22,23
-- Insufficient capacity delivered. 2,3,4,5,6,7,8,9,10.11.14.17,20,22,23.29,30,31
-- Insufficient pressure developed 5,14,16,17,20,22,29,30,31
-- Pump loses prime after starting. 2,3,5,6,7,8,11,12,13
-- Pump requires excessive power. 15,16,17,18,19,20,23,24.26,27,29,33,34,37
-- Stuffing box leaks excessively. 12,13,24,26,32,33,34,35,36,38.39,40
-- Pump vibrates or it is noisy. 2,3,4,9,10,11,21.23,24,25.26.27,28,30,35,41,42,43, 44,
45,46,47
-- Bearings have short life. 24,26,27,28,35,36,41,42,43,44,45,46,47
-- Pump overheats and seizes. 1,4,21,22,24.27,28,35,36,41
Causes Remedies
1 Pump not primed Ensure that casing is full y filled and water comes out from air-
cock .
2 Pump or suction pipe not completely filled with Check leaking foot valve in case of negative s uction
liquid
3 Suction lift too high. Reduce by lowering pump elevation or increase Water level.
4 Insufficient margin between pressure and vapor Check that NPS H available i s at least 1 meter more 1 meter
pressure. more than NPSH required.
5 Exces si ve amount of air in liquid. Check the reasons and eliminate. Gas gets entrapped in liquid.
Air may be entering through suction j oi nts .
6 Air pocket in suction line. Ensure pipe fully filled and there i s nobend for negative suction.
7 Air leaks into suction line Tighten pipe joints with solution.
8 Air leaks into pump through stuffing boxes. Ensure stuffing box s eali n g.
9 Foot valve too small or leaking. Replace I Attend.
10 Foot valve partially clogged. Clean
11 Inlet of suction pipe insufficiently submerged. Ensure adequate submergence such that foot valve is not
exposed.
12 Water s eal pipe clogged. Clean or change.
13 Logging ring is improperly located in stuffing Position logging ring centrally under sealing holes of stuffing
box, preventing sealing fluid from entering to box.
form seal.
14 Speed too low. Check motor RPM, supply frequency, M otor nameplate speed
should be as specified on pump nameplate.
15 Speed too hi gh. Check motor RPM and supply frequency.
16 Direction of rotating wrong. Check correct directi on of rotation for motor before coupling to
motor.
17 Total head of system higher than design head of Check the causes and refer to M &P. M easure wi th pressure
pump. gauge.
18 Total head of system lower than pump design Check the causes and refer t o M&P. M easure wi th pressure
head. gauge.
19 Specific gravity of liquid different from design. Refer to M &P.
20 Viscosity of liqui d different from design. Refer to M &P
21 0peration at very low capacity. Check the causes and refer to M&P , Operate pump at rated
duty.
22 P arall el operation of pumps unsuitable for such Refer t o M&P with characterist i cs curves of pump.
operation.
23 Foreign matter in impeller. Open and clean.
24 M isalignment. Check with Dial gauge should be within limits and without
undue pipe stresses.
25 Foundations not rigi d. Check, vibration on Baseplate, check hollowness.
26 Shaft bent. Dismantle and check, Replace shaft.

Causes Remedies
27 Rotating part rubbing on stationary part. In correct assembly, correct the ass embly.
28 Bearing worn. Check lubrication, shaft run out, alignment, replace if required
29 Wearing rings worn. Replace.
30 Impeller damaged. Replace.
31 Casing gasket defective, permitting internal Replace.
leakage.
32 Shaft or shaft sleeves worn or scored at packing. Replace.
33 Packing improperly installed. Use correct grade and size of packing
34 Type of packing incorrect for operating condi- Use correct grade and size of packing.
tion.
35 Shaft running' out of center because of worn Rectify.
bearings or misalignment.
36 Rotor out of balance, causing vibration. Balance the rotor.
37 Gland too tight, resulting i n no flow of liquid t o Adjust gland. Ensure sealing water flow
lubricate packing.
38 Cooling li qui d not being provided to water- Provide.
cooled stuffing boxes.
39 Excessive clearance at bottom of stuffing box Check pumps assembly.
between shaft and casing, causing packing t o be
forced into the pump.
40 Dirt or grit in sealing, li qui d leading to scoring of Provide clean li qui d for flushing.
shaft or shaft sleeve.
41 Exces si ve thrust caused by mechanical failure Check pump operation and assembly
inside pump or by failure of hydraulic balancing
device, if any (in case of multistage pump etc.)
42 Excessi ve grease or oil i n antifri ction bearing Attend.
housing or lack of cooling, causi ng excessive
bearing t emperature.
43 Lack of lubrication. Provide proper lub ricati on.
44 Improper installation of antifriction bearings R ectify or replace bearing.
(damage, incorrect assembly of stacked bea-
rings, use of unmatched bearings as a pair I etc.)
45 Dirt in bearings Investigat e the cause and cl ean bearing.
46 Rusting of bearings from wat er in housing Arrest water ingress.
47 Exces si ve cooling of w at er- cool ed bearing, Reduce cooling water flow.
resulting in condensation of atmospheric mois-
ture in bearing housing.
11 Decommissioning and recycling

The disposal of all material or debris must be done
in order to prot ect the envi ro nment.
The Wil o’s pumps do not contain any dangerous
substances. The major part of the pump is recyc-
lable. The disposal and recycling of the pump sets
must be done in accordance with the local in force
regul ations.
The dismounting must be done by qualified per-
sonal.
Clean and decontamination must be achieved
before any transportation or recycling
38
Wilo Mather and Platt – Sump Pumps
en Installation and Operating Instructions

Wilo Mather and Platt_SP_OIM_20131012_01
Disclaimer
Wilo-Mather and Platt is very grateful for your interest in its products. The basic objective of this
document is to provide instructions for maintaining and operating Wilo-Mather and Platt Sump Pumps.
Instructions are complied for the person having a working knowledge of Sump Pumps and the pumps
shall be installed under expert supervision and guidance.
With this document Wilo-Mather and Platt does not accept any liability for inaccurate installation,
operation or maintenance of the product at site. The authorities that install and maintain the pump shall
be responsible for hassle free installation operation or maintenance of the product.
This document is prepared with at most care to ensure correct and accurate information, enabling the
user to have trouble free installation and operational support. However, there can be few areas for
improvement to make this document error free.

Tel: +91 20 27442100/1/2/3/4,
Fax: +91 2027442111
www.matherplatt.com
Installation and operating instructions Wilo Mather and Platt – Sump Pumps 2
Fig. 1: Lifting of complete pump: (See Page No. 15 ; Point no.3.1)
CAUTION! : Do not lift the Pump with motor.
Always dismantle the motor before lifting the pump unit.
Fig. 2: PNV pump with self lubrication: (See Page No. 23 ; Point no. 9.3)
Fig. 3: PNV pump with external water lubrication : (See Page No. 23 ; Point no. 9.3)
Fig. 4: PNV pump with grease lubrication : (See Page No. 23 ; Point no. 9.3)
Fig. 5: Auxiliary Oil Pumps (AOP) : (See Page No. 23 ; Point no. 9.3.2)
Fig. 6: Emergency Oil Pump (EOP) : (See Page No. 23 ; Point no. 9.3.2)
Fig. 7: Closed type Impeller arrangement : (See Page No. 30 ; Point No. 10.5.1)
Fig. 8: Semi Open type Impeller arrangement : (See Page No. 30 ; Point No. 10.5.1)
Fig. 9: Suction Pipe details : (See Page No. 21 ; Point No. 7.6.2)
Fig. 10: Mechanical seal arrangement (On request) : (See Page No. 20 ; Point No. 7.4)
Fig. 11: Pump & motor shaft connection : (See Page No. 20,21 ; Point No. 7.5)
E: Motor Shaft Extension

G: Gap between shaft ends (Always maintain 10mm)
Fig. 12: Thrust bearing arrangement : (See Page No. 29 ; Point No. 10.5)
Fig. 13: Alignment of pump-motor coupling : (See Page No. 24 ; Point No. 9.7)
Fig. 14 : Details of Flexible coupling : (See Page No. 24 ; Point No. 9.7)
Fig. 15 : Details of Muff coupling assembly : (See Page No. 29 ; Point No. 10.5)
INDEX
1 General Information…………………………………….…………………………………………………………… 14
2 Safety………………….…………………………………………………………………………………………………… 14
2.1 Safety symbols………………………………………………………………………………………………………………………………………………… 14
2.2 Personnel qualifications………………………………………………………………………………………………………………….................... 14
2.3 Danger in event of non-observance of the safety instructions…………………………………………………………………… 14
2.4 Safety instructions for the operator………………………………………………………………………………………………………………… 14
2.5 Safety instructions for installation and maintenance work…………………………………………………………………………..... 15
2.6 Unauthorized modification and manufacture of spare parts…………………………………………………………………………… 15
2.7 Improper use…………………………………………………………………………………………………………………………………………………….. 15
2.8 Safety & control devices…………………………………………………………………………………………………………………………………… 15
3 Transport and interim storage…………………………………………………………………………………… 15
3.1 Handling……………………………………………………………………………………………………………………………………………………………. 15
3.2 Delivery…………………………………………………………………………………………………………………………………………………………….. 16
3.3 Storage……………………………………………………………………………………………………………………………………………………………… 16
3.4 Pump returning back to the supplier……………………………………………………………………………………………………………….. 16
3.5 Intended use…………………………………………………………………………………………………………………………………………………….. 16
4 Product Description ………………….………………………………………………………………………………. 17
5 Selection of motor and pump components ……………………………………………………………………… 18
5.1 Electrical motor selection…………………………………………………………………………………………………………………………………. 18
5.2 Coupling Selection …………………………………………………………………………………………………………………………………………… 18
6 Preparing Foundation …………………………………………………….…………………………………………………………… 19
6.1 Sole plate installation ………………………………………………………………………………………………………………………………………. 19
6.2 Leveling of Sole plate ………………………………………………………………………………………………………………………………………. 19
7 Installation ………………………………………………………………………………………………………………………………………………………… 20
8 Electrical connections ……………………………………………………………………………………………….. 22
9 Commissioning…………………………………………………………………………………………………………….. 22
9.1 List of Essential items………………………………………………………………………………………………………………………………………… 22
9.2 Pre starting checks…………………………………………………………………………………………………………………………………………….. 22
9.3 Bearing Lubrication……………………………………………………………………………………………………………………………………………. 23
9.4 Cleaning of bearings…………………………………………………………………………………………………………………………………………… 23
9.5 Availability of liquid…………………………………………………………………………………………………………………………………. 24
9.6 Direction of rotation……………………………………………………………………………………………………………………………… 24
9.7 Coupling Installation……………………………………………………………………………………………………………………………… 24
9.8 Starting the pump and running checks…………………………………………………………………………………………………… 24
9.9 Normal shutdown…………………………………………………………………………………………………………………………………… 24
9.10 Emergency shutdown……………………………………………………………………………………………………………………………… 24
10 Maintenance……………………………………………………………………………………………………………. 26
10.1 Routine maintenance……………………………………………..………………………………………………………………………………………….. 26
10.2 Overhaul maintenance………………………………………………………………………………………………………………………………………. 27
10.3 Disassembling the pump…………………………………………………………………………………………………………………………………… 28
10.4 Examination of Internal Components……………………………………………………………………………………………………………….. 28
10.5 Reassembling the pump……………………………………………………………………………………………………………………………………. 29
10.6 Recommended spare parts……………………………………………………………………………………………………………………………….. 30
11 Decommissioning and recycling…………………………………………………………………………………. 30
12 Dimensional details……………………………………………………………………………………………………. 31
13 Faults, causes and remedies ………………………………………………………………………………………. 32
WARNING!
1. General Information The user can suffer (serious) injuries. “Warning” implies
that (serious) injury to persons is probable if this
About this document information is disregarded.
The language of the original operating instructions is English.
All other languages of these instructions are translations of CAUTION!
the original operating instructions.
These installation and operating instructions are an integral There is a risk of damaging the pump/installation.
part of the product. They must be kept readily available at the “Caution” implies that damage to the product is likely if
place where the product is installed. Strict adherence to these the information is disregarded.
instructions is a precondition for the proper use and correct
operation of the product.
These installation and operating instructions correspond to 2.2 Personnel qualifications
the relevant version of the product and the underlying safety All personnel involved in the operation, installation,
standards valid at the time of going to print. Supplied pump inspection and maintenance of the unit must be qualified
will operate trouble free and satisfactorily on the condition to carry out the work involve.
that, it is installed with due care and maintained properly. If the personnel in question do not possess the necessary
For hassle free operating life, it is recommended that the knowledge and skill, appropriate knowledge and training
pump should operate under specified “Operating conditions”. must be provided.
Pump operating conditions are mentioned on the
“Nameplate” affixed to the pump. 2.3 Danger in event of non-observance of the
If operating parameters deviate from the specified parameters safety instructions
as on the “Nameplate”, please contact manufacturer.” Non-observance of safety instructions provided in these
operating instructions can result in the following risks:
 Failure of important product/installation functions
2. Safety  Failure of required maintenance and repair procedures
 Danger to persons from electrical, mechanical and
These operating instructions contain basic information which
bacteriological influences
must be adhered to during installation and operation. For this
reason, these operating instructions must, without fail, be  Property damage
read by the service technician and the responsible operator  Loss of any claims to damages
before installation and commissioning. The machine operator
list must be filled out completely. By signing this list, all
persons working on or with the product confirms that they 2.4 Safety instructions for the operator
have received, read and understood this operating & This appliance is not intended for use by persons (including
maintenance manual. children) with reduced physical, sensory or mental
It is not only the general safety instructions listed under the capabilities, or lack of experience and knowledge, unless
main point "safety" that must be adhered to but also the they have been given supervision or instruction concerning
special safety instructions with danger symbols included use of the appliance by a person responsible for their
under the following main points. safety. Children should be supervised to ensure that they
do not play with the appliance.
2.1 Safety symbols  If hot or cold components on the product/the unit lead
General danger symbol : to hazards, local measures must be taken to guard
This symbol indicates safety instructions where non- them against touching.
compliance would affect personal safety and could  Guards protecting against touching moving
result in loss of life. components (such as the coupling) must not be
removed whilst the product is in operation.
Danger due to electrical voltage  Leakages (e.g. from the shaft seals) of hazardous fluids
This symbol indicates electrical safety instructions where
(which are explosive, toxic or hot) must be led away so
non compliance will involve a high risk to personal safety
or the loss of life. that no danger to persons or to the environment arises.
National statutory provisions are to be complied with.
NOTE :  Highly flammable materials are always to be kept at a
This is not a safety symbol but indicates useful safe distance from the product.
information on using the product. It also draws  Danger from electrical current must be eliminated.
attention to the possible problems. Local directives or general directives [e.g. IEC, VDE etc.]
and local power supply companies must be adhered to.
Signal words:  Depending on the type, size and capacity (kW), the
DANGER! products produce a sound pressure up to 75 dB (A) to
Acutely dangerous situation. 110 dB (A).
Non-observance results in death or the most serious
of injuries.
 The actual sound pressure, however, depends on several
factors. These include, for example, type of prime mover,
3. Transport & Interim storage
installation type; fastening of accessories and pipeline, Immediately check the pump and transport packaging for
operating site condition, background noise, etc. damage in transit upon receipt. Take the necessary steps
 Once the product has been installed, we recommend within the period defined by the transport company in the
that the operator makes additional measurements under event of damage in transit.
all operating conditions.
DANGER! Risk of getting crushed!
2.5 Safety instructions for installation and
The installation or removal of the product must not be
maintenance work
performed by one person alone. Measures should be taken to
The operator must ensure that all installation and
bar persons from standing beneath a suspended load.
maintenance work is carried out by authorized and qualified
Further- more, it is also prohibited to move suspended loads
personnel, who are sufficiently informed from their own
over exposed workplaces where people are present. The
detailed study of the operating instructions.
fastening devices should be adapted to the conditions at
Work on the product/unit must only be carried out when at a
hand (weather, hooking system, load, etc.) Use suitable
standstill. It is mandatory that the procedure described in the
fastening devices to handle the weight of the product.
installation and operating instructions for shutting down the
product/unit be complied with.
Immediately on conclusion of the work, all safety and CAUTION! Risk of damage to the pump!
protective devices must be put back in position and/or re-
commissioned. Risk of damage due to improper handling during transport
and storage.
2.6 Unauthorized modification and manufacture of The pump should be protected against humidity, frost and
mechanical damage during transport and interim storage.
spare parts
Unauthorized modification and manufacture of spare parts
will impair the safety of the product/ personnel and will make
void the manufacturer's declarations regarding safety. 3.1 Handling (Refer Fig. 1 ; Page no.3)
Modifications to the product are only permissible after
consultation with the manufacturer. Original spare parts and CAUTION! Risk of damage to the pump!
accessories authorized by the manufacturer ensure safety. Risk of falling!
The use of other parts will absolve us of liability for
consequential events. Pumps should never be lifted with motor mounted on motor
stool. Lifting lugs provided on motor stool are to be used
2.7 Improper use only for lifting the pump during maintenance. Pump to be
The operating safety of the supplied product only guaranteed lifted /inserted in part by part. Safe working load of wire
for conventional use in accordance with Section 4 of the ropes reduces with increase in included angle. Never put
operating instructions. The limit values on any account must down or pick up the product when it is not secured. Tilting of
not fall under or exceed those specified in the catalogue/data the product should be avoided at all costs.
sheet. Only suitable lifting gear and load carrying equipment with
valid test certificates and adequate lifting capacity for the
loads involved (such as belts/ wire ropes/slings) should be
2.8 Safety & control devices
used for lifting & transporting the product.
Direct controls are applicable when the pump is supplied
along with motor/panels. When motor/ panel is in end user’s If chains are used, they should be secured against slipping
scope of supply, it is advised to go for CE approved motors along with protective cover to prevent damage to the
/panels. Environmental safety product, paint and/or injury to personnel. When lifting, care
Disposal of any unwanted/scrap material should be disposed to be taken so that pump flanges, shaft extensions etc. are
in appropriate way so as not to cause any harm to the not damaged.
environment. No hazardous material is used in Wilo Mather & To lift the pump see lifting diagrams - see also general
Platt pumps. safety Information, Point 2). These must have sufficient load
bearing capacity to ensure that the product can be
NOTE transported safely.
To avoid ambiguity in the use of the word

„replace” the words „replace” and „renew” are used in this
manual in the following context: Replace - To put back, in its
existing state, a part or component that has previously
been removed. Renew - To substitute a new part of
component for a worn or damaged one.
3.2 Delivery
On arrival, the delivered items must be inspected for damage 3.4 Pump returning back to the supplier
and check that all parts are present. Products which are delivered back to the plant must be clean
If any parts are damaged or missing, the transport company or and correctly packaged. In this context, clean means that
the manufacturer must be informed on the day of delivery. Any impurities have been removed and decontaminated if it has
claim made at a later date will be deemed invalid. Damage to been used with materials, which are hazardous to health.
parts must be noted on the delivery or freight documentation. The packaging must protect the product against damage.
3.3 Storage
Our vertical Sump pumps require preparation for storage & CAUTION! Guarantee not applicable!
regular maintenance during storage. The pump should be
considered in storage when it has been delivered to the job
Products, which are not suitably packaged for delivery back,
site & waiting for installation.
It is suggested that the check of parts & material against the are no longer covered by guarantee!
bill of materials be made jointly with the Wilo – Mather and
Platt’s representative & customer representative.
3.5 Intended use
NO CLAIMS FOR SHORTAGES WILL BE HONORED BY The pump supplied is intended for specific fluid. Refer pump
WILO-MATHER AND PLATT AFTER THE MATERIAL HAS data sheet and order confirmation. For any change in pumped
BEEN PLACED IN STORAGE. fluid refer Mather and Platt beforehand. If the operating
conditions are different of the specifications given in the
3.3.1 Short-term storage (less than 1 month) order, (i.e. type of liquid, temperature or duty point), the end
The equipments as shipped should have adequate protection user must ask a written agreement to Mather and Platt on the
for short-term storage in a covered, dry and ventilated new operating conditions before starting the pump.
location at the job site prior to installation.
If the pump is not installed immediately after delivery, it must
be stored in a dry and clean place with sufficient ventilation,
no vibration, no freezing and the temperature variations must
be smooth. Bearings and couplings must be protected against
sand, dust and foreign bodies. To avoid corrosion and jamming,
please lubricate the pump and make turn the rotating
elements for several turns at least once a week. Pre-packed
desiccants may be used to absorb moisture & keep the pump
dry. It must be removed before putting the pump on operation.
3.3.2 Long-term storage (more than 1 month)

If the equipment will be subject to extended storage condition
prior to installation, then the manufacturer must be informed
about storage duration, so that special protection can be
recommended.
 The machine must be protected from direct sunlight, heat,
dust, and frost.
 The rotors or propellers must be turned at regular intervals.
This prevents the bearing from locking.
 Heavy components must be placed on supports to keep
them off the ground.
 Shafting must be removed from the boxes & coated with
preservative, then re-boxed with preservative paper.
4.11 Delivery pipe
4. Product Description It is included in standard scope of supply. It brings the pump
liquid to mounting plate level.
4.1 Pump Casing Delivery pipe flanges are as per ANSI 150 class FF or RF
Volute type pump casing designed for high stress resistance We can also supply as per IS6392 table no. 17
and maximum performance.
4.12 Mounting plate
4.2 Impeller It is machined from both sides and carrying the
Impeller is of the closed type, with twisted vane design for entire pump weight.
maximum performance, dynamically balanced. Semi-Open
impeller design is available on request. It is keyed at the end 4.13 Motor Stool
of the shaft and secured by means of an impeller nut and It is fabricated from steel and is accurately machined for
locked by means of lock washer to ensure positive locking. parallelism of faces and concentric bores to maintain perfect
alignment of motor and pump shafts. Motor is mounted on
4.3 Back Cover motor stool.
It is provided with “O-Ring” for positive leak proof joint
between pump casing and back cover. Back cover holds the 4.14 Lubrication pipe line
throttle bush at the end of the impeller. Pipe lines are connected to bearing brackets to lubricate the
bush bearings by pumping liquid or external lubrication.
4.4 Stuffing Box
Stuffing box is provided with mechanical sea on request.
4.15 Bottom pipe
4.5 Bearings & lubrication It is the additional piece provided at the suction side
Press fitted bearing in the back cover and intermediate of casing. It is in between the suction strainer and
bearing brackets to support the shafts. The intermediate pump casing. It is provided when the installation
bush bearings shall be lubricated with the liquid handled by depth goes above 6m. It is mandatory in AOP & EOP
the pump and hence it is necessary that the liquid handled designed pumps.
should have sufficient lubricating properties. External water
should be supplied to lubricate the bearing, if liquid to be
handled contains suspended solids. 4.16 Product Name Plate
Double row angular contact ball bearings are grease Product Name plate is affixed on the motor stool.
lubricated and mounted at the top of the head shaft in the The data on the Name plate is as shown below,
bearing housing. It takes axial thrust and shaft and Impeller
weights.
4.6 Shaft
Top, Intermediate and pump shaft of ample strength and
rigidity. Bearing span is to keep as per API-610 standard.
4.7 Couplings
Flexible coupling M&P make pin and bush type coupling are
standard design. Other makes also supplied on request.
4.8 Muff coupling assembly

The accurately machined muff coupling and split collars are
meaned to connect the two shafts length wise.
4.9 Support pipes

Support pipes top, intermediate, bottom is fabricated from
steel/stainless steel pipes. Flanges are accurately machined
faced for parallelism. Holes are provided in pipes for over
flow. Description :
PNV-1 Name of the Product series
4.10 Intermediate bearing bracket
OA Order No.
It is rigid housing contains the bush bearings which in turn 3
supports and align the shaft perfectly. It is accurately face Q Duty point flow in m /hr
machined to maintain the parallelism and accurately bored to H Duty point head in meter
keep the perfect alignment.
RPM Motor Speed in RPM
Max.
5. Selection of Motor and Pump Coupling Shaft
Rating
Max. Gap
Dia. Torque hp/100 Speed
Components Size
COUPLING SELECTION
(Ø mm) (Nm) CHART rpm FOR STD
rpm
mm
PIN-BUSH
5.1 Electrical motor selection 96 30 125 1.75 7200 4
Select an electrical motor with sufficient power margin
regarding the motor rating. The table below will guide you in 112 42 250 3.5 6100 4
this selection 125 48 400 5.6 5500 4
140 55 520 7.3 4900 4
P2 ≤ 22 22 kW < P2 55 kW
Shaft power 160 60 750 10.5 4500 4
KW ≤ 55 kW < P2
180 70 1050 14.7 3800 4
Recommended 200
25 % 15% 10% 80 1450 20.3 3400 4
Power Margin
225 90 2400 33.7 3000 7
250 105 3000 42.1 2700 7
Example:
• Duty point: 100 m3/h – 30 m – pump efficiency 78 % 285 110 4900 68.8 2400 7
• Pump shaft power: 10.5 kW 320 125 6000 84 2100 7
• Electrical motor rating (including margin):
360 135 10000 140 1900 10
10.5 * 1.25 = 13 kW
• IEC motor power rating available: 15 kW 400 145 14000 196 1700 10
450 160 21000 295 1500 6
5.2 Coupling selection 500 180 27500 385 1350 6
Standard Pin-bush type flexible coupling is used to connect 560 200 33100 465 1200 6
top / head shaft to motor shaft. (Fig 16) 630A 160 46000 645 1050 6
Couplings can be selected with Cast Iron or Forged steel as
standard material. Select the size of the coupling in 630B 220 46000 645 1050 6
accordance with the recommendation of the coupling 710A 180 80000 1122 950 7
manufacturer. Strictly follow the coupling manufacturer’s 710B 240 80000 1122 950 7
instructions for fitting the coupling between pump and
motor. Use torque or power/100 rpm rating to select suitable 800A 220 110000 1543 850 7
coupling in suitable MOC. 800B 260 110000 1543 850 7
Then check if the rated coupling speed is more than pump
speed. 800C 290 110000 1543 850 7
Also check the motor shaft dia. for selected motor is less than 900A 250 190000 2666 750 7
or equal to the max. Shaft dia. mentioned in the coupling
catalogue. 900B 300 190000 2666 750 7
Additional service factor must be considered in coupling 900C 340 190000 2666 750 7
selection for special applications. 1000A 275 250000 3508 675 10
(Refer table on next page for coupling details in CI MOC)
1000B 320 250000 3508 675 10
Example: 1000C 380 250000 3508 675 10
 Power: 1000 hp, Pump speed: 980 rpm,
Service Factor: 1
(Power/100 rpm) Rating: hp * 100 * SF / rpm

: 1000*100*1/980 Notes:
: 102
Select coupling with hp /100 rpm rating more than 102  For Forged Steel / Cast Steel MOC kindly contact
Mather and Platt.
 For other types of couplings such Metaflex / Spacer-  Specified gap to be maintained between pump and
Membrane type / Rigid threaded type kindly consult Mather motor half coupling.
and Platt.
 Care should be taken to consider and maintain gap between
motor and pump half side of the coupling.
6. Preparing Foundation
6.2 Leveling of Sole Plate
The foundation should be sufficiently substantial to absorb
any vibration and to form a permanent, rigid support for the
sole plate. The strength of foundation must be adequate for
CAUTION!
the static and dynamic loads imposed and depend upon local The machined surfaces where level is being checked
soil conditions. must be clean and free from paint, burrs etc
The foundation must get large dimensions. Generally, the
weight of the foundation is around 2 to 3 time the pump set  Provide suitable packer plate (25 mm to 30 mm thick) or
taper wedges on the foundation one each of either side of
weight. In building the foundation, the top of the foundation
foundation bolt. It is advisable to provide thin layer of
should be left approximately equal to sole plate thickness plus cement below the packer plate.
25 mm for packers/shims below, to allow for grouting.  Lift the soleplate and lower it on the foundation. Insert the
Foundation bolts of the proper size should be embedded in foundation bolts through the holes in the soleplate and
the concrete, located by template. screw a nut on to each bolt until the bolt protrudes
through the nut by a length, which is sufficient to
accommodate a lock nut.
 Adjust the level of the soleplate by inserting shims
between the soleplate and the packer plate until the
soleplate is leveled. And support on all the packing wedges
at suitable height. For checking the levels & straightness,
I-beam type straight edge should be used extensively in
conjunctions with engineer’s master level. Level should be
achieved within 0.05 mm per 250 mm. Also ensure that
elevation of bedplate is adjusted suitably.
 For grouting use rich mix of 1:1:2 of cement, sand and
gravel below 25 mm, alternatively quick setting grout mix
can be used.
 When the grout has set, gently but firmly tighten the
foundation bolts. Do not distort the soleplate or loosen
the foundation bolts in the grout by excessive tightening.
Carefully re-check the level of the soleplate and make
adjustments that are necessary by fine shimming. Ensure
that the sole plate is leveled, as per the site datum level,
various centerlines etc.
Note:
Leave top of foundation rough! Do not finish with

trowel.
 A pipe sleeve about 2 ½ diameters large than the bolt should

be used to allow movement for the final positioning of the
bolts. For installations where a low level of noise is
expected, built the foundation in a pit lined with appropriate
insulation material in order to avoid vibration transmission
to the ground.
 Ensure that both Sole plate faces are parallel within
allowable value, free from any distortion as shown in fig.
Spirit level, straight edge along with engineer’s mater level
can be used to check flatness.
6.1 Sole Plate Installation

Sole plate has machined surfaces on both top and bottom
sides. The top surface of foundation over which the sole plate
rests must be left rough to assist in keying the final grout.
After the sole has been leveled by positioning steel packer
plates at suitable intervals on the foundation surface, ensure
that the surface beneath each packing plate is solid by
crushing any protrusion or alternatively each packer plate may
be placed on a thin screen of cement.
7. Installation 7.4 Mechanical seal (Refer Fig. 10 ; Pg. no. 10)
7.1 Location Pumps supplied with vapor proof construction or pressurized

The pump should be located to allow room for installation, designs are furnished with an upper stuffing box equipped to
access, ventilation, maintenance and inspection with ample take mechanical seal.
headroom for lifting. Refer to the general arrangement drawing
for the pump set. If the pump is furnished with external flush 7.5 Driver Mounting
lubricated bearings, the fluid lines must be accessible from the
pump location.  Before the motor is installed, be sure to connect the motor
Also important, especially in the larger flow units, is proper half coupling hub and the pump half coupling hub onto
sump design. When more than one pump is installed and used their respective shafts.
at the same time in the same sump, the location and spacing of
the pumps are important. Guidelines and the pump placement
 Carefully lift the motor and place it on the motor stool of
as outlined in the “Hydraulics Institute Standards” are
the pump.
recommended.
 Turn the motor frame to one of the four positions where
7.2 Part Assemblies the motor bolt holes line up to the motor stool. Select the
 Pump are shipped completely assembled except driver & position of the motor to suit the desired conduit box
mechanical seal location. Install the motor hold down bolts. In some
 When mechanical seal are furnished, they should be installed instances a motor adapter may be furnished. In this case
before the motor is put in place. the adapter must be installed before the motor can be
 The driver will be mounted after the pump is installed. mounted.
 When the pump shipped all the threads and all the openings
are covered. This protection should not be removed until  Motor to pump alignment is controlled by fits within the
installation. If the pump is removed from service, this adapter and cannot be adjusted.
protection should be reinstalled.
 Locate the coupling and source of electrical power but DO
7.3 Pump Mountings NOT INSTALL THE COUPLING DRIVE ELEMENT AT THIS
The pump may be mounted directly on the pit using the pump TIME.
mounting plate.
 Connect the motor terminals to the leads from the starter
a) The pump was checked during assembly at the factory to panel. Make sure the motor shaft and/or coupling is not
make sure the pump shaft rotated freely by hand. Handling touching any part of the pump shaft or pump half coupling.
during shipment, storage, or preparation for installation could Rotate the motor shaft by hand to make sure it is free to
have caused distortions resulting in pump shaft binding. Check rotate when energized.
the shaft to make sure that it will rotate freely by hand.
CAUTION!
b) Check all bolts and nuts for tightness, then carefully lower
the assembled pump into the pit, taking care not to damage
Never check driver rotation unless the pump and driver
lube lines or float control equipment. Make sure that any
shafts are disconnected and physically separated. Failure
equipment used to lift the pump or any of its components is
to follow this instruction can result in serious damage to
capable of supporting the weights encountered. Make sure
that all parts are properly rigged before attempting to lift. the pump and driver if rotation is in the wrong direction.
c) Pump mounting plate must maintain level from one side of  Run the motor and check for proper rotation which should
the plate to the other, and be supported evenly at all points be clockwise when looking down on top of the motor. If
before being bolted down. rotation is wrong, interchange any two motor connections
on three-phase motors. On single-phase motors, follow
d) If the sump doesn't provide a level mounting surface for the the motor manufacturer’s instructions. After changing the
pump, drive wedges under the mounting plate/pit cover until connections, again check the rotation to ensure that the
pump levels out. The wedges must be able to support the direction is correct.
weight of the entire pumping assembly and hold the assembly
steady enough that no excess vibration occurs.  Disconnect and lockout the power supply to the driver.
e) Do not bolt the discharge flange of the pump to the piping  The coupling can now be fully installed and join the driver
until the base-plate foundation is completely installed. and pump shafts together
f) Run piping to the discharge of the pump.  Install the coupling guarding.
There should be no piping loads transmitted to the pump after  While mounting the motor & installing the coupling
connection is made. following chart should be refer. (Ref. fig. 11 ; Pg. no. 11)
Motor Frame Dimension “E”
Size (mm)
CAUTION!
80 40
90 50 The check valve is required to prevent back-flow through
100, 112 60 the pump on shut-down. This flow can reverse rotation of
132 80 the pump, potentially damaging the pump, motor and
160, 180, 200 110 associated equipment.
225, 250, 280 140
315 170
“E” – Recommended motor shaft extension 7.6.4 Allowable nozzle loads
7.6 Piping
Protective covers are fitted to both the suction and discharge
flanges of the casing and must be removed prior to
connecting the pump to any pipes.
7.6.1 General piping

If the pump flange(s) have tapped holes, select flange
fasteners with thread engagement at least equal to the
fastener diameter but that do not bottom out in the tapped
holes before the joint is tight.
7.6.2 Suction piping (Ref. fig. 9 ; Pg. no. 10)

Pumps typically only have strainers attached to the suction
flange of the pump casing. An option for an extension from
the suction flange is available and is called a Suction pipe. A
suction pipe is useful for applications where there is adequate
NPSH at the lowest sump level but the discharge pressure is
critical and must be maintained at a maximum value compared
to using a longer column and shaft.
7.6.3 Discharge piping

Install a valve in the discharge line. This valve is required for
regulating flow and/or to isolate the pump for inspection and
maintenance. When fluid velocity in the pipe is high, for
example, 3 m/s (10 ft/sec) or higher, a rapidly closing
discharge valve can cause a damaging pressure surge. A
dampening arrangement should be provided in the piping.
All piping must be independently supported, accurately
aligned and preferably connected to the pump by a short
length of flexible piping. The pump should not have to support
the weight of the pipe. It should be possible to install Note :
discharge bolts through mating flanges without pulling or 1. Conversion of Forces in N  lbf * 4.448
prying either of the flanges. All piping must be tight.
2. Conversion of Moments in Nm  lbf-ft *1.356
 Use discharge piping one size larger than the pump
discharge. 7.7 Final free rotation check
 Discharge piping should be well supported and connected to After connecting the piping, rotate the pump drive shaft
the pump such that no strain or weight of the piping is
clockwise (viewed from motor end) by hand several complete
carried by the pump.
revolutions to be sure there is no binding and that all parts
 Check pump shaft for freedom of rotation by hand to make are free. If piping caused unit to be in a bind, correct piping to
sure any discharge piping strain is not causing binding. relieve strain on the pump.
 After the pump discharge, the increaser should be the first
item in the discharge line, followed by the check valve and
gate valve, respectively. 7.8 Auxiliary piping
 It is recommended that pressure indicating devices be Check to see if any other connections need to be made to
installed before and after the valves in the discharge line to pump, such as fluid injection to stuffing box for seal or
verify the pump is not being run dry and that the discharge packing lubrication (when furnished) and make the required
valves are not closed. connections.
Check to see that connections are made to the lubrication
fittings at pump manifold on mounting plate.
8. Electrical connections 9. Commissioning
WARNING! Danger of electric shock WARNING! Danger of injury
The electrical connection should be established by an The devices whether on pump/motor/electrical panels must
electrician approved by the local electricity supply company in never be dismantled or disabled. They must be checked by
compliance with the applicable local regulations [e.g. VDE an authorized technician for proper functioning before,
regulations]. start-up. Refer to motor & electrical panel instruction
 Current type and voltage of the mains connection must manuals for electrical safety & control devices information.
correspond to the specifications on the name plate.
 Refer to the motor and panels instruction manual at the time of
installation and connection. Motors or electrical control panels WARNING! Danger of pump damage!
are operated with alternating or industrial high-voltage current. Do not operate the pump away from specified operating
 The electrical connection is established via a fixed mains range. Operating beyond duty point may not only pose a risk
connection line. to the operator but will reduce the efficiency of the pump or
 The local regulations must be adhered to, ensure that there is a damage the pump itself.
provision for isolation of all energy sources and locking. If the Operation more than 5 minutes, at close valve condition is
machine has been switched off by, a protective device, it must not recommended.
not be switched on again until the error has been corrected.
For hot liquids this is not recommended at all. Ensure that
 The electrical system (machine including protective devices and always site NPSH-A is more than NPSH-R.
operating position) must always be grounded. Refer pump GA
drawing & respective manuals of motor/electrical control panel
for connecting earthing suitable as per motor rating and 9.1 List of Essentials to made available at site prior to
relevant regulations and standards including proper earthing lug start commissioning
size and fasteners.
 Under no circumstances may any connecting cables touch the  Set of I-Beams of erection.
pipeline or the pump or motor housing.  Set of Slings, Shackles, wire ropes, eye bolts, wrenches.
 If there is a possibility that people can come into contact with  Set of spanners, Allen keys, hammer, scrapper, screw drivers.
the machine and the pumped liquid (e.g. at construction sites),  Skilled manpower, ladder, sufficient lighting, Helmet, Safety
the grounded connection must be additionally equipped with a jacket, Safety Shoes etc.
fault current protection device.
 To ensure drip water protection and strain relief of the cable 9.2 Pre-starting checks
connections, use cables with an appropriate outer diameter and
screw the cable glands tight. Furthermore any cables nearby Prior to starting the pump it is essential that the following
screwed connections for outlet loops should be bent in order to checks be made.
divert any accumulating drip water. Close any unassigned cable
glands with the existing sealing discs and screw them tight.  Motor properly secured to the motor stool
 All fasteners are tightened correctly
8.1 Operation with frequency converter  Check that coupling guard in place
 Check bearing lubrication
The rotation speed can be adjusted in the operating limits of the  Ensure free rotation of shaft by hand when coupled
pump given in the technical data. The electrical motors can be  Sufficient submergence level is maintained.
driven by a frequency converter in order to adapt the pump  No blockage in the strainer at the suction end.
performance at the duty point required. Please contact WILO  Check that delivery pressure gauge is connected.
Mather and Platt before connecting the frequency converter to  Discharge line is having non return valve & get valve
the motor to make sure that the electrical motor is compatible installed.
with this driver. In any case, please inform WILO Mather and Platt  Test and make available all protection devices like alarm,
at the quotation stage if the pump set will be driven by a signals, interlock systems incorporated in the auxiliary and
frequency converter, this might influence the motor selection. main pumping control system.
 Strictly follow the Frequency converter manufacturer  Ensure that all electrical checks on motor, relay setting in
instructions panel etc have been carried out in accordance with the
 The minimum rotation speed of the pump should never go instructions of motor manufacturer.
below 40% of the nominal speed.  Ensure that cooling water arrangement is provided bearing
cooling and stuffing box.
9.3 Bearing Lubrication 9.3.2 Thrust bearing lubrication
Two types of bearings are used in vertical sump pumps. Line
shaft bearings are used to support pump shaft within the Grease lubricated double row angular contact thrust bearings are
column. These plain bearings are lubricated by external flush, used as standard. The bearing will leave the factory with grease
product lubrication or grease. already packed.
Thrust bearings: Double row angular contact bearings are used The replacement interval of the grease for these bearings is
to support the coupling end of the shaft. These ball bearings mentioned in the section 9.4.2
support coupling ends and take pump thrust. They are lubricated Oil lubricated bearings are used for the designs such as AOP &
by bearing grease or oil . EOP types. In these pumps the pumped oil is used for the
lubrication of bearings. (Ref. fig. 5&6, Pg. no. 7&8)
CAUTION !
9.4 Cleaning of Bearings
Operation of the unit without proper lubrication can result in Vertical sump pumps are supplied with oil or grease lubricated
bearing failures, pump seizures and pump failure.
bearing depending upon the suitability. If the unit has been in
store for a long period before commissioning, the bearings
9.3.1 Line Shaft Bearings should be cleaned and flushed out with clean white spirit or
Check to see that no damage has occurred to any lubrication good quality paraffin. Waste oil/paraffin & used cotton cloth
lines above the mounting plate during shipment or installation.
should not be used for this purpose, as particles of foreign
Check that connections are made to lubrication fittings at pump
matter may be left behind which would cause damage when the
manifold on mounting plate.
bearing is in service. Bearings should be then filled with
recommended grade and quality of fresh lubricant to the level.
9.3.1.1 External flush lubrication (Ref. fig.3; Pg. no.5)
a) Clean liquid from an external source must be used when Bearings are given an initial charge of grease before leaving
pumps are furnished with external flush lubrication connections. WILO Mather & Platt works and do not require any attention
Liquid is typically supplied continuously during operation. beyond the normal greasing routine before the first servicing
Lubrication is needed to dissipate heat and abrasives. period. Only greases recommended by pump manufacturer or
b) It is absolutely necessary that rubber bearings be wet at all their equivalent should be used. Bearings should never be over
times during operation. greased.
Capacity Connection CAUTION !

Source Pressure
per Bush tapping size
Do not overfill the thrust bearings with grease.
Delivery If too much grease is filled into the bearings, they can
External 0.3 to 0.5 At mounting
3 pressure*0.4 overheat.
clear water m /hr 2 plate ½” NPT
+ 1 kg/cm
9.4.1 Recommended Grease brands

9.3.1.2 Internal flush lubrication (Ref. fig.2; Pg. no. 4)
When conditions warrant, the pump can be furnished with Manufacturer Grease type
provisions for pumped product bearing lubrication. This is
accomplished by means of a lubrication line from the discharge Hindustan Oil Corporation Servogem-2/3
flange of the pump casing to the line shaft bearings Hindustan Petroleum Lithon-2/3
Changes in noise and vibration may indicate insufficient Bharat Petroleum Multipurpose grease-3
lubrication.
NOTE :
9.3.1.3 Grease lubrication (Ref. fig.4; Pg. no. 6) 1. Only lithium base Grease to be used.
Pumps furnished with grease-lubricated line shaft bearings will 2. Numbers mentioned stands for consistency.
leave the factory with lube lines and bearings already packed 3. Grease of two different grades should not be used.
with grease. The grease used will be of a water-resistant nature.
Each bearing should be re-greased prior to start-up through the
grease fittings located in the manifold on the pump mounting 9.4.2 Recommended Grease quantity and refilling
plate. Grease must be insoluble in the liquid being pumped. The intervals
recommended grease to be used which are mentioned in section
9.4.1 or equivalent. Consult local lubricant suppliers for the type Lubrication Intervals
Qty. of
of grease most compatible with the liquid being pumped. The Element Bearing (Operating Hrs.)
grease lubrication system is the same as the external flush Grease
No. Type
system with the exception of the manifold. For grease (gms)
1450 rpm 2900 rpm
lubrication the manifold contains grease fittings while the
external flush manifold contains fluid line taps. 1 3306 1200 500 15
2 3310 1100 400 20
3 3310 900 300 20
4 3313 800 250 25
9.5 Availability of liquid  Check that the driving unit is not being overloaded during
Efficient operation of the pump depends upon the fine running valve opening. Overloading may occur if the pump is
clearances of internal hydraulic components which are discharging into an empty system. If the pumping unit fails
lubricated by pumped fluid. Sufficient fluid must be available to to generate at least its rated delivery pressure it must be
ensure that the pump is flooded at all times to prevent seizure stopped immediately, the cause ascertained,
of the internal components. Wherever external  Check that the bearing is not overheating. Bearings will
flushing/lubrication is provided it should be available before normally run at a temperature of 30 ˚C to 35 ˚C above
starting the pump. ambient temperature. The ideal running temperature of
If on starting, a pump fails to generate its rated delivery head, as bearings is 40 ˚C to 60 ˚C for ball bearings and 40 ˚C to 55 ˚C
indicated on the pump nameplate, it must be stopped for spherical roller bearings. The temperature should never
immediately; the cause must be ascertained and rectified, exceed 85 ˚C for bearings. If the bearings are overheating its
before re-starting. cause should be investigated immediately.
Ensure that minimum submergence is available as  Check vibration of pump set and ensure that vibration level
recommended. Open all ancillary inlet and outlet isolating valves is within limits specified as per HIS standard (see page no. 25
such as air vents, leak-off connections etc. for reference)
 The pumps may be run for 8 hours trial operation and all the
CAUTION! Danger of Dry Run ! parameters like delivery pressure, current, bearing
temperature, etc. Be recorded periodically. Make the
following checks at regular intervals. It is recommended that
Any attempt to run the pump dry may result in seizure of the they be made at every change of shift.
rotating internal components.  Check the suction and discharge pressure gauge for normal
operating pressure, if there is significant drop in the suction
9.6 Direction of rotation or discharge pressure the pump may have lost its supply. In
It is absolutely essential that the rotation of the motor be the event of this fault occurring, the pump must be stopped
checked before installing the coupling drive element. Incorrect immediately and the cause of liquid loss eliminated.
rotation of the pump, for even a short time, can damage the  Check the mechanical seal or stuffing box assembly for
impeller, casing, shaft and shaft seal. Always check the direction overheating if applicable.
arrow which is cast on the motor stool.
9.7 Coupling Installation (Ref. fig. 13 & 14 ; Pg. no. 12) CAUTION!
Turn off the driver power and lock it out so that the driver
cannot be started during the coupling assembly. Non-spacer If pumps fails to generate its rated delivery pressure
couplings are used. Mount coupling hubs/sheaves on pump and as indicated on the pump nameplate. It must be
motor shafts prior to attaching motor to the motor stool. stopped immediately, the cause ascertained, the fault
The coupling should be installed as advised by the coupling
manufacturer. Remove all protective material from the coupling
rectified and then restart. (Refer point no. 13 for
and shaft before installing the coupling. detail information)
9.8 Starting the pump & running checks

9.9 Normal Shutdown
To avoid pump damage or injury to operating personnel during
start-up and operation, WARNING! Risk of Burns!
 DO NOT operates the pump outside of design parameters.
 DO NOT run with a closed discharge
If the fluid temperature and system pressure is high, close
 DO NOT operate with safety devices removed (such as
the isolation valves upstream (in case of barrel pumps) and
coupling guard)
 DO NOT run the pump dry. downstream of the pump. Initially let the pump cool.
 Minimum submergence level should be as per recommended Stop the driver of the pump.
 All flush lines must be started & regulated When the pump has come to rest, close the delivery valve.
Isolate any ancillary supplies.
 When all the foregoing pre-start checks are satisfactory, Start
the pump and check the direction of rotation (indicated by a
direction arrow on the motor stool) otherwise stop the pump
immediately for correction of direction of rotation. 9.10 Emergency Shutdown
In the event of any malfunction of the equipment, switch off
 Open the delivery valve slowly and bring the pump gradually
the pump set. When the pump has come to rest, close the
up-to its rated parameters indicated in the data sheet/name
discharge valves, isolate the driving unit power supply &
plate and based on pressure gauge and ammeter readings.
rectify the fault.
Unless the pump is fitted with a special leak off device, it
should not be run for a long period against a closed delivery
valve.
Hydraulic Institute Standard (HIS)
Acceptable field vibration limit chart (9.6.4.11)
10. Maintenance
 To keep daily logbook records of working parameters like
Maintenance and repair work should be carried out by qualified
suction and discharge pressure, flow rate, current drawn,
personnel only. bearing temperature, etc. These parameters should be
WARNING! Danger of electric shock! recorded twice a shift. Any sudden change should be a
signal for investigation. Refer Section Maintenance &
Any danger from electrical current should be ruled out. Inspection log.
The pump should be electrically isolated and secured against  Check bearings for normal temperature.
unauthorized switch-on prior to any maintenance or repair  Vibration & sound level readings should be taken once in a
fortnight and values compared with that of previous
work.
records.
Any damage to the connection cable should always be  For any abnormality observed from the visual/ manual
rectified by a qualified electrician only. inspection and through maintenance and inspection logs,
stop the pump and investigate.
WARNING! Risk of scalding!  Fault finding - Many of the common faults which occur on
centrifugal pumps and which can be diagnosed by
observations are given in the chart under section Faults,
At high fluid temperatures and system pressures, allow the
causes and remedies.
pump to cool down first and then de-pressurize the system.  Check dirt and dust is removed from areas around close
clearances, bearing housing and motors.
10.1 Routine maintenance and frequency of

inspection
Vertical sump pump requires very little routine maintenance;

however, serious troubles can be often avoided by regular
observation and analysis of various working parameters. Some
of the routine maintenance for this purpose are as under:
Routine maintenance
Bearings Check temperature Weekly
Oil / Grease @ Bearing Replenish Refer

Discharge Pressure 9.4.2
Check Pressure Daily
Flow through the Flushing pipes must be
Flushing Check Flow Weekly
Check the clearances between neck If value of clearance is more, neck ring
Clearances Yearly
ring and impeller should be replaced
Check Suction and Discharge
Total Dynamic Head Yearly
head
Check the alignment of pump
Alignment Half yearly For reference use pump motor GA Drawing
with motor
Notes:
In case fault cannot be diagnosed, please fill up the
form in section the Issue/Feedback and send it to
service department at Mather and Platt.
10.2 Overhaul maintenance Recommended “O” Ring Sizes (Casing to Back Cover)
 After a long period of service, wear will occur in parts of the

pump, necessitating the renewal of a few components. Pump Type Designation ‘O’ Ring Size
Logbook records will indicate wear as gradual deterioration of
PNV-1 50x32-125
performance is noticed. Once this is known, pumps should be ID 152.2 x DIA
taken for overhaul. It is recommended that yearly stripping & PNV-5 65x50-125
4.75
checking of wear & tear and clearances should be done and PNV-10 80x65-125
overhauling where required. PNV-2 50x32-160
ID 187.2 x DIA
 If related pair of components show a marked degree of wear in PNV-6 65x50-160
4.75
relation to the rest of the unit, then it may be sufficient to PNV-11 80x65-160
renew only the heavily worn components. If the wear is PNV-3 50x32-200
uniform throughout the pump, then all wearable components
PNV-7 65x40-200
may require renewal.
PNV-12 80x50-200 ID 234.2 x DIA
 Measurements should be taken and recorded of all wearable
components at the first, and every subsequent overhaul period. PNV-15 100x65-200 4.75
Reference to these records will enable an accurate assessment PNV-18 125x100-200
of the rate of wear to be made, and a reasonably accurate PNV-23 150x150-200
forecast regarding when a particular component may require PNV-4 50X32-250
renewal can be made. PNV-8 65x40-250
 Information regarding original design dimensions and PNV-13 80x50-250
clearances is furnished in data sheet. Any other information, if ID 282.5 x DIA
PNV-16 100x65-200
needed, can be requested from Service Department, Mather 4.75
PNV-19 125x100-250
Platt. Such requests must quote name plate number and type
of the pump in question. PNV-24 150x125-250
PNV-29 200x150-250
The parts most likely to be affected are: PNV-9 65x40-315
 Impeller PNV-14 80x50-315
 Neck Rings PNV-17 100x65-315
 Sleeves ID 344 x DIA
PNV-20 125x100-315
 Stuffing Box Bush 6.35
PNV-25 150x125-315
 Bearings PNV-30 200x150-315
 Coupling Bushes/ membrane set
PNV-35 250x200-315
PNV-21 125x100-400
ID 441 x DIA
Before commencing dismantling operations, ensure that the PNV-26 150x125-400
6.35
following tools and tackles are available: PNV-31 200x150-400
 A crane / chain pulley block suitable for handling the weight PNV-22 125x100-500
of pumping unit. ID 548 x DIA
PNV-27 150x125-500
 A selection of ring and open-ended spanners in 6.35
PNV-32 200x150-500
 British and Metric sizes.
 Eyebolts in British and Metric sizes.
 Cotton rope, wire rope and slings.
NOTE:
 Hardwood and metal packing blocks.
 Miscellaneous tools including a set of Allen keys, drills, pin Designation:
drivers, files etc.
 Extractor / puller for bearing and coupling. Suction Nozzle size (mm) x Discharge Nozzle size(mm) –
 The torque value to be set for a particular size of screw is Nominal Impeller Dia. (mm)
dependent upon:
 Material of screw
 Parent metal
 Whether the screw is untreated or plated
 Whether the screw is dry or lubricated
 The depth of the thread
Tightening torques – Untreated Screw;

Coefficient of Friction 0.14
10.3 Disassembling the Pump
10.4.1 Casing neck ring
Use an internal micrometer to measure the bore of casing ring,
10.3.1 Disassembling the top Motor taking measurements at intervals around the circumference to
 Isolate the pump motor electrically check for uneven wear. A comparison between this dimension
and that of the impeller neck will indicate the amount of
 Isolate the pump system hydraulically
diametrical clearance between the casing neck ring and the
 Clear the area of any equipment that might impede the free impeller neck. If this clearance is 150% or more than the
lifting of the pump original design clearance, or if the deterioration in hydraulic
 Disconnect and remove the driving coupling performances has been such that no further deterioration can
be tolerated during the next operation period, the neck ring
 Disconnect the electrical supply cables from the motor should be replaced.
terminal block
The impeller-wearing ring to casing neck ring clearance must
 Attach slings and lifting apparatus to the motor lifting be restored to the original design value by fitting small in-bore
attachments neck rings, bored out to suit the diameter of the impeller.
 Remove the screws / bolts, or nuts, from the motor flange and
lift the motor off from the motor stool. 10.4.2 Shaft Sleeves
The shaft sleeve should be examined to see if it is grooved or
 Support the motor on timber packing blocks with the coupling generally worn. The outside diameter of the sleeve should be
hub clear off the ground measured and a comparison made with the bore of the stuffing
box bush through which the sleeve passes. The amount of
clearance between the two can thus be checked to determine
10.3.2 Removing pump from pit whether or not it is within acceptable limits.
 Dismantle the discharge pipe line, delivery valves and non
return valve from the delivery pipe. 10.4.3 Impeller
 Then remove the complete pump assembly along with Inspect the impeller as follows:
mounting plate away from the sump.  Inspect the impeller for mechanical damage, corrosive
pitting, cavitations etc. If damage is extensive, the impeller
10.3.3 Disassembling of pump parts may need replacement.
 Remove the coupling key & take off the coupling half from top  Examine around the eye at neck portion for grooving; slight
pump shaft. grooving is acceptable but deep or profuse grooving must be
remedied by machining the impeller and fitting small-in-
 Remove Adjusting ring from the shaft.
bore neck ring.
 Dismantle the delivery pipe (TOP) from the casing.  To check wear around eye, use precision tools such as
outside micrometer to accurately measure outside diameter
 Remove bearing cover, unscrew lock washer and remove
of impeller. When this diameter is subtracted from internal
bearing cartridge along with bearing from top shaft.
diameter of neck ring, which is measured in sequence 2.1,
 Unscrew the fasteners and remove the motor stool. clearance obtained should not be more than 150% of
maximum designed clearance.
 Remove casing from the bottom support pipe along with the
strainer.
10.4.4 Shaft & keys
 No need to remove the strainer from casing unless it is to be Shaft should be checked for the trueness, or any other
cleaned or replaced. mechanical damage and corrosion. If the shaft is not true
 Remove the locking screw and unscrew the impeller nut.
within 0.1 mm TIR (Total Indicated Reading), it should be
replaced / repaired. Examine the shaft keys and keyways.
 Remove the impeller. Remove damaged or worn out keys.
 Unscrew the fasteners and remove the back cover along with
the bush bearing 10.4.5 Bearings
 Remove shaft sleeve from the shaft.  Visually inspect the bearings. The balls, the inner and outer
tracks must all be free from chipping, cracks, abrasion or
 Remove intermediate assembly consists of the support pipes discoloration.
and intermediate shafts and bearing brackets.  Inspect the bore for any sign of damage. The burrs of any
 Remove muff coupling assembly scratches caused during bearing withdrawal should be
carefully removed by the hand application of a fine oil stone,
 Remove the intermediate bracket/support pipe assembly the treatment being confined to the minimum possible area.
fasteners and remove top support pipe.  Visually inspect the outside diameter for signs of fretting;
any stains may be carefully polished off, but abrasion must
be kept to the absolute minimum that is required, followed
10.4 Examination of Internal Components by cleaning.
With the disassembled rotating element, the internal  Check that bearing rotates freely and smoothly. If there is
components and clearances should be checked. any doubt regarding the serviceability of the bearing it
should be renewed.
10.4.6 Bearing Cartridge At this stage the top shaft will be projected outside, above
the support pipe (top).
 Visually inspect the bore for any signs of fretting; any stains may
be carefully polished off, but abrasion must be kept to the j) Fit the motor stool on the mounting plate.
absolute minimum that is required, followed by cleaning.
 Where fretting has occurred, bearing and cartridge should be k) Fit the top pipe assembly to motor stool by fasteners with
cleaned and trial assembled. Bearing should be transitional fit. top shaft passing through the motor stool.
l) Mount the bearing in the bearing cartridge.

10.5 Reassembling the Pump
m) Slide the bearing spacer over the top shaft and insert the
Follow the procedure given below in case of pumps to be cartridge assembly through the shaft.
erected for the first time or pumps to be assembled after
dismantling for overhauling. Clean all the parts thoroughly with n) Now the total bearing cartridge assembly will rest on the
kerosene, petrol to remove dust, dirt etc. Check the sleeves bore stuffing box stool and fasten it.
and shaft outside diameter which is free from burs and
scratches. De-bur if required. Replace the parts with a new one if o) Insert the bearing lock washer over the shaft and place the
found damaged. Use new gaskets and O rings at the time of lock nut. Firmly tight the lock nut along with the shaft. Fold
reassembling. the lock washer arm in to the bearing lock nut slot.
a) Fit the bearing bush (pump end) in the back cover. Mount the p) Place the bearing cover over the bearing cartridge and fix it
support pipe (Bottom) on the back cover. Fix the screws by means of screws.
between support pipe and back cover.
b) Insert the shaft sleeve on pump shaft (Impeller end) with key q) Check the freeness of pump in horizontal condition.
and insert the intermediate sleeve at the other end (muff
coupling) and tighten the grub screw with the shaft. Insert the r) Mount the delivery pipe to the casing with gasket.
pump shaft through the back cover.
s) Fix the delivery pipe to the mounting plate by means of
c) Place the key in position and mount the Impeller. Place the clamping plate which is already welded to the delivery pipe and
lock washer, take care that the pinch projection in washer should It prevents direct load acts to the casing.
lock with the hole provided in the Impeller face and screw the
Impeller nut. Tighten the Impeller nut along with lock washer t) Make all the connections like delivery bend, valves, and non-
and fold it along with the impeller nut for securing the nut from return valve above the mounting plate. Precaution should be
unscrew. taken that no direct load will act on the delivery pipe, such a
d) Insert the assembly so far completed in to the pump casing way that the pipe extension and valve assembly should be
with O ring (in between back cover and casing) in proper supported.
position. Tighten the hex. nuts on pump casing studs
diametrically opposite evenly. CAUTION!
Ensure that the pump shaft rotates freely.
e) Fit the bearing bush (Intermediate) in the Intermediate
bearing bracket and mount it on the support pipe (bottom) top u) Mount the pump half coupling and tighten the lock screw.
face.
v) Make the motor electric connections. Mount the motor half
This completes the casing assembly. At this stage the pump coupling and tighten the screw of the coupling. Make sure the
shaft will be projected above the Intermediate bearing direction of rotation before mounting the motor on the motor
assembly. stool. The direction of rotation should be clockwise when
viewed from the top i.e. Non-driving end of the motor.
f) Insert the intermediate shaft sleeves on the Intermediate shaft
both ends and tighten the grub screw. NOTE:
Direction of rotation of pump should be clockwise
g) Connect the Intermediate shaft to the pump shaft by means when viewed from the top.
of muff coupling. The muff coupling sleeve first be slide on the
intermediate shaft. Put the keys on both ends of the shafts and w) Mount the motor on the motor stool. Check the angular
bring both the shaft ends close together in line. With slight alignment with the help of filler gauge and parallel alignment
adjustments of shaft fit the split collars on the both ends of the with the help of straight edge and filler gauge. Alignment
shafts and slide the muff coupling on the pump shaft till it rests should be within 0.05mm.
on the shaft step. Ensure proper fitting of the muff coupling
with both the shafts and tight the grub screws provided on the x) Grease the bearing with the help of grease gun. For further
muff coupling. greasing the bearing a separate grease feeder is supplied along
with the pump, which is mounted side of the motor stool.
h) Lower the intermediate support pipe and connect it to the
bottom support pipe. Tighten diametrically opposite bolts
evenly.
i) Repeat the same procedure till top shaft.
10.5.1 Adjusting the Impeller (Ref. fig. 7&8 ; Pg. no. 9)
11. Decommissioning and
Proper Impeller adjustment positions the Impeller inside the
casing assembly for maximum performance. recycling
The Impeller can be adjusted with complete rotor assembly by
means of adjusting screw with locknuts provided in bearing The disposal of all material or debris must be done in order to
cartridge. protect the environment.
Mather and Platt pumps do not contain any hazardous
To adjust the Impeller, release the locknuts in adjusting screw substances. The major part of the pump is recyclable. The
and unscrew all the fixing screws provided in bearing cartridge. disposal and recycling of the pump sets must be done in
By Unscrewing / screwing the adjusting screw in bearing accordance with the local in force regulations
cartridge the entire total rotor assembly moves up / down as
decided. The dismounting must be done by qualified personal
Clean and de contamination must be achieved before any
After adjusting the Impeller make sure to lock the locknuts in
transportation or recycling.
adjusting screws. Tighten the screws with bearing cartridge.
It is Important to position the Impeller correctly in relation to the
casing. No rubbing can be allowed with sidewalls or front walls
of the casing.
For the Semi-open Impeller the clearance between wear plate
and Impeller should be 0.35 to 0.5mm.
10.6 Recommended spare parts

In case of standard operation, we recommend the following list
of spare part regarding the period of functioning.
For 2 years of normal operation:
Part No. Part Description Qty. / Pump
1102 Neck Ring 1

1700 Impeller Nut 1
1500 Impeller 1
4250 O-Ring (Casing/Back cover) 1
2830 Pump Bearing Bush 1
2832 Pump Bearing Sleeve 1
1800 Pump Shaft 1
1805 Intermediate Shaft n-1
1803 Top Shaft 1
2801 Int. bearing Bush n
2050 Muff Coupling set n
2603 Thrust bearing 1
2834 Int. bearing sleeve n
4080 Gasket 1
NOTE:
n = No. of Intermediate bearing brackets
12. Dimensional details
13. Faults, Causes and Remedies
Symptoms Possible cause of trouble and remedies
(Each number is defined in the table below)
-- Pump does not deliver water. 1,2,3,4,6,11,14,16,17,22,23
-- Insufficient capacity delivered. 2,3,4,5,6,7,8,9,10.11.14.17,20,22,23.29,30,31
-- Insufficient pressure developed 5,14,16,17,20,22,29,30,31
-- Pump loses prime after starting. 2,3,5,6,7,8,11,12,13
-- Pump requires excessive power. 15,16,17,18,19,20,23,24.26,27,29,33,34,37
-- Stuffing box leaks excessively. 12,13,24,26,32,33,34,35,36,38.39,40
-- Pump vibrates or it is noisy. 2,3,4,9,10,11,21.23,24,25.26.27,28,30,35,41,42,43, 44,
45,46,47
-- Bearings have short life. 24,26,27,28,35,36,41,42,43,44,45,46,47
-- Pump overheats and seizes. 1,4,21,22,24.27,28,35,36,41
Causes Remedies
1 Pump not primed Ensure that casing is fully filled and water comes out from air-
cock
2 Pump column pipe not completely filled with Check water level and blockages at strainer
liquid
3 Suction lift too high Reduce by lowering pump elevation or increase Water level
4 Insufficient margin between pressure and vapor Check that NPSH available is at least 1 meter more 1 meter
pressure more than NPSH required
5 Excessive amount of air in liquid Check the reasons and eliminate. Gas gets entrapped in liquid.
Air may be entering through suction joints
6 Air pocket in suction line Ensure that air release valve is open
7 Air leaks into suction line Tighten pipe joints with solution
8 Air leaks into pump through stuffing boxes Ensure stuffing box sealing
9 Strainer broken Replace
10 Strainer partially clogged Shut off the pump, strainer usually gets cleaned due reverse flow
11 Inlet of suction pipe insufficiently submerged Ensure adequate submergence level as per pump manufacturers
recommendation
12 Water seal pipe clogged Clean or change
13 Logging ring is improperly located in stuffing Position logging ring centrally under sealing holes of stuffing
box, preventing sealing fluid from entering to box form
seal
14 Speed too low Check motor RPM, supply frequency, Motor nameplate speed
should be as specified on pump nameplate
15 Speed too high Check motor RPM and supply frequency.
16 Direction of rotating wrong Check correct direction of rotation for motor before coupling to
motor
17 Total head of system higher than design head of Check the causes and refer to M&P. Measure with pressure
pump gauge
18 Total head of system lower than pump design Check the causes and refer to M&P. Measure with pressure
head gauge
19 Specific gravity of liquid different from design Refer to Mather and Platt
20 Viscosity of liquid different from design Refer to Mather and Platt
21 Operation at very low capacity Check the causes and refer to M&P, Operate pump at rated
Duty
22 Parallel operation of pumps unsuitable for such Refer to Mather and Platt with characteristics curves of pump
Operation
23 Foreign matter in impeller Open and clean
24 Misalignment Check with Dial gauge should be within limits and without
undue pipe stresses
25 Foundations not rigid Check, vibration on soleplate, check hollowness
26 Shaft bent Dismantle and check, Replace shaft
Installation and operating instructions Wilo Mather and Platt –Sump Pumps 33
Causes Remedies
27 Rotating part rubbing on stationary part Incorrect assembly, correct the assembly
28 Bearing worn Check lubrication, shaft run out, alignment, replace if required
29 Wearing rings worn Replace
30 Impeller damaged Replace
31 Casing gasket defective, permitting internal Replace
leakage
32 Shaft or shaft sleeves worn or scored at packing Replace
33 Packing improperly installed Use correct grade and size of packing
34 Type of packing incorrect for operating Use correct grade and size of packing
condition
35 Shaft running' out of center because of worn Rectify
bearings or misalignment
36 Rotor out of balance, causing vibration Balance the rotor
37 Gland too tight, resulting in no flow of liquid to Adjust gland. Ensure sealing water flow
lubricate packing
38 Cooling liquid not being provided to water- Provide
cooled stuffing boxes
39 Excessive clearance at bottom of stuffing box Check pumps assembly
between shaft and casing, causing packing to be
forced into the pump
40 Dirt or grit in sealing, liquid leading to scoring of Provide clean liquid for flushing
shaft or shaft sleeve
41 Excessive thrust caused by mechanical failure Check pump operation and assembly
inside pump or by failure of hydraulic balancing
device, if any (in case of multistage pump etc.)
42 Excessive grease or oil in antifriction bearing Attend
housing or lack of cooling, causing excessive
bearing temperature
43 Lack of lubrication Provide proper lubrication
44 Improper installation of antifriction bearings Rectify or replace bearing
(damage, incorrect assembly of stacked bearings,
use of unmatched bearings as a pair etc.)
45 Dirt in bearings Investigate the cause and clean bearing.
46 Rusting of bearings from water in housing Arrest water ingress
47 Excessive cooling of water- cooled bearing, Reduce cooling water flow
resulting in condensation of atmospheric moisture
in bearing housing
Wilo-EMU FA... + T20.1...
Installation and operating instructions

Order no.: template
serial no. TMPT20XX
Table of Contents
1 Introduction 1-1
Preface 1-1
Structure of the manual 1-1
Personnel qualification 1-1
Illustrations 1-1
Copyright 1-1
Abbreviations and technical terms 1-1
Manufacturer's address 1-3
Rights of alteration 1-3
2 Safety 2-1
Instructions and safety information 2-1

Guidelines used and CE certification 2-2
General safety 2-2
Electrical work 2-2
Electrical connection 2-3
Ground connection 2-3
Operating procedure 2-3
Safety and control devices 2-3
Operation in an explosive atmosphere 2-4
Sound pressure 2-4
Pumped fluids 2-4
Warranty 2-5
3 Product description 3-1
Proper use and fields of application 3-1

Conditions of use 3-1
Construction 3-1
Type designation 3-4
Cooling 3-4
Name plate 3-5
Technical data 3-5
3-8
4 Transport and storage 4-1
Delivery 4-1
Transport 4-1
Storage 4-1
Returning to the supplier 4-2
E:\shares\Baprod\BA\subtec_m\general\us\content.fm 0-1
5 Installation 5-1
General information 5-1

Installation types 5-1
The operating area 5-1
Assembly accessories 5-1
Installation 5-1
Dry-run protection 5-6
Removal 5-6
5-6
6 Startup 6-1
Preparatory measures 6-1

Electrical system 6-1
Direction of rotation 6-2
Motor protection and activation types 6-2
After starting 6-3
7 Maintenance 7-1
Lubricants 7-2
Maintenance intervals 7-2
Maintenance tasks 7-3
Changing the lubricant 7-4
Sealing chamber 7-4
Repairs 7-6
8 Shutdown 8-1
Temporary shutdown 8-1

Final shutdown / storage 8-1
Restarting after an extended period of storage 8-1
8-2
9 Troubleshooting 9-1
Fault: The machine will not start 9-1

Fault: The motor starts, but the motor protection switch triggers shortly after start-up 9-1
Fault: Machine runs but does not pump 9-2
Fault: The machine runs, but not at the stated operating levels 9-2
Fault: The machine does not run smoothly and is noisy 9-3
Fault: Mechanical shaft seal leaks, sealing chamber monitor reports fault and switches the machine off 9-3
Further steps for troubleshooting 9-4
A List of machine operators and maintenance A-1
List of machine operators A-1
0-2 WILO EMU 3.0

Maintenance and inspection log A-2
B Assembly Sheet For the Anchor Bolts B-1
General product information B-1

Scope of proper use B-1
Transport and storage B-1
Setting the anchor bolts B-1
C Operation with a static frequency converter C-1
Selecting the motor and converter C-1

Minimum speed for submersible pumps
(well pumps) C-1
Minimum speed for waste water and sewage pumps C-1
Operation C-1
Max. voltage peaks and rise speed C-1
EMC C-2
Motor protection C-2
Operation up to 60 Hz C-2
Efficiency C-2
Summary C-2
D Ceram C0 data sheet D-1
General information D-1

Description D-1
Composition D-1
Properties D-1
Technical data D-1
Resistance D-2
Surface preparation D-3
Material preparation D-3
Application instructions D-3
Coating layers and material requirements D-3
Repeat coating intervals / subsequent coating D-3
Hardening time D-3
Material needed D-4
Working steps D-4
Cleaning tools D-4
Storage D-4
Safety precautions D-4
E Assembling the suspension unit E-1
Product description E-1

Proper use E-1
Transport and storage E-1
Maintenance tasks E-1
Assembling the various suspension units E-3
E:\shares\Baprod\BA\subtec_m\general\us\content.fm 0-3
R2 and DN36… to DN250… suspension unit installation E-3
DN300 … to DN600… suspension unit installation E-8
Startup E-10
F Data Sheet - Electrical Connection F-1
Safety notes F-1

Insulation resistance F-1
Monitoring equipment F-1
Wire designation of the connection lead F-2
G EC declaration of conformity G-1
0-4 WILO EMU 3.0

Introduction
1 Introduction
Dear Customer, Preface

Thank you for choosing one of our company’s products. You have purchased a product which has
been manufactured to the latest technical standards. Read this operating and maintenance manual
carefully before you first use it. This is the only way to ensure that the product is safely and eco-
nomically used.
The documentation contains all the necessary specifications for the product, allowing you to use it
properly. In addition, you will also find information on how to recognize potential dangers, reduce
repair costs and downtime, and increase the reliability and working life of the product.
All safety requirements and specific manufacturer’s requirements must be fulfilled before the prod-
uct is put into operation. This operating and maintenance manual supplements any existing
national regulations on industrial safety and accident prevention. This manual must also be acces-
sible to personnel at all times and also be made available where the product is used.
The manual is divided into several chapters. Each chapter has a clear heading which tells you what it Structure of the manual
describes.
The numbered chapters correspond to the standard chapters for a product. They contain all the
detailed information on your product.
Chapters numbered alphabetically are added for specific customers. They contain information
including the selected accessories, special coatings, connection diagrams and the declaration of
conformity.
The table of contents also acts as a brief reference, because all the important sections are given
headers. The header of each section is in the outside column, so that you can find everything, even
when skimming through the manual.
All important operating and safety instructions are highlighted. You can find detailed information
on the structure of these texts in chapter 2, “Safety”.
All personnel who work on or with the product must be qualified for such work; electrical work, for Personnel qualification
example may only be carried out by a qualified electrician. The entire personnel must be of age.
Operating and maintenance staff must also work according to local accident prevention regula-
tions.
It must be ensured that personnel have read and understood the instructions in this operating and
maintenance handbook; if necessary this manual must be ordered from the manufacturer in the
required language.
The illustrations used are of dummies and original drawings of the products. This is the only realis- Illustrations
tic solution for our wide range of products and the differing sizes enabled by the modular system.
More exact drawings and specifications can be found on the dimension sheet, the planning infor-
mation and/or the installation plan.
This operation and maintenance manual has been copyrighted by the manufacturer. The operation Copyright
and maintenance handbook is intended for the use by assembly, operating and maintenance per-
sonnel. It contains technical specifications and diagrams which may not be reproduced or distrib-
uted, either completely or in part, or used for any other purpose without the expressed consent of
the manufacturer.
Various abbreviations and technical terms are used in this operating and maintenance manual. Abbreviations and
Table 1 contains all the abbreviations, and Table 2 all the technical terms.
technical terms
E:\shares\Baprod\BA\subtec_m\general\us\introduction.fm 1-1
Introduction
Abbreviations Explanation
p.t.o. please turn over
re. regarding
approx. approximately
i.e. that means
pos. possible
if nec. if necessary
incl. including
min. minimum
max. maximum
etc. and so on
s.a. see also
e.g. for example
Table 1-1: Abbreviations
Technical term Explanation
The product is running at full speed, however, there is no liquid to be

Dry run pumped. A dry run is to be strictly avoided. If necessary, a safety device
must be installed.
This installation type requires the product to be immersed in the pumped

“wet” installa- fluid. It is completely surrounded by the pumped fluid. Please observe the
tion type values for the maximum submersion depth and the minimum water
coverage.
In this installation type, the product is installed dry, i.e. the pumped fluid
“dry” installa- is delivered to and discharged via a pipeline system. The product is not
tion type immersed in the pumped fluid. Please note that the surfaces of the product
become very hot!
With this installation type the product is equipped with a pedestal. It can
“transport-
be installed and operated at any location. Please observe the values for
able” installa-
the maximum submersion depth and the minimum water coverage,
tion type
and remember that the surfaces of the product become very hot.
“S1” operat- At the rated load, a constant temperature is reached that does not increase
ing mode (con- even in prolonged operation. The operating equipment can operate uninter-
tinuous ruptedly at the rated load without exceeding the maximum permissible tem-
operation) perature.
Table 1-2: Terms
1-2 WILO EMU 3.0

Introduction
Technical term Explanation
The period of service at the rated load is short in comparison to the subse-
“S2” operat- quent pause. The maximum operating period is indicated in minutes, for
ing mode example, S2-15. The operating equipment can operate during this time
(short-term uninterruptedly at the rated load without exceeding the maximum permissi-
operation) ble temperature. The pauses must continue until the machine temperature
no longer exceeds that of the coolant by more than 2K .
Siphoning operation is similar to dry running. The product operates at full

“Siphoning
speed, but only small amounts of liquid are pumped. Siphoning operation is
operation”
only possible with certain types; see the “Product description” chapter.
The dry-run protection is designed to automatically shut down the product

Dry-run pro-
if the water level falls below the minimum water coverage value of the
tection
product. This is made possible by installing a float switch.
The level control is designed to switch the product on or off depending on

Level control
the filling level. This is made possible by installing a float switch.
Table 1-2: Terms
WILO EMU GmbH Manufacturer's address

Heimgartenstr. 1
DE - 95030 Hof
Tel.: +49 9281 974-0
Fax: +49 9281 96528
Internet: www.wiloemu.com
E - mail: info@wiloemu.de
The manufacturer reserves the right to make technical alterations to systems or components. This Rights of alteration
operating and maintenance manual refers to the product indicated on the title page.
E:\shares\Baprod\BA\subtec_m\general\us\introduction.fm 1-3
Safety
2 Safety
This chapter lists all the generally applicable safety instructions and technical information. Further-
more, every other chapter contains specific safety instructions and technical information. All
instructions and information must be observed and followed during the various phases of the prod-
uct's lifecycle (installation, operation, maintenance, transport etc.). The operator is responsible for
ensuring that personnel follow these instructions and guidelines.
This manual uses instructions and safety information for preventing injury and damage to property. Instructions and safety
To make this clear for the personnel, the instructions and safety information are distinguished as
information
follows:
Instructions are indented by 10 mm and printed in 10pt bold script. Instructions contain text refer- Instructions
ring to previous text or particular sections of chapters, or highlight brief instructions. Example:
For machines approved for work in explosion zones, please refer to the
“Explosion protection in accordance with the .... regulation” chapter.
Safety information is indented by 5 mm and printed in 12pt bold script. Information only referring Safety information
to damage to property is printed in gray.
Information referring to personal injury is printed in black and always accompanied by a danger
symbol. Danger, prohibition or instruction symbols are used as safety symbols. Example:
Instruction
Danger sym- Danger sym- Prohibition
symbol, e.g.
bol: general bol, e.g. elec- symbol, e.g.
wear protec-
hazard trical current keep out
tive clothing
The safety symbols conform to the generally valid guidelines and regulations, for example DIN and
ANSI.
Each safety instruction begins with one of the following signal words:
Signal word Meaning
Danger Serious or fatal injuries can occur.
Warning Serious injuries can occur.
Caution Injuries can occur.
Caution
(Instruction
Serious damage to property can occur, including irreparable damage.
without
symbol)
Table 2-1: Signal words and what they mean
Safety instructions begin with a signal word and description of the hazard, followed by the hazard
source and potential consequences, and end with information on preventing it.
Example:
Beware of rotating parts!
The moving rotor can crush and sever limbs. Switch off the
machine and let the rotor come to a rest.
E:\shares\Baprod\BA\subtec_m\general\us\security.fm 2-1
Safety
Guidelines used and CE Our products are subject to

certification - various EC directives
- various harmonized standards
- various national standards.
Please consult the EU Declaration of Conformity for the precise information and the guidelines and
norms in effect. The EU Declaration of Conformity is issued in accordance with EU Directive 98/37/
EC, Appendix II A.
Also, various national standards are also used as a basis for using, assembling and dismantling the
product. These include the German accident prevention regulations, VDE regulations, German
Equipment Safety Law etc.
The CE symbol is found either on the type plate or next to the type plate. The type plate is attached
to the motor casing or to the frame.
General safety - Never work alone when installing or removing the product.
- The machine must always be switched off before any work is performed on it (assembly, dis-
mantling, maintenance, installation). The product must be disconnected from the electrical
system and secured against being switched on again. All rotating parts must be at a standstill.
- The operator should inform his/her superior immediately should any defects or irregularities
occur.
- It is of vital importance that the system is shut down immediately by the operator if any
problems arise which may endanger safety of personnel. Problems of this kind include:
- Failure of the safety and/or control devices
- Damage to critical parts
- Damage to electric installations, cables and insulation
- Tools and other objects should be kept in a place reserved for them so that they can be found
quickly.
- Sufficient ventilation must be provided in enclosed rooms.
- When welding or working with electronic devices, ensure that there is no danger of explosion.
- Only use fastening devices which are legally defined as such and officially approved.
- The fastening devices should be suitable for the conditions of use (weather, hooking system,
load, etc). If these are separated from the machine after use, they should be expressly marked
as fastening devices. Otherwise they should be carefully stored.
- Mobile working apparatus for lifting loads should be used in a manner that ensures the stabil-
ity of the working apparatus during operation.
- When using mobile working apparatus for lifting non-guided loads, measures should be taken
to avoid tipping and sliding etc.
- Measures should be taken that no person is ever directly beneath a suspended load. Further-
more, it is also prohibited to move suspended loads over workplaces where people are
present.
- If mobile working equipment is used for lifting loads, a second person should be present to
coordinate the procedure if needed (for example if the operator's field of vision is blocked).
- The load to be lifted must be transported in such a manner that nobody can be injured in the
case of a power cut. Additionally, when working outdoors, such procedures must be inter-
rupted immediately if weather conditions worsen.
These instructions must be strictly observed. Non-observance can result
in injury or serious damage to property.
Electrical work Our electrical products are operated with alternating or industrial high-voltage current. The local
regulations (e.g. VDE 0100) must be adhered to. The “Electrical connection” data sheet must be
observed when connecting the product. The technical specifications must be strictly adhered to.
If the machine has been switched off by a protective device, it must not
be switched on again until the error has been corrected.
2-2 WILO EMU 3.0

Safety
Beware of electrical current

Incorrectly performed electrical work can result in fatal injury!
This work may only be carried out by a qualified electrician.
Beware of damp
Moisture penetrating cables can damage them and render them
useless. Never immerse cable ends in the pumped fluid or other
liquids. Any unused wires must be disconnected.
The operator is required to know where the machine is supplied with current and how to cut off the Electrical connection
supply.
When the machine is connected to the electrical control panel, especially when electronic devices
such as soft startup control or frequency drives are used, the relay manufacturer's specifications
must be followed in order to conform to EMC. Special separate shielding measures e.g. special
cables may be necessary for the power supply and control cables.
The connections may only be made if the relays meet the harmonized EU
standards. Mobile radio equipment may cause malfunctions.
Beware of electromagnetic radiation

Electromagnetic radiation can pose a fatal risk for people with
pacemakers. Put up appropriate signs and make sure anyone
affected is aware of the danger.
Our products (machine including protective devices and operating position, auxiliary hoisting gear) Ground connection
must always be grounded. If there is a possibility that people can come into contact with the
machine and the pumped liquid (e.g. at construction sites), the grounded connection must be addi-
tionally equipped with a fault current protection device.
The electrical products conform to motor protection class IP 68 in accor-
dance with the valid norms.
When operating the product, always follow the locally applicable laws and regulations for work Operating procedure
safety, accident prevention and handling electrical machinery. To help to ensure safe working prac-
tice, the responsibilities of employees should be clearly set out by the owner. All personnel are
responsible for ensuring that regulations are observed.
Certain parts such as the rotor and propeller rotate during operation in order to pump the fluid. Cer-
tain materials can cause very sharp edges on these parts.
Beware of rotating parts
The moving parts can crush and sever limbs. Never reach into the
pump unit or the moving parts during operation. Switch off the
machine and let the moving parts come to a rest before mainte-
nance or repair work.
Our products are equipped with various safety and control devices. These include, for example suc- Safety and control
tion strainers, thermo sensors, sealed room monitor etc. These devices must never be dismantled
devices
or disabled.
Equipment such as thermo sensors, float switches, etc. must be checked by an electrician for
proper functioning before start-up (see the “Electrical Connection” data sheet). Please remember
Safety
that certain equipment requires a relay to function properly, e.g. posistor and PT100 sensor. This
relay can be obtained from the manufacturer or a specialist electronics dealer.
Staff must be informed of the installations used and how they work.
Caution
Never operate the machine if the safety and monitoring devices
have been removed or damage, or if they do not work.
Operation in an explo- Products marked as explosion-proof are suitable for operation in an explosive atmosphere. The
products must meet certain guidelines for this type of use. Certain rules of conduct and guidelines
sive atmosphere
must be adhered to by the operator as well.
Products that have been approved for operation in an explosive atmo-
sphere are labeled as explosion-protected “Ex” (e.g. T…Ex…). In addition,
an “Ex” symbol must be included on the type plate! When used in an
explosive atmosphere, the chapter entitled “Explosion protection
according to the …standard” must be observed!
Sound pressure Depending on the size and capacity (kW), the products produce a sound pressure of approximately
70 dB (A) and 110 dB (A).
The actual sound pressure, however, depends on several factors. These include, for example, the
installation type (wet, dry, transportable), fastening of accessories (e.g. suspension unit) and pipe-
line, operating site, immersion depth, etc.
Once the product has been installed, we recommend that the operator make additional measure-
ments under all operating conditions.
Caution: Wear ear protectors
In accordance with the laws in effect, guidelines, standards and
regulations, ear protection must be worn if the sound pressure is
greater than 85 dB (A)! The operator is responsible for ensuring
that this is observed!
Pumped fluids Each pumped fluid differs in regard to composition, corrosiveness, abrasiveness, TS content and
many other aspects. Generally, our products can be used for many applications. For more precise
details, see chapter 3, the machine data sheet and the order confirmation. It should be remem-
bered that if the density, viscosity or the general composition change, this can also alter many
parameters of the product.
Different materials and impeller shapes are required for different pumped fluids. The more exact
your specifications on your order, the more exactly we can modify our product to meet your
requirements. If the area of application and/or the pumped fluid change, please inform us of this so
that we can adapt the product to the new circumstances.
When switching the product into another pumped fluid, observe the following points:
- Products which have been operated in sewage or waste water must be thoroughly cleaned
with pure water or drinking water before use.
- Products which have pumped fluids which are hazardous to health must always be decontam-
inated before changing to a new fluid. Also clarify whether the product may be used in a dif-
ferent pumped fluid.
- With products which have been operated with a lubricant or cooling fluid (such as oil), this can
escape into the pumped fluid if the mechanical shaft seal is defective.
Danger - explosive fluids

It is absolutely prohibited to pump explosive liquids (e.g. gasoline,
kerosene, etc.). The products are not designed for these liquids!
2-4 WILO EMU 3.0

Safety
This chapter contains the general information on the warranty. Contractual agreements have the Warranty
highest priority and are not superseded by the information in this chapter!
The manufacturer is obliged to correct any defects found in the products it sells, provided that the
following requirements have been fulfilled:
- The defects are caused by the materials used or the way the product was manufactured or General information
designed.
- The defects were reported in writing to the manufacter within the agreed warranty period.
- The product was used only as prescribed.
- All safety and control devices were connected and inspected by authorized personnel.
If no other provisions have been made, the warranty period applies to the first 12 months after ini- Warranty period
tial start-up or to a max. of 18 months after the delivery date. Other agreements must be made in
writing in the order confirmation. They will remain valid at least until the agreed warranty period of
the product has expired.
Only original spare parts as supplied by the manufacturer may be used for repairs, replacements, Spare parts, add-ons and
add-ons and conversions. Only these parts guarantee a long working life and the highest level of conversions
safety. These parts have been specially designed for our products. Self-made add-ons and conver-
sions or the use of non-original spare parts can seriously damage the product and/or injure person-
nel.
The prescribed maintenance and inspection work should be carried out regularly. This work may Maintenance
only be carried out by qualified, trained and authorized personnel. The maintenance and inspec-
tion log supplied must be properly updated. This enables you to monitor the status of inspections
and maintenance work. Quick repairs not listed in this operation and maintenance manual and all
types of repair work may only be performed by the manufacturer and its authorized service centers.
The machine operator list must be filled out completely. By signing this list, all persons working on List of machine operators
or with the product confirms that they have received, read and understood this operating and
maintenance manual.
Damage as well as malfunctions that endanger safety must be eliminated immediately by autho- Damage to the product
rized personnel. The product should only be operated if it is in proper working order. During the
agreed warranty period, the product may only be repaired by the manufacturer or an authorized
service workshop! The manufacturer reserves the right to recall the damaged product to the fac-
tory for inspection!
No liability will be assumed for product damage if one or more of the following points applies: Exclusion from liability
- Incorrect design on our part due to faulty and/or incorrect information provided by the opera-
tor or customer
- Non-compliance with the safety instructions, the regulations and the requirements set forth
by German law and this operating and maintenance manual
- Incorrect storage and transport
- Improper assembly/dismantling
- Improper maintenance
- Unqualified repairs
- Faulty construction site and/or construction work
- Chemical, electrochemical and electrical influences
- Wear
This means the manufacturer’s liability excludes all liability for personal, material or financial injury.
Product description
3 Product description
The machine is manufactured with great care and is subject to constant quality controls. Trouble-
free operation is guaranteed if it is installed and maintained correctly.
Submersible motor pumps are used in pumping stations and sewage treatment plants and many Proper use and fields of
other installations to dispose of communal and industrial waste water. The dirty waste water may
application
also contain solid particles depending on the model of the machine.
Mostly, T motors are installed wet. Few motor types are suitable for a dry or a portable installation.
Use in siphoning mode is not permitted. According to the type of instal-
lation, the machine must be submerged in pumped liquid at least up to
the top edge of the pump or motor housing.
The machine can be used to pump slightly to very dirty water. In the standard version, the Conditions of use
pumped liquid has a permitted maximum density of 1050kg/m3 and a maximum viscosity of
approx. 1x10-6 m2/s. Additionally, special models are also available for use with abrasive and corro-
sive liquids. For information on these models, please consult the manufacturer. The exact details
about your machine version can be found in the technical data.
The machine is operated from the operating position intended for this purpose or by using the relay
supplied.
Depending on the model, the machine can be operated in different
installation types. Please also note the appropriate information on oper-
ating mode and minimum water coverage.
Please also note that this machine is not self-suctioning, which means
that the impeller must always be surrounded by fluid in order to pump.
The machine consists of the motor and the pump housing as well as the impeller which belongs to Construction
it. These are assembled in a modular design. This results in different views of the complete unit.
BA T TA
Fig. 3-1: View of the different units
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Product description
Motor The shaft and screw connections are made of stainless steel. The three-phase asynchronous motor
consists of a stator in the “F” or “H” insulation class as well as the motor shaft with rotor package.
The power supply cable is designed for the maximum mechanical load and is sealed against water
pressure from the pumped liquid. The motor cable lead connections are sealed from the pumped
liquid as well. The bearings used are permanently lubricated maintenance-free antifriction bearings.
Pump The pump housing is manufactured from different materials and, depending on the model, is sup-
plied with different connections. This means that the machine can be connected with the respec-
tive pipeline system. Some pump housings are supplied with a cleaning hole lid. This allows
blockages to be eliminated. Depending on the pump unit used, it can be equipped with a stationary
wear ring. The stationary wear ring is found in the intake port or directly in the pump housing. The
stationary and mobile wear ring determine the gap between the impeller and the intake port. If this
gap is too big, the performance of the machine decreases, and/or it can lead to blockages. For this
reason, the rings can be changed. As a result, wear and expenses for spare parts are minimized.
For machines with a screw impeller, the gap between the impeller and the intake port is set with
spacers.
Sealing Depending on the model, there are two types of sealing between the pump and the motor:
- Two separate mechanical shaft seals in a “face-to-face” arrangement
- Two mechanical shaft seals in a block seal cartridge made from stainless steel.
The sliding and counter-rings of the mechanical shaft seals used are made from SiC-SiC or
SiC carbon ceramic.
Bearing casing The bearing housing is located between the motor and pump housing and is made of gray cast iron
or cast stainless steel. The housing is equipped with a sealing chamber. The sealing chamber is filled
with medicinal white oil, this means a long-lasting lubrication of the sealing is guaranteed.
There is also a leak chamber. The leak chamber is normally empty and takes in the fluid which is
transferred inwards by the seal.
Impellers The impeller is fastened directly to the motor shaft and driven by it. The materials used are differ-
ent types of cast iron. If special protection against wear is required, suitable impellers can be made
of “Abrasit” hard-cast or coated with ceramic liquid. Different impellers can be used according to
application, e.g. channel, screw or vortex impeller. Closed impellers are generally equipped with a
mobile wear ring.
Safety and monitoring devices The motor is equipped with temperature sensors. These are to protect the motor from overheating.
The leak chamber is fitted with a float switch. This switches the machine off when the water
reaches a high level in the leak chamber. In addition, the machine is equipped with an electrode for
motor chamber and terminal chamber monitoring and can additionally be equipped with a sealed
chamber electrode. Depending on the connection, a warning signal can be displayed and/or the
machine switched off if water enters the motor chamber, terminal chamber or the sealing housing.
Details of the safety and monitoring devices used and how to connect
these can be found in the “Electrical connection plan” data sheet.
3-2 WILO EMU 3.0

Product description
Machine structure
Handle
Motor housing
Power supply line
Bearing casing
Discharge port
Pump housing
Fig. 3-2: Machine structure
Product description
Type designation The type code provides information about the design of the machine.
Example pump: FA 08.xx RFE
FA Submersible waste water pump
08 Discharge side connection (x10 = e.g. DN80)
xx Hydraulic performance rate
RF Material specifications (RF = stainless steel)
E Impeller models
Impeller models
E Single-blade impeller
D Three-blade impeller
M Cutting unit
S Screw impeller
V Four-blade impeller
W Impeller
Z Two-blade impeller
WR Impeller with mixer head
Example motor: T 17-6/12HEx
x Motor type (FK, FO, FKT, HC, T)
17 Package diameter
6 Number of poles
12 Package length in cm (rounded)
H Mechanical model
Ex Explosion certification
Mechanical models
H Rotary shaft seal/mechanical shaft seal
G 2 separate mechanical shaft seals
K Block seal cartridge
R Mixer model
P Motor for propeller-driven immersion pump KPR
Table 3-1: Type designation
Cooling The T motor is a dry runner. This means that the motor chamber is filled with air. The heat escapes
through the housing parts. Heat is transferred through them to the pumped fluid and/or the ambi-
ent air. Note the following information:
3-4 WILO EMU 3.0

Product description
- For wet and portable installation, the machines must be submerged up to the top edge of
the motor housing. The motor housing can be changed with some motor types. In this
case: The machines must be submerged up to the top edge of the pump housing and they
can only be used in short-term operation (S2-...).
- A few motor types can also be installed dry. These machines can usually only be used in
short term operation (S2-...).
Name plate
Symbol Name Symbol Name
P-Type Pump type MFY Year of manufacture
M-Type Motor type P Rated power
S/N Machine number F Frequency
Q Pump flow U Rated voltage
H Pump head I Rated current
N Speed IST Starting current
TPF Temperature of pumped fluid SF Service factor
IP Protection class ISF Current at service factor
OT Operating mode (s = wet / e = dry) MC Motor wiring
Cos M Cosine phi Max. submersion
IMø / S Impeller diameter/number of levels
Table 3-2: Name plate key
Technical data
Unit
Year of manufacture: 2008
Order no.:: template
Machine number: TMPT20XX
Product description: Wilo-EMU
Pump type: FA...
Version: A
Model: 0
Impeller diameter: - / corrected: -
Downstream device: -
Motor type: T20.1...
Version: A
Tabelle 3-3:
Product description
Model: 0
Discharge port: -
Suction port: -
Tabelle 3-3:
Operating point*
Q water flow: -
Hman head: -
Speed: -
Voltage: -
Frequency: 50 Hz
Tabelle 3-4:
Motor data*
Starting current: -
Rated current: -
Rated power: -
Activation type: direct
Cos phi: -
Max. starts per hour: 15 /h
Min. switching break: 3 min
Service factor: 1.00
Operating mode:
Wet installation: S1
Dry installation: -
Explosion coding: -
Explosion number: -
Tabelle 3-5:
Filling quantity/lubricant
Motor chamber: --- ---
Sealing room: - Esso Marcol 82 (White oil)
Cooling system: --- ---
Table 3-6:
3-6 WILO EMU 3.0

Product description
Coatings
Pump: -
Rotor: -
Tabelle 3-7:
Power supply connection

Connector: -
Relay: -
Power cable length: 10.00 m
Power cable 1
Number: 1
Type: -
Size: -
Power cable 2
Number: 0
Type: -
Size: -
Power cable 3
Number: 0
Type: -
Size: -
Trip line
Number: 0
Type: -
Size: -
Sealing chamber monitor
Number: 0
Type: -
Size: -
Tabelle 3-8:
General information
Type of erection: wet
Installation type: vertical
Tabelle 3-9:
Product description
Max. submersion: 12.5 m
Min. water coverage: 0.10 m
Max. pump fluid tempera-

40 °C
ture:
Dimensions: see dimension sheet/catalogue
Weight: see dimension sheet/catalogue
Sound pressure: system-dependent
Tabelle 3-9:
*Valid for standard conditions (pumped fluid: pure water. Density: 1kg/dm3,
Viscosity: 1*10-6 m²/s, temperature: 20°C, pressure: 1.013bar)
3-8 WILO EMU 3.0

Transport and storage
4 Transport and storage
On arrival, the delivered items must be inspected for damage and a check made that all parts are Delivery
present. If any parts are damaged or missing, the transport company or the manufacturer must be
informed on the day of delivery. Any claim made at a later date will be deemed invalid. Damage to
parts must be noted on the delivery or freight documentation.
Only the appropriate and approved fastening devices, transportation means and lifting equipment Transport
may be used. These must have sufficient load bearing capacity to ensure that the product can be
transported safety. If chains are used they must be secured against slipping.
The staff must be qualified for the tasks and must follow all applicable national safety regulations
during the work.
The product is delivered by the manufacturer/shipping agency in suitable packaging. This normally
precludes the possibility of damage occurring during transport and storage. The packaging should
be stored in a safe place if the location used is changed frequently.
Beware of frost
If drinking water is used as a coolant/lubricant, the product must
be protected against frost during transport. If this is not possible,
the product must be drained and dried out.
Newly supplied products are prepared that they can be stored for at least 1 year. The product Storage
should be cleaned thoroughly before interim storage.
The following should be taken into consideration for storage:
- Place the product on a firm surface and secure it against falling over. Submersible mixers,
auxiliary lifting devices and pressure shroud pumps should be stored horizontally and waste
water and sewage pumps, submersible sewage pumps and submersible motor pumps should
be stored vertically. Submersible motor pumps can also be stored horizontally. It should be
ensured that they cannot bend if stored horizontally. Otherwise excessive bending tension
may arise.
Danger from falling over

Never put down the product unsecured. If the product falls over,
injury can occur.
- Our products can be stored at temperatures down to -15 °C. The store room must be dry.
We recommend a frost-protected room with a temperature of between 5 °C and 25 °C for
storage.
Products that are filled with drinking water can only be stored in frost-
free rooms for up to 4 weeks. If longer storage is intended they should
be emptied and dried out beforehand.
- The product may not be stored in rooms where welding work is conducted as the resulting
gases and radiation can damage the elastomer parts and coatings.
- Any suction or pressure connections on products should be closed tightly before storage to
prevent impurities.
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Transport and storage
- The power supply cables should be protected against kinking, damage and moisture.
Beware of electrical current

Damaged power supply cables can cause fatal injury! Defective
cables must be replaced by a qualified electrician immediately.
Beware of damp
Moisture penetrating cables can damage them and render them
useless. Therefore, never immerse cable ends in the pumped fluid
or other liquids.
- The machine must be protected from direct sunlight, heat, dust, and frost. Heat and frost can
cause considerable damage to propellers, rotors and coatings.
- The rotors or propellers must be turned at regular intervals. This prevents the bearing from
locking and the film of lubricant on the mechanical shaft seal is renewed. This also prevents
the gear pinions (if present on the product) from becoming fixed as they turn and also renews
the lubricating film on the gear pinions (preventing rust film deposits).
Beware of sharp edges

Sharp edges can form on rotors and propellers. There is a risk of
injuries. Wear protective gloves.
- If the product has been stored for a long period of time it should be cleaned of impurities such
as dust and oil deposits before start-up. Rotors and propellers should be checked for smooth
running, housing coating and damage.
Before start-up, the filling levels (oil, motor filling etc.) of the individual
products should be checked and topped up if required. Products filled
with drinking water should be completely filled before start-up. Please
refer to the machine data sheet for specifications on filling.
Damaged coatings should be repaired immediately. Only a coating that is

completely intact fulfills the criteria for intended usage.
If these rules are observed, your product can be stored for a longer period. Please remember that
elastomer parts and coatings become brittle naturally. If the product is to be stored for longer than
6 months, we recommend checking these parts and replacing them as necessary. Please consult the
manufacturer.
Returning to the supplier Products which are delivered to the plant must be clean and correctly packaged. In this context,
clean means that impurities have been removed and decontaminated if it has been used with mate-
rials which are hazardous to health. The packaging must protect the product against damage. If you
should have any questions please contact the manufacturer.
4-2 WILO EMU 3.0

Installation
5 Installation
In order to prevent damage to the machine or serious injury during installation the following points
must be observed:
- Installation work – assembly and installation of the machine – may only be carried out by
qualified persons. The safety instructions must be followed at all times.
- The machine must be inspected for transport damage before any installation work is carried
out .
After pumping water containing lime, clay or cement, flush out the machine with clean water in General information
order to prevent encrustation and to prevent later break-downs.
If you are using level control, make sure that the minimum water coverage is present. Air pockets
may not be allowed to enter the pump housing or the pipeline system, and they must be removed
with a suitable ventilation system and/or a small inclination of the machine (with a portable instal-
lation). Protect the machine from frost.
Possible types of vertical installation for the machine: Installation types

- Wet installation with a suspension unit (BA)
- Dry installation (TA)
- Portable installation with a pump pedestal (T)
The operating area must be laid out for each machine. You must ensure that lifting gear can be fit- The operating area
ted without any trouble, since this is required for assembly and removal of the machine. It must be
possible to safely reach the machine in its operating and storage locations using the hoisting gear.
The machine must be located on a firm foundation.
Electric power cables must be laid out in such a way that safe operation and non-problematic
assembly/dismantling are possible at all times.
The structural components and foundations must be of sufficient stability to ensure safe and func-
tional operation. The operator or the supplier is responsible for the provision of the foundations and
their accuracy in terms of dimensions, stability and strength.
Never let the machine run dry. Therefore, we recommend installing a level control unit or a dry-run
protection system where there are great variations in the level.
Use guide and defector plates for the pumped fluid intake. If the water jet reaches the surface of
the water or the machine, air will be introduced into the pumped liquid. This will lead to unfavor-
able current and pumping conditions. As a result, the machine does not run smoothly and is sub-
jected to higher wear and tear.
Assembly accessories
The maximum bearing capacity must be greater than the weight of the machine, add-on units and Swiveling hoisting gear
cable. It is essential that the machine can be lifted and lowered without hindrance or endangering
personnel. There should be no objects or obstacles in the swiveling range of the hoisting gear.
The electric power cables should be fastened properly to the pipeline with cable holders or other Cable holders
suitable equipment. This should prevent loose hanging and damage to the electric power cables.
Depending on the cable length and weight, a cable holder should be fitted every two to three
meters.
Make sure you have the required tools (such as wrenches) and other material (such as plugs and Fixing materials and tools
anchor bolts). The fastening materials should be sufficiently stable to ensure safe assembly.
The following information should be taken into consideration when installing the machine: Installation
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Installation
- This work may only be carried out by qualified personnel. Electrical work may only be carried
out by qualified electricians.
- Lift the machine by the handle or lifting eyelets, never by the the power supply cable. When
assembling with chains, they must be connected with a shackle to the lifting eyelets or the
carrying handle. Fastening devices must have official approval.
- Please observe all guidelines, rules and legal requirements for working with and underneath
heavy suspended loads.
- Wear the appropriate protective clothing/equipment.
- If there is danger that poisonous or asphyxiating gases may collect, then the necessary
counter-measures should be taken.
- Please also observe all accident prevention guidelines, trade association safety guidelines and
the advice contained in this operating and maintenance manual.
- The coating of the machine is to be examined before installation. If defects are found, these
must be eliminated.
An intact coating is necessary for the best possible protection from
corrosion.
Danger of falling!
Installation work for the machine and its accessories is performed
directly on the edge of the basin. Carelessness or wearing inap-
propriate clothing could result in a fall. There is a risk of fatal
injury! Take all necessary safety precautions to prevent this.
If the motor housing should be taken out of the pumped fluid during
operation, the operating mode for emerged operation should be fol-
lowed. If you do not know this operating mode, the pump may not be
used with an emerged motor housing.
5-2 WILO EMU 3.0

Installation
A suspension unit must be installed for wet installation. This must be ordered separately from the Wet installation with a
manufacturer. The pipeline system on the discharge side is connected to this. The connected pipe- suspension unit
line must be self-supporting, i.e. it should not be supported by the suspension unit. The operating
area must be laid out so that the suspension unit can be installed and operated without difficulty.
For maintenance and/or repair work, the machine must be taken out of the operating area. The
suspension unit makes this possible at any time.
The machine must be completely submerged in pumped liquid up to the
top edge of the motor housing.
- Install the suspension unit in the operating area (Only use a suspension unit produced by the
manufacturer. Information about installation is located in the appendix of this operating
manual.).
- Prepare the machine for operation on a suspension unit.
- Check that the suspension unit is firmly fixed and functions properly.
- Have an expert connect the machine to the power supply and check the direction of rotation
in accordance with chapter 6.
- Lower the machine slowly onto the guide pipes in the operating area. Hold the electric power
cables slightly taut when lowering. When the machine is connected to the suspension unit,
make sure that the electric power cables are secured adequately against falling and/or
damage.
- For new installation: Flood the operating area and bleed the discharge pipe.
- Start the machine in accordance with chapter 6.
Deflector plate
Operating area
Intake
Pipeline
Minimum level
Machine Suspension unit
Fig. 5-1: Example of wet installation
Installation
Dry installation There is a divided operating area when the machine is installed in this manner. The pumped liquid is
collected in the collector tank, and the machine is fitted in the machine room. The operating area
should be prepared according to the design or the manufacturer's planning guide. The machine is
assembled in the machine room at the place listed and connected with the discharge and pressure
side of the pipe system. The machine itself is not immersed in the pumped liquid.
The pressure and discharge side pipeline must be self-supporting, i.e. it may not be supported by
the machine. In addition, the machine must be connected to this without vibration or tension. Elas-
tic connectors (compensators) must be used. The machine does not need to be taken out of the
operating area for maintenance or repair work. It is possible, however, that the pipe system will
need to be dismantled.
The machine is not self-suctioning which means that the pump housing
must be filled completely with the pumped liquid. The min. liquid level in
the collector tank must be the same height as the top edge of the pump
housing.
With this installation type, the sliders on the intake and discharge side must be closed before the
machine can be disconnected from the piping system. The power supply cables must be laid out
safely, so that they are not damaged and do not present a danger to anyone.
Beware of burns
The housing parts can heat up to well above 40°C. There is a
danger of burns. After switching it off, let the machine cool down
to ambient temperature.
Machine room
Collector tank
Slider
Discharge
side
pipeline
Minimum level Intake side pipeline Machine
Fig. 5-2: Dry installation example
5-4 WILO EMU 3.0

Installation
The machine is fitted with a pump pedestal for this type of installation. It is fitted to the intake port Portable installation
and ensures that the machine is in a secure position on a firm base. This installation type makes
optional positioning in the operating area possible. For use on a soft foundation, a hard base must
be used to prevent the machine from subsiding. A hose is connected to the discharge side.
With this type of installation, the machine must be fixed to the floor for longer operating times.
This prevents vibrations as well as guaranteeing quiet and low-wearing running.
The machine must be completely submerged in pumped liquid up to the
top edge of the motor housing.
- Place the machine upright.

- Attach the hose to the discharge port.
- Lay out the power supply cable.
- Have an expert connect the machine to the power supply and check the direction of rotation
in accordance with chapter 6.
- Fasten a chain or rope to the handle if necessary.
- Lift the machine and place it at the intended operating position (pit, shaft).
- Check that it is upright and standing on a firm base. Do not let it subside.
- Pull the power supply cable taut and lay it so that it cannot be damaged.
- Lay the hose so that it cannot be damaged. Fasten the hose wherever necessary (i.e. at a
drain).
- Start the machine in accordance with chapter 6.
Beware of burns
The housing parts can heat up to well above 40°C. There is a dan-
ger of burns. After switching it off, let the machine cool down to
ambient temperature.
Pit
Hose
Minimum level
Machine
Fig. 5-3: Portable installation example
Installation
Dry-run protection The machine must always be submerged up to the top edge of the pump housing. Make sure that
no air enters the pump housing.
For optimum reliability, we recommend installing a dry-run protection system. Correct running is
ensured by float switches or electrodes. The float switch / electrode is fastened in the pit and
switches off the machine when the water level falls below the minimum coverage level.
For dry installations, the float switch must be fitted at an appropriate height in the collector tank.
Please observe the information about the minimum water coverage.
If dry-run protection is only put into effect with one float or electrode
when filling levels deviate strongly, then the machine may turn on and
off constantly!
This can result in the maximum number of motor start-ups being
exceeded.
Corrective measures
Manual reset The motor is switched off when the water level falls below the minimum coverage level and
switched back on when a sufficient water level is reached.
Separate reactivation point Using a second switching point (additional float or electrode), a sufficient difference is obtained
between the activation and deactivation points. This prevents constant switching. This function
can be put into effect with a level control relay.
Removal When removing the machine, make sure that it is first disconnected from the mains.
For dry installations, the piping system must be drained or shut off. Afterwards, the machine can
be disconnected from the pipeline and lifted out of the operating area with a hoisting gear.
On portable installations, the machine can be lifted out of the pit after it has been disconnected
from the mains and the discharge pipe has been emptied. You may have to disconnect the hose
first. Here too, you should use appropriate lifting gear if the pit is deep, or the machines are heavy.
On wet installations with suspension units, the machine is raised out of the pit using the chain or
lifting cable with the help of a hoisting gear. This does not have to be emptied especially for this
purpose. Make sure the power supply cable does not become damaged.
Beware of poisonous substances!
Machines which pump fluids hazardous to health present a fatal
risk. These machines must be decontaminated before any other
work is carried out. Wear the necessary protective clothing/
equipment when doing so.
5-6 WILO EMU 3.0

Startup
6 Startup
The "Startup" chapter contains all the important instructions for the operating personnel for start-
ing up and operating the machine safely.
The following specifications must be adhered to and checked:
- Type of installation
- Operating mode
- Minimum water coverage / max. submersion
If the machine has not been operated for some time, check these speci-
fications again and rectify any faults you find.
The operation and maintenance handbook must always be kept either by

the machine or in a place specially reserved for it where it is accessible
for operating personnel at all times.
In order to prevent damage or serious injury during startup of the machine, the following points
must be observed:
The machine may only be started up by qualified personnel. The safety
advice must be followed at all times.
- Every person working on the machine must have received, read and understood this operat-
ing and maintenance manual. This must also be confirmed with a signature in the machine
operator list.
- Activate all safety devices and emergency stop elements before startup.
- Electrical and mechanical settings may only be made by specialists.
- This machine may only be used under the working conditions specified in this handbook.
The machine has been designed and constructed using the very latest technology. Under normal Preparatory measures
working conditions it will operate reliably and for long periods. The one condition for this is that all
instructions and advice are observed.
Minor oil leakage in the mechanical shaft seal on delivery is no cause for concern. However, it must
be removed prior to submersion in the pumped liquid.
Please check the following:
- Cable guidance – no loops, slightly taut
- Check the temperature and submersion depth of the pumped liquid – see machine data sheet
- If a hose is used on the discharge side, it should be flushed out with clean water before use to
prevent any sediment causing blockages
- The pump sump must be cleaned for wet installation
- Clean the discharge and intake side pipe system and open all sliders
- The pump housing must be flooded, i.e. it should be completely full of fluid, with no air in it at
all. Bleeding can take place using a suitable bleeding device in the system, or, if available, with
bleeder screws on the discharge port.
- Check that all accessories, the pipe system and suspension unit are properly fitted
- Check all level control and dry-run protection systems
An insulation test and filling level check must be carried out prior to
start-up, as described in chapter 7.
Observe the relevant local and national regulations when laying out and selecting the electric lines Electrical system
as well as when connecting the motor. The motor must be protected by a motor protection switch.
Have the motor connected in accordance with the "Electrical connection" data sheet. Pay attention
to the direction of rotation. If the direction of rotation is incorrect, the machine will not perform as
specified, and under certain circumstances, can become damaged. In accordance with the machine
E:\shares\Baprod\BA\subtec_m\sewage\us\startup.fm 6-1
Startup
data sheet, check the operating voltage and make certain that the current consumption remains
uniform during all phases.
Make sure that all temperature sensors and monitoring devices, such as the sealing chamber moni-
tor, are connected and that their function is tested. For details on this, see the "Electrical connec-
tion plan" data sheet.
Beware of electrical current!

Electrical current can cause fatal injuries if not handled correctly!
All machines with free cable ends (i.e. without plugs) must be
connected by a qualified electrician.
Direction of rotation The machine must be connected in accordance with the data sheet “Electrical connection plan”.
Rotation direction is controlled by a rotating field tester. This tester is switched on when the pump
is connected and displays the rotation direction of the rotating field. There must be a clockwise
rotating field for the machine to run correctly.
If a counter-clockwise rotating field is displayed, two phases must be swapped.
The pump and performance data specified can only be achieved when
there is a clockwise rotating field. The machine is not designed for oper-
ation with a counter-clockwise rotating field.
Motor protection and

activation types
Motor protection The minimum requirement is a thermal relay / motor protection switch with temperature compen-
sation, differential triggering and an anti-reactivation device in accordance with VDE 0660 or the
appropriate national regulations. If the machines are connected to electrical systems in which faults
frequently occur, we recommend installing additional protective devices (overvoltage, undervolt-
age or phase failure relays, lightning protection). Local and national regulations must be adhered to
when connecting the machine.
Activation types for cables

with free ends (without plugs)
Direct activation Motor protection should be set to the rated current when fully loaded. At partial load, we recom-
mend that motor protection is set 5% above the measured current at the operating point.
Star-delta activation If the motor protection is installed in the line:

Set the motor protection to 0.58 x the rated current. The maximum start-up time in star-delta
mode is 3 seconds.
If the motor protection is not installed in the line:
Set the motor protection to the rated current when fully loaded.
Starting transformer/soft start Motor protection should be set to the rated current when fully loaded. At partial load, we recom-
mend that motor protection is set 5% above the measured current at the operating point. The
maximum start-up time at reduced voltage (approx. 70%) is 3 seconds.
Operation with frequency The machine can be operated on frequency transformers.

transformers
Observe the data sheet in the appendix of this manual.
Activation types with plugs /

relays
Units with plugs Connect the plug to the socket provided and press the On/Off switch on the relay.
6-2 WILO EMU 3.0

Startup
Please observe the relay manual. Units with relays
The rated current is briefly exceeded during the start-up procedure. Once this process has ended, After starting
the operating current should no longer exceed the rated current.
If the motor does not start immediately after the machine is switched on, it must be switched off
immediately. The start pauses specified in the technical data must be adhered to before starting up
again. If the fault recurs, the machine must be switched off again immediately. The machine may
only be started again once the fault has been rectified.
The following items should be monitored:
- Operating voltage (permissible deviation +/- 5% of the rated voltage)
- Frequency (permissible deviation +/-2% of the rated frequency)
- Current consumption (permissible deviation between phases is a maximum of 5%)
- Voltage difference between the individual phases (max. 1%)
- Starts and stops per hour (see technical data)
- Air entry in the infeed, a deflector plate should be fitted if necessary
- Minimum water immersion level, level control unit, dry-run protection
- Smooth running
- Check for leaks, if need be, follow the necessary steps as set out in “Maintenance”
As mechanical shaft seals have a certain running-in phase, it is possible
that minor leaks may occur. This running-in phase lasts approx. 1 - 3
months. Change the oil several times during this phase. Please consult
the manufacturer if leakage continues after this running-in phase has
ended.
The maximum limit range deviation for operational data is +/-10% of the rated voltage and +3% Operation in the limit range
to –5% of the rated frequency. Significant deviation from the operational data is to be expected
(also see DIN VDE 0530, Section 1). The permissible voltage difference between the individual
phases is a maximum of 1%. Continuous operation in the limit range is not recommended.
E:\shares\Baprod\BA\subtec_m\sewage\us\startup.fm 6-3
Maintenance
7 Maintenance
The machine and the entire system must be inspected and maintained at regular intervals. The time
limit for maintenance is set by the manufacturer and applies to the general conditions of use. The
manufacturer should be consulted if the system is to be used with corrosive and/or abrasive
pumped liquids, as the time limit between inspections may need to be reduced.
Note the following information:
- The operating and maintenance manual must be available to the maintenance personnel and
its instructions followed. Only the repair and maintenance measures listed here may be per-
formed.
- All maintenance, inspection and cleaning work on the machine and the system may only be
carried out by trained specialists exercising extreme care in a safe workplace. Proper protec-
tive clothing is to be worn. The machine must be disconnected from the electricity supply
before any work is carried out. There must be no way that it can be inadvertently switched on.
Additionally, the appropriate protective measures as defined by the BGV/GNV should be
enforced when working in basins and/or containers.
- Above a weight of 50kg, only hoisting gear which has been officially approved and which is in
a technically perfect condition should be used for lowering and raising the machine.
Make sure that all fastening devices, ropes and safety devices of the
hand winch are in a technically perfect condition. Work may only com-
mence if the auxiliary hoisting gear has been checked and found to be in
perfect working order. If it is not inspected, danger to personnel may
result.
- Electrical work on the machine and system must be carried out by an electrician. For machines
approved for work in areas subject to explosion danger, please refer to the “Explosion protec-
tion in accordance with the .... regulation” chapter. Defective fuses must be replaced. Under
no circumstances are they to be repaired. Only fuses at the specified current and of the pre-
scribed type may be used.
- When working with inflammable solvents and cleaning agents, fires, unshielded lighting and
smoking are prohibited.
- Machines which circulate fluids hazardous to health, or which come into contact with them,
must be decontaminated. It must be ensured that no dangerous gases can form or are
present.
If injuries involving hazardous pumping liquids or gases occur, first-aid
measures must be performed in accordance with the notices in the
workplace and a doctor should be called immediately.
- Ensure that all necessary tools and materials are available. Tidiness and cleanliness guarantee
safe and problem-free operation of the machine. After working on the machine all cleaning
materials and tools should be removed from it. All materials and tools should be stored in an
appropriate place.
- Operating supplies such as oil and lubricants must be collected in appropriate vessels and
properly disposed of (in accordance with the 75/439/EEC directive and with §§5a, 5b AbfG).
Appropriate protective clothing is to be worn for cleaning and maintenance jobs. This is to be
disposed of in accordance with waste code TA 524 02 and EC Directive 91/689/EEC. Only
lubricants expressly recommended by the manufacturer may be used. Oils and lubricants
should not be mixed. Only use genuine parts made by the manufacturer.
A trial run or functional test of the machine must be performed as
instructed in the general operating conditions.
E:\shares\Baprod\BA\subtec_m\sewage\us\t20_1\maintenance.fm 7-1
Maintenance
Lubricants You will find an overview of the lubricants used below:
Gear oil Transformer oil

Manufacturer (DIN 51 519 / ISO VG (DIN 57370 / VDE White oil
220 Type CLP) 0370)
Aral Degol BG 220 Isolan T Autin PL*
ONDINA G13*, 15*,

Shell Omala 220 Diala D
G17*
Esso Spartan EP 220 UNIVOLT 56 MARCOL 52*, 82*
BP Energol GR-XP 220 Energol JS-R Energol WM2*
DEA Falcon CLP 220 Eltec GK 2
Pharmaceutical 30*,
Texaco Meropa 220 KG 2
40*
ELF mineral oil TRANSFO 50 ALFBELF C15
Tripol Food Proof 1810/220*
Table 7-1: Lubricant overview
The following can be used as grease in accordance with DIN 51818/NLGI class 3:
- Esso Unirex N3
- Tripol Molub-Alloy-Food Proof 823 FM*
When using white oil, note the following:
- The machine lubricants may only be topped up or replaced with lubricants from the same
manufacturer.
- Machines which have previously been operated using other lubricants must first be thor-
oughly cleaned before they can be operated using white oil.
Lubricants which are approved for use with foodstuffs in accordance
with USDA-H1 are marked with an asterisk.
The specified lubricants are used in the sealing chamber.
Maintenance intervals Overview of the maintenance intervals needed:
Before initial start-up or after - Checking the insulation resistance

a longer period of storage - Fill level check in sealing room/chamber – lubricant must reach up to the lower edge of the
filling opening
Monthly - Monitoring the current consumption and voltage

- Checking the used relays for posistors, sealing room monitor, etc.
Every six months - Visual inspection of the power supply cable

- Visual inspection of the cable holder and the cable bracing
- Visual inspection of accessories, e.g. the suspension device and hoisting gears
8,000 operating hours or after - Checking the insulation resistance

two years, whichever is earlier - Changing the lubricant in the sealing room/chamber
- Emptying the leakage chamber (not present in all models)
- Functional inspection of all safety and control devices
7-2 WILO EMU 3.0

Maintenance
- Coating check and touch-up as required
- General overhaul 15,000 operating hours or af-

If it is used in highly abrasive or corrosive material, the maintenance ter five years, whichever is
intervals should be reduced by 50%! earlier
Overview of the individual maintenance intervals: Maintenance tasks
The current consumption and voltage is to be monitored periodically during all 3 phases. This Monitoring the current con-
remains constant during normal operation. Slight fluctuations are a result of the composition of the sumption and voltage
pumped fluid. The current consumption can assist in early detection and correction of damage and/
or faulty operation in the impeller/propeller, bearings and/or the motor. More extensive resulting
damage can thus be largely prevented and the risk of a total failure can be reduced.
Check the relays used are functioning fault-free. Defective devices must be immediately replaced, Checking the used relays for
because these cannot ensure safe operation of the machine. The test procedure details should be posistors, sealing room moni-
followed closely (in the operating instructions for each relay). tor, etc.
To check the insulation resistance, the power supply cable must be disconnected. The resistance Checking the insulation resis-
can then be measured with an insulation tester (measuring voltage = 1000V DC). The following val- tance
ues may not be exceeded:
The insulation resistance may not be below 20mega-ohms during initial operation. For all further
measurements the value must be greater than 2mega-ohms.
Insulation resistance too low: Moisture may have penetrated the cable and/or the motor.
Do not connect the machine, consult manufacturer.
The power supply line must be examined for bubbles, cracks, scratches, chafed areas and/or Visual inspection of the power
crushed sections. If damage is found, the power cable must be exchanged immediately. supply cable
The cables may only be changed by the manufacturer or an authorized/
certified service workshop. The machine may not be used again until the
damage has been adequately rectified.
When the machine is used in basins or pits, the lifting cables/cable holders (carabiners) and the Visual examination of the ca-
cable bracing are subject to constant wear. Regular inspections are necessary in order to prevent ble holders (carabiners) and
the lifting cables/cable holders (carabiners) and/or cable bracing from wearing out and to prevent the cable bracing
the electricity cable from being damaged.
The lifting cables/cable holders (carabiners) and the cable bracing are to
be immediately replaced if any signs of wear appear.
Inspect accessories such as suspension units and hoisting gear to check whether they are secured Visual inspection of accesso-
in a stable manner. Loose and/or defective accessories should be repaired immediately or replaced. ries
Monitoring devices are temperature sensors in the motor, sealing room monitors, motor protection Functional inspection of safe-
relays, overvoltage relays, etc. ty and control devices
Motor protection and overvoltage relays and other trip elements can generally be triggered manu-
ally for test purposes.
To inspect the sealing room monitor or the temperature sensor, the machine must be cooled to
ambient temperature and the electrical supply cable of the monitoring device in the switch cabinet
must be disconnected. The monitoring device is then tested with an ohmmeter. The following val-
ues should be measured:
Bi-metal sensor: Value = “0” - throughput
PTC sensor: A PTC sensor has a cold resistance of between 20 and 100ohms. For 3 sensors in series
this would result in a value of between 60 and 300ohms.
Maintenance
PT 100 sensor: PT 100 sensors have a value of 100ohms at 0°C. Between 0°C and 100°C this value
increases by 0.385ohms per 1°C. PT 20 sensors have a value of 107.7ohms at 20°C.
Moisture sensor: This value must approach infinity. If there is a low value, there may be water in the
oil. Also observe the instructions of the optionally available evaluation relay.
In the case of larger deviations, please consult the manufacturer.
Please consult the appropriate operating manual for details on inspecting the safety and monitor-
ing devices on the auxiliary lifting gear.
General overhaul During this the bearings, shaft seals, O rings and power supply cables are inspected and replaced as
required in addition to normal maintenance work. This work may only be conducted by the manu-
facturer or an authorized service workshop.
Changing the lubricant The drained lubricant must be checked for dirt and water content. If the lubricant is very dirty and
contains more than 1/3 water, it must be changed again after four weeks. If there is again water in
the lubricant then, it seems likely that a seal is defective. In this case, please consult the manufac-
turer.
If a sealing room or leakage monitoring system is being used, the display will light up again within
four weeks of changing the lubricant if a seal is defective.
The general procedure for changing lubricants is as follows:
Switch off the machine, let it cool down, disconnect it from the mains
(have this done by an electrician), clean it and place it vertically on a
solid base.
Warm or hot lubricants may be pressurized. The leaking lubricant may
cause burns. For that reason, let the machine cool down to ambient tem-
perature before you touch it.
Secure it from falling over and/or slipping. For certain housing coatings
(e.g. Ceram C0) the plugs are protected with plastic covers. These must
be removed and put back on after a successful lubricant change. They
must be lined with an acid-resistant sealant (such as SIKAFLEX 11FC).
Sealing chamber As there are several versions and designs of these motors, the exact location of the screw plugs
varies depending on the pump unit used.
1 Slowly and carefully remove the filling plug (D+) from the sealing room.
The lubricant may be pressurized.
2 Remove the drain plug (D-). Drain the lubricant and collect it in a suitable reservoir. Clean the
drain plug, fit with a new sealing ring and screw it in again. For complete drainage, the
machine must be slightly tipped on to its side.
Make sure that the machine cannot fall and/or slip away.
3 Fill lubricant by means of the opening in the filling plug (D+). Comply with the specified
lubricants and filling quantities.
4 Clean the filling plug (D+), fit with a new sealing ring and screw it in again.
7-4 WILO EMU 3.0

Maintenance
1 Slowly remove the screw plug (L) from the leak chamber and drain the collected fluid. Emptying the leak chamber
2 Clean the screw plug (L), fit with a new sealing ring and screw it in again.
D+
D-
Fig. 7-1: Position of the screw plugs
Maintenance
Repairs The following repairs can be carried out on this machine:

- Changing the impeller and pump unit
- Changing the impeller and stationary wear rings
When carrying out repair work, the following information should always be noted:
- Round sealing rings as well as existing seals should always be replaced.
- Screw fixings such as spring washers or the self-locking Nord-Lock screw fixing should
always be replaced.
- If no self-locking Nord-Lock screw fixing is used as a locking screw or it is not possible to use
these, then no dacromet-coated screw should be used. In this case, screws made from the
material A2 or A4 must be used. The correct torques must be observed.
- Never use brute force during this work.
In general, the following applies to repairs:
Switch off the machine, disconnect it from the mains (have this done by
an electrician), clean it and place it on a solid base in a horizontal posi-
tion. Secure it from falling over and/or slipping. For certain housing
coatings (e.g. Ceram C0) the plugs are protected with plastic covers.
These must be removed and put back on after a successful lubricant
change. They must be lined with an acid-resistant sealant (such as
SIKAFLEX 11FC).
The following applies when using a self-locking Nord-Lock screw fixing:

- Do not use any rustproof screws
- Only use with dacromet-coated screws (strength level 10.9)
Changing the impeller and There are two ways to change the impeller. With the first version, the pump housing is dismantled
pump unit first, so that the impeller can then be changed.
With the second version, the intake port on the pump housing is dismantled. Version two is used
when the impeller is wider than the flange connection on the pump housing. In this version, the
impeller must be dismantled before the pump unit is changed.
Version 1 (see illustration) 1 Loosen and remove the hexagon nuts.

2 Secure and remove the pump housing from the sealing housing with suitable equipment,
e.g. hoisting gear. Place on a secure base.
3 Fasten the impeller with suitable equipment, loosen and remove the fastening screw.
Pay attention to the locking screw.
4 Remove the impeller from the shaft using a suitable extractor.

5 Clean the shaft.
6 Attach a new impeller to the shaft.
Make sure that the sliding surfaces do not become damaged.
7 Apply the screw fixing to the new fastening bolt and screw it into the shaft. Fasten the
impeller and tighten the fastening screw with the correct torque (see table).
8 Place the pump unit on the sealing housing and fasten it with hexagon nuts (1).
9 It must be possible to turn the impeller by hand.
7-6 WILO EMU 3.0

Maintenance
Bearing casing (5)
Hex nut (1)
Impeller (4)
Cylinder screw (3)
Pump housing (2)
Fig. 7-2: Changing the impeller - version 1
Maintenance
Version 2 1 Unscrew the fastening for the intake port from the pump housing.
2 Remove the intake port from the pump housing and place it on a secure base.
3 Fasten the impeller with suitable equipment, loosen and remove the fastening screw. Pay
attention to the locking screw.
4 Remove the impeller from the shaft using a suitable extractor.
5 Clean the shaft.
6 Attach a new impeller to the shaft. Make sure that the sliding surfaces do not become dam-
aged.
7 Apply a new screw fixing to a new fastening bolt and screw it into the shaft. Fasten the
impeller and tighten the fastening screw with the correct torque (see table).
8 Attach the intake port to the pump housing and secure it. It must be possible to turn the
impeller by hand.
Changing the stationary and The stationary and mobile wear ring determine the gap between the impeller (mobile wear ring) and
mobile wear ring the intake port (stationary wear ring). If this gap is too big, the performance of the machine
decreases, and/or it can lead to entanglements. Both rings are designed so that they can be
replaced. This minimizes wear on the intake port and and impeller, consequently reducing expense
for spare parts.
The correct manual for changing the mobile and stationary wear rings is
supplied with the replacement part.
Changing sealing parts Changing sealing parts on the liquid side such as the block seal cartridge and the mechanical seal
shaft requires a certain amount of specialist knowledge about these sensitive components. In addi-
tion to this, in order to carry out the work, much of the machine must be dismantled.
Only original parts may be used for replacement.
Inspecting and replacing these parts is performed by the manufacturer during the general overhaul
or by specially trained personnel.
For machines approved for work in areas subject to explosion danger, please refer to the “Explosion
protection in accordance with the .... regulation” chapter.
Torque values Overview of the correct torques for dacromet-coated screws with Nord-Lock screw fixing
Thread Tensile strength 10.9
Nm kp m
M5 9.2 0.94
M6 15.0 1.53
M8 36.8 3.75
M10 73.6 7.50
M12 126.5 12.90
M16 316.3 32.24
M20 621.0 63.30
M24 1069.5 109.02
M27 1610.0 164.12
M30 2127.5 216.87
Table 7-2: Dacromet-coated screws with Nord-Lock screw fixing
7-8 WILO EMU 3.0

Maintenance
Overview of the correct torques for rustproof screws without screw fixing:
Thread Nm kp m Thread Nm kp m
M5 5.5 0.56 M16 135.0 13.76

M6 7.5 0.76 M20 230.0 23.45
M8 18.5 1.89 M24 285.0 29.05
M10 37.0 3.77 M27 415.0 42.30
M12 57.0 5.81 M30 565.0 57.59
Table 7-3: Rustproof screws without Nord-Lock screw fixing
Shutdown
8 Shutdown
This chapter provides an overview of the various ways to shut down the machine.
For this type of shutdown, the machine remains installed and is not cut off from the electricity sup- Temporary shutdown
ply. For temporary shutdown, the machine must remain completely submerged so that it is pro-
tected from frost and ice. Make sure the operating room and the pumped fluid cannot be covered
by ice.
This ensures that the machine is always ready for operation. During longer shutdown periods, carry
out a regular (monthly to quarterly) function run for a period of 5 minutes.
Caution
Only carry out a function run under the proper conditions of oper-
ation and use (see “Product Description”). Never run the machine
dry. This can result in irreparable damage!
Switch off the system, disconnect the machine from the electricity supply and dismantle and store Final shutdown / storage
it. Note the following information concerning storage:
Beware of hot parts!

When removing the machine, be careful of the temperature of the
housing components. These can heat up to well above 40°C. Let the
machine cool down to ambient temperature before you touch it.
Caution
For machines filled with drinking water, drain out the water and
let the machine dry out if it is not operated for more than
4 weeks, or if there is a risk of freezing.
- Clean the machine.

- Store it in a clean, dry place, protect the machine against frost.
- Place it down vertically onto a firm foundation and secure it against falling.
- Seal the intake and discharge ports of pumps with suitable material (such as foil).
- Support the electric connecting lead on the cable lead-in to help avoid a permanent deforma-
tion.
- Protect the ends of the electric power cable from moisture.
- Protect the machine from direct sunshine as a preventive measure against brittleness in elas-
tomer parts and the propeller and casing coating.
- When storing the machine in a garage please remember: Radiation and gases which occur
during electric welding destroy the elastomers of the seals.
- During lengthy periods of storage, regularly (for example every six months) turn the impeller
or propeller by hand. This prevents indentations in the bearings and stops the rotor from rust-
ing up.
- See also “Transport and Storage”.
Before restarting the machine, clean it of dust and oil deposits. Then carry out the necessary main- Restarting after an ex-
tenance actions (see “Maintenance”). Check that the mechanical shaft seal is in good order and
tended period of storage
working properly.
E:\shares\Baprod\BA\subtec_m\general\us\shutdown.fm 8-1
Troubleshooting
9 Troubleshooting
In order to prevent damage or serious injury while rectifying machine faults, the following points
must be observed:
- Only attempt to rectify a fault if you have qualified staff. This means each job must be carried
out by trained specialist staff, for example electrical work must be performed by a trained
electrician.
- Always secure the machine against an accidental restart by disconnecting it from the electric
system. Take appropriate safety precautions.
- Always have a second person make sure the machine is switched off in an emergency.
- Secure moving parts to prevent injury.
- Independent work on the machine is at one's own risk and releases the manufacturer from
any warranty obligation.
Fault: The machine will

Cause Remedy
not start
Electricity supply interrupted – short circuit or

Have the motor and wires checked by a spe-
earth connection in the cable or motor wind-
cialist and replaced if necessary
ings
Have a specialist inspect the connection and

correct them as necessary
Have the motor protection switch adjusted
Fuses, the motor protection switch and/or
according to the technical specifications, and
monitoring devices are triggered
reset monitoring equipment
Check that the impeller/propeller runs
smoothly. Clean it or free it as necessary
See fault: Mechanical shaft seal leaks, sealing

The moisture sensors (option) has interrupted
chamber monitor reports fault and switches
the power circuit (operator-related)
the machine off
Table 9-1: The machine will not start
Fault: The motor starts,

but the motor protection
Cause Remedy
switch triggers shortly
Have a specialist compare the setting of the after start-up
The thermal trigger on the motor protection
trigger with the technical specifications and
switch is incorrectly set
adjust it if necessary
Increased power consumption due to major Have an electrician check the voltage on each
voltage drop phase and rewire if necessary

Two-phase operation
correct it as necessary

Excessive voltage differences on the three
the switching system and correct it as neces-
phases
sary
Incorrect direction of rotation Swap the 2 phases from the mains supply
Table 9-2: The motor starts, but the motor protection switch triggers shortly after start-up
E:\shares\Baprod\BA\subtec_m\general\us\troubleshooting.fm 9-1
Shutdown
Once this work has been completed, the machine can be installed (see “Installation”) and
connected to the electricity supply by a specialist. See “Startup” a for instructions on restarting.
Only restart the machine if it is in perfect condition and ready for opera-
tion.
8-2 WILO EMU 3.0

Troubleshooting
Cause Remedy
Impeller/propeller impeded by adhesive mate- Switch off the machine, secure it against
rial, blockages and/or solid matter, increased being switched on again and free the impeller/
current consumption propeller or clean the suction port
The pumped fluid is too dense Contact the manufacturer
Table 9-2: The motor starts, but the motor protection switch triggers shortly after start-up
Fault: Machine runs but

does not pump
Cause Remedy
No pumped fluid Open the container intake or sliders
Clean the intake, slider, suction port or intake

Intake blocked
strainer
Switch off the machine, secure it against

Impeller/propeller blocked or obstructed being switched on again and free the impeller/
propeller
Defective hose or piping Replace defective parts
Intermittent operation Check the control panel
Table 9-3: Machine runs but does not pump
Fault: The machine runs,

but not at the stated op-
Cause Remedy
erating levels
Clean the intake, slider, suction port or intake
Intake blocked
strainer
Slide in the discharge line closed Fully open the slide

Impeller/propeller blocked or obstructed being switched on again and free the impeller/
propeller
Incorrect direction of rotation Replace 2 phases on the mains supply
Check the pipes, pressure shroud and/or pump

Air in the system
unit, and bleed if necessary
Check the slide in the discharge line, if neces-

Machine pumping against excessive pressure sary open it completely, use a different impel-
ler or contact the factory
Signs of wear Replace worn parts
Defective hose or piping Replace defective parts
Inadmissible levels of gas in the pumped liquid Contact the factory

Two-phase operation
Table 9-4: The machine runs, but not at the stated operating levels
9-2 WILO EMU 3.0

Troubleshooting
Cause Remedy
Check the supply and capacity of the system,

Excessive decrease in the water table during
and inspect the level control settings and
operation
function
Table 9-4: The machine runs, but not at the stated operating levels
Fault: The machine does

not run smoothly and is
Cause Remedy
noisy
Check the operational data of the machine
Machine is running in an impermissable oper-
and correct if necessary and/or adjust the
ation range
operating conditions
The suction port, strainer and/or impeller/pro- Clean the suction port, strainer and/or impel-
peller is blocked ler/propeller

The impeller is impeded
being switched on again and free the impeller
Inadmissible levels of gas in the pumped liquid Contact the factory

Two-phase operation
Incorrect direction of rotation Replace 2 phases on the mains supply
Signs of wear Replace worn parts
Defective motor bearing Contact the factory
The machine is installed with mechanical Check the installation, use rubber spacers if
strain necessary
Table 9-5: The machine does not run smoothly and is noisy
(Sealing chamber monitoring is optional, and is not available for all types. For details on this, see the Fault: Mechanical shaft
order confirmation or the electrical terminal connection plan.)
seal leaks, sealing cham-
Cause Remedy ber monitor reports fault
and switches the ma-
Condensation build-up due to lengthy stor- Operate the machine briefly (max. 5min.) chine off
age and/or temperature fluctuation without sealing chamber monitoring
Expansion tank (optional for polder pumps) is Install the expansion tank no more than 10m
too high above the top edge of the suction port
Increased leakage when running in new

Change the oil
mechanical shaft seals
Defective sealing chamber cables Replace the moisture sensors
Replace the mechanical shaft seal after con-

Mechanical shaft seal is defective
tacting the factory
Table 9-6: Mechanical shaft seal leaks, sealing chamber monitor reports fault and switches the machine off
E:\shares\Baprod\BA\subtec_m\general\us\troubleshooting.fm 9-3
Further steps for trouble- If the items listed here do not help you rectify the fault, contact our customer service. They can
help you as follows:
shooting
- Telephone or written help from customer service
- On-site support from customer service
- Checking and repairing the machine at the factory
Note that you may be charged for some services provided by our customer support.
Customer service will provide you with details on this.
List of machine operators and maintenance
A List of machine operators and mainte-

nance
All persons working on or with the product confirms with their signatures that they have received, List of machine operators
read and understood this operating and maintenance manual. In addition, they obligate themselves
to conscientiously follow the instructions provided. Non-observation releases the manufacturer
from any warranty obligations.
Name Starting date Signature
Table A-1: List of machine operators
E:\shares\Baprod\BA\subtec_m\general\us\annex_a.fm A-1
List of machine operators and maintenance
Maintenance and inspec- Every person is required to enter all maintenance and alteration work which then is to be confirmed
with the person's own signature and that of their supervisor.
tion log
This list is to be shown on request to representatives of controlling organizations, government
inspection teams and the manufacturer!
Maintenance / Signature of the

Date Signature
Revision on person in charge
Table A-2: Maintenance and inspection log
A-2 WILO EMU 3.0

Assembly Sheet For the Anchor Bolts
B Assembly Sheet For the Anchor Bolts
Anchor bolts consist of a metal anchor rod, a grout cartridge (a glass tube or plastic bag containing General product infor-
adhesive cement), a washer and a hexagonal nut. They create a firm connection in concrete foun-
mation
dations, thus enabling heavy loads to be supported. Once fitted, the anchor cannot be removed!
The anchor bolts supplied by WILO EMU GmbH may only be used for WILO auxiliary hoisting gear Scope of proper use
and accessories.
These anchor bolts may only be used in normal reinforced or non-reinforced concrete in a strength
class of min. C20/25 and max. C50/60 (according to EN 206:2000-12). The foundation for the
anchors should be dry. The anchor bolt is only suitable for non-cracked concrete. Anchor bolts are
also available for cracked concrete.
Before using the anchor bolts, make sure the background structure is strong enough to withstand
the reactive forces generated by the auxiliary hoisting gears and their accessories.
The anchor bolts are designed to fasten auxiliary hoisting gears and their accessories to the basis
edge and/or basin floor.
Take care not to damage the grout cartridge during transport, as otherwise the adhesive cement Transport and storage
will harden. Do not use faulty grout cartridges. Do not use grout cartridges after the expiration date
printed on them.
The cartridges must by transported only at temperatures between -5°C and 30°C and stored at
temperatures between 5°C to 25°C. The mortar cartridge must be kept in a cool, dry, dark place.
Beware of irritant substances!
The grout cartridges contain dibenzoyl peroxide. This substance is
caustic. Note the following information:
R36/38 Irritates eyes and skin
R43 Skin may react to contact
S37/39 Wear suitable protective clothing during work
S26 If it comes into contact with the eyes, wash them out with
water and call a doctor
S28 If it comes into contact with the skin, wash thoroughly with
water and plenty of soap
Setting the anchor bolts

Drill hole Drill hole Min. distance
Name Rod length
depth diameter from edge ar
HAS-R M8x80/14 110mm 80mm 10mm 100mm
HAS-R M12x110/28 160mm 110mm 14mm 135mm
HAS-R M16x125/38 190mm 125mm 18mm 155mm
HAS-R M16x125/108 260mm 125mm 18mm 155mm
HAS-E-R M20x170/48 240mm 170mm 24mm 210mm
HAS-E-R M24x210/54 290mm 210mm 28mm 260mm
Table B-1: Dimensions and tightening torque values
E:\shares\Baprod\BA\subtec_m\appendix\us\general\anchor_bolts.fm B-1
Drill hole Drill hole Min. distance

Name Rod length
depth diameter from edge ar
HIS-RN M16x170 170mm 170mm 28mm 210mm
Minimum Max. thickness of the part to be

Name Torque Tinst
thickness tb fastened
HAS-R M8x80/14 130mm 10Nm 14mm
HAS-R M12x110/28 160mm 40Nm 28mm
HAS-R M16x125/38 175mm 80Nm 38mm
HAS-R M16x125/108 175mm 80Nm 108mm
HAS-E-R M20x170/48 220mm 150Nm 48mm (without hexagon head)
HAS-E-R M24x210/54 260mm 200Nm 54mm (without hexagon head)
HIS-RN M16x170 220mm 80Nm (internal thread M16)
1 Drill the holes as shown in table 1 and the following drawing.

Note: The quality of the fastening depends on how well the anchor bolts
are correctly seated!
ar
tb
ar
B-2 WILO EMU 3.0

2 Carefully and thoroughly clean the holes using a brush and bellows.
3 Insert the grout cartridge carefully into the hole. Any air bubbles must face outwards. If the
drilled hole is too deep or broken at the edges, you may need to use more than one grout
cartridge.
4 Using a suitable insertion tool, turn and knock the anchor bolt into the mortar cartridge until
it reaches the insertion depth marking (1). The gap between the anchor bolt and the back-
ground structure must be completely filled with grout.
5 Carefully remove the insertion tool, do not remove a jammed insertion tool until trel has
elapsed – see Table 2.
t rel
Temp. in the
>+ 20°C >+ 10°C > 0°C >- 5°C
drill hole
Waiting time trel 8 min 20 min 30 min 1 hr
Waiting time
20 min 30 min 1 hr 5 hr
tcure
If the background structure is damp, the waiting time must be doubled!
Table B-3: Hardening time
6 Let the anchor bolts harden – see tcure in Table 2. While curing, do not move or place any
load on the anchor bolt.
t cure
7 When the anchor bolts has hardened, clean the bearing surface of any impurities such as dirt,
adhesive resin or drilling dust. The part to be attached must be firmly fitted to the base and
may not be in any way loose. Then bolt the part to the base and tighten it to the specified
torque (see Table 1). To secure the nut, coat it with Loctite 2701 locking glue and re-tighten
B-4 WILO EMU 3.0

it to the specified torque at least three times in order to compensate for any movement due
to setting.
T inst
Operation with a static frequency converter
C Operation with a static frequency

converter
WILO products can be operated with standard frequency converters. These are normally pulse-
width-modulated converters. However, the following points must be observed when operating the
converter:
Any standard WILO motor can be used. If the rated voltage is above 415 V, you must consult the Selecting the motor and
manufacturer. Because of the additional heating caused by harmonics, the rated power of the
converter
motor should be around 10% more than the power requirement of the pump. For converters with a
low-harmonic output, it may be possible to reduce the 10% power reserve. This is normally done
by using output filters. Ask the converter manufacturer.
The size of the converter depends on the rated motor current. Selecting the motor power in kW can
cause problems, since submersible motors have different specifications to standard motors. Waste
water motors are marked with the appropriate rated power (type sheet power in catalog).
Submersible pumps have water-lubricated bearings. A minimum speed is required in order for a Minimum speed for
lubricating film to form.
submersible pumps
Continuous operation at frequencies below 25 Hz (30 Hz 4-pole) must be avoided, since the lack (well pumps)
of lubrication and possible occurrence of mechanical vibrations may cause damage to the bearings.
The lowest speed range (up to 12.5 Hz) should be passed though within
2 seconds.
In practice, the speed should only be lowered to the extent that a pump flow of at least 10% of the
maximum flow remains. The precise value depends on the type – ask the manufacturer for details.
There is no prescribed minimum speed for waste water and sewage pumps. Minimum speed for waste
However, make sure that the motor operates without jerking or vibrating, especially in the lower water and sewage pumps
speed range. Otherwise, the mechanical shaft seals could be damaged and start leaking.
It is important that the pump motor operates across the entire control range without vibrations, Operation
resonance, oscillation or excessive noise (ask the manufacturer if necessary).
Increased motor noise caused by the harmonics of the power supply is normal.
When configuring the converter, always make sure the quadratic curve (U/F characteristic) for
pumps and fans is correctly set. This ensures that the output voltage at < 50 Hz frequencies is
adjusted to the power requirement of the pump. Newer converters feature an automatic power
optimization function which achieves the same effect. See the converter operating manual for this
setting and other parameters.
Submersible motors with water-cooled windings are more susceptible to voltage peaks than dry Max. voltage peaks and
motors.
rise speed
The following thresholds may not be exceeded:
Max. voltage rise speed: 500 V/μs
Max. voltage peak to earth: 1250 V
These values apply for well pumps < 1 kV and can usually be attained by replacing a sinusoidal filter
or dV/dt filter. For motors > 1 kV, the permissible values can be obtained from the plant. It remains
the case that the lowest possible pulse frequency should be set.
E:\shares\Baprod\BA\subtec_m\appendix\us\general\fc.fm C-1
Operation with a static frequency converter
EMC In order to comply with EMC (electromagnetic compatibility) regulations, it may be necessary to use
shielded wires, lay cables in metal tubes and install filters. The exact actions required to comply
with the EMC directives depend on the converter type, converter manufacturer, length of cable laid
and other factors. In individual cases it is therefore necessary to look up the actions to be taken in
the converter operating manual or contact the manufacturer directly.
Motor protection As well as the built-in electrical current monitor system in the converter, or the thermal relay in the
switching system, we recommend installing temperature sensors in the motor. Cold conductor
temperature sensors (PTC) and resistor temperature sensors (PT 100) are both suitable.
Explosion-proof motors (whose type code has the addition “Ex”) must
always be fitted with cold-type thermistors in frequency conversion
mode. Also, an approved motor protection relay for cold-type ther-
mistors (such as MSS) must be used.
Operation up to 60 Hz A WILO submersible motor can be adjusted up to 60 Hz provided the motor has been rated for the
pump’s higher power requirement. However, the rated power should be taken from the 50 Hz data
sheets.
Efficiency As well as the efficiency of the motor and the pump, the efficiency of the converter (approx. 95 %)
must also be taken into account. The efficiency of all components is lower when the speed is
reduced.
Formulas
Pump flow Pump head Power
2 3
n2 n2 n2
Q2 = Q1 * H2 = H1 * P2 = P1 *
n1 n1 n1
Table C-1: Formulas
Summary As long as all these points are taken into account and the instructions for the converter are fol-
lowed, speed-regulated operation with WILO products is possible without any problems.
C-2 WILO EMU 3.0

Ceram C0 data sheet
D Ceram C0 data sheet
WILO products are used for many different pumped liquids and installation sites. We want our coat- General information
ings to offer an even higher degree of protection against wear and corrosion. For this purpose, we
mainly use our Ceram coatings. However, only an intact coating provides the best possible protec-
tion.
Therefore check the coating after all installation and maintenance work, and repair any minor dam-
age immediately. In the event of major damage, please consult the manufacturer.
Ceram C0 is a sprayable, solvent-free, two-component aluminum-oxide-based coating material Description

which protects our products from corrosion under particularly harsh mechanical conditions.
Solvent-free epoxy polymer with solvent-free polyamine hardener and various extenders. Composition
- A tough, hard and long-lasting coating with high mechanical and chemical resistance and Properties
excellent resistance to abrasion.
- Excellent wet adhesion and compatibility with corrosion protection as a single-layer coating
on steel surfaces.
- Very good adhesion to steel surfaces.
- Replaces coatings containing tar.
- Cost-effective thanks to its durability, low maintenance and easiness to repair.
- Tested by the Federal Waterways Engineering and Research Institute (BAW).
- Solvent-free.
- High-gloss coating when hardened.
Technical data
Density (mixture) ASTM D 792 1.4 g/cm3
Adhesion / steel ISO 4624 15 N/mm2
DIN EN ISO
Impact resistance / hardness 9 J
6272
Temperature resistance: dry, long-

60 °C
term
Temperature resistance: dry, short-

120 °C
term
Depends on Information on
Temperature resistance: wet / fluid °C
pumped fluid request
Solid content (mixture) Volume 97 %
Weight 98 %
Table D-1: Technical data
E:\shares\Baprod\BA\subtec_m\appendix\us\general\c0.fm D-1
Ceram C0 data sheet
Resistance
Pumped fluid Temperature Resistance rating
Waste water, alkaline (pH 11) +20°C 1
Waste water, alkaline (pH 11) +40°C 1
Waste water, slightly acidic (pH 6) +20°C 1
Waste water, slightly acidic (pH 6) +40°C 1
Waste water, very acidic (pH 1) +20°C 2
Waste water, very acidic (pH 1) +40°C 3
Ammonium hydroxide (5%) +40°C 3
Decanol (fatty alcohol) +20°C 1
Decanol (fatty alcohol) +50°C 1
Ethanol (40%) +20°C 1
Ethanol (96%) +20°C 3
Ethylene glycol +20°C 1
Heating oil / diesel +20°C 1
Compressor oil +20°C 1
Methyl ethyl ketone (MEK) +20°C 3
Sodium hydroxide solution (5%) +20°C 1
Sodium hydroxide solution (5%) +50°C 2
Sodium chloride solution (10%) +20°C 1
Hydrochloric acid (5%) +20°C 2
Sulfuric acid (10%) +20°C 2
Sulfuric acid (20%) +20°C 3
Nitric acid (5%) +20°C 3
Toluene +20°C 2
Water (cooling/industrial water) +50°C 1
Xylene +20°C 1
Table D-2: Resistance
Total layer thickness: at least 400μm

Key: 1 = resistant; 2 = resistant for 40 days; 3 = resistant against overflow, immediate cleaning rec-
ommended
D-2 WILO EMU 3.0

Ceram C0 data sheet
In order to achieve the best results with this product, proper preparation of the surface is of critical Surface preparation
importance. The exact requirements change depending on the application, expected period of ser-
vice and original surface condition.
Make sure it is clean, dry and free of grease. The best results are attained by removing rust by blast- Steel
ing in accordance with DIN EN ISO 12944-4, standard cleanliness grade Sa 2.5 - 3. The roughness
should be at least 50μm deep. A test certificate for the blasting equipment must be available.
Please ask for our advice on preparing other surfaces.
The material is supplied in the agreed mixing ratio. Mix all the hardener component into the basic Material preparation
component, preferably using a mechanical mixer, also mixing around the walls and bottom of the
container. Only mix as much material as can be applied during the pot life.
The mixing ratio is 4:1 by weight.
Application instructions
The surface and air temperatures must be at least +10°C, and the relative air humidity at most Object requirements
80%. The temperature of the surface to be coated must be at least 3°C above the dew point. Low
temperatures slow down hardening and make application more difficult. For the coating to harden
completely, the surface temperature must be above the minimum hardening temperature. High air
humidity or temperatures below the dew point can cause condensation to form on the substrate or
the coating surface. This can cause problems of adhesion to the surface and between layers. These
object conditions must be maintained during the application and hardening period. If the tempera-
ture or humidity approach the threshold values, we recommend the use of heating or drying equip-
ment. Ceram C0 can be applied on small surfaces by roller or brush.
Pot life
Temperature 16°C 20°C 25°C 32°C
Pot life (minutes) 30 20 15 10
Table D-3: Pot life
This table shows the practical hardening time from the start of mixing.
Ceram C0 is applied in layers of 400μm to around 1000μm, depending on the media and intended Coating layers and mate-
duration of protection.
rial requirements
Theoretical yield: 1.8m2/kg at 400μm or 0.9m2/kg at 800μm.
Theoretical consumption: 0.60kg/m2 at 400μm or 1.15kg/m2 at 800μm.
In practice, consumption depends on the surface properties and the application method.
Use the following formula to determine how much is needed to cover a given surface:
Density x area (m2) x average thickness (mm) = consumption (kg)
Another layer of Ceram C0 can applied after around 16hours up to 24hours at +20°C. The surfaces Repeat coating intervals
must be clean, dry and free of oil or grease. If this interval is exceeded, the coating must be blasted.
In hot sunshine, the repeat coating interval is much shorter. Take suitable measures to prevent this.
/ subsequent coating
Hardening time
Temperature 15°C 25°C 30°C
Hand dry 8hours 4.5hours 4hours
Table D-4: Hardening time
E:\shares\Baprod\BA\subtec_m\appendix\us\general\c0.fm D-3
Ceram C0 data sheet
Light load 1day 13hours 10hours
Full load 6days 3days 2days
Chemically resistant 10days 6days 4days
Table D-4: Hardening time
Material needed - Cleaning agent for cleaning the surface

- Abrasive paper for roughening the surface (select the roughness according to the surface)
- Paintbrush for applying the coating (select the size according to the extent of the damage)
- 2 component coating (Ceram C0 + hardener)
- Vessel for mixing the two components
Working steps 1 Lift the WILO machine from the basin, place it on a secure surface and clean it.
2 Thoroughly clean the damaged area with suitable cleaning agent.
3 Roughen the surface around the damaged area.
4 Mix the 2 component coating (Ceram C0 + hardener) in a 4 to 1 ratio in a suitable vessel.
5 Wait 10 to 15minutes.
6 Apply the finished Ceram C0 coating to the damaged area with a suitable paintbrush. Make
sure the coating is of at least the minimum thickness: 400μm
If you are using a combination of different Ceram types (e.g. C2+C1),
please consult the manufacturer.
7 After repairing the damage, let the Ceram C0 completely dry. See “Hardening time”.
Cleaning tools Use a commercial solvent (acetone, alcohol or methyl ethyl ketone) to clean your tools immediately
after use. Once the material has dried, it can only be removed by abrasion.
Storage Store at temperatures between 10°C and 32°C, slight deviations during transport are acceptable.
The containers can be stored unopened for 12 months.
Safety precautions Before using any products, read the material DIN safety data sheet (MSDS) or the safety regulations
regarding them. Observe all applicable safety regulations when working in enclosed rooms.
D-4 WILO EMU 3.0

Assembling the suspension unit
E Assembling the suspension unit
The suspension units consist of a coupling base with a coupling flange, guide and mounting ele- Product description
ments. The coupling base and the guide and mounting elements are assembled together to form
the suspension unit. The coupling flange mounted on the pump part enables the unit to be guided
precisely by the guide element onto the coupling base and therefore to be coupled to the pipe sys-
tem.
The connection between the coupling flange and the coupling base is performed automatically and
is established using the units own weight. The seal between the coupling flange and the coupling
base is made by the sealing ring in the coupling flange. This is pressed onto the coupling base dur-
ing operation and thereby seals the connection.
Gray cast iron and stainless steel are the materials used for the suspension unit. The gray cast iron
parts can also be additionally coated with special materials, for example, liquid ceramics, to protect
against abrasive and aggressive materials.
Rust-free steel pipes conforming to DIN2463 are used as guide elements. These are used a single or
double pipe guides. This does not affect installation.
The coupling bases differ in shape, size and design. Installation is the same for all coupling bases.
The individual parts are secured with the mounting sets supplied. These consist of anchor bolts for
the coupling base, machine bolts with hexagonal nuts for holders for pipe mountings and wood
screws with wall plugs and washers for holders for shaft mounting.
Please observe the relevant information sheets for installing the anchor
bolts. The specifications for the torque of each machine bolt can be
found in the tightening torque tables. These are both contained in the
appendix of this manual.
Suspension units are used for submersed installation. This must be installed vertically in the operat- Proper use
ing area. The coupling flange acts as a guide between the machine and the coupling base. Suspen-
sion devices may not be inserted without guide elements.
This would result in the machine slipping from the coupling base and
could cause the machine to leak and cause its position to incline. It is
essential that guide elements are used.
Before installing the suspension device, check it for damage or defects. Defective or damaged parts Transport and storage
may not be installed. Damaged coatings should be touched up before installation.
If the suspension device is to be stored, it must be washed and dried thoroughly. It should be stored
in a dry area which is not susceptible to frost.
The components of the suspension unit should be regularly inspected for damage and looseness. Maintenance tasks
Damaged or defective parts should be replaced with original parts from the manufacturer immedi-
ately.
The suspension unit and the connected machine or system may only be
operated in perfect condition.
E:\shares\Baprod\BA\subtec_m\appendix\us\sewage\suspension_unit.fm E-1
Type designation Designation e.g. DN1 802 N3 / 24 R5 K6

- 1=connection type
- 2=diameter of the pump discharge port
- 3=model
- 4=number of guide elements
- 5=type of guide elements
- 6=coupling base model
1. Connection type - DN=discharge port with flange

- R=discharge port with thread
2. Diameter of the pump dis- - R=2“

charge port - DN=36 to 600
3. Model - =standard model

- L=low-pressure model
Suspension units which are marked with “L" can only be used up to a certain pump pressure, i.e. it is
possible that they may not be operated at the top limits of the performance range of the con-
nected machine. It has been designed that if a certain pump pressure is attained, the coupling
flange will disengage from the coupling base and the medium will flow out to the side. As a result,
the pump head and the pump quantity are significantly reduced.
Note the values specified for the operating point on the machine data
sheet.
- S=high-pressure model
Suspension devices designated with “S" are used for machines that have a very high operating
pressure. If a standard model is used here, the unit would disengage from the coupling base due to
the high operating pressure. These special suspension units have been designed so that they can
ensure an optimum connection between the coupling flange and the coupling base even at very
high pressure.
- xxxxxxxxxxübersetzenxxxxxxx
4. Number of guide elements - 1=single pipe guide

- 2=double pipe guide
5. Type of guide elements - R=pipe

- T=T-rail
6. Coupling base design - =without elbow

- K=with elbow
We differentiate between “with elbow" and “without elbow". Without elbow means that the cou-
pling base has a horizontal connection to the pipeline system. With elbow means that a 90°-arch is
integrated into the coupling base and a vertical connection to the pipeline system is available.
E-2 WILO EMU 3.0

Fig. E-1: Model “with elbow" and “without elbow"
Completely trouble-free operation can only be guaranteed if the unit is precisely installed. Assembling the various
When installing the suspension units, remember that the guide elements suspension units
must be entirely perpendicular and may not be twisted. If the guide ele-
ments do not run completely straight, please contact the manufacturer.
R2 and DN36… to
DN250… suspension unit
installation
- Place the top guide holder (1) in the position intended and mark the holes Installation of the guide hold-
- Remove the guide holder (1), drill the holes and insert wall plugs (2) er for shaft mounting
- Place the guide holder (1) in position and secure it loosely with the wood screws (3) and
washers (4) supplied.
Pit
Guide holder (1)
Wood screws (3)
Wall plug (2)
Washer (4)
Fig. E-2: Installation of the guide holder for shaft mounting
Installation of the guide hold- The pipe extension corresponds to a guide holder except that it has two
er or pipe extension for pipe holders. With single pipe models R2, DN36 and DN50, the holding rail (7)
mounting is omitted.
- Place the clamp (5) around the discharge pipe (6) and place the holding rail (7) on the clamp
(5) at the front.
- Loosely screw the holding rail (7) and clamp (5) together with the hexagon socket bolts (8)
and the hexagon nuts (9). Place a washer under the bolt (8) and the nut (9) on both sides. The
opening of the holding rail (7) should point to the front.
- Guide the guide holder (1) and the pipe extension (10) and both hammer head bolts (11) into
the holding rail (7), align them and secure them with the two hexagon nuts (12) and one
washer each. The securing system has been designed so that all bolts can be accessed after
installation.
Discharge pipe (6)

Clamp (5)
Guide holder (1)
Hexagon nut (12)
Hexagon nut (9)
Hammer head bolt (11)
Hexagon socket bolt (8) Holding rail (7)
Pipe extension (10)
Fig. E-3: Installation of the guide holder for pipe mounting, Illustration of the pipe extension
E-4 WILO EMU 3.0

- The guide element (13) is fixed by the rubber piece (14) to the appropriate holder for the Fixing the guide elements
guide element.
- The rubber piece (14) on the guide holder (1) is compressed when the hexagon head bolt (15)
is turned.
- The lower rubber piece (14a) fixes the lower guide element (13a) in place on the pipe exten-
sion (10). This is compressed by the hexagon nut (16).
- The top guide element (13b) is fixed in position by the top rubber piece (14b). After the lower
guide element (13a) has been secured, the top rubber piece (14b) is placed on and com-
pressed with the washer (17). Compress the top rubber piece (14b) until the top guide ele-
ment (13b) can be plugged firmly in the holder.
Guide element (13b)

Hexagonal bolt (15)
Washer (17)
Rubber
piece (14b)
Pipe extension (10)
Rubber
piece (14)
Guide holder (1)
Hexagon nut (16) Spacer ring (19)
Rubber piece (14a)

Guide element (13)
Guide element (13a)
Fig. E-4: Fixing the guide elements
Installing the suspension unit - Mount the top guide holder (1). Do not tighten too securely.
- Align the coupling base (18) vertically to the guide holder (1) on the base. Mark out the drill
holes, place the anchor bolts as described in the anchor bolts assembly sheet. After they have
hardened, secure the coupling base (18) to the anchor bolts.
- Place the guide element (13) on the holder on the coupling base (18).
- Loosen the top guide holder (1) and insert in the guide element (13).
- Secure the guide holder (1) to the discharge port or the background structure and screw tight.
- Fix the guide element (13) to the guide holder (1) by turning the hexagon head bolt (15).
When using guide elements that are longer than 6m, a pipe extension
must be installed every 6m. The pipe extension functions like a guide
holder for pipe securing, only that it has two holders. A spacer ring (19)
must be placed between the two holders with single pipe models.
- Mount the pipe extension to the discharge pipe (20).

- Place the lower guide element (13a) on the holder on the coupling base (18).
- Swivel the lower guide element (13a) under the pipe extension (10).
- Insert the pipe extension (10) in the lower guide element (13a) and secure the pipe extension
(10).
- Fix the lower guide element (13a) by turning the hexagon head nut (16).
- Plug on the rubber piece (14b) and screw on the washer (17). Turn the washer (17) to com-
press the rubber piece (14b) until the top guide element (13b) can be plugged in firmly.
- Place the top guide element (13b) on the top holder of the pipe extension (10).
- Unscrew the top guide holder (1) and insert in the top guide element (13b).
- Secure the guide holder (1) to the discharge port or the background structure and screw tight.
- Fix the top guide element (13b) to the guide holder (1) by turning the hexagon head bolt (15).
E-6 WILO EMU 3.0

Guide holder (1)
Hexagonal bolt (15)
Guide element (13)
Pipe extension (10)
Guide element (13b)
Guide element (13a)
Discharge pipe (20)
Guide element (13)
Coupling base (18)
Fig. E-5: Installing the suspension unit
DN300 … to DN600… - Mount the top guide holder (1).

Shaft mounting (installation in the shaft opening): Mark drill holes, remove holder, drill holes.
suspension unit installa-
Secure the holder with securing set 1 to the shaft opening. This consists of wood screws and
tion the appropriate wall plugs or anchor bolt sets.
Pipe mounting: The guide holder (1) is attached to the discharge pipe with a clamp (2). This
has slots which can be used to compensate small tolerance levels. Securing the clamp (2) and
the holder (1) is performed using securing set 2. This consists of four machine bolts, 4 hexa-
gon nuts and 8 washers.
- Align the coupling base (3) vertically to the guide holder (1) on the base. Mark drill holes,
remove coupling base (3) and drill holes.
- Secure the coupling base (3) with securing set 3. This consists of anchor bolts sets. Please
observe the relevant assembly instructions.
If you are using a foundation frame (5) (this can only be used with DN300
and DN500), the frame must already have been set into the foundation.
Securing set 3 then only consists of four hexagon nuts each with one
washer.
- Screw on the guide element (4) on the stud (6) on the coupling base (3).
- Swing the guide element (4) under the guide holder (1) and screw in the stud (7 short) from
the top. It may be necessary to remove the guide holder (1) during this.
- Screw on the cover cap (8) on the top part of the stud (7 short).
When using guide elements that are longer than 6m, a pipe extension
must be installed every 6m.
- The pipe extension (9) is mounted like a top guide holder (1) for pipe securing.
- Screw on the guide element (4) on the stud (6) on the coupling base (3).
- The lower guide element (4) is now swung underneath the guide holder (1) of the pipe exten-
sion (9) and the stud (10 long) is screwed in from the top. If necessary, the guide holder (1) of
the pipe extension (9) may need to be removed again or pushed to the side.
- The top guide element (4) is now screwed onto the top part of the stud (10 long).
- Swing the top guide element (4) under the guide holder (1) and screw in the stud (7 short)
from the top. It may be necessary to remove the guide holder (1) during this.
- Screw on the cover cap (8) on the top part of the stud (7 short).
To prevent contact corrosion, PVC washers can be inserted between the
guide element and the guide holder on these suspension devices.
E-8 WILO EMU 3.0

Cover cap (8)
Stud (7 short)
Guide holder (1) / shaft mounting
Guide element (4)

Securing set 1
Clamp (2)
Stud (10 long)
Securing set 2
Guide holder (1) / pipe extension (9)
Coupling flange (A)
Flat seal Gasket (B)
Stud (6)
Coupling base (3)
Securing set 3
Foundation frame (5) – optional
Fig. E-6: Assembling the suspension unit
Startup - Test if the suspension unit has been installed properly in the operating area. Check if the cou-
pling flange (A) is mounted on the discharge port (B) of the machine and the sealing rubber
(C) is properly inserted in the coupling flange (A). If this is not the case, mount it with the
appropriate bolts (D) in the unit and insert the sealing rubber (C) in the coupling flange (A).
- Place the machine on firm ground and lay out the power supply cable.
- Secure the cable/chain of the lifting gear with a suitable fastening device to the handle (E) or
to the eyelet on the unit.
- Lift up the machine and swing it over the operating area. Lower the unit carefully. Ensure that
the clasp (F) of the coupling range closes around the guide element.
- Lower the machine carefully into the operating area. Hold the power supply cable lightly taut.
Make sure that it does not become damaged.
- Lower the machine carefully onto the coupling base. If the machine is coupled to the pipe
system, take the cable out of the lifting gear and secure it and the power supply cables from
falling down and becoming damaged.
- Have the machine and the safety and monitoring devices installed connected to the electric-
ity mains by a qualified technician. Please refer to the “Electrical Connection Plan" data sheet
in this operating and maintenance manual.
- Switch the system on. Check immediately that no air is introduced into the medium and the
minimum water coverage level is ensured. If air is present in the pipeline system, this must be
removed immediately using the bleeding system.
Please observe the chapter entitled “Start-up” in this operating and
maintenance manual.
E
E
A
B
F C
A
F D
C
B
Fig. E-7: Coupling flange assembly
E-10 WILO EMU 3.0

Data Sheet - Electrical Connection
F Data Sheet - Electrical Connection
The motor must be connected only by an authorized electrician: The relevant local regulations must Safety notes
be observed when laying the cables and connecting the motor. The installation of motor protection
equipment is mandatory. Refer to the Machine Data Sheet for the electrical values. The motor turns
in the correct direction with a clockwise rotary field.
The insulation resistance must not fall below 20 MOhm on commissioning. The insulation resis- Insulation resistance
tance must be >= 2 MOhm for further tests. The direct measuring voltage is 1000 V.
Monitoring equipment
Wire Recommended
Triggered
Monitoring device identificat analyzing Threshold
condition
ion device
Motor monitoring
Bimetal sensor
(1st temperature 20/21 - - Switch off
circuit)
Low temperature:
Bimetal sensor
early warning
(2nd temperature 20/21/22 - -
High temperature:
circuit)
switch off
PTC sensor
(1st temperature 10/11 CM-MSS Preset Switch off
circuit)
Low temperature:
PTC sensor
early warning
(2nd temperature 10/11/12 CM-MSS Preset
High temperature:
circuit)
switch off
PT-100 winding Depending

1/2 DGW 2.01G Switch off
temperature sensor on winding*
PT-100 bearing
T1/T2 DGW 2.01G 100°C Switch off
temperature sensor
Pressure switch D20/D21 - - Switch off
Thermo float switch 20/21 - - Switch off
Leak monitoring
Seal chamber / motor

Warning or switch
chamber / terminal DK/DK NIV 101 30 KOhm
off
chamber monitoring
Seal chamber
DK/DK ER 143 30 KOhm Switch off
monitoring for Ex
Table F-1: * Limit temperature: insulation class F = 140°, insulation class H = 160°, for oil motors = 110°,
PVC wire = 80°, PE2 wire = 90°
E:\shares\Baprod\BA\subtec_m\e_plan\us\electric.fm F-1
Wire Recommended
Triggered
Monitoring device identificat analyzing Threshold
condition
ion device
Coupling relay
Leak chamber Warning or switch
K20/21 (CM-MSS or NIV -
monitoring off
101)
Protection device provided by customer
Bimetal relay / motor Rated motor

- - Switch off
protection switch current
Dry-run protection
- - - Switch off
with float
Dry-run protection
- NIV 105 30 KOhm Switch off
with electrode
Table F-1: * Limit temperature: insulation class F = 140°, insulation class H = 160°, for oil motors = 110°,
PVC wire = 80°, PE2 wire = 90°
When used in Ex-protected The temperature monitoring system should be connected in such a manner that if the early warning
areas is triggered an automatic switch on can be performed. If a switch off is triggered then switching on
again should only be possible if the release button has been manually activated!
Wire designation of the 1 designation

connection lead 2 core
3 main cable
4 control cable
5 electrode cable
6 green-yellow
7 blue
8 black
9 brown
10 protective conductor
11 motor connection cable
12 motor connection cable beginning
13 motor connection cable end
14 motor connection cable low speed
15 motor connection cable high speed
16 cold type thermistor as per DIN 44081
17 cold type thermistor beginning
18 cold type thermistor high temperature per DIN 44081
19 cold type thermistor low temperature as per DIN 44081
20 bimetallic thermistor (break contact) 250V 2A cos j = 1
21 bimetallic thermistor beginning
22 bimetallic thermistor high temperature (break contact)
23 bimetallic thermistor low temperature (break contact)
24 temperature control Pt 100 beginning as per DIN 43760 B
F-2 WILO EMU 3.0

25 temperature control Pt 100 end as per DIN 43760 B

26 leakage float (break contact) 250V 3A cos j = 1
27 motor overpressure switch (break contact) 250V 4A cos j = 1
28 thermal float (break contact) 250V 2A cos j = 1
29 sealing chamber control
30 bearing temperature control
31 bearing temperature control Pt 100 as per DIN 43760 B
32 motor - terminal and sealing chamber control
33 motor and terminal chamber control
34 thermal float and bimetallic thermistor (break contact) 250V 2A cos j = 1
35 Thermal float and cold type thermistors as per DIN 44081
36 Screening
37 Cold type thermistors end as per DIN 44081
38 Cold type thermistors tapping as per DIN 44081
39 white
40 Motor overpressure switch and cold type thermistors as per DIN 44081
41 Thermal float and motor over pressure switch (break contact) 250V 2A cos j = 1
42 Bi-metallic thermistors and motor overpressure switch (break contact) 250V 2A cos j = 1
43 red
44 motor chamber monitor
45 motor leak and sealing chamber monitor
46 motor and sealing chamber monitor
47 yellow
48 orange
49 green
50 white-black
51 Leak monitoring
52 Bimetal & Pt 100 temperature sensor start
53 Gray
54 Gray / (blue)
55 Cold conductor temperature sensor for winding/oil as DIN 44081
E:\shares\Baprod\BA\subtec_m\e_plan\us\electric.fm F-3
DATENBLATT - ELEKTRISCHER ANSCHLUSS
Sicherheitshinweise:
Der Anschluß des Motors darf nur von einer autorisierten Elektrofachkraft vorgenommen werden. Es sind bei der
Leitungsverlegung und beim Anschließen des Motors die VDE- und die örtlichen Vorschriften zu beachten. Der
Einbau eines Motorschutzes ist zwingend vorgeschrieben. Die elektrischen Werte sind aus dem
Maschinendatenblatt zu entnehmen. Bei rechtsdrehendem Drehfeld hat der Motor die richtige Drehrichtung.
Isolationswiderstand:
Bei Erstinbetriebnahme darf der Isolationswiderstand 20 MΩ nicht unterschreiten. Bei weiteren Prüfungen muß der
Isolationswiderstand ≥2 MΩ sein. Die Meßgleichspannung ist 1000 V
Aderbezeichnung der Anschlußleitung:

Bezeichnung 1) Ader 2)
Hauptleitung 3)
6) 10)
PE grün-gelb Schutzleiter
U 3
V 4 Motoranschlußleitung 11)
W 5
20 1
Bi-Metalltemperaturfühler (Öffner) 250V 2A cos ϕ =1 20)
21 2
WILOEMU GmbH 10311111.DOC

&$EFDMBSBUJPOPGDPOGPSNJUZ
&$EFDMBSBUJPOPGDPOGPSNJUZ
G EC declaration of conformity
"DDPSEJOHUP&$EJSFDUJWF&$
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4JHOBUVSF
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www.wilo.com
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info@wilo.am info@wilo.ge roberto.valenzuela@wilo.com.mx wilo@magicnet.mn wilo@wilo-tm.info March 2009
Wilo-MVIE 1,1 --> 4 kW / Wilo-HELIX-VE 1,1 --> 4 kW
D Einbau- und Betriebsanleitung RO Instrukcja montazu i obslugi

GB Installation and operating instructions CZ Návod k montáži a obsluze
F Notice de montage et de mise en service TR Montaj ve Kullanma K›lavuzu
NL Inbouw- en bedieningsvoorschriften
I Istruzioni di montaggio, uso e manutenzione
E Instrucciones de instalación y funcionamiento
P Manual de instalação e funcionamento
NL Inbouw- en bedieningsvoorschriften
S Monterings- och skötselinstruktioner
FIN Huolto- ja käyttöohje
DK Monterings- og driftsvejledning
PL Instrukcja montażu i obsługi
4.090.994-Ed.• •-09/11
Fig. 1
100 mm 200 mm Mini HA

Mini
2%
7
2
1
6
13
5
11
100 mm Mini
BP
3
7
Fig. 2
9 12
8
11
HC
ou / or
2 4 7 2
4 3 7
10
ou / or
100 mm
Mini
6 13
Fig. 3
PN16 PN25
R ØS R
MVI
4x ØT U 4x ØT ØU
6”
S
D C D C
F G F G
A B A B
E E
ØR
4x ØT
D C
PN25 VICTAULIC
F G
A B
E
HELIX
6”
D A E D A E
ØJ ØJ
C
C
PN16 PN25
ØH
ØG ØG
F F
H
B 20 B 20
HELIX
8”
ØG ØH
A D E
C
B
Fig. 4
Fig. 5
1
2
14
Fig. 6
16
15
17
10
ou / or
Fig. 7
16
15
17
10
ou / or
Fig. 8
16
15
17
Fig. 9
18 19
Fig. 10
Fig. 11
D Einbau- und Betriebsanleitung 12
GB Installation and operating instructions 36
F Notice de montage et de mise en service 60
NL Inbouw- en bedieningsvoorschriften 84
I Istruzioni di montaggio, uso e manutenzione xx
E Instrucciones de instalación y funcionamiento xx
P Manual de instalação e funcionamento xx
N
Deutsch
1. Allgemeines 2.3 Gefahren bei Nichtbeachtung der

Sicherheitshinweise
1.1 Über dieses Dokument Die Nichtbeachtung der Sicherheitshinweise kann
Die Sprache der Originalbetriebsanleitung ist die Gefährdung von Personen, der Pumpe oder der
Französisch. Alle weiteren Sprachen dieser Anlage zur Folge haben. Die Nichtbeachtung der
Sicherheitshinweise kann zum Verlust jeglicher
Anleitung sind eine Übersetzung der Original-
Schadenersatzansprüche führen.
betriebsanleitung.
Im Einzelnen kann Nichtbeachtung beispielsweise
Die Einbau- und Betriebsanleitung ist Bestandteil folgende Gefährdungen nach sich ziehen:
des Produktes und ist immer in unmittelbarer Nähe • Versagen wichtiger Funktionen der Pumpe/
zum Erzeugnis aufzubewahren. Die strikte Anlage.
Beachtung dieser Anweisungen ist Grund- • Versagen des vorgeschriebenen Wartungs- und
voraussetzung für die ordnungsgemäße Installation Instandsetzungsprozesses.
und den Verwendungszweck des Produkts. Die • Gefährdung von Personen durch elektrische,
Einbau- und Betriebsanleitung gilt ausschließlich für mechanische oder bakteriologische
dieses Produkt und entspricht den zum Zeitpunkt Einwirkungen.
ihres Drucks geltenden Sicherheitsvorschriften. • Sachschäden.
2. Sicherheit 2.4 Sicherheitshinweise für den Betreiber

Die bestehenden Vorschriften zur Unfallver-
Diese Betriebsanleitung enthält grundlegende hütung sind zu beachten.
Gefährdungen durch elektrische Energie müssen
Hinweise, die bei Montage, Betrieb und Wartung
ausgeschlossen sein. Es sind die örtlichen oder
zu beachten sind. Daher ist diese Betriebs-
allgemeinen Bestimmungen (IEC, VDE etc.) sowie
anleitung unbedingt vor Montage und Inbetrieb- die Vorschriften des Energieversorgungs-
nahme vom Monteur sowie dem zuständigen unternehmens einzuhalten.
Fachpersonal/Betreiber zu lesen.
Es sind nicht nur die unter diesem Hauptpunkt 2.5 Sicherheitshinweise für Inspektions- und
Sicherheit aufgeführten allgemeinen Sicherheits- Montagearbeiten
hinweise zu beachten, sondern auch die unter den Der Betreiber hat dafür zu sorgen, dass alle
folgenden Hauptpunkten mit Gefahrensymbolen Inspektions- und Montagearbeiten von autori-
eingefügten, speziellen Sicherheitshinweise. siertem und qualifiziertem Fachpersonal ausge-
führt werden, das sich durch eingehendes
2.1 Kennzeichnung von Hinweisen in der Studium der Betriebsanleitung ausreichend infor-
Betriebsanleitung miert hat.
Arbeiten an der Pumpe/Anlage dürfen nur durch-
Symbole geführt werden, wenn sich die jeweiligen Geräte
im Stillstand befinden.
Allgemeines Gefahrensymbol.
Gefahr durch elektrische Spannung. 2.6 Eigenmächtiger Umbau und

Ersatzteilherstellung
HINWEIS: .... Veränderungen der Pumpe/Anlage sind nur nach
Absprache mit dem Hersteller zulässig.
Signalwörter: Originalersatzteile und vom Hersteller autorisier-
GEFAHR! Akut gefährliche Situation. Nicht- tes Zubehör dienen der Sicherheit. Die
beachtung führt zu Tod oder schwersten Verwendung anderer Teile hebt die Haftung für
die daraus entstehenden Folgen auf.
Verletzungen.
WARNUNG! Der Benutzer kann (schwere) 2.7 Unzulässige Betriebsweisen
Verletzungen erleiden. „Warnung“ weist darauf Die Betriebssicherheit des gelieferten Produkts ist
hin, dass es bei Nichtbeachtung des Hinweises nur bei bestimmungsgemäßer Verwendung ent-
zu (schweren) Körperverletzungen kommen sprechend Abschnitt 4 der Einbau- und
kann. Betriebsanleitung gewährleistet. Die im Katalog/
Datenblatt angegebenen Grenzwerte dürfen kei-
VORSICHT! Es besteht Beschädigungsgefahr für nesfalls über- oder unterschritten werden.
die Pumpe/Anlage. „Vorsicht“ verweist auf
eine Anweisung, deren Nichtbeachtung zu 3. Transport und Zwischenlagerung
Materialschäden und Funktionsstörungen füh-
ren kann. 3.1 Auslieferung
HINWEIS: Ein nützlicher Hinweis zur Handhabung Die Pumpe wird ab Werk in einer Kiste oder auf
einer Palette verpackt ausgeliefert und ist gegen
des Produktes. Er macht auch auf mögliche
Staub und Feuchtigkeit geschützt.
Schwierigkeiten aufmerksam.
3.2 Kontrolle auf ordnungsgemäßen Transport
2.2 Personalqualifikation Bei Erhalt ist die Pumpe sofort auf
Das Personal für die Montage muss die entspre- Transportschäden zu überprüfen. Liegen Schäden
chende Qualifikation für diese Arbeiten aufwei- vor, sind diese sofort innerhalb der vorgeschrie-
sen. benen Fristen dem Spediteur zu melden.
12 WILO SE 09/2011
Deutsch
3.3 Lagerung 4. Anwendung

Die Pumpe ist bis zu ihrem Einbau so zu lagern,
dass sie gegen Feuchtigkeit, Frost und mechani- Pumpen zur Förderung klarer Flüssigkeiten im
sche Beschädigungen geschützt ist. Haushalt, in der Landwirtschaft und der Industrie.
Wasserzufuhr, Wasserversorgung – Versorgung
VORSICHT! Beschädigungsgefahr aufgrund un-
von Wassertürmen – Beregnungsanlagen, Bewäs-
sachgemäßer Verpackung!
serung – Hochdruckreinigung – Kesselspeisung
Wird die Pumpe nachträglich erneut transpor-
(empfohlen mit Bypass-Set) – Kondensat-
tiert, ist sie so zu verpacken, dass Transport-
förderung – Klimatechnik – Industriekreisläufe
schäden ausgeschlossen sind. und in Verbindung mit jeglicher Art von Bau-
• Dazu muss entweder die Originalverpackung kastensystemen.
oder eine Verpackung gleicher Qualität ver-
wendet werden.
5. Angaben zum Produkt
WARNUNG! Verletzungsgefahr!
Unsachgemäßer Transport kann zu Verletzungen 5.1 Typenschlüssel
führen! HELIX-V oder MVI E 4 14 - 1 / 16 / E / 3-2
• Bei der Handhabung der Pumpe dürfen nur zuläs-
sige Hebe- und Transportmittel verwendet wer-
den. Seilaufhängungen sind im Bereich der
Pumpenflansche bzw. am Außendurchmesser Vertikale
des Motors anzubringen (eine Sicherung gegen mehrstufige
Verrutschen ist unbedingt erforderlich!). Inline-Pumpe mit hoch-
effizienter Hydraulik
Vertikale mehr-
stufige Inline-Pumpe
Mit Frequenzumformer
Nennförderstrom
in m3
Stufenzahl
1: Pumpengehäuse aus
Edelstahl AISI 304 (1.4301)
+ Hydraulik aus Edelstahl AISI 304
(1.4301/1.4307)
2: Pumpengehäuse aus Edelstahl AISI 316L
(1.4404 oder 1.4409)
• Der Schwerpunkt der Pumpe liegt verhältnis- + Hydraulik aus Edelstahl AISI 316L (1.4404)
mäßig hoch und ihre Standfläche ist gering; 3: Pumpengehäuse aus Guss GJL-250
+ Hydraulik aus Edelstahl AISI 304
daher sind beim Transport die notwendigen (1.4301 oder 1.4307)
Vorsichtsmaßnahmen zu treffen, um die Pumpe
16: Flansche PN16
gegen ein Umstürzen zu sichern und somit
25: Flansche PN25
Gefährdungen von Personen auszuschließen.
P: Victaulic-Anschlüsse
Pumpe vorsichtig handhaben, sodass Geometrie E: O-Ringe Typ EPDM (WRAS/KTW)
und Ausrichtung der Anlage nicht verändert wer- V: O-Ringe Typ FKM
den.
3-phasig/2-polig
VORSICHT! Beschädigungsgefahr aufgrund un-
sachgemäßer Verpackung! 5.2 Technische Daten
Die Anschlagösen des Motors sind nur für den - Maximaler Betriebsdruck
Transport der Einheit Motor/Frequenzumformer • Gehäuse PN25: 25 bar
vorgesehen und nicht der kompletten Pumpe. • Gehäuse PN16: 16 bar
• Gehäuse mit Schnellanschluss
für "Victaulic"-Schelle: 25 bar
(nur MVIE 4, 8, 16 m3/h)
- Maximaler Zulaufdruck: 10 bar
- Wassertemperaturbereich
• Ausführung mit EPDM-
Dichtungen/-Gleitringdichtungen
(gemäß KTW – deutsche Vorschrift) und (gemäß
WRAS – britische Norm): –15 °C bis +120 °C
• Ausführung mit FKM-Dichtung/-
Gleitringdichtungen: –15 °C bis +90 °C
- Maximale Saughöhe: je nach Haltedruck-
höhe der Pumpe
- Umgebungstemperatur: -15 °C bis +40 °C
(Standardprodukt)
WILO SE 09/2011 13
Deutsch
- Umgebungsfeuchtigkeit: < 90 % ohne 6. Beschreibung und Funktion

Betauung
- Schalldruckpegel: 1,1 kW = 63 dB(A) 6.1 Beschreibung des Produkts
2,2 kW = 66 dB(A) Pumpe
4 kW = 71 dB(A) • Vertikale mehrstufige normalansaugende Pumpe
in Inlinebauweise (Saug- und Druckstutzen lie-
- Isolationsklasse: F
gen in einer Linie).
- Schutzart: IP55 • Abdichtung am Wellendurchgang durch Norm-
- Elektromagnetische Gleitringdichtung.
Verträglichkeit (*) • Hydraulikanschluss.
• Störaussendung - Ovalflansche am Gehäuse PN 16 (6"): Pumpe wird
1. Umgebung: EN 61800-3 mit Oval-Gegenflanschen aus Guss für Schraub-
leitungen, Dichtungen und Schrauben geliefert.
• Störfestigkeit -
Rundflansche PN16 (8") und PN25: Pumpe wird
2. Umgebung: EN 61800-3
mit Dichtungen und Schrauben ohne Gegen-
- Betriebsspannung: 400 V (±10 %) 50 Hz flansche geliefert (optionales Zubehör).
380 V (±10 %) 60 Hz Schnellanschluss (MVI 6") für „Victaulic“-Schelle:
440 V (±6 %) 60 Hz Pumpe wird ohne Schellen geliefert (optionales
- Querschnitt des Versorgungs- Zubehör).
kabels (4-adrig): Einheit Motor/Frequenzumformer
• 1,1 kW: 1,5 mm2 bis 2,5 mm2 • Trockenläufermotor mit genormtem Flansch und
• 2,2/4 kW: 2,5 mm2 bis 4 mm2 Wellenstumpf für Vertikalbetrieb mit montiertem
Frequenzumformer.
(*) Im Frequenzbereich zwischen 600 MHz und 1 GHz
• Pumpen- und Motorwelle sind durch eine
kann es in Ausnahmefällen großer Nähe (< 1 m
Kupplung mit Kupplungsschutz miteinander ver-
Abstand zum Umformer) zu in diesem Frequenzbereich
bunden.
betriebenen Sendern, Gebern oder ähnlichen Geräten
zu einer Störung der Anzeige bzw. der Angabe des 6.2 Betrieb
Drucks kommen. Der Pumpenbetrieb wird dadurch
Die elektronische Regelung hat folgende Haupt-
jedoch zu keiner Zeit beeinflusst.
vorteile:
• Sparsam im Energieverbrauch
5.3 Zubehör • Reduzierung der Fließgeräusche
Zubehör ist separat zu bestellen. • Anpassung der Pumpe an unterschiedliche
• IF-Modul PLR für den Anschluss an Betriebsanforderungen.
Schnittstellenkonverter/PLR. Die folgenden Betriebsarten sind verfügbar:
• IF-Modul LON für den Anschluss an LONWORKS- • „Drehzahlregelung“: Einstellung der Frequenz
Netz. Das IF-Modul wird direkt im Anschluss- durch manuelle Betätigung oder externen Befehl.
bereich des Umformers angeschlossen (Abb. 11). • „Konstanter Druck“: Regelung über einen
• Bypass-Set. Druckgeber und Einstellung eines Sollwerts
• Absperrschieber. (intern oder extern).
• Membrandruckbehälter/verzinkte Behälter. • „PID-Regelung. “: Regelung mithilfe eines
• Druckstoßbehälter. Sensors (Temperatur, Förderstrom, ...) und
• Gegenflansch, geschweißt (Stahl) oder Einstellung eines Sollwerts (intern oder extern).
geschraubt (Edelstahl).
• Schnellkupplung vom Typ „Victaulic“. 7. Installation und elektrischer Anschluss
• Rückflussverhinderer (mit Kegel oder Federklappe
VORSICHT! Gefahr von Sachschäden!
bei Betrieb unter konstantem Druck).
Unsachgemäße Behandlung kann zu Beschä-
• Fußventil mit Saugkorb. digungen führen. Nur entsprechend qualifiziertes
• Vibrationskompensatoren. Personal darf die Pumpe installieren.
• Wassermangelschutz.
• Drucksensor-Kit (Genauigkeit ≤ 1 %; Einsatz 7.1 Vorbereitung
zwischen 30 % und 100 % des Messbereichs). - Die Montage darf erst nach Abschluss aller
Schweiß- und Lötarbeiten und nach dem even-
Eine detaillierte Liste ist im Katalog enthalten.
tuell notwendigen Spülen des Hydrauliksystems
vorgenommen werden. Verunreinigungen kön-
nen zum Funktionsausfall der Pumpe führen.
- Die Pumpen sind gegen Witterungseinflüsse zu
schützen und müssen so installiert werden, dass
ihre ausreichende Belüftung gewährleistet ist
und sie weder Staub, Frost noch
Explosionsgefahr ausgesetzt sind.
- Die Pumpe ist an einer gut zugänglichen Stelle zu
montieren, damit sie später leicht zu kontrollieren,
zu warten (z. B. Gleitringdichtungen) und auszu-
tauschen ist. Der Lufteinlass des Elektronik-
moduls darf nicht verschlossen werden.
14 WILO SE 09/2011
Deutsch
7.2 Beschreibungen (Abb. 1, 2, 5, 6, 7, 8) • Vor dem endgültigen Festziehen der

1 - Fußventil mit Saugkorb Fundamentschrauben sicherstellen, dass die
2 - Absperrventil, saugseitig Pumpe exakt lotrecht ausgerichtet ist: Bei Bedarf
3 - Absperrventil, druckseitig Keile verwenden.
4 - Rückflussverhinderer HINWEIS: Beachten, dass die Höhe des
5 - Einlass-/Entlüftungsschraube Aufstellungsorts und die Temperatur des zu för-
6 - Füll-/Entleerungsstopfen dernden Wassers das Ansaugverhalten der Pumpe
7 - Leitungsbefestigungen oder Schellen vermindern können.
8 - Saugkorb
9 - Nachspeisebehälter HINWEIS: Bei Temperaturen über 80 °C die Pumpe
10 - Trinkwassernetz für Zulaufbetrieb (Vordruck-Funktion) vorsehen.
11 - Schalter, Trennschaltverstärker mit
Sicherungen VORSICHT! Gefahr von Sachschäden!
12 - Hubhaken Die Installation muss für den Druck ausreichend
13 - Sockel sein, den die Pumpe bei maximaler Frequenz und
14 - Schieber Nullfördermenge erzeugt.
15 - Druckgeber • Pumpengehäuse mit Ovalflanschen: Rohre mit
Gewinde, direkt auf die mitgelieferten Oval-
16 - Membrandruckbehälter
Gegenflansche verschraubbar.
17 - Absperrschieber für Druckbehälter
• Pumpengehäuse mit Rundflanschen: Rohr mit
18 - Anzeige Gegenflansch verschraubbar oder verschweißbar
19 - Stellknopf (Gegenflansche als Zubehör erhältlich).
BP - Bypass • Pumpe mit Schnellanschluss: mittels Schelle, die
HA - Maximale Saughöhe per Anschlussstück am Rohr befestigt wird
HC - Minimale Zulaufhöhe (Schelle und Schraubanschluss als Zubehör
erhältlich).
7.3 Aufstellung • Der Leitungsdurchmesser darf niemals kleiner als
Es gibt zwei Standardausführungen. der des Gegenflansches sein.
Abb. 1: Saugbetrieb • Die Fließrichtung des Fördermediums ist auf dem
Abb. 2: Zulaufbetrieb aus Nachspeisebehälter Typenschild der Pumpe angegeben.
(Pos. 9) oder Trinkwassernetz (Pos. 10). VORSICHT! Gefahr von Sachschäden!
• Pumpe an einem leicht zugänglichen Ort aufstel- Die Verbindungen der Rohrleitung mit entspre-
len, der vor äußeren Einflüssen geschützt ist chenden Materialien gut abdichten! Es darf keine
(übermäßige Regen- oder Sonneneinwirkung,
Luft in die Saugleitung eintreten; Saugleitung
Frost) und sich möglichst nah an der
stetig steigend (min. 2 %) verlegen (Abb.1).
Entnahmestelle befindet.
• Die Länge der Saugleitung möglichst kurz halten
• Bei schweren Pumpen zur Vereinfachung der
und möglichst alle Ursachen vermeiden, die zu
Demontage senkrecht über der Pumpe einen
Druckverlust führen (Krümmer, Ventile,
Haken oder eine Öse (Pos. 12) mit geeigneter
Verengungen).
Tragfähigkeit anbringen.
• Stützen oder Schellen (Abb. 1 und 2, Pos. 7) ver-
• Montage auf Betonsockel (mindestens 10 cm
wenden, damit das Gewicht der Leitung nicht
hoch) (Pos. 13) mit Verankerung im Fundament
allein von der Pumpe getragen wird.
(Aufstellplan siehe Abb. 3).
• Zwischen Sockel und Boden zur Vermeidung von VORSICHT! Gefahr von Sachschäden!
Schwingungs- und Schallübertragung Bei Installation der Pumpe im Zulaufbetrieb zum
Isoliermaterial (aus Kork oder verstärktem Schutz der Pumpe vor Druckschlägen den Rück-
Kautschuk) einbringen. flussverhinderer druckseitig einbauen.
Höhenverlust Höhenverlust HINWEIS: Zum Fördern von stark sauerstoffhalti-
Höhe Temperatur
(HA) (HA) gem oder heißem Wasser ist der Einbau eines
0m 0 mCL 20 °C 0,20 mCL Bypass-Sets (Abb. 1, Pos. BP) einzubauen.
500 m 500 mCL 30 °C 0,40 mCL Die Montage des Druckgebers erfolgt dann
1000 m 1000 mCL 40 °C 0,70 mCL druckseitig an der Leitung (Abb. 7).
50 °C 1,20 mCL
60 °C 1,90 mCL
70 °C 3,10 mCL
80 °C 4,70 mCL
90 °C 7,10 mCL
100 °C 10,30 mCL
110 °C 14,70 mCL
120 °C 20,50 mCL
WILO SE 09/2011 15
Deutsch
Abmessungen und Anschlussdurchmesser für

MVIE (siehe Abb. 3)
Ausführung PN25
Ausführung PN16
Pumpentyp VICTAULIC
B C D G ØT A E F S ØU R A E F ØS ØU R E F R
200 212 180 100 20 12 157 204 50 75 M10 G1" 172 250 75 85 14 DN25 210 50 Ø42,4
400 212 180 100 20 12 157 204 50 75 M10 G1"1/4 172 250 75 100 18 DN32 210 50 Ø42,4
6"
800 252 215 130 20 12 187 250 80 100 M12 G1"1/2 187 280 80 110 18 DN40 261 80 Ø60,3
1600/6 252 215 130 20 12 187 250 90 100 M12 G2" 187 300 90 125 18 DN50 261 80 Ø60,3
HELIX-VE (Abb. 3)
Ausführung PN16 Ausführung PN25

Pumpentyp
A B C D E F G ØH D E F G ØH
200/400 100 212 180 157 204 50 G1" 2xM10 172 250 75 DN25 4xM12
600 100 212 180 157 204 50 G1"1/4 2xM10 172 250 75 DN32 4xM16
6"
1000 130 255 215 190 250 80 G1"1/2 2xM12 190 280 80 DN40 4xM16
1600 130 255 215 190 250 90 G2" 2xM12 190 300 90 DN50 4xM16
2200 130 296 215 250 300 90 DN50 4xM16 250 300 90 DN50 4xM16
8"
3600 170 296 240 250 320 105 DN65 4xM16 250 320 105 DN65 8xM16
7.4 Elektrische Anschlüsse • (Pos. b) Das Kabel für Sensor, externen Sollwert
und Eingänge [aux]/[ext.off] muss unbedingt
GEFAHR! Lebensgefahr! abgeschirmt werden und ist in die
Eine unsachgemäße Installation und/oder ein Kabelverschraubungen der Größen M12 oder M16
unsachgemäßer elektrischer Anschluss können einzuführen. Die Metall-Kabelverschraubungen
lebensgefährliche Folgen haben. des Umformers sind für die Montage einer
• Der elektrische Anschluss darf nur von einem beim Kabelabschirmung vorgesehen; siehe die nachfol-
örtlichen Energieversorgungsunternehmen (EVU) gend beschriebene Montage.
zugelassenen Elektroinstallateur entsprechend
den geltenden Vorschriften ausgeführt werden.
• Die Vorschriften zur Vermeidung von Unfällen 1
beachten.
• Erdung der Anlage nicht vergessen.
WARNUNG! Überlastung des Stromnetzes mög- 2
lich!
Die unzureichende Auslegung des Stromnetzes
kann zu Funktionsbeeinträchtigungen des
3
Systems und sogar zu Kabelbränden infolge von
Überlastung des Stromnetzes führen.
4
Durch einen Anschlussfehler kann der Umformer
beschädigt werden.
Das Elektrokabel darf niemals mit der Leitung • Die elektrischen Eigenschaften (Frequenz,
oder mit der Pumpe in Berührung kommen. Spannung, Nennstromstärke) für die Einheit
Außerdem muss es vollständig gegen Feuchtig- Motor/Frequenzumformer sind auf dem
keit geschützt sein. Typenschild der Pumpe (Pos. 19) angegeben. Es ist
• (Pos. a) Das Versorgungskabel (3 Phasen + Erde) ist zu prüfen, ob die Einheit Motor/Frequenzumformer
in die Kabelverschraubung der Größe M25 einzu- für das Stromversorgungsnetz ausgelegt ist, an das
führen. er angeschlossen werden soll.
• Die nicht verwendeten Kabelverschraubungen • Der elektrische Schutz des Motors ist in den
müssen mithilfe der vom Hersteller vorgesehenen Umformer integriert. Dieser ist so auf die Daten der
Stopfen verschlossen werden (siehe unten). Pumpe eingestellt, dass sowohl der Schutz der
Pumpe als auch des Motors gewährleistet ist.
• Bei einem zu hohen Widerstand des Nullleiters
a muss vor der Einheit Motor/Frequenzumformer
eine entsprechende Schutzvorrichtung eingebaut
werden.
b
16 WILO SE 09/2011
Deutsch
• In jedem Fall ist ein Trennschaltverstärker mit

Sicherungen (Typ GF) zum Schutz des Systems
vorzusehen (Abb. 1 und 2, Pos. 11).
HINWEIS: Falls ein Fehlerstrom-Schutzschalter
zum Schutz von Personen eingebaut werden
muss, einen selektiven allstromsensitiven
Fehlerstrom-Schutzschalter mit Verzögerung
und VDE-Zulassung verwenden. Den
Schutzschalter entsprechend den auf dem
Typenschild der Pumpe angegeben Daten ein-
stellen.
HINWEIS: Diese Pumpe ist mit einem
Frequenzumformer ausgestattet und darf nicht
mit einem FI-Schutzschalter abgesichert werden.
Frequenzumformer können die Funktion von FI-
Schutzschaltern beeinträchtigen.
Ausnahme: Selektive allstromsensitive
Fehlerstrom-Schutzschalter sind zugelassen.
• Kennzeichnung: FI
• Auslösestrom: > 30 mA.
• Normengerechte Anschlusskabel verwenden.
• Auslösecharakteristik der Sicherungen: B
• Die Ausrichtung der Einheit
Motor/Frequenzumformer kann bei Bedarf ver-
ändert werden, indem die
Befestigungsschrauben des Motors gelöst wer-
den und der Motor in die gewünschte Position
gebracht wird.
Anschließend die Befestigungsschrauben wieder
fest anziehen.
• Sobald die Spannungsversorgung des Umformers
eingeschaltet wird, wird das Display 2 Sekunden
lang getestet, wobei alle Anzeigen des Displays
aktiviert werden.
WILO SE 09/2011 17
Deutsch
Belegung der Anschlussklemmen

• Schrauben lösen und den Deckel des Umformers
abnehmen.
Bezeichnung Belegung Hinweise

L1, L2, L3 Netzspannung Drehstrom 3~ IEC38
PE Erdanschluss Vorhandensein jeder Phase überprüfen.
IN1 Eingang Sensor Art des Signals: Spannung (0–10 V, 2–10 V)
(DDS-Klemme 9) Eingangswiderstand: Ri ≥ 10 kΩ
Art des Signals: Stromstärke (0–20 mA, 4–20 mA)
Eingangswiderstand: RB = 500 Ω
Einstellbar im Menü „Service“ <5.3.0.0>
IN2 Eingang externer Sollwert Art des Signals: Spannung (0–10 V, 2–10 V)
(10 V/20 mA, Eingangswiderstand: Ri ≥ 10 kΩ
Klemme 7) Art des Signals: Strom (0–20 mA, 4–20 mA)
Eingangswiderstand: RB = 500 Ω
GND (x2) Masseanschlüsse Für jeden der Eingänge IN1 und IN2.
+24 V Gleichstromversorgung für Sensor Maximale Stromstärke: 60 mA.
Die Stromversorgung ist gegen Kurzschlüsse abgesichert.
ext.off Eingang der Steuerung ON/OFF Der potenzialfreie externe Schalter ermöglicht das
„Priorität AUS“ Aktivieren und Deaktivieren der Pumpe.
bei potenzialfreiem externen Schalter Bei Anlagen mit häufigen Anlaufvorgängen (> 20 pro Tag)
muss das Aktivieren und Deaktivieren über „ext.off“
erfolgen.
SBM Relais „Verfügbarkeitsmeldung“ Im Normalbetrieb ist das Relais aktiv, wenn die Pumpe
läuft oder betriebsbereit ist.
Das Relais wird beim ersten Auftreten einer Störung oder
bei Netzausfall deaktiviert (die Pumpe hält an).
So wird ein Schaltkasten über die (ggf. temporäre)
Verfügbarkeit einer Pumpe informiert.
Potenzialfreier Schalter:
min.: 12 V DC, 10 mA
max.: 250 V AC, 1 A
SSM Relais „Störmeldung“ Nachdem eine Serie desselben Fehlertyps (von 1 bis 6,
je nach Schweregrad),
erkannt wurde, hält die Pumpe an, und dieses Relais
wird aktiviert (bis zum Eingreifen von Hand).
Potenzialfreier Schalter:
max.: 250 V AC, 1 A
PLR Anschlussklemmen für die Das als Zubehör erhältliche optionale IF-Modul PLR ist in
PLR-Kommunikationsschnittstelle den im Anschlussbereich des Umformers befindlichen
Mehrfachstecker einzustecken.
Das Modul ist gegen Polaritätsvertauschungen abgesi-
chert.
LON Anschlussklemmen für die Das als Zubehör erhältliche optionale IF-Modul LON ist in
LON-Kommunikationsschnittstelle den im Anschlussbereich des Umformers befindlichen
chert.
HINWEIS: Die Klemmen IN1, IN2, GND und ext.off
entsprechen den Anforderungen einer „ord-
nungsgemäßen Isolation“ (gemäß EN61800-5-1)
gegenüber den Klemmen des Netzes sowie
gegenüber den Klemmen SBM und SSM (und
umgekehrt).
18 WILO SE 09/2011
Deutsch
Netzanschluss Leistungsklemmbrett
Das 4-adrige Kabel an das Leistungsklemmenbrett
anschließen (Phasen + Erde). L1 L2 L3
Anschluss der Eingänge/Ausgänge Klemmbrett Eingänge/Ausgänge

