Steam Equipments Pvt Ltd

No-44, Tiny Co.Op. Industrial Estate

Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

OPERATING & MAINTENANCE INSTRUCTIONS

FOR

STEAM AND WATER ANALYSIS SYSTEM

PROJECT : SWAS

CLIENT :

SUPPLIER : STEAM EQUIPMENTS PVT. LTD

PLOT NO-44, TINY INDUSTRIAL ESTATE
KONDHWA BUDURK,
PUNE 411 048

TEL. NO. : +91 020 2693 0908/59/60/61

FAX NO. : +91 020 2693 0959
E-MAIL : [email protected]
http://www.steamequipments.com

We thank you for purchasing the above system from us. Before operating the system, we request you to
read the manual carefully .

Page No : Page 1 of 26 www.steamequipments.com

 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

CONTENTS

SECTION A - EQUPMENT DESCRIPTION

SECTION B - PLANT ITEM OPERATING INSTRUCTIONS

SECTION C - FULL SET OF FINAL DRAWINGS

SECTION D - TEST & GUARANTEE CERFICATES

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 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

SECTION A

EQUIPMENT DESCRIPTION

CONTENTS

1. INTRODUCTION

2. CONDITIONING EQUIPMENT

2.1 Continuous Sample Monitoring

2.2 Analyser Monitoring

3. TECHINCAL INFORMATION

3.1 Plant Data

3.2 Design and Operating Data

Page No : Page 3 of 26 www.steamequipments.com

 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

INTRODUCTION

1.0 The equipment is designed and assembled to enable conditioning of samples, of boiler
water and steam, by reducing the temperature and pressure to a suitable state whereby a
continuous sample may be presented on to on-line analyzer(s), and a manual sample may
be drawn off as required.

2.0 CONDITIONING EQUIPMENT

2.0 CONTINUOUS SAMPLE MONITORING

2.0.1 This equipment is used for the temperature and pressure reduction of all samples.
The equipment is mounted on a treated and painted mild steel rack complete with
sample counter. All items being easily accessible for maintenance purposes.
2.0.2 The sample circuit comprises of sample inlet isolation and blow down valves,
sample coolers, filter, pressure reducing valve and relief valve. & sample flow
indicators, For the high Temp. protection, we have used HIGH TEMPERATURE
SAMPLE SHUT-OFF VALVE (THERMAL SHUT-OFF VALVE). Which operates
without using any external power / Air supply . Individual sample flow indicaters are
provided to cater sample for individual analysers. Back pressure regulators are
installed on the outlet of grab sample. This maintains the constant flow & pressure
to the analysers.All the individual sample coolers are having cooling water isolation
valves; coolant flow indicators.

2.0.3 To enable operators to take a manual sample we have incorporated a manual

sample grab facility.

2.0.4 The primary sample coolers operate in a counter current mode with the sample
flowing in the opposite direction to the cooling water, this is to ensure that the
sample outlet temperature will be at its lowest, i.e approaching the coolant inlet
temperature.

2.0.5 Terminations
 Sample inlet connections are 6mm OD Double ferrule fittings
 Cooling water : ½” BSP (F)

Page No : Page 4 of 26 www.steamequipments.com

 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

2.2 ANALYSER MOUNTING

2.2.1 The Analysers are mounted on the same panel as shown on the general
arrangement drawings.

3.0 TECHNICAL INFORMATION

3.1 PLANT DATA

3.1.1 Process Supplies (by others)

Cooling Water for sample coolers : 38ºC and 3 Bar .
Chilled Water : 20ºC and 3 kg/cm2 (G) .

