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INSTRUCTION MANUAL
PNEUMATIC VERSION
Process Viscometer
VISCOSUM
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DAEHO FLOW INSTRUMENTS
1.0 INTRODUCTION
1.1 GENERAL
3
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1.0 INTRODUCTION 4
DAEHO FLOW INSTRUMENTS
1.1 GENERAL
Always quote the serial number, as printed on the "-" tagplate of the
Viscosum Sensor, when contacting the factory or local sales representative.
TYPE 7 1
SERIAL NO. 7 1 c O N ~ R O U E R ~
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DAEHO FLOW INSTRUMENTS
1.0 INTRODUCTION
6
The typenumber stamped on the "-" tagplate on the Viscosum housing identifies
the instruments as follows.
1 7
8
CONNECTION SIZE AND FLANGE RATING
DN50 JIS 10K
DN50 JIS 16K
DN65 JIS 10K
DN65 JIS 16K
2" ANSI 150 #
2 x 112" ANSI 150#
3
4
5
6
7
8
ELECTRIC MOTOR
1
2
220VAC/240VAC, 1PH 1
220VAC/380VACl 3PH
240VAC/415VAC, 3PH 2
250VAC/440VAC, 3PH
llOVAC, 1PH 3
11OVDC
1
2
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3
-5-
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DAEHO FLOW INSTRUMENTS
2.0 FUNCTION DESCRIPTION
a. SENSOR
The Viscosum sensor consists of a housing in which is mounted a capillary tube assembly as the measuring
element, together with a gear pump. An electric motor with reduction gear drives the pump in such a way
that the volume of oil flowing through the capillary tubes is constant. As the flow through the capillaries is
8
also laminar, the pressure differential across the capillaries is directly proportional to the viscosity of the
fuel oil.
The capillary tube assembly consists of a fluon plastic metal measuring capillary in a resilient stainless steel
housing and damping capillary to compensate for under pressure waves in the fuel lines. The use of a metal
capillary reduces the possibility of clogging by cold heavy fuel oil.
A thermometer indicates the actual fuel temperature.
Two pressure taps are provided to connect the differential pressure devel'oped across the capillaries to the
differential pressure transmitter (DPT). A mechanical coupling between the electric motor and the gear pump
provides a leak free power transmission and prevents overload of the electric motor.
==-.==--=----
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DAEHO FLOW INSTRUMENTS
d. STARTFR BOX
2.0 FUNCTION DESCRIPTION
The starter box is used for on-off control of the Viscosum Sensor Motor.
The starter box is equipped with a thermal relay for protection of sensor motor.
10
The viscosity control station receives a 0.2-1 bar control signal, representing the actual fuel viscosity,
from the differential pressure transmitter (DPT) and compares this signal with the desired (setpoint) viscosity
value. Any deviation between the actual viscosity and the desired viscosity results in a corrective air signal
to the steam or thermal oil control valve, t o bring the measured value to setpoint value.
b. CONTROL VALVE
The control valve regulates the flow of steam or thermal liquid to the fuel heater. Standard valve action is
air-to-close, to ensure heating medium still being suplied to the heater in the event of a control signal
failure, while maintaining the possibility of controlling the valve by means of the manual override
(when this option has been ordered).
C. AIRFILTER-REGULATOR
Provides regulated air supply to the differential pressure transmitter, the control station and the (option)
analog viscosity indicator.
OPTION
d. VISCOSITY RECORDER
For registration of the viscosity of the fuel oil a recorder can be ordered as optional extra, The input of the
recorder i s the 0.2-1.0 bar control signal from the differential pressure transmitter.
The viscosity indicator i s used to provide viscosity indication at a point remote from the point of actual
viscosity measurement, e.g. in the control room or on the bridge. The instrument can be supplied with
adjustable low and high viscosity alarm contacts which can be connected to the ship's alarm system.
The non-indicating pressure switch is pneumatically connected to the viscosity control signal from the
differential pressure transmitter and has two microswitches to signalise a low or high viscosity alarm via
the ship's alarm system.
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DAEHO FLOW INSTRUMENTS
Electric motor
Supply voltage : see Model Number lndentlfication code
Insulation class : VDE 0530 class F. Tropical insulation
Protection class : IP 55, ex-proof motor IP 54
Power consumption : 0.63 A
Protection class : IP 65
Cable glands : 2 x PG13.5, for 10 - 12.5 mm O.D. cable dia.
Operating voltage : same as viscosum sensor motor
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3.0 TECHNICAL SPEClFlCATlONS 12
DAEHO FLOW INSTRUMENTS I
Model no. : VC 30
Air signal : 140 kPa (1.4 bar ; 20 psi)
Input signal : 20 - 100 kPa (0.2 - 1.0 bar ; 3 - 15 psi) from
differential pressure transmitter
Output signal - -
: 20 100 kPa (0.2 - 1.0 bar ; 3 15 psi) to control valve
Pneumatic connections : 1.4" NPT female
Control mode : P+I (proportional + reset) ; reverse (standard) or direct acting ;
manual or automatic operation.