- (Pos. b) Das Kabel für Sensor, externen Sollwert und aux ext.off MP 20 mA/10 DDS
Eingänge [aux]/[ext.off] muss unbedingt abgeschirmt
1 2 3 4 5 6 7 8 9 10 11
werden.
nicht belegt nicht belegt
+24 V ...
GND ...
GND ...
In1 ...
In2 ...
Fern-
Sensor 20 mA/10 V
Externer Sollwert
steuerung
ON/OFF
• Mithilfe der Fernsteuerung kann die Pumpe in Betrieb Beispiel: Schwimmerschalter, Wassermangel-Druckregler
genommen und angehalten werden (potenzialfreier usw
Schalter); diese Funktion hat Vorrang vor den anderen
Funktionen.
• Die Fernsteuerung kann durch Überbrückung
der Klemmen (3 und 4) deaktiviert werden.
Anschlussklemmen für Kommunikationsschnittstelle

PLR Das als Zubehör erhältliche optionale IF-Modul PLR ist in
den im Anschlussbereich des Umformers befindlichen
chert.
LON Das als Zubehör erhältliche optionale IF-Modul LON ist in

den im Anschlussbereich des Umformers befindlichen
chert.
WILO SE 09/2011 19
Deutsch
Anschluss „Drehzahlregelung“ Anschlussklemmen Eingänge/Ausgänge

Manuelle Frequenzeinstellung:
aux ext.off MP 20 mA/10 DDS
1 2 3 4 5 6 7 8 9 10 11
Fern-
steuerung
Frequenzeinstellung über externe Steuerung:

1 2 3 4 5 6 7 8 9 10 11
In2 ...
Fern- Externer
steuerung Sollwert
Anschluss „Konstanter Druck“

Regelung per Druckgeber:
• 2 Adern ([20 mA/10 V]/+24 V)
1 2 3 4 5 6 7 8 9 10 11
• 3 Adern ([20 mA/10 V]/0 V/+24 V)
In1 ...
und Einstellung des Sollwerts über Drehknopf
Fern- Druck-
steuerung geber
Regelung per Druckgeber:

• 2 Adern ([20 mA/10 V]/+24 V)
1 2 3 4 5 6 7 8 9 10 11
• 3 Adern ([20 mA/10 V]/0 V/+24 V) In1 ...
In2 ...
und Regelung über externen Sollwert
Fern- Externer Druck-

steuerung Sollwert geber
Anschluss. „PID-Regelung“
Regelung per Sensor (Temperatur, Förderstrom, ...):
• 2 Adern ([20 mA/10 V]/+24 V)
1 2 3 4 5 6 7 8 9 10 11
• 3 Adern ([20 mA/10 V]/0 V/+24 V)
In1 ...
und Einstellung des Sollwerts über Drehknopf
Fern- Druck-
steuerung geber
Regelung per Sensor (Temperatur, Förderstrom, ...):

• 2 Adern ([20 mA/10 V]/+24 V)
1 2 3 4 5 6 7 8 9 10 11
• 3 Adern ([20 mA/10 V]/0 V/+24 V)
In1 ...
In2 ...
und Regelung über externen Sollwert
Fern- Externer Druck-

steuerung Sollwert geber
20 WILO SE 09/2011
Deutsch
GEFAHR! Lebensgefahr!
Durch das Entladen der Kondensatoren des Umformers
können gefährliche Spannungen anliegen.
• Nach dem Ausschalten der Stromversorgung daher stets
5 Minuten warten, bevor Eingriffe am Umformer vorge-
nommen werden.
• Sicherstellen, dass alle elektrischen Anschlüsse und
Kontakte spannungsfrei sind.
• Sicherstellen, dass die Anschlussklemmen richtig belegt
sind.
• Sicherstellen, dass Pumpe und Anlage ordnungsgemäß
geerdet sind.
Regelungsarten
IN1: Sensoreingang für Betrieb im Modus „Konstanter Druck“ oder „PID-Regelung“
Sensorsignal 4–20 mA Sensorsignal 0–10 V
100 % 100 %
Zwischen 0 und 2 mA wird davon
ausgegangen, dass das Kabel
getrennt ist
Sicherheits
Wert bereich Wert
in % in %
des Sensormess- des Sensormess-
bereichs bereichs
0 2 4 Eingangsstromstärke (mA) 20 0 Eingangsspannung (V) 10
Sensorsignal 0–20 mA Sensorsignal 2–10 V
100 % 100 %
Wert Wert
in %
des Sensormess- in %
bereichs des Sensormess-
bereichs
0 Eingangsstromstärke (mA) 20 0 2 Eingangsspannung (V) 10
WILO SE 09/2011 21
Deutsch
IN2: Eingang des externen Sollwerts für Betrieb im Modus „Konstanter Druck“ oder „PID-Regelung“
Sollwert 4–20 mA Sollwert 0–10 V
100 % 100 %
Bereich, in dem sich der Frequenz- Bereich, in dem sich der Frequenz-
umformer ausschaltet umformer ausschaltet
Sicherheits- Sicherheits-
Sollwert bereich Sollwert bereich
in % in %
des Sensormess- des Sensormess-
bereichs bereichs
0 2 4 Eingangsstromstärke (mA) 20 0 1 2 Eingangsspannung (V) 10
IN2: Eingang der externen Frequenzsteuerung im Modus „Drehzahlregelung“
Externes Signal 0–20 mA Externes Signal 0–10 V
100 % 100 %
Frequenz bereich Frequenz bereich
des Umformers des Umformers
~ 30 % ~ 30 %
Externes Signal 4–20 mA Externes Signal 2–10 V
100 % 100 %
Frequenz bereich Frequenz bereich
des Umformers des Umformers
~ 30 % ~ 30 %
22 WILO SE 09/2011
Deutsch
8. Inbetriebnahme 8.1.3 Beschreibung der Standardsymbole
8.1 Einstellung Symbol Beschreibung

8.1.1 Steuerungselemente Betrieb im Modus
Der Frequenzumformer nutzt die folgenden „Drehzahlregelung“.
Steuerungselemente: Betrieb im Modus „Konstanter Druck“
Ausführung mit Drehknopf oder „PID-Regelung“. .
Einstellung über den Drehknopf:
Eingang IN2 aktiviert
2
(externer Sollwert).
Zugangsverriegelung.
Wird dieses Symbol angezeigt, kön-
• Ein neuer Parameter wird durch einfaches Drehen nen die aktuellen Einstellungen bzw.
eingestellt. „+“ nach rechts und „–“ nach links. Messwerte nicht geändert werden.
• Durch Drücken des Drehknopfes wird die neue Die angezeigten Informationen
Einstellung übernommen. können nur gelesen werden.
Schalter BMS (Building Management System,
Gebäude-Management-System)
ON
PLR oder LON ist aktiviert.
Pumpe in Betrieb.
1 2
• Der Umformer besitzt eine Einheit mit zwei Pumpe ist angehalten.
Schaltern (Abb. 4, Pos. S) mit jeweils zwei
Stellungen:
• Über Schalter 1 kann vom Modus „OPERATION“
(Schalter 1 OFF) zum Modus „SERVICE“ (Schalter 1 8.1.4 Anzeige
ON) und umgekehrt umgeschaltet werden.
Die Stellung „OPERATION“ gibt den Betrieb in Statusseite des Displays
dem gewählten Modus frei und verriegelt den • Die Statusseite des Displays wird standardmäßig
Zugang zur Parametrierung (Normalbetrieb). angezeigt.
Die Stellung „SERVICE“ erlaubt das Parametrieren Der aktuelle Sollwert wird angezeigt.
der verschiedenen Funktionen. Die Grundeinstellungen werden mithilfe von
Symbolen angezeigt.
• Über Schalter 2 lässt sich die „Zugangs-
verriegelung“ aktivieren und deaktivieren.
8.1.2 Aufbau des Displays
1 4
2 5
4 3 4 Beispiel für die Statusseite
HINWEIS: In allen Menüs kehrt das Display wieder

zur Statusseite zurück, wenn der Drehknopf
• Sobald die Spannungsversorgung des Umformers
nicht innerhalb von 30 Sekunden betätigt wird;
eingeschaltet wird, wird das Display 2 Sekunden
in diesem Fall wird keine Änderung übernommen.
lang getestet, wobei alle Anzeigen des Displays
aktiviert werden.
Pos. Beschreibung
1 Nummer des Menüs
2 Anzeige des Werts
3 Anzeige der Einheit
4 Standardsymbole
5 Anzeige der Piktogramme
WILO SE 09/2011 23
Deutsch
Navigationselement <3.0.0.0>
• Die verschiedenen Funktionen des Umformers
werden über die Menüstruktur aufgerufen. Position Schalter 1 Beschreibung
Jedem Menü und Untermenü ist eine Nummer
zugeordnet. OPERATION OFF
Regelung Ein/Aus der
• Durch Drehen des Drehknopfes kann innerhalb
der gleichen Ebene eines Menüs geblättert wer- Pumpe.
SERVICE ON
den (z. B. 4000 -> 5000).
• Alle blinkenden Elemente (Wert, Menünummer,
<4.0.0.0>
Symbol oder Piktogramm) können geändert wer-
den, d. h. es kann ein neuer Wert, eine neue
Menünummer oder eine neue Funktion ausge- Position Schalter 1 Beschreibung
wählt werden.
OPERATION OFF Nur Lesen des Menüs
„Informationen“
Symbol Beschreibung möglich.
SERVICE ON
Wenn der Pfeil angezeigt wird: • Das Menü „Information“ zeigt die Mess-, Geräte-
• Drücken des Drehknopfes ermög- und Betriebsdaten an (Abb. 13).
licht den Zugang zu einem
Untermenü (z. B. 4000 -> 4100). <5.0.0.0>
Position Schalter 1 Beschreibung

Wenn der Zurück-Pfeil angezeigt wird:
• Drücken des Drehknopfes ermög- Nur Lesen des Menüs
OPERATION OFF
licht den Zugang zu einem „Service“ möglich.
übergeordneten Menü Einstellen des Menüs
SERVICE ON
(z. B. 4150 -> 4100). „Service“.
• Das Menü „Service“ ermöglicht den Zugang zur

Parametereinstellung des Umformers.
8.1.5 Beschreibung der Menüs
<6.0.0.0>
Liste (Abb. 12)
<1.0.0.0> Position Schalter 1 Beschreibung
Position Schalter 1 Beschreibung OPERATION OFF

Anzeige der Statusseite.
OPERATION OFF SERVICE ON
Einstellen des Sollwerts;
in beiden Fällen möglich.
SERVICE ON • Wenn eine oder mehrere Störungen vorliegen,
wird die Störungsseite angezeigt.
• Zum Einstellen des Sollwerts den Drehknopf dre- Der Buchstabe „E“ gefolgt von drei Ziffern wird
hen. Das Display wechselt zum Menü <1.0.0.0>, angezeigt (Kapitel 11).
und der Sollwert blinkt. Durch erneutes Drehen <7.0.0.0>
kann der Wert erhöht oder verringert werden.
• Zum Bestätigen des neuen Werts auf den
Position Schalter 1 Beschreibung
Drehknopf drücken; das Display kehrt zur
Statusseite zurück.
OPERATION OFF
<2.0.0.0> Anzeige des Symbols für
„Zugangsverriegelung“.
Position Schalter 1 Beschreibung SERVICE ON
Nur Ablesen der • Die „Zugangsverriegelung“ ist nur möglich, wenn

OPERATION OFF
Betriebsarten möglich. sich Schalter 2 in Stellung ON befindet.
Einstellen der VORSICHT! Gefahr von Sachschäden!
SERVICE ON
Betriebsarten. Jede falsche Einstellung kann zu einer
Funktionsbeeinträchtigung der Pumpe führen
• Betriebsarten sind „Drehzahlregelung“, und auf diese Weise Sachschäden an Pumpe
„Konstanter Druck“ und „PID-Regelung“ . oder Anlage verursachen.
• Die Einstellungen im Modus „SERVICE“ nur bei
Inbetriebnahme vornehmen und diesen Schritt
nur durch fachkundige Spezialisten ausführen
lassen.
24 WILO SE 09/2011
Deutsch
Abb. 12
Navigation in den Basismenüs bei Normalbetrieb

(Schalter1 = OFF in Position „OPERATION“)
Einstellung des Punktes
Regelungstyp
Pumpe Ein/Aus
Informationen
SERVICE
Quittierung
von Störungen
Wird angezeigt, wenn

ein Fehler vorliegt
WILO SE 09/2011 25
Deutsch
Abb. 13
Navigation in Menü <4.0.0.0> „Informationen“
Informationen
Istwerte
Druck Wird nicht angezeigt, wenn

oder % „Drehzahlregelung“ aktiviert ist
Leistung
Betriebsdaten
Betriebsstunden
Verbrauch
Zähler für
Netzunterbrechung
Istbedingungen
Iststatus
SSM-Relais
Iststatus Siehe Kapitel 11, Menü <5.7.6.0>
SBM-Relais Standard: „Verfügbarkeitsmeldung“
Eingangsstatus
ext.off
Gerätedaten
Bezeichnung
Pumpe
Software-Version
Benutzerschnittstelle
Software-Version
Motorregelung
26 WILO SE 09/2011
Deutsch
Parametrierung in den Menüs <2.0.0.0> und <5.0.0.0>

Die Parameter der Menüs <2.0.0.0> und <5.0.0.0> können im Modus „SERVICE“ geändert werden.
Es gibt zwei Einstellmodi:
• Modus „Easy“: Schnellmodus zum Parametrieren der 3 Betriebsarten.
• Modus „Expert“: Modus für den Zugang zu allen Parametern. ON
• Schalter 1 in Stellung ON bringen (Abb. 4, Pos. S). S
• Der Modus „SERVICE“ ist aktiviert.
Auf der Statusseite des Displays blinkt das nebenstehend gezeigte Symbol (Abb. 14). 1
Abb. 14
Modus „Easy“
SERVICE
Regelungstyp
Modus „Easy“
Einstellung des Punktes
Regelungstyp
Modus Expert
Modus Expert
Pumpe
Informationen
OPERATION
ON
SERVICE
1 2
Modus „Easy“
• Drehknopf 2 Sekunden lang gedrückt halten. Das Symbol für Modus „Easy“ wird angezeigt (Abb. 14).
• Drehknopf drücken, um die Auswahl zu bestätigen. Das Display springt zur Menünummer <2.0.0.0>.
Mithilfe des Menüs „Modus Easy“ könne die 3 Betriebsarten schnell parametriert werden (Abb. 15)
• „Drehzahlregelung“
• „Konstanter Druck“
• „PID- Regelung“
• Nach dem Festlegen der Einstellungen Schalter 1 wieder in Stellung OFF bringen (Abb. 4, Pos. S).
Modus „Expert“
• Drehknopf 2 Sekunden lang gedrückt halten. In den Expert-Modus wechseln; das Symbol
für den Modus „Expert“ wird angezeigt (Abb. 14).
• Drehknopf drücken, um die Auswahl zu bestätigen. Das Display springt zur Menünummer <2.0.0.0>.
Zunächst im Menü <2.0.0.0> die Betriebsart auswählen.
• „Drehzahlregelung“
• „Konstanter Druck“
• „PID- Regelung“
Jetzt gibt der Expert-Modus im Menü <5.0.0.0> den Zugang zu allen Parametern des Umformers frei (Abb. 16).
• Nach dem Festlegen der Einstellungen Schalter 1 wieder in Stellung OFF bringen (Abb. 4, Pos. S).
WILO SE 09/2011 27
Deutsch
Abb. 15
Drehzahlregelung
Mit internem Sollwert
Eingang externer Sollwert – IN2 MENÜ

deaktiviert – Auswahl OFF
EASY
Eingang externer Sollwert – IN2
aktiviert – Auswahl ON
Mit externem Sollwert

Auswahl des Signaltyps
Konstanter Druck
Sensoreingang – IN1
Auswahl des Druckgebers
Mit internem Sollwert


Mit externem Sollwert

PID-Regelung

PID-Parametrierung
Auswahl Wert „P“ (0.0–300.0)
PID-Parametrierung
Auswahl Wert „I“ (10 ms–300 s) Mit internem Sollwert
PID-Parametrierung
Auswahl Wert „D“ (0 ms–300 s)


PID-Parametrierung
Auswahl Wert „P“ (0.0–300.0)
PID-Parametrierung
Auswahl Wert „I“ (10 ms–300 s) Mit externem Sollwert
PID-Parametrierung
Auswahl Wert „D“ (0 ms–300 s)
28 WILO SE 09/2011
Deutsch
Abb. 16
MENÜ
EXPERT
SERVICE
Wird angezeigt, wenn „BMS“ aktiviert
BMS: Building Management System ist. Siehe Anleitung zu diesem Produkt
Wird nicht angezeigt, wenn
IN1 – „Sensoreingang“ „Drehzahlregelung“ aktiviert ist
Auswahl Sensor Wird nicht angezeigt, wenn
„PID-Regelung“ aktiviert ist
Auswahl Signalbereich
IN2 – „Eingang externe Steuerung“
Auswahl
Auswahl Signalbereich Wird nicht angezeigt, wenn

„IN2“ deaktiviert ist
Wird angezeigt, wenn

PID-Parameter „PID-Regelung“ aktiviert ist
Auswahl
Parameter „P“
Auswahl
Parameter „I“
Auswahl
Parameter „D“
Weitere Einstellungen
Auswahl Abschaltzeit Wird angezeigt, wenn

bei Nullförderstrom „Druckregelung“ aktiviert ist
Auswahl
reduzierte Frequenz
Auswahl Funktion
SBM-Relais
Auswahl
Werkseinstellung
WILO SE 09/2011 29
Deutsch
Zugangsverriegelung 8.3 Befüllung – Entlüftung

Um die Einstellungen der Pumpe zu sperren,
kann die Funktion „Zugangsverriegelung“ ver-
Die Pumpe niemals trocken laufen lassen,
wendet werden.
auch nicht für kurze Zeit!
Zum Aktivieren oder Deaktivieren wie folgt vor-
Pumpe im Zulaufbetrieb (Abb. 2).
gehen:
• Druckseitiges Absperrventil (Pos. 3) schließen.
• Schalter 2 in Stellung ON bringen (Abb. 4, Pos. S).
• Einlass-/Entlüftungsschraube (Pos. 5) öffnen,
Menü <7.0.0.0> wird aufgerufen.
saugseitiges Absperrventil (Pos. 2) öffnen und
• Den Drehknopf drehen, um die Verriegelung zu
die Pumpe vollständig befüllen.
aktivieren oder deaktivieren. Der aktuelle Status
• Die Einlass-/Entlüftungsschraube erst schließen,
der Verriegelung wird durch folgende Symbole
wenn Wasser austritt und keine Luftblasen mehr
angezeigt:
zu sehen sind.
Verriegelung aktiviert: Die Parameter
WARNUNG! Verbrennungsgefahr!
sind gesperrt, der Zugang zu den
Bei Heißwasser kann ein Wasserstrahl aus der
Menüs erfolgt nur im Anzeigemodus.
Entlüftungsöffnung austreten.
• Alle notwendigen Vorsichtsmaßnahmen für
Verriegelung deaktiviert: Die
Personen und die Einheit Motor/Frequenz-
Parameter können geändert werden,
umformer treffen.
der Zugang zu den Menüs ist zum
Ausführen von Änderungen freigege- Pumpe im Ansaugbetrieb (Abb. 1, 5)
ben. Zwei Fälle sind möglich:
• Schalter 2 in Stellung OFF bringen (Abb. 4, Pos. S). 1. Fall (Abb. 5.1)
Es wird wieder die Statusseite angezeigt. • Druckseitiges Absperrventil schließen (Abb. 1,
Pos. 3), saugseitiges Absperrventil öffnen
8.1.6 Einstellungen (Abb. 1, Pos. 2).
• Den Entlüftungsstopfen entfernen (Abb. 1, Pos. 5).
HINWEIS: Wird die Pumpe allein, d. h. ohne ein • Unteren Entleerungsstopfen am Pumpengehäuse
von uns integriertes System geliefert, ist die (Abb. 1, Pos. 6) lockern (ca. 4 Umdrehungen).
Auslieferungskonfiguration der Modus • Mithilfe eines in die Entleerungsöffnung einge-
„Drehzahlregelung“. führten Trichters Pumpe und Ansaugleitung voll-
ständig befüllen.
Modus „Drehzahlregelung“ (Abb. 1, 2)
• Wenn Wasser austritt und sich keine Luft mehr in
Der Betriebspunkt wird entweder durch manuelle
der Pumpe befindet, ist die Befüllung abge-
Einstellung oder durch externe Steuerung der
schlossen.
Frequenz eingestellt.
• Entlüftungsstopfen und unteren Entleerungs-
• Wir empfehlen, die Motordrehzahl bei
stopfen wieder zuschrauben.
Inbetriebnahme auf 2400 U/min einzustellen.
2. Fall (Abb. 5.2)
Modus „Konstanter Druck“ (Abb. 6, 7, 8) • Das Befüllen kann vereinfacht werden, indem an
Regelung über einen Druckgeber und Einstellung der Ansaugleitung der Pumpe ein mit Absperr-
eines Sollwerts (intern oder extern). schieber und Trichter ausgestattetes vertikales
• Durch Ergänzung mit einem Druckgeber (mit Rohr mit Ø ½" (Abb. 5, Pos. 14) installiert wird.
Behälter; Sensor-Bausatz als Zubehör lieferbar) HINWEIS: Das obere Ende des Rohrs muss sich
kann der Pumpendruck geregelt werden (ohne mindestens 50 mm über dem Entleerungshahn
Wasser im Membrandruckbehälter; den befinden.
Membrandruckbehälter bis zu einem Druck auf-
füllen, der 0,3 bar unter dem Regeldruck der • Druckseitiges Absperrventil schließen (Abb. 1,
Pumpe liegt). Pos. 3), saugseitiges Absperrventil öffnen
• Der Sensor muss eine Genauigkeit von ≤ 1 % (Abb. 1, Pos. 2).
aufweisen und in einem Bereich zwischen 30 % • Schieber (Abb. 5, Pos. 14) und Einlass-/
und 100 % seines Messbereichs verwendet wer- Entlüftungsschraube öffnen.
den; der Behälter hat ein Nutzvolumen von min- • Entleerungsstopfen (Abb. 1, Pos. 6) lockern
destens 8 Litern. (ca. 4 Umdrehungen).
• Wir empfehlen, den Druck bei Inbetriebnahme • Pumpe und Ansaugleitung komplett befüllen,
auf 60 % des Maximaldrucks einzustellen. bis Wasser aus der Einlass-/Entlüftungsschraube
austritt.
Modus „PID-Regelung“ • Schieber (Abb. 5, Pos. 14) schließen (kann an Ort
Regelung mithilfe eines Sensors (Temperatur, und Stelle verbleiben), Rohr entfernen, Einlass-/
Förderstrom, ...) und Einstellung eines Sollwerts Entlüftungsschraube (Abb. 1, Pos. 5) schließen,
(intern oder extern). Entleerungsstopfen (Abb. 1, Pos. 6) wieder
zuschrauben.
8.2 Vorbereitende Spülung VORSICHT! Gefahr falscher Bedienung!
Unsere Pumpen werden im Werk hydraulisch Bei einer Pumpe in Zulaufbetrieb und Modus
getestet, es ist daher möglich, dass sich noch „Konstanter Druck“ funktioniert das Erfassen
Wasser im Inneren befindet. Aus Gründen der des Nullförderstroms möglicherweise nicht.
Hygiene wird daher vor jedem Einsatz der Pumpe in • Rückflussverhinderer hinter dem Drucksensor
einem Trinkwassernetz eine Spülung empfohlen. montieren (d.h. saugseitig, wenn der Sensor an
der Pumpe montiert ist - siehe Abb. 6)
30 WILO SE 09/2011
Deutsch
8.4 Anlauf 9. Wartung

WARNUNG! Verbrennungsgefahr! Nur qualifiziertes Fachpersonal ist berechtigt,
Je nach Medientemperatur und Betriebszyklen Wartungs- und Instandsetzungsarbeiten
der Pumpe kann die Oberflächentemperatur durchzuführen!
(Pumpe, Motor) mehr als 68 °C betragen.
• Gegebenenfalls erforderliche Personenschutz- Es wird empfohlen, die Pumpe durch einen Kunden-
vorrichtungen installieren! diensttechniker warten und kontrollieren zu lassen.
VORSICHT! Gefahr von Sachschäden! GEFAHR! Lebensgefahr!
Bei Nullförderstrom (druckseitiges Bei Arbeiten an der elektrischen Ausrüstung
Absperrventil geschlossen) darf die Pumpe besteht Lebensgefahr infolge von Strom-
bei kaltem Wasser (T < 40 °C) nicht länger als schlägen.
10 Minuten laufen, bei warmem Wasser • Arbeiten an der elektrischen Ausrüstung dür-
(T < 60 °C) nicht länger als 5 Minuten über fen nur durch vom örtlichen Energieversor-
60 °C hinaus. gungsunternehmen zugelassene Elektro-
• Wir empfehlen die Einhaltung einer Mindest- installateure durchgeführt werden.
fördermenge von etwa 10 % des Nennförder- • Vor Arbeiten an der elektrischen Ausrüstung
stroms der Pumpe, damit sich im oberen Teil der diese spannungsfrei machen und gegen jegli-
Pumpe kein Gaseinschluss bildet. ches Wiedereinschalten der Spannung sichern!
• Druckseitiges Absperrventil geschlossen halten.
WARNUNG! Verbrennungsgefahr!
• Pumpe starten.
Es können sehr hohe Oberflächentemperaturen
• Einlass-/Entlüftungsschraube öffnen, damit die
Luft entweichen kann. Falls nach 20 Sekunden kein entstehen.
gleichmäßiger Wasserstrahl aus der Öffnung aus- • Vor Arbeiten an der Pumpe diese abkühlen lassen.
tritt, die Einlass-/Entlüftungsschraube schließen, • Bei allen Arbeiten Schutzbekleidung und
die Pumpe anhalten und dann ca. 20 Sekunden Schutzhandschuhe tragen.
warten, damit sich Luft sammeln kann. • Während des Betriebs ist keine besondere
• Pumpe erneut starten. Wartung notwendig.
HINWEIS: Falls nötig (vor allem bei Saughöhen über • Pumpe und Einheit Motor/Frequenzumformer
5 m) diese Schritte wiederholen. stets in einwandfrei sauberem Zustand halten.
• Bei frostsicherem Standort sollte die Pumpe auch
• Wenn aus der Entlüftungsöffnung ein gleichmä-
bei längerer Außerbetriebnahme nicht entleert
ßiger Wasserstrahl austritt (die Pumpe also Druck
werden.
liefert), langsam das druckseitige Absperrventil
öffnen. Die Pumpe muss jetzt angesaugt haben. • Kupplungs- und Motorlager sind für die kom-
• Stabilität des Drucks mit einem Manometer plette Lebensdauer gefettet und müssen daher
überprüfen, bei Druckschwankungen erneut ent- nicht geschmiert werden.
lüften. • Die Gleitringdichtung bedarf während des
• Falls dies fehlschlägt, Pumpe erneut füllen und Betriebs keinerlei Wartung. Sie darf niemals
von vorn mit den Arbeitsgängen beginnen. trocken laufen.
• Zum Abschließen der Entlüftung das druckseitige
Absperrventil und die Einlass-/Entlüftungs- Austauschintervalle.
schraube schließen. Pumpe für 20 Sekunden
HINWEIS: Es kann sich hier nur um Empfehlungen
anhalten. Danach die Pumpe erneut starten und
die Einlass-/Entlüftungsschraube öffnen. Falls handeln, da die Häufigkeit des Austausches von
Luft entweicht, Arbeitsschritte erneut durchfüh- den Betriebsbedingungen des Aggregats
ren. abhängt, d. h.:
• Druckseitiges Absperrventil öffnen, um die • Temperatur, Druck und Qualität des
Pumpe mit dem gewünschten Betriebspunkt zu Fördermediums für die Gleitringdichtung.
betreiben. • Belastung und Umgebungstemperatur für Motor
• Sicherstellen, dass die Stromaufnahme geringer und andere Bauteile.
oder gleich dem auf dem Typenschild der Einheit • Anlaufhäufigkeit: Dauer- oder zeitweiliger
Motor/Frequenzumformer angegebenen Wert ist. Betrieb.
Gleitring- Lager von Wicklung

Verschleißteil oder -komponente Umformer
dichtung Pumpe und Motor des Motors
≥ 15.000 h 25.000 h
10.000 h bis 12.000 h bis
Lebensdauer Max. Umgeb.temp. Max. Umgeb.temp.
20.000 h 50.000 h
40 °C 40 °C
Austausch- Dauerbetrieb 1 bis 2 Jahre 1,5 bis 5 Jahre 1 bis 3 Jahre 3 Jahre
intervall 15 Betriebsstunden/Tag
2 bis 4 Jahre 3 bis 10 Jahre – 6 Jahre
9 Monate im Jahr
WILO SE 09/2011 31
Deutsch
10. Störungen – Erkennung –

Instandsetzung
Störungen nur durch qualifiziertes Personal
beseitigen lassen!
Sicherheitsanweisungen beachten;
siehe Kapitel 9 zur Wartung.
Relais
Der Umformer ist mit zwei Ausgangsrelais für
die zentrale Steuerung ausgestattet. Beispiel:
Schaltkasten, Pumpenüberwachung.
SBM-Relais:
Für dieses Relais können im Menü „Service“
<5.7.6.0> 3 Betriebsarten eingestellt werden.
Modus: 1 (Standardeinstellung)
Relais „Verfügbarkeitsmeldung“
(Standardfunktion bei diesem Pumpentyp).
Das Relais ist aktiv, wenn die Pumpe funktioniert
oder betriebsbereit ist.
Das Relais wird beim ersten Auftreten einer
Störung oder bei Netzausfall deaktiviert (die
Pumpe hält an).
So wird ein Schaltkasten über die (ggf. temporä-
re) Verfügbarkeit einer Pumpe informiert.
Modus: 2
Relais „Störungsmeldung“.
Das Relais ist aktiv, wenn die Pumpe läuft.
Modus: 3
Relais „Aktivierungsmeldung“.
Das Relais ist aktiv, wenn die Pumpe unter
Spannung ist.
SSM-Relais:
Relais „Störmeldung“.
Nachdem eine Serie desselben Fehlertyps (von 1
bis 6, je nach Schweregrad) erkannt wurde, hält
die Pumpe an, und dieses Relais wird aktiviert Fehler 1 2 3 4 5 6
(bis zum manuellen Eingreifen).
Beispiel: 6 Störungen unterschiedlicher Dauer

innerhalb von 24 Stunden (gleitend). Relais
aktiv
Status des SBM-Relais in "Verfügbarkeitsmeldung".
SBM
Relais in
Ruhe-
zustand
Relais
aktiv
SSM
Relais in
Ruhe-
zustand
24 Stunden gleitend
32 WILO SE 09/2011
Deutsch
10.1 Störungsübersicht
Bei allen nachfolgend aufgeführten Störfällen tritt Folgendes ein:
• Das SBM-Relais schaltet in den Ruhezustand (bei Einstellung auf Modus „Verfügbarkeitsmeldung“).
• Das SSM-Relais wird aktiviert („Störmeldung“), wenn innerhalb von 24 Stunden die maximale Anzahl von Fehlern
eines Typs erreicht wird.
• Eine rote LED leuchtet auf.
Zeit Max.
vor
Reaktions- Berücksich- Fehler Wartezeit
Wartezeit bis inner-
Fehler- zeit vor Störung bis
code Anzeige tigung der zum automatischen halb Mögliche Ursachen Beseitigung zum
des Fehlers Störung
deren
nach Wiedereinschalten von
24 Reset
Anzeige Stunden
Die Pumpe ist überlastet, Zu hohe Dichte und/oder Viskosität
defekt des Fördermediums.
E001 60s Sofort 60 s 6 300 s
Die Pumpe ist durch Pumpe demontieren, defekte Bauteile
Fremdkörper blockiert ersetzen oder reinigen.
E004 Sofort, wenn Störung Die Versorgung des Umformers Spannung an den Klemmen des
~5s 300 s 6 Frequenzumformers überprüfen: 0s
(E032 beseitigt hat Unterspannung • Störung, wenn Netz < 330 V
E005 ~5s 300 s Sofort, wenn Störung 6 Die Versorgung des Umformers Spannung an den Klemmen des
Frequenzumformers überprüfen: 0s
(E033) beseitigt hat Überspannung
• Störung, wenn Netz > 480 V
E006 ~5s 300 s Sofort, wenn Störung 6 Eine Phase der Versorgung Stromversorgung überprüfen. 0s
beseitigt fehlt
Umformer funktioniert als
E007 Sofort Sofort Sofort, wenn Störung Keine Pumpe läuft rückwärts; Dichtheit der
beseitigt Grenze Generator. Warnung Klappe überprüfen. 0s
ohne Abschalten der Pumpe
Pumpe demontieren, reinigen und
E010 ~5s Sofort Kein 1 Die Pumpe ist blockiert defekte Bauteile ersetzen. Eventuell 60 s
Wiedereinschalten mechanische Störung des Motors
(Lager).
Pumpe wieder befüllen
E011 15 s Sofort 60 s 6 Die Pumpe läuft leer (siehe Kapitel 8.3). 300 s
oder trocken Dichtigkeit des Fußventils überprü-
fen.
Der Motor läuft heiß Kühlrippen des Motors reinigen.
E020 ~5s Sofort 300 s 6 Der Motor ist für eine 300 s
Umgebungstemperatur Umgebungstemperatur bis maximal
über +40 °C +40 °C ausgelegt.
Einheit Motor/Frequenzumformer der
E023 Sofort Sofort 60 s 6 Es liegt ein Motor- Pumpe demontieren und überprüfen 60 s
kurzschluss vor
oder ersetzen lassen.
E025 Sofort Sofort Kein 1 Eine Phase des Motors Verbindung zwischen Motor und 60 s
Wiedereinschalten fehlt Umformer überprüfen
Die Thermosonde des Motors Einheit Motor/Frequenzumformer der
E026 ~5s Sofort 300 s 6 ist defekt oder ist nicht richtig Pumpe demontieren und überprüfen 300 s
angeschlossen oder ersetzen lassen.
Der Frequenzumformer läuft Die Kühlrippen hinten und unter dem

Frequenzumformer und die
heiß Lüfterhaube reinigen.
E030
E031 ~5s Sofort 300 s 6 300 s
Der Umformer ist für eine
Umgebungstemperatur
über +40 °C Umgebungstemperatur bis maximal
+40 °C ausgelegt.
E042 ~5s Sofort Kein 1 Das Sensorkabel Korrekte Stromversorgung und 60 s

Wiedereinschalten (4–20mA) ist getrennt Verkabelung des Sensors prüfen.
E050 60 s Sofort Sofort, wenn Störung Keine Die BMS-Kommunikation ist Verbindung überprüfen. 300 s
beseitigt Grenze gestört
E070 Sofort Sofort Kein 1 Störung der internen Kundendienst kontaktieren. 60 s

Wiedereinschalten Kommunikation
E071 Sofort Sofort Kein Wiedereinschalten 1 EEPROM-Störung Kundendienst kontaktieren. 60 s
E072 Sofort Sofort Kein 1 Internes Problem des Kundendienst kontaktieren. 60 s
E073 Wiedereinschalten Umformers
E075 Sofort Sofort Kein 1 Störung des Relais für die Kundendienst kontaktieren. 60 s
Wiedereinschalten Einschaltstrombegrenzung
E076 Sofort Sofort Kein Wiedereinschalten 1 Störung des Sensorstroms Kundendienst kontaktieren. 60 s
E077 Sofort Sofort Kein Wiedereinschalten 1 24-V-Fehler Kundendienst kontaktieren. 60 s
E099 Sofort Sofort Kein 1 Pumpentyp unbekannt Kundendienst kontaktieren. Versorgung

Wiedereinschalten Aus/Ein
WILO SE 09/2011 33
Deutsch
10.2 Quittieren von Störungen

Störungen erst quittieren, nachdem die Ursache
beseitigt wurde.
• Nur fachkundige Techniker dürfen Störungen
beseitigen.
• Im Zweifelsfall den Hersteller hinzuziehen.
• Bei einer Störung wird anstelle der Statusseite
die Störungsseite angezeigt.
Zum Quittieren der Störungen wie folgt vorgehen:
• Drehknopf drücken.
Auf dem Display wird Folgendes angezeigt:
• Die Nummer des Menüs <6.0.0.0>.
• Die Anzahl der Fehler sowie die innerhalb von
24 Stunden maximal zulässige Anzahl des jewei-
Beispiel für eine ligen Fehlers (Beispiel: 1/6).
Störungsseite. • Die verbleibende Zeit in Sekunden bis zur auto-
matischen Reinitialisierung der Störung.
Beispiel für die

Statusseite.
• Zeitspanne bis zur automatischen

Reinitialisierung abwarten.
Eine systeminterne Zeitschaltung wird aktiviert.
Die Restzeit (in Sekunden) wird bis zum automa-
tischen Quittieren der Störung angezeigt.
• Nachdem die maximale Anzahl an Fehlern
erreicht und die letzte Zeitschaltung abgelaufen
ist, den Drehknopf drücken und so die Störung
quittieren.
Das System kehrt zur Statusseite zurück.
HINWEIS: Wenn eine Zeit vor Berücksichtigung
der Störung nach deren Anzeige programmiert ist
(Beispiel: 300 s), muss die Störung auf jeden Fall
manuell quittiert werden.
Die Zeitschaltung zur automatischen Reinitiali-
sierung ist nicht aktiv, und es wird „ - - - “ ange-
zeigt.
34 WILO SE 09/2011
Deutsch
10.3 Sonstige Störfälle

Weitere pumpeneigene, durch den Umformer
nicht erkennbare Störungen.
Fehler Ursache Beseitigung

Die Pumpe läuft, fördert jedoch nicht Die Pumpe läuft nicht schnell genug. Korrekte Einstellung des Sollwerts über-
prüfen (Übereinstimmung mit Sollwert).
Innere Bauteile sind durch Fremdkörper Pumpe demontieren und reinigen.
blockiert.
Saugleitung verstopft. Gesamte Leitung reinigen.
Lufteintritt in der Saugleitung. Dichtigkeit der gesamten Leitung bis zur
Pumpe überprüfen und abdichten.
Ansaugdruck zu gering, in der Regel Zu große Verluste beim Ansaugen oder
begleitet von Kavitationsgeräuschen. Saughöhe zu groß (Haltedruckhöhe der
installierten Pumpe und der
Gesamtinstallation überprüfen).
Die Pumpe vibriert Ungenügende Befestigung auf dem Muttern der Fundamentschrauben über-
Pumpensockel. prüfen und ggf. festziehen.
Fremdkörper verstopfen die Pumpe. Pumpe demontieren und reinigen.
Harter Lauf der Pumpe. Sicherstellen, dass sich die Pumpe ohne
anomalen Widerstand drehen lässt.
Der Pumpendruck ist zu gering Motorgeschwindigkeit unzureichend. Korrekte Einstellung des Sollwerts über-
prüfen.
Motor ist defekt. Motor ersetzen.
Schlechte Befüllung der Pumpe. Entlüftungsschraube öffnen und so lange ent-
lüften, bis keine Luftblasen mehr austreten.
Entleerungsstopfen ist nicht richtig ein- Überprüfen und korrekt festschrauben.
geschraubt.
Förderstrom ist unregelmäßig Saughöhe (Ha) nicht eingehalten. Die in dieser Betriebsanleitung genannten
Einbaubedingungen und -empfehlungen
überprüfen.
Die Saugleitung hat einen geringeren Die Saugleitung muss mindestens den-
Durchmesser als die Pumpe. selben Durchmesser wie die
Pumpenansaugöffnung aufweisen.
Der Saugkorb und die Saugleitung sind Demontieren und reinigen.
teilweise verstopft.
Der Druckgeber ist im Modus Einen Sensor mit vorschriftsmäßiger
„Konstanter Druck“ nicht richtig ange- Druck- und Genauigkeitseinteilung
passt. montieren, siehe Kapitel 5.3.
Die Pumpe hält im Modus „Konstanter Der Rückflussverhinderer ist nicht dicht. Ventil reinigen oder austauschen.
Druck“ bei Nullförderstrom nicht an Der Rückflussverhinderer ist nicht kor- Durch ein korrekt bemessenen Rückfluss-
rekt bemessen. verhinderer ersetzen, siehe <Kapitel 5.3>.
Der Druckbehälter hat für die bestehen- Austauschen oder einen weiteren
de Anlage eine unzureichende Kapazität. Behälter einbauen.
GEFAHR! Verletzungsgefahr! VORSICHT! Gefahr von Sachschäden!
Das Medium ist giftig, ätzend oder für den Der ordnungsgemäße Betrieb der Pumpe ist
Menschen gefährlich. nur bei Verwendung von Originalersatzteilen
• Unverzüglich den zuständigen Service-Techniker gewährleistet.
oder Vertragshändler benachrichtigen.
• Nur Originalersatzteile verwenden.
• Pumpe so reinigen, dass für den Techniker
keine Gefahr besteht.
11. Ersatzteile
Die Bestellung von Ersatzteilen erfolgt über
regionale Vertragshändler und/oder den
Kundendienst von Wilo.
Um Rückfragen oder Falschbestellungen zu ver-
meiden, bei Bestellung alle Daten des
Technische Änderungen vorbehalten!
Typenschildes angeben.
WILO SE 09/2011 35
English
1. General 2.3 Danger in the event of non-observance of the

safety instructions
1.1 About this document Non-observance of the safety instructions can
The language of the original operating instruc- result in risk of injury to persons and damage to
tions is French. All other languages of these ins- pump/unit. Non-observance of the safety
tructions are transations of the original operating instructions can result in the loss of any claims to
instructions. damages.
These installation and operating instructions are In detail, non-observance can, for example,
an integral part of the product. They must be kept result in the following risks:
readily available at the place where the product is • Failure of important pump/unit functions,
installed. Strict adherence to these instructions is • Failure of required maintenance and repair pro-
a precondition for the proper use and correct cedures
operation of the product. These installation and • Danger to persons from electrical, mechanical
operating instructions conform to the relevant and bacteriological influences,
version of the product and the underlying safety • Property damage.
standards valid at the time of going to print.
2.4 Safety instructions for the operator
2. Safety The existing directives for accident prevention
must be adhered to.
These operating instructions contain basic infor- Danger from electrical current must be eliminat-
mation which must be adhered to during installa- ed. Local directives or general directives [e.g. IEC,
tion and operation. For this reason, these operat- VDE etc.] and local power supply companies must
ing instructions must, without fail, be read by the be adhered to.
service technician and the responsible operator
before installation and commissioning. It is not 2.5 Safety instructions for inspection and installa-
only the general safety instructions listed under tion work
the main point "safety" that must be adhered to The operator must ensure that all inspection and
but also the special safety instructions with dan- installation work is carried out by authorised and
ger symbols included under the following main qualified personnel, who are sufficiently informed
points. from their own detailed study of the operating
instructions.
2.1 Indication of instructions in the operating Work to the pump/unit must only be carried out
instructions when at a standstill.
Symbols
2.6 Unauthorised modification and manufacture of
General danger symbol. spare parts
Danger due to electrical voltage. Modifications to the pump/unit are only permissi-
ble after consultation with the manufacturer.
NOTE: .... Original spare parts and accessories authorised by
the manufacturer ensure safety. The use of other
Signals: parts can nullify the liability from the results of
DANGER! Actuely dangerous situation. their usage.
Non-observance results in death or the most
serious of injuries. 2.7 Inadequate use
The operating safety of the supplied pump/unit is
WARNING! The user can suffer (serious) injuries. only guaranteed for conventional use in accor-
'Warning' implies that (serious) injury to per- dance with Section 4 of the operating instruc-
sons is probable if this information is disregard- tions. The limit values must on no account fall
ed. under or exceed those specified in the cata-
CAUTION! There is a risk of damaging the logue/data sheet.
pump/unit. 'Caution' implies that damage to
the product is likely if this information is disre- 3. Transport and storage
garded.
NOTE: Useful information on handling the prod- 3.1 Shipping
uct. It draws attention to possible problems. The pump is supplied ex works in a box or fixed to
a pallet with straps and is protected against dirt
2.2 Personnel qualifications and moisture.
The installation personnel must have the appro-
priate qualifications for this work. 3.2 Transport inspection
When delivered, check the pump immediately for
any transport damage. If a damage is discovered,
the necessary procedure involving the forwarding
agent must be taken within the specified period.
36 WILO SE 09/2011
English
3.3 Storage 4. Application

Before installation, the pump must be kept in a
dry place, frost-free and protected from any Pumps aimed at pumping clear liquids in building,
mechanical damage. agriculture and industry areas …
CAUTION! Danger of damage due to incorrect Water supply, water tower, sprinkling, high pres-
packaging! If the pump is transported again later sure washing, boiler supply (with mandatory by-
on, it must be well packed to avoid any damage pass kit) – lifting of condensates – air condition-
during transport. ing – industrial networks and integration in all
• Use the original packaging for this, or select a sim- modular systems.
ilar packaging.
WARNING! Danger of personal injury! 5. Product information
Inadequate transport can lead to personal injury!
• The pump must be transported using approved 5.1 Type key
load bearing equipments. Operate a slinging on HELIX-V or MVI E 4 14 - 1 / 16 / E / 3-2
the pump flanges and, if necessary, on the outer
motor diameter (safety device required to protect Verticale
against slipping!). multistages pump
in-line with high
hydraulic efficient
Vertical multistages
pump in-line
With converter for
electonic speed control
Nominal flowrate in m3
Number of stages
1: pump casing in stainless steel 304
+ hydraulic in stainless steel 304
2: pump casing in stainless steel 316L
+ hydraulic in stainless steel 316L
3: pump casing in cast iron
GJL-250 + hydraulic
in inox 304
• Due to high position of the centre of gravity and
small ground surface of this type of pumps, 16: Flanges PN16
beware of unstability during handling to avoid any 25: Flanges PN25
falling down that may cause a risk for the safety P: Victaulic couplings
of the persons. E: O rings EPDM (WRAS/KTW)
V: O rings VITON
Handle the pump carefully so as not to alter the
goemetry and the alignment of the unit. Three-phase - 2 poles
CAUTION! Danger of damage for the pump! 5.2 Technical data

The transport eyes on the motor should only be
used for transporting the motorconverter, - Maximum operating pressure
and are not approved for transporting the com- • pump casing PN25: 25 bar
plete pump. • pump casing PN16: 16 bar
• pump casing - rapid hose
coupling for Victaulic: 25 bar
(only 4, 8, 16 m3/h)
- Maximum suction pressure: 10 bar
- Water temperature range
• EPDM version for O’ring
and mechanical seal
(KTW approval – german
standard) and (WRAS approval
– british standard): - 15°C to + 120°C
• Viton version for O’ring
and mechanical seals: - 15°C to + 90°C
- Maximum suction head: according to NPSH
of the pump
- Ambient temperature: - 15°C to +50°C
(standard product)
WILO SE 09/2011 37
English
- Ambient humidity: < 90 % without 6. Description and function

condensation
- Acoustic pressure level: 1,1kW = 63dB(A) 6.1 Description of the product
2,2kW = 66dB(A) The pump
4kW = 71dB(A) • Multistage vertical pump not self-priming, with
- Insulation class: F ports in line on the same axis in bottom part.
- Protection class: IP55 • Shaft sealing by standardized mechanical seal.
• Hydraulic connection.
- Electromagnetic Oval flanges on the PN16 (6“) pump casing:
compatibility (*) pump supplied with oval cast iron counterflanges
• residential emission - for screw-on tube, rings and bolts.
1st environment: EN 61800-3 Round flanges PN16 (8“) and PN25: pump deliv-
• industrial immunity - ered with rings and bolts without counterflanges
2st environment: EN 61800-3 (accessories as option).
- Operating voltages: 400V (±10%) 50Hz Rapid hose coupling (MVI 6“) for "Victaulic"
380V (±10%) 60Hz bracket: pump delivered without brackets
440V (±6%) 60Hz (accessories as option).
- Section of the power cable The motor and its converter
(cable equipped of 4 wires): • Cage induction motor with standardized flange
• 1,1kW: 1,5 mm2 to 2,5 mm2 and shaft end for vertical operation fitted with
• 2,2/4kW: 2,5 mm2 to 4 mm2 its converter.
(*) In the frequency range between 600 MHz and 1 • Motor-pump linked by a coupling with safety
GHz, the display or the pressure indication in the dis- guards.
play might be disturbed in the direct vicinity (< 1 m
from the electronic module) of radio transmission 6.2 Function
installations, transmitters or similar devices working in
The basic advantages of the electronic control
this frequency range. The functioning of the pump is at
are:
no time affected.
• Energy savings.
• Reduction of flow noises.
5.3 Accessories • Adaptation of the pump to changing operating
Accessories must be ordered separately. requirements.
• IF-Module PLR for connecting to PLR/interface The operating modes are:
converter. • « Speed control »: setting of the frequency by
• IF-Module LON for connection to the LONWORKS hand or external control.
network. The IF Modul PLR is connected directly • « Constant pressure » : regulation through a
inside the connection area of the converter pressure sensor and setting point (internal or
(Fig. 11). external).
• By-pass kit. • « P.I.D. control »: regulation through a sensor
• Insulating valves. (temperature, flow,...) by P.I.D.control and setting
• Bladder or galvanised tank. point (internal or external).
• Tank for antihammer blow effect.
• Weld-on (Steel) or screw-on (Stainless Steel)
counterflange 7. Installation and electrical connection
• Rapid hose coupling like "Victaulic". CAUTION! Danger of material damage!
• Non-return valves (with nose or spring ring when Danger of damage due to inadequate handling.
operating in constant pressure). The pump should only be installed by skilled per-
• Strainer-foot valve. sonnel.
• Vibrationless sleeves.
• Protection kit against dry-running 7.1 Preparation
• Sensor kit for pressure regulation - The pump should only be installed when all
(accuracy : ≤ 1 % ; use between 30 % and 100 % welding and soldering works are completed and,
of the reading range). if necessary flushing of the pipe system. Dirt can
See catalogue for detailed list. cause pump failure.
- The pumps must be protected against bad
weather and in an environment protected from
some dust and from the frost, ventilated well and
in not explosive atmosphere.
- Install the pump in an easy-to-access location
so that later inspections, maintenance (e.g.
mechanical seal) or exchange is easily possible.
The air access to the dissipator of the converter
may not be limited.
38 WILO SE 09/2011
English
7.2 Description (Fig. 1, 2, 5, 6, 7, 8) NOTE: Beyond 80° C, plan to install the pump in
1 - Strainer-foot valve load.
2 - Pump suction valve
CAUTION! Danger of material damage!
3 - Pump discharge valve
The installation has to bear the pressure reached
4 - Non-return valve
when the pump runs at maximum frequency and
5 - Venting and filling plug
zero flow rate.
6 - Drain-priming plug
- Pump with oval flange pump casing : with
7 - Pipe supports or brackets
threaded screw-on tubes directly on the tapped
8 - Strainer
oval counterflanges delivered with the pump.
9 - Storage tank
- Pump with round flange pump casing: with
10 - Town water supply
weld-on or screw-on tube in the counterflanges
11 - Disconnecting switch with fuses
(counterflanges available as accessories).
12 - Lifting hook
- Pump casing with rapid hose coupling : with a
13 - Foundation block
bracket, to be installed with an end to be fixed
14 - Cock
on the pipe (bracket and threaded end available
15 - Pressure sensor
as accessories).
16 - Tank
- The diameter of the pipe must never be smaller
17 - Insulation valve of the tank
than the one of the counterflange.
18 - Display
- The direction of the fluid flow is indicated on the
19 - Adjustement button
pump identification sticker.
BP - By-pass
HA - Maximum suction head CAUTION! Danger of material damage!
HC - Minimum inlet pressure Connections have to be correctly sealed, no air
entrance is allowed on the suction pipe which
7.3 Installation shows a minimum mounting declivity of 2%
Two standard types. (Fig. 1).
Fig. 1: pump in suction - Limit the length of the suction pipe and avoid all
Fig. 2: pump in load on storage tank (item 9) or features that cause losses of head (bends, valves,
town water supply (item 10). tapers).
- Install the pump in a place easy to reach, pro- - Use supports or collars (Fig. 1, 2, item 7) so that
tected against extrema conditions (rain and sun the pump does not bear the weight of the pipes.
in excess, frost) and as close as possible from the
drawing point. CAUTION! Danger of material damage!
- For heavy pumps provide a point of attachment When the pump is in load, it is recommended to
(lifting hook) in the pump axis (item 12) to facili- connect the non-return valve to the pump dis-
tate removal. charge to protect it against hammer blow effects.
- Install the pump on a concrete block (at least 10 NOTE: To pump water with a large content of air
cm high) (item 13) and fix with anchor bolts or hot water, we recommend to install the
(installation plan see Fig. 3). bypass kit (Fig. 1, item BP). Mount the pressure
- Foresee an insulating material under the con- sensor on the discharge pipe (Fig. 7).
crete block (cork or reinforced rubber) to avoid
any noise and vibration transmission into the
installation.
- Before final tightening of anchor bolts, ensure
that the pump axis is vertical: use shims if neces-
sary.
NOTE: Keep in mind that the altitude of the
installation place and the water temperature may
reduce the suction possibilities of the pump.
Loss of Loss of
Altitude Temperature
head (HA) head (HA)
0m 0 mCL 20 °C 0,20 mCL
500 m 500 mCL 30 °C 0,40 mCL
1000 m 1000 mCL 40 °C 0,70 mCL
50 °C 1,20 mCL
60 °C 1,90 mCL
70 °C 3,10 mCL
80 °C 4,70 mCL
90 °C 7,10 mCL
100 °C 10,30 mCL
110 °C 14,70 mCL
120 °C 20,50 mCL
WILO SE 09/2011 39
English
Principal dimensions and connection

MVIE (Fig. 3a)
Version PN25
Version PN16
Pump type Victaulic
200 212 180 100 20 12 157 204 50 75 M10 G1” 172 250 75 85 14 DN25 210 50 Ø42,4
400 212 180 100 20 12 157 204 50 75 M10 G1”1/4 172 250 75 100 18 DN32 210 50 Ø42,4
6”
800 252 215 130 20 12 187 250 80 100 M12 G1”1/2 187 280 80 110 18 DN40 261 80 Ø60,3
1600/6 252 215 130 20 12 187 250 90 100 M12 G2” 187 300 90 125 18 DN50 261 80 Ø60,3
HELIX-VE (Fig. 3b)
Version PN16 Version PN25

Pump type
200/400 100 212 180 157 204 50 G1“ 2xM10 172 250 75 DN25 4xM12
600 100 212 180 157 204 50 G1“1/4 2xM10 172 250 75 DN32 4xM16
6”
1000 130 255 215 190 250 80 G1“1/2 2xM12 190 280 80 DN40 4xM16
1600 130 255 215 190 250 90 G2“ 2xM12 190 300 90 DN50 4xM16
2200 130 296 215 250 300 90 DN50 4xM16 250 300 90 DN50 4xM16
8”
3600 170 296 240 250 320 105 DN65 4xM16 250 320 105 DN65 8xM16
7.4 Electrical connections - (Pos. b) The sensor, external setpoint and

DANGER! Danger of death! [aux.]/[ext.off] input cable must be necessarily
Inadequate installation and electrical connections screened and must be inserted into the gland M12
can be life-threatening. or M16. The cable glands of the converter are
• Electrical connections shall only be made by adapted to the assembly with a shielding braid
approved specialised electricians and in compli- (see below).
ance with the applicable regulations.
• Accident prevention regulations must be
observed.
1
• Do not forget to connect to earth.
CAUTION! Danger of mains overload!
An inadequate mains design can lead to system
2
failures and can lead to cable fires due to mains
overload.
3
A connection error would damage the converter.
The power cable shall never touch the pipe or the
pump ; make sure that it is protected against any
humidity. 4
(Pos. a) The power cable (3 phases + earth) must be

fed through the cable gland M25. Nonallocated • The electric characteristics (frequency, voltage,
cable glands must remain sealed with the plugs nominal current) of the motor-converter are
provided by the manufacturer (see below). mentioned on the pump identification sticker
(item 19). Check that the motor-converter com-
plies with the mains supply used.
• The electric protection of the motor is integrated
into the converter. The parameters take into
a account the characteristics of the pump and must
ensure its protection and the one of the motor.
• In case of impedance between earth and neutral
point, install a protection before motor-convert-
er.
b • Provide a fuse-disconnecting switch (type gF) to
protect the mains installation (Fig. 1, 2, item 11).
40 WILO SE 09/2011
English
NOTE: If you have to install a differential circuit-

breaker for users protection, it must have a delay
effect. Adjust it according to the current men-
tioned on the pump identification sticker.
NOTE: This pump is equipped with a frequency
converter and may not be protected by a resid-
ual-current-operated protection switch.
Frequency converters can impair the function of
residual-current-operated protection circuits.
Exception: Residual-current-operated protection
switches which have a selective universal-cur-
rent-sensitive design are allowed.
• Labelling: RCD
• Trigger curren: > 30 mA.
• Use power cables conforming to standards.
• Trigger characteristic of the fuses: B
• You can change the orientation of the motor-
converter by quarter turn when removing the
fixing bolts of the motor and reorientating the
motor to the position wished. Re-screw bolts.
• As soon as the power supply of the converter has
been activated, a 2 second display test is carried
out, where all characters on the display are
shown.
WILO SE 09/2011 41
English
Connection terminal allocation

• Loosen the screws and remove the converter
cover.
Designation Allocation Notes

L1, L2, L3 Mains connection voltage Three-phase current 3 ~ IEC38
PE Earth connection
IN1 Sensor input Type of signal: Voltage (0 - 10 V, 2 - 10 V)
(DDS-terminal 9) Input resistance: Ri ≥ 10 kΩ
Type of signal: currrent (0 - 20 mA, 4 - 20 mA)
Input resistance: RB = 500 Ω
Can be configured in the « Service » menu <5.3.0.0>
IN2 External setpoint input Type of signal: Voltage (0 - 10 V, 2 - 10 V)
(10V/20mA Input resistance: Ri ≥ 10 kΩ
-terminal 7) Type of signal: currrent (0 - 20 mA, 4 - 20 mA)
Input resistance: RB = 500 Ω
GND (x2) Ground connections For both inputs IN1 and IN2
+ 24 V DC voltage for sensor Load max. : 60 mA
The voltage is short-circuit proof
Ext. off Control input (ON/OFF) The pump can be switched on/off via the external
« Overriding Off » potential-free contact.
for external potential-free switch In systems with a high switching frequency
(> 20 switch-ons/offs/day), switching on/off is to be
done via « ext. off ».
SBM « Available transfer » relay In normal operating, the relay is activated when the
pump runs or is in a position to run.
When a first defect appears or by main supply cutoff (the
pump stops), the relay is deactiveted.
Information is given to the control box, regarding the
availability of the pump, even temporarily.
Contact load:
minimum: 12 V DC, 10 mA
maximum: 250 V AC, 1 A
SSM « Failures transfer » relay After a series of detection (from 1 to 6 according to
significance) of the same type of defect, the pump
stops and this relay is activated (up to manual action).
Contact load:
minimum: 12 V DC, 10 mA
maximum: 250 V AC, 1 A
PLR Connection terminals of the interface The optional IF-Module PLR is to be pushed into the
PLR multiplug in the connection area of the converter.
The connection is twist-proof.
LON Connection terminals of the interface The optional IF-Module LON is to be pushed into the
LON multiplug in the connection area of the converter.
NOTE : The terminals IN1,IN2, GND and Ext. Off

meet the requirement for «safe isolation» (in
acc. with EN61800-5-1) to the mains terminals,
as well as to the SBM and SSM terminals (and
vice versa).
42 WILO SE 09/2011
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Connection to mains supply Power terminals

Connect the 4 wires cable on the power terminals
(phases + earth). L1 L2 L3
Connection of inputs / outputs Inputs / outputs terminals

• Le câble du capteur, de la consigne externe et de l’entrée aux ext.off MP 20mA/10 DDS
[ext.off] doit impérativement être blindé.
1 2 3 4 5 6 7 8 9 10 11
not used not used
+24V...
GND...
GND...
In1...
In2...
Remote
sensor 20mA/10V
External set value
control
ON/OFF
• The remote control allows the switching On or Off of the Example: Float switch, pressure gauge for dry-running…
pump (free contact), this function has priority on the
others.
• This remote control can be removed by shunting the ter-
minals (3 and 4).
Connection terminals of the interface

PLR The optional IF-Module PLR is to be pushed into the mul-
tiplug in the connection area of the converter.
LON The optional IF-Module LON is to be pushed into the

multiplug in the connection area of the converter.
WILO SE 09/2011 43
English
« Speed control » connection Connection of inputs / outputs

Setting of the frequency by hand:
aux ext.off MP 20mA/10 DDS
1 2 3 4 5 6 7 8 9 10 11
Remote
control
Setting of the frequency by external control:

1 2 3 4 5 6 7 8 9 10 11
In2...
Remote external
control set value
« Constant pressure » connection

Regulation through a pressure sensor:
• 2 wires ( [20mA/10V] / +24V )
• 3 wires ( [20mA/10V] / 0V / +24V ) 1 2 3 4 5 6 7 8 9 10 11
and setting point by the encoder (or the touch pads)
In1...
Remote pressure
control sensor
Regulation through a pressure sensor:

• 2 wires ( [20mA/10V] / +24V ) aux ext.off MP 20mA/10 DDS
• 3 wires ( [20mA/10V] / 0V / +24V ) 1 2 3 4 5 6 7 8 9 10 11
and setting point by the external set value
In1...
In2...
Remote external pressure

control set value sensor
« P.I.D. control » connection

Regulation through a sensor (temperature, flow...):
• 3 wires ( [20mA/10V] / 0V / +24V ) 1 2 3 4 5 6 7 8 9 10 11
and setting point by the encoder (or the touch pads)
In1...
Remote pressure
control sensor
Regulation through a sensor (temperature, flow...):

• 3 wires ( [20mA/10V] / 0V / +24V ) 1 2 3 4 5 6 7 8 9 10 11
and setting point by the external set value
In1...
In2...
Remote external pressure

control set value sensor
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DANGER! Danger of death!

Contact voltage hazardous due to the discharge of the
converter capacitors.
• Before any intervention on the converter, wait for 5 min-
utes after disconnecting of the supply voltage.
• Check whether all electrical connections and contacts are
voltage-free.
• Check the righ allocation of the connection terminals.
• Check the right earth connection of the pump and installa-
tion.
Control laws
IN1 : Input signal in « Constant pressure » and « P.I.D. control » mode
Sensor signal 4-20mA Sensor signal 0-10V
100% 100%
Between 0 and 2 mA, cable is
considered as broken
Safety
Value area Value
in % of the range in % of the range of

of measurement of measurement of the
the sensor sensorr
0 2 4 Input current (mA) 20 0 Input voltage (V) 10
Sensor signal 0-20mA Sensor signal 2-10V
100% 100%
Value Value
in % of the range in % of the range of

of measurement of measurement of the
the sensor sensor
0 Input current (mA) 20 0 2 Input voltage (V) 10
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IN2 : Input of the external set value control in « Constant pressure » and « P.I.D. control » mode
Set value 4-20mA Set value 0-10V
100% 100%
Area where converter stops Area where converter stops
Safety Safety
Set value area Set value area
in % of the range in % of the range

of measurement of of measurement of
the sensor the sensor
0 2 4 Input current (mA) 20 0 1 2 Input voltage (V) 10
IN2 : Input of external frequency control in « Speed control » mode
External Signal 0-20mA External Signal 0-10V
100% 100%
Safety Safety
Frequency area Frequency area
of the converter of the converter
~30% ~30%
External Signal 4-20mA External Signal 2-10V
100% 100%
Safety Safety
Frequency area Frequency area
of the converter of the converter
~30% ~30%
46 WILO SE 09/2011
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8. Operation • As soon as the power supply of the converter has

been activated, a 2 second display test is carried
8.1 Setting out, where all characters on the display are
shown.
8.1.1 Control elements
The converter operates using the following con- Pos. Description
trol elements:
The encoder 1 Menu number
Setting with encoder 2 Value display
3 Units display
4 Standard symbols
5 Icon display
• The selection of a new parameter is done only 8.1.3 Description of standard symbols
with a simple rotation, « + » on right and « - »
on left.
Symbol Description
• A short impulse on the encoder validates this
new setting. Operating in « Speed control »
mode.
The Touch pads
Setting with touch pads Operating in « Constant pressure »
or « P.I.D. control » mode.
Input IN2 activated
2
(external setpoint).
Access locked.
When this symbol appears, current
• The selection of a new parameter is done with settings or measurements cannot
impulsion on arrows of the touch pads, « + » on be changed. Information displayed
top and « - » on bottom. is only in reading.
• A short impulse on the centre of the touch pads
validates this new setting. BMS (building management system)
Switches PLR or LON is active.
ON
Pump runs.
1 2 Pump stops.
• This converter has got a block with two switches

with two positions each (Fig.4, item S): 8.1.4 Display
• Switch 1 allows to change the « OPERATION »
mode [switch 1->OFF] to « SERVICE » mode Display status page
[switch 1->ON] and conversely. The « OPERA- • The status page is shown as the standard view on
TION » position allows the selected mode to run the display.
and hinders the access to parameters input (nor- The currently set setpoint is displayed.
mal operating). The « SERVICE » position is used Basic settings are displayed using symbols.
to enter the parameters of the different opera-
tions.
• Switch 2 is for activating or deactivating the
« Access lock ».
8.1.2 Display structure
1 4
2 5
Example of display status page
NOTE: If the encoder is not activated within 30

4 3 4 seconds in all menus, the display returns to the
status page and the change is not registered.
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Navigation element <3.0.0.0>

• The arborescence of the menu allows to call the
Position Switch 1 Description
functions of the converter. A number is attrib-
uted to every menu and submenu.
• The rotation of the encoder (or an impulse on OPERATION OFF
Setting ON / OFF of the
arrow « + » or « - » of the touch pads) allows pump.
the scrolling of a same menu level SERVICE ON
(example 4000->5000).
<4.0.0.0>
• Any blinking elements (value, menu number,
symbol or icon) allow the choice of a new value, Position Switch 1 Description
a new menu number or a new function.
OPERATION OFF
Symbol Description Only reading for the
« Information » menu.
When the arrow appears: SERVICE ON
• An impulse on the encoder (or an
impulse on the centre of the touch • The « Information » menu displays measuring,
pads) allows the access to the sub- device and operating data, see,
menu (example 4000->4100). (Fig. 13).
<5.0.0.0>
When the arrow « return »” appears:
• An impulse on the encoder (or an Position Switch 1 Description
impulse on the centre of the touch
pads) allows the access to the hig- Only reading for the
OPERATION OFF
her menu (example 4150->4100). « Service » menu.
Setting for « Service »
SERVICE ON
8.1.5 Menu description menu.
• The « Service » menu allows to get access to the
List (Fig. 12)
converter parameter setting.
<1.0.0.0>
<6.0.0.0>
OPERATION OFF Adjustment of the setting OPERATION OFF

point, possible for both
Display of the error page.
SERVICE ON cases.
SERVICE ON
• To adjust the setting point, turn the encoder (or
• If one or several defects arise, the page of
press on one arrow of the touch pads). The dis-
defects appears.
play changes to menu <1.0.0.0> and the setpoint
The letter « E » followed by three digit code
begins to blink. The new rotation (or a new
appears (chapter 11).
action on arrows) allows increasing or decreasing
of the value. <7.0.0.0>
• To confirm the change, give an impulse on the
encoder (or the centre of the touch pads), the Position Switch 1 Description
display returns to the status page.
OPERATION OFF
<2.0.0.0> Display of « Access lock »
symbol.
Position Switch 1 Description SERVICE ON
Only on reading for ope- • The « Access lock » is available when the switch
OPERATION OFF
rating modes. 2 is in the ON position (chapter 8.5.3).
Setting for operating
SERVICE ON CAUTION! Material damage!
modes.
Inadequate setting changes can lead to pump
• The operating modes are the « Speed control », operation defects, which can lead to material
the « Constant pressure » and the damage on the pump or installation.
« P.I.D. control ». • Settings in « SERVICE » mode should only be
made during commissioning and only by skilled
technicians.
48 WILO SE 09/2011
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Fig. 12
Navigation of basic menus in normal operation

(Switch1 = OFF in «OPERATION » position)
Setting point
Controle type
Pump
Information
Service
errors
acknowledge
Appears when an error

is actived
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Fig. 13
Navigation of menu <4.0.0.0> « Informations »
Informations
Actual values
Pressure Not shown when
or% speed control is active
Power
Operation data
Operation hours
Comsuption
Power-on
counter
Actual conditions
SSM relay
See chapter 11 - Menu <5.6.7.0>
SBM relay Default “Available transfert”
ext. off
Device data
Pump name
User controller
software version
Motor controller
software version
50 WILO SE 09/2011
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Parametrization of <2.0.0.0> and <5.0.0.0> menu

In « SERVICE » mode, the menu parameters <2.0.0.0> and <5.0.0.0> can be modified.
Two setting modes exist:
• The « Easy Mode » : fast mode to get access to the 3 operating modes.
• The « Expert Mode » : mode to get access to all parameters. ON
• Put the switch 1 on ON position (Fig. 4, item S). S
• The « SERVICE » mode is activated.
This symbol blinks on the status page of the display (Fig. 14). 1
Fig. 14
EASY Mode
SERVICE
Control type
EASY Mode
Setting point
Control type
EXPERT Mode
EXPERT Mode
Pump
Information
OPERATION
ON
Service
1 2
Easy Mode
• Press the encoder during 2 secondes. The symbol « Easy Mode » appears (Fig. 14).
• Press the encoder to validate this choice. The display changes to menu number <2.0.0.0>.
The « Easy Mode » allows, quickly, the setting of the 3 operating modes (Fig. 15)
• Speed control »
• « Constant pressure »
• « P.I.D. control »
• After setting, put the switch 1 on OFF position (Fig. 4, item S).
Expert Mode
• Press the encoder during 2 secondes. Go to the expert mode, the symbol « Expert Mode » appears
(Fig. 14).
• Press the encoder to validate this choice. The display changes to menu number <2.0.0.0>.
At first, select the operating mode in menu <2.0.0.0>.
• « Speed control »
• « Constant pressure »
• « P.I.D. control »
Then in menu <5.0.0.0>, the expert mode gives access to all the converter parameters (Fig. 16).
• After setting, put the switch 1 on OFF position (Fig. 4, item S).
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Fig. 15
Speed control
With internal setpoint
External setpoint input - IN2

desactivated - Selection OFF
EASY
MENU
activated - Selection ON
With external setpoint

Selection of the signal type
Constant pressure
Sensor input - IN1
Selection of the pressure sensor
Sensor input - IN1

With internal setpoint


With external setpoint

P.I.D. Controle
Sensor input - IN1


parameterization P.I.D.
Selection value “P” (0.0-300.0)
Sélection value “I” (10ms-300s) With internal setpoint
selection value “D” (0ms-300s)


Selection value “P” (0.0-300.0)
Selection value “I” (10ms-300s) With external setpoint
Selection value “D” (0ms-300s)
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Fig. 16
EXPERT
MENU
Service
Only shown when “BMS” is active.

BMS - Building Management System See instructions of this product
IN1 - “Sensor input” Not shown when “Speed control”

is active
Sensor range Not shown when “PID Control”
is active
Selection of signal type
IN2 - External setpoint input
Selection
Selection of signal type Not shown when “IN2”

is disable
Only shown when “PID Control”

PID - parameters is active
Selection
parameters “P”
Selection
parameters “I”
Selection
parameters “D”
Other settings
zero flow delay Only show when

time “Constant Pressure” is active
Selection of
reduced frequency
Selection of
SBM relay
Factory settings
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Access lock Pump in load (Fig. 2).

In order to lock the pump settings, it is possible • Close the discharge valve (item 3).
to use the « Access lock ». • Open the venting plug (item 5), the suction valve
(item 2) and completely fill the pump.
To activate or deactivate it, proceed as follows:
• Close the venting plug only after water flows out
• Put the switch 2 on ON position (Fig. 4, item S).
and complete aeration.
The <7.0.0.0> menu is called up.
• Turn the encoder (or press on arrows of the WARNING! Danger of burn!
touch pads) to activate or deactivate the locking. In hot water, a stream of water may escape from
The current state of the locking is represented the venting plug port.
with the following symbols: • Take all required precautions as regards persons
and motor-converter.
Lock active: Parameters are locked,
the access to menus is allowed only Pump in suction (Fig. 1, 5)
on reading. Two possible cases:
Lock inactive: Parameters can be 1st case (Fig. 5.1)
changed, the access to menus is allo- • Close the discharge valve (Fig. 1, item 3), open
wed for setting. the suction valve (Fig. 1, item 2).
• Remove the venting plug (Fig. 1, item 5).
• Return the switch 2 on OFF position (Fig. 4, item • Unscrew about 4 turns the bottom drain-priming
S). The display returns to the status page. plug (Fig. 1, item 6) located on the pump casing.
• Put a funnel into the venting plug port and com-
8.1.6 Configurations pletely fill the pump and the suction pipe.
NOTE : If the pump is delivered as separate part, • After water flows out and total air exit, filling is
not integrated into a system we mounted, the achieved.
standard configuration mode is • Screw the venting plug and the bottom drain-
« Speed control ». priming plug back in.
2nd case (Fig. 5.2)
« Speed control » mode (Fig. 1, 2)
• Filling can be made easier by fitting a vertical
Setting of the frequency by hand or external
pipe (Fig. 5, item 14) fitted with a Ø ½" stopcock
control.
and a funnel, on the suction pipe of the pump.
• For the starting up, we recommend to set the
motor speed at 2400 RPM. NOTE: The length of the pipe must be at least 50
mm higher than the venting plug level.
« Constant pressure » mode (Fig. 6, 7, 8)
Regulation with a pressure sensor and setting • Close the discharge valve (Fig. 1, item 3), open
point (internal or external). the suction valve (Fig. 1, item 2).
• The addition of a pressure sensor (with tank; • Open the stopcock (Fig. 5, item 14) and the
sensor kit delivered as accessories) allows a venting device (Fig. 1, item 5).
pressure regulation of the pump (with no water • Unscrew about 4 turns the drain-priming plug
in the tank, pressurize the tank to a pressure 0.3 (Fig. 1, item 6).
bar less than the pressure regulation of the • Completely fill the pump and the suction pipe
pump). until water flows out of the venting plug (Fig. 1,
• The accuracy of the sensor shall be ≤ 1% and it is item 5).
used between 30 % and 100 % of the measuring • Close the stopcock (Fig. 5, item 14) (which can
scale range. The tank must have a useful volume be left in place), remove the pipe, close the
of 8L minimum. venting device (Fig. 1, item 5) and screw again
• For the starting up, we recommend a pressure set the drain-priming plug (Fig. 1, item 6).
value at 60% of its maximum pressure.
CAUTION ! Risk of misuse!
« P.I.D. control » mode Pump in load and in « Constant pressure » mode,
Regulation with a sensor (temperature, flow...) by the detection at zero flow can not run.
P.I.D.control and setting point (internal or exter- • Set the non-return valve before the pressure
nal). sensor (i.e. at pump suction if the sensor is
mounted on this one – Fig. 6).
8.2 Preliminary rinsing
The hydraulic features of every pump is tested in
factory, some water may remain in them. It is
recommended for hygien purposes, to carry out a
rinsing of the pump before any using with
potable water supply.
8.3 Filling - degassing

Never operate the pump dry, even briefly!
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8.4 Starting up 9. Maintenance

WARNING! Danger of burn! Maintenance and repairs may only be carried
Depending on conveyed fluid and the operating out by qualified experts !
cycles of the pump, surface temperature (pump,
motor) can exceed 68°C. It is recommended to have the pump maintained and
• Take necessary means to avoid injuries! checked by an after-sales service technician.
CAUTION! Danger of material damage! DANGER! Danger of death!

The pump must not operate at zero flow (closed There is a danger of electrocution, when working
discharge valve) for more than 10 minutes with on electrical equipments.
cold water (T°C < 40°C) and more than 5 minutes • Only electricians approved by the local electricity
beyond 60° C. supplier are allowed to work on electrical equip-
ments.
• We recommend to ensure a minimum flow of • Before working on electrical equipment, switch it
about 10 % of the pump nominal flow to avoid off and prevent it from being switched on again!
any vapour lock at the top of the pump.
• Keep the discharge valve closed. WARNING! Risk of burn!
• Start the pump. High surface temperatures may be reached.
• Open draining plug to drain air. If no water leaks • Allow the pump to cool off before all works.
within 20s, close the plug and stop the pump, • Always wear protective clothing and gloves when
then wait for 20s to allow the settling of the air. working!
• Start again the pump. • No special maintenance in operation.
NOTE: If necessary (particularly if the suction • Keep the pump and the motor-converter per-
height exceeds 5 m) repeat these operations. fectly clean.
• In case of prolonged stopping, if there is no risk
• If water leaks at draining plug (it means the pump of frost, it is better not to drain the pump.
delivers its pressure), slowly open the discharge • The bearing holding the coupling and the motor
valve. The pump has to be primed. bearings are lubricated for their total lifetime and
• Check pressure stability at discharge with a do not require any lubrication.
manometer, if instability, perfect air draining. • The mechanical seal does not require any main-
• In case of failure, do the filling in again and start tenance in operation. It must never operate dry.
the operation again.
• To perfect air draining, close the discharge valve
and the draining plug, then stop the pump 20s, Replacement frequencies
start the pump again and open the draining plug. NOTE: These are only recommendations, the
Do it as long as air comes out. replacement frequency depends on the operat-
• Open the discharge valve in order to have the ing conditions of the unit , i.e.:
wished working point. • Temperature, pressure and type of conveyed
• Check that the current input does not exceed the fluid for the mechanical seal.
value indicated on the motor-converter data • Load and ambient temperature for the motor and
plate. the other components.
• Starting frequency: continuous or intermittent
running.
Mechanical Pump and motor Motor

Parts or components subject to wear Converter
seal bearings winding
≥ 15 000 h 25 000 h
10 000 h to 12 000 h to
Indicative operating lifetime Amb. maxi Amb. maxi
20 000 h 50 000 h
40°C 40°C
Continuous 1 to 2 years 1,5 to 5 years 1 to 3 years 3 years

Replacement
frequency 15 hours per day
2 to 4 years 3 to 10 years - 6 years
9 months per year
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10. Faults, causes and remedies

Faults should only be remedied by qualified person-
nel!
Observe the safety instructions, see <chapter 10>
Maintenance.
Relays
The converter is fitted with 2 output relays aimed for
an interface to centralized control.
ex.: control box, pumps control.
SBM relay:
This relay can be configured in the « Service »
menu < 5.7.6.0 > in 3 operating states.
State: 1
« Available transfer » relay (normal operating for
this pump type).
The relay is activated when the pump runs or is
in a position to run.
When a first defect appears or by mains supply
cutoff (the pump stops), the relay is deactiveted.
Information is given to the control box, regarding
the availability of the pump, even temporarily.
State: 2
« Run transfer » relay.
The relay is activated when the pump runs.
State: 3
« Power on transfer » relay.
The relay is activated when the pump is con-
nected to the network.
SSM relay:
« Failures transfer » relay.
After a series of detection (from 1 to 6 according to
significance) of the same type of defect, the pump
stops and this relay is activated (up to manual action).
Example: 6 defects with a variable time limit on 24 Defects 1 2 3 4 5 6

sliding hours.
State of SBM relay is « Available transfer ».
Active
relay
SBM
Rest
relay
Active
relay
SSM
Rest
relay
24H00 sliding
56 WILO SE 09/2011
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10.1 Error table

All incidents hereafter mentioned give rise to:
• The deactivation of the SBM relay (When this one is parametrized in « available transfer » mode).
• The activation of the SSM relay « failure transfer » when the maximum quantity of one type of defect is reached
over a 24-hour range.
• Ligthening of a red LED.
Reaction Time before

time considera- Waiting time Max Waiting
Error before tion of the defects Faults time
N° error defect, before automatic over 24 Possible causes Remedies before
signalisa- after restart hours reset
tion signalisation
The pump is in overload, Density and/or viscosity of the con-
defective. veyed fluid are too big.
E001 60s immediate 60s 6 300s
The pump is obstructed by Dismantle the pump and replace the
particles. defective components or clean them.
E004 ~5s 300s Immediate if defect 6 The converter supply is in Check the converter terminals: 0s
(E032 deleted under voltage. • error if network < 330V
E005 ~5s 300s Immediate if defect 6 The converter supply is in Check the converter terminals: 0s
(E033) deleted over voltage. • error if network > 480V
E006 ~5s 300s Immediate if defect 6 A supply phase is missing. Check the supply. 0s
deleted
Immediate if defect The converter runs like a The pump veers, check the tightness
E007 immediate immediate deleted no limit generator. It is a warning, of the non-return valve. 0s
without stop of the pump.
Dismantle the pump, clean it and
E010 ~5s immediate no restart 1 The pump is locked. replace the defective parts. It may be a 60s
mechanical failure of the motor (bea-
rings).
Pump is no more primed or Prime the pump once again by filling

E011 15s immediate 60s 6 runs dry. it (see chapter 8.3). 300s
Check the tightness of the foot valve.
The motor heats. Clean the cooling ribs of the motor.

E020 ~5s immediate 300s 6 300s
Ambient temperature higher The motor is foreseen to run at an
than +40°C. ambient temperature of +40°C.
Dismantle the motor-converter of

E023 immediate immediate 60s 6 The motor is in short-circuit. 60s
the pump, check it or replace it.
E025 immediate immediate no restart 1 Missing phase of the motor. Check the connection between motor 60s
and converter.
The thermal sensor of the Dismantle the motor-converter of
E026 ~5s immediate 300s 6 motor is defective or has a 300s
wrong connection. the pump, check it or replace it.
Clean the cooling ribs rearside and

The converter heats. under the converter as well as the fan
E030 cover.
~5s immediate 300s 6 300s
E031
Ambient temperature higher The converter is foreseen to run at an
than +40°C. ambient temperature of +40°C.
E042 ~5s immediate no restart 1 The cable of the sensor Check the correct supply and the 60s
(4-20mA) is cut. cable connection of the sensor.
E050 60s immediate Immediate if defect no limit BMS communications time-out. Check the connection. 300s
deleted
E070 immediate immediate no restart 1 Internal communication Call the after-sales technician. 60s
error.
E071 immediate immediate no restart 1 EEPROM error. Call the after-sales technician. 60s
E072 immediate immediate no restart 1 Problem inside converter. Call the after-sales technician. 60s
E073
E075 immediate immediate no restart 1 Inrush current relay defect. Call the after-sales technician. 60s
E076 immediate immediate no restart 1 Current sensor defect. Call the after-sales technician. 60s
E077 immediate immediate no restart 1 24V defect Call the after-sales technician. 60s
E099 immediate immediate no restart 1 Unknown pump type. Call the after-sales technician. Power
off/on
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10.2 Acknowledging errors

CAUTION! Material damage!
Only acknowledge defect when they have been
remedied.
• Only skilled technicians are allowed to remedy the
defect.
• If doubt, contact the manufacturer.
• In the event of an error, the error page is dis-
played instead of the status page.
To acknowledge, proceed as follows.
• Press the encoder (or the centre of the touch
pads).
It appears on the display:
• The menu number <6.0.0.0> .
• The defect number and the maximum number
Example of error over 24 hours of the concerned defect (example:
page. 1/6).
• The remaining time before auto reset of the
defect, in seconds.
Example of status
page
• Wait for the auto reset time.

A timer runs within the system. The remaining
time (in seconds) is displayed until the error is
automatically acknowledged.
• When the maximum number of the defect is
reached and the last timer has elapsed, press the
encoder to acknowledge.
The system returns to the status page.
NOTE: When there is a time before considering of
the defect, after signalling (example : 300s), the
defect must always be manually acknowledged.
The auto reset timer is inactive and “- - -” is dis-
played.
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10.3 Other defaults

Other defects, not detected by the converter,
due to the pump.
Defaults Possible causes Remedies

The pump is running but no delivery The pump does not run quickly enough Check the adequate adjustment of the
requirement (conformity to the setpoint).
The internal parts are obstructed by Let dismantle the pump and clean it.
particles
Suction pipe is obstructed Clean the pipe.
Air in suction pipe Check tightness of the whole pipe up to
the pump and make it tight.
Suction pressure is too low, it causes Too high losses of load on suction or
generally cavitation noise suction head is too high (check the NPSH
of the pump installed and the installa-
tion).
The pump is vibrating Pump is loosed on its foundation Check and tighten completely the nuts
of the stud bolts.
Particles obstructing the pump Have the pump dismantled and clean it.
Difficult rotation of the pump Check the pump turns freely without
abnormal sticking.
No sufficient pressure for the pump The motor speed is not high enough Check if the setpoint is correctly adju-
sted.
The motor is defective Replace it.
Bad filling of the pump Open the venting device and vent until
there are no more air bubbles.
The drain-priming plug is not fully tigh- Check it and screw it again.
tened
The flow is irregular The suction head (Ha) is not observed Study again the installation conditions
and the recommendations described in
this instruction.
The suction pipe has a lower diameter The suction pipe must have at least the
than the one of the pump same diameter as the suction pump port.
The strainer and the suction pipe are Remove and clean.
partially obstructed
In « Constant pressure » mode, the Put a sensor with conforming pressure
pressure sensor is not adequate scale and accuracy, see chapter 5.3.
In « Constant pressure » mode, the pump The non-return valve is not tight Clean it or change it.
does not stop if the flow is zero The non-return valve is not adequate Replace it by an adequate non-return
valve, see chapter 5.3.
The tank has low capacity due to the Change it or add an other one on the
installation installation.
WARNING! Risk of wound! CAUTION! Danger of material damage!

The liquid is toxic, corrosive or dangerous for Perfect pump function can only be guaranteed
human being. when original spare parts are used.
• The qualified person in charge of the repairing
must be informed. • Only use original spare parts.
• Clean the pump to ensure complete safety of the
operator.
11. Spare parts

Spare parts may be ordered via local approved
technicians and/or the Wilo after-sales
service.
To avoid any questions or wrong orders, all data
of the name plate should be mentioned Subject to technical alterations!
when ordering.
WILO SE 09/2011 59
Français
1. Généralités 2.3 Dangers encourus en cas de non observation

des consignes
1.1 A propos de ce document La non observation des consignes de sécurité
La langue de la notice de montage et de mise en peut constituer un danger pour les personnes, la
service d’origine est le français. Toutes les autres pompe ou l’installation. Elle peut également
langues de la présente notice sont une traduc- entraîner la suspension de tout recours en garan-
tion de la notice de montage et de mise en servi- tie.
ce d’origine. Plus précisément, les dangers encourus peuvent
La notice de montage et de mise en service fait être les suivants :
partie intégrante du matériel et doit être dispo- • défaillance de fonctions importantes de la pompe
nible en permanence à proximité. Le strict res- ou de l'installation.
pect de ses instructions est une condition néces- • défaillance du processus d’entretien et de répa-
saire à l'installation et à l'utilisation conforme du ration prescrit.
matériel. La notice de montage et de mise en • dangers pour les personnes par influences élec-
service correspond uniquement à ce produit et triques, mécaniques ou bactériologiques.
répond aux normes de sécurité en vigueur à la • dommages matériels.
date de son impression.
2.4 Consignes de sécurité pour l’utilisateur
2. Sécurité Il convient d’observer les consignes en vue d’ex-
clure tout risque d’accident.
Ce manuel renferme des consignes essentielles Il y a également lieu d’exclure tout danger lié à l’é-
qui doivent être respectées lors du montage et de nergie électrique. On se conformera aux disposi-
l'utilisation. Ainsi il est indispensable que l'instal- tions de la réglementation locale ou générale [IEC,
lateur et l'opérateur du matériel en prennent VDE, etc.], ainsi qu’aux prescriptions de l’entrepri-
connaissance avant de procéder au montage et à se qui fournit l’énergie électrique.
la mise en service. Les consignes à respecter ne
sont pas uniquement celles de sécurité générale 2.5 Conseils de sécurité pour les travaux d’inspec-
de ce chapitre, mais aussi celles de sécurité parti- tion et de montage
culière qui figurent dans les chapitres suivants, L’utilisateur doit faire réaliser ces travaux par une
accompagnées d'un symbole de danger. personne spécialisée qualifiée ayant pris connais-
sance du contenu de la notice.
2.1 Signalisation des consignes de la notice Les travaux réalisés sur la pompe ou l’installation
ne doivent avoir lieu que si les appareillages cor-
Symboles respondants sont à l’arrêt.
Symbole général de danger.
2.6 Modification du matériel et utilisation de
Consignes relatives aux risques électriques. pièces détachées non agréées
Toute modification de la pompe ou de l'installa-
NOTE: .... tion ne peut être effectuée que moyennant l'au-
Signaux : torisation préalable du fabricant. L'utilisation de
pièces détachées d'origine et d'accessoires auto-
DANGER ! Situation extrêmement dangereuse. risés par le fabricant garantit la sécurité.
Le non-respect entraîne la mort ou des bles- L'utilisation d'autres pièces dégage la société de
sures graves. toute responsabilité.
AVERTISSEMENT ! L'utilisateur peut souffrir de
blessures (graves). « Avertissement » implique 2.7 Modes d'utilisation non autorisés
que des dommages corporels (graves) sont vrai- La sécurité de fonctionnement de la pompe/de
semblables lorsque l'indication n'est pas res- l'installation livrée n'est garantie que si les pres-
pectée. criptions précisées au chap. 4 de la notice de
montage et de mise en service sont respectées.
ATTENTION ! Il existe un risque d'endommager Les valeurs indiquées dans le catalogue ou la fiche
la pompe/installation. « Attention » Signale technique ne doivent en aucun cas être
une instruction dont la non observation peut dépassées, tant en maximum qu'en minimum.
engendrer un dommage pour le matériel et son
fonctionnement.
3. Transport et stockage avant utilisation
NOTE : Remarque utile sur le maniement du pro-
duit. Elle fait remarquer les difficultés éventuelles. 3.1 Expédition
La pompe est livrée départ usine dans une caisse
2.2 Qualification du personnel ou sanglée sur une palette et protégée contre la
Il convient de veiller à la qualification du person- poussière et l'humidité.
nel amené à réaliser le montage.
3.2 Inspection liée au transport
Dès réception, vérifier si la pompe n'a pas subi de
dommages durant son transport. En cas de défaut
60 WILO SE 09/2011
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constaté, prendre dans les délais prévus toutes 4. Application

dispositions nécessaires auprès du transporteur.
Pompes destinées au pompage de liquides clairs
3.3 Stockage dans les secteurs du bâtiment, de l'agriculture et
Jusqu'à son montage, la pompe doit être de l'industrie...
conservée dans un local sec, hors gel et à l'abri de Adduction d'eau, distribution d'eau -
tout dommage mécanique. Alimentation de château d'eau - Arrosage, irriga-
ATTENTION ! Risque de détérioration dû à un tion - Lavage haute pression - Alimentation de
conditionnement incorrect ! chaudières (avec kit by-pass recommandé) -
Si la pompe est à nouveau transportée ultérieure- Relevage de condensats - Climatisation - Circuits
ment, elle doit être conditionnée pour éviter tout industriels et en incorporation dans tous les
dommage dû au transport. systèmes modulaires.
• Pour ce faire, opter pour l'emballage d'origine ou
de qualité équivalente. 5. Caractéristiques du produit
AVERTISSEMENT ! Risque de blessures corpo-
relles ! Un transport non conforme peut entraîner 5.1 Dénomination
des blessures corporelles! HELIX-V ou MVI E 4 14 - 1 / 16 / E / 3-2
• La manutention de la pompe doit être effectuée à
l'aide de dispositifs de suspension de charge Pompe verticale
homologués. Procéder à un élingage au niveau multicellulaire in-line
des brides de la pompe et, le cas échéant au à haut rendement
diamètre extérieur du moteur (blocage impératif hydraulique
pour empêcher tout glissement !). Pompe verticale
multicellulaire in-line
Equipée d’un variateur
de vitesse
Débit nominal en m3
Nombre d’étages
1 : corps de pompe en inox 304
+ hydraulique en inox 304
2 : corps de pompe en inox 316L
+ hydraulique en inox 316L
3 : corps de pompe en fonte
GJL-250 + hydraulique
en inox 304
• En raison de la position haute du centre de gravité
et de la faible surface au sol de ces pompes, 16 : brides PN16
prendre les précautions nécessaires lors de la 25 : brides PN25
manutention pour éviter tout basculement pou- P : raccords Victaulic
vant présenter un risque pour la sécurité des per- E : joints toriques EPDM (WRAS/KTW)
sonnes. V : joints toriques VITON
Manipuler la pompe avec précautions pour respec- Triphasé - 2 pôles

ter la géométrie et l'alignement de l'ensemble.
5.2 Caractéristiques techniques
ATTENTION ! Risque de détérioration dû à un - Pression de service maxi
conditionnement incorrect ! • Corps PN25 : 25 bar
Les anneaux de manutention du moteur sont • Corps PN16 : 16 bar
exclusivement dédiés au transport du moto- • Corps raccord rapide pour
variateur et non de la pompe complète. collier type "Victaulic" : 25 bars
(uniquement 4, 8, 16 m3/h)
- Pression maxi à l'aspiration : 10 bars
- Plage de température d’eau
• version joints et garniture
mécanique EPDM
(homologation KTW – norme
allemande) et (homologation
WRAS – norme anglaise) : - 15°C à + 120°C
• version joints et garniture
mécanique Viton : - 15°C à + 90°C
- Hauteur d'aspiration maxi : suivant NPSH de la
pompe
WILO SE 09/2011 61
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- Température ambiante : - 15°C à +50°C amorçante, avec orifices en ligne sur le même
(produit standard) axe en partie basse.
- Humidité ambiante : < 90 % sans • Etanchéité au passage de l'arbre par garniture
condensation mécanique normalisée.
• Raccordement hydraulique.
- Niveau de pression
Brides ovales sur corps PN16 (6“) : pompe fournie
acoustique : 1,1kW = 63dB(A)
avec contre-brides fonte ovales pour tube à vis-
2,2kW = 66dB(A)
ser, joints et boulons.
4kW = 71dB(A)
Brides rondes PN16 (8“) et PN25 : pompe fournie
- Classe d’isolation : F avec joints et boulons sans contre-brides (acces-
- Indice de protection : IP55 soires en option).
- Compatibilité Raccord rapide (MVI 6“) pour collier type
électromagnétique (*) "Victaulic" : pompe fournie sans colliers (acces-
• émission résidentielle - soires en option).
1er environnement : EN 61800-3 Le moteur et son variateur de vitesse
• immunité industrielle - • Moteur fermé à bride et bout d'arbre normalisés
2ème environnement : EN 61800-3 pour fonctionnement vertical, équipé de son
- Tension d’utilisation : 400V (±10%) 50Hz variateur de vitesse.
380V (±10%) 60Hz • Liaison moteur-pompe assurée par un accouple-
440V (±6%) 60Hz ment avec protecteurs de sécurité.
- Section du câble
6.2 Fonctionnement
d’alimentation (4 fils) :
• 1,1kW : 1,5 mm2 à 2,5 mm2 Voici les principaux avantages de la régulation
• 2,2/4kW : 2,5 mm2 à 4 mm2 électronique :
(*) Dans la gamme de fréquence entre 600 MHz et • économie d'énergie,
1GHz, dans des cas exceptionnels de proximité immé- • réduction des bruits d'écoulement,
diate (< 1 m du variateur électronique) d'émetteurs, • adaptation de la pompe aux exigences de service
transmetteurs ou appareils similaires fonctionnant dans variables.
cette gamme de fréquence, l'affichage voire l'indica- Les différents types de fonctionnement sont les
tion de pression sur l'afficheur peut être perturbé. Le suivants :
fonctionnement de la pompe n'est à aucun moment • « Contrôle vitesse » : réglage de la fréquence
altéré. manuellement ou par commande externe.
• « Pression constante » : régulation grâce à un
5.3 Accessoires capteur de pression et réglage d’une consigne
Les accessoires doivent être commandés séparément. (interne ou externe).
• Module IF PLR pour connexion au convertisseur • « Contrôle P.I.D. » : régulation grâce à un capteur
d'interface/PLR. (de température, de débit,...) par contrôle du
• Module IF LON pour connexion au réseau LON- P.I.D. et réglage d’une consigne (interne ou
WORKS. Le module IF PLR se connecte directe- externe).
ment dans la zone de connexion du variateur
(Fig. 11).
7. Installation et raccordement électrique
• Kit by-pass.
• Vannes d'isolement. ATTENTION ! Risque de dommages matériels !
• Réservoir à vessie ou galvanisé. Risque de détérioration dû à une manipulation non
• Réservoir anti bélier. conforme. Seul du personnel spécialisé est habilité
• Contre bride à souder (Acier) ou à visser (Inox). à installer la pompe.
• Raccord rapide type "Victaulic".
• Clapets anti-retour (à ogive ou à battant avec res- 7.1 Préparation
sort si fonctionnement en pression constante). - Ne procéder au montage qu'une fois tous les tra-
• Clapet de pied de crépine. vaux de soudage et de brasage terminés et après
• Manchons anti-vibratoires. le rinçage éventuellement nécessaire du circuit
• Protection manque d'eau. hydraulique. La saleté peut rendre la pompe
• Kit capteur de pression de régulation (précision inopérationnelle.
≤ 1%; utilisation entre 30% et 100% de son - Les pompes doivent être protégées contre les
étendue de mesure). intempéries et installées dans un environnement
Pour la liste détaillée, consulter le catalogue. protégé de la poussière et du gel, bien ventilé et
en atmosphère non explosive.
- Monter la pompe à un emplacement facilement
6. Description et fonctionnement accessible pour faciliter tout contrôle ultérieur,
tout entretien (p. ex. garniture mécanique) ou
6.1 Description du produit tout remplacement. L'arrivée d'air du module
La pompe électronique ne doit pas être obstruée.
• Pompe verticale multicellulaire non auto-
62 WILO SE 09/2011
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7.2 Descriptif (voir Fig. 1, 2, 5, 6, 7, 8) NOTE : Au-delà de 80°C, prévoir une installation
1 - Clapet de pied-crépine pompe en charge.
2 - Vanne à l'aspiration pompe
ATTENTION ! Risque de dommages matériels !
3 - Vanne au refoulement pompe
L’installation doit supporter la pression atteinte par
4 - Clapet anti-retour
la pompe à fréquence maxi et débit nul.
5 - Bouchon remplissage/purgeur
- Pompe avec corps à brides ovales : par tubes
6 - Bouchon vidange – amorçage
filetés à visser directement sur les contre-brides
7 - Supports de tuyauterie ou colliers
ovales taraudées fournies avec la pompe.
8 - Crépine
- Pompe avec corps à brides rondes : par tube à
9 - Bâche de stockage
souder ou à visser dans les contre-brides
10 - Réseau d'eau de ville
(contre-brides disponibles en accessoires).
11 - Interrupteur, sectionneur avec fusibles
- Pompe avec corps à raccord rapide : par un col-
12 - Crochet de levage
lier, à installer avec un embout à fixer sur la
13 - Massif
tuyauterie (collier et embout fileté disponibles en
14 - Robinet
accessoires).
15 - Capteur de pression
- Le diamètre de la tuyauterie ne doit jamais être
16 - Réservoir
inférieur à celui de la contre-bride.
17 - Vanne d'isolement réservoir
- Le sens de circulation du fluide est indiqué sur
18 - Afficheur
l’étiquette d’identification de la pompe.
19 - Bouton de réglage
BP - By-pass ATTENTION ! Risque de dommages matériels !
HA - Hauteur d'aspiration maxi Bien étancher les raccordements avec des produits
HC - Hauteur de charge mini adaptés, aucune prise d’air ne doit être tolérée sur
cette tuyauterie qui sera en pente montante d’au
7.3 Montage moins 2 % (Fig. 1).
Deux cas type. - Limiter la longueur de la tuyauterie d'aspiration
Fig. 1 : pompe en aspiration et éviter au maximum les causes de pertes de
Fig. 2 : pompe en charge sur bâche de stockage charge (coudes, vannes, rétrécissements).
(rep. 9) ou sur réseau d'eau de ville (rep. 10).
- Utiliser des supports ou colliers (Fig. 1 & 2, rep.
- Installer la pompe dans un endroit facilement
7) pour éviter que le poids des tuyauteries ne soit
accessible, protégé des conditions extérieures
supporté par la pompe.
directes (pluie et soleil excessif, gel) et aussi près
que possible du lieu de puisage. ATTENTION ! Risque de dommages matériels !
- Pour les pompes dont la masse est importante, Dans le cas d’une installation pompe en charge
prévoir un point d'attache (crochet de levage) avec risque de coups de bélier, il est préférable de
dans l'axe de la pompe (rep. 12) pour permettre monter le clapet anti-retour au refoulement pour
un démontage aisé. protéger la pompe.
- Montage sur massif en béton (10 cm de hauteur
NOTE : Pour le pompage d'eau fortement aérée
mini) (rep. 13) avec fixation par boulons de scel-
ou d'eau chaude, nous recommandons la mise en
lement (plan de pose voir Fig. 3).
place d'un kit by-pass (Fig. 1, rep. BP). Le monta-
- Prévoir sous le massif de béton un matériau iso-
ge du capteur de pression se fera alors sur la
lant (liège ou caoutchouc armé) pour éviter la
tuyauterie de refoulement (Fig. 7).
transmission des bruits et des vibrations.
- Avant le serrage définitif des boulons de scelle-
ment, s'assurer que l'axe de la pompe est bien
vertical : utiliser des cales si nécessaire.
NOTE : Tenir compte que l'altitude du lieu d'instal-
lation et la température de l'eau pompée rédui-
sent les possibilités d'aspiration de la pompe.
Perte de Perte de
Altitude Température
hauteur (HA) hauteur (HA)
0m 0 mCL 20 °C 0,20 mCL
500 m 500 mCL 30 °C 0,40 mCL
1000 m 1000 mCL 40 °C 0,70 mCL
50 °C 1,20 mCL
60 °C 1,90 mCL
70 °C 3,10 mCL
80 °C 4,70 mCL
90 °C 7,10 mCL
100 °C 10,30 mCL
110 °C 14,70 mCL
120 °C 20,50 mCL
WILO SE 09/2011 63
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Encombrements et diamètres de raccordement

MVIE (Fig. 3a)
Exécution PN25
Exécution PN16
Type de pompe Victaulic
200 212 180 100 20 12 157 204 50 75 M10 G1” 172 250 75 85 14 DN25 210 50 Ø42,4
400 212 180 100 20 12 157 204 50 75 M10 G1”1/4 172 250 75 100 18 DN32 210 50 Ø42,4
6”
800 252 215 130 20 12 187 250 80 100 M12 G1”1/2 187 280 80 110 18 DN40 261 80 Ø60,3
1600/6 252 215 130 20 12 187 250 90 100 M12 G2” 187 300 90 125 18 DN50 261 80 Ø60,3
HELIX-VE (Fig. 3b)
Type de Exécution PN16 Exécution PN25

pompe
200/400 100 212 180 157 204 50 G1“ 2xM10 172 250 75 DN25 4xM12
600 100 212 180 157 204 50 G1“1/4 2xM10 172 250 75 DN32 4xM16
6”
1000 130 255 215 190 250 80 G1“1/2 2xM12 190 280 80 DN40 4xM16
1600 130 255 215 190 250 90 G2“ 2xM12 190 300 90 DN50 4xM16
2200 130 296 215 250 300 90 DN50 4xM16 250 300 90 DN50 4xM16
8”
3600 170 296 240 250 320 105 DN65 4xM16 250 320 105 DN65 8xM16
7.4 Raccordements électriques - (rep. b) Le câble du capteur , de la consigne

externe et de l’entrée [aux.]/[ext.off] doit impé-
DANGER ! Danger de mort ! rativement être blindé et doit être inséré dans le
Une installation et un raccordement électrique non presse-étoupe M12 ou M16. Les presse étoupes
conformes peuvent avoir des conséquences mor- métalliques du variateur sont adaptés au monta-
telles. ge d’une tresse de blindage, voir montage ci-
• Ne faire effectuer l'installation et le raccordement dessous.
électrique que par des électriciens spécialisés
agréés et conformément aux prescriptions en
vigueur. 1
• Observer les consignes de préventions des acci-
dents.
• Ne pas oublier de raccorder les mises à la terre. 2
AVERTISSEMENT ! Risque de surcharge du réseau !

Une configuration insuffisante du réseau peut
entraîner des défaillances du système, 3
voire même des incendies de câbles dus à une sur-
charge du réseau.
4
Une erreur de branchement pourrait endommager
le variateur. • Les caractéristiques électriques (fréquence, ten-
Le câble électrique ne devra jamais être en contact sion, intensité nominale) du moto-variateur sont
ni avec la tuyauterie, ni avec la pompe, et être à indiquées sur l’étiquette d'identification pompe
l'abri de toute humidité. (rep. 19). Vérifier que le moto-variateur est adapté
(rep. a) Le câble d'alimentation (3 phases + terre) au réseau sur lequel il va être utilisé.
doit être inséré dans le presse-étoupe M25. • La protection électrique du moteur est intégrée au
Les presse-étoupes non utilisés doivent rester variateur. Celui-ci est paramétré pour tenir compte
obturés à l'aide des bouchons prévus par le fabri- des caractéristiques de la pompe et assurer sa pro-
cant (voir ci-dessous). tection et celle du moteur.
• En cas de neutre impédant, installer une protection
adaptée en amont du moteur-variateur.
a • Dans tous les cas, prévoir un sectionneur à fusibles
(type gF) pour protéger l’installation (Fig. 1, 2, rep.
11).
b
64 WILO SE 09/2011
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NOTE : Si un disjoncteur différentiel pour la pro-

tection de personnes doit être installé, il doit
obligatoirement être à effet retardé. Choisir le
calibre du disjoncteur en fonction de l'intensité
figurant sur l’étiquette d'identification pompe.
NOTE : Cette pompe est équipée d'un convertis-
seur de fréquence et ne doit pas être protégée à
l'aide d'un disjoncteur différentiel FI. Les conver-
tisseur de fréquence peuvent nuire au fonction-
nement des disjoncteurs différentiels FI.
Exception : Les disjoncteurs différentiels FI à
détection tous-courants sélective sont autorisés.
• Marquage d'identification : FI
• Courant de déclenchement : > 30 mA.
• Utiliser des câbles électriques conformes aux
normes.
• Caractéristique de déclenchement des fusibles : B
• Il est possible de modifier l'orientation du
moteur-variateur par quart de tour en retirant les
boulons de fixation moteur et en réorientant le
moteur à la position souhaitée.
Revisser les boulons.
• Dès que l'alimentation électrique du variateur est
activée, un essai de 2 secondes de l'afficheur est
effectué au cours duquel tous les signes de l'af-
ficheur apparaissent.
WILO SE 09/2011 65
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Affectation des bornes de raccordement

• Dévisser les vis et retirer le couvercle du varia-
teur.
Désignation Affectation Remarques

L1, L2, L3 Tension d’alimentation réseau Courant triphasé 3 ~ IEC38
PE Borne de Terre vérifier la présence de chaque phase.
IN1 Entrée capteur Nature du signal : tension (0 - 10 V, 2 - 10 V)
(DDS-borne 9) Résistance d'entrée : Ri ≥ 10 kΩ
Nature du signal : courant (0 - 20 mA, 4 - 20 mA)
Résistance d'entrée : RB = 500 Ω
Paramétrable au menu « Service » <5.3.0.0>
IN2 Entrée consigne externe Nature du signal : tension (0 - 10 V, 2 - 10 V)
(10V/20mA-borne 7) Résistance à l'entrée : Ri ≥ 10 kΩ
Nature du signal : courant (0 - 20 mA, 4 - 20 mA)
Résistance à l'entrée : RB = 500 Ω
GND (x2) Raccords de masse Pour chaque entrée IN1 et IN2.
+ 24 V Alimentation continue pour capteur Courant maxi : 60 mA.
L’alimentation est protégée contre les courts-circuits.
Ext. off Entrée de commande ON/OFF Le contact externe à contact sec permet d'activer et de
« Priorité ARRÊT » désactiver la pompe.
pour un interrupteur externe à contact sec Sur des installations avec des nombres élevées de démar-
rages (> 20 par jour), il faut prévoir l'activation et la
désactivation via « ext. off ».
SBM Relais « report de disponibilité » En fonctionnement normal, le relais est actif lorsque la
pompe tourne ou est en mesure de tourner.
Le relais est désactivé pour un premier défaut ou une
coupure secteur (la pompe s'arrête).
Ceci permet d'informer un coffret de commande de la
disponibilité d'une pompe, même temporairement.
Contact sec :
minimale : 12 V DC, 10 mA
maximale : 250 V AC, 1 A
SSM Relais « report de défauts » Après une série de détection (de 1 à 6, selon la gravité)
d'un même type de défaut, la pompe s'arrête et ce relais
est activé (jusqu'à intervention manuelle).
Contact sec :
minimale : 12 V DC, 10 mA
maximale : 250 V AC, 1 A
PLR Bornes de raccordement de l'interface Le module IF PLR en option est à insérer dans le connec-
de communication PLR teur multiple placé dans la zone de connection du varia-
teur.
Le module est protégé contre les inversions de polarité.
LON Bornes de raccordement de l'interface Le module IF LON en option est à insérer dans le connec-
de communication LON teur multiple placé dans la zone de connection du varia-
teur.
NOTE : Les bornes IN1, IN2, GND et Ext. Off sont

conformes à l'exigence « isolation garantie »
(selon EN61800-5-1) par rapport aux bornes
réseau ainsi qu'aux bornes SBM et SSM (et inver-
sement).
66 WILO SE 09/2011
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Branchement au réseau Bornier de puissance

Brancher le câble 4 conducteurs sur le bornier de puissance
(phases + terre). L1 L2 L3
Branchement des entrées / sorties Bornier des entrées / sorties

• Le câble du capteur, de la consigne externe et de l’entrée aux ext.off MP 20mA/10 DDS
[ext.off] doit impérativement être blindé.
1 2 3 4 5 6 7 8 9 10 11
non utilisé non utilisé
+24V...
GND...
GND...
In1...
In2...
Commande
capteur 20mA/10V
Consigne externe
à distance
ON/OFF
• La commande à distance permet la mise en marche ou Exemple : interrupteur à flotteur, pressostat manque
l'arrêt de la pompe (contact sec), cette fonction est priori- d'eau…
taire sur les autres fonctions.
• Cette commande à distance peut être ôtée en shuntant
les bornes (3 et 4).
Bornes de raccordement de l'interface de communication

PLR Le module IF PLR en option est à insérer dans le connec-
teur multiple placé dans la zone de connection du varia-
teur.
LON Le module IF LON en option est à insérer dans le connec-

teur multiple placé dans la zone de connection du varia-
teur.
WILO SE 09/2011 67
Français
Branchement « Contrôle vitesse » Bornier des entrées / sorties

Réglage de la fréquence manuellement :
1 2 3 4 5 6 7 8 9 10 11
Commande
à distance
Réglage de la fréquence par commande externe :

1 2 3 4 5 6 7 8 9 10 11
In2...
Commande Consigne
à distance externe
Branchement « Pression constante »

Régulation avec un capteur de pression :
• 2 fils ( [20mA/10V] / +24V )
1 2 3 4 5 6 7 8 9 10 11
• 3 fils ( [20mA/10V] / 0V / +24V )
In1...
et réglage de la consigne par l’encodeur / le touch pads
Commande Capteur
à distance de pression
Régulation avec un capteur de pression :

• 2 fils ( [20mA/10V] / +24V )
1 2 3 4 5 6 7 8 9 10 11
• 3 fils ( [20mA/10V] / 0V / +24V ) In1...
In2...
et réglage par une consigne externe
Commande Consigne Capteur

à distance externe de pression
Branchement « Contrôle P.I.D. »

Régulation avec un capteur (de température, de
débit,...) : aux ext.off MP 20mA/10 DDS
1 2 3 4 5 6 7 8 9 10 11
• 2 fils ( [20mA/10V] / +24V )
• 3 fils ( [20mA/10V] / 0V / +24V )
In1...

Commande Capteur
à distance de pression
Régulation avec un capteur (de température, de

débit,...) : aux ext.off MP 20mA/10 DDS
1 2 3 4 5 6 7 8 9 10 11
• 2 fils ( [20mA/10V] / +24V )
• 3 fils ( [20mA/10V] / 0V / +24V )
In1...
In2...

Commande Consigne Capteur
à distance externe de pression
68 WILO SE 09/2011
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DANGER ! Danger de mort !

Tension dangereuse due à la décharge des condensa-
teurs du variateur.
• Avant toute intervention sur le variateur, attendre 5
minutes après coupure de l’alimentation.
• S'assurer que tous raccords et contacts électriques ne sont
pas sous tension.
• S’assurer de la bonne affectation des bornes de raccorde-
ment.
• S’assurer de la bonne mise à la terre de la pompe et de l'ins-
tallation.
IN1 : Entrée capteur en mode « Pression constante » et « Contrôle P.I.D. »
Signal capteur 4-20mA Signal Capteur 0-10V
100% 100%
entre 0 et 2 mA on considère
que le câble est coupé
zone de
Valeur sécurité Valeur
en % en %
de l’étendue de de l’étendue de
mesure du capteur mesure du capteur
0 2 4 Entrée en courant (mA) 20 0 Entrée en tension (V) 10
Signal capteur 0-20mA Signal Capteur 2-10V
100% 100%
Valeur Valeur
en %
de l’étendue de en %
mesure du capteur de l’étendue de
mesure du capteur
0 Entrée en courant (mA) 20 0 2 Entrée en tension (V) 10
WILO SE 09/2011 69
Français
IN2 : Entrée de la consigne externe en mode « Pression constante » et « Contrôle P.I.D. »
Consigne 4-20mA Consigne 0-10V
100% 100%
zone où le variateur s’arrête zone où le variateur s’arrête
zone de zone de
Consigne sécurité Consigne sécurité
en % en %
de l’étendue de de l’étendue de
mesure du capteur mesure du capteur
0 2 4 Entrée en courant (mA) 20 0 1 2 Entrée en tension (V) 10
IN2 : Entrée de la commande externe de la fréquence en mode « Contrôle vitesse »
Signal externe 0-20mA Signal externe 0-10V
100% 100%
zone de zone de
Fréquence sécurité Fréquence sécurité
du variateur du variateur
~30% ~30%
Signal externe 4-20mA Signal externe 2-10V
100% 100%
zone de zone de
Fréquence sécurité Fréquence sécurité
du variateur du variateur
~30% ~30%
70 WILO SE 09/2011
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8. Mise en route Pos. Description

8.1 Réglage 1 Numéro de menu
8.1.1 Eléments de commande 2 Affichage de valeur
Le variateur s'utilise à l'aide des éléments de com- 3 Affichage d’unité
mande suivants : 4 Symboles standards
Version encodeur 5 Affichage d’icônes
Réglage par l'encodeur
• Dès que l'alimentation électrique du variateur est
activée, un essai de 2 secondes de l'afficheur est
effectué au cours duquel tous les signes de l'af-
ficheur apparaissent.
• La sélection d'un nouveau paramètre est obtenue
par simple rotation, « + » droit et « - » gauche. 8.1.3 Description des symboles standard
• Une impulsion sur l'encodeur valide ce nouveau
réglage. Symbole Description
Version Touch pads Fonctionnement en mode

Réglage par le touch pads « Contrôle vitesse ».
Fonctionnement en mode « Pression
constante » ou « Contrôle P.I.D. ».
Entrée IN2 activée (valeur de con-
2
signe externe).
Verrouillage d'accès.
• La sélection d'un nouveau paramètre est obtenue Lorsque ce symbole apparaît, les
par une impulsion sur les flèches du touch pads, réglages ou les valeurs de mesure
« + » haut et « - » bas. actuelles ne peuvent pas être modi-
• Une impulsion au centre du touch pads valide ce fiés. Les informations affichées sont
nouveau réglage. uniquement en lecture.
BMS (building management system)
Switch
[système de gestion de bâtiment]
ON PLR ou LON est activé.
Pompe en fonctionnement.
1 2
• Ce variateur dispose d'un bloc de deux switchs Pompe à l’arrêt.
(Fig. 4, rep. S) à deux positions :
• Le switch 1 permet de basculer du mode « OPE- 8.1.4 Affichage
RATION » [switch 1->OFF] au mode « SERVICE »
[switch 1->ON] et inversement. Page d'état de l'afficheur
La position « OPERATION » autorise le fonction- • La page d'état s'affiche par défaut sur l'afficheur.
nement du mode choisi et condamne l'accès au La valeur actuel de consigne s'affiche.
paramétrage (fonctionnement normal). Les réglages de base sont indiqués à l'aide de
La position « SERVICE » permet d'effectuer le symboles.
paramétrage des différents fonctionnements.
• Le switch 2 permet d'activer ou de désactiver le
« Verrouillage d'accès ».
8.1.2 Structure de l'afficheur
1 4
2 5
Exemple de page d’état
4 3 4
NOTE : Dans tous les menus, si l’encodeur / le
touch pads n'est pas actionné avant 30
secondes, l'afficheur revient à la page d'état et
aucune modification n’est enregistrée.
WILO SE 09/2011 71
Français
Elément de navigation <3.0.0.0>

• L’arborescence du menu permet d'appeler les
fonctions du variateur. Un numéro est attribué à
chaque menu et sous-menu.
• La rotation de l’encodeur (ou une impulsion sur la OPERATION OFF
Réglage Marche / Arrêt de
flèche « + » ou « - » du touch pads) permet le la pompe.
défilement d’un menu de même niveau SERVICE ON
(exemple 4000->5000).
<4.0.0.0>
• Tout éléments (valeur, numéro de menu, symbole
ou icône) clignotants autorisent le choix d’une Position Switch 1 Description
nouvelle valeur, d’un nouveau numéro de menu
ou d’une nouvelle fonction. OPERATION OFF
Lecture seule du menu
Symbole Description « Informations ».
SERVICE ON
Lorsque la flèche apparaît :
• Une impulsion sur l’encodeur (ou • Le menu « Information » affiche des données de
au centre du touch pads) permet mesure, d'appareil et de fonctionnement,
l’accès à un sous-menu (Fig. 13).
(exemple 4000->4100).
<5.0.0.0>
Lorsque la flèche « retour arrière »
apparaît : Position Switch 1 Description
• Une impulsion sur l’encodeur (ou Lecture seule du menu
au centre du touch pads) OPERATION OFF
« Service ».
permet l’accès au menu supérieur
(exemple 4150->4100). Réglage du menu
SERVICE ON
« Service ».
8.1.5 Description des menus • Le menu « Service » permet d'accéder au réglage
des paramètres du variateur.
Liste (Fig. 12)
<6.0.0.0>
Position Switch 1 Description Position Switch 1 Description
OPERATION OFF OPERATION OFF

Réglage de la valeur de Affichage de la page des
consigne, possible dans défauts.
SERVICE ON les 2 cas. SERVICE ON
• Si un ou plusieurs défauts surviennent, la page de

<1.0.0.0>
défauts apparaît.
• Pour le réglage de la valeur de consigne, tourner
La lettre « E » suivi d’un code à trois chiffres
l’encodeur (ou appuyer sur l’une des flèches du
apparaît (chapitre 11).
touch pads). L'afficheur passe au menu <1.0.0.0>
et la valeur de consigne clignote. Une nouvelle <7.0.0.0>
rotation (ou une nouvelle action sur les flèches
du touch pads) permet de l'augmenter ou de la Position Switch 1 Description
réduire.
• Pour confirmer la nouvelle valeur, donner une OPERATION OFF
Affichage du symbole
impulsion sur l’encodeur, l'afficheur bascule à la
« Verrouillage d'accès ».
page d'état. SERVICE ON
Position Switch 1 Description • Le « Verrouillage d'accès » est accessible que si

le switch 2 se trouve en position ON.
Lecture seule des modes
OPERATION OFF ATTENTION ! Risque de dommages matériels !
de fonctionnement.
Tout réglage incorrecte peut entraîner des dys-
Réglage des modes de fonctionnements de la pompe et, par consé-
SERVICE ON
fonctionnement. quent, occasionner des dommages matériels sur
<2.0.0.0> la pompe ou l'installation.
• Les modes de fonctionnement sont le « Contrôle • N'effectuer les réglages en mode « SERVICE »
vitesse », la « Pression constante » et le que pour la mise en service et ne laisser que des
« Contrôle P.I.D. ». techniciens spécialisés y procéder.
72 WILO SE 09/2011
Français
Fig. 12
Navigation des menus de base en fonctionnement normal

(Switch1 = OFF en position « OPERATION »)
Réglage du point
Type de contrôle
Pompe
Marche / arrêt
Information
Service
Acquittement
des défauts
Apparaît lorsqu’une
erreure est activée
WILO SE 09/2011 73
Français
Fig. 13
Navigation du menu <4.0.0.0> « Informations »
Informations
Valeurs réelles
Pression N’apparaît pas lorsque le

ou% “Contrôle Vitesse” est activé
Puissance
Données de fonctionnement
Heures de
fonctionnement
Consommation
Compteur de
coupure réseau
Conditions réelles
Etat actuel du
relais SSM
Etat actuel du Voir chapitre 11 - Menu <5.7.6.0>
relais SBM Par défaut “report de disponibilité”
Etat de l’entrée
ext. off
Données d’appareil
Désignation
pompe
Version Logiciel
interface utilisateur
Version Logiciel
contrôle moteur
74 WILO SE 09/2011
Français
Paramètrage des menus <2.0.0.0> et <5.0.0.0>

En mode « SERVICE », les paramètres des menus <2.0.0.0> et <5.0.0.0> sont modifiables.
Il existe 2 modes de réglage :
• le « Mode Easy » : mode rapide permettant de paramètrer les 3 modes de fonctionnement.
• le « Mode Expert » : mode permettant l’accès à tous les paramètres. ON
• Placer le switch 1 en position ON (Fig. 4, rep. S). S
• Le mode « SERVICE » est activé.
Sur la page d'état de l'afficheur, le symbole ci-contre clignote (Fig. 14). 1
Fig. 14
Mode EASY
SERVICE
Type de Contrôle
Mode EASY
Réglage du point
Type de Contrôle
Mode EXPERT
Mode EXPERT
Pompe
Information
OPERATION
ON
Service
1 2
Mode Easy
• Appuyer pendant 2 secondes sur l’encodeur. Le symbole du « Mode Easy » est affiché (Fig. 14).
• Appuyer sur l’encodeur pour valider ce choix. L'afficheur bascule au numéro de menu <2.0.0.0>.
Le menu « Mode Easy » permet rapidement de paramètrer les 3 modes de fonctionnement (Fig. 15)
• « Contrôle vitesse »
• « Pression constante »
• « Contrôle P.I.D. »
• Après avoir effectuer les réglages remettre le switch 1 en position OFF (Fig. 4, rep. S).
Mode Expert
• Appuyer pendant 2 secondes sur l’encodeur. Se placer en mode expert, le symbole du
« Mode Expert » est affiché (Fig. 14).
• Appuyer sur l’encodeur pour valider ce choix. L'afficheur bascule au numéro de menu <2.0.0.0>.
Choisir d’abord le mode de fonctionnement au menu <2.0.0.0>.
• « Contrôle vitesse »
• « Pression constante »
• « Contrôle P.I.D. »
Ensuite au menu <5.0.0.0>, le mode expert donne accès à tous les paramètres du variateur (Fig. 16).
• Après avoir effectuer les réglages remettre le switch 1 en position OFF (Fig. 4, rep. S).
WILO SE 09/2011 75
Français
Fig. 15
Contrôle vitesse
Avec consigne interne
Entrée consigne externe - IN2 MENU

désactivée - Sélection OFF
EASY
Entrée consigne externe - IN2
activée - Sélection ON
Avec consigne externe

Sélection du type de signal
Pression constante
Entrée capteur - IN1

Sélection du capteur de pression

Avec consigne interne


Avec consigne externe

Controle P.I.D.


Paramétrage du P.I.D.
Sélection valeur “P” (0.0-300.0)
Sélection valeur “I” (10ms-300s) Avec consigne interne
Sélection valeur “D” (0ms-300s)


Sélection valeur “P” (0.0-300.0)
Sélection valeur “I” (10ms-300s) Avec consigne externe
Sélection valeur “D” (0ms-300s)
76 WILO SE 09/2011
Français
Fig. 16
MENU
EXPERT
Service
Apparaît lorsque le “BMS” est
BMS - Building Management System activé. Voir la notice de ce produit
N’apparaît pas lorsque le “Contrôle
IN1 - “Entrée capteur” de vitesse” est activé
Sélection capteur N’apparaît pas lorsque
“Contrôle PID” est activé
Sélection étendue signal
IN2 - “Entrée commande externe”
Sélection
Sélection étendue signal N’apparaît pas lorsque le

“IN2” est desactivé
Apparaît lorsque le
PID - Parmètres “Contrôle PID” est activé
Sélection
Paramètre “P”
Sélection
Paramètre “I”
Sélection
Paramètre “D”
Autres réglages
Sélection temps Apparaît lorsque la

d’arrêt débit nul “régulation pression” est activé
Sélection
fréquence réduite
Sélection fonction
relais SBM
Sélection
réglage usine
WILO SE 09/2011 77
Français
Verrouillage d'accès 8.3 Remplissage – dégazage

Afin de verrouiller les réglages de la pompe, il est
possible d'utiliser le « Verrouillage d'accès ».
Ne jamais faire tourner la pompe à sec, même un
Procéder comme suit pour activer ou désactiver : court instant !
• Placer le switch 2 en position ON (Fig. 4, rep. S).
Pompe en charge (Fig. 2).
Le menu <7.0.0.0> est appelé.
• Fermer la vanne au refoulement (rep. 3).
• Tourner l’encodeur / Appuyer sur les flèches du
• Ouvrir le purgeur (rep. 5), ouvrir la vanne à l'aspi-
touch pads pour activer ou désactiver le ver-
ration (rep.2) et procéder au remplissage complet
rouillage. L'état actuel du verrouillage est repré-
de la pompe.
senté par les symboles suivants :
• Ne refermer le purgeur qu'après sortie d'eau et
Verrouillage activé : Les paramètres totale évacuation de l'air.
sont verrouillés, l’accès aux menus est
AVERTISSEMENT ! Risque de brûlure !
autorisé en lecture seule.
En eau chaude, un jet d'eau peut s'échapper de
Verrouillage désactivé : Les l'orifice de purge.
paramètres peuvent être modifiés, • Prendre toutes les précautions nécessaires vis à
l’accès aux menus est autorisé pour vis des personnes et du moteur-variateur.
effectuer des réglages.
Pompe en aspiration (Fig. 1, 5)
• Remettre le switch 2 en position OFF (Fig. 4, rep. Deux cas sont possibles :
S). La page d'état s'affiche de nouveau. 1er cas (Fig. 5.1)
• Fermer la vanne au refoulement (Fig. 1, rep. 3),
8.1.6 Configurations ouvrir la vanne à l'aspiration (Fig. 1, rep. 2).
NOTE : Si la pompe est fournie seule, non inté- • Retirer le bouchon-purgeur (fig.1-rep.5).
grée dans un système monté par nos soins, le • Dévisser de 4 tours environ le bouchon inférieur
mode de configuration à la livraison est le de vidange-amorçage (fig.1-rep.6) situé sur le
« Contrôle vitesse ». corps de pompe.
• A l'aide d'un entonnoir, engagé dans l'orifice du
Mode « Contrôle vitesse » (Fig. 1, 2) purgeur, remplir complètement la pompe et la
Le point de fonctionnement est obtenu par tuyauterie d'aspiration.
réglage de la fréquence manuellement ou par • Après sortie d'eau et évacuation totale de l'air, le
commande externe. remplissage est terminé.
• Pour la mise en route, nous recommandons de • Revisser le bouchon-purgeur et le bouchon infé-
régler la vitesse du moteur à 2400 tr/mn. rieur de vidange-amorçage.
Mode « Pression constante » (Fig. 6, 7, 8)
2ème cas (Fig. 5.2)
Régulation grâce à un capteur de pression et
• Le remplissage peut être facilité en installant sur
réglage d’une consigne (interne ou externe).
la conduite d'aspiration de la pompe un tuyau
• L'ajout d’un capteur de pression (avec réservoir ;
vertical muni d'un robinet de fermeture (Fig. 5,
kit capteur livré en accessoire) permet une régu-
rep. 14) Ø ½" et d'un entonnoir.
lation de pression de la pompe (réservoir vide
d’eau, gonfler le réservoir à une pression infé- NOTE : La longueur du tuyau doit dépasser le
rieure de 0,3 bar à la pression de régulation de la niveau du purgeur d'au moins 50 mm.
pompe).
• Fermer la vanne au refoulement (Fig. 1, rep .3),
• Le capteur doit avoir une précision ≤ 1% et être
ouvrir la vanne à l'aspiration (Fig. 1, rep. 2).
utilisé entre 30% et 100% de son étendue de
• Ouvrir le robinet (Fig .5, rep. 14) et le purgeur.
mesure, le réservoir doit avoir un volume utile de
• Dévisser de 4 tours environ le bouchon
8L mini.
d'amorçage-vidange (Fig. 1, rep.6).
• Pour la mise en route, nous recommandons de
• Procéder au remplissage complet de la pompe et
régler une pression à 60% de la pression maxi-
de la conduite d'aspiration, jusqu'à écoulement
mum.
d'eau par le purgeur.
Mode « Contrôle P.I.D. »
• Fermer le robinet (Fig. 5, rep. 14) (celui-ci peut
Régulation grâce à un capteur (de température,
rester en place), retirer le tuyau, fermer le pur-
de débit,...) par contrôle du P.I.D. et réglage d’une
geur (Fig. 1, rep. 5) et revisser le bouchon
consigne (interne ou externe).
d’amorçage-vidange (Fig. 1, rep. 6).
8.2 Rinçage préliminaire ATTENTION ! Risque de mauvaise utilisation !
Pompe en charge et en mode « Pression
Chacune de nos pompes est testée hydraulique-
constante », la détection à débit nul peut ne pas
ment en usine, il se peut qu'il subsiste de l'eau
fonctionner.
dans celles-ci. Il est recommandé, pour des rai-
• Mettre le clapet anti-retour en amont du cap-
sons d'hygiène, d'effectuer un rinçage de la
teur de pression (soit à l'aspiration de la pompe si
pompe avant toute utilisation sur réseau d'eau
le capteur est monté sur celle-ci – Fig. 6).
potable.
78 WILO SE 09/2011
Français
8.4 Démarrage 9. Entretien

AVERTISSEMENT ! Risque de brûlure ! Seul le personnel qualifié est habilité à effec-
Suivant la température du fluide véhiculé et les tuer les travaux d'entretien et de réparation !
cycles de fonctionnement de la pompe, la
température des surfaces (pompe, moteur) peut Il est recommandé de faire entretenir et contrôler la
dépasser 68°C. pompe par un technicien S.A.V.
• Mettre en place des protections vis à vis des per- DANGER ! Danger de mort !
sonnes si nécessaire ! En cas de travaux sur les appareils électriques, il y
ATTENTION ! Risque de dommages matériels ! a un danger de mort par électrocution.
La pompe ne doit pas fonctionner à débit nul • Ne faire effectuer les travaux sur les appareils
(vanne au refoulement fermée) plus de 10 électriques que par des installateurs électriques
minutes en eau froide (T°C < 40°C) et plus de 5 agréés par le fournisseur d'énergie local.
mn au-delà de 60°C. • Avant d'intervenir sur les appareils électriques,
mettre ces dernier hors tension et les protéger
• Nous recommandons d'assurer un débit minimum contre toute remise sous tension !
égal à 10 % environ du débit nominal de la
pompe afin d'éviter la formation d'une poche AVERTISSEMENT ! Risque de brûlure !
gazeuse en partie haute de la pompe. Des températures de surface élevées peuvent
• Maintenir fermée la vanne au refoulement. être atteintes.
• Démarrer la pompe. • Laisser la pompe refroidir avant d'intervenir sur
• Ouvrir le purgeur pour évacuer l'air. En l'absence cette dernière.
d'un jet d'eau franc dans les 20s, refermer le pur- • Porter des vêtements de protection et des
geur et arréter la pompe puis attendre 20s envi- gants de protection pour tous les travaux.
ron pour laisser l'air décanter. • Aucun entretien particulier en cours de fonction-
• Redémarrer la pompe. nement.
NOTE : Si nécessaire (surtout si la hauteur d'aspiration • Maintenir la pompe et le moteur-variateur en
dépasse 5m), renouveler ces opérations. parfait état de propreté.
• En cas d'arrêt prolongé, s'il n'y a pas risque de
• Si un jet d'eau franc apparait au purgeur (signe gel, il est déconseillé de vidanger la pompe.
que la pompe délivre sa pression), ouvrir lente- • Le roulement maintenant l'accouplement et les
ment la vanne au refoulement. La pompe doit roulements moteurs sont graissés pour leur
être amorcée. durée de vie et ne nécessitent donc pas de grais-
• Contrôler la stabilité de la pression au refoule- sage.
ment à l'aide d'un manomètre, en cas d'instabi- • La garniture mécanique ne nécessite aucun
lité, parfaire la purge d'air. entretien en cours de fonctionnement. Elle ne
• En cas d'échec, refaire le remplissage et recom- doit jamais fonctionner à sec.
mencer l'opération.
• Pour parfaire la purge d'air, fermer la vanne au Fréquences de remplacement.
refoulement et le purgeur, puis arrêter la pompe
20s, remettre en route la pompe et ouvrir le pur- NOTE : Il ne peut s'agir que de recommandations,
geur. A renouveler tant qu'il sort de l'air. la fréquence de remplacement est liée aux
• Ouvrir la vanne au refoulement pour avoir le point conditions de service du groupe, à savoir :
de fonctionnement souhaité. • Température, pression et qualité du liquide véhi-
• Vérifier que l'intensité absorbée est inférieure ou culé pour la garniture mécanique.
égale à celle indiquée sur la plaque moteur- • Charge et température ambiante pour le moteur
variateur. et les autres composants.
• Fréquence de démarrage : service continu ou
intermittent.
Garniture Roulements Bobinage

Pièces ou composants sujets à usure Variateur
mécanique pompe et moteur moteur
≥ 15 000 h 25 000 h
10 000 h à 12 000 h à
Durée de vie indicative de fonctionnement Amb. maxi Amb. maxi
20 000 h 50 000 h
40°C 40°C
Fréquence de Continu 1 à 2 ans 1,5 à 5 ans 1 à 3 ans 3 ans
remplacement en 15 heures par jour
service 2 à 4 ans 3 à 10 ans - 6 ans
9 mois par an
WILO SE 09/2011 79
Français
10. Anomalies - Détection - Réparation

Ne faire effectuer le dépannage que par du per-
sonnel qualifié !
Observer les consignes de sécurité, voir chapitre
9 Entretien.
Relais
Le variateur de vitesse est équipé de deux relais
de sortie destinés à l'interface d'une gestion
centralisée. ex. : coffret de commande, sur-
veillance des pompes.
Relais SBM :
ce relais est paramétrable au menu « Service »
<5.7.6.0> en 3 état de fonctionnement.
Etat : 1 (réglé par défaut)
Relais « report de disponibilité » (fonctionne-
ment standard pour ce type de pompe).
Le relais est actif lorsque la pompe fonctionne ou
est en mesure de fonctionner.
Le relais est désactivé pour un premier défaut ou
une coupure secteur (la pompe s'arrête).
Ceci permet d'informer un coffret de commande
de la disponibilité d'une pompe, même tempo-
rairement.
Etat : 2
Relais « report de fonctionnement ».
Le relais est actif lorsque la pompe est en rota-
tion.
Etat : 3
Relais « report d’activation ».
Le relais est actif lorsque la pompe est sous ten-
sion.
Relais SSM :
relais « report de défauts ».
Après une série de détection (de 1 à 6, selon la
gravité) d'un même type de défaut, la pompe
s'arrête et ce relais est activé (jusqu'à interven- Défauts 1 2 3 4 5 6
tion manuelle).
Exemple : 6 défauts d'une durée variable sur

24H00 glissantes. relais
actif
Etat du relais SBM en « report de disponibilité ».
SBM
relais au
repos
relais
actif
SSM
relais au
repos
24H00 glissantes
80 WILO SE 09/2011
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10.1 Tableau des défauts

Tous les incidents listés ci-dessous, provoquent :
• La mise au repos du relais SBM (lorsque celui-ci est paramétré en mode « report de disponibilité »).
• L'activation du relais SSM « report de défaut » lorsque le nombre maxi d'un type de défaut est atteint sur une plage
de 24 heures.
• L'éclairage d’une LED rouge.
Temps de Temps
réaction avant prise Temps d’attente Défauts Temps
N° de avant en compte Pannes d’attente
défaut signalisa- du défaut avant redémarrage maxi Causes possibles Remèdes avant
tion du après automatique sur 24h reset
défaut signalisation
La pompe est en surcharge, Densité et/ou viscosité du fluide
défectueuse pompé trop importantes.
E001 60s immédiat 60s 6 Faire démonter la pompe, remplacer 300s
La pompe est obstruée par
des corps étrangers les composants défectueux ou
nettoyer.
E004 Immédiat si défaut L'alimentation du variateur Vérifier la tension aux bornes du

~5s 300s 6 variateur : 0s
(E032 supprimé est en sous-tension • défaut si le réseau < 330V
E005 Immédiat si défaut L'alimentation du variateur Vérifier la tension aux bornes du

(E033) ~5s 300s supprimé 6 est en sur-tension variateur : 0s
• défaut si le réseau > 480V
E006 ~5s 300s Immédiat si défaut 6 Une phase de l'alimentation Vérifier l'alimentation. 0s
supprimé est manquante
Le variateur fonctionne en
E007 immédiat immédiat Immédiat si défaut pas de La pompe dévire, vérifier l’étanchéité
supprimé limite génératrice. Avertissement, du clapet. 0s
sans arrêt de la pompe
Faire démonter la pompe, la nettoyer
E010 ~5s immédiat pas de redémarrage 1 La pompe est bloquée et remplacer les pièces défectueuses. 60s
Eventuellement, défaut mécanique du
moteur (roulements).
La pompe est désamorcée Réamorcer par remplissage pompe

E011 15s immédiat 60s 6 (voir chapitre 8.3). 300s
ou fonctionne à sec Vérifier l'étanchéité du clapet de pied.
Le moteur chauffe Nettoyer les ailettes de refroidisse-
ment du moteur.
E020 ~5s immédiat 300s 6 Le moteur est prévu pour fonctionner 300s
Température ambiante à une température ambiante
supérieure à +40°C maximum de +40°C.
Démonter le moteur-variateur de la
E023 immédiat immédiat 60s 6 Le moteur est en pompe et le faire contrôler ou 60s
court-circuit
remplacer.
E025 immédiat immédiat pas de redémarrage 1 Une phase du moteur est Vérifier la connection entre moteur et 60s
manquante variateur
La sonde thermique du Démonter le moteur-variateur de la
E026 ~5s immédiat 300s 6 moteur est défectueuse ou a pompe et le faire contrôler ou 300s
une mauvaise connection remplacer.
Nettoyer les ailettes de refroidisse-
Le variateur chauffe ment à l'arrière et sous le variateur
E030 ainsi que le capot ventilateur.
E031 ~5s immédiat 300s 6 300s
Le variateur est prévu pour fonction-
Température ambiante
supérieure à +40°C ner à une température ambiante
maximum de + 40°C.
E042 ~5s immédiat pas de redémarrage 1 Le câble du capteur Vérifier la bonne alimentation et le 60s
(4-20mA) est coupé câblage du capteur.
E050 60s immédiat Immédiat si défaut pas de La communication BMS est Vérifier la connexion. 300s
supprimé limite défectueuse
E070 immédiat immédiat pas de redémarrage 1 Défaut de communication Faire appel à un agent SAV. 60s
interne
E071 immédiat immédiat pas de redémarrage 1 Défaut EEPROM Faire appel à un agent SAV. 60s
E072 immédiat immédiat pas de redémarrage 1 Problème interne au Faire appel à un agent SAV. 60s
E073 variateur
E075 immédiat immédiat pas de redémarrage 1 Défaut du relais de limitation Faire appel à un agent SAV. 60s
du courant d’appel
E076 immédiat immédiat pas de redémarrage 1 Défaut courant capteur Faire appel à un agent SAV. 60s
E077 immédiat immédiat pas de redémarrage 1 Défaut 24V Faire appel à un agent SAV. 60s
E099 immédiat immédiat pas de redémarrage 1 Type de pompe inconnu Faire appel à un agent SAV. Power
off/on
WILO SE 09/2011 81
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10.2 Acquittement des défauts

N'acquitter les défauts qu'une fois leur cause éli-
minée.
• Seuls les techniciens spécialisés sont habilités à
éliminer les défauts.
• En cas de doute, consulter le fabricant.
• En cas de défaut, la page des défauts s'affiche à
la place de la page d'état.
Procéder comme suit pour acquitter les défauts.
• Appuyer sur l’encodeur / au centre du touch
pads.
Sur l’afficheur apparaît :
• Le numéro de menu <6.0.0.0> .
Exemple de page • Le nombre de défaut et le nombre maxi sur

de défaut. 24H00 du défaut concerné (exemple : 1/6).
• Le temps restant en seconde jusqu’à la réinitiali-
sation automatique du défaut.
Exemple de page
d’état.
• Attendre le délai de réinitialisation automatique.

Une temporisation interne au système est
activée. Le temps restant (en secondes) s'affiche
jusqu'à l'acquittement automatique du défaut.
• Après le nombre de défaut maxi atteint et expi-
ration de la dernière temporisation, appuyer sur
l’encodeur pour acquitter.
Le système retourne à la page d'état.
NOTE : Lorsqu’il y a un temps de prise en compte
après du défaut signalisation (exemple : 300s), le
défaut doit systématiquement être acquitté
manuellement.
La temporisation de réinitialisation automatique
est inactive et « - - - » s'affiche.
82 WILO SE 09/2011
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10.3 Autres incidents

Autres incidents, propres à la pompe, non détec-
tables par le variateur de vitesse.
Défauts Causes Remèdes

La pompe tourne mais ne débite pas La pompe ne tourne pas assez vite. Vérifier le bon réglage de la consigne
(conformité du point de consigne).
Les organes internes sont obstrués par Faire démonter la pompe et la nettoyer.
des corps étrangers.
Tuyauterie d'aspiration obstruée. Nettoyer toute la tuyauterie.
Entrées d'air par la tuyauterie d'aspira- Contrôler l'étanchéité de toute la
tion. conduite jusqu'à la pompe et étancher.
La pression à l'aspiration est trop faible, Trop de pertes de charge à l'aspiration
elle est généralement accompagnée de ou la hauteur d'aspiration est trop élevée
bruit de cavitation. (contrôler le NPSH de la pompe installée
et de l'installation).
La pompe vibre La pompe est mal serrée sur son socle. Vérifier et visser complètement les
écrous des boulons de scellement.
Corps étrangers obstruant la pompe. Faire démonter la pompe et la nettoyer.
Rotation dure de la pompe. Vérifier que la pompe tourne librement
sans opposer de résistance anormale.
La pompe ne donne pas une La vitesse du moteur est insuffisante. Vérifier le bon réglage de la consigne.
pression suffisante Le moteur est défectueux. Le remplacer.
Mauvais remplissage de la pompe. Ouvrir le purgeur de la pompe et purger
jusqu'à complète disparition des bulles
d'air.
Le bouchon de vidange-amorçage n'est Le contrôler et le revisser.
pas vissé à fond.
Le débit n'est pas régulier La hauteur d'aspiration (Ha) n'est pas Revoir les conditions d'installation et les
respectée. recommandations décrites dans ce manuel.
La tuyauterie d'aspiration est d'un La tuyauterie d'aspiration doit être au
diamètre inférieur à celui de la pompe. moins de même diamètre que l'orifice
d'aspiration pompe.
La crépine et la tuyauterie d'aspiration Démonter et nettoyer.
sont partiellement obstruées.
En mode « Pression constante », le cap- Mettre un capteur avec échelle de pres-
teur de pression n’est pas adapté. sion et précision conformes, voir cha-
pitre 5.3.
En mode « Pression constante », la Le clapet anti-retour n’est pas étanche. Le nettoyer ou le changer.
pompe ne s’arrête pas quand le débit est Le clapet anti-retour n’est pas adapté. Le remplacer par un clapet anti-retour
nul adapté, voir chapitre 5.3.
Le réservoir a une capacité insuffisante Le changer ou en ajouter un autre sur
compte tenu de l’installation. l’installation.
DANGER ! Risque de blessure ! ATTENTION ! Risque de dommages matériels !

Le liquide est toxique, corrosif ou dangereux Un fonctionnement impeccable de la pompe ne
pour l'homme. peut être garanti que par l'utilisation de pièces
• Informer impérativement le réparateur agréé. de rechange d'origine.
• Nettoyer la pompe de manière à assurer une
totale sécurité au réparateur. • N'utiliser que des pièces de rechange d'origine.
11. Pièces de rechange

La commande de pièces de rechange s'effectue
par l'intermédiaire de techniciens agréés locaux Sous réserve de modifications technique !
et/ou du service après-vente Wilo.
Afin d'éviter toutes questions ou commandes
erronées, veuillez indiquer toutes les données de
la plaque signalétique lors de chaque commande.
WILO SE 09/2011 83
Nederlands
1. Algemeen 2.3 Gevaren bij de niet-naleving van de veilig-

heidsaanwijzingen
1.1 Betreffende dit document De niet-naleving van de veiligheidsaanwijzingen
De taal van de originele inbouw- en bedienings- kan tot gevaren voor personen en de pomp/
voorschriften is Frans. Alle andere talen in deze installatie leiden. Het niet opvolgen van de veilig-
inbouw- en bedieningsvoorschriften zijn een heidsvoorschriften kan leiden tot het verlies van
elke aanspraak op schadevergoeding.
vertaling van de originele inbouw- en bedienings-
Meer specifiek kan het niet opvolgen van de vei-
voorschriften.
ligheidsrichtlijnen bijvoorbeeld de volgende
De inbouw- en bedieningsvoorschriften maken deel gevaren inhouden:
uit van het product en moeten steeds in de onmid- • uitvallen van belangrijke functies van de pomp/
dellijke nabijheid van het product worden bewaard. installatie.
De strikte inachtneming van deze aanwijzingen is • voorgeschreven onderhouds- en reparatiepro-
een basisvereiste voor de juiste installatie en het cedés die niet uitgevoerd worden.
gebruiksdoel van het product. De inbouw- en bedie- • gevaar voor personen door elektrische, mecha-
ningsvoorschriften gelden uitsluitend voor dit pro- nische of bacteriologische invloeden.
duct en voldoen aan de geldende veiligheidsvoor- • materiële schade.
schriften op het moment van publicatie.
2.4 Veiligheidsaanwijzingen voor de gebruiker
2. Veiligheid De bestaande voorschriften betreffende het
voorkomen van ongevallen dienen te worden
Deze inbouw- en bedieningsvoorschriften bevat- nageleefd.
ten belangrijke aanwijzingen die bij de montage, Gevaren verbonden aan het gebruik van elektri-
het bedrijf en het onderhoud in acht genomen sche energie moeten worden uitgesloten. Zowel
dienen te worden. Daarom dienen deze inbouw- de plaatselijke of algemene bepalingen (IEC, VDE
en bedieningsvoorschriften altijd vóór de monta- enz.) als de voorschriften van het energiebedrijf
ge en inbedrijfname door de monteur en het ver- moeten in acht worden genomen.
antwoordelijke vakpersoneel/de verantwoordelij-
ke gebruiker te worden gelezen. 2.5 Veiligheidsaanwijzingen voor inspectie- en
Niet alleen de algemene veiligheidsinstructies in montagewerkzaamheden
de paragraaf ”Veiligheid” moeten in acht worden De gebruiker dient er voor te zorgen dat alle
genomen, maar ook de specifieke veiligheids- inspectie- en montagewerkzaamheden worden
voorschriften onder de volgende punten die met uitgevoerd door bevoegd en bekwaam vakperso-
een gevarensymbool aangeduid worden. neel, dat door het bestuderen van de gebruiks-
handleiding voldoende geïnformeerd is.
2.1 Aanduiding van aanwijzingen in de bedienings- De werkzaamheden aan de pomp/installatie
voorschriften mogen alleen bij stilstand van de betreffende
apparaten worden uitgevoerd.
Symbolen
Algemeen gevarensymbool. 2.6 Eigenmachtige ombouw en vervaardiging van
reserveonderdelen
Gevaar vanwege elektrische spanning. Wijzigingen aan de pomp/installatie zijn alleen
toegestaan na overleg met de fabrikant. Originele
Aanwijzing: .... onderdelen en door de fabrikant toegestane
hulpstukken komen de veiligheid ten goede.
Signaalwoorden: Gebruik van andere onderdelen doet de aanspra-
GEVAAR! Acuut gevaarlijke situatie. Het niet kelijkheid van de fabrikant voor daaruit voort-
vloeiende gevolgen vervallen.
naleven leidt tot de dood of tot zeer zware ver-
wondingen.
2.7 Ongeoorloofde gebruikswijzen
WAARSCHUWING! De gebruiker kan (zware) De bedrijfszekerheid van het geleverde product
verwondingen oplopen. ”Waarschuwing” wijst kan alleen bij gebruik volgens de voorschriften
erop, dat niet inachtneming van de aanwijzin- conform paragraaf 4 van de inbouw- en bedie-
gen tot (zware) letsels kan leiden. ningsvoorschriften worden gegarandeerd. De in
de catalogus/het gegevensblad aangegeven
VOORZICHTIG! Er bestaat gevaar voor bescha- boven- en ondergrenswaarden mogen in geen
diging van de pomp/installatie. ”Voorzichtig” geval worden overschreden.
verwijst naar een aanwijzing waarvan de niet-
naleving kan leiden tot functiestoringen en de
beschadiging van materiaal. 3. Transport en opslag
Aanwijzing: Een nuttige aanwijzing voor het in 3.1 Levering
goede toestand houden van het product. De De pomp wordt af fabriek in een kist of op een
aanwijzing vestigt de aandacht op mogelijke pallet verpakt geleverd en is beschermd tegen
problemen. stof en vocht.
2.2 Personeelskwalificatie 3.2 Controle op reglementair transport

Het personeel voor de montage en de inbedrijf- De pomp moet direct bij ontvangst worden
stelling moet over de juiste kwalificatie voor deze gecontroleerd op transportschade. Schade dient
werkzaamheden beschikken. onmiddellijk binnen de voorgeschreven termijn te
worden gemeld bij de leverancier.
84 WILO SE 09/2011
Nederlands
3.3 Opslag 4. Gebruik

Tot aan de montage moet de pomp worden
bewaard op een plaats waar ze beschermd is Pompen voor het transport van heldere vloeistof-
tegen vocht, vorst en mechanische schade. fen in huishouden, landbouw en industrie.
Watertoevoer, watervoorziening – voorziening
Voorzichtig! Gevaar voor beschadiging op basis
voor watertorens – irrigatie-installaties, irrigatie
van slechte verpakking!
– hogedrukreiniging – ketelvoeding (aanbevolen
Als de pomp nadien opnieuw wordt getranspor-
met bypass-set) – condensaattransport – kli-
teerd, moet ze zodanig worden verpakt dat
maatinstallaties – industriecircuits en in combi-
schade door transport uitgesloten is.
natie met alle soorten modulesystemen.
• Daarvoor moet ofwel de originele verpakking of
een verpakking van dezelfde kwaliteit worden
gebruikt. 5. Productgegevens
Waarschuwing! Gevaar voor letsel!
5.1 Type-aanduiding
Ondeskundig transport kan letsel veroorzaken!
HELIX-V of MVI E 4 14 - 1 / 16 / E / 3-2
• Bij het hanteren van de pomp mogen alleen toe-
gestane hef- en transportmiddelen worden
gebruikt. Kabelbevestigingen moeten in de Verticale
buurt van de pompflens of aan de buitenkant van meertraps inline-
de motor worden aangebracht (een beveiliging pomp met hydrau-
tegen wegglijden is absoluut vereist!). lisch systeem met
hoog rendement
Verticale meertraps
inline-pomp
Met frequentie-
omvormer
Nominaal debiet in m3
Aantal trappen
1: Pomphuis van
roestvrij staal AISI 304 (1.4301)
+ hydraulisch systeem van roestvrij
staal AISI 304 (1.4301/1.4307)
2: Pomphuis van roestvrij staal AISI 316L
(1.4404 of 1.4409)
+ hydraulisch systeem van roestvrij
staal AISI 316L (1.4404)
• Het zwaartepunt van de pomp ligt relatief hoog 3: Pomphuis van gietijzer GJL-250
en het standvlak is klein; daarom dienen bij het + roestvrij staal van roestvrij
staal AISI 304 (1.4301 of 1.4307)
transport de noodzakelijke voorzorgsmaatre-
16: Flens PN16
gelen te worden getroffen, om de pomp tegen 25: Flens PN25
omvallen te beveiligen en gevaar voor personen P: Victaulic-aansluitingen
uit te sluiten. E: O-ringen type EPDM (WRAS/KTW)
Behandel de pomp voorzichtig, zodat de geome- V: O-ringen type FKM
trie en uitlijning van de installatie niet veranderen. 3-fasen/2-polig
Voorzichtig! Gevaar voor beschadiging op basis

5.2 Technische gegevens
van slechte verpakking! - maximale bedrijfsdruk
De oogschroeven van de motor zijn alleen • huis PN25: 25 bar
bestemd voor het transport van de eenheid • huis PN16: 16 bar
motor/frequentie-omvormer en niet voor de • huis met snelkoppeling
gehele pomp. voor ”Victaulic"-klemband: 25 bar
(alleen MVIE 4, 8, 16 m3/h)
- Maximale toevoerdruk: 10 bar
- Watertemperatuurbereik
• uitvoering met EPDM-afdichtingen/mechani-
sche afdichting (conform KTW – Duits voor-
schrift) en (conform WRAS – Britse norm):
–15 °C tot +120 °C
• uitvoering met FKM-afdichting/mechanische
afdichting: –15 °C tot +90 °C
- Maximale aanzuighoogte: afhankelijk van de
minimaal noodza-
kelijke toeloopdruk
van de pomp
- Omgevingstemperatuur: -15 °C tot +40 °C
(standaardproduct)
WILO SE 09/2011 85
Nederlands
- Omgevingsvochtigheid: < 90 % zonder 6. Beschrijving en werking

condensvorming
- Geluidsniveau: 1,1 kW = 63 dB(A) 6.1 Productomschrijving
2,2 kW = 66 dB(A) Pomp
4 kW = 71 dB(A) • Verticale meertraps normaal aanzuigende pomp
in Inlineconstructie (zuig- en drukstukken liggen
- Isolatieklasse: F
in een lijn).
- Beschermingsklasse: IP55 • Afdichting aan de asdoorgang door genormeerde
- Elektromagnetische mechanische afdichting.
compatibiliteit (*) • Hydraulische aansluiting.
• storingsuitzending - Ovale flens aan het huis PN 16 (6"): Pomp wordt
1. omgeving: EN 61800-3 geleverd met ovale tegenflens van gietijzer voor
schroefgeleidingen, afdichtingen en schroeven.
• storingsimmuniteit -
Ronde flens PN16 (8") en PN25: Pomp wordt
2. omgeving: EN 61800-3
geleverd met afdichtingen en schroeven zonder
- Bedrijfsspanning: 400 V (±10 %) 50 Hz tegenflens (optioneel toebehoren).
380 V (±10 %) 60 Hz Snelkoppeling (MVI 6") voor ”Victaulic"-klem-
440 V (±6 %) 60 Hz band: Pomp wordt zonder klemband geleverd
- Doorsnede van de (optioneel toebehoren).
voedingskabel (4-aderig): Eenheid motor/frequentieomvormer
• 1,1 kW: 1,5 mm2 tot 2,5 mm2 • Drooglopermotor met genormeerde flens en
• 2,2/4 kW: 2,5 mm2 tot 4 mm2 asstomp voor verticaal bedrijf met gemonteerde
frequentieomvormer.
(*) in het frequentiebereik tussen 600 MHz en 1 GHz
• Pomp- en motoras zijn met elkaar verbonden
kan bij wijze van uitzondering door een grote nabijheid
door middel van een koppeling met koppelings-
(< 1 m afstand tot de omvormer) van in dit bereik wer-
beveiliging.
kende zenders, sensoren of vergelijkbare apparatuur
een storing in de weergave of de waarde van de druk 6.2 Bedrijf
ontstaan. Het pompbedrijf wordt daardoor echter op
De elektronische regeling heeft de volgende
geen enkel moment beïnvloed.
voornaamste voordelen:
• Zuinig in het energieverbruik
5.3 Toebehoren • Reductie van de stromingsgeluiden
Toebehoren moeten afzonderlijk worden besteld. • Aanpassing van de pomp aan verschillende
• IF-module PLR voor de aansluiting aan de inter- bedrijfscondities.
faceconverter/PLR. De volgende bedrijfssituaties zijn beschikbaar:
• IF-module LON voor de aansluiting aan het • ”Toerentalregeling”: instelling van de frequentie
LONWORKS-netwerk. De IF-module wordt door handmatige bediening of extern bevel.
rechtstreeks in het aansluitbereik van de • ”Constante druk”: Regeling via een druksensor
omvormer aangesloten (afb. 11). en instelling van een gewenste waarde (intern of
• Bypass-set. extern).
• Afsluiter. • ”PID-regeling.”: Regeling met behulp van een
• Membraandrukvat/verzinkt reservoir. sensor (temperatuur, debiet, ...) en instelling van
• Drukstootreservoir. een gewenste waarde (intern of extern).
• Tegenflens, gelast (staal) of geschroefd
(roestvrij staal). 7. Installatie en elektrische aansluiting
• Snelkoppeling van het type ”Victaulic”.
VOORZICHTIG! Gevaar voor materiële schade!
• Terugslagklep (met kegel of veerklepje bij
Ondeskundige behandeling kan beschadiging
bedrijf onder constante druk). veroorzaken. Alleen gekwalificeerd personeel
• Voetventiel met zuigkorf. mag de pomp installeren.
• Trillingscompensatoren.
• Droogloopbeveiliging. 7.1 Voorbereiding
• Druksensor-kit (nauwkeurigheid ≤ 1 %; gebruik - De montage mag pas na beëindiging van alle las-
tussen 30% en 100% van het meetbereik). en soldeerwerkzaamheden en na het eventueel
vereiste doorspoelen van het hydraulische sys-
Een gedetailleerde lijst staat in de catalogus. teem worden uitgevoerd. Verontreinigingen
kunnen uitval van de pomp veroorzaken.
- De pompen dienen tegen weersinvloeden te
worden beveiligd en zo geïnstalleerd te worden,
dat er voldoende ventilatie gewaarborgd is en ze
niet worden blootgesteld aan stof, vorst of
explosiegevaar.
- De pomp dient op een goed toegankelijke plaats
te worden gemonteerd, zodat deze later gemak-
kelijk gecontroleerd, onderhouden (bijv. mecha-
nische afdichtingen) en vervangen kan worden.
De luchtopening van de elektronicamodule mag
niet worden afgesloten.
86 WILO SE 09/2011
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7.2 Beschrijvingen (afb. 1, 2, 5, 6, 7, 8) • Voor het definitieve vastdraaien van de funda-

1 - Voetventiel met zuigkorf mentschroeven verzekeren dat de pomp exact
2 - Afsluitkraan, zuigzijdig loodrecht is opgesteld: Indien nodig keggen
3 - Afsluitkraan, perszijdig gebruiken.
4 - Terugslagklep Aanwijzing: Let erop dat de hoogte van de plaats
5 - Inlaat-/ontluchtingsschroef van opstelling en de temperatuur van het te
6 - Vul-/aftapplug transporteren water het aanzuiggedrag van de
7 - Leidinghouders of klembanden pomp kunnen reduceren.
8 - Zuigkorf
9 - Buffertank Aanwijzing: Zorg bij temperaturen boven 80 °C
10 - Waterleidingnet dat de pomp in toevoerbedrijf (voordrukfunctie)
11 -Schakelaar, scheidingsschakelversterker kan lopen.
met zekeringen
12 - Hefhaak VOORZICHTIG! Gevaar voor materiële schade!
13 - Sokkel De installatie moet voldoende zijn voor de druk
14 - Schuifafsluiter die de pomp bij maximale frequentie en nulde-
15 - Druksensor biet genereert.
16 - Membraandrukvat • Pomphuis met ovale flenzen: leiding met
schroefdraad, direct schroefbaar op de meegele-
17 - Afsluiter voor druktank
verde ovale tegenflens.
18 - Indicatie
• Pomphuis met ronde flenzen: leiding met tegen-
19 - Regelknop flens, schroefbaar of lasbaar (tegenflens verkrijg-
BP - Bypass baar als toebehoren).
HA - Maximale aanzuighoogte • Pomp met snelkoppeling: met behulp van een
HC - Minimale toevoerhoogte klemband die met een aansluitstuk aan de lei-
ding wordt bevestigd (klemband en draadaan-
7.3 Opstelling sluiting als toebehoren beschikbaar).
Er zijn twee Standaarduitvoering. • De leidingdiameter mag nooit kleiner zijn dan die
Afb. 1: aanzuigbedrijf van de tegenflens.
Afb. 2: toevoerbedrijf uit de buffertank (pos. 9) • De stroomrichting van de vloeistof is aangege-
of het waterleidingnet (pos. 10). ven op het typeplaatje van de pomp.
• Zet de pomp op een goed toegankelijke plek die VOORZICHTIG! Gevaar voor materiële schade!
tegen invloeden van buitenaf beschermd is Dicht de verbindingen van de buisleiding met
(sterke regen of zoninstraling, vorst) en zich zo
geschikte materialen goed af! Er mag geen lucht
dicht mogelijk bij het aftappunt bevindt.
in de aanzuigleiding komen; leg de aanzuiglei-
• Breng bij zware pompen ter vereenvoudiging van
de demontage loodrecht boven de pomp een ding continu stijgend (min. 2 %) (afb.1).
haak of een oogschroef (pos. 12) met voldoende • De lengte van de aanzuigleiding zo kort mogelijk
draagvermogen aan. houden en zo veel mogelijk oorzaken vermijden
• Montage op betonsokkel (minimaal 10 cm hoog die tot drukverlies leiden (bochtstukken, ventie-
(pos. 13) met verankering in het fundament len, vernauwingen).
(opstelschema zie afb. 3). • Steunen of klembanden (afb. 1 en 2, pos. 7)
• Tussen sokkel en bodem ter voorkoming van gebruiken zodat het gewicht van de leiding niet
trillings- en geluidsoverdracht isolatiemateriaal alleen door de pomp wordt gedragen.
(van kurk of verstevigd rubber) aanbrengen. VOORZICHTIG! Gevaar voor materiële schade!
Bij installatie van de pomp in het toevoerbedrijf
ter bescherming van de pomp tegen watersla-
Hoogteverlies Hoogteverlies
Hoogte Temperatuur gen de terugslagklep aan de perszijde monte-
(HA) (HA)
ren.
0m 0 mCL 20 °C 0,20 mCL
500 m 500 mCL 30 °C 0,40 mCL Aanwijzing: Voor het transporteren van sterk
1000 m 1000 mCL 40 °C 0,70 mCL zuurstofhoudend of heet water moet een
50 °C 1,20 mCL bypass-kit (afb. 1 - pos. BP) worden ingebouwd.
60 °C 1,90 mCL De montage van de druksensor vindt dan perszij-
dig aan de leiding plaats (afb. 7).
70 °C 3,10 mCL
80 °C 4,70 mCL
90 °C 7,10 mCL
100 °C 10,30 mCL
110 °C 14,70 mCL
120 °C 20,50 mCL
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Afmetingen en aansluitdiameters voor MVIE

(zie afb. 3)
Uitvoering PN25
Uitvoering PN16
Pomptype VICTAULIC
200 212 180 100 20 12 157 204 50 75 M10 G1" 172 250 75 85 14 DN25 210 50 Ø42,4
400 212 180 100 20 12 157 204 50 75 M10 G1"1/4 172 250 75 100 18 DN32 210 50 Ø42,4
6"
800 252 215 130 20 12 187 250 80 100 M12 G1"1/2 187 280 80 110 18 DN40 261 80 Ø60,3
1600/6 252 215 130 20 12 187 250 90 100 M12 G2" 187 300 90 125 18 DN50 261 80 Ø60,3
HELIX-VE (afb. 3)
Uitvoering PN16 Uitvoering PN25

Pomptype
200/400 100 212 180 157 204 50 G1" 2xM10 172 250 75 DN25 4xM12
600 100 212 180 157 204 50 G1"1/4 2xM10 172 250 75 DN32 4xM16
6"
1000 130 255 215 190 250 80 G1"1/2 2xM12 190 280 80 DN40 4xM16
1600 130 255 215 190 250 90 G2" 2xM12 190 300 90 DN50 4xM16
2200 130 296 215 250 300 90 DN50 4xM16 250 300 90 DN50 4xM16
8"
3600 170 296 240 250 320 105 DN65 4xM16 250 320 105 DN65 8xM16
7.4 Elektrische aansluitingen • (pos. b) De kabel voor sensor, externe gewenste

waarde en ingangen [aux]/[ext.off] moet absoluut
Gevaar! Levensgevaar!
worden afgeschermd en in de kabelschroefver-
Een niet-vakkundig uitgevoerde installatie
bindingen van maat M12 of M16 worden inge-
en/of elektrische aansluiting kan levensgevaar-
voerd. De metalen kabelschroefverbindingen van
lijke gevolgen hebben.
de omvormer zijn bestemd voor de montage van
• De elektrische aansluiting mag uitsluitend con-
een kabelafscherming; zie de hieronder beschre-
form de geldende plaatselijke voorschriften wor-
ven montage.
den uitgevoerd door een elektrotechnicus die
erkend is door het energiebedrijf.
• Neem de voorschriften ter voorkoming van 1
ongevallen in acht.
• Vergeet de installatie niet te aarden.
Waarschuwing! Overbelasting van het stroom- 2
net mogelijk!
De ontoereikende dimensionering van het
stroomnet kan leiden tot functiestoringen in
3
het systeem en zelfs tot kabelbranden ten
gevolge van overbelasting van het stroomnet.
Voorzichtig! Gevaar voor materiële schade!
4
Een fout in de aansluiting kan tot beschadiging
van de omvormer leiden.
De elektrokabel mag nooit in contact komen • De elektrische eigenschappen (frequentie, span-
met de leiding of de pomp. Bovendien moet ning, nominale stroomsterkte) voor de eenheid
deze volledig beschermd zijn tegen vocht. motor/frequentie-omvormer zijn aangegeven op
• (pos. a) De voedingskabel (3 fasen + aarde) moet het typeplaatje van de pomp (pos. 19). Controleer
in de kabelschroefverbinding maat M25 worden of de eenheid motor/frequentieomvormer
ingevoerd. bestemd is voor het stroomnet waarop deze moet
• De niet-gebruikte kabelschroefverbindingen worden aangesloten.
moeten met behulp van de door de fabrikant • De elektrische beveiliging van de motor is geïnte-
voorziene stoppen worden afgesloten (zie ver- greerd in de omvormer. Deze is zo ingesteld op de
der). gegevens van de pomp dat zowel de beveiliging
van de pomp als die van de motor gewaarborgd is.
a • Bij een te hoge weerstand van de nulleider moet
voor de eenheid motor/frequentieomvormer een
overeenkomstige beveiliging worden ingebouwd.
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• In elk geval moet voor een signaalversterker met

zekeringen (type GF) ter bescherming van de
installatie gezorgd worden (zie afb. 1, 2, pos. 11).
Aanwijzing: Gebruik een selectieve lekstroom-
veiligheidsschakelaar met vertraging en VDE-
toelating en die gevoelig is voor alle types
stroom, indien voor de bescherming van perso-
nen een lekstroom-veiligheidsschakelaar moet
worden ingebouwd. De beveiligingsschakelaar
instellen conform de op het typeplaatje van de
pomp vermelde gegevens.
Aanwijzing: Deze pomp heeft een frequentie-
omvormer en mag niet met een lekstroom-vei-
ligheidsschakelaar worden beveiligd.
Frequentieomvormers kunnen de werking van
lekstroom-veiligheidsschakelaars beperken.
Uitzondering: selectieve alstroomgevoelige lek-
stroom-veiligheidsschakelaars zijn toegestaan.
• Aanduiding: FI
•Afschakelstroom: > 30 mA.
• Gebruik genormeerde aansluitkabels.
• Uitschakelkarakteristiek van de zekeringen: B
• De uitrichting van de eenheid motor/frequentie-
omvormer kan indien nodig worden gewijzigd
door de bevestigingsschroeven van de motor los
te draaien en de motor in de gewenste positie te
brengen.
Draai vervolgens de bevestigingsschroeven weer
goed vast.
• Zodra de voedingsspanning van de omvormer
wordt ingeschakeld, wordt het display gedurende
2 seconden getest, waarbij alle weergavemoge-
lijkheden van het display worden geactiveerd.
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Indeling van de aansluitklemmen

• Draai de schroeven los en verwijder het deksel
van de omvormer.
Omschrijving Toewijzing Aanwijzingen

L1, L2, L3 Netspanning Draaistroom 3~ IEC38
PE Aardaansluiting Aanwezigheid van elke fase controleren.
IN1 Ingang sensor Type signaal: Spanning (0–10 V, 2–10 V)
(DDS-klem 9) Ingangsweerstand: Ri ≥ 10 kΩ
Type signaal: Stroomsterkte (0–20 mA, 4–20 mA)
Ingangsweerstand: RB = 500 Ω
Instelbaar in het menu ”Service” <5.3.0.0>
IN2 Ingang externe gewenste waarde Type signaal: Spanning (0–10 V, 2–10 V)
(10 V/20 mA, klem 7) Ingangsweerstand: Ri ≥ 10 kΩ
Type signaal: Stroom (0–20 mA, 4–20 mA)
Ingangsweerstand: RB = 500 Ω
GND (x2) Aansluiting massa Voor elke ingang IN1 en IN2.
+24 V Gelijkstroomvoorziening voor sensor Maximale stroomsterkte: 60 mA.
De stroomvoorziening is beveiligd tegen kortsluiting.
ext. off Ingang van de besturing ON/OFF De potentiaalvrije externe schakelaar maakt het activeren
”Prioriteit UIT” en deactiveren van de pomp mogelijk.
bij potentiaalvrije externe schakelaar Bij installaties met veel starts (> 20 per dag) dient het
activeren en deactiveren via ”ext.off” te worden geregeld.
SBM Relais ”Beschikbaarheidsmelding” In het normale bedrijf is het relais actief wanneer de pomp
draait of bedrijfsklaar is.
Het relais wordt bij de eerste keer dat een storing
optreedt of bij stroomuitval gedeactiveerd (de pomp
stopt).
Zo wordt een schakelkast via de (evt. tijdelijke) beschik-
baarheid van een pomp geïnformeerd.
Potentiaalvrije schakelaar:
max.: 250 V AC, 1 A
SSM Relais ”Storingsmelding” Nadat een reeks van hetzelfde fouttype (van 1 tot 6, tel-
kens naargelang ernst) is herkend, stopt de pomp en
wordt dit relais geactiveerd (tot het handmatig ingrijpen).
Potentiaalvrije schakelaar:
max.: 250 V AC, 1 A
PLR Aansluitklemmen voor de De als toebehoren verkrijgbare optionele IF-module PLR
PLR-communicatie-interface moet in de meervoudige stekker in het aansluitbereik van
de omvormer worden gestoken.
De module is beveiligd tegen verwisseling van de polen.
LON Aansluitklemmen voor de De als toebehoren verkrijgbare optionele IF-module LON
LON-communicatie-interface moet in de meervoudige stekker in het aansluitbereik van
Aanwijzing: De klemmen IN1, IN2, GND en Ext.

Off voldoen aan de eisen van een ”correcte iso-
latie” (conform EN61800-5-1) ten opzichte van
de klemmen van het net alsook ten opzichte van
de klemmen SBM en SSM (en omgekeerd).
90 WILO SE 09/2011
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Netaansluiting Vermogensklemmenbord
De 4-aderige kabel op het vermogensklemmenbord
aansluiten (fasen + aarde). L1 L2 L3
Aansluiting van de ingangen/uitgangen Klemmenbord ingangen/uitgangen

- (pos. b) De kabel voor sensor, externe gewenste AUX ext. off MP 20 mA/10 DDS
waarde en ingangen [aux]/[ext.off] moet absoluut
1 2 3 4 5 6 7 8 9 10 11
worden afgeschermd.
niet bezet niet bezet
+24 V ...
In1 ...
In2 ...
GND...
GND...
Besturing
Sensor 20 mA/10 V
Externe gewenste
op afstand
ON/OFF
waarde
• Met behulp van de besturing op afstand kan de pomp Voorbeeld: Vlotterschakelaar, watergebrek-drukregelaar
in bedrijf genomen en gestopt worden (potentiaalvrije enz.
schakelaar); deze functie heeft voorrang voor de andere
functies.
Deze besturing op afstand kan door overbrugging van
de klemmen (3 en 4) worden gedeactiveerd.
Aansluitklemmen voor communicatie-interface

PLR De als toebehoren verkrijgbare optionele IF-module PLR
moet in de meervoudige stekker in het aansluitbereik van
LON De als toebehoren verkrijgbare optionele IF-module LON

moet in de meervoudige stekker in het aansluitbereik van
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Aansluiting ”Toerentalregeling” Aansluitklemmen ingangen/uitgangen

Handmatige frequentie-instelling: AUX ext. off MP 20 mA/10 DDS
1 2 3 4 5 6 7 8 9 10 11
Afstands-
bediening
Frequentie-instelling via externe besturing: AUX ext. off MP 20 mA/10 DDS

1 2 3 4 5 6 7 8 9 10 11
In2 ...
Afstands- Externe
bediening gewenste
waarde
Aansluiting ”Constante druk”

Regeling via druksensor:
AUX ext. off MP 20 mA/10 DDS
• 2 aders ([20 mA/10 V]/+24 V)
1 2 3 4 5 6 7 8 9 10 11
• 3 aders ([20 mA/10 V]/0 V/+24 V)
In1 ...
en instelling van de gewenste waarde via draaiknop
Afstands-
Druksensor
bediening
Regeling via druksensor:

• 2 aders ([20 mA/10 V]/+24 V)
1 2 3 4 5 6 7 8 9 10 11
• 3 aders ([20 mA/10 V]/0 V/+24 V) In1 ...
In2 ...
en regeling via externe gewenste waarde
Afstands- Externe
Druksensor
bediening gewenste
waarde
Aansluiting. ”PID-regeling”
Regeling per sensor (temperatuur, debiet, ...):
• 2 aders ([20 mA/10 V]/+24 V)
1 2 3 4 5 6 7 8 9 10 11
• 3 aders ([20 mA/10 V]/0 V/+24 V)
In1 ...
en instelling van de gewenste waarde via draaiknop
Afstands-
Druksensor
bediening
Regeling per sensor (temperatuur, debiet, ...):

• 2 aders ([20 mA/10 V]/+24 V)
1 2 3 4 5 6 7 8 9 10 11
• 3 aders ([20 mA/10 V]/0 V/+24 V)
In1 ...
In2 ...
en regeling via externe gewenste waarde
Afstands- Externe
Druksensor
bediening gewenste
waarde
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Gevaar! Levensgevaar!
Door het ontladen van de condensatoren van de omvor-
mer kunnen gevaarlijke spanningen aanwezig zijn.
• Na het uitschakelen van de stroomvoorziening daarom
altijd 5 minuten wachten voor ingrepen aan de omvor-
mer uitgevoerd worden.
• Ervoor zorgen dat alle elektrische aansluitingen en
contacten spanningsvrij zijn.
• Ervoor zorgen dat de aansluitklemmen op de juiste
plaats zijn aangesloten.
• Ervoor zorgen dat pomp en installatie correct geaard
zijn.
Regelingstypes
IN1: Sensoringang voor bedrijf in de modus ”Constante druk” of ”PID-regeling”
Sensorsignaal 4–20 mA Sensorsignaal 0–10 V
100 % Tussen 0 en 2 mA wordt ervan

100 %
uitgegaan dat de kabel
losgekoppeld is
Veiligheids-
Waarde Waarde
bereik
in % in %
van het sensor- van het sensor-
meetbereik meetbereik
0 2 4 Ingangsstroomsterkte (mA) 20 0 Ingangsspanning (V) 10
Sensorsignaal 0–20 mA Sensorsignaal 2–10 V
100 % 100 %
Waarde Waarde
in %
van het sensor- in %
meetbereik van het sensor-
meetbereik
0 Ingangsstroomsterkte (mA) 20 0 2 Ingangsspanning (V) 10
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IN2: Ingang van de externe gewenste waarde voor bedrijf in de modus ”Constante druk” of ”PID-regeling”
Gewenste waarde 4–20 mA Gewenste waarde 0–10 V
100 % 100 %
Bereik waarin de frequentie- Bereik waarin de frequentie-
omvormer zichzelf uitschakelt omvormer zichzelf uitschakelt
Veiligheids- Veiligheids-
Gewenste bereik Gewenste bereik
waarde waarde
in % in %
van het sensor- van het sensor-
meetbereik meetbereik
0 2 4 Ingangsstroomsterkte (mA) 20 0 1 2 Ingangsspanning (V) 10
IN2: ingang van de externe frequentiebesturing in de modus ”Toerentalregeling"
Extern signaal 0–20 mA Extern signaal 0–10 V
100 % 100 %
Frequentie bereik Frequentie bereik
van de van de
omvormer omvormer
~ 30 % ~ 30 %
0 2 4 Ingangsstroomsterkte (mA) 20 0 1 2 Ingangsspanning (V) 10
Extern signaal 4–20 mA Extern signaal 2–10 V
100 % 100 %
Frequentie bereik Frequentie bereik
van de omvormer van de omvormer
~ 30 % ~ 30 %
0 6 10 Ingangsstroomsterkte 20 0 3 5 Ingangsspanning (V) 10

(mA)
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8. Inbedrijfname 8.1.3 Beschrijving van de standaardsymbolen
8.1 Instelling Symbool Beschrijving

8.1.1 Besturingselementen Bedrijf in de modus
De frequentieomvormer maakt gebruik van de ”Toerentalregeling”.
volgende besturingselementen: Bedrijf in de modus ”Constante druk”
Uitvoering met draaiknop of ”PID-regeling”.
Instelling via de draaiknop:
Ingang IN2 geactiveerd
2
(externe gewenste waarde).
Toegangsblokkering.
Als dit symbool verschijnt, kunnen
• Een nieuwe parameter wordt door eenvoudig de actuele instellingen resp. meet-
draaien ingesteld. ”+” naar rechts en ”-” naar waarden niet worden gewijzigd.
links. De weergegeven informatie kan
Door op de draaiknop te drukken wordt de nieuwe alleen worden gelezen.
instelling overgenomen. BMS (Building Management System,
Schakelaar gebouwbeheersysteem)
PLR of LON is geactiveerd.
ON
Pomp in bedrijf.
1 2
Pomp is gestopt.
• De omvormer beschikt over een eenheid met
twee schakelaars (afb. 4, pos. S) met telkens
twee standen:
•Via schakelaar 1 kan van de modus ”OPERATION” 8.1.4 Indicatie
[schakelaar 1 OFF] naar de modus ”SERVICE”
[schakelaar 1 ON] en omgekeerd worden gescha- Statuspagina van het display
keld. • De statuspagina van het display wordt standaard
De stand ”OPERATION” schakelt het bedrijf in de weergegeven.
geselecteerde modus vrij en vergrendelt de toe- De actuele gewenste waarde wordt weergege-
gang tot de parametrering (normaal bedrijf). ven.
De stand ”SERVICE” laat het parametreren van de De basisinstellingen worden met behulp van
verschillende functies toe. symbolen weergegeven.
• Via Schakelaar 2 kan de ”toegangsblokkering”

worden geactiveerd en gedeactiveerd.
8.1.2 Opbouw van het display
1 4
2 5
Voorbeeld voor de statuspagina

4 3 4
Aanwijzing: In alle menu's gaat het display weer
naar de statuspagina terug, als de draaiknop niet
binnen 30 seconden wordt ingedrukt; in dit geval
• Zodra de voedingsspanning van de omvormer
worden wijzigingen niet toegepast.
wordt ingeschakeld, wordt het display gedurende
2 seconden getest, waarbij alle weergavemoge-
lijkheden van het display worden geactiveerd.
Pos. Beschrijving
1 Nummer van het menu
2 Weergave van de waarde
3 Weergave van de eenheid
4 Standaardsymbolen
5 Weergave van de pictogrammen
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Navigatie-element <3.0.0.0>
• De verschillende functies van de omvormer wor- Schakelaar
den via de menustructuur opgeroepen. Aan elk Positie 1 Beschrijving
menu en submenu is een nummer toegewezen.
• Door aan de draaiknop te draaien kan op hetzelf- OPERATION OFF
Regeling Aan/Uit van de
de niveau van een menu worden gebladerd (bijv.
4000->5000). pomp.
SERVICE ON
• Alle knipperende elementen (waarde, menunum-
mer, symbool of pictogram) kunnen worden
<4.0.0.0>
gewijzigd, d.w.z. er kan een nieuwe waarde, een
nieuw menunummer of een nieuwe functie wor- Schakelaar
den geselecteerd. Positie 1 Beschrijving
OPERATION OFF Alleen lezen van het

Symbool Beschrijving
menu ”Informatie”
Wanneer de pijl wordt weergegeven: SERVICE ON mogelijk.
• Het indrukken van de draaiknop
geeft toegang tot een submenu • Het menu ”Informatie” geeft de meet-, toestel-
(bijv. 4000 -> 4100). en bedrijfsgegevens weer (afb. 13).
<5.0.0.0>
Wanneer de terug-pijl wordt weerge- • Het menu ”Service” geeft toegang tot de para-
geven: meterinstellingen van de omvormer.
• Het indrukken van de draaiknop
Positie Schakelaar Beschrijving
geeft toegang tot een bovenge- 1
schikt menu bijv. 4150 -> 4100).
Alleen lezen van het
OPERATION OFF
menu ”Service” mogelijk.
8.1.5 Beschrijving van de menu's Instellen van het menu
SERVICE ON
”Service”.
Lijst (afb. 12)
<1.0.0.0> <6.0.0.0>
Positie Schakelaar Beschrijving Schakelaar

1 Positie Beschrijving
1
OPERATION OFF Instellen van de OPERATION OFF

Weergave van de status-
gewenste waarde; in
pagina.
SERVICE ON beide gevallen mogelijk. SERVICE ON
• Draai om de gewenste waarde in te stellen aan • Als er één of meerdere storingen aanwezig zijn,
de draaiknop. Het display gaat naar het menu wordt de storingspagina weergegeven.
<1.0.0.0> en de gewenste waarde knippert. Door De letter ”E” verschijnt, gevolgd door drie cijfers
opnieuw te draaien kan de waarde worden ver- (hoofdstuk 11).
hoogd of verlaagd.
<7.0.0.0>
• Druk om de nieuwe waarde te bevestigen op de
draaiknop; het display gaat terug naar de status- Schakelaar
Positie Beschrijving
pagina. 1
<2.0.0.0> OPERATION OFF Weergave van het
Schakelaar symbool voor
Positie 1 Beschrijving
SERVICE ON ”Toegangsblokkering”.
Alleen aflezen van de
OPERATION OFF bedrijfssituaties moge- • De toegangsblokkering is alleen mogelijk, als
lijk. schakelaar 2 zich in de stand ON bevindt.
Instellen van de bedrijfs- VOORZICHTIG! Gevaar voor materiële schade!
SERVICE ON
situaties. Elke onjuiste instelling kan nadelige invloed op
de werking van de pomp hebben en op deze
• Bedrijfssituaties zijn ”toerentalregeling”,
manier materiële schade aan pomp of installa-
”constante druk” en ”PID-regeling”.
tie veroorzaken.
• De instellingen in de modus ”SERVICE” alleen
bij inbedrijfname uitvoeren en deze stap alleen
door deskundige specialisten laten uitvoeren.
96 WILO SE 09/2011
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Afb. 12
Navigatie in de basismenu's bij normaal bedrijf

(schakelaar1 = OFF in positie ”OPERATION”)
Instelling van het punt
Regelingstype
Pomp Aan/Uit
Informatie
SERVICE
Resetten
van storingen
Wordt weergegeven
wanneer er een storing is
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Afb. 13
Navigatie in menu <4.0.0.0> ”Informatie”
Informatie
Actuele waarden
Druk Wordt niet weergegeven wanneer

of % ”Toerentalregeling” geactiveerd is
Vermogen
Bedrijfsgegevens
Bedrijfsuren
Verbruik
Teller voor
Netonderbreking
Actuele voorwaarden
Actuele status
SSM-relais
Actuele status Zie hoofdstuk 11, menu <5.7.6.0>
SBM-relais Standaard: ”Beschikbaarheidsmelding”
Ingangsstatus
ext. off
Apparaatgegevens
Omschrijving
Pomp
Softwareversie
Gebruikersinterface
Softwareversie
Motorregeling
98 WILO SE 09/2011
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Parametrering in de menu's <2.0.0.0> en <5.0.0.0>

De parameters van de menu's <2.0.0.0> en <5.0.0.0> kunnen in de modus ”SERVICE” worden gewijzigd.
Er zijn twee instelmodi:
• Modus ”Easy”: snelle modus voor het parametreren van de 3 bedrijfssituaties.
• Modus ”Expert”: modus voor de toegang tot alle parameters. ON
• Schakelaar 1 op stand ON zetten (afb. 4, pos. S). S
• De modus ”SERVICE” is geactiveerd.
Op de statuspagina van het display knippert het symbool dat ernaast wordt weergegeven (afb. 14). 1
Afb. 14
Modus ”Easy”
SERVICE
Regelingstype
Modus ”Easy”
Instelling van het punt
Regelingstype
Modus Expert
Modus Expert
Pomp
Informatie
OPERATION
ON
SERVICE
1 2
Modus ”Easy”
• Houd de draaiknop gedurende 2 seconden ingedrukt. Het symbool voor modus ”Easy” wordt
weergegeven (afb. 14).
• Druk op de draaiknop om de keuze te bevestigen. Het display gaat naar menunummer <2.0.0.0>.
Met behulp van het menu ”Modus Easy” kunnen de 3 bedrijfssituaties snel worden geparametreerd (afb. 15)
• ”Toerentalregeling”
• ”Constante druk”
• ”PID-regeling”
• Na het vastleggen van de instellingen schakelaar 1 weer op stand OFF zetten (afb. 4, pos. S).
Modus ”Expert”
• Houd de draaiknop gedurende 2 seconden ingedrukt. Naar de Expert-modus gaan; het symbool voor
de modus ”Expert” wordt weergegeven (afb. 14).
• Druk op de draaiknop om de keuze te bevestigen. Het display gaat naar menunummer <2.0.0.0>.
Eerst in het menu <2.0.0.0> de bedrijfssituatie selecteren.
• ”Toerentalregeling”
• ”Constante druk”
• ”PID-regeling”
Nu geeft de Expert-modus in menu <5.0.0.0> de toegang tot alle parameters van de omvormer vrij (afb. 16).
• Na het vastleggen van de instellingen schakelaar 1 weer op stand OFF zetten (afb. 4, pos. S).
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Afb. 15
Toerentalregeling
Met interne gewenste
waarde
Ingang externe gewenste waarde – IN2 MENU
gedeactiveerd – selectie OFF
EASY
Ingang externe gewenste waarde – IN2
geactiveerd – selectie ON
Met externe gewenste
waarde
Selectie van het signaaltype
Constante druk
Sensoringang – IN1
Selectie van de druksensor
Met interne gewenste

waarde


Met externe gewenste
waarde
PID-REGELING

PID-parametrering
Selectie waarde ”P” (0.0–300.0)
PID-parametrering Met interne gewenste

Selectie waarde ”I” (10 ms–300 s) waarde
PID-parametrering
Selectie waarde ”D” (0 ms–300 s)


PID-parametrering
Selectie waarde ”P” (0.0–300.0)
PID-parametrering Met externe gewenste

Selectie waarde ”I” (10 ms–300 s) waarde
PID-parametrering
Selectie waarde ”D” (0 ms–300 s)
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Afb. 16
MENU
EXPERT
SERVICE
Wordt weergegeven wanneer ”BMS” geacti-
BMS: Building Management System veerd is. Zie handleiding bij dit product
Wordt niet weergegeven wanneer

IN1 – ”sensoringang” ”Toerentalregeling” geactiveerd is
Selectie sensor Wordt niet weergegeven wanneer
”PID-regeling” geactiveerd is
Selectie signaalbereik
IN2 – ”Ingang externe besturing”
Selectie
Selectie signaalbereik Wordt niet weergegeven wanneer

”IN2” gedeactiveerd is
Wordt weergegeven wanneer

PID-parameter ”PID-regeling” geactiveerd is
Selectie
parameter ”P”
Selectie
parameter ”I”
Selectie
parameter ”D”
Overige instellingen
Selectie uitschakeltijd Wordt weergegeven wanneer

bij nuldebiet ”Drukregeling” geactiveerd is
Selectie geredu-
ceerde frequentie
Selectie functie
SBM-relais
Selectie fabrieks-
instelling
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Toegangsblokkering 8.3 Vulling – ontluchting

Om de instellingen van de pomp te blokkeren,
kan de functie toegangsblokkering worden
De pomp nooit droog laten lopen, ook niet voor
gebruikt.
korte tijd!
Om te activeren of te deactiveren, als volgt te
Pomp in toevoerbedrijf (afb. 2).
werk gaan:
• Sluit de perszijdige afsluitkraan (pos. 3).
• Schakelaar 2 op stand ON zetten (afb. 4, pos. S).
• Open de inlaat-/ontluchtingsschroef (pos. 5),
Menu <7.0.0.0> wordt opgeroepen.
open de zuigzijdige afsluitkraan (pos. 2) en vul de
• Draai aan de draaiknop, om de vergrendeling te
pomp volledig.
activeren of te deactiveren. De actuele status
• Sluit de inlaat-/ontluchtingsschroef pas, als er
van de vergrendeling wordt weergegeven door
water uitkomt en geen luchtbellen meer zicht-
de volgende symbolen:
baar zijn.
Vergrendeling geactiveerd: de para-
WAARSCHUWING! Gevaar voor verbranding!
meters zijn geblokkeerd, toegang tot
Bij heet water kan er een waterstraal uit de
de menu's alleen in weergavemodus.
ontluchtingsopening komen.
• Alle vereiste voorzorgsmaatregelen voor perso-
Vergrendeling gedeactiveerd: de para-
nen en de eenheid motor/frequentieomvormer
meters kunnen worden gewijzigd, toe-
treffen.
gang tot de menu's is vrijgegeven voor
het uitvoeren van wijzigingen. Pomp in het aanzuigbedrijf (afb. 1, 5)
• Schakelaar 2 op stand OFF zetten (afb. 4, pos. S). Er zijn twee mogelijkheden:
De statuspagina wordt opnieuw weergegeven. 1ste mogelijkheid (afb. 5.1)
• Sluit de perszijdige afsluitkraan (afb. 1, pos. 3),
8.1.6 Instellingen open de zuigzijdige afsluitkraan (afb. 1, pos. 2).
• De ontluchtingsplug verwijderen (afb. 1, pos. 5).
Aanwijzing: Als de pomp alleen wordt geleverd, • Maak de onderste aftapplug aan het pomphuis
dus zonder een door ons geïntegreerd systeem, (afb. 1, pos. 6) los (ca. 4 keer draaien).
is de configuratie bij levering de modus • Vul pomp en aanzuigleiding volledig met behulp
”Toerentalregeling”. van een in de aftapopening ingebrachte trechter.
• Als er water uitkomt en er zich geen lucht meer
Modus ”Toerentalregeling” (afb. 1, 2)
in de pomp bevindt, is het vullen afgesloten.
Het bedrijfspunt wordt ofwel door handmatig
• Ontluchtingsplug en onderste aftapplug weer
instellen of door externe besturing van de fre-
dichtschroeven.
quentie ingesteld.
• Wij bevelen aan het motortoerental bij inbedrijf- 2de mogelijkheid (afb. 5.2)
name op 2400 tpm in te stellen. • Het vullen kan eenvoudiger worden gemaakt
door aan de aanzuigleiding van de pomp met een
Modus ”Constante druk” (afb. 6, 7, 8) afsluiter en een trechter uitgeruste verticale buis
Regeling via een druksensor en instelling van een met Ø ½” (afb. 5, pos. 14) te installeren.
gewenste waarde (intern of extern). Aanwijzing: Het bovenste uiteinde van de buis
• Door aanvulling met een druksensor (met reser- moet zich minimaal 50 mm boven de aftapkraan
voir; sensor-montageset als toebehoren lever- bevinden.
baar) kan de pompdruk worden geregeld (zonder
water in het membraandrukvat; het membraan- • Sluit de perszijdige afsluitkraan (afb. 1, pos. 3),
drukvat vullen tot een druk die 0,3 bar onder de open de zuigzijdige afsluitkraan (afb. 1, pos. 2).
regeldruk van de pomp ligt). • Schuifafsluiter (afb. 5, pos. 14) en inlaat-/ont-
• De sensor moet een nauwkeurigheid van ≤ 1 % luchtingsschroef openen.
hebben en in een bereik tussen 30 % en 100 % • Aftapplug (afb. 1, pos. 6) loszetten (ca. 4 keer
van het meetbereik worden gebruikt; het reser- draaien).
voir heeft een schakelvolume van minimaal 8 • Pomp en aanzuigleiding volledig vullen tot er
liter. water uit de inlaat-/ontluchtingsschroef komt.
• Wij bevelen aan de druk bij inbedrijfname op • Sluit de schuifafsluiter (afb. 5, pos. 14) (kan op
60 % van de maximale druk in te stellen. zijn plaats blijven), verwijder de buis, sluit de
inlaat-/ontluchtingsschroef (afb. 1, pos. 5), draai
Modus ”PID-regeling” de aftapplug weer dicht (afb. 1, pos. 6).
Regeling met behulp van een sensor (tempera-
VOORZICHTIG! Gevaar van onjuiste bediening!
tuur, debiet, ...) en instelling van een gewenste
Bij een pomp in toevoerbedrijf en modus
waarde (intern of extern).
”Constante druk” functioneert het registreren
van het nuldebiet mogelijk niet.
8.2 Voorbereidende spoeling • Monteer een terugslagklep achter de druksensor
Onze pompen worden af fabriek hydraulisch (d.w.z. zuigzijdig, als de sensor aan de pomp is
getest. Daarom is het mogelijk dat er nog water in gemonteerd – zie afb. 6)
zit. Daarom wordt vanuit hygiënisch oogpunt aan-
bevolen om de pomp voor het gebruik in het
waterleidingnet te spoelen.
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8.4 Start 9. Onderhoud

WAARSCHUWING! Gevaar voor verbranding! Alleen gekwalificeerd vakpersoneel mag
Afhankelijk van de vloeistoftemperatuur en de onderhouds- en reparatiewerkzaamheden uit-
bedrijfscycli van de pomp kan de oppervlakte- voeren!
temperatuur (pomp, motor) hoger dan 68°C
zijn. Het wordt aanbevolen om de pomp door een techni-
• Installeer indien nodig de vereiste veiligheids- cus van de servicedienst te laten onderhouden en
voorzieningen voor personen! controleren.
VOORZICHTIG! Gevaar voor materiële schade! GEVAAR! Levensgevaar!
Bij nuldebiet (afsluitkraan aan de perszijde Bij werkzaamheden aan de elektrische uitrus-
gesloten) mag de pomp bij koud water ting bestaat levensgevaar als gevolg van
(T < 40 °C) niet langer dan 10 minuten draaien, stroomschokken.
bij warm water (T < 60 °C) niet langer dan • Werkzaamheden aan de elektrische uitrusting
5 minuten boven 60 °C. mogen alleen door worden uitgevoerd door
• Wij adviseren om een minimale volumestroom elektro-installateurs met een vergunning van
van ongeveer 10 % van het nominale debiet van de plaatselijke energiebedrijven.
de pomp aan te houden, om te voorkomen dat in • Schakel de spanning van de elektrische uit-
het bovenste gedeelte van de pomp een gasbel rusting uit en beveilig deze tegen herinschake-
ontstaat. ling van de spanning, voordat u er werkzaam-
• Houd de perszijdige afsluitkraan gesloten. heden aan uitvoert!
• Start de pomp.
• Inlaat-/ontluchtingsschroef openen zodat de WAARSCHUWING! Gevaar voor verbranding!
lucht kan ontsnappen. Indien er na 20 seconden Er kunnen zeer hoge oppervlaktetemperaturen
geen gelijkmatig stromende waterstraal uit de ontstaan.
opening komt, de inlaat-/ontluchtingsschroef • Voor werkzaamheden aan de pomp moet deze
sluiten, de pomp stopzetten en dan ca. afgekoeld zijn.
20 seconden wachten, zodat de lucht zich • Draag bij alle werkzaamheden veiligheidskle-
kan verzamelen. ding en veiligheidshandschoenen.
• Start de pomp opnieuw.
• Tijdens het bedrijf is geen speciaal onderhoud
Aanwijzing: Herhaal de stappen indien nodig noodzakelijk.
(vooral bij aanzuighoogtes boven 5 m). • Houd pomp en eenheid motor/frequentieomvor-
mer altijd in een onberispelijk schone toestand.
• Als uit de ontluchtingsopening een gelijkmatige
waterstraal komt (d.w.z. dat de pomp druk • Op een tegen vorst beveiligde plek mag de pomp
levert) langzaam de afsluitkraan aan de perszijde ook bij een langere buitenbedrijfstelling niet
openen. De pomp moet nu hebben aangezogen. worden geleegd.
• Controleer de stabiliteit van de druk met een • Koppelings- en motorlager zijn voor de volledige
manometer, ontlucht bij drukschommelingen levensduur ingevet en hoeven niet meer te wor-
opnieuw. den gesmeerd.
• Indien dit mislukt, vult u de pomp opnieuw en • De mechanische afdichting hoeft tijdens het
voert u de stappen nogmaals uit. bedrijf niet onderhouden te worden. Deze mag
• Sluit om het ontluchten te beëindigen de afsluit- nooit drooglopen.
kraan aan de perszijde en de inlaat-/ontluch-
tingsschroef. Zet de pomp 20 seconden stop. Intervallen voor vervanging.
Daarna de pomp opnieuw starten en de inlaat-/
ontluchtingsschroef openen. Voer de stappen Aanwijzing: Hier kunnen slechts aanbevelingen
opnieuw uit, indien er lucht ontsnapt. worden gedaan, omdat de intervallen voor ver-
• Afsluitkraan aan de perszijde openen om de vanging van de bedrijfsomstandigheden van het
pomp met het gewenste bedrijfspunt te gebrui- aggregaat afhankelijk zijn, en wel:
ken. • Temperatuur, druk en kwaliteit van de vloeistof
• Zorg ervoor dat de stroomopname lager dan of voor de mechanische afdichting.
gelijk is aan de waarde die is aangegeven op het • Belasting en omgevingstemperatuur voor motor
typeplaatje van de eenheid motor/frequentieom- en andere onderdelen.
vormer. • Startfrequentie: continu of periodiek bedrijf.
Aan slijtage onderhevig onderdeel Mechanische Lager van pomp Wikkeling

Omvormer
of component afdichting en motor van de motor
≥ 15.000 h 25.000 h
10.000 h 12.000 h Max. Max.
Levensduur
tot 20.000 h tot 50.000 h omgevingstemp. omgevingstemp.
40 °C 40 °C
Continu bedrijf 1 tot 2 jaar 1,5 tot 5 jaar 1 tot 3 jaar 3 jaar
Interval voor
vervanging
15 bedrijfsuren/dag
2 tot 4 jaar 3 tot 10 jaar – 6 jaar
9 maanden per jaar
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10. Storingen – herkenning – reparatie

Laat storingen alleen door gekwalificeerd perso-
neel verhelpen!
Neem de veiligheidsaanwijzingen in acht;
zie hoofdstuk 9 over onderhoud.
Relais
De omvormer is uitgerust met twee uitgangs-
relais voor de centrale besturing. Voorbeeld:
schakelkast, pompbewaking.
SBM-relais:
Voor dit relais kunnen in het menu ”Service”
<5.7.6.0> 3 bedrijfsmodi worden ingesteld.
Modus: 1 (standaardinstelling)
Relais ”Beschikbaarheidsmelding” (standaard-
functie bij dit pomptype).
Het relais is actief, als de pomp functioneert of
bedrijfsklaar is.
Het relais wordt bij de eerste keer dat een storing
optreedt of bij stroomuitval gedeactiveerd (de
pomp stopt).
Zo wordt een schakelkast via de (evt. tijdelijke)
beschikbaarheid van een pomp geïnformeerd.
Modus: 2
Relais ”Storingsmelding”.
Het relais is actief, als de pomp loopt.
Modus: 3
Relais ”Activeringsmelding”.
Het relais is actief, als de pomp onder spanning
staat.
SSM-relais:
Relais ”Storingsmelding”.
Nadat een reeks van hetzelfde fouttype (van 1
tot 6, telkens naargelang ernst) is herkend, stopt
de pomp en wordt dit relais geactiveerd (tot het
handmatig ingrijpen). Fout 1 2 3 4 5 6
Voorbeeld: 6 storingen van verschillende duur

binnen 24 uur (glijdend).
Relais
Status van het SBM-relais in
actief
”Beschikbaarheidsmelding”s.
SBM
Relais in
rust-
toestand
Relais
actief
SSM
Relais in
rust-
toestand
24 uur glijdend
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10.1 Overzicht storingen

Bij alle hierna opgesomde storingen vindt het volgende plaats:
• Het SBM-relais schakelt naar de rusttoestand (bij instelling op modus ”Beschikbaarheidsmelding”).
• Het SSM-relais wordt geactiveerd (”storingsmelding”), wanneer binnen 24 uur het maximale aantal fouten van een
type wordt bereikt.
• Een rode led gaat branden.
Tijd voor Max.