3.1.2 The Sample Conditioning Panel comprises : -

Line Nos.:

REFER P & I DIAGRAM

DESIGN AND OPERATING DATA

3.2.1 Line 1 - Main Steam
Sample Pressure - 250 Kg/Cm2
Sample Temperature - 560ºC
Sample flow - 60 LPH

Page No : Page 5 of 26 www.steamequipments.com

 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

SECTION B

PLANT ITEM OPERATING INSTRUCTIONS

CONTENTS

1. GENERAL OPERATING REQUIREMENTS

2 EQUIPMENT & ROUTINE CHECKS

3 OPERATING & MAINTENANCE LITERATURE

4 TROUBLE SHOOTING

Page No : Page 6 of 26 www.steamequipments.com

 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

PLANT ITEM OPERATING INSTRUCTIONS

1. GENERAL OPERATING REQUIREMENTS

WARNING: OBSERVE ALL RELEVANT SAFETY RULES

The equipment is part of the Feed and Steam Chemical Analysis System. Operation of the equipment is
dictated by the requirements of the Feed and Steam Chemical Analysis System. During normal operation,
the equipment should run for prolonged periods with little or no attention. However routine checks, made
once daily or as experience suggest, will help to preserve trouble free and efficient operation of the system.

2. EQUIPMENT AND ROUTINE CHECKS.

SAMPLE CONDITIONING MODULES:

Check that the sample flow rates are at the required levels, adjusting the flow indicator
control valves as necessary.

Check that the sample temperature on each line is in the range of 45deg. C., adjusting
the chilled water / cooling water flow control valve if necessary.

To keep the sample filters reasonably clear of debris, the filter element should be
removed and cleaned on a regular basis. This period will be determined with
experience, when the condition of the removed filter element is examined.

ANALYSERS.

Refer to Analyser Manufacturers Literature.

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 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

PLANT ITEM OPERATING INSTRUCTIONS

SAMPLE INLET ISOLATION VALVES

1. OPERATION:
Valves required checking before being put into operation. In addition, regular inspection is also
necessary during operation and prompt attention given if trouble arises. As a general rule,
valves should be subjected to scheduled maintenance in the manner normal to all running
machinery. Particular attention is drawn to the following important instructions.

LUBRICATION:

These valves do not normally require lubrication between the spindle and yoke bush. An
exception to this might be when the valve is subjected to exceptionally high temperatures, or
when the valve remains open or closed for long periods. In this instance, it may be helpful to
insert a suitable high temperature grease, such as ROCON MHT, on the thread faces. When a
valve is not operated for long periods, a partial working of the spindle about once per month is
recommended.

SEAT TIGHTNESS:

Even a new valve, with seating faces lapped to perfection, and with seat/disc contact
throughout the entire circumference, will be pressure-tight only when sufficient steam load is
applied. The hand wheels, however, are sized in order that the required torque can be exerted
manually. The use of steam keys or other wrenches should not be necessary, and can lead to
serious damage to the valve.

A general rule, applicable to small valves, is that tight seating can be achieved with up to a
quarter of a turn of the hand wheel after contact is made between the seating surfaces.
Closing the valve against foreign matter lodged on the seat can result in grooves or pit marks,
preventing tight shut-off, and can lead to ‘wire-drawing’ and the destruction of the seating
faces.

If leakage is detected on closing the valve, do not apply increased torque to the hand wheel in
an effort to obtain leak – free closing. Re-open the valve and allow the flow to clean foreign
matter from the seating faces, repeating more than once if necessary.

PACKING CHAMBER TIGHTNESS:

Packing rings used in high temperature service as received from packing manufacturers are
porous and should initially be compressed as much as possible to provide a good seal. Unless
otherwise requested, valves will normally be packed with GRAPHOIL packing rings.

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 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

Hydrostatic test pressure will condition the rings, especially the two or three lower ones. Gland
Bolts should be re-tightened after test to maintain tightness. The gland bolts should also be re-
tightened after the initial 5-7 cycles.

SAMPLE CONTROL VALVES

1. Description:

Needle Valves are ruggedly constructed from Bar stock material. The valves have a class 2500
rating and design incorporates full back seating and anti-blowout stem.

2. Maintenance:

There is no recommended maintenance for this series of valves, only to ensure the gland packing
does not leak, but due to the design this is highly unlikely. In the event of a valve malfunction the
complete valve should be replaced.