Proportional band : 5 - 200% (factory adjusted to 35 %)
Reset time : 0.05 - 15 minutes (factory adjusted to 5 minutes)
Viscosity scales :0 - 22 mPa.s / 0 - 25 cSt , 0 - 44 mPa.s / 0 - 50 cst
Control accuracy : 1 % F.S.
Static air consumption : 0.13 NM~/H
Pneumatic relay : Non-bleed type
Materials
Measuring element : Ni-Span C bellows
Encasing : Die-cast alumimium
Protection class : IP 54, weatherproof, tropically resistant
Mounting : Wall or flush panel
Mounting hardware : Mounting brackets and 4 rubber vibration
dampeners supplied with instrument.
Max. static working pressure : 100 kPa (1 bar ; 15 psi)
Overrange protection : 100 kPa (1 bar ; 15 psi)
Ambient temperature limits : -20 to 80C
Weight : 4 kilos
Model no. : VL 20
Type : Signal seated giobe valve
Connection size : DN 25 (I"), DN 40 (1-112") , DN 50 (2")
Flanges : DIN PN 10 / 16 / 25 / 40,
ANSI Class 150 RF, 300 RF,
JIS 10K, 16K, 20K
Materials
Body : Cast carbon steel ASTM A216, gr. WCB
Trim : AlSl 316
Packing : Steam valve : Teflon V-rings
Thermal liquid valve : stainless steel bellows seal
Actuator yoke : Cast iron
Actuator diaphragm : Neoprene with fabric insert
Cv value : DN 25 : 3.6 , 5.4, 13 ;
DN 40 : 13 , 23.5 , 32 ;
DN 50 : 21 , 35 , 50
Actuator
TYpe : Spring & diaphragm
Action : Air-to-close (std.) or air-to-open
Control signal -
: 0.2 - 1.0 bar ( 3 - 15 psi ; 20 100 kPa)
Air connection : 114" NPT female
Manual operation : Handwheel optional, supplied when ordered.
Weinht. excl. handwheel
Steam valve : DN 2 5 : 18 k g , DN 4 0 : 22 k g , DN 50 : 26 kg
Thermal oil valve : DN 25 : 22 k g , DN 40 : 26 k g , DN 50 : 30 kg
Weight of handwheel : 4.5 kg
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DAEHO FLOW INSTRUMENTS
13
Model no.
Type
3.0 TECHNICAL SPECIFICATIONS
: VF 70
: Reducing-relief type automatic regulator
Maximum supply pressure : 2,000 kPa (20 bar ; 300 psi)
Regulated output pressure :0 - 250 kPa (0 - 2.5 bar ; 0 -35 psi)
Air output capacity : Max. 34 Nm3lh
Connections : 114" NPT
Materials
Housing : Die-cast aluminium
Valve plug : Stainless steel
Range spring : Cadmium plated carbon steel
Diaphragm : Nylon reinforced Buna-N
Filter element : Sintered stainless steel
Filter mesh width : 0.005 mm
Ambient temperature range : -50 to 65t:
Accessories supplied : Wall mounting bracket
Output pressure gauge
Weight : 0.58 kilos
Model no. : VI 41
Type : Pneumatic 1-pen strip-chart recorder
Mounting : Wall or panel mounting
Measuring element : Triple bourdon tube
Input air signal : 20 - 100 kPa (0.2 - 1.0 bar ; 3 - 15 psi)
Air connectlon : 114" BSP female pipe connection tube damping screw
Materials
Measuring element : Phosphor bronze
Encasing : Steel
Protection class : Watertight acc. IP55
Recording paper
Drive :7 - day spring wound clock
Reading units : Same as control station. Refer to para 3.1
Paper width : 120 mm
Recording speed : 20 mmlh
Recording capacity : 30 days
Accessorles supplied : 6 fibre-tipped felt pens
12 chart rolls for 1 year operation
Weight : 11.5 kilos
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DAEHO FLOW INSTRUMENTS
Model no.
TYpe
Mounting
3.0 TECHNICAL SPECIFICATIONS
: VI 40
: Edge scale manometer
: Flush panel mounting
14
Model no. : VA 60
TYpe : Non-indicating pressure switch
Mounting : Wall or front panel mounting
Switch type : Two SPDT diaphragm pressure switches
lnput air signal : 20 - 100 kPa (0.2 - -
1.0 bar ; 3 15 psi)
Max. input pressure : 400 kPa (4 bar ; 60 psi)
Air connection : 114" NPT female
Cable gland : Pg 13.5, tor 10 - 12.5 mm cable diameter
Contact rating -
: 125 250 VAC/lOA ; 480 VACl3A ; 6 - 28 VDCl0.5A
Factory switch settings : Low 4 psi, high 7 psi, Also see para 2.5
Materials
Diaphragm -
: Stainless steel 17 7 PH
Housing -
: Die cast aluminium
Protection class : IP 54 (NEMA 4)
Welght : 0.95 kilos
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DAEHO FLOW INSTRUMENTS
i5 4.0 INSTALLATION INSTRUCTIONS
1. The sensor1DPT assembly must be installed as shown in figure 5, in a position where it will be
free from excessive vibrations, moisture and large fluctuations of temperature. Also refer to section
2.1 of this manual. Mounting to the main engine or other machinery is not recommended.
