HYDRATED LIME STORAGE SYSTEM PROCESS DESCRIPTION Document No

Transcription

1 Process Description Plant Bowen /s/ Gary Smith Approved Plant Review Board /s/ Tim Crump Approved Operations Manager /s/ Tim Banks Approved Plant Manager Date: PLANT BOWEN FLUE GAS DESULFURIZATION SYSTEM HYDRATED LIME STORAGE SYSTEM PROCESS DESCRIPTION Document No NOTE: If you are working with a printed copy of this document, it is NOT a controlled copy. Please be sure to check online for the most recent revision. Date Printed 2/23/2011 Page 1 of 95

2 T able of C ontents PROCESS DESCRIPTION Safety Considerations Process Description Introduction System Components Storage Silos (Unit 1 & 2 LI-SO-900A, Unit 3 & 4 LI- SO-9000B) Storage Silo Dust Collector (LI-DQ-9001A/B) Storage Silo Exhaust Fan (LI-MO-9000A/B) Rail/Truck Unload Blower Package A/B/C (LI-BW-9022A/B/C) Unloading Blower Condenser (LI-CD-9021A/B/C) Unloading Blower Dehumidifier (LI-DU-9056A/B) Transporter (LI-TK-9005A/B) Air Compressors (LI-CO-9010A/B/C) Summarized Controls Description Detailed Controls Description Process Flow Description Drawing References 73 Date Printed 2/23/2011 Page 2 of 95

3 PROCESS DESCRIPTION Safety Considerations 1. All Operating Companies Safety and Health Manuals shall be followed at all times. 2. The Southern Company Generation Clearance Procedure shall be followed at all times. 3. A thorough Job Safety Briefing (JSB) shall be completed before beginning work. 4. Employees should always use the proper Personal Protection Equipment (PPE) for the task they are performing. 5. Personnel must observe standard safety precautions when working around or with high temperature piping systems. 6. Personnel must be aware that components of this system are maintained in an automatic mode of operation. The equipment may start at any time without warning. 7. Personnel should remain clear of all rotating machinery, whether operating or in standby, at all times during unit operation. 8. Rotating machinery must never be placed in service without the appropriate equipment guards in place. 9. No attempt should be made to bypass or eliminate equipment safety interlocks. Doing so could result in equipment damage and possible injury to plant personnel. 10. Follow proper Confined Space Entry Procedures when entering confined spaces. 11. When employees are performing work on or associated with exposed lines or equipment energized at 50 volts or more, persons trained in First Aid including Cardiopulmonary Resuscitation (CPR), shall be available within 4 minutes per OSHA requirements. Date Printed 2/23/2011 Page 3 of 95

4 PROCESS DESCRIPTION Introduction The Silo Fill System controls the process of transferring hydrated lime (hydrated lime) from rail car/truck into two storage silos. The main components of the rail/truck unloading process are: air dehumidifiers, condensers, positive displacement blowers (PD Blowers), a piping system for selecting an air source (blower) for conveying material, convey piping, flexible hoses and couplings for allowing the transfer of material from either rail car or truck, storage silos with level inventory system, silo dust collection system, and the Railtruck Fill operators control panel. The silos are referred to as Storage Silo A and B, each with a usable capacity of 10,000 cubic feet. The total silo capacity is therefore 20,000 cubic feet. Air Sources (Blowers, Dehumidifiers) The air sources provide high velocity dried air for each unloading station. An air source consists of a blower and a two stage dehumidifier with its condenser. The ambient air is cooled below the dew point to remove the water. Next, the processed air passes through the desiccant wheel, where the remaining moisture is trapped through a process called sorption. The blower supplies the dried air to the unload stations for conveying. Date Printed 2/23/2011 Page 4 of 95

5 Introduction The silo fill system has three air sources. Unloading Blower A is the main blower for Storage Silo A and Unloading Blower B is the main blower for Storage Silo B. Either Unloading Blower A, or Unloading Blower B can be aligned to unload into either A or B Silo. Unloading Blower C serves as a backup for the main blowers and can be used to unload into either silo. The blowers can be selected, started, and stopped, from the DCS unloading screen or the Rail/Truck Fill Control Panel, and their status will be shown on the Rail/Truck Fill Control Panel. Each blower has a pressure (PSI) and temperature transmitter ( F), monitored by the control system. Based on the value of these transmitters, warnings or alarms are issued. By default, a dehumidifier starts simultaneously with the blower. From the DCS screen, a blower can be selected to run with or without a dehumidifier, A dehumidifier should only run if the blower is running. The DCS monitors the following information about each dehumidifier: running and faulted. If a blower is selected to run with a dehumidifier and a dehumidifier alarm occurs, the blower will stop as well. The condensers are not monitored by the control system. There are no alarms or DCS displays concerning the condensers. The piping system connects the unloading blowers with the unloading stations. The air source to be used is determined by a combination of five manual butterfly valves which must be set by the operator. The manual butterfly valves are equipped with limit switches which tell the control system which position they are set to (open/closed). By monitoring these switches, the controller can determine which blower is selected, and issue an alarm to alert the operator if the valves are not properly set. The air source for unloading to each silo is monitored by a mass flow transmitter. Air flow information is for monitoring only, and is not used for control purposes. Date Printed 2/23/2011 Page 5 of 95

6 Introduction Each storage silo has a station for unloading hydrated lime: the unloading station is utilized for both truck and rail car unloading. The operator must make two hose connections prior to unloading. These are the unloading blower and the convey line. Each of the connections are 6 inch manual hose connections with Cam-Lock couplings. Hydrated Lime Unloading Panel The operator must set the blower selection valves manually prior to starting the blower. Without a valid valve configuration, the system will not know which blower should run. Similarly, in the event of a silo overfill, the system would not know which blower to stop, to avoid a spill or prevent damage. For these reasons, the system must not allow the blowers to run without a valid valve configuration. Date Printed 2/23/2011 Page 6 of 95

7 Introduction The DCS will show the position of the valves based on the condition of the open and closed Limit Switches (LS), as follows: Open LS and not the Closed LS: indicates the valve is opened Not Open LS and Closed LS: indicates the valve is closed Open LS and Closed LS: (both) this will indicate an alarm Not Open LS and not the Closed LS: (neither) This will indicate an alarm If one of the necessary valves is moved while unloading, the blower will stop. After the valve is re-positioned, the blower will have to be manually re-started from the operator s control panel to resume the unloading process. Silo Blending The storage silos execute a blend cycle to help the material stay free flowing. If the silo is not in use, and blending is enabled, the sequence is as follows: The cycle repeats every 2 hrs Start a 2 minute blend cycle timer Pulse the silo aerations pistons to aerate the silo with one pulse of air for 1 second After that, delay for 10 seconds Repeat until the 2 minute timer is elapsed second If the silo is in use, and silo blending is enabled, the cycle is 10 minutes long as described below. This silo blending is in addition to the aeration that occurs as part of the conveying process: Cycle repeats every 2 hrs Start a 10 minute blend cycle timer Pulse the silo aerations pistons to aerate the silo with one pulse of air for 1 Delay 10 seconds, to allow the air to dissipate upward Repeat until the 10 minute timer is elapsed Date Printed 2/23/2011 Page 7 of 95

8 Introduction Storage Silo Level Inventory Each silo has 2 types of probes: Guided wave-type continuous level control "Emergency High" vibrating type point-level control Each silo is equipped with 2 guided wave-type continuous level transmitters which constantly monitor the storage silo inventory. The value of each guided wave-type level probe indicates the silo inventory as "Percent Full" (0 to 100%). The highest reading of the 2 guided wave probes is displayed on the Unloading Control Panel at the DCS and locally at the Unloading Control Panel. Only the highest reading of the 2 guided wave probes is considered when making decisions about the unloading process. The highest value of the guided wave probes is compared to the silo high level set point (set by the operator, via DCS). If the highest value is equal to or exceeds the silo high level set point, then the silo is full. There will be a delay of 3 seconds to avoid false alarms. This configuration with three (3) continuous level controls is chosen as an extra security measure: if one or two probes lose signal due to a malfunction, the backup probes will prevent a silo overfill or equipment damage. In addition to the three continuous level, each silo has an "Emergency High" vibrating level control probe. The normally open contact on the probe is used, because this probe is configured for "high-level fail-safe". In this configuration the input is ON when the probe is uncovered. When this probe becomes covered by material, it will stop vibrating and the input will go OFF. If the Emergency High level probe signal goes off for 3 seconds, the blower will stop immediately and the system will issue a "Silo Emergency High Level" alarm. This configuration is chosen since a loss of signal from the probe due to a malfunction, will mimic the silo full condition. Therefore, the system will not overfill and damage the storage silo due to a level probe failure. The Emergency High level probe serves as a backup for the guided wave level probes. Date Printed 2/23/2011 Page 8 of 95