COOLANT ISOLATION BALL VALVES

1. DESCRIPTION:

Small stainless steel ball valves are used for the isolation of the samples and small gunmetal /
carbon steel ball valves for the coolant supplies.

The ball valves are most unlikely to require attention, and no maintenance is therefore needed.
In the event of trouble arising with the valves, they should be treated as disposable items and
replaced.

The valves are in the open position with the handle parallel to the valve body, and closed with
the handle at right angles. The valves do not have the provision for venting to atmosphere in
any position.

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 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

BALL VALVES

SAMPLE ISOLATION 3 WAY BALL VALVES:

1. DESCRIPTION:

Small stainless steel ball valves are used for isolation of the sample, comprise a cast st. st. body
with removable stem, valve seat and end connectors.

The valves do not have the provision for venting to atmosphere in any position.

2. MAINTENANCE:

The Valves are most unlikely to require attention but in the unlikely event a spares kit is available.
This includes replacement ‘O’ rings, valve seats, packing washers and instructions.

Remove the hand wheel by using an Allen key in the socket set screw and turning anticlockwise.

Remove the valve body from its mounting panel or bracket by releasing the panel nut.

Disconnect from the sample pipe work.

Remove the gland-packing nut by turning anti-clockwise.

Remove the stem assembly from the body, replace stem ‘O’ rings and stem packing washers. N.B.
Do not discard gland packing – this is to be re-used.

To access the valve seats, secure the body using a suitable wrench and remove the end
connectors.

Care must be exercised when removing valve seats and ‘O’ rings from the body. Fit new seats and
‘O’ rings.

Re-assembly is the reversal of the removal procedure taking care not to allow the ingress of dirt /
contamination into the valve.

Page No : Page 10 of 26 www.steamequipments.com

 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

ASSEMBLY OF COMPRESSION FITTINGS:

These instructions are applicable to all twin-ring high pressure tube compression couplings in the size
range 6 mm od to 25 mm od. (1/4 inch OD to 1 inch OD).

1. The compression fittings are supplied ready assembled, finger-tight, with the sealing rings in the
correct order. It is neither necessary nor desirable to dismantle the fitting. In the event of the fitting
becoming dis-assembled, the parts must be re-assembled in the order and orientation shown in the
drawing, slipping each component over a short piece of tube of the correct size to ensure
alignment, and tightening to finger-tight.

2. Ensure that the correct size of compression fitting has been selected for the tube to be employed.
The tube should be a close sliding fit in the nut, rings and body.

3. Ensure that the tubing to be used is not scored, flattened or otherwise damaged. Cut the end of
the tube square and carefully deburr inside and outside.

4. Insert the tube into the fitting, ensuring that it passes right through the nut and both rings to rest
firmly on the internal shoulder of the body.

5. Select a spanner which is a close fit on the body of the fitting, or alternatively hold the body of the
fitting in a vice.

6. Using a spanner of the correct size, gently tighten the nut until the tubing will just not turn by hand.

7. Scribe a mark on the nut.

8. Using this mark as a reference, tighten the nut a further 1.1/4 turns.

9. The fitting is now ready for use at maximum pressure. It may be dismantled and re-assembled
many times. On re-assembly, the nut should be tightened to the above position and then slight
additional seating pressure applied with the spanner.

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 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

SAMPLE COOLERS

1. DESCRIPTION:

The sample coolers is a range of highly efficient units designed for the rapid cooling of samples of
boiler water and steam over the range of temperatures encountered within the power plant. The
coolers differ in the length, diameter and material of the cooling element (and hence the length of
the shell) required for the different thermal duties, and all replacement parts except the cooling coil,
associated stud couplings (used for securing the coil to the cooler lid), and shell are
interchangeable between the different coolers.

The cooler is partitioned into three concentric chambers by means of two axial tubular baffles. The
cooling water flows into the top of the inner chamber, and then passes to the outer chamber,
returning upwards to the outlet port.