Avoid bending strains on the sensor housing by using adequate fuel piping support.
2. Install the sensor1DPT assembly between fuel oil heater and fuel injection pump, as close as possible
to the outlet of the fuel heater.
Ensure that pipe length between heater and sensor is not more than 4 metres.
3. Include isolation valves and a bypass valve in the fuel piping, to permit normal engine operation
If the sensor must be taken out the line for servicing.
4. To enable removal of the electric motor with its gearbox for servicing approximately 20 Cms
clearance should be left to the side of the sensor.
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4.0 INSTALLATION INSTRUCTIONS
DAEHO FLOW INSTRUMENTS I
CAUTION :
The DPT is filled with glycerine to prevent fuel oil entering the instrument. To prevent loss of filling liquid
do NOT open valves on DPT manifold until viscosity control system will be taken into operation.
2. Install DPT (Fig.6) to bulkhead or other suitable support, using mounting bracket supplied. The process
lines between sensor and DPT must slope downwards. Therefore process connections at manifold
of DPT must be at least 10 cm below "+" and "-" output connections of sensor.
3. Connect "+" connection at sensor to "+" connection at DPT valve manifold and connect "-" connection
at sensor to "-" connection at DPT valve manifold, using 10 mm O.D. steel piping.
NOTE : + and - signs are marked on the sensor and in the sides of the DPT housing.
1. install starter box or motor switch at a convenient place in the engine room or control room.
1. Connect 1.4" bar (20 psi) regulated air supply to 114" NPT "IN" port of DPT.
2. Connect 114" NPT "OUT port of DPT to "process" connection of viscosity control station.
This output port must also be connected to the viscosity recorder, remote viscosity indicator andlor
alarm pressure switch, if these options have been supplied.
CAUTION : Remove shipping stops from process and air connections before making connections.
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DAEHo FLOW lNsTRuuEws 19
4.9 INSTALLATION OF AIRFILTER-REGULATOR
4.0 INSTALLATION INSTRUCTIONS
1. Install filter-regulator in upright position to wall or bulkhead, using the mounting bracket supplied.
Leave sufficient clearance below instrument to remove bowl for servicing.
2. Make pneumatic connections, using 6 x l m m or 318" O.D. copper tubing, or 114" O.D. copper pipe,
as follows :
a. Connect 114" NPTF "IN" port of regulator to compressed air supply with maximum air pressure
of 2,000 kPa (20 bar ; 300 psi).
b. Connect 114" NPTF "OUT" port of regulator to "IN" port of differential pressure transmitter
and to "SUPPLY" port of control station.
NOTE : The two remaining taps (stamped "G") are reduced pressure outlets.
One is used for the pressure gauge, the other one is plugged.
\
Supply air "Out", 1 / 4 " rip1 female
from compressor
max. 20 bar ( 3 0 0 ~ ~ 1 )
Connect to
'SUPPLY' connection of control slat~on
'IN' connectton of dlfferent~alpressure
lransrnlller
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4.0 INSTALLATION INSTRUCTIONS 20
1. Install recorder vertically to wall or in a panel, where it will be free as possible from vibration,
moisture and large fluctuations of temperature. Four (4) mounting holes 06.5mm are provided
in the panel mounting flange.
2. Connect the 114" EST fitting on top of the recorder with the 114" NPT "OUT" connection of the
differential pressure transmitter, using 6 x l m m or 318" O.D. copper tubing, or 114" brass pipe.
NOTE : The screw in the fitting on top of the recorder is a damping screw, to reduce excessive pulsations
which can cause poor record.
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DAEHO FLOW INSTRUMENTS
1. Install the pressure switch in any convenient place, which is accessible and where it is free from moisture,
large fluctuations of temperature, vibration or shock. Mount the switch to a wall or bulkhead using two (2)
M4 bolts or screws. The mounting bracket may be rotated in 90' increments to suit the mounting position.
2. Connect the 114" NPT pressure port to the 114" NPT "OUT" connection of the differential pressure
transmitter, using G x l m m or 114" tubing or piping.
3. Make electrical connections, through the Pg 13.5 conduit connector, to the ship's alarm system,
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using cable with 10 12.5mm O.D. See connection diagram of Fig, 17.
NOTE : Switches are factory preset to the values mentioned in section 2.5. If required low and high alarm
can be individually turned by screwdrive adjustment after removing lid on top of the instrument.
/
s h ~ p ' spannel
For electr~caiconnect~on
see f ~ g16
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install
sw~tchw ~ t h
(2) M4 screws.
