Installation, Operation and Maintenance Manual for the Potable Water System Model: PWS-01 (380 VAC Suppy x 24 VDC Controls)

Transcription

1 Installation, Operation and Maintenance Manual for the Potable Water System Model: PWS-01 (380 VAC Suppy x 24 VDC Controls) (Part No: KI40008AB) A part of

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3 Approval Sheet Divex Advitium Number: Document Title: KI-OM-5672 Installation, operation and maintenance manual for Potable Water System PWS VAC Rev Date By Check App Comments 0 10/12/2008 D. Henkel G. Dauth N. Maske First issue 1 29/06/2010 D. Henkel N. Maske R. Faustmann ECN: CT00289 Added item to spares list 2 29/07/2010 R. Carli N. Maske R. Faustmann ECN: CT Electrical update 3 10/05/2011 N. Maske R. Carli N. Maske ECN: CT /11/2013 D. Allan V. Garzon S. Coull ECN: Schematic & drawings Appendix B updated Original Issue Date: 10 December 2008 Original Document By: Checked By: Approved By: Diana Henkel George Dauth Nick Maske This document is produced and controlled by Divex Ltd, Enterprise Drive, Westhill, Aberdeen, Scotland, AB32 6TQ; Tel: +44(0) ; info@divexglobal.com It may not be communicated to a third party in part or whole without the prior written permission of Divex. i Approval Sheet

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5 Data Sheet Instruction & Maintenance Manual No: KI-OM-5672 Equipment Type: Potable Water System - PWS-01 Equipment Serial No: Customer: Vessel / Location: (If Known) Date of Issue: IMPORTANT Please quote the above information when contacting Divex regarding operational information or spare parts. iii Data Sheet

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7 Table of Contents Page Chapter 1 - General Description...1 Chapter 2 - Theory of Operation...5 Chapter 3 - Installation...11 Chapter 4 - Operating Instructions...13 Chapter 5 - Maintenance and Repair...15 Chapter 6 - Troubleshooting...17 Appendix A - Recommended Spares Appendix B - Drawings and Part Break Down Appendix C Water Pump Appendix D Water Regulator Appendix E Air Regulator v Table of Contents

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9 Chapter 1 - General Description Contents 1.1 General Description Warranty Statement... 3 Page 1 Chapter 1

10 1.1 General Description The Divex Potable Water System (PWS-01) has been specifically designed for use in professional diving systems. The system is designed to deliver hot and cold water at 7.5 ltr/ min at pressures up to 68 bar. The unit is simple to operate and requires a source of compressed air to drive the pumps, 380 VAC to operate the heaters, and a source of fresh water to deliver to the chamber. Once unit is set up, it can be left to operate without intervention and requires only minimal maintenance to keep it working at optimal performance. Fig 1.1 PWS Front View with Connecting Pipework 2 Chapter 1

11 Fig 1.2 PWS-01 Side View Warranty Statement In accordance with its terms of sale, Divex will normally warrant that any Potable Water System (Model PWS-01) supplied by it will conform, as at the date of delivery from Divex factory, with Divex then current specification thereof and that the same will be free of patent defects in materials or workmanship for a period of twelve months from the date of such delivery or for 3000 operating hours, whichever first occurs. Any part or sub-system which is established to the patently defective will normally, and at Divex option, be repaired or replaced upon the condition that such defective parts or subsystems are returned to Cape Town, South Africa, freight pre-paid and that upon completion of such repair or replacement, such parts or sub-systems will be returned to the customer FOB Cape Town, South Africa. By agreement with its customer, and upon prepayment by the customer of any transportation and on-site accommodation and subsistence expenses, Divex may despatch its own personnel to perform on-site repairs The foregoing specifications and warranty terms are subject to alteration without prior notice to the customer and do not form part of any contract made between Divex and its customer. 3 Chapter 1

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13 Chapter 2 - Theory of Operation Contents 2.1 Theory of Operation System Flow Description Electrical System Description The Performance of the PWS Page 5 Chapter 2