2. INSTALLATION:

The equipment should not be dropped, dragged or otherwise treated roughly. Sample or cooling
water pipe work must NOT be used for lifting purposes. Care must be taken to ensure that the joint
faces are not bruised and equipment is not damaged in any way.

No water should be allowed to remain in the cooler shell or sample pipe work if freezing is likely to
occur.

Cooler assemblies should be firmly mounted in a vertical position in a safe / secure but accessible
position. (Note the clearance required for the removal of the cooler shell for coil cleaning).

The sample pipe work should be routed in a safe manner protecting personnel against contact with
hot pipes by insulating where necessary.

Ensure an adequate supply of cooling water is available and connected.

On completion of installation, pressure test all pipe work and check for leaks.

3 GENERAL OPERATING PRECAUTIONS:

When operating this equipment, it must always be remembered that the sample is at high
temperature and pressure, and for this reason care must be taken to ensure that:-

a) Personal contact with hot sample inlet pipe work etc. is avoided.
b) Blowing down of sample lines is undertaken with caution, to avoid the possibility of
scalding.
c) No equipment is connected to the sample outlet, which is incapable of
withstanding the design parameters.
d) All valves must be operated slowly.

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 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

1. OPERATION:

PRE-START REQUIREMENTS AND PRECAUTIONS:

Check that the installation has been carried out in accordance with correct procedures.
Open the coolant inlet and outlet valves to the cooler fully. Check that the coolant is
flowing vigorously and allow the coolant to flow until all the air is eliminated from the
system (no air bubbles are in view in the sight glass) if fitted.

Check that all sample valves are closed. Carefully open the sample inlet valve until fully
open, followed by a quarter-turn in the opposite direction (to prevent the valve sticking on
the back – seat in the open position). Check for leaks.

Cautiously open the sample outlet valve until the sample begins to flow. Allow the sample
to flow at the rate of 2-3 litres / minute until the issuing sample becomes clear and free
from debris.

WARNING : If either the sample or coolant temperatures become too hot, close the sample inlet valve
and allow the coolant system to recover then continue in stages.

Adjust the sample outlet valve and run the sample as 1 liter / minute, allow the system to
settle down by running for approx. 5 minutes and check that the coolant outlet pipework
does not become hot. If it does then the temperature is too high and an increase in the
coolant flow is necessary.

START UP PROCEDURE:
After following the above procedure, the coolers may be left running continuously at the
design flow rate.

If it is decided to shut down between intermittent samples, then the above pre-start
procedure must be observed.

NOTE : With intermittent sampling, sufficient time should be allowed to purge the
upstream sample line of stagnant sample. The time required will depend
on the size and length of the line. A practical indication of whether the line
has been purged may be obtained by checking the temperature of the
sample inlet pipe, a high temperature indicating the presence of fresh
sample. However, care must be taken to avoid injury to personnel.

SHUTDOWN PROCEDURE:
In the following order :
1) Close the sample inlet valve.
2) Close the sample outlet valve.
3) Close the coolant inlet and outlet valves.

WINTERISATION:

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 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

To protect against freezing during boiler shutdowns:-

1) Ensure that coolant isolation valves are closed.
2) Remove the drain plug/relief valve at the bottom of the cooler and allow the shell to
empty completely.
It should be ascertained that water will not subsequently enter the shell before
replacing the drain plug loosely.
With the sample inlet ;and outlet valves closed.
3) Open fully the sample outlet valve, disconnect the coil at the connectors (if fitted)
and blow the coil through with compressed air or nitrogen, (before commencing
this procedure, all people in the immediate vicinity are to be warned and the
engineering notified of the intention to apply compressed air or nitrogen. Great
care must be taken when using nitrogen to avoid enclosed spaces and operators
must keep clear of exhausting Nitrogen Gas.

WARNING : Observe all relevant site safety rules) loosely reconnect until required for
normal operation again. Before re-using ensure that the connectors and drain plug are
fully retightened and then carry out the pre-start procedure.