\ 114" female NPT pressure port,
conner to couput s~gnall ~ n e
from Dif ferental Pressure
transm itter
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DAEHO FLOW INSTRUMENTS
5.0 DIMENSION DRAWING
26
5.3 STARTER BOX
(DIMENSION : mm)
i
c.
NOTE
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5.0 DIMENSION DRAWING
DAEHO FLOW INSTRUMENTS I
5.5 CONTROL VALVE
PNEUMATIC 2-WAY STEAM CONTROL VALVE (DIMENSION : mm)
HANDWHEEL OPTIONAL
7
TmONs
1/4 NPT
(DIMENSION : mm)
28
HANDWHEEL OPTIONAL
/I
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6.0 OPERATION INSTRUCTIONS
DAEHO FLOW INSTRUMENTS
This chapter describes general procedures for initial start-up of a Viscosum system.
Initial start-up of the system should always be done with diesel oil.
1. Close block valve (D & E, Fig. 28) and open equalizing valve (F, Fig. 28) on manifold of differential
pressure transmitter (DPT)
2. Open block valves and bypass valve (K, L & M, Fig. 29) around Viscosum sensor.
3. Close block valves and bypass valve (A, B & C, Fig. 291 around control valve..
5. Start booster pumps and after approximately 15 minutes close bypass valve i n fuel line (L, Fig. 29).
7. Unscrew plpe coupling i n sensing line to DPT on "-" side (see arrow In Fig. 28), to vent piping.
Walt until no more air bubbles come out wlth the diesll oll, Retighten coupling.
10. Observe vlscoslty reading of viscosity controller. If reading is not zero, re-adjust zero point of DPT,
i n accordance wlth section 7.7 and 7.8 of thls manual.
Close equalizing valve (F, Fig.28) on manlfold of differential pressure transmitter (DPT).
11. Check that control parameters of viscosity controller are at their desired valves.
Refer t o technical manual of controller supplied with the instrumentl.
12. Switch viscosity controller to MANUAL mode and check operation of steam valve,
as, described i n technical manual supplied with viscosity controller.
14. Switch viscosity controller to AUTOMATIC mode and adjust setpoint to a valve approximately
1 mPa.s higher than actual viscosity of diesel oil.
(Continued)
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DAEHO FLOW INSTRUMENTS
6.0 OPERATING INSTRUCTIONS
Ooen here
32
THERMAL OIL
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33 6.0 OPERATING INSTRUCTIONS
DAEHO FLOW INSTRUMENTS
16. Allow heavy fuel oil to enter fuel system. Viscosity controller will take up control of viscosity
as soon as actual fuel viscosity exceeds setpoint valve.
When the setpoint is at desire value and viscosity control has stabilized, the initial start-up procedures
are completed.
6.1.2 ROUTINE START-UP WITH DIESEL OIL AND CHANGE-OVER TO HEAVY FUEL
1. Check that bypass valve of DPT manifold (F, Fig. 28) is open.
2. Switch on booster pumps and allow diesel oil to enter fuel system.
3. Close bypass valve of DPT manifold (F, Fig. 28) and check that block valves of manifold
(D & E, Fig. 28) are open.
5. If viscosity reading on display of viscosity control station exceeds maximum limit of viscosity range,
switch off electric motor Viscosum sensor.
Switch viscosity controller to MANUAL and open steam control valve using regulator adjusting knob
on control station refer to Technical Manual supplied with control station, to add more heat to the fuel.
Then switch Viscosum electric motor on again and check whether viscosity reading is within
maximum operating limit.
6. Decrease controller setpoint to a value just above the measured actual fuel viscosity.
The viscosity controller will take up control of viscosity as soon as the measured viscosity
will exceed setpoint value.
9. Turn the system as described in the relevant chapter in the technical manual supplied
with the viscosity controller
When viscosity control has stabilized at the desired setpoint value, the start-up is comoplete.
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6.0 OPERATING INSTRUCTIONS 34
DAEHO FLOW INSTRUMENTS I
6.1 -3 ROUTINE START-UP ON HEAVY FUEL OIL
1. Check that bypass valve of DPT manifold (F, Flg. 28) is open.
3. Close bypass valve of DPT manifold (F,Flg. 28) and check that block valves of DPT manifold
(D & E, Flg. 28) are open.
5. Using regulator adjusting knob on viscosity controller, preheat fuel by opening steam control valve
to approximately 50 percent.
6. After approximately 20 minutes switch on electric motor of Viscosum sensor. Observe viscosity reading
by black pointer of viscosity controller. When reading is approaching maximum valve (see note below),
switch off electric motor of Viscosum sensor and increase valve opening by 10 percent.
NOTE :
"Maximum value" means maximum value of the Viscosum's viscosity range : 25 or 50 mPa.s.
This range i s coded in the type number on the "-" tagplate of the Viscosum sensor with cross-reference
to the identification code in section 1.2 of this manual.
8. If viscosity reads lower than maximum value of viscosity range, switch controller to AUTO.
The setpoint of the controller will be the same as the measured value at the moment of switching
over to automatic mode.