Reactietijd inacht- Wachttijd tot het aantal
Fout- voor neming van Storing Wachttijd
code weergave de storing na automatische fouten Mogelijke oorzaken Oplossing tot reset
van de fout de weergave herinschakelen in
ervan 24 uur
De pomp is overbelast, defect Te hoge dichtheid en/of viscositeit

van de vloeistof.
E001 60 s Onmiddellijk 60 s 6 300 s
De pomp is door vreemde voor- Pomp demonteren, defecte elemen-
werpen geblokkeerd ten vervangen of reinigen.
E004 Onmiddellijk wanneer De voeding van de omvormer Spanning op de klemmen van de fre-
(E032 ~5s 300 s de storing is verhol- 6 heeft onderspanning quentieomvormer controleren: 0s
pen • Storing als het net < 330 V
Onmiddellijk wanneer Spanning op de klemmen van de fre-
E005 ~5s 300 s De voeding van de omvormer
(E033) de storing is verhol- 6 heeft overspanning quentieomvormer controleren: 0s
pen • Storing als het net > 480 V
Onmiddellijk wanneer Een fase van de voeding ont-
E006 ~5s 300 s de storing is verhol- 6 Stroomvoorziening controleren. 0s
pen breekt
Onmiddellijk wanneer Geen Omvormer fungeert als genera- Pomp draait achterwaarts; Dichtheid
E007 Onmiddellijk Onmiddellijk de storing is verhol- tor. Waarschuwing zonder de 0s
grens van de klep controleren.
pen pomp uit te schakelen
Pomp demonteren, reinigen en defecte
E010 ~5s Onmiddellijk Geen herinschakeling 1 De pomp is geblokkeerd elementen vervangen. Eventueel mechani- 60 s
sche storing van de motor (lager).
Pomp weer vullen (zie hoofdstuk 8.3).
E011 15 s Onmiddellijk 60 s 6 De pomp draait leeg of droog Dichtheid van het voetventiel contro- 300 s
leren.
De motor raakt oververhit Koelribben van de motor reinigen.
E020 ~5s Onmiddellijk 300 s 6 Omgevingstemperatuur hoger De motor is bestemd voor een omge- 300 s
dan +40 °C vingstemperatuur tot maximaal +40 °C.
Er is een kortsluiting in de Eenheid motor/frequentieomvormer

E023 Onmiddellijk Onmiddellijk 60 s 6 van de pomp demonteren en contro- 60 s
motor leren of laten vervangen.
E025 Onmiddellijk Onmiddellijk Geen herinschakeling 1 Er ontbreekt een fase van de Verbinding tussen motor en omvor- 60 s
motor mer controleren
De thermosonde van de motor Eenheid motor/frequentieomvormer
E026 ~5s Onmiddellijk 300 s 6 is defect of is niet correct aan- van de pomp demonteren en contro- 300 s
gesloten leren of laten vervangen.
De frequentieomvormer raakt De koelribben achter en onder de fre-

oververhit quentieomvormer en de ventilatorkap
E030 ~5s Onmiddellijk 300 s 6 reinigen. 300 s
E031
Omgevingstemperatuur hoger De omvormer is bestemd voor een omge-
dan +40 °C vingstemperatuur tot maximaal +40 °C.
E042 ~5s Onmiddellijk Geen herinschakeling 1 De sensorkabel (4–20mA) is Correcte stroomvoorziening en beka- 60 s
losgekoppeld beling van de sensor controleren.
Onmiddellijk wanneer Geen De BMS-communicatie is
E050 60 s Onmiddellijk Verbinding controleren. 300 s
de storing is verholpen grens gestoord
E070 Onmiddellijk Onmiddellijk Geen herinschakeling 1 Storing van de interne commu- Contact opnemen met de service- 60 s
nicatie dienst.
E071 Onmiddellijk Onmiddellijk Geen herinschakeling 1 EEPROM-storing Contact opnemen met de service- 60 s
dienst.
E072 Onmiddellijk Onmiddellijk Geen herinschakeling 1 Interne probleem van de Contact opnemen met de service- 60 s
E073 omvormer dienst.
E075 Onmiddellijk Onmiddellijk Geen herinschakeling 1 Storing van het relais voor de Contact opnemen met de service- 60 s
inschakelstroombegrenzing dienst.
E076 Onmiddellijk Onmiddellijk Geen herinschakeling 1 Storing van de sensorstroom Contact opnemen met de service- 60 s
dienst.
E077 Onmiddellijk Onmiddellijk Geen herinschakeling 1 24-V-storing Contact opnemen met de service- 60 s
dienst.
Contact opnemen met de service- Voeding
E099 Onmiddellijk Onmiddellijk Geen herinschakeling 1 Pomptype onbekend dienst. Uit/Aan
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10.2 Bevestiging van storingen

Storingen pas bevestigen nadat de oorzaak werd
verholpen.
• Alleen vakkundige technici mogen storingen ver-
helpen.
• In geval van twijfel de fabrikant contacteren.
• Bij een storing wordt in plaats van de status-
pagina de storingspagina weergegeven.
Ga om de storingen te bevestigen als volgt te
werk:
• Druk op de draaiknop.
Op het display wordt het volgende weergegeven:
• Het nummer van het menu <6.0.0.0>.
• Het aantal storingen alsmede het binnen 24 uur
Voorbeeld voor maximaal toegestane aantal van de desbe-
een storingspagina. treffende storing (voorbeeld: 1/6).
• De resterende tijd in seconden tot de automati-
sche herinitialisering van de storing.
Voorbeeld voor
de statuspagina.
• Wacht de tijd tot de automatische herinitialise-

ring af.
Er wordt een systeeminterne tijdschakeling
geactiveerd. De resterende tijd (in seconden)
wordt weergegeven tot de storing automatisch
wordt bevestigd.
• Nadat het maximale aantal storingen is bereikt
en de laatste tijdschakeling afgelopen is, drukt u
op de draaiknop en bevestigt op deze manier de
storing.
Het systeem gaat terug naar de statuspagina.
Aanwijzing: Als er een tijd voor de inachtneming
van de storing na de weergave ervan is gepro-
grammeerd (bijvoorbeeld: 300 s), moet de sto-
ring in elk geval handmatig worden bevestigd.
De tijdschakeling voor de automatische herini-
tialisering is niet actief en er wordt ” - - - ”
weergegeven.
106 WILO SE 09/2011

Nederlands
10.3 Andere storingen

Overige storingen in de pomp die niet worden
herkend door de omvormer.
Fout Oorzaak Oplossing

De pomp loopt, maar transporteert niet De pomp loopt niet snel genoeg. Correcte instelling van de gewenste
waarde controleren (overeenstemming
met gewenste waarde).
Inwendige elementen zijn door vreemde Pomp demonteren en reinigen.
voorwerpen geblokkeerd.
Aanzuigleiding verstopt. Gehele leiding reinigen.
Lucht in de aanzuigleiding. Dichtheid van de gehele leiding tot aan
de pomp controleren en afdichten.
Aanzuigdruk te laag, meestal gecombi- Te groot verlies bij het aanzuigen of
neerd met cavitatiegeluiden. aanzuighoogte te hoog (minimale nood-
zakelijke toeloopdruk van de geïnstal-
leerde pomp en de gehele installatie
controleren).
De pomp vibreert Onvoldoende bevestiging op de pomp- Moeren van de fundamentschroeven
sokkel. controleren en evt. vastdraaien.
Pomp verstopt door vreemde voorwerpen. Pomp demonteren en reinigen.
Pomp loopt stroef. Controleren of de pomp zonder abnor-
male weerstand kan worden gedraaid.
De pompdruk is te laag Motorsnelheid onvoldoende. Correctie instelling van de gewenste
waarde controleren.
Motor is defect. Motor vervangen.
Pomp slecht gevuld. Ontluchtingsschroef openen en net zo
lang ontluchten tot er geen luchtbellen
meer uitkomen.
De aftapplug is niet correct vastge- Controleren en correct vastdraaien.
draaid.
Debiet is onregelmatig Aanzuighoogte (Ha) niet aangehouden. De inbouwvoorwaarden en -adviezen in
deze inbouw- en bedieningsvoorschriften
controleren.
De aanzuigleiding heeft een kleinere De aanzuigleiding moet minimaal dezelf-
diameter dan de pomp. de diameter hebben als de aanzuigope-
ning van de pomp.
De zuigkorf en de aanzuigleiding zijn Demonteren en reinigen.
gedeeltelijk verstopt.
De druksensor is in de modus Een sensor met correcte druk- en nauw-
”Constante druk” niet correct aange- keurigheidsverdeling monteren, zie
past. hoofdstuk 5.3.
De pomp stopt niet bij nuldebiet in de De terugslagklep is niet dicht. Ventiel reinigen of vervangen.
modus ”Constante druk” De terugslagklep is niet correct gedi- Door een correct gedimensioneerde terug-
mensioneerd. slagklep vervangen, zie <hoofdstuk 5.3>.
Het drukreservoir heeft onvoldoende Vervangen of een extra reservoir inbou-
capaciteit voor de bestaande installatie. wen.
GEVAAR! Gevaar voor letsel! Vermeld om vragen of verkeerde bestellingen te
De vloeistof is giftig, bijtend of gevaarlijk voor voorkomen bij de bestelling alle gegevens van
de mens. het typeplaatje.
• Onmiddellijk de verantwoordelijke servicetech-
nicus of dealer informeren. VOORZICHTIG! Gevaar voor materiële schade!
• Reinig de pomp zo dat er geen gevaar bestaat Het correcte bedrijf van de pomp is alleen
voor de technicus. gegarandeerd indien originele reserveonderde-
len worden gebruikt.
11. Reserveonderdelen • Gebruik alleen originele reserveonderdelen.
De bestelling van reserveonderdelen vindt plaats

via regionale dealers en/of de servicedienst van
Wilo.
Technische wijzigingen voorbehouden!
WILO SE 09/2011 107

D EG – Konformitätserklärung
GB EC – Declaration of conformity
F Déclaration de conformité CE
(gemäß 2006/42/EG Anhang II,1A und2004/108/EG Anhang IV,2,
according 2006/42/EC annex II,1A and2004/108/EC annex IV,2,
conforme 2006/42/CE appendice II,1A et 2004/108/CE appendice IV,2)
Hiermit erklären wir, dass die Bauart der Baureihe : MVIE

Herewith, we declare that the product type of the series:
Par le présent, nous déclarons que l’agrégat de la série :
(Die Seriennummer ist auf dem Typenschild des Produktes angegeben. /
The serial number is marked on the product site plate. /Le numéro de série est inscrit sur la plaque signalétique du produit.)
in der gelieferten Ausführung folgenden einschlägigen Bestimmungen entspricht:
in its delivered state complies with the following relevant provisions:
est conforme aux dispositions suivantes dont il relève:
EG-Maschinenrichtlinie 2006/42/EG
EC-Machinery directive
Directives CE relatives aux machines
Die Schutzziele der Niederspannungsrichtlinie 2006/95/EG werden gemäß Anhang I, Nr. 1.5.1 der Maschinenrichtlinie 2006/42/EG
eingehalten.
The protection objectives of the low-voltage directive 2006/95/EC are realized according annex I, No. 1.5.1 of the EC-Machinery directive
2006/42/EC.
o
Les objectifs protection de la directive basse-tension 2006/95/CE sont respectées conformément à appendice I, n 1.5.1 de la
directive CE relatives aux machines 2006/42/CE.
Elektromagnetische Verträglichkeit - Richtlinie 2004/108/EG

Electromagnetic compatibility - directive
Compatibilité électromagnétique- directive
Richtlinie energieverbrauchsrelevanter Produkte 2009/125/EG
Energy-related products
Produits liés à l’énergie
Die verwendeten 50 Hz Induktionslelektromotoren – Drehstrom, Käfigläufer, einstufig – entsprechen den Ökodesign-Anforderungen der
Verordnung 640/2009.
Which applies according to eco-design requirements of the regulation 640/2009 to the versions with an induction electric motor, squirrel
cage, three-phase, single speed, running at 50 Hz.
Qui s’applique suivant les exigences d’éco-conception du règlement 640/2009 aux versions comportant un moteur électrique à induction
à cage d’écureuil, triphasé, mono-vitesse, fonctionnant à 50 Hz.
Angewendete harmonisierte Normen, insbesondere: EN 809+A1, EN ISO 12100,

Applied harmonized standards, in particular: EN 60034-1, EN 60204-1,
Normes harmonisées, notamment: EN 61800-3, EN 61800-5-1
Bei einer mit uns nicht abgestimmten technischen Änderung der oben genannten Bauarten, verliert diese Erklärung ihre Gültigkeit.
If the above mentioned series are technically modified without our approval, this declaration shall no longer be applicable.
Si les gammes mentionnées ci-dessus sont modifiées sans notre approbation, cette déclaration perdra sa validité.
Bevollmächtigter für die Zusammenstellung der technischen Unterlagen ist: Pompes Salmson S. A.-Laval
Authorized representative for the completion of the technical documentation: Division Pumps & Sytems
Mandataire pour le complément de la documentation technique est : PBU Multistage & Domestic Pumps - Quality
80 Bd de l’Industrie
BP 0527
F-53005 Laval Cédex
Dortmund, 23.09.2011
Oliver Breuing WILO SE

Quality Manager Nortkirchenstraße 100
44263 Dortmund
Germany
Document:2117774.1
D EG – Konformitätserklärung
F Déclaration de conformité CE
(gemäß 2006/42/EG Anhang II,1A und2004/108/EG Anhang IV,2,
according 2006/42/EC annex II,1A and2004/108/EC annex IV,2,
conforme 2006/42/CE appendice II,1A et 2004/108/CE appendice IV,2)
Hiermit erklären wir, dass die Bauart der Baureihe : Helix VE

Herewith, we declare that the product type of the series:
Par le présent, nous déclarons que l’agrégat de la série :
(Die Seriennummer ist auf dem Typenschild des Produktes angegeben. /
The serial number is marked on the product site plate. /Le numéro de série est inscrit sur la plaque signalétique du produit.)
in its delivered state complies with the following relevant provisions:
est conforme aux dispositions suivantes dont il relève:
Directives CE relatives aux machines
Die Schutzziele der Niederspannungsrichtlinie 2006/95/EG werden gemäß Anhang I, Nr. 1.5.1 der Maschinenrichtlinie 2006/42/EG
eingehalten.
The protection objectives of the low-voltage directive 2006/95/EC are realized according annex I, No. 1.5.1 of the EC-Machinery directive
2006/42/EC.
o
Les objectifs protection de la directive basse-tension 2006/95/CE sont respectées conformément à appendice I, n 1.5.1 de la
directive CE relatives aux machines 2006/42/CE.
Elektromagnetische Verträglichkeit - Richtlinie 2004/108/EG

Electromagnetic compatibility - directive
Compatibilité électromagnétique- directive
Richtlinie energieverbrauchsrelevanter Produkte 2009/125/EG
Energy-related products
Produits liés à l’énergie
Die verwendeten 50 Hz Induktionslelektromotoren – Drehstrom, Käfigläufer, einstufig – entsprechen den Ökodesign-Anforderungen der
Verordnung 640/2009.
Which applies according to eco-design requirements of the regulation 640/2009 to the versions with an induction electric motor, squirrel
cage, three-phase, single speed, running at 50 Hz.
Qui s’applique suivant les exigences d’éco-conception du règlement 640/2009 aux versions comportant un moteur électrique à induction
à cage d’écureuil, triphasé, mono-vitesse, fonctionnant à 50 Hz.
Angewendete harmonisierte Normen, insbesondere: EN 809+A1, EN ISO 12100,

Applied harmonized standards, in particular: EN 60034-1, EN 60204-1,
Normes harmonisées, notamment: EN 61800-3, EN 61800-5-1
Bei einer mit uns nicht abgestimmten technischen Änderung der oben genannten Bauarten, verliert diese Erklärung ihre Gültigkeit.
If the above mentioned series are technically modified without our approval, this declaration shall no longer be applicable.
Si les gammes mentionnées ci-dessus sont modifiées sans notre approbation, cette déclaration perdra sa validité.
Bevollmächtigter für die Zusammenstellung der technischen Unterlagen ist: Pompes Salmson S. A.-Laval
Authorized representative for the completion of the technical documentation: Division Pumps & Sytems
Mandataire pour le complément de la documentation technique est : PBU Multistage & Domestic Pumps - Quality
80 Bd de l’Industrie
BP 0527
F-53005 Laval Cédex
Oliver Breuing WILO SE

44263 Dortmund
Germany
Document:2117785.1
NL I E
EG-verklaring van overeenstemming Dichiarazione di conformità CE Declaración de conformidad CE
Hiermede verklaren wij dat dit aggregaat in de geleverde uitvoering Con la presente si dichiara che i presenti prodotti sono conformi alle Por la presente declaramos la conformidad del producto en su estado de
voldoet aan de volgende bepalingen: seguenti disposizioni e direttive rilevanti: suministro con las disposiciones pertinentes siguientes:
EG-richtlijnen betreffende machines 2006/42/EG Direttiva macchine 2006/42/EG Directiva sobre máquinas 2006/42/EG
De veiligheidsdoelstellingen van de laagspanningsrichtlijn worden Gli obiettivi di protezione della direttiva macchine vengono rispettati Se cumplen los objetivos en materia de seguridad establecidos en la
overeenkomstig bijlage I, nr. 1.5.1 van de machinerichtlijn 2006/42/EG secondo allegato I, n. 1.5.1 dalla direttiva macchine 2006/42/CE. Directiva de Baja tensión según lo especificado en el
aangehouden. Anexo I, punto 1.5.1 de la Directiva de Máquinas 2006/42/CE.
Elektromagnetische compatibiliteit 2004/108/EG Compatibilità elettromagnetica 2004/108/EG Directiva sobre compatibilidad electromagnética 2004/108/EG
gebruikte geharmoniseerde normen, in het bijzonder: norme armonizzate applicate, in particolare: normas armonizadas adoptadas, especialmente:
zie vorige pagina vedi pagina precedente véase página anterior
P S N
Declaração de Conformidade CE CE- försäkran EU-Overensstemmelseserklæring
Pela presente, declaramos que esta unidade no seu estado original, está Härmed förklarar vi att denna maskin i levererat utförande motsvarar Vi erklærer hermed at denne enheten i utførelse som levert er i
conforme os seguintes requisitos: följande tillämpliga bestämmelser: overensstemmelse med følgende relevante bestemmelser:
Directivas CEE relativas a máquinas 2006/42/EG EG–Maskindirektiv 2006/42/EG EG–Maskindirektiv 2006/42/EG
Os objectivos de protecção da directiva de baixa tensão são cumpridos de Produkten uppfyller säkerhetsmålen i lågspänningsdirektivet enligt bilaga Lavspenningsdirektivets vernemål overholdes i samsvar med
acordo com o anexo I, nº 1.5.1 da directiva de máquinas 2006/42/CE. I, nr 1.5.1 i maskindirektiv 2006/42/EG. vedlegg I, nr. 1.5.1 i maskindirektivet 2006/42/EF.
Compatibilidade electromagnética 2004/108/EG EG–Elektromagnetisk kompatibilitet – riktlinje 2004/108/EG EG–EMV–Elektromagnetisk kompatibilitet 2004/108/EG
normas harmonizadas aplicadas, especialmente: tillämpade harmoniserade normer, i synnerhet: anvendte harmoniserte standarder, særlig:
ver página anterior se föregående sida se forrige side
FIN DK H
CE-standardinmukaisuusseloste EF-overensstemmelseserklæring &,NFHGFMFMĩTHJOZJMBULP[BU
Ilmoitamme täten, että tämä laite vastaa seuraavia asiaankuuluvia Vi erklærer hermed, at denne enhed ved levering overholder følgende Ezennel kijelentjük, hogy az berendezés megfelel az alábbi irányelveknek:
määräyksiä: relevante bestemmelser:
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#F[QFüOPTUODJFMFTNFSOJDFPO [LPNOBQU T¬EPESáJBWBOW[NZTMF Cilji Direktive o nizkonapetostni opremi so v skladu s ƱǀǆǃǍǀǂƻǂƻǔǃǍƻǈƻǋƻǂǊǉǋǀƿƼƻǍƻǂƻǈǃǌǅǉǈƻǊǋǀǁǀǈǃǀǌƻ
QS MPIZ* üTNFSOJDFPTUSPKPWïDI[BSJBEFOJBDI&4 QSJMPHP* ĵU%JSFLUJWFPTUSPKJI&(EPTFáFOJ ǌǕǌǍƻƽǀǈǃǌǕƾǆƻǌǈǉƪǋǃǆǉǁǀǈǃǀ* ǬǉǍƟǃǋǀǅǍǃƽƻǍƻǂƻ
ǇƻǓǃǈǃ&Ƭ
Elektromagnetická zhoda - smernica 2004/108/ES %JSFLUJWBPFMFLUSPNBHOFUOJ[ESVáMKJWPTUJ&4 &ǆǀǅǍǋǉǇƻƾǈǃǍǈƻǌǕǇǀǌǍǃǇǉǌǍ¾ƿǃǋǀǅǍǃƽƻ&Ʃ
QPVá WBOIBSNPOJ[PWBOOPSNZ OBKN uporabljeni harmonizirani standardi, predvsem: ưƻǋǇǉǈǃǂǃǋƻǈǃǌǍƻǈƿƻǋǍǃ
pozri predchádzajúcu stranu glejte prejšnjo stran ƽǁǊǋǀƿǈƻǍƻǌǍǋƻǈǃǑƻ
M
Dikjarazzjoni ta’ konformità KE
B'dan il-mezz, niddikjaraw li l-prodotti tas-serje jissodisfaw id-
EJTQPŅJ[[KPOJKJFUSFMFWBOUJMJČFKKJO
Makkinarju - Direttiva 2006/42/KE
L-objettivi tas-sigurta tad-Direttiva dwar il-VultaČČ#BYYIVNBLPOGPSNJ 8*-04&
mal-Anness I, Nru 1.5.1 tad-Direttiva dwar il-Makkinarju 2006/42/KE.
Kompatibbiltà elettromanjetika - Direttiva 2004/108/KE
44263 Dortmund
(FSNBOZ
kif ukoll standards armonizzati b'mod partikolari:
ara l-paČOBUBRBCFM
Argentina Canada Greece Latvia Romania Sweden
WILO SALMSON WILO Canada Inc. WILO Hellas AG WILO Baltic SIA WILO Romania s.r.l. WILO Sverige AB
Argentina S.A. Calgary, Alberta T2A 5L4 14569 Anixi (Attika) 1019 Riga 077040 Com. Chiajna 35246 Växjö
C1295ABI Ciudad T +1 403 2769456 T +302 10 6248300 T +371 7 145229 Jud. Ilfov T +46 470 727600
Autónoma de Buenos Aires bill.lowe@wilo-na.com wilo.info@wilo.gr mail@wilo.lv T +40 21 3170164 wilo@wilo.se
T+ 54 11 4361 5929 China wilo@wilo.ro
info@salmson.com.ar Hungary Lebanon Switzerland
WILO China Ltd. WILO Magyarország Kft WILO SALMSON Russia EMB Pumpen AG
Australia 101300 Beijing 2045 Törökbálint Lebanon WILO Rus ooo 4310 Rheinfelden
WILO Australia Pty Limited T +86 10 58041888 (Budapest) 12022030 El Metn 123592 Moscow T +41 61 83680-20
Murrarrie, Queensland, wilobj@wilo.com.cn T +36 23 889500 T +961 4 722280 T +7 495 7810690 info@emb-pumpen.ch
4172 Croatia wilo@wilo.hu wsl@cyberia.net.lb wilo@wilo.ru
T +61 7 3907 6900 WILO Hrvatska d.o.o. Taiwan
chris.dayton@wilo.com.au India Lithuania
10090 Zagreb WILO India Mather and WILO Lietuva UAB Saudi Arabia WILO-EMU Taiwan Co. Ltd.
Austria T +38 51 3430914 Platt Pumps Ltd. 03202 Vilnius WILO ME - Riyadh 110 Taipeh
WILO Pumpen wilo-hrvatska@wilo.hr Pune 411019 T +370 5 2136495 Riyadh 11465 T +886 227 391655
Österreich GmbH Czech Republic T +91 20 27442100 mail@wilo.lt T +966 1 4624430 nelson.wu@
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T +43 507 507-0 25101 Cestlice pun.matherplatt.co.in Morocco
WILO Maroc Serbia and Montenegro Turkey
office@wilo.at T +420 234 098711 WILO Beograd d.o.o. WILO Pompa Sistemleri
info@wilo.cz Indonesia SARLQUARTIER
Azerbaijan WILO Pumps Indonesia INDUSTRIEL AIN SEBAA 11000 Beograd San. ve Tic. A.Ş.
WILO Caspian LLC Denmark Jakarta Selatan 12140 20250 T +381 11 2851278 34956 İstanbul
1014 Baku WILO Danmark A/S T +62 21 7247676 CASABLANCA office@wilo.co.yu T +90 216 2509400
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info@wilo.az T +45 70 253312 contact@wilo.ma Slovakia
wilo@wilo.dk Ireland WILO Slovakia s.r.o. Ukraina
Belarus WILO Ireland The Netherlands 83106 Bratislava WILO Ukraina t.o.w.
WILO Bel OOO Estonia Limerick WILO Nederland b.v. T +421 2 33014511 01033 Kiew
220035 Minsk WILO Eesti OÜ T +353 61 227566 1551 NA Westzaan wilo@wilo.sk T +38 044 2011870
T +375 17 2535363 12618 Tallinn sales@wilo.ie T +31 88 9456 000 wilo@wilo.ua
wilo@wilo.by T +372 6 509780 info@wilo.nl Slovenia
info@wilo.ee Italy WILO Adriatic d.o.o. United Arab Emirates
Belgium Finland WILO Italia s.r.l. Norway 1000 Ljubljana WILO Middle East FZE
WILO SA/NV WILO Finland OY 20068 Peschiera WILO Norge AS T +386 1 5838130 Jebel Ali Free Zone -
1083 Ganshoren 02330 Espoo Borromeo (Milano) 0975 Oslo wilo.adriatic@wilo.si South - Dubai
T +32 2 4823333 T +358 207401540 T +39 25538351 T +47 22 804570 T +971 4 880 91 77
info@wilo.be wilo@wilo.fi wilo.italia@wilo.it wilo@wilo.no South Africa info@wilo.ae
Bulgaria Kazakhstan Poland Salmson South Africa
France
WILO Bulgaria Ltd. WILO Central Asia WILO Polska Sp. z.o.o. 1610 Edenvale USA
WILO S.A.S.
1125 Sofia 050002 Almaty 05-090 Raszyn T +27 11 6082780 WILO USA LLC
78390 Bois d'Arcy
T +359 2 9701970 T +7 727 2785961 T +48 22 7026161 errol.cornelius@ Rosemont, IL 60018
T +33 1 30050930
info@wilo.bg info@wilo.kz wilo@wilo.pl salmson.co.za T +1 866 945 6872
info@wilo.fr
info@wilo-usa.com
Brazil Great Britain Korea Portugal Spain
WILO Brasil Ltda WILO (U.K.) Ltd. WILO Pumps Ltd. Bombas Wilo-Salmson WILO Ibérica S.A. Vietnam
Jundiaí – SP – CEP DE14 2WJ Burton- 621-807 Gimhae Portugal Lda. 28806 Alcalá de Henares WILO Vietnam Co Ltd.
13.201-005 Upon-Trent Gyeongnam 4050-040 Porto (Madrid) Ho Chi Minh City, Vietnam
T + 55 11 2817 0349 T +44 1283 523000 T +82 55 3405890 T +351 22 2080350 T +34 91 8797100 T +84 8 38109975
wilo@wilo-brasil.com.br sales@wilo.co.uk wilo@wilo.co.kr bombas@wilo.pt wilo.iberica@wilo.es nkminh@wilo.vn
Further subsidiaries, representation and sales offices on www.wilo.com March 2012

WILO SE
44263 Dortmund
Germany
T 0231 4102-0
F 0231 4102-7363
wilo@wilo.com
www.wilo.de
Wilo-Vertriebsbüros in Deutschland
Nord Ost Süd-West West I
WILO SE WILO SE WILO SE WILO SE
Vertriebsbüro Hamburg Vertriebsbüro Dresden Vertriebsbüro Stuttgart Vertriebsbüro Düsseldorf
Beim Strohhause 27 Frankenring 8 Hertichstraße 10 Westring 19
20097 Hamburg 01723 Kesselsdorf 71229 Leonberg 40721 Hilden
T 040 5559490 T 035204 7050 T 07152 94710 T 02103 90920
F 040 55594949 F 035204 70570 F 07152 947141 F 02103 909215
hamburg.anfragen@wilo.com dresden.anfragen@wilo.com stuttgart.anfragen@wilo.com duesseldorf.anfragen@wilo.com
Nord-Ost Süd-Ost Mitte West II

WILO SE WILO SE WILO SE WILO SE
Vertriebsbüro Berlin Vertriebsbüro München Vertriebsbüro Frankfurt Vertriebsbüro Dortmund
Juliusstraße 52–53 Adams-Lehmann-Straße 44 An den drei Hasen 31 Nortkirchenstr. 100
12051 Berlin-Neukölln 80797 München 61440 Oberursel/Ts. 44263 Dortmund
T 030 6289370 T 089 4200090 T 06171 70460 T 0231 4102-6560
F 030 62893770 F 089 42000944 F 06171 704665 F 0231 4102-6565
berlin.anfragen@wilo.com muenchen.anfragen@wilo.com frankfurt.anfragen@wilo.com dortmund.anfragen@wilo.com
Kompetenz-Team Kompetenz-Team Werkskundendienst Wilo-International

Gebäudetechnik Kommune Gebäudetechnik
Bau + Bergbau Kommune Österreich Schweiz
WILO SE Bau + Bergbau Zentrale Wiener Neudorf: EMB Pumpen AG
Nortkirchenstraße 100 WILO SE, Werk Hof Industrie WILO Pumpen Österreich GmbH Gerstenweg 7
44263 Dortmund Heimgartenstraße 1-3 Wilo Straße 1 CH-4310 Rheinfelden
T 0231 4102-7516 95030 Hof WILO SE A-2351 Wiener Neudorf T +41 61 83680-20
F 0231 4102-7666 T 09281 974-550 Nortkirchenstraße 100 T +43 507 507-0 F +41 61 83680-21
F 09281 974-551 44263 Dortmund F +43 507 507-15 info@emb-pumpen.ch
T 0231 4102-7900 office@wilo.at www.emb-pumpen.ch
T 01805 W•I•L•O•K•D* www.wilo.at
Erreichbar Mo–Do 7-18 Uhr, Fr 7-17 Uhr. 9•4•5•6•5•3
F 0231 4102-7126 Vertriebsbüro Salzburg:
–Antworten auf kundendienst@wilo.com Gnigler Straße 56
– Produkt- und Anwendungsfragen A-5020 Salzburg
– Liefertermine und Lieferzeiten Täglich 7-18 Uhr erreichbar T +43 507 507-13
24 Stunden Technische F +43 662 878470
–Informationen über Ansprechpartner vor Ort
Notfallunterstützung office.salzburg@wilo.at
–Versand von Informationsunterlagen www.wilo.at
–Kundendienst-Anforderung
Standorte weiterer –Werksreparaturen Vertriebsbüro Oberösterreich:
Tochtergesellschaften –Ersatzteilfragen Trattnachtalstraße 7
–Inbetriebnahme A-4710 Grieskirchen
Die Kontaktdaten finden Sie
–Inspektion T +43 507 507-26
unter www.wilo.com.
–Technische F +43 7248 65054
Service-Beratung office.oberoesterreich@wilo.at
* 0,14 €/Min. aus dem Festnetz, –Qualitätsanalyse www.wilo.at
Mobilfunk max. 0,42 €/Min. Stand August 2012
Wilo-Multivert MVI 16.../ MVI 32.../ MVI 52.../ MVI 70.../ MVI 95...
D Einbau- und Betriebsanleitung

GB Installation and operating instructions
F Notice de montage et de mise en service
I Istruzioni di montaggio, uso e manutenzione
2 040 502 - Ed3/0805 pdf
MVI 16... /MVI 32... /MVI 52...
Fig. 1
MVI 70... /MVI 95...
Fig. 1
Fig. 2
Fig. 3
Fig. 4
D F
CE-Konformitätserklärung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Déclaration de conformité CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
1. Allgemeines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1. Généralités . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2. Sicherheit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2. Sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3. Transport und Zwischenlagerung . . . . . . . . . . . . . . . . . . . . . . 5 3. Transport et stockage avant utilisation . . . . . . . . . . . . . . . . . . 15
4. Beschreibung von Erzeugnis und Zubehör . . . . . . . . . . . . . . . 5 4. Description du produit et de ses accessoires . . . . . . . . . . . . . 15
5. Aufstellung / Einbau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 5. Installation / Montage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6. Inbetriebnahme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 6. Mise en service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7. Wartung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7. Entretien . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8. Störungen, Ursachen und Beseitigung . . . . . . . . . . . . . . . . . . 8 8. Pannes, causes et remèdes . . . . . . . . . . . . . . . . . . . . . . . . . . 18
GB I
EC declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Dichiarazione di conformità CE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
1. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1. Introduzione . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2. Sicurezza . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3. Transport and interim storage . . . . . . . . . . . . . . . . . . . . . . . . . 10 3. Trasporto e magazzinaggio . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4. Product and accessory description . . . . . . . . . . . . . . . . . . . . . 10 4. Descrizione del prodotto e degli accessori . . . . . . . . . . . . . . . 20
5. Assembly / Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5. Istruzioni di montaggio e installazione . . . . . . . . . . . . . . . . . . . 21
6. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 6. Messa in esercizio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 7. Manutenzione . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8. Problems, Causes and Solutions . . . . . . . . . . . . . . . . . . . . . . 13 8. Risoluzione di problemi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1
D EG - Konformitätserklärung
F Déclaration de conformité CEE
Hiermit erklären wir, dass die Bauarten der Baureihe : MVI 16

Herewith, we declare that this product: MVI 32
Par le présent, nous déclarons que cet agrégat : MVI 52
MVI 70
MVI 95

in its delivered state comply with the following relevant provisions:
est conforme aux dispositions suivants dont il relève:
Directives CEE relatives aux machines
Elektromagnetische Verträglichkeit - Richtlinie 89/336/EWG

Elektromagnetic compatability - directive i.d.F/ as amended/ avec les amendements suivants:
Compatibilité électromagnétique- directive 91/263/EWG
92/31/EWG
93/68/EWG
Niederspannungsrichtlinie 73/23/EWG
Low voltage directive i.d.F/ as amended/ avec les amendements suivants :
Direction basse-tension 93/68/EWG
Angewendete harmonisierte Normen, insbesondere: EN 809

Applied harmonized standards, in particular: EN 60034-1
Normes harmonisées, notamment:
Erwin Prieß WILO AG

44263 Dortmund
Document: 2060375.1
NL EG-verklaring van overeenstemming I Dichiarazione di conformità CE E Declaración de conformidad CE
Hiermede verklaren wij dat dit aggregaat in de Con la presente si dichiara che i presenti Por la presente declaramos la conformidad
geleverde uitvoering voldoet aan de volgende prodotti sono conformi alle seguenti del producto en su estado de suministro con
bepalingen: disposizioni e direttive rilevanti: las disposiciones pertinentes siguientes:
EG-richtlijnen betreffende machines 98/37/EG Direttiva macchine 98/37/CE Directiva sobre máquinas 98/37/CE
Elektromagnetische compatibiliteit Compatibilità elettromagnetica 89/336/CEE e Directiva sobre compatibilidad
89/336/EEG als vervolg op 91/263/EEG, seguenti modifiche 91/263/CEE, 92/31/CEE, electromagnética 89/336/CEE modificada por
92/31/EEG, 93/68/EEG 93/68/CEE 91/263/CEE, 92/31/CEE, 93/68/CEE
EG-laagspanningsrichtlijn 73/23/EEG als Direttiva bassa tensione 73/23/CEE e Directiva sobre equipos de baja tensión
vervolg op 93/68/EEG seguenti modifiche 93/68/CEE 73/23/CEE modificada por 93/68/CEE
Gebruikte geharmoniseerde normen, in het Norme armonizzate applicate, in particolare: 1) Normas armonizadas adoptadas, especialmente: 1)
bijzonder: 1)
P Declaração de Conformidade CE S CE- försäkran N EU-Overensstemmelseserklæring

Pela presente, declaramos que esta unidade Härmed förklarar vi att denna maskin i Vi erklærer hermed at denne enheten i
no seu estado original, está conforme os levererat utförande motsvarar följande utførelse som levert er i overensstemmelse
seguintes requisitos: tillämpliga bestämmelser: med følgende relevante bestemmelser:
Directivas CEE relativas a máquinas 98/37/CE EG–Maskindirektiv 98/37/EG EG–Maskindirektiv 98/37/EG
Compatibilidade electromagnética 89/336/CEE EG–Elektromagnetisk kompatibilitet – riktlinje EG–EMV–Elektromagnetisk kompatibilitet
com os aditamentos seguintes 91/263/CEE, 89/336/EWG med följande ändringar 89/336/EWG med senere tilføyelser:
92/31/CEE, 93/68/CEE 91/263/EWG, 92/31/EWG, 93/68/EWG 91/263/EWG, 92/31/EWG, 93/68/EWG
Directiva de baixa voltagem 73/23/CEE com EG–Lågspänningsdirektiv 73/23/EWG med EG–Lavspenningsdirektiv 73/23/EWG med
os aditamentos seguintes 93/68/CEE följande ändringar 93/68/EWG senere tilføyelser: 93/68/EWG
Normas harmonizadas aplicadas, especialmente: 1) Tillämpade harmoniserade normer, i synnerhet: 1) Anvendte harmoniserte standarder, særlig: 1)
FI CE-standardinmukaisuusseloste DK EF-overensstemmelseserklæring H EK. Azonossági nyilatkozat

Ilmoitamme täten, että tämä laite vastaa Vi erklærer hermed, at denne enhed ved Ezennel kijelentjük,hogy az berendezés az
seuraavia asiaankuuluvia määräyksiä: levering overholder følgende relevante alábbiaknak megfelel:
bestemmelser: EK Irányelvek gépekhez: 98/37/EG
EU–konedirektiivit: 98/37/EG
EU–maskindirektiver 98/37/EG
Sähkömagneettinen soveltuvuus 89/336/EWG Elektromágneses zavarás/türés: 89/336/EWG
seuraavin täsmennyksin 91/263/EWG Elektromagnetisk kompatibilitet: 89/336/EWG, és az azt kiváltó 91/263/EWG, 92/31/EWG,
92/31/EWG, 93/68/EWG følgende 91/263/EWG, 92/31/EWG, 93/68/EWG
93/68/EWG Kisfeszültségü berendezések irány-Elve:
Matalajännite direktiivit: 73/23/EWG seuraavin
täsmennyksin 93/68/EWG Lavvolts-direktiv 73/23/EWG følgende 73/23/EWG és az azt kiváltó 93/68/EWG
93/68/EWG Felhasznált harmonizált szabványok, különösen: 1)
Käytetyt yhteensovitetut standardit, erityisesti: 1)
Anvendte harmoniserede standarder, særligt: 1)
CZ Prohlášení o shod EU PL Deklaracja Zgodnoci CE RUS

Prohlašujeme tímto, že tento agregát Niniejszym deklarujemy z pen

v dodaném provedení odpovídá následujícím odpowiedzialnosci e dostarczony wyrób jest ,
píslušným ustanovením: zgdony z nastpujcymi dokumentami: ! "# $
Smrnicím EU–strojní zaízení 98/37/EG EC–dyrektywa dla przemysu maszynowego % !
98/37/EG :
Smrnicím EU–EMV 89/336/EWG ve sledu
91/263/EWG, 92/31/EWG, 93/68/EWG Odpowiednio
elektromagnetyczna &! EC ' '
89/336/EWG ze zmian 91/263/EWG, 98/37/EG
Smrnicím EU–nízké naptí 73/23/EWG ve
sledu 93/68/EWG 92/31/EWG, 93/68/EWG (! )
Normie niskich napi
73/23/EWG ze zmian 89/336/EWG $$! 91/263/EWG,
Použité harmonizaní normy, zejména: 1) 92/31/EWG, 93/68/EWG
93/68/EWG
Wyroby s zgodne ze szczegóowymi normami &! $ ) $!*%
zharmonizowanymi: 1) 73/23/EWG $$! 93/68/EWG
+ $) !
!, : 1)
GR μ!" #$" %$!&'" TR EC Uygunluk Teyid Belgesi 1) EN 809,

#" (.(. ((+,:" ;<")
;<=>?@JμR XYZ Y@ [\@]X? ^JYX _’ ^JY` Y<? Bu cihazn teslim edildii ekliyle aadaki EN 60034-1.
{^Y|_Y^_< [^\|}@_<~ Z{^?@[@ZR YZ~ standartlara uygun olduunu teyid ederiz:
^{X=@JR~ }Z^Y|RZ~ : AB-Makina Standartlar 98/37/EG
}<R~ EG _RYZ{| μR μ<^?`μ^Y^ 98/37/EG Elektromanyetik Uyumluluk 89/336/EWG ve
=R{Y\@μ^?<YZ{` _Jμ^YXY<Y^ EG- takip eden, 91/263/EWG, 92/31/EWG,
89/336/EWG X[~ Y\@[@[@Z`<{R 93/68/EWG
91/263/EWG 92/31/EWG, 93/68/EWG Alçak gerilim direktifi 73/23/EWG ve takip
}<^ ^μ<=`~ Y|_<~ EG–73/23/EWG X[~ eden, 93/68/EWG
Y\@[@[@Z`<{R 93/68/EWG
Ksmen kullanlan standartlar: 1)
?^\μ@?Z_μ?^ \<_Zμ@[@Z@μR?^ [\XYJ[^,
Z}Z^YR\^: 1)
WILO AG
Erwin Prieß Nortkirchenstraße 100
Quality Manager 44263 Dortmund
DEUTSCH
1 Allgemeines
Einbau- und Inbetriebnahme nur durch Fachpersonal
1.1 Verwendungszweck langfaserige Stoffe. Haupteinsatzgebiete sind Wasserversorgungs-
Die Pumpe wird eingesetzt zur Förderung von Kalt- und Warmwasser und Druckerhöhungsanlagen, Kesselspeisungen, industrieelle Um-
und anderen mineralölfreien Flüssigkeiten in EPDM-Ausführung (mine- wälzsysteme, Verfahrenstechnik, Kühlwasserkreisläufe, Feuerlösch-
ralölhaltige Flüssigkeiten VITON-Ausführung) ohne abreibende oder systeme sowie Wasch- und Beregnungsanlagen.
1.2 Angaben über das Erzeugnis

1.2.1 Anschluß- und Leistungsdaten (Tabelle 1)
Zulässige Fördermedien Trinkwasser nach Trinkwasserverordnung

Heizungswasser / Brauchwasser
Kondensat
Wasser-Glykol-Gemische 1)
Andere dünnflüssige Medien 2)
Zulässige Medientemperatur -15 °C bis +120 °C
(Katalogangaben beachten)
Maximale Umgebungstemperatur +40 °C
Max. zul. Betriebsdruck saugseitig (Zulaufdruck, s. Abs. 5.3) 16/10 bar
druckseitig, 2-poliger Motor 16/25 bar
druckseitig, 4-poliger Motor 16/16 bar
Anschlußspannungen DM: für P2 ≤ 4 kW 3 ~ 230/400 V ± 10 %, 50 Hz
für P2 ≥ 5,5 kW 3 ~ 400 V ± 10 %, 50 Hz
Normmotor für P2 ≤ 5,5 kW Normmotor V 18
für P2 ≥ 7,5 kW Normmotor V 18
Drehzahl 2-polige Ausführung 2900 1/min
4-polige Ausführung 1450 1/min
Netzseitige Absicherung siehe Motortypenschild
Isolationsschutzklasse F
Schutzart IP 55
höhere Schutzarten auf Anfrage
1) Werden Wasser-/Glykol-Gemische im Mischungsverhältnis bis 40 % Glykolanteil (oder Fördermedien mit anderer Viskosität als reines Wasser) eingesetzt, so sind die
Förderdaten der Pumpe entsprechend der höheren Viskosität, abhängig vom prozentualen Mischungsverhältnis zu korrigieren. Nur Markenware mit Korrosionsschutz-
Inhibitoren verwenden, Herstellerangaben beachten.
2) Wenn andere sowie aggressive chemische Flüssigkeiten gefördert werden sollen, unbedingt Katalogangaben beachten und zuvor die Zustimmung von WILO einzuholen.
Haupt- und Anschlußmaße (Tabelle 2, siehe auch Bild 3):
Types Ausführung PN16 Ausführung PN25

A B Y W Z E F J K A B Y W Z E F J K
MVI mm mm
1602 1614 DN50 194 252 20 215 130 300 90 125 4x18 194 252 20 215 130 300 90 125 4x18
3202 3216 DN65 235 235 35 195 195 320 105 145 4x18 260 260 35 220 220 320 120 145 8x18
5202 5212 DN80 260 260 30 220 220 320 105 160 8x18 260 260 30 220 220 320 105 160 8x18
7001 7007 DN100 261 350 45 280 199 380 140 180 8x19 261 350 45 280 199 380 140 190 8x23
9501 9506 DN100 261 350 45 280 199 380 140 180 8x19 261 350 45 280 199 380 140 190 8x23
Bei Ersatzteilbestellungen sind sämtliche Daten des Pumpen-/Motor-Typenschildes anzugeben.
4
DEUTSCH
1.2.2 Typenschlüssel Im einzelnen kann Nichtbeachtung beispielsweise folgende Gefähr-

MVI 16 08 3 / 16 / E / 3 - 400 - 50 - 2 / XX / X dungen nach sich ziehen:
– Versagen wichtiger Funktionen der Pumpe/Anlage,
Bauweise MVI
– Gefährdungen von Personen durch elektrische, mechanische und
(Mehrstufige, vertik.
bakteriologische Einwirkungen,
Edelstahl-(Inox-)
– Sachschäden.
Kreiselpumpe)
2.4 Sicherheitshinweise für den Betreiber
Förderstrom [m3/h]
Die bestehenden Vorschriften zur Unfallverhütung sind zu beachten.
(2-pol./ 50 Hz)
Gefährdungen durch elektrische Energie sind auszuschließen.
Anzahl der Laufräder in Vorschriften des VDE und der örtlichen Energieversorgungsunter-
Reihenanordn. nehmen beachten.
Werkstoffqualität: 2.5 Sicherheitshinweise für Inspektions- und Montagearbeiten
Hydraulik / Fußstück Der Betreiber hat dafür zu sorgen, daß alle Inspektions- und Montage-
1 nicht belegt arbeiten von autorisiertem und qualifiziertem Fachpersonal ausgeführt
2 1.4404 / 1.4408 (AISI 316 L) werden, das sich durch eingehendes Studium der Betriebsanleitung
3 1.4301 / GG25 (beschichtet) ausreichend informiert hat.
maximal zulässiger Betriebsdruck [bar] Grundsätzlich dürfen Arbeiten an der Pumpe/Anlage nur im Stillstand
PN 16 oder PN 25 durchgeführt werden.
EPDM-Dichtungen (KTW/WRAS) 2.6 Eigenmächtiger Umbau und Ersatzteilherstellung

VITON-Dichtungen Veränderungen der Pumpe/Anlage sind nur nach Absprache mit dem
Hersteller zulässig. Originalersatzteile und vom Hersteller autorisiertes
Anschlußspannung 3 ~ 400 V Zubehör dienen der Sicherheit. Die Verwendung anderer Teile kann die
3 ~ 230 V Haftung für die daraus entstehenden Folgen aufheben.
Frequenz 50 Hz, 60 Hz 2.7 Unzulässige Betriebsweisen
Motor 2- oder 4-polig Die Betriebssicherheit der gelieferten Pumpe/Anlage ist nur bei be-
stimmungsmäßiger Verwendung entsprechend Abschnitt 1 der Be-
Hersteller-Schlüssel triebsanleitung gewährleistet. Die im Katalog/Datenblatt angegebenen
Grenzwerte dürfen auf keinen Fall unter- bzw. überschritten werden.
2 Sicherheit
Diese Betriebsanleitung enthält grundlegende Hinweise, die bei Auf-
3 Transport und Zwischenlagerung
stellung und Betrieb zu beachten sind. Daher ist diese Betriebs- Bei Transport und Zwischenlagerung ist die Pumpe
anleitung unbedingt vor Montage und Inbetriebnahme vom Monteur ACHTUNG! gegen Feuchtigkeit, Frost und mechanische Be-
sowie dem zuständigen Betreiber zu lesen. Es sind nicht nur die unter schädigung zu schützen. Das Pumpenaggregat ist in horizontaler
diesem Hauptpunkt Sicherheit aufgeführten allgemeinen Sicherheits- Wellenlage zu transportieren. Bei der Zwischenlagerung ist
hinweise zu beachten, sondern auch die unter den folgenden Haupt- darauf zu achten, daß ein Umschlagen des Pumpenaggregates wegen
punkten eingefügten, speziellen Sicherheitshinweise. evtl. Kopflastigkeit ausgeschlossen ist.
2.1 Kennzeichnung von Hinweisen in der Betriebsanleitung
Die in dieser Betriebsanleitung enthaltenen Sicherheitshinweise, die bei
Nichtbeachtung Gefährdungen für Personen hervorrufen können, sind
mit dem allgemeinen Gefahrensymbol 4 Beschreibung von Erzeugnis und Zubehör
4.1 Beschreibung der Pumpe
Die Pumpe ist eine mehrstufige (1 – 16 Stufen), normalsaugende, verti-
kale Hochdruck-Kreiselpumpe in Inline-Bauweise, d. h. Saug- und
Druckstutzen liegen in einer Linie. Die Pumpe wird in 2 Druck-
bei Warnung vor elektrischer Spannung mit ausführungen, PN 16 und PN 25 mit angegossenen Rundflanschen,
angeboten.
Die Pumpe (Bild 1) steht auf einem Pumpenfuß aus Grauguß zur
Fundamentbefestigung (Pos. 13). Die Stufengehäuse (Pos. 4) sind mehr-
teilige Gliederkonstruktionen. Die Laufräder (Pos. 10) sind auf eine
gemeinsame Welle (Pos. 11) montiert. Das Druckgehäuse (Pos. 5)
besonders gekennzeichnet. gewährleistet die betriebssichere Abdichtung.
Bei Sicherheitshinweisen, deren Nichtbeachtung Gefahren für die Alle mediumberührenden Teile wie Stufengehäuse, Laufräder, Druck-
Pumpe/Anlage und deren Funktion hervorrufen können, ist das Wort gehäuse sind aus Chrom-Nickel-Stahl, Pumpenfuß (Pos. 12) mit
Flanschen (Pos. 6) aus beschichtetem GG 25 (bis 85 °C) oder aus
ACHTUNG! Chrom-Nickel-Stahl (auf Anfrage). Der Wellendurchgang des
Pumpengehäuses ist mit einer Gleitringdichtung (Pos. 3) abgedichtet.
eingefügt.
2.2 Personalqualifikation MVI32C, MVI52C, MVI70 und MVI95 sind mit
Das Personal für die Montage muß die entsprechende Qualifikation für einem Kartuschensystem für einen einfachen
diese Arbeiten aufweisen. Ersatz der standard Gleitringdichtung ohne
Demontage der Hydraulikeinheit versehen.
2.3 Gefahren bei Nichtbeachtung der Sicherheitshinweise
Die Nichtbeachtung der Sicherheitshinweise kann eine Gefährdung für
Personen und Pumpe/Anlage zur Folge haben. Die Nichtbeachtung Die "Spacer" Funktion erlaubt keine Demontage des Motores an
der Sicherheitshinweise kann zum Verlust jeglicher Schadenersatz- MVI32C, MVI52C, MVI70 und MVI95 bei Demontage der
ansprüche führen. Gleitringdichtungskartusche.
5
DEUTSCH
Pumpen- und Motorwelle sind über eine Kupplung (Pos. 9) miteinan- – Bei der Begrenzung des Zulaufdruckes von max. 10 bar ist zu
der verbunden. Alle mediumberührenden Bauteile der Trinkwasser- beachten, daß sich dieser Druck aus dem Nenndruck und der
ausführung (Ausführung E) sind KTW- und WRAS-freigegeben und Nullförderhöhe ergibt:
damit für Trinkwasser geeignet. P Zulauf ≤ PN - Pmax Pumpe
In Verbindung mit einem Frequenzumrichter kann die Pumpe drehzahl-
– Für gashaltiges oder heißes Fördermedium ist eine Bypass-Leitung
geregelt werden (siehe Absatz 5.3).
an der Pumpe zu installieren (Bild 2, Pos. BP), (Zubehör).
4.2 Lieferumfang
– Hochdruck-Kreiselpumpe, 5.2 Elektrischer Anschluß
– Einbau- und Betriebsanleitung. Der elektrische Anschluß ist von einem beim örtlichen EVU
zugelassenen Elektroinstallateur entsprechend den gelten-
4.3 Zubehör den VDE-Vorschriften auszuführen.
siehe Katalog/Datenblatt
– Stromart und Spannung des Netzanschlusses müssen den Angaben
auf dem Typenschild entsprechen,
– Pumpe/Anlage vorschriftsmäßig erden,
5 Aufstellung/Einbau – Alle Motoren müssen zur Absicherung gegen Motorüberlastung bau-
seits mit einem Motorschutzschalter ausgerüstet sein.
– Typenschilddaten der Pumpe und des Motors beachten,
Einstellung des Motorschutzschalters:
5.1 Montage Direktanlauf: Einstellung auf Motornennstrom nach Angaben des
Motortypenschildes.
Einbau erst nach Abschluß aller Schweiß- und
ACHTUNG! Lötarbeiten und der ggf. erforderlichen Spülung des
Y-Δ-Anlauf: Ist der Motorschutzschalter in die Zuleitung zur Y-Δ-
Schützkombination geschaltet, so erfolgt die Einstellung wie bei
Rohrsystems vornehmen. Schmutz führt zur Funk-tionsunfähigkeit der
Direktanlauf. Ist der Motorschutzschalter in einen Strang der
Pumpe.
Motorzuleitung (U1/V1/W1 oder U2/V2/W2) geschaltet, so ist der
– Pumpe an trockenem und frostsicherem Ort aufstellen. Motorschutzschalter auf den Wert 0,58 x Motornennstrom einzu-stellen.
– Die Aufstellungsfläche muß waagerecht und plan sein. Schiefstellung – Das Netzkabel kann wahlweise links oder rechts am Klemmenkasten
der Pumpe führt zu erhöhtem Lagerverschleiß, nur senkrechter eingeführt werden. Dazu wird die entsprechende Bohrung durch
Betrieb zulässig. Heraushebeln des vorgestanzten Deckels geöffnet, PG-Verschrau-
– Pumpe zur leichten Überprüfung und Demontage an gut zugäng- bung einschrauben und Anschlußleitung durch PG-Verschraubung
licher Stelle montieren. Pumpe immer exakt lotrecht auf einen aus- ziehen.
reichend schweren Betonsockel (Bild 2, Pos. 13) montieren. – Die Anschlußleitung ist vor Temperatur- und Schwingungs-Einflüssen
Zwischen Sockel und Boden Schwingungsdämpfer montieren. zu schützen, die vom Motor oder der Pumpe ausgehen können.
– Einbaumaße und Anschlußgrößen sind der Tabelle 2 im Absatz 1.2.1 – Bei Einsatz der Pumpe in Anlagen mit Fördermedien-Temperaturen
und Bild 3 zu entnehmen. über 90 °C muß eine entsprechend wärmebeständige Anschluß-
– Bei schweren Pumpen senkrecht über der Pumpe einen Haken leitung verwendet werden.
(Bild 2, Pos. 12) oder eine Öse mit geeigneter Tragfähigkeit (Gesamt- – Der Netzanschluß ist nach den Klemmenanschlußplänen für Dreh-
gewicht der Pumpe: siehe Katalog/Datenblatt) anbringen, woran bei strom im Klemmenkasten vorzunehmen (Bild 4).
Wartung oder Reparatur der Pumpe Hebezeug oder ähnliche – Der Klemmenkasten kann durch Drehen des Motors (Bild 1, Pos. 7)
Hilfsmittel angeschlagen werden können. Freies Ausbaumaß von um jeweils 90° in eine evtl. günstigere Position gebracht werden.
min. 200 mm berücksichtigen. Dazu sind die Verbindungsschrauben (Bild 1, Pos.1) von Laterne
(Bild 1, Pos. 8) und Motorflansch zu lösen.
Bei innenliegenden Verbindungsschrauben ist vorher der Kupp-
– Richtungspfeil auf dem Pumpengehäuse zeigt Fließrichtung an. lungsschutz (Bild 1, Pos. 2) zu entfernen. Bei der Montage des
– Saug- und Druckleitung spannungsfrei montieren. Kompensatoren Kupplungsschutzes das Eindrehen der Sicherungsschraube nicht
mit Längenbegrenzung zum Abfangen der Schwingungen einbauen. vergessen.
Die Rohre sind so zu befestigen (Bild 2, Pos. 7), daß die Pumpe
nicht das Gewicht der Rohre trägt. 5.3 Betrieb mit Frequenzumrichter
– Absperreinrichtungen (Bild 2, Pos. 2 u. 3) sind grundsätzlich vor und Die Pumpe kann in Verbindung mit einem Frequenzumrichter (Band-
hinter der Pumpe einzubauen, um bei Überprüfung oder Austausch breite 20–50 Hz) drehzahlgeregelt werden.
der Pumpe ein Entleeren und Wiederauffüllen der gesamten Anlage Anschluß und Betrieb sind der Einbau- und Betriebsanleitung des
zu vermeiden. Frequenzumrichters zu entnehmen.
– Zur Vermeidung von Druckverlusten wird empfohlen die Zulaufleitung Der Frequenzumrichter darf keine Spannungsanstieg-Geschwindig-
möglichst kurz zu wählen, die Nennweite für die Saugleitung um eine keiten über 2500 V/μs und Spannungsspitzen û > 1000 V erzeugen,
Nennweite größer zu wählen als der Pumpenanschluß und da sonst die Motorwicklung zerstört wird. Sind solche Spannungs-
Verengungen durch Bögen sowie Ventile zu vermeiden. anstiegs-Geschwindigkeiten möglich, ist zwischen Frequenzumrichter
– In der Druckleitung ist ein Rückflußverhinderer (Bild 2, Pos. 4) vorzu- und Motor ein LC-Filter (Motorfilter) zu installieren.
sehen.
– Bei höheren Differenzdrücken > 6 bar ist der Rückflußverhinderer
(Bild 2, Pos. 4) in die Saugleitung einzubauen. Druckseitig kann er 6 Inbetriebnahme
entfallen.
– Die Gleitringdichtung muß gegen Trockenlauf gesichert werden. Die Pumpe darf zum Schutz der Gleitringdichtung
ACHTUNG! nicht trocken laufen.
Bauseits ist ein Vordruck- bzw. Niveauwächter einzubauen.
– Bei mittelbarem Anschluß über einen Vorbehälter sollte die Zulauf- – Beide Absperrventile schließen, Entlüftungsschraube (Bild 2, Pos. 5)
leitung mit einem Saugkorb (Bild 2, Pos. 8) versehen sein, um zu 1,5 bis 2 Umdrehungen öffnen.
verhindern, daß grobe Verunreinigungen in die Pumpe gelangen. – Absperrventil (Bild 2, Pos. 2) auf der Saugseite langsam öffnen, bis
die Luft aus der Entlüftungsschraube ausgetreten ist und Förder-
medium austritt. Austretende Luft ist durch Zischen deutlich hörbar.
Entlüftungsschraube schließen.
– Druckseitiges Absperrventil (Bild 2, Pos. 3) langsam öffnen. Am
druckseitig installierten Manometer ist eine evtl. Druckinstabilität zu
prüfen, zu erkennen am Flattern des Manometerzeigers. Bei instabi-
lem Druck ist erneut zu entlüften.
6
DEUTSCH
Bei hohen Fördermedium-Temperaturen und System-

– Bei frostsicherem Standort sollte die Pumpe auch bei längerer
drücken kann der aus der Entlüftungsschraube austretende
Außerbetriebnahme nicht entleert werden.
Strahl zu Verbrühungen und Verletzungen führen. Die
Entlüftungsschraube darf deshalb nur geringfügig gelöst
Für Pumpen, die mit einem Schmiernippel unter dem lagergehäuse (siehe
werden.
Tabelle hierunter) ausgerüstet sind, bitte lesen Sie die
Nachschmierungsanweisungen die auf dem Aufkleber auf diesem
– Bei der Erstinbetriebnahme ist im Falle der Trinkwasserförderung das
Gehaüse angegeben sind.
System zu spülen, damit evtl. Schmutzwasser nicht in die
Trinkwasserleitung gelangt.
– Drehrichtungskontrolle für Drehstrommotoren: Durch kurzzeitiges
Einschalten überprüfen, ob die Drehrichtung der Pumpe mit dem
Pfeil auf der Laterne übereinstimmt. Bei falscher Drehrichtung
2 Phasen in der Netzleitung vertauschen.
Bei Pumpen mit Stern/Dreieck-Anlauf müssen die Anschlüsse zweier
Wicklungen vertauscht werden, z. B. U1 gegen V1 und U2 gegen V2.
– Eine zu hohe Temperatur des Fördermediums kann infolge
Dampfbildung zur Beschädigung der Pumpe führen. Die Pumpe
sollte deshalb bei Kaltwasserförderung nicht länger als 10 min, bei
Förderung von Medien > 60 °C nicht länger als 5 min gegen Type < 22 kW 22 kW 30 kW 37 kW 45 kW
geschlossenen Schieber laufen.
Es wird empfohlen, 10 % der Nennfördermenge nicht zu unter-
MVI 16
schreiten, um die Bildung eines Dampfpolsters in der Pumpe zu ver-
meiden.
– Bei Bildung eines Dampfpolsters ist die Pumpe durch vorsichtiges MVI 32 ✔
Öffnen der Entlüftungsschraube zu entlüften.
Die Pumpe kann einschließlich Motor Betriebstempe- MVI 52 ✔ ✔
raturen > 100 °C erreichen. Deshalb Vorsicht bei
Berührung der Pumpe. MVI 70 ✔ ✔ ✔ ✔
MVI 95 ✔ ✔ ✔ ✔
7 Wartung
Vor Wartungsarbeiten Anlage spannungsfrei schalten und
gegen unbefugtes Wiedereinschalten sichern. Keine
Arbeiten an laufender Pumpe vornehmen.
– Während der Einlaufzeit ist mit leichtem Tropfen der Gleitring-
dichtung zu rechnen. Bei starker Leckage infolge hohen Verschleißes
Gleitringdichtung von einem Fachbetrieb auswechseln lassen.
– Erhöhte Lagergeräusche und ungewöhnliche Vibrationen zeigen Für Pumpen, die mit einem Kupplungspuffer ver-
Verschleiß der Lager an. Lager von einem Fachbetrieb wechseln lassen. sehen sind, bitte überprüfen Sie vor neuer
– Bei nicht frostsicherem Standort sind Pumpe und Rohrleitungen in Montage.
der kalten Jahreszeit zu entleeren. Absperrventile schließen und
Ablaß- (Bild 2, Pos. 6) und Entlüftungsschraube der Pumpe öffnen
(Bild 2, Pos. 5).
Die Absperrventile sind unbedingt vor dem Öffnen der

Ablaßschraube zu schließen.
7
DEUTSCH
8 Störungen, Ursachen und Beseitigung

Störung Ursache Beseitigung
Pumpe läuft nicht keine Stromzufuhr Sicherungen, Kabel und Anschlüsse überprüfen
Motorschutzschalter hat abgeschaltet Motorüberlastung beseitigen
Pumpe läuft, aber fördert nicht falsche Drehrichtung Drehrichtung prüfen und ggfs. korrigieren
Leitung oder Teile der Pumpe sind mit Leitung und Pumpe kontrollieren und reinigen
Fremdkörpern verstopft
Luft in der Saugleitung Saugleitung abdichten
Saugleitung zu eng größere Saugleitung einbauen
Schieber nicht genügend geöffnet Schieber öffnen
Pumpe fördert nicht gleichmäßig Luft in der Pumpe Pumpe entlüften
Pumpe vibriert bzw. verursacht Fremdkörper in der Pumpe Fremdkörper beseitigen

Geräusche
Pumpe nicht genügend auf dem Sockel fixiert Ankerschrauben anziehen
Lagerschaden Kundendienst hinzuziehen
Motor überhitzt eine Phase unterbrochen Sicherungen, Kabel und Anschlüsse überprüfen
Motorschutz löst aus
Pumpe schwergängig:
Fremdkörper, Pumpe reinigen
Lager beschädigt Pumpe durch Kundendienst reparieren lassen
Umgebungstemperatur zu hoch für Kühlung sorgen
Läßt sich die Betriebsstörung nicht beheben, wenden Sie sich bitte an Ihren Sanitär- und Heizungsfachhandwerker oder an den WILO-
Kundendienst.
Technische Änderungen vorbehalten!
8
ENGLISH
1 General Information
Installation and commissioning only by qualified personnel
1.1 Uses boiler feeder pump, in industrial circulation systems, in process tech-
The pump is suitable for hot and cold water and other fluids free from nology, in cooling water systems, in fire extinguishers and in washing
mineral oil and without abrasives or long-fibred substances. The main and sprinkler installations.
areas of use are in water supply installations, as a booster pump, as a
1.2 Product data
1.2.1 Connection and electrical data (Table 1)
Pumping medium allowed Drinking water in acc. with Drinking Water Order
Heating water / service water
Condensate
Water/glycol mixture 1)
Other liquid media 2)
Permissible media temperature -15 °C to +120 °C
(Follow catalogue instructions)
Maximum ambient temperature +40 °C
Maximum permissible working pressure: at the inlet (inlet pressure see paragraph 5.3) 16/10 bar
at the outlet, for a 2 pole motor 16/25 bar
at the outlet, for a 2 pole motor 16/16 bar
Mains voltages DM: for P2 ≤ 4 kW: 3 ~ 230/400 V ± 10 %, 50 Hz
for P2 ≥ 5.5 kW: 3 ~ 400 V ± 10 %, 50 Hz
Standard motor for P2 ≤ 5.5 kW: V 18 standard motor
for P2 ≥ 7.5 kW: V 1 standard motor
Speed 2 pole version 2900 RPM
4 pole version 1450 RPM
Mains fuse protection see motor rating plate
Insulation class F
System of protection IP 55
better protective systems available
1) When using a water-glycol mixture containing up to 40 % glycol (or media with a viscosity different to that of pure water, the flow data for the pump must be adjusted accord-
ing to the higher viscosity of the flow media, regardless of the percentage of the viscous matter. Only use branded goods with corrosion protection-inhibitors, follow manufac-
turer’s instructions.
2) If other and also aggressive chemical fluids are to be pumped, be sure to follow catalogue instructions and first obtain the approval of WILO.
Principal dimensions and connection dimensions (Table 2, see also Fig. 3):
Types PN16 version PN25 version

MVI mm mm
1602 1614 DN50 194 252 20 215 130 300 90 125 4x18 194 252 20 215 130 300 90 125 4x18
3202 3216 DN65 235 235 35 195 195 320 105 145 4x18 260 260 35 220 220 320 120 145 8x18
5202 5212 DN80 260 260 30 220 220 320 105 160 8x18 260 260 30 220 220 320 105 160 8x18
7001 7007 DN100 261 350 45 280 199 380 140 180 8x19 261 350 45 280 199 380 140 190 8x23
9501 9506 DN100 261 350 45 280 199 380 140 180 8x19 261 350 45 280 199 380 140 190 8x23
When ordering spare parts, please give all the information on the pump/motor rating plate.
9
ENGLISH
1.2.2 Type key 2.4 Safety precautions for the operator

MVI 16 08 3 / 16 / E / 3 - 400 - 50 - 2 / XX / X Existing regulations for the prevention of accidents must be followed.
Dangers caused by electrical energy are to be excluded. Directives
Design MVI
issued by the VDE [German Association of Electrical Engineers] and
(Multistage, vertic.
the local electricity supply companies are to be observed.
Special steel-(Inox-)
centrifugal pump) 2.5 Safety information for inspection and assembly
The operator is responsible for ensuring that inspection and assembly
Flow rate [m3/h]
are carried out by authorised and qualified personnel who have
(2-pole/ 50 Hz)
studied the operating instructions closely.
Number of Work on the pump/machinery should only be carried out when the
impellers in row machine has been brought to a standstill.
Material quality: 2.6 Unauthorized modification and manufacture of spare parts
Hydraulic / Base Changes to the pump/machinery may only be made in agreement with
1 unoccupied the manufacturer. The use of original spare parts and accessories
2 1.4404 / 1.4408 (AISI 316 L) authorised by the manufacturer will ensure safety. The use of any other
3 1.4301 / GG25 (coated) parts may invalidate claims invoking the liability of the manufacturer for
maximum permissible working any consequences.
pressure [bar] PN 16 or PN 25 2.7 Improper use
EPDM seals (KTW/WRAS) The operating safety of the pump or installation supplied can only be
VITON seals guaranteed if it is used in accordance with paragraph 1 of the operat-
ing instructions. The limiting values given in the catalogue or data
Main voltage 3 ~ 400 V sheet must neither be exceeded nor allowed to fall below those speci-
3 ~ 230 V fied.
50 Hz or 60 Hz frequency
2- or 4-pole motor
Manufacturer’s key 3 Transport and storage
During transport and in storage the pump must be
WARNING! protected against moisture, frost and mechanical
2 Safety damage. The pump unit is to be transported with the shaft horizontal.
When storing, ensure that the pump unit cannot overturn as a result of
These instructions contain important information which must be top-heaviness.
followed when installing and operating the pump. These operating
instructions must therefore be read before assembly and commis-
sioning by the installer and the responsible operator. Both the general
safety instructions in the “Safety precautions” section and those in 4 Product and accessory description
subsequent sections indicated by danger symbols should be carefully
observed. 4.1 The pumps
The pump is a multistage (1–16 stages) normal suction vertical high
2.1 Danger symbols used in these operating instructions pressure centrifugal pump with an in-line design, i.e. the inlet and out-
Safety precautions in these operating instructions which, if not let pressure glands are in a line. The pump is available in 2 pressure
followed, could cause personal injury are indicated by the symbol: versions, PN 16 and PN 25 with integrally cast circular flanges.
The pump (Fig. 1) stands on a grey cast iron pump footplate which
serves as a fixing base (13). The stage casings (4) are in a multiple
modular construction. The impellers (10) are fitted on a single shaft
(11). The pressure casing (5) guarantees a fail-safe seal.
when warning of electrical voltage with All parts that come into contact with the medium, such as stage hous-
ings, impellers and pressure casings are made of chromium nickel
steel, the pump footplate (Pos. 12) with flanges (Pos. 6) of coated
GG 25 (up to 85 °C) or of chromium nickel steel (on request). The shaft
hole through the pump casing is sealed with an axial face seal (3).
The following symbol is used to indicate that by ignoring the relevant
safety instructions, damage could be caused to the pump/machinery
and its functions: MVI32C, MVI52C, MVI70 and MVI95 are equipped
with a cartridge system in order to ease standard
WARNING! mechanical seal replacement without disassemb-
ling the hydraulic parts.
2.2 Staff training
The personnel installing the pump must have the appropriate qualifica-
tions for this work.
“Spacer” feature allows not to disassemble motor on MVI32C,
2.3 Risks incurred by failure to comply with the safety precautions MVI52C, MVI70 and MVI95 when removing mechanical seal cartridge.
Failure to comply with the safety precautions could result in personal The pump and motor shafts are linked together by a clutch (9). All
injury or damage to the pump or installation. Failure to comply with the parts of the drinking water version (version E) which are in contact with
safety precautions could also invalidate any claim for damages. the fluid have been cleared by KTW and WRAS and are therefore sui-
In particular, failure to comply with these safety precautions could give table for use with drinking water.
rise, for example, to the following risks: The speed of the pump can be controlled when connected to a
– Failure of important pump or machinery functions, frequency converter (see paragraph 5.3).
– Personal injury due to electrical, mechanical and bacteriological
causes. 4.2 Products delivered
– Damage to property. – high pressure centrifugal pump
10
ENGLISH
– Installation and operating instructions – Check that the mains current and voltage comply with the data on
the rating plate.
4.3 Accessories
– Pump/installation must be earthed in compliance with regulations.
see catalogue or data sheet
– All motors must be fitted with a motor safety switch by the customer
to prevent the motor from overheating.
Adjusting the motor safety switch:
5 Assembly/Installation Direct starting current: Adjust to nominal current of the motor in
accordance with the data on the motor rating plate.
– See the rating plate of the pump and the rating plate of the motor Y-Δ-start: If the motor safety switch is connected as a star or triangu-
5.1 Assembly lar safety circuit combination at the supply line it can be adjusted in the
same way units operating on direct starting current. If the motor safety
Assembly should only take place once all welding switch is connected to the motor supply line in phase (U1/V1/W1 or
WARNING! and soldering work and the rinsing of the pipe net- U2/V2/W2), then the motor safety switch should be adjusted to the
work has been completed. Dirt will damage the pump. value of 0.58 of the nominal motor current.
– Install the pump in a dry place free of frost. – The mains cable can be inserted to the left or the right of the termi-
– Install in a horizontal and flat position. If the pump is positioned on nal box. Open the appropriate hole by removing the moulded cover,
an incline the bearing will wear more quickly. unscrew the PG connector and push the cable through the PG
– Install the pump in an easily accessible place to facilitate inspection connector.
and disassembly. Always install the pump exactly perpendicular on a – The supply cable must be protected against the effects of heat and
sufficiently heavy concrete base (Fig. 2, 3). Fit a vibration absorber vibrations which may come from the motor or the pump.
between the base and the floor. – When using the pump in machinery where the water temperature
– Dimensions for installation and connections are given in Paragraph exceeds 90 °C, a connecting pipe with corresponding heat
1.2.1, Table 2 and in Fig. 3. resistance must be used.
– In the case of heavy pumps fit a hook (Fig. 2, Pos. 12) or eye with a – Connections to the mains must be carried out in accordance with
suitable load-bearing capacity (total weight of pump: see catalogue/ the plan of terminal connections for rotary or alternating current in
data sheet) vertically above the pump, to which a hoist or similar the terminal box of the pump (Fig. 4).
device can be attached when maintaining or repairing the pump. – The terminal box can be better positioned by rotating the motor
Allow for a free size when completed of min. 200 mm. through steps of 90°. To this end the connecting screws (Fig. 1,
Pos. 1) of the lantern (Fig. 1, Pos. 8) and motor flange are to be
– The arrow on the pump casing indicates the direction of flow. loosened.
– Fit the inlet and outlet pipes without stress. Install below expansion In the case of internal connecting screws the clutch guard (Fig. 1,
joints of restricted length to absorb vibrations. The pipes must be Pos. 2) is to be removed beforehand. When assembling the clutch
attached (Fig. 2, 7) in such a way that the pump does not bear the guard, do not forget to tighten the safety screw.
weight of the pipes.
5.3 Operation with frequency converter
– Isolation mechanisms (Fig. 2, 2 & 3) must in principle be installed in
The speed of the pump can be controlled when connected to a
front of and behind the pump to avoid having to empty and refill the
frequency converter.
whole installation when inspecting or changing the pump.
See Installation and Operating Instructions of the frequency converter
– To avoid pressure loss it is recommended that you choose as short
for connection and operation.
an inlet pipe as possible, choose a nominal width for the suction
The frequency converter may not generate a speed due to increased
pipe which is larger by a nominal width than the pump connection
voltage greater than 2500 V/μs and voltage peaks û > 1000 V, as
and avoid constrictions caused by bends and valves.
otherwise the motor coil will be destroyed. If such speeds due to the
– A backflow preventer (Fig. 2, 4) should be fitted in the outlet pipe.
increased voltage are possible, an LC filter (motor filter) should be
– For differential pressures > 6 bar the backflow preventer (Fig. 2,
installed between the frequency converter and the motor.
Pos. 4) is to be fitted in the suction pipe. It is not required at the
outlet.
– The axial face seal should be protected against dry running. An inlet
pressure gauge or level gauge should be installed by the customer.
– If the pump is to be connected indirectly via a reservoir, a suction 6 Commissioning
strainer (Fig. 2, 8) must be provided in the inlet pipe by the customer In order to protect the axial face seal, the pump
to prevent coarse impurities entering the pump.
WARNING!
must not run dry.
– With limited nominal pressure PN, ensure that this pressure is pro- – Close both isolating valves and open the vent screw (Fig. 2, 5) by
duced from the inlet pressure and the zero flow level: one and a half or two turns.
P Inlet ≤ PN - Pmax pump – Slowly open the isolating valve (Fig. 2, 2) at the inlet until the air has
– For gaseous or hot pumping media a bypass pipe is to be fitted to escaped from the vent screw and the fluid to be pumped comes
the pump (Fig. 2, Pos. BP), (accessory). out. The escaping air will be clearly heard hissing. Tighten the vent
screw.
– Slowly open the isolating valve at the outlet (Fig. 2, 3). The mano-
meter installed at the outlet should be checked for any possible
5.2 Electrical connection pressure instabilities, indicated by a flickering manometer pointer. If
the pressure is unstable, allow more air to escape.
Electrical connection should be made by a qualified electri-
When the temperature of the liquid being pumped is high
cian. Current national regulations must be observed (e.g.
and the system is pressurised, any flow escaping from the
VDE regulations in Germany).
vent screw can cause scalding and injuries. The vent
screw should therefore be loosen only slightly.
– When used for the first time, if it is to be used to pump drinking
water the system must be flushed through, so that any dirty water
present will not contaminate the drinking water supply.
– Checking the direction of rotation (only for rotary current motors):
Check that the pump rotates in the same direction indicated by the
arrow on the pump casing by switching on for a short time. If this is
not the case, interchange 2 phases in the terminal box.
11
ENGLISH
For pumps with a star or triangular circuit starting current, the On pumps equipped with greaser under bearing box (table below), see
connections of two coils must be interchanged, e.g. U1 with V1 and greasing instructions written on sticker put on it:
U2 with V2.
– If the fluid temperature is too high, steam may form which may
damage the pump. The pump must therefore not run with the valve
closed for longer than 10 minutes when pumping cold water or for
longer than five minutes when pumping fluid where > 60 °C.
We recommend that the flow rate does not drop to below 10 % of

the nominal flow rate so as to avoid a build up of steam in the pump.
– If there is a build up of steam, this should be allowed to escape by
carefully opening the vent screw.
Both pump and motor can reach operating temperatures
> 100 °C. Therefore exercise caution when touching the Type < 22 kW 22 kW 30 kW 37 kW 45 kW
pump.
MVI 16
7 Maintenance MVI 32 ✔
Before carrying out any maintenance work, switch off the
pump and ensure that it cannot be switched on again by MVI 52 ✔ ✔
unauthorised people. Never carry out work on a running
pump.
– During the running-in period, there may be some dripping from the
MVI 70 ✔ ✔ ✔ ✔
axial face seal. In the event of a serious leak as a result of heavy
wear have the mechanical seal replaced by a specialist. MVI 95 ✔ ✔ ✔ ✔
– Increased bearing noise and unusual vibrations indicate a worn
bearing. In this case, have the bearing replaced by a specialist.
– If the pump is exposed to frost, the pump and pipework must be
emptied in the cold season. Close the isolating valve and open the
drain valve (Fig. 2, 6) and the vent screw (Fig. 2, 5) of the pump.
The isolating valve must be closed before the drain valve is For pumps equipped with coupling bush, check it
opened. before reassembling.
– If placed in a frost-free location, the pump does not have to be emp-
tied, even if it is out of service for a long period.
12
ENGLISH
8 Problems, Causes and Solutions

Problem Cause Solutions
Pump does not run no power check fuses, cables and connections
motor safety switch activated Eliminate motor overload
Pump runs but does not pump Incorrect direction of rotation check direction of rotation and correct if necessary
pipe or pump components blocked by Check and clean pipe and pump
foreign body
air in inlet pipe Seal inlet pipe
inlet pipe too narrow fit a larger inlet pipe
valve not sufficiently open open valve
Pump does not pump evenly air in the pump bleed the pump
Pump vibrates and is noisy foreign body in the pump remove foreign body
pump not properly fixed to the base tighten anchor bolts
bearing damaged consult customer services
Motor overheats one phase interrupted check fuses, cables and connections
motor cut-out activates
pump sluggish:
foreign body clean pump
bearing damaged have pump repaired by customer services
ambient temperature too high provide cooling
If the fault cannot be remedied, please contact your plumbing and heating specialist or your nearest WILO customer services or
representative.
Subject to technical alterations!
13
FRANÇAIS
1 Généralités (fluides contenant de l’huile minérale exécution VITON) et ne contenant

L’installation et la mise en service doivent être réalisées pas de matières abrasives ou à fibres longues. Ses principaux
uniquement par du personnel qualifié! domaines d’application sont les installations de distribution d’eau et
de surpression, les alimentations pour chaudières, les systèmes de
1.1 Applications circulation industriels, la technique des procédés, les circuits d’eau de
La pompe est conçue pour véhiculer de l’eau chaude et froide, ainsi refroidissement, les stations d’incendie ainsi que les stations de lavage
que d’autres fluides dépourvus d’huile minérale en exécution EPDM et les installations d’arrosage.
1.2 Caractéristiques du produit
1.2.1 Raccordement et puissance (tableau 1)
Fluides véhiculés autorisés Eau potable selon prescriptions en vigueur sur l’eau potable
Eau de chauffage / eau chaude sanitaire
Condensat
Mélange eau-glykol 1)
Autres fluides à faible indice de viscosité 2)
Température de fluide autorisée de -15 °C à +120 °C
(Respecter les indications du catalogue)
Température ambiante maximale +40 °C
Pression de service côté aspiration (pression à l'entrée, voir point 5.3) 16/10 bars
maximale admissible: côté refoulement, moteur 2 pôles 16/25 bars
côté refoulement, moteur 4 pôles 16/16 bars
Alimentation TRI: pour P2 ≤ 4 kW TRI ~ 230/400 V ± 10 %, 50 Hz
pour P2 ≥ 5,5 kW TRI ~ 400 V ± 10 %, 50 Hz
Moteur standard pour P2 ≤ 5,5 kW Moteur standard V 18
pour P2 ≥ 7,5 kW Moteur standard V 1
Vitesse de rotation Exécution 2 pôles 2900 tr/mn
Exécution 4 pôles 1450 tr/mn
Protection par fusibles Voir plaque signalétique du moteur
Catégorie de protection d'isolation F
Type de protection IP 55
Autre protection sur demande
1) Si l’on utilise un mélange eau/glycol où la proportion de glycol (ou de fluides véhiculés ne présentant pas la même viscosité que l’eau pure) ne dépasse pas 40 %, il convient
de rectifier les caractéristiques de refoulement de la pompe pour les adapter à la viscosité plus élevée, en fonction des proportions exprimées en pourcentage. N’utiliser que
des produits de marques dotés d’inhibiteurs de protection contre la corrosion, respecter les consignes du fabricant.
2) Lorsque d’autres fluides tels que des produits chimiques agressifs doivent être véhiculés, il convient d’observer scrupuleusement les indications du catalogue et de deman-
der au préalable l’accord de WILO.
Encombrements et diamètres de raccordement (tableau 2, voir également la figure 3):

Types Exécution PN 16 Exécution PN 25
MVI mm mm
1602 1614 DN50 194 252 20 215 130 300 90 125 4x18 194 252 20 215 130 300 90 125 4x18
3202 3216 DN65 235 235 35 195 195 320 105 145 4x18 260 260 35 220 220 320 120 145 8x18
5202 5212 DN80 260 260 30 220 220 320 105 160 8x18 260 260 30 220 220 320 105 160 8x18
7001 7007 DN100 261 350 45 280 199 380 140 180 8x19 261 350 45 280 199 380 140 190 8x23
9501 9506 DN100 261 350 45 280 199 380 140 180 8x19 261 350 45 280 199 380 140 190 8x23
Lors de toute commande de pièces détachées, il convient de mentionner toutes les données de la plaque signalétique.
14
FRANÇAIS
1.2.2 Dénomination 2.4 Consignes de sécurité pour l’utilisateur

MVI 16 08 3 / 16 / E / 3 - 400 - 50 - 2 / XX / X Observer les consignes en vue d’exclure tout risque d’accident.
Exclure les dangers liés à l’énergie électrique. Respecter les consignes
Exécution MVI de la VDE (Union des électrotechniciens allemands) et de votre distri-
(Pompe centrifuge buteur d’électricité local.
multicellulaire verticale
en acier inoxydable) 2.5 Consignes de sécurité pour les travaux d’inspection et de montage
L’utilisateur doit faire réaliser ces travaux par une personne spécialisée
Débit nominal [m3/h] qualifiée ayant pris connaissance du contenu de la notice.
(bipolaire/50 Hz) Les travaux réalisés sur la pompe/l’installation ne doivent avoir lieu que
Nombre de roues si elles sont à l’arrêt.
en alignement 2.6 Modification du matériel et utilisation de pièces de rechange
Qualité des matériaux: non agréées
Hydraulique / support Toute modification de la pompe/l’installation ne peut être effectuée
1 non couvert que moyennant l’autorisation préalable du fabricant. L’utilisation de
2 1.4404 / 1.4408 (AISI 316 L) pièces de rechange d’origine et d’accessoires agréés par le fabricant
3 1.4301 / GG25 (enduit) est une garantie de sécurité. L’utilisation d’autres pièces peut dégager
notre société de toute responsabilité.
Pression maxi admissible (bar)
PN 16 ou PN 25 2.7 Modes d’utilisations non autorisés
La sécurité de fonctionnement de la pompe/installation livrée n’est
Joints d’étanchéité EPDM (KTW/WRAS)
garantie que si les prescriptions précisées au chapitre 1 de la notice
Joints d’étanchéité VITON
d’utilisation sont respectées. Les valeurs indiquées dans le catalogue
Alimentation 3 ~ 400 V ou la fiche technique ne doivent en aucun cas être dépassées, tant en
3 ~ 230 V maximum qu’en minimum.
Fréquence 50 Hz, 60 Hz
Moteur 2 ou 4 pôles
Code fabricant 3 Transport et stockage avant utilisation
Lors du transport et du stockage avant utilisation, la
ATTENTION! pompe doit être protégée contre l’humidité, le gel et
les dommages mécaniques.
2 Sécurité La pompe doit être transportée à l’horizontale. Pendant le stockage
La présente notice contient des instructions primordiales, qui doivent avant utilisation, veiller à ce que la pompe ne subi se pas de chocs en
être respectées lors du montage et de la mise en service. C’est pour- cas de chute éventuelle.
quoi elle devra être lue attentivement par le monteur et l’utilisateur et
ce impérativement avant le montage et la mise en service. Il y a lieu
d’observer non seulement les instructions générales de sécurité de ce
point principal mais aussi les prescriptions de sécurité spécifiques
4 Description du produit et de ses accessoires
abordées dans les points suivants. 4.1 Description de la pompe
2.1 Signalisation des consignes de la notice La pompe est une pompe centrifuge haute pression multicellulaire
Les consignes de sécurité contenues dans cette notice qui, en cas de (1–16 cellules) non auto-amorçante et à axe vertical, installée en ligne,
non-observation, peuvent représenter un danger pour les personnes, c’est-à-dire que les tubulures d’aspiration et de refoulement se trou-
sont symbolisées par le logo suivant: vent sur une même ligne. La pompe est proposée en 2 exécutions de
pression, PN 16 et PN 25 avec bride circulaire faisant corps avec la
pièce coulée.
, La pompe (figure 1) se trouve dans une plaque d’assise en fonte grise
assurant la fixation du fondement (13). Les carters à étages (4) sont
ou cet autre logo pour prévenir les chocs électriques des constructions en plusieurs parties composées de plusieurs élé-
ments. Les roues (10) sont montées sur un arbre unique (11). Le carter
de pression (5) assure l’étanchéité pour garantir le fonctionnement.
Tous les éléments en contact avec le fluide comme les corps d’étage,
les roues mobiles, les carters de pression sont en acier au chrome-
Les consignes de sécurité dont la non-observation peut représenter nickel, la plaque d’assise (12) à brides (6) en fonte grise 25 enduite
un danger pour l’installation et son fonctionnement sont indiquées par (jusqu’à 85 °C) ou en acier au chrome-nickel (sur demande).
le mot: L’étanchéité au passage de l’arbre est assurée par une garniture
étanche à anneau glissant (3).
ATTENTION!
Les MVI32C, MVI52C, MVI70 et MVI95 sont
2.2 Qualification du personnel
équipées d’un système cartouche permettant le
Le personnel chargé du montage doit posséder les compétences
remplacement de la garniture sans démontage de
requises.
la partie hydraulique.
2.3 Dangers encourus en cas de non-observation des consignes
La non-observation des consignes de sécurité peut avoir des consé-
quences graves sur la sécurité des personnes et sur l’installation. Elle La fonction “spacer” permet son remplacement sans dépose du
peut également entraîner la suspension de tout recours en garantie. moteur sur les MVI32C, MVI52C, MVI70 et MVI95. Les arbres de la
Plus précisément, les dangers encourus peuvent être les suivants: pompe et du moteur sont reliés l’un à l’autre à l’aide d’un dispositif
– défaillance de fonctions importantes de la pompe/l’installation, d’accouplement (9). Toutes les pièces de l’installation pour eau pota-
– Dangers pour les personnes par influences électrique, mécanique ou ble (exécution E) en-trant en contact avec le liquide sont agréées KTW
bactériologique, ou WRAS et conviennent dès lors à toute application utilisant de l’eau
– Dégâts matériels. potable.
15
FRANÇAIS
Une connexion à un variateur de fréquence permet de régler la vitesse – En limitant la pression à l’entrée à 10 bar maxi, il convient de veiller à
de rotation de la pompe (voir point 5.3). ce que cette pression soit obtenue à partir de la pression nominale
PN et la hauteur de refoulement nulle:
4.2 Etendue de la fourniture P entrée ≤ PN - Pmaxi pompe
– Pompe centrifuge haute pression – Pour les fluides véhiculés chargés en gaz ou brûlants, il convient
– Notice de montage et de mise en service d’installer un by pass sur la pompe (figure 2, réf. BP), (accessoire).
4.3 Accessoires
Voir catalogue/feuille de données. 5.2 Raccordement électrique
Le raccordement électrique doit être effectué par un élec-
tricien agréé, conformément aux prescriptions locales en
5 Installation/Montage vigueur.
– Respecter les indications des plaques signalétiques de la pompe et – La nature du courant et la tension d’alimentation doivent correspon-
du moteur. dre aux indications figurant sur la plaque signalétique.
– La pompe/l’installation doivent être mises à la terre conformément
5.1 Montage aux instructions.
Le montage devra être réalisé après avoir terminé – Tous les moteurs doivent être équipés d’un discontacteur de protec-
ATTENTION! toutes les opérations de soudage et de brasage et, tion moteur assurant une protection par fusibles contre toute
le cas échéant, le nettoyage de la tuyauterie. La saleté risque en effet surcharge du moteur.
de gêner le fonctionnement correct de la pompe. Réglage du discontacteur de protection moteur:
Courant de démarrage direct: Réglez le courant nominal du moteur
– Installez la pompe dans un endroit sec et à l’abri du gel.
en fonction des indications de la plaque signalétique.
– La surface d’installation doit être horizontale et plane. Toute inclinaison
Courant de démarrage Y-triangle: Si le discontacteur de protection
de la pompe provoque l’usure prématurée du palier, seul un fonc-
moteur est connecté à l’alimentation comme une combinaison de cir-
tionnement en position verticale est autorisé.
cuit Y-triangle, le réglage s’effectue exactement de la même façon que
– Placez la pompe dans un endroit facile d’accès afin de simplifier les
dans le cas d’un courant de démarrage direct. Si le discontacteur de
travaux d’entretien et de démontage. La pompe doit toujours être
protection moteur est connecté en phase avec l’alimentation moteur
montée parfaitement à la verticale sur un socle en béton suffisam-
(U1/V1/W1 ou U2/V2/W2), il doit être réglé sur la valeur 0,58 x le cou-
ment lourd (figure 2, réf. 13). Placez des amortisseurs de vibrations
rant nominal du moteur.
entre le socle et le sol.
– Le câble de réseau peut, au choix, être placé à gauche ou à droite
– Les dimensions de montage et les côtes de raccordement sont
de la boîte à bornes. A cet effet, on ouvre le trou correspondant en
reprises dans le tableau 2 au point 1.2.1, ainsi qu’à la figure 3.
ôtant le couvercle prédécoupé, en vissant les raccords à vis PG et
– Dans le cas de pompes particulièrement lourdes, placez verticale-
en poussant la conduite de raccordement à travers les raccords à
ment au-dessus de la pompe un crochet ou un anneau pourvu
vis PG.
d’une force portante appropriée (poids total de la pompe: voir cata-
– Il convient de protéger la conduite de raccordement contre les influ-
logue/fiche technique) afin de pouvoir, pour l’entretien ou une répa-
ences thermiques et vibratoires pouvant provenir du moteur ou de la
ration, accrocher la pompe à un engin de levage ou à un autre outil
pompe.
similaire. Tenir compte d’une dimension libre après complètement de
– Si l’on utilise la pompe dans des installations dont la température du
minimum 200 mm.
fluide véhiculé dépasse 90 °C, il convient d’utiliser un câble de rac-
cordement résistant à une telle chaleur.
– La flèche sur le corps de pompe indique le sens de circulation du – Le raccordement au réseau doit être effectué conformément au
fluide. schéma de raccordement pour courant triphasé dans la boîte à
– Veillez à monter les tuyauteries d’aspiration et de refoulement sans bornes de la pompe (figure 4).
tension. Installez des compensateurs de dilatation afin d’absorber – En faisant pivoter le moteur (figure 1, réf. 7) de 90 °C, on peut placer
les vibrations. Les tuyauteries doivent être fixées (figure 2, réf. 7) de la boîte à bornes dans une position éventuellement plus appropriée.
sorte que leur poids ne soit pas supporté par la pompe. Pour ce faire, dévissez les vis de jonctions (figure 1, réf. 1) de la lan-
– En principe, il convient de placer des vannes de sectionnement (figu- terne (figure 1, réf. 8) et du connecteur du moteur.
re 2, réf. 2 et 3) en amont et en aval de la pompe; ce qui évitera de Pour les vis de jonction encaissées, on enlèvera au préalable la pro-
vider puis de remplir de nouveau la totalité de l’installation lors d’une tection d’accouplement (figure 1, réf. 2). Lorsque vous remonterez
vérification ou du remplacement de la pompe. cette dernière, n’oubliez pas de resserrer les vis de fixation.
– Limiter la longueur des tuyauteries d’aspiration et éviter toute cause 5.3 Fonctionnement avec variateur de fréquence
de pertes de charge (rétrécissement, coudes . . .). Il est possible de régler la vitesse de rotation de la pompe à l’aide d’un
– Il convient de prévoir un clapet antiretour (figure 2, réf. 4) sur la tubu- variateur de fréquence (bande passante 20–50 Hz).
lure de refoulement. Il convient de respecter les instructions de montage et de mise en ser-
– Pour des pressions différentielles supérieures à 6 bars, on installera vice du variateur de fréquence lors du raccordement et de la mise en
le clapet antiretour (figure 2, réf. 4) dans la tuyauterie d’aspiration. fonctionnement.
On pourra s’en passer côté refoulement. Le variateur de fréquence ne devra pas générer de crête de tension
– La garniture étanche à anneau glissant doit être protégée contre le supérieure à 2500 V/μs et des pointes de tension û > 1000 V, provo-
fonctionnement à sec. Il convient d’installer un dispositif de contrôle quant un risque de nuisance sonore et de dégradation du bobinage
de la pression d’admission ou du niveau. moteur. Si tel est le cas, on installera un filtre LC (filtre moteur) entre le
– En cas de raccordement indirect sur bâche par ex., la tuyauterie variateur de fréquence et le moteur.
d’aspiration doit être équipée d’une crépine d’aspiration (figure 2,
réf. 8), afin d’éviter que des impuretés n’entrent dans la pompe.
6 Mise en service
ATTENTION! Pour une protection optimale de la garniture
étanche à anneau glissant, la pompe ne devra
jamais fonctionner à sec.
– Fermez les deux vannes d’arrêt, tournez de 1,5 à 2 tours la vis de
dégazage (figure 2, réf. 5).
– Ouvrez lentement la vanne d’arrêt (figure 2, réf. 2) côté aspiration,
jusqu’à ce que l’air s’échappe de la vis de dégazage et que le fluide
16
FRANÇAIS
véhiculé s’écoule. L’air qui s’échappe est clairement audible par le – Si l’endroit n’est pas protégé contre le gel ou dans le cas de mises
sifflement produit. Resserrez la vis de dégazage. hors service prolongées, les pompes et les conduites doivent être
– Ouvrez lentement la vanne d’arrêt côté refoulement (figure 2, réf. 3). vidées pour l’hiver. Fermez les vannes d’arrêt et ouvrez la vis de
Vérifiez sur le manomètre installé côté refoulement s’il y a une éven- vidange (figure 2, réf. 6) et la vis de dégazage de la pompe (figure 2,
tuelle instabilité de pression, reconnaissable à l’oscillation du mano- réf. 5).
mètre. En cas de pression instable, il convient de recommencer
l’opération de purge de l’air. Les vannes d’arrêt doivent absolument être fermées avant
Lorsque l’on travaille avec des températures de fluides d’ouvrir la vis de vidange.
véhiculés élevées et des pressions importantes, le jet s’éch-
appant de la vis de dégazage peut occasionner des brûlu- – En cas d’arrêt prolongé, s’il n’y a pas de risque de gel, il est décon-
res et des blessures. C’est pourquoi la vis de dégazage ne seillé de vidanger la pompe.
peut être desserrée que très légèrement.
Pour les pompes équipées d'un graisseur sous le boîtier de roulement
– Lors de la première mise en service et si le liquide refoulé est de (tableau ci-dessous), voir les instructions de graissage figurant sur
l’eau potable, il convient de nettoyer le système correctement afin l'étiquette collée sur celui-ci :
d’éviter l’entrée d’eau souillée dans la conduite d’eau potable.
– Contrôle du sens de rotation pour les moteurs à courant triphasé:
vérifiez, par le biais d’une brève mise en marche, si le sens de rota-
tion de la pompe correspond à la flèche figurant sur la lanterne. Si
ce n’est pas le cas, il convient de permuter 2 phases au bornier
moteur.
Dans le cas de pompes dotées d’un circuit de démarrage étoile/tri-
angle, il faut permuter les connexions de deux bobines, par exemple
U1 et V1, et U2 et V2.
– Si la température du liquide véhiculé est trop élevée, la formation de
vapeur peut endommager la pompe. La pompe ne peut donc fonc-
tionner plus de 10 minutes en eau froide, ou plus de 5 minutes à Type < 22 kW 22 kW 30 kW 37 kW 45 kW
plus de 60 °C à débit nul (vanne de refoulement fermée).
Afin d’éviter la formation d’une poche gazeuse dans la pompe, il faut
veiller à ce que le débit ne soit pas inférieur à 10 % du débit nominal. MVI 16
– Si l’on observe effectivement une formation de vapeur, il convient
d’évacuer l’air de la pompe en ouvrant prudemment la vis de déga- MVI 32 ✔
zage.
La pompe, moteur compris, peut atteindre une tempéra- MVI 52 ✔ ✔
ture de fonctionnement > 100 °C. Attention aux risques de
brûlure. MVI 70 ✔ ✔ ✔ ✔
MVI 95 ✔ ✔ ✔ ✔
7 Entretien
Avant d’entamer des travaux d’entretien, veillez à mettre
l’installation hors tension et assurez-vous qu’aucune remi-
se en fonctionnement non autorisée n’est possible.
N’effectuez aucune tâche lorsque la pompe fonctionne. Pour les pompes équipées d’un tampon
– Pendant le temps de démarrage, il faut s’attendre à trouver des gout- d’accouplement, s’assurer du bon état avant
tes d’eau sur la garniture étanche à anneau glissant. Si les fuites sont tout remontage.
plus importantes en raison d’une usure plus marquée, faites rempla-
cer la garniture étanche par un technicien qualifié.
– Une augmentation des bruits en provenance du palier et des vibrati-
ons inhabituelles témoignent de l’usure du palier. Faites-le remplacer
par un technicien qualifié.
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8 Pannes, causes et remèdes

Problèmes Causes Remèdes
La pompe ne fonctionne pas Pas d’alimentation de courant Vérifier les fusibles, le câblage et les connexions
Le dispositif de protection du moteur a assuré la Eliminer toute surcharge du moteur
mise hors tension
La pompe fonctionne, mais ne Sens de rotation incorrect Vérifier le sens de rotation et le rectifier au besoin
débite pas La conduite ou les organes internes de la pompe Contrôler et nettoyer la conduite et la pompe
sont obstrués par des corps étrangers
Présence d’air dans la tuyauterie d’aspiration Rendre étanche la tuyauterie d’aspiration
tuyauterie d’aspiration trop étroite Installer une plus grande tuyauterie d’aspiration
La vanne n’est pas suffisamment ouverte Ouvrir la vanne
La pompe ne refoule pas de Présence d’air dans la pompe Evacuer l’air contenu dans la pompe
façon régulière
La pompe vibre ou fait du bruit Présence de corps étrangers dans la pompe Eliminer tous les corps étrangers
La pompe n’est pas bien fixée au socle Resserrer les vis d’ancrage
Palier endommagé Faire appel au SAV
Le moteur surchauffe Une phase est coupée Vérifier les fusibles, le câblage et les connexions
La protection du moteur s’enclenche La pompe est difficile à manier:
corps étrangers Nettoyer la pompe
palier endommagé Faire réparer la pompe par le SAV
Température ambiante trop élevée Assurer le refroidissement
S’il n’est pas possible de remédier au défaut, veuillez faire appel à un installateur agréé ou au SAV WILO le plus proche.
Sous réserve de modifications techniques!
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1 Introduzione
Per l’installazione e la messa in esercizio, rivolgersi
esclusivamente a personale specializzato materiale a fibroso. I campi d’applicazione principali sono gli impianti di
distribuzione idrica e aumento di pressione, di alimentazione caldaie,
1.1 Campo di applicazione sistemi di circolazione per applicazioni industriali, tecnica dei tratta-
La pompa è adatta per applicazioni nel sollevamento d’acqua calda, menti, circuiti idraulici di raffreddamento, sistemi antincendio, come
acqua fredda e liquidi non contenenti oli minerali, sostanze abrasive o anche autolavaggi e impianti d’irrigazione.
1.2 Specifiche tecniche
1.2.1 Caratteristiche e prestazioni (tabella 1)
materiali consentiti acqua potabile in base alla normativa vigente sull’acqua potabile
acqua di riscaldamento/acqua industriale
condensa
miscela acqua glicole 1)
altri liquidi 2)
temperatura media consentita da -15 °C a +120 °C
(attenersi alle istruzioni del presente manuale)
Massima temperatura ambiente +40 °C
Massima pressione d’esercizio (pressione all’entrata, vedere punto 5.3) 16/10 bar
ammessa lato aspirazione lato mandata, motore a 2 poli 16/25 bar
lato mandata, motore a 4 poli 16/16 bar
Tensioni di alimentazione DM: per P2 ≤ 4 kW 3 ~ 230/400 V ± 10 %, 50 Hz
per P2 ≥ 5,5 kW 3 ~ 230 V ± 10 %, 50 Hz
Motore standard per P2 ≤ 5,5 kW Motore standard V 18
per P2 ≥ 7,5 kW Motore standard V 1
Velocità di rotazione Modello a 2 poli 2900 1/min
Modello a 4 poli 1450 1/min
Protezione con fusibili lato alimentazione vedere la piastrina di identificazione del motore
classe di isolamento F
Tipo di protezione IP 55
Tipi di protezione superiori a richiesta
1) Sono consentite miscele di acqua e glicole non superiori alla percentuale di glicole del 40 % (oppure materiali con una viscosità diversa da quella dell’acqua pura), indipen-
dentemente dal rapporto percentuale tra i componenti la miscela e data l’elevata viscosità, è necessario correggere le prestazioni della pompa. Impiegare solo inibitori della
corrosione di qualità reperibili in commercio, applicare tutte le indicazioni del fabbricante allegate al prodotto.
2) Analogamente, per sollevare altre sostanze chimiche liquide nocive seguire scrupolosamente le indicazioni del presente manuale e rivolgersi a WILO.
Dimensioni principali e quote di collegamento (tabella 2, vedere anche figura 3):
Types Esecuzione PN16 Esecuzione PN25

MVI mm mm
1602 1614 DN50 194 252 20 215 130 300 90 125 4x18 194 252 20 215 130 300 90 125 4x18
3202 3216 DN65 235 235 35 195 195 320 105 145 4x18 260 260 35 220 220 320 120 145 8x18
5202 5212 DN80 260 260 30 220 220 320 105 160 8x18 260 260 30 220 220 320 105 160 8x18
7001 7007 DN100 261 350 45 280 199 380 140 180 8x19 261 350 45 280 199 380 140 190 8x23
9501 9506 DN100 261 350 45 280 199 380 140 180 8x19 261 350 45 280 199 380 140 190 8x23
Contestualmente all’ordine dei ricambi fornire tutti i dati contenuti nella targhetta di identificazione della pompa e del motore.
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1.2.2 Prospetto di riferimento 2.4 Norme di sicurezza per l’utente

MVI 16 08 3 / 16 / E / 3 - 400 - 50 - 2 / XX / X Applicare e rispettare tutte le norme antinfortunistiche.
Sono esclusi tutti i danni imputabili alla errori nella fornitura di energia
Tipo MVI elettrica. Rispettare le norme e leggi nazionali e locali relative all’eroga-
(Pompa centrifuga zione dell’energia elettrica sul territorio.
multistadio verticale,
in acciaio (inox)) 2.5 Norme di sicurezza per il montaggio e l’ispezione
È necessario che tutte le operazioni di montaggio e di controllo siano
Portata [m3/h] eseguite da personale qualificato dopo attenta lettura del presente
(bipolare / 50 Hz) manuale.
Numero stadi In generale, effettuare gli interventi sull’apparecchiatura quando non è
in funzione o sotto tensione elettrica.
Tipo materiale:
parte idraulica / parte esterna 2.6 Modifiche e pezzi di ricambio
1 senza rivestimento Qualsiasi modifica alle apparecchiature, alle macchine o agli impianti
2 1.4404 / 1.4408 (AISI 316 L) deve essere preventivamente concordata e autorizzata dal costruttore.
3 1.4301 / GG25 L’uso di pezzi di ricambio originali e di accessori autorizzati garantis-
3 (con rivestimento) cono la sicurezza delle apparecchiature e delle macchine. L’impiego di
parti o accessori non originali può pregiudicare la sicurezza e invalidare
Massima pressione d’esercizio
la garanzia.
ammessa (bar) PN 16 o PN 25
2.7 Condizioni di esercizio non consentite
guarnizioni EPDM (KTW/WRAS)
La sicurezza di funzionamento è assicurata solo per gli usi e le condi-
guarnizioni VITON
zioni descritti nel capitolo 1 del presente manuale. I valori limite indicati
Tensione di alimentazione 3 ~ 400 V sono vincolanti e non possono essere superati per nessun motivo.
3 ~ 230 V
Frequenza 50 Hz, 60 Hz
3 Trasporto e magazzinaggio
Motore a 2 oppore 4 poli
Durante le operazioni di trasporto e di magazzi-
Codice costruttore ATTENZIONE! naggio è necessario proteggere la pompa da umi-
dità, gelo e danni meccanici.
Il gruppo deve essere trasportato in posizione orizzontale. Durante il
2 Sicurezza magazzinaggio, è necessario proteggere la pompa da eventuali oscil-
lazioni che possano causarne la caduta.
Il presente manuale fornisce indicazioni fondamentali per l’installazione
e l’avvio della pompa. Prima di procedere all’installazione e alla messa
in servizio della pompa è necessario leggere attentamente le indica- 4 Descrizione del prodotto e degli accessori
zioni in esso contenute. Oltre al rispetto delle norme di sicurezza in
generale, devono essere rispettati tutti i punti specificamente e spe- 4.1 Descrizione della pompa
cialmente contrassegnati. Pompa centrifuga multistadio (1–16 giranti) ad alta pressione, normal-
mente aspirante, albero verticale e bocche in linea, tubazione di aspi-
2.1 Simboli utilizzati nelle istruzioni razione e di mandata si trovano sulla stessa linea. La pompa è dispo-
In questo manuale sono inserite informazioni e prescrizioni contras- nibile con due pressioni d’esercizio, PN 16 e PN 25 con flange circolari
segnati con simboli. Il mancato rispetto delle indicazioni di sicurezza in fusione.
contrassegnate dal simbolo di pericolo La pompa (figura 1) appoggia su una piastra in ghisa utilizzata per il
fissaggio al basamento (13). Le camere stadi (4) sono composti da
diverse parti, a loro volta costituiti da diversi elementi. Le giranti (10)
sono montate su un albero unico (11). La tenuta meccanica (5) garan-
o dal simbolo di pericolo corrente elettrica tisce la tenuta e assicura la sicurezza di funzionamento.
Tutte le parti a contatto con i liquidi pompati come le camere stadi, le
giranti e la camera di pressione sono realizzate in acciaio inossidabile.
Il basamento (12) con le flange (6) può essere in ghisa (GG) 25 rivestita
(fino a 85 °C) oppure in acciaio inossidabile (solo su richiesta). La tenuta
può nuocere all’incolumità delle persone e all’integrità delle cose. meccanica (3) garantisce la tenuta nel punto in cui l’albero esce dal
Il mancato rispetto delle norme di sicurezza contrassegnate con la parola corpo pompa.
ATTENZIONE!
può costituire pericolo per l’integrità e la funzionalità delle appa- MVI32C, MVI52C, MVI70 e MVI95 sono forniti di un
recchiature e delle macchine. sistema cartuccia che permette la sostituzione della
guarnizione senza smontaggio della parte idraulica.
2.2 Personale qualificato
Il personale addetto al montaggio deve possedere la qualifica neces-
saria all’espletamento del compito. La funzione "spacer" permette la sua sostituzione senza dépose del
motore sul MVI32C, MVI52C, MVI70 e MVI95.
2.3 Pericoli conseguenti al mancato rispetto delle norme di sicurezza Gli alberi pompa e motore sono accoppiati tramite
L’inosservanza delle indicazioni di sicurezza può rappresentare un peri- un sistema di accoppiamento (9). La pompa per acqua potabile
colo per le persone e per l’integrità delle apparecchiature e delle (modello E), ha tutti i componenti a contatto col liquido conformi alle
macchine. Il mancato rispetto delle indicazioni di sicurezza farà deca- norme KTW o WRAS e quindi adatte ad applicazioni per uso alimentare.
dere ogni diritto alla garanzia. Collegando la pompa al convertitore di frequenza consente di regolare
Le conseguenze dell’inosservanza delle indicazioni di sicurezza pos- la velocità di rotazione e di conseguenza le prestazioni idrauliche
sono essere: (vedere punto 5.3).
– guasti delle funzioni primarie dell’apparecchiatura,
– rischi di natura elettrica, batteriologica e/o meccanica per le persone. 4.2 Fornitura
– danni materiali. – Pompa centrifuga ad alta pressione
– Istruzioni di montaggio e installazione
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4.3 Accessori 5.2 Collegamenti elettrici

Vedere catalogo/tabella dati.
I collegamenti elettrici devono essere eseguiti da un instal-
latore elettrico qualificato, certificato ed essere conformi
alle leggi e norme CEI vigenti.
5 Istruzioni di montaggio e installazione
– Il tipo di rete e la tensione devono coincidere con le indicazioni ripor-
– Rispettare le indicazioni riportate sulla targhetta dati della pompa e tate sulla targhetta dati della pompa.
del motore. – Eseguire la messa a terra della pompa e dell’impianto nel rispetto
delle norme.
5.1 Montaggio
– I motori devono essere muniti di un salvamotore contro i sovraccarichi.
Effettuare il montaggio solo al termine delle opera- Taratura del salvamotore:
ATTENZIONE! zioni di saldatura e brasatura e dopo aver pulito a Corrente d’avviamento diretta: tarare la corrente nominale del motore
fondo le tubazioni. La presenza di sporcizia impedisce il corretto fun- secondo l’indicazione della targhetta dati.
zionamento della pompa. Corrente con avviamento stella-triangolo: se il salvamotore è colle-
– Installare la pompa in un luogo asciutto e al riparo dal gelo. gato sull’alimentazione rete, la taratura è esattamente identica alla
– La superficie d’installazione deve essere orizzontale e piana. Le incli- corrente d’avviamento diretta. Se il salvamotore è collegato sui con-
nazioni della pompa provocano l’usura prematura del supporto: il duttori di l’alimentazione del motore (U1/V1/W1 o U2/V2/W2), tarare al
funzionamento è ammesso solo in posizione verticale. valore 0,58 x la corrente nominale del motore.
– Posizionare la pompa in luogo accessibile onde facilitare le operazioni – Il cavo di rete può essere introdotto, a scelta, a sinistra o a destra
d’ispezione e smontaggio. La pompa deve essere montata esclusi- della morsettiera dei collegamenti. Allo scopo, scoprire il foro deside-
vamente in posizione perfettamente verticale e su un basamento in rato rimuovendo il coperchio, avvitare il pressacavo PG e guidare i
cemento sufficientemente pesante (figura 2, rif. 13). Inserire materiale conduttori attraverso il pressacavo PG.
assorbente le vibrazioni tra il basamento pompa e il pavimento. – Proteggere i conduttori di collegamento dal calore e dalle vibrazioni
– Le dimensioni di montaggio e le quote di collegamento sono ripor- provenienti dal motore o dalla pompa.
tate nella tabella 2 al punto 1.2.1. e anche alla figura 3. – Quando la pompa è utilizzata in impianti con temperatura dell’acqua
– Nel caso di pompe pesanti è consigliabile installare sopra la pompa superiore a 90 °C, utilizzare un cavo di collegamento resistente al
un gancio (figura 2, rif. 12) o un occhiello con portata adeguata (per calore.
il peso complessivo della pompa vedere il manuale e il foglio tec- – Il collegamento alla rete deve essere effettuato in conformità con lo
nico). Ciò facilita il sollevamento della pompa durante la manutenzio- schema elettrico riportato all’interno del coperchio morsettiera della
ne o le eventuali riparazioni. È necessario tenere conto della pompa (figura 4).
possibile dilatazione delle parti, pari a minimo 200 mm. – Ruotando il motore (figura 1, rif. 7) di 90°, è possibile collocare la
morsettiera in posizione più corretta. Allo scopo, allentare le viti di
connessione (figura 1, rif. 1) fra corpo pompa (figura 1, rif. 8) e motore.
– La freccia sul corpo pompa indica la direzione del flusso.
Estrarre le viti di connessione interne prima di rimuovere la prote-
– Montare le tubazioni di aspirazione e mandata evitando tensioni
zione dell’accoppiamento (figura 1, rif. 2). Nel rimontare la protezione
meccaniche sulla pompa. Utilizzare compensatori antivibranti di
dell’accoppiamento, non dimenticare di stringere le viti di fissaggio.
lunghezza limitata. Le condotture devono essere fissate (figura 2,
rif. 7) in modo che il peso non gravi sulla pompa. 5.3 Funzionamento con convertitore di frequenza
– Predisporre sempre a valle e a monte della pompa dei rubinetti È possibile regolare la velocità di rotazione della pompa con un con-
d’intercettazione (figura 2, rif. 2 e 3); al occasione di verifiche o sosti- vertitore di frequenza.
tuzione della pompa, non sarà necessario svuotare e riempire di Per il collegamento e la messa in funzione, rispettare le istruzioni di
nuovo l’intero impianto. montaggio e di installazione del convertitore di frequenza.
– Al fine di evitare perdite di pressione è consigliabile posare la con- Per evitare il sovraccarico, il danneggiamento e l’insorgere di rumori
duttura di mandata più corta possibile. Allo stesso modo, scegliere indesiderati, il convertitore di frequenza non deve generare picchi di
per la tubazione di aspirazione un diametro nominale di dimensioni tensione superiori a 1000 V e avere la velocità di salita superiore a
superiori a quelle del raccordo della pompa, evitare strozzature con 2500 V/μs. Quando il convertitore di frequenza non è in grado di assi-
tubi, gomiti e valvole. curare i parametri menzionati, inserire un filtro LC (filtro motore) fra
– Installare una valvola di non ritorno (figura 2, rif. 4) nella tubazione di convertitore e motore.
mandata.
– In presenza di differenze di pressione superiori a 6 bar, installare una
valvola di non ritorno sulla tubazione di aspirazione. Sul lato manda-
ta l’installazione non è necessaria.
6 Messa in eservizio
– La tenuta meccanica deve essere protetta dal funzionamento a La pompa non può funzionare a secco. Il funzio-
secco. Installare il dispositivo di protezione contro la marcia a secco. ATTENZIONE! namento in queste condizioni (anche per breve
– Nel collegamento indiretto al serbatoio, per evitare che le impurità tempo) danneggia irrimediabilmente la tenuta meccanica.
raggiungano l’interno della pompa, la tubazione di aspirazione deve – Chiudere le due valvole d’intercettazione, girare da 1,5 a 2 giri la vite
essere munita di un filtro a griglia (figura 2, rif. 8). di spurgo aria (figura 2, rif. 5).
– Nella limitazione della pressione d’ingresso a max. 10 bar, tenere in – Aprire lentamente la valvola d’intercettazione (figura 2, rif. 2) lato
considerazione che tale pressione è data dalla pressione nominale aspirazione, fino alla completa fuoriuscita dell’aria dalla vite di
con portata nulla: spurgo. L’aria che esce è chiaramente udibile dal sibilo prodotto.
P mandata ≤ PN - Pmax della pompa Stringere la vite di spurgo dell’aria.
– In caso d’impiego con liquidi contenenti gas o ad alta temperatura è – Aprire lentamente la valvola d’intercettazione sulla mandata (figura 2,
necessario collegare la pompa con un by-pass (figura 2, rif. BP), rif. 3). Verificare, sul manometro posto sul lato mandata, possibili
(Accessorio). irregolarità della pressione indicate dalle oscillazioni del manometro
stesso. In presenza di irregolarità di pressione, ricominciare le ope-
razione di spurgo dell’aria.
Con temperature elevate dei liquidi pompati e pressioni ele-
vate, il getto dalla vite di spurgo dell’aria può causare ustioni
e ferite. Allentare con cautela la vite di scarico.
– Alla prima messa in esercizio e con il pompaggio di acqua potabile,
per evitare l’arrivo di acqua sporca nelle condutture dell’acqua pota-
bile, pulire il sistema in maniera corretta.
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– Controllo del senso di rotazione (solo per i motori a corrente tri- – Se la pompa si trova in un luogo ben protetto dal gelo, non è neces-
fase): verificare, con una breve messa in esercizio, se il senso di sario svuotarla neppure in caso di disattivazione prolungata.
rotazione della pompa corrisponde a quello della freccia sul corpo
della pompa. In caso contrario, occorre scambiare 2 fasi del collega-
mento a rete.
Sulle pompe con avviamento stella / triangolo, è necessario scambi- Per le pompe fornite di un lubrificatore sotto la cassa di rotolamento
are i collegamenti di due avvolgimenti, per esempio U1 con V1 e U2 (tabella qui di seguito), vedere le istruzioni di lubrif cazione che appaio-
con V2. no sull'etichetta attaccata su quest'ultimo
– In caso di temperatura elevata del liquido pompato, la fuori uscita di
vapore può provocare guasti alla pompa. Pertanto, la pompa non
può funzionare più di 10 minuti con acqua fredda, o più di 5 minuti
con liquidi alla temperatura > 60 °C e con saracinesca chiusa.
Per evitare la formazione di vapore all’interno della pompa, accertarsi
che la portata non sia inferiore al 10 % della portata nominale.
– Se viene riscontrata una formazione di vapore, occorre scaricare
l’aria dalla pompa aprendo con prudenza la vite di spurgo.
Il motore della pompa può raggiungere una temperatura di
esercizio > 100 °C. Prendere le precauzioni necessarie
quando si deve toccare la pompa.
Type < 22 kW 22 kW 30 kW 37 kW 45 kW
7 Manutenzione MVI 16
Prima di effettuare operazioni di manutenzione, accertare
che l’impianto non sia sotto tensione e che sia impossibile MVI 32 ✔
la rimessa in funzione non autorizzata. Nessuna opera-
zione va effettuata durante il funzionamento della pompa. MVI 52 ✔ ✔
– All’accensione, è possibile trovare gocce d’acqua sulla tenuta mec-
canica. Quando la perdita è abbondante denota un’usura marcata, MVI 70 ✔ ✔ ✔ ✔
fare sostituire la tenuta meccanica da uno specialista qualificato.
– Rumori persistenti provenienti dal supporto e vibrazioni insolite indi-
MVI 95 ✔ ✔ ✔ ✔
cano che il cuscinetto è usurato. Farlo sostituire da personale qualifi-
cato.
– Quando il luogo d’installazione non è protetto da gelo oppure in
caso di messa a riposo prolungata, svuotare le pompe e le condut-
ture per il periodo invernale. Chiudere i rubinetti di arresto, aprire la
vite di scarico (figura 2, rif. 6) e la vite di spurgo dell’aria della pompa
(figura 2, rif. 5). Per le pompe fornite di un tappo d’accoppiamen-
to, garantirsi del buono stato prima di qualsiasi
rimontaggio.
Le valvole di arresto devono essere assolutamente chiuse
prima di aprire la vite di spurgo.
22
ITALIANO
8 Risoluzione di problemi
Problema Causa Soluzione
La pompa non funziona Non arriva tensione alla pompa Verificare i fusibili, il cablaggio e i collegamenti
Il salvamotore è intervenuto Eliminare le cause di sovraccarico al motore
La pompa funziona ma non manda Senso di rotazione errato Verificare il senso di rotazione, se necessario,
acqua correggerlo
Condotti o elementi della pompa ostruiti da corpi Controllare e pulire il condotto e la pompa
estranei
Presenza d’aria all’interno della tubazione di Sigillare la tubazione di aspirazione

aspirazione
Tubazione di aspirazione troppo piccola Installare una tubazione di aspirazione più grande
L’apertura della saracinesca non è sufficiente Aprire la saracinesca
La portata della pompa non è regolare Aria nella pompa Scaricare l’aria all’interno della pompa
La pompa vibra o fa rumore Corpi estranei all’interno della pompa Eliminare i corpi estranei
La pompa non è fissata correttamente alla base Serrare le viti di fissaggio
Supporti albero danneggiati Rivolgersi al servizio assistenza tecnica
Il motore surriscalda Una fase interrotta Verificare i fusibili, il cablaggio e i collegamenti

Interviene protezione del motore
La gestione della pompa è difficoltosa:
corpi estranei Pulire la pompa
supporto danneggiato Fare riparare la pompa dal servizio assistenza

tecnica
Temperatura ambiente eccessiva Assicurare le condizioni di raffreddamento
Se nonostante questi interventi gli inconvenienti persistono richiedere l’intervento dell’installatore oppure del Servizio Assistenza WILO
Con riserva di modifica!
23
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PLANT AUXILIARIES
HOT GAS GENERATOR AND ITS
AUXILIARIES - 1
JOB NO.17-3610
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JOB NO.17-3610
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ƐŽůĞƌĞƐƉŽŶƐŝďŝůŝƚǇŽĨƚŚĞŽƉĞƌĂƚŝŶŐƉĞƌƐŽŶŶĞů͘

JOB NO.17-3610
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Attention !

It is imperative that Part 1 is read and scrupulously applied -
Part 1 concerns safety recommendations which are of paramount importance for the
Prevention of accidents.
All information concerning safety and operation should be read before using the equipment

supplied.

This guide should be made available to all users by the person to whom it is addressed.
It is necessary to follow any precautions which are mentioned.

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• dŚĞŽƉĞƌĂƚŽƌƐĂƐǁĞůůĂƐƚŚŽƐĞƌĞƐƉŽŶƐŝďůĞĨŽƌŵĂŝŶƚĞŶĂŶĐĞŵƵƐƚďĞĐŽŵƉĞƚĞŶƚ͕ĂŶĚƚŽŚĂǀĞĂĐƋƵŝƌĞĚƚŚĞ
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ǁŚŝĐŚƚŚĞƐĞhƐĞƌΖƐŐƵŝĚĞůŝŶĞƐŚĂǀĞďĞĞŶǁƌŝƚƚĞŶ͘
• dŚĞ hƐĞƌΖƐ ŐƵŝĚĞůŝŶĞƐ ĂƌĞ ŶŽƚ ĞǆŚĂƵƐƚŝǀĞ͘ /ƚƐ ƉƵƌƉŽƐĞ ŝƐ ůŝŵŝƚĞĚ ƚŽ ďĞŝŶŐ Ă ŐƵŝĚĞ ƚŽ ƌĞĂĚĞƌƐ ĂůƌĞĂĚǇ
ƉƌĞƐƵŵĞĚĐŽŵƉĞƚĞŶƚǁŝƚŚŬŶŽǁůĞĚŐĞŽĨƚŚĞƐƚĂŶĚĂƌĚŽĚĞƐŽĨWƌĂĐƚŝĐĞ͘/ĨŝƚĐŽŶƚĂŝŶƐĂŶǇŽŵŝƐƐŝŽŶŽƌĂŶǇ
ĞǀĞŶƚƵĂů ŝŵƉƌĞĐŝƐĞ ŝŶƐƚƌƵĐƚŝŽŶƐ͕ ƚŚŝƐ ĐĂŶŶŽƚ ďĞ ƵƐĞĚ ƚŽ ƐŚŽǁ &^W> ƌĞƐƉŽŶƐŝďŝůŝƚǇ ŝŶ ƉĂƌƚ ĨŽƌ ĂŶǇ ǁƌŽŶŐ
ŽƉĞƌĂƚŝŽŶ Žƌ ŵŝƐƚĂŬĞ ŝŶ ŽƉĞƌĂƚŝŶŐ Žƌ ŵĂŝŶƚĞŶĂŶĐĞ͕ Žƌ ƚŽ ƐŚŽǁ ƚŚĂƚ &^W> ƌŽůĞ ĂƐ ĂĚǀŝƐŽƌ ŚĂƐ ŶŽƚ ďĞĞŶ
ĨƵůĨŝůůĞĚ͘
• &^W>ĐĂŶŶŽƚĂĐĐĞƉƚƌĞƐƉŽŶƐŝďŝůŝƚǇǁŚĞŶƚŚĞĨĂƵůƚƐŽďƐĞƌǀĞĚŚĂǀĞƚŚĞŝƌƐŽƵƌĐĞŝŶĞƋƵŝƉŵĞŶƚǁŚŝĐŚŚĂƐŶŽƚ
ďĞĞŶƐƵƉƉůŝĞĚďǇƚŚĞŵ͘
/Ŷ ƉĂƌƚŝĐƵůĂƌ͕ ƚŚŝƐ ŝƐ ƚŚĞ ĐĂƐĞ ǁŚĞŶ ďƵƌŶĞƌ ŵĂŶĂŐĞŵĞŶƚ ƐǇƐƚĞŵƐ Žƌ ĞůĞĐƚƌŝĐ ǁŝƌŝŶŐƐ Žƌ ƐŽŵĞ ŝŶƐƚƌƵŵĞŶƚ
ĐŽŶƚƌŽůƐǇƐƚĞŵƐĂƌĞŶŽƚŽĨ&^W>ƐƵƉƉůǇĂŶĚƚŚĂƚƐƵĐŚĞƋƵŝƉŵĞŶƚŝƐĚĞĨĞĐƚŝǀĞ͘
• dŚĞ ĐŽŶĚŝƚŝŽŶ ŽĨ ĞǆŝƐƚŝŶŐ ĞƋƵŝƉŵĞŶƚ Ăƚ ƐŝƚĞ ǁŚŝĐŚ ŝƐ ŶŽƚ ĐŽǀĞƌĞĚ ďǇ Ă ĐŽŶƚƌĂĐƚƵĂů ŐƵĂƌĂŶƚĞĞ ƉĞƌŝŽĚ ďǇ
&^W>͕ Ɛƚŝůů ŝŶ ĨŽƌĐĞ Ăƚ ƚŚĞ ŵŽŵĞŶƚ ŽĨ ƚŚĞ ĐĂƌƌǇŝŶŐ ŽƵƚ ŽĨƚŚĞĐŽŶƚƌĂĐƚͲŝŶƉĂƌƚŝĐƵůĂƌŶĞǁĞƋƵŝƉŵĞŶƚŶŽƚ
ƐƵƉƉůŝĞĚ ďǇ &^W> ĂŶĚ ŽůĚĞƌ ĞƋƵŝƉŵĞŶƚ ŽƵƚ ŽĨ ŐƵĂƌĂŶƚĞĞ͕ ǁŚĂƚĞǀĞƌ ƚŚĞ ŽƌŝŐŝŶ͕ ĨŽƌ ǁŚŝĐŚ ĂĚĞƋƵĂƚĞ
ŵĂŝŶƚĞŶĂŶĐĞďǇƚŚĞĐůŝĞŶƚĚĞƚĞƌŵŝŶĞƐŝƚƐĐŽŶĚŝƚŝŽŶƐͲŝƐŽĨƚŚĞĐůŝĞŶƚƐƌĞƐƉŽŶƐŝďŝůŝƚǇ͖ƚŚĞĐůŝĞŶƚƌĞĐŽŐŶŝƐĞƐ
ŚĂǀŝŶŐƚĂŬĞŶĂůůŶĞĐĞƐƐĂƌǇŵĞĂƐƵƌĞƐƚŽĞŶĂďůĞƚŚĞŝƌƵƐĞĚƵƌŝŶŐƚŚĞĐĂƌƌǇŝŶŐŽƵƚŽĨƚŚĞĐŽŶƚƌĂĐƚĂƐƉĞƌƚŚĞ
ƵƐƵĂůƌĞŐƵůĂƚŝŽŶƐ͕ƐƵĐŚƚŚĂƚƚŚĞǇǁŽƌŬǁŝƚŚŽƵƚĨĂƵůƚ͘
• hŶůĞƐƐ ǁƌŝƚƚĞŶ ŽƚŚĞƌǁŝƐĞ ĂŶĚƐƚŝƉƵůĂƚĞĚŝŶƚŚĞƚĞǆƚŽĨƚŚĞĐŽŶƚƌĂĐƚĨŽƌƚŚĞƉƌĞƐĞŶƚŐƵŝĚĞ͕ƚŚĞŝŶƐƚĂůůĂƚŝŽŶ
ŵƵƐƚďĞƉůĂĐĞĚ;ďǇƚŚĞůŝĞŶƚͿƵŶĚĞƌƉĞƌŵĂŶĞŶƚŚƵŵĂŶƐƵƌǀĞŝůůĂŶĐĞ͘
• dŚĞ&^W>ƉĞƌƐŽŶŶĞůĂƌĞƵŶĚĞƌŽƌĚĞƌƐĨƌŽŵƚŚĞůŝĞŶƚΖƐƌĞƉƌĞƐĞŶƚĂƚŝǀĞŝŶƚŚĞŚĞĂƚŝŶŐƉůĂŶƚ;ŽƌŽŶƚŚĞƐŝƚĞͿ
ĂƐ Ă ƐƵďͲƐƵƉƉůŝĞƌ ƐĞƌǀŝĐĞŵĂŶ͘ dŚĞ ůŝĞŶƚ ĂƐƐƵŵĞƐ ƚŚĞ ƌŽůĞ ŽĨ ŵĂŝŶ ĐŽŶƚƌĂĐƚŽƌ͖ ŶŽƚĂďůǇ ĞƐƚĂďůŝƐŚŝŶŐ
ĐŽŶĚŝƚŝŽŶƐ ĂŶĚ ƉůĂŶŶŝŶŐ ŽƉĞƌĂƚŝŽŶƐ͘ dŚĞ &^W> ƉĞƌƐŽŶŶĞů ĨŽůůŽǁ ŚŝƐ ŝŶƐƚƌƵĐƚŝŽŶƐ ĂŶĚ ŐŝǀĞƐ ĂƐƐŝƐƚĂŶĐĞ ŝŶ
ŽƌĚĞƌƚŽĐĂƌƌǇŽƵƚƚŚĞƚĂƐŬƐĞǆƉĞĐƚĞĚ͘
dŚĞĐŽŶƚƌŽůĂŶĚĐƵƐƚŽĚǇŽĨƚŚĞůŝĞŶƚΖƐŝƚĞŵƐƐŚĂůůŶŽƚďĞƚƌĂŶƐĨĞƌƌĞĚƚŽ&^W>͕ĂŶĚƐŚĂůůƌĞƐƚ͕ĂƚĂůůƚŝŵĞƐ͕
ǁŝƚŚƚŚĞůŝĞŶƚ͘
ZKDDEd/KE^KEZE/E'^&dz

• &ŽůůŽǁŝŶŐƵƌŽƉĞĂŶƐƚĂŶĚĂƌĚƐĂďŽƵƚƐĂĨĞƚǇŝŶĨŽƌĐĞĐŽŶĐĞƌŶŝŶŐŚĞĂƚŝŶŐƉůĂŶƚƐ;ŝŶƉĂƌƚŝĐƵůĂƌƚŚĞĚĞĐŝƐŝŽŶŶŽ͘
ϵϵͲϭϬϰϲĚĂƚĞĚϭϯ͘ϭϮ͘ϭϵϵϵĂŶĚĚĞĐƌĞĞĚĂƚĞĚϭϱ͘Ϭϯ͘ϮϬϬϬƌĞůĂƚĞĚƚŽƚŚĞƌƵŶŶŝŶŐŽĨƉƌĞƐƐƵƌŝǌĞĚĞƋƵŝƉŵĞŶƚ͕
ŽƌŵŽƌĞŐĞŶĞƌĂůůǇƚŚĞƵƌŽƉĞĂŶŝƌĞĐƚŝǀĞϵϳͬϮϯͬĚĂƚĞĚϮϵ͘Ϭϱ͘ϭϵϵϳͿŝƐŵĂŶĚĂƚŽƌǇ͘tŚĞŶŶŽƐƚĂŶĚĂƌĚŝƐ
ĂƉƉůŝĐĂďůĞ ƚŚĞ ƌĞƐƉĞĐƚ ŽĨ ƚŚĞ K ;ŽůůŽƋƵĞ ƵƌŽƉĠĞŶ ĞƐ KƌŐĂŶŝƐŵĞƐ ĚĞ ŽŶƚƌŽůͿ ƌĞĐŽŵŵĞŶĚĂƚŝŽŶƐ ŝƐ
ĂĚǀŝƐĞĚďǇ&^W>͘
• ŝƐƚĂŶĐĞ ďĞƚǁĞĞŶ ƚŚĞ ůĂƐƚ Žŝů ƐŚƵƚͲŽĨĨ ǀĂůǀĞ ĂŶĚ ƚŚĞ ďƵƌŶĞƌ͗ ĨŽƌ ƐĂĨĞƚǇ ƌĞĂƐŽŶƐ͕ ƚŚŝƐ ĚŝƐƚĂŶĐĞ ŵƵƐƚ ďĞ
ƌĞĚƵĐĞĚĂƐŵƵĐŚĂƐƉŽƐƐŝďůĞ͘ŵĂǆǀĂůƵĞŽĨĂďŽƵƚϭŵŝƐĂĚǀŝƐĂďůĞ͘
JOB NO.17-3610
KWZd/KEED/EdEEDEh>
• ůůƚŚĞƉĞƌƐŽŶŶĞůĐŽŶĐĞƌŶĞĚŵƵƐƚďĞƋƵĂůŝĨŝĞĚĂŶĚĐŽŵƉĞƚĞŶƚ͘
• ZĞƉůĂĐŝŶŐ ĞƋƵŝƉŵĞŶƚ ǁŝƚŚ ŽƚŚĞƌƐ ŽŶ ƚŚĞ ďƵƌŶĞƌ ůŝŶĞƐ ŵĂǇ ďĞ ĚĂŶŐĞƌŽƵƐ͘ EŽƚĂďůǇ ƚŚĞ ƌĞƉůĂĐĞŵĞŶƚ ŽĨ Ă
ǁŽƌŶƉĂƌƚďǇĂŶĞǁŽŶĞ;ŽƌĂĐůŽŐŐĞĚƉĂƌƚďǇĂĐůĞĂŶŽŶĞͿŽŶĂĐŽŵďƵƐƚŝďůĞĨƵĞůůŝŶĞŽƌĂƚŽŵŝƐŝŶŐĨůƵŝĚůŝŶĞ
;ĐŽŵƉƌĞƐƐĞĚĂŝƌ͕ƐƚĞĂŵͿŵĂǇůĞĂĚƚŽĂŵŽĚŝĨŝĐĂƚŝŽŶŽĨƚŚĞĨƵĞůĨůŽǁŽƌŽĨƚŚĞĐŽŵďƵƐƚŝǀĞĨůŽǁůĞĂĚŝŶŐƚŽĂ
ĨƵĞůͬĐŽŵďƵƐƚŝǀĞ ƌĂƚŝŽ ŵŽĚŝĨŝĐĂƚŝŽŶ ǁŚŝĐŚ ĐŽƵůĚ ĂůůŽǁ ƐƵď ƐƚŽĐŚŝŽŵĞƚƌŝĐ ŽƉĞƌĂƚŝŽŶ ;ƌĞůĞĂƐŝŶŐ ƵŶďƵƌŶƚ
ĞǆƉůŽƐŝǀĞ ŐĂƐ ŝŶ ƚŚĞ ĨƵƌŶĂĐĞͿ Žƌ ǁŝƚŚ ƚŽŽ ŵƵĐŚ ĞǆĐĞƐƐ Ăŝƌ ;ĐƌĞĂƚŝŶŐ ĨůĂŵĞ ŝŶƐƚĂďŝůŝƚǇ͕ ƌŝƐŬ ŽĨ ĞǆƉůŽƐŝŽŶͿ͘
^ŝŵŝůĂƌƌŝƐŬƐĞǆŝƐƚǁŚĞŶŵŽĚŝĨǇŝŶŐĨƵŶĐƚŝŽŶƐ͕ĂĚũƵƐƚŵĞŶƚƐ͕ƉĂƌĂŵĞƚĞƌƐĂŶĚƚŝŵŝŶŐƐŝŶĨůƵĞŶĐŝŶŐƐĂĨĞƚǇ͘dŚĞ
ůŝĞŶƚŵƵƐƚƚĂŬĞƉĂƌƚŝĐƵůĂƌĐĂƌĞǁŚĞŶĚŽŝŶŐƐŽ͘
• dŚĞŽĐĐƵƌƌĞŶĐĞŽĨƚŚĞĨŽůůŽǁŝŶŐĞǀĞŶƚƐĐĂƵƐĞƐĂŶŝŵŵĞĚŝĂƚĞƐŚƵƚĚŽǁŶĂŶĚƉƌĞǀĞŶƚĂƚŝǀĞŵĞĂƐƵƌĞƐǁŚŝĐŚ
ĐĂůůĨŽƌĐŽŵƉĞƚĞŶƚƉĞƌƐŽŶŶĞů͗
∗ ĨůĂŵĞƐĂƌĞŶŽƚŝŵŵĞĚŝĂƚĞůǇĞǆƚŝŶŐƵŝƐŚĞĚǁŚĞŶŝŶƐƚƌƵĐƚŝŽŶŝƐŐŝǀĞŶƚŽƐŚƵƚͲŽĨĨĨƵĞůƐƵƉƉůǇ͕
∗ ůĞĂŬŽĨŵĂŝŶĨƵĞů͕ŽƌŝŐŶŝƚŝŽŶĨƵĞůĞŝƚŚĞƌŝŶƚĞƌŶĂůŽƌĞǆƚĞƌŶĂů͕
∗ ŝŶƐƵĨĨŝĐŝĞŶƚĐŽŵďƵƐƚŝǀĞƉƵƌŐĞƚŝŵĞďĞĨŽƌĞƌĞůŝŐŚƚŝŶŐƵƉ͕
∗ ƉŽŽƌĞůĞĐƚƌŝĐĂůŝƐŽůĂƚŝŽŶ͕
∗ ƐƵƐƉŝĐŝŽƵƐŽĚŽƵƌǁŚŝĐŚĐŽƵůĚďĞĚƵĞƚŽĂůĞĂŬŽƌƉŽŽƌĐŽŵďƵƐƚŝŽŶ͕
∗ ƌŝƐŬŽĨƌĂŐƐ͕ĐĂůĂŵŝŶĞ͕ĚĞƉŽƐŝƚƐŝŶƐŝĚĞĨƵĞůůŝŶĞƐŽƌĐŽŵďƵƐƚŝǀĞĚƵĐƚƐ͕
∗ ĨŝƌŝŶŐƵŶĚĞƌůĂĐŬŽĨĂŝƌŽƌǁŝƚŚŚŝŐŚĞǆĐĞƐƐĂŝƌ͕
∗ ƵŶƐƚĂďůĞĨůĂŵĞ;ƐͿ͕
∗ ŝŶƐƚĂďŝůŝƚǇŽĨƉƌŽĐĞƐƐƉŚǇƐŝĐĂůǀĂůƵĞƐŽƌŽĨŵĞĂƐƵƌĞŵĞŶƚƐĂŶĚĂĐƚŝŽŶƐ͕
∗ ƵŶƵƐƵĂůǀŝďƌĂƚŝŽŶƐ͕ŽƌŶŽŝƐĞƐ͕ŽĨŵĞĐŚĂŶŝĐĂůŽƌĂĐŽƵƐƚŝĐĂůŽƌŝŐŝŶ͕
∗ ŝŵƉƌĞĐŝƐŝŽŶŽĨŵĞĐŚĂŶŝƐŵƐĨŽƌƐĞƚƚŝŶŐĨƵĞů͕ĐŽŵďƵƐƚŝǀĞ͕ĂƚŽŵŝǌŝŶŐĨůƵŝĚĨůŽǁƐ͘
• dŚĞĨŽůůŽǁŝŶŐĨĂĐƚƐĂƌĞĚĂŶŐĞƌŽƵƐ͕ĂŶĚĂŐĂŝŶƐƚWƌŽĨĞƐƐŝŽŶĂůŽĚĞƐŽĨWƌĂĐƚŝĐĞ͗
∗ ůĂĐŬ ŽĨ ĐŽŵƉůŝĂŶĐĞ ǁŝƚŚ ^ƚĂŶĚĂƌĚƐ Žƌ WƌŽĨĞƐƐŝŽŶĂů ŽĚĞƐ ŽĨ WƌĂĐƚŝĐĞ ŽĨ ƚŚĞ ƐƚĂƌƚͲƵƉ ƐĞƋƵĞŶĐĞ Žƌ
ĂƐƐŽĐŝĂƚĞĚƚŝŵĞƉĞƌŝŽĚƐ͕ŶŽƚĂďůǇĚƵĞƚŽŵŽĚŝĨŝĐĂƚŝŽŶƐ͕
∗ ĂďŶŽƌŵĂů ĂĚũƵƐƚŵĞŶƚ ŽĨ ƐĂĨĞƚǇ ŝŶƐƚƌƵŵĞŶƚƐ ĐŽŵƉŽŶĞŶƚ ƚŚƌĞƐŚŽůĚƐ ;ƉƌĞƐƐƵƌĞ͕ ƚĞŵƉĞƌĂƚƵƌĞ ƐǁŝƚĐŚĞƐ͕
ůŝŵŝƚƐǁŝƚĐŚĞƐ͕ĞƚĐͿ͕
∗ ƐŚƵŶƚ͕ ďǇͲƉĂƐƐ Žƌ ĚŝƐĐŽŶŶĞĐƚŝŽŶ ŽĨ ĐŽŵƉŽŶĞŶƚƐ ŝŶƐƚƌƵŵĞŶƚƐ͕ ĚĞƚĞĐƚŽƌƐ͕ ƉƌŽďĞƐ ǁŚŝĐŚ ĂƌĞ ŝŶǀŽůǀĞĚ ŝŶ
ƐĂĨĞƚǇŽƌŝŶĂůĂƌŵ͕ŶŽƚĂďůǇ͗
ĨůĂŵĞĚĞƚĞĐƚŽƌ;ƐͿ͕ŽƌƵƐĞŽĨĨůĂŵĞĚĞƚĞĐƚŽƌ;ƐͿǁŚŝĐŚĂƌĞĂůƌĞĂĚǇŬŶŽǁŶƚŽďĞƵŶƌĞůŝĂďůĞŽƌƵŶƐƵƌĞĂŶĚ
ŚĂǀŝŶŐƉƌĞƐĞŶƚĞĚƐŽŵĞŽƉĞƌĂƚŝŽŶĂůĚŝƐĐƌĞƉĂŶĐŝĞƐ͕
∗ ůĞĂǀŝŶŐ Ă ĐŽŵƉŽŶĞŶƚ Žƌ ŝŶƐƚƌƵŵĞŶƚ ŝŶǀŽůǀĞĚ ŝŶ ƐĂĨĞƚǇ Žƌ ŝŶ ĂůĂƌŵ ŝŶ ŽƉĞƌĂƚŝŽŶ ǁŚŝĐŚ ŚĂƐ ĂůƌĞĂĚǇ
ƉƌĞƐĞŶƚĞĚƐŽŵĞŽƉĞƌĂƚŝŽŶĂůĚŝƐĐƌĞƉĂŶĐŝĞƐ͕
∗ ƌĞĚƵĐŝŶŐƚŚĞĐŽŵďƵƐƚŝǀĞƉƵƌŐŝŶŐƚŝŵĞƐĞƋƵĞŶĐĞƐĨŽƌƚŚĞĨƵƌŶĂĐĞͬŐĞŶĞƌĂƚŽƌĂŶĚĨůƵĞŐĂƐĚƵĐƚƐ͕
∗ ŝŶƚĞƌǀĞŶƚŝŽŶƐŽŶƚŚĞŚĞĂƚŝŶŐĞƋƵŝƉŵĞŶƚǁŝƚŚŽƵƚƐƚŽƉƉŝŶŐĐŽŵďƵƐƚŝŽŶ͕
∗ ƵƐĞŽĨĂŶŝŶĚƵƐƚƌŝĂůƉƌŽŐƌĂŵŵĂďůĞĐŽŶƚƌŽůůĞƌ;/WͿǁŚŝĐŚŝƐŶŽƚƐĞĐƵƌĞĚďǇĂƐĞƉĂƌĂƚĞƌŝƐŬĐŚĂŝŶƌŝƐŝŶŐ
ƌĞůĂǇƐĨŽƌƚŚĞĞƐƐĞŶƚŝĂůƐĂĨĞƚŝĞƐŽĨƚŚĞŐĞŶĞƌĂƚŽƌ͕
∗ ŵŽĚŝĨŝĐĂƚŝŽŶ ŽĨ ƐŽĨƚǁĂƌĞ ǁŚŝĐŚ ůĞĂĚƐ ƚŽ ĂŶǇ ŽĨ ƚŚĞ ĂďŽǀĞ ĞǀĞŶƚƐ͘ ƌĞĐŽƌĚŝŶŐ ŽĨ Ăůů ƐŽĨƚǁĂƌĞ
ŵŽĚŝĨŝĐĂƚŝŽŶƐ;ĞǀĞŶŵŝŶŽƌͿŵƵƐƚďĞĂǀĂŝůĂďůĞŝŶŽƌĚĞƌƚŽĐŽŶĨŝƌŵƚŚĂƚŶŽƌŝƐŬĞǆŝƐƚƐ͕
∗ ƵƐĞ ŽĨ Ă ƉƌŽŐƌĂŵ ƐƚŽƌĞĚ ŝŶ Ă ZD ;ǀŽůĂƚŝůĞ ŵĞŵŽƌǇͿ͕ Ăůů ƉƌŽŐƌĂŵƐ ŵƵƐƚ ďĞ ƐƚŽƌĞĚ ŝŶ Ă ŶŽŶͲǀŽůĂƚŝůĞ
ŵĞŵŽƌǇ͕
∗ ƵƉƐĞƚƚŝŶŐƚŚĞĂŝƌͬĨƵĞůƌĂƚŝŽĨŽƌƐŽŵĞŽƉĞƌĂƚŝŽŶĂůƉŚĂƐĞƐŽĨƚŚĞĐŽŵďƵƐƚŝŽŶ͕
∗ ŝŐŶŝƚŝŽŶĂƚƚŽŽŚŝŐŚĂůŽĂĚ͕
∗ ŝŶǀĞƌƚŝŶŐƚŚĞĐŽŶŶĞĐƚŝŽŶƐŽŶĂůŝŵŝƚƐǁŝƚĐŚ͕
∗ ƵƉƐĞƚƚŝŶŐ ƐĂĨĞƚǇ ƐŚƵƚͲŽĨĨ ƚŝŵĞƐ ĨŽƌ ƚŚĞ ďƵƌŶĞƌ;ƐͿ ǁŚŝĐŚ ĂƌĞ ƐĞƚ ďǇ ƐƚĂŶĚĂƌĚƐ ŝŶ ĨŽƌĐĞ Žƌ K
ƌĞĐŽŵŵĞŶĚĂƚŝŽŶƐ͕
∗ ƐƚĂƌƚͲƵƉŽĨĂŶĞůĞĐƚƌŽƐƚĂƚŝĐƉƌĞĐŝƉŝƚĂƚŽƌƵŶŝƚďĞĨŽƌĞĐŽŵƉůĞƚĞƉƵƌŐŝŶŐŽĨƚŚĞĨƵƌŶĂĐĞͬŐĞŶĞƌĂƚŽƌĂŶĚĨůƵĞ
ŐĂƐĚƵĐƚƐŽĨĂƚůĞĂƐƚϯƚŝŵĞƐƚŚĞƚŽƚĂůǀŽůƵŵĞĂƚĂĨůŽǁǁŚŝĐŚŵƵƐƚďĞĂƚůĞĂƐƚϱϬйŽĨƚŚĞŵĂǆŝŵƵŵĨůŽǁ
;ŽƌϰƚŝŵĞƐƚŚĞƚŽƚĂůǀĂůƵĞ͕ďƵƚĨůŽǁŚĂƐƚŽďĞϰϬйŽĨŵĂǆŝŵƵŵͿ͕
∗ ĨŽƌĐŝŶŐǀĂůǀĞƐƚŽŽƉĞŶŽƌƐŚƵƚƉŽƐŝƚŝŽŶŽƌŵĂŶƵĂůŽƉĞƌĂƚŝŽŶŚĂǀŝŶŐĂŶŝŶĨůƵĞŶĐĞŽŶƚŚĞŶŽƌŵĂůƉŽƐŝƚŝŽŶ
ŽĨǀĂůǀĞƐ͕ĐŽĐŬƐ͕ĚĂŵƉĞƌƐ͕ƌĞŐŝƐƚĞƌƐ͕ŝŶĐůŝŶĞƌƐ͕ĞƚĐ͘͘͘ĨƵĞů͕ĐŽŵďƵƐƚŝǀĞ͕ŝŐŶŝƚŝŽŶĨƵĞů͕ĂƚŽŵŝǌŝŶŐĨůƵŝĚ͕
JOB NO.17-3610
KWZd/KEED/EdEEDEh>
∗ ŵĞĐŚĂŶŝĐĂů ĚŝƐĐŽŶŶĞĐƚŝŽŶ ŽĨ Ă ĐŽŵŵĂŶĚ ;ďǇ ƌŽĚ ĂƐƐĞŵďůǇ Žƌ ŽƚŚĞƌǁŝƐĞͿ ŽĨ ǀĂŶĞƐ͕ ĐŽĐŬƐ͕ ĚĂŵƉĞƌƐ͕
ƌĞŐŝƐƚĞƌƐ͕ ŝŶĐůŝŶĞƌƐ͕ ĞƚĐ͘͘͘ ŽŶ ĨƵĞů ĐŽŵďƵƐƚŝǀĞ ŝŐŶŝƚŝŽŶ ĨƵĞů͕ ĂƚŽŵŝǌŝŶŐ ĨůƵŝĚ͕ ŝĨ ƚŚĞ ƵŶŝƚ ŝƐ ŶŽƚ ƐŚƵƚĚŽǁŶ
;ƐƚŽƉƉĞĚͿ͕
∗ ƚŚĞ ƉƌĞƐĞŶĐĞ ŽĨ ǁĂƚĞƌ͕ Žŝů Žƌ ŝŵƉƵƌŝƚŝĞƐ ŝŶ ƚŚĞ ĐŽŵƉƌĞƐƐĞĚ Ăŝƌ ƵƐĞĚ ĨŽƌ ƐĂĨĞƚǇ ƐǇƐƚĞŵƐ Žƌ ĐŽŶƚƌŽů
ƐǇƐƚĞŵƐ͕
∗ ĂďŶŽƌŵĂů ƉƌĞƐƐƵƌĞ Ăƚ ƐƵƉƉůǇ ƉŽŝŶƚƐ ĨŽƌ ĐŽŵƉƌĞƐƐĞĚ Ăŝƌ ĨŽƌ ƐĂĨĞƚǇ ĐŽŶƚƌŽů͘ dŚŝƐ ƉƌĞƐƐƵƌĞ͕ ƚĂŬŝŶŐ ŝŶƚŽ
ĂĐĐŽƵŶƚĞǀĞŶƚƵĂůƐƵƉƉůǇĨůƵĐƚƵĂƚŝŽŶƐŽĨƚŚĞŶĞƚǁŽƌŬ͕ƐŚĂůůŝŶĂůůĞǀĞŶƚƵĂůŝƚŝĞƐƐƚĂǇ͗
− ĂƚůĞĂƐƚϭďĂƌĂďŽǀĞƚŚĞŵŝŶŝŵƵŵƉƌĞƐƐƵƌĞƐƉĞĐŝĨŝĞĚŝŶƚŚĞĐŽŶƚƌĂĐƚ͕
− ĂƚůĞĂƐƚϭďĂƌůŽǁĞƌƚŚĂŶƚŚĞŵĂǆŝŵƵŵƉƌĞƐƐƵƌĞƐƉĞĐŝĨŝĞĚŝŶƚŚĞĐŽŶƚƌĂĐƚ͕
ĂƚƚŚĞŝŶůĞƚŽĨĞĂĐŚƐĂĨĞƚǇĐŽŵƉŽŶĞŶƚĐŽŶĐĞƌŶĞĚ͕
∗ ƉƌĞƐĞŶĐĞ ŽĨ ĐŽŶĚĞŶƐĞĚ ǁĂƚĞƌ ŝŶ ƚŚĞ ĂƚŽŵŝǌŝŶŐ ƐƚĞĂŵ ůŝŶĞ ŽĨ ƚŚĞ ďƵƌŶĞƌ;ƐͿ ;ƐƵĐŚ ƉƌĞƐĞŶĐĞ ĐĂƵƐĞƐ ďĂĚ
ůŝƋƵŝĚĨƵĞůĂƚŽŵŝǌĂƚŝŽŶŝŶƚŚĞĨƵƌŶĂĐĞǁŝƚŚƉŽƐƐŝďůĞĂĐĐƵŵƵůĂƚŝŽŶŽĨƵŶďƵƌŶƚŐĂƐŽƌĞǀĞŶůŝƋƵŝĚĚĞƉŽƐŝƚƐ͖
ŝƚŵĂǇĂůƐŽůĞĂĚƚŽĂŵŽĚŝĨŝĐĂƚŝŽŶŽĨƚŚĞůŝƋƵŝĚĨƵĞůĨůŽǁĂŶĚĐŽŬĞĚĞƉŽƐŝƚƐŽŶƚŚĞďƵƌŶĞƌŚĞĂĚĐĂƵƐŝŶŐĂ
ĚĞƚĞƌŝŽƌĂƚŝŽŶŝŶĐŽŵďƵƐƚŝŽŶĐŽŶĚŝƚŝŽŶƐͿ͕
∗ ĂďŶŽƌŵĂůƉƌĞƐƐƵƌĞŽƌĨůŽǁŽĨĨƵĞů͕
∗ ĂďŶŽƌŵĂůƉƌĞƐƐƵƌĞŽĨƚŚĞĂƚŽŵŝǌŝŶŐƐƚĞĂŵ͕
∗ ŝŶǀĞƌƚŝŶŐĐŝƌĐƵŝƚƐĐŽŶƚƌŽůůŝŶŐĐŽŵƉƌĞƐƐĞĚĂŝƌĨŽƌƐĂĨĞƚǇ͕
∗ ŝŶǀĞƌƚŝŶŐƚŚĞ&ůĞǆŝďůĞŚŽƐĞŽƌƉŝƉŝŶŐĐŽŶŶĞĐƚŝŽŶƐƚŽƚŚĞďƵƌŶĞƌƐ͕
∗ ŝŶǀĞƌƚŝŶŐƚŚĞĂƐƐĞŵďůǇŽƌĚĞƌĂŶĚͬŽƌƉŽƐŝƚŝŽŶŝŶŐŽƌĚĞƌŽĨďƵƌŶĞƌĂƚŽŵŝǌŝŶŐƐĞƚƐ͕
∗ ŶĞǁĂƚƚĞŵƉƚƚŽƐƚĂƌƚƚŚĞĨƵƌŶĂĐĞͬŐĞŶĞƌĂƚŽƌĂĨƚĞƌŽŶĞĂďŽƌƚĞĚƚƌǇǁŝƚŚŽƵƚĂŶǇƉĂƌƚŝĐƵůĂƌƉƌĞĐĂƵƚŝŽŶ͘/ƚŝƐ
ĐƌƵĐŝĂůĂĨƚĞƌŽŶĞĨĂŝůĞĚĂƚƚĞŵƉƚ͕ĂŶĚďĞĨŽƌĞĂŶǇĨƵƌƚŚĞƌĂƚƚĞŵƉƚ͕ƚŽĨŝŶĚŽƵƚƚŚĞƌĞĂƐŽŶĨŽƌƚŚĞĨĂŝůƵƌĞ
ƚŚĞŶƚŽƌĞƐŽůǀĞƚŚĞƉƌŽďůĞŵ͕ĂŶĚƚŽĐĂƌƌǇŽƵƚĂĨƵƌŶĂĐĞͬŐĞŶĞƌĂƚŽƌĂŶĚĨůƵĞŐĂƐĚƵĐƚƐƉƵƌŐĞĨŽƌĂŵƵĐŚ
ůŽŶŐĞƌƉĞƌŝŽĚƚŚĂŶƵƐƵĂů͕
∗ ŝŶƐƵĨĨŝĐŝĞŶƚĐůĞĂŶŝŶŐŽĨƚŚĞƉŝƉŝŶŐďĞĨŽƌĞĂŶĞǁƐƚĂƌƚͲƵƉǁŚŝĐŚĐŽƵůĚďĞďůŽĐŬĞĚŽƌĐůŽŐŐĞĚďǇĂŶǇƚŚŝŶŐ
ƐƵĐŚĂƐĚĞƉŽƐŝƚƐ͕ŝŵƉƵƌŝƚŝĞƐ͕ƌĂŐƐ͕ĨůƵĨĨ͕ĐĂůĂŵŝŶĞ͕ǁĞůĚŝŶŐďŝƚƐ͕ĂůƐŽĂƉƉůǇŝŶŐƚŽĨƵĞůĨůŽǁĐŽŶƚƌŽůǀĂůǀĞƐ
;ůŝƋƵŝĚ Žƌ ŐĂƐ ĨƵĞůƐͿ͕ ŝŶ ƉĂƌƚŝĐƵůĂƌ ǁŚĞŶ ƉŝƉĞǁŽƌŬ ŵŽĚŝĨŝĐĂƚŝŽŶƐ ŚĂǀĞ ďĞĞŶĐĂƌƌŝĞĚŽƵƚǁŚĞƌĞǁĞůĚŝŶŐƐ
ŚĂǀĞďĞĞŶŵĂĚĞ͘
ůůĚĞƉŽƐŝƚƐŽƌĐůŽŐŐŝŶŐƐŵƵƐƚďĞƌĞŵŽǀĞĚĂƐƚŚĞǇŵĂǇĞŝƚŚĞƌďůŽĐŬŽƌĞůƐĞďĞĐŽŵĞůŽĚŐĞĚŝŶƐŝĚĞĂƐŚƵƚͲ
ŽĨĨĚĞǀŝĐĞĂŶĚŝŵƉĞĚĞŝƚƐĐůŽƐŝŶŐŽƌŝƚƐƐĞĂůŝŶŐ͘
• ĨƚĞƌĂŶǇŝŶĐŝĚĞŶƚ͕ƚŚĞŝŶƐƚĂůůĂƚŝŽŶƐŚŽƵůĚŶŽƚďĞƌĞƐƚĂƌƚĞĚǁŝƚŚŽƵƚƉƌŽƉĞƌĐŽƌƌĞĐƚŝǀĞŵĞĂƐƵƌĞƐďĞŝŶŐƚĂŬĞŶ͘
• EŽƚĂďůǇ͕ĂŶǇƌĞƉůĂĐĞŵĞŶƚŽĨĂĐŽŵƉŽŶĞŶƚŽƌĞƋƵŝƉŵĞŶƚƉĂƌƚǁŚŝĐŚĐŽƵůĚŵŽĚŝĨǇƚŚĞĐŽŵďƵƐƚŝǀĞͬĨƵĞůƌĂƚŝŽ
ŵƵƐƚŐŝǀĞƌŝƐĞƚŽƉĂƌƚŝĐƵůĂƌĐĂƌĞǁŚĞŶĐŚĞĐŬŝŶŐ͘
tŚĞŶƚŚĞůŝĞŶƚĚĞĐŝĚĞƐƚŽƌĞƋƵĞƐƚ&^W>ĂƐƐŝƐƚĂŶĐĞƐĞƌǀŝĐĞĨŽƌƚŚĞŶĞǁƐƚĂƌƚŝŶŐͲƵƉ͕ŝƚŝƐŝŶĐƵŵďĞŶƚŽŶƚŚĞ
ůŝĞŶƚ ƚŽ ĐĂƌĞĨƵůůǇ ŝŶĨŽƌŵ &^W> ĂďŽƵƚ ĂŶǇ ŝŶƚĞƌǀĞŶƚŝŽŶ ƚŚĞ ůŝĞŶƚ ŚĂƐ ŵĂĚĞ ŽŶ ĂŶǇ ĐŽŵƉŽŶĞŶƚ Žƌ
ĞƋƵŝƉŵĞŶƚ͕ĂƐǁĞůůĂƐƚŽĐĂƌĞĨƵůůǇŝŶĨŽƌŵ&^W>ĂďŽƵƚĂŶǇƌŝƐŬ;ƐͿƌĞůĂƚĞĚƚŽƚŚĞƉůĂŶƚŽƌƵŶŝƚĐŽŶĚŝƚŝŽŶ͘
• tŚĞŶ ƌĞͲƐƚĂƌƚŝŶŐ Ă ƉůĂŶƚ Žƌ ƵŶŝƚ͕ ĨƵƌƚŚĞƌ ƚŽ Ă ƌĞƉĂŝƌ Žƌ ŵŽĚŝĨŝĐĂƚŝŽŶ͕ ŝƚ ŝƐ ŵĂŶĚĂƚŽƌǇ ƚŽ ĐĂƌƌǇ ŽƵƚ Ă
ĐŽŵďƵƐƚŝŽŶĐŚĞĐŬŽǀĞƌĂůůŝƚƐŽƉĞƌĂƚŝŽŶĂůƌĂŶŐĞ͘
• sĞƌŝĨŝĐĂƚŝŽŶĂŶĚDĂŝŶƚĞŶĂŶĐĞŽĨƐĂĨĞƚǇĞƋƵŝƉŵĞŶƚ͗
ƵƌŝŶŐƚŚĞŐƵĂƌĂŶƚĞĞƉĞƌŝŽĚ͕ƚŚĞƵƐĞƌŵƵƐƚŽďƚĂŝŶ͕ƵŶĚĞƌŝƚƐƐŽůĞƌĞƐƉŽŶƐŝďŝůŝƚǇ͕ƚŚĂƚĂŶǇŝŶƚĞƌǀĞŶƚŝŽŶŽŶ
ƚŚĞŐŽŽĚƐƐƵƉƉůŝĞĚďǇ&^W>ďĞĂĐŚŝĞǀĞĚĞǆĐůƵƐŝǀĞůǇďǇ&^W>ƉĞƌƐŽŶŶĞů͘
ĨƚĞƌ ƚŚĞ ĞŶĚ ŽĨ ƚŚĞ ŐƵĂƌĂŶƚĞĞ ƉĞƌŝŽĚ͕ ƚŚĞ ƵƐĞƌ ŵƵƐƚ ŽďƚĂŝŶ ƵŶĚĞƌ ŝƚƐ ƐŽůĞ ƌĞƐƉŽŶƐŝďŝůŝƚǇ ƚŚĂƚ ĂŶǇ
ŝŶƚĞƌǀĞŶƚŝŽŶ ŽŶ ƚŚĞ ŐŽŽĚƐďĞĐĂƌƌŝĞĚŽƵƚĞǆĐůƵƐŝǀĞůǇďǇĂĚĞƋƵĂƚĞůǇƚƌĂŝŶĞĚƉĞƌƐŽŶŶĞůǁŚŽŚĂǀĞĂĐƋƵŝƌĞĚ
ƚŚĞŵĂŶĚĂƚŽƌǇƐŬŝůůĞŶĂďůŝŶŐƚŚĞŵƚŽŵĂƐƚĞƌĂůůƐĂĨĞƚǇĂŶĚƌĞůŝĂďŝůŝƚǇƉƌŽďůĞŵƐǁŝƚŚƌĞůĂƚŝŽŶƚŽƚŚĞƵƐĞŽĨ
ƐƵĐŚŐŽŽĚƐ͘
ƵƌŝŶŐ Ăůů ƚŚĞ ΗůŝĨĞƚŝŵĞ ĐǇĐůĞΗ ŽĨ ƚŚĞ ƉůĂŶƚ Žƌ ƵŶŝƚ ;ŝŶ ƚĞƌŵƐ ŽĨ ƚŚĞ ŝŶƚĞƌŶĂƚŝŽŶĂů ƐƚĂŶĚĂƌĚ ŶŽ͘ ϲϭϱϬϴ
ĐŽŶĐĞƌŶŝŶŐ ŽƉĞƌĂƚŝŽŶĂů ƐĂĨĞƚǇͿ͕ ƚĞƐƚƐ ĐŽŶĐĞƌŶŝŶŐ ƚŚĞ ƉůĂŶƚ Žƌ ƵŶŝƚ ŽƉĞƌĂƚŝŽŶ ŵƵƐƚ ďĞ ƉĞƌĨŽƌŵĞĚ ŽŶ Ăůů
ƐĂĨĞƚǇĐŽŵƉŽŶĞŶƚƐŽƌĞƋƵŝƉŵĞŶƚ͕ǁŝƚŚĂĨƌĞƋƵĞŶĐǇĂƐĚĞĨŝŶĞĚďǇĂŶĂƵƚŚŽƌŝƐĞĚďŽĚǇ͕ŝŶŽƌĚĞƌƚŽŵĂŝŶƚĂŝŶ
ƚŚĞůĞǀĞůŽĨƐĂĨĞƚǇŽĨƚŚĞƉůĂŶƚŽƌƵŶŝƚ͘
JOB NO.17-3610
KWZd/KEED/EdEEDEh>
dŚĞ ĂƚƚĞŶƚŝŽŶ ŽĨ ƚŚĞ ƵƐĞƌ ŝƐ ƉĂƌƚŝĐƵůĂƌůǇ ĚƌĂǁŶ ƚŽ ƚŚĞ ŶĞĐĞƐƐŝƚǇ ŽĨ ŬĞĞƉŝŶŐ ƚŚĞ ŝŶƐƚƌƵŵĞŶƚĂƚŝŽŶ ;ƉƌŽďĞƐ͕
ĚĞƚĞĐƚŽƌƐ͕ ŝŶĚŝĐĂƚŽƌƐ͕ ƌĞĐŽƌĚĞƌƐ ĂŶĚ ĞƋƵŝƉŵĞŶƚ ƌĞƐƉŽŶƐŝďůĞ ĨŽƌ ƌĞĂůŝƐŝŶŐ Ă ĨƵŶĐƚŝŽŶ ǁŚŝĐŚ ĐŽŶĚŝƚŝŽŶƐ ƚŚĞ
ƐĂĨĞƚǇůĞǀĞůͿŝŶŐŽŽĚĐŽŶĚŝƚŝŽŶ͕ŝŶĂĚĚŝƚŝŽŶƚŽƚŚŽƐĞǁŚŝĐŚŵĂǇŝŶĨůƵĞŶĐĞƚŚĞĐŽŵďƵƐƚŝǀĞͬĨƵĞůƌĂƚŝŽ͘EŽƚĂďůǇ͗

∗ ƚŝŐŚƚŶĞƐƐ ŽĨ ĞĂĐŚ ƐĂĨĞƚǇ ƐŚƵƚͲŽĨĨ ǀĂůǀĞ ĨŽƌ ĨƵĞů ĨůŽǁ ;ĂŶĚ ŝŐŶŝƚŝŽŶ ĨƵĞůͿ ĂŶĚ ƉĞƌĨĞĐƚ ŽƉĞƌĂƚŝŽŶ ŽĨ ƚŚĞŝƌ
ƉŝůŽƚƐ;ŝŶŐĞŶĞƌĂůĐŽŵƉƌĞƐƐĞĚĂŝƌĐŽŶƚƌŽůůĞĚƐĂĨĞƚǇǀĂůǀĞƐ͕ϮŽƌϯǁĂǇƐͿ͕
∗ ƐĂĨĞƚǇƐŚƵƚͲŽĨĨƚŝŵĞ͗tŚĞŶĂƐŚƵƚͲŽĨĨ;ƐƚŽƉƉŝŶŐͿŝƐŶĞĐĞƐƐĂƌǇŽƌƌĞƋƵŝƌĞĚ͕ƚŚĞĞǆĞĐƵƚŝŽŶƚŝŵĞŵƵƐƚďĞ
ůĞƐƐƚŚĂŶϭƐĞĐŽŶĚ͕
∗ ƉĞƌĨĞĐƚŽƉĞƌĂƚŝŽŶŽĨƚŚĞƌŝƐŬĐŚĂŝŶ;ŽĨƚŚĞ^Ϳ;ŝŶĐůƵĚŝŶŐƉĞƌĨĞĐƚǁŝƌŝŶŐĂŶĚĐŽŶŶĞĐƚŝŽŶƐͿĐŽŵŵĂŶĚŝŶŐ
ĞĂĐŚƐĂĨĞƚǇƐŚƵƚͲŽĨĨǀĂůǀĞĨŽƌĨƵĞůĨůŽǁ;ŝŶĐůƵĚŝŶŐŝƚƐƉŝůŽƚͿ͕
∗ ƉĞƌĨĞĐƚŽƉĞƌĂƚŝŽŶŽĨĨƵƌŶĂĐĞƉƵƌŐŝŶŐƐĞƋƵĞŶĐĞ;ďǇĐŽŵďƵƐƚŝǀĞͿǁŝƚŚŝŶĂƐƵĨĨŝĐŝĞŶƚƚŝŵĞĂŶĚĨůŽǁ͕
∗ ƉĞƌĨĞĐƚŽƉĞƌĂƚŝŽŶŽĨĂůůŝŶƐƚƌƵŵĞŶƚƐĂŶĚĚĞƚĞĐƚŽƌƐŝŶĐŚĂƌŐĞŽĨĚĞƚĞĐƚŝŶŐĂŶǇĞǀĞŶƚƵĂůĂŶŽŵĂůǇŽĨƚŚĞ
ĐŽŵďƵƐƚŝǀĞͬĨƵĞůƌĂƚŝŽ͕ŶŽƚĂďůǇ͗
KǆǇŐĞŶĂŶĂůǇƐĞƌƐͲK͗ƌĞŐƵůĂƌƉĞƌŝŽĚŝĐĐŚĞĐŬŝƐƌĞƋƵŝƌĞĚƚŽĞŶƐƵƌĞŶŽĚƌŝĨƚŝŶŐĂŶĚƚŽĞŶƐƵƌĞƚŚĂƚƚŚĞ
ŵĂŝŶƐĂĨĞƚŝĞƐ͗ŝŶƐƵĨĨŝĐŝĞŶƚKϮйŽƌĞǆĐĞƐƐŽĨKĂƌĞŽƉĞƌĂƚŝŶŐƉĞƌĨĞĐƚůǇ͕
Ŷ ŝŵŵĞĚŝĂƚĞ ĐŽƌƌĞĐƚŝǀĞ ĂĐƚŝŽŶ ŝƐ ŵĂŶĚĂƚŽƌǇ ǁŚĞŶ ĂŶ ĂďŶŽƌŵĂů ŝŶĚŝĐĂƚŝŽŶ ;ĞĂƐǇ ƚŽ ǀĞƌŝĨǇ ǁŝƚŚ ŚĂŶĚ
ĂŶĂůǇƐĞƌƐͿŝƐŽďƐĞƌǀĞĚ͕
∗ ĨůĂŵĞĚĞƚĞĐƚŽƌƐŽƌŝŽŶŝƐĂƚŝŽŶĚĞƚĞĐƚŽƌƐŽĨƚŚĞďƵƌŶĞƌŝŐŶŝƚĞƌƐ͕ĂŶǇĂďŶŽƌŵĂůŝƚǇƐŚŽƵůĚůĞĂĚƚŽŝŵŵĞĚŝĂƚĞ
ƌĞƉůĂĐĞŵĞŶƚ͘dŚĞƉƌĞƐĞŶĐĞŽĨĐŽŶĚĞŶƐĞĚǁĂƚĞƌŝŶĨůĂŵĞĚĞƚĞĐƚŽƌƐ;ƐĐĂŶŶĞƌͬďŽǆͿŽƌŝŐŶŝƚĞƌƐŵƵƐƚůĞĂĚ
ƚŽĂŶŝŵŵĞĚŝĂƚĞƉƌĞǀĞŶƚŝǀĞƌĞƉůĂĐĞŵĞŶƚ͕
∗ ĨƵĞůĨůŽǁĂŶĚĐŽŵďƵƐƚŝŽŶĂŝƌĨůŽǁŵĞĂƐƵƌŝŶŐŝŶƐƚƌƵŵĞŶƚƐ͗ƉĞƌŝŽĚŝĐĐŚĞĐŬƐ;ƐĞĞŵĂŶƵĨĂĐƚƵƌĞƌƐŵĂŶƵĂůƐͿ͕
∗ ƉƌĞƐƐƵƌĞƐǁŝƚĐŚĞƐͬƚĞŵƉĞƌĂƚƵƌĞƐĂĨĞƚǇƐǁŝƚĐŚĞƐ͗ĂƐĂďŽǀĞ͕
∗ ŐĂƐůĞĂŬĚĞƚĞĐƚŽƌƐ͕ĂƚŵŽƐƉŚĞƌĞ͗ĂƐĂďŽǀĞ͕
∗ ĂƵƚŽŵĂƚŝŽŶĂŶĚĐŽŶƚƌŽůͬƌĞŐƵůĂƚŝŽŶŝŶƐƚƌƵŵĞŶƚƐ͗ĂƐĂďŽǀĞ͕
∗ ŵŽƌĞŐĞŶĞƌĂůůǇ͕ĂŶǇĂďŶŽƌŵĂůŽďƐĞƌǀĂƚŝŽŶŽƌĚĞĨĞĐƚǁŚĞŶĚĞƚĞĐƚĞĚ͕ŵƵƐƚďĞŝŵŵĞĚŝĂƚĞůǇĂŶĂůǇƐĞĚŝŶ
ŽƌĚĞƌƚŽĨŝŶĚŽƵƚƚŚĞŽƌŝŐŝŶĂŶĚĐĂƵƐĞĂŶĚƚĂŬĞĂĐŽƌƌĞĐƚŝǀĞĂĐƚŝŽŶǁŝƚŚŽƵƚĂŶǇĚĞůĂǇ͕ŝŶŽƌĚĞƌƚŽĂǀŽŝĚ
ĂŶǇ ƌŝƐŬ ŽĨ ĚĞƚĞƌŝŽƌĂƚŝŽŶ ŽĨ ƚŚĞ ĐŽŵďƵƐƚŝŽŶ ƉƌŽĐĞƐƐ ĂŶĚ ŝƚƐ ƉĞƌŵĂŶĞŶƚ ĐŽŶƚƌŽů ĂƐ ǁĞůů ĂƐ ŽĨ ƚŚĞ
ĐŽŵďƵƐƚŝǀĞͬĨƵĞůƌĂƚŝŽ͕ǁŚŝĐŚŵĂǇůĞĂĚƚŽĂŶĂĐĐŝĚĞŶƚ͕
∗ ĞǆƉůŽƐŝŽŶƌĞůŝĞĨǀĂůǀĞƐ;ŽƌƚƌĂƉƐ͕ĚĂŵƉĞƌƐͿŽĨƚŚĞŐĞŶĞƌĂƚŽƌ;ƐͿŽƌĨƵƌŶĂĐĞ;ƐͿ͕ŬŝůŶ;ƐͿ;ŐŽŽĚĂĚũƵƐƚŵĞŶƚĂŶĚ
ƐĞƚƉŽŝŶƚ͕ŶŽŽǀĞƌĐŚĂƌŐĞ͕ƌŝƐŬŽĨĨĂůůŝŶŐŵĂƐƚĞƌĞĚͿ͕
∗ ƐĂĨĞƚǇƌĞůŝĞĨǀĂůǀĞƐ͕ĞǆƉůŽƐŝŽŶƚƌĂƉƐ͕ĚŝƐĐŚĂƌŐĞǀĂůǀĞƐ͕ĐŚĞĐŬǀĂůǀĞƐŽŶĐŝƌĐƵŝƚƐŽĨƉƌĞƐƐƵƌŝƐĞĚ
ĨƵĞů͗ĂƐĂďŽǀĞ͘
∗ ƐƵĨĨŝĐŝĞŶƚ ƐĐƌĞǁŝŶŐ ŽĨ ĂƐƐĞŵďůŝĞƐ ;ĨůĂŶŐĞƐ͕ ƐĐƌĞǁƐͿ ŽĨ ƉƌĞƐƐƵƌŝƐĞĚ ĐŝƌĐƵŝƚƐ ŽǀĞƌĂůů ŝĨ ƚŚĞǇ ĂƌĞ Ăƚ ŚŝŐŚ
ƚĞŵƉĞƌĂƚƵƌĞ;ŚĞĂǀǇŽŝů͕ƚŚĞƌŵĂůŽŝůͿ͘
DŽƌĞ ŐĞŶĞƌĂůůǇ͕ ƚŚĞ ƚŝŵĞ ƉĞƌŝŽĚ ŽĨ ĐŚĞĐŬƐ ŵƵƐƚ ĐŽŵƉůǇ ǁŝƚŚ ƵƌŽƉĞĂŶ ^ƚĂŶĚĂƌĚƐ ŝŶ ĨŽƌĐĞ ĂŶĚ ^ƚĂŶĚĂƌĚ
ŽĚĞƐŽĨWƌĂĐƚŝĐĞŶŽƚĂďůǇƚŚĞKZĞĐŽŵŵĞŶĚĂƚŝŽŶƐ͘
tĞĂĚǀŝƐĞƚŚĞůŝĞŶƚƚŽŝŵƉŽƐĞĂǁĞĞŬůǇĐŚĞĐŬůŝƐƚŽĨǀĞƌŝĨŝĐĂƚŝŽŶƐĨƌŽŵƚŚĞŝƌƐƚĂĨĨ͘

dŚĞƵƐĞƌŵƵƐƚŝŶĂĚĚŝƚŝŽŶƚĂŬĞƉĂƌƚŝĐƵůĂƌĐĂƌĞƚŚĂƚ͗
∗ ƚŚĞĞƋƵŝƉŵĞŶƚŝƐǁĞůůƉƌŽƚĞĐƚĞĚĂŐĂŝŶƐƚƚŚĞƉƌĞƐĞŶĐĞŽĨǁĂƚĞƌ͕ŚƵŵŝĚŝƚǇĂŶĚĐůŝŵĂƚŝĐĐŽŶĚŝƚŝŽŶƐ͘
∗ ƚŚĞĐŽŽůŝŶŐĚĞǀŝĐĞƐĂŶĚǀĞŶƚŝůĂƚŝŽŶĂƌĞŝŶŐŽŽĚĐŽŶĚŝƚŝŽŶ͘
∗ ƚŚĞǀĞŶƚŝŶŐĚĞǀŝĐĞƐĂƌĞŝŶŐŽŽĚĐŽŶĚŝƚŝŽŶ͘
∗ ƚŚĞĞĂƌƚŚŝŶŐĐŝƌĐƵŝƚƋƵĂůŝƚǇŝƐƉĞƌŝŽĚŝĐĂůůǇĐŚĞĐŬĞĚ͘
• KƉĞƌĂƚŝŽŶƐ ĨŽƌ ŵŽĚŝĨŝĐĂƚŝŽŶ Žƌ ƌĞƉůĂĐĞŵĞŶƚ ŽĨ ĞůĞĐƚƌŝĐĂů ĞƋƵŝƉŵĞŶƚ ƐŚŽƵůĚ ŽŶůǇ ďĞ ĐĂƌƌŝĞĚ ŽƵƚ ĂĨƚĞƌ
ƐŚƵƚĚŽǁŶŽĨƚŚĞĐŽƌƌĞƐƉŽŶĚŝŶŐƐƵƉƉůǇĐŝƌĐƵŝƚ͕ŝŶƚŚĞĂďƐĞŶĐĞŽĨĂŶǇǀŽůƚĂŐĞ͘
JOB NO.17-3610
KWZd/KEED/EdEEDEh>

/ŶƐƚƌƵĐƚŝŽŶƐƚŽďĞǁƌŝƚƚĞŶĂŶĚĚŝƐƚƌŝďƵƚĞĚďǇƚŚĞůŝĞŶƚƚŽŝƚƐƉĞƌƐŽŶŶĞů
DĂŝŶƚĞŶĂŶĐĞ͕ĐŚĞĐŬŝŶŐĂŶĚƵƐĞŽĨƚŚĞŝŶƐƚĂůůĂƚŝŽŶĞƋƵŝƉŵĞŶƚ;ŝŶĐůƵĚŝŶŐďƵƚŶŽƚůŝŵŝƚĞĚƚŽĐŽŶƚƌŽůĂŶĚƐĂĨĞƚǇ
ĚĞǀŝĐĞƐͿƐŚŽƵůĚďĞƐƵďũĞĐƚƚŽƐĞƌǀŝĐĞŝŶƐƚƌƵĐƚŝŽŶƐǁŚŝĐŚĂƌĞƚŽďĞĐůĞĂƌ͕ƉƌĞĐŝƐĞ͕ĂŶĚĂǀĂŝůĂďůĞƚŽĂůůƉĞƌƐŽŶŶĞů
ĐŽŶĐĞƌŶĞĚ͕ ƐŽ ƚŚĂƚ ƚŚĞǇ ĐĂŶŶŽƚ ŝŐŶŽƌĞ ŝƚ͘ /ƚ ŝƐ ƚŚĞ ůŝĞŶƚΖƐ ĚƵƚǇ ƚŽ ĞŶƐƵƌĞ ƚŚĂƚ Ăůů ŽƉĞƌĂƚŽƌƐ ŚĂǀĞ ƌĞĂĚ ĂŶĚ
ƚĂŬĞŶŝŶƚŽĂĐĐŽƵŶƚƚŚĞĐŽŶƚĞŶƚŽĨƚŚĞƐĞΗhƐĞƌŐƵŝĚĞůŝŶĞƐΗ͘
dŚĞĂďŽǀĞĚŽĐƵŵĞŶƚƐĂƌĞƚŽďĞƌĞŐƵůĂƌůǇŬĞƉƚĂǀĂŝůĂďůĞďǇƚŚĞůŝĞŶƚ͗

ϭ͘ /ŶĂůůĐĂƐĞƐ
◊ ŵĂŝŶƚĞŶĂŶĐĞůŽŐďŽŽŬ͕ĨŽƌĞĂĐŚƐƚĞĂŵŽƌƐƵƉĞƌŚĞĂƚĞĚǁĂƚĞƌĞƋƵŝƉŵĞŶƚ͕ŽŶǁŚŝĐŚĂƌĞƌĞĐŽƌĚĞĚƚŚĞ
ƚĞƐƚƐ͕ĞǆĂŵŝŶĂƚŝŽŶƐ͕ĐůĞĂŶŝŶŐƐĂŶĚƌĞƉĂŝƌƐ͘
◊ ŶŝŶƐƚĂůůĂƚŝŽŶďŽŽŬůĞƚ͕ŝŶǁŚŝĐŚĂƌĞŵĞŶƚŝŽŶĞĚ͗
⇒ dŚĞĐŚĂƌĂĐƚĞƌŝƐƚŝĐƐŽĨƚŚĞĞƋƵŝƉŵĞŶƚƵƐĞĚ
⇒ dŚĞĐŽŶĚŝƚŝŽŶƐŽĨŽƉĞƌĂƚŝŽŶŽĨƚŚĞƚŚĞƌŵĂůƉƌŽĚƵĐƚŝŽŶĞƋƵŝƉŵĞŶƚƐĞƚƐ
⇒ dŚĞƌĞƐƵůƚƐŽĨƚĞƐƚƐĐĂƌƌŝĞĚŽƵƚĚƵƌŝŶŐƉĞƌŝŽĚŝĐǀŝƐŝƚƐĂƐƉĞƌƌĞŐƵůĂƚŝŽŶƐ͘
&ƵƌƚŚĞƌŵŽƌĞ͕ƚŚĞĐŽŵƉĞƚĞŶƚƉĞƌƐŽŶŶĞůƐŚŽƵůĚ͗
◊ ŶƐƵƌĞĂƉĞƌŵĂŶĞŶƚƉƌĞƐĞŶĐĞŝŶƚŚĞďƵŝůĚŝŶŐǁŚĞƌĞƚŚĞŐĞŶĞƌĂƚŽƌŝƐƐŝƚƵĂƚĞĚǁŝƚŚĂĚŝƌĞĐƚǀŝĞǁŽĨƚŚĞ
ƐĂĨĞƚǇ ĂŶĚ ĐŽŶƚƌŽů ĞƋƵŝƉŵĞŶƚ͕ Žƌ ŝŶ Ă ďƵŝůĚŝŶŐ ŶĞǆƚ ĚŽŽƌ ǁŚĞƌĞ ƚŚĞ ƐĂĨĞƚǇ ĂŶĚ ĐŽŶƚƌŽů ĞƋƵŝƉŵĞŶƚ ŝƐ
ƐŝƚƵĂƚĞĚ͘
◊ WĞƌŝŽĚŝĐĂůůǇ ĐŚĞĐŬ ƚŚĞ ƉƌŽƉĞƌ ŽƉĞƌĂƚŝŽŶ ŽĨ ƚŚĞ ĚĞǀŝĐĞƐ ĂĐƚŝŶŐ ŽŶ ƚŚĞ ƐĂĨĞƚǇůĞǀĞů͗ƚŚĞƐĞĐŚĞĐŬƐ͕ƚŚĞŝƌ
ĚĂƚĞĂŶĚŚŽƵƌ͕ĂƐǁĞůůĂƐƚŚĞŽďƐĞƌǀĂƚŝŽŶƐ͕ƐŚŽƵůĚďĞƌĞĐŽƌĚĞĚŝŶƚŚĞƌĞĐŽƌĚďŽŽŬŽĨƚŚĞůŝĞŶƚ͘

Ϯ͘ ĐĐŽƌĚŝŶŐƚŽĞĂĐŚĐĂƐĞ͗
◊ tŝƚŚƉĞƌŵĂŶĞŶƚƉƌĞƐĞŶĐĞ;ŐĞŶĞƌĂůĐĂƐĞͿ͗
⇒ ƌĞĐŽƌĚďŽŽŬ͕ŐŝǀŝŶŐŝĚĞŶƚŝƚǇŽĨƚŚĞƉĞƌƐŽŶŶĞůĂŶĚƚŚĞƚǇƉĞŽĨŝŶƚĞƌǀĞŶƚŝŽŶ͘
◊ tŝƚŚŽƵƚƉĞƌŵĂŶĞŶƚŚƵŵĂŶƉƌĞƐĞŶĐĞ;ƉĂƌƚŝĐƵůĂƌĐĂƐĞ͕ŝĨĞǆƉƌĞƐƐůǇƐƚŝƉƵůĂƚĞĚŝŶƚŚĞĐŽŶƚƌĂĐƚĐŽŶĐĞƌŶĞĚ
ďǇƚŚĞƐĞΗhƐĞƌŐƵŝĚĞůŝŶĞƐΗͿ͗
⇒ ƌĞĐŽƌĚŽĨƚŚĞŝŶƐƚĂůůĂƚŝŽŶ͕ŽƌĂŶĂƵƚŽŵĂƚŝĐƌĞĐŽƌĚŝŶŐĚĞǀŝĐĞŽŶǁŚŝĐŚŝƐƐŚŽǁŶ͗
− dŚĞĐĂƌƌǇŝŶŐŽƵƚŽĨƚŚĞƉĞƌŝŽĚŝĐĐŚĞĐŬƐĨŽƌƚŚĞƐĂĨĞƚǇĚĞǀŝĐĞƐǁŝƚŚĂƐŝŐŶĂƚƵƌĞďǇƚŚĞƉĞƌƐŽŶŶĞůŚĂǀŝŶŐ
ŵĂĚĞƚŚĞĐŚĞĐŬƐ͘
− ĂƌƌǇŝŶŐŽƵƚŽĨƚŚĞƉĞƌŝŽĚŝĐĐŚĞĐŬƐ͘
− tĂƚĞƌĂŶĂůǇƐŝƐĐŚĞĐŬĐĂƌƌŝĞĚŽƵƚ͘
− ůůŝŶĐŝĚĞŶƚƐ͕ƚĞƐƚƐ͕ǁŽƌŬĐĂƌƌŝĞĚŽƵƚŝŶƚŚĞŝŶƐƚĂůůĂƚŝŽŶ͘
dŚĞŝŶƐƚĂůůĂƚŝŽŶůŽŐďŽŽŬĂĐƚƐĂƐĂƌĞĐŽƌĚďŽŽŬĚƵƌŝŶŐĂĨĂƵůƚ͕ŽƌĂŶŝŶƚĞƌǀĞŶƚŝŽŶƌĞƋƵŝƌŝŶŐĂƌĞƚƵƌŶƚŽ
ŽƉĞƌĂƚŝŽŶǁŝƚŚƉĞƌŵĂŶĞŶƚŚƵŵĂŶƉƌĞƐĞŶĐĞ͘
dŚĞƌĞĐŽƌĚďŽŽŬĂŶĚƚŚĞůŽŐďŽŽŬŽĨƚŚĞŝŶƐƚĂůůĂƚŝŽŶĂƌĞƚŽďĞƉƌĞƐĞŶƚĞĚĚƵƌŝŶŐƚŚĞŽĐĐĂƐŝŽŶŽĨĞĂĐŚ
ŝŶƐƉĞĐƚŝŽŶ͘
JOB NO.17-3610
KWZd/KEED/EdEEDEh>
WZdϮͲd,E/>d
,Kd'^'EZdKZ
^ƌ͘EŽ͘ ĞƐĐƌŝƉƚŝŽŶ hŶŝƚ sĂůƵĞ
ϭ YƚǇ͘ŽĨ,'' EŽ;ƐͿ͘ KŶĞ
dŽŐĞŶĞƌĂƚĞŚŽƚŐĂƐĞƐƚŽ
Ϯ ƉƉůŝĐĂƚŝŽŶ ŐĞŶĞƌĂƚĞƐƚĞĂŵt,Zh
ŽŝůĞƌ
ϯ ,''ŽƌŝĞŶƚĂƚŝŽŶ sĞƌƚŝĐĂů
'ZƵƌŶĞƌ͗ŽĂů&ŝƌĞĚǁŝƚŚ
ϰ dǇƉĞŽĨƵƌŶĞƌ Ͳ
>Kͬ,^ĨŽƌƐƚĂƌƚͲƵƉ
ϱ &ƵĞů&ŝƌĞĚ
ϱ͘ϭ DĂŝŶ WƵůǀĞƌŝǌĞĚŽĂů
ϱ͘Ϯ &Žƌ^ƚĂƌƚͲƵƉ >Kͬ,^
ϲ ZĞŐŝƐƚĞƌƌĂĨƚ>ŽƐƐ ŵŵt фϮϱϬ
ϳ dƵƌŶŽǁŶ&ŽƌWƵůǀĞƌŝǌĞĚŽĂů Ͳ ϭ͗ϯ
ϴ dƵƌŶŽǁŶZĂƚŝŽKŝů ϭ͗ϯ
ϵ ,ĞĂƚZĞůĞĂƐĞZĂƚĞƉĞƌ,'' DŬĐĂůͬŚƌ ϴ͘ϰ;tŝƚŚŽĂůͿ
ϭϬ ,''KƵƚůĞƚdĞŵƉĞƌĂƚƵƌĞ ĚĞŐ͘ ϰϰϬͲϰϱϬ
<ŝŶĚůǇŶŽƚĞĚŝůƵƚŝŽŶĂŝƌƉŽƌƚƐ
ƉƌĞƐƐƵƌĞĚƌŽƉŝƐĐĂůĐƵůĂƚĞĚ
ďĂƐĞĚŽŶϮϬŵŵǁĐ͘dŚĞ,''
ϭϭ ,ŽƚŝƌWƌĞƐƐƵƌĞĂƚ,''KƵƚůĞƚ ŵŵt
ŽƵƚůĞƚƉƌĞƐƐƵƌĞƐŚĂůůďĞ
ŵĂŝŶƚĂŝŶĞĚƚŽŚĂǀĞŶĞŐĂƚŝǀĞ
ĚƌĂĨƚŝŶǇŽƵƌƐǇƐƚĞŵ͘
ϭϮ ,''KƵƚůĞƚ,Žƚ'ĂƐ&ůŽǁĂƚϰϰϬͲϰϱϬĞŐĞů <ŐͬŚƌ ϭϵϴϬϬϬ
ϭϯ ŽĂů&ůŽǁZĂƚĞ <ŐͬŚƌ ϭϱϬϬ

ϭϰ 'ƌŽƐƐĐĂůŽƌŝĨŝĐĞsĂůƵĞŽĨŽĂů <ĐĂůͬŬŐ ϱϲϬϬ
ϭϱ ŽĂůƉĂƌƚŝĐůĞƐŝǌĞ DŝĐƌŽŶ фϭϬϬ
ϭϲ &ŝƌŝŶŐĐĂƉĂĐŝƚǇǁŝƚŚ>KĨƵĞů DŬĐĂůͬŚƌ Ϯ͘ϱϮ
ϭϳ 'ƌŽƐƐĂůŽƌŝĨŝĐsĂůƵĞŽĨ>Kͬ,^ <ĐĂůͬŬŐ ϭϬϬϬϬ
ϭϴ ŽŵďƵƐƚŝŽŶŝƌ&ůŽǁZĂƚĞ <ŐͬŚƌ ϭϱϱϬϬ
ϭϵ ŽŵďƵƐƚŝŽŶŝƌdĞŵƉ ĞŐ ϰϬ
ŝůƵƚŝŽŶĂŝƌƌĞƋ͘ĨůŽǁƉĞƌďƵƌŶĞƌĨƌŽŵŽŽůĞƌ
ϮϬ <ŐͬŚƌ ϭϴϭϭϬϬ
sĞŶƚƚŽ,''
Ϯϭ ŝůƵƚŝŽŶŝƌdĞŵƉĨƌŽŵŽŽůĞƌ ĞŐ ϯϬϱ
JOB NO.17-3610
KWZd/KEED/EdEEDEh>
ŝůƵƚŝŽŶŝƌWƌĞƐƐƵƌĞΛŝŶůĞƚŽĨ,''ĚŝůƵƚŝŽŶĂŝƌ
ϮϮ ŵŵt ;ͲϮϬͿ
ŶŽǌǌůĞĨƌŽŵĐŽŽůĞƌĨƌŽŵŽŽůĞƌsĞŶƚƚŽ,''
Ϯϯ ŽĂůŽŶǀĞǇŝŶŐŝƌƌĞƋƵŝƌĞĚƉĞƌďƵƌŶĞƌ <ŐͬŚƌ ϵϳϬ

Ϯϰ ŵĞƌŐĞŶĐǇŽŽůŝŶŐŝƌ&ůŽǁZĂƚĞ <ŐͬŚƌ ϰϳϬϬ
Ϯϱ ŵĞƌŐĞŶĐǇŽŽůŝŶŐĂƚWƌĞƐƐƵƌĞ ŵŵt ϱϬ
&Žƌ>Kͬ,^
ϭ dĞŵƉĞƌĂƚƵƌĞŽĨĨƵĞůĂƚďƵƌŶĞƌŝŶůĞƚ ĞŐ ϰϬ
Ϯ sŝƐĐŽƐŝƚǇŽĨΛϰϬĞŐĐĞů Đ^ƚ Ϯ͘ϱͲϭϱ͘ϳ
ϯ ^ƉĞĐŝĨŝĐŐƌĂǀŝƚǇΛϭϱĞŐĞů Ϭ͘ϴϴ
ϰ ĚĞŶƐŝƚǇ <Őͬŵϯ ϴϴϬ
ϱ WƌĞƐƐƵƌĞĂƚƵƌŶĞƌ/ŶůĞƚ <ŐͬĐŵϮ;ŐͿ ΕϭϬ
ϲ Kŝů&ůŽǁZĂƚĞĂƚƵƌŶĞƌ <ŐͬŚƌ ϮϱϮ
ϳ KŝůWƌĞƐƐƵƌĞĂƚWŝƉĞƌĂĐŬ/ŶůĞƚ <ŐͬĐŵϮ;ŐͿ ΕϭϮ
ϴ Kŝů&ůŽǁZĂƚĞĂƚWƵŵƉKƵƚůĞƚ <ŐͬŚƌ ϯϬϮ
ϵ KŝůWƌĞƐƐƵƌĞĂƚWƵŵƉKƵƚůĞƚ <ŐͬĐŵϮ;ŐͿ ϭϱ
ƚŽŵŝƐŝŶŐŝƌΛWŝƉĞZĂĐŬ/ŶůĞƚ
ϭ WƌĞƐƐƵƌĞ <ŐͬĐŵϮ;ŐͿ ϰ
Ϯ dĞŵƉ͘ ĞŐ͘ ϰϬ
ϯ &ůŽǁZĂƚĞ <ŐͬŚƌ ϱϬ
/ŶƐƚƌƵŵĞŶƚŝƌΛWŝƉĞZĂĐŬ/ŶůĞƚ
ϭ WƌĞƐƐƵƌĞ <ŐͬĐŵϮ;ŐͿ ϲͲϳ
Ϯ dĞŵƉ͘ ĞŐ͘ ϰϬ
ϯ &ůŽǁZĂƚĞ <ŐͬŚƌ ϲϱ
WŝůŽƚdǇƉĞ
ϭ dǇƉĞŽĨ/ŐŶŝƚŝŽŶ^ǇƐƚĞŵ Ͳ ,ŝŐŚŶĞƌŐǇ/ŐŶŝƚĞƌ;,/Ϳ
& WŽǁĞƌ^ƵƉƉůǇ
&ϭ /ŶƐƚƌƵŵĞŶƚͬWĂŶĞůWŽǁĞƌ s ϮϮϬ
&Ϯ ^ŽůĞŶŽŝĚsŽůƚĂŐĞ s ϮϮϬ
&ϯ DŽƚŽƌ^ƵƉƉůǇ s ϰϭϱ

JOB NO.17-3610
KWZd/KEED/EdEEDEh>
&ϰ EŽŶhW^hƚŝůƚǇ^ƵƵƉůǇ s ϮϯϬ
&ϱ sĂƌŝĂƚŝŽŶ/ŶsŽůĂƚŐĞ нͬͲϭϬй
&ϲ sĂƌŝĂƚŝŽŶ/Ŷ&ƌĞƋƵĞŶĐǇ нͬͲϱй
' ŽĂůŽŵƉŽƐŝƚŝŽŶ
WƵůǀĞƌŝǌĞĚŽĂů й ZtK>
'ϭ hůƚŝŵĂƚĞŶĂůǇƐŝƐ tƚй
'ϭ͘ϭ ĂƌďŽŶ й ϱϳ͘ϳϱ
'ϭ͘Ϯ ,ǇĚƌŽŐĞŶ й ϯ͘ϵϲ
'ϭ͘ϯ EŝƚƌŽŐĞŶ й ϭ͘ϭϮ
'ϭ͘ϰ ^ƵůƉŚƵƌ й Ϭ͘Ϭϴ
'ϭ͘ϱ KǆǇŐĞŶ й ϭϮ͘Ϭϵ
'ϭ͘ϲ DŽŝƐƚƵƌĞ й ϭ͘ϱ
'ϭ͘ϳ ƐŚ й Ϯϯ͘ϱ
'Ϯ WƌŽǆŝŵĂƚĞŶĂůǇƐŝƐ й
'Ϯ͘ϭ &ŝǆĞĚĂƌďŽŶ й ϰϬͲϱϬ
'Ϯ͘Ϯ sŽůĂƚŝůĞDĂƚƚĞƌ й ϮϱͲϯϱ
'Ϯ͘ϯ ŽĂůƐŚ й ϭϱͲϮϱ

ϳͲϭϮͲZĂǁŽĂů
'Ϯ͘ϰ ŽĂůDŽŝƐƚƵƌĞ й
ϭ͘ϱͲϱͲ&ŝŶĞĐŽĂů
, ^/dd
,ϭ ŵďŝĞŶƚƚĞŵƉĞƌĂƚƵƌĞ
,ϭ͘ϭ DĂǆŝŵƵŵĚƌǇďƵůďƚĞŵƉĞƌĂƚƵƌĞ Σ ϱϬ
,ϭ͘Ϯ DŝŶŝŵƵŵĚƌǇďƵůďƚĞŵƉĞƌĂƚƵƌĞ Σ ϮϬ
,ϭ͘ϯ DĞĂŶĚƌǇďƵůďƚĞŵƉĞƌĂƚƵƌĞ Σ ϯϮ
,ϭ͘ϰ tĞƚďƵůďƚĞŵƉĞƌĂƚƵƌĞ Σ Ϯϴ

,Ϯ WůĂŶĚĞƐŝŐŶƚĞŵƉĞƌĂƚƵƌĞ Σ ϯϱ
,ϯ ůĞĐƚƌŝĐĂůĞƋƵŝƉŵĞŶƚĚĞƐŝŐŶƚĞŵƉĞƌĂƚƵƌĞ Σ ϱϬ
JOB NO.17-3610
KWZd/KEED/EdEEDEh>
,ϰ tŝŶĚ^ƉĞĞĚ ŵͬƐ ϰϰ

,ϱ ZĞůĂƚŝǀĞ,ƵŵŝĚŝƚǇ;WĞƌĨŽƌŵĂŶĐĞͿ й ϳϬ
,ϲ ƌĞĂůĂƐƐŝĨŝĐĂƚŝŽŶ ^ĂĨĞĂŶĚEŽŶ,ĂǌĂƌĚŽƵƐ
ƌĞĂĐůĂƐƐŝĨŝĐĂƚŝŽŶŽĨ>KƚĂŶŬĂƌĞĂ;ƚĂŶŬ
,ϳ ,ĂǌĂƌĚŽƵƐ͕//ͬ//͕dϯ
ŝŶƐƚƌƵŵĞŶƚƐͿ
,ϴ DĂǆŝŵƵŵŶŽŝƐĞůĞǀĞů Ě фϴϱΛϭ͘ϬŵƚƌƐĚŝƐƚĂŶĐĞ
,ϵ ^ĞŝƐŵŝĐŽŶĞ ŽŶĞͲ//
,ϭϬ ^ŝƚĞĞůĞǀĂƚŝŽŶ ϭϬϲŵƚƌƐĂďŽǀĞD^>
,ϭϭ ǀĞƌĂŐĞZĂŝŶĨĂůů ŵŵ ϴϱϬ
:ĞƚƚŝƉĂůĞŵ͕ZĞŶƚĂĐŚŝŶƚĂůĂ͕
,ϭϮ WůĂŶƚ>ŽĐĂƚŝŽŶ 'ƵŶƚƵƌƚ͕͘ŶĚŚƌĂWƌĂĚĞƐŚ͕
/ŶĚŝĂ
/ WZ&KZDE'hZEdWZDdZ
/ϭ WĞƌĨŽƌŵĂŶĐĞWĂƌĂŵĞƚĞƌ sĂůƵĞ
/ϭ͘ϭ ,ŽƚŐĂƐŐĞŶĞƌĂƚŽƌŚĞĂƚƌĞůĞĂƐĞĐĂƉĂĐŝƚǇ фϴ͘ϰDŬĐĂůͬŚƌʹǁŝƚŚŽĂů
/ϭ͘Ϯ ,ŽƚŐĂƐŐĞŶĞƌĂƚŽƌŽƵƚůĞƚƚĞŵƉĞƌĂƚƵƌĞ ϰϰϬͲϰϱϬΣнϭй
/ϭ͘ϯ &ƵĞůĨůŽǁƌĂƚĞŚŽƚŐĂƐŐĞŶĞƌĂƚŽƌ ϭϱϬϬŬŐͬŚƌ
/ϭ͘ϰ dƵƌŶĚŽǁŶ ϭ͗ϯ
/Ϯ EŽƚĞ
/Ϯ͘ϭ ϭ͘DĞĂƐƵƌĞŵĞŶƚͬŝŶƐƚƌƵŵĞŶƚĞƌƌŽƌŽĨϭйƐŚĂůůďĞĂůůŽǁĞĚ͘
,''ŽƵƚůĞƚƚĞŵƉĞƌĂƚƵƌĞŐƵĂƌĂŶƚĞĞĚĂďŽǀĞŝƐĂǀĞƌĂŐĞƚĞŵƉĞƌĂƚƵƌĞĚƵƌŝŶŐƉĞƌĨŽƌŵĂŶĐĞƚĞƐƚ
ĚƵƌĂƚŝŽŶŝĨĞƋƵŝƉŵĞŶƚŝƐŽƉĞƌĂƚĞĚĂƚĚĞƐŝŐŶĐĂƉĂĐŝƚǇĂŶĚĐŽŵďƵƐƚŝŽŶĂŝƌĂŶĚĐŽŽůĞƌĂŝƌŝƐƌĞŐƵůĂƚĞĚ
/Ϯ͘Ϯ
ĂƐƌĞƋƵŝƌĞĚƚŽĂĐŚŝĞǀĞƚŚŝƐƚĞŵƉĞƌĂƚƵƌĞ͘dŚĞƚĞŵƉĞƌĂƚƵƌĞƐŚĂůůďĞŵĞĂƐƵƌĞĚĨƵƌƚŚĞƌĂǁĂǇĨƌŽŵ
,''͕ƉƌĞĨĞƌĂďůǇĂƚƚŚĞŝŶůĞƚŽĨŵŝůů͕ƐŽƚŚĂƚƚĞŵƉĞƌĂƚƵƌĞŵĞĂƐƵƌĞĚŝƐŵŽƌĞƐƚĂďůĞ͘
&ŽƌĐĂƉĂĐŝƚǇŵĞĂƐƵƌĞŵĞŶƚ͕ĨƵĞůĨůŽǁƌĂƚĞǁŝůůďĞŵĞĂƐƵƌĞĚ͘dŚĞĨƵĞůĐĂůŽƌŝĨŝĐǀĂůƵĞ;>,sͿ
ĐŽŶƐŝĚĞƌĞĚďǇƵƐĨŽƌƚŚŝƐĐĂƉĂĐŝƚǇƌĂƚŝŶŐŝƐϱϲϬϬŬĐĂůͬŬŐĚƵƌŝŶŐƉĞƌĨŽƌŵĂŶĐĞƚĞƐƚŝŶŐŽĨ,''͕
/Ϯ͘ϯ
ǇŽƵͬǇŽƵƌĐůŝĞŶƚƐŚĂůůƉƌŽǀŝĚĞƵƐǁŝƚŚĐĂůŽƌŝĨŝĐǀĂůƵĞĚĞƚĂŝůƐͬƵůƚŝŵĂƚĞĂŶĂůǇƐŝƐŽĨĨƵĞůĨŽƌŽƵƌ
ƌĞĨĞƌĞŶĐĞ͘