To protect against freezing with the boiler operating, allow the cooler to run continuously with a sample flow
rate of 30 kg/hr with coolant flowing normally,

5 MAINTENANCE:

The coil should be examined for condition every 6 months or sooner as conditions
Dictate.

5.1 TO DISMANTLE COOLER IN SITU FOR COIL EXAMINATION:

1) Ensure that the sample-isolating valve at the sampling point or probe on the main plant is
CLOSED and LOCKED. Close and lock off all sample isolation valves on the cooler and
both the inlet and outlet coolant isolation valves. Open the sample outlet valve on the
cooler to ensure that the sample pipe work is de-pressurized.

2) Remove the drain plug/relief valve at the bottom of the cooler and drain the water from the
shell.

3) Remove the 4 bolts and buts securing the body of the lid.

4) Carefully lower the shell away from the lid.

5) Examine the coil, particularly in the vicinity of the sample inlet, for signs of pitting.

5.2 TO REASSEMBLE THE COOLER IN SITU FOLLOWING COIL EXAMINATION:

1) Fit a new gasket in position on the shell clamp ring.

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 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

2) Carefully slide the shell over the cooling coil into position.

3) Fit and tighten diagonally the 4 lid securing bolts and nuts to a torque of 30 NM

6.2 ASSEMBLING THE COOLER:

1) Fit a new gasket in position on the shell clamp ring.

2) Carefully slide the shell over the cooling coil into position.

3) Fit and tighten diagonally the 4 lid securing bolts and nuts to a torque of 30 NM.

4) Replace the drain plug / relief valve in the bottom of the cooler.

6.5 RETURNING THE COOLER TO SERVICE.

1) Support the cooler in position, fit and tighten the two securing nuts.

2) Re-connect the coolant pipe work.

3) If the sample lines have compression fittings, re-connect the sample pipe-work
with the inlet and outlet pipes in the original position using new compression rings,
the original nuts should be re-usable

4) Test all joints and valve stem seals for pressure tightness in accordance with local
safety practices.

6.6 RECOMMENDED TEST PRESSURES :

Sample side – 1.5 x working pressure.

Coolant side - 1.5 x working pressure.

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 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

SAMPLE FILTERS

DESCRIPTION:

High-pressure filters are used to prevent debris from reaching the equipment downstream.

The filter has a forged body of SS-316 and a closely fitting perforated st.st. screen.

INSTALLATION:

Ensure hat the filter is suitable for the requirement service by checking the tag marking
and the rating cast on the body.
Before installation, carefully inspect the strainer for possible damage during transport
or handling.
Strainers should be installed as close as possible to machinery or valve to be
protected. The arrow cast marked on the strainer body must point in the direction of
the flow.
Install the strainer in the pipeline using counter flanges, gaskets and fasteners
corresponding with the strainer ends and suitable for the fluid to be filtered.
Make sure that all bolts and plug are properly tightened.
It is recommended that a quick clean up of the strainer is made a few hours after
startup by operating the drain plug.

Should the pressure drop be found in excess of the normal figures, a complete maintenance check should
be performed.

3.0 MAINTENANCE;

3.1 Complete maintenance should be carried out at least once a year, or whenever the
pressure drop is found to be in excess of the normal figures.
3.2 For complete maintenance, follow the steps below:-
3.2.1 Ensure that the line has been shut-off and de-pressurised.
3.2.2 Loosen cover bolts and buts and remove cover and gasket.
3.2.3 Withdraw Basket/Screen and carefully inspect for damage. If any hole in the
screen is found obstructed, clean it with compressed air and / or any suitable tool.
If the screen is broken or distorted, replace it.

Never reinstall a broken or distorted screen!

3.2.4 Carefully clean the inside of the filter body.

3.2.5 Fit a new gasket.
3.2.6 Install the new screen or the old cleaned screen.
Ensure that the Basket / Screen is seated correctly.
3.2.7 Replace cover and tighten bolts and nuts.