9. Every 5 minutes decrease setpoint by 5 mPa.s, until the desired viscosity value is reached.
When the fuel system is completely filled with HFO and the control station is in the automatic mode,
the behaviour of the system has to be checked and adjusted. This is best done by observing the actual
viscosity reading directly after a substantial change in the fuel consumption of the main engine.
When the process is hunting (the viscosity is oscillating around setpoint value), increase the proportional
band and/or increase the reset time at the viscosity control station, until the process behaves properly.
Proper viscosity control is characterised by a fast return of the measured actual viscosity value
(indicated by the black pointer) to setpoint value, with only one or two oscillations around the setpoint.
If the actual viscosity value returns very slowly to the setpoint value, decrease the proportional band
and/or decrease the reset time, until the process behaves properly.
If despite continued adjustment, the process can not be brought into good control, refer to the trouble
shooting procedures in section 8 of this manual.
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DAEHO FLOW INSTRUMENTS
6.0 OPERATING INSTRUCTIONS
6.1.5 SHUT-DOWN WITH CHANGE-OVER FROM HEAW FUEL OIL TO DIESEL OIL
2. When the fuel system is completely filled wlth diesel oil, switch off electric motor of Viscosum sensor.
2. Close steam valve completely, uslng regulator adjusting knob on vlscoslty controller.
When the viscosum sensor or the differential pressure transmitter is malfunctioning, there is no viscosity
signal available to the viscosity controller. Hence no vlscoslty control is possible.
To enable operation of the fuel system on HFO the heatlng must then be manually controlled.
Refer to chapter 8 for trouble shooting and possible corrective actions which can be performed to
re-instate the normal functioning of the Viscosum sensor or the differential pressure transmitter.
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6.2 VISCOSITY CONTROL STATION
CONTROLLER / Fig. 30
1) P. band adjustment knob
2) Set point indicator
3) Set point knob
4) Integral Action knob
5) AIM Selector
6) Regulator knob
If the control unit has an automatic/manual selector, set the selector t o the "AUTOMATIC" operating position.
1- Connect the unit to an air suppl!, 31 1.4 bar and temporarily open the bleed valve of the reducer filter
until any condensate has been completely discharged.
2- Make certain that there are no air leaks i n the connection to the control valve.
3- Use the knob (3) t o position the red indicator (2) to the desired value.
4- Use the ring (1) to adjust the proportional band to a width of 20% making certain that the action of
the instrument (direct or reverse) is type of operation requied.
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DAEHO FLOW INSTRUMENTS
6.2.1 (continued)
37 6.0 OPERATING INSTRUCTIONS
5- Turn the integral knob (4) to bring the automatic selector to the value of 0.5 repetitions a minute
(for the P+I control).
6- If the pneumatic valve Is equipped wlth a bypass, make certain that the valve is actually closed
and the downstream cutoff valve Is fully open.
7- If the control setting tends to fluctuate, with continuous oscillations of the black Indicator with respent
to the red Indicator, gradually increase the wldth of the proportlonal band In steps beyond the value of 20%
initially specified. If increaslng the width of the proportlonal band dose not reduce the fluctuation, turn the
integral control knob (4) to reduce the number of repetltions per mlnute (e.g. 0.2 repetltions/minute).
Do not go below values of 0.15 repetltions/minute.
8- If the fluctuation disappear, slowly and gradually reduce the wldth of the proportional band until there
is a slight fluctuation, and then lncrease the width of the band as necessary until stablllty i s restored;
If necessary, turn the Integral action knob (4) to gradually Increase the number of repetltions/minute above
0.5 repetltlons/mlnute to use the maximum acceptable automatic adjustment speed I n the system, as long
as it dose not cause fluctuations.
9- To make certain that you have selected appropriate values, both for wldth of the proportional band
and for the automatic adjustment velocity, artificially initiate a disruption by rapidly moving the red
Indicator about 5mm from the setpolnt. If oscillation occurs, slightly wlden the proportional band,
repeating the operation until stablllty is restored. The best control Is obtained wlth the narrowest
proportlonal band whlch is compatible with the stability of the process at the various loads.(see Fig. 30)
The actlon of the pneumatic control elements can be changed from dlrect action (output signal increase as
the variable increase) to reverse action (output signal increase as the variable decreases) or vice-versa,
simply by moving the selector ring to the desired type of operatlon.
However, the viscosity mode should be reverse mode.
The Automatic/Manual selection panel Is used when the operator wishes to override the automatic control
system and to operate the system manually, when control operations are difficult or when problems are
encountered. The control panel consists of a two-position switch (Automatic and Manual), a control knob
and a pressure gauge which indicates the value of the signal output from the panel.
Before operating the control unit equipped with an Automatic/Manual selector switch, make certain
that the proportional band and the manual adjustment have already been set described above.
Naturally, the automatic/manual selector panel can also be used to switch back and forth between automatic
and manual operation.