9 Introduction Storage Silo Dust Collection The Silo Dust Collector captures the dust produced by the unloading process while allowing clean air to vent through the filters to the outside. The dust collector contains several rows of cylindrical cartridge filters, specially mounted to trap the dust on the outside of the filter, and let the clean air pass through to the center and vent through the top. In the course of normal operation, dust collector cartridges become coated with dust, which must be periodically removed. If the accumulated dust on the filter cartridges is not removed, over time the dust collectors will become blinded with dust and prevent proper venting of the silo. To remove the dust, the control system fires a solenoid to inject a blast of air downward through the center of the cartridges, forcing the excess dust on the outside to be removed by the pressure. This process is called Reverse Pulse Jet Cleaning. Reverse Pulse Jet Cleaning Date Printed 2/23/2011 Page 9 of 95

10 Introduction The timing board will execute the reverse pulse jet cleaning when a command from the control system is received. The timing board configured to clean an entire row of cartridges with each pulse of air. When a stop command is received, the timing board will remember which cartridge was cleaned last and will start the next cleaning cycle on the following row. The timing board is set to pulse each filter row for 0.3 seconds, with a delay of 10 seconds between each filter row. These time set points are adjustable on the timing board, not in software. The differential pressure across the filters is monitored by a pressure transducer which is wired directly to the timing board on the dust collector. In addition, the differential pressure is re-transmitted from the control board via 4-20 ma current signal to the control system. The control system monitors the differential pressure across the filters and controls the cleaning cycle. When running the cleaning cycle, the control system uses a Manual Over-Ride provision on the timing board. A relay is provided for this purpose. To initiate the cleaning cycle, the control system must close the relay contact wired to the manual override input on the dust collector timing board. Also, the settings on the timing board must be manually adjusted to maximum pressure to give the control system control over when and for how long to run the cleaning cycle control system. The Dust Collector has two modes of operation: Automatic Manual In Automatic mode, the control system will monitor the differential pressure across the filters and start the cleaning cycle when the differential pressure rises above 6 in. wc ( start cleaning set point). The cleaning cycle will continue until the pressure drops below 3 in. wc ("stop" cleaning set point). Both cleaning set points may be adjusted from the DCS screen. In "Manual" mode, the control system will force the cleaning cycle to run, regardless of the pressure reading. Date Printed 2/23/2011 Page 10 of 95

11 Introduction Transfer To The Day Bin The main components of the transfer system are: the compressed air system with compressed air piping for the entire system, a transporter located at the bottom of each storage silo, four day bins with level inventory system, the day bin dust collection system, and the convey lines with air assists and an automatic hose switch for day bin selection. Unit 1 and Unit 2 Day Bins are filled with silo and transporter "A", and Unit 3 and Unit 4 Day Bins are filled with silo and transporter "B". The transfer of hydrated lime from each silo to its day bins is controlled by a transfer system. Therefore, two identical transfer systems need to be created. Each transfer system has its own DCS screen. Date Printed 2/23/2011 Page 11 of 95

12 Introduction Air Sources (Compressed Air) The compressed air system provides dry air at 110 PSI to all necessary pneumatic devices in the hydrated lime injection system. The air provided by this system is used to open and close valves, aerate the storage silos, clean the dust collectors, pressurize the transporter to start the convey cycle and also to operate the convey switches and the air assist for the convey line. The air sources consist of two air surge tanks, three compressors, three air dryers and piping with manual valves, and four pressure transmitters. The two air tanks are connected to each other by a 3" pipe with manual valves. The manual valves are in place to allow the operator to isolate the desired tank for maintenance and run the system from one air tank. The compressed air produced by compressor(s) and dried by the air dryer(s) is stored in the air surge tanks. Each air surge tank has a capacity of 1040 gallons. The air pressure in each air surge tank is monitored by a pressure transmitter. The values from these two pressure transmitters are for monitoring only. There are pressure transmitters installed downstream of each surge tank. The value from these main pressure transmitters is the actual system air pressure, used as an interlock for all system operations. System air pressure ready (greater than 90 psig) is used as a permissive on all sub-systems that use compressed air. The control system monitors the system air pressure and will issue an alarm if the pressure falls below the low pressure alarm point (90 psig). Date Printed 2/23/2011 Page 12 of 95

13 Introduction There are two identical transfer systems: transfer system "A" to service Unit 1 and Unit 2 day bins and transfer system B to service Unit 3 and Unit 4 Day Bins. Each transfer system has two modes of operation: Automatic Manual In "Automatic" Mode, the transfer system responds to calling signals from the day bins. When in Automatic mode, the transfer system plays an active role and coordinates all aspects of transferring hydrated lime from the storage silos to the day bins. The operator need only select each day bin to be "in" or "out of service". Date Printed 2/23/2011 Page 13 of 95

14 Introduction In "Manual" Mode, the transfer system supervisory logic is inactive and will not initiate any changes to the convey line switch, nor issue any commands to the transporter. The operator can use the DCS panel to manually set the convey line switch and to (manually) start the transporter load and transfer cycles. Certain permissives are not reinforced in manual mode. For example, the operator can change the position of the switch without purging the convey line. The operator can stop a loading cycle before completed. Safety related interlocks are enforced. For example: the convey line switch will not be allowed to move if a transport cycle is in process. Date Printed 2/23/2011 Page 14 of 95

15 Introduction Day Bin Inventory The system has four day bins, referred to as Unit 1 Day Bin thru Unit 4 Day Bin. Each day bin has a capacity of 2,200 cubic feet. Unit 1 and Unit 2 Day Bins draw hydrated lime from storage silo "A", and Unit 3 & Unit 4 Day Bins draw from storage silo "B". The main features used when monitoring the inventory of the four day bins are: level probes and DCS displays and controls, which inform the operator about the activity and changes in status of the four day bins. The day bins and the storage silos use the same type of level probes. Just like the silos, the day bins will have: 2 guided wave-type continuous level controls 1 "Emergency High" vibratory type point-level control Each day bin has 2 guided wave-type continuous level probes, which constantly monitor its inventory. The value of each level probe is displayed on the DCS, but only the highest value is taken into consideration when calling for more material. The output of each guided wave-type level probe is a numeric value, expressing the day bin "Percent Full" (0 to 100%). The highest value from the three guided wave probes is compared to the following set points: emergency high level set point, high level set point, calling set point, and priority low set point. See previous section. This configuration with three (3) continuous level controls is chosen as an extra security measure: if one or two probes lose signal due to malfunction, there will be a backup and the day bin will not be overfilled and damaged. Each day bin also has an "Emergency High" vibrating probe which serves as a backup for the probes continuous level. The normally open contact on the probe is used, as this probe is configured for "high level fail safe". In this configuration the input is ON when the probe is uncovered. When covered, the emergency probe will stop vibrating and the input will go off. Information about the status and activity of the day bins is displayed on the DCS screen. Based on these controls, the operator can make interpretations about the operation of the transfer system and spot possible issues before they become problems. The operator can select a day bin to be "In Service" or "Out of Service". When a day bin is "In Service" it will call for material, receive hydrated lime from the storage silos and also feed the weigh hopper below the day bin. The day bin status displayed on the DCS will update between: Timing, Calling, Ok, Receiving, Full. Date Printed 2/23/2011 Page 15 of 95