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 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

3.2.8 Slowly pressurize the line, checking for leaks.

3.2.9 Write on the filter body or tag the date of the maintenance operation.

SAMPLE PRESSURE REDUCING VALVE

1. GENERAL :

The Pressure Reducer is Rod-in-Tube type design as recommended by ASME PTC 19.11. These type
pressure reducers are used for the sample having pressure more than 30 Bar. Generally these kind of
reducers are totally maintenance free and cleanable in place.

To apply the pressure , rotate the knob provided. Generally these are factory set and can be adjusted by
rotating the know. The releas the pressure rotate the know be anti-clock wise direction

Online cleaning is also possible with these kind of pressure reducers. Once you feel that the sample is not
flowing through the pressure reducers, then change the position of Ball valve provided below the pressure
reducer to Drain position and rotate the pressure reducer in anti-clock wise direction. The sample will get
flushed by its own pressure and drain to sample sink provided. Once you see the blockages are removed,
reapply to pressure by rotating the know in clockwise direction and change the 3 way ball position. In the
even the chocking is more, then remove the locking nut provided on below knob, extract the taper rods and
clean with any cleaning solution.

Please make sure that the pressure reducer knob are not over tighten and this valve is not isolation valve.
There will be always a minimum flow in the pressure reducers. While installing, please make sure that the
tubes are not bent to block the movement of taper rods.

SAMPLE PRESSURE RELIEF VALVE

1. DESCRIPTION:

The relief valve is one of a series of adjustable in-line valves constructed from st. st. 316 with a soft
Viton ‘O’ ring to ensure a leak tight seal. Once set to the required pressure, the valve should
require no further attention unless it fails to shut off tightly.

2.1 ADJUSTING THE SET PRESSURE:

To adjust the relief valve, insert a standard screwdriver into the locking screw,
Unlock the locking screw by turning it anti-clockwise until the hexagonal key slides into the
adjusting screw.
Turn both screws to the desired cracking pressure. (Clockwise increases the opening
pressure, anti-clockwise decreases the pressure).

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 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

Retract the screwdriver key into the locking screw.

Lock the locking screw against the adjusting screw by turning the locking screw clockwise.

2.2 REPLACEMENT OF PARTS

The system must be isolated and depressurized before removing the valve.
To dismantle the valve the adjusting and lock screws must be removed to relieve the spring
pressure.
The insert lock screw and the insert proppet can then be removed.
The ‘O’ ring should be examined and if damaged replaced.
All parts should then be cleaned, replaced if necessary and then reassembled in reverse
order of above.

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 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

TEMPERATURE GUAGE

1. GENERAL:

Each instrument has a sealed system consisting of Mercury filled element. This in turn operates
the pointer of the instrument to indicate the temperature of the surface to which it is attached. The
gauge is fastened to the pipe work via a collect and spring arrangement.

2. MAINTENANCE:

No maintenance is required. If carefully installed, the instruments will function correctly for many
years. The operator is advised to check & calibrate the instruments occasionally if conditions are
not ideal

THERMOWELLS

Thermowells are used where thermometers maybe subjected to high pressure or corrosion. They are also
required where thermometers are to be removed without draining the system.

Although response time is greater than where no thermowell is used, accuracy is not affected.

The thermowell is machined from solid brass bar and will accept a thermometer stem with a ½” male
connection thread.

Page No : Page 19 of 26 www.steamequipments.com

 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

SAMPLE PRESSURE GUAGES

PRESSURE GUAGE

1) GENERAL:

Gauges are fitted to check the sample line pressure and to assist in the setting of any pressure
reducing device.

2) OPERATION:

2.1 WORKING PRESSURE:

If the working pressure is steady, the gauges should NOT be operated CONTINUOUSLY
beyond 75% of the maximum graduation. If the pressure is fluctuating, never use a gauge
continuously beyond 60% of the maximum graduation.

2.2 MAXIMUM PRESSURE:

The gauges must never be worked beyond the end of the scale, and or not designed to
withstand overloads.