To switch between automatic and manual operation, bring the pneumatic signal output from the control
panel to the same pressure as the control signal (read on the output pressure gauge of the instrument)
and move the selector from the position "A" to the position "M".
-36-
6.0 OPERATING INSTRUCTIONS
DAEHO FLOW INSTRUMENTS I
6.3 AIRFILTER - REGULATOR
This pressure-reducing regulator (Fig. 31) is a simple automatic device which controls the downstream
pressure by balancing the force set by a spring against the force produced by the desired output
pressure acting on a diaphragm.
When the spring force Is greater than the output pressure force, the diaphragm assembly moves downward
and the Inlet supply valve opens, premitting the controlled pressure to Increase.
When the regulated pressure force is greater than the force set by the spring, the diaphragm assembly
moves upward, closing the pilot valve and uncovering the relief port.
The air than escapes to atmosphere through the relief opening i n the bonnet until the spring and pressure
forces are balanced.
The required output pressure is set by turning the range adjust screw and is indicated on the pressure gauge.
A spring loading drain valve is used for periodic draining of the liquid which collects In the bowl.
y
- DRAIN VALVE
The non-indicating pressure switch is pneumatically connected to the measuring signal from
the differential pressure transmitter.
This control air signal acts on a diaphragm which, in turn, actuates either of two microswitches
when predetermined high or low viscosity values are reached.
Low alarm point setting 4 psl (0.27 bar), corresponding with a viscosity of 8.75 mPa.s (35 sR1) for indicator
with a maximum scale reading of 50 mPa.8 (220 sR1).
or :
35 mPa.s (100 sR1)for indicator with a maximum scaie reading of 100 mPa.s (440 sR1).
High alarm point setting 7 psi (1.47 bar), corresponding with a viscosity of 17.5 mPa.s (80 sR1) for indicator
with a maximum scale reading of 50 mPa.s (220 sR1)
or :
38 mPa.s (160 sR1) for Indicator with a maximum scale reading of 100 mPa.s (440 sR1).
Circuit 2. h ~ g hcontact
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DAEHO FLOW INSTRUMENTS
7.1 GENERAL
7.0 MAINTENANCE
Under normal conditions the viscosum requires a minimum of maintenance. "Normal" means :
a. A clean operating environment,
b. Viscosum system components installed i n accordance with the installation instructions given.
40
c. Operation of the viscosity control system in accordance with this manual and other related publications
issued by DAEHO.
d. Uninterrupted electric power supply at the specified normal values.
-39-
7.0 MAINTENANCE
DAEHO FLOW INSTRUMENTS
The nozzle assembly and the dynamic restriction of the differential pressure transmitter must be cleaned
once a year. An accumulation of dirt at the flapper may cause a zero shift and a clogged dynamic
restriction will cause an output signal that is not related to the actual differential pressure developed
in the Viscosum sensor.
1. Remove cover of DPT and note the calibration values Inside the DPT cover
(see Fig. 33, for a typical example).
2. If the operating span of the DPT needs to be adjusted, this can be done by turning the range ring
(Fig. 34).
BUSAN-KOREA
T.82-51-831-3720
F.82-51-831-3750
O DAEHO FLOW INSTRUMENTS CO.,LTD 0
SER.NO.JI
0 DpT
VT 20 MAT'L 7 1
Range rlng
--
- - Zero adjust screw
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DAEHO FLOW INSTRUMENTS
7.5 (continued)
CAUTION :
A l w a y s c l o s e b l o c k v a l v e (Fig.28) w h e n DPT i s removed f r o m s e r v i c e ,
o r l o s s o f g l y c e r i n s e a l i n g liquid will o c c u r .
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DAEHO FLOW INSTRUMENTS
7.8.1 GENERAL
7.0 MAINTENANCE
MONTHLY SERVICING
This should be done when the viscosity control system is out of operation, or interference with
viscosity control will occur.
3. Using regulator knob (6, Fig. 30) adjust output pressure to 0.2 bar. The output can be read from the
output gauge of the control station.
When the valve action is air-to-close, valve should now be fully closed.
When the valve action is air-to-open, valve should be fully open.
6. While valve is opening or closing, check that valve stem moves smoothly.
If valve stem does not move smo~thlycheck alignment of packing box.
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7.0 MAINTENANCE
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DAEHO FLOW INSTRUMENTS
ATTENZIONE: BEFORE PERFORMING THE PERIODICAL MAINTENANCE MAKE SURE THAT THE AIR
FILTER REGULATOR IS CLOSED.
To clean the air fllter regulator loosen the screws (A) and (B) and remove the filter cartridge (C).
To clean the filter use a solvent such as gasollne and blow compressed alr In the cartrldge.
The life of the dlaphragm (D) loosen the screw (El and completely release the spring (F).
Loosen the screws (G) and remove the bonnet (HI.