16 Introduction An "Out of Service" day bin will not call for or receive material, but will continue feeding the weigh hopper in use. The system will display day bin as "Out of Service". The reasons to place a day bin "Out of Service" may be: To halt transfers to maintain the day bin. To run the day bin empty to calibrate level probes. To halt transfers to perform dust collector maintenance. In addition to information about the current status, the DCS will also display timer values that relate to the activity of each day bin. "FULL" indicates for how long the day bin has been full. This timer is important, because it can alert the operator to a failed level probe. Suppose the level probe is bad, and indicates full when, in reality, it is really getting low. An operator should be able to determine when an abnormal situation occurs, and the bin continues to indicate full when operational experience indicates that the bin level should be decreasing. "LAST' indicates how long ago the day bin received the last transport load. This is another way an operator can spot level probes that are not working properly. "CALLING" indicates for how long the bin has been calling for. This timer can inform the operator the transfer process is running smoothly or alert him when the system is waiting for something. For example, if the transfer system is in automatic mode, but the needed transporter is in manual. In this case, the transfer system will not issue any commands; it will wait for the operator to switch the needed transporter for automatic operation. "COUNT' indicates the number of loads the bin has received since the count was last reset (reset is manual through the DCS). It can give a rough indication of consumption, and help the operator spot a variety of problems. Date Printed 2/23/2011 Page 16 of 95

17 Introduction Operation of the Transporter A transporter is located below each storage silo. Its purpose is to convey a fixed quantity of hydrated lime from the silo to the calling day bin. Each Transporter has a capacity of 150 cubic feet. Each transporter can be individually selected for Automatic or Manual Mode from the Transporter Control window. Each transporter uses the following components: silo discharge equipment, vibrating level probes, air sources for pressurizing the system, pressure transducer and vent valves for releasing pressure. Date Printed 2/23/2011 Page 17 of 95

18 Introduction The silo discharge equipment includes the following components: transporter inlet valve, silo discharge valve, omni aerated spool section and silo aeration pistons. They are operated according to the sequence describing the Load Cycle. Before opening the transporter, the silo aerating pistons are energized to aerate the silo. The aeration is followed by a time delay, to allow the air to dissipate upward in silo. The silo will be periodically aerated to blend the hydrated lime and eliminate possible bridging. Once the silo is aerated, the transporter inlet valve will be opened. Upon proof that the inlet valve is opened, the silo discharge valve will open. The air flow to the omni spool section will run as long as the silo discharge valve is opened, to enhance the flow of material. At the end of the loading cycle, close the silo discharge first. After a time delay, close the transporter inlet valve. This sequence of operating the discharge and inlet valves is important, as it prevents excess wear on the inlet valve. The inlet valve has to be protected because it holds pressure during the transport cycle. For this reason, the inlet valve should not be operated with material resting on the seal surface. Each transporter has a high and a low vibratory level probe. The normally open contact is used for both. In this configuration, the input is ON when the probe is uncovered and OFF when the probe is covered. This configuration is chosen because the transporters are configured for "high-level fail-safe". When the load cycle begins, the high level probe is uncovered (input ON). The loading cycle continues until material covers the high level probe (input off) or loading is stopped (Load Stop/transfer commands from DCS, in manual mode). If the high level probe fails during a loading cycle, it will mimic a full transporter situation (input off). Therefore the transporter and the valves will not be damaged as a result of overfilling. The low level probe is ignored by the filling logic. When the transport cycle starts, the low level probe is covered by hydrated lime (input OFF). Transporting continues for at least the duration of the minimum convey timer and until the low level probe becomes uncovered (input on). The purpose of the low level probe is to avoid purging the convey line at the end of each transport cycle. This allows for faster conveying. The minimum convey time is set by the operator, and can be modified. The high level probe is ignored by the transport logic. The system uses compressed air to pressurize the transporter and convey hydrated lime to the day bins. The Transporter Top Air, Air Pad, Tangential Jets and Pilot Air solenoids are energized to inject regulated compressed air into the transporter and enhance the flow of hydrated lime down the convey line during transporting. They are operated according to the Transport Cycle. Date Printed 2/23/2011 Page 18 of 95

19 Introduction The pressure in each transporter is monitored through a pressure transmitter The analog value (PSI) is displayed on DCS. When the transport cycle begins, the pressure inside the transporter is 0 PSI. The transporter is pressurized and the material starts conveying when the pressure rises above 15 PSI (the high pressure set point). During transporting, the pressure continues to rise up to the transport air set point (set by manual regulator), In "full line concept" the transport cycle stops when the low level probe is uncovered. If the system is executing a "purge cycle", the transport cycle continues until the pressure falls below 15 psi. During the transport cycle all valves will be closed, to maintain the pressure. Once the transport cycle stops, the transporter will go through a venting sequence. First, open the solid vent valve, to slowly release the pressure. When the pressure inside the transporter falls below 3 psi, open the orifice vent valve. The solid vent valve and the orifice vent valve will remain open while the transporter is Idle or Loading. Both vent valves close at the same time, after the inlet valve to begin a transport cycle. When the transporter is in "Automatic" mode, it will respond to load and transport commands from the transfer supervisor system, which is monitoring the day bins and controlling the convey line switch. While the transporter is in "Manual" mode, the operator can initiate load and transfer, through the DCS. Manual load cycles can only be initiated while the transporter is Idle. A manual load cycle ends under one of the following circumstances: manual Stop Load command from DCS, manual Transport command from DCS or transporter full. When the loading cycle stops, the transporter goes back to Idle status and waits for more commands. The Load Time is displayed on DCS and reset only after the next command is received. Manual transfer is possible only when the convey line switch is in a valid configuration. If this prerequisite is not satisfied, the transfer command is ignored. When the transfer is complete, the transporter will go through a venting cycle, to release pressure and return to Idle state when the pressure falls below the low pressure set point. Transfer Time is displayed on DCS and reset only once the transporter receives the next command. A manual transport can be initiated with the transfer system in manual or automatic. Date Printed 2/23/2011 Page 19 of 95

20 Introduction Day Bin Dust Collection The Day Bin dust collector captures dust from the conveying process while allowing clean air to vent through the filters to the outside. The dust collector contains several cylindrical rows of cartridge filters, mounted such that the dust is trapped on the outside of the filter, and clean air passes through to the center, and vents through the top. In the course of normal operation, dust collector cartridges become coated with dust, which must be periodically removed. If the accumulated dust on the filter cartridges is not removed, over time the dust collectors will become blinded with dust and prevent proper venting of the day bin. To remove the dust, the control system fires a solenoid to inject a blast of air downward through the center of the cartridges, forcing excess dust on the outside to be removed by the pressure. This process is called reverse pulse jet cleaning. The reverse pulse jet cleaning process is executed by a timing board, when a command from the control system is received. The timing board is specially connected to clean an entire row of cartridges with each pulse of air. When a stop command is received, the timing board will remember which cartridge row was last cleaned, and will start the next cleaning cycle on the following row. The timer board is set to pulse each filter bank (row) for 0.3 seconds, with a delay 30 seconds between each filter row. These time set points are adjustable on the timing board, not in software. Note: The only difference between the day bin dust collector cycle and the silo dust collector cycle is the 30 second delay on cleaning each filter row. (On the silo dust collector cycle this delay is 10 seconds, because it is operating with hydrated lime that was delivered through a dilute phase conveying.) The differential pressure across the filters is monitored by a pressure transducer which is wired directly to the timing board of the dust collector. In addition, the analog differential pressure is re-transmitted from the control board via 4-20 ma current signal to the control system. The control system monitors the pressure and controls the cleaning cycle. To run the cleaning cycle, the control system uses a "manual over-ride" provision on the timing board. A relay is provided for this purpose. To run the cleaning cycle, the control system must close the relay contact wired to the "manual over-ride'' input on the dust collector timing board. Date Printed 2/23/2011 Page 20 of 95