JOB NO.17-3610
KWZd/KEED/EdEEDEh>
WZdϯͲZd/KE
ϯ͘ϭͲ^h:d

dŚĞƉƌĞƐĞŶƚůĞĂĨůĞƚŝƐĂŝŵĞĚĂƚŝŶĚŝĐĂƚŝŶŐŐĞŶĞƌĂůŐƵŝĚĞůŝŶĞƐĨŽƌĂƐƐĞŵďůǇĂŶĚĨŝƚƚŝŶŐŽĨ&^W>ΖƐĞƋƵŝƉŵĞŶƚ͘

/ƚƌĞůĂƚĞƐĞƐƉĞĐŝĂůůǇ͗
• dŚĞĂƐƐĞŵďůǇŽƌĚĞƌŽĨŵĂŝŶĞƋƵŝƉŵĞŶƚ
• WĂƌƚŝĐƵůĂƌĐĂƵƚŝŽŶƐƚŽďĞƚĂŬĞŶĚƵƌŝŶŐĨŝƚƚŝŶŐ

/ƚ ĚƌĂǁƐ ĂƚƚĞŶƚŝŽŶ ƚŽ ƚŚĞ ƉƌĞĐĂƵƚŝŽŶƐ ƚŽ ďĞ ƚĂŬĞŶ ĂĐĐŽƌĚŝŶŐ ƚŽ ŵĂƚĞƌŝĂů ƉĂƌƚŝĐƵůĂƌŝƚŝĞƐ͘ dŚŝƐ ůĞĂĨůĞƚ ŵƵƐƚ
ƚŚĞƌĞĨŽƌĞ ďĞ ĐŽŶƐŝĚĞƌĞĚ ĂƐ ďĂƐŝĐ ŐƵŝĚĞůŝŶĞƐ ƚŽ ƵŶĚĞƌƐƚĂŶĚŝŶŐ ĂŶĚ ŝŶƐƚĂůůŝŶŐ ƚŚĞ ƉůĂŶƚ͘ /ƚ ĐŽƵůĚ ďĞ ŵŽĚŝĨŝĞĚ
ĂĐĐŽƌĚŝŶŐƚŽůŽĐĂůĨĂďƌŝĐĂƚŝŽŶĐŽŶĚŝƚŝŽŶƐĂŶĚƐŝƚĞƉƌĂĐƚŝĐĞ͘
ZĞƐƉŽŶƐŝďŝůŝƚǇĨŽƌƚŚĞĂƐƐĞŵďůǇ͕ŚŽǁĞǀĞƌ͕ƌĞƐƚƐǁŝƚŚƚŚĞůŽĐĂůtŽƌŬƐ^ƵƉĞƌǀŝƐŽƌ͘
ϯ͘ϮͲWZ>/D/EZzd/KE^
ϯ͘Ϯ͘ϭͲWƌĞĐĂƵƚŝŽŶƐŽŶƌĞĐĞŝƉƚ

• dŚĞĞƋƵŝƉŵĞŶƚǁĂƐĐĂƌĞĨƵůůǇĐŚĞĐŬĞĚďĞĨŽƌĞĚŝƐƉĂƚĐŚĂŶĚƐŚŽƵůĚďĞŝŶƉĞƌĨĞĐƚǁŽƌŬŝŶŐŽƌĚĞƌŽŶƌĞĐĞƉƚŝŽŶ
ĂƚƐŝƚĞ͘
• ƐƐŽŽŶĂƐƚŚĞĞƋƵŝƉŵĞŶƚĂƌƌŝǀĞƐĂƚƐŝƚĞ͕ŝƚƐŚŽƵůĚďĞǀĞƌǇĐĂƌĞĨƵůůǇĐŚĞĐŬĞĚ͘^ƉĞĐŝĂůĂƚƚĞŶƚŝŽŶƐŚŽƵůĚďĞ
ƚĂŬĞŶŽǀĞƌƚŚĞĨƌĂŐŝůĞŝƚĞŵƐ͖ŝŶƐƚƌƵŵĞŶƚĂƚŝŽŶĞƚĐ͕͘ǁŚŝĐŚƐŚŽƵůĚŶŽƚŚĂǀĞďĞĞŶĚĂŵĂŐĞĚĚƵƌŝŶŐƚƌĂŶƐƉŽƌƚ
ĂŶĚŚĂŶĚůŝŶŐ͘
• /ŶƚŚĞĐĂƐĞŽĨĂƉƌŽďůĞŵ͕ƚĂŬĞƚŚĞŶĞĐĞƐƐĂƌǇĂĐƚŝŽŶƚŽǁĂƌĚƐƚŚĞƚƌĂŶƐƉŽƌƚĂƚŝŽŶĐŽŵƉĂŶǇĂŶĚŝŵŵĞĚŝĂƚĞůǇ
ĐŽŶƚĂĐƚ&^W>ĨŽƌŝŶĨŽƌŵĂƚŝŽŶͬĂĐƚŝŽŶ͘
ϯ͘Ϯ͘ϮͲWƌĞĐĂƵƚŝŽŶƐƚŽďĞƚĂŬĞŶĚƵƌŝŶŐůŽŶŐƐƚŽƌĂŐĞ

&ŽƌƐƚŽƌĂŐĞƉĞƌŝŽĚƐŽǀĞƌϲŵŽŶƚŚƐ͕ƚŚĞĨŽůůŽǁŝŶŐƉƌĞĐĂƵƚŝŽŶƐƐŚŽƵůĚďĞƚĂŬĞŶĨŽƌŝƚĞŵƐǁŚŝĐŚĂƌĞĨŝƚƚĞĚǁŝƚŚ
ďĞĂƌŝŶŐƐ͘

ƵƌŝŶŐƚŚĞƐƚŽƌĂŐĞƉĞƌŝŽĚ͕ƚƵƌŶƐŚĂĨƚŽŶĐĞǁĞĞŬďǇŚĂŶĚƐŽƚŚĂƚďĞĂƌŝŶŐƐĂŶĚŽƚŚĞƌƐĚŽŶŽƚƐƚĂǇƉŽƐŝƚŝŽŶĞĚŝŶ
ƚŚĞƐĂŵĞǁĂǇĨŽƌƚŽŽůŽŶŐ͘
• ůĞĐƚƌŝĐŵŽƚŽƌ
• WƵŵƉƐ
• &ĂŶƐ
• ĐƚƵĂƚŽƌƐ
• ŶĚƐŽŽŶ͘

ϯ͘ϯͲ&KZ^^D>z

ϯ͘ϯ͘ϭͲ'ĞŶĞƌĂůǀĞƌŝĨŝĐĂƚŝŽŶƐ

WŽƐŝƚŝŽŶŝŶŐĂƌĞĂ͗

ĞĨŽƌĞĨŝƚƚŝŶŐƚŚĞĞƋƵŝƉŵĞŶƚ͕ĐŚĞĐŬ͗
• ƚŚĞƉŽƐŝƚŝŽŶŝŶŐĂƌĞĂĨŝƚƐƚŚĞƐŝǌĞŽĨƚŚĞĞƋƵŝƉŵĞŶƚ
• ƚŚĞƉŽƐŝƚŝŽŶŝŶŐĂƌĞĂŝƐĐŽŵƉůĞƚĞůǇĨůĂƚǁŝƚŚŶŽŝƌƌĞŐƵůĂƌŝƚŝĞƐ
JOB NO.17-3610
KWZd/KEED/EdEEDEh>

^ƵƉƉŽƌƚŝŶŐƐƚƌƵĐƚƵƌĞƐͬĞƋƵŝƉŵĞŶƚ͗

dŚŝƐĐŚĞĐŬŝƐŵĂŝŶůǇĨŽƌƚŚĞĚŝŵĞŶƐŝŽŶƐĂŶĚƉŽƐŝƚŝŽŶŝŶŐŽĨƚŚĞƐƵƉƉŽƌƚŝŶŐƐƚƌƵĐƚƵƌĞƐ͘

&ƌĞĞƐƉĂƌĞͬĂĐĐĞƐƐ͗

ŚĞĐŬƚŚĂƚƚŚĞƐŝǌĞŽĨƚŚĞĞƋƵŝƉŵĞŶƚƚŽďĞŝŶƐƚĂůůĞĚŝƐĐŽŵƉĂƚŝďůĞǁŝƚŚƚŚĞĂĐĐĞƐƐĂƌĞĂƐĨŽƌĞƐĞĞŶ͘
ϯ͘ϯ͘ϮͲ,ĂŶĚůŝŶŐĐŽŶĚŝƚŝŽŶƐ

WƌĞĐĂƵƚŝŽŶƐ
• ǀŽŝĚƐŚŽĐŬƐǁŚŝĐŚƌŝƐŬĚĂŵĂŐŝŶŐƚŚĞĞƋƵŝƉŵĞŶƚ
• &ŽůůŽǁƚŚĞĨŝǆŝŶŐͬůŝĨƚŝŶŐƉŽŝŶƚƐ͘

>ŝĨƚŝŶŐƉŽŝŶƚƐ
• tŚĞƌĞƚŚĞĞƋƵŝƉŵĞŶƚĚŽĞƐŶŽƚŚĂǀĞůŝĨƚŝŶŐůƵŐƐ͗
Ύ/ƚŝƐĂĚǀŝƐĂďůĞƚŽƵƐĞƚĞǆƚŝůĞůŝĨƚŝŶŐƐƚƌĂƉƐ͘
Ύ>ŝĨƚŝŶŐƉŽŝŶƚƐĂƌĞŽŶƚŚĞŵĞƚĂůůŝĐĐŚĂƐƐŝƐ͕ŽƌŵĞƚĂůůŝĐĂƌĞĂƐŽŶƐƚƌĞŶŐƚŚĞŶĞĚƉĂƌƚƐ͘

WŽŝŶƚƐŶŽƚƚŽďĞůŝĨƚĞĚ
• KŶǁĞĂƌĂƌĞĂƐůŝŬĞůǇƚŽĚĞĨŽƌŵ
• KŶƚŚĞĨŽůůŽǁŝŶŐŝƚĞŵƐ͗
ΎsĂůǀĞƐ͕ƐƚŽƉĐŽĐŬƐ
Ύ&ůŽǁŵĞƚĞƌƐ
ΎŽŶƚƌŽůǀĂůǀĞƐΘ^ŚƵƚŽĨĨsĂůǀĞƐ
ΎWŝƉŝŶŐ
ΎƚĐ͘͘͘

dŚŝƐůŝƐƚŝƐũƵƐƚĂƐĞůĞĐƚŝŽŶ͘
ϰ͘ϯ͘ϯͲŚŽŽƐŝŶŐƚŚĞǁĂǇƚŽŚĂŶĚůĞƚŚĞĞƋƵŝƉŵĞŶƚ

• dŚĞĞƋƵŝƉŵĞŶƚƐŚŽƵůĚďĞŚĂŶĚůĞĚĂĐĐŽƌĚŝŶŐƚŽŚŽǁŚĞĂǀǇƚŚĞůŽĂĚŝƐ͘
• dŚĞůŝĨƚŝŶŐĐĂƉĂĐŝƚǇƐŚŽƵůĚďĞĂƚůĞĂƐƚϭ͘ϱƚŝŵĞƐƚŚĞůŽĂĚ͘
JOB NO.17-3610
KWZd/KEED/EdEEDEh>
WZdϰͲWZ>/D/EZz,<&KZ^dZdͲhW
ϰ͘ϭͲ'EZ>/d/^

ĨƚĞƌĨŝŶĂůĞƌĞĐƚŝŽŶ;ŽƌďĞĨŽƌĞƌĞƐƚĂƌƚͲƵƉŽĨƚŚĞƉůĂŶƚĂĨƚĞƌĂƉůĂŶƚƐŚƵƚĚŽǁŶĨŽƌŵĂŝŶƚĞŶĂŶĐĞͿ͕ƚŚĞĨŽůůŽǁŝŶŐƐ
ŝŶƐƉĞĐƚŝŽŶƐŵƵƐƚďĞĐĂƌƌŝĞĚŽƵƚ͗
• sĞƌŝĨǇƚŚĂƚĂůůƚŚĞƉŝƉŝŶŐŝƐĐŽŶŶĞĐƚĞĚ͘
• sĞƌŝĨǇƚŚĂƚĂůůĞƋƵŝƉŵĞŶƚĂƌĞŝŶƉůĂĐĞĂŶĚĐŽƌƌĞĐƚůǇĐŽŶŶĞĐƚĞĚ;ƉƵŵƉ͕ŵĂŶŽŵĞƚĞƌ͙Ϳ͘
• sĞƌŝĨǇƚŚĂƚĂůůŵĂŶƵĂůůǇŽƉĞƌĂƚĞĚǀĂůǀĞƐͬĚĂŵƉĞƌƐĂƌĞĐůŽƐĞĚ͘
• sĞƌŝĨǇƚŚĞŐŽŽĚƉŽƐŝƚŝŽŶŽĨĂůůƚŚĞůŝŵŝƚƐǁŝƚĐŚĞƐ͘
• sĞƌŝĨǇƚŚĞƐƚĂƚƵƐŽĨĂůůĂƵƚŽŵĂƚŝĐǀĂůǀĞƐ;ŶŽƌŵĂůůǇĐůŽƐĞĚ͕ŶŽƌŵĂůůǇŽƉĞŶͿ͘
• sĞƌŝĨǇƚŚĂƚĂůůůŽĐĂůĞůĞĐƚƌŝĐĂůĐĂďŝŶĞƚŚĂǀĞƚŚĞŝƌŐĞŶĞƌĂůƐǁŝƚĐŚŝŶƐƚŽƉƉŽƐŝƚŝŽŶ͘
• ŚĞĐŬƚŚĂƚĂůůƚŚĞĐŽŶƚƌŽůĐĂďŝŶĞƚĂƌĞƉŽǁĞƌĞĚŽĨĨ͘
• WĞƌĨŽƌŵĂĐŽŶƚŝŶƵŝƚǇĐŚĞĐŬŽŶĂůůƚŚĞǁŝƌĞƐ͘
• ŚĞĐŬƉƌŽŐƌĂŵŵŝŶŐŽĨĐŽŶƚƌŽůůĞƌƐ͘
• ŚĞĐŬƚŚĂƚĂůůĐŚĂŝŶͲŐƵĂƌĚĂŶĚŚĞĂƚƉƌŽƚĞĐƚŝŽŶĂƌĞŝŶƉůĂĐĞ͘
• ŶƐƵƌĞĂǀĂŝůĂďŝůŝƚǇŽĨĂůůƚŚĞĚŝĨĨĞƌĞŶƚƵƐĞĚĨůƵŝĚƐ͘
• ^ĞůĞĐƚƚŚĞĂƚŽŵŝƐŝŶŐƵŶŝƚǀĞƌƐƵƐĨůƵŝĚƵƐĞĚƚŽƐƚĂƌƚ͘
• /ŶƐĞƌƚŝŐŶŝƚĞƌĂŶĂƚŽŵŝƐŝŶŐŐƵŶŝŶƚŚĞďƵƌŶĞƌ͘
• ŚĞĐŬƚŝŐŚƚŶĞƐƐŽĨƚŚĞĨůĞǆŝďůĞĐŽŶŶĞĐƚŝŽŶƐ͘
ϰ͘ϮʹK/>/^dZ/hd/KE

ϱ͘Ϯ͘ϭʹKŝůŵĂŝŶƚĂŶŬƐ

ŚĞĐŬůŝƐƚ
• ůůŵĂƚĞƌŝĂůŝƐŝŶŐŽŽĚƐŚĂƉĞ͘
• ŽŶŶĞĐƚŝŽŶƐŽĨƉŝƉŝŶŐƵƉĂŶĚĚŽǁŶƐƚƌĞĂŵĂƌĞĐŽƌƌĞĐƚůǇŵĂĚĞ͘
ϱ͘Ϯ͘ϮʹKŝůƚƌĂŶƐĨĞƌƉƵŵƉŝŶŐƐĞƚ

ŚĞĐŬůŝƐƚ
• ŽŶŶĞĐƚŝŽŶƐŽĨƉŝƉŝŶŐůŝŶĞƐƵƉĂŶĚĚŽǁŶƐƚƌĞĂŵĂƌĞĐŽƌƌĞĐƚůǇŵĂĚĞ͘
• ^ƚƌĂŝŶĞƌƐƐĐƌĞĞŶƐĂƌĞĐůĞĂŶĞĚĂŶĚŝŶƐƚĂůůĞĚ͘
• WƵŵƉƐŵƵƐƚďĞĨƌĞĞƚŽƌŽƚĂƚĞďǇŚĂŶĚ;ĐŚĞĐŬĂĨƚĞƌůŽŶŐƐƚŽƉĂůƐŽͿ͘
• ^ƚƌĂŝŐŚƚŝŶůŝŶĞƉŽƐŝƚŝŽŶŽĨƉƵŵƉƐĚƌŝǀĞ͘
• /ĨƚŚĞƚǁŽĂďŽǀĞƉŽŝŶƚŚĂǀĞďĞĞŶĐŚĞĐŬĞĚǁŝƚŚƐƵĐĐĞƐƐ͕ƚƌǇƚŚĞƌŽƚĂƚŝŽŶǁĂǇďǇĂƐŚŽƌƚĞůĞĐƚƌŝĐŝŵƉƵůƐŝŽŶ͘
• ůůŵĂƚĞƌŝĂůŝƐŝŶŐŽŽĚƐŚĂƉĞ͘
• ĐƚƵĂƚĞĂůůƚŚĞǀĂůǀĞƐďǇŚĂŶĚƚŽĚĞƚĞĐƚĂŶĚĞǀĞŶƚƵĂůŚĂƌĚƉŽŝŶƚ͘
ϰ͘ϯʹ,Kd'^'EZdKZhZEZ

&^W> ƵƌŶĞƌƐ ĂƌĞ ƐŚŽƉ ŝŶƐƉĞĐƚĞĚ ďĞĨŽƌĞ ƐŚŝƉŵĞŶƚ͘ ^ŽŵĞ ĨƵƌƚŚĞƌ ǀĞƌŝĨŝĐĂƚŝŽŶ ƐŚĂůů ďĞ ƌĞĂůŝǌĞĚ ĂĨƚĞƌ
ŝŶƐƚĂůůĂƚŝŽŶ͘
dŚĞƉŽƐŝƚŝŽŶŽĨƚŚĞĐŽŵďƵƐƚŝŽŶŚĞĂĚƌĞƐƉĞĐƚƚŽƚŚĞĞĚŐĞŽĨƚŚĞĚƌĂƵŐŚƚƐůĞĞǀĞĂŶĚƚŚĞƉŽƐŝƚŝŽŶŽĨƚŚĞďƵƌŶĞƌ
ƚŝƉƌĞƐƉĞĐƚƚŽƚŚĞĨůĂŵĞƐƚĂďŝůŝǌŝŶŐŚƵďĂƌĞŽĨƉƌŝŵĞŝŵƉŽƌƚĂŶĐĞĨŽƌĂŶŽƉƚŝŵĂůŽƉĞƌĂƚŝŽŶŽĨƚŚĞ'ZďƵƌŶĞƌ͘
EŽƚĞ͗dŚĞƐĞƉƌŝŵĞĚŝŵĞŶƐŝŽŶƐĂŶĚĂĚũƵƐƚŵĞŶƚƐƐŚŽƵůĚďĞƌĞĐŽƌĚĞĚ͕ĨŽƌĨƵƚƵƌĞƌĞĨĞƌĞŶĐĞ͘
&ƌŽŵŝŶƐŝĚĞƚŚĞďŽŝůĞƌ
EĞĐĞƐƐĂƌǇǀĞƌŝĨŝĐĂƚŝŽŶƐĂƌĞĂƐĨŽůůŽǁƐ͗
JOB NO.17-3610
KWZd/KEED/EdEEDEh>

ƌĂƵŐŚƚƐůĞĞǀĞ͗
ΎǇůŝŶĚƌŝĐŝƚǇ
ΎŽŶĐĞŶƚƌŝĐŝƚǇ
Ύ>ĞŶŐƚŚ
ΎŝĂŵĞƚĞƌ
Ύ^ƚƌƵĐƚƵƌĂůŝŶƚĞŐƌŝƚǇ

^ǁŝƌůĞƌ͗
ΎŝƌĞĐƚŝŽŶŽĨƌŽƚĂƚŝŽŶ
Ύ&ŽƌǁĂƌĚƉŽƐŝƚŝŽŶŝŶŐŽĨƚŚĞĐŽŵďƵƐƚŝŽŶŚĞĂĚŝŶƌĞůĂƚŝŽŶƚŽƚŚĞĞĚŐĞŽĨƚŚĞĚƌĂƵŐŚƚƐůĞĞǀĞ͘
Ύ hƐĞ ƚŚĞ ĂĚũƵƐƚŵĞŶƚ ĚĞǀŝĐĞ ůŽĐĂƚĞĚ ŽŶ ƚŚĞ ƐǁŝƌůĞƌ ĚŽŽƌ͕ ůŝŶŬĞĚ ƚŽ ƚŚĞ ũĂĐŬĞƚ ƉŝƉĞ ƵƐŝŶŐ ƚŚĞ ƚǁŽ ;ϮͿ
ƚŚƌĞĂĚĞĚƌŽĚƐΘŶƵƚƐĂƐƐĞŵďůŝĞƐƚŽƉŽƐŝƚŝŽŶƚŚĞĐŽŵďƵƐƚŝŽŶŚĞĂĚ͘
Ύ ĞŶƚĞƌŝŶŐ ŽĨ ƚŚĞ Ăŝƌ ĚŝĨĨƵƐĞƌ ŝŶƐŝĚĞ ƚŚĞ ĚƌĂƵŐŚƚ ƐůĞĞǀĞ͘ ZĞŵŽǀĞ ƚŚĞƉĞƌĨŽƌĂƚĞĚƉůĂƚĞĨƌŽŵƚŚĞǁŝŶĚďŽǆ
ƐŝĚĞ͕ ƚŽ ŚĂǀĞ ĂĐĐĞƐƐ ƚŽ ƚŚĞ ĂǆŝƐ ƐŝƚƚŝŶŐ ĚĞǀŝĐĞ ĨŽƌ ƚŚĞ ũĂĐŬĞƚ ƉŝƉĞ͘ 'ĞŶĞƌĂůůǇ͕ ƚŚĞƌĞ ĂƌĞ ƚŚƌĞĞ ůĞŐƐ ƚŚĂƚ
ƉĞƌŵŝƚĐĞŶƚĞƌŝŶŐŽĨƚŚĞĐŽŵďƵƐƚŝŽŶŚĞĂĚǁŝƚŚŝŶƚŚĞĚƌĂƵŐŚƚƐůĞĞǀĞ͘^ĐƌĞǁƐŽŶƚŚĞƐĞůĞŐƐǁŝůůƉĞƌŵŝƚǇŽƵ
ƚŽĂĐŚŝĞǀĞƉƌŽƉĞƌĐĞŶƚĞƌŝŶŐŽƌƚŚĞĐŽŵďƵƐƚŝŽŶŚĞĂĚ͘

ƚƚŚĞďƵƌŶĞƌĨƌŽŶƚ
− ůŝŐŶĨůĂŵĞƐĐĂŶŶĞƌ;ƐͿŝŶŽƌĚĞƌƚŽĂĐŚŝĞǀĞĂŶŽƉƚŝŵĂůƐĐĂŶŶŝŶŐŽĨƚŚĞĨůĂŵĞ͘
− sĞƌŝĨǇƚŚĞ&ůĂŶŐĞƉĂŝƌŝŶŐĂŶĚƚŝŐŚƚĞŶƚŚĞĨůĂŶŐĞƐŽŶƚŚĞďƵƌŶĞƌĨƵĞůŐĂƐŵĂŶŝĨŽůĚ͕ŝĨŶĞĐĞƐƐĂƌǇ͘
− &ŝƚƚŚĞĨƵĞůŽŝůďƵƌŶĞƌŝŶƚŽũĂĐŬĞƚƉŝƉĞ͘
− ĂƌƌǇŽƵƚŐĂƐ͕ĂŝƌĂŶĚĞůĞĐƚƌŝĐĂůĞƋƵŝƉŵĞŶƚĐŽŶŶĞĐƚŝŽŶƐ͘
− sĞƌŝĨǇƚŚĞĞůĞĐƚƌŝĐĂůĐŽŶŶĞĐƚŝŽŶƐƚŽŝŐŶŝƚŽƌĂŶĚƐĐĂŶŶĞƌ;ƐͿ͘
− EŽƚĞĂůůƌĞůĞǀĂŶƚĚŝŵĞŶƐŝŽŶƐŽŶƚŽƚŚĞĨƌŽŶƚƉůĂƚĞ͘
JOB NO.17-3610
KWZd/KEED/EdEEDEh>
WZdϱͲ^dZdͲhW
ϱ͘ϭͲ'EZ>ZDZ<^

ĞĨŽƌĞĂŶǇŽƉĞƌĂƚŝŽŶ͕ǇŽƵŵƵƐƚƌĞĂĚĂŶĚŬŶŽǁƚŚĞŝŶƐƚĂůůĂƚŝŽŶƌĞĐŽŵŵĞŶĚĂƚŝŽŶŽĨĂůůĞƋƵŝƉŵĞŶƚƐ͕ƚŚĂƚŝƐ͗

• ZĞĂĚƚŚĞƐƵƉƉůŝĞƌĚŽĐƵŵĞŶƚĂƚŝŽŶ͘
• WƌĞƉĂƌĞŶĞĐĞƐƐĂƌǇĚƌĂǁŝŶŐƐ͕ĞƋƵŝƉŵĞŶƚƐĂŶĚƚŽŽůƐ͘
• <ŶŽǁ ĂŶĚ ďĞ ŝŶ ĂĐĐŽƌĚĂŶĐĞ ǁŝƚŚ ĨƵŶĐƚŝŽŶĂů ĐŽŶĚŝƚŝŽŶƐ͕ ƐƉĞĐŝĨŝĐ ĐŚĂƌĂĐƚĞƌŝƐƚŝĐƐ ;ĨƵĞů ƚǇƉĞ͕ ĨůŽǁ ƌĂƚĞ͕
ƉƌĞƐƐƵƌĞ͕ƚĞŵƉĞƌĂƚƵƌĞ͕͘͘͘͘͘͘ͿĂŶĚĂŶǇůŽĐĂůĐŽŶĚŝƚŝŽŶƐ͘
• sĞƌŝĨǇƚŚĞŐŽŽĚƐƚĂƚĞŽĨĞĂĐŚĚĞǀŝĐĞƚŽďĞŝŶƐƚĂůůĞĚ͘
• ŽŶŶĞĐƚŝŽŶƐŽĨƉŝƉŝŶŐůŝŶĞƐƵƉĂŶĚĚŽǁŶƐƚƌĞĂŵĂƌĞĐŽƌƌĞĐƚůǇŵĂĚĞ͘
• ĞĐĂƌĞĨƵůŽĨĐŽŶŶĞĐƚŝŽŶƚŝŐŚƚŶĞƐƐ;ũŽŝŶƚƚǇƉĞ͕ƚŝŐŚƚĞŶŝŶŐƚŽƌƋƵĞ͕ĐŽŶŶĞĐƚŝŽŶĐŽŵƉĂƚŝďŝůŝƚǇ͕ǁĞůĚƐƚǇƉĞĂŶĚ
ĐŽŶĚŝƚŝŽŶƐͿ͘
• 'ŝǀĞĂƐƵƉƉůǇƉƵůƐĞƚŽƚŚĞŵŽƚŽƌƐƚŽĐŚĞĐŬƚŚĞƌŽƚĂƚŝŽŶǁĂǇ;ŝĨŝƚŝƐƚŚĞǁƌŽŶŐǁĂǇ͕ĐŚĂŶŐĞƚŚĞĞůĞĐƚƌŝĐĂů
ĐŽŶŶĞĐƚŝŽŶͿ͘
• WƌĞƐƐƵƌĞŐĂƵŐĞƐĂƌĞŝŶƐƚĂůůĞĚ͘
• WƵŵƉƐĂŶĚĨĂŶƐĂƌĞĨƌĞĞƚŽƌŽƚĂƚĞďǇŚĂŶĚ;ĐŚĞĐŬďĞĨŽƌĞůŽŶŐƐƚŽƉĂůƐŽͿ͘
• ĐƚƵĂƚĞĂůůƚŚĞǀĂůǀĞƐďǇŚĂŶĚƚŽĚĞƚĞĐƚĂŶĞǀĞŶƚƵĂůŚĂƌĚƉŽŝŶƚ͘
ϱ͘ϮͲ^&dzZh>^

dŚĞ ďĂƐŝĐ ĐĂƵƐĞ ŽĨ ĞǆƉůŽƐŝŽŶƐ ŝƐ ƚŚĞ ŝŐŶŝƚŝŽŶ ŽĨ ĂŶ ĂĐĐƵŵƵůĂƚŝŽŶ ŽĨ Ă ĐŽŵďƵƐƚŝďůĞ ĂŶĚ Ăŝƌ ŵŝǆƚƵƌĞ ǁŝƚŚŝŶ Ă
ĐŽŶĨŝŶĞĚƐƉĂĐĞ͘

ůů ŐĂƐĞŽƵƐ ĨƵĞůƐ ĐĂŶ ĨŽƌŵ ĂŶĞǆƉůŽƐŝǀĞŵŝǆƚƵƌĞǁŝƚŚĂŝƌ͘ŽŶƐĞƋƵĞŶƚůǇ͕ĨŽƌŝŶƐƚĂůůĂƚŝŽŶƐĂĨĞƚǇŝƚŝƐŶĞĐĞƐƐĂƌǇ
ƚŚĂƚďƵƌŶĞƌŽƉĞƌĂƚŝŽŶďĞƉůĂĐĞĚƵŶĚĞƌƉĞƌŵĂŶĞŶƚƉƌĞǀĞŶƚĐŽŶĚŝƚŝŽŶƐĨĂǀŽƵƌĂďůĞĨŽƌƚŚĞĨŽƌŵĂƚŝŽŶŽĨƐƵĐŚĂ
ŵŝǆƚƵƌĞƚŽŽĐĐƵƌ͘

KƉĞƌĂƚŝŽŶ ŵƵƐƚ ďĞ ŝŶĚĞƉĞŶĚĞŶƚ ĨƌŽŵ ĞƌƌŽƌƐ͕ ǁŚŝĐŚ ĐĂŶ ďĞ ĂǀŽŝĚĞĚ ƚŚƌŽƵŐŚ ƚŚĞ ƐƚƌŝĐƚ ĂƉƉůŝĐĂƚŝŽŶ ŽĨ ƚŚĞ
ŽƉĞƌĂƚŝŶŐƉĞƌƐŽŶŶĞů͘

ĂŶŐĞƌŵĂǇĞǆŝƐƚĚƵƌŝŶŐƚŚĞŽƉĞƌĂƚŝŽŶŽĨƚŚĞŝŶƐƚĂůůĂƚŝŽŶŝŶƚŚĞĨŽůůŽǁŝŶŐĐĂƐĞƐ͗
• hŶďƵƌŶƚŽŝůŝŶƚŚĞĐŽŵďƵƐƚŝŽŶŐĂƐĞƐ͘
• ^ƵĚĚĞŶ ĨůĂŵĞ ĨĂŝůƵƌĞ͕ ǁŝƚŚ ƵŶĐŽŶƐƵŵŵĂƚĞĚ Žŝů ďĞŝŶŐ ĐŽŶƚŝŶƵĂůůǇ ĚŝƐĐŚĂƌŐĞĚ ŝŶƚŽ ƚŚĞ ĨƵƌŶĂĐĞ ǁŝƚŚŽƵƚ
ďƵƌŶŝŶŐ͘
• tŽƌŬŝŶŐĚĞĨĞĐƚ͘
• hŶƐƵĐĐĞƐƐĨƵůĂƚƚĞŵƉƚƐĂƚŝŐŶŝƚŝŽŶǁŝƚŚŽƵƚƉƌŽƉĞƌƉƵƌŐŝŶŐ͘

tŚĂƚĞǀĞƌ ƚŚĞ ƉĂƌƚŝĐƵůĂƌ ĂƌƌĂŶŐĞŵĞŶƚƐ ĂĚŽƉƚĞĚ ĨŽƌ ƚŚŝƐ ƐĂĨĞƚǇ ƐǇƐƚĞŵ ŵĂǇ ďĞ͕ ƚŚĞ ĨŽůůŽǁŝŶŐ ƌƵůĞƐ ŵƵƐƚ ďĞ
ƐƚƌŝĐƚůǇŽďƐĞƌǀĞĚ͗
• dŚĞƉƌĞƐĞŶĐĞŽĨĂďŶŽƌŵĂůǁŽƌŬŝŶŐĐŽŶĚŝƚŝŽŶƐŵƵƐƚůĞĂĚƚŽŝƌƌĞǀĞƌƐŝďůĞĐůŽƐŝŶŐŽĨƚŚĞƐĂĨĞƚǇƐŚƵƚͲŽĨĨǀĂůǀĞƐ͘
• ƌĞĂŬĚŽǁŶŝŶĞůĞĐƚƌŝĐĂůĐƵƌƌĞŶƚŵƵƐƚŝŵŵĞĚŝĂƚĞůǇůĞĂĚƚŽƚŚĞŝŶƚĞƌƌƵƉƚŝŽŶŽĨƚŚĞƐĂĨĞƚǇƐŚƵƚͲŽĨĨǀĂůǀĞƐĂŶĚ
ƚŚĞŽƉĞŶŝŶŐŽĨƚŚĞƐĂĨĞƚǇǀĞŶƚǀĂůǀĞ͘

ϱ͘ϯͲ,Kd'^'EZdKZhZEZ

dŚĞ ŶŽŶͲ ĨƵůĨŝůůŵĞŶƚ ŽĨ ƚŚĞ ƌĞƋƵŝƌĞŵĞŶƚƐ ŽĨ ƚŚĞƐĞ ůĂǁƐ ŝŶ ĨŽƌĐĞ ďǇ ƚŚĞ ďƵǇĞƌ͕ ƚŚĞ ƵƐĞƌ Žƌ ĂŶǇ ƚŚŝƌĚ ƉĂƌƚǇ
ŝŶĐůƵĚŝŶŐ ďƵƚ ŶŽƚ dŚĞ ŽƉĞƌĂƚŝŽŶ ŽĨ Ă ďƵƌŶĞƌ ŝƐ ƐƵďũĞĐƚ ƚŽ ĐŽŵƉůŝĂŶĐĞ ǁŝƚŚ ĂƉƉůŝĐĂďůĞ ƉƌŽĨĞƐƐŝŽŶĂů ĐŽĚĞ ŽĨ
ƉƌĂĐƚŝĐĞĂŶĚůŽĐĂůƌĞŐƵůĂƚŝŽŶƐ͘
JOB NO.17-3610
KWZd/KEED/EdEEDEh>
ůŝŵŝƚĞĚ ƚŽ ĂŶ ŽƚŚĞƌ ŵĂŶƵĨĂĐƚƵƌĞƌ Žƌ sĞŶĚŽƌ ŚĂǀŝŶŐ ƐƵƉƉůŝĞĚ ŐŽŽĚƐ ŝŶ ƌĞůĂƚŝŽŶ ƚŽ ďƵƌŶĞƌ ŽƉĞƌĂƚŝŽŶ ƐŚĂůů ŶŽƚ
ĞŶŐĂŐĞ&^W>ΖƐ>ŝĂďŝůŝƚǇ͘
ϱ͘ϰͲsϮhZEZ

ϭͲ'ĞŶĞƌĂůŝƚŝĞƐ

ƚŽŵŝƐĂƚŝŽŶƉƌŝŶĐŝƉůĞ
dŚĞsϮŽŝůďƵƌŶĞƌŐƵŶŝƐĂŵŝǆĞĚĂƚŽŵŝƐĂƚŝŽŶƚǇƉĞ͕ĐŽŵďŝŶŝŶŐŵĞĐŚĂŶŝĐĂůĂƚŽŵŝƐĂƚŝŽŶǁŝƚŚĞŵƵůƐŝŽŶĞĨĨĞĐƚ
ďǇĂĚĚŝƚŝŽŶŽĨĂŶĂƵǆŝůŝĂƌǇƉƌĞƐƐƵƌŝƐĞĚĨůƵŝĚ;ĚƌŝĞĚƐƚĞĂŵŽƌĐŽŵƉƌĞƐƐĞĚĂŝƌͿƚŽƉƌŽĚƵĐĞĂŐĞŶƵŝŶĞůǇĨŝŶĞĂŶĚ
ŚŽŵŽŐĞŶĞŽƵƐĞŵƵůƐŝŽŶ͘

sϮĂĚǀĂŶƚĂŐĞƐ
dŚŝƐďƵƌŶĞƌŐƵŶŚĂƐƚŚĞĨŽůůŽǁŝŶŐĨĞĂƚƵƌĞƐ͗
− 'ƌĞĂƚĨůĞǆŝďŝůŝƚǇĨŽƌĂĚĂƉƚĂƚŝŽŶƚŽƐƉĞĐŝĂůƐŝƚĞĐŽŶĚŝƚŝŽŶƐ͘
− ǆĐĞůůĞŶƚƉĞŶĞƚƌĂƚŝŽŶŽĨĂƚŽŵŝƐĞĚŽŝůĞůĞŵĞŶƚĂƌǇũĞƚƐŚĞůƉŝŶŐĂŝƌͲŽŝůŵŝǆŝŶŐĂƚĂůůƌƵŶŶŝŶŐůĞǀĞůƐ͘
− tŝĚĞƌĂŶŐĞŽĨĚŝƐĐŚĂƌŐĞǀĂƌŝĂƚŝŽŶƚŚĂƚĐĂŶƌĞĂĐŚϭϱƚŽϭƚƵƌŶĚŽǁŶƌĂƚŝŽ͘
− ŽŶƐƚĂŶƚĂƚŽŵŝƐĞĚŽŝůũĞƚĚŝǀĞƌŐĞŶĐĞĂůůŽǁŝŶŐďƵƌŶĞƌĂĚĂƉƚĂƚŝŽŶƚŽǀĂƌŝŽƵƐƚǇƉĞƐŽĨĨƵƌŶĂĐĞĐŚĂŵďĞƌƐ͘
− dŚĞĚŝǀĞƌŐĞŶĐĞĂŶŐůĞŚĂƐďĞĞŶĐŚŽƐĞŶďĞƚǁĞĞŶϲϱΣƚŽϭϭϬΣĨŽƌƚŚĞ'ZƚǇƉĞďƵƌŶĞƌƐ͕ƚŚĞƐĞĂŶŐůĞƐďĞŝŶŐ
ƐƵŝƚĂďůĞĨŽƌŵĂũŽƌŝƚǇŽĨƐƚĂŶĚĂƌĚďŽŝůĞƌƐ͘

&ŽƌƐƉĞĐŝĂůĂƉƉůŝĐĂƚŝŽŶƐĂĚŝĨĨĞƌĞŶƚĚŝǀĞƌŐĞŶĐĞĂŶŐůĞĐĂŶďĞĞŶǀŝƐĂŐĞĚ͘

ŽŶƐƵŵƉƚŝŽŶ
ƵǆŝůŝĂƌǇĂƚŽŵŝƐŝŶŐĨůƵŝĚĐŽŶƐƵŵƉƚŝŽŶŝƐŵŝŶŝŵŝƐĞĚĂƐĨŽůůŽǁƐ͗
− ŽŵƉƌĞƐƐĞĚĂŝƌ;ĚƌŝĞĚĂŶĚĐůĞĂŶĞĚͿĂďŽƵƚϭϮйŽĨĨƵĞůͲŽŝůǁĞŝŐŚƚĂƚƚŚĞŵĂǆŝŵƵŵŚŽƵƌůǇĨůŽǁƌĂƚĞ͘
− ^ƚĞĂŵ;ĚƌŝĞĚƐĂƚƵƌĂƚĞĚƐƚĞĂŵŽƌůŝŐŚƚůǇƐƵƉĞƌŚĞĂƚĞĚͿĂďŽƵƚϭϬйŽĨĨƵĞůͲŽŝůǁĞŝŐŚƚĂƚƚŚĞŵĂǆŝŵƵŵŚŽƵƌůǇ
ĨůŽǁƌĂƚĞ͘
− tĂƚĞƌ ĐŽŶƚĞŶƚ ŝŶ ƚŚĞĂƚŽŵŝƐŝŶŐĨůƵŝĚǁŝůůƉƌŽĚƵĐĞƌĂƉŝĚĂďƌĂƐŝŽŶŽĨƚŚĞĂƚŽŵŝƐĂƚŝŽŶƵŶŝƚƐĚĞƚƌŝŵĞŶƚĂůƚŽ
ĞĨĨŝĐŝĞŶƚĐŽŵďƵƐƚŝŽŶ͘

/DWKZdEdZDZ<͗/ŶŽƌĚĞƌƚŽĂǀŽŝĚǁĂƚĞƌĐŽŶƚĞŶƚŝŶĂƚŽŵŝƐŝŶŐƵŶŝƚƐǁŚĞŶĂƚŽŵŝƐŝŶŐĨůƵŝĚŝƐƐƚĞĂŵ͕ŝƚŝƐ
ŝŵƉĞƌĂƚŝǀĞƚŚĂƚƚŚĞƐƚĞĂŵŵƵƐƚďĞĂďƐŽůƵƚĞůǇĚƌǇĂŶĚŝĨŝƚŝƐƉŽƐƐŝďůĞ͕ƐůŝŐŚƚůǇƐƵƉĞƌŚĞĂƚĞĚĂƚĂƚĞŵƉĞƌĂƚƵƌĞ
ŽĨĂďŽƵƚϮϱϬΣ͘
ŽŶŽƚŚĞƐŝƚĂƚĞƚŽĐŽŶƚĂĐƚƵƐĨŽƌƐƉĞĐŝĂůĂƉƉůŝĐĂƚŝŽŶƐŝĨƚŚĞƐĞƌĞƋƵŝƌĞŵĞŶƚƐĐĂŶŶŽƚďĞƌĞƐƉĞĐƚĞĚ͘

ϮͲsϮKƉĞƌĂƚŝŶŐĐǇĐůĞ

dŚĞ ĨƵĞů Žŝů ĞŶƚĞƌƐ ƚŚĞ ǁĞůĚĞĚ ŶƵƚ ΀/ƚĞŵ ϳ΁ ǀŝĂ ƚŚĞ ĐĞŶƚƌĂů ĐŝƌĐƵŝƚ ƚŚĞŶ ĨůŽǁƐ ƚŚƌŽƵŐŚ ƚŚĞ ƐǁŝƌůŝŶŐ ĂƚŽŵŝƐĞƌ
΀/ƚĞŵ ϱ΁ ǁŚĞƌĞ ŝŶƚĞŶƐĞ ƌŽƚĂƚŝŽŶ ŝƐ ŝŵƉĂƌƚĞĚ ƵƉŽŶ ƚŚĞ Žŝů ďǇ ƚŚĞ ƚĂŶŐĞŶƚŝĂů ĐŚĂŶŶĞůƐ ůŽĐĂƚĞĚ ŝŶ ƚŚĞ ƐǁŝƌůŝŶŐ
ĂƚŽŵŝƐĞƌ͘dŚĞƌŽƚĂƚŝŶŐŽŝůŝƐƚŚĞŶĨŽƌĐĞĚƚŚƌŽƵŐŚƚŚĞŽƌŝĨŝĐĞƉůĂƚĞƐĞĐƚŝŽŶ΀/ƚĞŵϰ΁ĂŶĚĂũĞƚĨůŽǁŽĨŽŝůĞŶƚĞƌƐ
ƚŚĞĞŵƵůƐŝĨŝĞƌĐŚĂŵďĞƌ΀/ƚĞŵϯ΁͘
dŚĞĂƚŽŵŝƐŝŶŐĨůƵŝĚ;ƐƚĞĂŵŽƌĐŽŵƉƌĞƐƐĞĚĂŝƌͿĞŶƚĞƌƐƚŚĞǁĞůĚĞĚŶƵƚǀŝĂƚŚĞŽƵƚƐŝĚĞĐŚĂŶŶĞůƐĂŶĚŝƚƉĂƐƐĞƐ
ƚŚƌŽƵŐŚƚŚĞƐǁŝƌůŝŶŐĂƚŽŵŝƐĞƌ΀ϱ΁ĂŶĚƚŚĞŽƌŝĨŝĐĞƉůĂƚĞ΀ϰ΁ǁŝƚŚŽƵƚĞŶĐŽƵŶƚĞƌŝŶŐƚŚĞĨƵĞůŽŝůĨůŽǁ͘
dŚĞĂƚŽŵŝƐŝŶŐĨůƵŝĚƚŚĞŶĞŶƚĞƌƐƚŚĞĞŵƵůƐŝĨŝĞƌĐŚĂŵďĞƌǀŝĂƚŚĞĞŵƵůƐŝĨŝĞƌĐŚĂŶŶĞůƐ΀ϯ΁͘
ŚŽŵŽŐĞŶŝƐĞĚŵŝǆƚƵƌĞŽĨĨŝŶĞůǇƉƵůǀĞƌŝƐĞĚĨƵĞůŽŝůĂŶĚƐƚĞĂŵĞǆŝƚƐǀŝĂƚŚĞŵƵůƚŝŶŽǌǌůĞƚǇƉĞŽƌŝĨŝĐĞƐ΀/ƚĞŵϮ΁͘
dŚĞĨƵĞůŽŝůĨůŽǁƌĂƚĞĚĞƉĞŶĚƐŽŶƚŚĞĨƵĞůŽŝůŝŶůĞƚƉƌĞƐƐƵƌĞĂŶĚĂůƐŽƚŚĞĂƚŽŵŝƐŝŶŐĨůƵŝĚŝŶůĞƚƉƌĞƐƐƵƌĞ͘
JOB NO.17-3610
KWZd/KEED/EdEEDEh>

ϰͲƵƌŶĞƌŝŐŶŝƚŝŽŶŐƵŝĚĞ

tŚĞƌĞĂƐƵĨĨŝĐŝĞŶƚƐƚĞĂŵƉƌĞƐƐƵƌĞŝƐŶŽƚĂǀĂŝůĂďůĞĚƵƌŝŶŐƚŚĞŝŐŶŝƚŝŽŶƉĞƌŝŽĚŽĨĂƐƚĞĂŵďŽŝůĞƌ͕ŽŶĞĐĂŶƌĞƉůĂĐĞ
ƚŚĞĂƚŽŵŝƐŝŶŐƐƚĞĂŵĨůƵŝĚďǇĐŽŵƉƌĞƐƐĞĚĂŝƌ͘
/ŶƚŚŝƐĐĂƐĞŝƚŝƐĨŽƌďŝĚĚĞŶƚŽĞǆĐĞĞĚƚŚĞϭͬϰůŽĂĚŽĨƚŚĞ,'';ϮϱйDZͿ

ϱͲWƵƌŐŝŶŐĂŶĚĐůĞĂŶŝŶŐŐƵŝĚĞ

/ƚŝƐƌĞĐŽŵŵĞŶĚĞĚƚŽĐůĞĂŶƚŚĞďƵƌŶĞƌΖƐŽŝůŐƵŶƉĞƌŝŽĚŝĐĂůůǇĚƵƌŝŶŐĂŶŽďůŝŐĂƚŽƌǇĂƵƚŽŵĂƚŝĐŽƌŵĂŶƵĂůƐŚƵƚͲ
ĚŽǁŶ͘
/ŶĂůůĐĂƐĞƐƚŚĞƉƵƌŐĞĂŶĚĐůĞĂŶŝŶŐƐĞƋƵĞŶĐĞŵƵƐƚďĞĚŽŶĞǁŝƚŚƚŚĞŝŐŶŝƚŝŽŶŐĂƐƚŽƌĐŚŝŐŶŝƚĞĚ;ŝ͘Ğ͗͘ǁŝƚŚĨůĂŵĞ
ƉƌĞƐĞŶĐĞͿ͘

ϲͲsϮDĂŝŶƚĞŶĂŶĐĞ

KƵƌďƵƌŶĞƌƐĂƌĞƌĞůĂƚŝǀĞůǇƐĞůĨͲĐůĞĂŶŝŶŐĂƚƚŚĞĐŽŵďƵƐƚŝŽŶŚĞĂĚ͕ĂůůŽǁŝŶŐĂůŽŶŐŽƉĞƌĂƚŝŽŶƉĞƌŝŽĚǁŝƚŚŽƵƚĂŶǇ
ŵĂŝŶƚĞŶĂŶĐĞ͘dŚŝƐŝƐŐĞŶĞƌĂůůǇĂďŽƵƚŽŶĞǁĞĞŬŝŶŶŽƌŵĂůǁŽƌŬŝŶŐĐŽŶĚŝƚŝŽŶƐĂŶĚŐŝǀĞŶŐŽŽĚƋƵĂůŝƚǇŽĨĨƵĞůŽŝů
ĂŶĚĂƚŽŵŝƐŝŶŐƐƚĞĂŵ͘

,ŽǁĞǀĞƌ͕ŝƚŝƐƌĞĐŽŵŵĞŶĚĞĚƚŽƚŚŽƌŽƵŐŚůǇĐůĞĂŶƚŚĞsϮŽŝůŐƵŶƵŶŝƚƐĚƵƌŝŶŐĂůůďƵƌŶĞƌƐŚƵƚͲĚŽǁŶƐ͘
WůĞĂƐĞƌĞĨĞƌƚŽƉƉĞŶĚŝǆ/ĨŽƌĂŶĞǆƉůŽĚĞĚǀŝĞǁŽĨƚŚĞsϮŽŝůďƵƌŶĞƌĂŶĚĐŽŵƉŽŶĞŶƚƐ͘
− ĨƚĞƌƌĞŵŽǀŝŶŐŽŝůŐƵŶ͕ĐŽŽůƚŚĞsϮĂƚŽŵŝƐŝŶŐƵŶŝƚƐďǇƉůƵŶŐŝŶŐƚŚĞŽŝůŐƵŶŝŶƚŽĂŝĞƐĞůKŝůďĂƚŚŽƌŽƚŚĞƌ
ƐƉĞĐŝĂůĐůĞĂŶĞƌƐŽůǀĞŶƚ͘
− hŶƐĐƌĞǁǁŝƚŚƐƉĞĐŝĂůůǇƐƵƉƉůŝĞĚǁƌĞŶĐŚƚŚĞůŽĐŬŝŶŐͲŶƵƚ΀/ƚĞŵϭ΁͘
− ZĞŵŽǀĞƚŚĞĂƚŽŵŝƐŝŶŐĞůĞŵĞŶƚƐĂŶĚƉůƵŶŐĞƚŚĞŵŝŶĂƉƉƌŽƉƌŝĂƚĞĐůĞĂŶĞƌƐŽůǀĞŶƚƐŝŶŽƌĚĞƌƚŽĚŝƐƐŽůǀĞŽŝů
ƌĞƐŝĚƵĞƐ͘
− ůĞĂŶĞĂĐŚĐŽŵƉŽŶĞŶƚĐĂƌĞĨƵůůǇǁŝƚŚĐůĞĂŶďƌĂƐƐtŽŽů;ĨŽƌĞǆĂŵƉůĞͿĂŶĚĐůĞĂŶĐůŽƚŚƐ͘

ZDZ<͗EĞǀĞƌƵƐĞŵĞƚĂůůŝĐƚŽŽůƐ͘

− /ŶŽƌĚĞƌƚŽĂǀŽŝĚĨƵĞůŽŝůůĞĂŬĂŐĞ͕ǀĞƌŝĨǇƚŚĂƚƚŚĞƉŽůŝƐŚĞĚƐƵƌĨĂĐĞƐŽĨĞĂĐŚĞůĞŵĞŶƚĂƌĞŝŶĂŐŽŽĚĐŽŶĚŝƚŝŽŶ
ĂŶĚǁŝƚŚŽƵƚƐĐŽƌĞƐďĞĐĂƵƐĞŽŝůƚŝŐŚƚŶĞƐƐŝƐďǇŵĞƚĂůͬŵĞƚĂůĐŽŶƚĂĐƚŽŶůǇ͘/ĨǇŽƵĚŝƐĐŽǀĞƌĂŶǇƐĐŽƌĞŽŶƚŚĞ
ƉŽůŝƐŚĞĚŵĞƚĂůƐƵƌĨĂĐĞ͕ǇŽƵŵƵƐƚƉŽůŝƐŚƚŚŝƐƐƵƌĨĂĐĞǁŝƚŚĂƉƉƌŽƉƌŝĂƚĞĨŝŶĞƉŽůŝƐŚŝŶŐƉĂƐƚĞ͘
− /ĨƐĐŽƌĞƐƌĞŵĂŝŶĂĨƚĞƌƉŽůŝƐŚŝŶŐ͕ƚŚĞĂƚŽŵŝƐŝŶŐĞůĞŵĞŶƚǁŝůůŚĂǀĞƚŽďĞƌĞƉůĂĐĞĚďǇĂŶĞǁŽŶĞ͘

ŽŶƐĞƋƵĞŶƚůǇŝƚŝƐŶĞĐĞƐƐĂƌǇƚŽŚĂŶĚůĞƚŚĞĂƚŽŵŝƐŝŶŐĞůĞŵĞŶƚƐǁŝƚŚĐĂƌĞ͘

− ĞĨŽƌĞƌĞĂƐƐĞŵďůŝŶŐŽĨsϮƵŶŝƚƐƚŚĞƚŚƌĞĂĚĞĚƉĂƌƚƐ;ůŽĐŬŝŶŐͲŶƵƚ͕΀/ƚĞŵϭ΁ĂŶĚǁĞůĚĞĚŶƵƚ΀/ƚĞŵϳ΁ŵƵƐƚďĞ
ŐƌĞĂƐĞĚǁŝƚŚŚŝŐŚŚĞĂƚƉƌŽŽĨŐƌĞĂƐĞŝŶŽƌĚĞƌƚŽŵĂŬĞůĂƚĞƌĚŝƐŵĂŶƚůŝŶŐĞĂƐŝĞƌ͘
− dŚĞŶƌĞĂƐƐĞŵďůĞĐĂƌĞĨƵůůǇĂŶĚŝŶĐŽƌƌĞĐƚŽƌĚĞƌ;ƌĞĨĞƌƚŽƉƉĞŶĚŝǆ/ͿƚŚĞǀĂƌŝŽƵƐĂƚŽŵŝƐŝŶŐĞůĞŵĞŶƚƐ͗&ŝƌƐƚ
ƚŚĞ ŵƵůƚŝŶŽǌǌůĞ ŝŶ ƚŚĞ ůŽĐŬŝŶŐͲŶƵƚ͕ ƚŚĞŶ ƚŚĞ ĞŵƵůƐŝĨŝĞƌ͕ ƚŚĞŶ ƚŚĞ ŽƌŝĨŝĐĞ ƉůĂƚĞ ĂŶĚ ĨŝŶĂůůǇ ƚŚĞ ƐǁŝƌůŝŶŐ
ĂƚŽŵŝƐĞƌ͘
− ĞĨŽƌĞƚŚĞƚŝŐŚƚĞŶŝŶŐƵƉ͕ĐŚĞĐŬƚŚĞĐŽƌƌĞĐƚďĞĂƌŝŶŐŽĨƚŚĞŵƵůƚŝŶŽǌǌůĞŽŶƚŚĞůŽĐŬŝŶŐͲŶƵƚ͕ĂŶĚƚŚĞŶƐĐƌĞǁ
ŵĂŶƵĂůůǇ͘
− ĞĨŽƌĞĨŝŶĂůƚŝŐŚƚĞŶŝŶŐƵƉǁŝƚŚĂĚǇŶĂŵŽŵĞƚƌŝĐǁƌĞŶĐŚ͕ĂǀŝƐƵĂůĐŚĞĐŬŵƵƐƚďĞŵĂĚĞƚŽŵĂŬĞƐƵƌĞƚŚĂƚ
ƚŚĞŵƵůƚŝŶŽǌǌůĞŝƐŝŶĂŐŽŽĚƉŽƐŝƚŝŽŶ͘
JOB NO.17-3610
KWZd/KEED/EdEEDEh>

− dŚĞĨŝŶĂůƚŝŐŚƚĞŶŝŶŐŵƵƐƚďĞĚŽŶĞǁŝƚŚĂƚŽƌƋƵĞǁƌĞŶĐŚƐĞƚĂƚƚŚĞĨŽůůŽǁŝŶŐǀĂůƵĞƐ͘
• &ŽƌsϮŵŽĚĞůϴϵс ϳϬ ŵ<Ő
• &ŽƌsϮŵŽĚĞůϲϳс ϰϱ ŵ<Ő
• &ŽƌsϮŵŽĚĞůϯϰϱс ϯϬ ŵ<Ő
• &ŽƌsϮŵŽĚĞůϭϮ с ϲ ŵ<Ő

− ŶǇ ĐůĞĂƌĂŶĐĞ͕ ďĂĚ ĂƐƐĞŵďůŝŶŐ͕ ďĂĚ ƚŝŐŚƚĞŶŝŶŐ ǁŝůů ƌĞƐƵůƚ ŝŶ ĨƵĞů Žŝů ůĞĂŬĂŐĞ ďĞƚǁĞĞŶ ĨƵĞů Žŝů ĂŶĚ ƐƚĞĂŵ
ĐŝƌĐƵŝƚƐ ĂŶĚ ŝŶ ƚŚŝƐ ĐĂƐĞ Ă ĚŝƐĂƐƚƌŽƵƐ ĂƚŽŵŝƐĂƚŝŽŶ ǁŝƚŚ ďĂĚ ĐŽŵďƵƐƚŝŽŶ ĂŶĚ ĚĞƉŽƐŝƚƐ ŽĨ ĐŽŬĞ ŽŶ ƚŚĞ
ŵƵůƚŝŶŽǌǌůĞ͘

ϳͲ^ƉĂƌĞWĂƌƚƐ

− dŽŽƌĚĞƌƐƉĂƌĞͲƉĂƌƚƐƉůĞĂƐĞƐƚĂƚĞƚŚĞƚǇƉĞŽĨsϮĂƚŽŵŝƐŝŶŐƵŶŝƚƐ͗;ŝ͘Ğ͗͘sϮϲϳŽƌϯϰϱ͘͘͘͘Ϳ
− dŚĞƌĞĨĞƌĞŶĐĞŶƵŵďĞƌ;ǁŝƚŚϰŶƵŵďĞƌƐͿŝŶĚŝĐĂƚĞĚŽŶƚŚĞΗDĂŶƵĨĂĐƚƵƌĞƌŝĚĞŶƚŝĨŝĐĂƚŝŽŶƉůĂƚĞΗ
;Ğ͘Ő͗͘ϲϰϰϴͿ͘

tĞƌĞĐŽŵŵĞŶĚǇŽƵŬĞĞƉŝŶƐƚŽĐŬƚŚĞĨŽůůŽǁŝŶŐƐƉĂƌĞͲƉĂƌƚƐ͗
• ŽŶĞ΀ϭ΁ůŽĐŬŝŶŐͲŶƵƚ ΃/ƚĞŵϭ
• ƚǁŽ΀Ϯ΁ŵƵůƚŝŶŽǌǌůĞƐ ΃/ƚĞŵϮ
• ƚǁŽ΀Ϯ΁ŽƌŝĨŝĐĞƉůĂƚĞƐ ΃/ƚĞŵϰ
• ƚǁŽ΀Ϯ΁ƐǁŝƌůŝŶŐĂƚŽŵŝƐĞƌƐ ΃/ƚĞŵϱ
• ŽŶĞ΀ϭ΁ĚŝƐƚƌŝďƵƚŽƌ ΃/ƚĞŵϲ;ŽŶůǇŶĞĐĞƐƐĂƌǇǁŝƚŚsϮŵŽĚĞůϲϳͿ
• ŽŶĞ΀ϭ΁ĐŽŵƉůĞƚĞsϮďƵƌŶĞƌŐƵŶ
• ŽŶĞ΀ϭ΁ƐĞƚ;ϭϬͿŽĨĐŽƉƉĞƌŐĂƐŬĞƚƐĨŽƌĨƵĞůŽŝůĂŶĚĂƚŽŵŝƐŝŶŐĨůƵŝĚƚŝŐŚƚŶĞƐƐƚǇƉĞDͲϯϲϯϯ

EKd ͗ dŽ ŽďƚĂŝŶ ďĞƐƚ ĐŽŵďƵƐƚŝŽŶ ƌĞƐƵůƚƐ ǁĞ ƌĞĐŽŵŵĞŶĚ ƚŚĞ ƵƐĞ ŽĨ ŽŶůǇ ŐĞŶƵŝŶĞ W/>>Z ƉĂƚĞŶƚĞĚ sϮ
ĂƚŽŵŝƐŝŶŐƉĂƌƚƐ͘

JOB NO.17-3610
KWZd/KEED/EdEEDEh>

&h>K/>sϮdKD//E',
;ǁŝƚŚƚǁŽƐĞƉĂƌĂƚĞĚĐŝƌĐƵŝƚƐͿ

JOB NO.17-3610
KWZd/KEED/EdEEDEh>

WZdϲͲD/EdEE
ϲ͘ϭ͘Ͳ'EZ>D/EdEE

dŚĞ ŶĞĐĞƐƐĂƌǇ ŵĂŝŶƚĞŶĂŶĐĞ ŽĨ ƚŚĞ ŐŽŽĚƐ ĐŽŶƐŝƐƚƐ ŝŶ ĂƐƐƵƌŝŶŐ ƚŚĂƚ Ăůů ƉĂƌƚƐ ďĞ ŵĂŝŶƚĂŝŶĞĚ ŝŶ ŐŽŽĚ ǁŽƌŬŝŶŐ
ŽƌĚĞƌ͘ /ƚ ŝƐ ŝŵƉŽƌƚĂŶƚ ƚŚĂƚ ƚŚĞ ĞƋƵŝƉŵĞŶƚƐ ĐŽŶĐĞƌŶĞĚ ƐŚŽƵůĚ ďĞ ŵĂŝŶƚĂŝŶĞĚ ďǇ Žƌ ƵŶĚĞƌ ƚŚĞ ƐƵƉĞƌǀŝƐŝŽŶ ŽĨ
ĐŽŵƉĞƚĞŶƚƉĞƌƐŽŶƐŝŶĂĐĐŽƌĚĂŶĐĞǁŝƚŚŐŽŽĚƉƌĂĐƚŝĐĞĂŶĚĂĐĐŽƌĚŝŶŐƚŽĂŶǇŝŶƐƚƌƵĐƚŝŽŶƐƐƉĞĐŝĂůůǇĂĚǀŝƐĞĚĂŶĚ͕
ǁŚĞƌĞĂƉƉƌŽƉƌŝĂƚĞ͕ǁŝƚŚƉĂƌƚŝĐƵůĂƌƌĞĨĞƌĞŶĐĞƚŽŝŶĨŽƌŵĂƚŝŽŶƐƉĞĐŝĨŝĞĚŽŶƐƵďͲƐƵƉƉůŝĞƌůĞĂĨůĞƚƐ͘

/ƚ ŝƐ ƚŚĞ WƵƌĐŚĂƐĞƌΖƐ ƌĞƐƉŽŶƐŝďŝůŝƚǇ ƚŽ ĞŶƐƵƌĞ ƚŚĂƚ Ă ƐĂĨĞ ƐǇƐƚĞŵ ŽĨ ǁŽƌŬ ƐŚĂůů ďĞ ĂĚŽƉƚĞĚ ďǇ Ăůů ƉĞƌƐŽŶŶĞů
ŝŶǀŽůǀĞĚŝŶƚŚĞŵĂŝŶƚĞŶĂŶĐĞĂŶĚƚŚĂƚĂĐĐĞƐƐŽĨƐƉĞĐŝĨŝĐĞƋƵŝƉŵĞŶƚŝƐƌĞƐƚƌŝĐƚĞĚƚŽĂƵƚŚŽƌŝƐĞĚƉĞƌƐŽŶŶĞůŽŶůǇ͘

ůůŵŽǀŝŶŐƉĂƌƚƐŽĨƚŚĞĞƋƵŝƉŵĞŶƚƐƵƉƉůŝĞĚĂƌĞƐƵŝƚĂďůǇŐƵĂƌĚĞĚƚŽƉƌĞǀĞŶƚŝŶũƵƌǇƉĞƌƐŽŶŶĞů͘ƋƵŝƉŵĞŶƚŵƵƐƚ
ďĞĞůĞĐƚƌŝĐĂůůǇŝƐŽůĂƚĞĚďĞĨŽƌĞƌĞŵŽǀĂůŽĨŐƵĂƌĚƐ͘

ĂƌĞŵƵƐƚďĞƚĂŬĞŶƚŽĂǀŽŝĚƚŚĞŐĞŶĞƌĂƚŝŽŶŽĨůŽĐĂůĨƌŝĐƚŝŽŶĂůŚĞĂƚĐĂƵƐĞĚďǇŵŝƐĂůŝŐŶŵĞŶƚŽĨŵĞĐŚĂŶŝĐĂůƉĂƌƚƐ
ŽƌƚŚĞŐĞŶĞƌĂƚŝŽŶŽĨƐƉĂƌŬƐďǇŵĞƚĂůůŝĐĐŽŶƚĂŵŝŶĂŶƚƐŽĨƚŚĞĨĞĞĚĞŶƚĞƌŝŶŐŵĞĐŚĂŶŝĐĂůĞƋƵŝƉŵĞŶƚ͘

/ŶƐƉĞĐƚŝŽŶĚŽŽƌƐŵƵƐƚŶŽƚďĞŽƉĞŶĞĚǁŚĞŶƚŚĞƉůĂŶƚŝƐŝŶŽƉĞƌĂƚŝŽŶ͘

'ŽŽĚ ŚŽƵƐĞŬĞĞƉŝŶŐ ŝƐ ŝŵƉŽƌƚĂŶƚ ĂŶĚ ĂŶǇ ƐƉŝůůĂŐĞƐ Žƌ ůĞĂŬĂŐĞƐ ŽĨ ĨůĂŵŵĂďůĞ ĚƵƐƚ ŵƵƐƚ ďĞ ĐůĞĂŶĞĚ ƵƉ
ŝŵŵĞĚŝĂƚĞůǇƚŽĂǀŽŝĚĂĐĐƵŵƵůĂƚŝŽŶƐ͘

/ĨŵĂŝŶƚĞŶĂŶĐĞŝŶǀŽůǀĞƐǁŽƌŬŝŶŐŝŶƐŝĚĞŽƌĂƌŽƵŶĚĐŽŵďƵƐƚŝŽŶĐŚĂŵďĞƌ͕ĂůůŶĞĐĞƐƐĂƌǇƐĂĨĞƚǇƉƌĞĐĂƵƚŝŽŶƐŵƵƐƚ
ďĞƚĂŬĞŶ;ƐĂĨĞƚǇŚĂƌŶĞƐƐĞƐ͕ƉƌŽƚĞĐƚŝǀĞĐůŽƚŚŝŶŐ͕ƐĂĨĞƚǇŚĞůŵĞƚƐĂŶĚƐĂĨĞƚǇŐůĂƐƐĞƐͿ͘/ĨŵĂŝŶƚĞŶĂŶĐĞŝŶǀŽůǀĞƐĂŶǇ
ǁĞůĚŝŶŐ͕ĐƵƚƚŝŶŐ͕ƉĞƌŵŝƚƐŵƵƐƚďĞŝƐƐƵĞĚďǇƚŚĞKƉĞƌĂƚŝŽŶƐĞƉĂƌƚŵĞŶƚƚŽĐŽŶĨŝƌŵŝƚŝƐƐĂĨĞĨŽƌƚŚŝƐǁŽƌŬƚŽďĞ
ĐŽŶĚƵĐƚĞĚ͕ĂŶĚĂůůĞĂƌƚŚƐƚŽĞůĞĐƚƌŽŶŝĐĞƋƵŝƉŵĞŶƚŝŶƚŚĞǀŝĐŝŶŝƚǇƐŚŽƵůĚďĞĚŝƐĐŽŶŶĞĐƚĞĚ͘

/Ĩ ŵĂŝŶƚĞŶĂŶĐĞ ǁŽƌŬ ŝƐ ďĞŝŶŐ ƉĞƌĨŽƌŵĞĚ ĚƵƌŝŶŐ Ă ƐŚƵƚͲĚŽǁŶ͕ ĞŶƐƵƌĞ ƚŚĂƚ Ăůů ƚŽŽůƐ ĂŶĚ ŵĂƚĞƌŝĂůƐ ŚĂǀĞ ďĞĞŶ
ƌĞŵŽǀĞĚĨƌŽŵƚŚĞĞƋƵŝƉŵĞŶƚĂĨƚĞƌƚŚĞǁŽƌŬŝƐĐŽŵƉůĞƚĞĚ͘
ůůŝŶƐƚƌƵŵĞŶƚƐĂŶĚŐĂƵŐĞƐƐŚŽƵůĚďĞƌĞŐƵůĂƌůǇĐŚĞĐŬĞĚĨŽƌĂĐĐƵƌĂĐǇ͘


ƵƌŶĞƌDĂŶĂŐĞŵĞŶƚ^ǇƐƚĞŵ

WZK:d ͗ ϭyϲ͘ϴϱDtt,Z^WZK:d͘

WhZ,^Z ͗ dŚǇƐƐĞŶ<ƌƵƉƉ/ŶĚƵƐƚƌŝĞƐ/ŶĚŝĂWǀƚ>ƚĚ͘

Eh^Z ͗ WZ^<d/DEd/Eh^dZ/^>/D/d

KhDEdEK͘ ͗ ϭϳͲϯϲϭϬͲD^ͲϬϭ

d ͗ Ϭϯ͘ϭϬ͘ϮϬϭϳ

&^:ŽďEŽ ͗ ϭϳͲϯϲϭϬ

^h/>d
ZĞǀ͗ ĞƐĐƌŝƉƚŝŽŶ ŚĞĐŬĞĚ ƉƉƌŽǀĞĚ ĂƚĞ

Ϭϯ ZĞǀŝƐĞĚ/ŶƚĞƌŶĂůůǇ &:^ Ê Ϭϲ͘Ϭϭ͘ϮϬϭϳ
ϬϮ ZĞǀŝƐĞĚŝŶƚĞƌŶĂůůǇ &:^ Ê ϯϬ͘ϭϮ͘ϮϬϭϳ
Ϭϭ ZĞǀŝƐĞĚŝŶƚĞƌŶĂůůǇ &:^ Ê Ϯϳ͘ϭϭ͘ϮϬϭϳ
ϬϬ /ŶŝƚŝĂů/ƐƐƵĞ &:^ Ê Ϭϯ͘ϭϬ͘ϮϬϭϳ

WZK:d ϭyϲ͘ϴϱDtt,Z^WZK:d ZsEK͘ ϯ

WhZ,^Z dŚǇƐƐĞŶ<ƌƵƉƉ/ŶĚƵƐƚƌŝĞƐ/ŶĚŝĂWǀƚ͘>ƚĚ͘ d Ϭϲ͘Ϭϭ͘ϮϬϭϴ
Eh^Z WĂƌĂƐĂŬƚŝĞŵĞŶƚ/ŶĚƵƐƚƌŝĞƐ>ŝŵŝƚĞĚ W'EK͘ ϭŽĨϵ
&^:KEϬ͘ ϭϳͲϯϲϭϬͲD^ͲϬϭ ,<z &:^
K͘EK ϭϳͲϯϲϭϬ WWz Ê

SYSTEM OVERVIEW

ƋƵŝƉŵĞŶƚ ͗ ,''
YƚǇ͘ ͗ ϬϭEŽ͘
DĂŝŶ&ƵĞů ͗ Pulverized Coal
^ƚĂƌƚͲƵƉ&ƵĞů ͗ >Kͬ,^
/ŐŶŝƚŝŽŶ ͗ ,/
&ůĂŵĞ^ĐĂŶŶĞƌ ͗ ^ĂĨǇĞƌ;DĂŬĞ͗&ŝǀĞƐWŝůůĂƌĚ͕YƚǇ͗ϮEŽƐͿ
ŽŶƚƌŽůƐƵƉƉůǇ ͗
• ^ŽůĞŶŽŝĚsĂůǀĞ ͗ ϮϯϬs͕ϱϬ,ǌ
• /ŐŶŝƚŝŽŶ ͗ ϮϯϬs͕ϱϬ,ǌ
• hW^^ƵƉƉůǇ ͗ ϮϯϬs͕ϱϬ,ǌ

• >ŽĐĂůWĂŶĞů;Ǉ&^Ϳ ͗ tŝƚŚ ŽŶůǇ ŝŶĚŝĐĂƚŝŶŐ >ĂŵƉƐ͕ WƵƐŚͲďƵƚƚŽŶƐ ŵŽƵŶƚĞĚ ŽŶ ŝƚ
ĨŽƌďƵƌŶĞƌƐƚĂƌƚͬƐƚŽƉŽƉĞƌĂƚŝŽŶĨƌŽŵ>ŽĐĂů͘
• ^WĂŶĞů;EŽƚďǇ&^Ϳ͗ &ŽƌƌĞŵŽƚĞŽƉĞƌĂƚŝŽŶĂŶĚŵŽŶŝƚŽƌŝŶŐŽĨƵƌŶĞƌŽƉĞƌĂƚŝŽŶ
ĂŶĚŽŵďƵƐƚŝŽŶĐŽŶƚƌŽůůŽŐŝĐ͘

• ƵƌŶĞƌKƉĞƌĂƚŝŽŶ^ĞƋƵĞŶĐĞ͗
• ^ƚĂƌƚͲƵƉ/ŶƚĞƌůŽĐŬƐ͘
• KŝůƵƌŶĞƌ^ƚĂƌƚͲƵƉ^ĞƋƵĞŶĐĞ
• KŝůƵƌŶĞƌ^ƚŽƉͬdƌŝƉ/ŶƚĞƌůŽĐŬƐ
• ^ĐĂǀĞŶŐŝŶŐǇĐůĞ͘
• ŽĂůƵƌŶĞƌ^ƚĂƌƚͲƵƉ^ĞƋƵĞŶĐĞ
• ŽĂůƵƌŶĞƌ^ƚŽƉͬdƌŝƉ/ŶƚĞƌůŽĐŬƐ

ZĞĨĞƌĞŶĐĞŽĐƵŵĞŶƚƐ͗
• WΘ/ϭϳͲϯϲϭϬͲϬϭͲϬϬ


Eh^Z WĂƌĂƐĂŬƚŝĞŵĞŶƚ/ŶĚƵƐƚƌŝĞƐ>ŝŵŝƚĞĚ W'EK͘ ϮŽĨϵ
EKd͗

/ŶĚŝĐĂƚŝŽŶƐǁŝůůŐůŽǁŽŶƚŚĞ>ŽĐĂůWĂŶĞůƐĐŽƌƌĞƐƉŽŶĚŝŶŐƚŽƚŚĞƵƌŶĞƌ͛ƐƐƚĂƚƵƐ͘
>ŽĐĂůWĂŶĞůǁŝůůŚĂǀĞŽŶůǇ/ŶĚŝĐĂƚŝŽŶůĂŵƉ͕ůŽŐŝĐĨŽƌƐĂŵĞŚĂƐƚŽďĞŝŵƉůĞŵĞŶƚĞĚŝŶƚŚĞĐůŝĞŶƚ͛Ɛ^ƐǇƐͲ
ƚĞŵ͘

hZEZKWZd/KEW,/>K^KW,z

^YhEK&KWZd/KE

WƵƚƚŚĞWŽǁĞƌƐƵƉƉůǇƐǁŝƚĐŚƚŽΗKEΗƉŽƐŝƚŝŽŶĨƌŽŵ^WĂŶĞůĂŶĚΗWKtZ^hWW>zKEΗŝŶĚŝĐĂƚŝŽŶǁŝůůŐůŽǁŝŶ
^ƉĂŶĞů;ĨƌŽŵĐůŝĞŶƚͿ͘KƉĞƌĂƚŽƌŚĂƐƚŽƐĞůĞĐƚ>ŽĐĂůŵŽĚĞŽƉĞƌĂƚŝŽŶŽƌƌĞŵŽƚĞŽƉĞƌĂƚŝŽŶǁŝƚŚƐĞůĞĐƚƐǁŝƚĐŚ
ƉƌŽǀŝĚĞĚ ŽŶ ^ WĂŶĞů͘ Η>K> KWZd/KE ^>dΗ Žƌ ΗZDKd KWZd/KE ^>dΗ ŝŶĚŝĐĂƚŝŽŶ ǁŝůů
ŐůŽǁŝŶ^ͬ>ŽĐĂůWĂŶĞů͘EŽǁƚŚĞ^ƐǇƐƚĞŵǁŝůůĐŚĞĐŬĨŽƌƚŚĞĨŽůůŽǁŝŶŐƐƚĂƌƚƵƉŝŶƚĞƌůŽĐŬƐ͗Ͳ

ͲͲ^dZdhW/EdZ>K<^ʹ

^ǇƐƚĞŵWĞƌŵŝƐƐŝǀĞK<;^ͲϮͿ
KŝůWƵŵƉZƵŶŶŝŶŐ;^ʹϮϱŽƌ^ͲϮϴͿ
KŝůŝŶůĞƚƉƌĞƐƐƵƌĞK<;t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϭͿ
KŝůŽŶƚƌŽůsĂůǀĞŝŶ>&ƉŽƐŝƚŝŽŶ;t,Z^ͲYϮ,WͲ,''ͲdͲϬϬϭͿ
ƚŽŵŝǌŝŶŐŝƌƐƵƉƉůǇK<;t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϯͿ
&ƵĞůKŝů^ŚƵƚŽĨĨsĂůǀĞŝŶůŽƐĞƉŽƐŝƚŝŽŶ;t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϬϭͿ
ŵĞƌŐĞŶĐǇƐƚŽƉĐŽŵŵĂŶĚŶŽƚĞǆĞĐƵƚĞĚ
/ŶƐƚƌƵŵĞŶƚŝƌƉƌĞƐƐƵƌĞK<;t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϰͿ
ŽŵďƵƐƚŝŽŶĂŝƌ&ĂŶƌƵŶŶŝŶŐ;^ʹϭϳŽƌ^ͲϮϬͿ
ŽŵďƵƐƚŝŽŶĂŝƌĚĂŵƉĞƌŽƉĞŶ;t,Z^ͲYϮ,WͲ,''Ͳ^KͲϬϬϳͬt,Z^ͲYϮ,WͲ,''Ͳ^KͲϬϬϴͿ
ŽŵďƵƐƚŝŽŶĂŝƌĨůŽǁK<;t,Z^ͲYϮ,WͲ,''Ͳ&dͲϬϬϭͿ
ŽŵďƵƐƚŝŽŶĂŝƌƉƌĞƐƐƵƌĞK<;t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϱͿ
EŽΗ&ůĂŵĞKEΗ^ŝŐŶĂů
,/ŝŶZĞƚƌĂĐƚƉŽƐŝƚŝŽŶƉƌŽǀĞĚ;t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϬϱͿ
ŝůƵƚŝŽŶŝƌƉƌĞƐƐƵƌĞK<;t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϲͿ
,''WƌĞƐƐƵƌĞEŽƚ,ŝŐŚ;t,Z^ͲYϮ,WͲ,''ͲWdͲϬϬϰͿ
ŽĂů>ŝŶĞ^ŚƵƚŽĨĨsĂůǀĞŝŶůŽƐĞWŽƐŝƚŝŽŶ;t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϬϰͿ
,ŽŝƐƚŝŶŐĂŵƉĞƌŝŶŽƉĞŶƉŽƐŝƚŝŽŶ;t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϭϭͿ
ŵĞƌŐĞŶĐǇ&ĂŶEŽƚZƵŶŶŝŶŐ;^ͲϯϭͿ
ZŽŽƚůŽǁĞƌƐŶŽƚZƵŶŶŝŶŐ;^ͲϯϰŽƌ^ͲϯϳͿ
ŝůƵƚŝŽŶĂŵƉĞƌKƉĞŶ;t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϭϯͿ
WƌĞƐƐƵƌĞdƌĂŶƐŵŝƚƚĞƌĂƚ,''EŽƚŚŝŐŚ;t,Z^ͲYϮ,WͲ,''ͲWdͲϬϬϮͿ


Eh^Z WĂƌĂƐĂŬƚŝĞŵĞŶƚ/ŶĚƵƐƚƌŝĞƐ>ŝŵŝƚĞĚ W'EK͘ ϯŽĨϵ
KŶĐĞƚŚĞĂďŽǀĞůŝŵŝƚƐĂƌĞƐĂƚŝƐĨŝĞĚ͕ΗWhZ'Zz͟ŝŶĚŝĐĂƚŝŽŶůĂŵƉǁŝůůďĞŝůůƵŵŝŶĂƚĞĚŽŶ>ŽĐĂůͬ^WĂŶĞů͘
EŽǁŽƉĞƌĂƚŽƌŶĞĞĚƐƚŽƉƌĞƐƐWƵƌŐĞƐƚĂƌƚĨƌŽŵ^ͬ>ŽĐĂůWĂŶĞůŝƌƌĞƐƉĞĐƚŝǀĞŽĨƐĞůĞĐƚŝŽŶŽĨ>ŽĐĂůͬ^ƐĞůĞĐƚŝŽŶ͘
tŝƚŚ WƵƌŐĞ ^ƚĂƌƚ ĐŽŵŵĂŶĚ͕ ^ ǁŝůů ŐĞŶĞƌĂƚĞ ϭϬϬй ĐŽŵŵĂŶĚ ƚŽ ŽŵďƵƐƚŝŽŶ ŝƌ ůŽǁĞƌ s& ŽĨ ďŽƚŚ ƚŚĞ
ďƵƌŶĞƌƐĂŶĚ͞WhZ'Ͳ/EͲWZK'Z^^ΗǁŝůůƐƚĂƌƚƚŽĨůŝĐŬĞƌŽŶƚŚĞ>ŽĐĂůƉĂŶĞů

^ǁŝůůŵŽŶŝƚŽƌƚŚĞŽŵďƵƐƚŝŽŶďůŽǁĞƌs&^ƉĞĞĚĂŶĚĂĨƚĞƌŝƚƌĞĂĐŚĞƐƚŽϭϬϬй͕^ǁŝůůƐƚĂƌƚƚŚĞƉƵƌŐŝŶŐ
ƚŝŵĞƌĂŶĚ͞WhZ'Ͳ/EͲWZK'Z^^͟ůĂŵƉǁŝůůŐůŽǁƐƚĞĂĚŝůǇŝŶ>ŽĐĂůWĂŶĞůĂŶĚƌĞƐƉĞĐƚŝǀĞŵĞƐƐĂŐĞǁŝůůĚŝƐƉůĂǇŽŶ
^͘WƵƌŐŝŶŐƚŝŵĞǁŝůůďĞŽĨϱŵŝŶƵƚĞƐ͘ĞůĂǇŝƐƚŽďĞĞŶƐƵƌĞĚ͘ĨƚĞƌƉƵƌŐĞƉĞƌŝŽĚŽǀĞƌ͕ΗWhZ'KDW>dΗ
ůĂŵƉǁŝůůƐƚĂƌƚƚŽĨůŝĐŬĞƌŽŶƚŚĞ>ŽĐĂůƉĂŶĞů͘ůƐŽǁŝƚŚƉƵƌŐĞĐŽŵƉůĞƚĞ͕^ǁŝůůŐĞŶĞƌĂƚĞůŽǁĨŝƌĞĐŽŵŵĂŶĚƚŽ
ĐŽŵďƵƐƚŝŽŶĂŝƌďůŽǁĞƌs&;ϮϱйĐŽŵŵĂŶĚͿ

^ ǁŝůů ŵŽŶŝƚŽƌ ƚŚĞ ĐŽŵďƵƐƚŝŽŶ ďůŽǁĞƌ s& ƐƉĞĞĚ ĂŶĚ ǁŚĞŶ ƚŚĞ ƐĂŵĞ ƌĞŵĂŝŶƐ ďĞƚǁĞĞŶ ;Ϯϱ ƚŽ ϯϬ йͿ͕
͞WhZ'KDW>d͟ůĂŵƉǁŝůůƐƚŽƉĨůŝĐŬĞƌŝŶŐĂŶĚŐůŽǁƐƚĞĂĚŝůǇŽŶ>ŽĐĂůƉĂŶĞůĂŶĚƌĞƐƉĞĐƚŝǀĞŵĞƐƐĂŐĞǁŝůůŝŶͲ
ĚŝĐĂƚĞŽŶ^͘

/ĨƵƌŝŶŐWƵƌŐĞƚŝŵĞĂŶǇŽĨƚŚĞĂďŽǀĞůŝƐƚĞĚŝŶƚĞƌůŽĐŬĨĂŝůƐ͕ŽƉĞƌĂƚŽƌŚĂƐƚŽƌĞƐŽůǀĞƚŚĞŝƐƐƵĞĂŶĚƐƚĂƌƚƚŚĞƉƵƌŐĞ
ƉƌŽĐĞƐƐĂŐĂŝŶ͘

EŽƚĞ͗ tŚĞŶ ŐŝǀĞŶ ĐŽŵŵĂŶĚ ŽĨ ,ŝŐŚ ĨŝƌĞ Žƌ >Žǁ &ŝƌĞ͕ ŝĨ ƌĞƐƉĞĐƚŝǀĞ ĐŽŵďƵƐƚŝŽŶ Ăŝƌ ĚĂŵƉĞƌ ƉŽƐŝƚŝŽŶ ŝƐ ŶŽƚ
ĂĐŚŝĞǀĞĚǁŝƚŚŝŶŽŶĞŵŝŶƵƚĞ͕ƐĞƋƵĞŶĐĞǁŝůůƚƌŝƉĂŶĚWƵƌŐĞ^ĞƋƵĞŶĐĞ&ĂŝůĂůĂƌŵǁŝůůĂƉƉĞĂƌŽŶ>ŽĐĂůĂŶĚ^
WĂŶĞů͘KƉĞƌĂƚŽƌŚĂƐƚŽƐƚĂƌƚĨƌŽŵWƵƌŐĞƌĞĂĚǇĐŽŶĚŝƚŝŽŶ͘
sĂůƵĞƐŐŝǀĞŶŝŶƚŚŝƐǁƌŝƚĞͲƵƉĂƌĞŝŶĚŝĐĂƚŝǀĞ͕ĂĐƚƵĂůǀĂůƵĞƐŶĞĞĚƚŽĐŚĞĐŬĂƐƉĞƌƐŝƚĞĐŽŶĚŝƚŝŽŶƐďǇŽŵŵŝƐƐŝŽŶͲ
ŝŶŐŶŐŝŶĞĞƌ͘

tŝƚŚŽŵďƵƐƚŝŽŶďůŽǁĞƌƌƵŶŶŝŶŐĨĞĞĚďĂĐŬ͕ĂŵƉĞƌŵŽƵŶƚĞĚŝŶŵĞƌŐĞŶĐǇĂŝƌůŝŶĞƐŚŽƵůĚďĞŝŶĐůŽƐĞĐŽŶĚŝͲ
ƚŝŽŶ

ƵƌŶĞƌKƉĞƌĂƚŝŽŶ͗

tŝƚŚ ƚŚĞ WƵƌŐĞ ĐŽŵƉůĞƚĞ ĂŶĚ ĂďŽǀĞ ŵĞŶƚŝŽŶĞĚ ƐƚĂƌƚƵƉ ĐŽŶĚŝƚŝŽŶ ƐĂƚŝƐĨŝĞĚ͕ ͞>Kͬ,^ hZEZ Zz dK
&/Z͟ŝŶĚŝĐĂƚŝŽŶůĂŵƉǁŝůůŐůŽǁŝŶ>ŽĐĂůWĂŶĞůĂŶĚƌĞƐƉĞĐƚŝǀĞŵĞƐƐĂŐĞǁŝůůĂƉƉĞĂƌŽŶ^WĂŶĞů͘EŽǁƚŚĞŽƉͲ
ĞƌĂƚŽƌĐŽƵůĚƐƚĂƌƚ>Kͬ,^ďƵƌŶĞƌďǇƉƌĞƐƐŝŶŐΗ>Kͬ,^hZEZ^dZdΗWƵƐŚďƵƚƚŽŶ͕ĞŝƚŚĞƌĨƌŽŵ>ŽĐĂůWĂŶͲ
ĞůŽƌ^WĂŶĞů;ĚĞƉĞŶĚŝŶŐƵƉŽŶ>ŽĐĂůͬZĞŵŽƚĞƐĞůĞĐƚŝŽŶͿĂƚƚŚĂƚƚŝŵĞ>Kͬ,^&sƐŚŽƵůĚďĞŝŶ>&ƉŽƐŝƚŝŽŶ
ĂůŽŶŐǁŝƚŚƚŚĞŵŝŶŝŵƵŵs&^ƉĞĞĚŽĨŽŵďƵƐƚŝŽŶĂŝƌďůŽǁĞƌ͘/ĨƚŚĞďƵƌŶĞƌƐƚĂƌƚĐŽŵŵĂŶĚŚĂƐŶŽƚďĞĞŶĞǆĞͲ
ĐƵƚĞĚǁŝƚŚŝŶϭϬŵŝŶĨƌŽŵƉƵƌŐĞĐŽŵƉůĞƚĞĚƚŚĞŶWƵƌŐĞǇĐůĞ ǁŽƵůĚŐĞƚƚƌŝƉĂŶĚŶĞĞĚƐƚŽďĞƌĞƐƚĂƌƚĞĚĨƌŽŵ
ƉƵƌŐĞƐĞƋƵĞŶĐĞ͘

&ŽůůŽǁŝŶŐƐĞƋƵĞŶĐĞŽĨŽƉĞƌĂƚŝŽŶǁŽƵůĚďĞĂĚĂƉƚĞĚ͗Ͳ

tŝƚŚƉƌĞƐƐŝŶŐ͞>Kͬ,^ƵƌŶĞƌƐƚĂƌƚ͟W͕,ŝŐŚŶĞƌŐǇ/ŐŶŝƚĞƌĨŽƌƚŚĞƌĞƐƉĞĐƚŝǀĞďƵƌŶĞƌǁŝůůďĞĞŶĞƌŐŝǌĞĚĂŶĚ
ΗhZEZ,/KEΗŵĞƐƐĂŐĞǁŝůůďĞĚŝƐƉůĂǇŝŶ^͘,/ǁŝůůďĞŬĞƉƚŝŶĞŶĞƌŐŝǌĞĚĐŽŶĚŝƚŝŽŶĨŽƌϭϱƐĞĐŽŶĚƐ͘ůŽŶŐ
ǁŝƚŚ,/ŵĂŝŶĨƵĞů>Kͬ,^^ŚƵƚŽĨĨsĂůǀĞΘĂƚŽŵŝǌŝŶŐĂŝƌůŝŶĞƐŚƵƚŽĨĨsĂůǀĞǁŝůůďĞĞŶĞƌŐŝǌĞĚƚŽŽƉĞŶ͘

ĨƚĞƌϭϱƐĞĐŽŶĚƐ͕,/ǁŝůůďĞĚĞͲĞŶĞƌŐŝǌĞĚ͘/ĨĚƵƌŝŶŐƚŚŝƐŝŐŶŝƚŝŽŶƉĞƌŝŽĚ;ϭϱƐĞĐŽŶĚƐͿ͕ĨůĂŵĞŝƐŶŽƚĞƐƚĂďůŝƐŚĞĚ
ĂŶĚ ƉƌŽǀĞĚ ďǇ ĨůĂŵĞ ƐĐĂŶŶĞƌ ͕ ƚŚĞŶ ĂůŽŶŐ ǁŝƚŚ ,/͕ ďŽƚŚ ĂƚŽŵŝǌŝŶŐ Ăŝƌ ĂŶĚ >Kͬ,^ ^^KsƐ ǁŝůů ŐĞƚ ĚĞͲ
ĞŶĞƌŐŝǌĞĚĂŶĚ͞&>D&/>hZ͟ŵĞƐƐĂŐĞǁŝůůŝŶĚŝĐĂƚĞŽŶ^WĂŶĞůĂŶĚŝŶĚŝĐĂƚŝŽŶůĂŵƉǁŝůůŝůůƵŵŝŶĂƚĞĚŽŶ
ůŽĐĂůĐŽŶƚƌŽůƉĂŶĞů͘

/ĨǁŝƚŚŝŶϭϱ ƐĞĐŽŶĚƐ͕&ůĂŵĞŝƐ ƐĞŶƐĞĚďǇ&ůĂŵĞ^ĐĂŶŶĞƌ͕͞hZEZ&>DKE͟ ŵĞƐƐĂŐĞǁŝůůĚŝƐƉůĂǇŽŶ^͘
^^KsĨŽƌ>Kͬ,^ůŝŶĞǁŝůůƌĞŵĂŝŶĞŶĞƌŐŝǌĞĚĂŶĚ͞>Kͬ,^hZEZ;yсϭ͕ϮKZϯͿKE͟ŝŶĚŝĐĂƚŝŽŶůĂŵƉǁŝůů
ďĞŝůůƵŵŝŶĂƚĞĚŽŶ>ŽĐĂůWĂŶĞůͬ^͘

ĨƚĞƌϰϱƐĞĐŽĨĞƐƚĂďůŝƐŚŝŶŐŵĂŝŶďƵƌŶĞƌ͞hZEZZ>^&KZDKh>d/KE͟ŵĞƐƐĂŐĞǁŝůůĚŝƐƉůĂǇŽŶ^
ĂŶĚŝŶĚŝĐĂƚŝŽŶůĂŵƉǁŝůůďĞŝůůƵŵŝŶĂƚĞĚŝŶ>W͕ĨŝƌŝŶŐƌĂƚĞĐŽƵůĚďĞĂĚũƵƐƚĞĚďǇ^WĂŶĞůĂƐƉĞƌ,ĞĂƚĚĞŵĂŶĚ͘


Eh^Z WĂƌĂƐĂŬƚŝĞŵĞŶƚ/ŶĚƵƐƚƌŝĞƐ>ŝŵŝƚĞĚ W'EK͘ ϰŽĨϵ
^ǁŝůůĐŚĞĐŬƚŚĞĨŽůůŽǁŝŶŐŝŶƚĞƌůŽĐŬƐĂĨƚĞƌŽƉĞŶŝŶŐƚŚĞŵĂŝŶƐŚƵƚŽĨĨǀĂůǀĞƐ͘

&ŽůůŽǁŝŶŐĐŽŶĚŝƚŝŽŶƐǁŝůůƚƌŝƉƚŚĞĞƐƚĂďůŝƐŚĞĚƌƵŶŶŝŶŐŽĨƚŚĞŵĂŝŶďƵƌŶĞƌƐ͗Ͳ

ͲͲdZ/W/EdZ>K<^Ͷ
^ǇƐƚĞŵWĞƌŵŝƐƐŝǀĞEŽƚK<
KŝůWƵŵƉEŽƚZƵŶŶŝŶŐ;^ʹϮϱŽƌ^ͲϮϴͿ
KŝůŝŶůĞƚƉƌĞƐƐƵƌĞ>Žǁ;t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϭͿ
KŝůKƵƚůĞƚƉƌĞƐƐƵƌĞ,ŝŐŚ;t,Z^ͲYϮ,WͲ,''ͲW^,ͲϬϬϮͿ
ƚŽŵŝǌŝŶŐŝƌWƌĞƐƐƵƌĞ>Žǁ;t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϯͿ
/ŶƐƚƌƵŵĞŶƚŝƌƉƌĞƐƐƵƌĞ>Žǁ;t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϰͿ
ŽŵďƵƐƚŝŽŶĂŝƌ&ĂŶEŽƚƌƵŶŶŝŶŐ;^ʹϭϳŽƌ^ͲϮϬͿ
ŽŵďƵƐƚŝŽŶĂŝƌĨůŽǁ>Žǁ;t,Z^ͲYϮ,WͲ,''Ͳ&dͲϬϬϭͿ
ŽŵďƵƐƚŝŽŶĂŝƌƉƌĞƐƐƵƌĞ>Žǁ;t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϱͿ
&ůĂŵĞ&ĂŝůƵƌĞ
ŝůƵƚŝŽŶŝƌƉƌĞƐƐƵƌĞ>Žǁ;t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϲͿ
ŽŵŵĂŶĚĂŶĚĨĞĞĚďĂĐŬŵŝƐŵĂƚĐŚ
,''ƌĞĨĞĐƚŽƌǇdĞŵƉŚŝŐŚ;t,Z^ͲYϮ,WͲ,''Ͳd/dͲϬϬϵͿ
,''ŽŶĞdĞŵƉŚŝŐŚ;t,Z^ͲYϮ,WͲ,''Ͳd/dͲϬϭϬͿ
,''WƌĞƐƐƵƌĞ,ŝŐŚ;t,Z^ͲYϮ,WͲ,''ͲWdͲϬϬϰͿ
,''KƵƚůĞƚdĞŵƉ,ŝŐŚ;t,Z^ͲYϮ,WͲ,''ͲddͲϬϬϲͬϬϬϳͬϬϬϴͿ
WƌĞƐƐƵƌĞdƌĂŶƐŵŝƚƚĞƌĂƚ,''ŚŝŐŚ;t,Z^ͲYϮ,WͲ,''ͲWdͲϬϬϮͿ
ŽĂů>ŝŶĞ^ŚƵƚŽĨĨsĂůǀĞEŽƚŝŶůŽƐĞWŽƐŝƚŝŽŶ;t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϬϰͬͬƵƌŝŶŐŽŶůǇKŝů&ŝƌĞͿ
ZŽŽƚůŽǁĞƌƐZƵŶŶŝŶŐ;^ͲϯϰŽƌ^ͲϯϳͬͬƵƌŝŶŐŽŶůǇKŝů&ŝƌĞͿ
,ŽŝƐƚŝŶŐĂŵƉĞƌEŽƚŝŶŽƉĞŶƉŽƐŝƚŝŽŶ;t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϭϭͿ
ŵĞƌŐĞŶĐǇ&ĂŶZƵŶŶŝŶŐ;^ͲϯϭͿ
ŝůƵƚŝŽŶĂŵƉĞƌEŽƚŝŶKƉĞŶWŽƐŝƚŝŽŶ;t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϭϯͿ

ŽŵŵĂŶĚĂŶĚ&ĞĞĚďĂĐŬDŝƐŵĂƚĐŚ͗tŚĞŶĞǀĞƌĂŶŽƉĞŶŽŵŵĂŶĚŝƐŐŝǀĞŶƚŽƐŚƵƚŽĨĨǀĂůǀĞĂŶĚŝĨƚŚĞƌĞƐƉĞĐͲ
ƚŝǀĞĨĞĞĚďĂĐŬĨŽƌŽƉĞŶƉŽƐŝƚŝŽŶŽĨƚŚĞƐĂŵĞŝƐŶŽƚƌĞĐĞŝǀĞĚǁŝƚŚŝŶĐĞƌƚĂŝŶƚŝŵĞŝŶƚĞƌǀĂů;ϱƐĞĐŽŶĚƐͿ͕ĂŶĂůĂƌŵ
ƐŝŐŶĂůŝƐŐĞŶĞƌĂƚĞĚǁŚŝĐŚŝƐŬŶŽǁŶĂƐŽŵŵĂŶĚĂŶĚ&ĞĞĚďĂĐŬDŝƐŵĂƚĐŚůĂƌŵ͘tŝƚŚƚŚŝƐƐŝŐŶĂůŽƉĞƌĂƚŽƌŚĂƐ
ƚŽĐŚĞĐŬĨŽƌƚŚĞŽƉĞƌĂƚŝŽŶŽĨĂůůƚŚĞǀĂůǀĞƐ͘ůƐŽǁŚĞŶƚŚĞŽƉĞŶĐŽŵŵĂŶĚŝƐǁŝƚŚĚƌĂǁŶŽĨĂƐŚƵƚͲŽĨĨǀĂůǀĞĂŶĚ
ƚŚĞĐůŽƐĞĨĞĞĚďĂĐŬŝƐŶŽƚĂĐŚŝĞǀĞĚǁŝƚŚŝŶĐĞƌƚĂŝŶƚŝŵĞŝŶƚĞƌǀĂů;ϱƐĞĐŽŶĚƐͿĂŶĂůĂƌŵĂƐǁĞůůĂƐƚƌŝƉƐŝŐŶĂůǁŝůůďĞ
ŐĞŶĞƌĂƚĞĚǁŚŝĐŚƚƌŝƉƐƚŚĞƐĞƋƵĞŶĐĞ͘


Eh^Z WĂƌĂƐĂŬƚŝĞŵĞŶƚ/ŶĚƵƐƚƌŝĞƐ>ŝŵŝƚĞĚ W'EK͘ ϱŽĨϵ

ƵƌŶĞƌEŽƌŵĂů^ŚƵƚĚŽǁŶ

&ŽƌĂŶŽƌŵĂůƐŚƵƚĚŽǁŶ͕WƌĞƐƐƚŚĞ͞ƵƌŶĞƌ^ƚŽƉ͟ƉƵƐŚďƵƚƚŽŶĨƌŽŵ^ͬ>W͘W>ǁŝůůĞǆĞĐƵƚĞĐŽŵͲ
ŵĂŶĚƚŽĚĞͲĞŶĞƌŐŝǌĞĂůůƐŚƵƚŽĨĨǀĂůǀĞƐĂŶĚƌƵŶŶŝŶŐďƵƌŶĞƌǁŝůůǁŝƚŚĚƌĂǁĨƌŽŵŽƉĞƌĂƚŝŽŶ͕͞

&ĂŝůƵƌĞŽĨĂŶǇĂďŽǀĞůŝƐƚĞĚŝŶƚĞƌůŽĐŬ;ƵƌŶĞƌdƌŝƉ/ŶƚĞƌůŽĐŬͿǁŝůůĂůƐŽĨŽůůŽǁƚŚĞƐĂŵĞƉƌŽĐĞƐƐĂƐƐƚĂƚͲ
ĞĚĂďŽǀĞ

&ŽƌŵĞƌŐĞŶĐǇ^ŚƵƚĚŽǁŶ

ǇƉƌĞƐƐŝŶŐĞŵĞƌŐĞŶĐǇƐƚŽƉƉƵƐŚďƵƚƚŽŶ;/ƌƌĞƐƉĞĐƚŝǀĞŽĨŵŽĚĞƐĞůĞĐƚŝŽŶͿƉŚǇƐŝĐĂůƐƵƉƉůǇƚŽƚŚĞĞŶͲ
ƚŝƌĞĨŝĞůĚ^^KsƐƐŚĂůůďĞĐƵƚͲŽĨĨ͕ƐĞƋƵĞŶĐĞǁŝůůďĞƚƌŝƉƉĞĚ͘

>Kͬ,^'hE^sE'/E'z>

tŚĞŶĞǀĞƌƚŚĞƌƵŶŶŝŶŐƵƌŶĞƌƚƌŝƉƐŽƌǁŝƚŚĚƌĂǁŶĨƌŽŵƐĞƌǀŝĐĞďǇƉƌĞƐƐŝŶŐƚŚĞΗhZEZ^dKW͟WƵƐŚďƵƚƚŽŶ͕
>Kͬ,^ŐƵŶƐĐĂǀĞŶŐŝŶŐĐǇĐůĞĨŽƌƚŚĞƌĞƐƉĞĐƚŝǀĞďƵƌŶĞƌǁŝůůďĞŝŶŝƚŝĂƚĞĚƐŽƚŚĂƚƚŚĞ>Kͬ,^ůŝŶĞƐĂĨƚĞƌ^ŚƵƚ
ŽĨĨǀĂůǀĞƐĂƌĞŬĞƉƚĐůĞĂŶ͘&ŽůůŽǁŝŶŐƐĞƋƵĞŶĐĞŽĨŽƉĞƌĂƚŝŽŶǁŽƵůĚďĞĂĚŽƉƚĞĚ͗Ͳ

>Kͬ,^ ƐŚƵƚ ŽĨĨ ǀĂůǀĞ ǁŽƵůĚ ďĞ ĚĞͲĞŶĞƌŐŝǌĞĚ ƚŽ ĐůŽƐĞ͘ dŚĞ ĐǇĐůĞ ǁŽƵůĚ ďĞ ƐƚĂƌƚĞĚ ĂĨƚĞƌ >Kͬ,^ ƐŚƵƚ ŽĨĨ
ǀĂůǀĞĐůŽƐĞƉŽƐŝƚŝŽŶƉƌŽǀĞĚ͘

dŚĞƌĞƐƉĞĐƚŝǀĞ,/ǁŽƵůĚďĞĞŶĞƌŐŝǌĞĚĨŽƌϭϱƐĞĐŽŶĚƐ͘ZĞƐƉĞĐƚŝǀĞƚŽŵŝǌŝŶŐŝƌǀĂůǀĞĂŶĚƌĞƐƉĞĐƚŝǀĞ^ĐĂǀĞŶŐͲ
ŝŶŐsĂůǀĞƐǁŝůůďĞĞŶĞƌŐŝǌĞĚƚŽŽƉĞŶ͘

ĨƚĞƌϭϱƐĞĐŽŶĚƐ͕ƚŚĞ,/ǁŽƵůĚďĞĚĞͲĞŶĞƌŐŝǌĞĚ͘/ĨǁŝƚŚŝŶƚŚŝƐƚŝŵĞƉĞƌŝŽĚ&ůĂŵĞŝƐĞƐƚĂďůŝƐŚĞĚƚŚĞŶƚŚĞƐĐĂǀͲ
ĞŶŐŝŶŐǀĂůǀĞƐƌĞŵĂŝŶŽŶĨŽƌϯϱƐĞĐŵŽƌĞ͕ĞůƐĞƚŚĞǇǁŝůůŐĞƚĚĞͲĞŶĞƌŐŝǌĞĚƚŽĐůŽƐĞ͘

^ĐĂǀĞŶŐŝŶŐǇĐůĞǁŝůůƚƌŝƉǁŝƚŚĨŽůůŽǁŝŶŐŝŶƚĞƌůŽĐŬƐ͗

ͲͲdZ/W/EdZ>K<^Ͷ

ƚŽŵŝǌŝŶŐŝƌWƌĞƐƐƵƌĞ>Žǁ;t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϯͿ
^ǇƐƚĞŵWĞƌŵŝƐƐŝǀĞŶŽƚŽŬ;^ͲϮͿ
/ŶƐƚƌƵŵĞŶƚŝƌƉƌĞƐƐƵƌĞ>Kt;t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϰͿ
&ůĂŵĞ&ĂŝůƵƌĞ
ŽŵŵĂŶĚĂŶĚĨĞĞĚďĂĐŬŵŝƐŵĂƚĐŚ

/ĨƐĐĂǀĞŶŐŝŶŐĐǇĐůĞƚƌŝƉƐƚŚĞŶŽŝůĐŽůůĞĐƚĞĚĂƚƚŚĞĚŽǁŶƐƚƌĞĂŵŽĨƚŚĞ^KsƐŚĂůůďĞŵĂŶƵĂůůǇĚƌĂŝŶĞĚďǇƚŚĞŽƉͲ
ĞƌĂƚŽƌƚŽŬĞĞƉƚŚĞŽŝůůŝŶĞĚŽǁŶƐƚƌĞĂŵŽĨ^KsĐůĞĂŶ͘


Eh^Z WĂƌĂƐĂŬƚŝĞŵĞŶƚ/ŶĚƵƐƚƌŝĞƐ>ŝŵŝƚĞĚ W'EK͘ ϲŽĨϵ
K>hZEZ^dZdhW^YhE͗

ŽĂůĨŝƌŝŶŐĐĂŶďĞŝŶƚƌŽĚƵĐĞĚĂĨƚĞƌĨƵƌŶĂĐĞƚĞŵƉĞƌĂƚƵƌĞŚĂƐƌĞĂĐŚĞĚϴϬϬΣ͘KƉĞƌĂƚŽƌŚĂƐƚŽƚƵƌŶŽŶŽĂů>ŝŶĞ
ZŽŽƚƐůŽǁĞƌĂŶĚŬĞĞƉŽĂů&ĞĞĚŝŶŐƐǇƐƚĞŵƌĞĂĚǇĨŽƌŽƉĞƌĂƚŝŽŶ͘

ĨƚĞƌ,'ƌĞĂĐŚŝŶŐϴϬϬΣ͕^ǇƐƚĞŵǁŝůůŵŽŶŝƚŽƌƚŚĞĨŽůůŽǁŝŶŐŝŶƚĞƌůŽĐŬƐ

ŽĂůWĞƌŵŝƐƐŝǀĞKŬ;^ͲϬϭͿ
ŽĂů>ŝŶĞZŽŽƚƐůŽǁĞƌKŶ;^ʹϯϰͬ^ͲϯϳͿ
s&ĐŽŵďƵƐƚŝŽŶĂŝƌĨĂŶĚĞůŝǀĞƌǇĂŝƌĨůŽǁǁŝƚŚϯϬйĞǆĐĞƐƐĂŝƌ͕ĂĐĐŽƌĚŝŶŐĂŝƌͬŽŝůĐƵƌǀĞ
,'' dĞŵƉDŽƌĞ dŚĂŶϴϬϬΣ ͕;t,Z^ͲYϮ,WͲ,''Ͳd/dͲϬϭϬͿ͘ŽŶƚƌŽůĨƵƌŶĂĐĞƚĞŵƉĞƌĂƚƵƌĞďǇƚŚĞĐŽŵͲ
ďƵƐƚŝŽŶĂŶĚĚŝůƵƚŝŽŶĂŝƌ͘
Kŝů&sĂƚƉŽƐŝƚŝŽŶǁŚĞŶĨƵƌŶĂĐĞƚĞŵƉĞƌĂƚƵƌĞƌĞĂĐŚϴϬϬΣ;t,Z^ͲYϮ,WͲ,''ͲdͲϬϬϭͿ
K/>ƵƌŶĞƌŽŶƚŝůů&ƵƌŶĂĐĞdĞŵƉƌĞĂĐŚƚŽϭϮϬϬĞŐ
,ŽŝƐƚŝŶŐĂŵƉĞƌŝŶŽƉĞŶƉŽƐŝƚŝŽŶ;t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϭϭͿ
ŵĞƌŐĞŶĐǇ&ĂŶEŽƚZƵŶŶŝŶŐ;^ͲϯϭͿ
ŝůƵƚŝŽŶĂŵƉĞƌŝŶKƉĞŶWŽƐŝƚŝŽŶ;t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϭϯͿ
^ǇƐƚĞŵWĞƌŵŝƐƐŝǀĞK<
/ŶƐƚƌƵŵĞŶƚŝƌƉƌĞƐƐƵƌĞEŽƚ>Žǁ;t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϰͿ
ŽŵďƵƐƚŝŽŶĂŝƌĨůŽǁEŽƚ>Žǁ;t,Z^ͲYϮ,WͲ,''Ͳ&dͲϬϬϭͿ
ŽŵďƵƐƚŝŽŶĂŝƌƉƌĞƐƐƵƌĞEŽƚ>Žǁ;t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϱͿ
ŝůƵƚŝŽŶŝƌƉƌĞƐƐƵƌĞEŽƚ>Žǁ;t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϲͿ
,''ƌĞĨĞĐƚŽƌǇdĞŵƉEŽƚŚŝŐŚ;t,Z^ͲYϮ,WͲ,''Ͳd/dͲϬϬϵͿ
,''ŽŶĞdĞŵƉEŽƚŚŝŐŚ;t,Z^ͲYϮ,WͲ,''Ͳd/dͲϬϭϬͿ
,''WƌĞƐƐƵƌĞEŽƚ,ŝŐŚ;t,Z^ͲYϮ,WͲ,''ͲWdͲϬϬϰͿ
,''KƵƚůĞƚdĞŵƉEŽƚ,ŝŐŚ;t,Z^ͲYϮ,WͲ,''ͲddͲϬϬϲͬϬϬϳͬϬϬϴͿ
WƌĞƐƐƵƌĞdƌĂŶƐŵŝƚƚĞƌĂƚ,''EŽƚŚŝŐŚ;t,Z^ͲYϮ,WͲ,''ͲWdͲϬϬϮͿ
ƚŽŵŝǌŝŶŐŝƌWƌĞƐƐƵƌĞŶŽƚ>Žǁ;t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϯͿ

tŝƚŚĂůůĂďŽǀĞŝŶƚĞƌůŽĐŬŚĞĂůƚŚǇ͞K>hZEZZzdK&/Z͟ŝŶĚŝĐĂƚŝŽŶǁŝůůŝůůƵŵŝŶĂƚĞŽŶ>ŽĐĂůWĂŶĞůĂŶĚ
ƌĞƐƉĞĐƚŝǀĞ ŵĞƐƐĂŐĞ ǁŝůů ĂƉƉĞĂƌ ŽŶ ^ WĂŶĞů͘ EŽǁ ŽƉĞƌĂƚŽƌ ĐĂŶ ĞǆĞĐƵƚĞ ŽĂů ƵƌŶĞƌ ƐƚĂƌƚ ĐŽŵŵĂŶĚ ĨƌŽŵ
^ͬ>ŽĐĂůWĂŶĞů;ĂƐƉĞƌ^ĞůĞĐƚŝŽŶͿďǇƉƌĞƐƐŝŶŐŽĂůƵƌŶĞƌ^ƚĂƌƚ͘dŚŝƐǁŽƵůĚŝŶŝƚŝĂƚĞƚŚĞĨŽůůŽǁŝŶŐƐĞƋƵĞŶĐĞ͗Ͳ

,ŝŐŚŶĞƌŐǇ/ŐŶŝƚĞƌĨŽƌƚŚĞƌĞƐƉĞĐƚŝǀĞďƵƌŶĞƌǁŝůůďĞĞŶĞƌŐŝǌĞĚĂŶĚΗhZEZ,/KEΗŵĞƐƐĂŐĞǁŝůůďĞĚŝƐƉůĂǇ
ŝŶ^͘,/ǁŝůůďĞŬĞƉƚŝŶĞŶĞƌŐŝǌĞĚĐŽŶĚŝƚŝŽŶĨŽƌϭϱƐĞĐŽŶĚƐĨŽƌƚŚĞƐƵƉƉŽƌƚĨŝƌŝŶŐ͘

ĨƚĞƌ/ŐŶŝƚŝŽŶWĞƌŝŽĚŝƐŽǀĞƌ,/ǁŝůůŐĞƚĚĞͲĞŶĞƌŐŝǌĞĚ͘ůƐŽǁŝƚŚŽĂůƵƌŶĞƌƐƚĂƌƚĐŽŵŵĂŶĚ͕^ǁŝůůŐĞŶĞƌĂƚĞ
͞K>hZEZKE͟ĐŽŵŵĂŶĚƚŽ^͘͞ŽĂůƵƌŶĞƌKE͟ŝŶĚŝĐĂƚŝŶŐůĂŵƉǁŝůůŐůŽǁĐŽŶƚŝŶƵŽƵƐůǇŽŶ>ŽĐĂůWĂŶĞů
ĂŶĚZĞƐƉĞĐƚŝǀĞŵĞƐƐĂŐĞǁŝůůĚŝƐƉůĂǇŽŶ^WĂŶĞů͘


Eh^Z WĂƌĂƐĂŬƚŝĞŵĞŶƚ/ŶĚƵƐƚƌŝĞƐ>ŝŵŝƚĞĚ W'EK͘ ϳŽĨϵ
tŝƚŚŽĂůƵƌŶĞƌKŶĐŽŵŵĂŶĚĨƌŽŵ͕^ŶĞĞĚƐƚŽŐĞŶĞƌĂƚĞŶĞĐĞƐƐĂƌǇĐŽŵŵĂŶĚƚŽŽĂůĨĞĞĚŝŶŐƐǇƐƚĞŵƐŽĂƐ
ƚŽŝŶũĞĐƚŽĂůŝŶ,''͘ŽĂůĨĞĞĚŝŶŐǁŝůůƐƚĂƌƚǁŝƚŚĨŝǆĞĚŵŝŶŝŵƵŵƌĂƚĞƐƵŝƚĂďůĞĨŽƌŽĂůƐƚĂƌƚƵƉĐŽŶĚŝƚŝŽŶĂĚͲ
ũƵƐƚĞĚĂƚƐŝƚĞĚƵƌŝŶŐĐŽŵŵŝƐƐŝŽŶŝŶŐ͘s&ĐŽŵďƵƐƚŝŽŶĂŝƌĨĂŶŝƐŝŶĐƌĞĂƐĞƚŽƐƵƉƉůǇŵŽƌĞĂŝƌĂĚũƵƐƚĞĚĂƚƐŝƚĞĚƵƌͲ
ŝŶŐĐŽŵŵŝƐƐŝŽŶŝŶŐ͘
ĨƚĞƌϰϱƐĞĐŽŶĚƐĚĞůĂǇŽĨŵĂŝŶďƵƌŶĞƌĞƐƚĂďůŝƐŚĞĚĂŶĚƉƌŽǀĞĚ͕ůŽǁĨŝƌĞŚŽůĚŽŶĐŽĂů͕ĨĞĞĚŝŶŐƐǇƐƚĞŵĂŶĚs&
;sĂƌŝĂďůĞ&ƌĞƋƵĞŶĐǇƌŝǀĞͿǁŝůůďĞƌĞůĞĂƐĞĚďǇŐĞŶĞƌĂƚŝŶŐƌĞůĞĂƐĞĨŽƌŵŽĚƵůĂƚŝŽŶŽƵƚƉƵƚĨƌŽŵ^͘ŽĂůĨĞĞĚͲ
ŝŶŐƌĂƚĞĐĂŶƚŚĞŶďĞŵŽĚƵůĂƚĞĚĂƐƉĞƌƉƌŽĐĞƐƐƌĞƋƵŝƌĞŵĞŶƚĂŶĚŽŵďƵƐƚŝŽŶŝƌĨĂŶƚŚƌŽƵŐŚŽŵďƵƐƚŝŽŶĐŽŶͲ
ƚƌŽůƐĨƌŽŵ^ĐƵƌǀĞĂŝƌͬĐŽĂů͘
^ǇƐƚĞŵǁŝůůĐŽŶƚŝŶƵŽƵƐůǇŵŽŶŝƚŽƌĨŽůůŽǁŝŶŐŝŶƚĞƌůŽĐŬƐĂŶĚŝŶĐĂƐĞŽĨĨĂŝůƵƌĞŽĨĂŶǇŽĨƚŚĞƐĞ/ŶƚĞƌůŽĐŬƐ͕ďƵƌŶĞƌ
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• ŽŵŵĂŶĚĂŶĚ&ĞĞĚďĂĐŬŵŝƐŵĂƚĐŚ
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ƵƌŶĞƌ ĐĂŶ ďĞ ǁŝƚŚĚƌĂǁŶ Ăƚ ĂŶǇƚŝŵĞ ďǇ ƉƌĞƐƐŝŶŐ ďƵƌŶĞƌ ^ƚŽƉ WƵƐŚ ďƵƚƚŽŶ ĨƌŽŵ ƚŚĞ ^ͬůŽĐĂů ƉĂŶĞů͘ /Ŷ ĞǆͲ
ƚƌĞŵĞĐŽŶĚŝƚŝŽŶŽƉĞƌĂƚŝŽŶĐĂŶďĞƐƚŽƉƉĞĚǁŝƚŚŵĞƌŐĞŶĐǇ^ƚŽƉWƵƐŚďƵƚƚŽŶ͘
EŽƚĞ͗
dŚĞŽŝůďƵƌŶĞƌĐĂŶďĞƐǁŝƚĐŚĞĚŽŶǁŚŝůĞĐŽĂůďƵƌŶĞƌŝŶŽƉĞƌĂƚŝŽŶǁŝƚŚŽƵƚƚŚĞƉƵƌŐĞĐǇĐůĞ͘

Eh^Z WĂƌĂƐĂŬƚŝĞŵĞŶƚ/ŶĚƵƐƚƌŝĞƐ>ŝŵŝƚĞĚ W'EK͘ ϴŽĨϵ
,ŽŝƐƚŝŶŐĂŵƉĞƌĂŶĚŽĨĨĞĞWŽƚĂŵƉĞƌ
,ŽŝƐƚŝŶŐĂŵƉĞƌĂŶĚĐŽĨĨĞĞWŽƚĚĂŵƉĞƌŝƐĐŽŶƚƌŽůůĞĚƚŚƌŽƵŐŚ^ŽŶůǇ͘ƚĂŶǇƉŽŝŶƚŽĨƚŝŵĞŽƵƚŽĨƚŚĞƐĞƚǁŽ
ŽŶĞŵƵƐƚďĞŝŶŽƉĞŶƉŽƐŝƚŝŽŶ͘WƌŝŽƌƚŽďƵƌŶĞƌůŝŐŚƚͲƵƉ͕,ŽŝƐƚŝŶŐĚĂŵƉĞƌŵƵƐƚďĞŝŶŽƉĞŶƉŽƐŝƚŝŽŶƚŽŵĂŝŶƚĂŝŶ
ƚŚĞƉƌŽƉĞƌƐƵĐƚŝŽŶŝŶƚŚĞŚĂŵďĞƌ͘KƉĞƌĂƚŽƌƚŽĞŶƐƵƌĞƚŚĂƚĂƚĂŶǇŵŽǀĞŵĞŶƚĐŽĨĨĞĞƉŽƌƚĚĂŵƉĞƌĂŶĚŚŽŝƐƚŝŶŐ
ĚĂŵƉĞƌĐĂŶŶŽƚďĞŝŶĐůŽƐĞĐŽŶĚŝƚŝŽŶƚŽŐĂƚŚĞƌ͘ƵĞƚŽĂŶǇĂďŶŽƌŵĂůĐŽŶĚŝƚŝŽŶ͕ŝĨ,''ŽƵƚůĞƚďĞĐŽŵĞƐŝŶ
ƉƌĞƐƐƵƌŝǌĞĚĐŽŶĚŝƚŝŽŶ͕ŽĨĨĞĞƉŽƚĚĂŵƉĞƌƐŚŽƵůĚďĞŽƉĞŶ͘
/ŶŶŽƌŵĂůŽƉĞƌĂƚŝŽŶ,ŽŝƐƚŝŶŐĚĂŵƉĞƌƐŚŽƵůĚďĞŝŶŽƉĞŶĐŽŶĚŝƚŝŽŶĂŶĚŽĨĨĞĞWŽƚĂŵƉĞƌƐŚŽƵůĚďĞŝŶĐůŽƐĞ
ĐŽŶĚŝƚŝŽŶ͘
ŽŵďƵƐƚŝŽŶŽŶƚƌŽů
ƵƌŝŶŐK/>ĨŝƌŝŶŐKŝů>ŝŶĞ&sĂŶĚŽŵďƵƐƚŝŽŶĂŝƌ>ŝŶĞs&ǁŝůůŽƉĞƌĂƚĞŝŶDĂŶƵĂůŵŽĚĞ͘ĂƐĞĚŽŶƚŚĞ,ĞĂƚ
ƌĞƋƵŝƌĞŵĞŶƚŽƉĞƌĂƚŽƌŚĂƐƚŽĂĚũƵƐƚƚŚĞŝƌĨƵĞůƌĂƚŝŽ͘/ĨĞŵĂŶĚŝƐŵŽƌĞƚŚĞŶƐƵƉƉůǇ͕ŽƉĞƌĂƚŽƌŚĂƐƚŽŽƉĞŶƚŚĞ
ĐŽŵďƵƐƚŝŽŶĂŝƌs&ĨŝƌƐƚĂŶĚƚŚĞŶKŝů>ŝŶĞ&s͘/ĨĞŵĂŶĚŝƐůĞƐƐƚŚĞŶƚŚĞƐƵƉƉůǇ͕ŽƉĞƌĂƚŽƌŚĂƐƚŽƌĞĚƵĐĞƚŚĞ
Žŝů&sŽƉĞŶŝŶŐĂŶĚƚŚĞŶĐŽŵďƵƐƚŝŽŶĂŝƌs&͘
KŶĐĞƌĞƋƵŝƌĞĚdĞŵƉĞƌĂƚƵƌĞŝƐĂĐŚŝĞǀĞĚ;хϴϬϬĞŐ͘ͿƚŚĞŶŽƉĞƌĂƚŽƌĐĂŶƐƚĂƌƚƚŚĞŽĂůĨŝƌŝŶŐďĂƐĞĚŽŶƚŚĞƌĞͲ
ƋƵŝƌĞŵĞŶƚ͘ŽĂůĨŝƌŝŶŐĐĂŶďĞĐŽŶƚƌŽůĂƵƚŽŵĂƚŝĐĂůůǇŽƌŵĂŶƵĂůůǇ͘/ŶŵĂŶƵĂůŽƉĞƌĂƚŝŽŶ͕ŽĂůůŽĂĚĂŶĚŽŵďƵƐͲ
ƚŝŽŶĂŝƌs&ƐƉĞĞĚǁŝůůďĞǀĂƌǇďǇŽƉĞƌĂƚŽƌ͕ǁŚŝůĞŝŶƵƚŽŽƉĞƌĂƚŝŽŶŽŵďƵƐƚŝŽŶĂŝƌs&^ƉĞĞĚĂŶĚĐŽĂůůŽĂĚ
ǁŝůůďĞǀĂƌǇĂƵƚŽŵĂƚŝĐĂůůǇďĂƐĞĚŽŶƚŚĞĚĞŵĂŶĚ;ƌĞĨĞƌĐŽŵďƵƐƚŝŽŶĐŽŶƚƌŽůůŽŐŝĐͿŚŽǁĞǀĞƌĚƵƌŝŶŐĂƵƚŽŵŽĚĞ
ŽŝůĨŝƌŝŶŐŚĂƐƚŽďĞƐƚŽƉƉĞĚ͘ƵƚŽŵŽĚĞĐĂŶŽŶůǇďĞŝŶŝƚŝĂƚĞĚŝŶĐŽĂůĨŝƌŝŶŐŝĨƐƵƉƉŽƌƚŝŶŐĨŝƌŝŶŐ;/͘Ğ͘KŝůĨŝƌŝŶŐͿŝƐ
ŶŽƚƉƌĞƐĞŶƚ͘

Eh^Z WĂƌĂƐĂŬƚŝĞŵĞŶƚ/ŶĚƵƐƚƌŝĞƐ>ŝŵŝƚĞĚ W'EK͘ ϵŽĨϵ
JOB NO.17-3610
KWZd/KEED/EdEEDEh>
WZdϴͲ/>>K&DdZ/>
CLIENT ISGEC FORM NO. FR-12
PROJECT CONSUMAR MOROCCO AMD NO. 0
EQUIPMENT STARTUP BURNER DOC. NO. 15-3098-BOM
PO NO. P10103119/JB0936 REVISION 0
Fives Combustion Systems Pvt. Ltd. FCS JOB 15-3098 DATE 14.04.2015
BILL OF MATERIALS
SECTION - A PF UNIT
SECTION - B MAIN PIPE RACK
LDO PIPE LINE
ATOMISING AIR LINE / SCAVENGING LINE
INSTRUMENT AIR LINE
SECTION - C START-UP BURNER WITH ITS ACCESSORIES
SECTION - D C & I ITEMS
SECTION - E INTERCONNECTING PIPING
SECTION - F COMMISSIONING SPARES
SECTION -G FUEL STORAGE & ACCESSORIES-LOOSE SUPPLY
AS BUILT
1 31.10.2017 C & I Scope added FJS SND

0 14.04.2015 Initial Issue-Bill of Material DJ RR
REV. DATE DESCRPTION CHKD BY APPRD BY
WZK:d ϭyϲ͘ϴϱDtt,Z^WZK:d͘
WhZ,^Z dŚǇƐƐĞŶŬƌƵƉƉ/ŶĚƵƐƚƌŝĞƐ/ŶĚŝĂWǀƚ͘>ƚĚ͘
Eh^Z WZ^<d/DEd/Eh^dZ/^>/D/d
&^:KEϬ͘ ϮϬϭϳͲϯϲϭϬ REV No 3
Fives Combustion Systems Pvt. Ltd. KEĂŵĞ KD Date 30-01-2018
Sr. BBU Tag No. Item Description Size Service Location Qty. Make Model B/M/ Loose/
No. Number (NB) I/S Mounted
0 SECTION A: Day Oil Tank (990 Ltr)

F01 3 WHRS-AQC2HP-HGG-BV-001 VALVE BALL; soc weld 40 I/L DOT 1 KSB ---- B M
F01 3 WHRS-AQC2HP-HGG-BV-002 VALVE BALL; soc weld 15 Vent DOT 1 KSB ---- B M
F01 3 WHRS-AQC2HP-HGG-BV-003 VALVE BALL; soc weld 40 Drain DOT 1 KSB ---- B M
F01 10a WHRS-AQC2HP-HGG-BV-004 VALVE BALL; soc weld 20 O/L DOT 1 KSB ---- B L
Level Pune
F01 3 WHRS-AQC2HP-HGG-LI-001 Level Measurement 25 OIL DOT 1 FBG – GS1WWG B M+L
Indicatior Techtrol
WHRS-AQC2HP-HGG-LSL-001/ Pune
F01 10a Level Switch Level Measurement 80 OIL DOT 1 DS – CESM11R B L
WHRS-AQC2HP-HGG-LSH - 001 Techtrol
0 SECTION B: PF UNIT
C01 2 WHRS-AQC2HP-HGG-BV-006 VALVE BALL; soc weld 20 I/L Filter 1 KSB ---- B M
C01 2 WHRS-AQC2HP-HGG-BV-007 VALVE BALL; soc weld 20 I/L Filter 1 KSB ---- B M
C01 2 WHRS-AQC2HP-HGG-BV-008 VALVE BALL; soc weld 15 I/L DPT-001 1 KSB ---- B M
C01 2 WHRS-AQC2HP-HGG-BV-010 VALVE BALL; soc weld 15 Drain Filter-1 1 KSB ---- B M
C01 2 WHRS-AQC2HP-HGG-BV-011 VALVE BALL; soc weld 15 O/L DPT-001 1 KSB ---- B M
C01 2 WHRS-AQC2HP-HGG-BV-012 VALVE BALL; soc weld 15 Vent Filter-1 1 KSB ---- B M
C01 2 WHRS-AQC2HP-HGG-BV-013 VALVE BALL; soc weld 15 Drain Filter-2 1 KSB ---- B M
C01 2 WHRS-AQC2HP-HGG-BV-014 VALVE BALL; soc weld 15 Vent Filter-2 1 KSB ---- B M
C01 2 Simplex Filter Filter Filter PFU PFU 2 FCS ---- M M
Type : Screw type,Pr : 17
kg/cm2; Capacity:8.6 LPM,
C01 2 WHRS-AQC2HP-HGG-P-001 Pump 20 PFU PFU 1 Tushaco T3SFP-10/28 B M
Speed:2900 Rpm;
Suction/Disch size : 20NB
Type : Screw type,Pr : 17
kg/cm2; Capacity:8.6 LPM,
C01 2 WHRS-AQC2HP-HGG-P-002 Pump 20 PFU PFU 1 Tushaco T3SFP-10/28 B M
Speed:2900 Rpm;
Suction/Disch size : 20NB
C01 2 WHRS-AQC2HP-HGG-BV-016 VALVE BALL; soc weld 15 ISOL PG-002 1 KSB ---- B M
C01 2 WHRS-AQC2HP-HGG-NR-018 VALVE NRV; soc weld of 9
Page 115 O\L Pump 1 KSB ---- B M
C01 2 WHRS-AQC2HP-HGG-NR-019 VALVE NRV; soc weld 15 O\L Pump 1 KSB ---- B M
C01 2 WHRS-AQC2HP-HGG-BV-020 VALVE BALL; soc weld 15 O\L Pump 1 KSB ---- B M
C01 2 WHRS-AQC2HP-HGG-BV-021 VALVE BALL; soc weld 15 O\L Pump 1 KSB ---- B M
C01 2 WHRS-AQC2HP-HGG-ST-022 Strainer Y - Type; soc weld 15 O\L Pump 1 Fliteration --- B M
C01 2 WHRS-AQC2HP-HGG-BV-023 VALVE BALL; soc weld 15 O/L PFU 1 KSB ---- B M
C01 2 WHRS-AQC2HP-HGG-BV-024 VALVE BALL; soc weld 15 I/L BPRV 1 KSB ---- B M
C01 2 WHRS-AQC2HP-HGG-BV-025 VALVE GLOBE; soc weld 15 BYPASS BPRV 1 KSB ---- B M
C01 2 WHRS-AQC2HP-HGG-BV-026 VALVE BALL; soc weld 15 O/L BPRV 1 KSB ---- B M
C01 2 WHRS-AQC2HP-HGG-BV-027 VALVE BALL; soc weld 15 DRAIN PFU 1 KSB ---- B M
C01 2 WHRS-AQC2HP-HGG-PRV-001 VALVE BPRV 15 BYPASS PFU 1 Nirmal BP/04-B SERIES B M
7MF4433-1FA02-1PC7-
C01 2 WHRS-AQC2HP-HGG-DPT-001 DPT Diff pressure across strainer NA OIL PFU 1 Siemens B M
Z A01+C11+Y01+Y21
WHRS-AQC2HP-HGG-M-001 / Motor for Pump - 0.75
C01 2 Motor NA NA PFU 2 CGL NA B M
WHRS-AQC2HP-HGG-M-002 KW,FLP
LFBSPG-V-150-S4S-
WHRS-AQC2HP-HGG-PG-001 / Pressure After Pump ,
C01 2 1/2" NPT (M) NA PFU 2 GIC S6S-S6S-S4S-T15NTM- B M
WHRS-AQC2HP-HGG-PG-002 Gauge Range : 0 - 25 Kg/cm2
0TO25-KSC-L
LFBSPG-V-150-S4S-
Pressure At PF unit outlet
C01 2 WHRS-AQC2HP-HGG-PG-003 1/2" NPT (M) NA PFU 1 GIC S6S-S6S-S4S-T15NTM- B M
Gauge Range : 0 - 25 Kg/cm2
0TO16-KSC-L
0 SECTION C: MAIN PIPERACK
0 LDO PIPE LINE
C02 2 WHRS-AQC2HP-HGG-BV-031 VALVE BALL; soc weld 15 I/L LDO 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-BV-032 VALVE BALL; soc weld 15 I/L PG-004 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-BV-033 VALVE BALL; soc weld 15 I/L PSL-001 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-BV-034 VALVE BALL; soc weld 15 I/L FM 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-BV-036 STRAINER Y-TYPE 15 I/L FM 1 Filteration --- B M
C02 2 WHRS-AQC2HP-HGG-BV-038 VALVE BALL; soc weld 15 O/L FM 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-BV-039 VALVE BALL; soc weld 15 I/L FCV 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-BV-040 VALVE BALL; soc weld 15 BYPASS FM 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-GB-041 VALVE GLOBE; soc weld 15 BYPASS FCV 1 KSB ---- B M
C02 10b WHRS-AQC2HP-HGG-FCV-001 VALVE FCV 15 LDO LDO LINE 1 MIL MIL 29000 (38-21125) B M
C02 2 WHRS-AQC2HP-HGG-BV-042 VALVE BALL; soc weld Page 215
of 9 O/L FC 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-BV-043 VALVE BALL; soc weld 15 DRAIN FCV 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-SSOV-001 VALVE SSOV-001 15 SSOV-001 LDO LINE 1 Rotex ROTEX / QTF 63E 6 B M
C02 2 WHRS-AQC2HP-HGG-GB-044 VALVE GLOBE; soc weld 15 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-NR-045 VALVE NRV; soc weld 15 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-BV-047 VALVE BALL; soc weld 15 ISOL PSH-001 1 KSB ---- B M
INTERCON
C02 10a WHRS-AQC2HP-HGG-BV-048 VALVE BALL; soc weld 15 O/L 1 KSB ---- B L
NECTING
BSPG-V-150-S4S-S6S-
Pressure AT Pipe rack inlet
C02 2 WHRS-AQC2HP-HGG-PG-004 1/2" NPT(M) OIL LDO LINE 1 GIC S6S-S4S-T15NTM- B M
Gauge Range : 0 to 25 Kg/cm2
0TO16-KSC-L
Pressure AT Pipe rack inlet
C02 2 WHRS-AQC2HP-HGG-PSL-001 1/2" NPT(M) OIL LDO LINE 1 Switzer DM-601-B35-S1-33-A-Z B M
switch Range : 1.6 TO 16 kg/cm2
7MF4433-1FA02-1AC7-
C01 2 WHRS-AQC2HP-HGG-DPT-002 DPT Diff pressure across strainer NA OIL LDO LINE 1 Siemens B M
Z A01+C11+Y01+Y21
R025S114CCAZEZYZZ
C01 2 WHRS-AQC2HP-HGG-FM-001 FM Flow meter 1/2" OIL LDO LINE 1 Emerson B M
+ 1700I12ABFEZZZ
BSPG-V-150-S4S-S6S-
Pressure AT Pipe rack Outlet
C02 2 WHRS-AQC2HP-HGG-PG-005 1/2" NPT(M) OIL LDO LINE 1 GIC S6S-S4S-T15NTM- B M
Gauge Range : 0 to 16 Kg/cm2
0TO16-KSC-L
Pressure AT Pipe rack Outlet
C02 2 WHRS-AQC2HP-HGG-PSH-002 1/2" NPT(M) OIL LDO LINE 1 Switzer DM-601-B35-S1-33-A-Z B M
switch Range : 1.6 to 16 Kg/cm2
0 ATOMIZING PIPE LINE / INST PIPE LINE
C02 2 WHRS-AQC2HP-HGG-BV-051 VALVE BALL; soc weld 15 I/L ATOM LINE 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-ST-055 Strainer Y - Type 15 ATOM LINE 1 Filteration --- B M
C02 2 WHRS-ACQ2HP-HGG-GB-0058 VALVE GLOBE; soc weld 15 O/L ATOM LINE 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-BV-059 VALVE BALL; soc weld 15 O/L ATOM LINE 1 KSB ---- B M
INTERCON
C02 10a WHRS-AQC2HP-HGG-BV-060 VALVE BALL; soc weld 15 O/L 1 KSB ---- B L
NECTING
C02 2 WHRS-AQC2HP-HGG-BV-061 VALVE BALL; soc weld 15 ISOL 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-BV-063 VALVE BALL; soc weld 15 ISOL PSL-004 1 KSB ---- B M
Page 3 of 9
C02 2 WHRS-AQC2HP-HGG-BV-064 VALVE BALL; soc weld 15 ISOL FCV 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-BV-065 VALVE BALL; soc weld 15 ISOL SSOV 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-BV-066 VALVE BALL; soc weld 15 ISOL SPARE 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-GB-072 VALVE GLOBE; soc weld 15 I/L INST AIR 1 KSB ---- B M
C02 2 WHRS-AQC2HP-HGG-BV-067 VALVE BALL; soc weld 15 1 KSB ---- B M
BSPG-V-150-S4S-S6S-
Pressure At Air Line Inlet
C02 2 WHRS-AQC2HP-HGG-PG-006 1/2" NPT(M) Air ATOM LINE 1 GIC S6S-S4S-T15NTM-0TO6- B M
Gauge Range : 0 to 6
KSC-L
C02 2 WHRS-AQC2HP-HGG-PSL-003 1/2" NPT(M) Air ATOM LINE 1 Switzer DM-601-B33-S1-33-A-Z B M
Switch Range : 1 to 10
7MF4433-1FA02-1AC7-
C01 2 WHRS-AQC2HP-HGG-DPT-003 DPT Diff pressure across strainer NA Air ATOM LINE 1 Siemens B M
Z A01+C11+Y01+Y21
BSPG-V-150-S4S-S6S-
C02 2 WHRS-AQC2HP-HGG-PG-007 1/2" NPT(M) Air ATOM LINE 1 GIC S6S-S4S-T15NTM-0TO6- B M
KSC-L
20106-10-4R-B5-
WHRS-AQC2HP-HGG-XS-002 / Solenoid valve in atom air
C02 2 SV 1/2" NPT Air ATOM LINE 2 Rotex M6+230VAC-50Hz-16- B M
WHRS-AQC2HP-HGG-XS-003 line and scavenign air line
CO-H
BSPG-V-150-S4S-S6S-
Pressure At Inst Air Line Inlet
C02 2 WHRS-AQC2HP-HGG-PG-008 1/2" NPT(M) Air INST AIR 1 GIC S6S-S4S-T15NTM- B M
0TO10-KSC-L
Pressure At Inst Air Line Inlet
C02 2 WHRS-AQC2HP-HGG-PSL-004 1/2" NPT(M) Air INST AIR 1 Switzer DM-601-B33-S1-33-A-Z B M
Switch Range : 1 to 10
DSPG-V-15-S4S-S4S-
Pressure At Inst Air Line Inlet COOLING
C02 2 WHRS-AQC2HP-HGG-PG-013 1/2" NPT(M) Air 1 GIC S4S-S6S-S6S-T15NTM- B M
Gauge Range : 0 to 600 mmWc AIR
0TO600-MMW-L
D01 10a WHRS-AQC2HP-HGG-BV-075 VALVE BALL; soc weld 15 ISOL PG-012 1 KSB ---- B L
D01 10a WHRS-AQC2HP-HGG-FH-001 HOSE FLEX, SS 15 ---- Oil Inlet 1 Aeroflex ---- B L
D01 10a WHRS-AQC2HP-HGG-FH-002 HOSE FLEX, SS 15 ---- Air inlet 1 Aeroflex ---- B L
10a Hose FLEX, SS 15 FS cooling 1 Aeroflex ---- B L
10a Hose FLEX, SS 15 HEI Cooling 1 Aeroflex ---- B L
10a Hose FLEX, SS 15 HEI Retract 1 Aeroflex ---- B L
10a Hose FLEX, Rubber 125 Coal Inlet 1 Kantech ---- B L
D01 10a WHRS-AQC2HP-HGG-FS-001 SCANNER FLAME SCANNER Scan Burner 1 FCS SA510AC-C67 B L
D01 11 WHRS-AQC2HP-HGG-HEI-005 IGNITOR HEI IGNITOR Page 4 of 9 1 FCS ___ B L
DSPG-V-15-S4S-S4S-
WHRS-AQC2HP-HGG-PG-011 / Pressure At Inst Air Line Inlet
D01 10a 1/2" NPT(M) Air Burner 2 GIC S4S-S6S-S6S-T15NTM- B L
WHRS-AQC2HP-HGG-PG-012 Gauge Range : 0 to 100 mmWc
0 TO100-MMW-L
0 INTERCONNECTING LINE- CAB & DA TO HGG / BURNER
D05 10a WHRS-AQC2HP-HGG-BV-079 VALVE BALL; soc weld 15 ISOL PSL-005 1 KSB ---- B L
D05 10a WHRS-AQC2HP-HGG-BV-081 VALVE BALL; soc weld 15 ISOL PT-003 1 KSB ---- B L
FCS+ROT
D05 10a WHRS-AQC2HP-HGG-DMP-007 DAMPER BUTTERFLY --- O/L CAB-001 1 Rotex - QTF 110 B M
EX
FCS+ROT
D05 10a WHRS-AQC2HP-HGG-DMP-008 DAMPER BUTTERFLY --- O/L CAB-002 1 Rotex - QTF 110 B M
EX
D05 10a WHRS-AQC2HP-HGG-GT-086 VALVE GATE; soc weld 15 ISOL PG-010 1 KSB ---- B L
D05 10a WHRS-AQC2HP-HGG-GT-085 VALVE GATE; soc weld 15 ISOL PSL-006 1 KSB ---- B L
SPC-D-S-BG-MP2+LB2-
D05 10b WHRS-AQC2HP-HGG-DMP-002 Power cyliner DILUTION AIR DAMPER Air DA 1 FCS+Rotex B M
50/200
COMBUSTION AIR
D05 6a Blower CA 2 Reitz RGE 040-028020-191 B L
BLOWER
COMBUSTION AIR
D05 6a MOTOR BLOWER - Air CA 2 CGL NA B M
30 KW
DSPG-V-15-S4S-S4S-
PRESSURE Combustion Air Line
D05 10a WHRS-AQC2HP-HGG-PG-009 AIR CA 1 GIC S4S-S6S-S6S-T15NTM- B L
GAUGE Range : 0 to 100 mmWc
0TO100-MMW-L
PRESSURE Combustion Air Line PS1-W1-BA-M37-F-55-A-
D05 10a WHRS-AQC2HP-HGG-PSL-005 AIR CA 1 Switzer B L
SWITCH Range : 0 to 10 mbar W-C-Z
7MF4433-1BA02-1AC7-
D05 10a WHRS-AQC2HP-HGG-FT-001 DPT Across Annubar AIR CA 1 Siemens B L
Z A01+C11+Y01+Y21
7MF4433-1CA02-1AC7-
D05 10a WHRS-AQC2HP-HGG-PT-003 PT Combustion Air Line AIR CA 1 Siemens B L
Z A01+C11+Y01+Y21
D05 10a WHRS-AQC2HP-HGG-TE-002 TE "RTD" AIR DA 1 GIC NA B L
7NG3136-0AC11-Z
D05 10a WHRS-AQC2HP-HGG-TT-002 TT Dilution air line DA 1 Siemens B L
U03+Y01
CCPG-V-150-S4S-S6S-
PRESSURE Dilution air line
D05 10a WHRS-AQC2HP-HGG-PG-010 AIR DA 1 GIC S6S-S4S-T15NTM- B L
GAUGE Range : (-50) to 50 mmWC
(-)50TO50-MMW-L
PRESSURE Dilution air line PS1-W1-BA-M02-F-55-A-
D05 10a WHRS-AQC2HP-HGG-PSL-006 AIR DA 1 Switzer B L
SWITCH Range : (-50) to 50 mmWC W-C-Z
0 INTERCONNECTING LINE- EAB TO HGG / BURNER
EMERGENCY AIR CB
D05 6b BLOWER Air EAB- 1 CHB 15 II R0 B M
BLOWER DOCTOR
DC MOTOR- EMERGENCY AIR
D05 6b WHRS-AQC2HP-HGG-M-005 Air EAB- 1 CGL NA B M
1.5KW BLOWER Page 5 of 9
WHRS-AQC2HP-HGG-DMP-009/ Rotary
D05 10a FOR BUTTERFLY DAMPER Air EAB- 2 Rotex Rotex - QTF 63 B M
WHRS-AQC2HP-HGG-DMP-012 actuator
0 HOT GAS GENERATOR
E01 10a WHRS-AQC2HP-HGG-GT-077 VALVE GATE; soc weld 15 ISOL PT-001 1 KSB ---- B M
E01 10a WHRS-AQC2HP-HGG-GT-078 VALVE GATE; soc weld 15 ISOL PT-002 1 KSB ---- B M
E01 10a WHRS-AQC2HP-HGG-FS-002 SCANNER FLAME SCANNER Scan Burner 1 FCS SA510AC-C67 B L
WHRS-AQC2HP-HGG-TE-006
E01 10a WHRS-AQC2HP-HGG-TE-007 TE "K" Type TC AIR HGG Outlet 3 GIC NA B L
WHRS-AQC2HP-HGG-TT-006
7NG3136-0AC11-Z
E01 10a WHRS-AQC2HP-HGG-TT-007 TT HGG Outlet AIR HGG Outlet 3 Siemens B L
U03+Y01
WHRS-AQC2HP-HGG-PT-001 / 7MF4433-1BA02-1AC7-
E01 10a PT Pressure Transmitter Air HGG 2 Siemens B L
WHRS-AQC2HP-HGG-PT-002 Z A01+C11+Y01+Y21
WHRS-AQC2HP-HGG-TE-010 /
E01 10a TE "R" Type thermocouple 1 1/2" Flanged Air HGG 2 GIC NA B L
WHRS-AQC2HP-HGG-TIT-010 /
D01 10a TIT Temp indcation transmitter Air HGG 2 Selec PIC101A-VI-230 B L
WHRS-AQC2HP-HGG-TIT-009
5711-L-W-A-7-N-H-G-C
E01 10b WHRS-AQC2HP-HGG-DS-001 DS Dust switch at HGG Bottom Air + Dust HGG Bottom 1 Switzer B L
.
E01 10a DAMPER COMB. AIR INLET COMB. AIR 1 FCS ____ M M
E01 10a DAMPER PRIMARY DILU. AIR INLET DILU. AIR 1 FCS ____ M M
SECONDARY DILU. AIR I
E01 10a DAMPER DILU. AIR 1 FCS ____ M M
/ L-1
SECONDARY DILU. AIR I
E01 10a DAMPER DILU. AIR 1 FCS ____ M M
/ L-2
Linear
10a Hose FLEX, SS 15 1 Aeroflex ---- B L
Acuator
10a Hose FLEX, SS 15 View port 1 Aeroflex ---- B L
10a Hose FLEX, SS 15 FS cooling 1 Aeroflex ---- B L
0 HOT GAS OUTLET LINE
E02 4 WHRS-AQC2HP-HGG-CPD-001 Damper COFFEE POT DAMPER Flue gas HGG Outlet 1 Ind Fan ____ B L
E02 5 WHRS-AQC2HP-HGG-HD-001 Damper HOISTING DAMPER Flue gas HGG Outlet 1 EAS ____ B L
E01 9 Bellow Expansion Bellow Flue gas HGG Outlet 1 STANFAB ____ B L
E01 10a WHRS-AQC2HP-HGG-TE-004 TE "K" Type TC Flue gas HGG Outlet 3 GIC NA B L
7NG3136-0AC11-Z
E01 10a WHRS-AQC2HP-HGG-TT-004 TT HGG Outlet Flue gas HGG Outlet 3 Siemens B L
U03+Y01
0 COAL CONVEYING 6 of 9
PageSYSTEM (LOSS IN WEIGHT SYSTEM)
&Ϭϯ ϴ ŽĂůtĞŝŐŚ&ĞĞĚĞƌ^ǇƐƚĞŵ schenck L

&Ϭϯ 10a s>s /Z>K<s>s ϱΖΖ ƉƵůǀ͘ŽĂů ϭ ZŝĞĐŽ >ͲϮϬϬ^Y B L
&Ϭϯ ϭϬď WHRS-AQC2HP-HGG-KEGV-004 s>s <E/&'s>s ϱΖΖ ƉƵůǀ͘ŽĂů ϭ ƌĂǇ &/'ϵϱϬ B L
&Ϭϯ ϳĂ WHRS-AQC2HP-HGG-RB-001 >KtZ ZKKd>KtZ ŝƌ ϭ <ĂǇ ϱD< B L
&Ϭϯ ϳĂ WHRS-AQC2HP-HGG-RB-002 >KtZ ZKKd>KtZ ŝƌ ϭ <ĂǇ ϱD< B L
ZKKd
&Ϭϯ ϳď WHRS-AQC2HP-HGG-M-006 DKdKZ ϭϴ͘ϱ<t ____ ϭ '> ____ B L
>KtZͲϭ
ZKKd
&Ϭϯ ϳď WHRS-AQC2HP-HGG-M-007 DKdKZ ϭϴ͘ϱ<t ____ ϭ '> ____ B L
>KtZͲϮ
ϵ ůďŽǁ ϰϱĚĞŐƌĞĞ͕ĂƐƚďĂƐĂůƚ ϭϮϱE ϰ ĞĐĐĂŶ ____ B L
ϵ ůďŽǁ ϵϬĚĞŐƌĞĞ͕ĂƐƚďĂƐĂůƚ ϭϮϱE ϰ ĞĐĐĂŶ ____ B L
Roots
7MF4433-1FA02-1AC7-
&Ϭϰ ϭϬď WHRS-AQC2HP-HGG-PT-004 PT Pressure Transmitter Air Blower 1 Siemens B L
Z A01+C11+Y01+Y21
Discharge
0 SECTION - E: INTERCONNECTING PIPING (F02)

9 BOM as per Engg Drawing Loose Piping and Fittings ____
0 SECTION - F- COMMISSIONING SPARES (D03)
D03 12 Ignitor tip Ignitor tip 2 ____ B L
View port
D03 12 View port glass 3 ____ B L
glass
D03 12 Bulb Bulb for indicating lamp 5 ____ B L
D03 12 Flex hose Flex hose with connectors 15 NB 1 ____ B L
D03 12 SOV SOV 1 ____ B L
D03 12 AFR AFR 1 shavo SB10-2N-M1T-RGK-NN B L
D03 12 Nozzle tip Oil Burner nozzle tip 1 B L
0 SECTION - D C&I
&ŽƌŝŶƐƚƌƵŵĞŶƚƚĞƌŵŝŶĂƚŝŽŶ PF + Pipe
Junction Refer Drawing No
D01 11 ĚƵůǇŵŽƵŶƚĞĚǁŝƚŚĐĂďůĞ Rack + 3 Nos Ex-Protecta ____ B M
Boxes 17.3610-03-C01
ŐůĂŶĚ Burner
&ŽƌŝŶƐƚƌƵŵĞŶƚƚĞƌŵŝŶĂƚŝŽŶ PF + Pipe
Junction Refer Drawing No
D02 11 ĚƵůǇŵŽƵŶƚĞĚǁŝƚŚĐĂďůĞ Rack + 5 Nos Ex-Protecta ____ B L
Boxes 17.3610-03-C01
ŐůĂŶĚ Burner
Refer Drawing No
D03 11 LPBS &ŽƌWƵŵƉ PF Unit 1 No Ex-Protecta ____ B L
17.3610-03-C02
For Burner operation from Refer Drawing No
D04 11 Local panel NA 1 No Rittal ____ B L
field 17.3610-03-C05
HEI Power Refer Drawing No
D05 11 For HEI Page 7 of 9 Burner 1 No Rittal ____ B L
Pack 17.3610-03-C03
DC Starter DC Started panel for DC Maruti

D06 10b NA NA 1 No ____ B L
Panel Motor Automation
D07 11 Cable For instrument termination 1 Lot Udaypyro ____ B M
D07 11 Cable 2C X 1.54 Sq.mm 213 mtrs Udaypyro ____ B L
D07 11 Cable 4C X 1.54 Sq.mm 45 mtrs Udaypyro ____ B L
D07 11 Cable 1P X 1.0 Sq.mm 225 mtrs Udaypyro ____ B L
D07 11 Cable "R" Type TC Cable 30 mtrs Stock ____ R L
D07 11 Cable "K" Type TC Cable 35 mtrs Stock ____ R L
D08 11 Cable Gland For Cable Termination 1 Lot ____ B M
D08 11 Cable Gland 1P X 1.0 Sq.mm 45 Nos Ex-Protecta ____ B L
D08 11 Cable Gland 2C X 1.54 Sq.mm 23 Nos ____ B L
Tubbing &
D09 11 Fitting (MOC For instrument mounting 1 Lot ____ B M
: SS 316)
Tubbing &
D09 11 Fitting (MOC 1/2" NPT X 3/8" OD 5 Nos ____ B L
: SS 316)
Tubbing &
: SS 316)
Tubbing &
D09 11 Fitting (MOC 3/8" OD Tube 7.5 mtrs True way ____ S L
: SS 316)
Tubbing &
: SS 316)
Tubbing &
D09 11 Fitting (MOC 1/2" OD Tube 6 mtrs ____ S L
: SS 316)
Tubbing &
: SS 316)
Manifold /
D10 11 Gauge cock For instrument mounting 1 Lot ____ B M
valve
Manifold /
D10 11 Gauge cock 3 Way Gauge Cock Valve 2 Nos ____ B L
valve P.S.Enterpr
Manifold / ice
D10 11 Gauge cock 3 Way Manifold "T" type 4 Nos ____ B L
valve Page 8 of 9
Manifold /
D10 11 Gauge cock 3 Way Manifold "H" type 1 No ____ B L
valve
D11 11 Cable Tray ĂďůĞůĂǇŝŶŐ 1 Lot ____ S M
D11 11 Cable Tray ϮϬϬŵŵĐĂďůĞƚƌĂǇ 25 mtrs ____ S L
Reputed
D11 11 Cable Tray ϭϬϬŵŵĐĂďůĞƚƌĂǇ 30 mtrs ____ S L
D11 11 Cable Tray ϱϬŵŵĐĂďůĞƚƌĂǇ 10 mtrs ____ S L
Page 9 of 9
JOB NO.17-3610
KWZd/KEED/EdEEDEh>
WZdϵͲd,E/>^W/&/d/KE^;d^WͿ
^Z͘EK͘ EDK&/dD K͘EK͘
ϭ͘ >s>/E/dKZ d^WͲ>/ͲϬϭ
Ϯ͘ >s>^t/d, d^WͲ>^ͲϬϮ
ϯ͘ /&&͘WZ^^hZdZE^D/ddZ d^WͲWdͲϬϯ
ϰ͘ WZ^^hZ'h' d^WͲW'ͲϬϰ
ϱ͘ DKdKZd^,d;Ϭͺϳϱ<tͿ d^WͲDŽƚŽƌͲϬϱ
ϲ͘ DKdKZd^,d;ϭ͘ϱ<tͿ d^WͲDŽƚŽƌͲϬϱ
ϳ͘ DKdKZd^,d;ϭϴͺϱ<tͿ d^WͲDŽƚŽƌͲϬϱ
ϴ͘ DKdKZd^,d;ϯϬ<tͿ d^WͲDŽƚŽƌͲϬϱ
ϵ͘ WZ^^hZ^t/d,^ d^WͲW^ͲϬϲ
ϭϬ͘ &>KtDdZ d^WͲ&DͲϬϳ
ϭϭ͘ WZ^^hZdZE^D/ddZ d^WͲWdͲϬϴ
ϭϮ͘ &>DÊEZ d^WͲ&^ͲϬϵ
ϭϯ͘ Zdt/d,d,ZDKt>> d^WͲdͲϭϭ
ϭϰ͘ dDWZdhZdZE^D/ddZ d^WͲddͲϭϮ
ϭϱ͘ EEhZ d^WͲͲϭϯ
ϭϲ͘ ZŽƚĂƌǇĐƚƵĂƚŽƌ d^WͲZͲϭϰ
ϭϳ͘ >ŝŶĞĂƌĐƚƵĂƚŽƌ d^WͲ>Ͳϭϱ
ϭϴ͘ ^K>EK/s>s d^WͲ^sͲϭϲ
ϭϵ͘ ^ZtWhDW d^WͲ&KWͲϭϳ
ϮϬ͘ <WZ^^hZZ'h>d/E's>s d^WͲWZsͲϭϴ
Ϯϭ͘ &>KtKEdZK>s>s d^WͲ&sͲϭϵ
ϮϮ͘ ^&dz^,hdK&&s>s d^WͲ^^KsͲϮϬ
Ϯϯ͘ >>s>s;^K<dt>Ϳ d^WͲDsͲϮϮͲϭ
Ϯϰ͘ '>Ks>s;^K<dt>Ϳ d^WͲDsͲϮϮͲϮ
Ϯϱ͘ 'ds>s;^K<dt>Ϳ d^WͲDsͲϮϮͲϯ
Ϯϲ͘ EKEZdhZEs>s;^K<dt>Ϳ d^WͲDsͲϮϮͲϰ
Ϯϳ͘ K&&WKdDWZ d^WͲWͲϮϯ
Ϯϴ͘ ,K/^d/E'DWZ d^WͲ,ͲϮϰ
JOB NO.17-3610
KWZd/KEED/EdEEDEh>
Ϯϵ͘ KDh^d/KE/Z>KtZ d^WͲͲϮϱ

ϯϬ͘ DZ'Ez/Z>KtZ d^WͲͲϮϲ
ϯϭ͘ K>KEsz/E'/Z>KtZ d^WͲͲϮϴ
ϯϮ͘ ZKdZz/Z>K<s>s d^WͲZsͲϮϵ
ϯϯ͘ <ŶŝĨĞĚŐĞ'ĂƚĞsĂůǀĞ d^WͲ<'sͲϯϬ
ϯϰ͘ Dd>>/yWE^/KE>>Kt d^WͲͲϯϭ
ϯϱ͘ &>y/>,K^^ d^WͲ&,Ͳϯϯ
JOB NO.17-3610
KWZd/KEED/EdEEDEh>
WZdϭϬͲZt/E'ΘKhDEd^
^Z͘EK͘ ^Z/Wd/KE Zt/E'ͬK͘EK͘
ϭ͘ '͘K&,'' ϭϳͲϯϲϭϬͲϬϮͲϬϭ
Ϯ͘ Z&ZdKZzK&,'' ϭϳͲϯϲϭϬͲϬϭͲϰϬ
ϯ͘ WΘ/ ϭϳͲϯϲϭϬͲϬϭͲϬϬ
ϰ͘ '͘K&Kd ϭϳͲϯϲϭϬͲϬϭͲϬϮ
ϱ͘ '͘K&W͘&hE/d ϭϳͲϯϲϭϬͲϬϭͲϬϯ
ϲ͘ '͘W&W/WZ< ϭϳͲϯϲϭϬͲϬϭͲϬϰ
ϳ͘ hd/E'&ZKDh^dZdK,'' ϭϳͲϯϲϭϬͲϬϮͲϲϯ
ϴ͘ KD͘/Z>KtZ ϭϳͲϯϲϭϬͲϬϮͲϲϰ
ϵ͘ DZ'Ez/Z>KtZ ϭϳͲϯϲϭϬͲϬϮͲϲϱ
ϭϬ͘ /^KDdZ/ ϭϳͲϯϲϭϬͲϬϮͲϲϳ
ϭϭ͘ :hEd/KEKyZt/E' ϭϳͲϯϲϭϬͲϬϯͲϬϭ
ϭϮ͘ >W^Zt/E' ϭϳͲϯϲϭϬͲϬϯͲϬϮ
ϭϯ͘ ,/WKtZW< ϭϳͲϯϲϭϬͲϬϯͲϬϯ
ϭϰ͘ ,KK<ͲhWZt/E' ϭϳͲϯϲϭϬͲϬϯͲϬϰ
ϭϱ͘ >K>WE>'͕KDΘt/Z/E'Zt/E' ϭϳͲϯϲϭϬͲϬϯͲϬϱ
ϭϲ͘ >K'/Zt/E' ϭϳͲϯϲϭϬͲϬϯͲϬϲ
ϭϳ͘ KDh^d/KEKEdZK>>K'/ ϭϳͲϯϲϭϬͲϬϯͲϬϵ
ϭϴ͘ >dZ/>>K>/^d ϮϬϭϳ͘ϯϲϭϬͲ/KͲϬϮ
ϭϵ͘ >^,h> Ͳ
ϮϬ͘ /EWhdͬKhdWhd>/^d Ͳ
Ϯϭ͘ ^dZdZWE> WͬDϭϳͬϭϮϮϰͬϬϭ

JOB NO.17-3610
KWZd/KEED/EdEEDEh>
WZdϭϭͲ>/dZdhZ^
^Z͘EK͘ EDK&/dD D<

ϭ͘ DEh>s>s^;Ăůů͕'ĂƚĞ͕'ůŽďĞΘEŽŶͲZĞƚƵƌŶsĂůǀĞƐͿ <^
Ϯ͘ >s>/E/dKZ WhEd,dZK>
ϯ͘ >s>^t/d, WhEd,dZK>
ϰ͘ WhDW dh^,K
ϱ͘ <WZ^^hdZZ'h>d/E's>s E/ZD>
ϲ͘ WZ^^hZ'h' '/
ϳ͘ Zdt/d,d,ZDKt>> '/
ϴ͘ &>KtKEdZK>s>s D/>
ϵ͘ WZ^^hZ^t/d, ^t/dZ
ϭϬ͘ &>KtDdZD DZ^KE
ϭϭ͘ &>y/>,K^ ZK&>y
ϭϮ͘ &>DÊEZ &/s^W/>>Z
ϭϯ͘ WKtZz>/EZ ZKdy
ϭϰ͘ ;&ĂŶͿ Z/d
ϭϱ͘ WZ/DZz/Z>KtZ <z
ϭϲ͘ WΘKK>/E'/Z>KtZ KdKZ
ϭϳ͘ DKdKZ '>
ϭϴ͘ ^K>EK/s>s ZKdy
ϭϵ͘ dDWZdhZ/E/dKZ ^>
ϮϬ͘ yWE^/KE>>Kt ^dE&
Ϯϭ͘ /Z&/>dZZ'h>dKZ ^,sK
ϮϮ͘ WZ^^hZͬ/&&͘WZ^^hZdZE^D/ddZ ^/DE^
Ϯϯ͘ ZKdZz/Z>K<s>s Z/K
Ϯϰ͘ <E/&'ds>s Zz
Ϯϱ͘ ^&dz^,hdK&&s>s ZKdy
Ϯϲ͘ ,K/^d/E'DWZ ^^z^dD^
Ϯϳ͘ ,//'E/dZ &^
Ϯϴ͘ dDWZdhZdZE^D/ddZ ^/DE^
Ϯϵ͘ >s>^t/d, ^t/dZ
ϯϬ͘ DKdKZ '>
ϯϭ͘ K&&WKdDWZ /E͘&E^
ϯϮ͘ t/',&Z^ ^,E<
N2, N3 , N4, N5,, N26
N 180°
W E N29, N30, N31 180°
180°
S
N10B
GUIDE SUPPORT AT 180° 90°
270° 90° 270°
N8A, N8B,N10A, 270° 90°
N12
N25
315° 0°
N9
0° 0°
GUIDE SUPPORT AT 90° & 270° GUIDE SUPPORT AT 0° N1 , N7, N11, N13, N24
HGG SUPPORT DETAIL
HGG GUIDE SUPPORT DETAIL
N13
N12
N11
HGG SHELL / SURFACE TEMP IN °C
N1
N2
N15, N16, N17, N18
COMB. AIR INLET FLANGE (N1)
HGG OUTLET FLANGE (N5)
N19, N20, N21, N22, N23 LOAD DETAIL :
DEAD WEIGHT OF EQUIPMENT : 23000Kg.
N27 N8A, N14 REFRACTORY WEIGHT : 57500 Kg.
EXPANSION WITHOUT OUTER INSULATION TOTAL WEIGHT : 80500 Kg.
N10A
TECHNICAL DATA
N3
SITE JOINT
EXPANSION WITH OUTER INSULATION
N8B
N24, N25, N26
NOTE :
N4
PRIMARY DILU. AIR INLET FLANGE (N2) SECONDARY DILU. AIR INLET -1 (N3)
TOTAL QTY : 1 NO.
N28
SITE JOINT
N5 N29, N30, N31
N10B
N7
SECONDARY DILU. AIR INLET -2 (N4)
AS BUILT ITEM DESCRIPTION / SPECIFICATION QTY. MATERIAL REMARKS
E01
GA OF HGG Fives Combustion
Systems Pvt. Ltd.
17-3610 17-3610-02-A01
4
DETAIL-1 3
A
DETAIL-2 3
DETAIL-1 3
DETAIL-A 3
DETAIL-3 3
DETAIL -B C
B
DETAIL-2 3 SECTION-DD 3
4
4
4 D D
DETAIL - Z
DETAIL -C
ELEVATION 3
4 DETAIL-3 3 4
-
DUCTING FROM DEDUSTER TO
HGG Fives Combustion
Systems Pvt. Ltd.
17-3610 17--3610-02-B63
1 2 3 4 TOTAL WT. 6078.402 Kg. QTY.01 NO.
3
4
4
3
4 3
3
4 3
3
3 3
3
1 2 3
3
3
3 3
3
A 3 3
3 4
3
3 3
3
3
3
4
A
D1
4 1 2 3
1 2 3
4
-
DUCTING FROM DEDUSTER TO
4
HGG Fives Combustion
Systems Pvt. Ltd.
17-3610 17--3610-02-B63
BELLOW : REF DRAWING NO. EB.FTS.2744P.01 & EB.FTS.2744P.02
QTY.01 NO. NOTE :-
1.MITER BEND TO BE MODE BY PIPE CUTTING
2. DUCTING CLIENT SCOPE
TOTAL WT. 3666.322 Kg.
PLAN
Z Z
VIEW-X
PIPE SUPPORT
SEC.ZZ
SUPPORT 'S1'
DETAIL FOR BASE PLATE
DETAIL 'D1'
DETAIL 'D2'
UNIT TOTAL
ITEM DESCRIPTION QTY. MATL. REMARKS
SIDE VIEW
00 ELEVATION
DUCTING FROM COMB.AIR
BLOWER TO HGG Fives Combustion
Systems Pvt. Ltd.
17-3610 17-3610-02-B64
00
DUCTING FROM COMB.AIR
BLOWER TO HGG Fives Combustion
Systems Pvt. Ltd.
17-3610 17-3610-02-B64
PLAN
SUPPORT 'S2'
NOTE :-
1.MITER BEND TO BE MODE BY PIPE CUTTING
QTY.01 NO. 2. DUCTING CLIENT SCOPE
TOTAL WT. 1616.744 Kg.
SUPPORT 'S2'
COMB.AIR BLOWER DUCT
UNIT TOTAL
00 ELEVATION SIDE VIEW
DUCTING FROM EMERGENCY
Fives Combustion
AIR BLOWER TO HGG
Systems Pvt. Ltd.
17-3610 17-3610-02-B65
17-3610-01-A40
REFRACTORY OF HGG
17-3610
ANCHOR PITCH DETAIL
REFRACTORY DETAIL
ITEM QTY.(NOS) WEIGHT
DESCRIPTION SIZE / REF. NO. (WITH 10% EXTRA) MATERIAL SYMBOL
No. IN Kg.
OIL RETURN FROM PF UNIT TO DOT
QTY.01NO.
TOTAL WT. ~15.997 Kg.
UNIT TOTAL
CHAPTER NO. F02 FOR INFORMATION FOR APPROVAL FOR MANUFACTURING
DATE BY TITLE
DRAWN ISOMETRIC Fives Combustion
CHECKED
Systems Pvt. Ltd.
APPROVED
Designer and manufacturer of Fives Pillard and CBL products
FCS JOB NO. PROJECT:
REV.
17-3610
CAD NO. SCALE
DRG.No. 17-3610-02-B67
SHEET 1 OF 6
DOT TO PF UNIT
QTY.01NO.
UNIT TOTAL
DATE BY TITLE
CHECKED
Systems Pvt. Ltd.
APPROVED
REV.
17-3610
CAD NO. SCALE
DRG.No. 17-3610-02-B67
SHEET 2 OF 6
OIL LINE: PF UNIT TO MAIN PIPE RACK
QTY.01NO.
UNIT TOTAL
DATE BY TITLE
CHECKED
Systems Pvt. Ltd.
APPROVED
REV.
17-3610
CAD NO. SCALE
DRG.No. 17-3610-02-B67
SHEET 3 OF 6
OIL LINE PIPE RACK TO BURNER
QTY.01NO.
UNIT TOTAL
DATE BY TITLE
CHECKED
Systems Pvt. Ltd.
APPROVED
REV.
17-3610
CAD NO. SCALE
DRG.No. 17-3610-02-B67
SHEET 4 OF 6
ATOM.AIR LINE PIPE RACK TO BURNER
QTY.01NO.
UNIT TOTAL
DATE BY TITLE
CHECKED
Systems Pvt. Ltd.
APPROVED
REV.
17-3610
CAD NO. SCALE
DRG.No. 17-3610-02-B67
SHEET 5 OF 6
INST.AIR LINE PIPE RACK TO BURNER
QTY.01NO.
TOTAL WT. ~15.14Kg.
UNIT TOTAL
DATE BY TITLE
CHECKED
Systems Pvt. Ltd.
APPROVED
REV.
17-3610
CAD NO. SCALE
DRG.No. 17-3610-02-B67
SHEET 6 OF 6
WZK:d ϭyϲ͘ϴϱDtt,Z^WZK:d͘ Zs/^/KEEK͘ ϭ
WhZ,^Z ƚŚǇƐƐĞŶŬƌƵƉƉ/ŶĚƵƐƚƌŝĞƐ/ŶĚŝĂWǀƚ͘>ƚĚ͘ d Ϯϵ͘ϭϭ͘ϮϬϭϳ
Eh^Z WZ^<d/DEd/Eh^dZ/^>/D/d ^,dEK͘ ͲͲͲ
&^:KEϬ͘ ϮϬϭϳ͘ϯϲϭϬ WZz &:^
&ŝǀĞƐŽŵďƵƐƚŝŽŶ^ǇƐƚĞŵƐWǀƚ͘>ƚĚ͘ KhDEdEK ϮϬϭϳ͘ϯϲϭϬͲ/KͲϬϮ WWZKsz Ê
>dZ/>>K>/^d
^h/>d
ϭ Ϯϵ͘ϭϭ͘ϮϬϭϳ &ŝŶĂů>ŽĂĚhƉĚĂƚĞĚ &:^ &:^ Ê

Ϭ Ϯϵ͘Ϭϴ͘ϮϬϭϳ /E/d/>/^^h&KZ/E&KZDd/KE &:^ &:^ Ê
Zs d /^Z/Wd/KE WZWZz ,<z WZ͘z
ůĞĐƚƌŝĐĂů>ŽĂĚ>ŝƐƚ
WKtZ
^ƌŶŽ͘ /dD^Z/Wd/KE sK>d' dzW KE^hDWd/KE Ydz dKd>;<tͿ ZĞǀ
;<tͿ
ϭ >ŽĐĂůŽŶƚƌŽůƉĂŶĞů ϮϯϬs͕ϱϬ,ǌ ͲͲͲͲ ϭ͘Ϭ ϭ ϭ͘Ϭ
Ϯ ^ŽůĞŶŽŝĚsĂůǀĞƐ ϮϯϬs͕ϱϬ,ǌ KŶͲKĨĨƵƚǇ Ϭ͘Ϭϭϴ ϴ Ϭ͘ϭ
ϯ DŽƚŽƌĨŽƌŽŵďƵƐƚŝŽŶŝƌ&ĂŶ;ϭtнϭ^Ϳ ϰϭϱs͕ϱϬ,͕ϯW, s& ϯϬ͘Ϭ Ϯ ϲϬ͘Ϭ
ϰ DŽƚŽƌĨŽƌŵĞƌŐĞŶĐǇŽŽůŝŶŐŝƌ&ĂŶ ϭϭϬs ƐƚĂƌƚĞƌ ϭ͘ϱ ϭ ϭ͘ϱ
ϱ DŽƚŽƌĨŽƌKŝůWƵŵƉ;ϭtнϭ^Ϳ ϰϭϱs͕ϱϬ,͕ϯW, K> Ϭ͘ϳϱ Ϯ ϭ͘ϱ
ϲ &ŽƌŽĂůŽŶǀĞǇŝŶŐƐǇƐƚĞŵ ϰϭϱs͕ϱϬ,͕ϯW, ϱ͘ϱ ϭ ϱ͘ϱ
ϳ &ŽƌZŽŽƚƐďůŽǁĞƌ;ϭtнϭ^Ϳ ϰϭϱs͕ϱϬ,͕ϯW, K> ϭϴ͘ϱ Ϯ ϯϳ͘Ϭ
ϴ ZŽƚĂƌǇŝƌůŽĐŬǀĂůǀĞ ϰϭϱs͕ϱϬ,͕ϯW, ZK> Ϭ͘ϳϱ ϭ Ϭ͘ϳϱ
ϵ ůĞĐƚƌŝĐĂůĐƚƵĂƚŽƌĨŽƌ,ŽƐƚŝŶŐĚĂŵƉĞƌ ϰϭϱs͕ϱϬ,͕ϯW, ZK> Ϯ͘Ϯ ϭ Ϯ͘Ϯ
ϭϬ ůĞĐƚƌŝĐĂůĐƚƵĂƚŽƌĨŽƌŽĨĨĞĞƉŽƚĂŵƉĞƌ ϰϭϱs͕ϱϬ,͕ϯW, ZK> Ϭ͘ϱϱ ϭ Ϭ͘ϲ
ϭϭ ůĞĐƚƌŽŵĂŐŶĞƚĨŽƌŽĨĨĞĞƉŽƚĚĂŵƉĞƌ ϮϯϬs͕ϱϬ,ǌ KŶͲKĨĨƵƚǇ Ϭ͘Ϯ ϭ Ϭ͘Ϯ
EKd^͗
ůŝĞŶƚƚŽĐŽŶƐŝĚĞƌƐƵĨĨŝĐŝĞŶƚŵĂƌŐŝŶŽŶĂďŽǀĞĚĂƚĂ
WZK:d ϭyϲ͘ϴϱDtt,Z^WZK:d͘ Zs/^/KEEK͘ ϭ

WhZ,^Z ƚŚǇƐƐĞŶŬƌƵƉƉ/ŶĚƵƐƚƌŝĞƐ/ŶĚŝĂWǀƚ͘>ƚĚ͘ d Ϯϵ͘ϭϭ͘ϮϬϭϳ
Eh^Z WZ^<d/DEd/Eh^dZ/^>/D/d ^,dEK͘ ͲͲͲ
&^:KEϬ͘ ϮϬϭϳ͘ϯϲϭϬ WZz &:^
&ŝǀĞƐŽŵďƵƐƚŝŽŶ^ǇƐƚĞŵƐWǀƚ͘>ƚĚ͘ KhDEdEK ϮϬϭϳ͘ϯϲϭϬͲ/KͲϬϮ WWZKsz Ê
WƌŽũĞĐƚŽĚĞ ϮDϬϬϰϬ d Ϭϴ͘Ϭϯ͘ϮϬϭϴ
ϭǆϲ͘ϴϱDtt,ZWd/sWKtZ
WƌŽũĞĐƚ WZW͘ sW<
W>Ed
WZ^<d/DEd/Eh^dZ/^
ŶĚůŝĞŶƚ ,<͘ Ê^ͬ<
>/D/d͕W
ŽŶƚƌĂĐƚŽƌ WWZ͘ ^^
ŽĐƵŵĞŶƚ ,''ƚŽW>ĂďůĞ^ĐŚĞĚƵůĞ
ŽĐƵŵĞŶƚEƵŵďĞƌ ϮDϬϬϰϬͲϳϰϬϰͲͲϯϳϬϭ ZĞǀŝƐŝŽŶ Ϭ
ĂďůĞ&ƌŽŵ ĂďůĞdŽ ĂďůĞĞƚĂŝůƐ KƵƚŐŽŝŶŐĂďůĞĞƚĂŝůƐ W>ĞƚĂŝůƐ

ĂďůĞdĂŐ
/ŶƐƚƌƵŵĞŶƚdĂŐEƵŵďĞƌ ĞƐĐƌŝƉƚŝŽŶ dǇƉĞKĨ :ďEŽ dĞƌŵŝŶĂů :>ŽĐĂƚŝŽŶ ^ŝǌĞKĨĂďůĞ ĂďůĞĨƌŽŵ: ĂďůĞĨƌŽŵ:ƚŽ ĂƌĚEŽ ŚĂŶŶĞů dĞƌŵŝŶĂů ZĞŵĂƌŬ&Žƌ
EŽ
/ŶƉƵƚ EƵŵďĞƌ ƚŽ^ ^dĂŐEŽ͘ EŽ EƵŵďĞƌ ZĞǀŝƐŝŽŶ
ϭͲ/Ͳ:ͲϬϭ
t,Z^ͲYϮ,WͲ,''Ͳ ϭ
ϭͲ/Ͳ:ϬϭͲϬϬϭ >Kͬ,^>/E^^KsKWED͘ / Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;Ǉ&^Ϳ y/ͺϱϭ ϵ ϭϳ͕ϭϴ
W^>ͲϬϬϭ Ϯ
t,Z^ͲYϮ,WͲ,''Ͳy^Ͳ ϯ
>Kͬ,^>/E^^Ks>K^WK^/d/KE / y/ͺϱϭ ϭϬ ϭϵ͕ϮϬ
ϬϬϭͲ^ ϰ
ϭͲ/Ͳ:ͲϬϭͲϬϬϮ ϮWǆϭ͘Ϭ^Ƌ͘ŵŵ;Ǉ&^Ϳ
t,Z^ͲYϮ,WͲ,''Ͳy^Ͳ ϱ
>Kͬ,^>/E^^KsKWEWK^/d/KE / y/ͺϱϭ ϭϭ Ϯϭ͕ϮϮ
ϬϬϭͲ^K ϲ
t,Z^ͲYϮ,WͲ,''Ͳ >Kͬ,^>/EKhd>dWZ^^hZ ϳ
ϭͲ/Ͳ:ͲϬϭͲϬϬϯ / Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;Ǉ&^Ϳ y/ͺϱϮ ϯ ϱ͕ϲ
W^,ͲϬϬϮ ^t/d,,/', ϴ
ϮϰĐǆϭ͘ϱ^Y
t,Z^ͲYϮ,WͲ,''Ͳ dKD//E'/Z>/EWZ^^hZ ϵ W/W/E'
ϭͲ/Ͳ:ͲϬϭͲϬϬϰ / ϭͲ/Ͳ:ͲϬϭ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;Ǉ&^Ϳ DD;dŬŝŝ t,Z^Ͳ,''ͲW>ͲϬϭ y/ͺϱϮ ϰ ϳ͕ϴ
W^>ͲϬϬϯ ^t/d,>Kt ϭϬ ^</
^ĐŽƉĞͿ
t,Z^ͲYϮ,WͲ,''Ͳ /E^dZhDEd/Z>/EWZ^hZ ϭϭ
ϭͲ/Ͳ:ͲϬϭͲϬϬϱ / Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;Ǉ&^Ϳ y/ͺϱϮ ϱ ϵ͕ϭϬ
W^>ͲϬϬϰ ^t/d,>Kt ϭϮ
t,Z^ͲYϮ,WͲ,''Ͳ>^>Ͳ ϭϯ
ϭͲ/Ͳ:ͲϬϭͲϬϬϲ Kd>s>^t/d,>Kt / Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;Ǉ&^Ϳ y/ͺϱϭ ϳ ϭϯ͕ϭϰ
ϬϬϭ ϭϰ
t,Z^ͲYϮ,WͲ,''Ͳ ϭϱ
ϭͲ/Ͳ:ͲϬϭͲϬϬϳ Kd>s>^t/d,,/', / Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;Ǉ&^Ϳ y/ͺϱϭ ϴ ϭϱ͕ϭϲ
>^,ͲϬϬϭ ϭϲ
WƌŽũĞĐƚ ϭǆϲ͘ϴϱDtt,ZWd/sWKtZW>Ed WZW͘ sW<
WZ^<d/DEd/Eh^dZ/^
>/D/d͕W

ĂďůĞ&ƌŽŵ ĂďůĞdŽ ĂďůĞĞƚĂŝůƐ KƵƚŐŽŝŶŐĂďůĞĞƚĂŝůƐ
ĂďůĞdĂŐ /ŶƐƚƌƵŵĞŶƚdĂŐEƵŵďĞƌ ĞƐĐƌŝƉƚŝŽŶ dǇƉĞKĨ :ďEŽ dĞƌŵŝŶĂů :>ŽĐĂƚŝŽŶ ^ŝǌĞKĨĂďůĞ ĂďůĞĨƌŽŵ: ĂďůĞĨƌŽŵ:ƚŽ ĂƌĚEŽ ŚĂŶŶĞů dĞƌŵŝŶĂů ZĞŵĂƌŬ&Žƌ
EŽ /ŶƉƵƚ EƵŵďĞƌ ƚŽ^ ^dĂŐEŽ͘ EŽ EƵŵďĞƌ ZĞǀŝƐŝŽŶ
ϭͲKͲ:ͲϬϮ
t,Z^ͲYϮ,WͲ,''Ͳy^Ͳ ϭ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;
ϭͲKͲ:ϬϭͲϬϬϭ >Kͬ,^>/E^^KsKWED K yKͺϮϮ ϭϬ ϭϵ͕ϮϬ
ϬϬϭͲY^ Ϯ Ǉ&^Ϳ
t,Z^ͲYϮ,WͲ,''Ͳy^Ͳ ϯ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;
ϭͲKͲ:ͲϬϭͲϬϬϮ dKD//E'/Z>/E^KsKWED͘ K yKͺϮϮ ϭϭ Ϯϭ͕ϮϮ
ϬϬϮͲY^ ϰ Ǉ&^Ϳ
t,Z^ͲYϮ,WͲ,''Ͳy^Ͳ ϱ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;
ϭͲKͲ:ͲϬϭͲϬϬϯ ^sE'/E'/Z>/E^KsKWED͘ K yKͺϮϮ ϭϮ Ϯϯ͕Ϯϰ
ϬϬϯͲY^ ϲ Ǉ&^Ϳ
ϳ
^WZ K
ϴ
ϵ ϳǆϭ͘ϱ^ƋŶ
^WZ K ϭͲKͲ:ͲϬϮ W/W/E'^</ t,Z^Ͳ,''ͲW>ͲϬϮ
ϭϬ ŵŵ;Ǉd<//Ϳ
ϭϭ
^WZ K
ϭϮ
ϭϯ
^WZ K
ϭϰ
ϭϱ
^WZ K
ϭϲ
ŶĚůŝĞŶƚ WZ^<d/DEd/Eh^dZ/^>/D/d͕W ,<͘ Ê^ͬ<

ϭͲ/ͲKͲ:ͲϬϯ
ϭ
^WZ / Ϯ
ϯ
ϰ
t,Z^ͲYϮ,WͲ,''Ͳ >Kͬ,^>/E&sͬWDKh>d/KE ϭWǆϭ͘Ϭ^Ƌ͘ŵŵ;z
ϭͲ/ͲKͲ:ϬϯͲϬϬϮ K ϱ yKͺϭϬ Ϯ ϯ͕ϰ
&sͲͬWͲϬϬϭ D͘ &^Ϳ
ϲ
ϳ
^WZ / ϴ
ϵ
ϭϬ
t,Z^ͲYϮ,WͲ,''Ͳ ϭWǆϭ͘Ϭ^Ƌ͘ŵŵ;z
ϭͲ/ͲKͲ:ϬϯͲϬϬϯ >Kͬ,^>/EWdZK^^^dZ/EZ / ϭϭ y/ͺϮϭ Ϯ ϯ͕ϰ
WdͲϬϬϮ &^Ϳ
ϭϮ
ϭϯ
t,Z^ͲYϮ,WͲ,''Ͳ dKD//E'/Z>/EWdZK^^ ϭWǆϭ͘Ϭ^Ƌ͘ŵŵ;z ϲWyϭƐƋŵŵ t,Z^Ͳ,''ͲW>Ͳ
ϭͲ/ͲKͲ:ϬϯͲϬϬϰ / ϭͲ/ͲKͲ:ͲϬϯ ϭϰ W/W/E'^</ y/ͺϮϭ ϯ ϱ͕ϲ
WdͲϬϬϯ ^dZ/EZ &^Ϳ ;ďǇd<//Ϳ Ϭϯ
ϭϱ
ϭϲ
t,Z^ͲYϮ,WͲ,''Ͳ /&&͘WZ^^hZZK^^^dZ/EZ͕W& ϭWǆϭ͘Ϭ^Ƌ͘ŵŵ;z
ϭͲ/ͲKͲ:ϬϯͲϬϬϭ / ϭϳ y/ͺϮϭ ϭ ϭ͕Ϯ
WdͲϬϬϭ hE/d &^Ϳ
ϭϴ

ϭͲ/Ͳ:ͲϬϰ
t,Z^ͲYϮ,WͲ,''Ͳ KDh^d/KE/Z>/EWZ^^hZ ϭ
ϭͲ/Ͳ:ͲϬϰͲϬϬϭ / Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;z&^Ϳ y/ͺϱϯ ϭ ϭ͕Ϯ
W^>ͲϬϬϱ ^t/d,>Kt Ϯ
t,Z^ͲYϮ,WͲ,''Ͳ KDh^d/KE/Z>/EDWZͲ ϯ
/ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;z&^Ϳ y/ͺϱϮ ϴ ϭϱ͕ϭϲ
^ͲϬϬϳ ϭ>K^WK^/d/KE ϰ
ϭͲ/Ͳ:ͲϬϰͲϬϬϮ
t,Z^ͲYϮ,WͲ,''Ͳ KDh^d/KE/Z>/EDWZͲ ϱ
/ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;z&^Ϳ y/ͺϱϮ ϵ ϭϳ͕ϭϴ
^KͲϬϬϳ ϭKWEWK^/d/KE ϲ
t,Z^ͲYϮ,WͲ,''Ͳ KDh^d/KE/Z>/EDWZͲ ϳ
/ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;z&^Ϳ y/ͺϱϮ ϭϬ ϭϵ͕ϮϬ
^ͲϬϬϴ Ϯ>K^WK^/d/KE ϴ
ϭͲ/Ͳ:ͲϬϰͲϬϬϯ
t,Z^ͲYϮ,WͲ,''Ͳ KDh^d/KE/Z>/EDWZͲ ϵ
/ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;z&^Ϳ y/ͺϱϮ ϭϭ Ϯϭ͕ϮϮ
^KͲϬϬϴ ϮKWEWK^/d/KE ϭϬ Ϯϰyϭ͘ϱƐƋ t,Z^Ͳ,''ͲW>ͲϬϰ
t,Z^ͲYϮ,WͲ,''Ͳ DZ'EzKK>/E'>/E ϭϭ ŵŵ;ďǇd<//Ϳ
/ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;z&^Ϳ y/ͺϱϮ ϭϮ Ϯϯ͕Ϯϰ
^ͲϬϬϵ DWZͲϭ>K^WK^/d/KE ϭϮ
ϭͲ/Ͳ:ͲϬϰͲϬϬϰ
t,Z^ͲYϮ,WͲ,''Ͳ DZ'EzKK>/E'>/E ϭϯ
/ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;z&^Ϳ y/ͺϱϮ ϭϯ Ϯϱ͕Ϯϲ
^KͲϬϬϵ DWZͲϭKWEWK^/d/KE ϭϰ
t,Z^ͲYϮ,WͲ,''Ͳ />hd/KE/Z>/EWZ^^hZ ϭϱ
ϭͲ/Ͳ:ͲϬϰͲϬϬϱ / Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;z&^Ϳ y/ͺϱϯ Ϯ ϯ͕ϰ
W^>ͲϬϬϲ ^t/d,>Kt ϭϲ
ϭͲ/Ͳ:ͲϬϰ EZ,''
t,Z^ͲYϮ,WͲ,''Ͳ K>KEsz/E'>/EDWZ ϭϳ
/ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;z&^Ϳ y/ͺϱϮ ϲ ϭϭ͕ϭϮ
^ͲϬϬϰ >K^WK^/d/KE ϭϴ
ϭͲ/Ͳ:ͲϬϰͲϬϬϲ
t,Z^ͲYϮ,WͲ,''Ͳ K>KEsz/E'>/EDWZ ϭϵ
/ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;z&^Ϳ y/ͺϱϮ ϳ ϭϯ͕ϭϰ
^KͲϬϬϰ KWEWK^/d/KE ϮϬ
t,Z^ͲYϮ,WͲ,''Ͳ DZ'EzKK>/E'>/E Ϯϭ
/ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;z&^Ϳ y/ͺϱϯ ϵ ϭϳ͕ϭϴ
^ͲϬϭϮ DWZͲϮ>K^WK^/d/KE ϮϮ
ϭͲ/Ͳ:ͲϬϰͲϬϬϳ
t,Z^ͲYϮ,WͲ,''Ͳ DZ'EzKK>/E'>/E Ϯϯ
/ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;z&^Ϳ y/ͺϱϯ ϭϬ ϭϵ͕ϮϬ
^KͲϬϭϮ DWZͲϮKWEWK^/d/KE Ϯϰ
Ϯϱ
^WZ
Ϯϲ ϳyϭ͘ϱ^Ƌŵŵ t,Z^Ͳ,''ͲW>ͲϬϰ
t,Z^ͲYϮ,WͲ,''Ͳ^Ͳ Ϯϳ ;ďǇd<//Ϳ
ϭͲ/Ͳ:ͲϬϰͲϬϬϴ h^d^t/d,d,''Khd>d / Ϯǆϭ͘ϱ^Ƌ͘ŵŵ;z&^Ϳ
ϬϬϭ Ϯϴ
Ϯϵ
^WZ
ϯϬ

ĂďůĞdĂŐ /ŶƐƚƌƵŵĞŶƚdĂŐEƵŵďĞƌ ĞƐĐƌŝƉƚŝŽŶ dǇƉĞKĨ :ďEŽ dĞƌŵŝŶĂů :>ŽĐĂƚŝŽŶ ^ŝǌĞKĨĂďůĞ ĂďůĞĨƌŽŵ: ĂďůĞĨƌŽŵ:ƚŽ^ ĂƌĚEŽ ŚĂŶŶĞů dĞƌŵŝŶĂů ZĞŵĂƌŬ&Žƌ
EŽ /ŶƉƵƚ EƵŵďĞƌ ƚŽ^ dĂŐEŽ͘ EŽ EƵŵďĞƌ ZĞǀŝƐŝŽŶ
ϭͲKͲ:ͲϬϱ
t,Z^ͲYϮ,WͲ,''Ͳy^Ͳ KDh^d/KE/Z>/EDWZͲϭ ϭ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ
ϭͲKͲ:ϬϱͲϬϬϭ K yKͺϮϭ ϭ ϭ͕Ϯ
ϬϬϳͲY^ KWED͘ Ϯ ;z&^Ϳ
t,Z^ͲYϮ,WͲ,''Ͳy^Ͳ KDh^d/KE/Z>/EDWZͲϮ ϯ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ
ϭͲKͲ:ͲϬϱͲϬϬϮ K yKͺϮϭ Ϯ ϯ͕ϰ
ϬϬϴͲY^ KWED͘ ϰ ;z&^Ϳ
t,Z^ͲYϮ,WͲ,''Ͳy^Ͳ DZ'EzKK>/E'>/EDWZͲ ϱ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ ϭϰyϭ͘ϱƐƋ
ϭͲKͲ:ͲϬϱͲϬϬϯ K t,Z^Ͳ,''ͲW>ͲϬϱ yKͺϮϭ ϯ ϱ͕ϲ
ϬϬϵͲY^ ϭKWED͘ ϲ ;z&^Ϳ ŵŵ
t,Z^ͲYϮ,WͲ,''Ͳy^Ͳ K>KEsz/E'>/EDWZ ϳ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ
ϭͲKͲ:ͲϬϱͲϬϬϰ K yKͺϮϭ ϱ ϵ͕ϭϬ
ϬϬϰ KWED͘ ϴ ;z&^Ϳ
t,Z^ͲYϮ,WͲ,''Ͳy^Ͳ ϵ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ
ϭͲKͲ:ͲϬϱͲϬϬϱ hZEZ,//E^ZdWK^/d/KE K yKͺϮϮ ϭϯ Ϯϱ͕Ϯϲ
ϬϬϱ ϭϬ ;z&^Ϳ
t,Z^ͲYϮ,WͲ,''Ͳy^Ͳ hZEZWKtZW<KED͘dK ϭϭ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ
ϭͲKͲ:ͲϬϱͲϬϬϲ K ϭͲKͲ:ͲϬϱ EZ,'' &^ &^ WŽǁĞƌƉĂĐŬͲdͲϭ;ϯ͕ϰ͕ϱͿ
ϬϬϲ WKtZW<:dϭͲϰ͕ϱ ϭϮ ;z&^Ϳ
ϭϯ
^WZ
ϭϰ
t,Z^ͲYϮ,WͲ,''Ͳy^Ͳ DZ'EzKK>/E'>/EDWZͲ ϭϱ Ϯǆϭ͘ϱ^Ƌ͘ŵŵ
ϭͲKͲ:ͲϬϱͲϬϬϴ K yKͺϮϭ ϰ ϳ͕ϴ
ϬϭϮ ϮKWED͘ ϭϲ ;z&^Ϳ
ϭϳ ϭϰyϭ͘ϱƐƋ t,Z^Ͳ,''ͲW>ͲϬϱ;
^WZ
ϭϴ ŵŵ ƐĂŵĞĂďŽǀĞĐĂďůĞͿ
ϭϵ
^WZ
ϮϬ

ĂďůĞdĂŐ
EŽ /ŶƐƚƌƵŵĞŶƚdĂŐ ĞƐĐƌŝƉƚŝŽŶ dǇƉĞKĨ :ďEŽ dĞƌŵŝŶĂů :>ŽĐĂƚŝŽŶ ^ŝǌĞKĨĂďůĞ ĂďůĞĨƌŽŵ: ĂďůĞĨƌŽŵ:ƚŽ^ ĂƌĚEŽ ŚĂŶŶĞů dĞƌŵŝŶĂů ZĞŵĂƌŬ&Žƌ
EƵŵďĞƌ /ŶƉƵƚ EƵŵďĞƌ ƚŽ^ dĂŐEŽ͘ EŽ EƵŵďĞƌ ZĞǀŝƐŝŽŶ
ϭͲ&^Ͳ:ͲϬϲ
WKtZ^hWW>zϮϰsнWK> ϭ Z
WKtZ^hWW>zϮϰsDͲWK> W^ Ϯ >< Ͳ Ͳ
Ͳ
/E^dZhDEdZd,dK'ZKhE/E' ϯ zͬ'
ϭΗKDDKEΗKEdd&>DKE ϰ ZKtE
ϭΗEKΗKEdd&>DKE WKd&Z ϱ W/E< ϵǆϬ͘ϳϱнϰǆϬ͘ Ͳ Ͳ Ͳ
&>DÊEZ
ϭΗEΗKEdd&>DKE ϲ 'ZE ϯϰ^Ƌ͘ŵŵ
ϭͲ&^Ͳ:ͲϬϲͲϬϬϭ ϮΗKDDKEΗZzKEdd ϳ 'Zz WZ& Ͳ Ͳ
t,Z^ͲYϮ,W
ϮΗEKΗZzKEdd WKd&Z ϴ s/K>d >Ϯ͘ϱ Ͳ Ͳ Ͳ
,''Ͳ&^ͲϬϬϭ
ϮΗEΗZzKEdd ϵ >h Dƚƌ͘;z&^Ϳ
WK^/d/sWK>K&ϰ͘͘͘ϮϬŵ>KKW ϭϬ KZE'
/ Ͳ Ͳ Ͳ
E'd/sWK>K&ϰ͘͘͘ϮϬŵ>KKW ϭϭ z>>Kt
WK^/d/sWK>K&Z^ϰϴϱ>/E<;Ϳ ϭϮ t,/d
KDD͘ Ͳ Ͳ Ͳ
E'd/sWK>K&Z^ϰϴϱ>/E<;Ϳ ϭͲ&^Ͳ:ͲϬϲ ϭϯ EZ,'' K>͘>^^
t,Z^ͲYϮ,WͲ,''Ͳ ϭϰ
hZEZ,//E^ZdWK^/d/KE / y/ͺϱϯ ϳ ϭϯ͕ϭϰ
^ͲϬϬϱ ϭϱ
ϭͲ&^Ͳ:ͲϬϲͲϬϬϮ ϮWǆϭ͘ϱ^Ƌ͘ŵŵ;z&^Ϳ
t,Z^ͲYϮ,WͲ,''Ͳ ϭϲ
hZEZ,/ZdZdWK^/d/KE / y/ͺϱϯ ϴ ϭϱ͕ϭϲ
^KͲϬϬϱ ϭϳ
ϭϴ
ϭϵ
ϳyϭ͘ϱƐƋŵŵ t,Z^Ͳ,''ͲW>ͲϬϲ
ϮϬ
Ϯϭ
ϮϮ
Ϯϯ
Ϯϰ
WZ^<d/DEd/Eh^dZ/^
>/D/d͕W

ĂďůĞdĂŐ
EŽ /ŶƐƚƌƵŵĞŶƚdĂŐ dǇƉĞKĨ dĞƌŵŝŶĂů ĂďůĞĨƌŽŵ: ĂďůĞĨƌŽŵ:ƚŽ ĂƌĚEŽ ŚĂŶŶĞů dĞƌŵŝŶĂů ZĞŵĂƌŬ&Žƌ
ĞƐĐƌŝƉƚŝŽŶ :ďEŽ :>ŽĐĂƚŝŽŶ ^ŝǌĞKĨĂďůĞ
EƵŵďĞƌ /ŶƉƵƚ EƵŵďĞƌ ƚŽ^ ^dĂŐEŽ͘ EŽ EƵŵďĞƌ ZĞǀŝƐŝŽŶ
ϭͲ&^Ͳ:ͲϬϳ
WKtZ^hWW>zϮϰsнWK> ϭ Z
WKtZ^hWW>zϮϰsDͲWK> W^ Ϯ >< Ͳ Ͳ
Ͳ
/E^dZhDEdZd,dK'ZKhE/E' ϯ zͬ'
ϭΗKDDKEΗKEdd&>DKE ϰ ZKtE
ϭΗEKΗKEdd&>DKE WKd&Z ϱ W/E< ϵǆϬ͘ϳϱнϰǆϬ͘ Ͳ Ͳ Ͳ
&>DÊEZ
ϭΗEΗKEdd&>DKE ϲ 'ZE ϯϰ^Ƌ͘ŵŵ
ϭͲ&^Ͳ:ͲϬϳͲϬϬϭ ϮΗKDDKEΗZzKEdd ϳ 'Zz WZ& &^
t,Z^ͲYϮ,W
ϮΗEKΗZzKEdd WKd&Z ϴ s/K>d >Ϯ͘ϱ Ͳ Ͳ Ͳ
,''Ͳ&^ͲϬϬϮ
ϮΗEΗZzKEdd ϵ >h Dƚƌ͘;z&^Ϳ
WK^/d/sWK>K&ϰ͘͘͘ϮϬŵ>KKW ϭϬ KZE'
/ Ͳ Ͳ Ͳ
E'd/sWK>K&ϰ͘͘͘ϮϬŵ>KKW ϭϭ z>>Kt
WK^/d/sWK>K&Z^ϰϴϱ>/E<;Ϳ ϭϮ t,/d
KDD͘ Ͳ Ͳ Ͳ
E'd/sWK>K&Z^ϰϴϱ>/E<;Ϳ ϭϯ K>͘>^^
ϭϰ
t,Z^ͲYϮ,WͲ
ϭͲ&^Ͳ:ͲϬϳͲϬϬϮ hZEZ/E>dWZ^^hZdZy͘ / ϭϱ ϭWǆϭ͘Ϭ^Ƌ͘ŵŵ;z&^Ϳ y/ͺϮϭ ϱ ϵ͕ϭϬ
,''ͲWdͲϬϬϭ
ϭϲ
ϭͲ&^Ͳ:ͲϬϳ ϭϳ EZ,''
t,Z^ͲYϮ,WͲ
ϭͲ&^Ͳ:ͲϬϳͲϬϬϯ ,''/E>dWZ^^hZdZy͘ / ϭϴ ϭWǆϭ͘Ϭ^Ƌ͘ŵŵ;z&^Ϳ y/ͺϮϭ ϲ ϭϭ͕ϭϮ
,''ͲWdͲϬϬϮ
ϭϵ
ϮϬ
t,Z^ͲYϮ,WͲ
ϭͲ&^Ͳ:ͲϬϳͲϬϬϰ KDh^d/KE/Z>/EWZ^^hZdZy͘ / Ϯϭ ϭWǆϭ͘Ϭ^Ƌ͘ŵŵ;z&^Ϳ y/ͺϮϮ ϯ ϱ͕ϲ
,''ͲWdͲϬϬϯ
ϮϮ
Ϯϯ ϲWyϭƐƋŵŵ;
t,Z^ͲYϮ,WͲ t,Z^Ͳ,''ͲW>ͲϬϳ
ϭͲ&^Ͳ:ͲϬϳͲϬϬϱ KDh^d/KE/Z>/E&>KtdZy͘ / Ϯϰ ϭWǆϭ͘Ϭ^Ƌ͘ŵŵ;z&^Ϳ ďǇd<//Ϳ y/ͺϮϮ ϰ ϳ͕ϴ
,''Ͳ&dͲϬϬϭ
Ϯϱ
Ϯϲ
^WZ Ϯϳ
Ϯϴ
Ϯϵ
^WZ
ϯϬ
WZ^<d/DEd/Eh^dZ/^
>/D/d͕W