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DAEHO FLOW INSTRUMENTS
DAILY SERVICING
7.0 MAINTENANCE
1. Wind-up clockwork.
2. Check writing pen. Replace if necessary.
3. Check chart roll speed. Adjust If necessary.
MONTHLY SERVICING
1. Pull pen arm (1, Fig, 39) into longitudinal direction and turn to the right.
The pen is now free from the chart table.
2. Fold back left-hand and right-hand chart guides (4).
3. Push left-hand and right-hand lower catches (7) downwards and pull out chart carrier (8).
Remove used chart roll from lower carrier (8).
4. Push left-hand and right-hand upper catches (3) downwards. The chart table can now be turned forward,
as Fig. 40, shows.
5. Remove end of used chart roll and install a new roll in upper chart carrier (9).
Snap chart table back in its operation position.
6. Insert beginning of new chart roll under clip of lower chart carrier (8).
Replace carrier in Its holder.
7. Tighten roll by turning tension knob (2) and adjust chart position to local time.
8. Fold down chart guides (4) and place pen (10) on chart.
1. PEN ARM
2. TENSION KNOB
3. UPPER CATCH -
3. UPPER CATCH
4. CHART GUIDE
4. CHART GUIDE
DIRECnON OF CHART MOVEMENT
5. ON-OFF LEVER
8 . WIND-UP SHUT
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7.0 MAINTENANCE
DAEHO FLOW INSTRUMEWS I
7.10.2 TO REPLACE WRITING PEN
1. Pull pen arm (1, Fig. 39) in longitudinal direction and turn it to the right.
2. Push left-hand and rlght-hand upper catches (3) downwards and turn chart table forward (as Fig. 40 shows)
3. Adjust chart speed by sliding "arrow" towards "+" or "-" posltion as required.
4. Re-install chart table and pen arm.
3 - 15 p ~ RECEIVER
l
Fig. 40, Tilted chart table for installation of new chart roll or adjustment of chart speed.
MONTHLY SERVICING
1.When performing monthly zero check of differential pressure transmitter, check that reading of analog
viscosity indicator is indencial to indication of control station.
Excessive deviation indicates air piping or instrument failure.
2. Check that alarm switch points (If alarm option is supplied) are at their desired levels.
POSSIBLE CAUSE
8.0 TROUBLE SHOOTING
Internal leakages in the Viscosum sensor Replace damaged parts of contact DAEHO instruments
or nearest service representative for repair. I
(damaged O-ring or gear pump).
Measuring capillary in Viscosum sensor fouled. Clean measuring capillary as described in section 9.3.
Fuel too cold during normal system operation, Increase output signal of viscosity controller to
due t o insufficient heating. control valve, i n accordance with instructions in the
technical manual of these components.
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DAEHO FLOW INSTRUMENTS
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DAEHO FLOW INSTRUMENTS
Check for leakage in the nozzle line connections at the nozzle and at the relay. If satisfactory, remove flexible
tubing from relay and close hole with finger, If pressure increases the problem is in the nozzle assembly.
50
Remove nozzle assembly and clean or replace as necessary. If pressure does not increase, the problem is
in the relay. Contact the factory or nearest DAsH service agent.
Move flapper away from nozzle. If output decreases, check friction in shaft, linkage and overtravel spring.
If output does not decrease, remove nozzle's flexible tubing at relay. If output decreases, the problem is
does not decrease when the nozzle line at the relay is open, the problem is i n the relay.
Check the push-button orifice (refer to Fig. 25)
This difficulty will manifest itself by the appearance of process hunting when there had been none before.
Before proceeding with any other check, increase (widen) the proportional band adjustment with a screwdriver
Increasing the proportional band effects a slower, but more stable control.
If widening the band does no help, the feedback may be inoperative (clogged tube or broken feedback
capsule).
If the control operation continues to hunt, set the proportional band adjustment back to its initial value and
decrease the reset time.
When continued adjustment fails to bring the process into control it is best t o look for erratic behaviour
of the process or other system components.
The control valve for steam or thermal liquid must sized correctly. It should be large enough to maintain the
process for most load conditions. If it operates near the full open position continually, it is probably undersize
and does not have sufficient control. If it operates near the closed position, it is probably oversize. For valve
sizing formula, refer to Technical Manual 728 or product Bulletin 764 "control Valves for Viscosum Systems".
Erratic valve action can occur from sticking of the stem due to corrosion or misalignment of the packing box.
Also refer to MAINTENANCE, para 7.8.
8.7 AIRFILTER-REGULATOR
Excessive air leakage through the bleed hole and failing regulated pressure signal usually indicates
a ruptured regulator diaphragm. replace airfilter-regulator if defective.
If the difficulties are in the indicator, check the internal mechanism for corrosion, loose pointer,
links or movement.