14 2.1 Theory of Operation The PWS-01 comprises two air-driven ratio pumps; one supplied with heated fresh water and the other fed directly from the fresh water supply. The main controls are the air regulator which is used to set maximum pump outlet pressure and the thermostat which is used to set the maximum hot water temperature System Flow Description The flow schematic for the system is shown in Fig 2.1. Fresh water is fed into the PWS-01 at the Fresh Water Inlet Port (1). It passes through the 5 micron Carbon Block Filter (2) which will prevent particulate matter from entering the system and possibly damaging the pumps. The water passes through a Pressure Regulator (3) which is set to approximately 1 bar. The water path splits with one branch feeding into the Electric Heater Tank (4) and the other going directly to the Cold Water Pump (12). The Heater Tank contains a Pressure Relief Valve (5) to protect the tank from over pressure. The tank is equipped with an adjustable Thermostatic Switch (6) which will regulate the water temperature between 30 and 75 ºC. The tank is also equipped with a Zinc Anode (7) to minimise any corrosion. The temperature of the heated water inside the Electric water heater is indicated by an analogue thermometer (9). Both the Hot and Cold Water Pumps (10, 12) are pressure ratio pumps which deliver an output water pressure 10 times the input air pressure; these pumps will delivery 65 bar from 6.5 bar air input. The pump units will deliver a maximum flow rate of ± 7.5 ltr/min at ± 34 bar. The outlet pressure of each stream is indicated by the Hot and Cold Water Pressure Gauges (11, 13). The hot and cold water passes from the system to the chamber through Hot and Cold Water Outlet ports (14, 15). The pumps are driven by air at pressures of up to 6.5 bar. Air enters at the Air Inlet port (16). Pumping action can be started or stopped using the air shut off valve (17). Water and particulate matter are removed from the air in the Filter/Regulator/Separator unit (18). The required pump air pressure is set and controlled by the Air Pressure Regulator (19). This Regulator is adjusted to vary the output pressure of the water pumps. The regulated air pressure is monitored on the pressure gauge attached to the regulator. The air passes through a Lubricator (20) where it picks up a small amount of oil to lubricate the pistons in the pumps. The air system is protected by an Air Pressure Relief Valve (21). 6 Chapter 2

15 Fig 2.1 Flow schematic 7 Chapter 2

16 Fig 2.2 Electrical Panel Layout 8 Chapter 2

17 Fig 2.3 Electrical Schematic 9 Chapter 2

18 2.1.2 Electrical System Description The Electrical Schematic for the PWS-01 is shown in Fig 2.3. The electrical circuit consists of the heater elements and their controls. The input power is 380 VAC, 50 Hertz, 3 Phase, 20 Amps maximum. The power to the heaters is routed through contactor K1. The heaters are two 380 VAC units connected in parallel, each capable of delivering 4.5 kilowatts of heat into the water tank. The coil of contactor K1 is controlled by the thermostatic switch and the main power switch. The main 380 VAC power is connected to F1 & F2 (1 Amp), which supplies PS1 and reduces the voltage to 24 VDC. The control circuit is protected by F3 (5 Amp fuse). The hour meter logs cumulative operating time to assist with system maintenance planning. The thermostatic switch is mounted on the water tank where it senses the temperature inside the tank. The switch opens, shutting off the power to the heaters when the set point temperature is reached. The right hand side LED indicator mounted in the electrical enclosure indicates when power is on and the left hand side indicates when power is supplied to heater elements The Performance of the PWS Flow Rate Hot Water Cold Water Water Pressure with 6.8 bar Air inlet 0.46 m 3 /hour 0.46 m 3 /hour 68 bars Temperature Range ºC Hot Water Tank Storage Capacity Safety Pressure Relief setting Approximately 60 ltr 1.3 bar 10 Chapter 2

19 Chapter 3 - Installation Contents 3.1 Installation Page 11 Chapter 3

20 3.1 Installation Reference is made in this Section to Fig 1.2 and Appendix B. To operate the PWS, the following utilities are required: Electrical Water Air 380 V, 20 Amp 50 Hz NOTE: Only 1 phase of a 3-Phase supply is used Fresh Water with minimum flow of 18 ltr/min at 2 bar bar at 2.8 surface m 3 /min All inlet fittings for the PWS are 3/4 inch NPT female. It is recommended that the fresh water circuit be plumbed with at least 1/2" pipe. The air circuit should be plumed with a 3/4 inch pipe or larger. The electrical services should be wired with at least 4 mm 2 conductors. The output water lines should be capable of withstanding pressures to 100 bar. 12 Chapter 3