ϭͲ/Ͳ:ͲϬϴ
ϭ
t,Z^ͲYϮ,WͲ,''Ͳ ,''Kͬ>/&&͘WZ^^hZdZy͘ZK^^ ϭWǆϭ͘Ϭ^Ƌ͘ŵŵ
ϭͲ/Ͳ:ͲϬϴͲϬϬϭ / Ϯ y/ͺϮϮ ϱ ϵ͕ϭϬ
WdͲϬϬϰ />h͘/Z ;Ǉ&^Ϳ
ϯ
ϰ
ϭWǆϭ͘Ϭ^Ƌ͘ŵŵ
^WZ / ϱ
;Ǉ&^Ϳ
ϲ
ϳ
t,Z^ͲYϮ,WͲ,''ͲddͲ ϭWǆϭ͘Ϭ^Ƌ͘ŵŵ
ϭͲ/Ͳ:ͲϬϴͲϬϬϯ ,''Khd>ddDW͘dZy͘ / ϴ dŽ>WdͲϯ;ϱ͕ϲͿ
ϬϬϳ ;Ǉ&^Ϳ
ϵ
ϭϬ
ϭͲ/Ͳ:ͲϬϴͲϬϬϰ ,''Khd>ddDW͘dZy͘ / ϭϭ y/ͺϮϱ ϳ ϭϯ͕ϭϰ
ϬϬϴ ;Ǉ&^Ϳ
ϭϮ
ϭϯ
ϭͲ/Ͳ:ͲϬϴͲϬϬϱ t,Z/E>ddDW͘dZy͘ / ϭϰ y/ͺϮϮ ϴ ϭϱ͕ϭϲ
ϬϬϯ ;Ǉ&^Ϳ
ϭϱ
ϭϲ t,Z^Ͳ,''ͲW>Ͳ
t,Z^ͲYϮ,WͲ,''ͲddͲ ϭͲ/Ͳ:ͲϬϴ EZ,'' ϭWǆϭ͘Ϭ^Ƌ͘ŵŵ ϭϮWyϭƐƋŵŵ
ϭͲ/Ͳ:ͲϬϴͲϬϬϲ t,Z/E>ddDW͘dZy͘ / ϭϳ Ϭϴ y/ͺϮϯ ϳ ϭϯ͕ϭϰ
ϬϬϰ ;Ǉ&^Ϳ
ϭϴ
ϭϵ
ϭͲ/Ͳ:ͲϬϴͲϬϬϳ t,Z/E>ddDW͘dZy͘ / ϮϬ y/ͺϮϯ ϴ ϭϱ͕ϭϲ
ϬϬϱ ;Ǉ&^Ϳ
Ϯϭ
ϮϮ
ϭͲ/Ͳ:ͲϬϴͲϬϬϴ />hd/KE/Z>/EdDW͘dZy͘ / Ϯϯ y/ͺϮϮ ϳ ϭϯ͕ϭϰ
ϬϬϮ ;Ǉ&^Ϳ
Ϯϰ
Ϯϱ
t,Z^ͲYϮ,WͲ,''Ͳ />hd/KE/Z>/EDWZͬW ϭWǆϭ͘Ϭ^Ƌ͘ŵŵ
ϭͲ/Ͳ:ͲϬϴͲϬϬϵ K Ϯϲ yKͺϭϭ ϭ ϭ͕Ϯ
ͬWͲϬϬϮ DKh>d/KED͘ ;Ǉ&^Ϳ
Ϯϳ
Ϯϴ
ϭͲ/Ͳ:ͲϬϴͲϬϭϬ ,''Khd>ddDW͘dZy͘ Ϯϵ y/ͺϮϰ ϳ ϭϯ͕ϭϰ
ϬϬϲ ;Ǉ&^Ϳ
ϯϬ
WZ^<d/DEd/Eh^dZ/^
>/D/d͕W

WKtZW<
dϮͲϭ
WKtZW<ͲϬϬϭ WKtZW< ,//'E/dZ ,sKͬW dϮͲϮ ϯ,s> Ͳ Ͳ Ͳ
dϮͲϯ
Ǉ&^ Ǉ&^
ϭͲ/Ͳ:ͲϬϴͲϬϬϮ Zd, dϭͲϭ
Ϯǆϭ͘ϱ^Ƌ͘ŵŵ Ͳ Ͳ Ͳ
WKtZ^hWW>z͘ϮϯϬs͕ϱϬ,ǌ͘ dϭͲϮ
W^ WKtZW< EZ,''
&ZKD>WͲd,/Ͳϭ͕Ϯ dϭͲϯ
hZEZWKtZW<KED͘ dϭͲϰ ϳĐϭ͘ϱƐƋŵŵ;
ϭͲ/Ͳ:ͲϬϴͲϬϬϯ K Ϯǆϭ͘ϱ^Ƌ͘ŵŵ t,Z^Ͳ,''ͲW>ͲϬϵ yKͺϮϮ ϭϰ Ϯϳ͕Ϯϴ
&ZKDϭͲKͲ:ͲϬϱͬϭϭ͕ϭϮ dϭͲϱ ǇƚŬ//
Ͳ Ͳ Ͳ

Cable From Cable To Cable Details Outgoing Cable Details
Cable Tag Instrument Tag Number Description Type Of Jb No Terminal JB Location Size Of Cable Cable from Cable from JB Card No Channel Terminal Remark For
No Input Number JB to DCS to DCS Tag No. No Number Revision
1-AI-JB-01
TB -1 / 1
INDICATION LAMP DO TB -1 / 30 tkII
DETAILS SHOWN BELOW

TB-2/1
PUSH BUTTON DI TB-2/20 tkII
TBS -1
POWER SUPPLY (NON-UPS)) TBS -2 tkII 3C X 2.5 sq mm
TBS -3
TBHEI -1
HEI POWER SUPPLY TBHEI -2 2C x 1.5 (BY FCS)
TBUS -1
POWER SUPPLY (NON-UPS)) TBUS -2 BY CLIENT
TBUS -3
TB-3 / 1
t,Z^ͲYϮ,WͲ,''Ͳ&DͲ
LDO / HSD FLOW METER AI TB-3 / 2 1P x 1.0 (BY FCS) Local control Panel TB-3 (1,2)
ϬϬϭ
TB-4 / 1
t,Z^ͲYϮ,WͲ,''Ͳ&DͲ LDO / HSD FLOW METER TO
AI TB-4/ 2 BY CLIENT XAI_32 3 5,6
ϬϬϭ DCS
TB-3 / 3
t,Z^ͲYϮ,WͲ,''ͲdͲ
LDO / HSD FCV POSITION AI TB-3 / 4 1P x 1.0 (BY FCS) Local control Panel TB-3 (3,4)
ϬϬϭ
TB-4 / 3
t,Z^ͲYϮ,WͲ,''ͲdͲ LDO / HSD FCV POSITION TO
ϬϬϭ DCS
TB-3 / 5
t,Z^ͲYϮ,WͲ,''ͲddͲ
HGG OUTLET TEMPERATURE AI TB-3 / 6 1P x 1.0 (BY FCS) Local control Panel TB-3 (5,6)
ϬϬϲ
ϬϬϲ
NEAR 12 P X 1 sq mm (
Local Panel WHRS-HGG-PLC-10
TB-4 / 5 BURNER by TKII )
t,Z^ͲYϮ,WͲ,''ͲddͲ HGG OUTLET TEMPERATURE
ϬϬϳ TO DCS
TB-3 / 7
t,Z^ͲYϮ,WͲ,''Ͳ&^Ͳ
FLAME INTENSITY AI TB-3 / 8 1P x 1.0 (BY FCS) Local control Panel TB-4 (7,8)
ϬϬϭ
TB-4 / 7
FLAME INTENSITY TO DCS AI TB-4/ 8 BY CLIENT XAI_32 4 7,8
ϬϬϭ
TB-3 / 9
t,Z^ͲYϮ,WͲ,''ͲdͲ "R" TYPE TC
REFRACTORY -1 TEMPERATURE AI TB-3 / 10 Local control Panel TB-4 (9,10)
ϬϬϵ CABLE(BY FCS)
TB-4 / 9
t,Z^ͲYϮ,WͲ,''ͲdͲ REFRACTORY -1 TEMPERATURE
ϬϬϵ TO DCS
TB-3 / 11
t,Z^ͲYϮ,WͲ,''ͲdͲ "R" TYPE TC
REFRACTORY -2 TEMPERATURE AI TB-3 / 12 Local control Panel TB-4 (11,12)
ϬϭϬ CABLE(BY FCS)
TB-4 /11
t,Z^ͲYϮ,WͲ,''ͲdͲ REFRACTORY -2 TEMPERATURE
ϬϭϬ TO DCS
TBFS-1
t,Z^ͲYϮ,WͲ,''Ͳ&^Ͳ FLAME SCANNER POWER
TBFS-2 2C x 1.5 (BY FCS) - - - - -
ϬϬϭ SUPPLY
TBFS-3
t,Z^ͲYϮ,WͲ,''Ͳ&^Ͳ FLAME SCANNER POWER
TBFS-4 2C x 1.5 (BY FCS) - - - - -
ϬϬϭ SUPPLY
TBFM-1
t,Z^ͲYϮ,WͲ,''Ͳ&DͲ
FLOW METER POWER SUPPLY TBFM-2 2C x 1.5 (BY FCS) - - - - -
ϬϬϭ
LCP - INDICATION LAMPS

TB -1 / 1
WHRS-AQC2HP-HGG-IL - INDICATION LAMP - LOCAL
DO ( With Potential ) TB -1 / 2 XDO_22 1 1,2
001 MODE SELECTED
TB -1 / 3
WHRS-AQC2HP-HGG-IL - INDICATION LAMP - REMOTE
DO ( With Potential ) TB -1 /4 XDO_22 2 3.4
002 MODE SELECTED
TB -1 /5
WHRS-AQC2HP-HGG-IL - INDICATION LAMP - PURGE
DO ( With Potential ) TB -1 /6 XDO_22 3 5,6
003 READY
TB -1 /7
WHRS-AQC2HP-HGG-IL - INDICATION LAMP - PURGE IN
DO ( With Potential ) TB -1 / 8 14 C X 1.5 sq.mm WHRS-HGG-PLC-11 XDO_22 4 7,8
004 PROGRESS
TB -1 /9
WHRS-AQC2HP-HGG-IL - INDICATION LAMP - HGG LDO
005 BURNER READY TO START
TB -1 / 11
WHRS-AQC2HP-HGG-IL - INDICATION LAMP - COAL
006 BURNER READY TO START
TB -1 / 13
INDICATION LAMP -Powerpack /
Powerpack / IL-07 DO ( With Potential ) TB -1 / 14 XDO_20 7 13,14
IL-07
tKII ( from LCP to
1
TB -1 / 15 DCS )
WHRS-AQC2HP-HGG-IL -
INDICATION LAMP - FLAME ON DO ( With Potential ) TB -1 / 16 XDO_20 8 15,16
008
TB -1 / 17
WHRS-AQC2HP-HGG-IL - INDICATION LAMP - LDO / HSD -
009 BURNER ON
TB -1 / 19
010 BURNER ON
TB -1 / 21
WHRS-AQC2HP-HGG-IL - INDICATION LAMP - LDO / HSD
DO ( With Potential ) TB -1 / 22 14 C X 1.5 sq.mm WHRS-HGG-PLC-12 XDO_21 6 11,12
011 BURNER TRIP
TB -1 / 23
012 BURNER TRIP
TB -1 / 25
WHRS-AQC2HP-HGG-IL - INDICATION LAMP -
013 SCAVENGING ON
TB -1 / 27
WHRS-AQC2HP-HGG-IL - INDICATION LAMP - BURNER
014 RELEASE FOR MODULATION
LCP - PUSH BUTTONS

TB -1 / 1
WHRS AQC2HP HGG IL
PUSH BUTTON - PURGE START DI TB -1 / 2 XDI_53 13 25,26
001
TB -1 / 3
WHRS-AQC2HP-HGG-IL - PUSH BUTTON - OIL BURNER
DI TB -1 /4 XDI_54 1 1,2
002 START
TB -1 /5
WHRS-AQC2HP-HGG-IL - PUSH BUTTON - OIL BURNER
DI TB -1 /6 XDI_54 2 3.4
003 STOP
TB -1 /7
WHRS-AQC2HP-HGG-IL - PUSH BUTTON - COAL BURNER
DI TB -1 / 8 XDI_54 3 5,6
004 START
TB -1 /9
WHRS-AQC2HP-HGG-IL - PUSH BUTTON - COAL BURNER
DI TB -1 / 10 24 C X 1.5 sq.mm WHRS-HGG-PLC-13 XDI_54 4 7,8
005 STOP
TB -1 / 11
SPARE DI TB -1 / 12 - - -
006
TB -1 / 13
PUSH BUTTON - EMERGENCY
Powerpack / IL-07 DI TB -1 / 14 XDI_54 5 9,10
STOP
TB -1 / 15
PUSH BUTTON - HEI START DI TB -1 / 16 XDI_54 8 15,16
008
TB -1 / 19
PUSH BUTTON - RESET DI TB -1 / 20 XDI_54 9 17,18
010
ĂďůĞ&ƌŽŵ ĂďůĞdŽ ĂďůĞĞƚĂŝůƐ KƵƚŐŽŝŶŐĂďůĞĞƚĂŝůƐ WΘ/

ĂďůĞdĂŐ
/ŶƐƚƌƵŵĞŶƚdĂŐEƵŵďĞƌ ĞƐĐƌŝƉƚŝŽŶ dǇƉĞKĨ :ďEŽ dĞƌŵŝŶĂůEƵŵďĞƌ :>ŽĐĂƚŝŽŶ ^ŝǌĞKĨĂďůĞ ĂďůĞĨƌŽŵ: ĂďůĞĨƌŽŵ:ƚŽ ĂƌĚEŽ ŚĂŶŶĞů dĞƌŵŝŶĂů ZĞĨĞƌĞŶĐĞ ZĞŵĂƌŬ&Žƌ
EŽ
/ŶƉƵƚ ƚŽ^ ^dĂŐEŽ͘ EŽ EƵŵďĞƌ EŽ ZĞǀŝƐŝŽŶ
t,Z^ͲYϮ,WͲ,''Ͳ^Ͳ h^d^t/d,d,'' ϰ
ϭͲ/Ͳ:ͲϬϵͲϬϬϭ / 1-DI-JB-09 Near HGG WƌĞĨĞďĂďůĞ
ϬϬϭ Khd>d ϲ
ϭ
h^d^t/d,WKtZ
ϭͲ/Ͳ:ͲϬϵͲϬϬϮ / 1-DI-JB-09 Near HGG Ϯyϭ͘ϱ
^hWW>z Ϯ
ͲͻǤͲ͵ǤʹͲͳ
ʹǤͲͲͶͲ Ͳ͵ǤͳͳǤʹͲͳ͹ ʹͳǤͳͳǤʹͲͳ͹ ʹͺǤͳʹǤʹͲͳ͹
ͺ

ͳ͸Ǥͺͷ

Ǥ

AS BUILT ʹͲͲͶͲǦ͹ͶͲͶǦǦ͵ͲͲͳ ͳ ʹ ͵ Ͷ

ǤǤ

Ƭ Ǥ

Ǥ

ͳ t,Z^ͲYϮ,WͲ,''Ͳ>^>ͲϬϬϭ Kdͬ,^>s>^t/d,>Kt ʹͶ ʹ͹͹ ͳ͸ͲͲ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ʹ t,Z^ͲYϮ,WͲ,''Ͳ>^,ͲϬϬϭ Kdͬ,^>s>^t/d,,/', ʹͶ ͳͲͺ͵ ͳ͸ͲͲ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ

͵ t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϭ >Kͬ,^>/E/E>dWZ^^hZ^t/d,>Kt ʹͶ ͳͲǤʹȋ Ȍ ͳǤ͸ͳ͸ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ

Ͷ t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϬϭ >Kͬ,^>/E^^KsWK^/d/KE>K^ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ͷ t,Z^ͲYϮ,WͲ,''Ͳ^KͲϬϬϭ >Kͬ,^>/E^^KsWK^/d/KEKWE ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ

͸ t,Z^ͲYϮ,WͲ,''ͲW^,ͲϬϬϮ >Kͬ,^>/EKhd>dWZ^^hZ^t/d,,/', ʹͶ ͳʹ̺ ͳǤ͸ͳ͸ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ

͹ t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϯ dKD//E'/Z>/EWZ^^hZ^t/d,>Kt ʹͶ ͵ǤͶȋ Ȍ ͳͳͲ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ

ͺ t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϰ /E^dZhDEd/Z>/EWZ^^hZ^t/d,>Kt ʹͶ ͶǤͷȋ Ȍ ͳͳͲ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ

ͻ t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϬϰ K>KEsz/E'>/EDWZWK^/d/KE>K^ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ͳͲ t,Z^ͲYϮ,WͲ,''Ͳ^KͲϬϬϰ K>KEsz/E'>/EDWZWK^/d/KEKWE ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ͳͳ t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϬϳ KD͘/Z>/EDWZWK^/d/KE>K^ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ͳʹ t,Z^ͲYϮ,WͲ,''Ͳ^KͲϬϬϳ KD͘/Z>/EDWZWK^/d/KEKWE ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ͳ͵ t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϬϴ KD͘/Z>/EDWZWK^/d/KE>K^ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ͳͶ t,Z^ͲYϮ,WͲ,''Ͳ^KͲϬϬϴ KD͘/Z>/EDWZWK^/d/KEKWE ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
DZ'EzKK>/E'>/EDWZWK^/d/KE
ͳͷ t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϬϵ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
>K^
ͳ͸ t,Z^ͲYϮ,WͲ,''Ͳ^KͲϬϬϵ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
KWE
ͳ͹ t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϭϮ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
>K^
ͳͺ t,Z^ͲYϮ,WͲ,''Ͳ^KͲϬϭϮ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
KWE

ͳͻ t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϱ KD͘/Z>/EWZ^^hZ^t/d,>Kt ʹͶ ͵ͷͲȋ Ȍ ͹Ǥͷ͹ͷ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ

ȋǦͷͲȌ
ʹͲ t,Z^ͲYϮ,WͲ,''ͲW^>ͲϬϬϲ />>h͘/Z>/EWZ^^hZ^t/d,>Kt ʹͶ ȋǦʹͲȌ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ͷͲ
&>DÊEZZzKEdd;&>D
ʹͳ t,Z^ͲYϮ,WͲ,''Ͳ&^ͲϬϭͬZĞĂĚǇ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ÊEZͲϭͿ
&>DÊEZKEKEdd;&>DÊEZͲ
ʹʹ t,Z^ͲYϮ,WͲ,''Ͳ&^ͲϬϭͬKŶ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ϭͿ
&>DÊEZZzKEdd;&>D
ʹ͵ t,Z^ͲYϮ,WͲ,''Ͳ&^ͲϬϮͬZĞĂĚǇ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ÊEZͲϮͿ
&>DÊEZKEKEdd;&>DÊEZͲ
ʹͶ t,Z^ͲYϮ,WͲ,''Ͳ&^ͲϬϮͬKŶ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ϮͿ
ʹͷ t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϬϱ hZEZ,//E^ZdWK^/d/KE ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ʹ͸ t,Z^ͲYϮ,WͲ,''Ͳ^KͲϬϬϱ hZEZ,/ZdZdWK^/d/KE ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
K&&WKdDWZΗ>K^ΗE>/D/d
ʹ͹ t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϭϬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
^t/d,
ʹͺ t,Z^ͲYϮ,WͲ,''Ͳ^KͲϬϭϬ K&&WKdDWZΗKWEΗE>/D/d^t/d, ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
K&&WKdDWZΗ>K^ΗdKZYh>/D/d
ʹͻ t,Z^ͲYϮ,WͲ,''Ͳd^ͲϬϭϬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
^t/d,
K&&WKdDWZΗKWEΗdKZYh>/D/d
͵Ͳ t,Z^ͲYϮ,WͲ,''Ͳd^KͲϬϭϬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
^t/d,
͵ͳ K&&WKdDWZ>ͬZ^>d&< ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͷ
K&&WKdDWZ>K>^dKWWKWZd
͵ʹ &<;>^Ϳ
ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͷ
͵͵ K&&WKdDWZdZ/WW&<;K>Ϳ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͷ
K&&WKdDWZ&Z,>d,z
͵Ͷ &<;Ϳ
ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͷ
,K/^d/E'WKdDWZΗ>K^ΗE>/D/d
͵ͷ t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϭϭ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
^t/d,
,K/^d/E'WKdDWZΗKWEΗE>/D/d
͵͸ t,Z^ͲYϮ,WͲ,''Ͳ^KͲϬϭϭ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
^t/d,
,K/^d/E'DWZΗ>K^ΗdKZYh>/D/d
͵͹ t,Z^ͲYϮ,WͲ,''Ͳd^ͲϬϭϭ ʹͶ ǤǤ ǤǤ ǤǤ Ͷ
^t/d,
,K/^d/E'DWZΗKWEΗdKZYh>/D/d
͵ͺ t,Z^ͲYϮ,WͲ,''Ͳd^KͲϬϭϭ ʹͶ ǤǤ ǤǤ ǤǤ Ͷ
^t/d,
͵ͻ ,K/^d/E'DWZ>ͬZ^>d&< ʹͶ ǤǤ ǤǤ ǤǤ Ͷ

,K/^d/E'DWZ>K>^dKWWKWZd
ͶͲ &<;>^Ϳ
ʹͶ ǤǤ ǤǤ ǤǤ Ͷ
Ͷͳ ,K/^d/E'DWZdZ/WW&<;K>Ϳ ʹͶ ǤǤ ǤǤ ǤǤ Ͷ

,K/^d/E'DWZ&Z,>d,z&<
Ͷʹ ;Ϳ
ʹͶ ǤǤ ǤǤ ǤǤ Ͷ
Ͷ͵ WͲϭ WhZ'^dZd ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ͶͶ WͲϮ K/>hZEZ^dZd ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
Ͷͷ WͲϯ K/>hZEZ^dKW ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
Ͷ͸ WͲϰ K>hZEZ^dZd ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
Ͷ͹ WͲϱ K>hZEZ^dKW ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
Ͷͺ WͲϳ DZ'Ez^dKWKDDE ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
Ͷͻ WͲϴ ,/^dZd ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
ͷͲ WͲϭϬ ZĞƐĞƚ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
ͷͳ ^Ͳϭ K>hZEZWZD/^^/s ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ͷʹ ^ͲϮ ^z^dDWZD/^^/sK< ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ

ͷ͵ ^Ͳϴ &ĞĞĚĞƌKŶ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ

ͷͶ ^Ͳϵ 'ĞŶĞƌĂů&ĂƵůƚ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ

ͷͷ ^ͲϭϬ ZĞĂĚǇƚŽƐƚĂƌƚ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ

ͷ͸ ^Ͳϭϭ dŽƚĂůŝǌĞƌWƵůƐĞ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ

ͷ͹ ^ͲϭϮ ^ĐƌĞǁWƌĞĨĞĚĞƌKŶ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ

ͷͺ ^Ͳϭϯ t͘&DŽƚŽƌKǀĞƌůŽĂĚĞĚ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ

ͷͻ ^Ͳϭϰ ĞůƚƌŝĨƚ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ

͸Ͳ ^Ͳϭϱ ^ĐƌĞǁDŽƚŽƌKǀĞƌůŽĂĚĞĚ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ

͸ͳ ^Ͳϭϲ ŐŝƚĂƚŽƌDŽƚŽƌKǀĞƌůŽĂĚĞĚ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ

͸ʹ ^Ͳϭϳ s&ͲϭΗKŶͬZƵŶŶŝŶŐΗ&ĞĞĚďĂĐŬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
͸͵ ^Ͳϭϴ s&Ͳϭ&ĞĞĚĞƌŚĞĂůƚŚǇ&ĞĞĚďĂĐŬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
͸Ͷ ^Ͳϭϵ s&ͲϭZĞŵŽƚĞ^ĞůĞĐƚĞĚ&ĞĞĚďĂĐŬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
͸ͷ ^ͲϮϬ s&ͲϮΗKŶͬZƵŶŶŝŶŐΗ&ĞĞĚďĂĐŬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
͸͸ ^ͲϮϭ s&ͲϮ&ĞĞĚĞƌŚĞĂůƚŚǇ&ĞĞĚďĂĐŬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
͸͹ ^ͲϮϮ s&ͲϮZĞŵŽƚĞ^ĞůĞĐƚĞĚ&ĞĞĚďĂĐŬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
͸ͺ ^ͲϮϯ KŝůWƵŵƉͲϭDŽƚŽƌƌŝǀĞ,ĞĂůƚŚǇĨĞĞĚďĂĐŬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
͸ͻ ^ͲϮϰ KŝůWƵŵƉͲϭDŽƚŽƌƌŝǀĞZĞŵŽƚĞ^ĞůĞĐƚĞĚ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
͹Ͳ ^ͲϮϱ KŝůWƵŵƉͲϭDŽƚŽƌƌŝǀĞKŶ&ĞĞĚďĂĐŬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
͹ͳ ^ͲϮϲ KŝůWƵŵƉͲϮDŽƚŽƌƌŝǀĞ,ĞĂůƚŚǇĨĞĞĚďĂĐŬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
͹ʹ ^ͲϮϳ KŝůWƵŵƉͲϮDŽƚŽƌƌŝǀĞZĞŵŽƚĞ^ĞůĞĐƚĞĚ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
͹͵ ^ͲϮϴ KŝůWƵŵƉͲϮDŽƚŽƌƌŝǀĞKŶ&ĞĞĚďĂĐŬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
͹Ͷ ^ͲϮϵ DZƌŝǀĞ,ĞĂůƚŚǇĨĞĞĚďĂĐŬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
͹ͷ ^ͲϯϬ DZƌŝǀĞZĞŵŽƚĞ^ĞůĞĐƚĞĚ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
͹͸ ^Ͳϯϭ DZƌŝǀĞKŶ&ĞĞĚďĂĐŬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
͹͹ ^ͲϯϮ ZŽŽƚƐůŽǁĞƌͲϭƌŝǀĞ,ĞĂůƚŚǇĨĞĞĚďĂĐŬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
͹ͺ ^Ͳϯϯ ZŽŽƚƐůŽǁĞƌͲϭƌŝǀĞZĞŵŽƚĞ^ĞůĞĐƚĞĚ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
͹ͻ ^Ͳϯϰ ZŽŽƚƐůŽǁĞƌͲϭƌŝǀĞKŶ&ĞĞĚďĂĐŬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ͺͲ ^Ͳϯϱ ZŽŽƚƐůŽǁĞƌͲϮƌŝǀĞ,ĞĂůƚŚǇĨĞĞĚďĂĐŬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ͺͳ ^Ͳϯϲ ZŽŽƚƐůŽǁĞƌͲϮƌŝǀĞZĞŵŽƚĞ^ĞůĞĐƚĞĚ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ͺʹ ^Ͳϯϳ ZŽŽƚƐůŽǁĞƌͲϮƌŝǀĞKŶ&ĞĞĚďĂĐŬ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͳ
ͺ͵ t,Z^ͲYϮ,WͲ,''Ͳ^ͲϬϬϭ ƵƐƚ^ǁŝƚĐŚĂƚ,''ŽƵƚůĞƚ ʹͶ ǤǤ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
ʹǤͲͲͶͲ Ͳ͵ǤͳͳǤʹͲͳ͹ ʹͳǤͳͳǤʹͲͳ͹ ʹͺǤͳʹǤʹͲͳ͹ ͲͻǤͲ͵ǤʹͲͳͺ

ͳ͸Ǥͺͷ

Ǥ

ʹͲͲͶͲǦ͹ͶͲͶǦǦ͵ͲͲͳ ͳ ʹ ͵ Ͷ

ǤǤ

Ƭ Ǥ

Ǥ

ϭ t,Z^ͲYϮ,WͲ,''Ͳy^ͲϬϬϭ >Kͬ,^>/E^^KsKWED͘ ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
Ϯ t,Z^ͲYϮ,WͲ,''Ͳy^ͲϬϬϮ dKD//E'/Z>/E^^KsKWED͘ ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϯ t,Z^ͲYϮ,WͲ,''Ͳy^ͲϬϬϯ ^sE'/E'/Z>/E^^KsKWED͘ ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϰ t,Z^ͲYϮ,WͲ,''Ͳy^ͲϬϬϳ KD͘/Z>/EDWZKWED͘ ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϱ t,Z^ͲYϮ,WͲ,''Ͳy^ͲϬϬϴ KD͘/Z>/EDWZKWED͘ ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϲ t,Z^ͲYϮ,WͲ,''Ͳy^ͲϬϬϵ DZ'EzKK>/E'>/EDWZKWED͘ ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϲ t,Z^ͲYϮ,WͲ,''Ͳy^ͲϬϭϮ DZ'EzKK>/E'>/EDWZKWED͘ ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϳ t,Z^ͲYϮ,WͲ,''Ͳy^ͲϬϬϰ K>KEsz/E'>/EDWZKWED͘ ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϴ t,Z^ͲYϮ,WͲ,''Ͳy^ͲϬϬϱ hZEZ,//E^ZdD͘ ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
Ƭ
ϵ WŽǁĞƌƉĂĐŬͬ/>ͲϬϳ hZEZWKtZW<KEDͬ͘,/KE ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵

ϭϬ ^Ͳϰϭ ^ƚĂƌƚͬ^ƚŽƉŵĚ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ

ϭϭ ^ͲϰϮ &ĂƵůƚZĞƐĞƚ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ

ϭϮ ^Ͳϰϯ ƵƐƚŽŵĞƌΖƐ/ŶƚĞƌůŽĐŬ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ

ϭϯ ^Ͳϰϰ ŐŝƚĂƚŽƌ^ƚĂƌƚͬ^ƚŽƉ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ

ϭϰ />Ͳϭ >ŽĐĂůDK^>d ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϭϱ />ͲϮ ZDKdDK^>d ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
ϭϲ />Ͳϯ WhZ'Zz ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
ϭϳ />Ͳϰ WhZ'/EWZK'Z^^ͬKDW>d ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
ϭϴ />Ͳϱ >Kͬ,^hZEZZzdK^dZd ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
ϭϵ />Ͳϲ K>hZEZZzdK^dZd ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
ϮϬ />Ͳϴ &>DKE ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
Ϯϭ />Ͳϵ >Kͬ,^hZEZKE ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
ϮϮ />ͲϭϬ Ϭ>hZEZKE ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
Ϯϯ />Ͳϭϭ >Kͬ,^hZEZdZ/W ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
Ϯϰ />ͲϭϮ K>hZEZdZ/W ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
Ϯϱ />Ͳϭϯ ^sE'/E'KE ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
Ϯϲ />Ͳϭϰ hZEZZ>^&KZDKh>d/KE ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͵
Ϯϳ ^Ͳϯϱ WƵŵƉͲϭKŶŵĚ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
Ϯϴ ^Ͳϯϲ WƵŵƉͲϮKŶŵĚ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
Ϯϵ ^Ͳϯϳ DZKŶD Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϯϬ ^Ͳϯϴ ZŽŽƚƐůŽǁĞƌͲϭKŶŵĚ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϯϭ ^Ͳϯϵ ZŽŽƚƐůŽǁĞƌͲϮKŶŵĚ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϯϮ ^ͲϰϬ ^ƚĂƌƚͬ^ƚŽƉŵĚĨŽƌs&Ͳϭ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϯϯ ^Ͳϰϭ ^ƚĂƌƚͬ^ƚŽƉŵĚĨŽƌs&ͲϮ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϯϰ K&&WKdDWZ&KZtZD Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͷ
ϯϱ K&&WKdDWZZsZ^D Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͷ
ϯϲ K&&WKdDWZ^dKWD Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͷ
ϯϳ ,K/^d/E'DWZ&KZtZD Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͷ
ϯϴ ,K/^d/E'DWZZsZ^D Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͷ
ϯϵ ,K/^d/E'DWZ^dKWD Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͷ
ϰϬ ŽĨĨĞƌƉŽƚĂŵƉĞƌŽŶŵĚ;DĂŐŶĞƚͿ ʹ͵Ͳ Ǥ ǤǤ ǤǤ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ͷ

ʹǤͲͲͶͲ Ͳ͵ǤͳͳǤʹͲͳ͹ ʹͳǤͳͳǤʹͲͳ͹

ͳ͸Ǥͺͷ

Ǥ

ʹͲͲͶͲǦ͹ͶͲͶǦǦ͵ͲͲͳ ͳ ʹ

ǤǤ

Ƭ Ǥ

Ǥ

t,Z^ͲYϮ,WͲ,''Ͳ
ͳ /&&WZ^^hZZK^^^dZ/EZ͕W&hE/d ʹ Ǥ ǤǤ ͳ͸Ͳͳ͸ͲͲ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ǦͲǤͷȀʹȋȌ ͳ
WdͲϬϬϭ

t,Z^ͲYϮ,WͲ,''Ͳ /&&WZ^^hZZK^^^dZ/EZ͕D/E^</K/>
ʹ WdͲϬϬϮ >/E
ʹ Ǥ Ǥ ͳ͸Ͳͳ͸ͲͲ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ǦͲǤͷȀʹȋȌ ͳ

t,Z^ͲYϮ,WͲ,''Ͳ /&&WZ^^hZZK^^^dZ/EZ͕D/E^</dKD
͵ WdͲϬϬϯ /Z>/E
ʹ Ǥ Ǥ ͳ͸Ͳͳ͸ͲͲ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ǦͲǤͷȀʹȋȌ ͳ

t,Z^ͲYϮ,WͲ,''Ͳ
Ͷ >Kͬ,^>/E&>KtDdZ ʹ Ǥ Ǥ ͲǦͺͳ͸Ͳ Ȁ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
&DͲϬϬϭ
t,Z^ͲYϮ,WͲ,''ͲdͲ

ͷ >Kͬ,^>/E&sWK^/d/KEdZy͘ ʹ Ǥ Ǥ ͲǦͳͲͲ Ψ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϬϬϭ
͸ &>D/EdE^/dz;&>DÊEZͲϭͿ Ͷ Ǥ Ǥ ͲǦͳͲͲ Ψ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
Ϭϭ
͹ &>D/EdE^/dz;&>DÊEZͲϮͿ Ͷ Ǥ Ǥ ͲǦͳͲͲ Ψ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϬϮ
t,Z^ͲYϮ,WͲ,''ͲWdͲ
ͺ hZEZ/E>dWZ^^hZdZy͘ ʹ Ǥ Ǥ ͳͲʹͲͲ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ Ǧͷ ͳ
ϬϬϭ
ͻ ,''/E>dWZ^^hZdZy͘ ʹ Ǥ Ǥ ͳͲʹͲͲ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ǦͲ ͳ
ϬϬϮ
t,Z^ͲYϮ,WͲ,''Ͳ
ͳͲ ,''Z&dKZzdDW͘ ʹ Ǥ Ǥ ̶̶ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
d/dͲϬϬϵ
t,Z^ͲYϮ,WͲ,''Ͳ ǦͻͷͲ

ͳͳ ,''/E>ddDW ʹ Ǥ Ǥ ̶̶ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
d/dͲϬϭϬ ǦͳͲͷͲ
ͳʹ KD͘/Z>/EWZ^^hZdZy͘ ʹ Ǥ Ǥ ͳͲ͸ͲͲ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ǦͷͲ ͳ
ϬϬϯ

t,Z^ͲYϮ,WͲ,''Ͳ&dͲ
ͳ͵ KD͘/Z>/E&>KtdZy͘ ʹ Ǥ Ǥ ͳͲͳͲͲ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϬϬϭ

t,Z^ͲYϮ,WͲ,''Ͳ
ͳͶ ,''Kͬ>/&&͘WZ^^hZdZy͘ZK^^/>h͘/Z ʹ Ǥ Ǥ ͳͲͳͲͲ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ǦͲ ͳ
WdͲϬϬϰ

,''Kͬ>
t,Z^ͲYϮ,WͲ,''ͲddͲ ǦͶͺͲ
ͳͷ dDW͘ ʹ Ǥ Ǥ ̶̶ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϬϬϲ ǦͷͲͲ
dZy͘
,''Kͬ>
ͳ͸ dDW͘ ʹ Ǥ Ǥ ̶̶ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϬϬϳ ǦͷͲͲ
dZy͘
,''Kͬ>
ͳ͹ dDW͘ ʹ Ǥ Ǥ ̶̶ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϬϬϴ ǦͷͲͲ
dZy͘
ͳͺ t,Z/ͬ>dDW͘dZy͘ ʹ Ǥ Ǥ ̶̶ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϬϬϯ
ͳͻ t,Z/ͬ>dDW͘dZy͘ ʹ Ǥ Ǥ ̶̶ ͳ͹Ǧ͵͸ͳͲǦͲͳǦͲͲ ͳ
ϬϬϰ
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ŝůůKĨDĂƚĞƌŝĂůŽĐEŽ͗͘WͬDϭϳͬϭϮϯϴͬϬϰ
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Ϯϲ yϰ͕yϱ ŽŶƚƌŽůdĞƌŵŝŶĂůƐ ůŵĞǆ <hdϰ Ϯϳ
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ϮͿ YƚǇƌĞƋƵŝƌĞĚ ϭEŽ͘
ϯͿ ƵƚǇ ŽŶƚŝŶƵŽƵƐ
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ϲͿDŽĚĞů &'ʹ'^ϭtt' Zϭ
ϳͿ dǇƉĞ DĞĐŚĂŶŝĐĂů&ůŽĂƚƚǇƉĞ>ĞǀĞůŝŶĚŝĐĂƚŽƌ
ϴͿ ^ĞƌǀŝĐĞ&ůƵŝĚ >Kͬ,^
ϵͿ KƉĞƌĂƚŝŶŐdĞŵƉƌĂƚƵƌĞ ϰϬΣ
ϭϬͿ KƉĞƌĂƚŝŶŐWƌĞƐƐƵƌĞ ƚŵŽƐƉŚĞƌŝĐ
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ϭϮͿ &ůƵŝĚsŝƐĐŽƐŝƚǇ Ϯ͘ϱʹϭϱ͘ϳ^dΛϰϬĞŐ
ϭϯͿ &ůƵŝĚĞŶƐŝƚǇ ϴϴϬ<Őͬŵϯ
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ϭϱͿ >ĞĂƐƚŽƵŶƚŽĨƐĐĂůĞ ϱŵŵ
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ϮϬͿ dĂŶŬ^ŚĞĞůDĂƚĞƌŝĂů /^ϮϬϲϮ
ϮϮͿ &ůŽĂƚDĂƚĞƌŝĂů ^^ϯϭϲǆTϮϬϬŵŵ
ϮϯͿ &ůŽĂƚĂůŝďƌĂƚŝŽŶZĂŶŐĞ;ŵŵͿ ϬͲϭϲϬϬŵŵ
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ϮϲͿ ĂůŝďƌĂƚĞĚ^ĐĂůĞŽĂƌĚ
ŶƵŵĞƌŝĐĂů
ϮϳͿ WƵůůĞǇƐƐĞŵďůǇ ZĞƋƵŝƌĞĚ
ϮϴͿ ^ƉƌŝŶŐdĞŶƐŝŽŶƐƐĞŵďůǇ ZĞƋƵŝƌĞĚ
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ϮϰͿƵƌƌĞŶƚƌĂƚŝŶŐ ϱŵƉƐ͕ϮϮϬs
ϭͬϮΗEWd;&ͿǁŝƚŚŽƵďůĞŽŵƉƌĞƐƐŝŽŶƚǇƉĞEŝĐŬůĞWůĂƚĞĚĂďůĞ
ϮϱͿĂďůĞĞŶƚƌǇ
'ůĂŶĚƐ;Ǉ&^Ϳ
ϮϲͿŝƐƉůĂĐĞƌ ^^ϯϭϲ
ϮϳͿŝƐƉůĂĐĞƌĂƐƐĞŵďůǇ ^^ϯϭϲ
ϮϴͿŽĚǇ;tĞƚƚĞĚƉĂƌƚƐͿ ^^ϯϭϲ
ϮϵͿ&ůĂŶŐĞ ^
DK
ϯϬͿŝƐƉůĂĐĞƌƐŝǌĞ ϬͲϭϲϬϬŵŵ
ϯϭͿ^ǁŝƚĐŚŚŽƵƐŝŶŐĂŶĚĐŽǀĞƌ ĂƐƚů ZϮ
ϯϮͿŶĐůŽƐƵƌĞƉƌŽƚĞĐƚŝŽŶ &W͕yͲ//ͬ// ZϮ
ϯϯͿƌĞĂůĂƐƐŝĨŝĐĂƚŝŽŶ &W͕yͲ//ͬ// ZϮ
EŽƚĞƐ͗
ϭͿsĞŶĚŽƌƚŽWƌŽǀŝĚĞ>ĞǀĞů^ǁŝƚĐŚ'ƌŐ͘ĂůŽŶŐǁŝƚŚŵŽƵŶƚŝŶŐĂƌƌĂŶŐĞŵĞŶƚĨŽƌĂƉƉƌŽǀĂů
ϮͿ^ǁŝƚĐŚƐŚĂůůďĞĂĚũƵƐƚĂďůĞƚŚƌŽƵŐŚŽƵƚƚŚĞƌĂŶŐĞ
ϯͿ^ĞƚƉŽŝŶƚůĞǀĞůŵĞĂƐƵƌĞŵĞŶƚŝƐĨƌŽŵdŽƉWƌŽĐĞƐƐĨůĂŶŐĞŝŶĐůƵĚŝŶŐŶŽǌǌůĞůĞŶŐƚŚ
^h/>d
WZK:d ϭyϲ͘ϴϱDtt,Z^WZK:d͘ KEK͘ d^WͲ>^ͲϬϮ
WhZ,^Z ƚŚǇƐƐĞŶŬƌƵƉƉ/ŶĚƵƐƚƌŝĞƐ/ŶĚŝĂWǀƚ͘>ƚĚ͘ ZsEK͘ Ϯ
&^:KEϬ͘ ϮϬϭϳ͘ϯϲϭϬ ,< &:^
&ŝǀĞƐŽŵďƵƐƚŝŽŶ^ǇƐƚĞŵƐWǀƚ͘>ƚĚ͘ ,WdZ &Ϭϭ WWZz Ê
d,E/>^W/&/d/KE^&KZ/&&͘WZ^^hZdZE^D/ddZ
hŶŝƚƐ͗ &ůŽǁͲх >ŝƋƵŝĚͲ<ŐͬŚƌ 'ĂƐͲEŵϯͬŚƌ WƌĞƐƐƵƌĞͲхŬŐͬĐŵϮ dĞŵƉĞƌĂƚƵƌĞͲхĞŐ
ϭ &ƵŶĐƚŝŽŶ͗dƌĂŶƐŵŝƚ ϭϱ ůĞŵĞŶƚ͗ŝĂƉŚŐƌĂŵ
Ϯ dǇƉĞ͗ϮͲtŝƌĞ^ŵĂƌƚdǇƉĞ ϭϲ tĞƚƚĞĚWĂƌƚDĂƚĞƌŝĂů͗^^ϯϭϲ>
ϯ ĂƐĞ͗ŝĞĂƐƚůƵŵŝŶŝƵŵ ϭϳ ůĞŵĞŶƚDĂƚĞƌŝĂů͗^^ϯϭϲͬ,ĂƐƚŽůůŽǇ
ϰ DŽƵŶƚŝŶŐ͗ϮΗƉŝƉĞǁŝƚŚĐĐĞƐƐŽƌŝĞƐ ϭϴ WƌŽĐĞƐƐŽŶŶĞĐƚŝŽŶ͗&ůĂŶŐĞ
WƌŽĐĞƐƐŽŶŶ͘>ŽĐŶ͗DĂŶƵĨĂĐƚƵƌŝŶŐƐƚĚ͘
ϱ ŶĐůŽƐƵƌĞ͗^ĂĨĞ
ϭϵ ŝĂƉŚƌĂŐŵ^ĞĂů͗E
ϲ ůĞĐ͘ƌĞĂůĂƐƐ͗tWƚŽ/Wϲϱ;ZĞĨĞƌEŽƚĞͲϰͿ
ϮϬ KǀĞƌWƌĞƐƐƵƌĞ>ŝŵŝƚ͗ϭϯϬйŽĨƌĂŶŐĞ
ϳ /ŶƚƌŝŶƐŝĐĂůůǇ^ĂĨĞ͗E
Ϯϭ KƉƚŝŽŶƐ͗
ϴ ŝƌ^ƵƉƉůǇ͗E ϯͲsĂůǀĞDĂŶŝĨŽůĚ͗ΗdΗƚǇƉĞŵĂŶŝĨŽůĚďǇ&^
ϵ WŽǁĞƌ^ƵƉƉůǇ͗>ŽŽƉWŽǁĞƌĞĚ;Ϯϰs͕ϮǁŝƌĞdǇƉĞͿ ϮϮ ĐĐƵƌĂĐǇ͗фсϬ͘ϬϳϱйŽĨĐĂůŝďƌĂƚĞĚƐƉ ZϮ
ϭϬ ĂďůĞŶƚƌǇ͗ϭͬϮΗEWd Ϯϯ ZĞƉĞĂƚĂďŝůŝƚǇ͗цϬ͘ϬϱйŽĨƐƉĂŶŽƌďĞƚƚĞƌ
ϭϯ KƵƚWƵƚ͗ϰͲϮϬŵǁŝƚŚĚŝŐŝƚĂůƐŝŐŶĂů
ĂƐĞĚŽŶ,ZdƉƌŽƚŽĐŽů

ϭϰ ŝƐƉůĂǇ͗>

KƉĞƌĂƚŝŶŐ ĂůŝďƌĂƚŝŽŶ /ŶƐƚƌƵŵĞŶƚ ^ĞƌŝǀĞ&ƵĞů
YƚǇ tŝƚŚƐƚĂŶĚ
dĂŐEŽ͘ ĚŝĨĨ͘ƉƌĞƐ͘ ZĂŶŐĞ ZĂŶŐĞ DŽĚĞůEŽ͘;ZϮͿ
WƌĞƐƐƵƌĞ
ŵŵtĐ ŵŵtĐ ŬŐͬĐŵϮ EŽ
ϬͲϬ͘ϳ ϭϲϬƚŽϭϲϬϬϬ W&ƵŶŝƚĐƌŽƐƐ ϳD&ϰϰϯϯͲϭ&ϬϮͲϭWϳͲ
t,Z^ͲYϮ,WͲ,''ͲWdͲϬϬϭ ϬͲϬ͘ϱ<ŐͬĐŵϮ ϭ ƚŽŵ͘
ŬŐͬĐŵϮ ŵŵt ĨŝůƚĞƌ ϬϭнϭϭнzϬϭнzϮϭ
DĂŝŶWŝƉĞƌĂĐŬ
Ϯ
ϬͲϬ͘ϳ ϭϲϬƚŽϭϲϬϬϬ ϳD&ϰϰϯϯͲϭ&ϬϮͲϭϳͲ
t,Z^ͲYϮ,WͲ,''ͲWdͲϬϬϮ ϬͲϬ͘ϱ<ŐͬĐŵ ĐƌŽƐƐŽŝů>ŝŶĞ ϭ ϭϮ<ŐͬĐŵϮ
ŬŐͬĐŵϮ ŵŵt ϬϭнϭϭнzϬϭнzϮϭ
^ƚƌĂŝŶĞƌ
DĂŝŶWŝƉĞƌĂĐŬ
ϬͲϬ͘ϳ ϭϲϬƚŽϭϲϬϬϬ ϳD&ϰϰϯϯͲϭ&ϬϮͲϭϳͲ
t,Z^ͲYϮ,WͲ,''ͲWdͲϬϬϯ ϬͲϬ͘ϱ<ŐͬĐŵϮ ĐƌŽƐƐƚŽŵŝƌ ϭ ϰ<ŐͬĐŵϮ
ŬŐͬĐŵϮ ŵŵt ϬϭнϭϭнzϬϭнzϮϭ
>ŝŶĞ^ƚƌĂŝŶĞƌ
ϬƚŽϲϬ ϬƚŽϲϬ ϭϬƚŽϮϬϬ ϳD&ϰϰϯϯͲϭϬϮͲϭϳͲͲ
t,Z^ͲYϮ,WͲ,''ͲWdͲϬϬϰ ĐƌŽƐƐƵƌŶĞƌ ϭ ƚŽŵ͘
ŵŵt ŵŵt ŵŵt ϬϭнϭϭнzϬϭнzϮϭ
ϬƚŽϱϬ ϬƚŽϭϬϬ ϭϬƚŽϮϬϬ ϳD&ϰϰϯϯͲϭϬϮͲϭϳͲ
t,Z^ͲYϮ,WͲ,''Ͳ&dͲϬϬϭ ĐƌŽƐƐŶŶƵďĂƌ ϭ ϭϬϬŵŵt
ŵŵt ŵŵt ŵŵt ϬϭнϭϭнzϬϭнzϮϭ
EKd^͗
ϭͿdƌĂŶƐŵŝƚƚĞƌŚĂǀĞŝŶďƵŝůƚǌĞƌŽ͕ƐƉĂŶΘƌĂŶŐĞĂĚũƵƐƚŵĞŶƚĨĂĐŝůŝƚǇ͘
ϮͿDĂŬĞ͗^ŝĞŵĞŶƐ ZϮ
ϯͿ^^dĂŐWůĂƚĞZĞƋƵŝƌĞĚ
ϰͿWdĐƌŽƐƐƐƚƌĂŝŶĞƌŝŶW&ƵŶŝƚŝƐĨůĂŵĞƉƌŽŽĨƌĞƐƚĂƌĞǁĞĂƚŚĞƌƉƌŽŽĨ
^h/>d
WZK:d ϭyϲ͘ϴϱDtt,Z^WZK:d͘ KEK͘ d^WͲWdͲϬϯ
&ŝǀĞƐŽŵďƵƐƚŝŽŶ^ǇƐƚĞŵƐWǀƚ͘>ƚĚ͘ ,WdZ ϬϭͬϬϮͬϬϭͬϬϱ WWZz Ê

!"#$%&&'"(% $)! '"()*+,( - .
/ ' ' ',''
.
0
&ŝǀĞƐŽŵďƵƐƚŝŽŶ^ǇƐƚĞŵƐ 12 .
03

1
Wǀƚ͘>ƚĚ͘
d,E/>^W/&/d/KE&KZWZ^^hZ'h'
^ƌ͘EŽ ^ƉĞĐŝĨŝĐĂƚŝŽŶ ZĞǀ ZĞŵĂƌŬƐ

&! 2=%$(="
. =%")": )$!9G2==<=%")":
3 )*7 )E!
<<
)*7=7=$ )!()*7 ?)67*9#5):%$!
* !*!$)*7 *)"7! !!7 3
$!*7* )5)9*)=" !*!$$==5
0 )"(=?<*!$)*7 *!$&$==5:7*
"97= %$! !*!$$==5='
4 $! %$!7!<!" 2=%$(="

7!<!"*!$*7 3

=9#!*!$)*7 3

. =+!<!" 3

3 99%$*9 C
D=51

A!$=(B% <!" )9$=<!!$=)"!$

=""!9)="
;.H I8

17*":!)E!

0 =""!9)="7=9*)=" 2==<

+!$$*":!$=!9)="
3D=51

4 27=?=%&$=!9)=" $=+)(!(
. )*&$*<!*7
.
*%:!=9# !F%)$!( 3

.. *")5=7(
.3 "%66!$
. 79!$)"!1)7!( !F%)$!( !5!$ *67!
. 7% *)="*<&!$
. *&&$=+*7
8"*9#)":;* #!<*!$)*7 *776!2 1

.8*":! *776! = &!9)>!(*!:*%:!"=$<*77=&!$*! )"!<)((7!)$(=5! 9*7!
38$*?)": =%7(6! %6<)!(?))"="!!!#*5!$7*9!<!"
87!<!"=""!9)="@$:="!7()":

#&%"! ** #

'(
)

!!""!##$

!# #%&!!
ThyssenKrupp Industries India
Sheet
Parasakti Cement MOTOR DATASHEET Rev.
No.
Industries Ltd.
1 of 5
^ƌ͘EK͘ /dD^Z/Wd/KE hE/d^ s>h^Θd/>^

ϭ͘ EĂŵĞŽĨDĂŶƵĨĂĐƚƵƌĞƌ 'WKtZΘ/Eh^dZ/>
^K>hd/KE>d͘
Ϯ͘ &ƌĂŵĞƐŝǌĞΘĚĞƐŝŐŶĐŽĚĞ ϴϬ
ϯ͘ sĞŶĚŽƌǁŽƌŬŽƌĚĞƌŶƵŵďĞƌͬDĂĐŚŝŶĞŶƵŵďĞƌ Ϭ͘ϳϱ&Ϯ
ϰ͘ ŽĚĞƐĂŶĚƐƚĂŶĚĂƌĚƐ /^ͬ/
ϱ͘ ƉƉůŝĐĂƚŝŽŶ WƵŵƉ
ϲ͘ dŽƚĂůƋƵĂŶƚŝƚǇ EŽƐ͘ ϭEŽͬWƵŵƉ͕dŽƚĂů͗ϮEŽƐ
ϳ͘ dǇƉĞŽĨŵŽƚŽƌ ϯWŚ͘/ŶĚƵĐƚŝŽŶDŽƚŽƌ
ϴ͘ ^ĞƌǀŝĐĞ;KƵƚĚŽŽƌͬ/ŶĚŽŽƌͬ,ĂǌĂƌĚŽƵƐͿ ,ĂǌĂƌĚŽƵƐ
ϵ͘ dǇƉĞŽĨĞŶĐůŽƐƵƌĞΘĐŽŽůŝŶŐ &W͕yͲ//ͬ//
ϭϬ͘ ZĂƚĞĚŽƵƚƉƵƚĂƚĚĞƐŝŐŶĂŵďŝĞŶƚŽĨϱϬĚĞŐ͘ Ŭt Ϭ͘ϳϱ
ϭϭ ZĂƚĞĚǀŽůƚĂŐĞ s ϰϭϱs
ϭϮ EŽŽĨƉŚĂƐĞƐ EŽƐ͘ ϯWŚ͘
ϭϯ ZĂƚĞĚĨƌĞƋƵĞŶĐǇ ,ǌ ϱϬ,ǌ
ϭϰ ƵƚǇĐǇĐůĞ ^ϭ
ϭϱ ZĞƋƵŝƌĞĚ<tƌĂƚŝŶŐŽĨƚŚĞĚƌŝǀĞŶĞƋƵŝƉŵĞŶƚ Ŭt E
ϭϲ DŽƚŽƌĨƵůůůŽĂĚƚŽƌƋƵĞ <ŐͲŵ Ϭ͘Ϯϱ
ϭϳ ^ƚĂƌƚŝŶŐƚŽƌƋƵĞĂƐйŽĨ&>d й ϮϬϬ
ϭϴ͘ WƵůůŽƵƚƚŽƌƋƵĞĂƐйŽĨ&>d й ϮϱϬ
ϭϵ͘ ^ĞƌǀŝĐĞĨĂĐƚŽƌ ϭ
ϮϬ͘ ZĂƚĞĚƐƉĞĞĚ ZWD ϮϴϳϬ
Ϯϭ͘ sŽůƚĂŐĞǀĂƌŝĂƚŝŽŶƌĂŶŐĞ й ϭϬ
ϮϮ͘ &ƌĞƋƵĞŶĐǇǀĂƌŝĂƚŝŽŶƌĂŶŐĞ й ϱ
Ϯϯ͘ ŽŵďŝŶĞĚǀŽůƚĂŐĞĂŶĚĨƌĞƋƵĞŶĐǇǀĂƌŝĂƚŝŽŶƐ й ϭϬ
Ϯϰ͘ &ƵůůůŽĂĚĐƵƌƌĞŶƚ ŵƉ ϭ͘ϲϰ
Ϯϱ͘ EŽůŽĂĚĐƵƌƌĞŶƚ ŵƉ ϭ͘ϭϱĂƉƉƌŽǆ͘
Ϯϲ͘ ZĂƚĞĚƉŽǁĞƌĨĂĐƚŽƌ Ϭ͘ϴϮ
Ϯϳ͘ ĨĨŝĐŝĞŶĐǇ
Ă͘ ĨĨŝĐŝĞŶĐǇĐůĂƐƐĂƐƉĞƌ/^ϭϮϲϭϱ /Ϯ ;ĂƐƉĞƌ/ͲϲϬϬϯϰͿ
ď͘ ƚϭϬϬйůŽĂĚ й ϳϳ͘ϰ
Đ͘ ƚϳϱйůŽĂĚ й ϳϳ
Ě͘ ƚϱϬйůŽĂĚ й ϳϰ
Ğ͘ ƚŶŽůŽĂĚ
Ϯϴ͘ WŽǁĞƌĨĂĐƚŽƌ
Ă͘ ƚϭϬϬйůŽĂĚ Ϭ͘ϴϮ
Đ͘ ƚϱϬйůŽĂĚ Ϭ͘ϲϱ
ď͘ ƚϳϱйůŽĂĚ Ϭ͘ϳϱ
Ě͘ ƚEŽůŽĂĚ
Ϯϵ ^ƚĂƌƚŝŶŐƉŽǁĞƌĨĂĐƚŽƌ
ϯϬ͘ dŽƚĂůůŽƐƐĞƐ Ŭt
ϯϭ͘ DĞƚŚŽĚŽĨƐƚĂƌƚŝŶŐ K>
ϯϮ͘ ^ƚĂƌƚŝŶŐĐƵƌƌĞŶƚĂƚƌĂƚĞĚǀŽůƚĂŐĞ йŽĨ&> ϲϬϬ
ϯϯ͘ DŝŶŝŵƵŵǀŽůƚĂŐĞƌĞƋƵŝƌĞĚĂƚƐƚĂƌƚŝŶŐƚŽĂĐĐĞůĞƌĂƚĞĚƌŝǀĞŶ й ϳϱ
ĞƋƵŝƉŵĞŶƚ
Sheet
No.
Industries Ltd.
2 of 5
ϯϰ͘ DĂǆŝŵƵŵƉĞƌŵŝƐƐŝďůĞƚŝŵĞĂƚϳϱйǀŽůƚĂŐĞĚƵƌŝŶŐƌƵŶŶŝŶŐ ^ĞĐ

ĂƚĨƵůůůŽĂĚ͘
ϯϱ ^ƚĂƌƚŝŶŐƚŝŵĞ
tŝƚŚŵĞĐŚĂŶŝƐŵĐŽƵƉůĞĚŽŶůŽĂĚŽƌŵĞĐŚĂŶŝƐŵĐŽƵƉůĞĚ
ƚŚƌƵĚŝƌĞĐƚĐŽƵƉůŝŶŐ͘
Ă͘ ƚϴϬйǀŽůƚĂŐĞ ^ĞĐ Ϯ
ď͘ ƚϭϬϬйǀŽůƚĂŐĞ ^ĞĐ Ϯ
Đ͘ ƚϭϭϬйǀŽůƚĂŐĞ ^ĞĐ Ϯ
ϯϲ͘ ^ƚĂƌƚŝŶŐƚŝŵĞ
tŝƚŚŽƵƚŵĞĐŚĂŶŝƐŵĐŽƵƉůĞĚŽƌŵĞĐŚĂŶŝƐŵĐŽƵƉůĞĚƚŚƌƵ
ĨůƵŝĚĐŽƵƉůŝŶŐǁŚĞƌĞŝƚŵĂǇďĞƉƌĞƐƵŵĞĚƚŚĂƚůŽĂĚŝƐ
ƚƌĂŶƐĨĞƌƌĞĚƚŽŵŽƚŽƌƐŚĂĨƚŽŶůǇĂĨƚĞƌĂƚƚĂŝŶŝŶŐĂůŵŽƐƚĨƵůů
ůŽĂĚ͘
Ă͘ ƚϴϬйǀŽůƚĂŐĞ ^ĞĐ ϭ͘ϲ
ď͘ ƚϭϬϬйǀŽůƚĂŐĞ ^ĞĐ ϭ͘ϲ
Đ͘ ƚϭϭϬйǀŽůƚĂŐĞ ^ĞĐ ϭ͘ϲ
ϯϳ͘ EĞŐĂƚŝǀĞƉŚĂƐĞƐĞƋƵĞŶĐĞĐƵƌƌĞŶƚǁŝƚŚƐƚĂŶĚĐĂƉĂĐŝƚǇ
;ƵƌƌĞŶƚ͕ƚŝŵĞĂŶĚĐŚĂƌĂĐƚĞƌŝƐƚŝĐƐͿ
ϯϴ͘ >ŽĐŬĞĚƌŽƚŽƌǁŝƚŚƐƚĂŶĚƚŝŵĞ;,ŽƚĂŶĚŽůĚƐƚĂƌƚĐŽŶĚŝƚŝŽŶͿ ^ĞĐ
Ă͘ ƚϴϬйǀŽůƚĂŐĞ ^ĞĐ ϭϮͬϮϰ
ď͘ ƚϭϬϬйǀŽůƚĂŐĞ ^ĞĐ ϴͬϭϲ
Đ͘ ƚϭϭϬйǀŽůƚĂŐĞ ^ĞĐ ϳͬϭϯ
ϯϵ͘ EŽ͘ŽĨ,ŽƚƐƚĂƌƚƐ EŽƐ͘ ϯ
ϰϬ͘ EŽ͘ŽĨŽůĚƐƚĂƌƚƐ EŽƐ͘ Ϯ
ϰϭ͘ EŽ͘ŽĨƋƵŝͲƐƉĂĐĞĚƐƚĂƌƚƐƉĞƌŚŽƵƌ EŽƐ͘ &ŽƵƌ;ϰͿ
ϰϮ͘ /ŶƐƵůĂƚŝŽŶ
Ă͘ ůĂƐƐŽĨŝŶƐƵůĂƚŝŽŶ &
ď͘ ZĞĨĞƌĞŶĐĞĂŵďŝĞŶƚƚĞŵƉĞƌĂƚƵƌĞ ĞŐ͘ ϱϬ
Đ͘ dĞŵƉĞƌĂƚƵƌĞƌŝƐĞŽĨǁŝŶĚŝŶŐ ĞŐ͘ ϳϬ
Ě͘ ǇǁŝŶĚŝŶŐƌĞƐŝƐƚĂŶĐĞŵĞƚŚŽĚ ĞŐ͘ ϳϬ
ϰϯ͘ dŚĞƌŵĂůƚŝŵĞĐŽŶƐƚĂŶƚ;,ĞĂƚŝŶŐͬŽŽůŝŶŐͿ ϯϬͬϲϬ
ϰϰ͘ tŝŶĚŝŶŐĐŽŶŶĞĐƚŝŽŶ ^ƚĂƌ
ϰϱ͘ dǇƉĞŽĨďĞĂƌŝŶŐƐ͗ ^ĞĂůĞĚďĞĂƌŝŶŐ
Ă͘ ƌŝǀŝŶŐĞŶĚ ϲϯϬϰ;ďĂůůͿ
ď͘ EŽŶͲĚƌŝǀŝŶŐĞŶĚ ϲϯϬϰ;ĂůůͿ
Đ͘ ZĞĐŽŵŵĞŶĚĞĚůƵďƌŝĐĂŶƚ EŽůƵďƌŝĐĂƚŝŽŶƌĞƋƵŝƌĞĚ
Ě͘ YƚǇ͘ŽĨůƵďƌŝĐĂŶƚƌĞƋƵŝƌĞĚĞĂĐŚďĞĂƌŝŶŐ E
Ğ͘ ZĞĐŽŵŵĞŶĚĞĚŐƌĞĂƐŝŶŐĐǇĐůĞ ϰϬϬϬϬŚŽƵƌƐ;ůŝĨĞĐǇĐůĞͿ
Ĩ͘ tŚĞƚŚĞƌďĞĂƌŝŶŐŝŶƐƵůĂƚŝŽŶƉƌŽǀŝĚĞĚ͍WƌŽǀŝĚĞĚĞƚĂŝůƐ͘ zĞƐͬEŽ EK
Ő͘ ĞĂƌŝŶŐƚĞŵƉ͘ƌŝƐĞĂďŽǀĞĂŵďŝĞŶƚƚĞŵƉ E
;ϭͿ ůĂƌŵĂƚ
;ϮͿ dƌŝƉĂƚ
;ϯͿ DĂǆŝŵƵŵďĞĂƌŝŶŐƚĞŵƉƌŝƐĞ
;ϰͿ DĂǆ͘ĂůůŽǁĂďůĞƚĞŵƉƌŝƐĞďǇďĞĂƌŝŶŐǀĞŶĚŽƌ
Ś͘ tŚĞƚŚĞƌĞǆĐĞƐƐŐƌĞĂƐĞŽƵƚůĞƚƉƌŽǀŝĚĞĚ͍WƌŽǀŝĚĞĚĞƚĂŝůƐ EŽ
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ǁŝƚŚŝŶĚŝĐĂƚŝŶŐŝŶĚƌĂǁŝŶŐ͘
ϰϲ͘ tŝŶĚŝŶŐZdƐ E
Ă͘ YƵĂŶƚŝƚǇ EŽƐ͘
ď͘ dǇƉĞ
Đ͘ ^ŝŵƉůĞǆͬƵƉůĞǆ
ϰϳ͘ ĞĂƌŝŶŐZdƐ E
ď͘ dǇƉĞ
ϰϴ͘ dŚĞƌŵŝƐƚĞƌ E
ď͘ dǇƉĞ
ϰϵ͘ ŽůŽƌƐŚĂĚĞƐŽĨƉĂŝŶƚǁŝƚŚƉĂŝŶƚƚŚŝĐŬŶĞƐƐ >ŝŐŚƚŐƌĞǇĨŝŶŝƐŚƚŽƐŚĂĚĞZ>
ϳϬϯϮͬdŚŬ͗ϴϬŵŝĐƌŽŶ
ϱϬ͘ ^ƉĂĐĞŚĞĂƚĞƌĚĞƚĂŝůƐ sŽůƚĂŐĞ͕ E
ǁĂƚƚƐ
ϱϭ͘ ĞŐƌĞĞŽĨƉƌŽƚĞĐƚŝŽŶ /WͲϱϱ
ϱϮ͘ ŝƌĞĐƚŝŽŶŽĨƌŽƚĂƚŝŽŶ ůŽĐŬǁŝƐĞĨƌŽŵ
ϱϯ͘ &ĂƵůƚǁŝƚŚƐƚĂŶĚĐĂƉĂĐŝƚǇŽĨƚĞƌŵŝŶĂůďŽǆ ŬͬƐĞĐ ϱϬ<ĨŽƌϬ͘ϮϱƐĞĐƐ
ϱϰ͘ dĞƌŵŝŶĂůďŽǆŽƌŝĞŶƚĂƚŝŽŶ dŽƉ
ϱϱ͘ dĞƌŵŝŶĂůďŽǆĚĞŐƌĞĞŽĨƌŽƚĂƚŝŽŶ ĚĞŐƌĞĞ E
ϱϲ͘ DĂǆŝŵƵŵƐŝǌĞĂŶĚŶƵŵďĞƌŽĨĐĂďůĞƐƚŚĂƚĐĂŶ ϭZͲϯͲϲŵŵϮ
ďĞĂĐĐŽŵŵŽĚĂƚĞĚŝŶŵŽƚŽƌƚĞƌŵŝŶĂůďŽǆ͘
ϱϳ͘ dƌŽƉŝĐĂůŝǌĞĚ͍WƌŽǀŝĚĞĚĞƚĂŝůƐ͘ EK
ϱϴ͘ dǇƉĞŽĨŵŽƵŶƚŝŶŐ &ŽŽƚDŽƵŶƚĞĚ
ϱϵ͘ DĞƚŚŽĚŽĨĐŽƵƉůŝŶŐǁŝƚŚĚƌŝǀĞŶĞƋƵŝƉŵĞŶƚ E
ϲϬ͘ EŽ͘ĂƌƚŚŝŶŐƚĞƌŵŝŶĂůƐ ϭ
Ă͘ KŶŵŽƚŽƌďŽĚǇ EŽƐ͘ ϭ
ď͘ KŶƚĞƌŵŝŶĂůďŽǆ EŽƐ͘ E
Đ͘ 'ƌŽƵŶĚŝŶŐƉĂĚƐƐŝǌĞŶŽƐ͘ΘůŽĐĂƚŝŽŶ ϮŽŶŵŽƚŽƌďŽĚǇΘϭŽŶd
ϲϭ͘ EŽŝƐĞ>ĞǀĞů Ě фϴϱĚďĂΛϭŵƚƌ
ϲϮ͘ sŝďƌĂƚŝŽŶůĞǀĞů ƐƉĞƌ/^ͲϭϮϬϳϱ
ϲϯ͘ DĂǆŝŵƵŵƉĞƌŵŝƐƐŝďůĞǀŽůƚĂŐĞĚƵƌŝŶŐŚŝŐŚƐƉĞĞĚďƵƐ ϭϱϬй
ƚƌĂŶƐĨĞƌΘƐƉĞĐŝĂůĚĞƐŝŐŶĨĞĂƚƵƌĞ͘
ϲϰ͘ dĞƌŵŝŶĂůďŽǆĞƐǁŝƚŚĂĐĐĞƐƐŽƌŝĞƐͲ
^ĞƉĂƌĂƚĞƚĞƌŵŝŶĂůďŽǆĞƐƐŚĂůůďĞƉƌŽǀŝĚĞĚĨŽƌĞĂĐŚ
ĂĐĐĞƐƐŽƌǇ
;ĂͿ DĂŝŶd E
;ďͿ ^ƉĂĐĞŚĞĂƚĞƌd E
;ĐͿ Zdнdd E
;ĚͿ EĞƵƚƌĂůd E
ϲϱ͘ DĂŝŶƚĞƌŵŝŶĂůďŽǆĚĞƚĂŝůƐ
ĂͿ&ĂƵůƚůĞǀĞůƉĞƌŵŝƐƐŝďůĞ ϱϬ<ĨŽƌϬ͘ϮϱƐĞĐƐ
ďͿ>ŽĐĂƚŝŽŶǀŝĞǁĞĚĨƌŽŵ
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ĐͿdǇƉĞŽĨŐůĂŶĚΘŵĂŬĞ
ĚͿĂďůĞŐůĂŶĚƐŝǌĞΘŶŽ͘
ĞͿĂďůĞĞŶƚƌǇ
ĨͿtŚĞƚŚĞƌƵŶͲĚƌŝůůĞĚŐůĂŶĚƉůĂƚĞƉƌŽǀŝĚĞĚ͍ zĞƐͬEŽ zĞƐ
ϲϱ͘ 'Ϯ
DŽƚŽƌ'Ϯ Ϭ͘ϬϬϬϭ
Ϯ
>ŽĂĚ'Ϯ <Őŵ Ϭ͘ϬϬϬϭ
ϲϱ͘ >ŝĨƚŝŶŐĂƌƌĂŶŐĞŵĞŶƚ
ϲϳ͘ EĞƚtĞŝŐŚƚŽĨDŽƚŽƌ
ϲϴ͘ ^ŚŝƉƉŝŶŐĚŝŵĞŶƐŝŽŶƐΘǁĞŝŐŚƚ
ϲϵ ŚĂƌĂĐƚĞƌŝƐƚŝĐƐĐƵƌǀĞƐĨƵƌŶŝƐŚ
ĂͿ^ƉĞĞĚǀƐ͘ĐƵƌƌĞŶƚĂƚƌĂƚĞĚǀŽůƚĂŐĞ zĞƐͬEŽ
ďͿ^ƉĞĞĚǀƐ͘ƚŽƌƋƵĞĂƚϭϭϬй͕ϭϬϬй͕ϵϬйĂŶĚϴϬйŽĨƌĂƚĞĚ zĞƐͬEŽ
ǀŽůƚĂŐĞƐƵƉĞƌŝŵƉŽƐĞĚŽŶůŽĂĚd^ĐƵƌǀĞ
ĐͿdŚĞƌŵĂůǁŝƚŚƐƚĂŶĚĐƵƌǀĞĨŽƌŚŽƚΘĐŽůĚĐŽŶĚŝƚŝŽŶƐ zĞƐͬEŽ
ĚͿĨĨŝĐŝĞŶĐǇǀƐ͘ůŽĂĚ zĞƐͬEŽ
ĞͿW͘&͘ǀƐ͘ůŽĂĚ zĞƐͬEŽ
ĨͿƵƌƌĞŶƚǀƐ͘ƚŝŵĞ zĞƐͬEŽ
ŐͿEĞŐĂƚŝǀĞƉŚĂƐĞƐĞƋƵĞŶĐĞĐƵƌǀĞ zĞƐͬEŽ
ϳϬ͘ ƌĂǁŝŶŐĚŽĐƵŵĞŶƚƚŽĨƵƌŶŝƐŚ
ĂͿ'ĞŶĞƌĂůĂƌƌĂŶŐĞŵĞŶƚŽĨŵŽƚŽƌ zĞƐͬEŽ
ďͿDĂŝŶƚĞƌŵŝŶĂůďŽǆΘƵǆƚĞƌŵŝŶĂůďŽǆ' zĞƐͬEŽ
ĐͿZdͬdͬd,ͬ^,ƚĞƌŵŝŶĂůĐŽŶŶĞĐƚŝŽŶĚŝĂŐƌĂŵ zĞƐͬEŽ
ĞͿdĞƌŵŝŶĂůǀŽůƚĂŐĞĚĞĐĂǇĐƵƌǀĞĂĨƚĞƌŵŽƚŽƌƉŽǁĞƌ zĞƐͬEŽ
ƐƵƉƉůǇƐǁŝƚĐŚĞĚŽĨĨ
ĨͿ^ƚĂƚŝĐĂŶĚĚǇŶĂŵŝĐǁĞŝŐŚƚƐ zĞƐͬEŽ
ŐͿ^ƚĂƌƚŝŶŐƚŝŵĞĐĂůĐƵůĂƚŝŽŶ zĞƐͬEŽ
ĚͿ/ŶƐƚƌƵĐƚŝŽŶŵĂŶƵĂůƐ zĞƐͬEŽ
ϳϭ ƋƵŝǀĂůĞŶƚĐŝƌĐƵŝƚƉĂƌĂŵĞƚĞƌƐĨŽƌŵŽƚŽƌƌĂƚŝŶŐхϳŬt;Zϭ͕
yϭ͕Zŵ͕yŵ͕ZϮ͕yϮ͕ǀĂůƵĞƐĂƚƐůŝƉϭĂŶĚĂƚĨƵůůůŽĂĚƐůŝƉͿ
ϳϮ &Žƌs&ŽƉĞƌĂƚĞĚŵŽƚŽƌ EŽƚƉƉůŝĐĂďůĞ
Ă ^ƵŝƚĂďůĞĨŽƌŽƉĞƌĂƚŝŽŶŽŶ/'dĚƌŝǀĞ zĞƐͬEŽ
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ď tŝŶĚŝŶŐƚƌĞĂƚŵĞŶƚĚĞƚĂŝůƐ
Đ ^ƵŝƚĂďůĞĨŽƌƐƉĞĞĚǀĂƌŝĂƚŝŽŶŽĨ й
Ě ůůŽǁĂďůĞйd,sŽůƚĂŐĞ й
Ğ ůůŽǁĂďůĞйd,ƵƌƌĞŶƚ й
Ĩ ůůŽǁĂďůĞĚǀͬĚƚ s
Ő ůůŽǁĂďůĞƚŽƌƋƵĞƉƵůƐĂƚŝŽŶ й

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ϭ͘ EĂŵĞŽĨDĂŶƵĨĂĐƚƵƌĞƌ 'W/^>
Ϯ͘ &ƌĂŵĞƐŝǌĞΘĚĞƐŝŐŶĐŽĚĞ ^,ϭϭϮD
ϯ͘ sĞŶĚŽƌǁŽƌŬŽƌĚĞƌŶƵŵďĞƌͬDĂĐŚŝŶĞŶƵŵďĞƌ Ͳ
ϰ͘ ŽĚĞƐĂŶĚƐƚĂŶĚĂƌĚƐ /^ϰϳϮϮͬ/ϲϬϬϯϰͲϭ
ϱ͘ ƉƉůŝĐĂƚŝŽŶ ůŽǁĞƌ
ϲ͘ dŽƚĂůƋƵĂŶƚŝƚǇ EŽƐ͘ ϭEŽͬůŽǁĞƌ
ϳ͘ dǇƉĞŽĨŵŽƚŽƌ >ĂŵŝŶĂƚĞĚǇŽŬĞŵŽƚŽƌ
ϴ͘ ^ĞƌǀŝĐĞ;KƵƚĚŽŽƌͬ/ŶĚŽŽƌͬ,ĂǌĂƌĚŽƵƐͿ KƵƚĚŽŽƌ
ϵ͘ dǇƉĞŽĨĞŶĐůŽƐƵƌĞΘĐŽŽůŝŶŐ tWƚŽ/Wϱϱ͕/ϬϬϰϭ
ϭϬ͘ ZĂƚĞĚŽƵƚƉƵƚĂƚĚĞƐŝŐŶĂŵďŝĞŶƚŽĨϱϬĚĞŐ͘ Ŭt ϭ͘ϱϬ
ϭϭ ZĂƚĞĚǀŽůƚĂŐĞ s ϭϭϬs
ϭϮ EŽŽĨƉŚĂƐĞƐ EŽƐ͘ E
ϭϯ ZĂƚĞĚĨƌĞƋƵĞŶĐǇ ,ǌ E
ϭϱ ZĞƋƵŝƌĞĚ<tƌĂƚŝŶŐŽĨƚŚĞĚƌŝǀĞŶĞƋƵŝƉŵĞŶƚ Ŭt Ϭ͘ϵϬ;&ĂŶƐŚĂĨƚƉŽǁĞƌĂƚ
ŽƉĞƌĂƚŝŶŐƚĞŵƉĞƌĂƚƵƌĞͿ
ϭϲ DŽƚŽƌĨƵůůůŽĂĚƚŽƌƋƵĞ Ϭ͘ϳϳ<'D
ϭϳ ^ƚĂƌƚŝŶŐƚŽƌƋƵĞĂƐйŽĨ&>d й ϮϬϬй
ϭϴ͘ WƵůůŽƵƚƚŽƌƋƵĞĂƐйŽĨ&>d й E
ϭϵ͘ ^ĞƌǀŝĐĞĨĂĐƚŽƌ ϭ
ϮϬ͘ ZĂƚĞĚƐƉĞĞĚ ZWD ϭϵϬϲ
Ϯϭ͘ sŽůƚĂŐĞǀĂƌŝĂƚŝŽŶƌĂŶŐĞ й ͲϭϬйdKϭϬй
ϮϮ͘ &ƌĞƋƵĞŶĐǇǀĂƌŝĂƚŝŽŶƌĂŶŐĞ й E
Ϯϯ͘ ŽŵďŝŶĞĚǀŽůƚĂŐĞĂŶĚĨƌĞƋƵĞŶĐǇǀĂƌŝĂƚŝŽŶƐ й E
Ϯϰ͘ &ƵůůůŽĂĚĐƵƌƌĞŶƚ ŵƉ ϭϲ͘Ϭ;ZDͿͬϬ͘ϯϰ;&/>Ϳ
Ϯϱ͘ EŽůŽĂĚĐƵƌƌĞŶƚ ŵƉ Ϯ͘Ϭ
Ϯϲ͘ ZĂƚĞĚƉŽǁĞƌĨĂĐƚŽƌ E
Ϯϳ͘ ĨĨŝĐŝĞŶĐǇ ϴϭй
Ă͘ ĨĨŝĐŝĞŶĐǇĐůĂƐƐĂƐƉĞƌ/^ϭϮϲϭϱ E&KZDKdKZ^
ď͘ ƚϭϬϬйůŽĂĚ ϴϭй
Đ͘ ƚϳϱйůŽĂĚ ϳϲй
Ě͘ ƚϱϬйůŽĂĚ ϲϵй
Ğ͘ ƚŶŽůŽĂĚ Ϭй
Ϯϴ͘ WŽǁĞƌĨĂĐƚŽƌ E
Ă͘ ƚϭϬϬйůŽĂĚ E
Đ͘ ƚϱϬйůŽĂĚ E
ď͘ ƚϳϱйůŽĂĚ E
Ě͘ ƚEŽůŽĂĚ E
Ϯϵ ^ƚĂƌƚŝŶŐƉŽǁĞƌĨĂĐƚŽƌ E
ϯϬ͘ dŽƚĂůůŽƐƐĞƐ Ŭt ϯϲϱtĂƚƚƐ
ϯϭ͘ DĞƚŚŽĚŽĨƐƚĂƌƚŝŶŐ ZĞĚƵĐĞĚǀŽůƚĂŐĞƚŚƌƵƐƚĂƌƚĞƌ
ϯϮ͘ ^ƚĂƌƚŝŶŐĐƵƌƌĞŶƚĂƚƌĂƚĞĚǀŽůƚĂŐĞ йŽĨ&> ϮϱϬйŽĨ&>
ϯϯ͘ DŝŶŝŵƵŵǀŽůƚĂŐĞƌĞƋƵŝƌĞĚĂƚƐƚĂƌƚŝŶŐƚŽĂĐĐĞůĞƌĂƚĞĚƌŝǀĞŶ s ϴϬйŽĨƌĂƚĞĚǀŽůƚĂŐĞ
ĞƋƵŝƉŵĞŶƚ
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ϯϰ͘ DĂǆŝŵƵŵƉĞƌŵŝƐƐŝďůĞƚŝŵĞĂƚϳϱйǀŽůƚĂŐĞĚƵƌŝŶŐƌƵŶŶŝŶŐ ^ĞĐ ϱ͘ϮƐĞĐ

ϯϱ ^ƚĂƌƚŝŶŐƚŝŵĞ E
Ă͘ ƚϴϬйǀŽůƚĂŐĞ ^ĞĐ ϰ͘ϴƐĞĐ
ď͘ ƚϭϬϬйǀŽůƚĂŐĞ ^ĞĐ ϯ͘ϴƐĞĐ
Đ͘ ƚϭϭϬйǀŽůƚĂŐĞ ^ĞĐ ϯ͘ϰƐĞĐ
ůŽĂĚ͘
Ă͘ ƚϴϬйǀŽůƚĂŐĞ ^ĞĐ ϭ͘ϮϬƐĞĐ
ď͘ ƚϭϬϬйǀŽůƚĂŐĞ ^ĞĐ Ϭ͘ϵϯ^ĞĐ
Đ͘ ƚϭϭϬйǀŽůƚĂŐĞ ^ĞĐ ϭ͘ϬϭƐĞĐ
ϯϳ͘ EĞŐĂƚŝǀĞƉŚĂƐĞƐĞƋƵĞŶĐĞĐƵƌƌĞŶƚǁŝƚŚƐƚĂŶĚĐĂƉĂĐŝƚǇ EĨŽƌĐŵŽƚŽƌƐ
ϯϴ͘ >ŽĐŬĞĚƌŽƚŽƌǁŝƚŚƐƚĂŶĚƚŝŵĞ;,ŽƚĂŶĚŽůĚƐƚĂƌƚĐŽŶĚŝƚŝŽŶͿ ^ĞĐ EĨŽƌĐŵŽƚŽƌƐ
Ă͘ ƚϴϬйǀŽůƚĂŐĞ ^ĞĐ
ď͘ ƚϭϬϬйǀŽůƚĂŐĞ ^ĞĐ
Đ͘ ƚϭϭϬйǀŽůƚĂŐĞ ^ĞĐ
ϯϵ͘ EŽ͘ŽĨ,ŽƚƐƚĂƌƚƐ EŽƐ͘ Ϯ,
ϰϬ͘ EŽ͘ŽĨŽůĚƐƚĂƌƚƐ EŽƐ͘ ϯ
ϰϭ͘ EŽ͘ŽĨƋƵŝͲƐƉĂĐĞĚƐƚĂƌƚƐƉĞƌŚŽƵƌ EŽƐ͘ Ϯ
ϰϯ͘ dŚĞƌŵĂůƚŝŵĞĐŽŶƐƚĂŶƚ;,ĞĂƚŝŶŐͬŽŽůŝŶŐͿ Ϯ͘ϱ,ƌƐͬϭ͘ϳ,ƌƐ
ϰϰ͘ tŝŶĚŝŶŐĐŽŶŶĞĐƚŝŽŶ ^ƚĂďƐŚƵŶƚ
ϰϱ͘ dǇƉĞŽĨďĞĂƌŝŶŐƐ͗ ^ĞĂůĞĚďĂůůďĞĂƌŝŶŐƐ
Ă͘ ƌŝǀŝŶŐĞŶĚ ϲϮϬϴ
ď͘ EŽŶͲĚƌŝǀŝŶŐĞŶĚ ϲϮϬϲ
Đ͘ ZĞĐŽŵŵĞŶĚĞĚůƵďƌŝĐĂŶƚ ^ĞĂůĞĚĨŽƌůŝĨĞ
Ě͘ YƚǇ͘ŽĨůƵďƌŝĐĂŶƚƌĞƋƵŝƌĞĚĞĂĐŚďĞĂƌŝŶŐ E
Ğ͘ ZĞĐŽŵŵĞŶĚĞĚŐƌĞĂƐŝŶŐĐǇĐůĞ ϰϱϬϬϬŚŽƵƌƐ;ůŝĨĞĐǇĐůĞͿ
Ĩ͘ tŚĞƚŚĞƌďĞĂƌŝŶŐŝŶƐƵůĂƚŝŽŶƉƌŽǀŝĚĞĚ͍WƌŽǀŝĚĞĚĞƚĂŝůƐ͘ zĞƐͬEŽ E
Ő͘ ĞĂƌŝŶŐƚĞŵƉ͘ƌŝƐĞĂďŽǀĞĂŵďŝĞŶƚƚĞŵƉ
;ϭͿ ůĂƌŵĂƚ E
;ϮͿ dƌŝƉĂƚ E
;ϯͿ DĂǆŝŵƵŵďĞĂƌŝŶŐƚĞŵƉƌŝƐĞ E
;ϰͿ DĂǆ͘ĂůůŽǁĂďůĞƚĞŵƉƌŝƐĞďǇďĞĂƌŝŶŐǀĞŶĚŽƌ E
Ś͘ tŚĞƚŚĞƌĞǆĐĞƐƐŐƌĞĂƐĞŽƵƚůĞƚƉƌŽǀŝĚĞĚ͍WƌŽǀŝĚĞĚĞƚĂŝůƐ E
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ď͘ dǇƉĞ
ď͘ dǇƉĞ
ϰϴ͘ dŚĞƌŵŝƐƚĞƌ E
ď͘ dǇƉĞ
ϱϬ͘ ^ƉĂĐĞŚĞĂƚĞƌĚĞƚĂŝůƐ sŽůƚĂŐĞ͕ E
ǁĂƚƚƐ
ϱϭ͘ ĞŐƌĞĞŽĨƉƌŽƚĞĐƚŝŽŶ /Wϱϱ
ϱϮ͘ ŝƌĞĐƚŝŽŶŽĨƌŽƚĂƚŝŽŶ ŝŝƌĞĐƚŝŽŶĂů
ϱϰ͘ dĞƌŵŝŶĂůďŽǆŽƌŝĞŶƚĂƚŝŽŶ dKWd
ϱϱ͘ dĞƌŵŝŶĂůďŽǆĚĞŐƌĞĞŽĨƌŽƚĂƚŝŽŶ ĚĞŐƌĞĞ ϵϬ
ϱϲ͘ DĂǆŝŵƵŵƐŝǌĞĂŶĚŶƵŵďĞƌŽĨĐĂďůĞƐƚŚĂƚĐĂŶ ϭǆϮǆϮϱ^Ƌŵŵ
ϱϳ͘ dƌŽƉŝĐĂůŝǌĞĚ͍WƌŽǀŝĚĞĚĞƚĂŝůƐ͘ zĞƐ
ϱϵ͘ DĞƚŚŽĚŽĨĐŽƵƉůŝŶŐǁŝƚŚĚƌŝǀĞŶĞƋƵŝƉŵĞŶƚ ŝƌĞĐƚ
ϲϬ͘ EŽ͘ĂƌƚŚŝŶŐƚĞƌŵŝŶĂůƐ
Ă͘ KŶŵŽƚŽƌďŽĚǇ EŽƐ͘ ϭŶŽƐ
ď͘ KŶƚĞƌŵŝŶĂůďŽǆ EŽƐ͘ ϭŶŽƐ
Đ͘ 'ƌŽƵŶĚŝŶŐƉĂĚƐƐŝǌĞŶŽƐ͘ΘůŽĐĂƚŝŽŶ E
ϲϭ͘ EŽŝƐĞ>ĞǀĞů Ě ϴϮĚďĂΛϭŵƚƌ͘
ϲϮ͘ sŝďƌĂƚŝŽŶůĞǀĞů sĞůŽĐŝƚǇ͗ϭ͘ϴŵŵͬƐĞĐ
ŝƐƉůĂĐĞŵĞŶƚ͗ϮϱDŝĐƌŽŶƐ
ĂĐĐĞƐƐŽƌǇ
;ĂͿ DĂŝŶd EŽƚĞĚĂŶĚĐŽŶĨŝƌŵ
;ĐͿ Zdнdd E
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ďͿ>ŽĐĂƚŝŽŶǀŝĞǁĞĚĨƌŽŵ Z,^ĨƌŽŵ
ĐͿdǇƉĞŽĨŐůĂŶĚΘŵĂŬĞ dƚǇƉĞ
ĚͿĂďůĞŐůĂŶĚƐŝǌĞΘŶŽ͘ ϭ͟
ĞͿĂďůĞĞŶƚƌǇ ϭǆϮǆϮϱ^Ƌŵŵ
ĨͿtŚĞƚŚĞƌƵŶͲĚƌŝůůĞĚŐůĂŶĚƉůĂƚĞƉƌŽǀŝĚĞĚ͍ zĞƐͬEŽ EŽ
ϲϱ͘ 'Ϯ
DŽƚŽƌ'Ϯ Ϭ͘ϭϲϴ
Ϯ
>ŽĂĚ'Ϯ <Őŵ Ϭ͘ϴϰϴ
ϲϱ͘ >ŝĨƚŝŶŐĂƌƌĂŶŐĞŵĞŶƚ >ŝĨƚŝŶŐŚŽŽŬƐ
ϲϳ͘ EĞƚtĞŝŐŚƚŽĨDŽƚŽƌ ϭϭϱ<'
ϲϴ͘ ^ŚŝƉƉŝŶŐĚŝŵĞŶƐŝŽŶƐΘǁĞŝŐŚƚ >͗ϵϬϬ͕t͗ϱϮϲ͕,͗ϳϯϬ
EĞƚtĞŝŐŚƚ͗ϭϭϱŬŐ
'ƌŽƐƐǁĞŝŐŚƚ͗ϭϴϱŬŐ
ĂͿ^ƉĞĞĚǀƐ͘ĐƵƌƌĞŶƚĂƚƌĂƚĞĚǀŽůƚĂŐĞ zĞƐͬEŽ zĞƐ͕ZĞƋƵŝƌĞĚ
ďͿ^ƉĞĞĚǀƐ͘ƚŽƌƋƵĞĂƚϭϭϬй͕ϭϬϬй͕ϵϬйĂŶĚϴϬйŽĨƌĂƚĞĚ zĞƐͬEŽ zĞƐ͕ZĞƋƵŝƌĞĚ
ĐͿdŚĞƌŵĂůǁŝƚŚƐƚĂŶĚĐƵƌǀĞĨŽƌŚŽƚΘĐŽůĚĐŽŶĚŝƚŝŽŶƐ zĞƐͬEŽ zĞƐ͕ZĞƋƵŝƌĞĚ
ĚͿĨĨŝĐŝĞŶĐǇǀƐ͘ůŽĂĚ zĞƐͬEŽ zĞƐ͕ZĞƋƵŝƌĞĚ
ĞͿW͘&͘ǀƐ͘ůŽĂĚ zĞƐͬEŽ EŽ͕E
ĨͿƵƌƌĞŶƚǀƐ͘ƚŝŵĞ zĞƐͬEŽ zĞƐ͕ZĞƋƵŝƌĞĚ
ŐͿEĞŐĂƚŝǀĞƉŚĂƐĞƐĞƋƵĞŶĐĞĐƵƌǀĞ zĞƐͬEŽ EŽ
ĂͿ'ĞŶĞƌĂůĂƌƌĂŶŐĞŵĞŶƚŽĨŵŽƚŽƌ zĞƐͬEŽ z^
ďͿDĂŝŶƚĞƌŵŝŶĂůďŽǆΘƵǆƚĞƌŵŝŶĂůďŽǆ' zĞƐͬEŽ z^
ĐͿZdͬdͬd,ͬ^,ƚĞƌŵŝŶĂůĐŽŶŶĞĐƚŝŽŶĚŝĂŐƌĂŵ zĞƐͬEŽ E
ĞͿdĞƌŵŝŶĂůǀŽůƚĂŐĞĚĞĐĂǇĐƵƌǀĞĂĨƚĞƌŵŽƚŽƌƉŽǁĞƌ zĞƐͬEŽ E
ĨͿ^ƚĂƚŝĐĂŶĚĚǇŶĂŵŝĐǁĞŝŐŚƚƐ zĞƐͬEŽ EK
ŐͿ^ƚĂƌƚŝŶŐƚŝŵĞĐĂůĐƵůĂƚŝŽŶ zĞƐͬEŽ EK
ĚͿ/ŶƐƚƌƵĐƚŝŽŶŵĂŶƵĂůƐ zĞƐͬEŽ ůŽŶŐǁŝƚŚŵŽƚŽƌƐƵƉƉůǇ
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ϳϮ &Žƌs&ŽƉĞƌĂƚĞĚŵŽƚŽƌ NA
Ă ^ƵŝƚĂďůĞĨŽƌŽƉĞƌĂƚŝŽŶŽŶ/'dĚƌŝǀĞ zĞƐͬEŽ E
ď tŝŶĚŝŶŐƚƌĞĂƚŵĞŶƚĚĞƚĂŝůƐ 'ĞůŽĂƚ
Đ ^ƵŝƚĂďůĞĨŽƌƐƉĞĞĚǀĂƌŝĂƚŝŽŶŽĨ й ZĂƚĞĚƐƉĞĞĚƚŽĨŝĞůĚǁĞĂŬŝŶŐ
ƐƉĞĞĚ
Ě ůůŽǁĂďůĞйd,sŽůƚĂŐĞ й E
Ğ ůůŽǁĂďůĞйd,ƵƌƌĞŶƚ й E
Ĩ ůůŽǁĂďůĞĚǀͬĚƚ s E
Ő ůůŽǁĂďůĞƚŽƌƋƵĞƉƵůƐĂƚŝŽŶ й E

EŽƚĞƐ

ϭ͘ sĞŶĚŽƌƚŽĨŽůůŽǁĂůůĂƚƚĂĐŚĞĚƐƉĞĐŝĨŝĐĂƚŝŽŶ
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ϭ͘ EĂŵĞŽĨDĂŶƵĨĂĐƚƵƌĞƌ '>
Ϯ͘ &ƌĂŵĞƐŝǌĞΘĚĞƐŝŐŶĐŽĚĞ EϭϴϬD
ϯ͘ sĞŶĚŽƌǁŽƌŬŽƌĚĞƌŶƵŵďĞƌͬDĂĐŚŝŶĞŶƵŵďĞƌ ϭϴ͘ϱ<ϰ
ϰ͘ ŽĚĞƐĂŶĚƐƚĂŶĚĂƌĚƐ /^ͲϭϮϲϭϱͬ/ͲϲϬϬϯϰͲϯϬ
ϲ͘ dŽƚĂůƋƵĂŶƚŝƚǇ EŽƐ͘ ϭEŽͬůŽǁĞƌ͕dŽƚĂů͗ϮEŽƐ
ϵ͘ dǇƉĞŽĨĞŶĐůŽƐƵƌĞΘĐŽŽůŝŶŐ tWƚŽ/Wϱϱ͕/ϰϭϭ
ϭϬ͘ ZĂƚĞĚŽƵƚƉƵƚĂƚĚĞƐŝŐŶĂŵďŝĞŶƚŽĨϱϬĚĞŐ͘ Ŭt ϭϴ͘ϱ
ϭϱ ZĞƋƵŝƌĞĚ<tƌĂƚŝŶŐŽĨƚŚĞĚƌŝǀĞŶĞƋƵŝƉŵĞŶƚ Ŭt ϭϴ͘ϱϬͲϮϱ,W
ϭϲ DŽƚŽƌĨƵůůůŽĂĚƚŽƌƋƵĞ ϭϭϵEŵ
ϭϴ͘ WƵůůŽƵƚƚŽƌƋƵĞĂƐйŽĨ&>d й Ϯϳϱ
ϭϵ͘ ^ĞƌǀŝĐĞĨĂĐƚŽƌ ϭ͘Ϭ
ϮϬ͘ ZĂƚĞĚƐƉĞĞĚ ZWD ϭϰϲϬ
Ϯϰ͘ &ƵůůůŽĂĚĐƵƌƌĞŶƚ ŵƉ ϯϰ
Ϯϱ͘ EŽůŽĂĚĐƵƌƌĞŶƚ ŵƉ ϭϮ
Ϯϲ͘ ZĂƚĞĚƉŽǁĞƌĨĂĐƚŽƌ Ϭ͘ϴϯ
Ă͘ ĨĨŝĐŝĞŶĐǇĐůĂƐƐĂƐƉĞƌ/^ϭϮϲϭϱ /Ϯ
ď͘ ƚϭϬϬйůŽĂĚ ϵϭ͘Ϯ
Đ͘ ƚϳϱйůŽĂĚ ϵϭ͘Ϯ
Ě͘ ƚϱϬйůŽĂĚ ϵϬ͘ϱ
Ğ͘ ƚŶŽůŽĂĚ
Ă͘ ƚϭϬϬйůŽĂĚ Ϭ͘ϴϯ
Đ͘ ƚϱϬйůŽĂĚ Ϭ͘ϳϵ
ď͘ ƚϳϱйůŽĂĚ Ϭ͘ϲϵ
Ě͘ ƚEŽůŽĂĚ EͲĂ
ϯϬ͘ dŽƚĂůůŽƐƐĞƐ Ŭt Ϯ͘Ϭϴ
ϯϭ͘ DĞƚŚŽĚŽĨƐƚĂƌƚŝŶŐ K>
ϯϯ͘ DŝŶŝŵƵŵǀŽůƚĂŐĞƌĞƋƵŝƌĞĚĂƚƐƚĂƌƚŝŶŐƚŽĂĐĐĞůĞƌĂƚĞĚƌŝǀĞŶ s ϳϱй
ĞƋƵŝƉŵĞŶƚ
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ϯϱ ^ƚĂƌƚŝŶŐƚŝŵĞ Ϭ͘ϭϳ^ĞĐ
Ă͘ ƚϴϬйǀŽůƚĂŐĞ ^ĞĐ Ϭ͘Ϯϯ
ď͘ ƚϭϬϬйǀŽůƚĂŐĞ ^ĞĐ Ϭ͘ϭϳ
Đ͘ ƚϭϭϬйǀŽůƚĂŐĞ ^ĞĐ Ϭ͘ϭϱϲ
ůŽĂĚ͘
Ă͘ ƚϴϬйǀŽůƚĂŐĞ ^ĞĐ Ϭ͘ϮϮ
ď͘ ƚϭϬϬйǀŽůƚĂŐĞ ^ĞĐ Ϭ͘ϭϰ
Đ͘ ƚϭϭϬйǀŽůƚĂŐĞ ^ĞĐ Ϭ͘ϭϮϱ
Ă͘ ƚϴϬйǀŽůƚĂŐĞ ^ĞĐ ϭϲͬϯϭ
ď͘ ƚϭϬϬйǀŽůƚĂŐĞ ^ĞĐ ϭϬͬϮϬ
Đ͘ ƚϭϭϬйǀŽůƚĂŐĞ ^ĞĐ ϴͬϭϳ
ϯϵ͘ EŽ͘ŽĨ,ŽƚƐƚĂƌƚƐ EŽƐ͘ Ϯ
ϰϬ͘ EŽ͘ŽĨŽůĚƐƚĂƌƚƐ EŽƐ͘ ϯ
ϰϯ͘ dŚĞƌŵĂůƚŝŵĞĐŽŶƐƚĂŶƚ;,ĞĂƚŝŶŐͬŽŽůŝŶŐͿ ϯϬͬϲϬ
ϰϰ͘ tŝŶĚŝŶŐĐŽŶŶĞĐƚŝŽŶ ĞůƚĂ
ϰϱ͘ dǇƉĞŽĨďĞĂƌŝŶŐƐ͗ ĂůůďĞĂƌŝŶŐ
Ă͘ ƌŝǀŝŶŐĞŶĚ ϲϯϭϬͲ
ď͘ EŽŶͲĚƌŝǀŝŶŐĞŶĚ ϲϮϭϬͲ
Đ͘ ZĞĐŽŵŵĞŶĚĞĚůƵďƌŝĐĂŶƚ ^ĞĂůĞĚ
Ě͘ YƚǇ͘ŽĨůƵďƌŝĐĂŶƚƌĞƋƵŝƌĞĚĞĂĐŚďĞĂƌŝŶŐ >ƵďƌŝĐĂŶƚĨŽƌ>/ĨĞ
Ő͘ ĞĂƌŝŶŐƚĞŵƉ͘ƌŝƐĞĂďŽǀĞĂŵďŝĞŶƚƚĞŵƉ EŽƚĂƉƉůŝĐĂďůĞ
;ϭͿ ůĂƌŵĂƚ
;ϮͿ dƌŝƉĂƚ
Ś͘ tŚĞƚŚĞƌĞǆĐĞƐƐŐƌĞĂƐĞŽƵƚůĞƚƉƌŽǀŝĚĞĚ͍WƌŽǀŝĚĞĚĞƚĂŝůƐ
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ď͘ dǇƉĞ
ď͘ dǇƉĞ
ϰϴ͘ dŚĞƌŵŝƐƚĞƌ Eͬ
Ă͘ YƵĂŶƚŝƚǇ EŽƐ͘ Eͬ
ď͘ dǇƉĞ Eͬ
ϱϬ͘ ^ƉĂĐĞŚĞĂƚĞƌĚĞƚĂŝůƐ sŽůƚĂŐĞ͕ Eͬ
ǁĂƚƚƐ
ϱϮ͘ ŝƌĞĐƚŝŽŶŽĨƌŽƚĂƚŝŽŶ t
ϱϰ͘ dĞƌŵŝŶĂůďŽǆŽƌŝĞŶƚĂƚŝŽŶ dKW
ϱϲ͘ DĂǆŝŵƵŵƐŝǌĞĂŶĚŶƵŵďĞƌŽĨĐĂďůĞƐƚŚĂƚĐĂŶ ϮyϯyϮϱ^Ƌŵŵ
ϱϳ͘ dƌŽƉŝĐĂůŝǌĞĚ͍WƌŽǀŝĚĞĚĞƚĂŝůƐ͘
ϱϵ͘ DĞƚŚŽĚŽĨĐŽƵƉůŝŶŐǁŝƚŚĚƌŝǀĞŶĞƋƵŝƉŵĞŶƚ ƐƉĞƌĐƵƐƚŽŵĞƌ
ď͘ KŶƚĞƌŵŝŶĂůďŽǆ EŽƐ͘ EͬĂ
Đ͘ 'ƌŽƵŶĚŝŶŐƉĂĚƐƐŝǌĞŶŽƐ͘ΘůŽĐĂƚŝŽŶ ϮŽŶŵŽƚŽƌďŽĚǇĂŶĚϭŝŶƐŝĚĞ
d
ϲϭ͘ EŽŝƐĞ>ĞǀĞů Ě фϴϱĚďĂΛϭŵƚƌ͘
ϲϮ͘ sŝďƌĂƚŝŽŶůĞǀĞů /ϲϬϬϯϰͲϭϰ
ĂĐĐĞƐƐŽƌǇ
;ĂͿ DĂŝŶd
;ĐͿ Zdнdd E
ďͿ>ŽĐĂƚŝŽŶǀŝĞǁĞĚĨƌŽŵ Z,^
Sheet
No.
Industries Ltd.
4 of 5
ϲϱ͘ 'Ϯ
DŽƚŽƌ'Ϯ Ϭ͘ϵϭĂƐƉĞƌƌĞƋƵŝƌĞ
Ϯ
>ŽĂĚ'Ϯ <Őŵ Ϭ͘Ϭϵ
ϲϱ͘ >ŝĨƚŝŶŐĂƌƌĂŶŐĞŵĞŶƚ ǇĞŽůƚ
ϲϳ͘ EĞƚtĞŝŐŚƚŽĨDŽƚŽƌ ϭϲϬ<'
ϳϮ &Žƌs&ŽƉĞƌĂƚĞĚŵŽƚŽƌ Eͬ
Ă ^ƵŝƚĂďůĞĨŽƌŽƉĞƌĂƚŝŽŶŽŶ/'dĚƌŝǀĞ zĞƐͬEŽ
Sheet
No.
Industries Ltd.
5 of 5

Sheet
No.
Industries Ltd.
1 of 5

ϭ͘ EĂŵĞŽĨDĂŶƵĨĂĐƚƵƌĞƌ '>
Ϯ͘ &ƌĂŵĞƐŝǌĞΘĚĞƐŝŐŶĐŽĚĞ EϮϮϱ^
ϯ͘ sĞŶĚŽƌǁŽƌŬŽƌĚĞƌŶƵŵďĞƌͬDĂĐŚŝŶĞŶƵŵďĞƌ ϯϬ<ϰ
ϰ͘ ŽĚĞƐĂŶĚƐƚĂŶĚĂƌĚƐ /^ͲϭϮϲϭϱͬ/ͲϲϬϬϯϰͲϯϬ
ϲ͘ dŽƚĂůƋƵĂŶƚŝƚǇ EŽƐ͘ ϭEŽͬůŽǁĞƌ
dŽƚĂů͗ϮEŽƐ
ϵ͘ dǇƉĞŽĨĞŶĐůŽƐƵƌĞΘĐŽŽůŝŶŐ tWƚŽ/Wϱϱ͕/ϰϭϭ
ϭϬ͘ ZĂƚĞĚŽƵƚƉƵƚĂƚĚĞƐŝŐŶĂŵďŝĞŶƚŽĨϱϬĚĞŐ͘ Ŭt ϯϬ
ϭϱ ZĞƋƵŝƌĞĚ<tƌĂƚŝŶŐŽĨƚŚĞĚƌŝǀĞŶĞƋƵŝƉŵĞŶƚ Ŭt ϯϬ<t
ϭϲ DŽƚŽƌĨƵůůůŽĂĚƚŽƌƋƵĞ ϭϵϲ͘ϮϵEŵ
ϭϴ͘ WƵůůŽƵƚƚŽƌƋƵĞĂƐйŽĨ&>d й ϮϱϬ
ϭϵ͘ ^ĞƌǀŝĐĞĨĂĐƚŽƌ ϭ͘Ϭ
ϮϬ͘ ZĂƚĞĚƐƉĞĞĚ ZWD ϭϰϲϬ
Ϯϰ͘ &ƵůůůŽĂĚĐƵƌƌĞŶƚ ŵƉ ϱϭ
Ϯϱ͘ EŽůŽĂĚĐƵƌƌĞŶƚ ŵƉ ϭϴ
Ϯϲ͘ ZĂƚĞĚƉŽǁĞƌĨĂĐƚŽƌ Ϭ͘ϴϴ
Ă͘ ĨĨŝĐŝĞŶĐǇĐůĂƐƐĂƐƉĞƌ/^ϭϮϲϭϱ /Ϯ
ď͘ ƚϭϬϬйůŽĂĚ ϵϮ͘ϯ
Đ͘ ƚϳϱйůŽĂĚ ϵϮ͘ϯ
Ě͘ ƚϱϬйůŽĂĚ ϵϮ
Ğ͘ ƚŶŽůŽĂĚ
Ă͘ ƚϭϬϬйůŽĂĚ Ϭ͘ϴϴ
Đ͘ ƚϱϬйůŽĂĚ Ϭ͘ϴϲ
ď͘ ƚϳϱйůŽĂĚ Ϭ͘ϴϮ
Ě͘ ƚEŽůŽĂĚ EͲĂ
ϯϬ͘ dŽƚĂůůŽƐƐĞƐ Ŭt
ϯϭ͘ DĞƚŚŽĚŽĨƐƚĂƌƚŝŶŐ s&
ϯϯ͘ DŝŶŝŵƵŵǀŽůƚĂŐĞƌĞƋƵŝƌĞĚĂƚƐƚĂƌƚŝŶŐƚŽĂĐĐĞůĞƌĂƚĞĚƌŝǀĞŶ s ϳϱй
ĞƋƵŝƉŵĞŶƚ
Sheet
No.
Industries Ltd.
2 of 5

ϯϱ ^ƚĂƌƚŝŶŐƚŝŵĞ Ϭ͘Ϯϱ^ĞĐ
Ă͘ ƚϴϬйǀŽůƚĂŐĞ ^ĞĐ Ϭ͘Ϯϱ
ď͘ ƚϭϬϬйǀŽůƚĂŐĞ ^ĞĐ Ϭ͘ϯϱ
Đ͘ ƚϭϭϬйǀŽůƚĂŐĞ ^ĞĐ Ϭ͘ϮϮϱ
ůŽĂĚ͘
Ă͘ ƚϴϬйǀŽůƚĂŐĞ ^ĞĐ Ϭ͘ϯϮ
ď͘ ƚϭϬϬйǀŽůƚĂŐĞ ^ĞĐ Ϭ͘ϮϬ
Đ͘ ƚϭϭϬйǀŽůƚĂŐĞ ^ĞĐ Ϭ͘ϭϳϱ
Ă͘ ƚϴϬйǀŽůƚĂŐĞ ^ĞĐ ϭϵͬϯϴ
ď͘ ƚϭϬϬйǀŽůƚĂŐĞ ^ĞĐ ϭϮͬϮϰ
Đ͘ ƚϭϭϬйǀŽůƚĂŐĞ ^ĞĐ ϭϬͬϮϬ
ϯϵ͘ EŽ͘ŽĨ,ŽƚƐƚĂƌƚƐ EŽƐ͘ ϯ
ϰϬ͘ EŽ͘ŽĨŽůĚƐƚĂƌƚƐ EŽƐ͘ Ϯ
ϰϯ͘ dŚĞƌŵĂůƚŝŵĞĐŽŶƐƚĂŶƚ;,ĞĂƚŝŶŐͬŽŽůŝŶŐͿ ϰϱͬϵϬ
ϰϰ͘ tŝŶĚŝŶŐĐŽŶŶĞĐƚŝŽŶ ĞůƚĂ
ϰϱ͘ dǇƉĞŽĨďĞĂƌŝŶŐƐ͗ ĂůůďĞĂƌŝŶŐ
Ă͘ ƌŝǀŝŶŐĞŶĚ ϲϯϭϮͲ
ď͘ EŽŶͲĚƌŝǀŝŶŐĞŶĚ ϲϮϭϮͲ
Đ͘ ZĞĐŽŵŵĞŶĚĞĚůƵďƌŝĐĂŶƚ ^ĞĂůĞĚ
Ě͘ YƚǇ͘ŽĨůƵďƌŝĐĂŶƚƌĞƋƵŝƌĞĚĞĂĐŚďĞĂƌŝŶŐ >ƵďƌŝĐĂŶƚĨŽƌ>/ĨĞ
Ő͘ ĞĂƌŝŶŐƚĞŵƉ͘ƌŝƐĞĂďŽǀĞĂŵďŝĞŶƚƚĞŵƉ EŽƚĂƉƉůŝĐĂďůĞ
;ϭͿ ůĂƌŵĂƚ
;ϮͿ dƌŝƉĂƚ
Ś͘ tŚĞƚŚĞƌĞǆĐĞƐƐŐƌĞĂƐĞŽƵƚůĞƚƉƌŽǀŝĚĞĚ͍WƌŽǀŝĚĞĚĞƚĂŝůƐ
Sheet
No.
Industries Ltd.
3 of 5
ď͘ dǇƉĞ
ď͘ dǇƉĞ
ϰϴ͘ dŚĞƌŵŝƐƚĞƌ /ŶĞĂĐŚWŚĂƐĞ
Ă͘ YƵĂŶƚŝƚǇ EŽƐ͘ ϯEŽƐ
ď͘ dǇƉĞ WdͲϭϯϬ
ϱϬ͘ ^ƉĂĐĞŚĞĂƚĞƌĚĞƚĂŝůƐ sŽůƚĂŐĞ͕ ϮϰϬs
ǁĂƚƚƐ
ϱϮ͘ ŝƌĞĐƚŝŽŶŽĨƌŽƚĂƚŝŽŶ t
ϱϰ͘ dĞƌŵŝŶĂůďŽǆŽƌŝĞŶƚĂƚŝŽŶ Z,^ĨƌŽŵ
ϱϲ͘ DĂǆŝŵƵŵƐŝǌĞĂŶĚŶƵŵďĞƌŽĨĐĂďůĞƐƚŚĂƚĐĂŶ ϮyϯyϮϱ^Ƌŵŵ
ϱϳ͘ dƌŽƉŝĐĂůŝǌĞĚ͍WƌŽǀŝĚĞĚĞƚĂŝůƐ͘
ϱϵ͘ DĞƚŚŽĚŽĨĐŽƵƉůŝŶŐǁŝƚŚĚƌŝǀĞŶĞƋƵŝƉŵĞŶƚ ƐƉĞƌĐƵƐƚŽŵĞƌ
ď͘ KŶƚĞƌŵŝŶĂůďŽǆ EŽƐ͘ EͬĂ
Đ͘ 'ƌŽƵŶĚŝŶŐƉĂĚƐƐŝǌĞŶŽƐ͘ΘůŽĐĂƚŝŽŶ ϮŽŶŵŽƚŽƌďŽĚǇĂŶĚϭŝŶƐŝĚĞ
d
ϲϭ͘ EŽŝƐĞ>ĞǀĞů Ě фϴϱĚďĂΛϭŵƚƌ͘
ϲϮ͘ sŝďƌĂƚŝŽŶůĞǀĞů /ϲϬϬϯϰͲϭϰ
ĂĐĐĞƐƐŽƌǇ
;ĂͿ DĂŝŶd z
;ďͿ ^ƉĂĐĞŚĞĂƚĞƌd z
;ĐͿ Zdнdd E
Sheet
No.
Industries Ltd.
4 of 5
ďͿ>ŽĐĂƚŝŽŶǀŝĞǁĞĚĨƌŽŵ
ϲϱ͘ 'Ϯ
DŽƚŽƌ'Ϯ ϭ͘ϱϴƐƵŝƚĂďůĞĨŽƌ>ŽĂĚKĨϭϵ͘ϱϴ
<ŐŵϮ
>ŽĂĚ'Ϯ <ŐŵϮ ϭϵ͘ϱϴ
ϲϱ͘ >ŝĨƚŝŶŐĂƌƌĂŶŐĞŵĞŶƚ ǇĞŽůƚ
ϲϳ͘ EĞƚtĞŝŐŚƚŽĨDŽƚŽƌ ϮϱϮ
ϳϮ &Žƌs&ŽƉĞƌĂƚĞĚŵŽƚŽƌ
Sheet
No.
Industries Ltd.
5 of 5
Ă ^ƵŝƚĂďůĞĨŽƌŽƉĞƌĂƚŝŽŶŽŶ/'dĚƌŝǀĞ zĞƐͬEŽ zĞƐ


d,E/>^W/&/d/KE^&KZWZ^^hZ^t/d,^
hE/d^͗ &ůŽǁͲх >ŝƋƵŝĚͲ<ŐͬŚƌ 'ĂƐͲEŵϯͬŚƌ WƌĞƐƐƵƌĞͲхŬŐͬĐŵϮ dĞŵƉĞƌĂƚƵƌĞͲхĞŐ
ϭ dǇƉĞ͗^ĞĂůĚŝĂƉŚƌĂŐŵ͕ƉŝƐƚŽŶĂĐƚƵĂƚĞĚ ϭϯ ůĞŵĞŶƚŵĂƚů͗^^ϯϭϲ Zϭ
Ϯ DŽƵŶƚŝŶŐ͗ŝƌĞĐƚ͕dŽƉ tĞƚƚĞĚƉĂƌƚƐ͗^^ϯϭϲ Zϭ
ϯ ĂƐĞDĂƚů͗͘ŝĞĂƐƚůƵŵŝŶŝƵŵ ϭϰ ŝĨĨĞƌĞŶƚŝĂů͗&ŝǆĞĚ͕ŵŝŶŝŵƵŵ
ϰ ƌĞĂĐůĂƐƐŝĨŝĐĂƚŝŽŶ͗EŽŶͲ,ĂǌĂƌĚŽƵƐͬ^ĂĨĞ ϭϱ ŝĂƉŚĂƌŐŵ^ĞĂů͗E͘
ϱ ŶĐůŽƐƵƌĞ͗tWƚŽ/Wϲϱ ϭϲ WƌŽĐĞƐƐŽŶŶĞĐƚŝŽŶ͗ϭͬϰΗEWd;DͿ Zϭ
ϲ KƵƚƉƵƚ͗WŽƚĞŶƚŝĂůĨƌĞĞĐŽŶƚĂĐƚ ϭϳ ĐĐƵƌĂĐǇ͗нͬͲϭй&^
ϳ ŽŶƚĂĐƚƌĂƚŝŶŐ͗ϱŵƉ͘KĨϮϯϬs͕ϱϬ,ǌ ϭϴ KǀĞƌZĂŶŐĞWƌŽƚĞĐƚŝŽŶ͗ZĞƋƵŝƌĞĚ
ϴ ĂďůĞĞŶƚƌǇ͗ϭͬϮΗEWd;&Ϳ ϭϵ ůŽǁŽƵƚWƌŽƚĞĐƚŝŽŶ͗ZĞƋƵŝƌĞĚ
ϵ dǇƉĞŽĨƐǁŝƚĐŚ͗DŝĐƌŽƐǁŝƚĐŚ ϮϬ DĂŬĞ͗^ǁŝƚǌĞƌ Zϭ
ϭϬ EŽ͘ŽĨƐǁŝƚĐŚĞƐ͗ Ϯϭ DĂŶŝĨŽůĚ͗ϮtĂǇ;Ǉ&^Ϳ
ϮEŽƐ͘^Wd;ϭEKнϭEͿ
ϮϮ ^ĞƚƚĞƌ^ĐĂůĞ͗ůĂĐŬŐƌĂĚƵĂƚŝŽŶŽŶǁŚŝƚĞůŝŶĞƌƐĐĂůĞ͘
ϭϭ WƌŽĐĞƐƐĐŽŶŶĞĐƚŝŽŶ͗ϭͬϮΗEWd;DͿ 'ƌĂĚƵĂƚŝŽŶϬͲϭϬϬйǁŝƚŚƌĞĚƉŽŝŶƚĞƌĨŽƌƐĞƚƉŽŝŶƚƐ
ŽŶŶĞĐƚŝŽŶ>ŽĐĂƚŝŽŶ͗ŽƚƚŽŵ ZϮ
Ϯϯ ĂďůĞ'ůĂŶĚ͗EŝĐŬůĞWůĂƚĞĚƌĂƐƐ͕Ǉ&^
ϭϮ ^ĞƚƉŽŝŶƚĂĚũ͗dŚƌŽƵŐŚŽƵƚƌĂŶŐĞ
^ĞƚƉŽŝŶƚ ZĂŶŐĞ
KƉĞƌĂƚŝŶŐWƌĞƐƐƵƌĞ DĂǆ͘^ĞƌǀŝĐĞ
dĂŐEŽ ŬŐͬĐŵϮ;ŐͿͬ ŬŐͬĐŵϮͬ YdzEŽƐ ^ĞƌǀŝĐĞ DŽĚĞůEŽ;ZϭͿ dǇƉĞ;ZϭͿ
ŬŐͬĐŵϮ;ŐͿͬŵŵt dĞŵƉ͘Σ
ŵŵt ŵŵt
t,Z^Ͳ
DĂŝŶWŝƉĞZĂĐŬ DͲϲϬϭͲϯϱͲ^ϭͲ
YϮ,WͲ,''Ͳ ϭϮ<ŐͬĐŵϮ;ŐͿ ϭϬ͘Ϯ;&Ϳ ϰϬ ϭ͘ϲdKϭϲĂƌ ϭ ŝĂƉŚƌĂŐŵ
Kŝů/ŶůĞƚ ϯϯͲͲ
W^>ͲϬϬϭ
t,Z^Ͳ
DĂŝŶWŝƉĞZĂĐŬ DͲϲϬϭͲϯϱͲ^ϭͲ
YϮ,WͲ,''Ͳ ϭϬ<ŐͬĐŵϮ;ŐͿ ϭϮ;ZͿ ϰϬ ϭ͘ϲdKϭϲĂƌ ϭ ŝĂƉŚƌĂŐŵ
KŝůKƵƚůĞƚ ϯϯͲͲ
W^,ͲϬϬϮ
t,Z^Ͳ
DĂŝŶWŝƉĞZĂĐŬ DͲϲϬϭͲϯϯͲ^ϭͲ
YϮ,WͲ,''Ͳ ϰŬŐͬĐŵϮ;ŐͿ ϯ͘ϰ;&Ϳ ϰϬ ϭƚŽϭϬĂƌ ϭ ŝĂƉŚƌĂŐŵ
ƚŽŵ/ŶůĞƚ ϯϯͲͲ
W^>ͲϬϬϯ
t,Z^Ͳ
DĂŝŶWŝƉĞZĂĐŬ DͲϲϬϭͲϯϯͲ^ϭͲ
YϮ,WͲ,''Ͳ ϲ<ŐͬĐŵϮ;ŐͿ ϰ͘ϱ;&Ϳ ϰϬ ϭƚŽϭϬĂƌ ϭ ŝĂƉŚƌĂŐŵ
/ŶƐƚŝƌ/ŶůĞƚ ϯϯͲͲ
W^>ͲϬϬϰ
t,Z^Ͳ W^ϭͲtϭͲͲ
YϮ,WͲ,''Ͳ ϯϱϬŵŵtĐ ϮϱϬ;&Ϳ ϰϬ ϳ͘ϱƚŽϳϱŵĂƌ ϭ ŽŵďƵƐƚŝŽŶĂŝƌůŝŶĞ DϰϱͲ&ͲϱϱͲͲtͲ ŝĂƉŚƌĂŐŵ
W^>ͲϬϬϱ Ͳ
t,Z^Ͳ W^ϭͲtϭͲͲ
;ͲϱϬͿƚŽϱϬ
YϮ,WͲ,''Ͳ ;ͲͿϮϬƚŽϮϬŵŵtĐ ;ͲϮϬͿ;&Ϳ ϰϬ ϭ ŝůƵƚŝŽŶĂŝƌůŝŶĞ DϬϮͲ&ͲϱϱͲͲtͲ ŝĂƉŚƌĂŐŵ
ŵĂƌ
W^>ͲϬϬϲ Ͳ
EŽƚĞƐ
ϭͿEсEŽƚƉƉůŝĐĂďůĞ
^h/>d
WZK:d ϭyϲ͘ϴϱDtt,Z^WZK:d͘ KEK͘ d^WͲW^ͲϬϲ
Eh^Z WZ^<d/DEd/Eh^dZ/^>/D/d d Ϭϯ͘ϭϭ͘ϮϬϭϳ
&ŝǀĞƐŽŵďƵƐƚŝŽŶ^ǇƐƚĞŵƐ &^:KEϬ͘ ϮϬϭϳ͘ϯϲϭϬ ŚŬĞǇ͘ &:^
Wǀƚ͘>ƚĚ͘ ŚĂƉƚĞƌEŽ ϬϮͬϬϱ WWZz Ê
d,E/>^W/&/d/KE^&KZD^^&>KtDdZ
hE/d^͗ &ůŽǁͲх>ŝƋƵŝĚͲ<ŐͬŚƌ'ĂƐͲEŵϯͬŚƌ WƌĞƐƐƵƌĞͲхDDtͬŬŐͬĐŵϮ dĞŵƉĞƌĂƚƵƌĞͲхΣ
ϭͿdĂŐEŽ͘ t,Z^ͲYϮ,WͲ,''Ͳ&DͲϬϬϭ
ϮͿYƚǇƌĞƋƵŝƌĞĚ ϭEŽ
'ĞŶĞƌĂů ϯͿƵƚǇ ŽŶƚŝŶƵŽƵƐ
ϰͿ^ĞƌǀŝĐĞ &ůŽǁDĞĂƐƵƌĞŵĞŶƚ
ϱͿ>ŝŶĞƐŝǌĞ KƵƚůĞƚ>ŝŶĞ ϭϱE͕^ĐŚϰϬ ϭϱE͕^ĐŚϰϬ
ϳͿdǇƉĞŽĨ&ůŽǁDĞƚĞƌ ŽƌŝŽůŝƐƚǇƉĞ͕DĂƐƐĨůŽǁŵĞƚĞƌ
ϴͿ&ůŽǁDĂǆŝŵƵŵ ϮϱϬŬŐƐͬŚƌ
ϵͿ&ůŽǁDŝŶŝŵƵŵ ϴϬŬŐƐͬŚƌ
ϭϬͿ/ŶůĞƚWƌĞƐƐƵƌĞ ϭϮŬŐͬĐŵϮ ;ŐͿ
ϭϭͿůůŽǁĂďůĞĞůƚĂW ĂůĐƵůĂƚĞĚĞůƚĂW Ϭ͘ϱ<ŐͬŵϮ sd^
^Zs/ ϭϮͿ&ůŽǁŝŶŐDĞĚŝĂ >Kͬ,^
d ϭϯͿĞŶƐŝƚǇŽĨ&ƵĞů ϴϴϬŬŐͬŵϯ
ϭϰͿsŝƐĐŽƐŝƚǇ Ϯ͘ϱʹϭϱ͘ϳ^dΛϰϬĞŐ
ϭϱͿKƉĞƌĂƚŝŶŐdĞŵƉĞƌĂƚƵƌĞͬĞƐŝŐŶ ϰϱΣ ϱϬΣ
ϭϲͿ^'ͬDŽůtƚ͘
ϭϳͿĂůŝďƌĂƚŝŽŶƌĂŶŐĞ ϰŵсϬŬŐͬŚƌ
ϭϴͿ ϮϬŵсϯϳϱ<ŐͬŚƌ
ϮϭͿZĂŶŐĞŽĨDĞƚĞƌ ϬͲϴϭϲϬ<ŐͬŚƌ Zϭ
ϮϮͿdƌĂŶƐŵŝƚƚĞƌ ZĞƋƵŝƌĞĚ
ϮϯͿŶĚĐŽŶŶĞĐƚŝŽŶ &ůĂŶŐĞŶĚ͕ϯϬϬη͕Z&;^Dϭϲ͘ϱͿ Zϭ
ϮϰͿ^ŝǌĞŽĨŵĞƚĞƌ ϭͬϮ/ŶĐŚ
ϮϱͿDK
^ĞŶƐŽƌ tĞƚƚĞĚWĂƌƚƐ͗^^ϯϭϲŽƌďĞƚƚĞƌ
^ĞŶƐŽƌŚŽƵƐŝŶŐ tĞĂƚŚĞƌWƌŽŽĨ/Wϲϱ
ϮϲͿDĞƚĞƌĂĐĐƵƌĂĐǇ нϬ͘ϱйŽĨŵĞĂƐƵƌĞĚǀĂůƵĞ
ϮϳͿsŽůƵŵĞĐĐƵƌĂĐǇ Ͳ
ϮϴͿDĂŬĞ ŵĞƌƐŽŶ Zϭ
&>KtDdZ
ϮϵͿDŽĚĞůEŽ͘ ZϬϮϱ^ϭϭϰz Zϭ
d
ϯϬͿsĞŶĚŽƌƌĂǁŝŶŐEŽ͘ ƐƉĞƌǀĞŶĚŽƌĐĂƚĂůŽŐ
ϯϭͿDĞƚĞƌDŽƵŶƚŝŶŐ ŝƌĞĐƚĨŝĞůĚDŽƵŶƚĞĚ
ϯϮͿKƵƚƉƵƚ ϰͲϮϬŵǁŝƚŚ,ZdWƌŽƚŽĐŽů
ϯϯͿWŽǁĞƌ^ƵƉƉůǇ ϮϮϬs͕ϱϬ,ǌ
ϯϰͿŶĐůŽƐƵƌĞ tĞĂƚŚĞƌWƌŽŽĨ/Wϲϱ
ϯϱͿdƌĂŶƐŵŝƚƚĞƌDŽĚĞů ϭϳϬϬ/ϭϮ& Zϭ
ϯϲͿĂďůĞĞŶƚƌǇ ϭͬϮΗEWdĨŽƌƉŽǁĞƌĐĂďůĞΘϭͬϮΗEWdĨŽƌƐŝŐŶĂůĐĂďůĞ
ϯϳͿŝŐŝƚĂů/ŶĚŝĐĂƚŽƌ >ŽĐĂůĚŝŐŝƚĂůŝŶĚŝĐĂƚŽƌƚŽďĞƉƌŽǀŝĚĞĚ
ϯϴͿWĂŝŶƚŝŶŐ sĞŶĚŽƌƐ^ƚĂŶĚĂƌĚ
NOTES:
ϭͿ^^ƚĂŐƉůĂƚĞƚŽďĞƉƌŽǀŝĚĞ
ϮͿZĞƉĞĂƚĂďŝůŝƚǇ͗нϬ͘Ϭϱй
AS BUILT
WZK:d ϭyϲ͘ϴϱDtt,Z^WZK:d͘ KEK͘ d^WͲ&DͲϬϳ
Wǀƚ͘>ƚĚ͘ ,WdZ ϬϮ WWZz Ê
d,E/>^W/&/d/KE^&KZWZ^^hZdZE^D/ddZ
hŶŝƚƐ͗ &ůŽǁͲх >ŝƋƵŝĚͲ<ŐͬŚƌ 'ĂƐͲEŵϯͬŚƌ WƌĞƐƐƵƌĞͲхŬŐͬĐŵϮ dĞŵƉĞƌĂƚƵƌĞͲхĞŐ
ϭ &ƵŶĐƚŝŽŶ͗dƌĂŶƐŵŝƚ ϭϮ KƵƚƉƵƚ͗ϰͲϮϬŵǁŝƚŚĚŝŐŝƚĂůƐŝŐŶĂů
ĂƐĞĚŽŶ,ZdƉƌŽƚŽĐŽů
Ϯ dǇƉĞ͗ϮͲtŝƌĞ^ŵĂƌƚ
ϭϯ ŝƐƉůĂǇ͗>
ϯ ĂƐĞ͗ŝĞĂƐƚůƵŵŝŶŝƵŵ
ϭϰ ůĞŵĞŶƚ͗ŝĂƉŚƌĂŐŵ
ϰ DŽƵŶƚŝŶŐ͗ϮΗƉŝƉĞǁŝƚŚĐĐĞƐƐŽƌŝĞƐ
ϭϱ ůĞŵĞŶƚDĂƚĞƌŝĂů͗^^ϯϭϲ
ϱ ŶĐůŽƐƵƌĞ͗^ĂĨĞ
ϭϲ tĞƚƚĞĚWĂƌƚƐDĂƚů͗ϯϭϲ>^^d
ϲ ůĞĐ͘ƌĞĂůĂƐƐ͗tWƚŽ/Wϲϱ
ϭϳ WƌŽĐĞƐƐŽŶŶĞĐƚŝŽŶ͗ϭͬϮΗEWd^ƵŝƚĂďůĞƚŽΗdΗƚǇƉĞDĂŶŝĨŽůĚ
ϳ /ŶƚƌŝŶƐŝĐĂůůǇ^ĂĨĞ͗E WƌŽĐĞƐƐŽŶŶ͘>ŽĐŶ͗ŽƚƚŽŵ
ϴ ŝƌ^ƵƉƉůǇ͗E
ϭϴ ŝĂƉŚƌĂŐŵ^ĞĂů͗E
ϵ WŽǁĞƌ^ƵƉƉůǇ͗>ŽŽƉWŽǁĞƌĞĚ;Ϯϰs͕ϮǁŝƌĞdǇƉĞͿ
ϭϵ KǀĞƌWƌĞƐƐƵƌĞ>ŝŵŝƚ͗ϭϯϬйŽĨŵĂǆ͘ƐƉĂŶ
ϭϬ ĂďůĞŶƚƌǇ͗ϭͬϮΗEWd;&Ϳ
ϮϬ KƉƚŝŽŶƐ͗
ϭϭ ĐĐƵƌĂĐǇ͗фсϬ͘ϬϳϱйŽĨĐĂůŝďƌĂƚĞĚƐƉĂŶ Zϭ ϯͲsĂůǀĞDĂŶŝĨŽůĚ͗zĞƐΗdΗdǇƉĞ;Ǉ&^Ϳ
ZĞƉĞĂƚĂďŝůŝƚǇ͗цϬ͘ϬϱйŽĨƐƉĂŶŽƌďĞƚƚĞƌ

KƉĞƌĂƚŝŶŐ ĂůŝďƌĂƚŝŽŶ dƌĂŶƐŵŝƚƚĞƌ KƉĞƌĂƚŝŶŐ
dĂŐEŽ͘ YƚǇ͘ WƌĞƐƐƵƌĞ ZĂŶŐĞ ZĂŶŐĞ dĞŵƉĞƌĂƚƵƌĞ ^ĞƌǀŝĐĞ DŽĚĞůEŽ͘;ZϭͿ ZĞŵĂƌŬƐ
ŵŵt;ŐͿ ŵŵt;ŐͿ ŵŵt;ŐͿ Σ
t,Z^ͲYϮ,WͲ hZEZ/E>d ϳD&ϰϰϯϯͲϭϬϮͲϭϳͲ
ϭ ;ͲϱϱͿƚŽϱϬ ;ͲϱϱͿƚŽϱϬ ϭϬƚŽϮϬϬŵŵt ϰϬ
,''ͲWdͲϬϬϭ WZ^^hZdZy͘ ϬϭнϭϭнzϬϭнzϮϭ
t,Z^ͲYϮ,WͲ ,''/E>d ϳD&ϰϰϯϯͲϭϬϮͲϭϳͲ

ϭ ;ͲϱϱͿƚŽϱϬ ;ͲϱϱͿƚŽϱϬ ϭϬƚŽϮϬϬŵŵt ϰϬ
,''ͲWdͲϬϬϮ WZ^^hZdZy͘ ϬϭнϭϭнzϬϭнzϮϭ
t,Z^ͲYϮ,WͲ KD͘/Z>/E ϳD&ϰϰϯϯͲϭϬϮͲϭϳͲ

ϭ ϬͲϯϱϬ ϬͲϱϬϬ ϭϬƚŽϲϬϬŵŵt ϰϬ
,''ͲWdͲϬϬϯ WZ^^hZdZy͘ ϬϭнϭϭнzϬϭнzϮϭ
EKd^͗
ϮͿDĂŬĞ͗^ŝĞŵĞŶƐ Zϭ
^h/>d
WZK:d ϭyϲ͘ϴϱDtt,Z^WZK:d͘ KEK͘ d^WͲWdͲϬϴ
Eh^Z WZ^<d/DEd/Eh^dZ/^>/D/d d ϯϭ͘ϭϬ͘ϮϬϭϳ
&ŝǀĞƐŽŵďƵƐƚŝŽŶ^ǇƐƚĞŵƐWǀƚ͘>ƚĚ͘ ,WdZ ϬϭͬϬϱ WWZz Ê
WZK:d ϭyϲ͘ϴϱDtt,Z^WZK:d͘ KEK͘ d^WͲ&^ͲϬϵ
WhZ,^Z ƚŚǇƐƐĞŶŬƌƵƉƉ/ŶĚƵƐƚƌŝĞƐ/ŶĚŝĂWǀƚ͘>ƚĚ͘ ZsEK͘ Ϭ
Eh^Z WZ^<d/DEd/Eh^dZ/^>/D/d d Ϯϵ͘Ϭϴ͘ϮϬϭϳ
&^:KEϬ͘ ϮϬϭϳ͘ϯϲϭϬ W'EK͘ ϭK&ϭ
&ŝǀĞƐŽŵďƵƐƚŝŽŶ^ǇƐƚĞŵƐ
Wǀƚ͘>ƚĚ͘
d,E/>^W/&/d/KEK&&>DÊEZ
^ƌ͘EŽ ^ƉĞĐŝĨŝĐĂƚŝŽŶ ZĞǀ ZĞŵĂƌŬƐ
t,Z^ͲYϮ,WͲ&^ͲϬϭͬt,Z^ͲYϮ,WͲ&^Ͳ
ϭ dĂŐEŽ͘
ϬϮ
Ϯ YƚǇ͘ ϬϮEŽƐ
ϯ DĂŬĞ &ŝǀĞƐWŝůůĂƌĚ
ϰ dǇƉĞŽĨ&ƵĞů >Kͬ,^
ϱ dǇƉĞŽĨ^ĐĂŶŶĞƌ ^ĂĨǇƌWĂĐŬƐĐĂŶ
ϲ ůĞĐƚƌŝĐĂůĐůĂƐƐŝĨŝĐĂƚŝŽŶ /WͲϲϱEŽŶͲ&ůĂŵĞƉƌŽŽĨ
ϳ DŽĚĞů ^ϱϭϬͲϲϳ
ϴ DĞĂƐƵƌŝŶŐWƌŝŶĐŝƉůĞ &ůĂŵĞ&ƌĞƋƵĞŶĐǇ
ϵ >ŽĐĂƚŝŽŶ ^ĂĨĞ
ϭϬ DŽƵŶƚŝŶŐĐŽŶŶĞĐƚŝŽŶ
ϭϬ͘ϭ ŽŶŶĞĐƚŝŽŶǁŝƚŚďƵƌŶĞƌ &ůĂŶŐĞŽŶŶĞĐƚŝŽŶ
ϭϬ͘Ϯ ŽŽůŝŶŐĂŶĚǀĞŶƚŝŶŐŝƌŽŶŶĞĐƚŝŽŶ͘ ϯͬϴΗEWd;&Ϳ
ϭϭ ŽŽůŝŶŐĂŶĚǀĞŶƚŝŶŐŝƌ ŽŵƉƌĞƐƐĞĚŝƌ
ϭϭ͘ϭ DŝŶ͘&ůŽǁ ϱEŵϯͬ,ƌ;ǀĞŶƚŝŶŐĂŝƌƐĞĂůƌĞƋƵŝƌĞĚͿ
ϭϭ͘Ϯ DŝŶ͘WƌĞƐƐƵƌĞ ϲŬŐͬĐŵϮ;ĂĚũƵƐƚĂďůĞͿ

ϭϮ WŽǁĞƌƐƵƉƉůǇ ϮϰsͲϭϱйͬнϭϬй
ϭϯ ^ĞŶƐŝŶŐZĂŶŐĞͬŶŐůĞ ϭϴϱŶŵͬϭϱΣ
ϭϰ ,ŽƵƐŝŶŐŵĂƚĞƌŝĂů ůƵŵŝŶƵŵ
ϭϱ dĞŵƉĞƌĂƚƵƌĞƌĂŶŐĞ ͲϮϬΣƚŽнϳϬΣ
ϭϲ WŽǁĞƌƌĞƋƵŝƌĞŵĞŶƚ ϭϬsĂƉƉƌŽǆ͘
ϭϳ &ůĂŵĞƌĞůĂǇĐŽŶƚĂĐƚ ϭEKнϭEĐŽŶƚĂĐƚ͕ZdϮϱϬsͲϮ
ϭϴ &ĂƵůƚƌĞůĂǇĐŽŶƚĂĐƚ ϭEKнϭEĐŽŶƚĂĐƚ͕ZdϮϱϬsͲϮ
ϭϵ &ůĂŵĞƐŝŐŶĂů ϰͲϮϬŵ͕ϯϬϬŽŚŵƐ;ŵĂǆͿ
ϮϬ ŽŵŵƵŶŝĐĂƚŝŽŶWŽƌƚ Z^ϰϴϱ
Ϯϭ ^ŝǌĞͬtĞŝŐŚƚ ϯϲϬǆϭϯϬŵŵͬϰ͘ϴŬŐ
/WĐĞƌƚŝĨŝĐĂƚĞƌĞƋƵŝƌĞĚ͘KƚŚĞƌĂƐƉĞƌ
ϮϮ ƉƉƌŽǀĂůƐ
sĞŶĚŽƌ^ƚĚ͘
Ϯ͘ϱŵƚƌƐ
Ϯϯ ĐĐĞƐƐŽƌŝĞƐ
^ƚĚ͘^ĐĂŶŶĞƌĐĂďůĞ;ϭϬ͘ϱŵŵKͿ
Ϯϰ ZĞŵŽƚĞŽŶƚƌŽů ZĞƋƵŝƌĞĚ
Ϯϱ ZĞŵŽƚĞŽŶƚƌŽůYƚǇ ϭEŽ
Ϯϲ ^ǁŝǀĞůŵŽƵŶƚƐƐĞŵďůǇ ^ǁŝǀĞůDŽƵŶƚĂƐƐĞŵďůǇ;ďǇ&^Ϳ
Ϯϳ &sĞƌƐŝŽŶĂďůĞ'ůĂŶĚ E
^h/>d
Ϭ Ϯϵ͘Ϭϴ͘ϮϬϭϲ &ŝƌƐƚ/ƐƐƵĞ &:^ &:^ Ê

ZĞǀ͘EŽ ĂƚĞ ZĞǀŝƐŽŶĞƐĐƌŝƉƚŝŽŶ Ǉ͘ ŚŬĞǇ͘ ƉƉĚǇ͘
d,E/>^W/&/d/KE^&KZZdt/d,d,ZDKt>>
ϯ
Zd ϭϮ͘^ŚĞĂƚŚDĂƚĞƌŝĂů͗^^ϯϭϲ
ϭ͘dǇƉĞ͗WdͲϭϬϬ;ϯtŝƌĞͿ ϭϯ͘ĐĐƵƌĂĐǇ͗ůĂƐƐ Zϭ
Ϯ͘EŽ͘ŽĨůĞŵĞŶƚƐ͗ƵƉůĞǆ ϭϰ͘^ŚĞĂƚŚK͗ϴŵŵ
ϯ͘ĂůŝďƌĂƚŝŽŶ^ƚĚ͗/EϰϯϳϲϬ ϭϱ͘^ŚĞĂƚŚ/͗E
ϰ͘/ŶƐƵůĂƚŝŽŶ͗ŽŵƉĂĐƚŵĂƐƐŽĨDŐŽ;WƵƌŝƚǇĂďŽǀĞϵϵ͘ϰйͿ d,ZDKt>>

ϱ͘WƌŽĐĞƐƐŽŶŶĞĐƚŝŽŶ͗ϭͬϮΗEWd;DͿ Zϭ ϭϲ͘ŽŶƐƚƌƵĐƚŝŽŶ͗&ĂďƌŝĐĂƚĞĚ
ϲ͘ŶĐůŽƐƵƌĞ͗tĞĂƚŚĞƌƉƌŽŽĨƚŽ/Wϲϱ ϭϳ͘tĞůůŵĂƚĞƌŝĂů͗^^ϯϭϲ
ϳ͘,ĞĂĚ͗ŝĞĂƐƚůƵŵŝŶŝƵŵ ϭϴ͘K͗Ϯϭ͘ϯŵŵ Zϭ
ϴ͘:ƵŶĐƚŝŽŶdǇƉĞ͗hŶŐƌŽƵŶĚĞĚ ϭϵ͘/͗ϭϯ͘ϴϴŵŵ Zϭ
ϵ͘,ĞĂĚĂƐƐůǇ͗^ƉƌŝŶŐ>ŽĂĚĞĚǁŝƚŚ^ĐƌĞǁĞĚĂƉΘ^^ĐŚĂŝŶ ϮϬ͘/ŶƐƚƌƵŵĞŶƚŽŶŶ͗͘ϭͬϮΗEWd;&Ϳ Zϭ
ϭϬ͘dĞƌŵŝŶĂů͗ͲEŝĐŬĞůƉůĂƚĞĚƌĂƐƐ;^ƉƌŝŶŐůŽĂĚĞĚͿ Ϯϭ͘WƌŽĐĞƐƐŽŶŶĞĐƚŝŽŶ͗DϯϯyϮ;DͿ
ϭϭ͘EŽ͘ŽĨŶƚƌŝĞƐ͗ϮEŽƐ;ϭWůƵŐŐĞĚ͕ϭͬϮΗEWdͿ ϮϮ͘tĞůůŝŶƐĞƌƚŝŽŶůĞŶŐƚŚ͗сZĞĨĞƌdĂďůĞ
Ϯϯ͘dŽƚĂůůĞŶŐƚŚсZĞĨĞƌdĂďůĞ
Ϯϰ͘DĂŬĞ͗'/ Zϭ
DĂǆ͘^ĞƌǀŝĐĞ
DĂǆ͘^ĞƌǀŝĐĞ tĞůů/ŶƐĞƌƚŝŽŶ dŽƚĂů>ĞŶŐƚŚ
dĂŐEŽ͘ YƚǇ͘ WƌĞƐƐƵƌĞ ^ĞƌǀŝĐĞ DŽĚĞůEŽ͘ ZĞŵĂƌŬ
dĞŵƉ͘Σ >ĞŶŐƚŚ;hͿŵŵ ŵŵ;ZϭͿ
ŵŵt
t,Z^ͲYϮ,WͲ,''Ͳ
ϭEŽ ϯϬϮ ;ͲϮϬͿƚŽϮϬ ŝůƵƚŝŽŶĂŝƌůŝŶĞ ϭϰϬϬ ϭϱϭϬ E
dͲϬϬϮ
EŽƚĞ͗
ϭͿZdƐŚĂůůďĞƐƵƉƉůŝĞĚĂƐĂŶĂƐƐĞŵďůǇĐŽŵƉůĞƚĞǁŝƚŚƚŚĞƌŵŽǁĞůůƐ
ϮͿ'ƌĂǁŝŶŐƐŚŽƵůĚďĞƐƵďŵŝƚƚĞĚǁŝƚŚŝŶŽŶĞtĞĞŬĂĨƚĞƌWKWůĂĐĞŵĞŶƚ
ϯͿZĞƐƉŽŶƐĞdŝŵĞфϭϬ^ĞĐƐ
ϰͿ^^dĂŐĞƉůĂƚĞZĞƋƵŝƌĞĚ
^h/>d
WZK:d ϭyϲ͘ϴϱDtt,Z^WZK:d͘ KEK͘ d^WͲdͲϭϭ
&ŝǀĞƐŽŵďƵƐƚŝŽŶ^ǇƐƚĞŵƐWǀƚ͘>ƚĚ͘ ,WdZ WWZz Ê
d,E/>^W/&/d/KE^&KZd,ZDKKhW>t/d,d,ZDKt>>
hE/d^͗ &ůŽǁͲх >ŝƋƵŝĚͲ<ŐͬŚƌ 'ĂƐͲEŵϯͬŚƌ WƌĞƐƐƵƌĞͲхŬŐͬĐŵϮ dĞŵƉĞƌĂƚƵƌĞͲхĞŐ
ϭ͘dǇƉĞ͗Η<ΗdǇƉĞ ϭϯ͘ĐĐƵƌĂĐǇ͗ůĂƐƐͲ// Zϭ
ϯ͘ĂůŝďƌĂƚŝŽŶ^ƚĚ͗E^/ͲDϵϲ͘ϭ͘ ϭϱ͘^ŚĞĂƚŚ/͗E

ϱ͘WƌŽĐĞƐƐŽŶŶĞĐƚŝŽŶ͗ϭͬϮΗEWd;DͿ ϭϲ͘ŽŶƐƚƌƵĐƚŝŽŶ͗&ĂďƌŝĐĂƚĞĚ
ϲ͘ŶĐůŽƐƵƌĞ͗tĞĂƚŚĞƌƉƌŽŽĨƚŽ/Wϲϱ ϭϳ͘tĞůůŵĂƚĞƌŝĂů͗^^ϯϭϲ
ϵ͘,ĞĂĚĂƐƐůǇ͗^ƉƌŝŶŐ>ŽĂĚĞĚǁŝƚŚ^ĐƌĞǁĞĚĂƉΘ^^ĐŚĂŝŶ ϮϬ͘/ŶƐƚƌƵŵĞŶƚŽŶŶ͗͘ϭͬϮΗEWd;&Ϳ
ϭϬ͘dĞƌŵŝŶĂů͗ͲEŝĐŬĞůƉůĂƚĞĚƌĂƐƐ;^ƉƌŝŶŐůŽĂĚĞĚͿ Ϯϭ͘WƌŽĐĞƐƐŽŶŶĞĐƚŝŽŶ͗ϭϭͬϮΗ&ůĂŶŐĞĚ
DĂǆ͘^ĞƌǀŝĐĞ tĞůů/ŶƐĞƌƚŝŽŶ dŽƚĂů>ĞŶŐƚŚ
dĂŐEŽ͘ YƚǇ͘ WƌĞƐƐƵƌĞ ^ĞƌǀŝĐĞ DŽĚĞůEŽ͘ ZĞŵĂƌŬ
dĞŵƉ͘Σ >ĞŶŐƚŚ;hͿŵŵ ŵŵ;ZϭͿ
ŵŵt
t,Z^ͲYϮ,WͲ,''Ͳ
dͲϬϬϲͬt,Z^Ͳ
YϮ,WͲ,''ͲdͲ ϯEŽƐ ϰϱϬ ;ͲͿϰϬ ,''KƵƚůĞƚ ϭϱϭϬ ϭϲϭϬ E
ϬϬϳͬt,Z^ͲYϮ,WͲ
,''ͲdͲϬϬϴ
t,Z^ͲYϮ,WͲ,''Ͳ
dͲϬϬϯͬt,Z^Ͳ
YϮ,WͲ,''ͲdͲ ϯEŽƐ ϰϱϬ ;ͲͿϰϬ t,Z^/ŶůĞƚ ϭϲϬϬ ϭϳϬϬ E
ϬϬϰͬt,Z^ͲYϮ,WͲ
,''ͲdͲϬϬϱ
EŽƚĞ͗
ϭͿdƐŚĂůůďĞƐƵƉƉůŝĞĚĂƐĂŶĂƐƐĞŵďůǇĐŽŵƉůĞƚĞǁŝƚŚƚŚĞƌŵŽǁĞůůƐ
ϰͿtŝƌĞ'ĂƵŐĞ͗ϭϳt'ĨŽƌdǇƉĞΗ<Η Zϭ
ϱͿ^^dĂŐĞƉůĂƚĞZĞƋƵŝƌĞĚ

d,E/>^W/&/d/KE^&KZd,ZDKKhW>t/d,d,ZDKt>>
ϯ
ϭ͘dǇƉĞ͗ΗZΗdzW ϭϯ͘ĐĐƵƌĂĐǇ͗ůĂƐƐͲ// Zϭ
ϯ͘ĂůŝďƌĂƚŝŽŶ^ƚĚ͗E^/ͲDϵϲ͘ϭ͘ ϭϱ͘^ŚĞĂƚŚ/͗E

ϱ͘WƌŽĐĞƐƐŽŶŶĞĐƚŝŽŶ͗ϭͬϮΗEWd;DͿ ϭϲ͘ŽŶƐƚƌƵĐƚŝŽŶ͗&ĂďƌŝĐĂƚĞĚ
ϲ͘ŶĐůŽƐƵƌĞ͗tĞĂƚŚĞƌƉƌŽŽĨƚŽ/Wϲϱ ϭϳ͘tĞůůŵĂƚĞƌŝĂů͗ƌĞĨĞƌƌĞŵĂƌŬƐ
ϵ͘,ĞĂĚĂƐƐůǇ͗^ƉƌŝŶŐ>ŽĂĚĞĚǁŝƚŚ^ĐƌĞǁĞĚĂƉΘ^^ĐŚĂŝŶ ϮϬ͘/ŶƐƚƌƵŵĞŶƚŽŶŶ͗͘ϭͬϮΗEWd;&Ϳ
ϭϬ͘dĞƌŵŝŶĂů͗ͲEŝĐŬĞůƉůĂƚĞĚƌĂƐƐ;^ƉƌŝŶŐůŽĂĚĞĚͿ Ϯϭ͘WƌŽĐĞƐƐŽŶŶĞĐƚŝŽŶ͗ϭϭͬϮΗ&ůĂŶŐĞĚ
DĂǆ͘^ĞƌǀŝĐĞ tĞůů/ŶƐĞƌƚŝŽŶ
dĂŐEŽ͘ YƚǇ͘ WƌĞƐƐƵƌĞ ^ĞƌǀŝĐĞ dŽƚĂů>ĞŶŐƚŚ DŽĚĞůEŽ͘ ZĞŵĂƌŬ
dĞŵƉ͘Σ >ĞŶŐƚŚ;hͿŵŵ
ŵŵt
t,Z^ͲYϮ,WͲ,''Ͳ
ϭEŽ ϭϬϬϬ ;ͲͿϮϬ ,''ŚĂŵďĞƌ ϲϱϬ ϳϱϬ E ZĞĨĞƌEŽƚĞͲϰ
dͲϬϬϵ
t,Z^ͲYϮ,WͲ,''Ͳ
ϭEŽ ϵϬϬ ;ͲͿϮϬ ,''ZĞĨĞĐƚŽƌǇ ϰϵϬ ϱϵϬ sd^ ZĞĨĞƌEŽƚĞͲϱ
dͲϬϭϬ
EŽƚĞ͗
ϭͿdƐŚĂůůďĞƐƵƉƉůŝĞĚĂƐĂŶĂƐƐĞŵďůǇĐŽŵƉůĞƚĞǁŝƚŚƚŚĞƌŵŽǁĞůůƐ
ϰͿWůĞĂƐĞĐŽŶƐŝĚĞƌĞĚϰϱϬŵŵŽĨ/ŶĐŽŶĞůϲϬϬĂŶĚƌĞƐƚŽĨ^^ϯϭϲ
ϱͿWůĞĂƐĞĐŽŶƐŝĚĞƌĞĚϭϵϬŵŵŽĨ/ŶĐŽŶĞůϲϬϬĂŶĚƌĞƐƚŽĨ^^ϯϭϲ
ϲͿ^^dĂŐWůĂƚĞZĞƋƵŝƌĞĚ

d,E/>^W/&/d/KE^&KZdDWZdhZdZE^D/ddZ
hE/d^͗ &ůŽǁͲх 'ĂƐͲ WƌĞƐƐƵƌĞͲхŵŵǁĐͬŬŐͬĐŵϮ dĞŵƉĞƌĂƚƵƌĞͲхΣ
ϭ͘&ƵŶĐƚŝŽŶ͗dƌĂŶƐŵŝƚ ϭϭ͘ZĞƉĞĂƚĂďŝůŝƚǇ͗E
Ϯ͘dǇƉĞ͗ϮͲtŝƌĞ^ŵĂƌƚƚǇƉĞ ϭϮ͘KƵƚƉƵƚ͗ϰͲϮϬŵǁŝƚŚ,ĂƌƚWƌŽƚŽĐŽů
ϯ͘ĂƐĞ͗ŝĞĂƐƚůƵŵŝŶŝƵŵ ϭϯ͘^ĞƌǀŝĐĞ͗ZĞĨĞƌdĂďůĞ
ϰ͘DŽƵŶƚŝŶŐ͗ϮΗƉŝƉĞǁŝƚŚĐĐĞƐƐŽƌŝĞƐ ϭϰ͘/ŶƉƵƚdǇƉĞ͗ZĞĨĞƌdĂďůĞ
ϱ͘ŶĐůŽƐƵƌĞ͗^ĂĨĞ ϭϱ͘ĐĐĞƐƐŽƌŝĞƐ͗ϮŝŶĐŚŚŽƌŝǌŽŶƚĂůƉŝƉĞŵŽƵŶƚŝŶŐďƌĂĐŬĞƚ
ϲ͘ƌĞĂĐůĂƐƐŝĨŝĐĂƚŝŽŶ͗tWƚŽ/Wϲϱ ϭϲ͘tŝƌĞďƌĞĂŬDŽŶŝƚŽƌŝŶŐ͗z^

ϳ͘ŝƌ^ƵƉƉůǇ͗E͘͘ ϭϳ͘ŝƐƉůĂǇ͗>
ϴ͘WŽǁĞƌƐƵƉƉůǇ͗Ϯϰs;ϮǁŝƌĞ͕>ŽŽƉWŽǁĞƌͿ ϭϴ͘ŽůĚ:ƵŶĐƚŝŽŶŽŵƉĞŶƐĂƚŝŽŶ͗ƵŝůƚͲŝŶ
ϵ͘ĂďůĞĞŶƚƌǇ͗ϭͬϮΗEWd;&Ϳ ϭϵ͘DŽĚĞůEŽ͗͘ϳE'ϯϭϯϲͲϬϭϭͲhϬϯнzϬϭ Zϭ
ϭϬ͘ĐĐƵƌĂĐǇ͗нͬͲϬ͘ϮйŽĨƐƉĂŶ
ĂůŝďƌĂƚŝŽŶ YƚǇ͘ dƌĂŶƐŵŝƚƚĞƌ

dĂŐEŽ͘ ^ĞƌǀŝĐĞƚĞŵƉ;ΣͿ ^ĞƌǀŝĐĞ /ŶƉƵƚƚǇƉĞ
ZĂŶŐĞΣ ;/ŶEŽƐͿ ZĂŶŐĞΣ
t,Z^ͲYϮ,WͲ,''ͲddͲ Zd ^ĂŵĞĂƐŝŶƉƵƚ
ϬͲϯϱϬ ϭ ϯϭϬ ŝůƵƚŝŽŶĂŝƌůŝŶĞ
ϬϬϮ ;WdͲϭϬϬͿ ƌĂŶŐĞ
t,Z^ͲYϮ,WͲ,''ͲddͲ ^ĂŵĞĂƐŝŶƉƵƚ
ϬͲϱϬϬ ϯ ϰϱϬ ,''KƵƚůĞƚ Η<ΗdǇƉĞd
ϬϬϮͬϬϬϯͬϬϬϰ ƌĂŶŐĞ
t,Z^ͲYϮ,WͲ,''ͲddͲ ^ĂŵĞĂƐŝŶƉƵƚ
ϬͲϱϬϬ ϯ ϰϱϬ t,Z^ŝŶůĞƚ Η<ΗdǇƉĞd
ϬϬϱͬϬϬϲͬϬϬϳ ƌĂŶŐĞ
EKd^
ϮͿDĂŬĞ͗^ŝĞŵĞŶƐ Zϭ
^h/>d
WZK:d ϭyϲ͘ϴϱDtt,Z^WZK:d͘ KEK͘ d^WͲddͲϭϮ
Wǀƚ͘>ƚĚ͘ ,WdZ Ϭϭ WWZz Ê
ZĞǀ͘
ĞƐĐƌŝƉƚŝŽŶ d^WK&EEhZ&KZKDh^d/KE/Z>/E
ĞƚĂŝů
ϭͿdĂŐEŽ͘ t,Z^ͲYϮ,WͲ,''Ͳ&ͲϬϬϭ
ϮͿYƚǇƌĞƋƵŝƌĞĚ ϭEŽ͘
'ĞŶĞƌĂů ϯͿDĂŬĞ DŽĚĞůEŽ͘ ^ǁŝƚǌĞƌ ϯϰϭͲ^ͲϵϬͲ, Zϭ
ϰͿ^ĞƌǀŝĐĞ ŽŵďƵƐƚŝŽŶĂŝƌ&ůŽǁŵĞĂƐƵƌĞŵĞŶƚ
ϱͿƵƚǇ ŽŶƚŝŶƵŽƵƐ
ϲͿ
ϳͿdǇƉĞ &ůĂŶŐĞĚdǇƉĞ
ϴͿKƉĞƌĂƚŝŶŐdĞŵƉ͘ DĂǆ KƉĞƌĂƚŝŶŐ ϱϬΣ ϰϬΣ
ϵͿ'ĂƐ^ƉĞĐŝĨŝĐ'ƌĂǀŝƚǇ ϭ
ϭϬͿ'ĂƐDŽůĞĐƵůĂƌǁĞŝŐŚƚ Ϯϴ͘ϵϲ
WƌŽĐĞƐƐ ϭϭͿ&ůŽǁƌĂƚĞŵĂǆŝŵƵŵĚĞƐŝŐŶ ϭϳϭϬϬ<ŐͬŚƌ
ĂƚĂ ϭϮͿ&ůŽǁƌĂƚĞŵŝŶŝŵƵŵ ϱϳϬϬEŵϯͬŚƌ
ϭϯͿĞŶƐŝƚǇĂƚĨůŽǁŬŐƐͬŵϯ ϭ͘ϮϵΛEdW
ϭϰͿ&ůŽǁƉƌĞƐƐƵƌĞ ϯϱϬŵŵt
ϭϱͿ^ƉĞĐŝĨŝĐŚĞĂƚƌĂƚŝŽƉͬǀ ϭ͘ϰ Zϭ
ϭϲͿŝĨĨĞƌĞŶƚŝĂůƉƌĞƐƐƵƌĞΛŵĂǆĨůŽǁ Ϯϳ͘ϯϰŵŵtĐ Zϭ
ϭϳͿŝĨĨĞƌĞŶƚŝĂůƉƌĞƐƐƵƌĞΛŵŝŶĨůŽǁ ϯ͘Ϭϯϳŵŵt Zϭ
ϭϴͿWĞƌŵĂŶĞŶƚͬůůŽǁĂďůĞƉƌĞƐƐƵƌĞůŽƐƐ Ϯϳ͘ϯϱŵŵtĐ Zϭ
ϭϵͿĐĐƵƌĂĐǇ цϭй
ϮϬͿZĞƉĞĂƚĂďŝůŝƚǇ цϬ͘ϭй
ϮϳͿ
ϮϴͿdǇƉĞ ŝƌĐƵůĂƌ
ϮϵͿDĂƚĞƌŝĂůŽĨƵĐƚͬWŝƉĞ ĂƌďŽŶƐƚĞĞů
ϯϬͿEŽŵŝŶĂůƐŝǌĞ ϮϰΗ^ĐŚϭϬ
ƵĐƚ ϯϭͿ/ŶƐŝĚĞĚŝĂ ϮϰΗ^ĐŚϭϬ
ĂƚĂ ϯϮͿ
ϯϯͿhƉƐƚƌĞĂŵƐƚƌĂŝŐŚƚůĞŶŐƚŚƌĞƋƵŝƌĞĚ ϳ Zϭ
ϯϰͿŽǁŶƐƚƌĞĂŶƐƚƌĂŝŐŚƚůĞŶŐƚŚƌĞƋƵŝƌĞĚ ϯ Zϭ
ϯϱͿ
ϯϵͿ
ϰϬͿWƌŽďĞĚŝĂŵĞƚĞƌ ϭͬϮ/ŶĐŚ Zϭ
ϰϭͿDĂƚĞƌŝĂůŽĨĐŽŶƐƚƌƵĐƚŝŽŶ ^^ϯϭϲ
WƌŽďĞ ϰϮͿEŽŽĨƐƵƉƉŽƌƚƐ ^ŝŶŐůĞ^ƵƉƉŽƌƚ
ĂƚĂ ϰϯͿWƌŽďĞŝŶƐĞƌƚŝŽŶůĞŶŐƚŚ WƌŽďĞƐŚŽƵůĚĂůŵŽƐƚƚŽƵĐŚƚŚĞďŽƚƚŽŵ
ϰϰͿ/ŶƐƚƌƵŵĞŶƚĐŽŶŶĞĐƚŝŽŶ KǀĂůĚĂƉƚŽƌƐƐƵŝƚĂďůĞĨŽƌΗ,ΗƚǇƉĞŵĂŶŝĨŽůĚ
ϰϱͿtĞůĚŽůĞƚ ĂƌďŽŶ^ƚĞĞů
ϰϲͿWƌŽďĞ,ĞĂĚ&ůĂŶŐĞ ϯͬϰΗ͕ϭϱϬZ&͕͘^͘ Zϭ
ϰϳͿDŽƵŶƚŝŶŐ&ůĂŶŐĞ ĂƌďŽŶ^ƚĞĞů͕ϯͬϰΗ͕ϭϱϬZ&͕tĞůĚEĞĐŬƚǇƉ Zϭ
ϰϴͿtĞůĚEŝƉƉůĞ ^
ϰϵͿ'ĂƐŬĞƚ ^Θ'ƌĂƉŚŝƚĞ
ϱϬͿDŽƵŶƚŝŶŐĚŝƌĞĐƚŝŽŶ ,ŽƌŝǌŽŶƚĂůƚŽĚƵĐƚ
ϱϭͿ&ůŽǁĚŝƌĞĐƚŝŽŶ >ĞĨƚƚŽZŝŐŚƚ;,ŽƌŝǌŽŶƚĂůͿ
ϱϮͿDŽƵŶƚŝŶŐŚĂƌĚǁĂƌĞƐ zĞƐ
ϱϰͿWƌŽďĞ,ĞĂĚ ^^ϯϭϲ
Kd,Z ϱϱͿ'ƌĂǁŝŶŐĨŽƌĂƐƐĞŵďůǇ zĞƐ
d/>^ ϱϲͿ
EKd^ ϭͿsĞŶĚŽƌƚŽƐƵďŵŝƚ'ĚƌĂǁŝŶŐͬYWͬ^ŝǌŝŶŐĂůĐƵůĂƚŝŽŶĂĨƚĞƌWKWůĂĐĞŵĞŶƚ
^h/>d
WZK:d ϭyϲ͘ϴϱDtt,Z^WZK:d͘ KEK͘ d^WͲͲϭϯ
&ŝǀĞƐŽŵďƵƐƚŝŽŶ^ǇƐƚĞŵƐ&^:KEϬ͘ ϮϬϭϳ͘ϯϲϭϬ ,< &:^
Wǀƚ͘>ƚĚ͘ ,WdZ Ϭϱ WWZz Ê
dĞĐŚŶŝĐĂů^ƉĞĐƐĨŽƌZŽƚĂƌǇĐƚƵĂƚŽƌ
hŶŝƚƐ͗ &ůŽǁͲх >ŝƋƵŝĚͲх 'ĂƐͲх WƌĞƐƐƵƌĞͲхŵŵtͬŬŐͬĐŵϮ dĞŵƉĞƌĂƚƵƌĞͲхΣ
ϭͿdĂŐEŽ͘ WHRS-AQC2HP-HGG-DMP-009 / WHRS-AQC2HP-HGG-DMP-012
ϮͿYƚǇƌĞƋƵŝƌĞĚ ϮEŽƐ͘
ϯͿ^ĞƌǀŝĐĞ ŵĞƌŐĞŶĐǇĂŝƌĚĂŵƉĞƌ
'ĞŶĞƌĂů ϰͿƵƚǇ;ŽŶͲŽĨĨͬZĞŐƵůĂƚŝŶŐͿ KŶͲKĨĨ
ϱͿdǇƉĞŽĨĐƚŝŽŶ;ŝƌĞĐƚͬZĞǀĞƌƐĞͿ ŝƌĞĐƚ
ϲͿdŽƌƋƵĞƌĞƋƵŝƌĞĚ dǇƉĞ ϯϬED;/ŶĐůƵĚŝŶŐ^DͿ YƵĂƌƚĞƌƚƵƌŶƌŽƚĂƌǇĂĐƚƵĂƚŽƌ
ϳͿdǇƉĞŽĨŵŽƵŶƚŝŶŐ 'ĂŝƚĞƌ &ƌĂŵĞ E
ϴͿdǇƉĞ ĐƚŝŽŶ WŶĞƵŵĂƚŝĐͲŽƵďůĞĐƚŝŶŐ KŶͲKĨĨ
ϵͿ^ƉƌŝŶŐƌĂŶŐĞ E
ϭϬͿ&ĂŝůƵƌĞWŽƐŝƚŝŽŶ ŝƌƚŽ ^ƚĂǇƉƵƚ KƉĞŶ
ϭϭͿŽŶŶĞĐƚŝŽŶ ϭͬϰΗEWd;&Ϳ
ĐƚƵĂƚŽƌ /ŶƚĞŐƌĂůůǇĐĂƐƚƉƌĞƐƐƵƌĞĚŝĞĐĂƐƚ
ϭϮͿĐƚƵĂƚŽƌǆƚĞƌŶĂůDĂƚĞƌŝĂů ZĂĐŬŵĂƚĞƌŝĂů ůƵŵŝŶŝƵŵ
ĂůƵŵŝŶŝƵŵ
ϭϯͿ^ƉƌŝŶŐͬŝĂƉŚƌĂŐŵDĂƚĞƌŝĂů E
ϭϰͿŝƌ>ŽĐŬƌĞůĂǇ >ŽĐŬŝŶŐWƌĞƐƐƵƌĞ ZĞƋƵŝƌĞĚ ϯ͘ϱŬŐͬĐŵϮ;ŐͿ
ϭϱͿ,ĂŶĚǁŚĞĞů E
ϭϲͿdǇƉĞ 'ĂƵŐĞƐ
ϭϳͿŝƌƐƵƉƉůǇWƌĞƐƐƵƌĞ
WŽƐŝƚŝŽŶĞƌ
ϮϬͿŶĐůŽƐƵƌĞ
E
ϮϭͿ/ŶƉƵƚ^ƵƉƉůǇ KƵƚƉƵƚWƌĞƐƐƵƌĞ
WŽƐŝƚŝŽŶ ϮϮͿdǇƉĞŽĨKƵƚƉƵƚ /ŶƉƵƚ^ƵƉƉůǇ
dƌĂŶƐŵŝƚƚĞƌ ϮϯͿĂďůĞ'ůĂŶĚ
ϮϰͿdǇƉĞ DŽƵŶƚĞĚĨŽƌ Inductive proximity switch Open - Close Position
>ŝŵŝƚ^ǁŝƚĐŚ ϮϱͿYƵĂŶƚŝƚǇ ZĂƚŝŶŐ 2 Nos 24 VDC
ϮϲͿŶĐůŽƐƵƌĞ WP , IP 65
ϮϳͿdǇƉĞ ^ŝǌĞ Relieving Type 1/4 Inch
ϮϴͿ&ŝůƚĞƌůĞŵĞŶƚ &ŝůƚĞƌ^ŝǌĞ Sintered Bronze 5 micron
ŝƌ^Ğƚ
ϮϵͿKƵƚƉƵƚ YƚǇ͘ 6 Kg / cm2 1
ϯϬͿ'ĂƵŐĞ^ŝǌĞ ŽǁůDĂƚĞƌŝĂů 2" Dial Metallic Bowl
ϯϭͿ/ŶƐƚƌƵŵĞŶƚĂŝƌƐƵƉƉůǇĐŽŶŶĞĐƚŝŽŶ ϭͬϰΗEWd;&Ϳ
dĞƌŵŝŶĂƚŝŽŶ ϯϮͿdĞƌŵŝŶĂůďŽǆƉƌŽǀŝĚĞĚ ZĞƋƵŝƌĞĚĨŽƌůŝŵŝƚƐǁŝƚĐŚ
ĚĞƚĂŝůƐ ϯϯͿůĞĐƚƌŝĐĂůĐŽŶŶĞĐƚŝŽŶ ϭͬϮΗEWd;&Ϳ;ϬϮEŽƐ͘Ϳ
ϯϰͿĂďůĞŐůĂŶĚƉƌŽǀŝĚĞĚ Ǉ&^
ϯϱͿWŝŶŝŽŶDĂƚĞƌŝĂů ůĞĐƚƌŽůĞƐƐŶŝĐŬĞůƉůĂƚĞĚƐƚĞĞů
DK ϯϲͿƐĞĂůƐ EZ
ϯϳͿKͲƌŝŶŐ EZ
32) Solenoid Valve (5/2 Way) 230 VAC (With Inbuilt manual Override)
Solenoid Valve 33) SV MOC Qty SS 1 No
34) Solenoid Valve Coil Enclosure WP with Class "H" insulation WP to IP 65
ϯϴͿDĞĐŚĂŶŝĐĂůƉŽƐŝƚŝŽŶŝŶĚŝĐĂƚŽƌ E
ĐĐĞƐƐŽƌŝĞƐ
ϯϵͿdƌƵŶŝŽŶŵŽƵŶƚƉůĂƚĞƐ E
ϰϬͿsĂůǀĞ ĐƚƵĂƚŽƌ ĂŵƉĞƌͲǇ&^ ZŽƚĞǆͬYd&ϲϯ R1
ϰϭͿͬW DŽĚĞůEŽ E E
DĂŬĞΘDŽĚĞů ϰϮͿ^ŽůĞŶŽŝĚsĂůǀĞ DŽĚĞůEŽ ZŽƚĞǆ ϱϭϰϬϬͲϲͲϮZϱͲDϲͲϮϯϬsͲϭϲͲ, R1
EŽ ϰϯͿŝƌ^ĞƚDĂŬĞ DŽĚĞůEŽ ^ŚĂǀŽ ϭϭͲϰÊͲϮϬϭDͲDϲ<EͲEE R1
ϰϰͿŝƌ>ŽĐŬsĂůǀĞ DŽĚĞůEŽ ZŽƚĞǆ ALR5-2N R1
ϰϱͿ>ŝŵŝƚ^ǁŝƚĐŚ DŽĚĞůEŽ WΘ& NBN4-12GM-40-ZO R1
Notes
1) Packing material and Gasket Material shall be Asbestos Free.
2) GA Drawing should be submitted with in one Week after PO Placement
3) Area Clssification : WP to IP 65
4) SS tag plate to be provieded
AS BUILT
WZK:d ϭyϲ͘ϴϱDtt,Z^WZK:d͘ KEK͘ d^WͲZͲϭϰ
Eh^Z WZ^<d/DEd/Eh^dZ/^>/D/d d ϬϮ͘ϭϭ͘ϮϬϭϳ
&ŝǀĞƐŽŵďƵƐƚŝŽŶ^ǇƐƚĞŵƐWǀƚ͘>ƚĚ͘ ,WdZ Ϭϱ WWZz Ê
dĞĐŚŶŝĐĂů^ƉĞĐƐĨŽƌZŽƚĂƌǇĐƚƵĂƚŽƌ
hŶŝƚƐ͗ &ůŽǁͲх >ŝƋƵŝĚͲх 'ĂƐͲх WƌĞƐƐƵƌĞͲхŵŵtͬŬŐͬĐŵϮ dĞŵƉĞƌĂƚƵƌĞͲхΣ
ϭͿdĂŐEŽ͘ t,Z^ͲYϮ,WͲ,''ͲDWͲϬϬϳͬt,Z^ͲYϮ,WͲ,''ͲDWͲϬϬϴ
ϮͿYƚǇƌĞƋƵŝƌĞĚ ϮEŽƐ͘
ϯͿ^ĞƌǀŝĐĞ ŽŵďƵƐƚŝŽŶŝƌĂŵƉĞƌ
'ĞŶĞƌĂů ϰͿƵƚǇ;ŽŶͲŽĨĨͬZĞŐƵůĂƚŝŶŐͿ KŶͲKĨĨ
ϲͿdŽƌƋƵĞƌĞƋƵŝƌĞĚ dǇƉĞ ϭϲϬED;/ŶĐůƵĚŝŶŐ^DͿ YƵĂƌƚĞƌƚƵƌŶƌŽƚĂƌǇĂĐƚƵĂƚŽƌ
ϳͿdǇƉĞŽĨŵŽƵŶƚŝŶŐ 'ĂŝƚĞƌ &ƌĂŵĞ E
ϵͿ^ƉƌŝŶŐƌĂŶŐĞ E
ϭϬͿ&ĂŝůƵƌĞWŽƐŝƚŝŽŶ ŝƌƚŽ ^ƚĂǇƉƵƚ KƉĞŶ
ϭϭͿŽŶŶĞĐƚŝŽŶ ϭͬϰΗEWd;&Ϳ
ĐƚƵĂƚŽƌ /ŶƚĞŐƌĂůůǇĐĂƐƚƉƌĞƐƐƵƌĞĚŝĞĐĂƐƚ
ϭϮͿĐƚƵĂƚŽƌǆƚĞƌŶĂůDĂƚĞƌŝĂů ZĂĐŬŵĂƚĞƌŝĂů ůƵŵŝŶŝƵŵ
ĂůƵŵŝŶŝƵŵ
ϭϰͿŝƌ>ŽĐŬƌĞůĂǇ >ŽĐŬŝŶŐWƌĞƐƐƵƌĞ ZĞƋƵŝƌĞĚ ϯ͘ϱŬŐͬĐŵϮ;ŐͿ
ϭϲͿdǇƉĞ 'ĂƵŐĞƐ
ϭϳͿŝƌƐƵƉƉůǇWƌĞƐƐƵƌĞ
WŽƐŝƚŝŽŶĞƌ
ϮϬͿŶĐůŽƐƵƌĞ
E
ϮϭͿ/ŶƉƵƚ^ƵƉƉůǇ KƵƚƉƵƚWƌĞƐƐƵƌĞ
WŽƐŝƚŝŽŶ ϮϮͿdǇƉĞŽĨKƵƚƉƵƚ /ŶƉƵƚ^ƵƉƉůǇ
dƌĂŶƐŵŝƚƚĞƌ ϮϯͿĂďůĞ'ůĂŶĚ
ϮϰͿdǇƉĞ DŽƵŶƚĞĚĨŽƌ /ŶĚƵĐƚŝǀĞƉƌŽǆŝŵŝƚǇƐǁŝƚĐŚ KƉĞŶͲůŽƐĞWŽƐŝƚŝŽŶ
>ŝŵŝƚ^ǁŝƚĐŚ ϮϱͿYƵĂŶƚŝƚǇ ZĂƚŝŶŐ ϮEŽƐ Ϯϰs
ϮϲͿŶĐůŽƐƵƌĞ tW͕/Wϲϱ
ϮϳͿdǇƉĞ ^ŝǌĞ ZĞůŝĞǀŝŶŐdǇƉĞ ϭͬϰ/ŶĐŚ Zϭ
ϮϴͿ&ŝůƚĞƌůĞŵĞŶƚ &ŝůƚĞƌ^ŝǌĞ ^ŝŶƚĞƌĞĚƌŽŶǌĞ ϱŵŝĐƌŽŶ
ŝƌ^Ğƚ
ϮϵͿKƵƚƉƵƚ YƚǇ͘ ϲ<ŐͬĐŵϮ ϭ
ϯϬͿ'ĂƵŐĞ^ŝǌĞ ŽǁůDĂƚĞƌŝĂů ϮΗŝĂů DĞƚĂůůŝĐŽǁů
ϯϭͿ/ŶƐƚƌƵŵĞŶƚĂŝƌƐƵƉƉůǇĐŽŶŶĞĐƚŝŽŶ ϭͬϰΗEWd;&Ϳ
dĞƌŵŝŶĂƚŝŽŶ ϯϮͿdĞƌŵŝŶĂůďŽǆƉƌŽǀŝĚĞĚ ZĞƋƵŝƌĞĚĨŽƌůŝŵŝƚƐǁŝƚĐŚ
ĚĞƚĂŝůƐ ϯϯͿůĞĐƚƌŝĐĂůĐŽŶŶĞĐƚŝŽŶ ϭͬϮΗEWd;&Ϳ;ϬϮEŽƐ͘Ϳ
ϯϰͿĂďůĞŐůĂŶĚƉƌŽǀŝĚĞĚ Ǉ&^
ϯϱͿWŝŶŝŽŶDĂƚĞƌŝĂů ůĞĐƚƌŽůĞƐƐŶŝĐŬĞůƉůĂƚĞĚƐƚĞĞů
DK ϯϲͿƐĞĂůƐ EZ
ϯϳͿKͲƌŝŶŐ EZ
ϯϮͿ^ŽůĞŶŽŝĚsĂůǀĞ;ϱͬϮtĂǇͿ ϮϯϬs;/ŶďƵŝůƚŵĂŶƵĂůKǀĞƌƌŝĚĞͿ
^ŽůĞŶŽŝĚsĂůǀĞ ϯϯͿ^sDK YƚǇ ^^Ͳϯϭϲ ϭEŽ
ϯϰͿ^ŽůĞŶŽŝĚsĂůǀĞŽŝů ŶĐůŽƐƵƌĞ tWǁŝƚŚůĂƐƐΗ,ΗŝŶƐƵůĂƚŝŽŶ tWƚŽ/Wϲϱ
ϯϴͿDĞĐŚĂŶŝĐĂůƉŽƐŝƚŝŽŶŝŶĚŝĐĂƚŽƌ E
ĐĐĞƐƐŽƌŝĞƐ
ϯϵͿdƌƵŶŝŽŶŵŽƵŶƚƉůĂƚĞƐ E
ϰϬͿsĂůǀĞ ĐƚƵĂƚŽƌ ĂŵƉĞƌͲǇ&^ ZŽƚĞǆͲYd&ϭϭϬ Zϭ
ϰϭͿͬW DŽĚĞůEŽ E E
DĂŬĞΘDŽĚĞů ϰϮͿ^ŽůĞŶŽŝĚsĂůǀĞ DŽĚĞůEŽ ZŽƚĞǆ ϱϭϰϬϬͲϲͲϮZϱͲDϲͲϮϯϬsͲϭϲͲ, Zϭ
EŽ ϰϯͿŝƌ^ĞƚDĂŬĞ DŽĚĞůEŽ ^ŚĂǀŽ ϭϭͲϰÊͲϮϬϭDͲDϲ<EͲEE Zϭ
ϰϰͿŝƌ>ŽĐŬsĂůǀĞ DŽĚĞůEŽ ZŽƚĞǆ >ZϱͲϮZ Zϭ
ϰϱͿ>ŝŵŝƚ^ǁŝƚĐŚ DŽĚĞůEŽ WΘ& EEϰͲϭϮ'DͲϰϬͲK Zϭ
Notes
1) Packing material and Gasket Material shall be Asbestos Free.
2) GA Drawing should be submitted with in one Week after PO Placement
3) Area Clssification : WP to IP 65
4) SS tag plate to be provieded
WZK:d ϭyϲ͘ϴϱDtt,Z^WZK:d͘ KEK͘ d^WͲZͲϭϰ

&ŝǀĞƐŽŵďƵƐƚŝŽŶ^ǇƐƚĞŵƐWǀƚ͘>ƚĚ͘ ,WdZ Ϭϱ WWZz Ê
Tech. Specs for Linear Actuator

!" #2 $%&
ϭͿdĂŐEŽ͘ WHRS-AQC2HP-HGG-DMP-002
ϮͿYƚǇƌĞƋƵŝƌĞĚ ϭEŽ
ϯͿ^ĞƌǀŝĐĞ /ŶƐĞƌƚͲZĞƚƌĂĐƚŵĞĐŚĂŶŝƐŵ
General ϰͿƵƚǇ;ŽŶͲŽĨĨͬZĞŐƵůĂƚŝŶŐͿ ZĞŐƵůĂƚŝŶŐ
ϲͿ&ŽƌĐĞƌĞƋƵŝƌĞĚ dǇƉĞ 514 N @ 4 Kg.cm2 >ŝŶĞĂƌ
ϳͿWŝƐƚŽŶZŽĚŽŶŶĞĐƚŝŽŶ ŽƌĞŝĂ &ŽƌŬ ϱϬE
ϵͿ^ƚƌŽŬĞ>ĞŶŐƚŚ ϮϬϬŵŵ
ϭϬͿ&ĂŝůƵƌĞWŽƐŝƚŝŽŶ ŝƌƚŽ ^ƚĂǇƉƵƚ /ŶƐĞƌƚ
ϭϭͿǇůŝŶĚĞƌDŽƵŶƚŝŶŐ dƌƵŶŶŝŽŶ
Actuator
ůƵŵŝŶŝƵŵŝĞĂƐƚŽĂƚĞĚ ,ŝŐŚůůŽǇ^ƚĞĞů
ϭϮͿĐƚƵĂƚŽƌǆƚĞƌŶĂůDĂƚĞƌŝĂů ^ƚĞŵͬWŝƐƚŽŶZŽĚŵĂƚĞƌŝĂů
ϭϰͿŝƌ>ŽĐŬƌĞůĂǇ >ŽĐŬŝŶŐWƌĞƐƐƵƌĞ WƌŽǀŝĚĞĚ ϯ͘ϱŬŐͬĐŵ2;ŐͿ '(
ϭϲͿdǇƉĞ 'ĂƵŐĞƐ ůĞĐƚƌŽͲWŶĞƵŵĂƚŝĐ;^ŵĂƌƚͿ ZĞƋƵŝƌĞĚ
Positioner
ϭϲ͘ϭͿ/ŶƉƵƚůĞǀĞů ĐĐƵƌĂĐǇ ϰͲϮϬŵ нϬ͘ϱйŽĨƐƉĂŶ
Position
ϭϳͿdǇƉĞ KƵƚƉƵƚůĞǀĞů E
Transmiter
ϭϴͿdǇƉĞ DŽƵŶƚĞĚĨŽƌ /ŶĚƵĐƚŝǀĞƉƌŽǆŝŵŝƚǇƐǁŝƚĐŚ KƉĞŶͲůŽƐĞWŽƐŝƚŝŽŶ
Limit Switch ϭϵͿYƵĂŶƚŝƚǇ ŽŶƚĂĐƚƐͬZĂƚŝŶŐ ϮEŽƐ Ϯϰs
ϮϬͿŶĐůŽƐƵƌĞ tW͕/Wϲϳ
ϮϭͿdǇƉĞ ^ŝǌĞ ZĞůŝĞǀŝŶŐdǇƉĞ ϭͬϰ/ŶĐŚ
ϮϮͿ&ŝůƚĞƌůĞŵĞŶƚ &ŝůƚĞƌ^ŝǌĞ ^ŝŶƚĞƌĞĚƌŽŶǌĞ ϱŵŝĐƌŽŶ
Air Set
ϮϯͿ/ŶƉƵƚ YƚǇ͘ ϲ<ŐͬĐŵϮ ϭ
ϮϵͿ'ĂƵŐĞ^ŝǌĞ ŽǁůDĂƚĞƌŝĂů ϮΗŝĂů dƌĂŶƐƉĂƌĞŶƚWŽůǇĐĂƌďŽŶĂƚĞ
ϮϰͿ/ŶƐƚƌƵŵĞŶƚĂŝƌƐƵƉƉůǇĐŽŶŶĞĐƚŝŽŶ ϭͬϰΗEWd
Termination ϮϱͿdĞƌŵŝŶĂůďŽǆƉƌŽǀŝĚĞĚ ZĞƋƵŝƌĞĚĨŽƌůŝŵŝƚƐǁŝƚĐŚ
details ϮϲͿůĞĐƚƌŝĐĂůĐŽŶŶĞĐƚŝŽŶ ϭͬϮΗEWd;&Ϳ;ϬϮEŽƐ͘Ϳ
ϮϳͿĂďůĞŐůĂŶĚƐƉƌŽǀŝĚĞĚ Ǉ&^
ϮϴͿWŝƐƚŽŶƐĞĂůƐ EZ
MOC
ϮϵͿKͲƌŝŶŐ EZ
ϯϬͿDĞĐŚĂŶŝĐĂůƉŽƐŝƚŝŽŶŝŶĚŝĐĂƚŽƌ ZĞƋƵŝƌĞĚ
Accessories
ϯϭͿdƌƵŶŝŽŶŵŽƵŶƚƉůĂƚĞƐ ZĞƋƵŝƌĞĚ
ϯϮͿ^ŽůĞŶŽŝĚsĂůǀĞ;ϱͬϮtĂǇͿ
Solenoid Valve ϯϯͿ^sDK YƚǇ E
ϯϰͿ^ŽůĞŶŽŝĚsĂůǀĞŽŝů ŶĐůŽƐƵƌĞ
ϯϱͿĂŵƉĞƌ Ǉ&^
ϯϲͿǇůŝŶĚĞƌͲDĂŬĞ DŽĚĞůEŽ͘ Rotex SPC-D-S-BG-MP2+LB2-50/200 '(
ϯϳͿWŽƐŝƚŝŽŶĞƌͲDĂŬĞ DŽĚĞůEŽ͘ Siemens 6DR5120-0NN00-0AA0 '(
Make & Model
No.
ϯϴͿ>ŝŵŝƚƐǁŝƚĐŚͲDĂŬĞ DŽĚĞůEŽ͘ P&F NBN4-12GM-40-ZO '(
ϯϵͿ&ZͲDĂŬĞ DŽĚĞůEŽ͘ Shavo / Placka 11-4SN-201M-M6KN-NS '(
ϰϬͿŝƌ>ŽĐŬsĂůǀĞͲDĂŬĞ DŽĚĞůEŽ͘ Rotex ALR5-2R '(
ϯϯͿ^sDĂŬĞ DŽĚĞůEŽ͘ NA NA
Notes
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TECHNICAL SPECIFICATIONS FOR SCREW PUMP
UNITS: Flow-> Liquid- kgs/hr Pressure-> kg/cm2 Temperature-> ° C
1) Tag No. PROVIDE LATER
2) Qty required 2 Nos.
GENERAL 3) Duty Continuous, Firing
4) Service Schedule HSD / LDO
5) Inlet Line size Outlet Line size 20 NB S 40 15 NB S 40
7) Pump type Screw type
8) Flow capacity (Design) 302 kg/hr (5.7 LPM)
Offered capAcity (Design) 454 kg/hr (8.6 LPM)
9) Discharge pressure 17 kg/cm2 (g)
SERVICE 10) Flow specific gravity @ 15°C 0.88
11) Viscosity 2.5-15.7 CST @ 40C Temp
DATA 12) Pump speed 2900 rpm
13) Safety relief valve type In built, Spring loaded type
14) Safety relief valve set pr. 18.5 kg/cm2 (g)
15) Operating temperature Max. Min. 45 °C 40 °C
16) NPSHR PROVIDE LATER
17) Pump suction size 20NB
18) Pump discharge size 20NB
19) Type of mounting Foot mounted-Horizontal
20) Direction of rotation Clockwise from drive end
PUMP 21) Shaft seal Mechanical
23) Drive rating / Speed / Frame Size 0.75KW / 1HP / 2900 rpm
24) Pump make COLFAX
25) Pump model T3SFP-10/28
26) End connection for suction/discharge FLANGED
Matching flanges for suction & discharge Yes required each for suction & discharge with fastners
GD2 Value 0.00010 kg/m2
28) Pump casing CAST IRON
MATERIAL 29) Liner AL Alloy
OF 30) Screw 16MnCRS5
CONST 31) Seal STD MECHANICAL
32) Relief valve Yes
ACCESORY 33) Base plate Yes
34) Coupling Yes
35) Coupling guard Yes
36) Pump Seal NA
37) Gasket for Seal NA
SPARES 38) Oil Ring for Seal NA
39) Pump Bearing NA
40) Bushes for Bearings NA
NOTES : 1) VTS: Vendor to Specify

2) Vendor to provide Pump Characteristic curves & Pump GA drawings with all details after order placement.
3) Site data: Temp. Performance 45 degree
Min. 40 degree
4) Relative humidity: Perfomance. 70%
5) Elevation : 106 m above MSL
6) Matching flanges and its fastners should be included in offer
7) Foundation bolts not required.
8) Area classification : Hazardous IIA / IIB , T3
9) Frame size of Motor shall be confirmed later
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TECHNICAL SPECIFICATIONS FOR BACK PRESSURE REGULATING VALVE
UNITS: Flow-> Liquid- Gas-Pressure-> MM WC/ kg/cm2 Temperature-> ° C
1) Tag No. WHRS-AQC2HP-HGG-PRV-001
2) Qty required 1 No.
3) Duty Continuous
GENERAL
4) Service LDO
5) Line size Inlet 15 NB
6) Line size Outlet 15 NB
7) Type of Valve Self Actuated
8) Flow Maximum 408 Kg/Hr.
9) Flow Minimum 156 Kg/Hr.
10) Inlet Pressure 17 Kg/cm2 g
SERVICE DATA 11) Outlet Pressure Atmospheric
12) Set Pressure 15 Kg/cm2 g
13) Viscosity Max 15.7 CSt at 40C temperature
14) Flow Specific Gravity 0.88
15)Operating Temperature 40 °C
16) Valve size 15 NB
17) Ends Flanged to 150# RF
18) Valve Selected CV 0.42
19) Calculated CV max. 0.125
20) Calculated CV min 0.048
VALVE DATA 21) Stem Travel NA
22) Valve Leakage Class VI
23) Spring Range Min required : 14-16 kg/cm2g
24) Make NIRMAL
25) Model No. MBP04215F118111 (BP/04-B Series)
26) Sensing Connection Internal
27) Valve Body A 216 Gr.WCB
28) Trim SS316
29) Packing Glandless
30) Diaphragm Nitrile
MATERIAL OF
31) Spring SS316
CONSTRUCTION
32) Piston Actuator NA
33) BOTTOM A 216 Gr.WCB
34) Spring casing A 216 Gr.WCB
35) CAP A 216 Gr.WCB
NOTE:
1) Gasket material shall be asbestos free.
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TECHNICAL SPECIFICATIONS FOR FLOW CONTROL VALVE
UNITS: Flow-> Liquid- kgs/hr Pressure-> kg/cm2 Temperature-> deg C
General 1) Tag No. WHRS-AQC2HP-HGG-FCV-001
3) Service LDO Flow Control
4) Inlet Line size Outlet Line Size 15 NB S40 15 NB S40
Body 5) Type of Valve Port Size GLOBE 4.5 mm R1
6) Body Size No. of Ports 15NB 1 R1
7) Guiding TOP
8) Ends : Flgd. Size / Rating ANSI 150# RF R1
9) Facing & Finish SPIRAL 125-250 AARH
10) Body Material ASTM A 216 GR. WCC R1
11) Bonnet Type Integral Extended Zϭ
12) Seat Material 17-4 PH (H900) R1
13) Packing material PTFE R1
14) Trim Type Modular linear, contoured, fully guided Zϭ
15) Trim material Solid Stellite No.6 R1
16) % of opening Max Min 71.8% 13.8% R1
18) ANSI Leakage Class Class IV
19) Type Pneumatic
20) Signal 6-24 psi Zϭ
21) Failure Position Air to Close Open
Actuator 22) Air supply pressure 4 Kg/cm2(g)(Min) 6 Kg/cm2(g) (max)
23) Connection 1/4" NPT(F) SS 316 Tubing
25) Stem / Piston Rod material SS R1
27) Handwheel YES R1
28) Type SMART SINGLE ACTING R1
Positioner 29) Input 4-20 mA
30) Enclosure WP IP 66 R1
31) Output 4-20 mA
Position 31) Model 6DR5110-0NN00-0AA0
Transmitter 32) Enclosure type inbuilt with positioner
33) Type Qty. Relieving type 1 Nos.
34) Filter Element Sintered bronze
Air Set 35) Filter Size 5 Microns
36) Output Adjustable from 0 to 10 kg/cm2g
37) Bowl material Clear Transparent polycarbonate with metallic cover
38) Gauge 2" Dial size to indicate output pressure
39) Fluid State LDO Liquid
40) Flow Liq-Max Design Max Min 252 Kg/hr 84 Kg/hr
MCR Max Min NA
41) Flow Vap-Max Min Shut off Pressure - 15 Kg/cm2(g)
Service 42) Inlet Pressure 12 kg/cm2 g 12 kg/cm2 g
Condition 43) Delta P @Max flow / Min flow 2 Kg/cm2 g 6 kg/cm2 g
44) Outlet Pressure Max Min 10 Kg/cm2 g 6 Kg/cm2 g
45) Temp. Operating Max Min 45 Deg C 40 Deg C
46) S.G. of Fluid. 0.88
47) Viscosity of Fluid Max 15.7 CSt at 40C temperature
Limit Switch 48) Quantity Contacts / Rating 1 24V DC, 2 wire
49) Enclosure Type WP IP 65 1 NO, Proximity Type
Valve Data 50) Cv Min. Cv Max 0.223 0.04282 R1
51) Cv Selected 0.31
52) Predicted Sound Level dBA / Allowable < 85 dBA at 1.0 mtr.
Make 53) Valve Actuator MIL MIL
54) Position Transmitter Positioner SIEMENS SIEMENS R1
55) Limit switch Air set with Gauges P&F SHAVO
56) Pneumatic tubing Air Lock Valve MIL STD NA
Model No 57) Valve Actuator MIL 29000 (38-21125) 18 R1
58) Position Transmitter with Positioner 6DR40048J 6DR51100NN000AA0 R1
59) Limit switch Air set with Gauges NBN4-12GM-40-Z0 11-4SN-200M-M6KN-NS R1
60) Air Lock Valve NA
NOTES:
1) Control Valve sizing calculation shall be accompanied with data sheets.
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TECHNICAL SPEC. FOR SHUT OFF VALVE (FOR OIL LINE)
UNITS: Flow-> Liquid- kgs/hr Pressure-> kg/cm2 Temperature-> deg C
1) Tag No. WHRS-AQC2HP-HGG-SSOV-001
2) Qty. 1 No.
3) Service Location On - Off Oil line (Pipe Rack)
4) Inlet Line I.D. Outlet Line I.D. 15 NB S40 15 NB S40
5) Type of Valve Port Ball Full Bore
6) Body Size No. of Ports 15 NB One
7) Guiding Top
8) End Conn: Flgd. Size & Rating ANSI 150# RF
9) Facing & Finish Serrated
10) Body Material ASTM A 216 Gr.WCB
Body 11) Trim material SS316
12) Packing Material PTFE
13) Lubricator NO
14) Trim Form On - Off
15) Body Seal Asymmetrical, Non-Twisting, BUNA - N Ring
16) Other Wetted Parts - MOC SS316
17) Soft Seating MOC PTFE
18) ANSI Leakage Class Class VI
19) Type SPRING RETURN
Actuator 20) Air supply pressure 4 BAR
21) Failure Position Close (Air to open)
22) Handwheel & Location NA
23) Type 3/2 Direct acting, Universal solenoid valve
Solenoid 24) Supply voltage Enclosure type 230 V AC, 50 Hz Safe, Weather proof to IP 67, SS
Valve 25) Body material Qty SS Bar Stock 1 No
26) Solenoid Valve Yes
27) I/P Converter NA
Options 28) Filter With Gauge YES
29) Limit Switch 2 No. Proximity, 2 wire
Limit Switch rating 24V DC, 1 NO
30) Limit switch box Safe, Weather proof to IP 67
31) Pneumatic tubing SS316, 1/4" O/D
32) Fluid State LDO Liquid
33) Flow Liquid-Max (Design) Max. Min 252 kgs/hr 84 Kgs/hr
(MCR) Max. Min
34) Flow Vapour Max. Min. --
35) Flow water Min. --
36) Inlet Pressure Max 12 kg/cm2 (g)
Service 37) Delta P @ Flow rate - Max allowable 0.05 kg/cm2
Conditions 38) Delta Pressure Shut Off 15 kg/cm2 (g)
39) Temperature Oper. Maximum Minimum 45 Deg C 40 Deg C.
40) S.G. 0.88
41) Cp / Cv Visc. (oper) -- 15.7 Cst at 40C temperature
42) Flash % %solids --
43) Deg. Of Superheat Critical Pressure --
44) Vapour Pressure --
45) Selected Cv. NA
46) Cv Min. Cv Max NA NA
Valve Data 47) Cv Nor. NA
48) Predicted Sound Level dBA < 85 db @ 1 mtr distance
Make & Model 49) Valve / Actuator ROTEX / QTF 63E 6
50) Solenoid Valve ROTEX / 30308-5-2R-B5+230VAC-16-H
51) Limit switch Air set P&F / NBN4-12GM-40-Z0 SHAVO/SB10 Shavo / Placka
NOTES : 1) Valve to be supplied as assembly
2) Closing time shall be less than < 2 sec
3) Flow direction shall be marked on valve body.
4) VTS : - Vendor to Specify
5) All Tubing should be SS316
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KZ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϬϴ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϬϵ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϭϬ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϭϭ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϭϮ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϭϯ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϭϰ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϭϱ
Zh
Ϭϭ t,Z^ͲYϮ,WͲ,''ͲsͲϬϭϲ ϭϱE ϭϳ ϭϳ >K
t,Z^ͲYϮ,WͲ,''ͲsͲϬϭϳ KZ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϮϬ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϮϭ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϮϯ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϮϰ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϮϲ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϮϳ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϮϴ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϯϮ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϯϯ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϯϰ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϯϱ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϯϳ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϯϴ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϯϵ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϰϬ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϰϮ Zh
ϬϮ t,Z^ͲYϮ,WͲ,''ͲsͲϬϰϯ ϭϱE ϭϵ ϭϳ >K
KZ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϰϲ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϰϳ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϱϭ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϱϮ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϱϯ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϱϰ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϱϲ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϱϵ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϲϭ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϲϮ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϲϯ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϲϰ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϲϱ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϲϲ Zh
ϬϮ t,Z^ͲYϮ,WͲ,''ͲsͲϬϳϯ ϭϱE ϭϮ ϭϳ >K
KZ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϲϳ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϲϴ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϲϵ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϳϬ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϳϭ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϳϱ Zh
Ϭϭ t,Z^ͲYϮ,WͲ,''ͲsͲϬϳϲ ϭϱE Ϯ ϭϳ ŝƌ
KZ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϰϴ Zh
&ϬϮ t,Z^ͲYϮ,WͲ,''ͲsͲϬϲϬ ϭϱE Ϯ ϭϳ >K
KZ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϳϵ
Zh
Ϭϱ t,Z^ͲYϮ,WͲ,''ͲsͲϬϴϬ ϭϱE ϯ ϭϳ ŝƌ
t,Z^ͲYϮ,WͲ,''ͲsͲϬϴϭ
KZ

Ϭ Ϯ͘ϭϭ͘ϮϬϭϳ &ŝƌƐƚ/ƐƐƵĞ ,^ ^ ZZ
ZĞǀŝƐŽŶ
ZĞǀ͘EŽ ĂƚĞ WƌĞƉĂƌĞĚǇ͘ ŚĞĐŬĞĚǇ͘ ƉƉƌŽǀĞĚǇ͘
ĞƐĐƌŝƉƚŝŽŶ
^ŚĞĞƚEŽ͘ϮŽĨϮ
ŽĐ͘EŽ d^WͲDsͲϮϮͲϮ
'>Ks>s ZĞǀ͘EŽ Ϭ
&ŝǀĞƐŽŵďƵƐƚŝŽŶ^ǇƐƚĞŵƐ ;^K<dt>Ϳ ůŝĞŶƚ d</>
Wǀƚ͘>ƚĚ͘ ŶĚhƐĞƌ WZ^<d/DEd
ZĞǀ͘ZĞŵĂƌŬ
^ƚĂŶĚĂƌĚ ^ϱϯϱϮ
ĞƐŝŐŶ &ŝƌĞ^ĂĨĞ zĞƐ
ZĂƚŝŶŐ ϴϬϬη
ŽĚǇ &ŽƌŐĞĚ ^dDϭϬϱ
ŽŶŶĞƚ ŽůƚĞĚ ^dDϭϬϱ
^ƚĞŵ ZŝƐŝŶŐ ϭϯйZ͘^d>
ŝƐĐ >ŽŽƐĞƉůƵŐƚǇƉĞ ^ƚĞůůŝĞĚ
ŽĚǇ^ĞĂƚƌŝŶŐ ZĞŶĞǁĂďůĞ ^ƚĞůůŝĞĚ
ŽƌƌŽƐŝŽŶŝŶŚŝďŝƚĞĚĚŝĞ
DĂƚĞƌŝĂů ZĞŶĞǁĂďůĞǁŝƚŚǀĂůǀĞ ĨŽƌŵĞĚĨůĞǆŝďůĞŐƌĂƉŚŝƚĞ
^ƚĞŵWĂĐŬŝŶŐ ǁŝƚŚďƌĂŝĚĞĚĂŶƚŝ
ŽƉĞŶŽŶƐƚƌĞĂŵ
ĞǆƚƌƵƐŝŽŶƌŝŶŐƐ
ŽŶŶĞƚŽůƚ ^dDϭϵϯ'ƌ͘ϳ
ŽĚǇEƵƚ ^dDϭϵϰ'ƌ͘Ϯ,
^^^ƉŝƌĂůtŽƵŶĚ͕'ƌĂĨŽŝů
ŽŶŶĞƚ'ĂƐŬĞƚ
&ŝůůĞƌ
&ĂĐĞƚŽ&ĂĐĞŝŵĞŶƐŝŽŶ ^ƚĂŶĚĂƌĚ sĞŶĚŽƌ^ƚĂŶĚĂƌĚ
DĂŬĞ <^
EŽƚĞƐ
ϭ ŝĚĚĞƌƐŚĂůůĐůĞĂƌůǇƐƉĞĐŝĨǇĚĞǀŝĂƚŝŽŶŝĨĂŶǇ͘
Ϯ ŝĚĚĞƌƐŚĂůůĐĞƚŝĨǇƚŚĞƐƵŝƚĂďŝůŝƚǇŽĨǀĂůǀĞĨŽƌŝŶƚĞŶĚĞĚƐĞƌǀŝĐĞĐŽŶĚŝƚŝŽŶ͘
ϯ ^ƚĞĂŵƐĞĂůͬŽĚǇƐĞĂůŵĂƚĞƌŝĂůƐŚĂůůďĞƉƌŽǀŝĚĞĚǁŝƚŚĐŽƌƌŽƐŝŽŶ
^h/>d
Ϭ Ϭϰ͘ϭϭ͘ϮϬϭϳ &ŝƌƐƚ/ƐƐƵĞ ,^ ^ ZZ
ZĞǀ͘EŽ ĂƚĞ ZĞǀŝƐŽŶĞƐĐƌŝƉƚŝŽŶ WƌĞƉĂƌĞĚǇ͘ ŚĞĐŬĞĚǇ͘ ƉƉƌŽǀĞĚǇ͘
^ŚĞĞƚEŽ͘ϭŽĨϮ
ŽĐ͘EŽ d^WͲDsͲϮϮͲϮ
'>Ks>s ZĞǀ͘EŽ Ϭ
&ŝǀĞƐŽŵďƵƐƚŝŽŶ^ǇƐƚĞŵƐWǀƚ͘>ƚĚ͘ ŶĚhƐĞƌ WZ^<d/DEd
YƚǇ͘ tŽƌŬŝŶŐWƌ͘ ^ĞƌǀŝĐĞ dǇƉĞŽĨ

ŚĂƉƚĞƌEŽ͘ dĂŐEŽ ^ŝǌĞ ZĞǀ͘ZĞŵĂƌŬ
EŽƐ͘ ;ŬŐͬĐŵϸŐͿ &ůƵŝĚ ŽƌĞ
Ϭϭ t,Z^ͲYϮ,WͲ,''Ͳ'ͲϬϮϱ ϭϱ ϭ ϭϱ >K &ƵůůŽƌĞ
ϬϮ t,Z^ͲYϮ,WͲ,''Ͳ'ͲϬϰϭ ϭϱ ϭ ϭϱ >K &ƵůůŽƌĞ
ϬϮ t,Z^ͲYϮ,WͲ,''Ͳ'ͲϬϰϰ ϭϱ ϭ ϭϱ >K &ƵůůŽƌĞ
ϬϮ t,Z^ͲYϮ,WͲ,''Ͳ'ͲϬϱϴ ϭϱ ϭ ϭϬ ŝƌ &ƵůůŽƌĞ
Ϭϭ t,Z^ͲYϮ,WͲ,''Ͳ'ͲϬϳϮ ϭϱ ϭ ϭϬ ŝƌ &ƵůůŽƌĞ
ZZZEWΘ/͗
Ϭ ϰ͘ϭϭ͘ϮϬϭϳ &ŝƌƐƚ/ƐƐƵĞ ,^ ^ ZZ
ZĞǀŝƐŽŶ
ŽĐ͘EŽ d^WͲDsͲϮϮͲϯ
'ds>s ZĞǀ͘EŽ Ϭ
&ŝǀĞƐŽŵďƵƐƚŝŽŶ^ǇƐƚĞŵƐ ;^K<dt>Ϳ ůŝĞŶƚ d</>
Wǀƚ͘>ƚĚ͘ ŶĚhƐĞƌ WZ^<d/DEd
ZĞǀ͘ZĞŵĂƌŬ
^ƚĂŶĚĂƌĚ ^Dϭϲ͘ϯϰ
ĞƐŝŐŶ &ŝƌĞ^ĂĨĞ zĞƐ
ŽŶŶĞƚ ŽůƚĞĚ ^dDϭϬϱ
^ƚĞŵ ZŝƐŝŶŐ ^ƚĞůůŝĞĚ
tĞĚŐĞŝƐĐ >ŽŽƐĞƉůƵŐƚǇƉĞ ^ƚĞůůŝĞĚ
ŽĚǇ^ĞĂƚƌŝŶŐ ZĞŶĞǁĂďůĞ ^ƚĞůůŝĞĚ
ŽƌƌŽƐŝŽŶŝŶŚŝďŝƚĞĚĚŝĞ
ZĞŶĞǁĂďůĞǁŝƚŚǀĂůǀĞ ĨŽƌŵĞĚĨůĞǆŝďůĞŐƌĂƉŚŝƚĞ
DĂƚĞƌŝĂů ^ƚĞŵWĂĐŬŝŶŐ ǁŝƚŚďƌĂŝĚĞĚĂŶƚŝ
ŽƉĞŶŽŶƐƚƌĞĂŵ
ĞǆƚƌƵƐŝŽŶƌŝŶŐƐ
ŽŶŶĞƚŽůƚ ^dDϭϵϯ'ƌ͘ϳ
ŽĚǇEƵƚ ^dDϭϵϰ'ƌ͘Ϯ,
^^^ƉŝƌĂůtŽƵŶĚ͕'ƌĂĨŽŝů
ŽŶŶĞƚ'ĂƐŬĞƚ
&ŝůůĞƌ
,ĂŶĚǁŚĞĞů ĂƌďŽŶ^ƚĞĞů
DĂŬĞ <^
EŽƚĞƐ
Ϯ ŝĚĚĞƌƐŚĂůůĐĞƚŝĨǇƚŚĞƐƵŝƚĂďŝůŝƚǇŽĨǀĂůǀĞĨŽƌŝŶƚĞŶĚĞĚƐĞƌǀŝĐĞĐŽŶĚŝƚŝŽŶ͘
ϯ ^ƚĞĂŵƐĞĂůͬŽĚǇƐĞĂůŵĂƚĞƌŝĂůƐŚĂůůďĞƉƌŽǀŝĚĞĚǁŝƚŚĐŽƌƌŽƐŝŽŶŝŶŚŝďŝƚŽƌ͘
^h/>d
Ϭ ϰ͘ϭϭ͘ϮϬϭϳ &ŝƌƐƚ/ƐƐƵĞ ED W ZZ
ZĞǀ͘EŽ ĂƚĞ ZĞǀŝƐŽŶĞƐĐƌŝƉƚŝŽŶ WƌĞƉĂƌĞĚǇ͘ ŚĞĐŬĞĚǇ͘ ƉƉƌŽǀĞĚǇ͘
ŽĐ͘EŽ d^WͲDsͲϮϮͲϯ
'ds>s ZĞǀ͘EŽ Ϭ
&ŝǀĞƐŽŵďƵƐƚŝŽŶ^ǇƐƚĞŵƐWǀƚ͘>ƚĚ͘
ŶĚhƐĞƌ WZ^<d/DEd
YƚǇ͘ tŽƌŬŝŶŐWƌ͘ ^ĞƌǀŝĐĞ

ŚĂƉƚĞƌEŽ͘ dĂŐEŽ ^ŝǌĞ dǇƉĞŽĨŽƌĞ ZĞǀ͘ZĞŵĂƌŬ
EŽƐ͘ ;ŬŐͬĐŵϸŐͿ &ůƵŝĚ
Ϭϭ t,Z^ͲYϮ,WͲ,''Ͳ'dͲϬϳϳ ϭϱE ϭ dD ŝƌ ZĞĚƵĐĞĚŽƌĞ
Ϭϭ t,Z^ͲYϮ,WͲ,''Ͳ'dͲϬϳϴ ϭϱE ϭ dD ŝƌ ZĞĚƵĐĞĚŽƌĞ
Ϭϱ t,Z^ͲYϮ,WͲ,''Ͳ'dͲϬϴϱ ϭϱE ϭ dD ŝƌ ZĞĚƵĐĞĚŽƌĞ
Ϭϱ t,Z^ͲYϮ,WͲ,''Ͳ'dͲϬϴϲ ϭϱE ϭ dD ŝƌ ZĞĚƵĐĞĚŽƌĞ
ZZZEWΘ/͗
Ϭ ϰ͘ϭϭ͘ϮϬϭϳ &ŝƌƐƚ/ƐƐƵĞ ED W ZZ
ZĞǀŝƐŽŶ
ŽĐ͘EŽ d^WͲDsͲϮϮͲϰ
EKEZdhZEs>s ZĞǀ͘EŽ Ϭ
ZĞǀ͘ZĞŵĂƌŬ
^ƚĂŶĚĂƌĚ ^ͲϱϯϱϮ
ĞƐŝŐŶ &ŝƌĞ^ĂĨĞ EŽ
ŽǀĞƌ ŽůƚĞĚ ^dDϭϬϱ
ŝƐĐͬWŝƐƚŽŶ ϭϯйZ͘^d>
ŽĚǇ^ƚĞŵZŝŶŐ ϭϯйZ͘^d>
DĂƚĞƌŝĂů dǇƉĞ >/&d,<dzW
ŽǀĞƌ^ƚƵĚďŽůƚ ^dDϭϵϯ'ƌ͘ϳ
ŽǀĞƌEƵƚ ^dDϭϵϰ'ƌ͘Ϯ,
^WtE^^ϯϭϲͲ
ŽǀĞƌ'ĂƐŬĞƚ
'Z&K/>&/>>Z
DĂŬĞ <^
EŽƚĞƐ
Ϯ ŝĚĚĞƌƐŚĂůůĐĞƚŝĨǇƚŚĞƐƵŝƚĂďŝůŝƚǇŽĨǀĂůǀĞĨŽƌŝŶƚĞŶĚĞĚƐĞƌǀŝĐĞ
ϯ ^ƚĞĂŵƐĞĂůͬŽĚǇƐĞĂůŵĂƚĞƌŝĂůƐŚĂůůďĞƉƌŽǀŝĚĞĚǁŝƚŚĐŽƌƌŽƐŝŽŶ
^h/>d
ZĞǀ͘EŽ ĂƚĞ ZĞǀŝƐŝŽŶĞƐĐƌŝƉƚŝŽŶ WƌĞƉĂƌĞĚǇ͘ ŚĞĐŬĞĚǇ͘ ƉƉƌŽǀĞĚǇ͘
ŽĐ͘EŽ d^WͲDsͲϮϮͲϰ
EKEZdhZEs>s ZĞǀ͘EŽ Ϭ
YƚǇ͘ tŽƌŬŝŶŐWƌ͘ ^ĞƌǀŝĐĞ ZĞǀ͘

ŚĂƉƚĞƌEŽ͘ dĂŐEŽ ^ŝǌĞ dǇƉĞŽĨŽƌĞ
EŽƐ͘ ;ŬŐͬĐŵϸŐͿ &ůƵŝĚ ZĞŵĂƌŬ
Ϭϭ t,Z^ͲYϮ,WͲ,''ͲEZͲϬϭϴ ϭϱE ϭ ϭϱ >K ZhKZ
Ϭϭ t,Z^ͲYϮ,WͲ,''ͲEZͲϬϭϵ ϭϱE ϭ ϭϱ >K ZhKZ
ϬϮ t,Z^ͲYϮ,WͲ,''ͲEZͲϬϰϱ ϭϱE ϭ ϭϱ >K ZhKZ
ϬϮ t,Z^ͲYϮ,WͲ,''ͲEZͲϬϰϵ ϭϱE ϭ ϭϱ /Z ZhKZ
ϬϮ t,Z^ͲYϮ,WͲ,''ͲEZͲϬϱϳ ϭϱE ϭ ϭϱ /Z ZhKZ
ZZZEWΘ/͗
ZĞǀŝƐŽŶ
TECHNICAL SPECIFICATIONS OF COFFEE POT DAMPER
UNITS: Flow-> Liquid- Gas- Pressure-> MM WC/ kg/cm2 Temperature-> ° C
1) Tag No. WHRS-AQC2HP-HGG-CPD-001
General 3) Make INDUSTRIAL FAN INDIA PVT LTD R1
4) Service HGG outlet
5) Duty ON - OFF
6) Size 1500 mm I/D (With Refractory) 1620 mm O/D (Without Refractory ) R1
7) Temperature Operating Design 440 °C 500 °C
8) End connections Flanged
9) Internal SS
10) Counter weight Yes
11) Sealing eff Tight shut off, 99.0%
13) Operating Action Energised to close, power failure to open
14) Operating Pressure -40 mmwc
15) Design Pressure -50 mmwc
16) Type Make/Model no E-pac -Electrical Rotary AUMA / SA12E45/GS125.2+VZ4(LR) R1
18) Mounting Central Trunion type
ACTUATOR 19) Actuator supply Motor Supply- 415VAC +/- 10% , 50HZ+/- 5 %
+ 20) Control Supply 220 VAC
Gearbox 21) Actuator motor rating 0.55kw / 2800 rpm R1
22)Travel Limit Switch 2 Nos with (2 NO+2NC potential free contact ) R1
23) Torque Limit switch 2 Nos with (2 NO+2NC potential free contact ) R1
24)Bellow Suitable neoprene coated nylon fabric bellow shall be
provided on a actuator drive rod to avoid any ingress of dust.
25) Operating Time VTS
26) Hand wheel YES R1
27) Material Of Construction
Body Flap IS 2062 with refractory SS409 with ceramic insulation R1
OTHER 28) GA Drawing IF-CP-3342-00/2014 R1

DETAILS 29) Wiring details of damper drawing 3-WDP-B1B R1
30) Total Weight (W/o Refractory) 6100 Kg R1
31) Location Out Door
32) Site Jetti palem, Rentachintala, Guntur Dt., Andhra Pradesh, India
SITE 33) Altitude 106 M above MSL

34) Ambient Temp in ΣC 35°C
CONDITIONS 35) Relative humidity 70%
36) Rain fall in cm 85
37) Wind Velocity mtr/sec 44
38) Earth quake factor (SEISMIC ZONE) ZONE II
39) Design temp for electrical equipments 50 °C
40) Atmosphere Weatherproof IP 65
Clinching 41) Size 250 mm Dia
Magnet 42) Supply Power Input 110 VDC
Note : 1) Vendor to provide IP 65 enclosure along with unit for switches and coil assembly for magnet
2) Vendor to provide detailed wiring diagram for actuator
3) GA and QAP shall be submitted for approval.
4) Electrical actuator shall be with Integral Starter
AS BUILT
WZK:d ϭyϲ͘ϴϱDtt,Z^WZK:d͘ KEK͘ d^WͲWͲϮϯ
Eh^Z WZ^<d/DEd/Eh^dZ/^>/D/d d ϮϬͲϬϭͲϮϬϭϴ
&ŝǀĞƐŽŵďƵƐƚŝŽŶ^ǇƐƚĞŵƐ &^:KEϬ͘ ϮϬϭϳ͘ϯϲϭϬ ,< ,^ͬW
Wǀƚ͘>ƚĚ͘ ,WdZ ϬϮ WWZz Ê
TECHNICAL SPECIFICATIONS OF HOISTING DAMPER
1) Tag No. WHRS-AQC2HP-HGG-HD-001
General 3) Make INDUSTRIAL FANS INDIA PVT. LTD R0
4) Service HGG outlet / Horizontal
5) Duty ON - OFF
6) Size 2400 mm I/D (Refractory) 2800 mm O/D (Refractory)
7) Temperature Operating Design 450 °C 500 °C
` 8) End connections Flanged
9) Internal SS409
10) Counter weight NA
11) Sealing eff Tight shut off ; 99.80%
13) Operating Action from RDOL starter. Forward and Reverse motor operation
13.1) Operating Pressure -40 mmwc
13.2) Design Pressure -50 mmwc
13.3) Operating Time 200 sec
ACTUATOR 14) Type Make/Model no Electrical AUMA/ SA12E180/GS125.2+VZ4
16) Mounting Refer GAD
17) Actuator supply Motor Supply- 415VAC +/- 10% , 50HZ+/- 5 %
18) Control Supply 220 VAC
19) Actuator motor rating 1.1kw /1400 rpm
20) Travel adjustment 2 Nos ( 2NO+2NC)
21) Over load protection 2 Nos ( 2NO+2NC)
Suitable neoprene coated nylon fabric bellow shall be provided

22) Bellow
on a actuator drive rod to avoid any ingress of dust.
23) Hand wheel Provided for manual operation in case of power failure
24) Material Of Construction
Body Slide Plate IS 2062 SS409
OTHER 25) GA Drawing Vendor to provide
DETAILS 26) Width of damper (face to face) 1200mm
27) Weight with Actuator and gearbox 6500 kg
28) Location Out Door
29) Site Jetti palem, Rentachintala, Guntur Dt., Andhra Pradesh, India
SITE 30) Altitude 106 M above MSL
31) Ambient Temp in Deg C 35°C
CONDITIONS 32) Relative humidity (RH) 70%
33) Rain fall in cm 85
34) Wind Velocity mtr/sec 44
35) Earth quake factor (SEISMIC ZONE) ZONE II
36) Design temp for electrical equipments 50 °C
38) Atmosphere Weatherproof IP 65
Note :
1) Vendor to provide IP 65 enclosure along with unit for switches and coil assembly for magnet
2) GA and QAP shall be submitted for approval.
3) Electrical Actuator shall be without integral starter
AS BUILT
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TECHNICAL SPECIFICATIONS FOR COMBUSTION AIR BLOWER
1) Tag No.
2) Qty 2 No.
3) Make Model No. Howden Solyvent HCMB-3-050 R1
GENERAL
4) Service For Combustion Air
5) Duty Continuous
6) Vendor drawing reference Yes
7) Plant site Location Hydrabad
8) Operating Pressure 350 mmWC
9) Temperature Minimum Maximum 40 °C 45 °C
10) Volumetric flow rate at normal 13,223 Nm3/hr 15407 m3/hr
11) Mass flow rate 17100 Kg/hr
12) Suction Pressure Atmospheric
13) Discharge Pressure 350 mmWC
SERVICE
DATA
14) Operating Air Density at 18°C / 45 °C / 0 °C 1.2129 Kg/m3 1.1097 Kg/m3 1.2932 Kg/m3
15) Site Elevation 106 Mtr above MSL
16) Relative humidity Minimum Maximum 70% 85%
17) Rainfall Maximum 850mm
18) Basic wind speed 44 m/sec
19) Wind Pressure --
20) Snow Load N/A
21) Seismic Zone Zone II
22) Type of Blower Centrifugal
23) Inlet Single
24) Casing Type Std.
25) Impeller type Backward Curved Blade
26) Connection to driver Belt Drive
27) Fan speed 2070 R1
28) Shaft Power 20.08 Kw R1
29) Fan efficiency (STATIC) 77% R1
30) Drive rating 30 Kw 4 pole R1
31) Pulley Size On GAD
32) V-Belt size On GAD
33) Coupling size NA
34) Starting Torque 2.85 R1
35) Fan moment of Inertia ( GD2) 12.52 R1
<85 db(A) at 1 m with acoustic insulation and inlet siilencer-
36) Noise level @ 1 mtr distance
BLOWER Insulation material in Fvies scope
DATA 37) Motor frame size Later
38) Mounting Base Frame Mounted (On Foundation)
39) Direction of rotation (Looking at motor drive end) Clockwise
40) Corrosion allowance N/A
41) Material of construction
Casing Structurals MS: 1079 MS R1
Impeller Disc/Shrd/Bl Shaft MS: 5 / 3 / 5 : IS: 2062/ IS: 1079/ IS: 2062 EN8 R1
Guide vanes Inlet butterfly damper R1
42) Impeller Size 794 mm R1
43) Casing Thickness 3 mm side plate, 3 mm scroll plate R1
44) Shaft dia @ Bearing 60 mm R1
45) Painting As per Vendor Standard (Ref note -2)- AS per HSIn std R1
46) Bearing Refer GAD
47) Lubrication Refer GAD
48) Total static weight Refer GAD
49) Dynamic load Refer GAD
50) Balancing of impeller As per ISO 1940 Gr. 6.3
51) Base structure for fan & Motor Yes
OTHER 52) Coupling / Guard NA R1
DATA 53) Pulley / V-Belt / Guard V-belt
54) Vibration pads NA
55) Foundation bolts Yes
AS BUILT
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Systems Pvt. Ltd. W' ϭK&Ϯ
TECHNICAL SPECIFICATIONS FOR COMBUSTION AIR BLOWER
56) Bird screen at suction Yes
57) Suction rain hood NA
58) Inlet Guide Vane NA
59) Type of control VFD Control
60) Suction Silencer If sound level <85 db(A) at 1 m then NA, else, required
Accessory 61) Filter Size NA
62) Inspection door in the casing Yes
63) Drain with hex plug Yes
64) Motor 30 Kw / 4 pole R1
65) Non Metallic Expansion Bellow at Blower Outlet Yes
66) Vendor Assembly Drawing Ref. Vendor to Provide
67) Flexible Inlet Connection NA
68) Performance Test Yes, to be Performed at derated speed R1
69) Mechanical Run Test yes
70) Balancing yes
TESTS
71) Dimensional Verification Yes, Required
72) Inspection Agency FCS
73) Blower Characteristic Curves Required
74) Bearings FAG / SKF
75) Filters NA
76) Pulleys HSIN Std R1
MAKES 77) V-Belts HSIN STd R1
78) Motor Siemens / ABB / BBL
79) Bellow Flex well / Flexocon R1
80) Inlet Butterfly Damper HSIN R1
Note :
1) Vendor to provide GA and QAP for Approval
2) Vendor to submit Material Test Certificate, Internal Test Reports, Guarantee Certificate etc.
3) Vendor has to provide fan speed vs torque curve and fan performance curve along with offer.
4) Motor for Blowers are in FCS scope of supply.
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Systems Pvt. Ltd. W' ϮK&Ϯ
TECHNICAL SPECIFICATIONS FOR EMERGENCY AIR BLOWER
1) Tag No.
2) Qty 1 No.
3) Make Model No. CB Doctor CHB 15 II R0 R2
GENERAL
4) Service For Emergency Cooling
5) Duty Continuous
7) Plant site Location Hydrabad
8) Operating Pressure 50 mmWC
9) Temperature Minimum Maximum 40 °C 45 °C
10) Volumetric flow rate at normal 4305 m3/hr R2
11) Mass flow rate 4700 Kg/hr
13) Discharge Pressure 50 mmWC
SERVICE
DATA
14) Operating Air Density at 45 °C 1.09 Kg/m3 R2
15) Site Elevation 106 Mtr above MSL
17) Rainfall Maximum 850 mm
20) Snow Load N/A
21) Seismic Zone Zone II
22) Type of Blower Centrifugal
23) Inlet Single
25) Impeller type Backward inclined Blade R2
26) Connection to driver Belt Drive
28) Shaft Power @ optg Temp 1 R2
29) Fan efficiency Static Total 61% 66% R2
30) Drive rating 1.5 Kw /4 pole DOL R1
31) Pulley Size To be shown on GAD
32) V-Belt size To be shown on GAD
33) Coupling size Not applicable for belt driven fan
34) Starting Torque 0.93 Nm R2
35-a) Rotor GD2 kg-m2 1 R2
35-b) GD2 with respect to motor shaft
1.9 R2
(without considering motor Gd2 value)
BLOWER 36) Noise level @ 1 mtr distance <85 db(A) at 1 m in free field condition
DATA 37) Motor frame size ASHC112M
Casing Structurals 2.5 / 2 mm, IS 1079 CS R2
Impeller Shaft 4 IS 2062 / 3 IS 1079 / 3 IS 1079; EN 8 / Equiv. R2
Guide vanes Inlet butterfly damper R1
42) Impeller Size Ø411 mm diameter R2
43) Casing Thickness 2.5 / 2 mm, IS 1079 R2
44) Shaft dia @ bearing end Ø40 mm diameter R2
Conseal touch-up (Acrylic based paint), Total DFT:
45) Painting
50 microns, Shade RAL: 5009. R2
46) Bearing Anti frictional R2
47) Lubrication Grease & (Should be included in GAD) R1
48) Total static weight ~ 220 Kg fan + Motor R2
49) Dynamic load Will be mentioned in GA drawing R2
52) Coupling / Guard Yes - Coupling not applicable. R2
OTHER DATA
53) V-Belt with Guard Yes - Noted R2
54) Vibration pads NA
55) Foundation bolts Yes
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Pvt. Ltd. W' ϭK&Ϯ
TECHNICAL SPECIFICATIONS FOR EMERGENCY AIR BLOWER
59) Type of control DOL
60) Suction Silencer If sound level <85 db(A) at 1 m then NA, else APPLICABLE
Accessory 61) Filter Size NA
64) Motor 1.5 Kw/ 4 pole R1
66) Vendor Assembly Drawing Ref. Yes
68) Performance Test Yes
69) Mechanical Run Test Yes
70) Balancing Yes
TESTS
71) Dimensional Verification Yes
74) Bearings FAG / SKF R1
75) Filters NA
76) Pulleys Vendor standard R1
MAKES
77) V-Belts Vendor standard R1
78) Motor CGL
79) Bellow Flex well / Flexocon R1
Note :
5) Please submit QAP for approval along with final offer
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Pvt. Ltd. W' ϮK&Ϯ
TECHNICAL SPECIFICATIONS FOR COAL CONVEYING AIR BLOWER
WHRS-AQC2HP-HGG-RB-001 ;
1) Tag No.
WHRS-AQC2HP-HGG-RB-002
2) Qty 2 No
3) Make Model No. KAY 5MK R2
4) Service For Coal Conveying Air

5) Duty Continuous
Jetti palem, Rentachintala, Guntur
7) Plant site Location
Dt, Andhra Pradesh, India
8) Operating Pressure 655 mBar (g)
Maximum Dry Minimum dry Mean dry bulb
Bulb Temp. bulb Temp Temp
0 50 20 32
9) Temperature C
elctric
plant design
wet bulb Temp equipment
Temp
design Temp
28 35 50
SERVICE
10) Volumetric flow rate at normal 640 m3/hr R2
DATA
11) Mass flow rate 722 Kg/hr R2
13) Discharge Pressure Discharge Temp. 6555 mmWC ATM+65 R2
3
14) Operating Air Density at Blower INLET 1.1274 Kg/m R2
15) Altitude above Mean sea level 106 M
17) Rainfall Maximum 850 mm (June - November)
20) Snow Load N/A
21) Seismic Zone Zone III
22) Type of Blower Twin Lobe - Roots Blower
23) Inlet Single
25) Impeller type Std.
26) Connection to driver Belt Drive / Coulped
28) Shaft Power 20.65 HP R2
30) Drive rating 25 HP R2
31) Fan moment of Inertia ( GD2) 0.086 KG.M2
BLOWER
32) Noise level @ 1 mtr distance <85 db(A) at 1 m & 88 dB(A) at 1meter on Inlet side
DATA
33) Motor frame size Later
Casing Structurals C.I.F.G : 260 , IS:210 IS 2062 R2
Lobe Shaft EN-8, C.I.F.G : 260, IS:210 EN-8, EN-9/07 OM55/EN-24 / 817 M 40 R2
38) Painting As per Vendor Standard (Ref note -2)
39) Total static weight Refer GAD
42) Coupling / Guard Yes
OTHER DATA
43) Pulley / V-Belt / Guard V-Belt R2
44) Vibration pads Yes R2
45) Foundation bolts Yes R2
AS BUILT
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TECHNICAL SPECIFICATIONS FOR COAL CONVEYING AIR BLOWER
49) IGV Type of control NA
50) Suction & Discharge Silencer Yes R2
Accessory 51) Filter Yes
54) Motor 18.5 KW
56) Vendor Assembly Drawing Ref. Vendor to Provide
58) Performance Test Yes, to be Performed
59) Mechanical Run Test Yes R2
60) Balancing NA
TESTS
61) Dimensional Verification Yes, Required
64) Bearings FAG / SKF
65) Filters KAY R2
MAKES
66) Pulleys KAY R2
67) V-Belts KAY R2
Note :
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TECHNICAL SPECIFICATIONS FOR ROTARY AIR LOCK VALVE
UNITS: Flow-> Liquid- kgs/hr Pressure-> kg/cm2
1) Tag No. WHRS-AQC2HP-HGG-RAV-001
2) Qty 1 No.
GENERAL 3) Location Below Screw conveyor
4) Make RIECO R1
5) Model No. AL-200 SQ R1
6) Material handled Coal (4 Grades)
7) Bulk density 0.85-0.9 T/m3
8) Maximum particle size Fines
9) Moisture content 1.5 TO 12% (% by mass)
DUTY 10) Other characteristics Mildly Abrasive
CONDITIONS 11) Temperature Ambient
12) Differential Pressure 400-700 mmWC
13) Application Airlock
14) Duty Continuous
15) Capacity design operationg 2.7 tph 1.5 tph R1
16) Rotary valve size ø 200 x 200 L
Rotary Valve 17) Rotor volume @ 100% fill VTS
specification 18) Filling factor design operationg 65% 52% R1
19) Rotor speed VTS
20) Inlet / Outlet flange opening 200 x 200 I/S
21) No. of pockets for rotor 6 Vanes closed end rotor, Cast Steel
22) Body Cast Steel
23) Rotor Fabricated from MS
24) Vane tips Spring steel, Adjustable, wear resistant
CONDITIONS 25) Shaft EN-8
DETAILS 26) Bearing Outboard mounted, Deep groove ball bearing
27) Bearing Make SKF / FAG
28) Vent port 1/4" BSP (F)
29) Shaft seals Gland packing, Graphite asbestos rope
30) Clearance Axial Clearance 0.2-0.3 mm 7-9 mm
31) Painting Two coats of Primer & two coats of finish paint
32) Type Geared motor
33) Motor Supply 415VAC +/- 10% , 50HZ +/- 5 %
DRIVE 34) Ambient temperature 35oC
SPECIFICATION 35) Insulation Class "F"
36) Enclosure IP-55
37) Design temp for electrical equipments 50oC
38) Rating (AGMA Class) 0.75 KW R1
39) Make ICB R1
40) Type BC-3
COUPLING
41) Make Fenner R1
1 Refer coal anlysis for reference
AS BUILT
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Datasheet of Knife Edge Gate Valve
UNITS: Flow-> Liquid- Gas- Pressure-> kg/cm2 g Temperature-> Deg C
Quantity Max. Max.