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51
9.0 PARTS LIST
DAEHO FLOW INSTRUMENTS
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9.0 PARTS LIST
DAEHO FLOW INSTRUMENTS I
9.2 ELECTRIC MOTOR BOX
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1
9.0 PARTS LIST 54
DAEHO FLOW INSTRUMENTS
ERELA Y ASSEMBL Y
SECTIONAL VIEW
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DAEHO FLOW INSTRUMENTS
9.3 (Continued)
PART NAME
9.0 PARTS LIST
38 1 Bracket T42001
39 1 Nut, Flapper Adjust Screw T44002
40 1 Adjusting Screw, Flapper T43003
41 1 Nozzle Retaining Nut T47004
42 1 Cover Assembly, conslstlng of Cover,
(4) Mtg. Screws, Gasket T94005 Die-cast Aluminium
43 1 Gasket, Cover T95006
44 1 Mounting Plate, Range Bar T40007
45 1 Flexure Group T39008
46 1 Screw T54001
47 1 Nozzle Assembly T45002
48 2 Washer T35003
49 1 Force Bar Assembly, consisting of items 50-55 T28004
50 1 Force Bar, Upper Section ~34005 ANSI-31 6
51 1 Separation Diaphragm T33006 Elgiloy
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9.0 PARTS LIST
DAEHO FLOW INSTRUMENTS I
9.3 (Continued)
I
ITEM. NO. Q'TY I PART NAME I PART NO. MATERIAL
1 Force Bar, Lower Section T32001
1 Plain Washer T31002
1 Spring Washer T30003
1 Nut T29004
1 Bracket T25148
1 Range Bar T55005
1
1 Relay Gasket T20111
2 Screw, long, Relay to Relay Block T89001
Relay Block T93002
Screw T I 3203
Screw, Relay Block Mtg. T I 4704
Screw, Bracket Mtg. T I 3505
314" Lg.
A
A
B
B
FLOW DIRECTION
Fig, 46. Pneumatic steam control valve with handwheel, model : VL20
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DAEHO FLOW INSTRUMENTS
9.5 (Continued)
Fig, 46.
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DAEHO FLOW INSTRUMENTS
9.5 (Continued)
Fig, 46.
9.0 PARTS LIST 60
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DAEHO FLOW INSTRUMENTS
1. The supplier warrants against defects in work- 6. The supplier reserves the right to have
62
manship or materials as well as for the corrent guarantee work carried out by third parties.
operation of the goods suppiied by him, if and
insofar this operation would be insufficient as a 7. Supplier's guarantee shall not apply if the
consequence of these defects. defects are the consequence of injudicious
putting into operation, of injudicious use,
2. This guarantee implies that the Supplier shaii incorporating instailation or storage by the
remedy these defects, or take back, in full or in Purchaser or the Owner, nor if after consuit-
part, the goods supplied and replace the ation with the Purchaser used materials or
defective parts by a new delivery, exciusiveiy at special materials are furnished by the Supplier,
the discretion of the Supplier. To this effect, the the application of which he is not familiar with.
Purchaser shaii return to Suppiier the goods
andlor parts involved, without being entitied to 8. Supplier's guarantee shall also not apply, if a
charge any of the costs arising from the return product or parts is ordered without giving
to the Supplier. Repair under guarantee in the written infirmation concerning the application.
Suppiier's factories is at no charge. Goods are
returned free of charge to nearest shipping port. 9. No guarantee shall be granted by the Supplier
for damages to goods suppiied arising within
3. if the guarantee work cannot be carried out in the terms referred to under section 5 of this
Supplier's factories, Purchaser shail aiiow the present article, If these damages are the
Supplier to perform this work, or have it consequence of corrosion caused by:
performed elsewhere, without being entitled to
charge any of the cost arising thereform to the a. iiquids, the material execution agreed upon
Supplier. if necessary, Purchaser shall in time put with the Purchaser is not resistant against
at Supplier's disposal ail necessary auxiliary and the use which by the Purchaser or
labourers, auxiliary tools and equipment, aids the Owner was not known to the Supplier at
and appiiances (fuels, oils, water, electricity, the time of acceptance of the order.
compressed air, etc.), at the correct place
without charging any of the cost arising b. liquids, the harmful action of which on the
therefrom to the Supplier. Any cost arislng material execution agreed upon with the
nonfuifiiment, or late fulfilment of any of the Purchaser was not known to the Supplier at
above provisions shaii be for Purchaser's account. the time of acceptance of the order, and of
The costs arising from making the goods available which It would not be demanded in reason
for repair, as weii as the repair hours, that the Supplier would have been able to
the travelling hours, travel and lodging expenses, know.
shall at ail time be for Purchaser's account.
10. Suppiier's liability under this guarantee shaii
4. if, in fulfiiment of the obligations under guarantee cease to exist, if during the guarantee period
Supplier repiaces any parts, the parts replaced the Purchaser or the Owner of the goods
shail become the property of the Supplier. furnished by the Supplier carries out repairs
and/or modifications to the goods suppiied on
5. The goods suppiied are guaranteed during a his own initiative, or has them carried out
period of 12 months. The guarantee period sets without Supplier's knowledge and his express
in at the moment the goods suppiied are put consent.
into use, provided this point of time is not later
than 6 months after the date of deiivery of the
goods.
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