3) MAINTENANCE:

Should any fault in the reading be suspected then the gauge should be isolated and removed from
it’s location. The gauge reading should then be checked alongside a calibrated gauge and if the
error is confirmed it would be returned to the manufacturer for repair.

Page No : Page 20 of 26 www.steamequipments.com

 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

HIGH TEMPERATURE SAMPLE SHUT-OFF VALVE (THERMAL SHUT-OFF VALVE)

1. GENERAL / OPERATION :

This valve is installed in the down stream of the sample cooler. The valve responds only to the temperature.
Under normal condition, this valve will be open. If the temperature rises within the operating temperature
(120 psig) , The thermal actuator modulates the valve to close the inlet orifice. The valve automatically re-
opens as the thermal actuator cools

2. MAINTENANCE:

Since this is totally concealed assembly, & there is no maintenance required. If required just clean the valve
externally by applying air pressure. This ensures Maintenance free-High temperature protection system.

SAMPLE FLOW METERS

1. OPERATION:

Flow indication is automatic on commencement of sample flow, and the float should ‘hang’
symmetrical, spinning gently. It should rise and fall freely in the metering tube, which is tapered
with the larger end at the top. The height reached by the float is determined by the area of gap
between the float and the tube at which the upward force from the fluid flow and the weight of the
float are equalized. The flow rate is read from the position of the topmost surface of the float
against the scale on the metering tube.

3. MAINTENANCE:

The metering tube, float and seals maybe removed without disturbing the flow meter body, or the
interconnecting pipe work. This enables cleaning or replacement of parts to be carried out with
considerably ease.

BALL VALVES

1. DESCRIPTION:

Small stainless steel ball valves are used for the isolation of the samples and small brass / carbon
steel ball valves for the coolant supplies.

The ball valves are most unlikely to require attention, and no maintenance is therefore needed. In
the event of trouble arising with the valves, they should be treated as disposable items and
replaced.

The valves are in the open position with the handle parallel to the valve body, and closed with the
handle at right angles. The valves do not have the provision for venting to atmosphere in any
position.

Page No : Page 21 of 26 www.steamequipments.com

 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

COOLANT FLOW INDICATORS

1. DESCRIPTION:

The flow indicator is a device incorporating flow fingers indicator. It is of very robust construction
and will withstand high temperature and pressure.

Four tie-bolts passing through retaining flanges hold the two thick glass disc ‘ windows’ in contact
with joints on either side of the body. The fingers are captive in the body by means of a spindle
secured into a webin the body casting.

2. CARE AND MAINTENANCE:

The flow indicator should be inspected periodically to ensure that the glass discs are clean and free
from erosion to the inner face and scratches etc. on the outer face, also that the spinner moves
freely when the cooling water is flowing.

Periodic removal of the discs may be necessary for cleaning, and for this purpose the c.w pipe work
should be isolated and drained down to at least below the level of the indicator.

Taking care to maintain reasonably uniform pressure on all bolts, as they are undone, loosen and
remove the four retaining bolts together with the flanges and glass discs. Check that the fingers
move freely. If they do not move freely, remove the stainless steel spindle, using a small pin
punch, and clean the fingers and spindle in soapy water. Replace and ensure that movement is
free, alternating the fingers so that they give an indication of flow.

Clean the glasses in soapy water, or if damaged, discard and replace with new.

Before fitting any glass disc, attach a single thickness of adhesive tape to the outer circumference
and to the non-joint face only of the disc, to prevent direct contact of the glass with metal parts, to
avoid accidental cracking. Ensure that there is no tape adhering to the inner joint face.

Clean the faces on the indicator body, and fit new gaskets. Re-assemble, taking care to preserve
even pressure on all bolts, avoiding excessive torque. Trim away any excess tape, taking care not
to scratch the glass.

If a complete replacement unit is to be fitted, do not use excessive torque in making pipe joints, as
this can damage the bronze body.