TAG No Type Size Pressure Temp. Fluid Location
(Nos) (mmWC) (C)
WHRS-AQC2HP-HGG- PULVERIZED
Gate 5" 1 7500 45 Coal Conveying Air Line
KEGV-004 COAL
Fluid Properties: Pulverized Coal
Molecular Weight of Air 29
Viscosity 0.011 cP
Air to Coal Ratio 3-5 : 1
Material of Construction:
Body: ASTM A 216 Gr. WCB End Connection Flanged 150# ANSI B16.5
Trim: Trim not applicable for KGV Process Pipe : 5'' , Sch 80
Seat : Metal (Integral part of valve body) Design Code MSS SP-81 R2
Gasket : Not applicable
Gate : SS310
Stem / Piston Rod : SS316
ACTUATION
Pneumatic Double Acting Cylinder Actuator
Cylinder Dia: 6" R2
Stroke Length : 5" approx R2
Air Supply Pr. : 4-6 kg / cm2
Solenoid Valve
Type : 5/2 way, Aluminium Body, Single Coil, Class F Insulation, Weatherproof IP67, Manual Override, Terminal Box with Cable Entry R2
Supply voltage : 230 V AC, 50 Hz Enclosure type : Weatherproof IP67 R2
Body material : Aluminium Qty : 1 No
Make : ROTEX Model : 51400-6-2R+220VAC-16
Limit Switch
Limit Switch 2 nos of 2 Wire, 24Vdc, 5mm Sensing, 18mm Dia, NO,Proximity Sensor for open and close position, Weather Proof IP67
Limit Switch rating 24V DC, 1 NO Make : P&F
Limit switch box Safe, Weather proof to IP 65 Model : NBB5-18GM40-Z0 R2
AFR
Make : SHAVO
Model : SB60K-2N-M6D-RGLN R2
AS BUILT
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Wǀƚ͘>ƚĚ͘ W' ϭK&ϭ
TECHNICAL SPECIFICATIONS FOR METALLIC EXPANSION BELLOW
1) Tag No. N.A
3) Make STANFAB ENGINEERING PVT. LTD. R1
General
4) Service Fluid Flue Gas
4a) Composition -
5) Duty Continuous
6) Location On HGG Outlet Duct
7) Type Metallic
8) Operating Temperature/Design Temp. 450 ° C/ 550 ° C
9a) Operating Pressure (-40) to 40 mm WC
9b) Test Pressure (-50) to 50 mm WC
10a) Duct Size : Refractory ID Duct ID Duct OD 2400 mm 2800 mm 2816 mm
10b) Free Length 200 mm
11) Bolt holes DAI-24 R1
12) End connection Flange MOC Flanged IS 2062 Gr A
Data 13) Axial Deflection ± 30 mm
14) Lateral Deflection ± 9 mm
15) Material of Construction of bellow SA240 TP304 R1
16) Insulation Yes inside (By Client)
17) Size Thickness 2816 1 mm R1
18) GA drawing Yes, Required in autocad for approval
19) Anchors Qty SS304 60 nos R1
20) Lug Qty 10 thk 8 nos R1
20) Control Rod Qty DIA-25 4 nos R1
NOTES :
1) Bellow material & dimensions to be decided by vendor to ensure performance
2) GA drawing showing construction features to be provided
3) Matching flanges are in FCS 's scope of supply
4) VTS - Vendor to Specify
5) Please refer attached sketch for Counter flange details
AS BUILT
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TECHNICAL SPECIFICATIONS FOR FLEXIBLE HOSES
For Flame Scanner Cooling
UNITS: Flow-> Pressure-> kg/cm2 Temperature-> °C
1) Tag No. Provide Later
2) Qty required 02 Nos
General 3) Make Aeroflex
4) Service Cooling air
5) Duty Continuous
6) Type SS304 corrugated with SS304 braided
7) Ambient Temperature (Min/Maxi.) 16 °C/ 50 °C
HOSE 8) Operting Pressure 5-6 Kg/cm2 g
9) Size 15NB
DATA 10) Length 1000 mm
11) End connection 1/2" BSP(F) Swivel nuts at both ends with adoptors
Scanner End : 3/8" NPT(M) X 1/2" BSP(M)
12) Adapter
Other End : 1/2" BSP(M) x 1/2''NPT(M)
13) Material of construction of adapters MS with zinc plated
Notes:
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ϮͿ Area Classification : Installation will be at Cement plant environment
AS BUILT
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TECHNICAL SPECIFICATIONS FOR FLEXIBLE HOSE
for View Port Cooling
UNITS: Pressure-> Kg/cm2 Temperature-> °C
4) Service Cooling Air
5) Duty Continuous
9) Size 15 NB
One End :1/2" NPT(M) X 1/2" BSP(M)
12) Adapter

Wǀƚ͘>ƚĚ͘ W' ϮK&ϵ
for Oil Gun inlet (LDO)
4) Service LDO
5) Duty Continuous
HOSE 8) Operting Pressure 12 kg/cm2
9) Size 15 NB
Oil gun End : 1/2" BSP(M) X Socket end with 20.5 mm ID
12) Adapter (REFER DRG)

Wǀƚ͘>ƚĚ͘ W' ϯK&ϵ
for Oil Gun Atomising Air
4) Service Atomising Air
5) Duty Continuous
HOSE 8) Operting Pressure 5-6 kg/cm2
9) Size 15 NB

Wǀƚ͘>ƚĚ͘ W' ϰK&ϵ
for HEI Ignitor Cooling Air
4) Service Cooling Air
5) Duty Continuous
9) Size 15 NB
11) End connection 1/2'' BSP(F) Swivel nuts at both ends with adoptors
Ignitor End : 3/4'' NPT(M) X 1/2" BSP(M)
12) Adapter
Other End : 1/2" BSP(M) x 1/2'' NPT(M)

Wǀƚ͘>ƚĚ͘ W' ϱK&ϵ
for HEI Retract Mechanism
2) Qty required 01Nos
4) Service Instrument Air
5) Duty Continuous
9) Size 15 NB
Power cylinder End : 1/4'' NPT(M) X 1/2" BSP(M)
12) Adapter

Wǀƚ͘>ƚĚ͘ W' ϲK&ϵ
for Linear Actuator Mechanism
2) Qty required 01Nos
4) Service Instrument Air
5) Duty Continuous
9) Size 15 NB
Power cylinder End : 1/4'' NPT(M) X 1/2" BSP(M)
12) Adapter

Wǀƚ͘>ƚĚ͘ W' ϳK&ϵ
TECHNICAL SPECIFICATIONS FOR RUBBER FLEXIBLE HOSES FOR COAL INLET
UNITS: Flow-> Air - kgs/hr Pressure-> kg/cm2 Temperature-> °C

1) Tag No.
2) Qty required 1 No
General 3) Make Kantech rubber industries
4) Service For Pulverized Coal
5) Duty Continuous
6) Type Rubber flexible hose
7) Min./Max. Ambient Temp 16 ϶C / 50 ϶C
HOSE 8) Nominal Pressure 0.039 bar (g)
9) Maximum Pressure 1 bar (g)
10) Test Pressure 1.5 Bar (g)
11) Size 125 NB
13) End connection Lapped flange 150# at both end

14) Material of construction of End Connection Rubber hose
Notes:
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ϮͿ Area Classification : Installation will be at cement plant environment in USA
3) Flanges should be ASME/ANSI B16.5,150#

Wǀƚ͘>ƚĚ͘ W' ϴK&ϵ
TECHNICAL SPECIFICATIONS FOR (SPARE) FLEXIBLE HOSE
for Oil Gun inlet (LDO)
4) Service LDO
5) Duty Continuous
HOSE 8) Operting Pressure 12 kg/cm2
9) Size 15 NB

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Operating Instructions
8222.81-10 ECOLINE
Two-Piece and Three-Piece Ball Valves
As per ASME B16.34
ECO-BLT 150 – 300 ECO-BLC 1000
1 Declaration of Conformity ……………………………………………………………………………… 2

2 General …………………………………………………………………………………………………….. 3
3 Safety ………………………………………………………………………………………………………. 3
3.1 Safety symbols in these operating instructions …………………………………………………… 3
3.2 Qualification and training of personnel …………………………………………………………….. 4
3.3 Danger of nonobservance of the safety instructions ……………………………………………... 4
3.4 Safety consciousness ………………………………………………………………………………... 4
3.5 Safety instructions for the user / operator …………………………………………………………. 4
3.6 Safety instructions for maintenance, inspection, and installation work ………………………… 4
3.7 Unauthorized modification and manufacturing of spare parts …………………………………… 4
3.8 Inadmissible modes of operation …………………………………………………………………… 4
4 Transport and Interim Storage ………………………………………………………………………… 4
4.1 Transport ……………………………………………………………………………………………… 4
4.2 Interim storage ………………………………………………………………………………………... 5
5 Description / Related Documents …………………………………………………………………….. 5
5.1 Marking ………………………………………………………………………………………………... 5
5.2 Functioning principle: ECO-BLC 150 – 300 ……………………………………………………….. 5
5.3 Functioning principle: ECO-BLC 1000 ……………………………………………………………... 6
5.4 Related documents ……………………………………………………………................................ 7
6 Installation ………………………………………………………………………………………………… 7
6.1 General ………………………………………………………………………………………………... 7
6.2 Installation position …………………………………………………………………………………… 7
6.3 Welding instructions / Installation of pipe ………………………………………………………….. 7
6.4 Actuated valves ………………………………………………………………………………………. 7
7 Commissioning / Decommissioning ……………………………………………………………………... 8
7.1 Commissioning ……………………………………………………………………………………….. 8
7.2 Decommissioning …………………………………………………………………………………….. 8
8 Maintenance / Repair ……………………………………………………………………………………. 8
8.1 Safety instructions ……………………………………………………………………………………. 8
8.2 Maintenance ………………………………………………………………………………………….. 9
9 Troubleshooting ………………………………………………………………………………………….. 9
9.1 General ………………………………………………………………………………………………... 9
9.2 Faults and remedies …………………………………………………………………………………. 10
EcoLine®
1 Declaration of conformity
Herewith we, KSB Aktiengesellschaft

Banhof Platz 1
91257 Pegnitz
Registered Office: Frankenthal (Pfalz)
Germany
Declare that the valves listed below satisfy the requirements laid down in the Pressure Equipment Directive
97/23/EC (PED).
Description of the valve – Type Two-Piece Ball Valves

EcoLine Type ECO-BLT 150 -300
Class 150-300
2”-12” (DN 50 – DN 300)
ASTM A216 WCB, ASTM A351 CF8, ASTM A351 CF8M
Three-Piece Ball Valves

EcoLine Type ECO-BLC 1000
1000 WOG
1¼” – 4” (DN 32 – DN 100)
ASTM A216 WCB, ASTM A351 CF8M
Suitable for Media Group 1
Conformity Assessment Procedure Module D1
Name and address of the authorizing TÜV Anlagentechnik GmbH

and monitoring notified body Am Grauen Stein
51105 Köln
Germany
Notified body identification no. 0035
Certificate no. 01 202 620/Q-02-0567/001
Reference standards and codes ASME B16.34
Dr. Christopher Lange

Head – Product Management / Development Valves
(This document has been prepared electronically and is valid without signature.)
2
EcoLine®
2 General
These operating instructions apply to KSB EcoLine For further questions or in case of damage to the
BL ball valves: Eco-BLT 150 – 300 two-piece valve, please contact your KSB Sales Office.
flanged and Eco-BLC 1000 three-piece socket weld
or threaded (see Sections 5.2, 5.3). For further questions and supplementary orders,
especially when ordering spare parts, please always
Development and production of KSB valves are state the type series version and, when applicable,
subject to QA system according to DIN/ISO 9001. the serial number. (The serial number is stamped on
the outside diameter of the right end flange.)
Correct installation, maintenance, and repair will
ensure trouble free operation of the valves. The specifications (operating data) of the valves are
listed in the technical documentation & type leaflet
The manufacturer does not assume any liability for of the related valve (see also section 5).
these valves in the operating instructions are not
fully observed. When returning valves to the manufacturer, please
refer to section 4.
The valves are marked to ASME B16.34 as required.
3 Safety
The valves must not be operated This manual contains basic instructions to be
Caution beyond the limits defined in the complied with during operation and maintenance. lt
operating instructions, contractual is therefore vital for the fitter and the operator/user
documentation, and type leaflets. Any use beyond to read this manual before installing/ commissioning
the above conditions will lead to overload which the the valve. Also, this manual must always be
valves can not withstand. available at the site where the valve is installed.
Nonobservance of this warning may lead lt is not enough to observe the general instructions
to personal injury or property damage, listed in the section “safety”, the specific safety
e.g.: instructions listed in the other sections should also
x Injury caused by escaping fluids (cold/hot, toxic be observed.
or under pressure).
x Incorrect operation or destruction of the valve. 3.1 Safety Symbols in these Operating
Instructions
The descriptions and instructions in this manual Safety instructions put forth in this instruction
refer to the standard versions but also apply to the manual whose nonobservance would involve the
related variants. risk of personal injury are specially marked with the
general hazard symbol:
These operating instructions do not consider:
x incidents which may occur during installation,
operation and maintenance.
x the local safety regulations. lt is the user’s
responsibility to ensure that they are observed, in accordance with DIN 4844 (safety sign W9), or
also by the installation staff involved. with the electric voltage warning sign:
For actuated valves, the specified connection
parameters and the installation and maintenance
instructions, including the operating manual for the

actuator, must be observed.
in accordance with DIN 4844 (safety sign W 8).
Handling a valve requires skilled
Caution and experienced personnel. Safety instructions whose nonobservance would
involve hazard to the valve and jeopardize its
The personnel in charge of operation, maintenance operation have been marked with the word
and installation of this valve must be aware of the
interaction between the valve and the plant.
Caution
Operator’s errors concerning the valve may have
serious consequences for the entire plant, e.g.: Instructions directly attached to the valve (e.g.
x fluid may escape. nominal pressure) must be complied with and
x downtime of the plant/machine. maintained in a legible condition.
x adverse effect, reduction, or increase of the
efficiency / function of a plant/machine.
3
EcoLine®
3.2 Qualification and Training of Personnel All work on a valve may only be performed when the
The personnel for operation, maintenance, valve is un-pressurized and has cooled down. This
Inspection and installation must be adequately means that the temperature of the medium in all the
qualified for the work involved. The personnel’s valve’s chambers must be lower than the
responsibilities, competence and supervision must vaporization point of the medium.
be clearly defined by the user. lf the personnel in
question is not already in possession of the requisite All work on actuated valves may only be done after
know-how, appropriate training and instructions the actuator has been disconnected from its energy
must be provided. lf deemed necessary, the supply. The procedure described in the operating
manufacturer/supplier will provide such training and instructions to shut down the actuator must be
instructions at the user’s request. In addition, the observed.
user is responsible for ensuring that the contents of
these operating instructions are fully understood by Valves in contact with hazardous media must be
the personnel in question. decontaminated.
3.3 Danger of Nonobservance of the Safety Immediately following completion of the work, all
Instructions safety relevant and protective devices must be re-
Nonobservance of the safety instructions may lead installed and/or re-enabled.
to personal injury and also to danger for the
environment and the valve itself. Nonobservance of Prior to re-commissioning, refer to the points listed
these safety instructions will also forfeit the user’s under Section 7.1 “Commissioning.”
warranty. Such noncompliance could, for example,
result in: 3.7 Unauthorized Modification and
x failure of essential functions of the valve. Manufacturing of Spare Parts
x failure of prescribed maintenance and repair The equipment shall not be altered or modified in
practices. any way prior to consultation with the manufacturer.
x hazard to people by electrical, mechanical, or Genuine spare parts and accessories authorized by
chemical effects. the manufacturer will ensure operational safety. The
x hazard to the environment due to leakage of manufacturer cannot be held responsible for
hazardous substances. damage resulting from the use of non-genuine parts
or accessories or changes in these parts.
3.4 Safety Consciousness
The safety instructions contained in this manual, the 3.8 Inadmissible Modes of Operation
applicable national accident prevention regulations Operational safety and reliability of the valve
and any of the user’s own applicable internal work, supplied is only warranted for its designated use as
operation or safety instructions must be fully defined in Section 2 “General” of the operating
complied with. instructions. The limits stated in the technical
documentation must not be exceeded under any
3.5 Safety Instructions for the User / circumstances.
Operator
Any hot or cold parts or moving parts of the valve 4 Transport & Interim Storage
(e.g. body, lever, gear operator, etc.) that could 4.1 Transport
pose a\ hazard must be protected by the user The valves in the as-supplied condition are ready for
against accidental contact. operation.
Leakage (e.g. at the stem seal) of hazardous For transport and storage, the valves must always
substance (e.g. explosive, toxic, hot) must be be maintained in the closed position and the
drained so as to avoid all danger to people or the connection ends must be plugged using suitable
environment. All relevant laws must be observed. means (e.g. covers, plastic sheets, etc.) to prevent
damage to the seats.
Electrical hazards must be effectively prevented.
(For details, please refer to the VDE standards To prevent damage, do not suspend the valve by its
and/or the local energy supply utility regulations). lever, stem or the actuator.
3.6 Safety Instructions for Maintenance, After delivery or prior to installation, the valve should
Inspection and Installation Work be checked for damage during transit.
The user is responsible for ensuring that all
maintenance, inspection and installation work is
carried out by authorized, adequately qualified staff
who are thoroughly familiar with this instruction
manual.
4
EcoLine®
4.2 Interim Storage perpendicular to the valve ports. The ball is tightly
The valves must be stored in such a way that pressed to the downstream seat ring by the
correct operation is assured even after prolonged preloading force of the seat ring and the pressure of
storage. This comprises: the medium to ensure the full closure of the valve.
x Storing valves in a dry and well-ventilated
warehouse. The seat ring material is PTFE, which has the
x Storing in the closed position (to protect the advantages of low friction coefficient and excellent
seats from damage). corrosion resistance.
x Covering ends with caps or flange protectors to
keep the valve interior free of dust and foreign Anti-static design: Springs (16) and ball bearings
material. (17) at the body/stem interface and the stem/ball
x Taking suitable measures against interface keeps the stem and the ball in contact with
contamination, moisture, frost and corrosion. the body, which prevents the buildup of electrical
charge.
When stored for a long period of time, valves shall
be have anti-corrosive coating on outside machined Blow-out proof stem: The stem is assembled from
surfaces and shall be regularly inspected to ensure inside of the body, so the stem can’t blow out even
they remain in good condition. when the gland and packing both are completely
loosened.
5 Description / Related Documents
The sectional drawings shown on pages 5 and 6 are Locking-device: As the requirement of the customer,
examples for the general design of our valves. For there can be designed a locking aperture on the
drawings and other information pertaining to a stopper to control the position of opened and closed.
specific valve series, please refer to the relevant
type leaflets. Position indicator: A groove on the stem indicates
the position of the valve. When the groove is parallel
5.1 Marking to the pipe, the valve is in the complete open
The valves are marked to PED 97/23/EC and ASME position. When the groove is perpendicular to the
B16.34. pipe, the valve is in the complete closed position.
In particular the marking contains at least following: 5.2.1 Sectional Drawing: ECO-BLT 150 – 300
x Manufacturer
x Year of production
x Valve type model or order no.
x Size (NPS or DN) 6
x Pressure class
x Material
By attaching a CE-marking to the valve the

conformity with the European Pressure Equipment
Directive 97/23/EC is explained. CE marking does
not apply to valve of size 1” (DN 25) and smaller.
5.2 Functioning Principle: ECO-BLT 150 –

300
This valve is used in industrial piping systems as an
on-off valve or a regulating valve.
The valve has a floating ball design. Its obturator is

a ball, which can be rotated through an angle of 90°
to realize the opening and closing of the valve.
Two seat rings (4) are installed in the body (1) and
the cap (2), between which the ball (3) is secured.
The stem (5) connects the ball to the lever (12).
Applying force to the lever, the ball can be freely
rotated between the seat rings.
When the valve is open, the ball hole and the valve
ports are in the same line, so the medium can pass
through with low flow resistance. When the stem
rotates at an angle of 90°, the ball hole is
5
EcoLine®
5.2.2 List of Components: ECO-BLT 150 – 300 Locking-device: As the requirement of the customer,
there can be designed a locking aperture on the
Part stopper to control the position of opened and closed.
Part Name
No.
1 Body Position indicator: A groove on the stem indicates
2 Cap the position of the valve. When the groove is parallel
3 Ball to the pipe, the valve is in the complete open
4 Seat position. When the groove is perpendicular to the
5 Stem pipe, the valve is in the complete closed position.
6 Gasket
7 Thrust Washer 5.3.1 Sectional Drawing: ECO-BLC 1000
8 Packing
9 Stem Packing
10 Gland
11 Gland Bolt
12 Handle
13 Stopper
14 Snap Ring
15 Body Bolt
16 Antistatic Spring
17 Antistatic Ball
5.3 Functioning Principle: ECO-BLC 1000

This valve is used in industrial piping systems as an
on-off valve or a regulating valve.
The valve has a floating ball design. Its obturator is

a ball, which can be rotated through an angle of 90°
to realize the opening and closing of the valve.
Two seat rings (4) are installed in the body (1) and
the caps (2), between which the ball (3) is secured.
The stem (5) connects the ball to the lever (12).
Applying force to the lever, the ball can be freely
rotated between the seat rings.
When the valve is open, the ball hole and the valve
ports are in the same line, so the medium can pass
through with low flow resistance. When the stem
rotates at an angle of 90°, the ball hole is
perpendicular to the valve ports. The ball is tightly
pressed to the downstream seat ring by the
preloading force of the seat ring and the pressure of
the medium to ensure the full closure of the valve.
The seat ring material is PTFE, which has the

advantages of low friction coefficient and excellent
corrosion resistance.
Anti-static design: Springs (16) and ball bearings

(17) at the body/stem interface and the stem/ball
interface keeps the stem and the ball in contact with
the body, which prevents the buildup of electrical
charge.
Blow-out proof stem: The stem is assembled from

inside of the body, so the stem can’t blow out even
when the gland and packing both are completely
loosened.
6
EcoLine®
5.3.2 List of Components: ECO-BLC 1000 Valves and pipes used for high (> 50 deg.
C) or low (< 0 deg. C) temperatures must
Part either be fitted with a protective insulation,
Part Name
No. or there must be warning signs installed showing
1 Body that it is dangerous to touch these valves.
2 Cap
3 Ball Valves with external moving elements
4 Seat must be fitted with protective covers, or
5 Stem other suitable measures must be taken to
6 Hex Nut prevent accidents.
7 Thrust Washer
8 Packing lf a valve is used as end-valve in a pipe,
9 Gland the valve should be protected against
unauthorized or unintentional opening to
10 Spring Washer
prevent personal injury or damage to
11 Stem Nut
property.
12 Locking Device
13 Handle The valve’s identification and nameplate shall be
14 Plastic Cover checked before installation to ensure the valve is
15 Bolt Washer suitable for the application.
16 Bolt
17 Antistatic Ball 6.2 Installation position
18 Antistatic Spring Flow may pass through a ball valve in either
direction. Ball valves may be installed in horizontal,
5.4 Related Documents inclined, or vertical pipe. When actuated valves are
installed in horizontal or inclined pipe, the actuator
Type Type Series Leaflet No. must be supported by some suitable means.
ECO-BLT 150 – 300 8222.51
ECO-BLC 1000 8222.53 6.3 Welding Instructions (Type ECO-BLC
1000 socket weld)
6 Installation Responsibility for welding the connecting pipes lies
6.1 General with the piping installation contractor.
To avoid leakage, deformation or
Caution rupture of the body, the piping When welding valves into the piping or when
should be laid out in such a way welding pipes after the valves have been installed,
that no thrust or bending forces act on the valve the welder
bodies when they are installed and operational. must make sure that no foreign particles, e.g. weld
beads, enter the valve body and remain there,
Only remove the covers from the because these will cause damage to the valve seats
Caution connection ends just before or the stem.
installation. The sealing faces of the
flanges, the pipe threads, or the socket weld The insertion depth as per Technical Rules must be
counterbore surfaces must be clean and complied with. A gap between the pipe end and the
undamaged. base of the socket will prevent inadmissible tensions
in the weld.
For flanged valves: the gaskets at the
connecting flanges must be precisely Do not attach the welding cable (opposite pole) to
entered. Use only joints and gaskets of movable parts of the valve, otherwise these parts
approved materials. All holes provided in the flanges may be scorched.
must be used for the flange connection.
6.4 Actuated valves
When painting the pipes, do not apply Read the instruction manual of the
paint to bolts and stem. lf construction Caution actuator before installation.
work is still in progress, the valves must
be protected against dust, sand and building Electrical cables may only be connected
material, etc. (cover by suitable means). by qualified personnel.
Do not use valves, levers, or gear The applicable electrical regulations (e.g.
operators as footholds! VDE), also for equipment in hazardous
locations, must be observed.
7
EcoLine®
All electrical equipment such as actuator, 8 Maintenance / Repair

switchboard, magnetic valve drive, limit switch etc. 8.1 Safety Instructions
must be installed in flood-proof dry locations. Maintenance and repair work may only be carried
out by skilled and qualified personnel.
Voltage and frequency must match the values
stated on the name plate. For all maintenance and repair work, the safety
instructions listed below and also the general notes
7 Commissioning / Decommissioning in section 3 must be observed.
7.1 Commissioning
7.1.1 General Always use suitable spare parts and tools, even in
Prior to commissioning the valve, the pressure, emergencies, otherwise correct operation of the
temperature and material data stated on the valve valves can not be assured.
should be compared to the actual operating
conditions in the piping system to check whether the 8.1.1 Dismantling of valves
valve can withstand the loads occurring in the Before removing the complete valve from the pipe,
system. or before repair or maintenance work on the valve
itself, the entire valve must be un-pressurized and
Possible pressure surges (water hammer) must not must have cooled down sufficiently so that the
exceed the highest admissible pressure of the valve. temperature of the medium in all the valve chambers
Adequate precautions should be taken. is lower than the vaporization point of the medium,
to prevent scalding.
In new pipe systems and especially after repair
work, the system should be flushed with the valves Dismantling a pressurized valve will
fully open to remove solids, e.g. weld beads, which Caution cause danger to life and limb!
may damage the seats.
lf toxic or highly inflammable substances or liquids
Venting the valve by loosening connecting whose residues may cause corrosion by interaction
bolting or the gland packing is dangerous with the air humidity were handled by the valve, then
and therefore not permitted. the valve should be drained and flushed or vented.
7.1.2 Operation Wear appropriate safety clothing and eye

The valves are closed by turning the lever protection or face guard/mask.
perpendicular to the flow and opened by turning the
lever ¼ rotation so the lever is parallel to the flow. Depending on the installation position, any liquid
remaining in the valve may have to be removed.
Operating torques are published in the Type Series
booklets. Prior to possible transport, the valves must be
flushed and drained carefully.
As the valve can be damaged by
Caution applying excessive forces, it is not lf you have any questions please contact your KSB
allowed to use additional levers to Sales Office.
operate the valve.
8.1.2 Removing Actuators
7.1.3 Functional Check lf actuators powered by an external source of
The following functions should be checked: energy (electric, pneumatic, hydraulic) need to be
removed from the valve or dismantled, the energy
Before commissioning, the shut-off function of the supply must be shut down prior to starting any repair
valves should be checked by repeated opening and work and the instructions in Sections 3 and 8.1 and
closing. the operating instructions of the actuator must be
observed.
The gland packing should be checked when it is
subjected to the full operating pressure and Actuators with integrated spring mechanism contain
temperature for the first time. lf necessary, retighten pre-loaded springs and shall only be dismantled with
the packing evenly and carefully. extreme care, using the requisite locking devices.
7.2 Decommissioning Springs under tension!

During extended shutdown periods, liquids liable to
change their condition due to polymerization,
crystallization, solidification etc. must be drained lf you have any questions please contact your KSB
from the piping system. If necessary, the piping Sales Office.
system should be flushed with the valves fully open.
8
EcoLine®
8.2 Maintenance
Our valves are largely maintenance free. To ensure
reliable operation and to reduce repair costs, all
valves, especially those which are seldom operated
or where access is difficult, should be checked
periodically.
The user is responsible for defining appropriate

intervals for checks and maintenance, depending on
the application of the valve.
The service life of valves can be extended by:

x lubricating movable parts (not for oxygen
valves) using suitable lubricants (to DIN 51825 /
equivalent).
x timely changing of the packing rings.
x timely replacing of the seat rings.
The safety instructions in Sections 3, 8.1 and the

notes in Section 9 must be observed.
8.3 Valve Reassembly

Valve reassembly shall be effected in reverse order
to dismantling.
To maintain functional reliability, new packing shall

be used whenever the valve is reassembled.
After reassembly and prior to commissioning / start-

up, the valve shall be subjected to a leak test in
accordance with API 598 and ASME B16.34.
9 Troubleshooting
9.1 General
All repair and service work must be carried out by
qualified personnel using suitable tools and genuine
spare parts.
We recommend having this work

Caution performed by our service
personnel.
The safety instructions in Sections 3 and 8

must be observed.
9
EcoLine®
9.2 Faults & Remedies
Problem Possible Cause Solution

The bolts are not tightened evenly or Re-tighten bolts evenly using a cross-
sufficiently. over pattern.
Leakage from the flange
Gasket failure. Replace the gasket.
between the body and cap(s)
Gasket pocket surfaces are
Repair
damaged.
The packing is too loose or unevenly Evenly tighten each packing ring one
compressed. by one.
Packing Leakage
Worn or damaged packing. Replace the packing.
Replace the seat ring and/or re-grind

The seating surface is worn out.
the ball.
There is dirt or foreign material

Seat Leakage Clean the seating surfaces.
between the seating surfaces.
Re-tighten botls evenly using a cross-

The ball is clamped too loosely.
over pattern.
The gland is pressed unevenly or too Evenly tighten each packing ring one
tightly. by one.
The stem does not operate
smoothly
There is dirt or foreign material
between the seating surfaces. Clean the seating surfaces.
lf you have any questions please contact your KSB Sales Office.
Do not replace packing while the valve is pressurized. The back seat bushing is not intended to
maintain a seal during packing replacement.
10
EcoLine®
Subject to technical modification without prior notice

20.12.2007
8222.81-10
KSB Aktiengesellschaft
Johann-Klein Strasse 9 • 67227 Frankenthal (Germany)
Tel.: +49 6233 86-0 • fax: +49 6233 86-3439 • e-mail valves@ksb.com • www.ksb.com
Operating instructions
0570.82/12-10
Shut-off Valves
BOAR-H/HE
NORIR 40
NORIR 160
NORIR 320
NORIR 500
NORIR-A
NORICHEMR
BOACHEMR
Start and Stop Control
Valves
ZJSVA/ZXSVA
Non-return Valves
NORIR 40
NORIR 160
NORIR 320
NORIR-A
RGS
NORICHEMR
Strainers
NORICHEMR
NORIR 40
1 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Marking of instructions in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Non-compliance with safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Safety awareness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Safety instructions for the operator / user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Safety instructions for maintenance, inspection and installation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.6 Unauthorized modification and manufacture of spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.7 Unauthorized modes of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Description / Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.1 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2 Drawings / documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.3 List of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.4 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.2 Operating data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.3 Installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.4 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.5 Valves with actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.6 Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7 Commissioning / start-up / shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.1 Commissioning / start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.2 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8 Servicing / maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8.3 Valve reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9 Trouble-shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9.2 -- Faults > Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PED 97/23/EC
1 Declaration of conformity
Hereby we, KSB Aktiengesellschaft
Bahnhofplatz 1
91257 Pegnitz
Head Office: Frankenthal (Pfalz)
Germany
declare that the valves listed below comply with the requirements of the Pressure Equipment Directive
97/23/EC.
Description of the valve types: Shut-off Valves

-- BOA-H/HE PN 25/40 DN 10-350
-- NORI 40 PN 25/40 DN 10-400
-- NORI 160 PN 63-160 DN 10-200
-- NORI 320 (ZXLF/ZXSF) PN 250/320 DN 65-200
-- NORI 320 (ZXSV) PN 250/320 DN 10-50
-- NORI 500 PN 250-500 DN 10-65
-- NORI-A PN 250-500 DN 10-50
-- NORICHEM PN 10-40 DN 10-200
-- BOACHEM PN 10-40 DN 15-100
Start and Stop Control Valves
-- ZJSVA/ZXSVA Pmax. = 600 bar DN 65/60-250/125
Non-return Valves
-- NORI 40 PN 25/40 DN 10-300
-- NORI 160 PN 63-160 DN 10-200
-- NORI 320 (RXL/RXS) PN 250-320 DN 65-200
-- RGS PN 250-500 DN 10-50
-- NORI-A PN 250-500 DN 10-50
Strainers
codes applied: AD 2000-directive / TRD 110, TRB 801 No. 45
Suitable for: Fluid groups 1 and 2
Conformity Assessment Procedure: Module H
Name and address of the notified body TÜV SÜD Industrie Service GmbH
responsible for approval and surveillance Steam and Pressure Engineering Department
Edisonstr. 15
90431 Nürnberg
Germany
Identification number of notified body: 0036
Certificate number: DGR-0036-QS-304-04
Valves DN d 25 fall under the Pressure Equipment Directive 97/23/EC Art. 3 §3. They must bear neither the
CE-marking nor the identification number of the notified body.
Rainer Michalik
Integrated Management
Date: 01.02.2007
(This document has been prepared electronically and is valid without signature)
2
Herewith we, KSB Aktiengesellschaft
Bahnhofplatz 1
91257 Pegnitz
Registered office: Frankenthal (Pfalz)
Germany
declare that the valves listed below satisfy the safety requirements laid down in the Pressure Equipment
Directive 97/23/EC (PED).
Description of valve types: Maintenance-free bellows-type shut-off valves

-- NORI 40 ZYLB/ZYSB PN 25/40 DN 15-300
Strainers
-- NORI 40 FSL/FSS PN 25/40 DN 15-300
Applicable standards: Design: DIN 3840

incl. AD 2000-A4 para. 6.2
Material: DIN EN 10213-1

DIN EN 10213-2
Pressure and leak test: DIN EN 12266-1
Final test: ZN 59091, ZN 59092

ZN 59095, ZN 59096
Marking: as per PED 97/23/EC, EN 19
Suitable for: Fluids in Groups 1 and 2
Conformity assessment procedure: Module H
Name and address of the notified body TÜV SÜD Industrie Service GmbH
responsible for approval and surveillance: Steam and Pressure Engineering Department
Edisonstr. 15
90431 Nürnberg
Germany
Identification number of the notified body: 0036
Certificate number: DGR-0036-QS-304-04
DN d 25 valves fall under Art. 3 §3 of the Pressure Equipment Directive 97/23/EC. They must neither bear the
CE marking nor the identification number of a notified body.
Rainer Michalik
Integrated Management
Date: 01.02.2007
(This document has been prepared electronically and is valid without signature.)
3
2 General instructions 3 Safety
These operating instructions apply to all KSB shut-off valves, These operating instructions contain fundamental information which
non-return valves, strainers and start and stop control valves as must be complied with during installation, operation and maintenance.
described in section 5, unless reference is made to other operating Not only must the general safety instructions laid down in this chapter
manuals in individual cases. on ”Safety” be complied with, but also the safety instructions outlined
Only correct installation, maintenance or repair will ensure smooth under specific headings.
operation of the valves.
The manufacturer shall not accept any liability if the instructions set 3.1 Marking of instructions in the manual
forth in this manual are not complied with. The safety instructions contained in this manual whose
The design, manufacture and testing of KSB valves are subject to a QM non-observance might cause hazards to persons are specially marked
system to DIN EN ISO 9001 as well as the European Pressure with the general hazard sign, namely
Equipment Directive 97/23/EC. Compliance with these requirements,
however, is based on normal, static loading, e.g.
-- flow velocities typical of the fluid handled
-- typical temperature gradients
Such measures may, for example, influence safety sign in accordance with DIN 4844 – W 9.
-- material selection The electrical danger warning sign is
-- wall thickness
-- seal selection
-- protection of valve areas prone to wear
-- prevention of excessive pressures and temperatures
-- special designs for control operation, etc. safety sign in accordance with DIN 4844 – W 8.
Valves exposed to creep-rupture conditions have a limited service life The word
and have to meet the applicable regulations stipulated in the technical
codes.
The valves must not be operated outside the
Caution
Caution permissible operating range, especially with regard
to pressure and temperature. The limits are indicated on the name plate is used to introduce safety instructions whose non-observance may
or currently applicable type series booklet (also see section 5.2). The lead to damage to the valve and its functions.
nominal pressure classes only apply up to a temperature of 50 qC. For Instructions attached directly to the valve (e. g. nominal pressure) must
temperatures exceeding 50 qC refer to the pressure-temperature always be complied with and be kept in a perfectly legible condition at
ratings included in the type series booklets.These ratings must not be all times.
exceeded under any circumstances. Operation of the valves outside
these conditions may result in overloads which may damage the valves.
The type series booklets can be found at www.ksb.com – product
catalogue.
Non-observance of this warning may cause personal injury and
damage to property, for example:
-- injuries resulting from fluid leakage (cold/hot, toxic, under
pressure, ...),
-- impairment of the valve’s function or its destruction.
The descriptions and instructions set forth in this manual refer to the
standard models but are also applicable to variants.
For actuated valves, the operating manual of the actuator must be
adhered to without fail.
These operating instructions do not take into account:
-- any eventualities and events which might occur during installation,
operation and maintenance,
-- local regulations; the operator must ensure that such regulations are
strictly observed by all, including the personnel called in for
installation.
The valve must only be operated by qualified
Caution personnel.
Incorrect operation of the valve may have a substantial impact on the
entire system, for example:
-- leakage of the fluid handled,
-- system / machine brought to a standstill
-- impairment / reduction / increase of the system’s / machine’s
function / effect.
For any queries you may have or in the case of damage, please contact
your nearest KSB sales office.
For any queries and repeat orders, in particular for purchasing spare
parts, please specify the type series / variant details, the order number,
as well as the year of construction, if possible.
The technical data (operating data) of the valves are specified in the
technical literature (type series booklet, valve characteristic, chemical
resistance chart) of the respective valve (cf. section 5).
4
3.2 Non-compliance with safety instructions 4 Transport and storage
Non-compliance with safety instructions can jeopardize the safety of The valves are delivered ready for operation, the obturator is in ’closed’
personnel, the environment and the valve itself. Non-compliance with position and the line connection ports are closed with suitable material
these safety instructions will also lead to forfeiture of any and all rights (caps, plugs, covers).
to claims for damages.
In particular, non-compliance can, for example, result in: 4.1 Transport
-- failure of important valve / system functions, Suitable precautions shall be taken to prevent damage during transport.
-- failure of prescribed maintenance and servicing practices, The valves must never be suspended by the
-- hazard to persons by electrical, mechanical and chemical effects,
Caution handwheel or by the actuator, if any.
-- hazard to the environment due to leakage of hazardous substances For transporting large valves, ropes shall be attached to the yoke arms
or to the cover flange.
3.3 Safety awareness Valves with actuators shall be transported by means of ropes attached
It is imperative to comply with the safety instructions contained in this to the connection ports and yoke arms, taking into account the centre
manual, the relevant national health and safety regulations and the of gravity.
operator’s own internal work, operation and safety regulations. Use any lifting lugs provided.
For the valve weights refer to the relevant manufacturer documentation
3.4 Safety instructions for the operator / user (type series booklet ----> section 5.2; order confirmation).
Any hot or cold valve components (e. g. body components or After delivery and prior to installation, check the valve for potential
handwheel) that could pose a hazard must be equipped with a guard damage acquired in transit.
by the operator.
Guards which are fitted to prevent accidental contact with moving parts 4.2 Storage
(e.g. coupling) must not be removed whilst the unit is operating.
Storage / interim storage of the valves must ensure that even after a
KSB recommends that leakages (e.g. at the stem seal) of hazardous prolonged period of storage the valves’ function is not impaired. The
fluids (e.g. explosive, toxic, hot) be contained so as to avoid any danger following requirements must be met:
to persons and the environment. All relevant laws must be heeded.
-- Storage is performed with the valve in the closed position (to protect
Electrical hazards must be eliminated. (For details please refer to VDE the seat / disc contact faces against damage),
regulations and the safety regulations laid down by the local energy
supply companies, for instance). -- Measures are taken to protect the valves against dirt, humidity, frost
and corrosion (e.g. by using foils or caps; indoor storage).
3.5 Safety instructions for maintenance,
inspection and installation work 5 Description / Related documents
The operator is responsible for ensuring that all maintenance,
inspection and installation work be performed by qualified personnel. 5.1 Marking
As a rule, work on the valve must only be carried out after the valve has The valves are marked in accordance with the Pressure Equipment
cooled down and valve pressure has been released. The fluid Directive 97/23/EC and the pertinent standards on valve types/design,
temperature must be below the vaporization temperature limit in all as well as TRD 110 (German Steam Boiler Regulations) and TRB 801
areas in contact with the fluid. No. 45 (German Pressure Vessel Regulations).
Work on (actuated) valves must be carried out only during standstill. Marking includes as a minimum:
The shutdown procedure described in the manual for taking the valve -- manufacturer
out of service must be adhered to without fail.
-- year of construction
Immediately following completion of the work, all safety-relevant and
-- type or order no.
protective devices must be re-installed and / or re-activated.
-- DN
Please observe all instructions set out in section 7
Commissioning / start-up before returning the valve to service. -- PN or max. permissible pressure/temperature
-- material
3.6 Unauthorized modification and manufacture The CE marking on the valve means it is in conformity with the
of spare parts European Pressure Equipment Directive 97/23/EC.
Modifications or alterations of the valve supplied are only permitted Class PN DN
after consultation with the manufacturer. Original spare parts and
d25 32 40 50 65 80 100 125 150 t200
accessories authorized by the manufacturer ensure safety. The use of
other parts can invalidate any liability of the manufacturer for 10
150
consequential damage. 16
25
3.7 Unauthorized modes of operation t300
t40
The warranty relating to the operating reliability and safety of the valve
supplied is only valid if the equipment is used in accordance with its
designated use as described in section 2 General of this manual. The
limits stated in the technical literature must not be exceeded under any
circumstances.
5
5.2 Drawings / documentation
The sectional drawings below provide examples of the general design / configuration of the valves. For illustrations relating to specific valve series
and further information please refer to the respective type series booklets.
5.2.1 Shut-off valves with gland packing
Type DN PN Material Type series booklet No.
NORIR 40 ZXL/ZXS 10-400 7621.1
25/40 P 250 GH / GP 240 GH+N
NORIR 40 ZXLF/ZXSF 10-200 7622.1
NORIR 160 ZXL/ZXS 10-200 63-160 7631.1
P 250 GH / 13 CrMo 4-5
4 5 / GP 240 GH+N / G 17 CrMo 5-5
55
NORIR 160 ZXLF/ZXSF 10-200 63-160 7633.1
NORIR 320 ZXLF/ZXSF 65-200 250/320 GP 240 GH+N / G 17 CrMo 5-5 7653.1
NORIR 320 ZXSV 10-50 250/320 16 Mo 3 / 13 CrMo 4-5 / 11 CrMo 9-10 7640.1
16 Mo 3 / 13 CrMo 4-5/ 11 CrMo 9-10 /
NORIR 500 ZXSV 10-65 250-500
15 NiCuMoNb 5 / X 10 CrMoVNb 9-1 / X 10 CrMoVNb 9-2
7641.1
NORIR-A ZXLR/ZXSR 10-50 250-500 16 Mo 3 / 13 CrMo 4-5 / 11 CrMo 9-10 7655.1

NORICHEMR ZYA/ZXA 10-200 10-40 1.4408 8111.1
Sectional drawings (shut-off valves with gland packing)
NORICHEMR ZYA
NORIR 40 ZXL NORIR 40 ZXLF NORIR 160 ZXS NORIR 160 ZXSF
NORIR 320 ZXSV NORIR 500 ZXSV NORIR-A ZXSR NORIR 320 ZXLF
6
5.2.2 Shut-off valves with bellows
BOAR-H/HE 10-350 7161.1
NORIR 40 ZXLBV/ZXSBV 10-200 P 250 GH / GP 240 GH+N 7168.1

25/40
NORIR 40 ZXLB/ZXSB 10-200 7165.1
NORIR 40 ZYLB/ZYSB 15-300 GP 240 GH+N 7160.1
BOACHEMR 10-100 7621.1

10 40
10-40 1 4408
1.4408
NORICHEMR ZYAB/ZXAB 10-200 8111.1
Sectional drawings (shut-off valves with bellows)
BOAR-H/HE NORIR 40 ZXLBV/ZXSBV NORIR 40 ZXLB/ZXSB NORIR 40 ZYLB/ZYSB

BOACHEMR NORICHEMR ZYAB/ZXAB
5.2.3 Start and stop control valves

P 250 GH / 15 NiCuMoNb 5 / 16 Mo 3 /
65/60- Pmax. =
ZXSVA/ZJSVA 13 CrMo 4-5 / 11 CrMo 9-10 / X 20 CrMo V 11-1 / 7253.1
250/125 600 bar
X 10 CrMoVNb 9-1 / X 10 CrMoVNb 9-2
Sectional drawing (start and stop control valves)
ZJSVA/ZXSVA
7
5.2.4 Non-return valves
NORIR 40 RXL/RXS 10-300 25/40 P 250 GH / GP 240 GH+N 7673.1
NORIR 160 RXL/RXS 10-200 63-160 P 250 GH / 13 CrMo 4-5 / GP 240 GH+N / G 17 CrMo 5-5 7681.1
NORIR 320 RXL/RXS 65-200 250/320 GP 240 GH+N / G 17 CrMo 5-5 7657.1
RGS 10-50 250-500 P 250 GH / 13 CrMo 4-5 / 11 CrMo 9-10 7692.1
16 Mo 3 / 13 CrMo 4-5 /
NORIR-A RXLR/RXSR 10-50 250-500
11 CrMo 9-10
7693.1
NORICHEMR RYA/RXA 10-200 10-40 1.4408 8112.1
Sectional drawings (non-return valves)
NORIR 40 RXL NORIR 160 RXS NORIR 320 RXS RGS
NORIR-A RXSR NORICHEMR RYA
5.2.5 Strainers
NORIR 40 FSL/FSS 15-300 25/40 GP 240 GH+N 7127.1
NORICHEMR FSA 10-200 10-40 1.4408 8113.1
Sectional drawing (strainer)
NORICHEMR FSA NORIR 40 FSL/FSS
8
5.3 List of components 5.4.2 Shut-off valves without separate bonnet
NORI 320 and NORI 500 shut-off valves without separate bonnet
Part No. Description
consist of a die-forged body (100) and a forged yoke (166) which holds
100 Body the disc stem (203) or throttling disc stem (204) and the actuating
139 Bonnet element. The bayonet-type connection between body (100) and yoke
160 Cover (166) is secured against turning by a hex. head bolt (901.1) and hex. nut
(920.1) with spring washer (930.1).
166 Yoke
In the body (100), fluid flow is shut off by the disc stem (203) or throttling
172 Bonnet
disc stem (204).
200 Stem
The valve seat/disc interface is made of wear-resistant material
203 Valve disc stem
(stellite). The gland packing (461), which seals off the body (100) and
204 Throttling disc stem the disc stem (203 or 204), is tightened at the gland cover (452) by
206 Upper stem means of two studs (902) with two hex. nuts (920.2) pressing the gland
207 Lower stem packing against the gland ring (457).
323 Cylindrical roller bearing The throttling disc stem (204) is secured against turning by the stud
350 Valve disc (562) on NORI 320 valves, or by a stop (579) pinned to the stem on
NORI 500 valves. At the same time, the pin or stop also serve to indicate
351 Check valve disc
the position of the disc inside the body.
352 Throttling valve disc
The threaded bush (544) runs in bearings in the yoke head and is
411.1 Joint ring
supported by the bolted connection (514). The handwheel is connected
411.2 Joint ring to the threaded bush (544) by a key (940) and secured with a circlip.
414 Thrust plate
442 Bellows
5.4.3 Start and stop control valves
452 Gland cover The main components of start and stop control valves are the
block-forged body (100), the bonnet (139) with gland packing (461), the
457 Gland ring
throttling valve disc (352) rigidly connected to the stem, and the yoke
461 Gland packing (166) with the actuating element.
501 Segmental ring The valve features a pressure seal bonnet. The pressure inside the
540 Yoke bush body (100) presses the bonnet (139) against the joint ring (411.1). The
544 Threaded bush contact faces in the body and on the throttling valve disc (352) are
562 Parallel pin stellited.
579 Stop The gland packing (461), which seals off the stem (200), is tightened by
729 Intermediate flange means of the studs (902.3) and nuts (920.1) at the gland cover (452).
758 Strainer insert The stem (200) is moved in axial direction by a rotating threaded bush
900.1 T-head bolt (544) which is fitted with cylindrical roller bearings (323). It lifts off the
throttling valve disc (352) or presses it against its seat in the valve body.
901.1 Hex. head bolt
The threaded bush (544) is positioned in the yoke head by an
902.1 Stud
intermediate flange (729) and socket head cap screws (914.1). The
903 Drain plug handwheel (961) is located on the threaded bush (544) and connected
914.1 Socket head cap screws by a key (940). It is secured by a circlip.
920.1/920.2 Hex. nut
5.4.4 Non-return valves
925 Stem nut
Non-return valves are check valves which close automatically if fluid
930.1 Spring washer
flow is reversed. Non-return valves with separate cover consist of the
940 Key pressure-retaining components of body (100) and cover (160), as well
950 Spring as the functional unit.
961 Handwheel The body (100) and cover (160) are connected by studs (902) and nuts
(920.1), and the joint is sealed off by the joint ring (411).
5.4 Function
The high-pressure non-return valve RGS is in pressure seal design. It
5.4.1 Shut-off valves with bolted bonnet is sealed by the bonnet (139), joint ring (411) and segmental ring (501).
The joint ring is pre-loaded via the nuts (920).
The valves consist of the pressure-retaining parts, i.e. body (100) and
yoke (166) or bonnet (172), and the functional unit. The check valve disc (351) is guided in the cover (160) or bonnet (139).
The position of the check valve disc (351) is determined both by the flow
The body (100) and yoke (166) or bonnet (172) are connected by studs conditions and by the spring (950), if any.
(902) and nuts (920.1), and the joint is sealed off by the joint ring (411).
On shut-off valves with gland packing, the trim mainly consists of the 5.4.5 Strainers
valve disc (350/352), stem (200) or throttling disc stem (204); the Strainers feature the same pressure-retaining components and sealing
actuating element is a handwheel (961) or actuator. design as non-return valves with separate cover (5.4.4)
The stem (200) passage in the yoke (166) is sealed by the gland The strainer insert (758) is clamped between the body seat and the
packing (461), which is tightened by means of two nuts (920.2) at the cover, where it removes particles from the flow, depending on the mesh
gland cover (452). size selected.
The contact faces of body (100) and/or valve disc (350) are made of
rust-proof materials.
On shut-off valves with bellows and back-up gland, the trim mainly
consists of the valve disc (350/352), stem (200), and bellows (442); the
actuating element is a handwheel (961) or actuator.
The passage of the stem (200) [or lower stem (207)] in the yoke (166)
or bonnet (172) is sealed off by the bellows (442) in accordance with the
German clean air regulations. The back-up gland packing (461) is
tightened by means of two nuts (920.2) at the gland cover (452) [or
threaded bush (544) BOA-H]. The bellows-type stem seal is
maintenance-free.
The contact faces of body (100) and/or valve disc (350) are made of
rust-proof materials.
9
6 Installation 6.3.3 Non-return valves
To ensure proper operation, non-return valves must always be installed
6.1 General in such a way that the fluid enters the valve beneath the check valve disc
(351). When equipped with a spring (950), they can be used in both
As a rule, the engineering contractor, construction company or
pipes with upward flow and pipes with downward flow.
operator / user are responsible for the positioning and installation of the
valves. Non-return valves without closing spring (950) shall only be installed in
horizontal position with the cover pointing upwards in horizontal pipes.
Planning and installation errors may impair the reliable function of the
valves and pose a substantial safety hazard. Compliance with the 6.3.4 Strainers
following requirements is of particular importance:
Strainers shall always be installed in such a way that the fluid flows
The piping must be laid such that detrimental thrust through the strainer insert from the inside towards the outside (cage
Caution and torsional forces are kept away from the valve effect of the strainer insert).
body (100) during installation and operation to avoid both leakage and We recommend to fit shut-off valves in the pipeline on both sides of the
damage to the body. strainer, so that the strainer can be replaced or cleaned without having
to drain the entire system. Strainers shall be installed with sufficient
The caps on the connection ports shall be removed
Caution immediately prior to installation.
clearance for removing the strainer insert. In both horizontal and vertical
pipes, we recommend to install the strainer with the strainer insert
When painting the pipelines and valves, do not apply paint to hanging downwards to facilitate cleaning. Compliance with the
the bolts, stems and plastic components (valve function will be directional arrow is essential. On strainers with magnetic insert we
impaired). If construction work is still in progress, the valves must be recommend to remove the entire cover to clean the magnet.
protected against dust, sand and building material (cover with suitable Please note: When replacing the strainer insert make sure that the weld
material). of the insert is not located in the strainer outlet port, so as to attain an
Do not use valve handwheels as footholds. optimum (high) Kv value.
For safety reasons, valves and piping systems operated at high 6.3.5 Special designs
(> 50 qC) or low (< 0 qC) temperatures must be insulated, or a Valves with separate throttling valve disc shall always be installed in
warning sign must point out the risk of personal injury involved when such a way that the pressure to be sealed off lies beneath the disc, to
touching the hot or cold components.
ensure a reliable throttling effect.
Valves with external moving elements must be fitted with protective
For higher differential pressures integral throttling valve disc-stem
covers, or other suitable measures must be taken to prevent accidents.
connections are required (e.g. NORI 320, NORI 500 valves). In such
Valves used as dead-end valves in a pipeline should be cases we recommend to install the valves so that the pressure lies
protected against unauthorized or unintentional opening, to above the disc.
prevent damage to property and/or personal injury. If you have questions concerning optimum valve selection or
permissible differential pressures for valves with throttling discs, please
6.2 Operating data contact the valve manufacturer.
The following maximum operating pressures must not be exceeded; re- Drainage, vent or manual start-up pipes are normally fitted with valve
fer to Section 3.7 as well as to the identical information in the respective combinations consisting of a shut-off valve (pressure beneath the disc)
type series booklets. and a throttling valve (integral throttling disc–stem connection,
pressure above the disc).
Permissible operating pressures in bar (static load)
Valves with pilot plug are always installed so that the pressure to be
Type series BOA£-H/HE, NORI£ 40
sealed off lies above the plug.
Nominal Material Permissible operating pressures in bar If the valves are to be used as dead-end valves, double shut-off should
pressure at temperatures in qC 1) be ensured for safety reasons.
PN 120 200 250 300 350 400 450
25 2) P 250 GH 1.0460 22.7 20.8 19.0 17.2 16.0 14.8 8.2 6.4 Installation instructions
40 2) GP 240 GH+N 1.0619+N 36.3 33.3 30.4 27.6 25.7 23.8 13.1
6.4.1 Flanged valves
1) Valves can be used down to --10 qC. 2) permissible up to +50 qC The mating flange faces must be clean and undamaged.
6.3 Installation position The gaskets on the mating flanges must be properly centered.
The valve bodies are marked with an arrow indicating flow direction, if Only fasteners and sealing elements made of approved
necessary. The valves must be installed such that the flow direction of materials shall be used. For the flange connection between valve and
the fluid corresponds to the direction shown by the arrow cast on the pipe use all flange bolt holes provided.
valve body. If no directional arrow is cast on the valve body, the valve Use suitable tools to tighten the bolts evenly and crosswise at the
can be installed in any position. permissible torques.
6.3.1 Shut-off valves 6.4.2 Welding instructions
Shut-off valves can be installed in any position. However, the best Responsibility for welding the valves into the piping and for any heat
installation position is with the stem pointing vertically upwards. Valves treatment required lies with the respective contractor or the plant
with bellows should not be installed with the stem pointing downwards, operator.
if possible, to prevent dirt deposits between the folds of the bellows.
When welding valves with butt or socket weld ends
Shut-off valves must be installed in the line so as to ensure that the fluid Caution into the piping or when performing welding jobs on a
enters the valve beneath the disc and flows out above the disc.
pipeline after the valves have been installed (pipeline installation) make
However, they can also be installed in lines with alternating flow. If the
sure that no contamination enters the valve body and stays there, to
valves are to be used for throttling applications, a throttling valve disc
prevent damage to the seat/disc interface or stem guiding elements.
must be used. For flow incidence on throttling valve discs please refer
to the respective type series booklets. If in doubt, please contact the When welding the valve into the pipeline, take special
KSB factory. Caution precautions e.g. welding in several steps, so that the
temperature rise in the middle of the valve body does not exceed the
6.3.2 Start and stop control valves max. permissible operating temperature. The valve must be in ’open’
Start and stop control valves must be installed so that the fluid enters position during welding.
the valve above the throttling valve disc (352) and flows out beneath the
The welding cable (opposite pole) must not be
disc. This avoids erosion due to the more favourable downward flow Caution attached to functional valve elements, to prevent
and achieves better tightness in the seat.
scorching.
10
On valves with socket weld ends, the insertion depth given in the The bonnet/cover bolting 902.1/920.1 with the joint ring (411.1) shall be
applicable technical code must be complied with. A gap between the gradually tightened crosswise, evenly and in clockwise direction after
pipe end and the socket base will prevent impermissible stresses in the the first loading or heating up of the valves and in the event of leakage
weld. at the joint ring (411.1). For tightening torques please contact the
manufacturer, if necessary.
6.5 Valves with actuator Open the valve by two full handwheel turns before
Valves with transmission gear and/or actuators must be installed with Caution re-tightening nuts 920.1, to prevent jamming of the
the stem in vertical position, if possible. If this requirement cannot be seat.
met, adequately support the actuator on site or consult the
Re-tightening the nuts (920.1) of the bonnet/cover bolting is particularly
manufacturer.
important for valves installed in heat transfer systems to DIN 4754.
Electrical connection shall be effected by suitably trained
personnel only.
7.1.4 Valves with actuator
6.6 Insulation On valves with electric / pneumatic /hydraulic actuators, the
strokes / actuating forces must be limited.
If the valve is to be insulated, make sure that the insulation does not
impair the function of the valve. KSB recommends to make sure that the Electrical actuators are factory-set ready for operation. They shall be
sealing areas at the cover joints and at the stem passage (gland wired as follows:
packing) are easily accessible and visible. Globe valve ”CLOSE” torque-dependent
Globe valve ”OPEN” travel-dependent
7 Commissioning / start-up / shutdown The wiring diagrams are given in the terminal boxes.
(Please also refer to section 6 Installation) For pneumatic/hydraulic actuators, the control pressures specified in
the order shall be complied with. Non-observance may damage the
7.1 Commissioning / start-up actuator.
Closing and opening torques or actuating forces shall be enquired from
7.1.1 General the manufacturer, if necessary.
Prior to commissioning / start-up compare the material, pressure and
temperature data on the valves with the operating conditions of the 7.2 Shutdown
piping to check the material’s chemical resistance and stability under
In the event of prolonged shutdowns, KSB recommends to drain fluids
load.
which change their physical condition due to changes in concentration,
Surge pressure (water hammer), which might occur, must not polymerization, crystallization, solidification, etc., from the piping. If
exceed the max. permissible pressure. Safety measures are required, flush the piping with the valves fully opened.
required to be taken.
In new systems and particularly after repair, the complete piping system 8 Servicing / maintenance
must be thoroughly flushed with the valves fully opened so that particles
and / or welding beads that might damage the seat/disc interface are 8.1 Safety instructions
removed.
Repair and maintenance work must only be performed by qualified
If the piping system is cleaned by means of a pickling procedure,
personnel taking into account the relevant health and safety
responsibility for the compatibility of the pickling media used and the
regulations.
pickling procedure itself lies with the pickling company.
It is imperative that the below safety instructions and the general
Venting the valve by undoing the bonnet/cover bolting or removing the
information on safety as per section 2, Safety, be observed for all
gland packing is dangerous and therefore not permitted.
servicing and maintenance work to be performed.
To prevent damage to the valve material or joint seals, the usual start-up
and shutdown velocities must be adhered to. Always use suitable spare parts and tools, even in
Caution emergencies, to ensure proper functioning of the
7.1.2 Valve actuation valves.
The valves are closed by turning the handwheel in clockwise direction
8.1.1 Valve dismantling
and opened by turning it in counter-clockwise direction (top view).
Direction symbols are found on the top of the handwheel. Before removing the complete valve from the pipeline or before repair
or maintenance work to the valve itself, i.e.
Valves with handwheels may only be actuated by
Caution hand. As the valve can be damaged by applying -- prior to undoing the flange bolting between valve and pipe
excessive forces, it is not allowed to use additional levers to move the -- prior to undoing the cover/yoke or pressure seal bonnet/cover from
handwheel. the body
Shut-off valves are normally used in such a way that they are either fully -- prior to removing any drain or vent plugs
open or fully closed. -- prior to undoing the gland cover to replace packing rings
For control functions in continuous operation, throttling discs should be -- prior to removing an actuator bolted directly to the yoke head
fitted.
-- prior to opening the yoke head for maintenance work to the bearing
Performing throttling operations without a throttling and threaded bush
Caution disc may result in an excessive noise level,
valve pressure must be released and the valve must be allowed
excessive wear or even destruction of the valve by cavitation.
to cool down such that the temperature is below the fluid’s
7.1.3 Functional test vaporization temperature in all areas in contact with the fluid in order to
effectively prevent any risk of scalding.
KSB recommends to check the following functions:
Check the shut-off function of the installed valves prior to
commissioning / start-up by opening and closing them several times.
Check the gland packing (461) for leakage when it is subjected to full
operating pressure and temperature for the first time. Re-tighten the
nuts (920.1) at the gland cover (452) evenly, if necessary.
On valves in pressure seal design, the hex. head bolts (901.1)
pre-loading the bonnet (139) and the joint ring (411.1) must always be
tightened under operating conditions such that leakage at the
bonnet/cover, which might be caused by the bonnet (139) sinking as a
result of low pressure inside the body (100), is avoided.
11
Danger of death when opening a valve under pressure! 9.2 -- Faults > Remedy
If toxic or easily inflammable fluids were handled, or fluids whose -- Leakage at the seat
residues may cause corrosion in conjunction with air humidity, drain the
valve and flush or vent it. Possible causes:
If required, wear safety clothing and a protective mask! -- contaminations/solids in the fluid
Depending on the installation position, fluid residues may be left in the -- erosion, corrosion, abrasion
valve; these must be collected and properly disposed of. -- excessive loads from pipeline forces or thermal stresses
Prior to any transport, flush and drain the valve thoroughly.
> Rework the seat / disc contact faces at the valve disc and body using
If you have any questions please contact the manufacturer.
a suitable reseating tool after the valve has been dismantled. The
8.1.2 Removing actuators re-seating process of the seat / disc contact faces shall be continued
until the contact faces exhibit a uniform bright surface.
If actuators powered by an external source of energy (electric,
pneumatic, hydraulic) need to be removed from the valves or -- Leakage at the cover gasket
dismantled, the energy supply must be shut down prior to starting any
work and the instruction in sections 3, 8.1.1 and the operating manual Possible causes:
of the actuator must be observed. -- gasket has settled as a result of high temperature fluctuations
Actuators with integrated spring mechanism contain -- impermissible pressure loads
pre-loaded springs. They shall only be dismantled with extreme -- poor maintenance
care, using the requisite locking devices.
-- poor gasket resistance to temperature and fluid handled
If you have any questions please contact the manufacturer.
D Bolted bonnet/cover
8.2 Maintenance > Re-tighten the bonnet/cover bolting (902/920.1 or 902.1)
All valve components have been designed to be largely > Replace the gasket (411)
maintenance-free. The materials of the moving parts have been
selected for minimum wear. after having removed the bonnet/cover bolting (902.1/920.1).
The operator/user is responsible for fixing appropriate inspection and Clean the sealing surfaces carefully before inserting a new gasket.
servicing intervals as required by the service conditions of the valves.
D Pressure seal bonnet/cover
The service life of valves can be prolonged by:
> Re-tighten the hex. head bolts (901.1) or the nuts as described in
Subject to technical modification without prior notice

-- actuating the valve (open-close) at least once or twice a year section 7.1.3
-- lubricating the movable parts such as stem (200) and gland bolts > Replace the gasket (411.1)
(not for oxygen valves) with standardized lubricants to DIN 51825, after removing the pressure seal bonnet/cover.
-- adding or changing packing rings in the gland packing (461) in time, Clean the sealing surfaces carefully before inserting a new gasket.
-- re-tightening or replacing the cover gasket (411.1) in time.
The safety instructions in sections 3, 8 and the instructions in sections -- Leakage at the gland packing
9 must be complied with. Possible causes:
8.3 Valve reassembly -- worn packing material
Valve reassembly shall be effected in reverse order to dismantling. -- poor maintenance
To maintain functional reliability, new gaskets and gland packings shall -- poor packing resistance to temperature and fluid handled
be used whenever the valve is reassembled.
> Re-tighten the gland packing at the nuts (920/920.2) of the gland
After reassembly and prior to commissioning / start-up, the valves shall
cover (452). Make sure that the friction forces at the stem do not
be subjected to a leak test in accordance with DIN 3230, Part 3.
increase too much.
> Replace the packing rings of the gland packing (461): Undo the nuts
9 Trouble-shooting (920.2) and lift off the gland cover (452).
Clean the gland packing chamber carefully before inserting new
9.1 General packing rings. Split packing rings shall be inserted in such a way that
KSB valves are robust in design. Nevertheless, malfunctions e.g. the cut edges are offset by 120q--180q.
caused by maloperation, lack of maintenance or improper use cannot Do not use additional sealing agents for
be ruled out completely. Caution non-asbestos gaskets and packing rings. With
All repair and maintenance work shall be performed by qualified anti-adhesive coatings, only use agents explicitly recommended by the
personnel using suitable tools and original spare parts. seal element manufacturer.
We recommend to have this work performed by our service personnel. If you have any questions please contact the manufacturer.
The safety instructions in sections 3 and 8must be complied with.
01.08.2008
0570.82/12-10
KSB Aktiengesellschaft
Bahnhofplatz 1 x 91257 Pegnitz (Germany)
Tel.: +49 9241 71-0 x fax: +49 9241 71-1795
E-mail: valves@ksb.com x www.ksb.com
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Instruction and Maintenance Manual For
Displacer Switch -DS
To get best intrinsic value of every Techtrol product it should be installed, maintained
properly and used within its specified limits. It will help to extend the working life of your
instrument.
Construction and operations : fig1
Displacer is connected to coupler moving within a seal Switch carraige

Micro switch
pipe by a flexible wire rope via a compression spring.
Lever
The coupler is magnetically linked to a follower Follower magnet
magnet, which operates a micro switch. The extent of Seal pipe
Spring housing
immersion of displacer in Liquid " during " Rising &
Falling Level " exerts a buoyant force on it equivalent Compression spring
to liquid displaced. (Archimedes Principle ). This force Spring base
Coupler rod
effects a vertical displacement of displacer, which
Flexible rope
changes the spring tension and causes the coupler
Displacer
resting on it, to move " In & Out " of the field of
follower magnets. This attracts & releases the follower magnet resulting in " Changeover "
of micro switch contacts as shown in fig.1
Unpacking :
1. Examine the switch and ensure that it is in accordance with required specification.
2. Visually examine the instrument for any damages or breakages.
3. Check and record the model number and serial number for future reference.
Pre - Installation procedure :

1. Ensure that, Spring base as shown in ( fig 1) is not loosened in transit. Screwed it
properly if found loosened.
ͳ

2. Remove the cover and connect continuity tester to `P' and `NO' contact of micro switch
3. Hold displacer switch in upright position and move coupler rod up and down. Ensure
change over of microswitch contacts (NO to NC) with free movement of follower magnet
lever.
4. In the same manner, check remaining switch contacts as per ordered model.
5. If the functioning of micro switch is all right, proceed for installation.
Installation :
Location :
ȌǤ
ȌȌȌ
OUTLET
Ensure mounting location Swtch mounting should be Ensure that the tank internals does
is away from inline of flow away from out flow/suction not ristrict the displacer movement.

Mounting:

ǤǤ
ǡ
ǤǡǡǤ
ǡǤ
ʹ

Styles of Installation:
͵
InternalDirectMountingInternalMountingwithStillwell ExternalMountingwithCage
One switch One switch One switch

carriage
carriage carriage
Pro.Flange Process Flange
Vent plug
Isolation
Perforated External
valve
still well Cage
Displacer
Drain plug
Tank Tank Tank
Ǥ
ͳǤǡ
fig4
Ƭ
ͶǤ
ʹǤ Ǥ
͵Ǥ Ǥ
ͶǤ ǡ
ǤǤ
ͷǤ
ƬȀǤ
͸Ǥ
ȀǡǤ
NoteǦLowestlevelofswitchmustbeat100mmmfromtankbottom.
͵

fig5
.
ͳǤ

Ǥ
L1
ʹǤ̵̵
L1
Displacers

L2
Split
Std Adj.diff
Displacer
Ǥ Fixed diff
͵ǤƬ

Ǥ
ͶǤ
ǤȋǡƬ ȌǤ

Note:Switcheswithfixeddifferentialarefactoryset
ǣ
͸
ȋȌ
ȀǤ
Ǥ

One switch

Head Clearance
Ø105
carriage
One switch
440
(approx)
carriage
185
L1 (min)
Const. B
200mm
Const. A
NO
L1 (min)

A1
P
NC
L2 200mm
NO
Split Adjustable A1 P
Displacer
Diff Std
NC
A NO
NO Displacer
A P

NC
P
NC Fixed
Diff
1Sw Carraige x 2 Split Displacers.
with Adjustable Diff.
1 Sw Carraige x 1 Std Displacer
with Fixed Diff.
Ͷ

Two switch

carriages Ø120
Head Clearance

650
(approx)
Two switch

320
carriages
L1 (min)
Const. D
200mm NO

Const. C
P
NC
NO
L2
P
NC
L1 (min)
Fixed 200mm
L3
Diff

NO
P
L2
NC
Split Std
Fixed Diff
Displacers Adjustable
Diff
Displacer
NO
P
NC
2 Sw carraige x 1 Std & 2 Split Displacers, one
with Fixed diff. and second with Adjustable diff. 2 Sw Carraige x 2 Std Displacers
with Fixed Differential

Ø124
Ø120
Head Clearance
Three
Two switch
(approx)
(approx)
720
switch carriages
390
320
carriages

Const. E
L1 (min) L1 (min)
200mm 200mm
Const. F
L2
L2
L3 Std Fixed Diff. L3 Adjustable

Displacer Diff
L4
Split
Displacers

Fixed Diff.
Std Displacer Adjustable
Diff
3 Sw Carraige x 3 Std. Displacers
with Fixed Diff.
2 Sw Carraiges x 4 Split Displacers
with Adjustable Diff.
Terminations and Wiring :
fig 6
Const. A & B Const. C, D & F Const. E
L1 L1 L2 L3
L1
NO P NC NO P NC
NO P NC NO P NC NO P NC NO P NC
L2
NO P NC NO P NC NO P NC
NO P NC NO P NC NO P NC
Single switching Dual switching Triple switching
2SPDT (DPDT)
2SPDT (DPDT) 2SPDT (DPDT)

ͷ

Each switch carraige is provided with two micro switches fig. 7

*QQVGT
Switch contacts : 2 SPDT (2 no + 2 NC). 5YKVEJECTTKCIG

01 .COR
Switch rating : 5 A, 230 VAC. 01
2 2
0% 0%
%QPVCEVQT

/QVQT
Ensure the switching load on the switch is within specified limit. . N

ǣ
ͳǤǤ
Cabling fig. 8
ʹǤȋͳǤͷʹȌǡ
ǡ
Ƭ Cable gland

Ǥǡ Cable
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TM
Techtrol Displacer Type
Magnetic Level Switch - DS Innovating Level Controls Since 1984
Available in six configurations to provide upto triple switchings for various

industrial applications to operate pumps & auxiliary devices. Each
configuration consists of displacers and switch carriages in various
combinations.
Salient Features :
þ Ease of handling & installation of large range switches
þ Single, double or triple switchings, adjustable at site
þ IP66 protection alongwith CE certification
þ Ex-proof Gr. IIB or IIC enclosures for hazardous area
þ Options:
- High temperature design with radiating fins
- Hermetically sealed microswitches
- ATEX protection for enclosure alongwith CE certification.
- NACE compliance
- IBR approved switches available (separate datasheet)
Construction & Operation :

A single standard or two split displacers are suspended from a wire rope and
connected to a coupler rod, carrying an actuator moving within a non- Fig 1
magnetic barrier tube via a compression spring (fig1). Initially when the
displacer is not immersed in liquid, the spring is in compressed condition
due to weight of the displacer so that the actuator is outside the magnetic
field at position P1.
During rising level, the displacer gets immersed in liquid, undergoes weight
loss (Archimedes Principle) causing an upward motion of the coupler rod,
which makes the spring assume its original status and move the actuator to
position P2 within the magnetic field, resulting in actuation of
microswitches, to provide change over contacts. Narrow differential (nd) is
achieved by using one standard displacer alongwith one switch carriage
(fig2) and wide differential (wd) is achieved by using two split displacers
alongwith one switch carriage (fig3) Narrow differential is fixed, however
wide differential can be modified by varying the distance between split
displacers.
Narrow differential with single standard displacer Fig 2
(single switching)
Specifications :
Enclosure : Cast Al, WP IP66 or
Cast Al, Ex d Gr.IIB or IIC T6 IP66 or
Cast Al, ATEX Ex d IIB or IIC T6 IP66
Cable Gland : 3/4"ET (WP) or 1/2" NPT (Ex d), Brass
Measuring Range : 200 to 15000mm
Switch Type : Microswitch or Microswitch in hermetically
sealed casing (optional) Wide differential with two split displacers Fig 3
(single switching)
Switch Contacts : DPDT (2 SPDT) rated for 5A, 250VAC
Optg. Differential : Refer Table-1 on page 3
Terminals 2
: Suitable for 1.5 mm cable conductor
Wire Rope : SS304 or SS316 or PP or PTFE
Displacer : Ø 60 x SS304 or SS316 or PP or
PVDF (config E) or PTFE (config A,B,C,D & F)
Displacer Type : Standard or Split
Spring MOC : SS316, PTFE / PVDF ctd SS316
Process Flange : CS,SS304,SS316 (metallic) or
PP or PTFE with steel cladding
a) Standard Displacer b) Split Displacers (pair) Fig 4
Perforated Stillwell : 65NB, CS or SS304/316 or PP
External Chamber : 80NB, CS or SS304/316 or A-106
Temperature : -20 to 70°C (PP),100°C (PVDF), 200°C (metallic)
or 300°C with radiating fins (optional)
Max. Test Pressure : Vacuum-10Kg/cm2(metallic), 2Kg/cm2 (PP/PTFE/PVDF)
or High pressure upto 100 Kg/cm (optional)
2
Min. Sp. gr. : 0.8 or Low sp.gr < 0.8 to 0.5 (optional)
The working of six configurations are shown here under. The switching points L1, L2, L3 & L4 can be
adjusted by relocating the displacers along the wire rope (range). Wide differential (wd) can be
achieved and modified by varying the distance between the split displacers. Innovating Level Controls Since 1984
A) Single switching x one standard displacer with narrow diff. B) Single switching x two Split displacers with wide diff.
þ L1 is adjustable þ L1& L2 are adjustable

þ Rising Level: Switch actuates at L1 & þ Wide diff. can be modified
remains actuated during further level þ Rising Level : Switch actuates at L1 &
rise remains actuated during further level
þ Falling Level: Switch de-actuates at rise.
(L1+nd) & remains de-actuated during þ Falling Level : Switch de-actuates at L2
further level fall & remains de-actuated during further
þ Application: Point switching of one level fall.
device i.e. Alarm or pump 'on or off ' at þ Application : Control action of one
L1 (SW1) device i.e. pump 'on-off ' between L1&
L2 (SW1)
Contact configurations:
Sw. Carriage 1
NO P NC NO P NC
1 DPDT potential free contacts
C) Dual switchings x two standard displacers with narrow diff. D) Dual switchings x one stdard displacer with narrow diff. & two
split displacers with wide diff.
þ L1 & L2 are adjustable þ L1, L2 & L3 are adjustable

þ Rising Level : Switch 2 actuates at L2 þ Wide diff. can be modified
& switch 1 at L1 and both remain þ Rising Level : Switch 2 actuates at
actuated during further level rise L2 & switch 1 at L1 and both
þ Falling Level : Switch 1 de-actuates at remains actuated during further
(L1+nd) & switch 2 at (L2+nd) and level rise
both remain de-actuated during further þ Falling Level : Switch 1 de- actuates
level fall at (L1+nd) & switch 2 at L3 and
þ Application : Point switchng of two both remain de-actuated during
devices i.e. Alarm or Pump-1 'on or off' further level fall
at L1 (SW1) & Alarm or Pump-2 'on or þ Application : Point switching &
off ' at L2 (SW2) control action i.e. Alarm at L1
(SW1) and pump 'on-off ' between
L2 & L3 (SW2) or vice versa, by
interchanging the position of
standard & split displacers.
Contact configurations:
Sw. Carriage 1 Sw.Carriage 2
NO P NC NO P NC NO P NC NO P NC
2 x DPDT potential free contacts
E) Triple switchings x three standard displacers with narrow diff. F) Dual switchings x two split displacers with wide diff.
þ L1,L2 & L3 are adjustable þ L1, L2, L3 & L4 are adjustable

þ Rising Level : Switch 3 actuates L3, þ Wide diff. can be modified
switch 2 at L2 & switch 1 at L1 and all þ Rising Level : Switch 2 actuates at
remain actuated during further level L3 & switch 1 at L1 & both remain
rise actuated during further level rise
þ Falling Level : Switch 1 actuates at þ Falling Level : Switch 1 de-actuates
(L1+nd), switch 2 at (L2+nd) & switch at L2 & switch 2 at L4 and both
3 at (L3+nd) and all remain de- remain de-actuated during further
actuated during further level fall level fall
þ Application : Point switching of three þ Applications : Control action of two
devices devices i.e. Pump 1 'on-off'
between L1 & L2 (SW1) & pump 2
'on-off' between L3 & L4 (SW2)
Contact configurations: Contact configurations:

Sw. Carriage 1 Sw.Carriage 2 Sw.Carriage 3 Sw. Carriage 1 Sw.Carriage 2
NO P NC NO P NC NO P NC NO P NC NO P NC NO P NC NO P NC NO P NC NO P NC NO P NC
3 x DPDT potential free contacts 2 x DPDT potential free contacts
Table 1 - Operating differentials for six configurations
Switch *Differential
Config. Carriages Displacers Innovating Level Controls Since 1984
(sp.gr.1)
A One Standard Narrow (40±5mm)

Model Identification :
B One Split Wide
x
DS - Range
C Two Two Standard Narrow (40±5mm)
Configuration
(Switch Carriage x Displacer)
One Standard + Narrow (40±5mm)
D Two One x One (standard) A
Two Split Wide
One x Two (split) B
Two x Two (standard) C
E Three Three Standard Narrow (65±5mm) Two x Three (standard + split) D
Three x Three (standard) E
F Two Four Split Wide Two x Four (split) F
Enclosure x Cable Gland
* Differential is inversely proportional to sp. gr.of liquid
Cast Al. WP IP-66 x 3/4"ET J
Cast Al. Ex d Gr.IIB x 1/2" NPT E
Installation : Cast Al. Ex d Gr.IIC x 1/2" NPT F
The switch can be installed internally on tank (fig 5a) or (config. A,B,C,D & F)
Cast Al. ATEX Ex d Gr.IIB x 1/2" NPT G
internally with stillwell for tanks having turbulence (fig 5b) or Cast Al. ATEX Ex d Gr.IIC x 1/2" NPT H
externally in a chamber to overcome limited space within the (config. A,B,C,D & F)
tank or where mechanical devices like stirrers operate (fig 5c) Others O
Displacer MOC
SS304 N
Internal Fig 5a Internal with stillwell Fig 5b
SS316 S
PP P
PVDF(Config. E) F
PTFE (Config. A,B,C,D,F) T
Others O
Process Conn. MOC
CS M
SS304 N
SS316 S
PP with steel cladding P
PTFE steel cladding T
Others O
Process Connection
80 NB, ANSI 150# flange 1
Others O
Stillwell / Ex. Chamber
External with Chamber Fig 5c High Temp Arrangement Fig 6 Without W
CS stillwell 2
SS304 stillwell 3
SS316 stillwell 4
PP stillwell 5
CS external chamber with 1" NB flange 6
SS304 external chamber with 1" NB flange 7
SS316 external chamber with 1" NB flange 8
A -106 external chamber with 1" NB flange A-105 9
Others O
Special Features (Optional)
Without W
*All dimensions in mm except specified
High temp with radiating fins (metallic) H

Hermetically sealed microswitches (Config A,B,C,D,F) S
Low specific gravity displacer L
Others O
Applications : Ordering Information :

Large Sumps & Fuel Tanks, Oil Sumps, Boiler Feed Water,
Model no x Range (mm) x Liquid & its Sp.gr x Operating
Acid / Alkali Dosing Tanks in Waste Water / Sewage / Effluent
Temperature and Pressure.
Treatment.
Pune Techtrol Pvt Ltd

INSPIRE | 9763672223
[CIN : U31909PN1991PTC063403]
S-18, MIDC, Bhosari, Pune - 411026. India
+91-20-66342900 ho@punetechtrol.com www.punetechtrol.com
Works : J-52/7, MIDC, Bhosari, Pune - 411026. India +91-20-67313600
Custom built specs./options available on demand. We reserve the right to modify design and specifications without prior notice. CAT/0014/REV-04/10-17
MIL 37/38, 6A
Instruction Manual
INS/37-38/REV-B/03-2006
Spring Diaphragm Pneumatic Actuator &

Side Mounted Handwheels
ISO 9001 : 2000

Certificate : 04100 2002 0157
Purchase Order No. :
The following instructions should be thoroughly

reviewed and understood prior to installing,
operating or performing maintenance on this
equipment. Throughout the text, safety and/or
caution notes will appear and must be strictly adhered to,
otherwise, serious injury or equipment malfunction could result.
MIL Controls Limited

Description (37 / 38 Pneumatic Actuator)
The spring-diaphragm actuator is a simple, powerful the diaphragm case, and yoke and a packing box around
mechanical device. There are two general types, the actuator stem prevents air leakage. The diaphragm
“Air-to-close” (Type 37) and “Air-to-open” (Type 38). acts as a flexible upper guide and the packing box assembly
Actuators are designated by case size: as Nos. 11, 13, as the lower guide for the actuator stem.
15, 18 and 24.
Air connections are ¼" NPT for actuators upto 18" and
The nominal range of a spring-diaphragm actuator is ½" for 24". Connections are located in the upper
the air pressure range in pounds per square inch (psi) diaphragm case for air-to-close actuators and in the yoke
for rated stroke under no load. Common ranges are for air-to-open actuators.
3-15 and 6-30 psi. The spring range and maximum
allowable supply pressure are marked on the tag plate. Standard Effective Maximum
For a 3-15 psi nominal range, the stem will start to stroke Actuator Diaphragm Stroke
when the air pressure reaches 3 psi and will complete Size Area (sq.in.) (in.)
the stroke when the pressure reaches 15 psi (plus or
minus 5%). 11 81.5 1
13 115.2 11/2
In the air-to-close actuator, conformation of the moulded
diaphragm to the diaphragm plate serves as a flexible 15 176 2
upper guide for the actuator stem (26). Nut (30) and
18 272 21/2
washer (41) above the diaphragm prevents air leakage.
The lower guide is an oil impregnated bronze bushing 18L 272 4
(37) located in the spring adjustor (36). The air-to-open 24 368 4
actuator differs from the air-to-close unit in that the
spring (22), spring barrel (71) and spring adjustor (36)
are located above the diaphragm plate (40) and diaphragm Caution: Do not exceed the recommended air pressure
(39) which are inverted. A gasket (19) at the joint of shown in the serial plate.
Maintenance
Air-to-close Actuators (Type 37) Air-to-open Actuators (Type 38)
Diaphragm replacement:
Diaphragm replacement: Procedure is the same as that
Caution: Before dismantling the actuator, all spring for air-to-close actuators except that the upper diaphragm
compression should be relieved by turning the spring case assembly including spring barrel (71), Spring (22),
adjustor (36), to prevent the upper case popping up Spring seats (33 & 34), nut (30) and diaphragm plate
when the cap screws (45) are removed. (40) must be removed to release the diaphragm. Install
a new diaphragm and reassemble the above parts.
This is especially important on actuators with a high
In case of leakage through lower diaphragm case and
initial spring setting. Remove cap screws (45), nuts (46)
yoke joint, replace the yoke gasket. For replacement of
and upper diaphragm case (43). Remove nut (30) and
yoke gasket, the entire diaphragm case assembly
washer (41) to release the diaphragm (39). If possible,
including the above mentioned parts and lower
the replacement diaphragm should be of the moulded
diaphragm case (44) & cap screw (18) have to be removed.
type supplied by MIL but in case of an emergency a
diaphragm may be cut from flat sheet stock for up to Spring adjustment: Procedure is similar to that
and including No. 15 actuators. To allow sufficient stroke, for air-to-close actuators except that supply air is piped
without restriction due to flatness of the diaphragm, to the 1/4" port in the yoke. Spring compression can
the diaphragm bolt circle should be about 10% greater be adjusted by turning the spring adjustor (36), which
than that of the diaphragm case. is at the top of the actuator.
Replace washer (41), nut (30) and upper diaphragm case. Packing box: The packing box is subject to low air
pressure only and requires minimum maintenance.
Spring adjustment: Connect an air supply, with a guage
and regulator should be piped to the upper diaphragm The packing rings have a square section and are of PTFE.
case for this adjustment. Spring compression can be The packing may be added to or completly replaced
adjusted by turning the spring adjustor (36). Adjust spring without dismantling either the actuator or the mechanism
compression so that the actuator stem (26) just begins (or valve) to which it is attached. Be sure to tighten
to move when air pressure reaches minimum pressure packing nut (20) lightly.
of the range stamped on the Serial Plate. This movement
is most easily detected by feeling the stem as air pressure
is applied. Caution: Do not over tighten the packing nut. It results
in sluggish performance.
Caution: Adjust Spring compression only when there
is no air pressure on diaphragm.
2
39 30 56 43
45
46 44
40
18
33
22
35
Air-to-close 22A
26
actuators 34
70
17
(Type 37) 36
56 37
57
Case Nos. 15, 18, 18L & 24

Case Nos. 11 &13
36
72
71
22 33
74
30
43
40
34
45
46
Air-to-open
18 39
44 actuators
19
26
41 (Type 38)
32 17
21
31
15
56
20
57
Figure 1
Case Nos. 11 &13 Case Nos. 15, 18, 18L & 24
Parts Reference
Ref. Ref. Ref.
Part Name Part Name Part Name
No. No. No.
*15 Gasket (Packing box) *32 Packing 46 Nut (Diaphragm Case)
17 Yoke 33 Spring Seat (Upper) 56 Stroke Scale
18 Cap Screw 34 Spring Seat (Lower) 57 Pointer Screw
(Lower Case to Yoke) # 35 Pipe Plug 70 Ball and Retainer
*19 Gasket 36 Spring Adjuster 71 Spring Barrel
(Lower Case to Yoke) # 37 Bushing 72 Spring Barrel Cap
20 Packing Nut (Spring Adjuster) 73 Ball Bearing Race
21 Snap Ring *39 Diaphragm 74 Cap Screw
22 Actuator Spring 40 Diaphragm Plate (Spring Barrel to
22 A Actuator Spring 41 Diaphragm Washer Upper Diaphragm Case)
26 Actuator Stem 43 Upper Diaphragm Case
30 Nut (Actuator Stem) 44 Lower Diaphragm Case
31 Packing Box 45 Cap Screw (Diaphragm Case)
* Recommended Spare Parts. # Only for Type 37, Direct Actuators Only for Type 38, Reverse Actuators
3
Actuator Removal
1 Removal of Actuators from Valves is most easily detected by feeling the stem as air pressure
is applied.
Caution : On actuator equipped with auxiliary
handwheel, ensure that this one is set on neutral Caution : Adjust spring compression only when there is
position prior to proceed with actuator removal or no air pressure on diaphragm.
installation and plug stem adjustment.
3. Actuator Assembly and Adjustment
1.1 Size 11,13 Air-to-close and Air-to-open 3.1 Size 11 & 13 Actuator
Actuators
On Air-to-close Actuator (Type 37)
1.a. On Air-to-close Actuator (Type 37) : Shut off air
supply pressure and disconnect air lines at the a. Push plug stem (5) down until the plug seats, then
actuator. replace locknuts (27), travel indicator disk (58) and
1.b. On Air-to-open Actuator (Type 38) : Fully retract locking plate (55#) on threaded end of plug stem.
actuator stem (26) and plug by applying air pressure. Carefully lower actuator and drive nut (9) over plug
stem and bonnet and turn plug stem (5) into actuator
2. Loosen stem locknuts (27), turn them down until
stem (26) as far as it will go. Install actuator on
threaded end of plug stem (5) and lock. Disengage
bonnet in required position and secure with drive
the locking plate (55) from actuator stem (26).
nut (9).
3. Unscrew drive nut (9). By means of a wrench applied
over the locknuts, turn the plug stem (5) out of Note : If the length of threaded stem engaged into
actuator stem (26). actuator stem is larger than valve stroke, it may be
necessary to screw plug stem into actuator stem during
Note : If the valve is of lower plug stroke, the length the lowering of actuator on bonnet, therefore before
of threaded stem engaged into actuator stem might be securing with drive nut.
larger than valve stroke; So, it may be necessary to lift
the actuator during unscrewing plug stem, after b. Connect a temporary supply air line on actuator.
unscrewing drive nut (9). Apply to diaphragm sufficient air pressure to extend
actuator stem (26) to valve stroke. Turn plug stem
4. PIug stem being unscrewed and actuator removed, out of actuator stem until plug is seated. Slightly
remove locking plate (55), locknuts (27) and travel release air pressure and tighten locking plate (55#),
indicator disk (58) from the plug stem. Remove drive stem locknuts (27) and travel indicator disk (58)
nut (9). against bottom of actuator stem.
5. Only on Air-to-open Actuator (Type 38) : Shut off air c. Adjust travel indicator scale (56) in front of travel
pressure and disconnect air lines at the actuator. indicator disk (58) when the plug is seated under the
1.2 Size 15, 18 & 24 Actuators supply pressure (max. signal of positioner). Relieve
air pressure and insure that the plug travels the rated
On Air-to-close Actuator (Type 37) stroke.
Shut off air supply and disconnect air lines at the actuator. On Air-to-open Actuator (Type 38)
Remove nut (53), screw (52) and clamps (51). Unscrew
a. Push plug stem (5) down until the plug seats, then
drive nut (9), then remove actuator from the valve bonnet.
replace locknuts (27), travel indicator disk (58) and
On Air-to-open Actuator (Type 38) locking plate (55#) on threaded end of plug stem.
Retract actuator stem and plug about few millimeters by Connect a temporary supply air line on actuator.
applying air pressure. Remove nut (53), screw (52) and Admit sufficient air pressure to fully retract actuator
clamps (51). Unscrew drive nut (9), then remove actuator stem.
from the valve. Shut off air pressure and disconnect air
lines at the actuator. Caution : Do not allow the plug to turn on the seat
during this operation.
2. Spring(s) Adjustment
Do not modify the setting of the actuator spring except b. Carefully lower actuator and drive nut (9) over plug
when it is really necessary, to replace the diaphragm for stem and bonnet and turn plug stem (5) into actuator
example. In this case proceed as follows : stem (26) as far as it will go. Install actuator on
bonnet in required position and secure with drive
With Air-to- Extend or Air-to-open Actuator nut (9). Relieve air pressure from actuator.
(Type 37 or 38)
An air supply, with a gauge and regulator should be piped Note: If the length of threaded stem engaged into the
to the 1/4” or 1/2" NPT air connection located on upper actuator stem is larger than valve stroke, then it may
diaphragm case (on Type 37) or on the yoke (on Type 38). be necessary to screw plug stem into actuator stem
With spring adjustor (36), adjust spring compression so during the lowering of actuator on bonnet, therefore
that the actuator stem (26) just begins to move when air before securing with drive nut.
pressure reaches minimum pressure of the range stamped
on the serial plate (initial of spring range). This movement # For 13" Actuators only.
4
Actuator Removal
c. Unscrew plug stem from actuator stem until plug is

seated. Increase air pressure to retract actuator stem
and plug about 1,5 mm (.06 in.) then unscrew plug
stem until plug is seated. Slightly increase air pressure
and tighten locking plate (55), stem locknuts (27)
and travel indicator disk (58) against bottom of
actuator stem.
Caution : Do not allow the plug to turn on the seat

during this operation.
d. Relieve air pressure and adjust travel indicator scale

(56) in front of travel indicator disk (58) when the
plug is seated under the spring tension. Apply air
pressure corresponding to the valve open and insure
that the plug travels the rated stroke.
3.2. Size 15, 18 & 24 Actuators
On Air-to-close Actuator (Type 37) : Figure 2B
a. Push plug stem (5) down until the plug seats.
b. Connect a temporary supply air line on actuator.
b. Install actuator on bonnet in required position and Admit sufficient air pressure to fully retract actuator
secure with drive nut (9). Connect a temporary supply stem. Install actuator on bonnet in required position
air line on actuator. Apply to diaphragm sufficient and secure with drive nut (9) .
air pressure to extend actuator stem (26) to rated
stroke. c. Relieve air pressure from actuator, then increase air
pressure to retract actuator stem (26) about 1,5 mm
c. Install the stem clamps (51) and travel indicator (.06 in.).
pointer (58) with screw (52) and nut (53). It may be
necessary to slightly raise or lower the actuator stem d. Install stem clamps (51) and travel indicator pointer
(26) to mate the threads of the actuator and plug (58) with screw (52) and nut (53). It may be necessary
stem with the stem clamp. The amount of thread to slightly raise the actuator stem (26) to mate the
engagement of both stems should be approximately threads of the actuator and plug stem with the stem
equal. Tighten clamp screw (52), then nut (53). clamp. The amount of thread engagement of both
stems should be approximately equal. Tighten clamp
d. Adjust travel indicator scale (56) in front of travel screw (52), then nut (53)
indicator pointer (58) when the plug is seated under
the supply pressure (max. signal of positioner). Relieve e. Relieve air pressure and adjust travel indicator scale
air pressure and insure that the plug travels the rated (56) in front of travel indicator pointer (58) when the
stroke. plug is seated under the spring tension. Apply air
pressure corresponding to the valve open and insure
On Air-to-open Actuator (Type 38) that the plug travels the rated stroke.
a. Push plug stem (5) down until the plug seats.
Parts Reference
5 Plug Stem
9 Drive Nut
26 Actuator Stem
26
27 Actuator Stem Nut
36 Spring Adjustor
51 Stem Connector Clamp
52 Clamp Screw *
52 53 Clamp Nut *
57 55 Locking plate #
56 Stroke Scale
57 Pointer Screw
58 Travel Indicator Pointer
(or Travel Indicator Disk)
Stem Lock Split Stem Clamp 72 Spring Barrel Cap
(On No 11 & 13 Spr. (On No 15, 18 & 24 Spr.
Diaph. Actuators) Diaph. Actuators * Replaced by Hexagonal Screws in certain ranges.
Figure 2A # For 13" Actuators only.
5
Description (6A - Side Mounted Handwheels)
The side mounted hand wheel provides a means of (but not both at the same time). It employs no clutching
manually operating the control valve during startups, device and may be adjusted and manually operated
emergency service, or in the event of air failure. It with air pressure on the diaphragm.
also provides for limiting plug travel in either direction
Operation
1) Manual operation 4) To limit travel - Direct actuator
To move plug down rotate handwheel clockwise. a) Upward travel - If necessary turn wheel (12) until
pointer (17) is at “Neutral Position” on hand wheel
To move plug upward rotate handwheel counter- position plate (16). Vent diaphragm pressure. Turn
clockwise. hand wheel clockwise until valve is at desired limit.
Lock hand wheel.
2) To shift from automatic to manual operation
b) Downward travel - If necessary turn wheel (12)
Lift hand wheel lock (19) from hand wheel spoke and until pointer (17) is at “Neutral Position” on hand
turn wheel until pointer (17) is at Neutral Position on wheel position plate (16). Apply sufficient air
Hand-wheel Position Plate (16). pressure to diaphragm to move plug to the desired
limit and turn hand wheel counter-clockwise until
3) To shift from automatic to manual operation crosshead (3) engages bell crank levers (10). Lock
hand wheel.
a) Direct Actuator (air to close) - Lift hand-wheel lock
from hand wheel spoke and spin wheel clockwise 5) To limit travel - Reverse actuator
until bell crank levers (10) are engaged by jackscrew
crosshead (3). Vent diaphragm pressure. Valve will a) Upward travel - If necessary turn wheel (12) until
remain at that point until manually adjusted as pointer (17) is at “Neutral Position” on handwheel
directed in (1) above. position plate (16). Apply sufficient air pressure
to diaphragm, to move plug to the desired limit
b) Reverse Actuator (air to open) - Lift hand-wheel and turn hand wheel clockwise until crosshead (3)
lock from hand wheel spoke and spin wheel engages bell crank levers (10). Lock handwheel.
counterclockwise until bell crank levers (10) are
engaged by jackscrew crosshead (3). Vent diaphragm b) Downward travel - If necessary turn wheel (12)
pressure. Valve will remain at that point until until pointer (1) is at “Neutral Position” on
manually adjusted. handwheel position plate (16). Vent diaphragm
pressure. Turn handwheel counter-clockwise until
valve is at desired limit. Lock handwheel.
The jackscrews (4) of the Hand-wheels have a dry-film

lubricant applied at the factory and need no attention.
Maintenance
Jackscrews which are not so treated, however, should be lubricated. Periodic lubrication of lever pin (6) is necessary by
means of lubricant fitting (24).
7
STEM CONNECTOR TYPES
ON ON
6A3 6A1-6A2
17
STEM CONNECTOR TYPES
6A Series Side Mounted Handwheel Unit mounted

on Direct (Air-to-close Type-37) Actuator
Parts Reference
Ref. Ref. Ref.
No. PART NAME PART NAME PART NAME
No. No.
1 Gasket (Packing box) 13 Handwheel Washer 26 Stud (Bracket)
2 Pointer Stud Nut 14 Handwheel Nut 26A Nut (Bracket)
3 Jackscrew Crosshead 15 Handwheel Position Plate Screw # 27 Stem Clamp
4 Jackscrew 16 Handwheel Position Plate # 28 Stem Clamp Crosshead
5 Yoke 17 Pointer # 29 Travel Indicator
6 Lever Pin 18 Travel Indicator Scale 30 Retaining Ring
7 Lever Pin washer 19 Handwheel Lock 31 Roller Bearing
8 Lever Pin Nut 20 Handwheel Lock Pin 32 Travel Indicator Scale Screw
9 Bracket Bearing 21 Thrust Bearing 33 Actuator Stem Crosshead
10 Bell Crank Lever 22 Set Screw (Bracket) * 34 Crosshead Stop Nut
11 Stud (Bracket) 23 Bearing Retainer * 35 Travel Indicator
11 A Nut (Bracket) 24 Lubricant Fitting
12 Handwheel 25 Handwheel Bracket
* only on 6A 1 and 6A 2 # Only on 6A3
6
MIL Controls Ltd. Branch Offices Overseas Sales Offices
A KSB Company
NEW DELHI CHINA
MIL Controls Limited KSB-Shanghai Office
KSB House, A-96, Sector 04, Rm. D-E1. 26/F., Zao-Feng Universe Building,
Gautam Budh Nagar, No. 1800 West Zhongshan Road, Shanghai,
Noida 201 301, India P.R. China. Post Code: 200235.
Tel: 91 (0)120 2541091 to 93, 2541501 to 03 Tel: (86)-21-6440 1668 Ext. 832
Fax: 91 (0)120 2550567, 2525626 Fax: (86)-21-6440 0228
Email: milnoida@ksb.co.in
REGD. OFFICE & WORKS / FINLAND
SPARE PARTS & AFTERSALES DEPARTMENTS MUMBAI KSB Finland Oy
MIL Controls Limited MIL Controls Limited Savirunninkatu 4, FI-04260
Meladoor , Mala 126, Maker Chamber III, Nariman Point, Kerava, Finland
PIN 680 741, Thrissur Dist., Kerala, India Mumbai - 400 021, India. Tel: 358 10 288 5427
T: 91 (0)480 2890272, 2890772, 2891773 Tel: 91 (0)22 56588787, Fax: 358 10 288 5685
F: 91 (0)480 2890952 56588757 to 59, 56588761
E: milservice@milksb.com, milf@vsnl.com, Fax: 91 (0)22 56588788 HONG KONG
W: www.milcontrols.com Email: milmumbai@vsnl.com, KSB Limited
mum-mil@ksb.co.in 17/F, Chuang’s City Tower,
MARKETING HEAD OFFICE 39 Morrison Hill Road,
MIL Controls Limited KOLKATA Causeway Bay, Hong Kong
N.H. 47, Thaikkattukara P.O., Aluva MIL Controls Limited Tel: 852 2147 1220
PIN 683 106, Ernakulam Dist, Kerala, India 2nd Floor, 30 Circus Avenue, Fax: 852 2147 1230
T: 91 (0)484-2624955, 2624876, 2628041 Kolkata 700 017, India Email: ksb_hk@pacific.net.hk
F: 91 (0)484-2623331 Tel: 91 (0)33 22470473, 22400117, 22400418
E: ksbmil@sancharnet.in, mail@milcontrols.com Fax: 91 (0) 33 22470588 MALAYSIA
Email: milcal@vsnl.net, cal-mil@ksb.co.in KSB Malaysia Pumps & Valves SDN BHD
11A, Jalan PJU 3 / 47, Sunway Damansara
CHENNAI 47810 Petaling Jaya,
MIL Controls Limited Selangor Darul Ehsan, Malaysia.
Guindy House, 2nd Floor, Tel: 60-03 7781 3026
95, Annai Salai, Fax: 60-03 7781 3020
Chennai 600 032, India Email: ksbamri@po.jaring.my
Tel: 91 (0)44 22352571 to 72, 22300629
Fax: 91 (0)44 22352749 MIDDLE EAST
Email: che-mil@ksb.co.in KSB Middle East FZE,
PO Box 18315
VADODARA Jebel Ali, Dubai, UAE.
MIL Controls Limited Tel: 9714-8830455
4-B, Ramakrishna Chambers, Fax: 9714-8830456
Productivity Road,
Vadodara 390 005, India SINGAPORE
Tel: 91 (0)265 2330532, 2333226 KSB Singapore (Asia Pacific) PTE Ltd
Fax: 91 (0)265 2314693 25 Tagore Lane, 02-08/09
Email: ksbad1@sancharnet.in Singapore Godown, Singapore 787602
Tel: 65 6555 0366
PUNE Fax: 65 6553 3500
MIL Controls Limited Email: sales@ksb-amri.com.sg
KSB Pumps Limited
D-II Block, MIDC TAIWAN
Chinchwad KSB Taiwan Co Ltd
Pune - 411 019 Virtuoso Enterprise Building, 12F-1, No.380,
Tel: 91 (0)20 2740 9100 Fushing South Road, Sec. 1, Taipei 106,
Fax: 91 (0)20 2747 0890 Taiwan, ROC
Tel: 886-2 2755 5858
Fax: 886-2 2703 3366
Email: ksbtwn@gmail.gcn.net.tw
TABLE OF CONTENTS
Numbering System ............................................................................................................................................................ 1
General Information .......................................................................................................................................................... 2
Cv Charts ............................................................................................................................................................................ 3
Anti-cavitation Option ...................................................................................................................................................... 3
Material of Construction ................................................................................................................................................ 4-5
Weights & Dimensions ...................................................................................................................................................... 6
Positioner Construction ..................................................................................................................................................... 7
PLUG & SEAT COMBINATIONS IN MIL 29000 SERIES
Trim No.0 Trim No.1 Trim No.2 Trim No.3 Trim No.4 Trim No.5 Trim No.6 Trim No.7 Trim No.8 Trim No.9
0.0018 0.005 0.011 0.021 0.041 0.11 0.26 0.51 0.91 1.51
Cv to Cv to Cv to Cv to Cv to Cv to Cv to Cv to Cv to Cv to
0.005 0.011 0.026 0.051 0.11 0.26 0.61 1.30 2.40 3.70
Orifice Dia. Orifice Dia. Orifice Dia. Orifice Dia. Orifice Dia.
2.0mm 1.6mm 4.50mm 9.50mm 14.30mm
MIL 29000 - Introduction
FOREWORD
MIL 29000 series Modified Micropak Control Valves adaption to actual field conditions. The actuator action
provides control of high pressure fluids with excellent can be easily reversed at site by just relocating the pivot
throttling control and wide range of options. pins.
FEATURES Standard High Performance Material

29000 Modified Micropak is manufactured using Forged
Unmatched Performance Stainless Steel body, Solid Stellite Plug and hardened
MIL 29000 series valves provide enhanced controllability 17- 4 PH SS Seat, to ensure longevity.
due to an inherent rangeability of 500:1. This also makes
the valve competent to handle wide variations in flow Easy Maintenance
compared to conventional microflow valves. Fully guided Micropak’s simple top entry Trims, integral Cage & Seat
Plug design ensures excellent plug stability and fine control and reduced components enable easy maintenance. The
under high pressure drop conditions. body made of superior material ensures long and trouble-
free operation. The construction has an integral bonnet
Innovative Design with Field Adjustable Cv with lesser soft parts, which helps to prevent leakage.
The compact construction with integral Rolling Diaphragm
type actuator (which employs Force Amplifying Actuator Optional Design
technology) has a modular option for Pneumatic The optional designs include Bellows Sealed Trims,
Positioner. 29000 series valves also have Cv adjustment Cryogenic construction and Multi-stage, Axial flow, Anti-
feature, which facilitates fine tuning at site and helps easy Cavitation Trim for severe service.
NUMBERING SYSTEM FOR MODIFIED MICROPAK VALVE
- - 2 9 - - -
Basic Construction Trim Cv* Range

Actuator Series Body Series Option Positioner
No. Min. Max.
0. Undefined 0 0.0018 0.005 0. Undefined

1. Parallel to 7. Air to Close
Pipe Line 1. Standard Trim 1 0.005 0.011
1. On-Off
with Field (No Positioner)
Adjustable Cv 2 0.011 0.026
2. Perpendicular 8. Air to Open
to Pipe Line 2. Anti Cavitation 3 0.021 0.051 2. With Integral
Trim with Field Pneumatic
4 0.041 0.11 Positioner
Adjustable Cv
29
5 0.11 0.26
3. Special** 3. With External
6 0.26 0.61 Electro-
Pneumatic
7 0.51 1.30 Positioner
8 0.91 2.40 4. With External
9 1.51 3.70 Smart
Positioner
* For selected discrete Cv values please refer Page 3. ** Available on request - Bellows Sealed, Cryogenic versions etc.
1
MIL 29000 - General Information
GENERAL INFORMATION
BODY Characteristics : Linear (Trim No.4 to 9)

Type : Globe : Modified Linear (Trim No. 0 to 3)
Sizes : Standard : 1” Flow direction : Flow to Open
Option : 0.5” & 0.75”
Material : Standard : Forged F316L
Option : Monel, Hastelloy C, Alloy 20 etc. ACTUATOR
Type : Spring opposed Rolling Diaphragm
Action : Direct/Reverse, easily selectable
TRIM without additional parts
Plug type : Contoured, Fully guided
Cv adjustment : Adjustable Knob/Lever
Option : Multi-stage Anti-cavitation
Handwheel : Top Mounted
Seat type : Clamped & Integral with Cage
Cv Ratio : 500:1 at max.Cv Air Connection : ¼” NPT
: 200:1 at min. Cv
TEMPERATURE RANGE / LEAKAGE CLASS

SEAT LEAKAGE CLASS
VALVE TYPE TEMPERATURE*
(as per ANSI/FCI 70.2)
Standard Valves -1000 C to + 3430 C

IV V
(Standard) (Optional)
Anti-Cavitation Valves -29 C to + 343 C
0 0
Please consult MIL for applications outside the temperature range

*
RATING / END CONNECTIONS
ANSI CLASS 150# to 1500#

VALVE
MAX.
SIZE
Cv
(Inch) Raised Flangeless Threaded NPT SW BW Flanged
0.5 2.4 * * * *
0.75 2.4 * * * *
1 3.7 * * * * *
* Available
ALLOWABLE PRESSURE DROPS, SPRING RANGES AND SUPPLY PRESSURES (Seat Leakage Class: IV & V as per FCI 70.2)
TRIM ALLOWABLE PRESSURE DROP SPRING RANGE AIR SUPPLY

RATED Cv RANGE
No. (Kg / cm2g) (psig) (psig)
0 0.0018 to 0.005
1 0.005 to 0.011
250 3-15 20
2 0.011 to 0.026
3 0.021 to 0.051
4 0.041 to 0.11
5 0.11 to 0.26 220 3-15 20
6 0.26 to 0.61
7 0.51 to 1.3
100 6-24 30
8 0.91 to 2.4
9 1.51 to 3.7 40 6-24 30
*For Air to Close Actuators in Cv Range 0.91 to 2.4, allowable pressure drop is 40kg/cm2g only.
2
MIL 29000 - Cv Charts
FLOW COEFFICIENTS (RATED Cv)
MIL 29000 series valves are far superior to conventional micro-flow valves that it provides the user with a very wide
range of nominal Cv ranges from 0.0018 to 3.70, using only eight plugs and five seats.
VALVE SIZE FLOW COEFFICIENT (Cv)

(Inch) (With Adjustable Cv Function) CRITICAL
TRIM FLOW
No. FACTOR
Mid
0.5” 0.75” 1” Min. Max. Cf
Setting**
* * * 0 0.0018 0.002 0.0026 0.0030 0.0033 0.0037 0.005 0.85

* * * 1 0.005 0.006 0.007 0.008 0.009 0.010 0.011 0.85
* * * 2 0.011 0.014 0.017 0.020 0.022 0.024 0.026 0.85
* * * 3 0.021 0.026 0.031 0.036 0.041 0.046 0.051 0.85
* * * 4 0.041 0.06 0.05 0.065 0.085 0.10 0.11 0.85
* * * 5 0.11 0.14 0.17 0.20 0.22 0.24 0.26 0.90
* * * 6 0.26 0.31 0.36 0.41 0.46 0.56 0.61 0.90
* * * 7 0.51 0.61 0.71 0.81 0.91 1.2 1.3 0.92
* * * 8 0.91 1.11 1.31 1.51 1.71 2.2 2.4 0.92
* 9 1.51 1.91 2.31 2.61 2.91 3.4 3.7 0.92
* Available. ** The Mid Setting allows for easy valve capacity adjustments in the field to meet changing service conditions.
SPECIAL MULTI-STAGE, ANTI-CAVITATION TRIM DESIGN (OPTIONAL)
The 29000 Multi-stage Trim design provides unmatched Anti-cavitation performance in low flow applications. It minimizes
erosion and vibration, which typically leads to failure in conventional microflow valves. This specially engineered trim
option is available with all standard Modified Micropak body designs.
SPECIFIC CHARACTERISTICS
Rated Cv Range : 0.051 to 0.61

(Trim No.3 to 6)
Critical Flow Factor Cf : >0.98
Temperature Range : -290C to +3430C
MATERIAL
Seat : 17-4 PH SS
(ASTM A 564 Gr. 630 H900)
Plug : Solid Stellite No. 12

or ASTM A276 type 440 C
Other Parts : As per standard construction
Figure 1
MULTI-STAGE ANTI-CAVITATION TRIM
3
MIL 29000 - Construction
17
16 18
15 21
14 19
13 20
12 13
11 22
10 23
9 24
8 25
26
7
4
Figure 2
CROSS SECTIONAL VIEW
2
4
MIL 29000 - Construction
MATERIAL OF CONSTRUCTION
TEMPERATURE RANGE -1000C 1800C 3430C
REF. NO. PART NAME STANDARD AND OPTIONAL MATERIAL
ASTM A 182 Gr F316L (FORGING)

1 Body
Option : Monel, Hastelloy C, Alloy 20 etc.
17-4 PH SS
Trim No. 4 to 9
(ASTM A 564 Gr 630 Condition H900)
2 Seat
Trim No. 0 to 3 Solid Stellite No. 6
Trim No. 4 to 9 Solid Stellite No. 6
3 Plug Trim No. 0 to 3 Solid Stellite No. 12
4 Seat Ring Gasket SS 316 L + Graphite (spiral wound)
5 Seat Ring Retainer 17-4 PH SS
6 Packing Spacer SS 316
7 Packing PTFE Graphite Special
8 Packing Follower SS 304
9 Packing Flange SS 304
10 Packing Nut SS 304
11 Packing Stud SS 304
12 Conical Spring Spring Steel
13 Clevis C20 Cadmium Plated
14 Retainer Clip SS 304
15 Pivot Pins 17-4 PH
16 Lever No.1 ASTM B211 AL 2024 T4
17 Cv Adjusting Knob SS 304
18 Hand Wheel Bakelite
19 Cover Polycarbonate
20 Actuator Bracket Aluminium
21 Scale Aluminium
22 Actuator Spring Spring Steel
23 Piston Aluminium
24 Rolling Diaphragm Buna N
25 Diaphragm Cover A36 Cadmium Plated
26 Locking Screw SS 316
(*)
: Other Material suitable for corrosive fluids and NACE Specification are available on request.
(**)
: Material noted throughout text is for reference only. MIL-KSB reserves the right to supply trade name material or equivalent.
5
MIL 29000 - Weights & Dimensions
APPROXIMATE DIMENSIONS AND WEIGHTS
Modified Micropak valve is widely used in all industries. This can be attributed to the overall compactness,
simplicity and the wide application range of the stainless steel body design.
Face to face distance Unpacked Weight

Type ANSI Class End Drawing
A (mm) (Kg)
150#-600# 128 8 to 10
Flanged 3A
900#-1500# 168 10 to 12
Raised Flangeless 150#-1500# 108 7.5 3B
Threaded (NPT) 150#-1500# 108 7.5 3C
Socket Weld 150#-1500# 120 7.5 3D
Butt Weld 150#-1500# 120 7.5 3E
Note: All dimensions are in mm.
260 50 55
130
φ60 12
Removal Clearance
110
Positioner
325
33
Figure 3
A DIMENSIONAL REFERENCE
Figure 3A Figure 3B Figure 3C Figure 3D Figure 3E

Flanged Raised Flangeless Threaded (NPT) Socket Weld Butt Weld
6
MIL 29000 - Positioner Construction
POSITIONER SUB ASSEMBLY
36
35
34
33
32
31
30
29
28
27
Figure 4
REF. PART NAME STANDARD REF. PART NAME STANDARD

No. MATERIAL No. MATERIAL
27 Manifold Block Aluminium 32 Diaphragm S/A -
28 Spring Spring Steel 33 Force Balancing Spring Spring steel
29 Gasket S/A - 34 Lever Arm Stop SS 304
30 Pilot S/A - 35 Lever No.2 SS 304
31 Positioner Block Aluminium 36 Spring Clamp SS 304
7
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Product Data Sheet
PS-00363, Rev. J
January 2015
Micro Motion® R-Series Coriolis Flow and

Density Meters
Multi-variable flow and density measurement
Basic liquid mass flow, volume flow, and density
measurement performance in a compact design
Rugged design minimizing process, mounting,
and environmental effects
Best fit-for-application
Cleanable, self-draining design for critical process
control service
Compact design enables installation flexibility
and reduced maintenance costs
Broad range of I/O offerings including HART,
Profibus-DP, FOUNDATION fieldbus, 4-20mA and
wireless capabilities
Exceptional reliability and safety

No moving parts to wear or replace minimizes
maintenance for long-term reliability
316L stainless steel construction for compatibility
with most fluids
Robust sensor design minimizes down time and
process interruption costs
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FRPSDFWGUDLQDEOH FRPSDFWGUDLQDEOH IXOOERUH IORZDQGGHQVLW\ ORZIORZ
R-Series Flow Meters January 2015
Micro Motion® R-Series flow meters

Micro Motion R-Series meters are designed for general utility use across a wide range of applications where
basic flow measurements are needed. Benefiting from the fundamental advantages of Coriolis technology
the Micro Motion R-series is an ideal replacement for mechanical flow meters.
Optimal flow measurement fit for general purpose applications

Rugged measurement in a compact, drainable design that maximizes process up time
Low frequency, high sensitivity fit-and-forget meter provides robust measurements even under
demanding process conditions
Multiple line sizes provide an ideal platform for batching, distribution, allocation and intra-plant
measurement applications
Industry-leading capabilities that unleash your process potential

Available with an extensive offering of transmitter and mounting options for maximum compatibility with
your system
State of the art, ISO-IEC 17025 compliant calibration stands achieving ±0.014% uncertainty drive best in
class measurement accuracy
The most robust communication protocol offering in the industry including Smart Wireless
True multi-variable technology measures necessary flow process variables simultaneously
Widest range of installation and process condition flexibility

Featuring a low pressure drop, low weight design that reduces installation and commissioning costs
Unmatched MVD transmitter technology with digital signal processing (DSP) delivers the fastest
response rates enabling accurate batch and process measurement
Table of Contents
Measurement principles.................................................3 Meter approvals and certifications............................... 10
Performance specifications ............................................4 Transmitter interface................................................... 11
Operating conditions: Environmental ............................8 Physical specifications ................................................. 11
Operating conditions: Process .......................................9 Ordering information .................................................. 14
2 www.micromotion.com
January 2015 R-Series Flow Meters
Measurement principles
As a practical application of the Coriolis effect, the Coriolis mass flow meter operating principle involves inducing a vibration of the
flow tube through which the fluid passes. The vibration, though it is not completely circular, provides the rotating reference frame
which gives rise to the Coriolis effect. While specific methods vary according to the design of the flow meter, sensors monitor and
analyze changes in frequency, phase shift, and amplitude of the vibrating flow tubes. The changes observed represent the mass flow
rate and density of the fluid.
Mass flow measurement

The measuring tubes are forced to oscillate producing a sine wave. At zero flow, the two tubes vibrate in phase with each other.
When flow is introduced, the Coriolis forces cause the tubes to twist resulting in a phase shift. The time difference between the
waves is measured and is directly proportional to the mass flow rate.
No flow With flow
Outlet pickoff
displacement Outlet pickoff
displacement
Inlet pickoff
displacement Inlet pickoff
displacement
Time Time Time difference
Temperature measurement
Temperature is a measured variable that is used to compensate for temperature influences on Young’s Modulus of Elasticity.
Meter characteristics
Measurement accuracy is a function of fluid mass flow rate independent of operating temperature, pressure, or composition.
However, pressure drop through the sensor is dependent upon operating temperature, pressure, and fluid composition.
Specifications and capabilities vary by model and certain models may have fewer available options. Please refer to the Online
Store Sizing and Selection Tool at the Micro Motion web site (www.micromotion.com/onlinestore) for detailed information
regarding performance and capabilities.
The letter at the end of the base model code (for example R100S) represents wetted part material and/or application
designation: S = stainless steel and P = high pressure.
Performance specifications
Reference operating conditions
For determining the performance capabilities of our meters, the following conditions were observed/utilized:
Water at 68 to 77 °F and 14.5 to 29 psig (20 to 25 °C and 1 to 2 barg)
Accuracy based on industry leading accredited calibration stands according to ISO/IEC 17025
All models have a density range up to 5 g/cm3 (5000 kg/m3)
www.micromotion.com 3
Accuracy and repeatability on liquids and slurries

Performance specifications Calibration code Y Calibration code A
Mass flow accuracy (1) ±0.5% of rate ±0.4% of rate
Volume flow accuracy (1) ±0.5% of rate (2)
Mass flow repeatability ±0.25% of rate ±0.2% of rate

Volume flow repeatability ±0.25% of rate
Density accuracy ±0.01 g/cm3 (±10.0kg/m3) ±0.003 g/cm3 (±3.0kg/m3)
Density repeatability ±0.005 g/cm3 (±5.0kg/m3) ±0.0015 g/cm3 (±1.5kg/m3)
Temperature accuracy ±1 °C ±0.5% of reading
Temperature repeatability ±0.2 °C
(1) Stated flow accuracy includes the combined effects of repeatability, linearity, and hysteresis.
(2) Valid at calibration conditions.
Accuracy and repeatability on gases

Performance specification All models
Mass flow accuracy (1) ±0.75% of rate
Mass flow repeatability (1) ±0.5% of rate

Temperature accuracy ±1 °C ±0.5% of reading
Temperature repeatability ±0.2 °C
(1) Stated flow accuracy includes the combined effects of repeatability, linearity, and hysteresis
Liquid flow rates

Nominal flow rate
Micro Motion has adopted the term nominal flow rate, which is the flow rate at which water at reference conditions causes
approximately 14.5 psig (1 barg) of pressure drop across the meter.
Mass flow rates for all models: 316L stainless steel (S) and high pressure (P)
Nominal line size Nominal flow rate Maximum flow rate

Model inch mm lb/min kg/h lb/min kg/h
R025 1/4” DN6 50 1,366 100 2,720
R050 1/2” DN15 155 4,226 300 8,160

R100 1” DN25 604 16,440 1,200 32,650
R200 2” DN50 1,917 52,160 3,200 87,100
Volume flow rates for all models: 316L stainless steel (S) and high pressure (P)
Nominal flow rate Maximum flow rate

Model gal/min barrels/h l/h gal/min barrels/h l/h
R025 6 9 1,366 12 23 2,720
R050 19 27 4,226 36 69 8,160

R100 72 103 16,440 144 274 32,650
R200 230 328 52,160 384 731 87,100
Gas flow rates

When selecting sensors for gas applications, pressure drop through the sensor is dependent upon operating temperature, pressure,
and fluid composition. Therefore, when selecting a sensor for any particular gas application, it is highly recommended that each
sensor be sized using the Online Store Sizing and Selection Tool at the Micro Motion web site (www.micromotion.com/onlinestore).
The below table indicates flow rates that produce approximately 25psig (1.7barg) pressure drop on natural gas.
Gas flow rates for all models: 316L stainless steel (S) and high pressure (P)
Mass Volume
Model lb/min kg/h SCFM Nm3/h
R025 17 468 388 659
R050 52 1,429 1,183 2,010

R100 200 5,452 4,514 7,670
R200 666 18,137 15,018 25,515
Notes
• Standard (SCFM) reference conditions are 14.7 psig and 60°F. Normal reference conditions are 1.013 barg and 0°C.
Zero stability
Zero stability is used when the flow rate approaches the low end of the flow range where the meter accuracy begins to deviate from
the stated accuracy rating, as depicted in the turndown section below. When operating at flow rates where meter accuracy begins to
deviate from the stated accuracy rating, accuracy is governed by the formula: accuracy = (zero stability/flow rate) x 100%.
Repeatability is similarly affected by low flow conditions.
Turndown capabilities
The graph and table below represent an example of the measurement characteristics under various flow conditions. At flow rates
requiring large turndowns (greater than 20:1), the zero stability values may begin to govern capability dependent upon flow
conditions and meter in use.
2.5
1:1
2.0
20:1
Accuracy, %
1.5 10:1
1.0
0.5
0
0 10 20 30 40 50 60 70 80 90 100
Flow rate, % of nominal
Turndown from nominal flow rate 20:1 10:1 1:1

Accuracy ±% 0.50 0.50 0.50
Pressure drop psig (barg) 0.1 (0.007) 0.813 (0.05) 54 (3.4)
Zero stability for all models: 316L stainless steel (S) and high pressure (P)
Zero stability
Model lb/min kg/h

R025 0.0061 0.165
R050 0.0180 0.492
R100 0.0750 2.046
R200 0.2398 6.540
Process pressure ratings

Sensor maximum working pressure reflects the highest possible pressure rating for a given sensor. Process connection type and
environmental and process fluid temperatures may reduce the maximum rating. Refer to the Technical Data Sheet for common
sensor and fitting combinations.
R-Series sensors comply with ASME B31.1 power piping code, ASME B31.3 process piping code, and Council Directive 97/23/EC of 29
May 1997 on pressure equipment.
Note
R-Series sensors with JIS process connections do not comply with ASME B31.1 power piping code.
Sensor maximum working pressure for all models: 316L stainless steel (S) and high pressure (P)
Model psig barg

All stainless steel models (R025S–R200S) 1,450 100
R025P 2,300 159
Case pressure
Case pressure for all models: 316L stainless steel (S) and high pressure (P)
Model Case maximum pressure (1) NAMUR NE132 Typical burst pressure
psig barg psig barg psig barg

R025 166 11 1,256 87 1,884 130
R050 135 9 1,020 70 1,530 105

R100 109 7 854 59 1,281 88
R200 64 4 507 35 760 52
R300 256 17 1,754 120 2,630 180
(1) One time case containment pressure over a period of a maximum of 50 hours.
Operating conditions: Environmental

Vibration limits
Meets IEC 68.2.6, endurance sweep, 5 to 2000 Hz, 50 sweep cycles at 1.0g.
Temperature limits
Sensors can be used in the process and ambient temperature ranges shown in the temperature limit graphs. For the purposes of
selecting electronics options, temperature limit graphs should be used only as a general guide. If your process conditions are close
to the gray area, consult with your Micro Motion representative.
Notes
• In all cases, the electronics cannot be operated where the ambient temperature is below –40°F (–40°C) or above +140°F (+60°C).
If a sensor is to be used where the ambient temperature is outside of the range permissible for the electronics, the electronics
must be located where the ambient temperature is within the permissible range, as indicated by the shaded areas of the
temperature limit graphs.
• Temperature limits may be further restricted by hazardous area approvals. Refer to the hazardous area approvals documentation
shipped with the sensor or available from the Micro Motion web site (www.micromotion.com).
• The extended-mount electronics option allows the sensor case to be insulated without covering the transmitter or core
processor, but does not affect temperature ratings. When insulating the sensor case at elevated process temperatures (above
140°F), please ensure electronics are not enclosed in insulation as this may lead to electronics failure.
Ambient and process temperature limits for all models: 316L stainless steel (S) and high pressure (P)

7DPE $ Tamb = Ambient temperature °F (°C)

Tproc = Process temperature °F (°C)
A = All available electronic options
B= Remote mount electronics only
ದದ
%
ದದ
ದ
ದ
7SURF

Operating conditions: Process

Process temperature effect
For mass flow measurement, process temperature effect is defined as the change in sensor flow accuracy due to process
temperature change away from the calibration temperature. Temperature effect can be corrected by zeroing at the process
conditions.
Process temperature effect for all models: 316L stainless steel (S) and high pressure (P)
Model code Mass flow rate (% of maximum rate) per °C

R025, R050, R100, R200 ±0.00175
Process pressure effect

Process pressure effect is defined as the change in sensor flow accuracy due to process pressure change away from the calibration
pressure. This effect can be corrected by dynamic pressure input or a fixed meter factor. See installation manual for proper setup and
configuration.
Process pressure effect for all models: 316L stainless steel (S) and high pressure (P)
Liquid or gas flow (% of rate)
Model code per psig per barg

R025, R050,R100 none none
R200 –0.001 –0.015
Meter approvals and certifications

Approvals and certifications
Type Approval or certification (typical)

CSA and CSA C-US Ambient temperature: –40 to +140 °F (–40 to +60 °C) Class I, Div. 1, Groups C and D
Class I, Div. 2, Groups A, B, C, and D Class II, Div.1, Groups E, F, and G
ATEX II 2G Ex ib IIB/IIC T1–T4/T5/T6 Gb
0575
II 2D Ex ib IIIC T(1)°C Db IP66
II 3G Ex nA IIC T1–T4/T5 Gc
II 3D Ex tc IIIC T(1) °C Dc IP66
IECEx Ex ib IIB/IIC T1–T4/T5/T6 Gb
Ex nA IIC T1-T4/T5 Gc
NEPSI Ex ib IIB/IIC T1–T6 Gb
Ex ibD 21 T450°C-T85°C Ex nA IIC T1–T6 Gc
DIP A22 T(1) T1-T6
Ingress Protection Rating IP 66/67 for sensors and transmitters
EMC effects Complies with EMC directive 2004/108/EC per EN 61326 Industrial
Complies with NAMUR NE-21 (22.08.2007)
Note:
• Approvals shown are for R-Series meters configured with a model 1700 transmitter. Meters with integral electronics may have
more restrictive approvals. Refer to the Product Data Sheet for each transmitter for details.
• When a meter is ordered with hazardous area approvals, detailed information is shipped along with the product.
• More information about hazardous approvals, including detailed specifications and temperature graphs for all meter
configurations is available on the R-Series product page at the Micro Motion web site (www.micromotion.com).
Industry standards
Type Standard
Industry standards and commercial NAMUR: NE132 (burst pressure, sensor flange to flange length), NE131
approvals Pressure Equipment Directive (PED)
Canadian Registration Number (CRN)
Dual Seal
ASME B31.3 Piping Code
SIL2 and SIL3 safety certifications
Transmitter interface
A Motion flowmeter system is highly customizable to provide a configuration that is tailor-fit to specific applications.
Robust transmitter offerings allow a multitude of mounting R-Series meters are available with an expansive selection of
options: input and output connectivity options including the following:
Compact mounting integral to the sensor 4-20 mA
Field mount variants for harsh conditions HART™
Compact control room DIN rail packages for optimal locating WirelessHART™
in a control cabinet EtherNet/IP
FOUNDATION™ fieldbus
PROFIBUS
Modbus®
Other protocols may be available on request
Physical specifications
Materials of construction
General corrosion guidelines do not account for cyclical stress, and therefore should not be relied upon when choosing a wetted
material for a Micro Motion meter. Please refer to the Micro Motion Corrosion Guide for material compatibility information.
Wetted part materials

Model Sensor weight
Nickel alloy C22
316L Stainless steel and Stainless steel lb kg
R025 • • 10 5
R050 • 11 5
R100 • 21 10
R200 • 42 20
Notes
• Weight specifications are based upon ASME B16.5 CL150 flange and do not include electronics.
• Heat jackets and steam kits are also available.
Non-wetted part materials

316L 304L Polyurethane-painted
Component Enclosure rating stainless steel stainless steel aluminum
Sensor housing — •
Core processor housing NEMA 4X (IP66/67) • •
Model 1700/2700 transmitter NEMA 4X (IP66) • •
housing
Flanges
Sensor type Flange types
Stainless steel 316L ASME B16.5 weld neck flange (up to CL600)
ASME B16.5 weld neck flange raised face (up to CL600)
EN 1092-1 weld neck flange form B1, B2, D (up to PN100)
JIS B2220 weld neck raised face (up to 20K)
VCO, VCR swagelok compatible fitting
Hygienic tri-clamp compatible
Note
For flange compatibility, please refer to the Online Store Sizing and Selection Tool at the Micro Motion web site
(www.micromotion.com/onlinestore).
Dimensions
These dimensional drawings are intended to provide a basic guideline for sizing and planning. They are representative of a 316
stainless steel model fitted with ASME B16.5 CL150 flange, and 1700 transmitter.
Face-to-Face (Dim. A, below) dimensions for all R-series meters with each available process connection can be found in the R-series
Technical Data Sheet.
Complete and detailed dimensional drawings can be found through the product link in our online store
(www.micromotion.com/onlinestore).
Note
• All dimensions ±1/8 inch (±3 mm).
• Representative of a 316 stainless steel model fitted with ASME B16.5 CL150 flange, and 1700 transmitter
Example dimensions for all models: 316L stainless steel (S), and high pressure (P)
7-3/16
(183)
D
A
Dim. A Dim. B Dim. C Dim. D
Model Inch mm Inch mm Inch mm Inch mm

R025 16 406 8-3/8 213 5-1/8 130 2-13/16 71
R050 18-1/8 460 8-3/8 213 6-3/4 171 2-15/16 75
R100 22-11/16 576 8-5/8 219 9-1/8 232 4-1/8 105

R200 24-3/4 629 9-9/16 267 12-9/16 319 5-5/8 143
Ordering information
Product code structure
5 6 & % ( = = =
Sensor series Se M Fi Ca El Co Ap La Ca M Fa
ns at tt se ec nd pr ng lib so ea ct
or er in tr ov ua r f s or
gs on ui t u
siz ia
lo ic t al ge atio wa rem y o
e ra s s s n re e pt
pp nt io
ap ns
lic
at pl
io ic
n at
io
n
Base model
Codes S and P are model designations used to identify the type of meter.
Model Material Availability

P High pressure
S 316L stainless steel S P
R025 1/4-inch (6 mm) S P
R050 1/2-inch (12 mm) S
R100 1-inch (25 mm) S
R200 2-inch (50 mm) S
Process connections
Model R025S
Code Description
113 1/2-inch CL150 ASME B16.5 F316/F316L Weld neck flange Raised face
116 DN15 PN40 DIN 2635 F316/F316L Weld neck flange Form C face
120 DN15 PN100/160 DIN 2638 F316/F316L Weld neck flange Form E face
121 1/2-inch Tri-Clamp 316L Hygienic fitting

compatible
Model R025S (Continued)
Code Description
122 15mm 20K JIS B 2220 F316/316L Weld neck flange Raised face
170 DN15 PN100/160 EN 1092-1 F316/F316L Weld neck flange Type B2
172 DN25 PN40 EN 1092-1 F316/F316L Weld neck flange Type B1

178 DN15 PN100 EN 1092-1 F316/F316L Weld neck flange Type D
222 DN15 DIN11851 316/316L Hygienic coupling
319 #8 VCO 316/316L Swagelok compatible 1/2-inch NPT female
fitting adapter
Model R025P
Code Description

319 #8 VCO 316/316L Swagelok compatible 1/2-inch NPT

fitting female adapter
Model R050S
Code Description
131 DN25 PN40 DIN 2635 F316/F316L Weld neck flange FormC face
Model R050S (Continued)
Code Description

239 #12 VCO 316/316L Swagelok compatible 3/4-inch NPT
fitting female adapter
322 3/4-inch Tri-Clamp 316L Hygienic fitting
compatible
Model R100S
Code Description
128 1-inch CL150 ASME B16.5 F316/F316L Weld neck flange Raised face
138 1-inch Tri-Clamp 316L Hygienic fitting
compatible
139 25mm 20K JIS B 2220 F316/F316L Weld neck flange Raised face

Model R200S
Code Description

341 1-1/2-inch CL150 ASME B16.5 F316/F316L Weld neck flange Raised face
351 1-1/2-inch Tri-Clamp 316L Hygienic fitting
compatible
352 2-inch Tri-Clamp 316L Hygienic fitting
compatible

378 DN50 PN100 DIN 2637 F316/F316L Weld neck flange FormE face
381 DN40 PN40 DIN 2635 F316/F316L Weld neck flange FormC face
382 DN50 PN40 DIN 2635 F316/F316L Weld neck flange Type C face
Case options
Code Case option
N Standard case
Electronics interface
Code Case option
Q 4-wire polyurethane-painted aluminum integral core processor for remotely mounted transmitter with MVD technology
A 4-wire stainless steel integral core processor for remotely mounted transmitter with MVD technology
V 4-wire polyurethane-painted aluminum integral core processor with extended mount for remotely mounted transmitter
with MVD technology
B 4-wire stainless steel integral core processor with extended mount for remotely mounted transmitter with MVD
technology
C Integrally mounted Model 1700 or 2700 transmitter.
W (1) MVDSolo; epoxy-painted aluminum integral core processor for direct host connection (for (OEMs)
D (1) MVDSolo; stainless steel integral core processor for direct host connection (for (OEMs)
Y (1) MVDSolo; extended-mount epoxy-painted aluminum integral core processor (for (OEMs)
E (1) MVDSolo; extended-mount stainless steel integral core processor for (OEMs)
(1) When electronics interface code W, D, Y, or E is ordered with approval code C, A, or Z, MVD Direct Connect™ I.S. barrier is supplied.
Conduit connections
Code Description Availability
A No gland
B 1/2-inch NPT - no gland
E M20 - no gland
F Brass/nickel cable gland (cable diameter 0.335 to 0.394 inches [8.5 to 10 mm])
G Stainless steel cable gland (cable diameter 0.335 to 0.394 inches [8.5 to 10 mm])
K JIS B0202 1/2G - no gland
L Japan - brass nickel cable gland
M Japan - stainless steel gland M L K G F E B A
All models with electronics interface codes Q, A, V, and B
M L K G F E B
All models with electronics interface code C
A
All models with electronics interface codes W, D, Y, and E
G F E B
Approval options
Code Description Availability
M Micro Motion Standard (no approval)
N Micro Motion Standard / PED compliant
C CSA (Canada only)
A CSA (US and Canada): Class I, Division 1, Groups C and D
Z ATEX - Equipment Category 2 (Zone 1) / PED compliant
I IECEx Zone 1
P NEPSI; only available with language option M (Chinese)
T TIIS - T4 Temperature Classification (Not available for quotes outside of Japan) N/C
S TIIS - T3 Temperature Classification (Not available for quotes outside of Japan)
J Hardware ready for TIIS approval (EPM Japan only) J S T P I Z A C N M
With electronics interface codes Q, A, V, B, and C
J S T P I Z A C N M
With electronics interface codes W, D, Y, and E
P Z A C N M
Languages
Code Language option
A Danish CE requirements document and English installation manual
C Czech installation manual
D Dutch CE requirements document and English installation manual
E English installation manual
F French installation manual
G German installation manual
H Finnish CE requirements document and English installation manual
I Italian installation manual
J Japanese installation manual

M Chinese installation manual
N Norwegian CE requirements document and English installation manual
O Polish installation manual
P Portuguese installation manual

S Spanish installation manual
W Swedish CE requirements document and English installation manual

B Hungarian CE requirements document and English installation manual
K Slovak CE requirements document and English installation manual
T Estonian CE requirements document and English installation manual
U Greek CE requirements document and English installation manual
L Latvian CE requirements document and English installation manual
V Lithuanian CE requirements document and English installation manual

Y Slovenian CE requirements document and English installation manual
Calibration
Code Calibration option
Y 0.5% mass flow and 0.01 g/cm3 (10 kg/m3) density calibration
A 0.4% mass flow and 0.003 g/cm3 (3.0 kg/m3) density calibration
Measurement application software

Code Measurement application software option
Z No measurement application software
Factory options
Code Factory option
Z Standard product
X ETO product
Certificates, tests, calibrations, and services

These option codes can be added to the end of the model code if needed, but no code is required when none of these options is
selected.
Note
There may be additional options or limitations depending on total meter configuration. Contact a sales representative before
making your final selections.
Material quality examination tests and certificates

Select any from this group.
Code Factory option
MC Material inspection certificate 3.1 (supplier lot traceability per EN 10204)

NC NACE certificate 2.1 (MR0175 and MR0103)
KH KHK package 3.1 — certificate package to accommodate approval in Japan. Includes:
Radiographic and tube wall examination
HSB witness primary containment hydrostatic and pneumatic testing
Material inspection certificate
Not available with codes RI, RC, HT, MC (because they are already included)
Radiographic testing
Select only one from this group.
Code Factory option

RE X-ray package 3.1 (radiographic examination certificate; weld map; radiographic inspection NDE qualification)
RT X-Ray package 3.1 (radiographic examination certificate with digital image; weld map; radiographic inspection NDE
qualification)
Pressure testing
Code Factory option
HT Hydrostatic test certificate 3.1 (wetted components only)
Dye penetrant examination

Code Factory option
D1 Dye penetrant test package 3.1 (sensor only, liquid dye penetration NDE qualification):
Weld examination
Code Factory option
WP Weld procedure package (weld map, weld procedure specification, weld procedure qualification record, welder
performance qualification)
Positive material testing

Select only one from this group.
Code Factory option
PM Positive material test certificate 3.1 (without carbon content)

PC Positive material test certificate 3.1 (including carbon content)
ASME B31.1 Power Piping design code certification

Code Factory option
GC B31.1 Power Piping design code certification
Special cleaning
Code Factory option
O2 Declaration of compliance oxygen service 2.1
GOST compliance
Code Factory option
GR Russian GOST calibration verification certificate
Sensor completion
Code Factory option

WG Witness general
SP Special packaging
Country specific approvals

Select one from the following if approval code G is selected.
Code Factory option

R1 EAC Zone 1 – Hazardous Approval (1)
B1 INMETRO Zone 1 – Hazardous Approval (1)
(1) Only available with approval code G.
R-Series Flow Meters Product Data Sheet
PS-00363, Rev. J January 2015
Emerson Process Management Emerson Process Management Emerson Process Management

Americas Europe/Middle East Asia Pacific
7070 Winchester Circle Central & Eastern Europe T: +41 41 7686 111 Australia T: (61) 3 9721 0200
Boulder, Colorado USA 80301 Dubai T: +971 4 811 8100 China T: (86) 21 2892 9000
www.MicroMotion.com Abu Dhabi T: +971 2 697 2000 India T: (91) 22 6662 0566
www.Rosemount.com France T: 0800 917 901 Japan T: (81) 3 5769 6803
T: +1 800 522 6277 Germany T: 0800 182 5347 South Korea T: (82) 2 3438 4600
T: +1 (303) 527 5200 Italy T: 8008 77334 Singapore T: (65) 6 777 8211
F: +1 (303) 530 8459 The Netherlands T: +31 (0) 70 413 6666
Belgium T: +32 2 716 77 11
Mexico T: 52 55 5809 5300 Spain T: +34 913 586 000
Argentina T: 54 11 4837 7000 U.K. T: 0870 240 1978
Brazil T: 55 15 3413 8000 Russia/CIS T: +7 495 981 9811
Venezuela T: 58 26 1300 8100
Chile T: 56 2 2928 4800
© 201Micro Motion, Inc. All rights reserved.
The Emerson logo is a trademark and service mark of Emerson Electric Co. Micro Motion, ELITE, ProLink, MVD and MVD Direct Connect marks are
marks of one of the Emerson Process Management family of companies. All other marks are property of their respective owners.
Micro Motion supplies this publication for informational purposes only. While every effort has been made to ensure accuracy, this publication is not
intended to make performance claims or process recommendations. Micro Motion does not warrant, guarantee, or assume any legal liability for the
accuracy, completeness, timeliness, reliability, or usefulness of any information, product, or process described herein. We reserve the right to
modify or improve the designs or specifications of our products at any time wihout notice. For actual product information and recommendations,
please contact your local Micro Motion representative.
Translation of the Original Instructions
Operating manual
Single Stage Radial Fan
Design RHE/RGE
See chapter 14 of this operating manual

for detailed addresses of all companies of the REITZ Group.
Please read this operating manual carefully. In case of
doubts or if uncertain points occur, please clarify them with
REITZ first.
The operating manual is, like spare parts lists and documen-
tations of sub-suppliers, a separate part of the complete
documentation. The complete documentation must be made
available to the personnel appointed to operating and
maintenance works.
OPERATING MANUAL: RADIAL FAN RHE/RGE
2011 REITZ Holding GmbH & Co. KG
Copyright on the operating manual
REITZ HOLDING holds the copyright in this operating manual.

This operating manual is intended for technical personnel that performs the following work related to the
fan: transport, mounting, commissioning and start-up, operation, operating, troubleshooting, mainte-
nance, repair, shutting-down, dismantling, disposal. Instructions and drawings of technical nature must
not be copied in parts or completely, distributed or used without authorization for the purpose of competi-
tion or information of third parties.
This operating manual was drawn up with the utmost care. REITZ HOLDING is not liable for possible
errors in this operating manual. Liabilities for indirect and / or direct damages that are related to the
delivery or the usage of this operating manual are excluded, as far as legally permitted.
This document is a translation. In case of discrepancy the original and obligatory version is the German
original.
BWA-RXE_Fettlager_englisch_03.doc 2011
Table of contents
Table of contents
1. Introduction ................................................................................................................ 1.1
1.1 EC Declaration of conformity and EC Declaration of incorporation .......................................... 1.1
1.2 Fan data sheet ........................................................................................................................ 1.1
1.3 Description .............................................................................................................................. 1.2
1.4 Intended use ........................................................................................................................... 1.2
1.4.1 Fans according to94/9/EG ....................................................................................................... 1.2
1.4.2 Limits for use of fans acc. to 94/9/EG (ATEX) ......................................................................... 1.3
1.5 Installations and mounting instructions to reduce noise and vibrations .................................... 1.4
1.6 General remarks ..................................................................................................................... 1.5
1.7 Nameplate ............................................................................................................................... 1.7
2. Safety instructions ..................................................................................................... 2.1

2.1 General remarks ..................................................................................................................... 2.1
2.2 Danger outline ......................................................................................................................... 2.1
2.3 Symbols .................................................................................................................................. 2.3
2.4 Safety regulations ................................................................................................................... 2.5
2.5 Regulations, standards............................................................................................................ 2.6
2.6 Electric connection conditions ................................................................................................. 2.8
2.7 Marking, danger signs ............................................................................................................. 2.9
2.8 Qualified person ...................................................................................................................... 2.9
2.9 Personal protective equipment .............................................................................................. 2.10
2.10 Risk of slipping, tripping or falling .......................................................................................... 2.11
2.11 Measures in case of electrical power outage ......................................................................... 2.11
3. Transport, Installation ............................................................................................... 3.1

3.1 General remarks ..................................................................................................................... 3.1
3.2 Safety instructions ................................................................................................................... 3.1
3.3 Regulations, standards............................................................................................................ 3.2
3.3.1 Load suspension devices ........................................................................................................ 3.3
3.4 Packing ................................................................................................................................... 3.4
3.5 Transport................................................................................................................................. 3.6
3.5.1 Transport damages ................................................................................................................. 3.7
3.5.2 Intermediate storage ............................................................................................................... 3.7
3.6 Installation ............................................................................................................................... 3.8
3.6.1 General remarks ..................................................................................................................... 3.9
3.6.2 Safety instructions ................................................................................................................... 3.9
3.6.3 Preparation for installation ..................................................................................................... 3.10
3.6.4 Mounting and Alignment ........................................................................................................ 3.11
3.6.4.1 General remarks ................................................................................................................... 3.11
3.6.4.2 Sequence of mounting .......................................................................................................... 3.11
3.6.4.3 Alignment of the belt pulleys .................................................................................................. 3.14
3.6.4.4 Screw connections ................................................................................................................ 3.15
3.7 Connections .......................................................................................................................... 3.17
3.7.1 General remarks ................................................................................................................... 3.17
Table of contents
3.7.2 Safety instructions ................................................................................................................. 3.17

3.7.3 Ducting of fan ........................................................................................................................ 3.18
3.7.4 Check of clearances .............................................................................................................. 3.19
3.7.4.1 Check of clearance for impeller with shroud .......................................................................... 3.20
3.7.4.2 Check of clearance for unshrouded impeller ......................................................................... 3.21
3.7.5 Use of flexible connections .................................................................................................... 3.22
3.7.5.1 Installation of flexible connections ......................................................................................... 3.22
3.7.6 Use of chutes ........................................................................................................................ 3.22
3.7.7 Electric connection conditions ............................................................................................... 3.23
3.7.7.1 Earthing................................................................................................................................. 3.23
3.7.7.2 Monitoring devices ................................................................................................................ 3.24
3.7.8 Seal connection..................................................................................................................... 3.24
4. Start-up ....................................................................................................................... 4.1

4.1 General remarks ..................................................................................................................... 4.1
4.2 Mechanical check .................................................................................................................... 4.1
4.2.1 Alignment ................................................................................................................................ 4.1
4.3 Electric check .......................................................................................................................... 4.2
4.3.1 Monitoring devices / auxiliary equipment ................................................................................. 4.2
4.3.2 Check of sense of rotation ....................................................................................................... 4.3
4.3.3 Commutating wrong sense of rotation ..................................................................................... 4.3
4.4 Start-up of fan ......................................................................................................................... 4.4
4.4.1 General remarks ..................................................................................................................... 4.4
4.4.2 Safety instructions ................................................................................................................... 4.5
4.4.3 Switching on of the fan ............................................................................................................ 4.6
4.4.3.1 Direct starting .......................................................................................................................... 4.7
4.4.3.2 Star-delta-starting .................................................................................................................... 4.7
4.4.3.3 Prevention of high negative torque impacts during test run ..................................................... 4.7
4.4.3.4 Fan operation with variable speed control ............................................................................... 4.7
4.4.4 Disconnecting of fan ................................................................................................................ 4.8
5. Operation, Operating ................................................................................................. 5.1

5.1 General remarks ..................................................................................................................... 5.1
5.3 Operational performance of the fan ......................................................................................... 5.1
5.4 Disconnecting of fan ................................................................................................................ 5.2
5.5 Emergency stop of fan ............................................................................................................ 5.2
5.6 Automatic operation of fan....................................................................................................... 5.5
5.6.1 Variable speed control with frequency converter ..................................................................... 5.5
5.6.2 Natural frequency of the impeller ............................................................................................. 5.6
5.6.3 Parameterising the variable speed control............................................................................... 5.6
5.6.4 Speed control range ................................................................................................................ 5.6
5.7 Separate ventilation................................................................................................................. 5.7
6. Trouble, Repair ........................................................................................................... 6.1

6.1 General remarks ..................................................................................................................... 6.1
Table of contents

6.3 Troubles .................................................................................................................................. 6.2
6.3.1 Bearing troubles ...................................................................................................................... 6.3
6.3.2 V-belt drive troubles ................................................................................................................ 6.4
7. Maintenance ............................................................................................................... 7.1

7.1 General remarks ..................................................................................................................... 7.1
7.3 Bearings .................................................................................................................................. 7.3
7.3.1 Anti-friction bearings................................................................................................................ 7.4
7.3.1.1 Lubrication instructions anti-friction bearings in single bearing housings ................................. 7.5
7.3.1.2 Lubrication instructions anti-friction bearings in a multiple bearing block ................................. 7.7
7.3.1.3 Remarks on lubrication intervals.............................................................................................. 7.9
7.3.2 Information on lubrication grease ............................................................................................ 7.9
7.4 Shaft seal .............................................................................................................................. 7.10
7.4.1 Standard seal ........................................................................................................................ 7.10
7.4.2 Shaft seal with graphite ring .................................................................................................. 7.10
7.4.3 Seal with special rings ........................................................................................................... 7.11
7.4.4 Shaft seal with grease barrier ................................................................................................ 7.11
7.4.5 Shaft seal with barrier gas ..................................................................................................... 7.11
7.4.6 Shaft seal of type REW6 (Ø 40 to Ø 120) .............................................................................. 7.12
7.4.7 Shaft seal of type REW6 (Ø 140 to Ø 240) ............................................................................ 7.12
7.5 Shaft earthing ........................................................................................................................ 7.13
7.6 V-belt drive ............................................................................................................................ 7.14
7.6.1 General remarks ................................................................................................................... 7.14
7.6.2 Belt tension ........................................................................................................................... 7.14
7.7 Marking, information sign ...................................................................................................... 7.16
7.8 Waste disposal ...................................................................................................................... 7.17
7.9 Revision ................................................................................................................................ 7.17
7.10 Maintenance schedule .......................................................................................................... 7.18
8. Repair work................................................................................................................. 8.1

8.1 General remarks ..................................................................................................................... 8.1
8.2 Fans in accordance with directive 94/9/EC ATEX .................................................................... 8.2
8.4 Spare parts ............................................................................................................................. 8.3
9. Annex .......................................................................................................................... 9.1

9.1 Additional technical information ............................................................................................... 9.1
9.1.1 Tightening moments for fastening screws ............................................................................... 9.1
9.1.2 Limiting values vibrations ........................................................................................................ 9.2
9.1.3 Limiting values bearing temperatures ...................................................................................... 9.3
9.2 Requests regarding field service staff ...................................................................................... 9.4
10. Fan shutdown ........................................................................................................... 10.1

10.1 General remarks ................................................................................................................... 10.1
10.2 Safety instructions ................................................................................................................. 10.1
Table of contents
10.3 Measures in case of extended shutdown............................................................................... 10.2

10.4 Measures in case of re-commissioning.................................................................................. 10.3
11. Dismantling............................................................................................................... 11.1

11.1 General remarks ................................................................................................................... 11.1
11.2 Safety instructions ................................................................................................................. 11.1
12. Safety data sheets .................................................................................................... 12.1

13. Expiry of service life, disposal ................................................................................ 13.1
14. Addresses of the REITZ group................................................................................ 14.1
Introduction
1. Introduction This general operating manual is valid for all fans of this
structural design including those that are designed in ac-
cordance to the Directive 94/9/EC on the approximation of
the laws of the Member States concerning equipment and
protective systems intended for use in potentially explosive
atmospheres (ATEX). All fans are designed and produced in
accordance with EC Machinery Directive 2006/42/EC.
1.1 EC Declaration of conformity and Being part of the overall documentation, these declarations
EC Declaration of incorporation are attached as separate documents to this operating
manual (see enclosure).
The fan design in accordance with EC directive 94/9/EC
(ATEX) will be certified by correspondent declaration of con-
formity.-
1.2 Fan data sheet The fan data sheet (see enclosure) is also attached as a
separate document to this operating manual. All relevant
technical data of the fan is clearly given in the fan data
sheet. It may also be called technical data sheet and is gen-
erated for each individual fan.
The fan data sheet contains the following information:
- Serial fan number
- Fan type
- Flow data (nominal data and operating points)
- Motor data
- Acoustic data
- Material data
- Type of coating
- Bearing details
- Details about V-belt drive
- Fan equipment and accessories
- Customer’s order number
- Customer’s type designation
For fans according to EC directive 94/9/EC (ATEX), an addi-
tional part of the documentation is the completed and signed
form of the questionnaire (RKU0063-… as amended from
time to time) and – if applicable – the indication of the certifi-
cation body where the documentation for fans of category II
was lodged.
BWA-RXE_Fettlager_englisch_03.doc 1.1
Introduction
1.3 Description The fan of RHE/RGE design is a welded single-stage radial

fan.
Power is transmitted from motor shaft to fan shaft by a V-belt
drive. The motor is mounted on an additional common base
of sectional steel. The motor of RHE fans is arranged at the
rear side of the base frame, RGE fan motors are installed
sideways.
Depending on the design type, the fan shaft runs
- in two grease-lubricated anti-friction bearings in single
bearing housings or
- in two grease-lubricated anti-friction bearings in a multiple
bearing block.
Further technical information that is not covered by this op-
erating manual can be requested from the manufacturer.
The fan can be designed for use in potentially explosive at-
mosphere. An individual nameplate indicates the equipment
group and category as per directive 94/9/EC (ATEX)
1.4 Intended use The fan is designed, calculated, produced, tested and
delivered in accordance with the design conditions stated in
the order.
The values given in the fan data sheet must not be exceed-
ed.
Any other or exceeding use is considered to be improper
use. Damages resulting from improper use are excluded
from the manufacturer’s liability.
1.4.1 Fans according to94/9/EG If the fan is designed in accordance to EC directive 94/9/EC
(ATEX), the intended use is restricted to
- the field of application
- the equipment group and category
- the explosion group for gases and vapours
- the gas or dust type
- the temperature class
These specifications can be found on the ATEX nameplate
at the fan and in the corresponding ATEX questionnaire.
Any other use or application in installation conditions deviat-
ing from those there stipulated is prohibited.
Introduction
1.4.2 Limits for use of fans acc. to The limiting conditions for the use of fans that are designed
94/9/EG (ATEX) according to Directive 94/9/EG are:
- Maximum inlet temperature under ambient atmospheres
in the temperature range from -20°C to +60°C
- Absolute pressure from 0.8 to 1.1 bar
- maximum 21% oxygen share in volume flow
If the operating conditions differ from the stated limiting con-
ditions, a special contract of work and labour has to be con-
cluded with REITZ. The design must be documented by a
separate ignition hazard assessment.
Introduction
1.5 Installations and mounting Take the following measures to reduce noise and to protect
instructions to reduce noise and the operating personnel’s health:
vibrations
- Connect the fan to the duct work at inlet and dis-
charge prior to fan start-up
- Mount the sound protection covers and hoods for
motor and bearing (if included in the delivery)
- Isolate the housing on-site if the fan is prepared for
insulation and this is included in the delivery
- Wear personal protective equipment (especially ear
protection) Æ see also chapter 2.2 Danger outline
Take the following measures to reduce the vibrations and to

avoid the transmission of vibrations to the duct work:
- Check the impeller according to the maintenance plan
(see chapter 7.10 Maintenance schedule) with regard to
sticking material, wear and tear, etc. since out-of-balance
might result in an increase in fan vibrations Æ see chapter
9.1.2 Limiting values vibrations
- Mount the flexible connections at inlet and discharge prior
to fan start-up (see also chapter 3.7.5 Use of flexible
connections)
- If the fan is intended for resilient mounting:
mount the fan on anti-vibration mounts (see chapter 3.6.4
Mounting and Alignment)
Introduction
1.6 General remarks This universal operating manual assists the operating
company to carry out the safe and proper transport, installa-
tion, commissioning, start-up and maintenance of the fan.
This operating manual exclusively refers to the fan, but not to
the electrical equipment like drive motors and other auxiliary
drives. The unit “fan and motor” will not turn into electrical
equipment when an electric drive is mounted. Please ob-
serve the operating and maintenance instructions of the mo-
tor manufacturer for mounting, installation and maintenance
of the electric motors and auxiliary drives.
This operating manual describes and represents compo-
nents that may not be included in your delivery.
In addition, our scope of delivery can include components
and additional equipment that are not mentioned in these in-
structions. In that case, please observe the corresponding
operating manuals of the relative producers. If applicable,
request them from REITZ.
This operating manual is subject to modifications due to fur-
ther technical development of the fan described herein.
Many images and drawings of this operating manual are
simplified representations. Due to improvements and modifi-
cations the fan operated by your company might vary from
the representations.
We reserve the copyright in this operating manual and the
attached drawings and further documents.
The manufacturer will not undertake liability for damages that
x occur during the warranty period resulting from:
- inadequate maintenance,
- improper operating and another than the intended use
- faulty mounting and installation,
- incorrect or inexpert connection of electric or mechanic
machines and devices.
x result or originate from unauthorized modifications or from
disregarding the manufacturer’s recommendations and
instructions.
x result from the use of accessories, equipment and/or
spare parts that are not recommended by or delivered
from the manufacturer.
Introduction
This operating manual serves to avoid personal injury, prop-

erty damage, functional failure as well as environmental
damage.
Read these instructions carefully and completely before start
of work. Should you have any questions or in case of doubts
please do not hesitate to contact REITZ.
Keep these instructions in a safe place. They must be ac-
cessible for the operating company at any time. Protect them
against harmful environmental influences and keep them in a
legible and complete condition. Store them near to the fan.
The following additional instructions apply for fans according
to directive 94/9/EC (ATEX):
If any technical modification at a fan that was designed and
constructed in accordance with directive 94/9/EC (ATEX),
that has not been agreed upon prior to the modification with
Reitz, is carried out the originally issued declaration of con-
formity will become invalid.
The validity of the declaration of conformity can be main-
tained, if a qualified person carries out applicable tests and
examinations after the technical modifications and prior to re-
commissioning of the fan and keeps records of the tests. In
particular, these inspections are the check of the gap meas-
ure, vibration test and further checks to ensure that the for-
mation of sparks is eliminated. The qualified person must be
authorized to install and mount the components in accord-
ance with §§ 14 and 15 of the German Health and Safety at
Work Regulations („Betriebssicherheitsverordnung Be-
trSichV“). In addition, the qualified person must be able to
recognize possible dangers for persons, property and envi-
ronment and to avoid them. A written confirmation of the
checks and examinations along with corresponding test re-
ports must be sent to Reitz without further request. Please
contact REITZ if any questions or uncertainties occur.
If the fan is of category II, we will inform the certification
body, to which the documentation has been sent, according-
ly.
Introduction
1.7 Nameplate The nameplate shows the following information:

- Manufacturer
- Address
- Designation of the machine
- Type designation
- Serial number
- Year of construction
- Technical data
- CE - sign
If technical information is or spare parts are required, all

above mentioned data must be communicated.
If the fan is designed in accordance with directive 94/9/EC
(ATEX), it has an additional nameplate with the following in-
formation:
- manufacturer
- address
- ATEX marking
- type designation
- serial number
- certification body
Figure 1
Figure 1: Example of an ATEX-nameplate
Safety instructions
2. Safety instructions
2.1 General remarks It is essential to read the operating manual prior to transport,
installation, commissioning, start-up, operating, repair and
maintenance. The instructions have to be observed.
2.2 Danger outline Radial fan – single-stage, structural design RHE/RGE
Kind of danger Location of danger Danger Additional measures

rubbing and abrasing brake (optional), all rotating explosion hazard by observe operating manual,
parts sparking and/or hot wear personal protective
surfaces equipment
impact and rubbing housing, impeller, motor, explosion hazard by observe operating manual
improper handling during sparking and / or hot and transport instructions
transport surfaces
corrosion housing, impeller, motor, deposits of corrosion observe operating manual
improper storage or increase the risk of ignition and the storage and
intermediate storage and sparking, explosion corrosion protection
hazard instructions
crushing, shearing, impact unloading, lifting, mounting danger to life, risk of injury pay attention to safe
and installation of the fan and property damage fastening and safe founda-
tion / floor conditions
entangling, winding, heat flinger, impeller, all danger to life, risk of injury observe operating manual
drawing-in, trapping, faulty rotating parts, brake and property damage
installation (optional)
electrical hazard directly by alive parts danger to life observe motor manufac-
turer’s operating manual
indirectly by faulty alive danger to life observe safety regulations
parts
thermal hazard caused by hot surfaces danger to life, risk of injury wearing of personal
contact and burn and property damage, risk protective equipment by
of explosion due to staff, if necessary, custom-
heightened ignition risk er must install safety areas
thermal hazard caused by hot surfaces e.g. housing, danger to life, risk of injury wearing of personal
improper installation, lifting lugs, drain, fan and property damage, risk protective equipment by
commissioning and start- pedestal of explosion due to staff, if necessary, custom-
up heightened ignition risk er must install safety areas
hazard generated by housing, impeller, bear- risk of property damages observe operating manual,
materials and foreign ings, driving elements, and danger of injury provide sufficient ventila-
substances and improper monitoring devices tion, avoid penetration and
use drag-in of foreign sub-
stances
high pressure ingress and shaft seal with purge danger to life, risk of injury observe the operating
ejection of fluids and gases medium connection and property damage manual, wearing of
personal protective
equipment
hazard generated by noise during operation the sound impairment of hearing observe the operating
emission exceeds 70 dB(A) ability, danger of injury manual, wearing of
personal protective
equipment
Safety instructions
Kind of danger Location of danger Danger Additional measures

combination of hazards danger for machinery, danger of injury, property observe operating manual
personnel and environment damages, environmental
if the commissioning, start- damages
up of the fan is not carried
out by sufficiently trained
staff members
Table 1 – danger outline
Safety instructions
2.3 Symbols The following symbols used in this operating manual need to
be particularly observed:
Observe carefully the safety instructions that are listed next
to the symbols in the following chapters. A label with these
symbols and the corresponding instructions is also fixed to
the fan.
DANGER!
Danger to life!
Serious physical injury with potential fatal conse-
quences.
DANGER!
Danger of death by electrocution!
quences.
Working must exclusively be carried out by author-
ized electrician
DANGER!
Risk of fatal injury from entangling, drawing-in or
trapping
quences.
Beware of automatic operation
DANGER!
Explosion hazard!
Spark formation or hot surfaces
quences.
WARNING!
Very hot surface – Do not touch!
Risk of burns. Severe personal injury
WARNING!
Risk of escaping of hot or dangerous gases.
CAUTION!
Risk related to exposure to noise!
Physical injury
Wear ear protection when fan is in operation.
Safety instructions
WARNING!
Environmental harm!
Considerable damage caused to the environment.
NOTICE!
Read the operating manual.
NOTICE!
Refers to useful information and explanations.
Safety instructions
2.4 Safety regulations The following instructions and regulations that are part of the
operating manual are strictly to be observed.
- safety regulations,
- regulations for the prevention of accidents,
- directives and accepted engineering standards.
Disregarding the safety regulations causes the risks of per-

sonal injury and damage to the fan.
Any work on fans that are marked according to directive
94/9/EC (ATEX) must exclusively be carried out by qualified
persons that are authorised as per §§ 14 and 15 of the Ger-
man Health and Safety at Work Regulations („Be-
triebssicherheitsverordnung BetrSichV“), unless these works
are carried out by trained personnel of Reitz.
Safety instructions
2.5 Regulations, standards Working on the fan must comply with the valid rules for the
prevention of accidents and the accepted engineering
standards.
x Betriebssicherheitsverordnung (German Health and Safe-
ty at Work Regulations (BetrSichV) – “Regulations on
safety and health protection for the provision of work
equipment and their use for work, on the safety of the op-
eration of plants that require special monitoring and on
the organisation of health and safety protection at factory
level” (translation of the full German title).
x VDMA 24165 “Ventilatoren – Sicherheitsanforderungen”
(Industrial fans, safety reguirements - VDMA – Verband
Deutscher Maschinen- und Anlagenbau eV – German
Engineering Federation)
x Regulations for the prevention of accidents (BGVs) of the
“Berufsgenossenschaften (BGs)“ (institutions for statutory
accident insurance and prevention in Germany)
- „Grundsätze der Prävention“ BGV A1
(General prescriptions) BGV A1
- „Elektrische Anlagen und Betriebsmittel“ BGV A3
(Electrical installations and operating material) BGV A3
- „Lärm“ BGV B3 (Noise) BGV B3
x Occupational Safety Regulations for safety and health at
work (BG rules -BGR)
- „Explosionsschutz-Regeln - Regeln für das Vermeiden
der Gefahren durch explosionsfähige Atmosphäre“
BGR 104 (bisher ZH 1/10).
(Explosion protection regulations – regulations for the
prevention of dangers caused by ignitable atmos-
pheres BGR 104 (so far ZH1/10)
- „Vermeidung von Zündgefahren infolge elektrostati-
scher Aufladungen“ BGR132 (bisherige ZH 1/200)
(Prevention of the ignition risk due to electro-static
charging – BGR 132 (so far ZH 1/200)
- “Betreiben von Arbeitsmitteln” BGR 500, Kap. 2.8 (Use
of work equipment BRG 500 chap. 2)
Safety instructions
x Harmonised European standards and national standards

- EN 1127-1 „Explosive atmospheres – Explosion pre-
vention and protection“
- DIN 24166 „Technische Lieferbedingungen für Ventila-
toren“
(German Industrial Standard - Technical delivery con-
ditions for fans)
- DIN EN 14986 „Konstruktion von Ventilatoren für den
Einsatz in explosionsgefährdeten Bereichen“
(Design of fans working in potentially explosive atmo-
spheres)^
x EU Directive
- 89/686/ECC “Personal protective equipment”
- 2009/104/EC „Use of work equipment“
Safety instructions
2.6 Electric connection conditions The operating company has to observe the instructions and
to meet the connection conditions of the local electric supply
company for the electric connection of the motor and the
auxiliary drives (if any) and the system.
All electric works on the machine and its connections
must exclusively be carried out by professional elec-
tricians that are authorized by the definition regarding
professionals (e.g. German definition DIN VDE 0105
and IEC 364).
It has to be ensured that type of current, voltage and fre-
quency of the electric power supply are suitable for the be-
low enlisted components and that the electric connections
are expertly made for:
- drive motor/s fan
- actuator/s damper/s
- monitoring devices
- other electric parts
If the fan is of explosion-proof design, the electric installation
has to meet the requirements of DIN EN 60079-14.
Safety instructions
2.7 Marking, danger signs Information directly arranged on the fan, e.g. sense of
rotation arrows, information signs, markings or danger signs
must be observed and kept in legible condition.
See an example of nameplate, danger signs and other mark-
ings positioning at the fan in chapter 7.7 Marking, information
sign.
2.8 Qualified person Qualified persons in terms of the § 2, clause 7 German

Health and Safety at Work Regulations („Betriebssicher-
heitsverordnung BetrSichV“) is personnel that due to profes-
sional training, work experience and their current occupa-
tional activity has the necessary expert knowledge for testing
the working devices.
Qualified persons only are allowed to carry out all works at
the fan, at fan components, at the fan equipment, mainte-
nance devices and electric components. Authorised person-
nel must also have sufficient knowledge about
- currently valid safety regulations,
- currently valid regulations for the prevention of accidents,
- directives and accepted engineering standards.
In addition, qualified personnel must:
- be authorized to carry out the necessary works
- be able to assess the works allocated to them with regard
to dangers, be able to recognize possible dangers and to
avoid them.
- have read these instructions prior to working
The person who is responsible for the safety of the system

authorises the personnel to carry out the works.
Safety instructions
2.9 Personal protective equipment The operating company and the plant engineering company
are responsible for the required protective measures on site
like coverage, barriers or personal protective equipment.
Operating personnel are all staff members that are in charge
of installation, mounting, operation, setting, maintenance,
cleaning, repair and transport of machinery.
Carrying out dangerous works and activities requires wear-
ing personal protective equipment in terms of EU Directive
89/689/EWG in order to avoid injuries or minimise the risk of
injury that might not be prevented through other measures.
The minimum equipment includes:
- helmet
- eye protection
- foot guard
- hand guard
- ear protection
- reflective jacket
- appropriate working clothes.
In dependence of the type of the works or their dangerous-

ness, wearing of further personal protective equipment and
taking further safety precautions (e.g. fall protection) may
become necessary.
When working on the fan, the following “Occupational Safety
Regulations for safety and health at work (BG rules -BGR)
are to be observed:
- „Wearing of protective clothing “ BGR 189
- „Wearing of foot and leg guards“ BGR 191
- „Use of head protection“ BGR 193
- „Use of ear protection“ BGR 194
- „Wearing of protective gloves“ BGR195
- „Use of protective equipment against falling“ BGR 198
Safety instructions
2.10 Risk of slipping, tripping or The operating company and the plant engineering company
falling are responsible for necessary precautionary protective
measures on site.
- Mark the transport aisles and keep them clear
- Sufficiently light the transport aisles and work-
places
- Remove unevenness of floor and installation
sites
- Keep the working environment tidy and clean
- Treads must be anti-slip and undamaged
- Eliminate the slip danger (e.g. remove packed
snow and black ice, keep the place in a dry con-
dition)
- Apply fall protection (e.g. safety harness) when
ladders are used to access the workplace
- There is the risk of falling from heights of more
than 1 metre above the floor and in case of hol-
lows or floor openings Æ install safety fence (e.g.
guard railing, barriers), use fast devices instead
of warning tape
- Ladders cannot serve as working places. It is not
allowed to carry out certain works from the lad-
der, when for example the ladder lacks stability,
the tool’s weight exceeds 10 kg, the area ex-
posed to wind exceeds 1 m².
- Install working platforms at places that have to
be maintained on a regular basis.
- Spilt working material is to be removed with suit-
able oil binding agent. Dispose of it in a safe
manner consistent with all applicable regulations.
- Remove completely leaked grease and dispose
of it properly and professionally in view of envi-
ronmental protection requirements.
2.11 Measures in case of electrical In case of main and/or auxiliary electrical power failure, the
power outage fan has to be put into a safe condition. The control system
must be designed so that the power breakdown or the
control system itself does not result in a dangerous
sitatuation, neither at the time of the mains failure nor at the
time when the enery is re-established or the control system
is again ready for operation.
Additional measures for fans, whose handled gas
temperature exceeds 80°C: In case the power fails, the hot
handled gas must absolutely be prevented from flowing in at
inlet of the fan and also from flowing back or backing up at
discharge of the fan. Install proper shut-off devices including
appropriate control systems on-site and keep them in an
operable state.
Transport, Installation
3. Transport, Installation
3.1 General remarks The fan and the equipment should only be transported and
lifted at the provided marked lifting lugs. Load suspension
devices as well as sling devices have to be in perfect condi-
tion and should only to be fastened at the provided lifting
lugs.
Personnel that lifts and transports the fan must:
- have read the operating manual,
- have understood the content of the chapter transport, es-
pecially the safety regulations, the regulations for the pre-
vention of accidents and the instructions for the transport
of the fan,
- be familiar with the hoists, the required load suspension
devices and the sling devices.
3.2 Safety instructions The safety instructions for lifting and transport of the
fan must be observed.
- Use hoists, load suspension devices and sling

devices with sufficient load capacity only (for
load / weight see fan data sheet or fan drawing)
- The angle of spread must not exceed 120° (see
Figure 3).
- Do not knot steel wire ropes and chains.
- Do not tie ropes from fibres with knots.
- Do not distort the ropes.
- Untwist distorted ropes prior to lifting.
- Do not kink the ropes at wire rope clamps.
- Thimbles (cable eye stiffeners), rope eyes, sus-
pension hooks and other lifting links must sus-
pend freely on the lifting hook.
- Use edge guards when the slings are laid on
sharp edges.
- Lift up the hook tackle when it is not used.
- Do not lift loads over people.
Observe the regulations for the prevention of accidents.
Auxiliary lifting lugs (e.g. at the motor) – if any – are suitable
only for lifting the corresponding single component.
We recommend an installation performed by
manufacturer’s skilled staff.
3.3 Regulations, standards The valid regulations for the prevention of accidents and the
accepted engineering standards apply to the lifting and
transport of the fan.
x Regulations for the prevention of accidents (e.g. German

BG regulations)
- „Allgemeine Vorschriften“ (General Instructions)
BGV A1
- „Krane“ (Cranes) BGV D6 (VBG 9)
- “Betreiben von Arbeitsmitteln” BGR 500, Kap. 2.8 (Use
of work equipment BRG 500 chap. 2)
x National standards (e.g. Standards of the German Insti-
tute for Standardisation)
- „Hebezeuge, Lastaufnahmeeinrichtungen“ (Hoists,
load suspension devices ) DIN 15003
- „Ösenhaken, Güteklasse 5“ (Eye hooks, quality class
5) DIN 7540
- „Schäkel“ (Shackles) DIN 82101
3.3.1 Load suspension devices x Fans are only to be lifted and transported with the
appropriate hoists and means of transport (weight
indication see fan data sheet or fan drawing).
transport and lifting lugs x Fasten sling devices at the especially provided
lifting lugs only (see Figure 2)
x Do not damage components or fan when fas-
tening sling devices.
x Do not fasten sling devices to the inlet, dis-
charge, bearings, motor or base frame.
This damages the fan and excludes and limits
the liability of the manufacturer.
x Use sling devices of appropriate length. Pay at-
tention to an even weight distribution.
Attention: Transport of fan is only permitted when
the weight is evenly distributed. The fan must be
kept in a nearly horizontal position throughout
complete fan lifting and transport activities.
Figure 2
x Observe the spread angle and the inclination an-

spread and inclination angle gle (see Figure 3)
The inclination angle αN must not exceed 60°,
that is to say the spread angle αS must not ex-
ceed 120°.
αN αS x Wear personal protective equipment (see chap-
ter 2.9)
load
Figure 3
3.4 Packing The fan and the equipment are packed in the factory in
accordance with
- the transport route,
- the storage at customer’s premises
- and / or customer’s requirements
If the impeller-shaft-bearing unit has not yet been assembled

with the fan at the factory, these fans are prepared in the fac-
tory for the transport by covering the area of the bearing
housings with weather protection foil.
Remove the foil covering only shortly before the first start-up
and commissioning in order to maintain warranty claims.
Bearing housings that have already been assembled to the
fan are protected by a cover hood made of galvanized steel
sheet, where applicable.
Types of packing:
x Fan components mounted on wooden pallet with protec-
tion covering (welded in plastic foil).
x Fan components mounted on wooden pallet with protec-
tion covering (welded in plastic foil) and special bearing
protection.
x Fan components mounted on wooden crate, protection
covering (welded in plastic foil) and special bearing pro-
tection.
x Seaworthy packing in closed wooden case Æ Figure 4).
Fan components must only be transported with transport

safety contrivances, with a protection covering (foil) and
desiccants, so that no dirt and humidity can enter in the
fan, in the anti-friction bearings or in the electric compo-
nents.
The protection covering must be removed prior to that in-

stallation of the fan components.
Symbol legend:
Keep dry
This side up
Glass - fragile
Centre of gravity
Fasten sling devices here

Figure 4
In case the fan or the equipment is packed and corrosion

protected for an extended period of time at the factory, the
separate „Instructions for Storage and Corrosion Protection
of Radial Fans“ must be observed.
3.5 Transport For lifting and transport of the fan components and
the equipment observe
- 2.4 Safety regulations,

- 2.5 Regulations, standards,
- 3.3.1 Load suspension devices
x Sling devices, e.g.