21 Introduction Also, the settings on the timing board must be manually adjusted to maximum pressure, to give the control system control over when and for how long to run the cleaning cycle. The Dust Collector has two modes of operation: Automatic Manual In "Automatic" mode, the control system will monitor the differential pressure across the filters and run the cleaning cycle during the transport cycle, when the pressure rises above the start cleaning pressure set point (6 in. wc). Logic needs to be created to "latch" the cleaning cycle until the pressure drops below the stop cleaning pressure set point (3 in. wc). Both pressure set points are adjustable from the DCS screen during start-up. In "Manual" mode, the control system will force the cleaning cycle to continually run, regardless of the pressure reading. Convey Line A convey line connects each silo with its two day bins. The convey line has air assists to enhance conveying, and a 2-way switch, for day bin selection. The Nol-Tec two-way switch allows the system to convey product from the transporter to either of the two day bins connected to the silo. The switch is operated by compressed air, and contains various sensors which indicate its status. Convey Line Switch Date Printed 2/23/2011 Page 21 of 95

22 Introduction Air Assists The convey line is used to transfer the hydrated lime from the silos to the day bins. After the transporter is full, it is pressurized and the hydrated lime is pushed out into the convey line as a continuous slug. The air assists will break up the continuous slug into several shorter slugs, reducing the total resistance and enhancing the flow. Because we stop the conveying process when the low probe of the transporter becomes uncovered, the convey line will remain full at the end of each cycle. This full line concept allows the system to serve the day bins faster, conserves air and reduces system wear and tear. The air-assists along the dense phase convey line are activated when pressure is applied to the system pilot line. The Pilot-Air solenoid allows a regulated air supply into the transfer system's pilot line to activate the air assists. This pilot air supply is regulated by a manual regulator, and controls the pressure at which the convey system will operate. The pilot air solenoid remains on throughout the conveying operation. When the convey cycle is complete, the pilot line solenoid is de-energized. In its de-energized state, the pilot air solenoid allows the pilot air line to vent to the atmosphere. This brings the pilot line air pressure to zero, and conveying will stop. Date Printed 2/23/2011 Page 22 of 95

23 Introduction Emergency Unloading For exceptional situations, when the transporter is out of order, each day bin has an emergency truck unloading system such that an operator can connect a truck for unloading directly into the day bin. The emergency truck unloading system has the following components: flexible hoses and couplings for connecting the truck, convey lines and the Truck Fill operators control panel. The truck unload operator must manually make the necessary hose connections prior to unloading with the 4" truck fill line. This system uses the truck mounted blower for truck unloading. Date Printed 2/23/2011 Page 23 of 95

24 System Components The Lime Storage System consists of the following: Storage Silo A (LI-SO-9000A) Storage Silo B (LI-SO-9000B) Transporter A (LI-TK-9005A) Transporter B (LI-TK-9005B) Storage Silo A Dust Collector (LI-DQ-9000A) Storage Silo B Dust Collector (LI-DQ-9000B) Storage Silo A Exhaust Fan (LI-MO-9000A) Storage Silo B Exhaust Fan (LI-MO-9000B) Rail/Truck Unload Blower Package A (LI-BW-9022A) Rail/Truck Unload Blower Package B (LI-BW-9022B) Rail/Truck Unload Blower Package C (LI-BW-9022C) Rail/Truck Unload Blower Package A Condenser (LI-CD-9021A) Rail/Truck Unload Blower Package B Condenser (LI-CD-9021B) Rail/Truck Unload Blower Package C Condenser (LI-CD-9021C) Rail/Truck Unload Blower Package A Dehumidifier (LI-DU-9020A) Rail/Truck Unload Blower Package B Dehumidifier (LI-DU-9020B) Rail/Truck Unload Blower Package C Dehumidifier (LI-DU-9020C) Air Compressor A (LI-CO-9010A) Air Compressor B (LI-CO-9010B) Air Compressor C (LI-CO-9010C) Date Printed 2/23/2011 Page 24 of 95

25 Storage Silos (Unit 1 & 2 LI-SO-900A, Unit 3 & 4 LI-SO-9000B) Number Sheet Rev Title S B S C D-1967D P&IDs SCRUBBER - FGD LIME INJECTION SYSTEM PROJECT, COMMON STORAGE SILOS, P & ID General Arrangements SCRUBBER - FGD - GENERAL ARRANGEMENT - FLOW DIAGRAM Vendor O&M Manuals NOL-TEC SYSTEMS INSTALLATION, OPERATION AND MAINTENANCE MANUAL Function The storage silos are sized to provide a ready inventory of Hydrated Lime adequate to support unit operations. Description The system has two storage silos, referred to as Storage Silo A, and Storage Silo B. Each storage silo has a capacity of 20,000 cubic feet, for a combined total capacity of 40,000 cubic feet. The main features used when monitoring the inventory of the storage silos are: level probes and DCS displays and controls, which inform the operator about the activity and changes in status of each of the two storage silos. Each storage silo has two stations for unloading hydrated lime: one station for truck and one for rail car. Therefore the silo unloading system consists of four unloading stations. The operator must make two hose connections prior to unloading. These are the air source and the convey line. Each are 6 inch manual hose connections with Cam-Lock couplings. Each silo is equipped with 3 Guided wave-type continuous level transmitters which constantly monitor the storage silo inventory. The value of each Guided wave-type level probe indicates the silo inventory as "Percent Full" (0 to 100%). The value of each level probe is displayed on the DCS and the highest value is shown on the operator's control panel. Only the highest reading of the 3 guidedwave type probes is considered when making decisions about the unloading process. The highest value of the guided-wave type probes is compared to the silo high level set point (set by the operator, via DCS). If the highest value is equal to or exceeds the silo high level set point, then the silo is full. Date Printed 2/23/2011 Page 25 of 95

26 Storage Silos (Unit 1 & 2 LI-SO-900A, Unit 3 & 4 LI-SO-9000B) There will be a delay of 3 seconds to avoid false alarms. This configuration with three (3) continuous level controls is chosen as an extra security measure: if one or two probes lose signal due to a malfunction, the backup probes will prevent a silo overfill or equipment damage. In addition to the three continuous level controls, each silo has an "Emergency High" vibrating level control probe. The normally open contact on the probe is used, because this probe is configured for "high-level fail-safe". In this configuration the input is ON when the probe is uncovered. When this probe becomes covered by material, it will stop vibrating and the input will go OFF. Date Printed 2/23/2011 Page 26 of 95

27 Storage Silos (Unit 1 & 2 LI-SO-900A, Unit 3 & 4 LI-SO-9000B) If the Emergency High level probe signal goes off for 3 seconds, the blower will stop immediately and the system will issue a "Silo Emergency High Level" alarm. This configuration is chosen since a loss of signal from the probe due to a malfunction, will mimic the silo full condition. Therefore, the system will not overfill and damage the storage silo due to a level probe failure. The Emergency High level probe serves as a backup for the three analog level probes. The storage silos execute a blend cycle to help the material stay free flowing. If the silo is not in use, and blending is enabled, the sequence is as follows: The cycle repeats every 2 hrs Start a 2 minute blend cycle timer Pulse the silo aerations pistons to aerate the silo with one pulse of air for 1 second After that, delay for 10 seconds Repeat until the 2 minute timer is elapsed. Date Printed 2/23/2011 Page 27 of 95