Page No : Page 22 of 26 www.steamequipments.com

 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

TROUBLE SHOOTING

SAMPLE CONDITIONING PANEL:

SYMPTOM POSSIBLE CAUSE ACTION

FAULT 1 Isolation valves closed Check that the probe isolation valves are fully
Loss of sample open.
Check that the sample inlet valve is fully
open.
Check that the sample outlet valve is fully
open.

Pressure reducing valve Change the position of 3 way ball valve to

is blocked with debris. drain and rotate the knob provided in anti-
clock direction. The sample will get flushed
with its own pressure. After few minutes, Re-
apply the pressure and change the 3 way ball
position to sampling mode

Filter blocked Remove and replace the complete filter

Broken or leaking sample Check the sample line, including the cooler
line coil and rectify as necessary.

FAULT 2 1. Insufficient coolant Open coolant isolation valve fully.

Sample running flowing Check that the flow indicator shows a good
hot flow.
Check that the coolant lines are not blocked
with debris.
Check that the pressure differential between
the coolant flow and return is correct. (A low
differential will cause allow coolant flow).
Check that the coolant relief valve (if fitted) is
not passing coolant.
Sample flow rate is too Decrease the sample flow rate to the correct
high level
Check that the sample relief valve is not
passing the sample.
Auxiliary coolant outlet Increase the coolant flow rate
temperature is too high Decrease the coolant temperature
Decrease the sample flowrate.

Page No : Page 23 of 26 www.steamequipments.com

 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

Chilled coolant outlet Check that chiller is operating

temperature is too high Check that pump is operating
Check that temperature control valve is
operating and / or adjust the chilled water
control valve

Page No : Page 24 of 26 www.steamequipments.com

 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

TROUBLE SHOOTING
SAMPLE CONDITIONING PANEL:

SYMPTOM POSSIBLE CAUSE ACTION

FAULT 3 Lack of process pressure / flow Await the return to normal operation
Sample at low Blow down valve or relief valve Close or reseat the valve
pressure passing
Isolation valves not fully open Open valves fully
Pressure reducing valve set too Reset the pressure-reducing valve.
low See specific instructions
FAULT 4 Debris trapped between the lid Close down the sampling system
Sample relief valve and seat Change the relief valve.
leaking Remove the faulty relief valve to the
workshop
Restart the system.
See specific relief valve instructions
for re-furbishing information

FAULT 5 Coolant supply failure Check cooling water flow at the

No flow in the coolant flow indicator
sample inlet at Check the coolant flow indicator, if
rotameter / Grab blocked clean or repair as necessary
sample Check that the isolating valves are
fully open.
Check coolant pipe work and cooler
for blockages, including before and
after the isolation valves.
The coolant temperature is too Check the chilled water supply to the
high sampling rack – it should be 5ºC

Thermal shut-off valve trip Physically check the sample

temperature. If it very , check point-1
& 2 in falut-5.
Sample flow rate too high Reduce the sample flow rate.

Coolant temperature too high Adjust the chilled water temperature

Page No : Page 25 of 26 www.steamequipments.com

 Steam Equipments Pvt Ltd
No-44, Tiny Co.Op. Industrial Estate
Kondhwa Budurk, Pune – 411048,
Phone / Fax : 020-26930908, 26930959
Email : [email protected]
http://www.steamequipments.com

ANALYSER PANEL:

Refer to appropriate manufacturer’s instruction manual for details of faults and

corrective procedures for each individual analyzer / transmitter.

SHUTDOWN PROCEDURE:

In the following order: -

2) Close all the sample inlet valves.
3) Close all the sample outlet valves.
4) Close all the coolant valves.
5) Stop chiller.

We thank you for using our system. If you have any suggestions / queries,

PLEASE CONTACT US ON

Steam Equipments Pvt Ltd

Plot No-44, Tiny Industrial Estate
Kondhwa Budurk , Pisoli Road
Pune – 411048, India
Phone : 020-2693 0908 . 2693 0959
Email:[email protected] ;
http://www.steamequipments.com

Page No : Page 26 of 26 www.steamequipments.com