- wire ropes,
- ropes from fibres,
- steel cables
must be fixed at lifting lugs and suspension hooks.
x Unload the fan with suitable hoists only. Disregard of this

instruction may cause the danger of crushing or shearing
of parts of the body.
Cautiously place the fan onto the floor or foundation
to avoid damages to the fan, the bearings and other
components.
x Observe permitted ground, floor, foundation or ceiling
load capacities.
x After unloading of fan components and equipment
- remove packing (depending on type of packing),
- check fan and equipment for damages,
- check accessories for completeness in accordance
with the delivery note,
- do not remove the cover foil and/or weather protection
hood of the anti-friction bearings.
x Transport the fan components and the equipment by suit-
able hoists / means of transport to the installation location
or storage place only.
x If the fan is transported to the installation location by vehi-
cle:
- lift the fan with suitable hoists onto the platform of the
vehicle,
- secure the fan against shifting and displacing by fas-
tening belts.
3.5.1 Transport damages Document any transport damage preferably with photo-
graphs and immediately report them to the forwarding agent,
insurance company and manufacturer.
3.5.2 Intermediate storage Please observe our separate “Instructions for Storage and
Corrosion Protection” for proper storage of fan, bearings,
shaft seal, V-belts, drives, actuators, monitoring devices and
other equipment.
3.6 Installation If the fan is not delivered in a completely assembled condi-

tion, observe the separate mounting instructions for the
assembly of fan which can be ordered from Reitz.
Further action to be taken if the fan has been partly pre-

assembled at REITZ:
Pay particular attention to the Reitz serial number
when the fans are assembled. Only assemble fan
parts of the same serial number. If several pre-
assembled fans of the same design are supplied, the
following fan parts are clearly marked with the indi-
vidual corresponding Reitz serial no.:
- lower housing parts
- upper housing parts
- rotor
In case the rotor is delivered in a transport safety contriv-
ance, keep this transport stand for possible future rotor dis-
mantling, rotor intermediate storage or transport on site
Fans of sectional splitting housing design:

Before the fan housing is assembled, seal the sectional split-
ting flanges as per the separate sealing instructions. The
sealing instructions are part of the separate mounting in-
structions for the assembly of fans. Observe further instruc-
tions of the mounting and assembly drawing, if any.
3.6.1 General remarks x Design conditions

The fan and the equipment are designed, tested and de-
livered in accordance with the design conditions specified
in the order.
The specifications made in the order are documented in
the fan data sheet. It is not permitted to deviate from the
conditions shown in the fan data sheet (e.g. different han-
dled gas).
Unless otherwise agreed upon, the electric components of

the machine are designed for a maximum ambient tem-
perature of 40°C and an altitude of site up to 1000 m asl
in accordance with the instructions of the German stand-
ard VDE0530.. Please observe the installation instructions
in the operating manual of the motor producers.
x Warranty
The warranty details refer to sing values and testing con-
ditions in accordance with the applicable EN DIN stand-
ards and/or the valid standards and regulations. The sys-
tem’s specific special characteristics and local conditions
must be taken into account by the system designer or the
project engineer when the order data are specified.
It is essential to convert the data for the operating
conditions in accordance with the existing local con-
ditions.
3.6.2 Safety instructions Installation works must exclusively be carried out by special-
ist personnel (see chapter 2.8)
It is recommended to request installation specialists
of the manufacturer.
3.6.3 Preparation for installation x Substructure of the fan like base plates, additional base
frames, sole plates, steel stages or foundations must:
- be designed in accordance with the weight and the

foundation load (Æ dimension sheet),
- ensure a vibration-free installation for operation or
standstill.
x Compare foundation dimensions with the fan dimension
sheet and the foundation plan and ensure that:
- there is sufficient space for installation, maintenance
and repair works,
- there is sufficient space for the intake and discharge of
the cooling air for the rotary current motor.
x Carry out required corrections on the foundation and
clean treated surfaces.
x Transport fan to the location of installation by suitable
hoists / means of transport (see chapter 3.3.1 Load sus-
pension devices)
3.6.4 Mounting and Alignment
3.6.4.1 General remarks Stability of fan is at risk when the installation site is
not even. This might increase the danger of crush-
ing and shearing of parts of the body.
Prior to the start of the installation the mounting place

has to be checked for evenness and dimension accu-
racy.
Steel foundations, foundation blocks and concrete
foundations that ensure a safe operation free from
impact, vibration and distortion are appropriate sub-
structures for the fan.
Assembling auxiliaries like alignment plates, fas-
tening screws, etc. can be obtained from the manu-
facturer.
Request installation specialists from the manufactur-
er, if necessary.
After mounting on the foundation the fan must be aligned.
Use appropriate measuring instruments, tools, jack screws
and shims for this work.
If the fan is installed within chemically aggressive at-
mosphere or outdoor o use alignment sheets made
of rustproof material.
3.6.4.2 Sequence of mounting The sequence of mounting depends on the fan design. Take
the appropriate fan design from the separate dimension
sheet or any additional order-related drawings.
with anti-vibration mounts

without
mounting on anti-vibration anti-vibration
anti-vibration mounts anti-vibration mounts
mounts mounts (spring
without mounting plate with mounting plate
type)
steel foundation X X X X
concrete foundation X - X X
X = possible
- = not possible
Table 2
x Fan without anti-vibration mounts and mounting on

steel foundation
Align the fan horizontally (if necessary, use alignment
plates) and fasten the fan with hexagon head screws.
For tightening moments see chapter 9.1.1 Tightening
moments for fastening screws
x Fan without anti-vibration mounts and mounting on

concrete foundation
Align the fan horizontally (if necessary, use alignment
plates) and screw the fan to the concrete foundation with
suitable fastening devices (e.g. heavy duty anchor bolts,
stone bolts).
For tightening moments see chapter 9.1.1 Tightening
moments for fastening screws
x Fan with anti-vibration mounts and mounting on steel
foundation
- Anti-vibration mounts without mounting plate
- Screw the anti-vibration mounts to the steel founda-
tion
- Carefully place the fan on the anti-vibration mounts
(correctly fit the set screw in the bore holes)
- Align the fan and screw it to the steel foundation.
- Anti-vibration mounts with mounting plate
- Carefully place the fan including the anti-vibration
mounts on the steel foundation
- Anti-vibration mounts (spring type) – spring phonola-
tors
- Screw the anti-vibration mounts (spring type) to the
steel foundation
(spring type), correctly fit the set screw in the bore
holes.
- Observe the mounting instructions of the producer
of the anti-vibration mounts (spring type), which can
be obtained from Reitz
x Fan with anti-vibration mounts and mounting on con-

trete foundation
- Anti-vibration mount with mounting plate
- Carefully place the fan including the anti-vibration
mounts on the concrete foundation
- Align the fan and bore the foundation holes for the
heavy duty anchor bolts through the bores provided
on the mounting plates.
- Screw the fan to the concrete foundation with suita-
ble fastening devices (e.g. heavy duty anchor bolts,
stone bolts). and observe the tightening moments Æ
see chapter 9.1.1
- Anti-vibration mounts (spring type) – spring phonola-
tors
- Screw the anti-vibration mounts (spring type) to the
concrete foundation
(spring type), correctly fit the set screw in the bore
holes.
- Observe the mounting instructions of the producer
of the anti-vibration mounts (spring type), which can
be obtained from Reitz
3.6.4.3 Alignment of the belt pulleys During transport motor and bearing can get dis-
placed.
The pulleys of fan and motor must be aligned to avoid unac-
ceptable operating conditions. Therefore, check the V-belt
drive for proper alignment before initial start-up and re-align
it if necessary.
Manufacturer’s skilled service staff has to be re-

quested for alignment.
Figure 5
x Remove protective cover of V-belt drive.
x Check the alignment of the belt pulleys with appropriate

1 - angular offset measuring tools.
2 - parallel and angular
offset
3 - parallel offset - angular offset = 0,5°
angular offset
- parallel offset, see table

Clearance values must fall short of the given values for
Figure 6
the clearances.
max. permissible
pulley-Ø
clearance
dd1/dd2 X1, X2
112 mm 0.5 mm
224 mm 1.0 mm
450 mm 2.0 mm
630 mm 3.0 mm
The alignment of the V-belt pulleys can be examined

with a ruler for parallel offset and for being conform
Figure 7 parallel offset with regard to angles.
The accuracy of alignment can be improved by using
a dial gauge or a laser-type optical sensor.
See chapter 7.6.2 Belt tension for the examination and alter-
ation of the belt tension.
3.6.4.4 Screw connections In principle, make sure for all screwed connections that there
is sufficient excess length after the screw or nut has been
tightened. The screw must project from the nut not less than
wrong right the length of the screw diameter.
Always position the screw head so that a loosening or even

loss of the screw can be immediately recognized. Always
position the nut on top in case of vertical screwing.
Figure 8
Figure 9 Example bearing screwing
Figure 10 Example motor screwing
Figure 11 Example frame screwing
Exception from the prescribed screw heat position:

When flexible connections are screwed, the screw ends
must always be turned away from the flexible connection.
Figure 12: representation of flexible connection with correct

screwed connections (example)
Tighten all screw connections with the proper tightening

moment, see chapter 9.1.1 Tightening moments for fastening
Figure 12 screws
3.7 Connections
3.7.1 General remarks The connection of the electric components of the fan must
be carried out in accordance with the following regulations,
as amended:
- Regulations issued by the local electric supply company
(e.g. German EVU),
- national associations for electronic regulations (eg. EN
DIN VDE regulations: VDE – German Association for
Electrical, Electronic & Information Technologies.)
- Installation and mounting instructions in the operating
manual of the motor producer.
3.7.2 Safety instructions Works on the fan or the equipment must exclusively be
carried out by specialist personnel, that due to professional
training, experiences and instructions has sufficient
knowledge about:
- Safety regulations,
- regulations for prevention of accidents,
- directives and accepted engineering standards
(e.g. VDE directives, DIN EN standards)
The specialist personnel must:
- be able to assess the works allocated to them, to recog-
nize possible dangers and to avoid them,
- be authorized by the person who is responsible for the
safety of the system to carry out the required works and
tasks.
All electric works on the components of the fan must exclu-
sively be carried out by professional electricians that are au-
thorized by definition regarding professionals (e.g. German
definition DIN VDE 0105 and IEC 364). The electricians must
observe the following regulations and instructions, as
amended:
- EN DIN VDE-regulations (e.g. Germany),
- IEC-regulations (International Electrotechnical Associa-
tion),
- Safety instructions,
- Transport, installation and maintenance instructions
Professional electricians are specialists, who due to profes-
sional training, experiences and instructions have knowledge
about valid appropriate standards, regulations and regula-
tions for prevention of accidents.
Furthermore they must be able to assess the works allocated
to them and to recognize and to eliminate possible dangers.
The professional electricians must be authorized by the per-
son who is responsible for the safety of the system to carry
out the required works and tasks.
3.7.3 Ducting of fan Distortions of the fan at the connections caused by

the ductwork are not permitted. Distortions cause
alterations, e.g. the gap at the nozzle decreases at
one side which might lead to rubbing in the inlet.
- Remove the transport covers from the connections.
- Move the duct work to be connected to the inlet and dis-
charge openings of the fan without causing offsets be-
tween the ducts and openings.
- Connect duct and conduits to the fan free-of-load.
3.7.4 Check of clearances Prior to the first commissioning of the fan, the radial clear-
ance between inlet cone and impeller nozzle must be
checked and recorded pursuant to the following instructions.
inlet cone
We cannot exclude possible shifts resulting from the
transport between inlet cone and impeller. The fan can only
be operated safely and trouble-free when the minimum
clearance is observed. Any warranty claim will be invalidated
if the minimum clearance is not maintained.
There are two different impeller designs:

- impeller with shroud (Figure 13)
incl. representation of the check points c to j
impeller nozzle
Figure 13
5*
- unshrouded impeller (Figure 14)
2
* number of check points according to the number of
blades
4
3
In dependence on impeller design start to check the gap in

Figure 14 case of:
- impeller with shroud:
check the gap at eight check points (see Figure 13)
- unshrouded impeller:
number of check points according to the number of the
blades (see Figure 14)
Then turn the impeller by 90° and again check the gap at all
check points. Repeat this process three times.
For fans of earlier design and for replacement deliv-

eries of impeller or unshrouded impeller, the clear-
ance dimensions can differ from the values given in
the table.
3.7.4.1 Check of clearance for The minimum radial clearance must amount to 3 mm at
impeller with shroud least.
Take further clearance measures from Table 3 minimum
clearance table.
inlet cone extends into the impeller nozzle impeller nozzle with gap
inlet cone impeller inlet cone impeller
Figure 15 Figure 15 Representation of different installation situation:

impeller „inlet cone extends into the impeller nozzle and
Standard Atex „nozzle with gap“
sNA/
DN D1 h Tol.sN sN sV
sVA
100 100 5
112 112 5
125 126 5 3 5 5
140 141 5 3 5 5
160 158 5 3 5 5
180 178 5 3 5 5
200 199 6 +/-0,5 3 5 5 Legend:
224 224 7 3 6 6
250 251 8 3 6 6 clearance installation type
280 282 9 3 6 6 measure
315 316 10 3 6 6 sN inlet cone extends into the
355 355 11 3,5 7 7 impeller nozzle (standard-
design)
400 398 12 3,5 7 7
450 447 14 3,5 7 7 sV nozzle with gap (standard-
500 501 16 3,5 7 7 design)
560 562 18 3,5 7 7 sNA inlet cone extends into the
630 631 20 3,5 7 7 impeller nozzle (ATEX-design)
710 708 22 3,5 7 7 sVA nozzle with gap (ATEX-design)
800 794 25 3,5 7 8
+/-1
900 891 28 3,5 7 9
1000 1000 48 3,5 7 10
1120 1120 35 3,5 7 11,5
1250 1265 25 4 8 12,5
1400 1403 35 4 8 14
1600 1575 40 4 8 16
1800 1768 40 4 8 18
2000 1985 45 4 8 20
Table 3 minimum clearance table
3.7.4.2 Check of clearance for The minimum axial clearance must amount to 10 at least.
unshrouded impeller
Take further clearance measures from Table 4 minimum
clearance table.
Standard Atex
DN D1 s s
100 100 10 10
112 112 10 10
125 126 10 10
140 141 10 10
160 158 10 10
180 178 10 10
200 199 10 10
224 224 10 10
250 251 10 10
280 282 10 10
315 316 10 10 Figure 16 representation of installation situation unshroud-
ed impeller
355 355 10 10
400 398 10 10
450 447 10 10
500 501 10 10
560 562 10 10
630 631 10 10
710 708 10 10
800 794 10 10
900 891 10 10
1000 1000 10 10
1120 1120 15 15
1250 1265 15 15
1400 1403 15 15
1600 1575 20 20
1800 1768 20 20
2000 1985 20 20
Table 4 minimum clearance table
3.7.5 Use of flexible connections Flexible connections are intended to prevent the transmis-
sion of structure-borne sound and vibration forces. They are
also used to reduce / prevent the transmission of forces from
the duct work to the fan. Furthermore alignment errors of the
ducts are reduced. The flexible connections should always
be arranged directly at the fan connection flange (except
when a damper is mounted on the fan).
If the fan is mounted on anti-vibration mounts, flexible con-
nections must be provided at the inlet and discharge on prin-
ciple.
3.7.5.1 Installation of flexible Do not install flexible connections before completion of the
connections duct work.
Flexible connections with hose clamps:
Pull flexible hose-type connections on the duct cautiously
and fix them with hose clamps.
Flexible connection with back flanges:
Pull flanged flexible connections cautiously (inclusive back
flanges) over the chute and arrange them between the fas-
tening flanges. Apply sealing or sealing cord under the chute
and fasten it by screw. All fastening screws must be tight-
ened equally and – if possible – crosswise.
For tightening moments see annex (o chapter 9.1.1).
3.7.6 Use of chutes Depending on arrangement and load, chutes must be

provided if:
- temperatures exceed 90 °C,
- velocities of flow exceed 30 m/s,
- pressure loads exceed 1000 daPa,
- aggressive or abrasive media are conveyed,
- the flexible connection is arranged at the inlet (as the flex-
ible connection is supported by the chute against the ex-
isting negative pressure and does not reduce the inlet
cross section of the fan),
- there are high noise level demands (the chute acts as a
connected duct with corresponding attenuation values).
- Fans working with potentially explosive atmosphere
Figure 17 should always be equipped with chutes for flexible con-
nections. The chutes have to operate in the direction of
flow.
- Always observe the flow direction when chutes are in-
stalled (see arrow in Figure 17 representation chute and
direction of flow)
Figure 17 representation of chute and direction of flow
3.7.7 Electric connection conditions Connect the power supply lead according to the
valid regulations of the local electric supply compa-
ny and observe in addition:
- the EN DIN VDE-regulations (e.g. Germany),
- the safety regulations,
- the regulations for the prevention of accidents.
As far as the low-voltage line is concerned, use for example

- earthing wire acc. DIN VDE 0255,
- plastic cable acc. DIN VDE 0273,
- cable lugs acc. DIN 46235
- terminal screws
and observe the instructions of the cable and sealing end

manufacturers.
The cross section of the power supply lead depends on the
type of cabling, rated voltage and rated power of the ma-
chine.
Cable ends with pressed-on cable lugs must be arranged
and connected in accordance with the connecting plan that is
to be found in the terminal box cover.
The power supply lead and the cable ends must not exert
any lateral and/or torsional power on the terminal studs dur-
ing or after the cable connecting work.
In case the fan is provided with electric protection devices
(e.g. position switch), adhere to the instructions of DIN EN
60204-1 Safety of machinery – Electrical equipment of ma-
chines.
3.7.7.1 Earthing If the fan and/or its equipment are provided with earthing
clamps, connect the system’s earthing to them.
Figure 18 Figure 18 o earthing link
3.7.7.2 Monitoring devices The fan can be equipped with vibration monitoring, bearing
condition monitoring and bearing temperature monitoring.
Furthermore, the temperature probes can be installed for
monitoring the temperature of the handled gas. Additional
monitoring devices are described in separate operating
manuals.
Connections of the monitoring devices must be connected in
accordance with the detailed wiring diagram.
Please observe the instructions in the annex of this operating
manual.
The annex shows the maximum warning and discon-
necting values.
Chapter 9.1.2 Limiting values vibrations
Chapter 9.1.3 Limiting values bearing temperatures
3.7.8 Seal connection The shaft seal for a sealing medium has a G ½“ connection
for a grease injector or a barrier gas connection provided on-
site by customer.
Figure 19 Æ shaft seal with grease seal

In general, the shaft seals are continuously to be
Figure 19 provided with the proper quantity of grease or barrier
gas that corresponds to the operational mode. Disre-
garding this requirement leads to an increased risk of
ignition and subsequently to an increased risk of inju-
ry to persons and severe property damage.
Barrier gas conduits with pressure reducer and pres-
sure gauges are available on request from the manu-
facturer.
Start-up
4. Start-up
4.1 General remarks Perform a start-up after installation and after each repair.
Check for compliance of the finished installation and present
operating conditions with the specified data of the fan data
sheet (o chapter 1.2).
The specialist personnel must be authorized by the person
who is responsible for the safety of the system to carry out
the required works and tasks for the start-up. (see chapter 2,
Safety instructions).
4.2 Mechanical check x Check all external fastening screws for tightness.
x Check impeller for unblocked run (rotate manually once)
Attention:
The impeller must not rub at the inlet.
x Remove possibly existing foreign substances from the fan
housing.
x Check all screwed connections of the duct connections for
tightness.
x Close the inspection openings properly.
x Remove transport securing devices, if any.
ATTENTION:
If the fan is provided with a transport safety device (e.g.
shaft support, etc.), the provisions for transport have to be
removed before the fan is start-up. In any case, it must be
easy to turn the impeller.
4.2.1 Alignment Check and document the alignment of the motor to the fan
(Æ chapter 3.6.4 Mounting and Alignment).
Start-up
4.3 Electric check x Check the operating voltage.

x Check for proper condition of earthing connections and
equipotential bonding connections.
The electric connections inside the switching cabinet
must comply with the regulations of the local power
supply company and the valid regulations (e.g. Ger-
man standard DIN VDE 0105) as well as the instruc-
tions of the producers of the drive motor and auxiliary
motors.
4.3.1 Monitoring devices / auxiliary x Check the connections and cabling of the monitoring
equipment devices and auxiliary equipment for compliance with the
detailed wiring diagram (o switch cabinet).
x Switch on measuring systems and check connected moni-
toring devices for functionality.
Start-up
4.3.2 Check of sense of rotation x Manually check the impeller for unblocked run.
x Switch on the motor and check the sense of rotation for
compliance with the sense of rotation arrow arranged at
the back of the fan.
x Motor sense of rotation must be the same as the fan’s
sense of rotation (see Figure 20)
x Disconnect the fan.
x The following motor connection results from the sense of
rotation:
Sense of rotation facing
Connection L1, L2, L3 the drive side (motor
shaft journal)
U1 - V1 - W1 clockwise
W1 - V1 - U1 counterclockwise
Figure 20
When checking the sense of rotation, only the as-

signed inspector is permitted to be present within the
danger area of the fan. Switch on motor and check
sense of rotation (observe valid regulations, e.g. DIN
VDE 0105).
x Ensure that the motor is switched dead.
x Secure against restart and mark with relevant in-
formation sign.
x Check for and ensure dead condition.
x Connect to earth and short-circuit.
x Cover or secure by barrier adjacent alive parts.
Figure 20 Æ check of sense of rotation
4.3.3 Commutating wrong sense of If two of the existing connecting lines are interchanged, the
rotation sense of rotation is altered. In this case the connecting
cables must be arranged inside the terminal box in accord-
ance with the terminal connecting plan shown above and the
sense of rotation.
Start-up
4.4 Start-up of fan
4.4.1 General remarks Check and inspect the following items prior to start-up:
- Is it possible to switch on the fan?

- Has the fan been checked mechanically and electrically
and do all results show faultless conditions?
- Are all connections / ductworks installed professionally?
- Are the air intake openings of the motor free and uncov-
ered?
- Has the clearance been checked? (see chapter 3.7.4),
- Are the safety devices in active and correct position?
- Are the power units, switchgears, monitoring devices and
the cable cross sections designed and checked by the
project engineer / operating company regarding the type
of starting, starting time and peak load?
- If the fan is provided with a transport safety device: Has
the transport safety device been removed?
- Check the belt tension after the first 50 operating hours
(see chapter 7.6 V-belt drive) and re-tension the V-belts if
necessary.
- Let the V-belts run several times after they have been in-
stalled. The belt pulleys will then set evenly. Check the
belt tension every six months. If necessary, re-tension the
belt or replace them.
Note on the bearing temperature during the first

commissiong phase:
Due to preservation reasons, the grease quantity is
far above the quantity that is required for the opera-
tion. The bearing temperature, therefore, can even
exceed 80°C during the first commissioning. After the
excessive amount of grease has leaked out, the
bearing temperature must return to normal operating
temperature in the range of 60°C to 80°C.
Start-up
4.4.2 Safety instructions x The start-up must exclusively be carried out by

specialist personnel that is appointed by the per-
son who is responsible for the system.
x Observe the valid safety instructions (e.g. DIN
VDE 0105)
x Before switching on the fan:
- finish all works on the fan,
- install all covers and safety devices,
- reverse the protection measures that were
carried out for the works on the fan (earthing
and short-circuit of the connecting cable, se-
curing against restart, etc).
The screws of safety devices for rotating parts are provided
with retentions. The screw retentions ensure that the screws
will remain on the safety devices if it is dismantled. Care
must be taken when mounting and dismantling the safety
devices in order to maintain the serviceability of the screw
retentions.
Start-up
4.4.3 Switching on of the fan It is only permitted to start-up the fan, if a sufficient
acceleration torque is available, covering the
complete range of acceleration up to the nominal
speed.
Start-up the fan with closed damper.
In case the fan is of gastight design, check the housing, the
shaft seal and the connections at inlet and discharge for
tightness.
Switch-on fan.
Monitor the following values and document them:
x During start-up
- current consumption,
- voltage,
- vibrations (quiet running),
- noises.
x After start-up
- current / voltage,
- vibrations,
- noises,
- bearing temperatures
- temperature increase at fan housing due to compres-
sion of handled gas.
After start-up charge the fan.

Monitor the following values of the fan and document them:
- current consumption / voltage,
- vibrations (quiet running),
- noises,
- bearing temperatures.
The fan must be disconnected, when
- specified values are exceeded

(see chapter 1.2 Fan data sheet)
- unacceptable vibration values or increased noise levels
of the fan occur,
- limit values are exceeded
(see chapter 9.1.2 Limiting values vibrations)
If the above mentioned malfunctions occur, contact
the service specialists of the manufacturer.
Start-up
4.4.3.1 Direct starting Direct starting (delta starting) of the motor does not only
cause a high starting torque but also a high starting current.
During starting the starting current is 6 to 8 times higher than
the rated current (depending on the type of rotor).
Account for this high consumption of current when selecting
the fuses.
4.4.3.2 Star-delta-starting During star-delta starting the drive motor only provides 1/3 of
the acceleration torque when star connected. From a certain
speed onwards, the load moment of the fan exceeds the ac-
celeration torque of the motor. The motor stops to acceler-
ate. In this state, the motor must be switched to delta con-
nection. The resulting peak load is significantly lower than
that of direct fan starting.
The connecting frequency of the electric motors is limited to
maximum six starting processes per hour. For this the in-
structions of the motor manufacturers must be observed.
4.4.3.3 Prevention of high negative On principle, the fan is only to be restarted after the total
torque impacts during test standstill of the impeller. This prevents torque impacts which
run can occur when the rotor is still running (even slightly) at the
time of restart. The torque impacts can cause significant
damages on components (rotor, bearings and belt pulleys).
4.4.3.4 Fan operation with variable If the fan has a variable speed control, observe the instruc-
speed control tions in 5.6 Automatic operation of fan.
Start-up
4.4.4 Disconnecting of fan x Disconnection of fan o open power switch

x Let the fan coast brakeless.
Observe valid regulations, e.g. DIN VDE 0105.
When working on live parts, observe the following:

x Ensure that the fan is switched dead.
formation sign.
x Cover or secure by barrier adjacent alive parts.
Operation, Operating
5. Operation, Operating
5.1 General remarks Specialist personnel only is permitted to start and disconnect
the fan. The specialist personnel must be appointed by the
person who is responsible for the system.
Furthermore all instructions concerning the factory and the
operation / operating of the operating company must be ob-
served.
5.2 Safety instructions Read the operating manual of the fan and the motor and
observe the instructions and information.
5.3 Operational performance of the During operation the fan must be checked regularly for:
fan
- current consumption and voltage
(values o rating plate),
- vibrations and noises (especially for rubbing noises) of the
fan, (vibration monitoring o chapter 9.1.2 Limiting values
vibrations),
- bearing temperatures by installed measuring device
(warning– / disconnecting temperatures o chapter 9.1.3
Limiting values bearing temperatures),
- condition of the shaft sealing.
Check at fan standstill:

- alignment of the belt pulleys (o chapter 3.6.4.3 Alignment
of the belt pulleys)
Disconnect the fan when
- the rated values for current, voltage and temperature are
exceeded,
- vibrations or increased noise levels occur on the fan,
- the shaft sealing leaks.
5.4 Disconnecting of fan Disconnect the fan by opening the power switch
Let the fan coast brakeless.
Observe the valid regulations, e.g. German DIN VDE
0105.
When working on live parts, observe the following:

- Ensure that the fan is switched dead.
- Secure against restart and mark with relevant in-
formation sign.
- Check for and ensure dead condition.
- Connect to earth and short-circuit.
- Cover or secure by barrier adjacent live parts.
5.5 Emergency stop of fan Automatic or semi-automatic operation

If the fan is installed in a ventilation system and is operated
by automatic or semi-automatic control, it must be ensured
that the fan can safely coast down to a standstill in case of
an emergency shut-down. The fan itself is not provided with
an emergency stop or power-off switch. The switch-off of the
fan in case of emergency must be provided for in the control
of the complete system. The operating company of the plant
is responsible for the proper setting of the system control.
In case the fan is provided with monitoring devices, the
emergency cut-off must be released as soon as the corre-
sponding limit values have been achieved.
Possible parameter for maintenance are:
- bearing temperatures
- bearing vibrations
- condition of anti-friction bearings
- wear and tear of anti-friction bearings
- speed (fan and motor)
- sense of rotation
- temperature of handled gas
We differentiate between the following limit values:

- prewarning: further operation subject to constant monitor-
ing
- main alarm: the fan must be disconnected immediately!
Unless otherwise prescribed by the motor manufacturer, the

limit values for prewarning and disconnection at main alarm,
that are indicated in chapter 9.1.2 Grenzwerte Schwingung-
en und Kapitel 9.1.3 Grenzwerte Lagertemperaturen are to
be observed.
Observe the following instructions about the monitoring de-

vices to avoid injury to persons, property damage and envi-
ronmental harm:
- ensure proper functioning of the readings recorder, of the
transmission electronics and of the evaluation unit
- immediately replace damaged or components that are no
longer serviceable
- properly connect the maintenance devices to the control
panel and carry out a functioning test
- set the measuring value accurateness and – tolerances in
accordance with the limit values for pre-warning and dis-
connection
- select reasonable scaling dimensions adapted to the
measuring range within the measuring values transmis-
sion chain, to ensure the highest possible resolution and
to avoid measuring results falsification
- pre-warning must be shown at the control panel by flash
on the display or light or acoustic signal
- main alarm must be shown at the control panel by flash
on the display or light or acoustic signal and the fan must
immediately be disconnected.
Carry out the following measures, when the limit values for
prewarning and main alarm are achieved:
- Check the facts and find out the reasons

- Check the readings recorder, the sensor system, the
evaluation units, etc.
- Immediately replace faulty sensors, reading recorders,
etc.
- Check the impeller for sticking material, wear and tear,
deformations, etc. and clean the impeller in case of stick-
ings and replace it in case of wear and tear and defor-
mations
- Check the bearings for oil level (at oil-lubricated bearings)
or grease quantity (at grease-lubricated bearings)
- Check the anti-friction bearings for wear and tear and re-
place them if necessary
- Do not re-set the signal until the cause of the limit exceed-
ing has been clearly identified
Attention:
Only the person or company responsible for the operation
of the plant (operating company) may re-set the main
alarm.
- Re-start the fan and check the machine’s behaviour
- If the limit values for prewarning or main alarm (discon-
nection) are again exceed, carry out the described
measures anew and immediately inform REITZ.
The monitoring devices serve to detect deviations from nor-

mal operation at an early stage and therefore to avoid dam-
age to machine parts (e.g. bearings, impeller, shaft sealing,
V-belt drives). Damages can be early determined with proper
diagnostic units and replacement of parts can be easily
scheduled.
5.6 Automatic operation of fan
5.6.1 Variable speed control with During automatic operation it must be ensured that the
frequency converter speed of the fan shaft does not oscillate around a preset
value (periodic control behaviour) in order to avoid probable
damage to the power train.
In addition, there must be enough time for the fan
- to start up until the operating or maximum speed is
achieved
- to coast down from operating speed to standstill
- to change the operating point and hence the fan speed.
In order to avoid considerable loads, in particular speed ac-
celerations and speed reductions in short periods of time, the
variable speed control with frequency converter has to be set
as “slow-reacting” as possible, so that symptoms of fatigue
of impeller, shaft, etc. will be minimised. The additional alter-
nating load that is generated by the control actions will be
almost avoided, if the speed change velocities indicated be-
fan speed: ramp time:
low are observed (ramp times of the frequency converter)
[min ]
-1
[s] The following classification applies (recommended values).
The ramp time may not fall below the given values.
750 38
1000 50
1200 60
1500 75
1800 90
3000 150
Irrespective the above, always consider the existing condi-
3600 180 tions of the individual application case (mass moment inertia
table: recommended values for ramp times of the impeller and the complete rotating unit, start up and
acceleration behaviour of the drive, current consumption,
Table 5 process-friendly control behaviour, etc.)
5.6.2 Natural frequency of the Resonances cannot be excluded since each fan component,
impeller in particular the impeller, has a natural frequency that can be
excited at certain fan speeds.
We design and construct our fans so that resonances gener-
ally do not occur in operation at constant rated speed.
If the fan is variable speed controlled, each change in speed
(frequency) can result in an excitation. Additional excitations
through the frequency converter control are also possible. If
natural frequencies of the components lie within the speed
range of the fan, these must be skipped when the variable
seed control is parameterised.
5.6.3 Parameterising the variable If the fan including the variable speed control has been
speed control delivered by Reitz, the factory-provided parameterisation has
to be kept. Any changes of the originally supplied parameter-
isation will invalidate any claim on our warranty. Changes in
or improper parameterisation may lead to
- operation behaviour that is not free-from-vibration as per
DIN IS 10816-3
- fatigue failure of impeller
- resonance vibrations on various components
- damage of components of the power train because the
fan is started-up and decelerated too quickly or due to too
frequent changes in operating points.
5.6.4 Speed control range We recommend not falling below a speed control range of
1:10 in order to maintain proper greasing of the bearing. In
particular, torsional vibrations of the power train may arise in
the range of 5 Hz output frequency of the variable speed
control. This range is therefore to be provided.
We recommend having the parameterisation and
commissioning done by a REITZ service technician.
5.7 Separate ventilation If the fan is provided with a separate cooling fan, observe the
following:
- If the fan is switched-on, the cooling fan must be in unin-
terrupted operation
- Connect the ventilation fan to the electric power supply in
accordance with the separate instructions of the manufac-
turer Æ observe the indications for voltage supply and
current consumption. If the instructions of the manufac-
turer are not available, request them from REITZ immedi-
ately.
- If the ventilation air fan fails, immediately switch of the
main fan.
ventilation It is not permitted to operate the fan without the sim-

air fan ultaneous operation of the ventilation air fan. Irre-
spective of the operation condition and speed of the
fan, the ventilation air fan has to continuously provide
sufficient cooling air. Insufficient cooling might lead to
excessive warming of the fan shaft and subsequently
Figure 21 to bearing damage. This in turn may result in fan fail-
ure and breakdown of the overall system.
Figure 21 Æ exemplary representation of fan with cooling air

fan
Trouble, Repair
6. Trouble, Repair
6.1 General remarks The repair of troubles on the fan must only be carried out by
specialist personnel that is appointed by the person who is
responsible for the system.
When trouble shooting is carried out, the entire surroundings
of the fan (equipment, motor, variable speed control, founda-
tion, kind of installation, switchboard plant, etc.) must be tak-
en into account.
Observe the particular instructions in the operating manuals
of the motor and variable speed control producers.
If damages occur during the warranty period, contact the
manufacturer.
6.2 Safety instructions When trouble shooting or repair is carried out,

observe the following:
- valid regulations, e.g. German DIN VDE 0105

- regulation for the prevention of accidents, e.g.
German regulations BGV A1 and BGV A3

formation sign.
x Connect to earth and short-circuit the fan.
x Cover or secure by barrier adjacent live parts.
x Ensure that the impeller is at standstill and can-
not be set unintentionally into motion.
Attention:
Stack draught or other air draught in the con-
nected duct work may set the impeller in motion.
Trouble, Repair
6.3 Troubles
Troubles Possible cause Remedy
unsteady run of fan material sticking to impeller blades. clean impeller carefully
impeller worn out exchange impeller
impeller deformed by thermal effect exchange impeller
distortion of fan by uneven founda- loosen foundation fastenings and
tion level foundation, subsequently re-
fasten the fan
improper adjustment of the anti- correct adjustment
vibration mounts or of the anti-
vibration mounts (spring-type)
stress due to incorrect installation of use flexible connections for the
the ductwork ducting
handled gas leaks from the shaft seal defective or worn out exchange sealing.
sealing
rubbing noises from the fan impeller rubs against inlet. loosen top part of housing and
readjust, if required, check ducting
and readjust it
motor noise check motor for bearing damages, if
required, exchange bearings
the current consumption stated on handled gas volume too high reduce the flow volume by using a
the motor name plate is exceeded damper until the permitted current
permanently consumption is reached
different speed due to 60 Hz net check frequency.
work
fan does not start up incorrect electric connection of the check electric connection
motor
trouble with star-delta starting, reduce change-over time from star
motor stops acceleration during star to delta
connection
start-up against too low system close dampers or install additional
resistance plate shutters
design of motor protective system cable cross section and motor
insufficient protective system must be designed
for the starting current during the
complete start-up
start-up time takes too long close dampers, check starting
torque of the motor MA/MN
drive motor defective check motor and exchange, if
required
motor too warm due to high choose permanent operation of the
connecting frequency fan and control the flow with
dampers or variable speed control
starting current too high incorrect voltage
provide for star-delta start-up,
insufficient local power supply
Table 6
Trouble, Repair
6.3.1 Bearing troubles

Trouble Possible cause Remedy
unsteady run damages on bearing races and exchange bearings.
rollers / balls,
bearing clearance too large
wear caused by dirt or insufficient protect bearings against contamina-

lubrication tion, use clean grease only
extraordinary running noise:
wailing or whistling noise bearing clearance too small use bearings with higher clearance
rumbling or irregular noise bearing clearance too high, exchange bearings
damages on bearing rolling surfac-
es,
dirt
inappropriate lubricant use appropriate grease only.
gradual change of running noise bearing clearance is changed by protect bearings against tempera-
thermal influences ture
damages on the bearing races (e.g.
caused by contamination or material
fatigue)
Table 7
Trouble, Repair
6.3.2 V-belt drive troubles

Trouble Possible cause Remedy
belt breaks shortly after installation force applied during installation, allow belt to be installed as indicat-
(torn belt) tensioning strand is damaged ed in the instructions (apply them
loosely)
foreign matter causes damage install a guard

during operation
blocked drive eliminate the cause
cracks and fractures in the V-belt excessive heat eliminate radiant sources,
substructure (embrittlement) shield off the belt;
improve air circulation;
shield off the drive
excessive cold use special type of belt
increase slipping of belt tension the belt as per mounting

instructions
chemical attack use special type of belt
strong vibrations insufficient belt tension check belt tension and increase it if
necessary
pulleys are not aligned align the belt pulleys
unbalanced belt pulleys balance the pulleys
twisted V-belts pulleys are not aligned align the pulleys.
wrong belt/groove profile match up belt and groove profile.
heavily worn out pulley grooves exchange pulleys
excessive vibrations tension the drive
insufficient tension check belt tension and increase it if

necessary
foreign matter in the belt grooves remove foreign matter and shield off
the drive
Continued on next page
Trouble, Repair
V-belt disorders (continued)
Disorder Possible cause Remedy
unusual wear of belt flanks wrong groove angle re-machine or re-place pulleys
worn out pulley grooves replace pulleys
wrong belt/groove profile match up belt and groove profile
pulleys are not aligned align pulleys
insufficient belt tension check belt tension and increase it if

necessary
belt rubs or hits against other remove the interfering compo-

components nents;re-align the drive
irregular noise pulleys are not aligned align pulleys
insufficient belt tension check belt tension and increase it if

necessary
drive is overloaded check drive ratios and adapt it to

operating conditions
belt feels spongy and benzene belt is affected by oil, grease and replace the belts
sticky chemicals clean pulleys with naphtha before
new belts are installed
uneven lengthening of the belt faulty pulley grooves replace pulleys
set of belts consists of used and always replace complete set of belts
new belts
set of belts consists of different belt only use one make of belts in a set
types of types
Maintenance
7. Maintenance
7.1 General remarks x All maintenance and service works on the fan may only
be carried out by specialist personnel that is appointed by
the person who is responsible for the plant, see chapter
2.8 Qualified person and chapter 2.9 Personal protective
equipment.
x Please observe the maintenance instructions for the elec-
tric drive as indicated in the operating manuals of the mo-
tor producers.
x Observe specified maintenance intervals and use speci-
fied lubricants and lubricant quantities only.
x Collect used oil, used grease and/or cleaning rags con-
taminated with oil / grease in containers correspondingly
marked and take care for proper disposal.
x Check all securing components of the screwed connec-
tions and exchange them for the new securing compo-
nents, if required.
Maintenance
7.2 Safety instructions x Carry out maintenance works (lubrication works

excepted) at standstill of the fan only, mainte-
nance works see chapter 7.10 Maintenance
schedule.
x Ensure that the fan is secured against restart and
marked by a corresponding information sign.
x Observe the safety instructions and the regula-
tions for prevention of accidents of the relevant
manufacturers when oil / lubricants, detergents or
spare parts are used.
x Maintenance works on the electric connections of
the fan or on electric auxiliary / control connec-
tions must exclusively be carried out by profes-
sional electricians who have to observe the valid
regulations (e.g. German DIN VDE 0105)

x Secure against restart and mark with correspond-
ing information sign.
x Cover or secure by barrier live parts.
x Ensure that the impeller is at standstill and can-
not be set unintentionally into motion.
Attention:
Stack draught or other air draught in the con-
nected duct work may set the impeller in motion.
Maintenance
7.3 Bearings This chapter describes the standard bearing design. If an

individual bearing solution applies, the special bearings are
described in a separate ”supplement to the operating manu-
al” or in an “order-related operating manual.
Depending on the design type, the fan shaft runs
- In two grease-lubricated anti-friction bearings in single
bearing housings or
- In two grease-lubricated anti-friction bearings in a multiple
bearing block.
Maintenance
7.3.1 Anti-friction bearings Maintenance of the anti-friction bearings:
- monitoring of the bearing temperature during operation,

- check of the bearings for running noises and vibrations
- lubrication of the anti-friction bearings,
- exchange of bearings.
If increased bearing temperatures (o chapter 9.1.3 Limiting

values bearing temperatures) or running noises and / or vi-
brations (o chapter 9.1.2 Limiting values vibrations) occur
during operation, disconnect the fan immediately to avoid
consequential losses.
Remove bearings and check them for damages.
If the bearing shows dark discoloured, dull, coarse or pol-
ished looking parts of the bearing races and / or of the roll-
ers / balls, install a new bearing.
Bearing removal / installation by Reitz-service staff

only.
If the removal / installation of the bearings are carried
out by the operating company, only the bearings rec-
ommended or delivered by the bearing manufacturer
must be installed. Furthermore the installation in-
structions of the manufacturer must be observed.
Only install bearings of the same type and clearance
range, for type of bearing see nameplate.
When ordering spare parts, specify fan type and se-
rial number (o nameplate).
Check and document the bearing temperature and vibration

velocity at the bearing regularly, but at least once a week in
order to maintain the operational reliability and availability of
the fan. If necessary, take measures such as maintenance at
bearings, belt drive, motor or impeller.
Maintenance
7.3.1.1 Lubrication instructions

anti-friction bearings in single
The anti-friction bearings are to be lubricated during opera-
bearing housings
tion with the indicated quantity and grease type at the
lubrication nipples M10x1 at the
- non-driven end and
- driven end.
Lubrication intervals, grease quantity and grease

type see plate “Maintenance of the bearings”.
The bearing temperature may increase after re-greasing for

grease pressed
out here a few hours. After the grease has reached the operating
consistency the values return to normal level.
design with taper
Used grease must be disposed of in a safe manner

consistent with all applicable regulations and in an
environmentally compatible way.
Figure 22Æ anti-friction bearings design single bearing hous-

grease pressed
ing
out here
design without taper
Figure 22
Maintenance
Table 8 Lubrication intervals of anti-friction bearings in single bearing housings

grease
quantity for
anti-friction grease re-lubricat.
housing lubricating intervals (operating hours)
bearings quantity* per anti-
friction
bearing (g)
-1 -1 -1
SNB/SNV nL = 3000 min nL = 1500 min nL = 1000 min (g) (g)
type with clamping sleeve – tapered bearing
607/080 2307K 4000 4000 4000 65 25
608/090 2308K 3600 4000 4000 85 30
609/100 2309K 3200 4000 4000 115 35
610/110 2310K 2950 4000 4000 150 45
611/120 2311K 2700 4000 4000 185 55
612/130 2312K 2500 4000 4000 220 60
613/140 2313K 2250 4000 4000 270 70
615/160 2315K 2000 3800 4000 370 85
616/170 2316K 1900 3600 4000 460 100
617/180 2317K 1800 3400 4000 550 110
618/190 2318K 1700 3300 4000 650 120
619/200 2319K 1600 3100 4000 750 135
515/130 22215K - 800 1350 350 45

516/140 22216K - 750 1250 460 50
517/150 22217K - 700 1200 550 55
518/160 22218K - 650 1100 650 65
519/170 22219K - 580 1000 750 75
520/180 22220K - 540 950 850 85
522/200 22222K - 460 850 1100 100
524/215 22224K - 410 750 1150 125
type without clamping sleeve – cylindrical bearing
315/160 2315 2000 3800 4000 650 85
316/170 2316 1900 3600 4000 750 100
317/180 2317 1800 3400 4000 850 110
318/190 2318 1700 3300 4000 975 120
319/200 2319 1600 3100 4000 1100 135
218/160 22218 - 650 1100 650 65

220/180 22220 - 540 1100 850 85
222/200 22222 - 460 850 1100 100
224/215 22224 - 410 750 1450 125
226/230 22226 - 380 680 1850 160
228 22228 - 350 600 2300 170
* grease quantity for first or new filling per bearing

The quantity listed in the table must be re-greased in order to ensure that all parts of the bearing
are provided with new grease during re-grease process.
Maintenance
7.3.1.2 Lubrication instructions

anti-friction bearings in a
The anti-friction bearings are to be lubricated during opera-
multiple bearing block
tion with the indicated quantity and grease type at the
lubrication nipples M10x1 at the
design AA non-driven end - non-driven end and
- driven end.
Lubrication intervals, grease quantity and grease

type see plate “Maintenance of the bearings”.
deep groove ball bearing / deep groove ball bearing

The bearing temperature may increase after re-greasing for
a few hours. After the grease has reached the operating
design AC non-driven end consistency the values return to normal level.
Replacement of lubricant
Grease quantity control devices govern the quantity of
grease in the anti-friction bearings. They provide the bear-
ings with the proper quantity of grease. Spare grease re-
mains in the bearing housings. After the bearings were re-
greased approximately ten times with the quantity that is in-
cylindrical roller bearing / deep groove ball bearing
dicated for the respective bearing type in the table “Lubrica-
tion intervals and quantity”, the used grease must be re-
design AK non-driven end moved from the bearing completely and the bearing must be
re-filled with new grease (see table “Lubrication intervals and
quantities” on page 7.4).
When re-greasing, it has to be ensured that the grease
quantity indicated in the said table is applied (weighing).
deep groove ball bearing / deep groove ball bearing Used grease must be disposed of in a safe manner
Figure 23
Figure 23 Æ anti-friction bearings design multiple bearing

block
Maintenance
Table 9 Lubrication intervals and quantities multiple bearing blocks

The exact designation of the multiple bearing block is indi-
multiple bearing block AA und AK
cated in the fan data sheet (o chapter 1.2).
Housing Non-locating Locating Lubrication intervals (operating houirs) c first re-lub-

bearing bearing filling or rication
deep deep nL [ min-1 ] re-filling quantity
groove ball groove ball
ZLG bearing bearing d 3600 d 3000 d 1800 d 1500
d 1000 g g
C3 C3 > 3000 > 1800 > 1500 > 1000
306 6306 6306 5080 6760 10150 13500 14800 3 9
307 6307 6307 4500 6000 9000 12000 14800 4 12
308 6308 6308 3980 5300 7950 10600 14800 6 18
309 6309 6309 3570 4760 7150 9500 14300 8 24
310 6310 6310 3230 4300 6450 8600 12900 10 30
311 6311 6311 2960 3940 5900 7900 11800 12 36
312 6312 6312 2720 3630 5450 7300 10900 16 48
313 6313 6313 2520 3360 5050 6700 10100 19 57
314 6314 6314 2350 3130 4700 6300 9400 23 69
315 6315 6315 2200 2940 4400 5900 8800 28 84
316 6316 6316 2070 2760 4150 5500 8300 32 96
317 6317 6317 -- 2600 3900 5200 7800 38 114
318 6318 6318 -- 2460 3700 4900 7400 44 132
319 6319 6319 -- 2340 3500 4700 7000 48 144
320 6320 6320 -- 2190 3300 4400 6600 57 171
322 6322 6322 -- 1950 3100 3650 -- 72 216
324 6322 6324 -- 1800 2880 3400 -- 100 300
multiple bearing block design AC The exact designation of the multiple bearing block is indi-
cated in the fan data sheet. (Æ chapter 1.2).
Housing Non-locating
bearing
Locating Lubrication intervals (operating hours) d c first re-lub-
bearing filling or rication
cylindrical deep nL [ min-1 ] re-filling quantity
roller groove ball
ZLG bearing bearing d 3600 d 3000 d 1800 d 1500
d 1000 g g
C3 C3 > 3000 > 1800 > 1500 > 1000
315 NJ 315 6315 -- 1700 2600 3500 5100 5 15
316 NJ 316 6316 -- 1600 2500 3400 5000 6 18
317 NJ 317 6317 -- 1500 2350 3200 4800 8 24
318 NJ 318 6318 -- 1300 2100 2900 4500 9 27
319 NJ 319 6319 -- 1220 1860 2200 -- 9 27
320 NJ 320 6320 -- 1100 1750 2100 -- 10 30
322 NJ 322 6322 - 1000 1600 1900 -- 10 30
324 NJ 324 6324 -- 930 1470 1750 -- 19 57
c basic grease quantity for the anti-friction bearing, not to be supplied by re-greasing
d refers to the cylindrical roller bearing
Maintenance
7.3.1.3 Remarks on lubrication Lubrication intervals depend on the conditions to which the
intervals grease is subjected such as bearing friction, speed, bearing
load and temperature.
lubrication intervals for other

The indicated lubricating intervals refer to a bearing tempera-
temperatures ture of 75°C. For other temperatures the interval must be
corrected in accordance with the table shown on the left.
temperature factor for lubri-
bearing housing ation interval Lubricants can not be mixed arbitrarily because of their most
75° C x 1.00 varying chemical composition.
80° C x 0.85 If a lubricant is used that differs from the first filling lubricant,
85° C x 0.70 consult the lubricant supplier about its applicability for the
given case.
90° C x 0.55
95° C x 0.45
100° C x 0.35
Table 10
7.3.2 Information on lubrication The bearings are filled with proper operational grease
grease quantities and ready for operation. Standard lubricants are
shown in the following list. In case other lubricants are used,
these are stipulated in the “supplements to the operating
manual” or in an individual order-related operating manual.
Ambient temperatures Prescribed
grease type
Take the type of grease from the plate „Maintenance of the
for normal climatic condi- SHELL bearings“
tions, i.e. ambient tempera- ALVANIA RL2
Grease type in accordance with Table 11
tures from –5°C up to +40°C
for low temperatures, i.e. MOBIL
ambient temperatures up to UNIREX S2
-40°C Other types of grease are not permitted.
Table 11
Lubricants must be disposed of in a safe manner
Maintenance
7.4 Shaft seal Depending on the individual requirements the fan can be
equipped with different seal systems.
If heightened temperatures or running noises occur at the
shaft sealing during operation, immediately switch down the
fan to prevent subsequent damage.
7.4.1 Standard seal Shaft seal with soft fibre ring (eg UNITEC 300) for a
temperature range up to +180°C
impeller
housing backplate
felt ring
impeller hub
Figure 24 o presentation of shaft seal

Figure 24
7.4.2 Shaft seal with graphite ring Shaft seal with cramped graphite-ring in sheet metal
housing
The seal with cramped graphite ring must be re-lubricated
monthly. Apply a small quantity of lubrication oil into the
clearance between the seal and shaft by oil can.
Figure 25 Figure 25 o presentation of shaft seal
Maintenance
7.4.3 Seal with special rings The shaft seal can be provided with one or two graphite
rings. This type of seal is also called labyrinth seal.
Lubrication of this sealing type is not possible.
Figure 26o Presentation of shaft seal with one

graphite ring
Figure 26
7.4.4 Shaft seal with grease barrier For improving the leak tightness a grease barrier can be
used. The grease barrier reduces the gas penetration
through the shaft seal.
Usage of the lubricator enables a maintenance-fee operation
of approximately 3 months.
Figure 27o Presentation of shaft seal

Figure 27
7.4.5 Shaft seal with barrier gas If barrier gas is used, it must be ensured that the pressure of
the barrier gas is always higher than the pressure at the
shaft seal that is created by the fan operation. Vacuum oper-
ation means higher barrier gas pressure than the maximum
static pressure increase, pressure operation means higher
barrier gas pressure than the total pressure increase.
It is obligatory to observe the instructions of the seal manu-
facturer.
Please note: Request technical data regarding minimum and
maximum barrier gas pressure from the manufacturer.
Equal or lower barrier gas pressure would enable the
penetration of solid matters into the sealing system
and therewith an increased wear or, in the worst
Figure 28 case, a total breakdown of the seal could be caused
Monitor the barrier gas consumption or the leakage
continuously. A significant increase of the values
points out wear of the sealing rings and / or repair
While carrying out inspection works, the shaft seal must be
checked for damages (e.g. corrosion) and must be cleaned.
If sealing components are damaged (scratches, cracks,
dents) the complete seal set must be renewed.
Figure 28o presentation of shaft seal
Maintenance
7.4.6 Shaft seal of type REW6 (Ø 40 The shaft seal of type REW6 can be used up to a seal
to Ø 120) diameter of 120mm. It is suitable for dry running and do not
require any lubrication.
The sealing rings are radially cut into several sections and
held together by means of a surrounding hose spring.
If it is necessary to replace the sealing rings, please observe
the separate mounting instruction of the manufacturer.
Further mounting remarks:

Seal the housing halves with non-adhesive sealing com-
Figure 29 pound (e.g. Epple Stukarit 203 or sealing grease E600N).
The radial shaft centre offset of the shaft may not exceed
± 1.5 mm
7.4.7 Shaft seal of type REW6 (Ø 140 The shaft seal of type REW6 can be used up to a seal
to Ø 240) diameter of 120mm. It is suitable for dry running and do not
require any lubrication.
The sealing rings are radially cut into several sections and
held together by means of a surrounding hose spring.
If it is necessary to replace the sealing rings, please observe
the separate mounting instruction of the manufacturer.
Figure 30
Maintenance
7.5 Shaft earthing If the fan is provided with a shaft earthing, check the correct
functioning regularly. There must be no gap between sliding
contact (e.g. carbon brush) and shaft. Choose the revision
intervals based on the operation conditions. We recommend
function checks every quarter of the year. Spare parts like
carbon brush, holders, etc. can be ordered from REITZ (indi-
cate serial fan number).
If a protection device covers the shaft earthing, please mark

the guard with a corresponding sign.
Figure 31: exemplary representations of shaft earthings
Figure 31
Proper setting of shaft earthing:
Set the holder of the carbon brush so that there is a
minimum gap of 2mm between holder and shaft
when the carbon brush is removed from the holder
(see Figure 32). This ensures that the holder cannot
get in contact with the shaft and hence excludes pos-
sible spark formation.
Adjust the holder so that the overall sliding contact of the

carbon brush is centrically to the shaft. The centre line of the
carbon brush must run through the shaft centre.
Pull back the holder and insert the carbon brush. The spring
tension force is at maximum with a new carbon brush and
will decrease with the increasing wear of the carbon brush.
Figure 32 Replacement of carbon brush (Adhere to minimum size):

The carbon brush has to be replaced when its minimum size
is less than 3mm; that is to say that a minimum thickness of
3mm must project from the holder at all points of the brush.
Maintenance
7.6 V-belt drive
7.6.1 General remarks Switch off the fan prior to any maintenance and
general servicing works and secure the fan against
re-start.
Inspect the V-belt drive in regular intervals.
Always replace the complete set of belts if one or more drive
belts of a multiple-belt drive system fail.
Do not use different makes of drive belts in one set
of belts. Do not use belt wax or belt spray.
Remove all deposits from the pulley rim.
7.6.2 Belt tension Check the belt tension at standstill of fan only and observe
the safety instructions.
Remove the V-belt protection box for checking the belt ten-
sion. Use a standard tension measuring instrument to de-
termine the deflection Ea. Compare the measured value with
the table (see page 7.15).
Refer to the presentation on the left as example of the
measuring method and device.
Increase the tension of the belt if it can be pushed in or
pulled out too far.
Install the V-belt protection box before re-starting the fan.
Figure 33 o example of a measuring method
Figure 33
Maintenance
Guide values for belt tension

Guide values for the deflection of V-belts as a function of the
applied testing force and the distance between pulley
centres (simplified method).
Profile Testing force Diameter of Deflection of belt ‚Ea‘ in mm

per V-belt small pulley with a distance between centres ‚A‘ in mm
dK (mm) 500 630 800 1000 1250 1600 2000 2500 3150
f (N)
SPZ 25 >100 d 125 14 17 22 28 34 44 55 - -
>140 d 160 13 16 20 25 31 40 50 63 -
11 14 18 22 28 36 45 56 71
>180 d 200
SPA 50 >180 d 200 15 19 24 30 38 48 60 75 95
>224 d 250 13 16 20 25 31 40 50 63 79
SPB 75 >224 d 250 15 19 24 30 38 48 60 75 95
>280 d 355 15 19 24 30 38 48 60 75 95
SPC 125 >315 d 355 15 19 24 30 38 48 60 75 95

400 14 17 22 28 34 44 55 69 87
450 13 16 20 25 31 40 50 63 79
500 11 14 18 22 28 36 45 56 71
A = distance between pulley centres in mm

f = testing force per V-belt in N
E = deflection per 100 mm distance between
centres in mm
Ea = deflection of the belt strand
ExA
Ea # >mm @
100
Figure 34
Figure 34o.Belt tension
Maintenance
7.7 Marking, information sign

The marking / information signs must be:
- cleaned with a rag,

- checked for tight fastening and legibility.
Legend:
1 name plate
2 sense of rotation arrow
3 warning notice inspection opening (optional)
4 sign “Maintenance of the bearings”
5 motor nameplate
6 earthing clamps (optional)
7 sign “danger symbols with explanations”
8 sign “Read operation manual”
9 sign “Attention – do not weld”
Figure 35
Figure 35 o Example for markings
The fan can be designed for use in potentially explosive at-

mosphere. An individual nameplate then indicates the
equipment group and category as per directive 94/9/EC
(ATEX
Figure 36
Figure 36 o example of an ATEX individual nameplate
Maintenance
7.8 Waste disposal Collect used oil, used grease or cleaning rags / wool
contaminated with oil / grease in containers corre-
spondingly marked and dispose of them in a safe
manner consistent with all applicable regulations and
in an environmentally compatible way.
7.9 Revision The required examinations and maintenance of fans that are
designed in accordance with directive 94/9/EC may only be
carried out by qualified personnel.
In general, half-yearly up to yearly revision intervals should
be sufficient under the conditions that:
- all checks in the course of the commissioning / start-up
and the maintenance works were carried out properly and
in due time, and
- each serious constitutional change that were recognized
by the continuous operation monitoring has been system-
atically investigated and repaired.
Maintenance
7.10 Maintenance schedule

Structural component Daily Weekly Quarterly Yearly
impeller An inspection of the impeller must be carried out immediately, if
x the permissible limiting values (see chapter 9.1.2 Limiting values vibrations) are
exceeded,
x changed impeller noises occur.
Examine the impeller every 5,000 operating hours and check it for alteration (cracks,
geometric alterations, balancing condition, wear and sticking material), but at least
once a year.
Check the impeller e.g. by non-destructive crack testing.
Fans that are subject to high dynamical stresses are to be checked in accordance with the
additional agreement (maintenance schedule) within the prescribed intervals.
bearings An inspection of the bearings must be carried out immediately, if
x the permissible limiting values (see chapter 9.1.2 Limiting values vibrations and
9.1.3 Limiting values bearing temperatures) are exceeded,
x changed running noises occur
x unusual alterations of the lubricant occur
x check the fixation of the bearing foot and re-tighten the screws if necessary
Re-lubrication intervals acc. to plate “Maintenance of the bearings” (see chapter
7.3.1.3 Remarks on lubrication intervals)
shaft seal The shaft sealing rings have to be checked and exchanged if the barrier gas
consumption or leakage increases. Exchange the shaft seal ring when the rings are
worn or damaged. If the seal ring consists of more than one part, replace the full seal
ring set.
shaft earthing Check the correct functioning of the shaft earthing regularly and in dependence of
the operating conditions and replace it, if required. Check the function monthly.
condensate drain Drain the accumulated condense water in regular intervals or when required in a
suitable drain receptacle and dispose of it in an environmentally compatible way.
V-belt drive Check the belt tension after the first 50 operating hours (see chapter 7.6 V-belt drive)
and re-tension the V-belts if necessary.
If noise levels change abruptly and / or vibrations occur abruptly, the belt drive must
be checked and if required, it must be re-aligned or exchanged.
check the align- check the align-
ment and fastening ment and fastening,
exchange the drive
belt, if necessary
motor pay attention to re-tighten screws, check motor, if
running noises and check bearings required, exchange
quiet running, bearings, observe
remove sticking maintenance
material (e.g. dust), instructions of
if required motor manufactur-
er, check the motor
feet fixation
earthing motor clean inside, clean inside,
terminal box tighten screws tighten screws
connections for collect measuring check for functiona- check for functiona- check for functiona-
monitoring devices and values and analyse lity lity lity
auxiliary equipment them
Maintenance
Structural component Daily Weekly Quarterly Yearly

flexible connections check at regular intervals and – if check, if required, check, if required,
and chutes required – after change of the processes. retighten screws retighten screws
and if worn-out, and, if worn out,
exchange flexible exchange flexible
connections connections
total fan pay attention to pay attention to check impeller, fan
operational noises operational noises bearings and motor
and quiet running, and quiet running, bearings, shaft
remove sticking check all screwed seal, belt drive and
material (dust) on connections for flexible connections
the fan, in particular tightness and re- for wear and, if
in the area of the tighten if necessary required, repair or
shaft sealing and exchange them
on the bearing
housing
The checks and controls in accordance with the mainte-

Table 12
nance schedule mainly contribute to the unrestricted contin-
uous functioning of the fan and hence to the complete sys-
tem and are regarded as being part of the operational com-
pany’s requisite obligations.
Repair work
8. Repair work
8.1 General remarks Authorized personnel only is entitled to repair fans that are
designed in accordance to the directive 94/9/EC (ATEX).
x Prior to removal / installation of spare parts, as:
- impeller,
- anti-friction bearings,
- sealing rings,
- V-belts,
- motor,
prepare everything to ensure smooth and faultless working
processes.
x Use appropriate removal / installation devices, tools and
heating devices for the anti-friction bearings.
x The working place for the removal of the parts must be
kept clean.
x Install only spare parts recommended and/or delivered by
the manufacturer. The special installation instructions
must be observed. These instructions are not part of this
operating manual and are to be requested from REITZ as
separate documents.
Repair work
8.2 Fans in accordance with di- Maintenance of fans that were designed in accordance with
rective 94/9/EC ATEX directive 94/9/EC may only be carried out by qualified
personnel (see chapter 2.8 Qualified person), see also
chapter 2.4 Safety regulations.
Example for the stages of the maintenance:
stage activity instructions responsible

maintenance e.g. re-grease bearings observe lubrication operating company
instructions
inspection e.g. check impeller for observe the instructions of operating company
wear and tear the operating manual
repair e.g. replace impeller observe the instructions of operating company
the operating manual
Table 13 Example for the stages of the maintenance
8.3 Safety instructions Repair work that has been carried out during the warranty
without our prior written agreement of the manufacturer,
leads to the extinction of all warranty rights.
Recommendation:
If repair works are required, request the service spe-
cialists of the manufacturer:
Carry out maintenance works at standstill of the fan
only.
Ensure that the fan is secured against restart and
marked by a corresponding information sign.
Observe the safety instructions and the regulations
for prevention of accidents.
Repair work
8.4 Spare parts When ordering spare parts, specify
- the exact name of the structural components

- the type of machine and
- the serial number.
The spare parts list (see enclosure) is a document separate-

ly attached to this operating manual. The clearly arranged list
comprises all main spare parts for the fan with exact descrip-
tion of the parts.
Type of machine and serial number are shown on the
name plate.
If required, send the manufacturer a sample of the
part to be exchanged.
Annex
9. Annex
9.1 Additional technical information
9.1.1 Tightening moments for Unless otherwise stated, use the following tightening mo-
fastening screws ments for connections with fastening screws and fastening
nuts: Data in Newton metre (Nm).
screws screws When installing the fan, reduce the tightening moments by
property property 10% so that the screw is not tightened to its yield point.
class class Values for set screws with metric coarse pitch thread bases
8.8 10.9 upon German Standard VDI2230 with a coefficient of fric-
M6 10 14
tions are
μ ges = μ K = μ G = 0,12.
M8 25 35
The tightening moments refer to slightly oiled screws and
M10 49 69
nuts.
M12 86 120
M16 210 295
M20 410 580
M24 710 1000
M27 1050 1500
M30 1450 2000
M36 2400 3555
Annex
9.1.2 Limiting values vibrations Table of limiting values for fans:
Evaluation Zones
Motor A B C D
Substructure or
Machinery Power Permissible
System of Continuous Unaccep-
Class New State for a short-
Installation operation table
in kW time
eff. velocity veff in mm/s
> 15 rigid ≤ 1,4 1,4 - 2.8 2,8 - 4,5 > 4,5
2 *)
≤ 300 flexible ≤ 2,3 2,3 - 4,5 4,5 - 7,1 > 7,1
rigid ≤ 2,3 2,3 - 4,5 4,5 - 7,1 > 7,1
1 > 300
flexible ≤ 3,5 3,7 - 7,1 7,1 - 11 > 11
*) Motors smaller than 15kW are not treated separately in the

DIN ISO 10816-3 and are therefore assigend to group 2.
The values assigned to the rating zones are not intended to
serve as acceptance values. The acceptance values have to
be specified between the machine manufacturer and the
customer. The values should serve as guidelines to avoid
major errors or unrealistic requirements.
The above shown warning and disconnecting values regard-
ing the working temperature are maximum values. They are
related to an ambient temperature of 40°C and an altitude of
installation of up to 1000 m asl. Under special circumstances
these values can be exceeded, if the preceding agreement
of the manufacturer is obtained.
Evaluation criteria regarding vibrations according to German
standard DIN ISO 10816/3.
If the vibration values level out between warning and discon-
necting and if the fan is carefully observed, the operating of
the fan can be continued until a proper point of time is de-
fined, so the process can be shut down in a controlled way.
Possible damages of the fan can not be excluded o if re-
quired, inform REITZ.
Annex
9.1.3 Limiting values bearing Warning at 80 °C

temperatures
Disconneting at 100 °C
Temperature is a long-time indicator for the machine load.
Excessive bearing load results in an increase in temperature
of the bearing. Provided that the anti-friction bearing is used
properly in accordance with the advised design instructions,
a nearly constant working temperature of the bearing will
turn up at constant working conditions after the initial opera-
tion phase. If the temperature changes without alteration of
the speed or the load or without addition or reduction of
warmth, this is an indication for a disturbed lubrication condi-
tion. Load changes due to malfunction of the non-located
bearing can be recognised by the temperature course of the
bearing. Bearing damages due to interruptions of the lubrica-
tion film or malfunction of the bearing can be recognized ear-
ly by using a temperature monitoring device for the bearing.
Running period damages due to fatigue and ageing can not
be detected by a temperature monitoring device for the bear-
ing.
The bearing temperature is measured by an electric temper-
ature probe directly on the outer ring of the bearing.
Permissible bearing temperatures
°C
120
disconnection 100 max. permissible temperature
pre-warning 80
60 working temperature
40
20
0
anti-friction bearing
Annex
9.2 Requests regarding field service For any queries or to require service specialists or spare
staff parts, we ask you to specify the following data:
x Serial number of the fan, (6-digit number, see fan data

sheet or name plate).
x Exact address of the operating company.
x Name of the person in charge who is to be contacted by
our service specialist.
x Describe the trouble and your observations as exact as
possible. The more exact the information, the easier for
us to support you efficiently and quickly. Please inform us
in detail by fax or e-mail.
See chapter 14 of this operating manual for detailed ad-
dresses of all companies of the REITZ Group
Fan shutdown
10. Fan shutdown
10.1 General remarks The definition – fan shutdown– means standstill of the fan for
a longer period of time. It is necessary to weather-proof the
fan.
In case the fans are intermediately stored for more than 3
months observe the instructions of the separate “Instructions
for Storage and Corrosion Protection”. If necessary, request
them from REITZ.
10.2 Safety instructions Works required for putting the fan out of action must exclu-
sively be carried out by specialist personnel, that due to
professional training, experiences and instructions has suffi-
cient knowledge about:
- Safety regulations,
- Regulations for prevention of accidents,
- Directives and accepted engineering standards (e.g.
German VDE-directives, DIN EN Standards).
- The specialist personnel must:

nize possible dangers and to avoid them.
safety of the plant to carry out the required works and
tasks.
Works on electric systems, like disconnecting the fan

from the electric supply, must exclusively be carried
out by professional electricians.
x Disconnect fan from the power supply.

x If a future re-commissioning is intended, protect all struc-
tural components against corrosion.
x Cover machine parts.
Dispose properly of all lubricants, oils and any other
materials dispose of them in a safe manner con-
sistent with all applicable regulations and in an envi-
ronmentally compatible way.
Fan shutdown
10.3 Measures in case of extended When the fan is put out of operation for more than three
shutdown months the following steps must be taken:
- Drive motors and actuators

bearing type relubrication quantity If there are drains, please open them, drain the accumu-
(in grams) lated water and re-close the openings. Check the terminal
ZLG306 20 box connections for tight screwing.
ZLG307 26 - Protect all bright parts (especially fan shaft) from corro-
ZLG308 36 sion.
ZLG309 50 - for single-bearing housings (fan shaft bearings)
ZLG310 67 press in grease until fresh grease leaks out from the dis-
ZLG311 86 charge bore and turn the shaft manually several times
ZLG312 108 - for multiple-bearing block (fan shaft bearings)
ZLG313 132 fill the space between housing covers and anti-friction
ZLG314 160 bearings with grease and turn the shaft manually several
ZLG315 192 times.
ZLG316 227
ZLG317 271 The values in Table 14 should serve as reference values:
ZLG318 316
ZLG319 308
ZLG320 368
ZLG322 466 The grease type that was filled in and the relubrication
ZLG324 657 grease type are indicated on the bearing plate (“Maintenance
of bearings”.
Table 14 Do not use another grease type.

Note on the time period of the fan shutdown:
If the fan is taken out of operation for a period of
more than twelve months, check the grease for de-
oiling or contamination (if condensate water intrudes
in the grease, it will change its consistency). The
grease has to be exchanged if it is de-oiled or con-
taminated.
Fan shutdown
10.4 Measures in case of re- Carry out the following steps:

commissioning
- Check the bearings and shaft seals for tightness
- Check whether the operating materials like oil or grease
have been filled in properly, re-fill or re-grease if neces-
sary or exchange the consumables
- Check the V-belts for damage, ruptures, cracks or embrit-
tlement
- Check drives and actuators for condensate water in the
terminal box and housing, if necessary, drain the water
and dry the interior.
- Remove the anti-corrosion coating from all bright parts
which could affect the functioning (e.g. shaft seal, shaft
earthing)
It is not permitted to employ damaged or corroded parts or

such parts that are unfit for operation.
Prior to a new start-up, chapter 4 Start-up must be

observed.
Dismantling
11. Dismantling
11.1 General remarks The definition “Dismantling” means the removal of the fan
and the subsequent re-mounting at a new location or the
scrapping of the fan.
Prior to a new start-up especially the chapters 1 to 5 of this
operating manual must be observed.
It is recommenced to request the field service staff of the
manufacturer to carry out the professional dismantling of the
fan.
11.2 Safety instructions Works required for dismantling the fan may exclusively be
carried out by specialist personnel, that due to professional
training, experiences and instructions has sufficient
knowledge about:
- safety regulations,
- regulations for prevention of accidents,
- directives and accepted engineering standards
(e. g. German VDE-directives, DIN EN-standards).
The specialist personnel must:
nize possible dangers and to avoid them.
safety of the plant to carry out the required works and
tasks.
Works on electric systems, like disconnecting the fan
from the electric supply, must exclusively be carried
out by professional electricians.
The dismantling must not start before all works that
are required for putting the fan out of action are fin-
ished and not before the start of the dismantling
works are permitted by an authorized assigned su-
pervisor.
x Initially all accessory parts like flexible connections and
louvre dampers must be removed.
x Subsequently remove the monitoring devices and the
safety hoods.
Overturning or dropping components can cause most
serious injuries or even death.
Secure all components to avoid sliding and dropping
of these parts during dismantling works and
transport.
Staying below suspended loads means danger to live
and therefore must be refrained from in any circum-
stance.
Safety data sheets
12. Safety data sheets The safety data sheets on bearing greases or oils can be
submitted on demand from REITZ.
Expiry of service life, disposal
13. Expiry of service life, disposal Dismantle and dispose of properly and in accordance with
the national and international laws and regulations of those
fan components and parts, whose service life has expired
due to wear and tear, corrosion, mechanical load, fatigue
and/or other effects that could not be directly discerned. The
same applies to the auxiliary materials used like oil, grease
or the like.
Deliberate or unintentional further application of used parts,
e.g. impellers, bearings, V-belts etc. may endanger persons,
harm the environment and/or damage the machine or the
complex system. The corresponding local regulations of the
operating company are to be observed and applied.
Addresses of the REITZ group
14. Addresses of the REITZ group Konrad Reitz Ventilatoren GmbH & Co. KG
Konrad-Reitz-Straße 1
37671 Höxter-Albaxen
phone: +49 (5271) 9 64 - 0 00
E-mail: info@reitz-ventilatoren.de
www.reitz-ventilatoren.de
24-h Hotline +49 (170) 56 32 768
Reitz Umwelttechnik + Ventilatoren GmbH & Co. KG

Gutenbergstraße 20-24
37235 Hessisch Lichtenau
phone: +49 (5602) 936 - 60
E-mail: info@reitz-umwelttechnik.de
www.reitz-umwelttechnik.de
24-h Hotline +49 (170) 56 32 768
Reitz Schweiz Ventilator AG

Zentweg 11
CH-3006 Bern
phone: +41 (31) 938 85 85
E-mail: info@reitz-schweiz.ch
www.reitz-schweiz.ch
24-h Hotline +41 (79) 62 21 247
Reitz Retrofit GmbH & Co. KG

Röttgerweg 12
51371 Leverkusen
phone: +49 (214) 202 99 100
E-mail: info@reitz-retrofit.de
www.reitz-retrofit.de
Reitz Fans (Suzhou) Co., Ltd.

No. 2, Minsheng Road
215126 SIP Suzhou, PRC
phone: +86 (512) 62 85 61 00
E-mail: info@reitz-china.com.cn
Reitz India Limited

VII Floor, Block - A
Q-City Gachibowli, Nanakramguda
Hyderabad – 500 032, India
phone: +91 (40) 4488 1888
E-mail: info@reitzindia.com
www.reitzindia.com
Reitz Wentylatory Polska Sp. z o.o.

ul. Dziadoszańska 10
61-248 Poznań, Polska
phone: +48 (61) 62 42 772
E-mail: gwp@reitz-wentylatory.pl
www.reitz-wentylatory.pl
Reitz France S.a.r.l.

20, Avenue de la Paix
F-67000 Strasbourg
phone: +49 (5271) 96 42 31
E-mail: mra@reitz-ventilatoren.de
Reitz Middle East FZE

P.O. Box – 9383, Y-3-210
Sharjah Airport Free Zone
Sharjah, UAE
phone: +971 50 1737486
E-mail: spk@reitzindia.com
Reitz SE-ASIA PTE LTD

31, Cantonment Road
Singapore-089747
phone: +65 622 44991
E-mail: sa@reitzindia.com
CB DOCTOR VENTILATOR S P VT. LTD .
3607 – 3608, GIDC, PHASE – IV
VATVA, AHMEDABAD, GUJARAT - 382445 (INDIA)
TEL : +91- 79 – 40268700, 25841152, 25841449
FAX : +91 – 79 – 40268799
E-MAIL ID : service@cbdoctor.co.in
Web: WWW.cbdoctor.co.in
info@cbdoctor.co.in
CB DOCTOR VENTILATOR PVT. LTD
OPERATION & MAINTENANCE, E&C

MANUAL
INDEX
INTRODUCTION
SAFETY RULES
GENERAL RULES
IMPORTANT NOTICE
GENERAL INSTRUCTIONS
ERRECTION INSTRUCTIONS
COMMISSIONING INSTRUCTIONS
MAINTENANCE INSTRUCTION
OPERATION FAULTS AND REMEDIES
SPARES LIST
THANK YOU FOR HAVING CHOSEN A CB DOCTOR FAN
Our fans have been designed by CBI Italy & CBV Belgium, and are manufactured by us to
the high quality standards that distinguish our product.
CB Doctor recommends the first thing you do on getting fan is to read the manual
carefully (if possible, with the fan nearby)
After having read this manual you will be able to get the best possible use out of the fan,
while protecting of yourself and others by following the safety precautions included.
We would like suggest carefully keeping this manual handy so that it can be consulted at
any time.
SAFETY RULES
GENERAL RULES
IMPORTANT NOTICE
CENTRIFUGAL TYPE FANS

GENERAL INSTRUCTIONS
Before erection of the fan the following procedure should be

followed. Failure to observe these instructions may lead to a fan
bearing seizure or damage to the motor.
x Check and ensure the fan casing, impeller, pedestal, motor and its
component have not become damages during transits and loading or
unloading.
x Check and ensure the fan orientation for correct the site orientation.
x ROTATION: Check the instructions on the motor nameplate and check

that the fan rotation is correct as shown by the direction arrow on the fan
casing. Reverse rotation with radial and forward curved bladed impellers
will give reduced performance and power consumption but can cause
severe overloading of the motor in the case of backward bladed impellers.
x Ensure that the Impeller and shaft have not become bending in transit.
x The fan shaft should be perfectly level within tolerance 0.05 mm.
ERECTION
FAN WITH CONCRETE BASE WITHOUT ISOLATORS
x When installing a fan with concrete foundation should be checked to

ensure that it is firm and even. Avoid stain on the fan casing by tightening
the foundation bolts a few turns each in rotation.
x Levelling should be within 0.05 mm in both axis (vertical and horizontal)

x Packer plates should be installed during grouting.
x When installing a fan with steel foundation should be checked to ensure
that it is firm and even. Avoid stain on the fan casing by tightening the
foundation bolts a few turns each in rotation. Isolator should be installed
at steel foundation to transfer the both frequency like natural and
operating.
FAN WITH CONCRETE BASE WITH ISOLATORS


x Packer plates should be installed during grouting.
FAN WITH METALIC BASE WITH ISOLATORS

BEARING ALIGNMENT
x Ensure that the shaft and bearings have not become misaligned in transit.
x Drive end bearing should be fix type and Non drive end bearing should
be free type for maintaining to thermal expansion.
Bearing clearance
For deferent type of bearings, see manufacturing company tables.
x If bearings are already aligned by manufacturer so should not check/

disturb at site. It can increase the vibration and temperature also.
x Ball or roller bearings are of the self-aligning Plummer block type
incorporating single row deep groove ball bearings or double row
ball/spherical roller bearings and are complete with seals against the
ingress of dust. They are initially charged with grease when assembled.
A grease nipple is fitted to the sealed units incorporating the deep groove
ball bearing to enable regressing if considered necessary (normally no
more than once a year).
x Good quality lithium base grease should be used.

x Fans fitted with Plummer blocks incorporating double row self- aligning
ball bearings or spherical roller bearings are suitably
x Packed with grease on assembly.
x Free space in the Plummer block should only be partly filled
x With grease (approximately 40%) since over filling can cause
x Over heating of the bearing.
x The re-greasing interval for these bearings is dependent on type,
size, speed, operating temperature and grease.
x Further information can be obtained from our service/ sales office.
Casing and cone alignment
x Ensure that the Fan casing and cone have not become misaligned in
transit.
x Gaps for all the point A, B and C should be equal to periphery.

VEE BELTS
x If the fan is driven through vee belts, the pulleys must be correctly
aligned within 0.05mm and the best tensioned in accordance with the
drive manufacturers instructions.
x Position the pulleys near to the fan and motor bearings in order to keep
the load imposed by the tension of the Vee belts to a minimum.
x Where keyless taper bushed pulleys are used, the protective grease film
should be removed from the bore and outside surface of the bush, also
from the tapered bore of the pulley.
x The grub screws in the bush should be tightened gradually and
alternatively until all are pulled up very tightly.
x The belts should be inspected from time to time and any slackness taken
up by moving the position of the motor on the slide by means of tension
screws.
x Under average conditions the majority of stretch takes place in vee belts
during the first few days under load.
x It is therefore recommended that newly installed vee belts be examined
and the tension increased if necessary after the first few days under load
and thereafter as equired.
x Excessive wear on the sides of the vee belt means misalignment of the
pulleys and this should be rectified at once.
x New and used vee belts should not be run together in the same set and
vee belts of different types and brands should not be mixed.
x Always fit all new or used matched vee belts in the same set.
x Extra care during the first few hours of operation will result in efficient
and long vee belt life.
COUPLING DRIVES
x If the fan is driven through coupling, the couplings must be correctly

aligned in radial and axial offset within 0.05mm and also should be
maintained to distance between both pairs 3 mm @150 to 300 mm dia in
accordance with the drive manufacturers instructions
.
COMMISSIONING INSTRUCTIONS FOR RADIAL FAN

CHECK LIST FOR DO’S
BEFORE STARTING UP THE FAN
x Check for lubricant in bearing housing is adequate enough

x Check tightness of foundation bolts and other bolts fixing impeller, bearings and motor
x Check for proper operation of inlet damper/inlet guide fane/inlet butter fly damper. Blades
should be in correct position
x Check for correct bearing clearance
x Ensure correct alignment of coupling as applicable
x Check for radial and axial clearances between impeller and inlet cone
x Ensure no foreign materials are left inside the fan casing and inside suction and delivery
ducts nearer to fan
x Check for correct direct rotation of fan
x Check the “Emergency Off” switch is functioning properly
x Check for water circulation, in case the water supply is needed for any functioning
x Ensure the functioning of thermometers
x Check the interlocks
x Check and ensure actuator functioning for open/close, wherever applicable
x Ensure installation of all safety guards and closing of man/hand holes and drain plugs
x Ensure installation of needed earthling for recommended machines
START UP AND TEST RUNNING
x Check for right direction of rotation of fan/motor; wrong rotation to be avoided totally
x Close the blades of inlet damper/Inlet Guide Vane/butter fly damper
x Close the blades of inlet and outlet dampers as applicable during starting
x Ensure the conditions laid down by motor the motor supplier are met with
x Check for vibration and temperature of fan and motor bearings
x Check and monitor motor current
x Check sufficient level of lubrication maintained in bearings
x Check for any abnormality in the fan and motor
x Test run for minimum 8 hours continuously
Note:- In case bearing temperature is high, motor loading is abnormal and /or vibration and noise
is excessive, then fan should be stopped immediately and defects should be diagnosed and
rectified before restarting fan once again
NORMAL OPERATION OF FAN:

x Check up for lubricator. Lubricate properly as per requirements, at regular intervals. Avoid
excess lubrication than recommended
x Check up lubrication of damper blade bearings/guide vane bearings also
x Check for the bearing temperature
x Check for the vibration and noise , at regular intervals, with calibrated instruments
x Check for water supply wherever needed/applicable
CHECK LIST FOR DON’T S

x Do not run the fan if any defect is noticed during test run
x Do not open the opening of damper blades/guide vane blades, unless the motor current
reaches to normal value well below safe ampherage
x Do not operate the fan/fans at very low volume and at very high pressure since might lead
to operation of fan in stall/surge zone
x Do not mix lubricants of two makes/ two grades/two quality since the property of each
lubricant is different for each supplier
x Do not operate/run the fan if any foreign matter is left inside the fan casing/ducting
x Do not run the fan continuously when the fan vibrations and temperatures are above
warning zones or in Trip zones. Refer the vibration severity chart as
applicable/recommended
Maintenance Instructions for Radial Fan

MAINTENANCE CHECK POINTS FOR EVERY 15 DAYS:-
x Check for the radial and axial gap between impeller and inlet cone/branch
x Check all the nuts and bolts for their proper tightness
x Check for any wear/damage of fan impeller blades and damper/guide vane blades
x Check for conditions of pulleys/belts and replace in case found damaged/worn out
x Use fine lubrication which is applicable as per manufacturer.
x Check whether safety guards are in good condition/ or else correct them and refix
x Ensure that threaded holes on bearing housings are not left opened free to avoid any entry
of dust/wear particles; close these holes with soft cloth/plugs temporarily as needed
x Cleaning for the impeller / pulleys inside outside to avoid any dust collection.
x Maintain and control the vibration, noise, temperature as per their acceptable limits.
LUBRICATION AND MAINTENANCE INTERVAL FOR DRIVE JOINT AND BEARINGS
STRICLY COMPLY WITH THE FOLLOWING TABLE

STRICLY COMPLY WITH THE FOLLOWING TABLE OF ISO 14694 FOR VIBRATION LEVEL
STRICLY COMPLY WITH THE FOLLOWING TABLE OF BELOW MAINTENANCE SCHEDULE

OPERATING FAULTS AND REMEDIES

GENERAL TIGHTENING TORQUE FOR BOLTS
CB DOCTOR VENTI LATORS P VT. LTD .
3607 – 3608, GIDC, PHASE – IV
VATVA, AHMEDABAD, GUJARAT - 382445 (INDIA)
TEL : +91- 79 – 40268700, 25841152, 25841449
FAX : +91 – 79 – 40268799
E-MAIL ID : service@cbdoctor.co.in
Web: WWW.cbdoctor.co.in
info@cbdoctor.co.in
Flame Proof Motors
0.18 kW to 335 kW
From 80 to 355 Frame
FLP Motors
THE WIDEST AVAILABLE RANGE

SQUIRREL CAGE MOTORS INDUSTRIAL APPLICATIONS
0.37 kw to 355 kw (Frames E 80 to E 355 LX) l Coal Mines.
l
SLIP RING MOTORS Petro Chemicals & Chemicals.
22 kw to 160 kw l Oil Mines & Rigs.
(Frames EW 250 M to EW 315 L)
l Fertilizers.
l Solvent extraction plants.
STANDARD SPECIFICATIONS
l Paints & Varnish Industry.
l VOLTAGE : 415 ± 10%
Other Voltage class (220 V - 660 V) l LPG Bottling plants.
available on request.
l Agro Chemicals.
l FREQUENCY : 50 ± 5% l Drugs & Pharmaceuticals.
25 HZ to 60 HZ available on request.
l General Industry.
l Combined variation : ± 10 % (absolute sum)
l INSULATION : Class F
Class 'H' can be given on request. SPECIAL PURPOSE MOTORS FOR
l RATING/DUTY : Continuous (S1) 1. Longwall mining equipment.
Intermittent duties available on request. 2. High pressure mine ventilation fans with
l
plug & socket arrangement.
MOUNTING : Horizontal foot mounting (B3)
Other mountings available on request. 3. Auxiliary mine ventilation fans with rod
mounting / flange mounting.
l PAINT : Epoxy anticorrosive painted surface
(Standard shade 631 as per IS - 5) 4. Belt conveyors and armoured face/ chain
conveyors.
l AMBIENT / TEMPERATURE RISE :
450C/750C. Higher Amb. upto 600C on request. 5. Side dump loaders, load haul dumpers
l TEMPERATURE CLASS : T4 6. Haulages (squirel cage and slipring motors).
l DEGREE OF PROTECTION : 7. Dewatering pumps.

IP 54 - E80 - E132 M 8. Sucker rod pumps.
E225 M to E355 LX
(IP55 with canopy can be offered.) 9. Mud agitators & mud pumps.
IP55 - Frame E 160L to E 200 L.
10. Slurry extraction pumps.
l ERTL / CCOE (PESO) / DGMS approvals as a
11. Air compressors & blowers.
standard feature. For BASEEFA approval please
contact nearest branch office/works.
SPECIAL DESIGN FEATURES AVAILABLE
APPLICABLE STANDARDS 1. Dual voltage (550/1100V) with 9 terminal
connections as per NCB 625
Enclosure - IS 2148
EN 50018 2. Non standard voltage and frequency variation
Performance - IS325
BS 5000 (Part 10) 3. Dual voltage (1:2 or 1: 3 ratio)
IEC60034 -1 Tripple voltage (1: 3 : 2 ratio)
Performance for Mines IS 3682 4. Energy efficient motors
Dimensions - Foot - IS 1231 High slip motors
IEC60072-1 Motors for frequent starts/stops/reversals
Flange - IS2223 5. 10,12,16,18,24,32 pole motors
BS4999
Part 414 6. Special performance requirements
7. Class H insulated motors
8. Low vibration and noise level
31
FLP Motors
9. Special Bearings l Separate terminal box for auxiliary

terminals (space heaters, thermisters) for
10. Tacho mounting frame 225 and above on request.
11. Special shaft material
12. Canopy TERMINAL STUD
l Fully non hygroscopic thermosetting moulded
13. Plug & socket arrangement glass filled compound.
(30 to 300 Amps, 650 & 1100V) for
underground equipments. l Increased clearances & creepages.
14. Flange/foot cum flange /rod mounting. l Anti loosening arrangement.
15. Special RV/RA for slipring motors. l Metallic bush insert to take tightening
pressure. Eliminates breakage of insulation
16. Space heaters, thermisters. (E160-315LX frames)
17. Multispeed motors.
18. Double /taper/non standard shaft extention BEARING CHART
19. Non standard paint shade FRAME DE NDE
20. Motors for use with variable frequency E80 6304-2Z 6304-2Z
inverter supply E90 6205-2Z 6205-2Z
E100 6206-2Z 6206-2Z
E112 6306-2Z 6306-2Z
TERMINAL BOX AND E132 6308-2Z 6208-2Z
TERMINAL ARRANGEMENT E160 6309-2RS 6309-2RS
l Cast iron construction, forming a E180 6310-2RS 6310-2RS
separate flame proof enclosure
E200 6312-2RS 6312-2RS
capable of containing internal
explosions. E225 6313-2RS 6313-2RS
E250-2P 6315 6315
l Standard position on right hand side viewed E/EW250-4P UP 6315 6315
from driving end side except in frames E 80,
E/EW 315 L & E 355 LX where it is on top. E280-2P 6315 6315
E/EW280-4P UP 6318 6318
l Terminal box on top on specific request. E315-2P 6315 6315
l New terminal box with spigotted cover & E/EW315-4P UP 6319 6319
gland plate/sealing box in frames E355LX-2p 6316 6316
E 160 to 355 LX with following advantages. E355LX-4p UP 6322 6322
- Inherently IP 55.
- Spaciously designed for accommodating
bigger cables.
- Double decker terminal arrangement

for easy termination of two cables.
- Anti loosening terminal arrangement

l For slipring motors, separate terminal
box for stator & rotor terminations
provided. Stator terminal box is on left hand
side while rotor terminal box is on right
hand side, viewed from driving end.
l Conduit plate is provided as standard
while sealing box provided for
group I gases.
32
FLP Motors
STATUTORY APPROVALS
COUNTRY
STATUTORY
AUTHORITY FLAME PROOF
NOTATION /MARK
SCOPE
ERTL KOLKATA
TESTING
DGMS DHANBAD
STANDARD
APPROVING
CCE NAGPUR
INDIA
APPROVING FLAMEPROOF MOTORS FOR

GROUP IIC ATMOSPHERE
DGFAS & L I
MUMBAI A complete range of Crompton
Greaves flameproof squirrel cage
APPROVING
motors for gas group IIC is now
BIS available for Indian Industries as an
IS:2148
import substitute. The motors are
LICENCE Ex
manufactured as per the most
stringent requirements for IIC
specified at the time
BASEEFA
Requirement to be
Baseefa atmosphere. The motors are duly

of enquiry / order
CERTIFICATE & Ex tested at ERTL.

LICENCE
OPTIONAL
UK.¶
ATEX CE MARK For more details, please contact our

nearest branch office / works.
LICENCE
ERTL DGMS CCE DGFAS & LI GROUP *

SUITABILITY
E 80 IIA, IIB ONLY
E 90L I, II A, II B.
E100L
I, IIA, IIB
E112 M, E 132 M.
E160L, E 180 L,
E200 L I, IIA, IIB
E225 S, E 225 M
I, II A, IIB.
E250 M
E280 M
I, IIA, IIB.
E315 M/L
E355LX IIA, IIB.
AVAILABLE Pending for approval. * For IIA, IIB Gas Groups

* STANDARD Temperature class T4. Other classes available on request.
CMRI : CENTRAL MINING RESEARCH INSTITUTE, DHANBAD.

DGMS : DIRECTORATE GENERAL OF MINES SAFETY, DHANBAD.
CCE : CHIEF CONTROLLER OF EXPLOSIVES, NAGPUR.
DGFAS & LI : DIRECTORATE GENERAL FACTORY ADVICE SERVICE & LABOUR INSTITUTE, MUMBAI.
BIS : BUREAU OF INDIAN STANDARDS, NEW DELHI.
BASEEFA : BRITISH APPROVALS SERVICE FOR ELECTRICAL EQUIPMENT IN FLAMMABLE ATMOSPHERES, UK.
ATEX : EUROPEAN DIRECTIVE
ERTL : ELECTRONIC REGIONAL TEST LABORATORY
NOTE:* Motors as per UK based standards can be supplied against specific enquiries.
33
FLP Motors
CABLE TERMINATION
CABLE SIZE REFERENCE CHART
MAX. CABLE SIZE TERMINAL STUD
FRAME SIZE GROUP I - COPPER
GROUP II - AL. mm2 MAIN EARTH AUX.
inch2
DOL STAR/DELTA DOL STAR/DELTA NOS. SIZE SIZE SIZE
E 80 NA NA 4 NA 3 M6 M6 NA
6 M6 NA
E 90L TO E 132 M 0.25 2 X 0.06 10 2X6 M6
3 M6 M6
50 2 X 50
E 160L TO E 200 L 0.25 2 X 0.06 6 M8 M8 M6
(95 WITH ADAPTOR)
E225S TO E315M 0.25 2 X 0.25 185 2 X 120 6 M10 M8 M6
2X0.25 6 M14 M8 M8
E 315 L & E355 0.25 Double Sealing Box 2 x 3C x 240 2 x 240
2X0.06 Double Sealing Double Sealing Box
Single Sealing Box Box 3 M16
EW250 M 185 3 M10 M8 M6

STATOR 0.25 NA NA
95 3 M8
ROTOR
EW280-EW 315 M 3 M10 M8 M6
STATOR 185
0.25 NA NA
ROTOR 185 3 M10
EW 315 L 240 3 M16 M8 M8

STATOR 0.25 NA NA
185 3 M10
ROTOR
NA -Not Available
Note : Motors upto & including 2.2 kw are with 3 leads. 3.7 kw & above are with 6 leads.
Following alternative methods of electrical connections/ cable entry can be provided:
1. CMRI / ERTL approved double compression glands.
2. For group I areas, cable clamps for single/double armoured cable with single/double cone arrangement.
3. Plug and socket arrangement (suitable for 1100 or 650 V) for PATC cables for group I areas. (E 160 L- E 355 LX)
4. Sealing box with entry thread for solid drawn conduit arrangement.
SHIPPING SPECIFICATIONS
FOOT MOUNTING MOTORS FLANGE MOUNTING MOTORS
FRAME NET GROSS DIMENSIONS VOL. FRAME NET GROSS DIMENSIONS VOL.
SIZE WT. WT. LxBxH CU.M. SIZE WT. WT. LxBxH CU.M.
KG KG mm KG KG mm
E80 23 27 345 X 220 X 335 0.025 E80 25 30 345 X 220 X 335 0.025
E90L 40 56 467 X 477 X 319 0.071 E90L 42 70 528 X 362 X 672 0.128
E100L 54 74 507 X 507 X 368 0.095 E100L 56 89 582 X 422 X 687 0.169
E112M 73 102 590 X 532 X 427 0.134 E112M 76 109 582 X 422 X 687 0.169
E132M 110 143 622 X 575 X 427 0.153 E132M 113 156 628 X 472 X 732 0.216
E160L 188 259 875 X 705 X 427 0.36 E160L 215 333 960 X 815 X 815 0.64
E180L 256 362 1025 X 825 X 700 0.59 E180L 260 378 960 X 815 X 815 0.64
E200L 263 369 1025 X 825 X 700 0.59 E200L 300 442 1065 X 885 X 840 0.79
E225S 330 382 1150 X 845 X 710 0.69 E225S 365 510 1065 X 885 X 840 0.79
E225M 400 449 1150 X 845 X 710 0.69 E225M 435 577 1065 X 885 X 840 0.79
E250M 680 818 1300 X 915 X 745 0.89 E250M 705 935 990 X 900 X 1245 1.11
E280M 966 1180 1500 X 1065 X 850 1.36 E280M 1000 1270 1070 X 1070 X 1430 1.64
E315M 1136 1389 1600 X 1170 X 925 1.73 E315M 1180 1508 1280 X 1210 X 1545 2.39
E315L 1752 2105 1830 X 1270 X 1156 2.69 E315L 1800 2214 1850 X 1450 X 1275 3.42
EW250M 740 1015 1730 X 1170 X 865 1.75 EW250M - - -
EW280M 1105 1460 2160 X 1220 X 1010 2.66 EW280M - - - -
EW315M 1300 1645 2160 X 1220 X 1010 2.66 EW315M - - - -
EW315L 1900 2430 2565 X 1245 X 1120 3.58 EW315L - - - -
E355LX 2150 2500 2565 X 1245 X 1120 3.58 - - - -
34
FLP Motors
PERFORMANCE FIGURES OF FLP SCR MOTORS FOR 45 AMBIENT 75 DEGREE RISE
OUTPUT P EFFICIENCY POWER FACTOR DOL STG.

O FRAME FL FLC GD SQ. NET WT
L SIZE RPM AMPS. FL 3/4 1/2 FL 3/4 1/2 STG.T STG.C KGM.2 KG
KW HP
E LOAD LOAD LOAD LOAD %FLT %FLC
0.18 0.25 2 E80 2850 0.54 64.0 61.0 55.0 0.72 0.68 0.61 250 650 0.003 23
4 E80 1400 0.55 68.0 64.0 59.0 0.67 0.63 0.57 200 500 0.007 23
6 E80 950 0.70 58.0 52.0 45.0 0.62 0.52 0.44 220 450 0.011 23
8 E90L 680 0.84 57.0 52.0 46.0 0.52 0.46 0.40 180 400 0.024 35
0.25 0.33 2 E80 2850 0.68 68.0 64.0 57.0 0.75 0.70 0.62 250 600 0.003 23
4 E80 1400 0.71 70.0 66.0 59.0 0.70 0.64 0.58 200 500 0.007 23
6 E80 930 0.89 60.0 54.0 48.0 0.65 0.54 0.48 200 400 0.011 23
8 E90L 670 1.17 57.0 52.0 46.0 0.52 0.46 0.40 180 400 0.024 38
0.37 0.50 2 E80 2820 0.87 72.0 69.0 63.0 0.82 0.76 0.65 250 550 0.003 23
4 E80 1410 0.97 72.0 69.0 65.0 0.74 0.7 0.64 225 500 0.007 23
6 E80 910 1.13 65.0 63.0 59.0 0.7 0.63 0.5 200 400 0.011 23
8 E90L 680 1.41 64.0 62.0 58.0 0.57 0.5 0.4 170 400 0.024 35
0.55 0.75 2 E80 2820 1.29 73.0 72.0 68.0 0.81 0.73 0.62 250 600 0.003 23
4 E80 1410 1.32 77.0 74.0 69.0 0.75 0.68 0.58 200 500 0.007 23
6 E80 910 1.56 69.0 66.0 60.0 0.71 0.63 0.5 200 400 0.011 23
8 E90L 685 1.69 72.0 68.0 62.0 0.63 0.55 0.42 170 400 0.034 38
0.75 1.00 2 E80 2820 1.72 75.0 73.0 68.0 0.81 0.73 0.6 250 600 0.003 23
4 E80 1410 1.81 77.0 74.0 69.0 0.75 0.68 0.58 200 500 0.007 23
6 E90L 925 2.07 72.0 68.0 61.0 0.7 0.62 0.52 180 500 0.024 35
8 E100L 700 2.26 71.0 67.0 61.0 0.65 0.58 0.45 175 400 0.038 49
1.10 1.50 2 E90L 2830 2.31 78.0 76.0 73.0 0.85 0.79 0.7 230 600 0.010 36
4 E90L 1415 2.62 77.0 75.0 71.0 0.76 0.7 0.6 200 500 0.018 35
6 E90L 925 2.95 74.0 69.0 62.0 0.70 0.62 0.52 200 500 0.034 38
8 E100L 700 3.27 72.0 68.0 61.0 0.65 0.58 0.45 175 400 0.050 51
1.50 2.00 2 E90L 2850 3.11 79.0 77.0 73.0 0.85 0.79 0.7 230 600 0.010 36
4 E90L 1415 3.34 80.0 79.0 77.0 0.78 0.72 0.65 200 550 0.025 38
6 E100L 945 3.53 80.0 77.0 71.0 0.74 0.66 0.54 200 500 0.038 49
8 E112M 715 4.04 76.0 72.0 65.0 0.68 0.6 0.5 170 450 0.130 61
2.20 3.00 2 E90L 2850 4.29 82.0 81.0 79.0 0.87 0.83 0.74 230 600 0.014 39
4 E100L 1430 4.55 82.0 81.0 78.0 0.82 0.78 0.7 200 600 0.040 49
6 E112M 945 5.10 80.0 79.0 77.0 0.75 0.7 0.6 200 500 0.106 60
8 E132M 715 5.38 79.0 78.0 76.0 0.72 0.65 0.55 180 400 0.300 93
3.70 5.00 2 E100L 2850 7.13 84.0 83.0 81.0 0.86 0.82 0.75 250 600 0.029 53
4 E112M 1430 7.57 84.0 82.0 79.0 0.81 0.78 0.73 200 600 0.099 63
6 E132M 945 7.57 85.0 84.0 82.0 0.8 0.76 0.72 200 550 0.205 94
8 E132M 700 8.71 81.0 79.5 77.0 0.73 0.66 0.57 180 400 0.340 98
5.50 7.50 2 E112M 2900 10.38 85.7 84.0 81.0 0.86 0.82 0.76 250 650 0.045 64
4 E132M 1450 10.59 86.0 85.0 83.0 0.84 0.8 0.71 200 600 0.227 93
6 E132M 945 11.11 85.0 84.0 82.0 0.81 0.77 0.73 200 500 0.330 98
8 E160L 710 12.00 85.0 85.0 83.0 0.74 0.7 0.62 150 500 0.460 120
7.50 10.00 2 E132M 2900 13.63 87.0 85.0 82.0 0.88 0.85 0.8 250 650 0.108 98
4 E132M 1450 14.28 87.0 86.0 85.0 0.84 0.8 0.71 200 600 0.269 98
6 E160L 970 11.00 87.5 87.0 85.0 0.8 0.76 0.68 175 500 0.46 120
8 E160L 710 12.00 85.0 85.0 83.0 0.76 0.72 0.64 150 500 0.64 146
9.3 12.5 2 E160L 2920 17 88.0 87.0 85.0 0.88 0.86 0.78 250 600 0.13 260
4 E160L 1460 17 88.5 88.5 86.5 0.84 0.81 0.73 175 500 0.31 260
6 E160L 970 18 87.5 87.0 84.0 0.80 0.76 0.68 200 550 0.59 260
8 E180L 720 20 86.0 86.0 84.0 0.74 0.70 0.60 175 500 0.99 260
11.0 15.0 2 E160L 2920 20 88.5 88.0 86.0 0.88 0.86 0.78 250 600 0.13 260
4 E160L 1460 21 89.0 89.0 86.0 0.82 0.79 0.70 200 500 0.36 260
6 E160L 975 22 88.0 87.5 86.0 0.80 0.76 0.68 200 550 0.64 260
8 E180L 720 24 87.0 87.0 85.0 0.74 0.70 0.60 175 500 1.16 285
15.0 20.0 2 E160L 2920 26 89.5 89.5 87.5 0.88 0.86 0.79 250 650 0.17 260
4 E160L 1460 27 90.0 90.0 88.0 0.85 0.83 0.75 200 500 0.47 260
6 E180L 975 29 90.0 90.0 88.0 0.79 0.73 0.66 250 600 1.16 285
8 E200L 725 33 88.5 88.5 86.5 0.71 0.65 0.55 225 500 2.14 310
35
FLP Motors

KW HP
18.5 25.0 2 E160L 2920 32 90.0 90.0 88.0 0.88 0.86 0.79 250 650 0.21 260
4 E180L 1475 34 91.0 91.0 90.0 0.84 0.80 0.72 200 500 0.81 285
6 E200L 975 34 91.1 91.1 89.9 0.84 0.80 0.70 200 550 1.69 310
8 E225S 725 39 89.0 88.5 87.0 0.75 0.71 0.63 150 500 3.30 330
22.0 30.0 2 E180L 2940 40 91.0 91.0 89.0 0.84 0.80 0.74 175 500 0.44 285
4 E180L 1475 40 92.0 92.0 90.0 0.84 0.80 0.72 200 500 0.95 285
6 E200L 975 40 91.5 91.5 90.1 0.84 0.80 0.70 200 500 2.04 310
8 E225M 725 46 89.0 88.5 87.0 0.75 0.71 0.63 175 500 3.90 400
30.0 40.0 2 E200L 2950 52 91.5 91.0 89.0 0.87 0.84 0.80 200 600 0.80 310
4 E200L 1475 53 92.0 92.0 90.5 0.86 0.82 0.76 225 600 1.62 310
6 E225M 980 53 91.5 91.0 89.5 0.86 0.84 0.80 200 600 3.70 400
8 E250M 735 63 90.5 87.0 88.5 0.73 0.69 0.61 175 550 7.49 680
37.0 50.0 2 E200L 2960 64 92.5 91.5 89.0 0.87 0.84 0.80 200 500 0.89 270
4 E225S 1480 63 92.5 92.0 90.5 0.89 0.85 0.77 250 600 2.70 330
6 E250M 975 65 92.0 91.5 90.0 0.86 0.82 0.74 200 600 7.51 680
8 E280M 740 75 91.5 91.0 89.5 0.75 0.71 0.63 200 500 14.15 966
45.0 60.0 2 E225M 2955 72 92.5 90.0 88.0 0.94 0.90 0.82 200 650 1.50 400
4 E225M 1480 76 93.0 92.5 91.0 0.89 0.85 0.77 250 600 3.20 400
6 E280M 987 78 93.0 92.5 91.0 0.86 0.82 0.74 200 600 14.15 966
8 E280M 740 91 92.0 91.5 90.0 0.75 0.71 0.63 200 600 14.15 966
55.0 75.0 2 E250M 2980 89 93.0 92.0 90.0 0.92 0.88 0.80 200 600 6.22 680
4 E250M 1480 93 93.0 92.5 91.0 0.88 0.84 0.76 225 600 6.26 680
6 E280M 987 96 93.0 92.5 91.0 0.86 0.82 0.74 200 600 14.15 966
8 E315M 742 108 93.5 93.0 91.0 0.76 0.72 0.62 150 500 24.20 1136
75.0 100.0 2 E280M 2970 121 93.6 93.0 92.0 0.92 0.90 0.86 175 600 7.25 966
4 E280M 1488 123 93.6 93.0 91.5 0.91 0.88 0.80 200 600 11.60 966
6 E315M 990 130 93.5 93.0 91.5 0.86 0.82 0.74 200 600 24.20 1136
8 E315M 742 148 93.0 92.5 91.0 0.76 0.72 0.62 150 500 24.20 1136
90.0 120.0 2 E280M 2970 142 94.0 93.5 91.5 0.94 0.90 0.82 175 600 7.25 966
4 E280M 1488 147 93.9 93.3 91.8 0.91 0.88 0.84 200 600 11.60 966
6 E315M 990 155 93.8 93.3 91.8 0.86 0.82 0.74 200 600 24.20 1136
8 E315L 742 176 93.5 93.0 91.5 0.76 0.72 0.62 150 500 33.33 1752
110.0 150.0 2 E315M 2980 173 94.0 93.0 91.5 0.94 0.90 0.82 175 600 10.76 1136
4 E315M 1488 180 94.5 93.5 92.0 0.90 0.86 0.78 175 600 20.30 1136
6 E315L 990 189 94.0 93.5 92.0 0.86 0.82 0.74 200 600 40.00 1752
8 E315L 742 210 93.5 93.0 91.5 0.78 0.74 0.66 150 500 40.00 1752
132.0 180.0 2 E315M 2980 207 94.5 93.0 91.5 0.94 0.90 0.82 175 600 10.76 1136
4 E315M 1488 215 94.7 93.5 92.0 0.90 0.86 0.78 175 600 20.30 1136
6 E315L 990 227 94.0 93.5 92.0 0.86 0.82 0.74 200 600 33.33 1752
8 E355LX 740 263 94.5 94.5 92.5 0.74 0.70 0.60 150 500 31.80 2500
160.0 215.0 2 E315L 2980 250 94.8 93.5 92.0 0.94 0.90 0.82 175 600 16.37 1752
4 E315L 1490 260 95.0 94.0 92.5 0.90 0.86 0.78 175 600 24.97 1752
6 E315L 990 274 94.5 94.0 92.5 0.86 0.82 0.74 200 600 40.00 1752
8 E355LX 743 304 95.0 94.0 92.0 0.77 0.73 0.63 140 500 36.80 2500
180.0 240.0 2 E315L 2980 280 95.0 94.5 92.5 0.94 0.90 0.82 175 600 16.37 1752
4 E315L 1488 292 95.3 95.3 94.0 0.90 0.88 0.84 175 600 24.97 1752
6 E355LX 990 307 95.0 94.5 93.0 0.86 0.82 0.76 140 500 33.50 2500
8 E355LX 743 335 94.5 94.5 92.0 0.79 0.75 0.67 125 400 51.10 2500
200.0 270.0 2 E315L 2980 317 94.5 94.0 92.5 0.93 0.90 0.82 175 600 16.37 1752
4 E315L 1488 324 94.5 94.0 92.5 0.91 0.88 0.84 200 650 31.10 1752
6 E355LX 990 349 95.0 95.0 93.5 0.84 0.81 0.72 130 500 29.70 2500
8 E355LX 743 371 95.0 95.0 94.0 0.79 0.75 0.66 110 400 58.10 2500
225.0 300.0 2 E355LX 2975 352 95.5 95.5 94.0 0.93 0.90 0.84 150 600 18.40 2500
4 E355LX 1488 356 95.5 95.5 93.5 0.92 0.88 0.84 150 600 28.00 2500
6 E355LX 991 390 95.5 95.0 94.0 0.84 0.80 0.70 130 500 31.70 2500
36
FLP Motors

KW HP
250.0 335.0 2 E355LX 2970 387 95.5 94.8 93.3 0.94 0.92 0.88 150 650 27.70 2500
4 E355LX 1488 395 95.7 95.2 93.8 0.92 0.88 0.84 150 600 29.60 2500
6 E355LX 990 434 95.5 95.0 94.0 0.84 0.80 0.70 130 500 35.60 2500
275.0 370.0 2 E355LX 2980 435 95.5 94.8 93.3 0.92 0.90 0.86 150 600 27.70 2500
4 E355LX 1490 440 95.5 95.0 93.3 0.91 0.88 0.81 140 650 31.60 2500
6 E355LX 990 477 95.5 95.0 94.0 0.84 0.80 0.74 160 500 39.80 2500
315.0 425.0 2 E355LX 2980 499 95.5 94.8 92.5 0.92 0.90 0.86 175 600 29.60 2500
4 E355LX 1490 502 96.0 95.1 93.6 0.91 0.88 0.82 140 650 35.50 2500
335.0 452.0 2** E355LX 2980 530 95.5 94.8 92.5 0.92 0.90 0.88 175 600 29.60 2500
4 E355LX 1490 534 96.0 95.4 93.8 0.91 0.88 0.82 175 600 39.70 2500
FL = Full Load; FLC = Full Load Current; FLT = Full Load Torque
SGT. T = Starting Torque; SGT. C = Starting Current
NOTE : All performance figures are subject to tolerances as per IS 325 - 1996
**40/80
37
FLP Motors
OUTLINE DIMENSION DRAWING FOR 3 PHASE SQUIRREL CAGE TEFC

FOOT MOUNTED TB ON TOP FLAME PROOF INDUCTION MOTORS (FRAME:E80)
CABLE ENTRY AS PER
CUSTOMER SPECIFIED.
L ±5
TAPPED HOLE +0.0

'Y'xDEEP -0.5
ED
N9/h9
F HD
HA H
G
GD
BA AA 4 HOLES
E ±0.5 C ±1 K DIA
B ±0.5 A ±0.5
BB EARTHING TERMINAL M6
AB
RINGED DIMENSIONS ARE AS PER IS:1231

ALL DIMENSIONS ARE IN mm
Frame A B C H AA AB BA BB K D E ED F GD G Y AC L HD HA
E80 125 100 50 80.0 / 28 152 25 124 10.0 / 19.009/ 40 27 6.00 / 6.00 / 15.5 / M6X16 165 274 268 11
79.5 10.5 18.996 5.97 5.97 15.3
OUTLINE DIMENSION DRAWING FOR 3 PHASE SQUIRREL CAGE

TEFC FOOT MOUNTED TB ON RHS FLAME PROOF INDUCTION MOTORS
SEALING BOX PROVIDED CABLE ENTRY PROVIDED AS
ONLY FOR GROUP I GASES PER CUSTOMER CABLE SIZE
`Y'-THREADED CENTRE L ±10 AD
HOLE AS PER IS:2540-1963
+0.0
N9/h9 -0.5
ED
HD
F
D fAC
G HA H
GD
GA
BA
B1 ±0.5 AA
A ±0.5 4 HOLES K DIA
±1
E ±0.5 C B ±0.5 EARTHING TERMINAL
M6 FOR E90L-E100L AB
BB
M8 FOR E112M-E132M

Frame A B C H AA AB BA BB K D E ED F GD G Y AD AC L HD HA
90.0 / 10.5/ 24.009/ 8.00 / 7.00 / 20.0 /

E90L 140 125 56 35 168 45 152 50 36 M8x19 240 210 335 195 13
89.7 10.0 23.996 7.957 6.91 19.8
100.0 / 12.5/ 28.009/ 8.00 / 7.0 / 24.0 /
E100L 160 140 63 38 198 51 170 60 44 M10X22 255 240 380 220 13
99.7 12.0 27.996 7.957 6.91 23.8
112.0 / 12.5/ 28.009/ 8.00 / 7.0 / 24.0 /
E112M 190 140 70 38 228 60 171 60 44 M10X22 265 270 400 245 14
111.7 12.0 27.996 7.957 6.91 23.8
E132M 216 178 89 132.0 / 48 254 64 216 12.5/ 38.018/ 80 60 10.0 / 8.0 / 33.0 / M12X28 285 320 500 290 16
131.7 12.0 38.002 9.957 7.91 32.8
38
FLP Motors

TEFC FOOT MOUNTED TB RHS FLAME PROOF INDUCTION MOTORS
(4 POLE & UP FOR ALL FRAMES 2 POLE & UP TO ND200L FRAMES)
'Y'THREADED CENTRE HOLES

AS PER IS:2540-1963 AC
AUXILIARY TERMINAL BOX ABOVE
160 FRAME ONLY WHEN REQUIRED AD
L ±10
+0.0
ED -0.5
N9/h9 F
GD
HD
G
HA
fD CABLE GLAND
H
FOR AUXILIRY
TERMINAL
AA
E ±0.5 C ±1.0 B ±0.5 BA
A ± 0.5
BB AB
CABLE ENTRY PROVIDED 4-HOLES 'K' DIA.
AS PER CUSTOMER CABLE SIZE EARTHING TERMINALS OF
M12 FOR 160-315M FRAMES

Frame A B B1 C H AA AB BA BB K D E ED F GD G Y AD AC L HD HA
4 POLE & UP
E160L 254 254 210 108 160.0 / 54 298 101 298 15.5 / 42.018 / 110 80 12.00 / 8.00 / 37.0 / M16X32 345 320 655 376 22
159.7 15.0 42.002 11.957 7.91 36.8
180 / 15.5 / 48.018 / 14.00 / 9.00 / 42.5 /
E180L 279 279 241 121 60 337 107 323 110 80 M16X32 362 370 725 418 22
179.7 15.0 48.002 13.957 8.91 42.3
200.0 / 19.5 / 55.030 / 16.00 / 10.00 / 49.0 /
E200L 318 305 - 133 66 381 105 356 110 80 M20X40 400 435 790 480 25
199.5 19.0 55.011 15.957 9.91 48.8
225.0 / 19.5 / 60.030 / 18.00 / 11.00 / 53.0 /
E225S 356 286 - 149 70 425 114 349 140 110 M20X40 402 490 832 525 25
224.5 19.0 60.011 17.957 10.91 52.8
225.0 / 19.5 / 60.030 / 18.00 / 11.00 / 53.0 /
E225M 356 311 - 149 70 425 114 375 140 110 M20X40 402 490 857 525 25
224.5 19.0 60.011 17.957 10.91 52.8
E250M 406 349 - 168 250.0 / 90 483 160 419 24.5 / 65.030 / 140 110 18.00 / 11.00 / 58.0 / M20X40 440 560 977 605 32
249.5 24.0 65.011 17.957 10.91 57.8
E280M 457 419 368 190 280.0 / 95 540 155 489 24.5 / 75.030 / 140 110 20.00 / 12.00 / 67.5 / M20X40 476 620 1094 660 38
279.0 24.0 75.011 19.948 11.91 67.3
E315M 508 457 - 216 315.0 / 100 597 190 533 28.5 / 80.030 / 170 140 22.00 / 14.00 / 71.0 / M20X40 516 705 1220 775 38
314.0 28.0 80.011 21.948 13.91 70.8
39
FLP Motors

FOOT MOUNTED TB RHS FLAME PROOF INDUCTION MOTORS (FOR 2 POLE)
'Y'THREADED CENTRE HOLES

AS PER IS:2540-1963 AC
AUXILIARY TERMINAL BOX
ONLY WHEN REQUIRED L ± 10 AD
+0.0
-0.5
ED
N9/h9 F
GD
HD
G
HA
fD CABLE GLAND
H
FOR AUXILIRY
TERMINAL
BA AA
E ±0.5 C ±1.0 B ±0.5 A ± 0.5
BB AB
CABLE ENTRY PROVIDED 4-HOLES 'K' DIA.
AS PER CUSTOMER CABLE SIZE EARTHING TERMINALS OF
M12 FOR 225-315M FRAMES

Frame A B B1 C H AA AB BA BB K D E ED F GD G Y AD AC L HD HA
E225S 356 286 - 149 225.0 / 70 425 114 349 19.5 / 55.030 / 110 80 16.00 / 10.0 / 49.0 / M20X40 402 490 802 525 25
224.5 19.0 55.011 15.957 9.91 48.8
E225M 356 311 - 149 225.0 / 70 425 114 375 19.5 / 55.030 / 110 80 16.00 / 10.0 / 49.0 / M20X40 402 490 827 525 25
224.5 19.0 55.011 15.957 9.91 48.8
E250M 406 349 311 168 250.0 / 90 483 160 419 24.5 / 60.030 / 140 110 18.00 / 11.00 / 53.0 / M20X40 440 560 977 605 32
249.5 24.0 60.011 17.957 10.91 52.8
280.0 / 24.5 / 65.030 / 18.00 / 11.00 / 58.0 /
E280M 457 419 368 190 95 540 155 489 140 110 M20X40 476 620 1094 660 38
279.0 24.0 65.011 17.957 10.91 57.8
E315M 508 457 - 216 315.0 / 100 597 190 533 28.5 / 65.030 / 140 110 18.00 / 11.00 / 58.0 / M20X40 516 705 1190 775 38
314.0 28.0 65.011 17.957 10.91 57.8
40
FLP Motors

FOOT MOUNTED FLAME PROOF TB ON TOP INDUCTION MOTORS
(FRAME E315L & E355LX)
'Y'THREADED CENTRE HOLES CABLE ENTRY PROVIDED AS

AS PER IS:2540-1963 PER CUSTOMER CABLE SIZE
L ± 10 AC
AD AD
+0.0
N9/h9 F -0.5
ED
GD
HD (MAX)
G
fD
H
AA
E ±0.5 C ±1 B1 ±0.5 BA A ± 0.5 HA
B ±0.5
AB
BB
4-HOLES 'K' DIA.
EARTHING TERMINALS OF M12

Frame A B B1 C H AA AB BA BB K D E ED F GD G Y AC L HD HA AD
2 POLE
315.0 / 28.5 / 70.030 / 20.0 / 12.0 / 62.5 /
E315L 508 508 - 216 100 610 204 655 140 110 M20X40 655 1350 875 38 480
314.0 28.0 70.011 19.948 11.91 62.3
355.0 / 28.5 / 75.030 / 20.00 / 12.00 / 67.5 /
E355LX 610 630 560 254 110 710 250 880 170 140 M24x50 720 1540 1005 40 600
354.0 28.0 75.011 19.948 11.91 67.3
4 POLE & UP
315.0 / 28.5 / 90.035 / 170 25.0 / 14.00 / 81.0 /
E315L 508 508 - 216 100 610 204 655 140 M24X50 655 1380 875 38 480
314.0 28.0 90.013 24.948 13.91 80.08
355.0 / 28.5 / 100.035/ 210 28.00 / 16.00 / 90.0 /
E355LX 610 630 560 254 110 710 290 880 160 M24x50 720 1580 1005 40 600
354.0 28.0 100.013 27.948 15.89 89.8
41
FLP Motors
TEFC FLANGE MOUNTED FLAME PROOF INDUCTION MOTORS (FRAME:E80)
L±5 CABLE ENTRY AS PER

CUSTOMER SPECIFIED.
LB
R
T
N9/h9
+0.0
F -0.5
ED HB
D
G
GD 45° fN SPIGOT
±0.5
P E
EARTHING TERMINAL M6
4 HOLES DRILL LA
f'S' ON 'M' PCD
EQUALLY SPACED
AS SHOWN

Frame D E ED F GD G Y AD AC L MTol NTol P S T LA LB HB
E80 19.009 / 40 27 6.00 / 6.00 / 15.5 / M6X16 205 165 274 165.3 / 130.014/ 200 12 3.5 10 245 188
18.996 5.97 5.97 15.3 164.7 129.989

TEFC FLANGE MOUNTED FLAME PROOF INDUCTION MOTORS
4-HOLES L±10
DRILLED f 'S' ON 'M' P.C.D.
E ±0.5 R
EQUALLY SPACED AS SHOWN LB
`Y'-THREADED CENTRE AD
HOLE AS PER IS:2540-1963
N9/h9 +0.0
45°
-0.5
fN SPIGOT
F ED
fP
fAC
HB
G
GD
T LA
SEALING BOX PROVIDED
EARTHING TERMINAL
ONLY FOR GROUP I GASES
M6 FOR E90-E100L
M8 FOR E112M-E132M

E90L 24.009 / 50 36 8.00 / 7.00 / 20.0 / M8x19 240 210 380 165.3 / 130.014/ 200 12 3.5 10 137 300
23.996 7.957 6.91 19.8 164.7 129.989
28.009 / 8.00 / 7.0 / 24.0 / 215.3 / 180.016/
E100L 60 44 M10X22 255 240 415 250 15 4 11 320 330
27.996 7.957 6.91 23.8 214.7 179.987
28.009 / 8.00 / 7.0 / 24.0 / 215.3 / 180.016/
E112M 60 44 M10X22 270 270 425 250 15 4 11 345 350
27.996 7.957 6.91 23.8 214.7 179.987
38.018 / 10.0 / 8.0 / 33.0 / 265.3 / 230.016/
E132M 80 60 M12X28 290 320 520 300 15 4 13 177 440
37.996 9.957 7.91 32.8 264.7 229.987
42
FLP Motors

TEFC FLANGE MOUNTED FLAME PROOF INDUCTION MOTORS
(4 POLE & UP FOR ALL FRAMES & 2 POLE & UPTO ND200L)
4-HOLES FOR FRAME 160-200 RO TOLERANCE ±1 CABLE ENTRY PROVIDED

8-HOLES FOR FRAME 225-315
AS PER CUSTOMER CABLE SIZE
DRILLED f`S' ON `M' P.C.D.
EQUALLY SPACED AS SHOWN CONCENTRICITY
'Y'THREADED CENTRE HOLES L±10
AS PER IS:2540-1963 +0
AD E +2 AUXILIARY TERMINAL BOX
LB ONLY WHEN REQUIRED
N9/h9 F
GD
HB
+0.0
-0.5
fN SPIGOT
ED
fAC
G
fP
(E)
f'D
45° T
LA
22.5°
EARTHING TERMINALS OF
PERPENDICULARITY M12 SIZE PROVIDED
CABLE GLAND FOR
AUXILIRY TERMINAL

E160L 42.018 / 110 80 12.00 / 8.00 / 37.0 / M16X32 345 320 300.5/
655 250.016 / 350 19 5 18 235 220
42.002 11.957 7.91 36.8 299.5 249.987
48.018 / 14.00 / 9.00 / 42.5 / 300.5 / 250.016 /
E180L 110 80 M16X32 362 370 750 350 19 5 18 261 245
48.002 13.957 8.91 42.3 299.5 249.987
55.030 / 16.00 / 10.00 / 49.0 / 350.5 / 300.016 /
E200L 110 80 M20X40 400 435 790 400 19 5 18 286 280
55.011 15.957 9.91 48.8 349.5 299.984
E225S 60.030 / 140 110 18.00 / 11.00 / 53.0 / M20X40 402 490 832 400.5 / 350.018 / 450 19 5 19 292 300
60.011 17.957 10.91 52.8 399.5 349.982
E225M 60.030 / 140 110 18.00 / 11.00 / 53.0 / M20X40 402 490 857 400.5 / 350.018 / 450 19 5 19 305 300
60.011 17.957 10.91 52.8 399.5 349.982
65.030 / 18.00 / 11.00 / 58.0 / 500.5 / 450.020 /
E250M 140 110 M20X40 440 560 977 550 19 5 22 343 355
65.011 17.957 10.91 57.8 499.5 449.980
E280M 75.030 / 140 110 20.00 / 12.00 / 67.5 / M20X40 476 620 1094 500.5 / 450.020 / 550 19 5 22 400 380
75.011 19.48 11.91 67.3 499.5 449.980
E315M 80.030 / 170 140 22.00 / 14.00 / 71.0 / M20X40 516 705 1220 601.0 / 550.022 / 660 24 6 25 445 460
80.011 21.948 13.91 70.8 599.0 549.978
43
FLP Motors

FLANGE MOUNTED FLAME PROOF INDUCTION MOTORS (2 POLE)
RO TOLERANCE ±1 CABLE ENTRY PROVIDED

8-HOLES FOR FRAME 225-315 AS PER CUSTOMER CABLE SIZE
DRILLED f`S' ON `M' P.C.D. CONCENTRICITY
'Y'THREADED CENTRE HOLES EQUALLY SPACED AS SHOWN L±10
AS PER IS:2540-1963 +0
AD E +2 AUXILIARY TERMINAL BOX
LB
ONLY WHEN REQUIRED
N9/h9 F
GD
HB
+0.0
-0.5
fN SPIGOT
ED
fAC
G
fP
(E)
fD
T
0 LA
22.5
EARTHING TERMINALS OF
PERPENDICULARITY M12 SIZE PROVIDED
CABLE GLAND FOR
AUXILIRY TERMINAL

E225S 55.030 / 110 80 16.00 / 10.0 / 49.0 / M20X40 402 490 400.5 /
802 350.018 / 450 19 5 19 292 300
55.011 15.957 9.91 48.8 399.5 349.982
55.030 / 16.00 / 10.0 / 49.0 / 400.5 / 350.018 /
E225M 110 80 M20X40 402 490 827 450 19 5 19 305 300
55.011 15.957 9.91 48.8 399.5 349.982
60.030 / 18.00 / 11.00 / 53.0 / 500.5 / 450.020 /
E250M 140 110 M20X40 440 560 977 550 19 5 22 343 355
60.011 17.957 10.91 52.8 499.5 449.980
E280M 65.030 / 140 110 18.00 / 11.00 / 58.0 / M20X40 476 620 1094 500.5 / 450.020 / 550 19 5 22 400 380
65.011 17.957 10.91 57.8 499.5 449.980
E315M 65.030 / 140 110 18.00 / 11.00 / 58.0 / M20X40 516 705 1190 601.0 / 550.022 / 660 24 6 25 445 460
65.011 17.957 10.91 57.8 599.0 549.978
44
FLP Motors

FLANGE MOUNTED FLAME PROOF INDUCTION MOTOR.(FRAME : E315L)
941±5
CONCENTRICITY
SEALING BOX ONLY L ± 10
WHEN REQUIRED.
6
560
(E)
f 549.978
f 550.022
f710
f 660
950
8-HOLES f24 EQUALLY SPACED
AS SHOWN ON 600±1 P.C.D. PERPENDICULARITY ED+0.0
-0.5
E+0
CABLE ENTRY AS PER +2 28 EARTHING TERMINALS
CUSTOMER SPECIFIED. OF M12 PROVIDED
'Y' THREADED CENTRE HOLE

AS PER IS:2540-1963
F N9/h9
GD
G
fD
SHAFT AND KEY

POLE
D TOL. E ED F TOL. GD TOL. G Y L
4P & UP 90.035/90.013 170 140 25.0/24.948 14.0/13.91 81.0/80.8 M24x50 1492
2 70.030/70.011 140 110 20.0/19.948 12.0/11.91 62.5/62.3 M20x40 1462
45
IM No. : IM/V/0015, Rev. 5
Date : 04.04.16
Page 1 of 7
MOUNTING, OPERATING, TESTING & MAINTENANCE INSTRUCTIONS

FOR ROTEX 2/2 & 3/2 DIRECT ACTING HIGH ORIFICE SOLENOID VALVE
MODEL 30308, 30309, 30329, 30333, 30334, P3005, P3012R, 20105, 20106, 20205, 20206
ROTEX retains all rights to this publication.
All details within this manual and the catalogue are subject to change without manner.
ROTEX will not be responsible for any damage whatsoever arising from the use of the Solenoid Valve, due to misuse or
incorrect installation or misinterpretation of the information contained herein.
SPECIFICATION OF THE SOLENOID VALVE
TYPE : 3 Port 2 Position – 30308, 30309, 30329, 30334 & P3005

2 Port 2 Position – Normally Closed 20105, 20106 and
Normally Open 20205, 20206
OPERATION : DIRECT ACTING HIGH ORIFICE UNIVERSAL SOLENOID VALVE
ORIFICE = NW : 5 mm for 30308, 30333, 30334, 20105, 20205, P3005,
7mm and 10mm for 30309, 30329, 20106, 20206
OPERATING PRESSURE : 0-10 bar for 30308, 30309, 30333, 30334, 20105, 20106, 20205, 20206,
0-16 bar for 30329 and 0-8 bar for P3005
MANUAL OVERRIDE : Not provided.
Push / Push & Turn Manual Override provided optionally.
SEALS & SEAT : NBR
ELECTRICAL INSULATION : Class F & H.
CONSTRUCTION
Body Aluminium Brass SS316 Aluminium

(Ú) (B2) (B5) (B1)
Internal Al.,Br., SS316 Brass, SS316 SS316 SS316
Core Tube SS304
Core Plug & Plunger SS430, Electro less Nickel Plated
Seals NBR (Ú) EPDM (S1) Viton (S2) F.Silicone (S19) Viton GLT (S2G)
Springs SS302
Manual Override Nil Ú Push & Turn (M6) Push Type (M8)
Note: (Ú) & B1 not applicable for valve model: 30334

IM No. : IM/V/0015, Rev. 5
Date : 04.04.16
Page 2 of 7
NOTE : 1) FOR “AC” (50 Hz & 60Hz) VOLTAGE, SELECT SOLENOID WITH “FR” OPTION.
2) INTRINSICALLY SAFE SOLENOID CANNOT BE SUPPLIED WITH VALVE
IDENTIFICATION ON THE SOLENOID VALVE
a) VALVE LABEL
Label on the ROTEX Solenoid Valve shows the following details :

(1)
ROTEX AUTOMATION LIMITED (1) Logo + Name & address of the Manufacturer
VADODARA-390010, INDIA (2) Valve Type / Code
FLUID CONTROL SYSTEM 30308 = Valve Model
{ { Suffix = Nil
TYPE
30308-5-2G-B2-S2 5 = Orifice
2G = Port Connection (BSP)
WO No. ATM MFG
B2 = Body Material (Brass)
1Q6437/01 0-10 9/2009
S2 = Seal Material (Viton)
110 V = Solenoid Voltage
50 Hz = Current (AC)
(3) (2) (4) (5) Solenoid Construction
(1) 22
= (Enclosure : Plug In)
H = Solenoid Class ‘H’ Insulation
Sp. Version = Nil
ROTEX AUTOMATION LIMITED (3) Work Order reference / Sr. No. of the Valve
VADODARA-390010, INDIA (4) Operating Pressure
FLUID CONTROL SYSTEM (5) Month & Year of manufacture
CODE : 30308-5-2G-B2-S2 (6) Valve Symbol
ATM 0-10 (7) Media
MEDIA AIR (8) ATEX Ex mark for Valve (Non Electrical Part)
(9) “CE” mark for ATEX and/or PED compliance.
DATE 9/2009
Sr. No. 1Q6437/01
(6) (2) (4) (3) (5) (7)

(1)
ROTEX AUTOMATION LIMITED

VADODARA-390010, INDIA
I M2 T6 T.F.No. TF/V/001
II 2GD T6
{ TYPE {
WO No. ATM MFG
(3) (2) (9) (8) (4) (5)

b) SOLENOID LABEL
(1)
(1) Logo + Name of the Manufacturer

ROTEX (2) Solenoid Type
VADODARA – 390010, III = Solenoid Size III
INDIA 110V = Solenoid Voltage
III-110V-50Hz-22-H-FR 50 Hz = Solenoid Current
07/2009-09/09 22 = Solenoid Construction (Plug In DIN)
H = Solenoid Class H Insulation
FR = Full Rectifier
IM No. : IM/V/0015, Rev. 5
Date : 04.04.16
Page 3 of 7
(2) (3) (3) Plan No. & Manufacturing Month / Year

c) PORT IDENTIFICATION
A solenoid Valve with NPT (F) threading is normally marked “N” near the port and with Metric threads are marked
“M”. For ports with BSP threads, there is no marking.
d) Voltage, current & other details are additionally marked / punched on the solenoid.
NOTE : The product without label is out of warranty and risk.
CONNECTION
VALVE TYPE FUNCTION IN OUT EXHAUST

NC 1 2 3
30308, 30333, 30334, P3005-5 NO 3 2 1
30329-7, 30329-10 Mixiing 1,3 2 -
Diverting 2 1,3 -
20105, 20106 NC 1 2 -
20205, 20206 NO 3 2 -
(A) OPERATING PRINCIPLE
The valve is 3/2 Direct Acting pressure balance design i.e. area at the Seat (Part-19) and balancing Plunger O Ring (Part-
80) are same, thereby air force acting on the Plunger Seat is nullified which makes the valve to work merely on the spring
force throughout its pressure range.
Because of this feature, the valve is Universe in nature and can be used as NC / NO / Diverting / Mixing type.
In the de-energised condition of the valve Port-1 is blocked and Port-3 is connection to Port-2. On energizing
the valve, Plunger (30) pulls up thereby connecting Port-1 and Port-2 and blocking Port-3. When the inlet is connected to
Port-1, air passes through the small hole provided in the Plunger and acts on upper side of Plunger O Ring (80). When
the valve is energized, the Plunger (30) pulls up because of which the lower orifice opens up thereby connecting
Port-1 to the outlet Port-3 and the upper orifice at Part-101gets blocked. In this condition force acting on the Plunger
(30) due to seat at Part- 101 and on the Plunger (30) due to Plunger O Ring (80) are same because of their equal area.
VALVE MODEL 30308, 30333, 30334, P3005, P3012R

IM No. : IM/V/0015, Rev. 5
Date : 04.04.16
Page 4 of 7
VALVE MODEL 30309, 30329

B) MOUNTING/INSTALLATION PROCEDURE :
1. ENSURE THAT :
a) While storing, keep the valve in cool, dry, dust free area.
b) On receipt of the valve, in case if the same is to be removed from the sealed plastic bag for
inspection/testing, put them back with dust plugs on its ports and sealing the plastic bag as soon as the
inspection/testing is over.
c) The valve should be removed from its card board and/or plastic bag just before the installation.
d) Flush lines before installing the valve.
e) To avoid pressure drop and to achieve optimum parameters, Pipe / Tube / Fitting from the source of
pressure to the valve and to the connected equipment should have ID which is t NW (Orifice) of the
valve.
f) To avoid pressure drop, if more than one valve is being operated simultaneously from a common header,
then minimum ID of the header can be calculated as under.
2
ID Header = (NW un)
n = Number of Valves operating at a time and which are connected to a common header,
NW = Orifice of the Valve.
g) Incorporate filter in the line to avoid hard particles entering into the valve.
h) The valve should be installed for the media for which it is intended for. This is to avoid the malfunction of
seals and the valve. In case if you intend to use valve for media other than the one specified on that
valve, check compatibility of media to Body Seal material and grease. Consult ROTEX in case if any
doubt.
i) Do not try to drill any additional holes or machine, modify any of the valve components.
j) In case if the valve is used for dangerous fluid gas/liquid then, the user is hereby advised to maintain
during operation and maintenance of the valve below LEL or above UEL to avoid explosion due to
internal spark as the valves have not been assessed for the same.
k) Inlet pressure does not exceed rated pressure.
l) Hemp-Filaments, ’Jute’ or even Teflon-Ribbons are normally not required, as the port connections of
ROTEX Valve is accurately machined.
m) To avoid over lap of the Teflon ribbon or cuts generated while tightening, getting carried away into the
valve. Do not cover first two thread pitches with Teflon tape or sealant.
n) For Solenoid Valve to be installed in European Union, check the applicability for ATEX. Refer
separate Instruction Manual for ATEX approved Solenoid Valve.
2. Provide Dust Cap on the exhaust port or ensure that the valve is mounted such a way that dust particles / rain
water / process fluid do not enter into the valve through exhaust port of the valve. You can connect bend pipe of
ID > NW of the valve so that the exhaust port is not directly (straight) open into the atmosphere.
3. The process fluid etc. : do not fall on the valve body.
IM No. : IM/V/0015, Rev. 5
Date : 04.04.16
Page 5 of 7
4. In case if the surrounding atmosphere has traces or some other substance other than Air, check its compatibility
with the Body material of the valve , Solenoid enclosure & other exposed parts.
5. In case if the valve is installed in potentially Hazardous area, check for the temperature class of the Solenoid to
avoid explosion due to heated Solenoid / other components.
6. Provide fuse of proper rating to avoid excess current passing through the Solenoid and thereby avoiding
over heating.
7. It is not likely however, the user is advised to protect the valve against lightening as the same is not assessed.
8. Check internal components (wetted) parts for its compatibility with fluid passing through the valve.
9. It is recommended to replace all the Rubber Parts including Plunger Assembly (Repair Kit – Code 99) in
case if the valve is to be installed and put in service after 2 years from the date of manufacture.
ELECTRICAL
1. Verify name plate affixed on the Solenoid.
2. For AC Voltage (50Hz or 60Hz), select solenoid with option “FR”.
3. Connect the power supply according to the voltage rating of the Solenoid
4. Ensure that the cover of Junction Box/Terminal Box is properly tightened wherever applicable.
5. Install valve in such a way that the rain water / other process fluid dripping along the cable does not fall on the
SOV and has no possibility to run along the cable and enter into the Terminal area.
6. Fill in the space between cable and gland entry with a proper sealant. If necessary, you may mount the valve
upside down or in any other direction.
7. Ensure that the Solenoid enclosure meets process and local authority requirement.
8. The Plug In, Terminal Box, FPJB, IS Solenoids are provided with test leads. Remove them before final
installation.
9. Check for proper connections for the Solenoid which are polarity sensitive e.g. (a) Latched Solenoid.
10. Refer separate manual for construction of the Solenoid and for specific instructions related to Solenoid
e.g. (a) Latched Solenoid (b) EExd Solenoid IP 67, IP 54
11. Ensure that the solenoid construction is selected properly meeting the environment in which the valve is supposed
to be installed e.g. use of Exd solenoid for valve to be installed in hazardous location or Weatherproof Solenoid
having IP 67 for outdoor installation.
12. Flying Lead Solenoid is not recommended to be used for outdoor or indoor application where water/liquid
splashing or high humidity is present.
13. Intrinsically Safe Solenoid can not be supplied with the Valve.
MANUAL OVERRIDE OPERATION – OPTIONALLY PROVIDED
(A) PUSH & TURN TYPE (M6)

When the solenoid is de-energised (Photo-1) and inlet and outlet ports connected to the applying rated pressure,
the valve can be operated either pressing the Manual Override, when the same is released, the valve returns back
to the normal position. The valve can also be locked in energized (Photo-2) position by pushing the Manual
Override and rotating clockwise. To avoid Manual Override returning back to normal condition, ensure that the
same is turned above 90º. The valve can be brought to normal condition by turning Manual Override anti
clockwise.
(B) PUSH TYPE (M8)

When the solenoid is de-energised, inlet and outlet ports connection and rated pressure applied, the valve can be
brought to energized position by pressing Manual Override / Lever. The valve remains in this position till Manual
Override / Lever is pressed. As soon as the same is released, the valve returns back to the normal position.
TESTING OF THE VALVE AT THE TEST BENCH

Check at least once in 3 years or following your routine maintenance schedule.
For Valve Model 30308, 30309, 30329, 30333, 30334, P3005, P3012R
a) Apply rated pressure at inlet port of the valve.
b) Plug outlet port.
c) Check operation of the valve and leakage at the exhaust ports and pilot vent at the rated and minimum working
pressure by applying 75% to 120% rated voltage.
d) While keeping the solenoid de-energised, check operation and leakage from exhaust and pilot vent ports of the
valve at the rated and minimum working pressure by operating Manual Override.
e) Without connecting air supply to the valve, operate Manual Override. Energise and De-energise Solenoid to
check for the plunger movement (normally movement should not be there) which can be checked by click sound.
After operating Manual Override if plunger movement is found, reduce length of the manual override by 0.3mm
from its taper end. Continue this till click sound stops.
f) Check the insulation resistance of the Solenoid by applying 500V DC at terminals and the solenoid housing. It
should be more than 100 Mega Ohms.
IM No. : IM/V/0015, Rev. 5
Date : 04.04.16
Page 6 of 7
For Valve Model 30308, 30309, 30329, 30333, 30334, P3005, P3012R
a) Apply rated pressure at inlet port of the valve.
b) Do not Plug outlet port.
c) For NC valve, without energizing the solenoid, check leakage at outlet port.
d) For NO valve after energizing the solenoid, check leakage at outlet port.
RECOMMENDED SPARES
a) Seal Kit (O Ring) (Code – 98).
b) Spare Solenoid Kit. (Code – )
c) Repair Kit (Code – 99)
SPARE ORDERING CODE

TYPE SUFFIX (a) (b) (c) (d) (e) SPARE CODE
BODY & MANUAL

ORIFICE PORT CONNECTION SEAL
INTERNAL OVERRIDE
VALVE TYPE Spare Part Description
Spare Solenoid Kit 97
Seal Kit 98
Repair Kit 99
SPECIAL TOOLS
x Guide Opening Tool : ROTEX Ref No. WN 1219 / M28 or WN1219 / M22 (ROTEX make).
RECOMMENDED MAINTENANCE PREVENTIVE

x Replacement of Complete Set of O Ring … … Once in 5 years or 2 million operations.
- Solenoid O Ring (Part 35), Guide O Ring (Part 32),
- MA O Ring (Part 22), Body O Ring (Part 20),
- Seat O Ring (Part 19), Piston O Ring (Part 18)
x Replacement of Plunger Assembly … … … Once in 5 years or 2 million operations
x Replacement of the Solenoid … … … As and when required.
x Check of Insulation Resistance, Resistance of the Solenoid… Once in a year (shouldbe > 100 MOhms @
500V DC.
x Check Resistance of the Solenoid… … … Replace Solenoid if the resistance reduces more
(Not applicable for Solenoid with IS, RC options or than 5% computed at 20ºC as compared to its
AC Solenoid with > 11 Watt power). Initial value.
MAINTENANCE – GENERAL INSTRUCTION

x The Solenoid Valve must be removed from the site and has to be maintained under safe conditions.
y All air and electrical connections must be switched off before removing valve from the line.
y It is recommended to replace complete set of O Ring even if one of the O Ring is damaged. This is to ensure
trouble free operation of the valve and will avoid its premature failure.
x Using Grease other than Silicon base Molykote M55 will lead to premature failure of O Rings of the ROTEX
Solenoid valve.
y If necessary to clean the components, do not use Kerosene, Diesel, Petrol to clean valve as this damages
the O Rings and other rubber material. Instead use light Detergent Soap Solution.
x Ensure that the components are free from dust, dirt, lint and metal burrs.
x Twisting of O Ring should be avoided. Ensure that the twist is removed before fitting matching part.
x While closing the matching part, the matching part should be pushed in a straight line. Turning motion should be
avoided.
x Pinching of O Ring at the groove corner at the time of closing gland should be avoided.
x User is requested to use safe practice for maintenance.
x It is important to place the dismantled Valve Parts on a clean paper or cloth in same sequence in which you have
dismantled them.
x Ensure to keep all the components of the valve separately to avoid their mixing up. The component appears tobe
same may have small differences which will cause malfunction if interchanged.
x In case of difficulty you should contact the Agent, Distributor or ROTEX directly.
x Using ROTEX genuine spares will Guarantee you trouble free operation and will avoid premature failure.
IM No. : IM/V/0015, Rev. 5
Date : 04.04.16
Page 7 of 7
(A) TO REPLACE SOLENOID

1) Open dome nut (Part 37) and pull out solenoid (Part 34)
2) Replace new solenoid ensuring the construction, voltage and current meets the requirements.
3) Tighten the dome nut (Part 37) applying torque of 0.2 kgm to 0.35 kgm to avoid over tightening of the
solenoid.
4) Measure and record resistance of the Solenoid.
(B) TO REPLACE GUIDE ASSEMBLY (CORE TUBE) (Part 33) / PLUNGER (Part 30), SET OF ‘O’ RING
1) Open dome nut (Part 37) and pull out solenoid (Part 34).
2) Open Guide Assembly (Core Tube) (Part 33) using guide opening tool / spanner.
3) Pull out Plunger Assembly (30) alongwith Sleeve (Parts 101 & 07).
4) Insert a small pin in the hole of magnet holder (Part ) and second pin in the Plunger (Part 30).
5) Open the same by rotating anti clockwise. Remove old ‘O’ Rings and clean metallic parts.
6) Replace all the ‘O’ Rings like Plunger O Ring(Part 80), Seat O Ring (Part 19) and reassemble magnet
holder I (Part 107) into the Plunger (Part 30) using small amount of Locktite 242 on the thread of magnet
holder (Part 107).
7) Reassemble Sleeve (Part 07) alongwith Sleeve O Ring (Part 105) and insert assembly in the body.
8) Fix the Guide Assembly (Part 33) ensuring that Guide O Ring (Part 32) and Sleeve O Ring (Part 105)
are well placed.
9) Check the valve for operation and leakage.
(C) REPLACEMENT OF MANUAL OVERRIDE (PART 8) – OPTIONALLY PROVIDED

1) Remove Grub Hex Socket Set Screw (Part 115) and pull out Manual Override (Part 8).
2) Replace new Manual Override applying light layer of Silicon Grease Molykot M55 and tighten the grub
screw fully till the Manual Override stops traveling in and out.
3) Open the Grub Hex Socket Set Screw slightly (1/4 turn) and check the smooth movement of the grub
screw.
4) Without connecting air supply to the valve, operate Manual Override. Energise and De-eneerigse
Solenoid to check for the plunger movement (normally movement should not be there) which can be
checked by click sound.
After operating Manual Override if plunger movement is found, reduce length of the manual override by
0.3mm from its tapper end. Continue this till click sound stops.
STORING,CLEANING AND MOUNTING OF ELASTOMERS : SYNTHETIC RUBBER PRODUCTS

x Store Plunger, O Ring Set in sealed polyethylene bag, kept in cool, dry, dust free area and avoid direct contact
with all light sources emitting ultra violet rays, or contact with fumes, solvents, fuels, lubricants, chemicals, acids,
disinfectants.
x Follow Maintenance General Instruction & specific procedures to replace O Ring set as listed above.
Manual Override “OFF” Manual Override “ON “ VALVE MODEL 30334

Photo – 1 Photo – 2
Contact :
ROTEX AUTOMATION LIMITED

987/11, GIDC, MAKARPURA, VADODARA – 390010, INDIA
Tel. : +91 265 2638136, 2638746, 2638795 Fax : +91 265 2638130
E-mail : rotexbrd@rotexindia.com Website : www.rotexindia.com
Humidity (non-condensing)
PIC101A CAUTION TERMINAL CONNECTIONS
95% RH
selec Process Indicator 1. When powering up for the first time, disconnect the output
Weight Connections.
200 gms (0.440 lbs) 2. Fuse Protection : The unit is normally supplied without a
power switch and fuses. Make wiring so that the fuse is
OP328-V01
Protection Level placed between the mains power supply switch and the
IP65 for faceplate controller. ( 2 pole breaker fuse- rating: 275V AC,1A for electrical
circuitry is highly recommended )
SAFETY PRECAUTIONS 3. Since this is a built-in-type equipment (finds place in main
control panel), its output terminals get connected to host
All safety related codifications, symbols and
PIC101A-T-230
equipment. Such equipment shall also comply with basic

instructions that appear in this operating manual or on the
EMI/EMC and other safety requirements like BSEN61326-1
equipment must be strictly followed to ensure the safety of the
and BSEN61010 respectively.
SPECIFICATIONS operating personnel as well as the instrument.
4. Thermal dissipation of equipment is met through
If the equipment is not handled in a manner specified by
ventilation holes provided on chassis of equipment. Such
Display the manufacturer it might impair the protection provided by the
ventilation holes shall not be obstructed else it can lead to a
4 digit, 7 segment digital display equipment. N L
safety hazard. V mA
+
+
+
5. The output terminals shall be strictly loaded to the
Keys Read complete instructions prior to installation and manufacturer specified values/range. 1 2 3 4 5 6 7 8 9 10
3 keys for digital setting operation of the unit.
INPUT SPECIFICATIONS WARNING : Risk of electric shock.

MECHANICAL INSTALLATION 21 22
For installing the Indicator
Input Type WIRING GUIDELINES Prepare the panel cutout with proper dimensions as shown 11 12 13 14 15 16 17 18 19 20
PIC101A-VI-230
For PIC101A-T-230 :
(in mm) below
Thermocouple (J,K,T,R,S), RTD (Pt100) WARNING
For PIC101A-VI-230 : Panel Cutout
Voltage: 0 - 10V DC 1. To prevent the risk of electric shock power supply to the Outline Dimensions (in mm)
(in mm)
Current : 0 - 20mA & 4- 20mA DC equipment must be kept OFF while doing the wiring Use only the correct thermocouple wire or
98mm
arrangement. Do not touch the terminals while power is compensating cable from the probe to
being supplied. instrument terminals avoiding joints in the
Sampling Time
cable if possible.
45mm
2. To eliminate electromagnetic interference use short wire
46mm
50mm
250 ms Failure to use the correct wire type will lead to
with adequate ratings; twists of the same in equal size shall
92mm
inaccurate readings.
be made. For the input and output signal lines, be sure to 3mm 76mm
Input Filter (FTC)
0.2 to 9.9 sec use shielded wires and keep them away from each other. Ensure that the input sensor connected at the
3. Cable used for connection to power source, must have 1. Prepare the panel cutout with proper dimensions as terminals and the input type set in the
a cross section of 1mm2 or greater. These wires shall have shown above. temperature controller configuration are the
Resolution 2. The equipment in its installed state must not come in
o insulation capacity made of at least 1.5kV. same.
1 / 0.1 (For PIC101A-T-230) close proximity to any heating sources, caustic vapors,
o 4. When extending the thermocouple lead wires, always
(Fix 1 resolution for R & S type TC) oils, steam, or other unwanted process by-products.
use thermocouple compensation wires for wiring. For the
Decimal point position selectable : 1/0.1/0.01/0.001 3. Use the specified size of crimp terminals (M3.5 screws) FRONT PANEL DESCRIPTION
RTD type, use a wiring material with a small lead resistance
(For PIC101A-VI-230) to wire the terminal block. Tighten the screws on the
( 5Ω max per line ) and no resistance differentials among
three wires. terminal block using the tightening torque with in the
Temperature Unit 5. A better anti-noise effect can be expected by using range of 1.2 N.m.
o selec PIC101
C / °F selectable (For PIC101A-T-230) standard power supply cable for the instrument. 4. Do not connect anything to unused terminals.
Indication Accuracy MAINTENANCE EMC GUIDELINES :

For PIC101A-T-230 : 1. The equipment should be cleaned regularly to avoid 1. Use proper input power cables with shortest
o
TC Inputs : ±0.25% of F.S. ±1 blockage of ventilating parts. connections and twisted type.
o
R & S Inputs : ±0.5% of F.S. ±2 2. Clean the equipment with a clean soft cloth . Do not use 2. Layout of connecting cables shall be away from any
(20 min of warm up time for TC Inputs) Isopropyl alcohol or any other cleaning agent. internal EMI source.
o
RTD Inputs : ±0.1% of F.S. ±1 FRONT KEYS DESCRIPTION
For PIC101A-VI-230: ±0.5% of F.S., ±1 digit INSTALLATION GUIDELINES ELECTRICAL PRECAUTIONS DURING USE
(F.S. = Full Scale) 1. This equipment, being built-in-type, normally becomes a Electrical noise generated by switching of inductive Functions Key press
part of main control panel and in such case the terminals do loads can create momentary disruption, erratic display, latch Programming Mode
Display Bias not remain accessible to the end user after installation and up, data loss or permanent damage to the instrument.
0 0 To view Configuration Press keys for 3 seconds.
-19.9 to 19.9 ( For PIC101A-T-230 ) internal wiring. Level
2. Do not allow pieces of metal, wire clippings, or fine To reduce noise :
POWER SUPPLY metallic fillings from installation to enter the product or else A) Use separate shielded wires for inputs. To view parameters on Key once to register/ view the
it may lead to a safety hazard that may in turn endanger life the same level. next function in operational menu.
Supply Voltage or cause electrical shock to the operator.
3. Circuit breaker or mains switch must be installed between To set parameter ranges. Key to scroll through the function
230V AC ± 20%, 50/60 Hz
ranges (ranging 0 to 9)
power source and supply terminals to facilitate power 'ON'
Power Consumption or ‘OFF’ function. However this switch or breaker must be To select digit Key to select digit from MSD to
5VA max @230V AC installed in a convenient position normally accessible to the LSD
operator.
4. Use and store the temperature controller within the NOTE: The unit will auto exit programming mode after 30
Temperature seconds of inactivity.
Operating : 0 to 50°C (32 to 122oF) specified ambient temperature and humidity ranges as
OR By pressing the keys for 3 seconds.
Storage : -20 to 75°C (-4 to 167oF) mentioned in this manual.
Doc. name: Operating-1108/PIC101A/ OP328-V01(Page 1 of 2)
CONFIGURATION INSTRUCTIONS INPUT RANGES ( Table 1)
FOR RTD
Press once to scroll parameter ranges Press for 3 sec to enter Configuration menu (from online) Press to shift the digit Input Ranges
Resolution 1/0.1°
Press to set parameter value & move to next parameter Press for 3 sec. to exit the Configuration menu °C -150 to 850
Pt100
KEY FUNCTIONS
°F -238 to 1562
OPERATIONAL MENU FOR THERMOCOUPLE

Input Ranges
POWER ON Resolution 1/0.1°
°C -199 to 750
selec PIC101 J
°F -328 to 1382
°C -199 to 1350
K
°F -328 to 2462
°C -199 to 400
PIC101A-T PIC101A-VI T
°F -328 to 750
Display Description Default Range Display Display Description Default Range Display °C 0 to 1750
(for 1 sec.) Value Condition (for 1sec.) Value Condition R&S
°F 32 to 3182
For PSWD Factory Set = 0085
For PSWD
Lock code Factory Set = 0085 Lock code
= LOCK = LOCK
ERROR DISPLAY ( Table 2 )
Input type 0-20 mA / 4-20 mA
J/K/T/R/S/RTD Input type mA When an error has occured, the display indicates
(Refer Table 1) 0-10 V error codes as given below.
Not prompted Decimal point Meaning
Display Resolution 1/0.1 1/0.1/0.01/0.001 Error
for R & S type selectable
Sensor break / over range
Display scaling point
Temperature unit °C/°F 1 -1999 to DSCH condition
low
Sensor reverse / under
Input scaling point 0.0/4.0 mA OR range condition
Filter time constant 0.2 to 9.9 sec.
low 0V to ISCH
1 Display scaling point
Display Bias -19.9° to 19.9° high DSCL to 9999
CALIBRATION ACCURACY DECLARATION
2 Input scaling point ISCL to 20.00mA/ Product is tested & calibrated by automatic
Password UNLK/LOCK high 10.00V technique. The calibration of this instrument is done
3 as per following accuracy :
Factory default Reverse scaling
NO / YES NO / YES
(Reset all) For PIC101A-T-230 :
TC Inputs : ±0.25% of F.S. ±1o
Filter time constant o
0.2 to 9.9 sec. R & S Inputs : ±0.5% of F.S. ±2
(20 min of warm up time for TC Inputs)
o
2 RTD Inputs : ±0.1% of F.S. ±1
Password UNLK/LOCK
For PIC101A-VI-230 : ±0.5% of F.S., ±1 digit
(F.S. = Full Scale)
Factory default3
(Reset all) NO / YES
Sources calibrated against:
Kusam-meco, model 405, Sr.No.:104446
NOTE : Initial calibration is valid for 18 months after the
1) For MSD by pressing key the values are scrolled from 0 to 9 and then ‘-’ and ‘-1’ then return to 0. Rest all the digit are scrolled Month/Year of manufacturing which is mentioned
between 0 to 9 on order code label.
2) If in configuration menu is selected as then the will prompted at power ON.
Press Key
3) To reset the parameters to factory default , select as ( Specifications are subject to change, since development is a
continuous process )
Press key again to move to next parameter
Selec Controls Pvt. Ltd.
4) For Invalid setting the parameter will prompt again with last valid setting.
Tel. No. : +91-22-40394200 / 40394202
Applicable for parameters such as , , , , & Fax No. : +91-22-28471733 I Toll free : 1800 227 353
Website: www.selec.com I Email: sales@selec.com
Doc. name: Operating-1108/PIC101A/ OP328-V01(Page 2 of 2)
TM
AIR FILTER / REGULATOR - VAYU MINIATURE
SB10 (G 8 , G ¼)
FEATURES
TM
• Shavo's VAYU Miniature Series Air Filter/Regulator combination unit

saves money, saves space.
• Aluminium Pressure Die Cast body powder - coated for longer life.
• Wide choice of Secondary Pressures and filter element.
• Also optional metal (non-transparent) bowl.
PARAMETERS SPECIFICATIONS
Pipe Threads G 1/8, 1/4 Parallel (F) - Standard
BSPTr./NPT - Optional
Body Material Aluminium Alloy die-cast
Filter Element Size 5, 25, 50 micron.
Filter Element Material Plastic (Polypropylene) - Standard
Sintered Bronze - Optional
Bowl Material Transparent Polycarbonate - Standard
Metal Zinc diecast - Optional
Maximum Inlet Pressure with PC Bowl : 150 psig (10.5 bar)
with Metal Bowl : 250 psig (17.5 bar)
Max. Operating Temp. (ambient) with PC Bowl : 50 C
0
with Metal Bowl : 80 C

0
Drain Manual - Standard

Automatic - Optional (operates only on flow change)
Regulator Type Relieving - Standard
Non-Relieving - Optional
Pressure Adjustment Non-rising plastic knob
Regulated secondary outlet Spring Range Gauge Range
Pressure (spring range) and 1-10 psi (0.07 - 0.7 bar) 0-35 psi (0 - 2.5 bar)
recommended Pressure gauge 3-30 psi (0.21 - 2.10 bar) 0-35 psi (0 - 2.5 bar)
ranges available in psi (bar) 5-50 psi (0.35 - 3.50 bar) 0-60 psi (0 - 4 bar)
10-100 psi (0.70 - 7.0 bar) 0-150 psi (0 - 10 bar)
3
Std. Nominal flow + at 145 psi inlet pressure 1/8" - 10.5 scfm (5 dm /sec)
3
and 14.5 psi drop in set sec. Value of 87 psi 1/4" - 12.6 scfm (6 dm /sec)
Gauge size 40 mm OD
Gauge Port size Rc 1/8 BSPTr.
Gauge connection Back
Mounting Bracket Optional
Panel mounting Standard - Available
+ Values indicated are with 50 micron elements, with finer elements these values will be lower.
FLOW CHARACTERISTIC OF SB10 - size 1/8"

7
SECONDARY PRESSURE (bar)
0
0 1 2 3 4 5 6 7 8
AIR FLOW (dm3/sec.)
Mumbai, India. Tel. : 022-65137434 Fax : 022-2769 6559 D001/1

1304
TM
AIR FILTER / REGULATOR - VAYU MINIATURE
SB10 (G 8 , G ¼)
(scfm)
10.5 scfm 50 10-100 psi SB10-1G-A2T-RNK-NN
(5 dm3/sec) SB10-1G-M2T-RNK-NN
12.6 scfm 50 10-100 psi SB10-2G-A2T-RNK-NN
(6 dm3/sec) SB10-2G-M2T-RNK-NN
Option Selector
Sample Model Number S B 1 0 - 2 B - M 2 T / R G K - N N
Position 0 1 2 3 4 5 6 7 8 9 10 11 12 13
0 S = Shavo
1 Product B = Filter Cum Regulator

Combination Unit
2 3 Series 10 = ''VAYU" Miniature - 1/8" Basic
1 = 1/8"
4 Size
2 = 1/4"
Main Port Gauge Port

A NPT BSPT
B BSPT BSPT 1.692 [43.0]
5 Port Thread
G BSP BSPT
1.500 [38.0]
N NPT NPT
J Japanese PT
Drain M = Manual
6
A = Automatic (Operates on Flow Change)
1 = 05 M Porous Plastic 2.171 [55.0]

2 = 25 M Porous Plastic
7 Filter Element 3 = 50 M Porous Plastic
6 = 05 M Sintered Bronze
2.846 [72.0]
Bowl T = P.C. Bowl

8
M = Metal Bowl without Sight Glass
1.096 [28.0]
R = Relieving
3.503 [89.0]
9 Relief
N = Non Relieving
10 Gauge N = No Gauge
G = With Pr. Gauge
A = 1 psi - 10 psi
C = 3 psi - 30 psi
11 Sec. Pr. Range E = 5 psi - 50 psi
K = 10 psi -100 psi
M = 15 psi - 150 psi
N = Nitrile (Std)
12 Elastomers E = EPDM
V = Viton
Mounting & N = No Mtg Bracket

13 B = Wall Bracket Fitted
Accessories
Mumbai, India. Tel. : 022-65137434 Fax : 022-2769 6559 D001/2

1304
Siemens Industry, Inc. USER'S MANUAL
UMSITRPDS3-1
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UMSITRPDS3-1 Contents
TABLE OF CONTENTS
Section and Title Page

Conventions, Symbols, and General Information................................................................. viii
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Contents UMSITRPDS3-1
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11.0 APPENDIX A - ONLINE CONFIGURATION MAP............................................. 11-1
12.0 APPENDIX B - HAZARDOUS AREA INSTALLATION ..................................... 12-1
13.0 APPENDIX C - ELEVATION AND SUPPRESSION CORRECTIONS ............... 13-1

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Online Configuration Map (with Model 275 Communicator)
Online Configuration Map (with Model 375 Communicator)
LIST OF FIGURES
Figure and Title Page

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LIST OF TABLES
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Changes for Revision 10, November 2010
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SITRANS P, Series DS III, and Procidia are trademarks of Siemens Industry, Inc. Viton and Kalrezare registered trademarks of
DuPont Performance Elastomers. Teflon is a registered trademark of E. I. du Pont de Nemours and Company. Hastelloy is a
registered trademark of Haynes International. Monel is a registered trademark of Special Metals Corporation. HART is a
registered trademark of the HART Communication Foundation. All product designations may be trademarks or product names of
Siemens Industry, Inc. or other supplier companies whose use by third parties for their own purposes could violate the rights of
the owners.
Siemens Industry, Inc. assumes no liability for errors or omissions in this document or for the application and use of information
included in this document. The information herein is subject to change without notice.
Procedures in this document have been reviewed for compliance with applicable approval agency requirements and are
considered sound practice. Neither Siemens Industry, Inc. nor these agencies are responsible for product uses not included in the
approval certification(s) or for repairs or modifications made by the user.

November 2010 vii

Conventions, Symbols, and General Information
Conventions and Symbols

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UMSITRPDS3-1 Introduction
1.0 INTRODUCTION
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1.1 CONTENTS
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November 2010 1-1

Introduction UMSITRPDS3-1

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1.2 PRODUCT DESCRIPTION
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TABLE 1-1 Measurements, Models and Figure References
Measurement Model And Measuring Cell Construction Refer To

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FIGURE 1-1 Gauge Construction, Pressure and Absolute Pressure Models
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FIGURE 1-2 Differential Construction; Differential, Flow, and Absolute Models
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FIGURE 1-3 Differential Pressure and Flow Models with H03 Option
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FIGURE 1-4 Flanged Liquid Level Models
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A. Digital Display B. Field Terminals

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1.3 RATING, APPROVAL, AND TAG PLATES
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4.3.6.2 Maximum Cable Length Calculation

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November 2010

4.3.9 Connection of Miscellaneous Hardware

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November 2010

4.3.10 Shielding and Grounding

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4.4 MECHANICAL INSTALLATION
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FIGURE 4-13 Differential Construction, Position Options
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November 2010

TABLE 4-2 Flange And Extension Dimensions
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November 2010

4.5 MECHANICAL INSTALLATION, All Models
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November 2010

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November 2010

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IMPORTANT
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WKHWUDQVPLWWHUWRUHPDLQSDUNHGDWDIL[HG
FXUUHQW
November 2010

5.5 TRANSMITTER ZERO AND SHUTOFF VALVE MANIPULATION
7KLVVHFWLRQGHVFULEHVVHWWLQJWUDQVPLWWHU]HURDQGDGMXVWLQJVKXWRIIYDOYHVIRUXVHZLWKOLYHSURFHVV
SUHVVXUHV7KHIROORZLQJFRPPLVVLRQLQJFDVHVDUHW\SLFDOH[DPSOHV'LIIHUHQWDUUDQJHPHQWVPD\EH
DGYLVDEOHGHSHQGLQJRQWKHV\VWHPFRQILJXUDWLRQ
WARNING
,PSURSHURSHUDWLRQRIWKHYDOYHVFDQUHVXOWLQVHULRXVLQMXU\RUFRQVLGHUDEOH
PDWHULDOGDPDJH

5HDGDQGXQGHUVWDQGWKHFRPSOHWHSURFHGXUHEHIRUHVWDUWLQJDSRVWLQVWDOODWLRQ
WHVW
5.5.1 Absolute Pressure

$EVROXWHSUHVVXUHWUDQVPLWWHUVZLWKJDXJHFRQVWUXFWLRQRUZLWKGLIIHUHQWLDOFRQVWUXFWLRQFDQEH
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WARNING

3URFHVVPDWHULDOFDQEHKD]DUGRXVWRSHRSOHDQGKDUPIXOWRHTXLSPHQW

November 2010

5.5.1.1 Measuring Gases

2SHUDWHWKHVKXWRIIILWWLQJVDVGHVFULEHGEHORZ5HIHUWR)LJXUHWRLGHQWLI\WKHYDOYHEHLQJ
PDQLSXODWHG
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2SHQWKHVKXWRIIYDOYHRQWKHSUHVVXUHWDS
2SHQSURFHVVVKXWRIIYDOYH$

7UDQVPLWWHUaboveWKHSUHVVXUHWDSSLQJSRLQW 7UDQVPLWWHUbelowWKHSUHVVXUHWDSSLQJSRLQW
QRUPDODUUDQJHPHQW H[FHSWLRQ

7UDQVPLWWHU 6KXWRIIYDOYH
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$6KXWRIIYDOYHWRWKHSURFHVV &RQGHQVDWLRQYHVVHORSWLRQDO
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FIGURE 5-2 Measuring Gases
November 2010

5.5.1.2 Measuring Vapor and Liquid

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SURFHGXUH
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$SSO\WRWKHWUDQVPLWWHUWKURXJKWKHWHVWFRQQHFWLRQVKXWRIIILWWLQJDSUHVVXUHFRUUHVSRQGLQJWR
]HUR
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7UDQVPLWWHU
6KXWRIIILWWLQJ
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FIGURE 5-3 Measuring Vapor and Liquid
November 2010

5.5.2 Differential Pressure and Flow

'LIIHUHQWLDOSUHVVXUHDQGIORZWUDQVPLWWHUVFDQEHFRPPLVVLRQHGXVLQJWKHIROORZLQJPHWKRGV
WARNING
3URFHVVPDWHULDOFDQEHKD]DUGRXVWRSHRSOHDQGKDUPIXOWRHTXLSPHQW6HULRXV
LQMXU\RUFRQVLGHUDEOHPDWHULDOGDPDJHPD\UHVXOWLI
x 7KHYHQWYDOYHDQGRUWKHVHDOLQJVFUHZDUHPLVVLQJRUDUHQRWVXIILFLHQWO\
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,QWKHFDVHRIKRWSURFHVVOLTXLGRUJDVWKHLQGLYLGXDORSHUDWLQJVWHSVPXVWEH
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RYHUKHDWHGOHDGLQJWRGDPDJH
5.5.2.1 Measuring Gases

SURFHGXUH
&ORVHDOOYDOYHV
2SHQERWKVKXWRIIYDOYHVDWWKHSUHVVXUHWDSV
2SHQWKHFRPSHQVDWLRQYDOYH
2SHQRQHDFWLYHSUHVVXUHYDOYH$RU%
&KHFNDQGFRUUHFW]HURP$LIQHFHVVDU\DW]HURPEDU
&ORVHWKHFRPSHQVDWLRQYDOYH
2SHQWKHRWKHUDFWLYHSUHVVXUHYDOYH$RU%
November 2010


7UDQVPLWWHUaboveWKHDFWLYHSUHVVXUHWDSVQRUPDO 7UDQVPLWWHUbelowWKHDFWLYHSUHVVXUHWDSV
DUUDQJHPHQW H[FHSWLRQ

7UDQVPLWWHU %ORZRXWYDOYH
&RPSHQVDWLRQYDOYH &RQGHQVDWLRQYHVVHOVRSWLRQDO
$FWLYHSUHVVXUHYDOYHV $FWLYHSUHVVXUHWDSV
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6KXWRIIYDOYHV

FIGURE 5-4 Measuring Gases
5.5.2.2 Measuring Liquids

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&ORVHDOOYDOYHV
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x ³7UDQVPLWWHUbelowWKHDFWLYHSUHVVXUHWDS´2SHQERWKEORZRXWYDOYHVRQHDIWHUWKHRWKHU
x ³7UDQVPLWWHUaboveWKHDFWLYHSUHVVXUHWDS´2SHQERWKYHQWYDOYHVVOLJKWO\XQWLODLUIUHH
OLTXLGHPHUJHV
&ORVHERWKEORZRXWYDOYHVRUYHQWYDOYHV
2SHQWKHDFWLYHSUHVVXUHYDOYH$DQGWKHYHQWYDOYHDWWKHKLJKSUHVVXUHFKDPEHURIWKH
WUDQVPLWWHUVOLJKWO\XQWLODLUIUHHOLTXLGHPHUJHV
&ORVHWKHYHQWYDOYH
2SHQWKHYHQWYDOYHDWWKHORZSUHVVXUHFKDPEHURIWKHWUDQVPLWWHUVOLJKWO\XQWLODLUIUHHOLTXLG
HPHUJHV
November 2010

&ORVHWKHDFWLYHSUHVVXUHYDOYH
2SHQWKHDFWLYHSUHVVXUHYDOYH%VOLJKWO\XQWLODLUIUHHOLTXLGHPHUJHVWKHQFORVHLW
&ORVHWKHYHQWYDOYHDWWKHORZSUHVVXUHFKDPEHU
2SHQWKHDFWLYHSUHVVXUHYDOYH$E\WXUQ
&KHFNDQGFRUUHFW]HURP$LIQHFHVVDU\DW]HUREDU
2SHQWKHDFWLYHSUHVVXUHYDOYHV$DQG%IXOO\

7UDQVPLWWHUaboveWKHDFWLYHSUHVVXUHWDSVQRUPDO 7UDQVPLWWHUbelowWKHDFWLYHSUHVVXUHWDSV
DUUDQJHPHQW H[FHSWLRQ

7UDQVPLWWHU 6KXWRIIYDOYHV
&RPSHQVDWLRQYDOYH %ORZRXWYDOYHV
$FWLYHSUHVVXUHYDOYHV $FWLYHSUHVVXUHWDSV
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FIGURE 5-5 Measuring Liquids
November 2010

5.5.3 Measuring Vapor

SURFHGXUH
Caution
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,IWKHFRPSHQVDWLRQYDOYHLVRSHQHGZKHQWKHVKXWRIIYDOYHVDQGDFWLYH

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YDSRUV

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FRQGHQVHG
2SHQWKHDFWLYHSUHVVXUHYDOYH$DQGWKHYHQWYDOYHDWWKHKLJKSUHVVXUHFKDPEHURIWKH
WUDQVPLWWHUVOLJKWO\XQWLODLUIUHHFRQGHQVDWHHPHUJHV
&ORVHWKHYHQWYDOYH
2SHQWKHYHQWYDOYHDWWKHORZSUHVVXUHFKDPEHURIWKHWUDQVPLWWHUVOLJKWO\XQWLODLUIUHH
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FIGURE 5-6 Measuring Vapor
2SHQWKHDFWLYHSUHVVXUHYDOYH%VOLJKWO\XQWLODLUIUHHFRQGHQVDWHHPHUJHVWKHQFORVHLW

&ORVHWKHYHQWYDOYHDWWKHORZSUHVVXUHFKDPEHU
2SHQWKHDFWLYHSUHVVXUHYDOYH$E\WXUQ
November 2010

&KHFNDQGFRUUHFW]HURP$LIQHFHVVDU\DW]HUREDU

2SHQWKHDFWLYHSUHVVXUHYDOYHV$DQG%IXOO\

7KLVFRPSOHWHVWKHSRVWLQVWDOODWLRQWHVWLQJ'LVFRQQHFWWHVWHTXLSPHQWFRQQHFWDQ\GLVFRQQHFWHGZLUHV
DQGUHVWRUHDQ\UHPRYHGSURWHFWLYHFRYHUVRQWKHWUDQVPLWWHURURWKHUGHYLFHV

November 2010

UMSITRPDS3-1 On-Line Operation
6.0 ON-LINE CONFIGURATION AND OPERATION
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WUDQVPLWWHURSHUDWLRQDQGFDQQRWEHDOWHUHG2WKHUGDWDLVXVHGE\WKHWUDQVPLWWHUWRUHVSRQGWRFKDQJHVLQ
SUHVVXUHZLWKDFKDQJHLQRXWSXWFXUUHQWRU+$57GLJLWDORXWSXWDQGLVDOWHUDEOHE\WKHXVHU7KLVGDWD
LQFOXGHVFRQILJXUDWLRQSDUDPHWHUVWKDWVHWXSWKHWUDQVPLWWHUIRUXVHLQDVSHFLILFSURFHVVHQYLURQPHQW

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6.1 LOCAL OPERATION AND DISPLAY

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PDJQHWLFSXVKEXWWRQVDUHXQGHUWKHKLQJHGFRYHU

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0 0RGH6HOHFW
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6.1.1 Digital Display
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FXUUHQWVHH)LJXUH7KHURRWVLJQDSSHDUVZKHQDVTXDUHURRWFKDUDFWHULVWLFLVXVHGIRUGLIIHUHQWLDO
SUHVVXUHRUIORZ+$57FRPPXQLFDWLRQVLVLQGLFDWHGE\IODVKLQJRIWKHFRPPXQLFDWLRQLQGLFDWRU

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+$57FRPPXQLFDWLRQLQGLFDWRU

FIGURE 6-1 Digital Display
November 2010

On-Line Operation UMSITRPDS3-1
6.1.2 Numeric Display

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x 7UDQVPLWWHUFXUUHQWRXWSXWP$RUVHOHFWLRQVKRZQLQWKHXQLWEDUJUDSKGLVSOD\
x 3UHVVXUHYDOXHLQSHUFHQWUHODWLYHWRWKHVHWUDQJH
x 0HDVXUHGYDOXHLQDVHOHFWDEOHHQJLQHHULQJXQLWVKRZQRQWKHXQLWEDUJUDSKGLVSOD\
Sign for the Measured Value

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Status Arrows

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TABLE 6-1 Operating Mode and Status Arrows
Operating Mode1 Status Ï (Display) Status Ð (Display)

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0RGHVHWIXOOVFDOH 8SSHUFXUUHQWOLPLWH[FHHGHG /RZHUFXUUHQWOLPLWH[FHHGHG
0RGHVHWGDPSLQJ 8SSHUGDPSLQJYDOXHH[FHHGHG /RZHUGDPSLQJYDOXHH[FHHGHG
0RGHVHW]HUREOLQG 8SSHUVHQVRUOLPLWH[FHHGHG /RZHUVHQVRUOLPLWH[FHHGHG
0RGHVHWIXOOVFDOHEOLQG 8SSHUVHQVRUOLPLWH[FHHGHG /RZHUVHQVRUOLPLWH[FHHGHG
0RGHVHW]HURSRVLWLRQ 0D[LPXPVSDQH[FHHGHGE\PRUH
FRUUHFWLRQ WKDQ
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0RGHRU VSDQ PLQLPXPVSDQ
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VHQVRUOLPLW VHQVRUOLPLW

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SPLQ PLQLPXPRSHUDWLQJLQSXWSUHVVXUHSPD[ PD[LPXPRSHUDWLQJLQSXWSUHVVXUH

Communication Indicator

{ +$57FRPPXQLFDWLRQLVDFWLYHZKHQWKHFLUFOHLVIODVKLQJ
November 2010

6.1.3 Unit/Bargraph Display

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EHORZ,WVKRZVWKHVHOHFWHGHQJLQHHULQJXQLWDVDSHUFHQWDJHHQJLQHHULQJXQLWRUFXUUHQWYDOXH,I
GHVLUHGDEDUJUDSKZKLFKUHSUHVHQWVWKHSHUFHQWDJHSUHVVXUHYDOXHLQWKHUDQJHIURPFDQ
DOWHUQDWHZLWKWKHHQJLQHHULQJXQLW7KHEDUJUDSKIXQFWLRQLVWXUQHGRIILQWKHGHIDXOWVHWWLQJ

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6.1.4 Error Message

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6.1.5 Output Signal Range

7KHRXWSXWVLJQDOLVGLYLGHGLQWRGHILQHGDUHDV

7KHWUDQVPLWWHUFRQYHUWVWKHPHDVXUHGSUHVVXUHLQWRDQRXWSXWFXUUHQWWKDWLV
QRUPDOO\LQWKHUDQJHRIP$

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PHVVDJHIRUWKHVHOHFWHGXQLWDSSHDUVDOWHUQDWHO\LQSODFHRIWKHHQJLQHHULQJXQLWRUEDUJUDSK7KH
RYHUIORZUDQJHVKRZQLQWKHIROORZLQJILJXUHFDQEHVHWXVLQJWKH+$57&RPPXQLFDWRU:KHQDQ
XSSHURUORZHUUDQJHOLPLWLVH[FHHGHGWKHRXWSXWFXUUHQWUHPDLQVOLQHDUDQGDVWDWXVDUURZDSSHDUVRQWKH
WUDQVPLWWHUGLVSOD\VHH7DEOH

November 2010


/LQHDUPRGXODWLRQUDQJH
/RZHUOLPLWRIWKHPRGXODWLRQUDQJHGHIDXOWYDOXH
8SSHUOLPLWRIWKHPRGXODWLRQUDQJHGHIDXOWYDOXH
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8SSHUIDXOWFXUUHQWYDOXHGHIDXOWYDOXH
5HFRPPHQGHGVHWWLQJUDQJHIRUORZHUIDXOWFXUUHQWUDQJHDQGORZHUPRGXODWLRQUDQJHOLPLW
5HFRPPHQGHGVHWWLQJUDQJHIRUXSSHUIDXOWFXUUHQWUDQJHDQGXSSHUPRGXODWLRQUDQJHOLPLW
6.1.6 Mode Display

$QRSHUDWLQJPRGHLVVHOHFWHGE\SUHVVLQJWKH0SXVKEXWWRQ7KHVHOHFWHG
PRGHLVVKRZQLQWKHORZHUOHIWTXDGUDQWRIWKHGLJLWDOGLVSOD\,QWKH
H[DPSOHDWULJKWPRGH(OHFWULF'DPSLQJKDVEHHQVHOHFWHGDQGD
GDPSLQJYDOXHRIKDVEHHQVHW

November 2010

6.2 LOCAL OPERATION WITH THE MAGNETIC PUSHBUTTONS
7KHWUDQVPLWWHUFDQEHFRQILJXUHGORFDOO\XVLQJWKHPDJQHWLFSXVKEXWWRQVVKRZQEHORZ7DEOHVKRZV
WKHRSHUDWLQJPRGHVDQGFRQILJXUDWLRQSDUDPHWHUVDFFHVVHGE\SUHVVLQJWKH0SXVKEXWWRQ7KHVH
FRQILJXUDWLRQSDUDPHWHUVDUHDOVRDYDLODEOHXVLQJWKH+$57&RPPXQLFDWRU

Note
$VHOHFWHGPRGHZLOOWLPHRXWDIWHUDERXWPLQXWHVRISXVKEXWWRQLQDFWLYLW\DQG
WKHGLVSOD\HGSDUDPHWHUYDOXHZLOOEHVWRUHG
$SROOLQJDGGUHVVRI]HURPXVWEHVWRUHGIRUWKHPDJQHWLFSXVKEXWWRQVWR
IXQFWLRQ7KHPDJQHWLFSXVKEXWWRQVZLOOEHGLVDEOHGLIDSROOLQJDGGUHVVRI
KDVEHHQVWRUHGDVLQGLFDWHGE\D&LQWKHORZHUOHIWTXDGUDQWRIWKHGLVSOD\

November 2010

TABLE 6-2 Parameters Accessible Using the Magnetic Pushbuttons
Configuration Mode Increase/Decrease Pushbuttons (Keys) Description See

Parameter 0 Ï,QFUHDVH Ð'HFUHDVH ÏDQGÐ Section
0HDVXUHGYDOXH 2XWSXWFXUUHQWLQP$RU
RULQSXWSUHVVXUHLQ
VHOHFWHGHQJLQHHULQJXQLWV
(UURUGLVSOD\ (UURU
=HUR ,QFUHDVHFXUUHQW 'HFUHDVHFXUUHQW 6HWWRP$ 2XWSXWFXUUHQWLQP$
)XOOVFDOH ,QFUHDVHFXUUHQW 'HFUHDVHFXUUHQW 6HWWRP$ 2XWSXWFXUUHQWLQP$
(OHFWULFGDPSLQJ ,QFUHDVHGDPSLQJ 'HFUHDVHGDPSLQJ 5DQJHWRVHFRQGV
=HUR³EOLQG ,QFUHDVHSUHVVXUH 'HFUHDVHSUHVVXUH 6HWWRVWDUWRI =HURLQWKHVHOHFWHG
VHWWLQJ´ VFDOH HQJLQHHULQJXQLW
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VHWWLQJ´ PHDVXULQJOLPLW HQJLQHHULQJXQLW
=HURIRUSRVLWLRQ 3UHVVERWK 5H]HURZKHQRULHQWHG
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6.2.1 Cancel Pushbutton Disable and Write Protection

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6.2.2 Set/Adjust Zero and Full Scale

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6.2.2.1 Theoretical Relationships

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November 2010


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November 2010


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6.2.2.2 Practical Applications

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November 2010

Adjust Zero and Full Scale

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WARNING

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6.2.3 Electric Damping

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6.2.4 Blind Setting of Zero and Full Scale

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6.2.4.1 Theoretical Relationships

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November 2010


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November 2010

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IMPORTANT
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6.2.5.1 Zero-Point Alignment at Absolute Pressure

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6.2.6 Fixed Current Output

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November 2010

6.2.8 Pushbutton and Function Disable

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TABLE 6-3 Pushbutton and Function Disable Options
Symbol Explanation
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Note
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6.2.9 Flow Measurement (Differential Pressure only)

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November 2010

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Note
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FIGURE 6-2 Switch Point of the Square Root Characteristic
November 2010

6.2.10 Select Measured Value to Display

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6.2.11 Select the Displayed Input Pressure Engineering Unit

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November 2010


bar
mbar
mm water column(20°C/68°F)
Inch water column (20°C/68°F)
Feet water column (20°C/68°F)
mm mercury column
Inch mercury column
psi
Pa
KPa
MPa
g/cm2
kg/cm2 0*D
Torr
ATM
Inch water column (4°C/39°F)
mm water column (4°C/39°F)
Calculated and displayed according to the dimension

set with HART.