28 Storage Silo Dust Collector (LI-DQ-9001A/B) Number Sheet Rev Title P&IDs S B SCRUBBER - FGD - P & ID D-1967D S Vendor O&M Manuals NOL-TEC SYSTEMS INSTALLATION, OPERATION AND MAINTENANCE MANUAL SCRUBBER -FGD-DUST COLLECTORS AND VACUUM FILTER RECEIVERS INSTALLATION MANUAL Function The storage silo dust collectors capture dust from the unloading and conveying process while allowing clean air to vent through the filters to the outside. Description The dust collector is a low pressure design, Model 60RD54C, manufactured by Nol- Tec Systems. The dust collector contains 54 dust collector filter bags arranged several cylindrical rows, mounted such that the dust is trapped on the outside of the filter bag, and clean air passes through to the center, and vents through the top. In the course of normal operation, dust collector bags become coated with dust, which must be periodically removed. If the accumulated dust on the filter bags is not removed, over time the dust collectors will become blinded with dust and prevent proper venting of the day bin. To remove the dust, the DCS fires a solenoid to inject a blast of air downward through the center of the filter bag assembly, forcing excess dust on the outside to be removed by the pressure. This process is called reverse pulse jet cleaning. The timing board will execute the reverse pulse jet cleaning when a command from the DCS is received. The timing board configured to clean an entire row of cartridges with each pulse of air. When a stop command is received, the timing board will remember which cartridge was cleaned last and will start the next cleaning cycle on the following row. The timing board is set to pulse each filter row for 0.3 seconds, with a delay of 10 seconds between each filter row. These time set points are adjustable on the timing board, not in software. Date Printed 2/23/2011 Page 28 of 95

29 Storage Silo Dust Collector (LI-DQ-9001A/B) The differential pressure across the filters is monitored by a pressure transducer which is wired directly to the timing board on the dust collector. In addition, the differential pressure is re-transmitted from the control board via 4-20 ma current signal to the DCS. The DCS monitors the differential pressure across the filters and controls the cleaning cycle. When running the cleaning cycle, the DCS uses a Manual Over- Ride provision on the timing board. A relay is provided for this purpose. To initiate the cleaning cycle, the DCS must close the relay contact wired to the manual override input on the dust collector timing board. Also, the settings on the timing board must be manually adjusted to maximum pressure to give the DCS control over when and for how long to run the cleaning cycle. The Dust Collector has two modes of operation: Automatic Manual In Automatic mode, the DCS will monitor the differential pressure across the filters and start the cleaning cycle when the differential pressure rises above 6 IWC ( start cleaning set point). The cleaning cycle will continue until the pressure drops below 3 IWC ("stop" cleaning set point). Both cleaning set points may be adjusted from the DCS screen. In "Manual" mode, the DCS will force the cleaning cycle to run, regardless of the pressure reading. Silo Dust Collector Assembly Date Printed 2/23/2011 Page 29 of 95

30 Storage Silo Exhaust Fan (LI-MO-9000A/B) Number Sheet Rev Title P&IDs S B SCRUBBER - FGD - P & ID Function The Storage Silo Exhaust Fan is installed to ventilate the equipment section of the Storage Silo Assembly. Description The Storage Silo Exhaust Fan is installed a thermostatically controlled 1/3 hp exhauster type fan which penetrates the skin of the equipment section of the Storage Silo Assembly exhausting to the outdoors. Date Printed 2/23/2011 Page 30 of 95

31 Rail/Truck Unload Blower Package A/B/C (LI-BW-9022A/B/C) Number Sheet Rev Title P&IDs S C SCRUBBER - FGD - P & ID S A Vendor O&M Manuals SCRUBBER - FGD GENERAL ARRANGEMENTS FLOW DIAGRAM Function The hydrated lime is delivered from railcars or trucks to the storage silos through dilute phase conveying, using high velocity dehumidified air. A blower and a 2 stage dehumidifier with its condenser are used for this purpose. The ambient air is cooled below the dew point to remove the water. Next, the processed air passes through the desiccant wheel, where the remaining moisture is trapped through a process called sorption. The blower supplies the dried air for conveying to ducts. Description Each Blower is a HPP-GD7CDL17 Positive Displacement Blower manufactured by Hardy Sys. Each Blower is powered by a 150 hp, 1800 rpm, TEFC, 60Hz, 3 phase, V motor. Each blower has a pressure, temperature and flow transmitter, monitored by the DCS. A blower can be selected to run with or without a dehumidifier. The selection is made at startup, from the blower control screen. The blowers and the dehumidifiers are operated according to the startup/shutdown sequence. If a dehumidifier is required for the current blower, a dehumidifier alarm will shutdown the feeder. The DCS monitors whether the dehumidifier is running or faulted. If a dehumidifier fault occurs, an alarm is issued. The air sources provide high velocity dried air for each unloading station. An air source consists of a blower and a 2 stage dehumidifier with its condenser. The ambient air is cooled below the dew point to remove the water. Next, the processed air passes through the desiccant wheel, where the remaining moisture is trapped through a process called sorption. The blower supplies the dried air to the unload stations for conveying. Date Printed 2/23/2011 Page 31 of 95

32 Rail/Truck Unload Blower Package A/B/C (LI-BW-9022A/B/C) The silo fill system has three air sources. Unloading Blower A is the main blower for Storage Silo A and Unloading Blower B is the main blower for Storage Silo B. Either Unloading Blower A, or Unloading Blower B can be aligned to unload into either A or B Silo. Unloading Blower C serves as a backup for the main blowers and can be used to unload into either silo. The blowers can be selected, started, and stopped, from the DCS unloading screen or the Rail/Truck Fill Control Panel, and their status will be shown on the Rail/Truck Fill Control Panel. Each blower has a pressure (PSI) and temperature transmitter ( F), monitored by the control system. Based on the value of these transmitters, warnings or alarms are issued. By default, a dehumidifier starts simultaneously with the blower. From the DCS screen, a blower can be selected to run with or without a dehumidifier. A dehumidifier should only run if the blower is running. The DCS monitors the following information about each dehumidifier: running and faulted. If a bower is selected to run with a dehumidifier and a dehumidifier alarm occurs, the blower will stop as well. The condensers are not monitored by the DCS. There are no alarms or DCS displays concerning the condensers. Date Printed 2/23/2011 Page 32 of 95

33 Rail/Truck Unload Blower Package A/B/C (LI-BW-9022A/B/C) The piping system connects the three (3) air sources with the four (4) unloading stations. The air source to be used is determined by a combination of five manual butterfly valves which must be set by the operator. The manual butterfly valves are equipped with limit switches which tell the control system which position they are set to (open/closed). By monitoring these switches, the controller can determine which blower is selected, and issue an alarm to alert the operator if the valves are not properly set. The air source for unloading to each silo is monitored by a mass flow transmitter. Air flow information is for monitoring only, and is not used for control purposes. Each storage silo has two stations for unloading hydrated lime: one station for truck and one for rail car. Therefore the silo unloading system consists of four unloading stations. The operator must make two hose connections prior to unloading. These are the air source and the convey line. Each are 6 inch manual hose connections with Cam-Lock couplings. The operator must set the blower selection valves manually prior to starting the blower. Without a valid valve configuration, the system will not know which blower should run. Similarly, in the event of a silo overfill, the system would not know which blower to stop, to avoid a spill or prevent damage. For these reasons, the system must not allow the blowers to run without a valid valve configuration. The DCS will show the position of the valves based on the condition of the open and closed Limit Switches (LS), as follows: Open LS and not the Closed LS: indicates the valve is opened Not Open LS and Closed LS: indicates the valve is closed Open LS and Closed LS: (both) this will indicate an alarm Not Open LS and not the Closed LS: (neither) This will indicate an alarm If one of the necessary valves is moved while unloading, the blower will stop. After the valve is re-positioned, the blower will have to be manually re-started from the operator s control panel to resume the unloading process. Date Printed 2/23/2011 Page 33 of 95

34 Rail/Truck Unload Blower Package A/B/C (LI-BW-9022A/B/C) PD Blower PD Blower Internal View (showing rotors) Date Printed 2/23/2011 Page 34 of 95

35 Rail/Truck Unload Blower Package A/B/C (LI-BW-9022A/B/C) Typical TEFC, 60Hz, 3 phase, V motor Unloading Blower Package Date Printed 2/23/2011 Page 35 of 95

36 Unloading Blower Condenser (LI-CD-9021A/B/C) Number Sheet Rev Title P&IDs S C SCRUBBER - FGD - P & ID S A Vendor O&M Manuals SCRUBBER - FGD INSTALLATION PURPOSES INDOOR/OUTDOOR UNIT- FACTORY MOUNTED Function The hydrated lime is delivered from railcars or trucks to the storage silos through dilute phase conveying, using high velocity dehumidified air. A blower and a 2 stage dehumidifier with its condenser are used for this purpose. The ambient air is cooled below the dew point to remove the water. Next, the processed air passes through the desiccant wheel, where the remaining moisture is trapped through a process called sorption. The dehumidifier supplies the dried air for conveying to ducts. Description Each Blower is equipped with a refrigerated condenser system. The condenser system is supplied by Hardy Systems Corporation, it is a 7.5 hp, R22 refrigerant system. The compressor unit and condenser are housed in a weather resistant enclosure and located outside the Lime Injection Building. The DX Coil located inside of the Lime Injection Building housed within the Dehumidifier package. A blower can be selected to run with or without a dehumidifier. The selection is made at startup, from the blower control screen. The blowers and the dehumidifiers are operated according to the startup/shutdown sequence. If a dehumidifier is required for the current blower, a dehumidifier alarm will shutdown the feeder. The DCS monitors whether the dehumidifier is running or faulted. If a dehumidifier fault occurs, an alarm is issued. Date Printed 2/23/2011 Page 36 of 95

37 Unloading Blower Condenser (LI-CD-9021A/B/C) Dehumidifier Compressor/Condenser Arrangement Dehumidifier Compressor/Condenser Unit Date Printed 2/23/2011 Page 37 of 95

38 Unloading Blower Dehumidifier (LI-DU-9056A/B) Number Sheet Rev Title P&IDs S C SCRUBBER - FGD - P & ID S S S A Vendor O&M Manuals SCRUBBER - FGD - INSTALL. PURPOSE - GEN. ARRGMENT - HCD-1125-EBA-SFCBS- LIME INJ.. DAY SILO DEHUMIDIFIER. LI-DU-9056A,B. MULTIPAGE SCRUBBER - FGD - INSTALL.PURPOSE- POSITIVE PRESSURE BLOWER PKGE. LIME INJECT. DAY SILO PD BLOWER. LI-BW-9057A,B. MULTIPAGE SCRUBBER - FGD - INSTALLATION PURPOSE - POSITIVE PRESSURE BLOWER PACKAGE Function The hydrated lime is delivered from railcars or trucks to the storage silos through dilute phase conveying, using high velocity dehumidified air. A blower and a 2 stage dehumidifier with its condenser are used for this purpose. The ambient air is cooled below the dew point to remove the water. Next, the processed air passes through the desiccant wheel, where the remaining moisture is trapped through a process called sorption. The dehumidifier supplies the dried air for conveying to ducts. Description The Dehumidifier Desiccant Dryer is a Munters Corporation Model HCD-1125-EBA- SFCBS. The dehumidifier utilizes Silca Gel as the desiccant and is rated to remove moisture at the rate of 37 lbs/hr. A blower can be selected to run with or without a dehumidifier. The selection is made at startup, from the blower control screen. The blowers and the dehumidifiers are operated according to the startup/shutdown sequence. If a dehumidifier is required for the current blower, a dehumidifier alarm will shutdown the feeder. The DCS monitors whether the dehumidifier is running or faulted. If a dehumidifier fault occurs, an alarm is issued. Date Printed 2/23/2011 Page 38 of 95

39 Unloading Blower Dehumidifier (LI-DU-9056A/B) Dehumidifier Arrangement Dehumidifier Installation Date Printed 2/23/2011 Page 39 of 95

40 Transporter (LI-TK-9005A/B) Number Sheet Rev Title S B Scrubber - FGD - P & ID D-1967D P&IDs Vendor O&M Manuals NOL-TEC Systems Installation, Operation and Maintenance Manual Function A transporter is located below each storage silo. Its purpose is to convey a fixed quantity of hydrated lime from the silo to the calling day bin. Description Each Transporter has a capacity of 150 cubic feet and can be individually selected for Automatic or Manual Mode from the Transporter Control window. Each transporter uses the following components: silo discharge equipment, vibratory level probes, air sources for pressurizing the system, pressure transducer and vent valves for releasing pressure. The silo discharge equipment includes the following components: transporter inlet valve, silo discharge valve, omni aerated spool section and silo aeration pistons. They are operated according to the sequence describing the Load Cycle. Before opening the transporter, the silo aerating pistons are energized to aerate the silo. The aeration is followed by a time delay, to allow the air to dissipate upward in silo. The silo will be periodically aerated to blend the hydrated lime and eliminate possible bridging. Once the silo is aerated, the transporter inlet valve will be opened. Upon proof that the inlet valve is opened, the silo discharge valve will open. The air flow to the omni spool section will run as long as the silo discharge valve is opened, to enhance the flow of material. At the end of the loading cycle, close the silo discharge first. After a time delay, close the transporter inlet valve. This sequence of operating the discharge and inlet valves is important, as it prevents excess wear on the inlet valve. The inlet valve has to be protected because it holds pressure during the transport cycle. For this reason, the inlet valve should not be operated with material resting on the seal surface. Date Printed 2/23/2011 Page 40 of 95

41 Transporter (LI-TK-9005A/B) Each transporter has a high and a low vibratory level probe. The normally open contact is used for both. In this configuration, the input is ON when the probe is uncovered and OFF when the probe is covered. This configuration is chosen because the transporters are configured for "high-level fail-safe". When the load cycle begins, the high level probe is uncovered (input ON). The loading cycle continues until material covers the high level probe (input off) or loading is stopped (Load Stop/transfer commands from DCS, in manual mode). If the high level probe fails during a loading cycle, it will mimic a full transporter situation (input off). Therefore the transporter and the valves will not be damaged as a result of overfilling. The low level probe is ignored by the filling logic. Date Printed 2/23/2011 Page 41 of 95

42 Transporter (LI-TK-9005A/B) When the transport cycle starts, the low level probe is covered by hydrated lime (input OFF). Transporting continues for at least the duration of the minimum convey timer and until the low level probe becomes uncovered (input on). The purpose of the low level probe is to avoid purging the convey line at the end of each transport cycle. This allows for faster conveying. The minimum convey time is set by the operator, and can be modified. The high level probe is ignored by the transport logic. The system uses compressed air to pressurize the transporter and convey hydrated lime to the day bins. The Transporter Top Air, Air Pad, Tangential Jets and Pilot Air solenoids are energized to inject regulated compressed air into the transporter and enhance the flow of hydrated lime down the convey line during transporting. They are operated according to the Transport Cycle. The pressure in each transporter is monitored through a pressure transmitter. The analog value (PSI) is displayed on DCS. When the transport cycle begins, the pressure inside the transporter is 0 PSI. The transporter is pressurized and the material starts conveying when the pressure rises above 15 PSI (the high pressure set point). During transporting, the pressure continues to rise up to the transport air set point (set by manual regulator), In "full line concept" the transport cycle stops when the low level probe is uncovered. If the system is executing a "purge cycle", the transport cycle continues until the pressure falls below 15 psi. During the transport cycle all valves will be closed, to maintain the pressure. Once the transport cycle stops, the transporter will go through a venting sequence. First, open the solid vent valve, to slowly release the pressure. When the pressure inside the transporter falls below 3 psi, open the orifice vent valve. The solid vent valve and the orifice vent valve will remain open while the transporter is Idle or Loading. Both vent valves close at the same time, after the inlet valve to begin a transport cycle. When the transporter is in "Automatic" mode, it will respond to load and transport commands from the transfer supervisor system, which is monitoring the day bins and controlling the convey line switch. While the transporter is in "Manual" mode, the operator can initiate load and transfer, through the DCS. Manual load cycles can only be initiated while the transporter is Idle. A manual load cycle ends under one of the following circumstances: manual Stop Load command from DCS, manual Transport command from DCS or transporter full. Date Printed 2/23/2011 Page 42 of 95

43 Transporter (LI-TK-9005A/B) When the loading cycle stops, the transporter goes back to idle status and waits for more commands. The Load Time is displayed on DCS and reset only after the next command is received. Manual transfer is possible only when the convey line switch is in a valid configuration. If this prerequisite is not satisfied, the transfer command is ignored. When the transfer is complete, the transporter will go through a venting cycle, to release pressure and return to Idle state when the pressure falls below the low pressure set point. Transfer Time is displayed on DCS and reset only once the transporter receives the next command. A manual transport can be initiated with the transfer system in manual or automatic. Date Printed 2/23/2011 Page 43 of 95