FIGURE 6-3 Displayable Engineering Units
November 2010

6.3 LOCAL OPERATION WITHOUT A DISPLAY OR WITH ACTIVATED KEYLOCK
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6.3.1 Set Zero and Full Scale

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November 2010

To set zero and full scale:

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WARNING

VDIHFLUFXLWV

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6HWWKHRXWSXWFXUUHQWE\SUHVVLQJHLWKHUDUURZSXVKEXWWRQ7KHVHWYDOXHLVVDYHGZKHQWKH
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November 2010

6.4 REMOTE CONFIGURATION AND OPERATION BY HART
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6.4.1 Process Data

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November 2010

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6.4.2 Setting Zero and Full Scale

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6.4.3 Blind Setting of Zero and Full Scale

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6.4.4 Zero Adjustment for Position Correction

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IMPORTANT
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]HURWREHVHW
Note
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November 2010

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x 9HQWLODWHIRUSUHVVXUHGLIIHUHQWLDOSUHVVXUHIORZDQGIODQJHGOHYHOWUDQVPLWWHUV
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6.4.5 Electric Damping

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6.4.6 Fast Measured Value Acquisition (fast response mode)

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7KHUHLVDQLQFUHDVHLQORZIUHTXHQF\QRLVHLQWKHPHDVXUHGYDOXH)RUEHVWDFFXUDF\FRQILJXUHWKH
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November 2010

6.4.7 Fixed Current Output

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To enable fixed current operation:
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,QWKH'LDJQRVWLFV6HUYLFHPHQXSUHVV6LPXODWLRQ
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To discontinue fixed current operation:
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6.4.8 Fault Current

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November 2010

6.4.9 Disabling the Transmitter Magnetic Pushbuttons and Write Protection

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TABLE 6-4 Pushbutton and Function Disable Options
Symbol Explanation
QRV\PERO 1RGLVDEOH
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// ,QSXWSXVKEXWWRQVIXOO\GLVDEOHG7KHGLVDEOHFDQEHUHOHDVHGRQO\YLD+$57

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To select a disable option or to disable a previous selection:
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,QWKH'LDJ6HUYLFHPHQXSUHVV&RQWURO0RGHV
,QWKH&RQWURO0RGHVPHQXSUHVV/RFDO.H\V&RQWURO0RGH7KHIROORZLQJRSWLRQVDSSHDU
x (QDEOHGWUDQVPLWWHUPDJQHWLFSXVKEXWWRQVLVIXOO\HQDEOHG
x 'LVDEOHGORFDOUHVHW/$
x =HURRQO\HQDEOHG/2
x =HURDQG6SDQHQDEOHG/6
x 'LVDEOHG+$57//
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To select write protection:
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,QWKH'LDJ6HUYLFHPHQXSUHVV&RQWURO0RGHV
,QWKH&RQWURO0RGHVPHQXSUHVV6HW:ULWH3URWHFW
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WKHSUHYLRXVPHQX3UHVV$%257WRUHWXUQWRWKHSUHYLRXVPHQXZLWKRXWVDYLQJDQ\FKDQJHV
November 2010

6.4.10 Measured Value Display

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6.4.11 Select Pressure Engineering Units

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6.4.12 Display/Bargraph
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November 2010

6.4.13 Sensor Trim

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FORVHWRWKHUDQJHRISURFHVVSUHVVXUHYDOXHV7KHDGMXVWPHQWSRLQWVDUHIUHHO\VHOHFWDEOHZLWKLQWKH
VHQVRU¶VQRPLQDOUDQJH

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WXUQHGGRZQDWWKHIDFWRU\DUHDGMXVWHGDWWKHORZHUDQGXSSHUOLPLWVRIWKHVHWPHDVXULQJUDQJH

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x $SVLWUDQVPLWWHULVWXUQHGGRZQWRWRSVL7RDFKLHYHWKHJUHDWHVWSRVVLEOHDFFXUDF\
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Note
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6.4.13.1 Trimming the Lower Sensor Adjustment Point

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6.4.13.2 Trimming the Upper Sensor Adjustment Point

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November 2010

6.4.14 D/A Trim

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6.4.15 Transmitter Current Adjustment

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6.4.17 Device Information

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6.4.18 Flow Measurement (Differential Pressure)

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6.4.19 Diagnostic Functions

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6.4.19.2 Calibration Timer and Service Timer

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November 2010

6.4.19.3 Min/Max Pointer

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FIGURE 6-5 Pressure Min/Max Pointer Example
6.4.19.4 Monitoring the Saturation Current

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FIGURE 6-6 Saturation Monitoring Examples
6.4.20 Simulation
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FIGURE 6-7 Simulation Circuit Diagram
6.4.21 Self Test and Master Reset

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November 2010

UMSITRPDS3-1 Calibration And Maintenance
7.0 CALIBRATION AND MAINTENANCE
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WARNING


Tools and Equipment Required

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November 2010

Calibration and Maintenance UMSITRPSD3-1
7.1 CALIBRATION
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November 2010

Calibration Procedure Section References

Calibration Needed Local (Pushbutton) HART Communicator
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7.2.1 Transmitter Exterior Inspection

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7.2.2 Transmitter Exterior Cleaning

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November 2010

7.2.3 Transmitter Enclosure Interior Inspection

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WARNING


IMPORTANT
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7.2.4 Transmitter Calibration

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7.2.5 Impulse Piping

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November 2010

7.3 TROUBLESHOOTING
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General transmitter troubleshooting steps:
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7.3.1 Analog Output

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November 2010

Transmitter Troubleshooting Steps

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November 2010

Check Impulse Piping

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Check Loop Power Supply/Wiring

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Check Transmitter Configuration

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Check for a Transmitter Stuck in Fixed Current (Loop Override) Mode

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Check for Variable Process Fluid Flow

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Check Primary Element
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November 2010

7.3.2 Digital Output (Communication)

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7.4 ASSEMBLY REMOVAL AND REPLACEMENT
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Device Parameters After Replacing Electronics Module or Measuring Cell
Parameter Description Stored Not Stored Configuration

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November 2010

7.4.1 Display Assembly

Removal
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November 2010

7.4.2 Replacing the Electronics Module

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FIGURE 7-3 Electronics Module Removal and Installation
November 2010

Installation
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November 2010

7.4.4 Terminal Board Assembly Removal and Replacement

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7.6 TRANSMITTER REPLACEMENT
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UMSITRAPDS3-1 Circuit Description
8.0 CIRCUIT DESCRIPTION
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Circuit Description UMSITRPDS3-1
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8.3 DIFFERENTIAL PRESSURE AND FLOW
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Circuit Description UMSITRPDS3-1

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UMSITRAPDS3-1 Model Designations and Specifications
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FIGURE 9-4 Models 7MF4433 and 7MF4533, Dimensions, With H03 Option
November 2010


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November 2010

Additional Model 7MF4433 Selections and Data* Order code
6WHHO A01
6WDLQOHVVVWHHO A02
3URFHVVIODQJH2ULQJLQVWHDGRI)309LWRQRI
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1%5%XQD1 A23
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6HWWLQJRISUHVVXUHLQGLFDWRULQQRQSUHVVXUHXQLWVVSHFLI\LQSODLQWH[WOPLQPKP86JSP Y22+Y01 or Y02

November 2010


Differential pressure and flow transmitter, two-wire, series DSIII, Model 7MF4533- -
6LOLFRQRLO 6WDQGDUG 1
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November 2010

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6WDLQOHVVVWHHO A02
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6HWWLQJRISUHVVXUHLQGLFDWLRQLQQRQSUHVVXUHXQLWVVSHFLI\LQSODLQWH[WOPLQPKP86JSP Y22+Y01 or Y02
November 2010

TABLE 9-9 Models 7MF4433 and 7MF4533, Specifications
Input
0HDVXUHGYDULDEOH 'LIIHUHQWLDOSUHVVXUHDQGIORZ
6SDQLQILQLWHO\DGMXVWDEOH 6SDQ 0D[SHUPLVVLEOHWH[WSUHVVXUH
WRPEDUWRLQ+2 EDUDSVL
WRPEDUWRLQ+2 EDUDSVL
WRPEDUWRLQ+2
WRPEDUWRLQ+2
WRPEDUWRLQ+2
WRPEDUWRLQ+2
WREDUWRSVL
WRPEDUWRLQ+2 EDUSVL
WRPEDUWRLQ+2
WRPEDUWRLQ+2
WRPEDUWRLQ+2
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/RZHUPHDVXULQJOLPLW
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November 2010
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November 2010

9.5 MODELS 7MF4633 AND 7MF4812, LEVEL
VSHFLILFDWLRQV

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FIGURE 9-5 Models 7MF4633 and 7MF4812, Dimensions

November 2010
TABLE 9-10 Models 7MF4633 and 7MF4812, Model Designation

Flanged level transmitter, two-wire, series DSIII, 7MF4633- Y -

6SDQ
WRPEDU WRSVL D
WRPEDU WRSVL E
WRPEDU WRSVL F
WREDU WRSVL
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November 2010


Additional Model 7MF4633 (7MF4812) Selections and Data* Order Code
2ULQJVIRUSURFHVVIODQJHVRQORZSUHVVXUHVLGHLQVWHDGRI)309LWRQ
37)(7HIORQ A20
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1%5%XQD1 A23
6HDOLQJVFUHZV137ZLWKYDOYHLQPDWHULDORISURFHVVIODQJHV A40
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6HWWLQJRISUHVVXUHLQGLFDWRULQSUHVVXUHXQLWVVSHFLI\LQSODLQWH[WPEDUEDUN3D03D Y21
6HWWLQJRISUHVVXUHLQGLFDWRULQQRQSUHVVXUHXQLWVVSHFLI\LQSODLQWH[WOPLQPKP86JSP Y22+Y01

November 2010

Flanged Level Transmitter Accessories
Mounting flange, mounted directly on transmitter, two-wire, 7MF4812-
0RXQWLQJ)ODQJH

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$GG=WRWKHRUGHUQXPEHUDQGDGG2UGHU&RGHV Order Code
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$FFHSWDQFHWHVWFHUWLILFDWHDFFRUGLQJWR(1 C12
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&DOFXODWLRQRIVSDQRIDVVRFLDWHGWUDQVPLWWHUHQFORVHFRPSOHWHGTXHVWLRQQDLUH Y05

November 2010

TABLE 9-11 Models 7MF4633 and 7MF4812, Specifications
Input
0HDVXUHGYDULDEOH /HYHO
WRPEDUJWRSVLJ 6HH0RXQWLQJ)ODQJH
/RZHUPHDVXULQJOLPLW
0HDVXULQJFHOOVLOLFRQHRLOILOOLQJ RIVSDQRUPEDUSVLDGHSHQGLQJRQPRXQWLQJIODQJH
Output
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PEDUSVLPHDVXULQJFHOO ULQVWHDGRIZLWKU
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3URFHVVWHPSHUDWXUH Note:$OZD\VWDNHLQWRDFFRXQWDVVLJQPHQWRIPD[SHUPLVVLEOHZRUNLQJ
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November 2010

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7R(1SUHVVXUHWUDQVPLWWHUZLWK WRNJWROE
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November 2010

9.6 SERVICE PARTS, ALL MODELS
7DEOHVWKURXJKOLVWWKHPHDVXULQJFHOOVDQGFLUFXLWERDUGVDYDLODEOHIRUVHUYLFLQJDWUDQVPLWWHU
GHVFULEHGLQWKLVSXEOLFDWLRQ

TABLE 9-12 Measuring Cells for Pressure, Service Parts
DS III and DS III PA series, 7MF4990- 0 - 0DC0

6LOLFRQRLO 1RUPDO 1
0HDVXULQJVSDQ
WREDUJ WRSVLJ B
WREDUJ WRSVLJ C
WREDUJ WRSVLJ D
WREDUJ WRSVLJ E
WREDUJ WRSVLJ F
WREDUJ WRSVLJ G
3URFHVVFRQQHFWLRQ
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$GGLWLRQDOVHOHFWLRQ$GG´±=´WRPRGHOQXPEHUDQGVSHFLI\2UGHU&RGH Order Code

November 2010
TABLE 9-13 Measuring Cells for Absolute Pressure, Gauge Construction, Service Parts
DS III and DS III PA series, Gauge Construction, 7MF4992- 0 - 0DC0

6LOLFRQRLO 1RUPDO 1
0HDVXULQJVSDQ
WRPEDUD WRSVLD D
WRPEDUD WRSVLD F
WREDUD WRSVLD G
WREDUD WRSVLD H
3URFHVVFRQQHFWLRQ
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2YDOIODQJHRIVWDLQOHVVVWHHOVSDQEDUSVLPD[LPXP
$GGLWLRQDOVHOHFWLRQ$GG³±=´WRPRGHOQXPEHUDQGVSHFLI\2UGHU&RGH Order Code

TABLE 9-14 Measuring Cells for Absolute Pressure, Differential Const., Service Parts
DS III and DS III PA series, Differential Construction, 7MF4993- - 0DC0

6LOLFRQRLO 1RUPDO 1
0HDVXULQJVSDQ
7RPEDUD 7RSVLD D
7RPEDUD 7RSVLD F
7REDUD 7RSVLD G
7REDUD 7RSVLD H
7REDUD 7RSVLD K E
7DQWDOXP 7DQWDOXP E
0RQHO 0RQHO H
*ROG *ROG L
3URFHVVFRQQHFWLRQ
6WDLQOHVVVWHHOSURFHVVIODQJHVFUHZV 2

6HHWKHQH[WSDJHIRUDGGLWLRQDOVHOHFWLRQVDQGGDWD
November 2010

Additional selections and data below

Add “–Z” to the order number and specify Order Codes Order Code
2ULQJVIRUSURFHVVIODQJHVLQVWHDGRI)309LWRQ
37)(7HIORQ A20
1%5%XQD1 A23
3URFHVVFRQQHFWLRQ*$ D16
5HPRWHVHDOIODQJHVQRWZLWK..RU. D20
3URFHVVIODQJHV
:LWKRXW K00
:LWKSURFHVVIODQJHPDGHRI
+DVWHOOR\ K01
0RQHO K02
K04
PHGLXP&)PD[LPXP

TABLE 9-15 Measuring Cells for Pressure and Flow, Differential Const., Service Parts
DS III and DS III PA series, differential construction, 7MF4994- - 0DC0

6LOLFRQRLO 1RUPDO 1
0HDVXULQJVSDQ
310:3SVL WRPEDUWRLQ+2 B
310:3SVL WRPEDUWRLQ+2 C
WRPEDUWRLQ+2 D
WRPEDUWRLQ+2 E
WRPEDUWRLQ+2 F
WRPEDUWRLQ+2 G
WREDUWRSVL H
7DQWDOXP 7DQWDOXP E
0RQHO 0RQHO H
*ROG *ROG L
3URFHVVFRQQHFWLRQ
0RXQWLQJWKUHDG81)7R(1 2

6HHWKHQH[WSDJHIRUDGGLWLRQDOVHOHFWLRQVDQGGDWD

November 2010
Add “-Z” to the order number and specify Order Codes Order Code
37)(7HIORQ A20
1%5%XQD1 A23
5HPRWHVHDOIODQJHVQRWZLWK..RU. D20
9HQWRQVLGHIRUJDVPHDVXUHPHQWV H02
6WDLQOHVVVWHHOSURFHVVIODQJHVIRUYHUWLFDOGLIIHUHQWLDOSUHVVXUHOLQHVQRWZLWK.
H03
.RU.
3URFHVVIODQJHV
:LWKRXW K00
:LWKSURFHVVIODQJHVRI
+DVWHOOR\ K01
0RQHO K02
K04
PHGLXP&)PD[LPXP

TABLE 9-16 Measuring Cells for Differential Pressure and Flow, Service Parts
DS III and DS III PA series, differential construction, 7MF4995- - 0DC0

1
6LOLFRQHRLO 6WDQGDUG
0HDVXULQJVSDQ
7RPEDU 7RLQ+2 D
7RPEDU 7RLQ+2 E
7RPEDU 7RLQ+2 F
7RPEDU 7RLQ+2 G
7REDU 7RSVL H
:HWWHGSDUWVPDWHULDOV6WDLQOHVVVWHHOSURFHVVIODQJHV
*ROG *ROG L
3URFHVVFRQQHFWLRQ


Add “-Z” to the order number and specify Order Code(s) Order Code
37)(7HIORQ A20
1%5%XQD1 A23
:LWKRXWSURFHVVIODQJH K00

November 2010

TABLE 9-17 Measuring Cells for Filling Level, Service Parts
DS III and DS III PA series, 7MF4996- - 0DC0

1
6LOLFRQRLO 6WDQGDUG
5DWHGPHDVXULQJUDQJH
PEDU SVL D
PEDU SVL E
PEDU SVL F
EDU SVL G
3URFHVVFRQQHFWLRQORZSUHVVXUHVLGH


Add “-Z” to order number and specify Order Code(s) Order Code
37)(7HIORQ A20
1%5%XQD1 A23
:LWKRXWSURFHVVIODQJHV K00

TABLE 9-18 Electronics and Connecting Boards, Service Parts
Product description Order Number

6,75$163'6,,,HOHFWURQLFVPRGXOH 7MF4997-1DK
6,75$163'6,,,WHUPLQDOERDUGIRUILHOGWHUPLQDOFRQQHFWLRQV 7MF4997-1DN
6,75$163'6,,,GLJLWDOGLVSOD\ 7MF4997-1BR

November 2010
9.7 ACCESSORIES
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TABLE 9-19 Accessories
MODEL 7MF...
DESCRIPTION 4433, 4033, 4633, PART NUMBER

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November 2010

9.9 HAZARDOUS AREA CLASSIFICATION
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Intrinsically Safe Operation in a Hazardous Area

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Installation in Zone 0

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November 2010
TABLE 9-20 Certificate and Approvals, All Models

Certificate and approvals
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9.9.1 CSA Hazardous Locations Precautions

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November 2010

CERTIFICATE OF NACE COMPLIANCE

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Wetted Parts Materials Code B (Hastelloy diaphragm with 316 stainless steel flanges)
DP Non-Wetted Materials Code 2 (stainless steel bolts with aluminum housing)
DP Non-Wetted Materials Code 3 (stainless steel bolts and housing)
Gauge Non-Wetted Materials Code 0 or 3 (aluminum or stainless steel housing)

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Certificate of NACE Compliance

November 2010

UMSITRPDS-1 Glossary
10.0 GLOSSARY
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November 2010

Glossary UMSITRPDS3-1

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November 2010

UMSITRPDS-1 Glossary
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November 2010

UMSITRPDS3-1 Appendix A - Online Configuration Map
11.0 APPENDIX A - ONLINE CONFIGURATION MAP
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November 2010

Appendix A - Online Configuration Map UMSITRPDS3-1

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November 2010

UMSITRPDS3-1 Appendix A - Online Configuration Map

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November 2010

UMSITRPDS3-1 Appendix B - Hazardous Area Installation
12.0 APPENDIX B - HAZARDOUS AREA INSTALLATION

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November 2010

Appendix B - Hazardous Area Installation UMSITRPDS3-1

FIGURE 12-1 Control Drawing
November 2010

UMSITRPDS3-1 Appendix B - Hazardous Area Installation

November 2010

Appendix B - Hazardous Area Installation UMSITRPDS3-1
November 2010

HOT GAS GENERATOR AND ITS
AUXILIARIES - 2
UMSITRPDS3-1 Appendix C - Elevation and Suppression Corrections
13.0 APPENDIX C - ELEVATION AND SUPPRESSION CORRECTIONS
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November 2010

Appendix C - Elevation and Suppression Correction UMSITRPDS3-1
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November 2010

UMSITRPDS3-1 Appendix C - Elevation and Suppression Corrections
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November 2010

Online Configuration Map for Siemens SITRANS P DSIII
Pressure Transmitters (with Model 275 HART COMMUNICATOR)
1 Pressure +
2 Type +
3 Device setup 1 Process variables 1 Pressure +
2 % range +
3 Analog output +
4 Sensor temperature +
2 Diagnostics/service 1 Diagnosis 1 Min/max pointer 1 Pressure pointer 1 Pressure maximum
2 Pressure minimum
3 Reset pointer
2 El Temperature pointer 1 E1 Temperature max
2 E1 Temperature min
3 Reset pointer
3 Sensor temperature pointer 1 Sensor temperature max
2 Sensor temperature min
3 Reset pointer
2 Operating hours 1 Operating hours E1
2 Operating hours S
3 Warnings/alarms 1 W/A time unit
2 Calibrate interval 1 Calibrate status
2 W/A acknowledge
3 Calibration timer >
4 Calibration warning
5 Calibration alarm
6 W/A activation
3 Service interval 1 Service status
2 W/A acknowledge
3 Service timer
4 Service warning
5 Service alarm
6 W/A activation
4 AO saturation 1 Saturation alarm
2 Alarm duration
3 Alarm activation
4 Status 1 Status summary
2 Hardware/Firmware status
3 Diagnostic alarm status
4 Diagnostic warning status
5 Simulation status
2 Simulation/Test 1 Simulation 1 Loop test
2 Inputs >
2 Test 1 Self test
2 Master reset
3 Control modes 1 Local keys control mode
2 Write protect (status)
3 Set write protect (enable)
4 Trim 1 Position correction
2 Sensor trim 1 Sensor trim points
2 Zero trim
3 Lower sensor trim
4 Upper sensor trim
3 Trim analog output 1 D/A trim
2 Scaled D/A trim
5 Restore manufacturer 1 All trims
trims 2 DAC trims
3 Position correction
4 Sensor trim
6 All measured values 1 Pressure +
2 Raw value
3 Sensor temperature +
4 El Temperature +
Continued in 5 AO +
Figure A-1 3 Basic setup 1 Tag
Part 2 2 (Engineering) units
3 Position correction Notes: 1. + = Active data displayed
4 LRV 2. HART Communicator, Rev 5; firmware Rev 2.2
5 URV 3. > = To additional menu(s)
6 Damping
7 Transfer function
Continued on other side.
Siemens Energy & Automation, Inc.
Rev. 1, March 2001
1
Online Configuration Map for Siemens SITRANS P DSIII, Continued
4 Detailed setup 1 Sensors 1 Pressure sensor 1 Pressure +
See Note 4 2 (Engineering) Units
2 Temperature sensor 1 Sensor temperature +
3 Device setup, 2 El temperature +
continued in 2 Signal condition 1 Process variables 1 Pressure +
Figure A-1, 2 % range +
Part 1 3 AO +
4 Sensor Temperature +
2 Position correction
3 Zero/span set 1 Keypad input 1 LRV
2 URV
3 Pressure (Eng.) Units
4 LSL
5 USL
2 Apply values
4 Damping
5 Transfer function
6 Measuring speed
3 Output condition 1 Analog output 1 AO +
2 Pressure
3 Alarms >
4 Lower AO limit
5 Upper AO limit
2 HART output 1 Poll address
2 Num request preambles
3 Num response preambles
4 Device information 1 Ranges and limits 1 Module range
2 Pressure USL
3 Pressure LSL
4 Pressure minimum span
2 Common device 1 Manufacturer
information 2 Model
3 Measurement type
4 Device order number
5 Explosion protection
6 Device ID
7 Pressure sensor S/N
8 Final assembly number
9 Electrical connector
Electrical housing material
Write protect
Tag
Date
Descriptor
Message
3 Sensor information 1 Process connection
2 Flange type
3 Flange material
4 Process flange bolt
5 Isolator material
6 Fill fluid
7 O-ring material
8 Drain & vent/plug material
9 Drain & vent/plug position
4 Remote seal 1 RS type
2 RS isolator material
3 RS fill fluid
4 Number of remote seal
5 Extension length
5 Local meter 1 Meter type
2 Unit tracking
3 Local display units
4 Bargraph
6 Revision numbers 1 Universal rev.
2 Field device revision
3 Software revision
4 Hardware revision
5 Reviews Step through configuration
2
Online Configuration Map for
Siemens SITRANS P DSIII Pressure Transmitter with
Model 375 Field Communicator
Notes:
1 Model 375 Field Communicator Firmware Rev. F1.6

2 Online 1 Pressure (PV) +
2 PV status 2 + = active data (measurement) display
3 Module type M = method (i.e. short procedure)
4 Identification 1 Operation Unit 1 Tag
2 Ext (Long) Tag --> M
3 Descriptor
4 Message
5 Date
2 Device 1 Manufacturer
2 Model
3 Device identification
4 Distributor
5 MLFB Order Number 1 MLFB Order No --> M
6 Measurement type
7 Fabrication-No
8 Final asembly number
9 Sensor serial number
10 Revisions 1 Universal rev.
2 Field device rev.
3 Software rev.
4 Hardware rev.
3 Basic Parameters 1 Pressure unit
2 LSL (Lower Sensor Limit)
3 USL (Upper Sensor Limit)
4 Minimum Span
5 LRV (Lower Range Value)
6 URV (Upper Range Value)
7 Pressure damping
8 Pressure xfer function xfer = transfer
5 Config Inp/Outp 1 Quick-Setup & Meas. 1 PV, Current, Status 1 PV +
2 AO (analogue output) +
3 PV % range +
4 Status see ---> 6 Diagnosis/Service
5 Measurement type
2 Meas.Val. & Status 1 Pressure Values 1 Pressure +
2 Pres status
3 Untrimmed pressure +
4 Untrimmed pres status
2 Temperature Values 1 Sens-Temp +
2 Sens-Temp status
3 Electr-Temp +
4 Electr-Temp status
3 Level, Vol, Mass Values 1 Level +
(shown if valid items) 2 Level status
3 Volume +
4 Volume status
5 Mass flow +
6 Mass status
4 Vol-, Mass- & Flow Values 1 Vol-Flow +
(shown if valid items) 2 Vol-Flow status
3 Mass-Flow +
4 Mass-Flow status
5 Appl & Stat 1 Customer Defined
(shown if valid items) 2 Customer Defined Status
3 Quick-Setup 1 Tag
2 Ext TAG --> M
3 PV is
4 PV unit
5 Position correction 1 Position corr --> M
6 LRV
7 URV
8 Pressure damping
9 Pressure xfer function
2 Input 1 Config Pres/Temp 1 Pressure sensor 1 Pressure +
2 Untrimmed pres +
3 Pressure units 1 Pres abs/rel
2 Pressure unit
3 Untrimmed pres unit
2 Temperature sensor 1 Sens-Temp +
2 Electr-Temp +
3 Temp units 1 Sens-Temp unit
2 Electr-Temp unit
3 Pres units see --> 1 Pressure sensor
4 Temp units see --> 1 Temperature sensor
Continued on pg 2 2 Display Process Variables 1 Process variables 1 PV measurement +
2 PV % range
3 AO
4 S Temperature +
5 El Temperature +
6 Untrimmed pressure +
Page 1
5 Config Inp/Outp, 2 Input, Continued 3 Meas Switch/Mapper 1 measurement
Continued 2 PV is
3 SV is
4 TV is
5 QV is
6 (measurement) config 1 Input scaling 1 Pres abs/rel
e.g. Level 2 Pressure unit
3 Input LRV
4 Input URV
2 Level scaling 1 Level unit
e.g. Level scaling 2 Level LRV
3 Level URV
3 Volume scaling 1 Volume unit
2 Vol LRV
3 Vol URV
2 Density unit
3 Density
3 Mass unit
e.g. Flow 2 Pressure unit
3 Input LRV
4 Input URV
2 Flow scaling 1 Vol flow unit
2 Vol flow LRV
3 Vol flow URV
2 Density unit
3 Density
3 Mass flow unit
e.g. Customer 2 Pressure unit
3 Input LRV
4 Input URV
3 Customer scaling 1 Cust unit (5 Ch)
2 Cust LRV
3 Cust URV
7 User linearization 1 Special Curve status --> only if meas not pres
if Level, Flow or Customer 2 No curve points
this is valid - otherwise not 3 Setup special char --> M
4 Display special char --> M
4 Meas.Limits & Span 1 Module range
2 Active Device Variables 1 Pressure 1 Pressure unit
2 Pres USL
3 Pres LSL
4 min span
5 Trimpoint sum
2 Sens-Temp 1 Sens-Temp unit
2 Sens-Temp USL
3 Sens-Temp LSL
4 Sens-Temp min.span
3 Electr-Temp 1 Electr-Temp unit
2 Electr-Temp USL
3 Electr-Temp LSL
4 Electr-Temp min.span
4 Untrimmed Pres 1 Untrimmed Pres unit
2 Untrimmed Pres USL
3 Untrimmed Pres LSL
4 Untr Pres min.span
additional if measurement 5 Level 1 Level unit
is mapped to level 2 Level USL
3 Level LSL
4 Level min.span
additional if measurement 6 Volume 1 Volume unit
is mapped to level 2 Volume USL
3 Volume LSL
4 Volume min.span
additional if measurement 7 Mass 1 Mass unit
is mapped to level 2 Mass USL
3 Mass LSL
4 Mass min.span
additional if measurement 5 Vol-Flow 1 Vol-Flow unit
is mapped to flow 2 Vol-Flow USL
3 Vol-Flow LSL
4 Vol-Flow min.span
additional if measurement 6 Mass-Flow 1 Mass-Flow unit
Continued on pg 3 is mapped to flow 2 Mass-Flow USL
3 Mass-Flow LSL
4 Mass-Flow min.span
additional if measurement 5 Customer 1 (PV) unit
is mapped to customer 2 Customer USL
3 Customer LSL
4 Customer min. span
Page 2
5 Config inp/outp, 3 Output 1 Analog output 1 Analog output +
Continued 2 Percent range +
3 Pres xfer function Linear
Sq Rt, lin to Strtpt
Sq Rt, 4 mA to Strtpt
Sq Rt, 2 steps lin to Startpt
NA/4 Startpoint square root
4/5 Zero and Span 1 Zero/Span set 1 Out Scaling PV >1
2 Apply values >2
5/6 Current Limits 1 Lower AO Limit
2 Upper AO Limit
6/7 Alarms / Failsafe 1 AO Alarm / FS Type (Hi/Lo)
2 Alarm / FS LRV
3 Alarm / FS URV
2 Sensor trim points 1 Lower sensor trim point
2 Upper sensor trim point
3 HART output 1 Polling address
2 Num request preambles
3 Num response preambles
4 Local meter 1 Meter type
2 Unit tracking
3 Local Display unit
4 LCD Settings 1 LCD Scaling, if On: 2 LCD Unit
5 Bargraph 3 LCD LRV
4 LCD URV
6 Access Control 1 Local keys control mode
2 Write protect
3 Set write protect --> M
5 Mech. Construction 1 No of electronic changes
Mech = mechanical 2 Design 1 Sensor 1 Fill fluid
2 Isolation material (diaphr)
3 O ring material
4 Module range
2 Remote Seal 1 Number remote seal (RS)
2 RS type
3 RS isolator material
4 RS fill fluid
5 Extension length
6 Extension type
7 Capillary length
3 Process Connection 1 Process Connection
2 DrainVent / plug mat
3 DrainVent / plug pos
4 Process flange bolt
5 Flange type
6 Flange material
4 Electronic Connection 1 Electr housing material
2 Electr connection
6 Diagnosis/Service 1 Status 1 Status summary
2 Extended device status
3 Hardw/Firmw status 1 RAM failure
2 ROM failure OFF = OK
3 Electronic EEPROM ON = Problem
# List continues
4 Diag Alarm Status 1 Calibration Alarm
2 Service Alarm
# List continues
5 Diag Warn Status 1 Calibration Warning
2 Service warning
# List continues
6 Simulation status 1 Pressure simulation
2 El simulation
3 Sensor temp simulation
2 Device 1 Selftest/Reset 1 Selftest --> M
2 Display Test --> M
3 Master reset --> M
4 Changes Config 1 Config changed counter
2 Sensor trim 1 Restore mfgr trims --> M mfgr = manufacturer
2 Sensor trim 1 Sensor trim points 1 Lower sensor trim point
2 Upper sensor trim point
2 Sensor trim 1 Pres zero trim--> M
2 Lower sensor trim --> M
3 Upper sensor trim --> M
3 Trimpoint summary
3 Trim analog output 1 D/A trim --> M
Continued on pg 4 2 Scaled D/A trim --> M
4 Position correction 1 Position corr --> M
3 Simulation/Test 1 Loop test --> M Simulation AO
2 Inputs --> M Simulation Fixed / Ramp
4 Access Control 1 Local keys control mode
2 Write protect
3 Set write protect --> M
Page 3
6 Diagnosis/Service, 3 Diagnostic settings 1 W/A time unit W/A = warning/alarm
Continued 2 Calib interval 1 Calib status
2 W/A acknowledge --> M
3 Calib timer 1 Calib time
2 Reset timer --> M
4 Calib warning
5 Calib alarm
6 W/A activation
3 Service interval 1 Service status
2 W/A acknowledge --> M
3 Service timer 1 Service time
2 Reset timer --> M
4 Service warning
5 Service alarm
6 W/A activation
4 AO saturation 1 AO alarm type
2 Saturation alarm
3 Alarm duration
4 Alarm activation
5 Limiter setup 1 Display limiter --> M
2 Setup limiter --> M
3 Limiter status --> M
4 Limiter: Ack W/A --> M Ack = acknowledge
5 CmpCnt: Ack W/A --> M CmpCnt = Comparation Counter
6 Reset counter. --> M
4 View 1 Operating hours 1 Operating hours Electr
2 Operating hours Sensor
3 Min/Max pointer 1 Pressure pointer 1 Pres max
2 Pres min
3 Reset pointer --> M
2 Electr-Temp pointer 1 Electr-Temp max
2 Electr- Temp min
3 Sens-Temp pointer 1 Sens-Temp max
2 Sens-Temp min
7 Certif & Approv 1 Explos. Protection
Certif=Certification Explos = Explosion
Approv=Approval DSIII_375HARTRev2
Page 4
Series 950
Unidirectional Knife Gate Valve
2"-24" (50-600mm) 150psi (10bar)

30"-36" (750-900mm) 100psi (7bar)
40" up to 60" (1000mm-1500mm)
50 to 100psi (3 to 7bar)
Series 950
Unidirectional Knife Gate Valve
The Bray/VAAS Series 950’s one-piece,

cast body design offers rugged performance
in applications ranging from general
purpose to severe media handling in an
economical semi-lug body.
Available with integral metal or

replaceable soft seat, the Bray/VAAS Shown with stem cover (optional).
Series 950 gate valve is easily

automated for on/off applications.
1 Designed for easy, quick conversion

between manual and pneumatic actuation.
Featuring a lubricant injection port
for continuous, smooth operation with
minimal maintenance.
2 Clevis design and horizontal bolting

stabilizes gate ensuring proper alignment.
2
3 Standard multi-layer square packing
provides exceptional gland sealing.
4 Optional energized quad seal

packing for enhanced gland sealing.
5 Standard integral metal seat and 4 3

optional replaceable zero leakage
resilient seats.
6 Deflection resistant gate design

ensures consistent alignment 5
for industry leading durability.
7 Unique body design with no dead 6

pockets enables self-draining of valve.
* Shown with replaceable

resilient seat (optional).
The High Performance Company Series 950 Unidirectional Knife Gate Valve
Standard Construction Actuator Options
Body Gate Seat Stem Gland Packing Topworks Direct Mounted Handwheel
CF8 304 Integral 304 304 PTFE impregnated synthetic fiber Steel Standard
CF8M 316 Integral 304 304 PTFE impregnated synthetic fiber Steel Bevel Gear
WCB 304 Integral 304 304 PTFE impregnated synthetic fiber Steel Pneumatic
CI/DI 304 Integral 304 304 PTFE impregnated synthetic fiber Steel Hydraulic
Lower pressure ratings apply for CI/DI body in sizes above 12 in./300mm Electric
Body Options Gate Options Seat Options Packing Options

CF3M Stainless Steel 316, 317 Stainless Steel Buna-N -35°-194°F/-37°-90°C PTFE impregnated synthetic fiber 232°C/450°F
SAF 2205 Duplex SAF 2507 Duplex EPDM -65°-248°F/-54°-120°C PTFE w/Buna-N Quad Seal 90°C/194°F
SAF 2507 Duplex SAF 2205 Duplex Viton® -15°-392°F/-26°-200°C ®
PTFE w/Viton Quad Seal 200°C/392°F
17-4PH Stainless Steel PTFE -235°-450°F/-148°-232°C
Copper Wiper 500°C/932°F
Additional material options Hastelloy® C
may be available upon request.
Consult factory for availability. Monel® Graphite 650°C/1202°F
Specifications & Standards Design MSS SP-81

Size Range 2"-60" (50-1500mm) Testing MSS SP-81
Pressure Up to 24" (600mm) 150psi (10bar) Face-to-face MSS SP-81
Rating 30"-36" (750-900mm) 100psi (7bar) Certification CE/PED, Canadian CRN
40"-60" (1000-1600mm) 50-100 psi (3-7bar)
Drilling* ASME B16.5 CL150, ASME B16.47 CL150
Body Style One-piece (Wafer, Semi-lug) *Additional drilling options available. Consult factory for availability.
Dimensions
in. A B C D E F G H I J Direct Mounted
(mm) Handwheel
2 1.89 4.76 3.62 13.05 14.15 18.10 7.99
–– –– ––
(50) 48 121 92 332 359 460 203
3 2.01 6.00 5.00 15.73 17.97 21.84 7.99
–– –– ––
80 51 152 127 400 457 555 203
4 2.01 7.50 6.18 17.36 20.67 24.49 7.99
–– –– ––
(100) 51 191 157 441 525 622 203
5 2.24 8.50 7.32 19.44 23.44 27.84 10.00
–– –– ––
(125) 57 216 186 494 595 707 254
6 2.24 9.53 8.50 20.94 25.87 31.31 10.00
–– –– ––
(150) 57 242 216 532 657 795 254
8 2.76 11.77 10.63 24.88 31.75 37.64 29.80 11.77 11.65 20.00
(200) 70 299 270 632 807 956 757 299 296 508
10 2.76 14.25 12.76 27.31 37.09 44.75 35.12 15.98 11.65 20.00
(250) 70 362 324 694 942 1137 892 406 296 508
12 2.99 17.01 14.76 30.70 42.50 50.14 41.06 15.98 11.65 20.00
(300) 76 432 375 780 1080 1274 1043 406 296 508
14 2.99 18.74 16.26 32.91 45.53 52.54 45.67 20.00 12.05 20.00 Pneumatic
(350) 76 476 413 836 1157 1334 1160 508 306 508 Actuator
16 3.50 21.26 18.50 36.26 50.59 57.95 49.61 20.00 12.05 20.00
(400) 89 540 470 921 1285 1472 1260 508 306 508
18 3.50 22.76 21.02 41.10 57.44 64.86 57.80 20.00 12.05 20.00
(450) 89 578 534 1044 1459 1647 1468 508 306 508
20 4.49 25.00 22.99 45.59 63.60 72.57 63.27 20.00 12.05 20.00
(500) 114 635 584 1158 1616 1843 1607 508 306 508
24 4.49 29.53 27.24 53.31 75.63 84.38 74.92 20.00 12.05 20.00
(600) 114 750 692 1354 1921 2143 1903 508 306 508
Dimensions are approximate and subject to change. Consult factory for certified drawings. Bevel Gear
Weights
In 2 3 4 5 6 8 10 12 14 16 18 20 24
Size
mm 50 80 100 125 150 200 250 300 350 400 450 500 600
lb 20 29 35 53 55 79 132 176 254 324 408 573 672
HANDWHEEL
kg 9 13 16 24 25 36 60 80 115 147 185 260 305
PNEUMATIC lb 35 44 55 84 88 132 220 324 419 496 584 805 937
ACTUATOR kg 16 20 25 38 40 60 100 147 190 225 265 365 425 Consult factory for
GEAR lb 99 179 198 298 397 463 650 772 hydraulic and electric
–– –– –– –– –– actuators dimensions.
OPERATOR kg 45 80 90 135 180 210 295 350
Series 950 Unidirectional Knife Gate Valve Full product range at bray.com
m
Bray International, Inc.
Houston, TX, USA +281.894.5454
Bray/VAAS India
Chennai +91.44.2496.1391
Benelux
Heerhugowaard +31.72.572.1410
Brazil
Paulinia Sp-Brazil +55.19.3517.6161 Bray World Headquarters
Canada Houston, TX - USA
Montréal +514.344.2729
Chile
Santiago +56.2739.2966
China
Hangzhou, Zhejiang +86.571.828.52200
Colombia
Bogota +57.1.876.6084
France
Maubeuge +0033.3.27.59.41.89
Germany Bray India

Krefeld +49.2151.53360
India
Gujarat +91.2667.664444
Italy
Milano +39.02.9237.0196
Mexico
Zapopan, Jalisco +52.33.3836.4460
Middle East
Dubai +00971.0.4.887.6979
Pacific Bray/VAAS India

Melbourne, Australia +613.9580.9755
Peru
Lima +511.251.0251
To find a distributor in your area visit
Poland us online at www.bray.com
Oswiecim +48.33.842.1968
Russia
Moscow +7.495.36.36.222
Singapore
Ubi Techpark +65.6742.1428
South Africa
Sandton +27.10.007.3222
South Korea
Seoul +82.2.2190.3809
All statements, technical information, and recommendations in this bulletin are for general use only. Consult Bray/VAAS representatives or factory for
United Kingdom the specific requirements and material selection for your intended application. The right to change or modify product design or product without prior
notice is reserved. Patents issued and applied for worldwide.
Inchinnan +44.141.812.5199 Bray® is a registered trademark of BRAY INTERNATIONAL, Inc. © 2015 Bray International. All rights reserved. V-6014_EL_950_03-2017
Bray/ VAAS
Unidirectional Series Knife Gate Valve
940/950/952/980/985 Series
Operation and Maintenance Manual
Unidirectional Series
Operations and Maintenance Manual
Table of Contents
Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder-Operated Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Manual Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Packing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Actuator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Packing Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
For information on this product and other Bray products please visit us at our web page - www.bray.com.
Definition of Terms - Safety Instructions

READ AND FOLLOW THESE INSTRUCTIONS
SAVE THESE INSTRUCTIONS
DEFINITION OF TERMS
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
Used without the safety alert symbol indicates a potential situation which, if not avoided,
NOTICE may result in an undesirable result or state, including property damage.
HAZARD-FREE USE
This device left the factory in proper condition to be safely installed and operated in a hazard-free manner. The notes and
warnings in this document must be observed by the user if this safe condition is to be maintained and hazard-free opera-
tion of the device assured.
Take all necessary precautions to prevent damage to the valve due to rough handling, impact, or improper storage. Do not
use abrasive compounds to clean the valve, or scrape metal surfaces with any objects.
The control systems in which the valve is installed must have proper safeguards to prevent injury to personnel, or damage to
equipment, should failure of system components occur.
QUALIFIED PERSONNEL
• A qualified person in terms of this document is one who is familiar with the installation, commissioning, and operation
of the device and who has appropriate qualifications, such as:
• Is trained in the operation and maintenance of electrical equipment and systems in accordance with established safety
practices
• Is trained or authorized to energize, de-energize, ground, tag, and lock electrical circuits and equipment in accordance
with established safety practices
• Is trained in the proper use and care of personal protective equipment (PPE) in accordance with established safety
practices
• Is trained in first aid
• In cases where the device is installed in a potentially explosive (hazardous) location – is trained in the commissioning,
operation, and maintenance of equipment in hazardous locations
1
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All installation, commissioning, operation, and maintenance must be performed under strict observation of all applicable
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INTRODUCTION
The Bray/ VAAS Series 940/950/952/980/985 provides repeatable unidirectional shutoff in a rugged, single-piece cast body.
Featuring both metal and soft seating, the Bray/ VAAS Unidirectional Series gate valve caters to all types of unidirectional
sealing requirements across a wide range of industries.
Additional information about Unidirectional Series valves – including application data, engineering specifications, and
actuator selection is available from your Bray/ VAAS distributor or sales representative.
UNPACKING
Ensure the box is not damaged externally. Remove the valve from the packaging and check for any damage to the valve
and its components during transit.
Valve size and brief material specification of body (markings such as “SS” or “DI”) are marked on the valve body. A stainless
steel nameplate (below) afixed to the yoke of the valve contains most of the relevant information on the valve including
Bray/VAAS work order number and unique serial number of the valve. These details should be quoted for all requirements
of service and spares.
SERIAL NUMBER
SIZE MODEL FLG. DRILL BODY GATE
SEAT PACKING CWP MAX TEMP
STORAGE
Wrap the valve with a polyethylene cover. Cover the ports for pneumatic actuator/accessories with plastic caps. Store
these valves in the same packing indoors and without direct exposure to the environment.
If the valve is to be stored for a long period of time before installation, it should be stored in a vertical position (preferable) and
in a cool, clean area to prevent damaging effects on the packing.
Gate should be off the seat to prevent compression set.
2
INSTALLATION
• Valves can be mounted with flow in one direction. Flow directions are indicated on the valve as these would depend
on the application for which the valve is used. However, to enable correct orientation, the seat side of the valve can be
identified with the word “SEAT” marked on the body and on the gate top side.
• On horizontal lines, if there is a possibility of particles/solids settling at the bottom, it is preferable to install the valve so
that the stem is above horizontal/inclined/vertical.
• Install the valve between flanges using fasteners & gaskets.
• Bolt holes in the chest area are always blind tapped and care should be taken not to bottom the bolts while tightening.
Refer to GA Drawing/ Technical Bulletin for quantity and size of blind tapped holes on valve chest area. If the correct
size bolts are not available, use studs and nuts for chest area bolts to avoid damage of body.
Support should be used for valves size 8” and over when installed in vertical pipe. Failure to do so can result in improper
valve operation and/or valve failure.
COMMISSIONING GUIDELINES
• Gland packing is tightened to hold the specified pressure and tested for no leakage before dispatch. However, this may
require some adjustment at site due to loosening in transit etc.
• Check for gland leakage after the valve is subjected to pressure and if any leak is observed, tighten the gland uniformly
in a cris-cross pattern until the leakage stops.
Wrong electrical supply to accessories will damage the equipment. Do not over tighten the gland nuts as this may cause
excessive friction and premature damage to packing.
Cylinder Operated Valves

1. Connect instrument quality air, preferably through an air filter/regulator of adequate size. The recommended air pres-
sure is 80-120 psi (5-8 bar). Refer to the appropriate bulletin/drawing for port and cylinder size details.
2. Ensure the supply air is free from moisture, dirt, and other foreign particles. Drain the filter regulator before operating
the actuator so that pipe rust and dirt if any in the air line will be removed before actuation.
3. If valves are supplied with electrical accessories like limit switch and solenoid valve, ensure wiring is done as per local
electrical safety codes and regulations. Ensure correct electrical supply is given to electrical accessories for proper func-
tioning and safety of the equipment.
4. Open the valve by energizing the solenoid valve/giving air supply to cylinder and operate the valve 2-3 times.
Manual valves
Open/Close the valve manually and observe valve operation.
3
MAINTENANCE
NOTICE
Any modification or use of unauthorized parts voids any and all warranty considerations.
Lubrication
The manual valve stem should be lubricated at regular intervals for smooth operation of the valve. A lubrication nipple is
provided on the collar. Cylinder operated valves do not require routine lubrication.
NOTICE
If the cylinder actuator is disassembled for repair, the cylinder wall and seals need to be lubricated with a lithium-based
grease prior to reassembly.
Manual Valve Stem Cylinder Actuator
4
Packing Replacement
Relieve line pressure before loosening gland nuts to avoid injury and/or equipment damage.
1. Relieve the line pressure.

2. Fully close the valve.
3. Ensure the line is empty, and flush if necessary.
Manual Valves
1. Ensure the valve is fully closed.
2. Disconnect the stem from the gate (2) by removing the
clevis bolts & nuts (6). 1
3. Rotate the Handwheel (1) counter-clockwise by holding
the stem from rotation, so that the stem retracts fully
from the gate.
4. If valves are supplied with bellows, ensure stem is not
rotating, as rotation will damage the bellows.
6
5. Remove the gland nuts (5) and the gland (4).
6. Remove the old packing (3) from the packing chamber,
one layer at a time, using a long thin tool to pry it out.
4
7. If the lowest layer is a wiper ring (copper, Inconel etc.),
clean it with a common solvent; if damaged, replace
5
with a new one.
8. Insert the new packing one at a time ensuring that the
gate (2) is in full contact with the seat (gate fully down)
3
and not rubbing the bottom of the packing chamber.
Stagger the cut end of the packing so they do not line
up.
2
9. Tap each packing (3) ring firmly and evenly into the
chamber before installing the next ring; the ends of
each ring should meet but not overlap.
10. Install the packing gland (4) and gland nuts (5).
11. Ensure the gap between the gland and the gate is uni-
form all around
12. Tighten the gland nuts (5) finger tight plus one half
turn.
13. Lower the stem by rotating the handwheel clockwise
while holding the stem and fasten the stem to the gate
with nuts and bolts.
Cylinder operated valves

1. Switch off the electrical supply to the solenoid and limit switches.
2. Remove the cylinder tubing and vent the air inside the cylinder.
5
3. Disconnect the piston rod from the gate by removing the clevis bolts & nuts.
4. Apply air slightly to the bottom port of the actuator so that the piston rod is retracted from the gate.
5. Remove the actuator assembly from the valve by removing the fasteners connecting the yokes to the valve body.
6. Remove the gland nuts (5) and the gland (4).
7. Remove the old packing (3) from the packing chamber, one layer at a time, using a long thin tool to pry it out.
8. If the lowest layer is a wiper ring (copper, Inconel etc.), clean it with a common solvent; if damaged, replace with a new
one.
9. Insert the new packing one at a time ensuring that the gate (2) is in full contact with the seat (gate fully down) and not
rubbing the bottom of the packing chamber. Stagger the cut end of the packing so they do not line up.
10. Tap each packing (3) ring firmly and evenly into the chamber before installing the next ring; the ends of each ring should
meet but not overlap.
11. Install the packing gland (4) and gland nuts (5).
12. Ensure the gap between the gland and the gate is uniform all around
13. Tighten the gland nuts (5) finger tight plus one half turn.
14. Mount the actuator assembly to the valve by attaching the fasteners connecting the yokes to the valve body.
NOTICE
If leakage is observed from the packing area after installing the valve in the pipeline and the valve is pressurized or charged with
media, tighten the gland nuts evenly side to side just enough to stop leakage. Do not over-tighten the gland nuts.
Seat Replacement
Relieve line pressure before attempting to remove the valve from the line to avoid personnel injury and/or equipment
damage. If the valve has a pneumatic actuator, solenoid valve, limit switches, or other accessories, disconnect electrical
and pneumatic supply.
1. Relieve the line pressure and close the valve. Flush the line if necessary.
2. Remove the valve from the line by loosening the flange mounting bolts, studs,
and nuts.
3. Clamp the valve in the vertical position to a fixture. Do not block the valve port
when clamping the valve. An overhead hoist may be needed for larger size
valves.
4. Disconnect the stem from the gate by removing the clevis, bolts, and nuts.
5. Remove one set of superstructure bolting and tilt the super structure to one side
as shown at right.
6. Lift the gate up until it fully clears the seat area and remove the old seat by tilt-
ing the top of the seat away from the body.
7. Insert the new seat with the bottom part first and lower the gate fully.
8. Bolt the super structure to the body again and then fasten the stem to gate
bolts.
6
ACTUATOR MAINTENANCE
Pneumatic Cylinder
The Bray/VAAS pneumatic cylinder actuator is a low maintenance design and does not require routine maintenance. It has
an FRP tube which is lubricated for life with a special coating on the inside wall. Filtered dry, instrument quality air (non-
lubricated) should be used for its operation at the specified air supply pressure.
Recommended spare parts

Following are parts recommended as spares, which may be stocked. Following are general recommended spares for valves.
Provide the valve serial number and work order number from the nameplate for proper parts.
• Gland packing
• Spare Seat
• Cylinder repair kit
Packing Details
Valve size, inch Packing Size, mm Length, mm Quantity

2 Sq. 8 180 3
3 Sq. 10 225 3
4 Sq. 10 280 3
5 Sq. 10 330 3
6 Sq. 10 395 3
8 Sq. 10 490 3
10 Sq. 10 580 3
12 Sq. 10 690 3
14 Sq. 12.7 765 3
16 Sq. 12.7 975 3
18 Sq. 16 1005 3
20 Sq. 16 1120 4
24 Sq. 16 1320 4
28 Sq. 19 1520 4
30 Sq. 19 1640 4
32 Sq. 19 1830 4
34 Sq. 19 1950 5
36 Sq. 19 2035 5
7
Troubleshooting
Trouble Possible cause Solution
Media oozing out of gland packing Packing deteriorated Replace packing
Seat is worn out or torn Replace seat
In fully closed position, valve leaks
Gate is scratched Replace gate
a) Remove the clevis fasteners

b) Loosen the superstructure fasteners
c) Adjust the alignment of the stem and
Misalignment between gate and stem
gate
High torque during valve seating and d) Connect the clevis fasteners
unseating e) Retighten superstructure fasteners
Packing is not tighten properly Adjust gland nuts
Superstructure fasteners loosen Tighten the super structure fasteners
Pneumatic operated valves: Increase supply

Insufficient air supply
pressure
Valve jerks during open and close
Solenoid valve dust accumulation Remove and clean solenoid valve
Piston rod seal damaged Replace seal
a) Check for valve orientation, flow direc-

tion and flow indication
Unable to close or open the gate Gate is bent
b) Re-orient the valve
c) Replace gate
All statements, technical information, and recommendations

in this bulletin are for general use only. Consult Bray/VAAS Bray/VAAS
representatives or factory for the specific requirements and Division of Bray International, Inc.
material selection for your intended application. The right to 13333 Westland East Blvd.
change or modify product design or product without prior notice
is reserved. Patents issued and applied for worldwide.
Houston, Texas 77041
Tel: 281.894.5454 • www.bray.com
Bray® is a registered trademark of
Bray International, Inc.
© 2015 Bray International, Inc. All rights reserved.
OM_Series_940_12_20_2016
8
%DOO 9DOYH
Three Piece / Two Piece Design GENERAL INSTRUCTIONS
INSTALLATION
OPERATION &
MAINTENANCE
MANUAL
FLOATING BALL VALVE
1
%DOO 9DOYH
Content
General Instructions Page No
1. Introduction 3
2. Transportation, Reception and Storage 3
3. Do’s and Don’ts 4
4. Installation 5
5. Operation of the valve 5
6. Preventive Maintenance 5
7. Trouble Shooting 6
8. Ordering the Spares 7
9. Disassembly and Assembly Instructions for floating 7
2PC Valve 8
10. Address for Correspondence Works & Marketing branches 9
2
%DOO 9DOYH
1. Introduction
Scope
The manual is provided to ensure proper installation, operation & maintenance for the Ball
Valves manufactured and supplied by ROTEX (A Ball Division of Rotex Manufacturers &
Engineers Pvt. Ltd.) The valves are identified by marking on the body or on a name plate or both.
2. Transportation, Reception and Storage
• While loading & unloading check for any “arrow” mark on as indicating upward position.
• Always place the valve preferably on rubber sheets layed on ground.
• Ensure that all valves end are covered with protective end caps.
• Always store the valve under roof, in a dry and clean atmosphere, protected from rain &
Storm
• Before installation of stock valves, it is advisable to conduct hydrostatic/pneumatic test.
2.1 Storing the Valve
3
%DOO 9DOYH
3. Do’s and Don’ts

Do’s
It is recommended always to use the Installation, Operation & Maintenance
Manual before installing, operating or repairing of any Ball Valve(s).
• Use specified/ recommended MOC for specified application.

• Before installation of “ROTEX” standard valve, it is advised for user to ascertain the
Compatibility of the material
• Periodically ensure the tightness of Body-Adapter joint bolting, operability & the
Electrical continuity of the valve
• Always use dry, moisture free air while opening the valve with pneumatic actuator or for
Cleaning purposes, always wear warm clothes while working with cryogenic liquids.
Ensure that thorough ventilation is provided while working on the close equipment for
Oxygen transfer
• Ensure that the end protections are removed before installation of valve in line.
Don’ts
• Do not drag the valve on bare floor.
• Do not try to rectify the valve leakage by reworking of seats. Leaking seats have to be
Replaced with the new ROTEX genuine seats.
• Do not allow any such process which may generate spark; particularly working in H2 or
O2 service line or any such inflammable fluids.
• Do not allow dirt, scales, oil or grease to flow through valve & pipeline for oxygen
service.
• Do not allow to replace (even temporarily) the pressure relieving device which is
installed for its intended use by a threaded blind plug.
• Do not inhale the cold gases/ fumes for long duration while working with cryogenic
liquids.
4
%DOO 9DOYH
4. Installation
• Before installation, ensure that the valve end protectors are removed & gasket
is placed for Flanged end valves. Clean the valve ends & bore using
• Methylene chloride or trichloroethylene or as per the Customer’s specification.
• Clean the pipeline to avoid damage of the soft seat due to debris, scaling, etc.
• Keep the valve in fully open condition.
• Never install the Valve with the Actuator on the underneath side in the pipeline.
4.1 Avoid this mounting position.
5. Operation of the Valve(s)
• Ensure that the force applied on the hand wheel of the gearbox or lever shall not
Exceed 360 N.
• Clockwise rotation of Hand wheel closes the valve & anti-clockwise rotation open the
Valves for gear operated valves.
• For lever operated valves, if the position of the lever is in line with pipeline, then the
Valve is in open condition. The valve is in close position when lever is perpendicular to pipe
axis.
• Do not disturb the Gear box open/ close adjustment bolts setting; unless & until it is required.
6. Preventive Maintenance
• Periodically check for any damage to valve seats, ball & stem of the valve.
• While doing periodical checks, it is recommended that the seats, gaskets, seals and
Packing should be replaced by genuine spares.
• A repaired valve is always subjected to set of tests before installation.
5
%DOO 9DOYH
7. Trouble Shooting
The following table lists the possible malfunctions that might occur after prolonged use.
Malfunction Probable cause Actions

Damaged ball surface Replace the ball.
Will not open or close Damaged seats Replace seats.

Check ball Open/Close
Ball might not be closed fully
settings.
Impurities between the ball and Flush the ball from inside.
Irregular ball movement seats or ball – body cavity and ball Clean the sealing surfaces
Seats. and seats
Accumulation or solidification of
Flush valve to get the
material
material out of body.
in the body
Valve too hard to Swelling seats Install correct trim.

operate
/ valve torque too high Grease the stem. If still
Corrosion between stem and won’t operate disassemble
valve body the valve and replace
damaged parts
Operator not installed properly Check operator
Water hammer or noisy Error in valve sizing or flow Confirm valve sizing with
operation of fluid with high velocity. respect to flow.
Gland nut loose Tighten gland nut.
Damaged stem, stem sealing
Leakage through stem Replace the stem.
surface
Damaged stem seal Replace the stem seal.
Worn or damaged stem O-ring
Replace ‘O’ ring/ gasket.
Leakage through body- seal.
adaptor joint Relaxation of studs due to gasket Retighten the studs evenly in
creep criss-cross manner
6
%DOO 9DOYH
8. Ordering the spares

When ordering for spare parts, always convey the following information.
Size of the valve

Valve rating
Sr. No. / Batch No. Available on name plate or body of the valve
Mfg. Date
Part No.
Name of the part
Number of pieces required. Available on general arrangement drawing
P. O. Number
Note: Selection and use of the valve for a specific application requires close consideration of
detailed aspects. Due to the nature of the product, this manual cannot cover all the individual
situations that may occur when installing, using or servicing the valve.
9. General Instructions for Disassembly & Reassembly of Valves

(Lever/ Gear Operated or Actuated)
CAUTION!!!
Pipeline and valve must be depressurized by shutting off the valves & the bleed line, then
cycling the valve once & leaving it half open to relieve the pressure from the body cavity.
A) Disassembly – Floating Ball Valves
1. Valve shall be positioned vertically by resting body side flanges on clean ground surface
(preferably covered with rubber sheet).
2. Remove the handle, lever, gear box or actuator.
3. Open the body adapter joint by loosening the Nuts in crisscross pattern
4. Remove the body seal from the body adapter and body gasket from the body.
5. Remove the ball from the body & the seats from body & body adapter.
6. Remove the stem by removing stem holding devices as applicable.
7. Push stem into Body cavity & take it out.
8. Remove all stem seals.
9. All the components should be stored in a clean place.
7
%DOO 9DOYH
B) Reassembly – Floating Ball Valves
• Before reassembly, inspect the valve for any damage on Body-Adaptor & all internals.
• Damaged internals to be replaced by genuine & with recommended parts only.
1. Follow the same step as mentioned in A) 1).

2. Apply suitable coat to bolting to prevent from corrosion.
3. Insert body seats in position.
4. Insert the stem seal bottom & the stem ‘O’ rings on the stem & install the stem from inside the
body.
5. Insert the top stem seal, the spacer, the disc springs or stem bush into the stem as
applicable.
6. Ensure proper locking of stem with lock nut, washer or mounting plate as applicable.
7. Align stem A/F parallel with the body bore.
8. Gently slide the ball over the stem A/F.
9. Place seal & seat in body adaptor.
10. Position the gasket with the body & position studs.
11. Assemble the valve by putting adapter on the body & tighten the body nuts in a crisscross
pattern.
12. Put the operating member i.e. lever/ handle / G.O. or Actuator in position into body & tighten
them.
13. Ensure smooth operation of valve during opening and closing.
8
%DOO 9DOYH
Rotex Manufacturer & Engineers Pvt. Ltd.

Manpada Road, Dombivili (E)- 421204
Maharashtra, INDIA.
Ph. :+91 251 2871033/ 2871390/2871103/2871989
2870890/2871558
Fax : +91 251 2871191 / 2870663
E-mail : sales-bby@rotexindia.com
www.rotexindia.com
Rotex Manufacturer & Engineers Pvt. Ltd.

114,New India Industrial Estate, Off. Mahakali
Caves Road, Andheri (E), Mumbai – 400 093
Maharashtra, INDIA.
Ph. :+91 22 6695 2161/2/3
Fax : +91 22 6692 3783
E-mail : sales-bby@rotexindia.com
www.rotexindia.com
9
DNL / DXL RANGE
VERSATILE LIMIT SWITCH
Installation
Operation and
Maintenance
Manual
RTX-IOM-LS-R02-0416 Page 1 of 42
www.rotexautomation.com
Table of Contents
1. Introduction ............................................................................................................. 5
1.1. Definitions .............................................................................................................. 6
2. Operation principal ................................................................................................. 6
3. Identification of limit switch ..................................................................................... 7
3.1. DNLF SERIES........................................................................................................ 7
3.2. DXLW SERIES....................................................................................................... 7
4. Installation procedure ............................................................................................. 8
4.1. Cam setting .......................................................................................................... 10
4.1.1. Cam setting for switch 1A .............................................................................. 11
4.1.2. Cam setting for switch 2A .............................................................................. 12
4.1.3. Cam Settings for switch 3A............................................................................ 13
4.1.4. Cam settings for switch 4A ............................................................................ 14
4.2. Termination details ............................................................................................... 17
4.2.1. Termination details for switch 1A ................................................................... 17
5. Testing of micro switches ..................................................................................... 23
5.1. Initial check up before testing micro switches ...................................................... 23
5.2. Testing of micro switches (by using multi-meter) ................................................. 23
6. Testing of proximity sensors ................................................................................. 23
6.1. Initial check up before testing proximity sensors .................................................. 23

6.2. Testing of proximity sensors (by measuring voltage) ........................................... 23
6.3. Testing of proximity sensors (by measuring current) ............................................ 24
7. Maintenance ......................................................................................................... 24
8. Trouble shooting ................................................................................................... 25
8.1. Trouble shooting for micro switches ..................................................................... 25
8.2. Trouble shooting for proximity sensors ................................................................ 25
9. Tool kit .................................................................................................................. 25
10. Disassembly ......................................................................................................... 26
10.1. Cover disassembly ........................................................................................ 26
10.2. Shaft disassembly ......................................................................................... 27
10.2.1. Shaft disassembly for switch 1A .................................................................... 28
10.3. Switch disassembly ....................................................................................... 30
10.3.1. Disassembly of Switch 1A ............................................................................. 30
11. Assembly .............................................................................................................. 33
12. Dimentional details ............................................................................................... 35
13. 35
14. Assembly details ................................................................................................... 36
14.1. Assembly details for DNLF 1A ....................................................................... 36
14.4. ............................................................................................................................ 37
15. Certificates............................................................................................................ 39
16. 41
17. Packaging & store ................................................................................................ 42
18. Assistance ............................................................................................................ 42
1. Introduction
Thank you for choosing ROTEX product. Each product is fully inspected after the
production to offer you the highest quality. In order to fully utilize the product, we
strongly recommend users to read this manual carefully and understood.
x This manual provides information on installation, operation and maintenance

procedures and related instructions for the ROTEX make versatile limit switch.
x The aim of this literature is to support the use of products in correct manner,
and all the technical information provided in the catalogue.
x The manual should be given to the end user.
x The manual can be changed or revised without any prior notice. Any changes
in product's specification, structure, and/or any components may not result
immediate revised version of the manual.
x The manual should not be duplicated or reproduced for any purpose without
any consent of Rotex Manufacturers & Engineers Private Limited, INDIA.
Manufacturer Warranty
x For the safety, it is vital to follow instructions in the manual. It is not ROTEX’s
liability for any damages which caused by users' negligence.
x It is not ROTEX's liability for any damages or accidents which resulted by any
alteration or modification of the product and parts. If alteration or modification
is necessary, please contact the ROTEX directly.
x ROTEX warrants the product from the date of original retail purchase of the
product for one (1) year, except as otherwise stated.
x ROTEX warranty will not cover the products that the product have been
subjected to abuse, accident, alteration, modification, tampering, negligence,
misuse, faulty installation, lack of reasonable care, repair or service in any way
that is not contemplated in the documentation for the product, or if the model
or serial number has been altered, tampered with, defaced or removed;
damages that occurs in shipment, failure due to power surge, and cosmetic
damage. Improper or incorrectly performed maintenance or report voids this
Limited Warranty.
x For detailed warranty information, please contact :
ROTEX MANUFACTERURS & ENGINEERS PRIVATE LIMITED, Manapada road,
Dombivli (e), Maharashtra, India, Pin – 421204.
1.1. Definitions
WARNING:
W
x If not observed, user incurs a high risk of severe damage to product
and/or fatal injury to personnel.
CAUTION:
x If not observed, user may incur damage to product and/or injury to
personnel.
NOTE:
x Advisory and information comments provided to assist maintenance
personnel to carry out maintenance procedures.
2. Operation principal
Limit switch box mounts to an actuator via mounting bracket, usually sold
separately. The unit shaft directly couples to actuator shaft via NAMUR adaptation,
or via coupling provided in mounting kit.
As actuator rotates the unit shaft, adjustable cam on the shaft actuate mechanical
or proximity switches inside the unit enclosure, at the limits of rotary travel set by
the customer.
The switches are prewired to terminal strip in the enclosure, permitting easy
connection of switch output to external electrical monitoring system or indication
devices.
The visual indicator on the enclosure cover indicates 900 rotary travel between
OPEN & CLOSED valve position, unless ordered optionally for other angular
strokes or 3-way valve application.
3. Identification of limit switch
3.1. DNLF SERIES
DNLF 1 A 2 4 R # # # # # M1
MODEL
SWITCH OF SWITCH
NO OF SWITCH
CABLE ENTRY SIZE
BODY AND COVER MATERIAL
COLOUR
INIDICATOR
TEMPERATURE RANGE
CABLE ENTRY
BRACKET
3.2. DXLW SERIES
DXLW 1 A 2 4 R # # # # M1
MODEL
SWITCH OF SWITCH
NO OF SWITCH
CABLE ENTRY
BODY AND COVER MATERIAL
COLOUR
INIDICATOR
TEMPERATURE RANGE
BRACKET
4. Installation procedure
The equipment must be installed in the accordance with the laws, guide lines and
rules applicable within the country.
WARNING:
x Ensure that Supply Voltage should not exceed more than > 20 % of Rated
voltage. (for current and voltage ratings refer catalogue)
x No mechanical rework allowed by customer. Mechanical rework will increase
clearance will increase between Housing and cover.
x Do not open cover / cable gland when limit switch is under operation or in
energized condition.
CAUTION:
x The current and voltage limitation has to be observed as per the tag
plate.
x The wiring and connection should be carried out with proper gland
and care should be taken to avoid water seepage.
x Confirm the area is non-hazardous before opening the cover of the
enclosure for making electrical connections.
x The plugs given along with box are to be removed and metallic plug
to be used.
x Ensure cable gland is properly fitted using sound engineering
practice ensuring that rain water / other fluids do not enter in the
limit switch box.
x The person who operates the limit switch should have enough
knowledge of electrical engineering.
CAUTION IP67 / IP68:

limit switch box.
to be used.
x Tighten the cover bolts fully to avoid water seepage inside the limit
switch box.
x Use UCIL SYNCHEM make GRIP SEAL CABLE JOINING COMPOUND
or equivalent to seal cable gland. For precaution & application of
sealing compound use original manufacturers operational manual.
NOTE:
x The box should be left in the original packing until it is required for the use.
x It should be stored in the enclosed area with temperature limit 4 o to 40 o C.
x Operating temperature range -20°C to +80°C
The limit switch box is installed on the supplied bracket with fastener and left loose.
The box is then mounted on the actuator while taking care that the shaft enters in
the slot of the actuator pinion.
Assembly of limit switch and actuator should allow the play between shaft and
pinion and never between actuator body and bracket. For that while assembling
keep a clearance ‘C’ between shaft and pinion. Where 0.2mm < C < 0.5mm
Connect the wiring through the cable gland required by the cable diameter. And
connect the wires to the terminal strip. Take care to check the symbols on the PCB.
The switch 1 is at the bottom and switch 2 is at the top. Correspondingly the COM1,
NO1, NC1 are corresponding to the switch1
COM: - Common terminal.
NC: - Normally closed contact open when actuated.
NO: - Normally open contact closes when actuated.
4.1. Cam setting
The setting of cam is crucial operation. The cams

are self-locking due to the male and female gears
perfectly matching.
The top cam is red in colour and is to be used for closed position this red cam has
to be rotated clock wise to actuate the switch for closed indication.
Similarly, the bottom cam is yellow in colour and is to be used for open position
cam has to be rotated counter clock wise to actuate the switch for open indication.
Actuate the assembly so as the valve closes.
4.1.1. Cam setting for switch 1A
Operate the actuator to bring the valve in closed condition. Use the red cam to set
the closed position. The cam has to be depressed and rotated (clock wise) till the
click on the micro switch is heard.
Operate the actuator to bring the valve in open condition. Use the yellow cam to set
the open position. The cam has to be lifted and rotated (counter clock wise) till the
click from micro switch is heard.
4.1.2. Cam setting for switch 2A
multimeter gives sensation for fully closed valve position.
Operate the actuator to bring the valve in open condition. The red cam has to be lifted
and rotated (counter clock wise) in 900 so that the multimeter gives sensation for fully
open valve position.
4.1.3. Cam Settings for switch 3A
multimeter gives sensation for fully open valve position.
4.1.4. Cam settings for switch 4A
First loosen the locking screw. Now rotate the valve to ensure that cam rotation is
right, If not adjust the cam accordingly.
Operate the actuator to bring the valve in closed condition. Cam has to be rotated
(clock wise) till the multimeter gives sensation for fully closed valve position.
First loosen the locking screw. Now rotate the valve to ensure that cam rotation is
right, If not adjust the cam accordingly.
Operate the actuator to bring the valve in open condition. Cam has to be rotated
(counter clock wise) till the multimeter gives sensation for fully closed valve
position.
click on the micro switch is heard.
click from micro switch is heard.
multimeter gives sensation for fully open valve position.
4.2. Termination details
4.2.1. Termination details for switch 1A
5. Testing of micro switches
5.1. Initial check up before testing micro switches
1. Ensure voltage is 8 v / 24v in open wire (PLC/DCS output) before connecting to
COM & NO terminals.
2. Connect both wires to COM & NO terminal. There should not be any loose
connection.
3. Ensure target (metal) should be in front of the switch sensing area (adjust both cam
accordingly with respect to valve operation).
5.2. Testing of micro switches (by using multi-meter)

1. Connect multi-meter (ohm-meter) across COM & NO terminal.
2. Check micro switch operation with continuity test.
6. Testing of proximity sensors

6.1. Initial check up before testing proximity sensors
1. Ensure voltage is 8 v / 24v in open wire (PLC/DCS output) before connecting to
COM & NC terminals.
2. Connect both wires to COM & NC terminal with right polarity. There should not be
any loose connection.
3. Ensure target (metal) should be in front of the switch sensing area (adjust both cam
accordingly with respect to valve operation).
4. Ensure distance between target & switch sensing area should be as specified (max.
1 to 3 mm)
6.2. Testing of proximity sensors (by measuring voltage)

1. Connect multi-meter (voltmeter) across COM & NC terminal.
2. For NO switch –Ensure voltage should be 8 volt / 24 volt when target is far away.
Voltage should be dropped when target in front of the switch.
3. For NC switch – Ensure Voltage should be dropped when target is far away.
Voltage should be 8 / 24 volt when target is in front of the switch.
NO sensors – When target is far away, voltage NO sensors – When target in front of switch,
shows 24 volt voltage drops
6.3. Testing of proximity sensors (by measuring current)
1. Connect multi-meter (Mili-ameter) in series with COM/NC terminal
2. For NO switch – Ensure current should be low (or zero) when target is away.
When target in front of switch, full load current should be there.
3. For NC switch – current should be low when target is in front of the switch.
When target is far away, full load current should be there.
NO sensors – When target is far away, current NO sensors – When target is in front of the
shows 0 mA switch, current value is 33.3 mA (as per load)
7. Maintenance
CAUTION for IP67 / IP68:
x Ensure cable gland is properly fitted using sound engineering practice
ensuring that rain water / other fluids do not enter in the limit switch
box.
x The plugs given along with box are to be removed and metallic plug to
be used.
switch box.
x Use UCIL SYNCHEM make GRIP SEAL CABLE JOINING COMPOUND or
equivalent to seal cable gland. For precaution & application of sealing
compound use original manufacturers operational manual.
x NOTE:
x The limit switch must be removed from installation prior to maintenance.
x All the wiring and supply has to be disconnected prior to disassembly.
x All the spares used or replaced must be original from Rotex.
It is important to verify the model/version of limit switch box and spares to be
replaced. In case of difficulty consult Rotex distributor.
1. The Rotex limit switch is designed to operate for one million cycles without
servicing. Call Rotex when you are approching this milestone for a preventive
maintenance kit and instructions.
2. Install, operate and maintain as per the instructions and recommendations of
this manual.
3. Any deviation from the above will cease the responsibilities of ROTEX.
8. Trouble shooting
8.1. Trouble shooting for micro switches
Failure Check list Corrective action
No feedback Check voltage & current Correct DCS output /
correct loose connection
Check cam position Adjust Cam properly
PCB soldering issue / PCB tack issue Re-solder it / replace PCB
due to corrosion
Faulty micro switches Replace micro switch
8.2. Trouble shooting for proximity sensors

Failure Check list Corrective action
No feedback Check polarity Correct it
Check voltage & current Correct DCS output / correct loose
connection
Check target position & its distance Adjust Cam properly (adjust target
towards sensing area position as specified by max. 1 to 3
mm distance)
PCB soldering issue / PCB tack issue Re-solder it / replace PCB
due to corrosion
Faulty proximity sensors Replace sensors
9. Tool kit
Tool Tool specification

1. Screw driver (tip style - sloted) for switch 3 mm
2. Screw driver (tip style - sloted) for plug 6-8 mm
3. Screw driver (tip style - phillips) for dome indicator 4 mm
4. Allen key for cover 5 mm
10. Disassembly
WARNING:
x All electric and pneumatic connections should be removed before
starting disassembly.
CAUTION:
x Do not place dismantled part on any diary/work bench but keep it on
clean paper/cloth in same sequence as you have dismantled it.
NOTE:
x It is advisable to replace all the rubber parts using genuine ROTEX spare kit.
10.1. Cover disassembly
The cover bolts are loosen and then rotated till

they are free.
Pull out the cover vertically, note that the shaft

is still in housing.
To disassembal the top dome indicator remove the screw. Observe the o-ring for
weathering effect. Replace the parts as required. It is advisable to replace all the
rubber part together. All parts are included in the set of kit
10.2. Shaft disassembly

For all shafts listed below, after dismanteling, observe the o-ring damage and cam
damage. Replace shaft or o-ring as required.
10.2.1. Shaft disassembly for switch 1A
Circlip should be removed to bring the shaft out from the box. Use screwdriver to
remove the circlip.
remove the circlip.
remove the circlip.
remove the circlip.
remove the circlip.
emove the circlip.
10.3. Switch disassembly
10.3.1. Disassembly of Switch 1A
Dismantle the screw to take out the PCB. Dismantle the screw to take out microw
switch cover. Now you can acces the micro switches. Use multimeter to locate the
error by using the zero resistence method. The ohmic value should be less than 0.2
ohms. Incase of burnt contact the contacts may show open contact. Replace the
PCB completely with the switches .
Dismantle the screw to take out sensor mounting plate. Dismantle the screw to take
out cylindrical proximity sensor.
Dismantle the screw to take out the PCB. Dismantle the screw to take out microw
switch cover. Now you can acces the proximity switches. Incase of burnt contact
the contacts may show open contact. Replace the PCB completely with the
switches.
Dismantle the screw to take out the PCB. Incase of burnt contact the contacts may
show open contact. Replace the PCB completely with the switches.
Dismantle the screw to take out microw switch cover with micro switches. Take out
the PCB. Incase of burnt contact the contacts may show open contact. Replace the
PCB completely with the switches.
Dismantle the screw to take out the PCB. Dismantle the screw to take out the
hermatically sealed microw switch. Incase of burnt contact the contacts may show
open contact. Replace the PCB completely with the switches.
11. Assembly
CAUTION for IP67 / IP68:
limit switch box.
to be used.
switch box.
x Use UCIL SYNCHEM make GRIP SEAL CABLE JOINING COMPOUND
or equivalent to seal cable gland. For precaution & application of
sealing compound use original manufacturers operational manual.
NOTE:
x Follow the sequences as given below to ensure proper assembly.
x ROTEX recommends “ROTEX V09” grease for greasing. Apply the grease
with soft brush or similar.
1. Install the shaft in housing with grease as a lubricant. Install the circlip. Check
the rotation by hand and check for the play. The play should be less than
0.05mm. If play is more it is not safe to install the box.
2. Install the PCB/ switch/ sensor and switch cover, fasten the screw to ensure the
no movement of PCB is possible. This may cause the faulty signal. Rotate the
cam to ensure that the cam is showing the valve positions correctly. Check the
mating surface of cover and housing there should not be any mark within the
flame path area. It is important if the surface is found faulty must be consulted
with expert on EN norms to certify the usage.
3. Insert cover on the shaft. The shaft has

to be lightly lubricated. Take care that
gasket is in the position and all
fasteners are on the cover. Insert the
top end of the shaft in cover so that it
touches the indicator. Now rotate the
cover till the cover slides down. Align
the cover and body and tighten the bolts
fully. Tighten all the bolts and check with
slip gauge of size 0.05 mm. It should not
enter from any face joint area. In case it
does, the box cannot be used. Repack
the limit switch box to safe storage.
12. Dimentional details
13.
14. Assembly details
14.1. Assembly details for DNLF 1A
14.4.
15. Certificates
1. CCOE 2. BIS
3. ERDA 4. CMRI
5. DGMS 6. KL
7. ATEX 8. INMETRO
16.
9. IECEX 10. CUTR
11. UL
17. Packaging & store
1. When not in use, LIMIT SWITCH BOX should be kept in a sealed plastic bag in
a cardboard box to prevent moisture or dust from contacting product.
2. LIMIT SWITCH BOX should be stored in a dry place free from water and dust.
3. Store at temperature between 40°F and 120°F (4°C and 49°C).
4. Locate in an area to avoid damage by impact.
18. Assistance
For technical questions or assistance, contact any authorized distributor

of ROTEX or:
ROTEX MANUFACTURERS AND ENGINEERS PRIVATE LIMITED

Manpada Road, Dombivli (East)-421204
Maharastra, INDIA.
Tel: +91 251 2871033/ 2871390/ 2871196/ 2871989
Fax: +91 251 2871191
aftersales@rotexautomation.com
To find your local ROTEX representative:
For more information about ROTEX and its network, Please visit
OPERATION AND INSTRUCTION
MANUAL FOR
HOISTING DAMPER
CUSTOMER : FIVES COMBUSTION SYSTEM

PVT LTD, VADODARA
PROJECT : 1X6.85 WHRB based CPP,

Parasakti Cement Industries Ltd,
A.P
P.O NO. : 15189/E2017.3610 dt. 14/11/2017
EAS Systems
Regd. Off. PLOT NO.176, 1ST FLOOR,
SHREE RAM BHAVAN, WEST MARREDPALLY,
SECUNDERABAD –500 026, TELANGANA
PH – 040-66486066, FAX –040- 27706066
WORKS: PLOT NO-701, 702, DOOLAPALLI ROAD,

IDA, JEEDIMETLA, HYDERABAD- 500 055
EAS Systems
Installation and Pre Commission Checks for

Dampers
1. Check for any foreign objects like welding electrodes

stubs / Flux inside the damper near sealing area.
2. Before operating with Electical/Pneumatic actuator,
Check the operation Manually from full open to close and
ensure smooth operation.
3. Check the Damper installation / Orientation w.r.t Flow
Direction as per drawing.
4. Limit Switches and Torque switches operation shall be
ensured by manually operating the switches and tripping
at the end positions and overload. Before Electrical
Operation of Damper the limit switches and Torque
switches shall be taken in to the circuit
5. No Load operation of the Damper shall be carried out with
actuator after erection & before putting in service.
6. Damper should be erected perfectly straight and
perpendicular to the axis. Water leveling and alignment
shall be checked after erection. There shall not be any
Skewness (or) Distortion of Damper frame. This will
obstruct free movement of the blade and gaps between
the seal and blade..
7. Damper blade to be checked for any obstructions for the
movement due to fouling with Duct.
EAS Systems
8. Guillotine Damper rack enclosures should be fitted before

operation to prevent dust ingress/ accumulation.
9. Damper tag number and actuator tag number should be
Co-related and actuators shall be assembled accordingly.
10. Refractory lining if applicable shall be carried out carefully
by experienced team without damaging the seals and
insulation shall clear the blade path.
11. During regular maintenance, damper internal shall be
checked for dust/ ash accumulation on seals and Blade
and shall be cleaned thoroughly.
12. For large size dampers, duct spool shall be welded to the
counter flanges , bolted to the damper and shall be lifted
as unit. The spools shall be welded to the duct to prevent
any distortion / un due load coming on the damper frame
due to welding and alignment.
EAS SYSTEMS
Hyderabad
DATA SHEET FOR THE ELECTRICAL ACTUATORS WITH INTEGRAL STARTER
ITEM : MOTORISED HOISTING DAMPER

REF. DRG.NO: EAS-3-104-0996
PROJECT : 1X6.85 WHRB based CPP,
CLIENT: FIVES COMBUSTION SYSTEM PVT LTD, VADODARA
END USER : Parasakti Cement Industries Ltd,A.P
1 DUTY ON/OFF
2 SUPPLY 415V,50Hz,3Phase.
3 OUTPUT TORQUE 800Kg-m
4 INSULATION CLASS F WITH TEMP. RISE LIMITED TO CLASS B
5 MOTOR DUTY S2-15Min
6 AMBIENT TEMP. .- 20 °C TO + 80 °C
7 THERMO SWITCHES 3 No's,ONE IN EACH WINDING
8 MOTOR ENCLOSURE IP 67
9 LIMIT SWITCHES 4 No's , EACH WITH 2NO+2NC CONTACTS
10 TORQUE SWITCHES 2 No's , EACH WITH 2NO+2NC CONTACTS
11 SWITCH CONTACT RATING 5A / 0.4A AT 250AC/DC
12 LOCAL POSITION INDICATOR DIAL TYPE MECHANICAL
3 No's, 3/4" BSC & 2 No's,1"BSC(SUITABLE FOR POWER
13 CABLE GLANDS 6 Sq.mm X 3 Core ARMOURED CABLE) WITH Ni. PLATED BRASS
D.C CABLE GLANDS
6 Sq.mm FOR POWER & 4 Sq.mm FOR CONTROL
14 TERMINALS
CABLES,SCREW TYPE
15 GEAR BOX WORM TYPE ,QUARTER TURN
16 ENCLOSURE IP67
17 OPERATING TIME 01 200 SEC (Full Open to Full Close)
18 SPACE HEATERS PROVIDED , 230V,A.C,1Ph
19 MOTOR RATING/RPM 1.1 KW / 2800RPM, 415 VAC +/-10%, 50 Hz +/-5%, 3 phase
20 MODEL NO. SA12E180/GSD160+GZ14
21 NO.OF STARTS PER HOUR 150
22 DRAWING NO. 3-WDP-A2B
23 HAND WHEEL FOR MANUAL OPERATION
24 STARTER WITH INTEGRAL STARTER
25 FULL LOAD CURRENT 7.5 A
26 FAIL SAFE CONDITION 01 STAYPUT
27 MAKE AUMA INDIA

28 QTY 1 No
Document No.: DOC-045,Rev.01,Sh.1/1 Prepared PVVP

9-Jan Revised as per TKII Comments Approved PR
SIDE SEAL ARRG.
DETAIL-A SECTION-XX
DETAIL-B
DUCT & DAMPER ORIENTATION
TAG NO.
TECHNICAL DATA FOR ACTUATOR TECHNICAL DATA FOR DAMPER
COUNTER FLANGE DETAIL
POS.NO. DESCRIPTION MAT`L/MAKE SIZE QTY
GENERAL ARRANGEMENT OF
HOISTING DAMPER
SECTION-ZZ
FIVES COMBUSTION SYSTEMS PVT. LTD,
VADODARA
EAS EAS SYSTEMS EAS-3-104-0996 03

Operation & Instructions Manual
SA 3 - SA 100
SAR 3 - SAR 100
Warnings and notes
Failure to observe the warnings and notes may lead to serious injuries or damage. Qualified
personnel must be thoroughly familiar with all warnings and notes in these operation instructions.
Correct transport, proper storage, mounting and installation, as well as careful commissioning are
essential to ensure a trouble-free and safe operation.
The following references draw special attention to safety-relevant procedures in these operation
instructions. Each is marked by the appropriate pictograph.
This pictograph means: Note!

“Note” marks activities or procedures which have major influence on the correct operation.
Non-observance of these notes may lead to consequential damage.
This pictograph means : Warning!

“Warning” marks activities or procedures which, if not carried out correctly can affect the safety of
persons or material.
Only original AUMA spare parts should be used for the proper functioning of the
equipments. Failure to use original spare parts voids the warranty and exempts
AUMA from any liability.
2
Transport and Storage
Transport:
= Transport to the place of Installation (till the last destination)
= Avoid packages from exposing to open atmospheres during transit
= Protect against rains
Storage:
= Store in well ventilated and dry rooms
= Protect against humidity from floor by storage on wooden frame, on pallets, in cage boxes
or on shelves
= Cover actuators with plastic foil to protect against dust and dirt etc.
= Protect suitably against mechanical damages
= During long time storage, protect bright surfaces especially output drive parts and
mounting surface by applying long life corrosion protection agent. Also check once in six
months for corrosion. If corrosion has started, clean and apply corrosion protection agent.
3
(1)
(7)
(8)
(9)
4
1. Electric connection
For 3 phase AC - motors:

These should be connected in panel control circuit (Refer
Thermo switches are provided to protect Motor windings.
Check whether terminal links are fitted to suit type of motor and power supply
(fig.1).
Connect wires R-S-T to terminal pins U1-V1-W1 (fig. 2), for flame proof
enclosure at clip-on terminals.
For single - phase or DC - motors, see instructions in terminal compartment.
Connect control wires according to the wiring diagram.
Terminal Plan), else our warranty is void.
Terminal plan is inside the terminal compartment.

Note : The two circuits of each switch (fig. 3) are suitable only for the same
potential.
CAUTION
2. Remove cover at switch compartment (fig.4) Check whether limit-switch has tripped (fig.5)
Valve completely closed : WSR tripped Valve completely opened : WOL tripped
3. Engage manual drive :

Push declutch lever as indicated by arrow (fig. 6). If resistance is felt, turn
handwheel slowly while lever is pressed till manual drive engages.
4. Operate valve to intermediate position manually (fig. 7)
Direction OPEN ( ) turn handwheel anti-clockwise. Direction CLOSED ( )
turn handwheel clockwise. Switch cam at (Z) or (O) should rotate 90°
and release the switch (fig. 8) if set properly.
5. Ensure sealing faces at control plug are clean and check whether O-ring is ok.
Apply thin film of non - acid grease to sealing faces, then replace plug cover
(fig. 9).
5
6
6. Connect to mains. Switch on motor momentarily. Manual drive will be disengaged
automatically.
Check direction of rotation (fig. 10), observing arrows at limit switch counter gear (fig.11). If
incorrect, stop immediately and change sense of rotation (if 3 phase AC-motor, exchange any
two phases).
7. Start actuator in OPEN direction and switch off by manually tripping limit switch WOL (fig. 12).
8. Start actuator in CLOSED direction and switch off by manually tripping torque switch DSR.
Trip switch by operating lever easily only! (fig. 13). For actuators with double torque switch,
check OPEN direction in the same way.
9. For position seated closing: Start actuator in CLOSED direction and switch off by manually
tripping limit switch WSR (fig. 14).
10. If actuator does not stop, check connection of terminals and the control wiring.
11. Determine over-run of actuator in both directions by visual inspection (amount of additional
rotation of spindle or valve movement after actuator is switched off ).
12. Engage manual drive and operate actuator to fully closed position (fig. 15), while observing the
switch cam for limit switch WSR.
For position seating : When the switch has tripped (fig. 16) continue turning handwheel to
the final position and check whether the remaining travel corresponds
to the over-run. If not, reset to suit. See point 14.
For torque seating : Limit switch WSR must trip shortly before reaching end-position
CLOSED (fig. 16).
13. Operate actuator manually to OPEN-position (fig. 17). Check in the same way as described
above for position seating, see point 12 (fig. 18).
7
8
14. Resetting limit-switching:
— Operate valve away from end-position to account for over-run or to the desired switch tripping
point.
— Push thrust bolt I inwards and turn (fig. 19). The bolt remains in this position.
— For CLOSED position turn spindle marked (Z), (for OPEN position spindle marked,
O) slowly as indicated by arrow (fig. 19). Distinct "clicks" can be felt and heard. Continue
turning the spindle until the cam operates the switch. At this stage, the spindle should not
"click" any more and should not be turned any further.
If inadvertently you override the tripping point, continue turning the spindle slowly in the
same direction till the switch cam goes back to its original position. Repeat setting
instructions as above described.
— Turn thrust bolt I till it snaps back into its original position by spring action.
15. Torque switching (fig. 20)
If the actuator is switched off by torque switch over its travel before reaching an end-
position, please check whether the valve stem is damaged or dirt adhering to it. If
necessary, and with the valve maker’s consent, the setting of the tripping torque may
be raised slightly.
16. Setting : Figures on the torque switch operating cam indicate the valves in Nm (1 mkp = 10
Nm. 1 lbsft. = 1.36 Nm).
Loosen screw and turn the cam till the desired torque coincides with the arrow mark, then
fasten lock-screw.
17. Immediately after start-up : Ensure sealing faces at cover and housing are clean. Check
whether O-ring is correctly in position and apply a thin film of non-acid grease. Replace the
cover and fasten with 4 screws (fig. 21).
18. Fasten control cover screws and tighten glands at conduit entries.
9
(23)
10
Setting of optional equipment
19. Mechanical position indicator : The two dials have a slip clutch for easy adjustment. At valve fully
closed, turn dial (CLOSED) till the arrow is in alignment with the mark on the show glass.
Operate valve into fully OPEN position and adjust dial marked (OPEN) till the arrow mark is in
alignment with the mark on the cover.
Note: The dial (CLOSED) must be held in position while adjusting dial (OPEN). (fig. 22).
20. Electric position transmitter
Through a reduction gearing (selected to suit turns required by valve travel) a potentiometer will be
driven. A suitable power supply unit supplies a low voltage current. The valve position can be read
on a remote instrument with a percentage scale.
21. Setting
Operate valve to the fully CLOSED position (= 0%). Set potentiometer to its starting position by
turning the wiper 1), which has a slip clutch (fig. 23).
Adjust the position meter to zero by trimming potentiometer in the power supply unit (fig. 24).
Operate valve to the fully OPEN position (= 100%). Adjust the position meter to max. range with
the help of the trimming potentiometer in the power supply unit (fig. 24). Check indication for both
end positions. If required, make slight re - adjustment.
1
) applies only to open potentiometer as shown in figure 23.
11
12
SA 3 - SAR 100
Spare Parts SAR 3 - SAR 100
When placing orders for spare parts it is essential to mention order number, work’s number and type of the actuator
(refer to name plate). Parts with number in a circle, e.g. 8 , will be supplied complete only.
Part Designation Part Designation Part Designation

No. No. No.
1 Gear box housing 041 Blinker switch (SPST) 44.01 Set screw
2 Switch compartment cover 043 Spring washer 44.02 Grease nipple
3 External bearing retainer 045 Lock washer 44.03 Thrust bearing
4 Internal bearing retainer 047 Lock washer 44.04 Thrust bearing race
5 Declutch lever 048 Fillister head screw
6 Clutch roller pin, short 052 Support washer 5.1 Terminal box cover
7 Clutch roller pin, long 058 Star washer 5.2 Terminal mounting plate
8 Clutch fork assembly 5.01 Pin carrier (control)
14 Declutch tripping arm 2.1 Motor pinion 5.02 Socket carrier (control)
15 Retaining plate 2.2 Spur gear 5.03 Plug pin (control)
16 Return spring 2.3 Motor mounting flange 5.04 Plug socket (control)
17 Spacer 2.4 Shield 5.05 Fillister head screw
18 Bushing 2.6 Worm gear 5.06 Lock washer
19 Retaining ring (SA 6 only) 2.7 Motor 5.07 Conduit gland
21 Worm shaft assembly 2.8 O-ring 5.08 Thrust washer
23 Bearing flange 2.02 O-ring 5.09 Seal ring
24 Hollow drive shaft 2.05 Hexagon head bolt 5.010 O-ring
25 Compressing spring 2.06 Lock washer
26 Clutch Ring 2.09 Flat washer 6.1 Pin carrier (motor)
27 Helical gear (SA 6 only) 2.010 Hexagon head bolt 6.2 Socket carrier (motor)
29 Handwheel 2.011 Lock washer 6.7 Plug pin (motor)
30 Handwheel retainer 2.012 Fillister head screw 6.8 Plug socket (motor)
36 Pinion gear (Shaft assembly) 2.013 Lock washer
37 Compression spring 7.1 Limit switch (SPDT)
3.1 Indicator assembly 7.2 Torque switch (SPDT)
01 O-ring (Clutch roller pin) 3.5 Indicator glass 7.05 Fillister head screw
02 O-ring (Declutch lever) 3.6 Glass retaining ring 7.06 Lock washer
03 O-ring (drive assly. flanges) 3.01 O-ring
04 O-ring (bearing retainer) 3.02 Fillister head screw 9.1 Potentiometer *
05 O-ring (Handwheel) 3.03 Lock washer 9.1 Potentiometer with Drive Gears*
06 O-ring (Bearing flange) 9.01 Fillister head screw
07 O-ring (Switch comp. cover) 4.4 Stem protection tube 9.02 Lock washer
010 Quad ring 4.7 Stub shaft (type D)
013 Oil seal 4.8 Mounting flange (type D & F) 31 Limit switch drive assembly
014 Oil seal 4.11 Mounting flange (type A) 44 Limit switch counter gear
017 Ball bearing 4.12 Stem nut (type A) 45 Torque switch drive assembly
021 Circlip 4.13 Bearing locknut 46 Reduction gearing assembly
022 Circlip 4.21 Mounting flange (types B & C)
023 Circlip 4.22 Dog drive sleeve (type C) Optional Accessories:
024 Circlip 4.23 Thrust ring
025 Circlip 4.24 Keyway drive sleeve (type B) Resistive Position Transmitter :
027 Snap ring 4.75 Drive socket (type E) RWG 2002
028 Lid 4.05 Stud bolt RWG 1001
030 Hexagon head bolt 4.06 Flat washer RWG 2002G
031 Hexagon head bolt 4.07 Hexagon nut RWG 2002DG
032 Thin shank hex head bolt 4.08 Cap
033 Counter sunk oval head screw 4.09 Hexagon head bolt Inductive Position Transmitter:
034 Hexagon head bolt 4.010 Lock washer IWG 1002
035 Fillister head screw 4.011 Parallel key IWG 1003
039 Parallel key 4.012 Lock washer
Power Supply Unit PS01
Electronic Positioner CU01
*state resistance when ordering
13
14
15
16
Procedure for enlarging the pilot bore of ‘E’ Type output drive sockets used in actuators and gearboxes.
Procedure:-
Dismantle the Drive socket Part No.4.75 by

loosening draw bolt part No.4.06.
Enlarge the pilot bore to required size.
Enlarge bore lenght of the drive socket
shall not exceed the length L* as indicated
in the table.
‘E’ type Dreive socket 9Pilot bore) Key way position should be in line with the
relief hole provided in the drive socket.
Pilot bore Dia Max bore Keyway The hole is provided to do the keyway
Actuator Model (D) Dia length (L*)
slotting on slotting machine.
SA3 - SA6 10 20 67
SA12 - SA15 10 32 67
SA25 - SA60 15 45 72
SA100 20 60 112
Note : All dimensions are in mm
Note: If you find any difficulty while enlarging the pilot bore drive socket, please feel free to contact auma
India for assistance at email ID : service@auma.co.in
17
Do’s and Don’t’s - Troubleshooting tips
Setting of Limit switches:
Improper methods of declutch mechanism leading to premature failure of tripping arm
Re - set torque by loosening the adjustment screw
Improper tightening of covers or missing of o-rings during fitment
In the events of interchangeability check for the e-pac wiring diagram number
18
Do not press mechanical interlock of reversing contactors manually
Additional Tips
= Do not operate the actuator with improper wiring.
= Do not interchange the cards without checking the e-pac code.
= Do not interchange the e-pac without checking the OLR rating.
= Improper sealing of cable glands resulting in water entry at site inadvertently damaging all
the electronic cards.
= Do not operate the actuator in manual mode while electrically operating.
= Please check the input voltage rating of the motor before giving supply.
= Do not run the NORM actuator without panel.
= Do not bypass the thermo-switch connection in the loop
19
All auma actuators are 100% tested and factory checked. Actuators are supplied ready for
service. Most of the actuators are supplied to valve manufacturers for mounting to valves. It
is usual for the valve manufacturer to set the switches and test the motorized valve.
Special care should be taken when commissioning. Wrong connection or faulty

control wiring may result in damage to the motorized valve.
In case the actuators will not be mounted or commissioned for a long period, take care for
adequate (dry) storage, refer to our instruction sheet “Transport, Storage and
Commissioning of auma - actuators”.
Regd. Office & Works : Delhi Branch:

38-A & 39-B, II Phase, Peenya Industrial Area 1310, Tower 'A', Corenthum Complex
Bangalore - 560 058. Sector - 62, Noida - 201 301
Ph : 080-28394366 Fax: 080-28392809 Mb: 93111 95850 (Veeresh), 92120 39339 (Ragesh)
E-mail : info@auma.co.in E-mail : aumandl@auma.co.in
Pune Branch:
712, 713, Bldg. No. 1, "Siddharth Towers"
Kothrud, Pune - 411 038.
Ph : 020 - 25410465 Telefax: 020 - 25443186
E-mail : aumapune@auma.co.in DD/MN-001 ISSUE 7/13
SAFYR PACKSCAN FLAME DETECTOR NOT-15-G / 8
ASSEMBLY, ADJUSTMENT AND MAINTENANCE MANUAL
1/33
FLAME DETECTOR
SAFYR - PACKSCAN
SA510AC-ADF and SA510AC-C67
th
April 21 2011 Edition
CE 0081 II 2 G Ex d IIC T6
(for SA510AC–ADF model)
USER MANUAL
Caractère Auto-contrôlé
Avis Technique
FIVES PILLARD - 13, rue Raymond Teisseire

13272 Marseille Cedex 8 - France
Phone (33) 4 91 80 90 21 - Fax (33) 4 91 25 72 71
E-mail fivespillard@fivesgroup.com Web http://www.fivesgroup.com
CONTENTS
PRECAUTIONS ON ASSEMBLY...............................................................................................................
FIVES PILLARD
2/33
1 - OPERATING PRINCIPLE ........................................................................................................................page 5

2 - CHARACTERISTICS ...............................................................................................................................page 6
2.1 - Weight and dimensions .......................................................................................................page 6
2.2 - Characteristics of utilisation .................................................................................................page 6
2.3 - Functions .............................................................................................................................page 7
2.4 - Utilities required ...................................................................................................................page 7
2.5 - Components.........................................................................................................................page 7
3 - OPENING THE FLAME DETECTOR .......................................................................................................page 8
3.1 - Replacing the internal fuses ................................................................................................page 9
3.2 - Opening for parametering of detector switch .......................................................................page 10
4 – CHOICE OF EXTERNAL ENTRY ...........................................................................................................page 11
4.1 – RS485 link...........................................................................................................................page 11
4.2 – Choice of threshold ...........................................................................................................page 11
5 - CONFIGURATION OF FLAME DETECTOR............................................................................................page 11

5.1 - Configuration with internal switch ........................................................................................page 12
* Switch 1: Selection of configuration type........................................................................page 12
* Switch 2: Utilisation of relay n° 2 ....................................................................................page 12
* Switches 3 and 4: Selection of detection threshold ........................................................page 13
* Switches 5 and 6: Relay activation time .........................................................................page 13
* Switch 7: Relay reversion time .......................................................................................page 13
* Switch 8: Display of detection level ................................................................................page 14
5.2 - Configuration via menu and remote control .........................................................................page 14
5.2.1 - Menu options ...................................................................................................page 15
5.2.2 - Input of access code ........................................................................................page 17
5.2.3 - Menu details.....................................................................................................page 17
Style of displaying flame level............................................................page 17
Flame detection threshold..................................................................page 17
Flame detection relay activation time.................................................page 17
Flame detection relay reversion time .................................................page 17
Utilisation of Relay 2 ..........................................................................page 18
Adjustment of menu display brightness .............................................page 18
Selection of menu display language ..................................................page 18
Change of access code .....................................................................page 18
Display of the flame detector setting..................................................page 19
Adjusting the output current 4..20mA ................................................page 19
PILLARD Configuration......................................................................page 19
6 - MOUNTING THE FLAME DETECTOR ON BURNER ..............................................................................page 19
7 - ELECTRIC CONNECTIONS ....................................................................................................................page 20
7.1 - Power supply .......................................................................................................................page 20
7.2 - 4..20mA Output....................................................................................................................page 21
7.3 - RS485 serial link ..................................................................................................................page 21
7.4 - Flame presence safety contact ............................................................................................page 21
7.5 - Relay N° 2 contact ...........................................................................................................page 21
7.6 - Cabling.................................................................................................................................page 22
8 - RESOLVING OPERATING PROBLEMS .................................................................................................page 22
8.1 - Power Supply .......................................................................................................................page 22
8.2 - Output 4..20mA....................................................................................................................page 22
8.3 - Error Display ........................................................................................................................page 22
8.4 - No signal at one of output relays .........................................................................................page 23
8.5 - Using the external contact for a second threshold...............................................................page 23
8.6 – Relation between bargraph, 4-20mA, and signal level........................................................page 24
9 – PRECAUTIONS FOR USING THE DETECTOR IN AN SIL ENVIRONMENT.........................................page 25
10 – PUTTING INTO SERVICE ....................................................................................................................page 25
11 - EC TYPE CERTIFICAT..........................................................................................................................page 26
12 - MANUFACTURERS CERTIFICATION OF EC CONFORMITY..............................................................page 30
13 - APAVE TECHNICAL CERTIFICATE .....................................................................................................page 31
14 - ASCERT CERTIFICATE ........................................................................................................................page 32
15 – SIL CERTIFICATE ................................................................................................................................page 33
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LIST OF ILLUSTRATIONS
Figure 1: ADF Type Flame detector dimensions ................................................................ page 6
Figure 2: C67 Type Flame detector dimensions................................................................. page 6
Figure 3: Flame detector components ................................................................................ page 8
Figure 4: Flame detector rear panel ................................................................................... page 8
Figure 5: Replacement the Fuses....................................................................................... page 9
Figure 6: Access to parametering setting switches ............................................................ page 10
Figure 7: Location of the SW1 and SW2 switches ............................................................. page 10
Figure 8: Flange and Joint fitting diagram .......................................................................... page 20
Figure 9: Cabling diagram .................................................................................................. page 23
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PRECAUTIONS ON ASSEMBLY
Precautions for using the detector in an SIL environment
The safety function of the SAFYR PACKSCAN detector is to signal the presence or absence
of a flame.
The risk comprises the sending of a flame signal when there is no flame.
Refer to paragraph 9 of page 25 of this document to meet the requirements of SIL 2

according to standard EN61508.
Foreword:
It is incumbent to the user to take all the necessary measures to ensure that personnel
operating the equipment installed are appropriately trained and qualified and that the latter
adhere imperatively to the terms of the present manual.
All connection cabling shall be installed in accordance with correct trade practices and
currently valid regulations.
Preliminary verifications:
Check that the presence of sweeping air corresponds to recommended flow rates.
Check for presence of the air ring when using compressed air, or the absence of that air
ring when using blown air (point 17, figure 3 page 8)
Thread in the connection cable in a manner ensuring that it remains at a minimum
distance of 50 cm from any power and high-voltage cables present.
Ensure that ambient temperature does not exceed 70 °C, and that the detector is
protected from any interference generated by electric equipment (start-up transformers,
motor, high-power
relays, ...).
Before any powering on:
Ensure that the supply voltage is at 24V DC.
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1 – OPERATING PRINCIPLE
Operation of the SAFYR Packscan Flame Detector is based on the detection of the pulsation characteristics of
the flames.
The SAFYR PACKSCAN Flame Detector includes a 'high pass' filter that selects the frequency components of
the combustion phenomenon in the visible band (from 320 to 1100 Nm).
This result was achieved due to the use of:

A photodiode cell with silicon sensor, delivering in the presence of the radiation of a flame a complex AC
signal within the band 0 to 150 Hz
A section destined to eliminate the direct voltage
An amplifier stage associed to a signal processing device
A digital filter, high pass
Self Checking Device
1st Safety Check:

The silicon cell (unlike other captors operates under pressure) does not generate a signal if it is:
not in the presence of light,
in short circuit,
broken
2nd Security Check:

The signal of the cell is then transformed and processed at the entrance of the microcontroller. The
microcontroller analyses the precise frequency and according to the chosen filter, delivers a logical signal of a
variable duration.
The micro-controller eliminates all frequencies of normal time, that's to say potential currents induced by the
proximity of the vision cable with power cables or by hertzian way.
3rd Security Check:

The logical signal issued by the micro-controller orders a device especially designed to take two successive
capacities, each one having for its goal to maintain in working position the flame relay during the time it
discharges. If for any reason, the signal was fixed in position 1 or 0, the time to open the relay contact which is
operating a function of the corresponding capacity would be in the case of the SAFYR 3 seconds.
Display and records
After processing, the signal is integrated in order to obtain a continuous signal representative of the
measurement level. The latter is displayed in bar graph form to be used as a reference for setting the sensitivity
and direction of sights. The signal is also available at terminal points for recording or remote data input
(4-20 mA, maximum impedance of 300 ).
Note: This output current 4-20mA only gives an evaluation and a tendency of the level of flame detected, and
must not in any case be used as a signal of the presence of flame.
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2 - CHARACTERISTICS
2.1 – Weight and Dimensions
Size : Total length maximum 360 mm

Weight : 4,8 kg
360
302
ø 130
G1"1/4J
52
3/8"NPT
43,5
Figure 1: ADF Flame detector dimensions
345
302
ø 130
G1"1/4J
52
3/8"NPT
43,5
Figure 2: C67 type Flame detector dimensions
2.2 – Characteristics of utilisation
Ambient operating temperature : -20°C to +70°C

Storage temperature : -30°C to +90°C
Protection rating (according to EN60529) : IP65
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2.3 - Functions
The SAFYR PACKSCAN flame detector is used to provide an indication of flame presence through measurement
of the pulses emitted by a flame.
Its general characteristics are as follows:
24V DC power supply

ADF housing certified CE 0081 II 2 G Ex d IIC T6 for ADF version (certificates p 25)
An ON-OFF relay contact (SPDT) for the ‘Flame Presence’
An ON-OFF relay contact (SPDT) adjustable for ‘Flame Presence’ or ‘Scanner State’ display output
A 4..20mA Current Loop contact at flame level
Two wires able to be used:
- either at serial port RS485 with JBUS protocol to dialogue with a PC
- or in external commutation of filters of detection
An 8-character alpha-numeric display to show data and flame level via Bar graphs
A green LED indicator lamp displaying detection of the flame
A yellow LED indicator lamp indicating use of the self-check function.
2.4 – Utilities required
Electric
24V DC power supply
Power consumption when operating: 10 VA average.
CAUTION : When power on, the supply current could be superior. You must use a higher power capacity than
the normal operating power.
Cooling and venting air

Compressed air:
Flow rate of 3 - 7Nm3/h
The venting air seal must be installed, see Figure 3,
OR
Blown air:
Minimum pressure of 80 mmCE above the internal pressure of the equipment on which the sights
are mounted, flow rate of 2 to 5 Nm³/h.
The venting air seal shall not be installed, refer to Figure 3, page 8
2.5 - Components
Within the body can be found:

1 photodiode sensitive to the radiation of the flame
1 electronic management and control unit
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8/33
1 : ADF version Cable gland

C67 version Connector 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
2 : Rear cover
3 : AR fixation screw
4 : 125mA Quick Fuse
(Exit 4-20mA)
5 : Electronic Module
6 : 1A Fuse
(24V= Power Supply)
7 : Switch Choice E/S
8 : 8 switch block
9 : Ribbon cable
10 : Connector
11 : 1A Spare part Fuse
12 : Photodiodode Circuit
13 : Assembly clip
14 : Housing
15 : Front Cover
16 : Hexagonal screw
17 : Air ring
18 : Viewfinder support
19 : Knurled screw Figure 3 : Flame Detector Components
8 characters alphanumeric
Yellow Led
"Self Check"
display with led matrix The rear panel of the detector has
in ADF version the cable gland must
imperatively be ATEX0014X Exd II 2 G / D Ex
Green Led
TYPE SAFYR PACKSCAN "Flame presence" d II C -20 ° C +80 ° C IP65 at least 1 / 2 "NPT
SA 510AC ADF
cable diameter 10.5 mm, in C67 version the
connector must impearatively be ITT Cannon
TR1619PFS -20 ° C +80 ° C IP65 at leasta
N° Tp amb. max 70°C
display window composed of:
LCIE 03 ATEX 6347X an 8-character alpha-numeric display
EEx d IIC T6
two LED indicator lamps (1 for self-
II2G
check 1 for flame presence)
Figure 4 : Flame detector rear panel
3 – OPENING THE DETECTOR
A./ ANY OPENING OF THE SAFYR PACKSCAN FLAME

DETECTOR SHALL ONLY BE PERFORMED BY
QUALIFIED PERSONNEL IN PREMISES
APPROPRIATE FOR THE HANDLING OF
ELECTRONIC EQUIPMENT.
B./ OPENING OF THE SAFYR PACKSCAN FLAME

DETECTOR SHALL ONLY BE PERFORMED VIA THE
‘SIGHTING MODULE’ SIDE (Side where the aiming lens
is located) BY UNSCREWING THE 3 HEXAGONAL
SCREWS, POINT 16 FIGURE 3 PAGE 8.
FIVES PILLARD
9/33
3.1 – Replacement of Internal Fuses
ATTENTION: THIS DELICATE OPERATION MUST ONLY BE UNDERTAKEN BY QUALIFIED PERSONNEL

POSSESSING RELEVANT ELECTRONIC EXPERIENCE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Figure 5 : Replacing the Fuses
Turn off the flame detector

Release the body of the detector from its support (18) by loosening the 3 knurled screws (19)
Remove the 3 hexagonal screws (16)
Carefully remove the front cover (15) of the detector (Attention, the detector unit includes a photocell detector
sensor which is linked to the electronic unit (5) by a ribbon cable (9)
Separate the detector unit by removing the ribbon cable (9) from the connector (10)
Remove the 8 screws (3)
Undo and slip the rear lid (2) from the body (14) delicately.
Replace the faulty fuse (4) for the output current 4-20mA or (6) for the supply 24V by the relevant spare fuse
(11) available on the detector unit front cover Refit the front lid (2) to the body (14) and the 8 screws (3)
Reconnect the scanner head to the electronic card by reconnecting the ribbon cable (9) to the connector (10)
Refit the lid (15) into its case (14) taking care of the linking cable
Refit the 3 hexagonal screws (16) and tighten them strongly
Gently insert the 3 knurled screws (19) onto the hexagonal screws (16)
Position the viewer on its support (18) and tighten the 3 knurled screws (19)
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3.2 – Opening for parametering of detector switch
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Figure 6: Access to the parameter setting switches
Withdraw the 3 knurled screws (19)

Take off the support (18)
Unscrew the 3 hexagonal screws (16)
Gently slip out the front cover (15) from the box (14)
ATTENTION: The viewer module is linked by a ribbon cable (9) to the printing circuits (5)
Deconnect the ribbon cable (9) from the connector (10)
The printing circuit containing the switch bloc (7) and (8) is thus accessible
Upon removal of the viewer module, the 8 switch block SW1, and the SW2 switch, become visible on the printing
circuit of the electronic module :
SW2
switch
SW2 switch
SW1 switch
RS485 Seuil Ext.
SW2
Printed board
Cable to the
head scanner
Figure 7 : Location of the SW1 and SW2 switches
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4 – CHOICE OF EXTERNAL ENTRY
The connection cable comprises 1 white wire and 1 colourless wire of 0.34mm² , use of either is possible to:
connect the flame detector to a standard computer PC or a controller by connection series RS485,
or to choose the threshold of detection of flame by an external contact.
4.1 – RS485 Link
To use the RS485 Link in order to communicate with a computer or a remote control by JBUS protocol, position
the SW2 switch on the left of the 'RS485' (see figure 7, page 10).
The 0.34mm² white and non coloured cables serving the RS485 link and becoming respectively the pole '+' (or
'A') and the pole '-' (or 'B') of the link.
Please contact FIVES PILLARD for further information about the use of this link.
4.2 – Choice of Threshold
To be able to choose between the two pre-determined detection thresholds with the help of an external contact,
position the SW2 switch on the right 'Seuil Ext.' (see figure 7, page 10);
The 0.34mm2 white wires and non coloured cables enable the selection of the threshold by connecting them, or
not.
ATTENTION: These two wires must only be connected with a dry contact, free of any potential (switch, relay
contact, etc)
When the SW2 switch is in position 'Seuil Ext.' (see figure 7, page 10), the detector configuration menu proposes
2 different detector thresholds:
The detection threshold 'Open Contact', when the two 0.34mm2 white and non coloured wires are not
connected together
The detection threshold 'Closed Contact', when the two 0.34mm2 white and non coloured wires are
connected together
At this time, when the change from the two 'connected' wires to 'no connected' or the vice versa, the detector
display indicates a new threshold is being used.
5 - CONFIGURATION OF FLAME DETECTOR
The following configurations are possible on the SAFYR PACKSCAN flame detector:
Activation time of flame detection relay (0.5s to 5s)

Reversion time of flame detection relay (1s to 3s)
Flame detection threshold (5 levels)
Type of display of the detection level (By Bar graph or by frequency)
Utilisation of relay n° 2 (In ‘Flame Detection’ or ‘Scanner State’ modes)
The above configurations can be performed via:

the integrated RS485 serial link
an infra-red link (IR remote control not supplied)
internal switches (requiring dismantling of the sights, refer to § 3.2, page 10)
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5.1 - Configuration by internal switches
The flame detector can be configured with the use of the 8 switches block SW1 present within the detector.
In order to validate the switch configuration, it is mandatory to set switch n° 1 to the ‘ON’ position.
In order to access the switches, it is necessary to open the flame detector in accordance with the instructions
provided in paragraph 3.2, page 10.
ANY OPENING OF THE FLAME DETECTOR OR MODIFICATION OF ITS CONFIGURATION

SHALL BE PERFORMED UNDER THE SOLE RESPONSIBILITY OF THE USER.
CONFIGURATION ON MANUFACTURE:
On delivery, configuration of the 8 switches is set as follows:
Configuration via serial link or remote control

Relay 2 used in ‘Scanner State' mode
Low detection threshold level (10Hz)
Activation of flame detection relay set at 1s
Reversion of flame detection relay set at 1s
Display of flame level in Bar graph form
Switch 1: Selection of configuration type
Switch n° 1 indicates if the configuration of the SAFYR PACKSCAN software is carried out by the switch unit, or via
the serial link and the remote control.
Switch 1 is in the ‘Configuration by switch’ position.
Switch 1 is in the ‘Configuration via serial link or remote control' position.
With switch 1 in the ‘ON’ position, it is then possible to parameter:
Switch 2: Utilisation of relay n° 2
Relay n° 2 is used in ‘Scanner State' mode:

Its contact is closed when the self-check system detects no defects (Sensor
defect, High ambient temperature, No Correct operation of electronics)
Relay n° 2 is used in ‘Flame Detection’ mode:

The state of the relay 2 contact is identical to that of the flame detection relay
IMPORTANT NOTE: In the case where the relay n° 2 contact is used in ‘Flame Detection’ mode, that
contact must not serve as a safety contact (of risk sequence type), but only as a display contact or
secondary contact.
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Switches 3 and 4: Selection of detection threshold
Very Low detection threshold

(Flame frequency must be higher than 5Hz)
Low detection threshold

Medium detection threshold

High detection threshold

Switches 5 and 6: Detection relay activation time

Relay ‘activation time’ represents the minimum period during which flame presence shall be detected by the
flame detector without interruption, before ‘Flame Detection’ data is communicated.
Activation time of 0.5 seconds
Activation time of 1 second
Activation time of 2 seconds
Activation time of 5 seconds
Switch 7: Detection relay reversion time

Relay ‘reversion time’ represents the maximum period during which the flame shall no longer be detected by the
cell before losing ‘Flame Detection’ data.
Reversion time of 1 second CAUTION:

A reversion time of 3 seconds of the flame detection
relay shall be tolerated only in the case of surveillance of a
FUEL OIL flame.
If the cell monitors a GAS flame, the relay reversion time
Reversion time of 3 second must be of 1 second.
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Switch 8: Display of detection level
Display in Bar graph form
Display in Frequency form
5.2 - Configuration by menu and remote control
Configuration by menu can be undertaken with the help of the infrared 'PILLARD RC1'
Remote Control, by using the ' ', ' ', 'OK' and 'ESC' buttons.
It is necessary preferably to select the detector requiring configuration beforehand in order to
avoid the neighbouring detectors following suit.
For this, position the remote control near the window of the back part of the selected detector
and press the red key 'Select' of the remote control for 5 seconds.
A menu will appear on the screen indicating that the detector is properly selected, you can then move away (from
1 to 2 metres) to continue to configure this detector.
As soon as the configuration is complete, press briefly on the 'Select' button to deselect the detector.
Note: All detectors, selected beforehand and not receiving any new order by the remote control, will de-select
automatically at the end of 5 minutes
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5.2.1 – Menu options
NO FLAME Displayed outside Menu
Information Display of flame level:
Next
Display Type OK
Display: Bar graph By Bar graph

Next
Display: Frequency By flame frequency
Detection threshold Flame detection threshold:
5Hz Threshold frequency must be > 5Hz
10Hz Threshold Freq must be > 10Hz
Next 15Hz Threshold Freq must be > 15Hz
Tempo ON Activation time of the flame

detection relay
Tempo ON: 0.5s ½ second
Tempo ON: 1s 1 second
Tempo ON: 2s 2 seconds

Next
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OK
Tempo OFF Reversion time of the flame
detection relay
Tempo OFF: 1s
1 second
Next
Tempo OFF: 3s
3 seconds
OK
Relay 2 Config Utilisation of relay n° 2
Relay 2 = Flame Presence The relay n° 2 contact reflects the state

of the flame detection relay.
Next
Relay 2 = Scanner State The relay n° 2 contact indicates that no
self-check defect has been detected
OK
Display Brightness Display brightness :
Value: 1 Minimum brightness (17%)
Value: 2 34% brightness

Next
Value: 6 Maximum brightness (100%)
OK
Display language Language used in the Menu
Language : French French language

Next
Language : English English language
Change of Password Modification of password
Adjustment of 4..20mA Adjustment of the output current
PILLARD Reserved
For FIVES PILLARD people only
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5.2.2 – Input of access code
Certain configuration options may lead to non-compliance with standards and legislation currently adopted in the
countries in which the flame detector is used.
In order to protect against any modifications performed by non-qualified persons, a 4-digit access code may be
requested.
To input the above code, increase or decrease the first number by pressing the ' ' and ' ’ keys and then press
‘OK’ to select the number shown.
The second number will then be requested. Repeat the same operation as above for the remaining three
numbers.
Once the code has been correctly validated, it will no longer be requested during the minute that follows.
The access code set on manufacture is '0000'.
5.2.3 – Menu details
Style of displaying flame level

Scroll the menu options with the ' ' and ' ’ keys and confirm via ‘OK’ the option ‘Type of Display’.
Then choose between the options ‘Display: Bar graph’ or ‘Display: Value in Hertz’ using the ' ' and ' ’ keys and
confirm with the ‘OK’ key.
Display Bar graph: Enables the display of flame detection level on a scale graded from 0 to 8 digits
Frequency Display in Hertz: Enables the display of flame frequency by displaying the number of pulses. It
can be noted that a mini vertical bar graph on the last character of the display is also presented on this
type of display.
NB: Display of the frequency value is often useful during the sights adjustment phase of the detection cell, in
order to obtain higher accuracy. Display by Bar graph then becomes useful to rapidly and easily consult the
current level of detection.
Flame detection threshold

Scroll the menu options with the ' ' and ' ’ keys and confirm via ‘OK’ the option ‘Detection threshold’. An
access code is then requested (refer to paragraph 5.2.2 ‘Input of access code’ page 16).
Then select the required level between ‘5Hz Threshold’ and ‘40Hz Threshold’, using the ' ' and ' ’ buttons then
confirming with 'OK’.
The 'Flame detection' information is given if the measured frequency is higher than the threshold selected.
When the flame detector is configured with two different thresholds selected by the two dedicated cable wires,
(see § 4.2 page 11) this detection threshold becomes the 'Open Contact detection threshold', and the menu
propose to configure a second detection threshold known as 'Closed contact detection threshold'.
Flame detection relay activation time

Scroll through the menu options using the ' ' and ' ’ buttons then confirming with 'OK’ the option ‘Tempo ON’.
An access code is then requested (refer to paragraph 5.2.2 ‘Input of access code’ page 16).
Then select the required delay between ‘0.5 seconds’ and ‘5 seconds’ with the ' ' and ' ’ buttons and confirm
via the ‘OK’ key.
The ‘activation time’ of the relay corresponds to the minimum period during which flame presence shall be
detected by the cell without interruption before ‘Flame Detection’ data is communicated.
CAUTION: Adhere to the standards and legislation currently adopted in the country in which the flame detector is
used.
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Flame detection relay reversion time

Scroll the menu options using the ' ' and ' ’ buttons then confirming with 'OK' the option ‘Tempo OFF’. An
access code is then requested (refer to paragraph 5.2.2 ‘Input of access code’ page 16).
Then select the required delay between ‘1 second’ and ‘3 seconds’ the ' ' and ' ’ buttons then confirming with
'OK’.
The ‘reversion time’ of the relay corresponds to the maximum period during which flame presence shall no
longer be detected by the cell, before loss of the ‘Flame Detection’ data.
CAUTION: Adhere to the standards and legislation currently adopted in the country in which the flame detector
is used. As a general rule, flame detection relay reversion time in 3 seconds is only permitted in the
case of FUEL OIL flame surveillance. If the cell surveys a GAS flame, the reversion time must be
limited to 1 second.
Utilisation of Relay 2
Scroll through the menu options with the ' ' and ' ’ buttons then confirming with 'OK’ the option ‘Relay #2
Config’. An access code is then requested (refer to paragraph 5.2.2 ‘Input of access code’ page 16).
Then select the utilisation mode required between ‘Flame Detection’ or ‘Scanner State’ the ' ' and ' ’ buttons
then confirming with 'OK’.
If Relay 2 is used in ‘Scanner State’, its contact is activated when the self-check system detects no defects
(Sensor Error, High ambient temperature, Uncorrect electronics operation).
If Relay 2 is used in ‘Flame Detection’ mode, the state of its contact reflects that of the frame detection relay.
IMPORTANT: In the case where the Relay 2 contact is used in 'Flame Detection' mode, that contact
shall not serve as a safety contact (Risk sequence for example), but only as a display
or secondary contact.
Adjustment of Display Brightness

Scroll the menu options the ' ' and ' ’ buttons then confirming with 'OK’ the option ‘Display Brightness’.
Then select the level of display brightness between ‘Value: 1’ and ‘Value: 6’ with the ' ' and ' ’ buttons until data
displayed is clearly legible and confirm with the ‘OK’ key.
Value 1 corresponds to minimum display brightness (in dark to normal environments, value 6 corresponding to
maximum brightness (in very sunny conditions).
Selection of Menu Display Language

Scroll the menu options with the ' ' and ' ’ buttons then confirming with 'OK’ the option ‘Language’.
Then select the required language for displaying the menus: ‘Language: French’ or ‘Language: English’ the ' '
and ' ’ buttons then confirming with 'OK’.
Change of access code

Certain configuration options may lead to non-compliance with standards and legislation currently adopted in the
countries in which the flame detector is used.
In order to protect against any modifications performed by non-qualified persons, a 4-digit access code may be
requested.
In order to change the access code set on manufacture (‘0000’), scroll through the menu options the ' ' and ' ’
buttons then confirming with 'OK’ the option ‘Change of Access Code’.
The original access code is then requested (refer to paragraph 5.2.2 ‘Input of access code’ page 16).
After validation of the previous code, the new code selected will be requested twice for verification purposes. The
latter code is subsequently validated and becomes the new access code.
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Display of the flame detector setting

To scroll through the complete flame detector setting configuration on the display screen, choose the
'Information' option on the menu with the ' ' and ' ’ buttons then confirm with 'OK’.
Then, the information will be displayed on the display screen in the following order :
The current setting configuration
' Modifiable Config.' : the current setting is that modified by the remote control or by the serial link.
' Switched Config.' : the current setting is that modified by the 8 switch block SW1 (see § 5.1 page 12)
Use of the relay number 2
The detection threshold/s
The flame detection relay activation time
The flame detection relay reversion time
The actual temperature in the flame detector box
The maximum temperature recorded in the flame detector box
The serial number of the flame detector
The serial link RS485 JBUS slave number
The program version number of the 2 internals microcontrollers
The display of the internal setting
The display of the recorded internal errors ('Memo = XXX')
The display of special internal settings ('Flag = XXX')
The information contained in the last three items may be needed if FIVES PILLARD's assistance is required.
Adjusting the Output Current at 4..20mA

Scroll through the menu options the ' ' and ' ’ buttons then confirm with 'OK’ the option ‘4..20mA Adjustment’.
Then choose ‘4mA Adjustment’ or ‘20mA Adjustment’ with the ' ' and ' ’ buttons to adjust the value between
4mA and/or 20mA then confirming with ‘OK’.
When the 4mA or 20mA setting has been chosen, press the buttons' ' et ' ’ to adjust the value of the current.
This value is reflected immediately on the output current. Press 'OK' to accept the new setting, or 'ESC' to
cancel.
PILLARD Configuration
This option allows our personnel to modify internal parameters of the detector, and is thus withheld.
A specific access code permits access to this option.
6 – MOUNTING THE FLAME DETECTOR ON BURNER

The detector must be positioned on the burner face such that its aim will allow an efficient flame discrimination.
An attachment system composed of two flanges and a swivel can be supplied on option in order to facilitate
adjustment of aiming.
3 HOLES Ø 12 ON 3 Screws HM10X55 SWEEPING AIR RING
DRILL Ø 120
TO BE REMOVED IF BLOWN AIR
IS USED
Ø 1"1/4
14° MAX
~128
135 °
Ø 73
90 ° 14° MAX
~110 SWEEPING AIR INLET

3/8" NPT
Figure 8: Flange and joint fitting diagram
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The detector is supplied with sweeping air via a 3/8 inch NPT connection.
The air used must be clean, dry and oil-free.
In the case of use of “instrument grade” compressed air, it is mandatory to also install the air ring (refer to Figure
3
3, page 8, item 17). Air flow rate shall be between 3 and 7 Nm /h.
If blown air alone is available for use, the above air ring must be withdrawn. Air pressure must then be at a level
at least 80 mm CE above the internal pressure of the equipment, at a flow rate of 2 to 5 Nm 3/h.
The flame detector must never be subjected to ambient temperatures exceeding 70°C, nor to interference due to
the proximity of electric equipment (start-up transformers, high-power relays,...)
7 – ELECTRIC CONNECTIONS
The SAFYR PACKSCAN detector is supplied in standard issue with a 2.5 m long, high- temperature (180°C)
connection cable with nine 0.75 mm² shielded conductors and 4 conductors of 0.34mm²
Wire colour Description Utilisation

Red + Power supply
Supply to sights of 24V DC power (0.3A in operation)
Black - Power supply
Green/Yellow Ground Link to grounding
Brown Common Flame Contact
‘Flame Detection’ Contact
Pink Idle Flame Contact (in ‘Operational’ position when detecting flames)
Green Operational Flame Contact
Gray Common Contact Relay 2 Operational-Idle Contact of the 2nd relay that can be
Blue Idle Contact Relay 2 set in ‘Flame Detection’ or ‘Detector Operations
Violet Operation contact Relay 2 Normal’ modes
Orange + 4..20 mA
Current Loop output Current (Flame Level)
Yellow - 4..20mA
White + RS485 or External Input Serial Link for dialog and commands with a PC, or
Non coloured - RS485 or External Input external selection of threshold
CAUTION: If the length of the cable supplied is insufficient, a junction box will need to be provided in order to
increase linkage length whilst adhering exactly to the following stipulations:
Use a shielded cable comporting flexible 0.75 mm² conductors.
The junction box must be mandatory minimum IP65, IP65 cable glands fitted least properly tightened,
accepts a cable diameter of 10.5 mm, and sufficiently distant from any device or cable that generate
noise. (according installation junction box and gland ATEX model see page 8)
It is essential to correctly link together all the grounding braids of the different cables.
Particular care shall be taken with the linkage cables that must use different cable ducts to those used by
power cables and high-voltage start-up cables (minimum distance away of 50 cm).
Cable shielding (green/yellow wire) must be grounded.
7.1 – Power Supply
The flame detector shall be supplied with 24V DC power -15% / +10%, 10 VA.
Wire Description
Red Positive pole of 24V
Black Negative pole of 24V
CAUTION: When power on, the supply current should be superior. You must increase the supply current from 10
to 20%.
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7.2 - 4..20mA Output

The level of flame detection is available in the form of a 4..20mA current.
Maximum load impedance is of 300 .
Wire Description
Orange Positive pole of 4..20mA loop
Yellow Negative pole of 4..20mA loop
7.3 - RS485 Serial Link

A serial link of RS485 type enables dialog between a computer (of PC type) or a PLC and the flame detector,
using the JBUS protocol.
Dialog is established in 9600 Bds, 8 bits, 1 stop bit, no parity mode.
Please contact the Fives Pillard company for more information if you would like to use this function.
Wire Description
White Positive pole of RS485 link (pole A)
Colourless Negative pole of RS485 link (pole B)
7.4 – Flame presence safety contact

The presence of a flame is indicated by the closing of a dry contact.
That contact is to be used for secured detection of flame presence (hard wired safety link, automated functions..)
Wire Description
Brown Common contact wire
Pink Normally Close output of contact
Green Normally Open output of contact
When a flame is detected , the ‘Flame Presence’ contact closes, thus linking the ‘Common wire’ of the contact
(Brown wire) to the ‘Normally Open’ output of the contact (Green wire).
If a flame is not detected, the ‘Flame Presence’ contact is open, thus linking the ‘Common wire’ of the contact
(Brown wire) to the ‘Normally Closed’ output of the contact (Pink wire).
7.5 - Relay N° 2 Contact

A second relay is present in the detector and can be used as follows:
either as a second ‘Flame Presence’ contact
The signification of this contact is then identical to that of the first ‘Flame Presence’ relay (refer to § 4.4
above).
As the second relay does not use the detector's self-check safety system, its contact shall not serve as a
safety contact, but only as a display contact or secondary contact.
or as a ‘Detector Operations Normal’ contact.
The passage to the ‘Normally Open’ position of this contact then indicates that the cell is correctly
operating (no tube defects, no self-check defect, etc...).
If any defect whatever is detected, the contact will go to the ‘Normally Closed’ position.
Wire Description
Gray Common contact wire
Blue Normally Close output of contact
Violet Normally Open output of contact
Maximum contact switching level: 250 V - 2A.

In the presence of highly inductive loads (high-power relay coils), it is essential to transit via an intermediate relay.
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7.6 - Cabling
1AT Red
+ +
24V =
Black
- -
Green
3A Brown Flame
Presence
Pink
Violet
3A Grey
Relay N° 2
Blue
125mA Orange
+ +
Flame
4..20mA
Yellow Level
- -
+
RS485 White
- +
SW2
JBUS
Threshold Non colored Link
-
choice
PACKSCAN Flame Detector

Cable Output
Figure 9: Cabling Diagram
8 – RESOLVING OPERATING PROBLEMS
8.1 – Supply
Check the voltage supply of the detector: 24V continuous (20V to 27V =), 10VA
Check the internal fuse supply (fusible 1AT, format TR5, see paragraph 3.2 page 10 for its replacement)
8.2 – Output 4..20mA
If no current is available at the exit of the detector, by connecting a continuous milliamperemeter directly on the
detector, check the internal fuse (quick fuse 125mA, format TR5, see paragraph 3.2 page 10 for its replacement).
If the exit current is not in range 4 to 20mA, and no defect is present on the detector, an adjustment of the value
of the 4mA and value of the 20mA is possible using the menu (see page 20).
8.3 – Error Display
In the case of an error with the self-checking of the detector, a message is displayed:
'Freq Err' : The frequency measured is constant; (normally the flame frequency varyies continuously).
The display of this defect normally indicates the measure of an electric light source for
example
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'Err Rel 1' : Defect of self-checking of the position of the relay of flame presence. The relay is not in the
position (Running or Stop/Standstill) desired.
'Err Rel 2' : Defect of self-checking of the position of the relay n° 2. The relay is not in the position
(Running or Stop) desired.
'Tp High' : defect of temperature. The temperature inside the flame detector is higher than 80°C.
'Err Dial' : Error of dialogue between the internal electronic charts.
The fault 'Tp High' is almost certainly due to an excessive ambient temperature, due to a lack of sweeping air
(see paragraph 2.4, page 7). If this is corrected the problem will be resolved.
The defect 'Freq Err' normally indicates the detection of an electric light source. Modifiying the orientation of the
viewfinder should resolve this problem.
Any other faults necessitate return the equipment to our workshops for repairs.
8.4 – No signal from any of the Output Relays
The contacts of the exit relays are protected by a fuse from 3.15A; this is to avoid coal mining, or welding, due to
an excessive current and to exceeding their recommendations (2A under 250V~).
If there is no more connection between the 'common' and the 'normally open', and with the 'common' and the
'normally close' of one of the contacts, the flame detector must be returned to our buildings for the replacement
of the fuse.
CONTACT Wire Designation

Brown Common contact
Flame Presence Pink Normally Close output of contact
Green Normally Open output of contact
Grey Common contact
Relay 2 Blue Normally Close output of contact
Violet Normally Open output of contact
8.5 - Using the external contact for a second threshold
It is possible to configure two detection thresholds (shut-off frequencies) selectable from an external contact.
With the flame detector switched off, remove the sighting port as shown in paragraph 3.2 on page 10, and, with
the help of a long slim screwdriver, delicately flip the SW2 switch to the right, to the "Seuil Ext." position.
SW2 switch
SW2 switch
SW1 switch
RS485 Seuil Ext.
SW2
Printed board
Cable to the
head scanner
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Close the detector and switch on again.
From now on, the white wire and the colourless wire on the connection cable will be used to select one of the two
detection thresholds (shut-off frequency) according to whether they are connected together or not.
With the SW2 switch in the "Seuil ext" position, the configuration menu managed by the infrared remote is
modified so as to display two options:
"Open contact detection threshold" enables the minimum frequency to be entered when the white wire
and the colourless wire are not connected
"Closed contact detection threshold" enables the minimum frequency to be entered when the white wire
and the colourless wire are connected together.
Furthermore, the "Information" menu is modified such that it displays the detection threshold level currently in
use, and the level of the other threshold.
Finally, after each modification in the connection whether between the white wire and the colourless wire or not,
the display will briefly show the threshold level in use.
NOTE: If the configuration of the flame detector is programmed for "internal switch configuration"
(switch n°1 of unit SW1 in the 'ON' position, see paragraph 5.1 of page 12):
The detection threshold corresponding to the 'Open Contact' state (white wire and colourless
wire not being connected together) is the same as that programmed by switches 3 and 4 of
unit SW1 (paragraph 5.1 page 13)
The detection threshold corresponding to the "Closed Contact' state (white wire and
colourless wire being connected together) is the same as that programmed by the menu
"contact threshold closed" (and programmed at 25Hz in the workshop)
8.6 – Relation between Bargraph – 4..20mA Output – Flame Level Detection
According to the threshold selected, both the number of bargraph segments and the 4-20mA signal output
change for a given level of flame detection :
Flame level detection Bargraph display 4..20mA Relay

Level = 0 No Flame 4 mA OFF
0 < Level < Threshold / 2 (1 thin segment) 4 mA OFF
Threshold / 2 < Level < Threshold (2 thins segments) 4 to 8 mA OFF
(3 segments) 8 mA ON
(3 to 6 segments) 8 to 20 mA ON
(8 segments) 20mA ON
0 < Level < Threshold / 2 Level > Threshold x 2
Level = Threshold
Threshold / 2 < Level < Threshold
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9 – PRECAUTIONS FOR USING THE DETECTOR IN AN SIL ENVIRONMENT
The safety function of the SAFYR PACKSCAN is to signal the presence or absence of a flame.
The risk comprises the sending of a flame signal when there is no flame.
The detector is SIL 2 as per EN61508 if the following conditions are met :
Relay 2 must be configured and used as a "Scanner State" relay. In this configuration, the relay signals
that the detector is functioning properly. Its contact opens whenever a self-checking fault occurs (see
page 22).
The MTTR (Mean Time To Repair) must be less than 72 hours. This means either to have a spare
detector or be sure to be able to order, have delivered and have the new device installed in less than 72
hours.
Every two years, the detector proper functioning must be checked (correct signalling of the presence
and absence of flame).
Any display fault (signal lamps and display) implies the return of the unit for an After-Sales Service.
10 – PUTTING INTO SERVICE
Position the flame detector on the burner front plate such that the line of sight allows an efficient discrimination of
the flames.
DETECTOR
GOOD BAD
BURNER AXIS
SIG
HT
AX
IS
BURNER FACE
The line of sight must include the whole of the flame to be monitored
There must not be any object obstructing this line of sight.
A swivel mount assembly is available as an option to enable mechanical positioning of the sighting
angle.
Refer to paragraph 6 of page 19 for the mechanical fitting of the detector on the burner.
Do not forget to put the sweeping air in service in order to protect the detector from dust and burner heat.
After having wired the detector according to paragraph 7 of page 20, and checked the voltages to the detector, it
can be energised.
The detector workshop settings should allow a simple and quick flame detection.
It will then be possible to fine-tune these adjustments in order to have a precise and reliable detection.
Indeed, using the menu and remote, you can :
Display the detection level in "Frequency" in order to improve accuracy.

Orientate the scanner head in order to obtain the maximum display value for all burner operation rates
Choose the detection threshold in order to obtain a sufficient safety level (for example, a threshold equal to
the minimum value measured, divided by 2 or 1.5)
Adjust the flame relay rising and drop time according to the process and the current legislation in force.
Switch the detection level display to "bargraph" in order to obtain simple quality information which is easy to
interpret.
For more advanced adjustments, refer to paragraph 5 on page 11 : "Configuration of the flame detector"
FIVES PILLARD
26/33
11 – EC TYPE CERTIFICAT
FIVES PILLARD
27/33
FIVES PILLARD
28/33
FIVES PILLARD
29/33
FIVES PILLARD
30/33
12 – MANUFACTURERS CERTIFICATION OF CONFORMITY
We, the undersigned : FIVES PILLARD Company

13 rue Raymond Teisseire
13008 MARSEILLE
FRANCE
Certify that PILLARD Flame Detector Type : SAFYR PACKSCAN
Manufactured in compliance with the following applicable Directive ATEX 94/9/EC, conforms to the EC Certificate Type LCIE
03 ATEX 6347 X and contains a Production Quality Standard notice LCIE 04 ATEX Q 8004.
Conditions of use of the PILLARD SAFYR PACKSCAN Flame Detector are specified by their classification:
II 2 G - Ex d IIC T6
Hence:
II : Group II, apparatus destined to be used in places other than mines or flammable surface installations.
2 : Category 2, probably present, but occasionally exposure to explosive atmosphere.
G : Presence of gas or fumes.
Ex : Electric materials planned for explosive atmospheres
d : Protection by flame proof enclosure.
IIC : Explosive atmosphere can consist of acetylene, carbon disulfide and hydrogen.
T6 : Maximum surface temperature 85°C
The equipment conforms to the Standards:
EN 60079-0 (2006) : general rules

EN 60079-1 (2007) : flame proof enclosure "d"
The Agency responsible for monitoring the quality of production is the LCIE (n°0081):
LCIE
33, avenue du Général Leclerc – BP 8
92266 Fontenay aux Rose cedex
FRANCE
The equipment qualification tests are based on the following standards:
- concerning EC Electromagnetic Compatibility Directive (CEM) (2004/108/CE)

EN 61000-6-2 (2007) : Immunity
EN 61000-6-4 (2006) : Emissions
th
Marseilles, October 19 2010
FIVES PILLARD
31/33
13 – AVIS TECHNIQUE APAVE
FIVES PILLARD
32/33
14 – ASCERT CERTIFICATE
FIVES PILLARD
33/33
15 – SIL CERTIFICATE
FIVES PILLARD
1
HEEI IGNITOR & ACTUATOR ASSEMBLY

2
^z^dD^Z/Wd/KE

dŚŝƐ ŵĂŶƵĂů ĐŽŶƚĂŝŶƐ ŝŶƐƚĂůůĂƚŝŽŶ͕ KƉĞƌĂƚŝŽŶ ĂŶĚ DĂŝŶƚĞŶĂŶĐĞ ŝŶƐƚƌƵĐƚŝŽŶƐ ƉĞƌƚĂŝŶŝŶŐ ƚŽ ƚŚĞ
&^ŵĂŬĞ,ŝŐŚŶĞƌŐǇůĞĐƚƌŝĐĂů/ŐŶŝƚĞƌ;,/ͿĂĐƚƵĂƚŽƌĂƐƐĞŵďůǇΘĐŽŶƚƌŽůĐĂďůĞ͘dŚĞĂĐƚƵĂƚŽƌ
ĂƐƐĞŵďůǇĂŶĚĐŽŶƚƌŽůĐĂďůĞĂƌĞĐŽŵƉŽŶĞŶƚƉĂƌƚƐŽĨƚŚĞ&^ƌĞƚƌĂĐƚĂďůĞ,/ŝŐŶŝƚĞƌƐǇƐƚĞŵ͘dŽ
ĐŽŵƉůĞƚĞƚŚĞ,/ĂƐƐĞŵďůǇ͖ƉŽǁĞƌƉĂĐŬ͕ƐƉĂƌŬƌŽĚĂƐƐĞŵďůǇ͕ĂŶĚƉŽǁĞƌĐĂďůĞĂƌĞƌĞƋƵŝƌĞĚ͘

,/dhdKZ^^D>z^W/&/d/KE

WŽǁĞƌ^ƵƉƉůǇ ͗ ϮϯϬs͕нϭϬйͲϭϱй͕ϱϬ,ǌ
/ŶƐƚƌƵŵĞŶƚŝƌWƌĞƐƐƵƌĞ ͗ ϰͲϳŬŐͬĐŵϸ
/ŶƐƚƌƵŵĞŶƚŝƌhƐĂŐĞ ͗ ϭϬ^&D
/ŶƐƚƌƵŵĞŶƚŝƌŽŶŶĞĐƚŝŽŶ ͗ ϭͬϰ͟EWd
/ŶƐĞƌƚŝŽŶ>ĞŶŐƚŚ ͗ ϴ͟;ƐƚĂŶĚĂƌĚͿͬϭϮ͟
ŽŽůŝŶŐŝƌ;WƵƌŐĞŝƌͿ ͗ ϭϬ^&DΛϭƉƐŝŐĂďŽǀĞĨƵƌŶĂĐĞƉƌĞƐƐƵƌĞ

'EZ>^Z/Wd/KE

dŚĞ &^ ŵĂŬĞ ,/ ĐƚƵĂƚŽƌ ƐƐĞŵďůǇ ŝƐ ĂŶ ĞůĞĐƚƌŝĐͬƉŶĞƵŵĂƚŝĐ ƐǇƐƚĞŵ ƚŚĂƚ ĂĚǀĂŶĐĞƐ ĂŶĚ
ƉŽƐŝƚŝŽŶƐ ƚŚĞ ,/ ^ƉĂƌŬ ZŽĚ ĂƐƐĞŵďůǇ ŝŶ ƚŚĞ ĨƵƌŶĂĐĞ͘ dŚĞ ^ƉĂƌŬ ZŽĚ ĂƐƐĞŵďůǇ ĂůŽŶŐ ǁŝƚŚ
ƉŽǁĞƌ ĐĂďůĞƐ ŝƐ ĚĞƐŝŐŶĞĚ ƚŽ ĞĨĨŝĐŝĞŶƚůǇ ĚĞůŝǀĞƌ ƚŚĞ ŚŝŐŚ ǀŽůƚĂŐĞ ĞŶĞƌŐǇ ĨƌŽŵ ƚŚĞ ƉŽǁĞƌ ƉĂĐŬ
ƚĞƌŵŝŶĂůďůŽĐŬƚŽƚŚĞĨƵĞůŝŐŶŝƚŝŽŶǌŽŶĞ͘dŚĞƉŽǁĞƌĐĂďůĞŝƐĐŽŶŶĞĐƚĞĚƚŽƚŚĞďĂĐŬŽĨƚŚĞ^ƉĂƌŬ
ZŽĚ ĂƐƐĞŵďůǇ ĂŶĚ ŚĂƌĚ ǁŝƌĞĚ ƚŽ ƚŚĞ ,ŝŐŚ sŽůƚĂŐĞ ƚĞƌŵŝŶĂů ďůŽĐŬ ŝŶ ƚŚĞ ƉŽǁĞƌ ƉĂĐŬ͘ tŚĞŶ
ŐŝǀĞŶƚŚĞ͞^ƚĂƌƚ/ŶƐĞƌƚ͟ĂŶĚ͞^ƚĂƌƚ^ƉĂƌŬ͟ĐŽŵŵĂŶĚƐĨƌŽŵƚŚĞĐƵƐƚŽŵĞƌ͛ƐďƵƌŶĞƌŵĂŶĂŐĞŵĞŶƚ
ƐǇƐƚĞŵ͕ƚŚĞƌĞƚƌĂĐƚŝŶŐ,/ƐǇƐƚĞŵǁŝůůŽƉĞƌĂƚĞ͘

dŚĞ͞^ƚĂƌƚ/ŶƐĞƌƚ͟ĞŶĞƌŐŝǌĞƐƚŚĞĞůĞĐƚƌŝĐͬƉŶĞƵŵĂƚŝĐƐǇƐƚĞŵŝŶƚŚĞ,/ĐƚƵĂƚŽƌǁŚŝĐŚĂĚǀĂŶĐĞƐ
ƚŚĞ ^ƉĂƌŬ ZŽĚ ĂƐƐĞŵďůǇ ŝŶƚŽ ƚŚĞ ĨƵƌŶĂĐĞ͕ ǁŚĞƌĞ ƚŚĞ ůŝŵŝƚ ƐǁŝƚĐŚ ŐŝǀĞƐ ŝŶƐĞƌƚĞĚ ƉŽƐŝƚŝŽŶ
ĨĞĞĚďĂĐŬ͘dŚĞƵƌŶĞƌDĂŶĂŐĞŵĞŶƚƐǇƐƚĞŵŝŶƚĞƌƌƵƉƚƐƚŚĞ͞^ƚĂƌƚ^ƉĂƌŬ͟ĐŽŵŵĂŶĚƐƚŽƚŚĞ,/
ƉŽǁĞƌ ƉĂĐŬ ĂĨƚĞƌ ƚŚĞ ƚŝŵĞ ƚƌŝĂů ĨŽƌ ŝŐŶŝƚŝŽŶ ĞǆƉŝƌĞƐ͘ dŚĞ ,/ ĂĐƚƵĂƚŽƌ ƌĞƚƌĂĐƚƐ ƚŚĞ ^ƉĂƌŬ ZŽĚ
ĂƐƐĞŵďůǇĂŶĚƌĞƚƌĂĐƚƉŽƐŝƚŝŽŶƉƌŽǀĞĚǁŝƚŚƚŚĞŚĞůƉŽĨƌĞƚƌĂĐƚůŝŵŝƚƐǁŝƚĐŚ͘

^WZ<ZK

dŚĞƐƉĂƌŬƌŽĚĐŽŶƐŝƐƚƐŽĨĂĐĞŶƚƌĂůŝŶƐƵůĂƚĞĚĐŽŶĚƵĐƚŽƌǁŚŝĐŚƉƌŽǀŝĚĞƐƚŚĞĐƵƌƌĞŶƚĨůŽǁƉĂƚŚƚŽ
ƚŚĞ ƐƉĂƌŬ ƉůƵŐ͘ dŚĞ ĐĞŶƚĞƌ ĐŽŶĚƵĐƚŽƌ ƵƐĞƐ Ă ĐĞƌĂŵŝĐ ŝŶƐƵůĂƚŽƌ ƚŽ ĐĞŶƚĞƌ ƚŚĞ ĐŽŶĚƵĐƚŽƌ
ĐŽŶŶĞĐƚŝŽŶĂƚƚŚĞƐƉĂƌŬƉůƵŐ͘

3
^WZ<W>h'

dŚĞƐƉĂƌŬƉůƵŐŝƐůŽĐĂƚĞĚŽŶƚŚĞĞŶĚŽĨƚŚĞƐƉĂƌŬƌŽĚƚŚĂƚŝƐƉŽƐŝƚŝŽŶĞĚŝŶƚŽƚŚĞĨƵĞůƐƉƌĂǇŝŶƐŝĚĞ
ƚŚĞĨƵƌŶĂĐĞ͘dŚĞƐƉĂƌŬƉůƵŐŝƐĂŚŝŐŚƚĞŵƉĞƌĂƚƵƌĞƐŚƵŶƚĞĚƐƵƌĨĂĐĞƚǇƉĞƉůƵŐ͘dŚĞƐƉĂƌŬƉůƵŐŝƐĂ
ĐŽŶƐƵŵĂďůĞŝƚĞŵĂŶĚŵƵƐƚďĞƌĞƉůĂĐĞĚǁŝƚŚƵƐĞ͘

WKtZ>

dŚĞƉŽǁĞƌĐĂďůĞŝƐĂƚǁŽĐŽŶĚƵĐƚŽƌĐĂďůĞ͘KŶĞůĞĂĚŝƐŵĂƌŬĞĚĂƐƚŚĞƉƌŝŵĂƌǇ͞н͟ĂŶĚƚŚĞŽƚŚĞƌ
ŝƐ ƚŚĞ ƌĞƚƵƌŶ ͞Ͳ͘͟ tŚŝůĞ ƚŚŝƌĚ ŽŶĞ ŝƐ ƵƐĞĚ ĨŽƌ ĞĂƌƚŚ ĐŽŶŶĞĐƚŝŽŶ͘ dŚĞ ƉŽǁĞƌ ĐĂďůĞ ƉƌŽǀŝĚĞƐ Ă
ĨůĞǆŝďůĞĞůĞĐƚƌŝĐĂůĐŽŶŶĞĐƚŝŽŶĨƌŽŵƚŚĞƉŽǁĞƌƉĂĐŬ͘

/E^d>>d/KE/E^dZhd/KE

^dKZ'

tŚĞŶ ƐƚŽƌŝŶŐ ƚŚĞ ,/ ^ƉĂƌŬ ZŽĚƐ͕ ^ƉĂƌŬ WůƵŐƐ͕ ĂŶĚ ƉŽǁĞƌ ĐĂďůĞ ƉƌŝŽƌ ƚŽ ŝŶƐƚĂůůĂƚŝŽŶ͕ ŬĞĞƉ
ĞƋƵŝƉŵĞŶƚŝŶĂĐŽǀĞƌĞĚĂŶĚĚƌǇůŽĐĂƚŝŽŶ͘<ĞĞƉƵŶŝƚƐŝŶĂĨĂĐƚŽƌǇĐĂƌƚŽŶƐǁŚŝůĞŝŶƐƚŽƌĂŐĞ͘

^WZ<ZK

&ůĞǆŝďůĞ ĂŶĚ ƌŝŐŝĚ ƐƉĂƌŬ ƌŽĚƐ ŵƵƐƚ ďĞ ůŽĐĂƚĞĚ ŝŶ ŐƵŝĚĞ ƚƵďĞƐ ĨŽƌ ƐƵƉƉŽƌƚ ĂŶĚ ĂƉƉůŝĐĂƚŝŽŶ ŽĨ
ĐŽŽůŝŶŐ Ăŝƌ͘ ZŽĚ ƌĞŵŽǀĂů ĐůĞĂƌĂŶĐĞƐ ƐŚŽƵůĚ ďĞ ĐŚĞĐŬĞĚ ƚŽ ĂůůŽǁ ƉĞƌŝŽĚŝĐ ƌŽĚ ŝŶƐƉĞĐƚŝŽŶ ĂŶĚ
ƌĞƉůĂĐĞŵĞŶƚ ŽĨ ƚŚĞ ƐƉĂƌŬ ƉůƵŐ͘ tŚĞŶ ŚĂŶĚůŝŶŐ ƚŚĞ ƐƉĂƌŬ ƌŽĚ͕ ĐĂƌĞ ŵƵƐƚ ďĞ ƚĂŬĞŶ ƚŽ ĂǀŽŝĚ
ďƌĞĂŬŝŶŐ ƚŚĞ ŚŽƚ ĞŶĚ ĐĞƌĂŵŝĐ ŝŶƐƵůĂƚŽƌ Žƌ ĞǆƉŽƐŝŶŐ ƚŚĞ ƌŽĚ ŝŶƚĞƌŶĂůƐ ƚŽ ŵŽŝƐƚƵƌĞ͕ Ěŝƌƚ Žƌ Žŝů͘
WƌŽƚĞĐƚ ƌŽĚ ĞŶĚƐ ǁŝƚŚ ĐĂƉƐ ǁŚĞŶ ƚŚĞ ƉŽǁĞƌ ĐĂďůĞ Žƌ ƐƉĂƌŬ ƉůƵŐ ŝƐ ƌĞŵŽǀĞĚ͘ Ž ŶŽƚ ƌĞŵŽǀĞ
ƉƌŽƚĞĐƚŝǀĞĞŶĚĐĂƉƐĨƌŽŵƐƉĂƌĞƐƉĂƌŬƌŽĚƐƵŶƚŝůƌĞĂĚǇƚŽƵƐĞ͘

^WZ<W>h'

dŚĞƐƉĂƌŬƉůƵŐ;dŝƉͿŝƐĚĞƐŝŐŶĞĚƚŽƉƌŽĚƵĐĞƌĂƉŝĚƉƵůƐĞƐĂĐƌŽƐƐƚŚĞŽƵƚĞƌƐƵƌĨĂĐĞŽĨƚŚĞƉůƵŐƚŝƉ͘
/ŶƉƌŽĚƵĐŝŶŐƚŚĞƐĞĂƌĐƐŵĞƚĂůŝƐĞƌŽĚĞĚĨƌŽŵƚŚĞĞŶĚŽĨƐƉĂƌŬƉůƵŐƚŝƉ͘WĞƌŝŽĚŝĐƌĞƉůĂĐĞŵĞŶƚŽĨ
ƚŚĞƐƉĂƌŬƉůƵŐŝƐƌĞƋƵŝƌĞĚ͘ dŚĞƐƉĂƌŬƉůƵŐ ŚĂƐ Ă ƚŚƌĞĂĚĞĚ ĞŶĚ ƚŚĂƚŝƐƐĐƌĞǁĞĚŽŶƚŽ ƚŚĞƐƉĂƌŬ
ƌŽĚ͘
4

WKtZ>

WƌŝŽƌƚŽŝŶƐƚĂůůĂƚŝŽŶ͕ƐƚƌĞƚĐŚƚŚĞĐĂďůĞƚŽ ĞŶƐƵƌĞŐŽŽĚƐĞĂƚŝŶŐŽĨƚŚĞĞůĞĐƚƌŝĐĂůĐŽŶŶĞĐƚŽƌƐĂŶĚ
ŝŶƐƵůĂƚŽƌƐ͘ tŚĞŶ ƌŽƵƚŝŶŐ ƚŚĞ ƉŽǁĞƌ ĐĂďůĞ ďĞƚǁĞĞŶ ƚŚĞ ƉŽǁĞƌ ƉĂĐŬ ĂŶĚ ƚŚĞ ƐƉĂƌŬ ƌŽĚ͕ ĂǀŽŝĚ
ĐŽŝůŝŶŐ ƚŚĞ ĐĂďůĞƐ ƐŝŶĐĞ ƚŚŝƐ ŵĂǇ ƌĞĚƵĐĞ ƚŚĞ ĞŶĞƌŐǇ ƚƌĂŶƐĨĞƌƌĞĚ ƚŽ ƚŚĞ ƐƉĂƌŬ ƚŝƉ ĚƵĞ ƚŽ
ĂĚĚŝƚŝŽŶĂůƌĞĂĐƚĂŶĐĞ͘

dŚĞƉŽǁĞƌĐĂďůĞŝƐƐŚŝĞůĚĞĚƚŽƉƌĞǀĞŶƚŶŽŝƐĞŝŶƚĞƌĨĞƌĞŶĐĞƚŽŽƚŚĞƌĚĞǀŝĐĞƐ͘ŽŶŽƚďƵŶĚůĞŽƌƚŝĞ
ĐĂďůĞƐ ƚŽ ƚŚĞ ,/ ƉŽǁĞƌ ĐĂďůĞ͘ <ĞĞƉ ĐĂďůĞ ĐůĞĂƌ ŽĨ ĨůĂŵĞ ƐĐĂŶŶĞƌƐ ĂŶĚ ĞůĞĐƚƌŝĐĂů ĞƋƵŝƉŵĞŶƚ
ĐĂďůĞƐ͘dŚĞ͞ƉƌŝŵĂƌǇ͟Žƌ͞н͟ǁŝƌĞŝƐĐŽŶŶĞĐƚĞĚƚŽƚŚĞƉŽƐŝƚŝǀĞƚĞƌŵŝŶĂůŽŶƚŚĞƉŽǁĞƌƉĂĐŬŚŝŐŚ
ǀŽůƚĂŐĞ ƚĞƌŵŝŶĂů ďůŽĐŬ͘ dŚĞ ͞ZĞƚƵƌŶ͟ Žƌ ͞Ͳ͟ ǁŝƌĞ ŝƐ ĐŽŶŶĞĐƚĞĚ ŶĞŐĂƚŝǀĞ ƚĞƌŵŝŶĂů ŽŶ ƚŚĞ ƐĂŵĞ
ƚĞƌŵŝŶĂůďůŽĐŬ͘ŽŶŶĞĐƚƚŚĞďŽŶĚŝŶŐŐƌŽƵŶĚǁŝƌĞƚŽƚŚĞŐƌŽƵŶĚŝŶŐůƵŐŝŶƚŚĞƉŽǁĞƌƉĂĐŬ͘^ĞĞ
ƚŚĞ,/WŽǁĞƌŝŶƐƚƌƵĐƚŝŽŶŽŽŬůĞƚĨŽƌǁŝƌŝŶŐĚĞƚĂŝůƐ͘

dŚĞƐŽůĞŶŽŝĚǀĂůǀĞ͕ƉŽǁĞƌĐǇůŝŶĚĞƌ͕ůŝŵŝƚƐǁŝƚĐŚĞƐĂŶĚƐƉĂƌŬƌŽĚŽĨƚŚĞ,/ĂĐƚƵĂƚŽƌĂƐƐĞŵďůǇ
ƐŚŽƵůĚďĞŵŽƵŶƚĞĚĂƐƉĞƌƚŚĞĚŝĂŐƌĂŵŐŝǀĞŶďĞůŽǁ͘

EŽƚĞ͗ŽŶŽƚƌĞǀĞƌƐĞƚŚĞƉƌŝŵĂƌǇĂŶĚƌĞƚƵƌŶǁŝƌŝŶŐ͘

5

6

7

WZd>/^d͗

ϭ 'h/^hWWKZdW/W
Ϯ DKhEd/E'&>E'
ϯ DKhEd/E'K>d^^D>z
ϰ ^dE͕,/dhdKZ
ϱ DKhEd/E'Z<d͕,/dhdKZ
ϲ WKtZz>/EZ
ϳ ^K>EK/s>s
ϴ >/D/d^t/d,
ϵ KEdZK>ZD^WZ<ZK
ϭϬ :hEd/KEKy;EͿ
ϭϭ >
ϭϮ 'Zh^Zt
ϭϯ W>dDKhEd/E'K>d
ϭϰ /'E/dZ^WZ<W>h'
ϭϱ &>y/>,K^
ϭϲ >dZKdZD/E>Ky;&>DWZKK&Ϳ
8
WZ/E/W>^K&KWZd/KE

,ŝŐŚ ĞŶĞƌŐǇŝŐŶŝƚŝŽŶŝƐ ĂŵĞƚŚŽĚ ŽĨ ŝŐŶŝƚŝŶŐƚŚĞ ďƵƌŶĞƌĨůĂŵĞ ĚŝƌĞĐƚůǇ ďǇ ĂŚŝŐŚ ĞŶĞƌŐǇƐƉĂƌŬ͘
/ŐŶŝƚŝŽŶŝƐĂĐĐŽŵƉůŝƐŚĞĚďǇĚŝƐĐŚĂƌŐŝŶŐŚŝŐŚĞŶĞƌŐǇƉƵůƐĞƐŽĨĞůĞĐƚƌŝĐĂůƉŽǁĞƌŝŶƚŚĞďƵƌŶĞƌĨƵĞů
ǌŽŶĞ͘ZĞĂƐŽŶĂďůǇĂƚŽŵŝǌĞĚĨƵĞůŽŝůĐĂŶďĞŝŐŶŝƚĞĚĞĨĨĞĐƚŝǀĞůǇ͘

^WZ<W>h'

dŚĞƐƉĂƌŬƉůƵŐŝƐĂƐŚƵŶƚĞĚƐƵƌĨĂĐĞƚǇƉĞƉůƵŐ͘dŚĞƐŚƵŶƚŝƐĂƐĞŵŝͲĐŽŶĚƵĐƚŽƌŵĂƚĞƌŝĂůůŽĐĂƚĞĚ
ďĞƚǁĞĞŶ ƚŚĞ ŵĞƚĂů ƐŚĞůů ĂŶĚ ƚŚĞ ĐĞŶƚƌĂů ĞůĞĐƚƌŽĚĞ͘ Ɛ ƚŚĞ ƉŽƚĞŶƚŝĂů ĂĐƌŽƐƐ ƚŚĞ ĞůĞĐƚƌŽĚĞ
ŝŶĐƌĞĂƐĞƐ͕ĂƐŵĂůůĂŵŽƵŶƚŽĨĐƵƌƌĞŶƚƉĂƐƐĞƐĂĐƌŽƐƐƚŚĞƐĞŵŝͲĐŽŶĚƵĐƚŽƌ͘

dŚŝƐĐƵƌƌĞŶƚŝŶĐƌĞĂƐĞƐǁŚĞŶĂŝƌŝŶƚŚĞŐĂƉŝŽŶŝǌĞƐ͘tŚĞŶŝŽŶŝǌĂƚŝŽŶŽĐĐƵƌƐ͕ƐƚŽƌĞĚŚŝŐŚĞŶĞƌŐǇ
ĚŝƐĐŚĂƌŐĞƐ ďĞƚǁĞĞŶ ƚŚĞ ĐĞŶƚĞƌ ĞůĞĐƚƌŽĚĞ ĂŶĚ ƚŚĞ ƐŚĞůů ŽĨ ƚŚĞ ƐƉĂƌŬ ƉůƵŐ ƚŝƉ͘ dŚĞ ĚŝƐĐŚĂƌŐĞ
ĂƉƉĞĂƌƐŵƵĐŚůŝŬĞĂŶĞůĞĐƚƌŝĐǁĞůĚŝŶŐĂƌĐ͘

,/ĐƚƵĂƚŽƌƐƐĞŵďůǇ

dŚĞ ,/ ĂĐƚƵĂƚŽƌ ŵĞĐŚĂŶŝƐŵ ŝƐ ĂŶ Ăŝƌ ƌĞƚƵƌŶ ƉŶĞƵŵĂƚŝĐ ĐǇůŝŶĚĞƌ͘ tŚĞŶ ƚŚĞ Ăŝƌ ĐǇůŝŶĚĞƌ
ƐŽůĞŶŽŝĚ ǀĂůǀĞ ŝƐ ĞŶĞƌŐŝǌĞĚ ĂŶĚ ƚŚĞ ŝŶƐƚƌƵŵĞŶƚ Ăŝƌ ŝƐ ĂǀĂŝůĂďůĞ͕ ƚŚĞ ĐǇůŝŶĚĞƌ ƉŝƐƚŽŶ ŵŽǀĞƐ Ă
ŶŽŵŝŶĂůϴŝŶĐŚĞƐĚƵƌŝŶŐƚŚĞŝŐŶŝƚŝŽŶƉĞƌŝŽĚ͘tŚĞŶƚŚĞƐŽůĞŶŽŝĚŝƐĚĞͲĞŶĞƌŐŝǌĞĚ͕ƚŚĞƐƉĂƌŬƌŽĚ
ĂƐƐĞŵďůǇŝƐƌĞƚƌĂĐƚĞĚ͘>ŝŵŝƚƐǁŝƚĐŚĞƐĂƌĞŵŽƵŶƚĞĚƚŽŐŝǀĞĨĞĞĚďĂĐŬĨŽƌŝŶƐĞƌƚĞĚĂŶĚƌĞƚƌĂĐƚĞĚ
ƉŽƐŝƚŝŽŶ͘

d,KZzK&WW>/d/KE

/Ŷ ŽƌĚĞƌ ƚŽ ŚĂǀĞ ŝŐŶŝƚŝŽŶ͕ ƚŚĞ ĐŽŵďƵƐƚŝŽŶ Ăŝƌ ĂŶĚ ĨƵĞů ŵŝǆƚƵƌĞ ŵƵƐƚ ďĞ ǁŝƚŚŝŶ ƚŚĞ ůŝŵŝƚƐ ŽĨ
ĐŽŵďƵƐƚŝŽŶǁŝƚŚƚŚĞŚŝŐŚĞŶĞƌŐǇƐƉĂƌŬƉƌĞƐĞŶƚƚŽƉƌŽǀŝĚĞƚŚĞŚĞĂƚĨŽƌŝŐŶŝƚŝŽŶ͘dŚĞůŽĐĂƚŝŽŶŽĨ
ĞĂĐŚŽĨƚŚĞƐĞĞůĞŵĞŶƚƐƉƌŽǀŝĚĞƐĨŽƌĐŽŶƐŝƐƚĞŶƚůŝŐŚƚŽĨĨŽĨƚŚĞĨƵĞůŝŶƵƐĞ͘ĂƌĞŵƵƐƚďĞƚĂŬĞŶŝŶ
ƚŚĞŝŶŝƚŝĂůƐĞƚƵƉƚŽĞŶƐƵƌĞƚŚĞƉƌŽƉĞƌůŽĐĂƚŝŽŶŽĨƚŚĞƐƉĂƌŬǁŝƚŚŝŶƚŚĞĂŝƌĂŶĚĨƵĞůŵŝǆƚƵƌĞ͘

KŶĐĞƚŚĞŝŐŶŝƚŝŽŶŽĨƚŚĞĨƵĞůŚĂƐƚĂŬĞŶƉůĂĐĞ ƚŚĞ,ŝŐŚŶĞƌŐǇ^ƉĂƌŬŝƐƐƚŽƉƉĞĚĂŶĚƚŚĞĨƵĞůŝƐ
ĂůůŽǁĞĚƚŽĐŽŶƚŝŶƵĞĐŽŵďƵƐƚŝŽŶƵŶĚĞƌŝƚƐŽǁŶŝŐŶŝƚŝŽŶ͘

dŚĞƉŽƐŝƚŝŽŶŽĨƚŚĞƐƉĂƌŬƉůƵŐĂŶĚƐƉĂƌŬƌŽĚ;ǁŚĞŶŝŶƌĞƚƌĂĐƚͿŵƵƐƚŽĨĨĞƌƉƌŽƚĞĐƚŝŽŶĨƌŽŵĚŝƌĞĐƚ
ĨůĂŵĞĐŽŶƚĂĐƚĂŶĚĂƐǁĞůůĂƐƚŚĞƌĂĚŝĂŶƚŚĞĂƚŽĨĐŽŵďƵƐƚŝŽŶ͘/ĨƚŚĞƉŽƐŝƚŝŽŶŝŶŐƌĞƋƵŝƌĞĚĨŽƌĨƵĞů
ŝŐŶŝƚŝŽŶŝƐĚĂŵĂŐŝŶŐƚŽƚŚĞƐƉĂƌŬƌŽĚŽƌƚŝƉ͕ƚŚĞƌŽĚŵƵƐƚďĞƌĞƉŽƐŝƚŝŽŶĞĚĂĨƚĞƌĨƵĞůŝŐŶŝƚŝŽŶŚĂƐ
ďĞĞŶĐŽŵƉůĞƚĞĚ͘

9

D/EdEE/E&KZDd/KE

dŚĞ ƐƉĂƌŬ ƌŽĚ ĂŶĚ ƐƉĂƌŬ ƉůƵŐ ŵƵƐƚ ďĞ ĐŚĞĐŬĞĚ ƉĞƌŝŽĚŝĐĂůůǇ͘ dŚĞ ƐƉĂƌŬ ƉůƵŐ ŝƐ Ă ĐŽŶƐƵŵĂďůĞ
ŝƚĞŵ͘/ƚŵƵƐƚďĞƌĞƉůĂĐĞĚĂĨƚĞƌĂƉĞƌŝŽĚŽĨƚŝŵĞ͘

dŚĞƐƉĂƌŬƉůƵŐƐĂŶĚƐƉĂƌŬƌŽĚƐƐŚŽƵůĚďĞŝŶƐƉĞĐƚĞĚĞǀĞƌǇϯŵŽŶƚŚƐƚŽŐĂŐĞǁĞĂƌ͘dŚĞƌĂƚĞŽĨ
ǁĞĂƌ ŝƐĚŝƌĞĐƚůǇ ĚĞƚĞƌŵŝŶĞĚ ďǇ ƚŚĞ ĂŵŽƵŶƚ ŽĨƵƐĞ͕ ƚŚĞ ƚŝŵĞ ĚƵƌĂƚŝŽŶ ŽĨƚŚĞƐƉĂƌŬŝŶŐĂŶĚƚŚĞ
ƚĞŵƉĞƌĂƚƵƌĞŽĨƚŚĞƐƉĂƌŬƉůƵŐ͘/ĨĂƐƉĂƌŬƉůƵŐŝƐǁĞĂƌŝŶŐŽƵƚƋƵŝĐŬůǇĐŚĞĐŬƚŚĞƚŝŵŝŶŐŽƉĞƌĂƚŝŽŶ
ĂŶĚƵƐĞƌĂƚĞŽĨƚŚĞƉůƵŐ͘^ƉĂƌŬƉůƵŐǁĞĂƌŝŶŐĂŶĚƌŝƐŬŽĨĚĂŵĂŐĞĂƌĞŚŝŐŚĞƐƚǁŚĞŶƚŚĞƉůƵŐŝƐ
ĞǆƉŽƐĞĚĚŝƌĞĐƚůǇƚŽĨůĂŵĞ͘ŽŶŽƚůĞĂǀĞƐƉĂƌŬƉůƵŐƌŽĚŝŶĂĨůĂŵĞĨŽƌŵŽƌĞƚŚĂŶϮϬƐĞĐŽŶĚƐĂƚ
ĂŶǇƚŝŵĞ͘

dŽƉƌŽƉĞƌůǇŝŶƐƉĞĐƚƚŚĞŝŐŶŝƚĞƌƉůƵŐ͕ŝƚŝƐŶĞĐĞƐƐĂƌǇƚŽƌĞŵŽǀĞƚŚĞ,/ƌŽĚĨƌŽŵƚŚĞŐƵŝĚĞƉŝƉĞ
ĂƐƐĞŵďůǇ͘WƌŽĐĞĞĚĂƐĨŽůůŽǁƐ͗

ϭͿ ŚĞĐŬƚŚĂƚĂůůƉŽǁĞƌƚŽƚŚĞŝŐŶŝƚŝŽŶƐǇƐƚĞŵŝƐŽĨĨ͘ŝƐĐŽŶŶĞĐƚƚŚĞĞůĞĐƚƌŝĐƉŽǁĞƌĐĂďůĞĨƌŽŵ
ƚŚĞƌŽĚ͘

ϮͿ /ĨƚŚĞƐƉĂƌŬƌŽĚŝƐƵƐĞĚǁŝƚŚĂƉŶĞƵŵĂƚŝĐĂĐƚƵĂƚŽƌ͕ůŽŽƐĞŶƵƉĂŶĚƌĞŵŽǀĞƚŚĞĐůĞǀŝƐƉŝŶŽŶ
ƚŚĞŽŶƚƌŽůƌŵĐůĂŵƉ͘/ĨƚŚĞƐƉĂƌŬƌŽĚĂƉƉůŝĐĂƚŝŽŶŝƐƐƚĂƚŝŽŶĂƌǇƚǇƉĞ͕ůŽŽƐĞŶƚŚĞƐĞƚůŽĐŬŝŶŐ
ƐĐƌĞǁŽƌĨŝƚƚŝŶŐƚŚĂƚƉŽƐŝƚŝŽŶƐƚŚĞƌŽĚŝŶƉůĂĐĞ͘

ϯͿ >ŽŽƐĞŶ ƚŚĞ ͞WĂĐŬŝŶŐ EƵƚ͟ Θ ƌĞŵŽǀĞ ƚŚĞ ,/ ƌŽĚ ĂƐƐĞŵďůǇ ǁŝƚŚ ͞ŽŶƚƌŽů ƌŵ͟ ͞WĂĐŬŝŶŐ
EƵƚ͕͟͞WĂĐŬŝŶŐ͟Θ͞ĞĂƌŝŶŐ͟ĨƌŽŵƚŚĞŐƵŝĚĞƉŝƉĞĂƐƐĞŵďůǇ͘

ϰͿ ĞĨŽƌĞƌĞŵŽǀŝŶŐƚŚĞƐƉĂƌŬƉůƵŐĨƌŽŵƚŚĞƐƉĂƌŬƌŽĚĂƐƐĞŵďůǇ͕ǁŝƉĞƚŚĞƉůƵŐĂŶĚƌŽĚĞŶĚƚŽ
ĐůĞĂŶƵƐŝŶŐĂƌĂŐǁĞƚƚĞĚǁŝƚŚƐŽůǀĞŶƚĂŶĚĚƌǇŝƚĨŽƌƐŽŵĞƚŝŵĞ͘/ĨƚŚĞƉůƵŐĂŶĚƐƉĂƌŬƌŽĚĞŶĚ
ĂƌĞĐŽǀĞƌĞĚǁŝƚŚĐĂƌďŽŶ͕ƵƐĞǁŝƌĞďƌƵƐŚŽƌĞŵĞƌǇĐůŽƚŚƚŽƌĞŵŽǀĞŝƚ͘,ŽǁĞǀĞƌ͕ K EKd
^ZWKZt/ZZh^,d,d/W&K&d,/'E/dZW>h'͊

ϱͿ ůĂŵƉŽŶĨůĂƚƐĂƚĞŶĚŽĨĞůĞĐƚƌŽĚĞĂƐƐĞŵďůǇĂŶĚƐƉĂƌŬƉůƵŐǁŝƚŚǁƌĞŶĐŚĞƐ͘dƵƌŶƚŚĞƐƉĂƌŬ
ƉůƵŐ ƚŽ ƵŶƐĐƌĞǁ͘ /ŶƐƉĞĐƚ ƚŚƌĞĂĚƐ͕ ĐŽŶŶĞĐƚŽƌ ƉŝŶ͕ ĂŶĚ ĐĞƌĂŵŝĐ ĐƵƉ ŽŶ ƚŚĞ ďĂĐŬ ĞŶĚ ŽĨ ƚŚĞ
ƉůƵŐ͘ZĞƉůĂĐĞƚŚĞƉůƵŐŝĨŝŶƚĞƌŶĂůƐĂƌĞĚĂŵĂŐĞĚ͘

ϲͿ dŚĞƚŝƉĨĂĐĞŽĨƚŚĞƐƉĂƌŬƉůƵŐƐŚŽƵůĚŶĞǀĞƌďĞďƌƵƐŚĞĚŶŽƌĂŶǇĂƚƚĞŵƉƚŵĂĚĞƚŽĐůĞĂŶŽƵƚ
ƚŚĞŐĂƉ͘ĂƌďŽŶŽŶƚŚĞƚŝƉĂŝĚƐŽƉĞƌĂƚŝŽŶŽĨƚŚĞƉůƵŐ͘/ŶƐƉĞĐƚƚŚĞƚŚƌĞĂĚƐĂŶĚŽƵƚĞƌƐŚĞůů
ĨŽƌ ǀŝƐŝďůĞ ĐƌĂĐŬƐ Žƌ ĞǆĐĞƐƐŝǀĞ ĚĞƚĞƌŝŽƌĂƚŝŽŶ ĚƵĞ ƚŽ ŚŝŐŚ ƚĞŵƉĞƌĂƚƵƌĞ Žƌ ƉƌŽůŽŶŐĞĚ ƵƐĞ͘
ŝƐĐĂƌĚŝĨƚŚĞŽƵƚĞƌƐŚĞůůŝƐĐƌĂĐŬĞĚŽƌǁĂƌƉĞĚ͘ŚĞĐŬƚŚĞĐĞŶƚĞƌĞůĞĐƚƌŽĚĞ͕ŝĨƚŚĞƐƉĂƌŬƉůƵŐ
ƚŝƉŝƐďĂĚůǇďƵƌŶĞĚ͕ďƌŽŬĞŶŽƌƉŝƚƚĞĚƚŽƚŚĂƚƚŚĞĂŝƌŐĂƉĞǆĐĞĞĚƐϭͬϴ͟ĂůůĂƌŽƵŶĚ͕ƌĞƉůĂĐĞƚŚĞ
ƉůƵŐ͘

ϳͿ /ŶƐƉĞĐƚ ƚŚĞ ĐŽŶŶĞĐƚŝŽŶ ĞŶĚ ŽĨ ƚŚĞ ƐƉĂƌŬ ƌŽĚ͘ /Ĩ ŝƚ ŝƐ ŶĞĐĞƐƐĂƌǇ ƚŽ ĐůĞĂŶ͕ ƵƐĞ Ă ĐůĞĂŶ ĐůŽƚŚ
ǁƌĂƉƉĞĚ ŽŶ Ă ǁŽŽĚĞŶ ǁĞƚ ǁŝƚŚ ĐůĞĂŶŝŶŐ ĨůƵŝĚ ĂŶĚ ƐǁĂďƐ ƚŚĞ ŽƵƚƐŝĚĞ ŽĨ ƚŚĞ ĐŽŶŶĞĐƚŽƌ͘
ůŽǁƚŽĐůĞĂŶ͘ŚĞĐŬƚŚĂƚƚŚĞƐŽĐŬĞƚŝƐĐĞŶƚĞƌĞĚŝŶƚŚĞĨŝƚƚŝŶŐ͘hƐĞĂĐůĞĂŶϬ͘ϬϬϵϯ͟ĚŝĂŵĞƚĞƌ
ƐŵŽŽƚŚŵĞƚĂůƉŝŶƚŽƚĞƐƚĨŝƚ͘
10

ϴͿ ůĞĂŶƚŚĞ ŐƵŝĚĞ ƉŝƉĞ ĂƐ ŶĞĐĞƐƐĂƌǇ͘ZĞŵŽǀĞ ĂŶǇ ďƵƌƌƐ ǁŝƚŚ ĂĨŝŶĞĨŝůĞ͘/Ĩ ƚŚĞ ƚŚƌĞĂĚĞĚ ĞŶĚ
ƐŚŽǁƐŝŶĚŝĐĂƚŝŽŶƐŽĨďƵƌŶŝŶŐ͕ĐůĞĂŶƵƉĂŶĚƌĞƐƚŽƌĞ͕ŝĨƚŚĞŐƵŝĚĞƉŝƉĞŝƐĚŝƐƚŽƌƚĞĚ͕ĐŽůůĂƉƐĞĚ͕
ŽƌďĞŶƚ͕ƌĞƉůĂĐĞŝƚ͘

ϵͿ ƐƐĞŵďůĞŝŶƌĞǀĞƌƐĞŽƌĚĞƌŽĨĚŝƐĂƐƐĞŵďůǇ͘ZĞĐŽŶŶĞĐƚƚŚĞŚŝŐŚǀŽůƚĂŐĞĐĂďůĞ͘dŝŐŚƚĞŶ Ăůů
ĨŝƚƚŝŶŐƐ͘

Kd,ZD/EdEE/E&KZDd/KE

ϭͿ Ž ŶŽƚ ŝŶƐĞƌƚ /ŐŶŝƚĞƌ ƐƐĞŵďůǇ ŵŽƌĞ ƚŚĂŶ ƚŚĞ ƌĞƋƵŝƌĞĚ ŝŶ ŽƌĚĞƌ ƚŽ ƉƌŽƚĞĐƚ ƚŚĞ
ĂƐƐĞŵďůǇĨƌŽŵĨƵƌŶĂĐĞƌĂĚŝĂƚĞĚŚĞĂƚ͕ǁŚĞŶƚŚĞ/ŐŶŝƚĞƌŝƐŶŽƚŝŶĨŝƌŝŶŐ͘dŚĞDsŽŝůŐƵŶ
ĂŶĚ ƚŚĞ ,/ /ŐŶŝƚĞƌ ŐƵŝĚĞ ƚƵďĞ ƐŚŽƵůĚ ďĞ ŝŶƐŝĚĞ ƚŚĞ ƐƵƉƉŽƌƚ ƚƵďĞ ĂƉƉƌŽǆŝŵĂƚĞůǇ
ϵϮŵŵŝŶƚŚĞZdZdƉŽƐŝƚŝŽŶ͘

ϮͿ ,/ŝƐĐĂƉĂďůĞŽĨĚŝƌĞĐƚůǇŝŐŶŝƚŝŶŐƚŚĞŵĂŝŶďƵƌŶĞƌĨƵĞů͘dŚŝƐƚǇƉĞ ŽĨŝŐŶŝƚĞƌƐŚĂůůŶŽƚ
ďĞƵƐĞĚƵŶůĞƐƐƐƵƉĞƌǀŝƐŝŽŶŽĨƚŚĞŝŶĚŝǀŝĚƵĂůŵĂŝŶďƵƌŶĞƌĨůĂŵĞŝƐƉƌŽǀŝĚĞĚ͘

ϯͿ dŚĞ ĨŝƌĞ ƐŚŽƵůĚ ďĞ ŽďƐĞƌǀĞĚ Ăƚ ĨƌĞƋƵĞŶƚ ŝŶƚĞƌǀĂůƐ͘ dŚĞ ĨŝƌĞ ƐŚŽƵůĚ ďĞ ƐƚĂďůĞ ǁŝƚŚ ŶŽ
ĐŽŬŝŶŐ͕ŶŽƐƉĂƌŬůĞƐ͕ŶŽƐŵŽŬĞĂŶĚĂůŝŐŚƚŽĨŽƌĂŶŐĞĐŽůŽƌ͘

ϰͿ DĂŝŶƚĂŝŶƚŚĞĞǆƉŽƐĞƐůŝĚŝŶŐƐƵƌĨĂĐĞƐďǇŬĞĞƉŝŶŐĂƐĐůĞĂŶĂƐƉŽƐƐŝďůĞƚŽƌĞĚƵĐĞǁĞĂƌŽŶ
ƚŚĞƐĞĂůŝŶŐƐƵƌĨĂĐĞƐ͘ůĞĂŶƐůŝĚŝŶŐƐŚĂĨƚƐǁŝƚŚůŝŐŚƚŽŝůĂŶĚƌĞŵŽǀĞĂŶǇĨŽƌĞŝŐŶŐƌĞĂƐĞ
ŽƌŚĞĂǀǇŽŝů͘/ĨƚŚĞƐŚĂĨƚŵŽǀĞŵĞŶƚŝƐƐƚŝĐŬǇ͕ĂĚĚĂĚƌŽƉŽĨůŝŐŚƚŽŝůŽŶƚŽƚŚĞƐŚĂĨƚĂŶĚ
ǁŽƌŬŝƚŝŶƚŽƚŚĞďĞĂƌŝŶŐĂŶĚƐĞĂů͘ĨƚĞƌǁŽƌŬŝŶŐƚŚĞŽŝůŝŶƚŽƚŚĞďĞĂƌŝŶŐǁŝƉĞƚŚĞƐŚĂĨƚ
ĚƌǇǁŝƚŚĂĐůŽƚŚ͘

ϱͿ DĂŝŶƚĂŝŶƚŚĞĂŝƌƐƵƉƉůǇĂƐĐůĞĂŶĂŶĚĚƌǇŝŶƐƚƌƵŵĞŶƚĂŝƌƋƵĂůŝƚǇ͕ĂŝƌƐƵƉƉůǇϱƚŽϭϬ^&D
ĂƚϲϬƚŽϵϬW^/͘

ϲͿ DĂŝŶƚĂŝŶƚŚĞŝŐŶŝƚĞƌƉůƵŐďǇĐůĞĂŶŝŶŐŽƌƌĞƉůĂĐŝŶŐĂƐŝƚďĞĐŽŵĞƐǁŽƌŶŽƌĚŝƌƚǇ͘/ŶƐƉĞĐƚ
ƚŚĞ,//ŐŶŝƚĞƌƚŝƉĨƌĞƋƵĞŶƚůǇ͘

ϳͿ dŚĞ ƐƉĂƌŬ ƉůƵŐ ĂŶĚ ƐƉĂƌŬ ƌŽĚ ĂƐƐĞŵďůǇ ĂƌĞ ŶŽƚ ĚĞƐŝŐŶĞĚ ĨŽƌ ĞǆƚĞŶĚĞĚ ĞǆƉŽƐƵƌĞ ƚŽ
ĨůĂŵĞŽƌŚŝŐŚƚĞŵƉĞƌĂƚƵƌĞ͘ǆƉŽƐƵƌĞƚŽĨůĂŵĞŽƌŚŝŐŚƚĞŵƉĞƌĂƚƵƌĞƐŚŽƵůĚďĞůŝŵŝƚĞĚ
ǁŝƚŚŝŶϮϬƐĞĐŽŶĚƐ͘

ϴͿ dŽƉƌĞƐĞƌǀĞƚŚĞ,//ŐŶŝƚĞƌĐŽŵƉŽŶĞŶƚƐ͕ƚŚĞƌĞĐŽŵŵĞŶĚĞĚƚŝŵĞĚĐǇĐůĞĨŽƌƚŚĞ,/
/ŐŶŝƚĞƌĨŽƌŵĂǆŝŵƵŵŝƐϭϱƐĞĐŽŶĚƐŽŶĐǇĐůĞƐƉĂƌŬŝŶŐ͕ŽĨĨĐǇĐůĞϯŵŝŶƵƚĞƐ͘

ϵͿ WƌŽǀŝĚĞƉƵƌŐŝŶŐĂŝƌĂƚв͞EWd;&ͿĐŽŶŶĞĐƚŝŽŶĂƚƚŚĞƌĂƚĞŽĨϭϬ^&DĂƚϭW^/ĂďŽǀĞƚŚĞ
&ƵƌŶĂĐĞƉƌĞƐƐƵƌĞ͘
11

ZKDDE^WZ^͗

ϭ͘ WKtZz>/EZ
Ϯ͘ K>EK/s>s
ϯ͘ >/D/d^t/d,
ϰ͘ ^WZ<d/W

^&dzWZhd/KE^

dŚĞ &^ ,/ ƐǇƐƚĞŵ ŝƐ Ă ,/', sK>d' ƐǇƐƚĞŵ ƚŚĂƚ ŝƐ ƉŽƚĞŶƚŝĂůůǇ >d,>͘ dŚĞ ƉŽǁĞƌ ƉĂĐŬ͕
ƐƉĂƌŬƌŽĚĂƐƐĞŵďůǇĂŶĚƉŽǁĞƌĐĂďůĞĂůůŝŶǀŽůǀĞ,ŝŐŚsŽůƚĂŐĞ͘

tŚĞŶ ƚĞƐƚŝŶŐ Žƌ ƚƌŽƵďůĞ ƐŚŽŽƚŝŶŐ ĞƋƵŝƉŵĞŶƚ ƐƚĂǇ ĐůĞĂƌ ŽĨ ƚŚĞ ƐƉĂƌŬ ƌŽĚ ĂƐƐĞŵďůǇ ǁŚŝůĞ ƚŚĞ
,/ŝƐŽƉĞƌĂƚŝŶŐ͘tŚĞŶĐŽŶŶĞĐƚŝŶŐ ŽƌĚŝƐĐŽŶŶĞĐƚŝŶŐ ƚŚĞƉŽǁĞƌĐĂďůĞƚŽƚŚĞƉŽǁĞƌƉĂĐŬ͕ƵƐĞ
ƚŚĞĨŽůůŽǁŝŶŐƐĂĨĞƚǇŐƵŝĚĞ͗

͘ ůǁĂǇƐŚĂǀĞĂĚĞĚŝĐĂƚĞĚΘĐůĞĂƌůǇŵĂƌŬĞĚŵĞĂŶƐŽĨĚŝƐĐŽŶŶĞĐƚŝŶŐƉŽǁĞƌ͘
͘ ůǁĂǇƐĂůůŽǁĨŝǀĞŵŝŶƵƚĞƐĨŽƌƚŚĞĐĂƉĂĐŝƚŽƌ;ŝŶƚŚĞƉŽǁĞƌƉĂĐŬͿƚŽĨƵůůǇĚŝƐĐŚĂƌŐĞďĞĨŽƌĞ
ǁŽƌŬŝŶŐŽŶƚŚĞĂƐƐĞŵďůǇ͘
͘ ŶǇƚŝŵĞƉŽǁĞƌŝƐĂƉƉůŝĞĚƚŽƚŚĞƐǇƐƚĞŵ͕ƚŚĞĐĂƉĂĐŝƚŽƌƐǇƐƚĞŵŵĂǇďĞĐŚĂƌŐĞĚ͘ŽŶŽƚ
ǁŽƌŬŝŶƚŚĞƉĂŶĞůƵŶƚŝůƐǇƐƚĞŵŚĂƐďĞĞŶĚŝƐĐŚĂƌŐĞĚĂƐŝŶƐĞĐƚŝŽŶ͟͞ĂďŽǀĞ͘
͘ tŚĞŶǁŽƌŬŝŶŐǁŝƚŚƚŚĞƉĂŶĞů͕ĚŽŽƌŽƉĞŶƐƚĂǇĐůĞĂƌŽĨĂůůŚŝŐŚǀŽůƚĂŐĞǁŝƌĞƐĂŶĚĞŶƐƵƌĞ
ƚŚĞƉŽǁĞƌƉĂĐŬƉĂŶĞůŝƐǁĞůůŐƌŽƵŶĚĞĚ͘
͘ KŶůǇ ƉĞƌƐŽŶƐ ĞǆƉĞƌŝĞŶĐĞĚ ǁŝƚŚ ŚŝŐŚ ǀŽůƚĂŐĞ ĞƋƵŝƉŵĞŶƚ ƐŚŽƵůĚ ĂĐĐĞƐƐ ƚŚĞ ƉŽǁĞƌ ƉĂĐŬ
ƉĂŶĞů͘

WůŽƚŶŽ͘ϮϯϬ͕ dĞů͗ нϵϭϮϲϲϮͲϯϬϴϮϬϬ
WĂĚƌĂͲ:ĂŵďƵƐĂƌŚŝŐŚǁĂǇ͕ нϵϭϮϲϲϮͲϮϰϰϰϱϵ
ĂďŚĂƐĂͲϯϵϭϰϰϬ͕ нϵϭϮϲϲϮͲϮϰϰϰϴϯ
dĂůƵŬĂWĂĚƌĂ͕ &Ăǆ͗нϵϭϮϲϲϮͲϯϬϴϮϮϮ
ŝƐƚƌŝĐƚsĂĚŽĚĂƌĂ͘ ŵĂŝů͗ĨĐƐ͘ŵĂƌŬĞƚŝŶŐΛĨŝǀĞƐŐƌŽƵƉ͘ĐŽŵ
'ƵũĂƌĂƚ͕/E/͘ tĞďĚĚƌĞƐƐ͗ǁǁǁ͘ĨŝǀĞƐŐƌŽƵƉ͘ĐŽŵ

USER’S MANUAL
HEEI POWER PACK
INSTRUCTION, OPERATION &

MAINTENANCE MANUAL FOR
HIGH ENERGY ELECTRIC IGNITER POWER
PACK
Page 2 of 10

tZE/E'

dŚŝƐ ƐǇƐƚĞŵ ĐŽŶƚĂŝŶƐ ,ŝŐŚ sŽůƚĂŐĞ ĂŶĚ ,ŝŐŚ ĐƵƌƌĞŶƚ ƚŚĂƚ ĐŽƵůĚ Ŭŝůů Žƌ ƐĞƌŝŽƵƐůǇ ŝŶũƵƌĞ
ƉĞƌƐŽŶƐĐŽŵŝŶŐŝŶĐŽŶƚĂĐƚ ǁŝƚŚ ƚŚĞŵ͘ dŚŝƐ ŵĂŶƵĂů ŵƵƐƚďĞƌĞĂĚ ĂŶĚ ƵŶĚĞƌƐƚŽŽĚ ďĞĨŽƌĞ
ĂŶǇĂƚƚĞŵƉƚŝƐŵĂĚĞƚŽŝŶƐƚĂůů͕ŽƉĞƌĂƚĞŽƌƌĞƉĂŝƌƚŚŝƐĞƋƵŝƉŵĞŶƚŽƌĂŶǇŽĨŝƚƐĐŽŵƉŽŶĞŶƚƐ͘
^ƚĂǇ ĐůĞĂƌ ĨƌŽŵ ƚŚĞ ŝŐŶŝƚŝŽŶ ƐǇƐƚĞŵ ;,/ ĚĞǀŝĐĞ͕ ƉŽǁĞƌ ƉĂĐŬ ĞŶĐůŽƐƵƌĞ͕ ŽƵƚƉƵƚ ƉŽǁĞƌ
ĐĂďůĞ͕ ƐƉĂƌŬ ƉůƵŐ ƌĞƚƵƌŶͿ ǁŚĞŶ ŝƚ ŝƐ ƉŽǁĞƌĞĚ͘ <ĞĞƉ ƚŚĞ ƐǇƐƚĞŵ ĞŶĐůŽƐƵƌĞ ƐĞĐƵƌĞůǇ
ŐƌŽƵŶĚĞĚĂůůƚŚĞƚŝŵĞ͘

ŽŶŽƚƌĞŵŽǀĞƚŚĞŝŐŶŝƚĞƌƚŝƉŽƌĐŽŵĞŝŶĐŽŶƚĂĐƚǁŝƚŚƚŚĞĞƋƵŝƉŵĞŶƚƵŶƚŝůƚŚĞŝŶƉƵƚƉŽǁĞƌ
ŚĂƐ ďĞĞŶ ĚŝƐĐŽŶŶĞĐƚĞĚ ĨŽƌ ĨŝǀĞ ;ϱͿ ŵŝŶƵƚĞƐ ƚŽ ĂůůŽǁ ƚŚĞ ƐƚŽƌĂŐĞ ĐĂƉĂĐŝƚŽƌƐ ƚŽ ĚŝƐĐŚĂƌŐĞ
ƚŚƌŽƵŐŚƚŚĞďůĞĞĚĞƌƌĞƐŝƐƚŽƌ͘

EŽƚĞ͗/ĨĂŶǇƉƌŽďůĞŵŽĐĐƵƌƐŝŶƐƉĂƌŬŐĂƉ͕ĚŽŶ͛ƚĚŝƐŵĂŶƚůĞŽƌƌĞƉĂŝƌŝƚ͕ƐŝŶĐĞŝƚŝƐŝƐŽƚŽƉĞ
ĂƐƐŝƐƚĞĚƐǇƐƚĞŵ͘ŽŶŽƚĚĞƐƚƌŽǇŝƚ͕ŬŝŶĚůǇƌĞƚƵƌŶďĂĐŬƚŽ&^͘

d,E/>^W/&/d/KE^͗

ŶĐůŽƐƵƌĞ ͗ EDͲϰ͕/WͲϲϲ;^ĂĨĞƌĞĂͿͬǆĚ͘//ͬ//͕/Wϲϱ
^ƵƉƉůǇsŽůƚĂŐĞ ͗ ϮϯϬs͕нϭϬйͲϭϬй͕ϱϬ,ǌцϱ,ǌ
ƵǆZĞůĂǇŽŵŵĂŶĚ͗ϮϰsͬϭϭϬsͬϮϰϬs;ĐůŝĞŶƚƚŽƐƉĞĐŝĨǇͿ
DĂǆ͘WƌŝŵĂƌǇƵƌƌĞŶƚ ͗ ϭ͘ϱ
^ƚŽƌĞĚŶĞƌŐǇ ͗ ϭϮ:ŽƵůĞƐ
^ƉĂƌŬZĂƚĞ ͗ DŝŶŝŵƵŵϰƐƉĂƌŬƐƉĞƌƐĞĐŽŶĚ
ŵďŝĞŶƚdĞŵƉĞƌĂƚƵƌĞ ͗ ϲϱΣ
KƵƚƉƵƚǀŽůƚĂŐĞ ͗ ϮϬϬϬs͘

EKd^͗
DĂǆŝŵƵŵůĞŶŐƚŚŽĨ,ŝŐŚsŽůƚĂŐĞŽƵƚƉƵƚĐĂďůĞŝƐϯϬĨĞĞƚ͘dŽĂǀŽŝĚƉƌŽďůĞŵƐ͕ŵŽƵŶƚ
ƉŽǁĞƌƉĂĐŬĂƐŶĞĂƌĂƐƉŽƐƐŝďůĞƚŽƚŚĞďƵƌŶĞƌ͘

Page 3 of 10

&/'Ͳϭ;^&ZͿ

Page 4 of 10

&/'ͲϮ;,ZZKh^ZͿ

Page 5 of 10
/E^d>>d/KE/E^dZhd/KE^͗

dŽĞŶƐƵƌĞƐĂĨĞƚǇŝŶƚŚĞĨŝĞůĚ͕ĨŽůůŽǁĚĞƚĂŝůĞĚŝŶƐƚĂůůĂƚŝŽŶŝŶƐƚƌƵĐƚŝŽŶƐĂƐďĞůŽǁ͗

^dKZ'͗

^ƚŽƌĞƉŽǁĞƌƉĂĐŬƵŶŝƚƐŝŶĂĚƌǇ͕ĐŽǀĞƌĞĚůŽĐĂƚŝŽŶŝŶŽƌŝŐŝŶĂůƐŚŝƉƉŝŶŐĐĂƌƚŽŶƐ͘ǀŽŝĚ
ƚŽƵĐŚŝŶŐŝŶŶĞƌĞůĞĐƚƌŽŶŝĐƐƐŝŶĐĞƐƚĂƚŝĐĞůĞĐƚƌŝĐŝƚǇͬŵŽŝƐƚƵƌĞͬĚƵƐƚĐĂŶƉŽƐƐŝďůǇĚĂŵĂŐĞƚŚĞ
ĞůĞĐƚƌŽŶŝĐƵŶŝƚ͘

DKhEd/E'͗

DŽƵŶƚƚŚĞƉŽǁĞƌƉĂĐŬŶĞĂƌƚŽƚŚĞƐƉĂƌŬƉůƵŐĂƐƐĞŵďůǇƚŽĂǀŽŝĚůŽŶŐŚŝŐŚͲǀŽůƚĂŐĞŽƵƚƉƵƚ
ĐĂďůĞůĞŶŐƚŚ;ϯϬĨĞĞƚŵĂǆŝŵƵŵͿ͘ZĞĨĞƌƚŽ&ŝŐƵƌĞϭͲĨŽƌƐĂĨĞĂƌĞĂŵŽĚĞůƐŽƌƌĞĨĞƌƚŽ&ŝŐƵƌĞ
ϮͲĨŽƌŚĂǌĂƌĚŽƵƐĂƌĞĂŵŽĚĞůƐ͘/ĨŝŶƐƚĂůůĞĚŽƵƚĚŽŽƌ͕ƚŚĞĞŶĐůŽƐƵƌĞŵƵƐƚďĞƉŽƐŝƚŝŽŶĞĚ
ƵƉƌŝŐŚƚǁŝƚŚŝƚƐĐĂďůĞƐŝĚĞĨĂĐŝŶŐĚŽǁŶƚŽƚŚĞŐƌŽƵŶĚƚŽĂǀŽŝĚǁĂƚĞƌĂĐĐƵŵƵůĂƚŝŽŶƐ͘dŚĞ
ĞŶĐůŽƐƵƌĞĚŽŽƌƐŚŽƵůĚŶŽƚďĞůĞĨƚŽƉĞŶŝŶĂŚƵŵŝĚŽƌĚƵƐƚǇĞŶǀŝƌŽŶŵĞŶƚ͘

>EdZz͗

&ŽƌƐĂĨĞĂƌĞĂĞŶĐůŽƐƵƌĞ͕ƚŚƌĞĞĐĂďůĞĞŶƚƌǇŽĨϯͬϰŝŶĐŚ͘d͘ĂƚďŽƚƚŽŵŚĂƐƉƌŽǀŝĚĞĚĂŶĚĨŽƌ
ŚĂǌĂƌĚŽƵƐĂƌĞĂĞŶĐůŽƐƵƌĞƚŚƌĞĞЪŝŶĐŚ͘d͘ŚĂƐƉƌŽǀŝĚĞĚ͘KŶůǇůŝƋƵŝĚͲƚŝŐŚƚĐŽŶŶĞĐƚŽƌƐ
ƐŚŽƵůĚďĞƵƐĞĚƚŚƌŽƵŐŚƚŚĞƐĞŚŽůĞƐ͘

>&/dd/E',K>DK/&/d/KE^͗

dŚĞƐŝǌĞŽĨĐĂďůĞŚŽůĞƐĐĂŶďĞŵŽĚŝĨŝĞĚĨŽƌĚŝĨĨĞƌĞŶƚŝŶƉƵƚͬŽƵƚƉƵƚĐĂďůĞƐďƵƚƚŚĞũŽďŵƵƐƚ
ďĞĚŽŶĞďǇĂĐůĞĂŶƉƌŽĐĞĚƵƌĞ͘ĞĨŽƌĞƚŚĞĐĂďůĞĞŶƚƌǇĚƌŝůůŝŶŐƐ͕ƚŚĞŝŶŶĞƌƉůĂƚĞĂůŽŶŐǁŝƚŚ
ĐŝƌĐƵŝƚďŽĂƌĚƐŵƵƐƚďĞƌĞŵŽǀĞĚƚŽĂǀŽŝĚĂŶǇĐŽŶƚĂŵŝŶĂƚŝŽŶƐŝŶĐĞƚŚĞĚƌŝůůĨŝůŝŶŐƐĚĞďƌŝƐ
ĐĂŶĞĂƐŝůǇďĞƐŚŽƌƚͲĐŝƌĐƵŝƚĂŶĚĚĂŵĂŐĞƚŚĞĞůĞĐƚƌŽŶŝĐƐ͘ůůƚŚĞĚƌŝůůĨŝůŝŶŐƐŵƵƐƚďĞĐůĞĂŶĞĚ
ƉƌŝŽƌƚŽƌĞƐƚŽƌŝŶŐƚŚĞĐŝƌĐƵŝƚďŽĂƌĚďĂĐŬŝŶƉůĂĐĞ͘,ĂŶĚůĞƚŚĞĚĞǀŝĐĞǁŝƚŚĐĂƌĞ͕ĂŶĚĂǀŽŝĚ
ƚŽƵĐŚŝŶŐƚŽĂŶǇĞůĞĐƚƌŽŶŝĐĐŽŵƉŽŶĞŶƚƐĂŶĚĂǀŽŝĚƐƚĂƚŝĐĞůĞĐƚƌŝĐŝƚǇ͘

^WZ<W>h''ZKhE/E'͗

dŽƉƌŽƚĞĐƚ,/ƵƐĞƌƐĨƌŽŵŝŶũƵƌǇĚƵĞƚŽŝŶĐŽƌƌĞĐƚͲǁŝƌŝŶŐ͕ƚŚĞŽƵƚƉƵƚƉŽǁĞƌĐĂďůĞƌĞƚƵƌŶ
ŵƵƐƚďĞĂƚƚĂĐŚĞĚƚŽƚŚĞŐƌŽƵŶĚĞĚďƵƌŶĞƌŽƌďĞŐƌŽƵŶĚĞĚďǇĂŶĞǆƚƌĂŐƌŽƵŶĚǁŝƌĞƚŽ
ŶĞĂƌďǇďƵŝůĚŝŶŐƐƚĞĞů͘

Page 6 of 10
E>K^hZ'ZKhE/E'͗

&ŽƌƚŚĞƐĂŵĞƌĞĂƐŽŶĂŶĚƚŽĐŽŵƉůǇǁŝƚŚEĂƚŝŽŶĂůůĞĐƚƌŝĐŽĚĞ;EͿ^ĂĨĞƚǇƐƚĂŶĚĂƌĚ͕Ăůů
ŵĞƚĂů,/ĞŶĐůŽƐƵƌĞƐŵƵƐƚďĞŐƌŽƵŶĚĞĚƚŽĂůŽĐĂůŐƌŽƵŶĚƌŽĚ͕ŵĞƚĂůƉůƵŵďŝŶŐ͕ŵĞƚĂů
ďƵŝůĚŝŶŐŐƌŽƵŶĚŽĨŶĞĂƌďǇĞůĞĐƚƌŝĐŝƚǇŽƵƚůĞƚ͘DĞƚĂůĞŶĐůŽƐƵƌĞĐĂŶďĞĐŽŶŶĞĐƚĞĚƚŽŐƌŽƵŶĚ
ǀŝĂŝƚƐŽƵƚƉƵƚƉŽǁĞƌĐĂďůĞŐƌŽƵŶĚǁŝƌĞĂŶĚŝŶƉƵƚƉŽǁĞƌŐƌŽƵŶĚǁŝƌĞ͘

ŶĐůŽƐƵƌĞ'ƌŽƵŶĚŝŶŐDĞƚŚŽĚ͗

dŚĞĞŶĐůŽƐƵƌĞĐĂŶďĞƉƌŽƉĞƌůǇŐƌŽƵŶĚĞĚƚŚƌŽƵŐŚƚŚĞƚŚƌĞĞͲǁŝƌĞŽƵƚƉƵƚƉŽǁĞƌĐĂďůĞŝĨ
ƐƉĂƌŬƉůƵŐƐŚŝĞůĚŝƐƐĞĐƵƌĞůǇĂƚƚĂĐŚĞĚƚŽĂŐƌŽƵŶĚĞĚďƵƌŶĞƌĐŚĂƐƐŝƐŽƌƵƐĞĂŶĞǆƚĞƌŶĂů
ŐƌŽƵŶĚǁŝƌĞƚŽĐŽŶŶĞĐƚďĞƚǁĞĞŶĐŽŶĚƵŝƚŐƌŽƵŶĚůƵŐĂŶĚĞĂƌƚŚŐƌŽƵŶĚ͘

&/'Ͳϯ

t/Z/E'͗

dŚĞĞŶĐůŽƐƵƌĞŝƐƉƌŽǀŝĚĞĚǁŝƚŚĐĂďůĞĞŶƚƌǇĂƚƚŚĞďŽƚƚŽŵ͘>ŝƋƵŝĚͲƚŝŐŚƚĐŽŶŶĞĐƚŽƌƐŵƵƐƚďĞ
ƵƐĞĚĂƚƚŚĞĞŶƚƌŝĞƐ͘ĚĚŝƚŝŽŶĂůĐĂďůĞĞŶƚƌŝĞƐŝŶƚŚĞĞŶĐůŽƐƵƌĞĂƌĞŶŽƚƌĞĐŽŵŵĞŶĚĞĚ͘

hd/KE͊ŶǇĐĂďůĞĞŶƚƌǇŵŽĚŝĨŝĐĂƚŝŽŶĨŽƌĞŶĐůŽƐƵƌĞŵƵƐƚďĞĚŽŶĞĂĨƚĞƌƚŚĞĞůĞĐƚƌŽŶŝĐ
ƉĂŶĞůďĞŝŶŐƌĞŵŽǀĞĚĨŝƌƐƚ͘dŚĞƉĂŶĞůƐŚŽƵůĚŶŽƚďĞƌĞƐƚŽƌĞĚƵŶƚŝůĂůůĚƌŝůůĨŝůŝŶŐƐŝŶƐŝĚĞƚŚĞ
ĞŶĐůŽƐƵƌĞĂƌĞƚŚŽƌŽƵŐŚůǇĐůĞĂŶĞĚ

hd/KE͊,/',sK>d'E'Z͊
WŽǁĞƌƉĂĐŬŽƉĞƌĂƚĞƐĂƵƚŽŵĂƚŝĐĂůůǇǁŚĞŶĐŽŶŶĞĐƚĞĚƚŽĞŶĞƌŐŝǌĞĚƉŽǁĞƌƐƵƉƉůǇ͘dŚĞƌĞŝƐ
ŶŽƉŽǁĞƌƐǁŝƚĐŚŽŶ,/ƉŽǁĞƌƉĂĐŬƚŽĐŚĂŶŐĞďĞƚǁĞĞŶ͚ƚƵƌŶͲŽŶ͛ĂŶĚ͚ƚƵƌŶͲŽĨĨ͛
ĐŽŶĚŝƚŝŽŶƐ͘,ŝŐŚǀŽůƚĂŐĞƌĞƐŝĚĞƐŽŶƚŚĞƵŶŝƚŽŶĐĞŝŶƉƵƚƉŽǁĞƌĨĞĞĚƐŝŶ͘

Page 7 of 10
KWZd/E'WZ/E/W>͗

hŶŝƚ ƐŚŽƵůĚ ďĞ ƉŽǁĞƌĞĚ ǁŝƚŚ ĂƉƉƌŽƉƌŝĂƚĞ ƉŽǁĞƌ ƐƵƉƉůǇ͘ Ɛ ƐŽŽŶ ĂƐ ƵŶŝƚ ŝƐ ƉŽǁĞƌĞĚ͕
ĐƵƌƌĞŶƚ ĨůŽǁƐ ƚŚƌŽƵŐŚ ƉƌŝŵĂƌǇ ǁŝŶĚŝŶŐ ŽĨ dƌĂŶƐĨŽƌŵĞƌ͘ dŚŝƐ ĐĂƵƐĞƐ ƚŚĞ ǀŽůƚĂŐĞ ƚŽ ďĞ
ĚĞǀĞůŽƉĞĚ ŝŶ ƚŚĞ ƐĞĐŽŶĚĂƌǇ ǁŝŶĚŝŶŐ͘ ƚ ƚŚĞ ŽƵƚƉƵƚ ŽĨ ƚƌĂŶƐĨŽƌŵĞƌ͕ ĐĂƉĂĐŝƚŽƌ ϭ ŐĞƚƐ
ĐŚĂƌŐĞĚ ƚŚƌŽƵŐŚ ϭ͕ Zϭ͕ ĂŶĚ >ϭ Θ ĐĂƉĂĐŝƚŽƌ Ϯ ŐĞƚƐ ĐŚĂƌŐĞĚ ƚŚƌŽƵŐŚ Ϯ͕ ZϮ͘ tŝƚŚ ĞĂĐŚ
ĐŚĂŶŐĞŽĨƉŽůĂƌŝƚǇ͕ƉƵůƐĂƚŝŶŐĐƵƌƌĞŶƚĐŚĂƌŐĞƐƚŚĞƐƚŽƌĂŐĞĐĂƉĂĐŝƚŽƌƐ͘

Ɛ ƚŚĞ ǀŽůƚĂŐĞ ĂĐƌŽƐƐ ƚŚĞ ĐĂƉĂĐŝƚŽƌ ĐƌŽƐƐĞƐ ƉƌĞƐĞƚ ǀŽůƚĂŐĞ͕ ^ƉĂƌŬ 'ĂƉ ĨŝƌĞƐ ĂŶĚ ŝƚ ƉĂƐƐĞƐ
ƚŚĞ ƐƚŽƌĞĚ ĞŶĞƌŐǇ ƚŽ ŝŐŶŝƚĞƌ ĞůĞĐƚƌŽĚĞ͘ ůĞĐƚƌŽĚĞ ŝƐ ƐŚƵŶƚĞĚ ƚǇƉĞ ƐƉĂƌŬ ƚŝƉ ŵĂĚĞ ƵƉ ŽĨ
ƐĞŵŝͲĐŽŶĚƵĐƚŽƌŵĂƚĞƌŝĂů͘ƐƚŚĞŐĂƉŝŽŶŝǌĞƐ͕ƚŚĞĞŶĞƌŐǇŝƐĚŝƐĐŚĂƌŐĞĚŝŶƚŚĞŐĂƉĐĂƵƐŝŶŐĂ
ŚĞĂǀǇ ƐƉĂƌŬ͘ dŚĞƐĞ ƌĞƐŝƐƚŽƌƐ ǁŝůů ĚŝƐƐŝƉĂƚĞ ƚŚĞ ĞŶĞƌŐǇ͘ Ɛ ƚŚĞ ĞŶĞƌŐǇ ŝƐ ĚŝƐƐŝƉĂƚĞĚ ŝŶ
ĞůĞĐƚƌŽĚĞ͕ƚŚĞĐĂƉĂĐŝƚŽƌƐϭΘϮƐƚĂƌƚƐĐŚĂƌŐŝŶŐĨŽƌƚŚĞŶĞǆƚĐǇĐůĞ͘

KEEd/KEd/>^͗

/ŶƉƵƚŝƐƚŽďĞƉƌŽǀŝĚĞĚĂƚ dϭͲϭ
ĂƌƚŚ
dϭͲϮ
WŚĂƐĞ
dϭͲϯ
EĞƵƚƌĂů
dϭͲϰ
^ƉĂƌĞdŽƌƵǆZĞůĂǇŽŵŵĂŶĚ
dϭͲϱ
^ƉĂƌĞdŽƌƵǆZĞůĂǇŽŵŵĂŶĚ

KƵƚƉƵƚŝƐƚŽďĞƚĂŬĞŶĨƌŽŵ dϮͲϭ ,dKƵƚƉƵƚ
dϮͲϮEŽƚŽŶŶĞĐƚ
dϮͲϯ,dZĞƚƵƌŶ

&/'Ͳϰ

Page 8 of 10

^zDK> ^Z/Wd/KE

Zϭ ZĞƐŝƐƚŽƌ
ZϮ ZĞƐŝƐƚŽƌ
Zϯ ZĞƐŝƐƚŽƌ
ϭ ŝŽĚĞ
Ϯ ŝŽĚĞ
ϭ ĂƉĂĐŝƚŽƌĂŶŬ
Ϯ ĂƉĂĐŝƚŽƌĂŶŬ
>ϭ /ŶĚƵĐƚŽƌ
d dƌĂŶƐĨŽƌŵĞƌ
^WZ<'W ,ŝŐŚsŽůƚĂŐĞ^ƉĂƌŬ'ĂƉ
dϭΘdϮ dĞƌŵŝŶĂůƐƚƌŝƉƐ

&/'Ͳϱ

Page 9 of 10

WKtZW<DKhEd/E'Θt/Z/E'͗

dϭŝƐƵƐĞĚƚŽǁŝƌĞŝŶƉƵƚĐŽŶŶĞĐƚŝŽŶƐ
dϮŝƐƵƐĞĚĨŽƌŽƵƚƉƵƚĐŽŶŶĞĐƚŝŽŶƐ
&ŽƌŝŶƉƵƚĐŽŶŶĞĐƚŝŽŶƐ͕ƵƐĞǁŝƌĞŽĨŵŝŶŝŵƵŵϮ͘ϱƐƋ͘ŵŵ͘
&ŽƌŽƵƚƉƵƚ,dͬ,dZĞƚƵƌŶͬĂƌƚŚ͕ƵƐĞĐĂďůĞƐƵƉƉůŝĞĚďǇ&^
WŽǁĞƌ ƉĂĐŬ ƐŚŽƵůĚ ďĞ ŝŶƐƚĂůůĞĚ ďĞůŽǁ ĞǇĞ ůĞǀĞů ĨŽƌ ĐŽŶǀĞŶŝĞŶĐĞ ĚƵƌŝŶŐ ŵĂŝŶƚĞŶĂŶĐĞ͘
ǀŽŝĚ ůŽĐĂƚŝŶŐ ŶĞĂƌ ĨƵƌŶĂĐĞ ŚŽƚ ƐƉŽƚƐ͕ ĐĂƐŝŶŐ ŐĂƐ ůĞĂŬƐ ĂŶĚ ĚŝƌĞĐƚ ĐŽŶƚĂĐƚ ǁŝƚŚ ƚŚĞ ǁŝŶĚ
ďŽǆ͘ ^ĞĐƵƌĞůǇ ďŽůƚ ƚŚĞ ĞŶĐůŽƐƵƌĞ ĚŝƌĞĐƚůǇ ƚŽ ďƵŝůĚŝŶŐ ƐƚĞĞů ĨŽƌ ŐŽŽĚ ŐƌŽƵŶĚŝŶŐ͘ /ƚ ŝƐ
ƌĞĐŽŵŵĞŶĚĞĚƚŽĂƚƚĂĐŚďƵŝůĚŝŶŐŐƌŽƵŶĚǁŝƌĞ͘

/ŶƉƵƚ Θ KƵƚƉƵƚ ĐŽŶŶĞĐƚŝŽŶƐ ŵƵƐƚ ďĞ ĚŽŶĞ ǁŝƚŚ ƌĞĐŽŵŵĞŶĚĞĚ ĐĂďůĞƐ ĂŶĚ ƐĞĐƵƌĞĚ ƚŝŐŚƚ͘
>ŽŽƐĞĐŽŶŶĞĐƚŝŽŶƐŵĂǇƌĞƐƵůƚŝŶĨŝƌĞŚĂǌĂƌĚ͘

WZhd/KE^͗

dŚĞƉŽǁĞƌƐƵƉƉůǇƐŚŽƵůĚďĞŬĞƉƚŽŶĨŽƌϭϱƐĞĐŽŶĚƐ͘tĂŝƚĨŽƌŵŝŶŝŵƵŵϯϬƐĞĐŽŶĚƐďĞĨŽƌĞ
ŶĞǆƚĂƚƚĞŵƉƚ͘dĂŬĞƉƌŽƉĞƌĐĂƌĞǁŚŝůĞƌŽƵƚŝŶŐƚŚĞŚŝŐŚǀŽůƚĂŐĞĐĂďůĞǁŝƌŝŶŐ͘ǀŽŝĚĐŽŝůŝŶŐ
ƚŚĞ,dĐĂďůĞďĞƚǁĞĞŶĞǆĐŝƚĞƌĂŶĚƐƉĂƌŬƌŽĚ͘dŚŝƐŵĂǇƌĞĚƵĐĞƚŚĞĞŶĞƌŐǇƚƌĂŶƐĨĞƌƌĞĚƚŽƚŚĞ
ƐƉĂƌŬƌŽĚƚŝƉĚƵĞƚŽĂĚĚŝƚŝŽŶĂůƌĞĂĐƚĂŶĐĞ͘

dZKh>^,KKd/E'͗

WZK>Dʹ^WZ<EKd'EZd

ϭ͘ ŚĞĐŬǁŝƚŚsŽůƚŵĞƚĞƌĂƚƚĞƌŵŝŶĂůƐdϭͲϮͬdϭͲϯ;ĞŶƐƵƌĞĂǀĂŝůĂďŝůŝƚǇŽĨƉƌŽƉĞƌƌĂƚĞĚ
ǀŽůƚĂŐĞͿ͘
Ϯ͘ ZĞŵŽǀĞĞůĞĐƚƌŝĐĂůƐƵƉƉůǇĂŶĚǁĂŝƚĨŽƌϱŵŝŶƵƚĞƐ͘ŝƐĐŚĂƌŐĞƚŚĞĐĂƉĂĐŝƚŽƌƐƵƐŝŶŐĂŶ
ŝŶƐƵůĂƚĞĚƐŝŶŐůĞĐŽƌĞǁŝƌĞ͘
ϯ͘ ŶƐƵƌĞ ƉƌŽƉĞƌ ĞĂƌƚŚ ĐŽŶŶĞĐƚŝŽŶƐ ĂƐ ǁĞůů ĂƐ ĐŽƌƌĞĐƚ ƚĞƌŵŝŶĂƚŝŽŶ ŽŶ ďŽƚŚ dϭ ĂŶĚ
dϮƚĞƌŵŝŶĂůŐƌŽƵƉƐ͘
ϰ͘ ŶƐƵƌĞ ,d ĐĂďůĞ ƉƌŽƉĞƌůǇ ĐŽŶŶĞĐƚĞĚ Ăƚ ƚŚĞ ĞůĞĐƚƌŽĚĞ ĂŶĚ ĐŚĞĐŬ ƐƉĂƌŬ ƚŝƉ ŝƐ
ƉƌŽƉĞƌůǇĨŝƚƚĞĚƚŽƚŚĞĞůĞĐƚƌŽĚĞĞŶĚ͘
ϱ͘ ƐƐƵƌĞƚŚĂƚ,/ĞŶĐůŽƐƵƌĞŝƐƐĞĐƵƌĞůǇĐŽŶŶĞĐƚĞĚƚŽůŽĐĂůŐƌŽƵŶĚĂůůƚŚĞƚŝŵĞ͘
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O & M Manual - Pcil - 1

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INDEX

VOLUME DESCRIPTION VOLUME DESCRIPTION

SECTION DESCRIPTION PAGE NO.

A Overall Plant Description

2 Site Specific Design Data

3 Mechanical Equipment Description Summary

4 Electrical Equipment Description Summary

5 Control and Instrumentation Equipment Description Summary

6 Anticipated Performance Data Sheet

B Plant Startup and Shutdown Procedure

D Recommended Water Quality

E Boiler and Auxiliary Control and Protection Concept

The advantages of WHR boiler are such as:

Waste Heat Recovery Boiler on Cement Plant

Boiler Piping ASME B31.1 approved by IBR

Flue Gas Data (For PH Boiler)

Flue gas flow Nm³/Hr 1,62,925

Sr. Component Deg C.

Flue Gas Data (For AQC- Boiler)

PARAMETERS UNITS VALUE

Flue gas flow (Cooler Exhaust) Nm³/Hr 1,42,000

Flue Gas Temperature ( Cooler Exhaust) Deg C 305

Flue Gas Flow ( HAG Outlet) Nm³/Hr 1,53,200

AQC Boiler Inlet Temperature °C Deg C 440

Flue gas pressure at Tapping point (Cooler Exhaust) mmWC -20

Flue gas pressure at HAG Inlet (Deduster Outlet) mmWC -35

Flue Gas Composition :-

1 Boiler inlet 440

2 HP Super heater 2 Outlet 400

Flue gas Pressure profile

2 Flue gas Pressure at outlet Tapping -170 - 670

3 Pressure drop across I/L & O/L Tapping 150 80

Water & Steam Temperature profile for AQC & PH Boiler

Sr. Component (Pressure) AQC Boiler PH Boiler

1 Inlet of Condensate Pre heater 5.0 Not Applicable

3 Deaerator Operating Pressure 1.44

4 Economizer outlet 19 Not Applicable

5 HP Steam drum operating pressure

COOLING WATER FOR BOILER AUXILIARIES

CHEMICALS FOR DOSING

13 Internals --- Demister Pad & Baffles

13 Internals --- Demister Pad & Baffles

12 No. of Modules --- 2

2 Design pressure kg/cm²(g) 5

WHRS-AQC2HP- WHRS-AQC2HP- WHRS-AQC2HP- WHRS-AQC2HP-

Working Pressure Kg/cm² 15.3 15.3 15.1 14.5

SET PRESSURE Kg/cm² 18 19 17.5 17

Relieving Capacity TPH 7.62 8.02 3.9 36.47

QUANTITY --- One One One One

DESCRIPTION UNITS LP DRUM LP DRUM LP SH OUTLET ECO

WHRS-AQC2LP- WHRS-AQC2LP- WHRS-AQC2LP- WHRS-AQC2HP-

SET PRESSURE Kg/cm² 4 5 3.5 32

Relieving Capacity TPH 0.72 0.93 0.66 34.6

QUANTITY --- One One One One

LEVEL INDICATOR FOR STEAM DRUM

LEVEL GAUGE FOR BLOW DOWN TANK

2 Major parts --- Storage tank – 1 no (Common for AQC HP &

2 Pump capacity lph 0-5

INSULATION & Al. CLADDING

2 Density 100-150 kg/m³

DETAIL SPECIFICATION OF PR. PARTS AND EQUIPMENTS FOR PH BOILER

Make --- Fainger Lesser Fainger Lesser Fainger Lesser

Medium --- Saturated Steam Saturated Steam Superheated Steam