44 Air Compressors (LI-CO-9010A/B/C) Description The air sources consist of two air surge tanks, three 350 hp Ingersoll Rand, H-350, liquid cooled, oil free rotary screw air compressors, three air dryers and piping with manual valves, and four pressure transmitters. Date Printed 2/23/2011 Page 44 of 95

45 Air Compressors (LI-CO-9010A/B/C) INTELLISYS CONTROLLER I EMERGENCY STOP Pressing this switch stops the compressor immediately. The compressor can not be restarted until the switch is manually reset. Turn the switch knob clockwise to reset. Date Printed 2/23/2011 Page 45 of 95

46 Air Compressors (LI-CO-9010A/B/C) POWER ON LIGHT This indicates the control voltage and the line voltage are available for starting. The operator panel is divided into two areas. The bottom row of four buttons provides direct control over the starting, stopping, unloading and loading of the compressor. These are defined by the symbols printed on the buttons themselves, as shown here. START Pressing this button will start the compressor if the display shows Ready To Start. The compressor will start and load if there is sufficient demand for air. STOP Pressing this button will activate the unloaded stop sequence. If the compressor is running loaded, it will unload and continue to run unloaded for an adjustable 10 to 30 seconds and then stop. If the compressor is running unloaded, it will stop immediately. Date Printed 2/23/2011 Page 46 of 95

47 Air Compressors (LI-CO-9010A/B/C) UNLOAD Pressing this button will cause the compressor to unload and remain unloaded. The display will indicate the machine is Running Unloaded, and Mode:UNLOAD. LOAD Pressing this button will cause the compressor to load if the compressor is running and if the Discharge Pressure is less than the Online Pressure. This also returns the machine to the operating mode that is specified by the Mode of Operation set point. The other five buttons provide access to various operator-selectable functions and machine operating conditions. The purpose of each of these buttons is defined by the display screen and the particular function being performed at that time. ARROWS These up and down buttons have multiple functions relating to the right half of the display screen. When lists are presented, the buttons are used to move up or down through the items on the list. The small arrow(s) displayed in the upper right corner of the display screen indicate when you can move up (designated by arrow head pointing up) and/or down (designated by arrow head pointing down) through the list. When the value of a specific machine operating parameter is highlighted on the display screen for the purpose of changing that value, the buttons are used to change the value itself. Date Printed 2/23/2011 Page 47 of 95

48 Air Compressors (LI-CO-9010A/B/C) DISPLAY BUTTONS The functions of the three buttons below the display screen change and are defined by the words immediately above them in the bottom line of the screen. Each function, such as MAIN MENU, STATUS, SET, etc., is described in appropriate sections in this manual. Date Printed 2/23/2011 Page 48 of 95

49 Air Compressors (LI-CO-9010A/B/C) DISPLAY SCREEN The display screen is divided into three functional areas, as seen in the typical CURRENT STATUS screen shown above. The left side continuously shows the package discharge pressure in large numbers, with the line directly below the numbers showing the running condition of the machine, and the line below that showing the present mode of operation. The right side shows various items or lists such as the machine s CURRENT STATUS readings, the MAIN MENU, the OPERATOR SETPOINTS list, etc. Any of the lists can be moved up or down by pressing the arrow buttons to the right of the screen. The small arrow(s) displayed in the upper right corner of the screen indicate when you can move up (designated by arrow head pointing up) and/or down (designated by arrow head pointing down) through a list. The arrow buttons are also used to change an individual item s value. At certain times, items and/or their values are highlighted. This means they are displayed as light characters on a dark background. The bottom of the screen is divided into thirds with the words in each small box showing the function of the button directly beneath it. The words will change in these boxes depending on what actions are permitted at any particular time. The action resulting from pressing each of these buttons is indicated in the Figure above, which can be used as a quick reference of how to step the controller screen through any desired function. Date Printed 2/23/2011 Page 49 of 95

50 Air Compressors (LI-CO-9010A/B/C) CURRENT STATUS The CURRENT STATUS screen is considered the normal display that the controller shows. The following items and their present values can be displayed on the right side of the screen by pressing the up and down arrow buttons. CURRENT STATUS Items Discharge Temperature Inlet Vacuum Airend Discharge Temperature Inlet Filter Injected Temperature Total Hours Sump Pressure Loaded Hours Separator Pressure Drop % Load Modulation Unloaded Inlet Vacuum Coolant Pressure Time & Date Coolant Filter Software Title and Version Date Printed 2/23/2011 Page 50 of 95

51 BWN-1/ Rev Air Compressors (LI-CO-9010A/B/C) The controller automatically returns the display to this CURRENT STATUS screen from other screens if no buttons are pressed within 30 seconds. The MAIN MENU screen can be accessed from the CURRENT STATUS screen by pressing the MAIN MENU button, identified by the words MAIN MENU in the bottom line of the screen directly above the center button. Date Printed 2/23/2011 Page 51 of 95

52 Air Compressors (LI-CO-9010A/B/C) NOTE - Use the UP and DOWN arrows to move between selections. Items will be highlighted in inverse display mode. * Selecting the highlighted item will display the corresponding menu. ** Selecting the highlighted item will place the value in edit mode. This is indicated by only the value being displayed in inverse display mode. *** The UP and DOWN arrows will alter the value. Depressing Cancel will exit the edit mode and leave the value unchanged. Depressing Set will save the new value and flash the value to indicate acceptance. **** Depressing Cancel will exit calibration mode. Depressing Calibrate will calibrate selected sensor. ***** Use UP and DOWN arrows to scroll through list of status items. Date Printed 2/23/2011 Page 52 of 95

53 Air Compressors (LI-CO-9010A/B/C) MAIN MENU The MAIN MENU screen is the point from which various operator functions can be accessed. Refer to the reference diagram in Figure above. Each of the functions can be chosen by using the up and down arrows to highlight it on the screen. The controller will go to the highlighted function if the SELECT button is pressed or will return to the CURRENT STATUS screen if the STATUS button is pressed. Date Printed 2/23/2011 Page 53 of 95

54 Air Compressors (LI-CO-9010A/B/C) ALARM HISTORY Alarm History displays each of the Alarm messages for the last 15 Alarms experienced by the machine. It also gives access to displaying the machine operating conditions that existed at the time of each Alarm. The first one shown, Alarm History 1, was the most recent Alarm to occur. Note that multiple, consecutive EMERGENCY STOP Alarms are not recorded as separate Alarms, only the first one will be shown. Each of the last 15 Alarm messages can be seen by moving the Alarm History list up and down using the arrow buttons. Pressing the SELECT button when one of the Alarms is highlighted will display the list of machine values that existed at the time that particular Alarm occurred. The name and value of each of the items listed below can be seen by moving the list up and down using the arrow buttons. Pressing the ALARM HIST. button will return the display to the ALARM HISTORY screen. ALARM HISTORY Items - Discharge Pressure Coolant Filter - Discharge Temperature Inlet Vacuum - Airend Discharge Temperature Inlet Filter - Injected Temperature Total Hours - Sump Pressure Loaded Hours - Separator Press. Drop % Load Modulation - Unloaded Inlet Vacuum - Coolant Pressure - Time & Date Alarm histories can be exited by pressing either the STATUS or MAIN MENU buttons. If no buttons are pressed within 30 seconds, the display will return to the CURRENT STATUS screen. Date Printed 2/23/2011 Page 54 of 95

55 Air Compressors (LI-CO-9010A/B/C) WARNINGS When a Warning occurs, a question mark will flash on the display screen and appear in large letters as shown above. The display message will indicate what caused the warning. If multiple Warnings exist, the small up/down arrows will appear in the upper right corner of the display screen. The multiple Warnings can be seen by pressing the up and down arrow buttons. Pressing the STATUS button will display the CURRENT STATUS screen with the WARNING button indicating a Warning still exists.pressing the WARNING button will return the display to the WARNING screen and the RESET button. The possible Warning messages are as follows. AIREND DISCHARGE TEMP- This will occur if the Airend Discharge (2ATT) exceeds 97% of the alarm limit, 228 F (109 C), and is not adjustable. CHANGE COOLANT FILTER- This warning will occur if the high side pressure is 20 psig (1.4 bar) greater than the low side pressure of 1 DPS, and the Injected Coolant temperature (2CTT) is greater than 120 F (49 C). CHANGE INLET FILTER- This will occur if the Inlet Vacuum (1AVPT) is greater than 0.7 psig (.05 bar) and the machine is fully loaded (inlet valve is completely open). CHANGE SEPR ELEMENT- This warning will occur if the pressure on the Separator (3APT) is 12 psig (.8 bar) greater than the pressure at the Package Discharge (4APT), and the machine is fully loaded. When a Warning occurs, a question mark will flash on the display screen and appear in large letters as shown above. The display message will indicate what caused the warning. HIGH DISCHARGE PRESS- This can occur if the machine s loading function is being controlled by a host device, such as a sequencer or an lsc. This warning will occur when the package discharge pressure is above the maximum offline pressure (rated pressure plus 3 psig [.2 bar]) for more than 3 seconds. This warning will cause the compressor to unload. The host device will not be able to load the compressor until the package discharge pressure falls to the rated pressure of the machine. SENSOR FAILURE 4ATT- This will occur if the Package Discharge Temperature Sensor (4ATT) is recognized as missing or broken. Date Printed 2/23/2011 Page 55 of 95

56 Air Compressors (LI-CO-9010A/B/C) AUXILIARY 1 (OR 2) - This warning will occur if either of the auxiliary contacts closes. HIGH SUMP/LINE DIF - This warning will occur if the compressor is running loaded, the injected coolant temperature is greater than or equal to 120 deg. F, (49 C) the package discharge pressure is greater than 90 psig, (6.3 bar) the sump pressure is greater than the compressor s rated pressure, and the sump pressure is 25 psig (1.8 bar) or more above the package discharge pressure. COMMUNICATION FAIL 1 (or 2-4) - This warning will occur if the compressor is the lead unit while using integral sequencing and is unable to communicate with another compressor. SERVICED REQUIRED - The Intellisys has 2 levels of service. The service level can be set at the factory or by an Ingersoll-Rand service representative. Either service level will issue a SERVICE REQUIRED warning at 150 hours. This warning is a reminder for initial service and can be cleared by the operator. Level 1 - If service level 1 (default) is selected, a SERVICE REQUIRED warning will be issued every 2000 operating hours. This warning is to serve as a reminder to have the unit serviced and can be cleared by the operator. Level 2 - If service level 2 is selected, service warnings will be issued every 2000 operating hours (default) or in 3, 6, 9, or 12 month intervals, as selected at the factory or by an I-R service representative. Service warnings at level 2 are issued in 3 stages. First a 100 HOURS TO SERVICE or 14 DAYS TO SERVICE (depending on the service interval type) warning will be issued. This warning will let the operator know that the time for service is approaching and can be cleared by the operator. Following that, 100 hours or 14 days later a SERVICE REQUIRED warning will be issued. This warning can be temporarily cleared by the operator, however it will return 24 hours later if service has not been performed by an I-R service representative. A new service period will start when service is performed. If another 100 hours or 14 days elapses and service has not been performed, an ALARM-SERVICE REQUIRED warning will be issued. This warning can only be cleared by an I-R service representative. SENSOR FAILURE 6APT - This warning will occur if the separator delta-p sensor option is installed and sensor 6APT is recognized as missing or broken. Date Printed 2/23/2011 Page 56 of 95

57 Air Compressors (LI-CO-9010A/B/C) ALARMS When an Alarm occurs, an exclamation mark will flash on the display screen as shown above. The display message will indicate what caused the Alarm. Pressing the STATUS button will display the ALARM STATUS screen with the ALARM button indicating an Alarm still exists. Alarm Status is the list of machine operating conditions that existed at the time of the Alarm. The name and value of each of the items listed can be seen by moving the list up and down using the arrow buttons. Pressing the ALARM button will return the display to the Alarm screen and the RESET button. The Alarm needs to be reset by the operator by pressing the RESET button twice. Any exceptions to this are explained in the alarm descriptions. The possible Alarm messages are as follows. CHECK INLET CONTROL- This will occur if the machine is unloaded and the inlet vacuum is less than 3 psig (.2 bar). CHECK INLET CTRL SYS 1 (2) - This will occur if the inlet butterfly valve fails to open or close properly. A 1 means the inlet valve failed to closer properly. A 2 means the inlet valve failed to open properly. CHECK MOTOR ROTATION- This will occur if the machine is started and the compressor has incorrect rotation. CONTROL POWER LOSS- This will occur if the controller detects a loss of the 110 VAC or 120 VAC control power. EMERGENCY STOP- This will occur if the Emergency Stop button is engaged. The button must be disengaged before the alarm can be cleared. FAN MOTOR OVERLOAD- This will occur if a fan motor overload is sensed. HIGH AIREND DISCH TEMP- This will occur if the airend discharge temperature is greater than 228 F (109 C). Date Printed 2/23/2011 Page 57 of 95

58 Air Compressors (LI-CO-9010A/B/C) LOW SUMP AIR PRESSURE- This will occur if the machine is running fully loaded and the sump pressure drops below 20 psig (1.4 bar). LOW UNLOAD SUMP PRESS- This will occur if the machine is running unloaded and the sump pressure is less than 15 psig (1.0 bar) for 15 seconds. MAIN MOTOR OVERLOAD- This will occur if a drive motor overload is sensed. CHECK SET POINTS- This will occur if the controller has determined some of the data stored in memory contains unacceptable values. When this occurs, the sensors should be calibrated and all the set points checked. It is normal for this alarm to occur after changing controller software. REMOTE START FAILURE- This will occur if the Remote Start button is pressed after the machine is running or if the Remote Start button remains closed. REMOTE STOP FAILURE- This will occur if the Remote Stop button remains open and either Start button is pressed. SENSOR FAILURE 1AVPT (or 3APT, 4APT, 5CPT,2CTT, 2ATT, 3CTT) - This will occur if a sensor is recognized as missing or broken. This does not apply to sensor 4ATT. STARTER FAULT 1SL (2SL)- This will occur if the starter contacts open while the machine is running. It will also occur if the machine is given the stop command and the starter contacts do not open. 1SL refers to the auxiliary circuit on starter contact 1M. 2SL refers to the auxiliary circuit on starter contacts 2M and 1S. STEPPER LIMIT SWITCH- This will occur if both limit switches are activated at the same time. INVALID CALIBRATION- This will occur during the calibration process if the sensor reads greater than 20% of scale. LOW COOLANT PRESSURE- This will occur if the compressor is running and the following conditions are met. The coolant must be less than 1 psi and either the sump pressure is greater than 10 psi or the inlet vacuum is less than 12 psi. Date Printed 2/23/2011 Page 58 of 95

59 Air Compressors (LI-CO-9010A/B/C) The two air receiver tanks are connected to each other by a 3" pipe with manual valves. The manual valves are in place to allow the operator to isolate the desired tank for maintenance and run the system from one air tank. The compressed air produced by compressor(s) and dried by the air dryer(s) is stored in the air surge tanks. Each air receiver tank has a capacity of 1040 gallons. The air pressure in each air surge tank is monitored by a pressure transmitter. The values from these two pressure transmitters are for monitoring only. The system has a third pressure transmitter, downstream of the surge tanks. The value from these main pressure transmitters is the actual system air pressure, used as an interlock for all system operations. System air pressure ready (absence of an alarm) is used as a permissive on all sub-systems that use compressed air. The DCS monitors the system air pressure and will issue an alarm if the pressure falls below the low pressure alarm point (75 PSI). The alarm set point may be included on the DCS, for operator adjustments if the customer wishes. Date Printed 2/23/2011 Page 59 of 95