21 Chapter 4 - Operating Instructions Contents 4.1 Operating Instructions Initial Set Up Initial Operation Normal Operation Shut Down Page 13 Chapter 4

22 4.1 Operating Instructions The PWS is very simple to operate; however, there are a few things to pay particular attention to, these are: Initial Set Up After all plumbing and wiring installations are made; the water circuits must be primed. This applies primarily to the hot water tank; and can be achieved by opening a hot water tap down stream of the hot water pump to allow water to fill the tank when the water supply is turned on. This must be done before the electrical water heating elements are switched on Initial Operation Prior to initial operation, the water valve, air valve and main power switch should be in "off" position and the tank drain closed. Utilities (water, air and power) can then be turned on in the following sequence: 1. Turn the water inlet valve to the open position. 2. When the water circuit is primed (see section 4.1 above), turn the air inlet valve to the open position, and set air the air regulator for an outlet pressure of 6.8 bar as indicated on the air pressure gauge on the front of the unit. 3. Open valves in chamber to purge outlet fluid lines of air. 4. With chamber valves closed, hot and cold water outlet pressures should be at or near 68 bar. Note Outlet water pressures under flowing condition are dependent on chamber pressure; if chamber is near surface pressure, outlet water pressures will be low. Check outlet water plumbing and repair any leaks. After water and air circuits are operating satisfactorily. Verify the 380 VAC supply to the main switch in the electrical box. Turn main power switch to the "on" position and verify that inlet current is 18 to 20 amperes (when heater is on, which should occur when the thermostat is set higher than the inlet water temperature). The water in the tank will reach 65 ºC from 15.5 ºC in about twenty minutes, although this time is dependant on the mixing that occurs within the tank as it could take longer to homogenise. The unit is now fully operational Normal Operation Normal operation is initiated by opening the fresh water valve and purging the hot water tank of any air. Next, open the air supply valve and switch on the electric power. Set the hot water tank thermostat to the desired hot water temperature. The system is now ready for operation Shut Down When the system has to be shut down, the air valve and main power switch should be put in "off" position. The water must be drained from the hot water tank and the water filter to prevent freezing in cold climates and to extend the life of the equipment during extended shut downs. This is done by opening the tank drain and applying compressed air to the fresh water input line. 14 Chapter 4

23 Chapter 5 - Maintenance and Repair Contents 5.1 Maintenance and Repair Periodic Maintenance Component Information Sheets Page 15 Chapter 5

24 5.1 Maintenance and Repair Periodic Maintenance There are only a few items which require maintenance in the PWS The 5 µm water filter cartridge should be checked weekly and replaced if dirty. 2. The air filter should be checked weekly and cleaned if necessary. 3. The lubricator oil level should be checked weekly and oil added when necessary. The oil should be a good quality SAE 10 non detergent type or equivalent. 4. Check lubrication oil flow: approximately 2 drops per min during pumping operation is acceptable. 5. The zinc anode in the hot water tank should be checked monthly and replaced as necessary Component Information Sheets Component information sheets are included for the following: 1. Water pumps. 2. Water pressure regulator. 3. Air regulator. 16 Chapter 5

25 Chapter 6 - Troubleshooting Contents 6.1 Fluid circuit Electrical Circuit Page 17 Chapter 6

26 6.1 Fluid circuit Problem Probable cause Solution Low output pressure Water will not heat Relief valve leaks Pump will not run Low output flow or pressure drop after initial water flow Low air pressure. Low air pressure at source. Restriction in air line. Insufficient pressure or flow in water inlet lines. Faulty valves in pump. Thermostat set too low. Improper power to unit. Heater element burned out. Particle lodged in seat. Inlet water pressure regulator set too high. Inlet water pressure regulator faulty. Air supply off. Air control valves not operating in pump. Restriction in air line. Insufficient volume of air available at required pressure. Reset air regulator. Reset source pressure. Clear restriction. Increase source pressure or pipe size then check pressure regulating valve. Replace check valves as per the procedure in Appendix C. Reset thermostat. Correct source of power. Replace heater element. Disassemble, clean and reassemble. Reset regulator. Replace regulator. Turn supply on. Service as per procedure in Appendix C. Clear restriction. Increase size of air supply line. 18 Chapter 6

27 6.2 Electrical Circuit Problem Probable cause Solution Contactor buzzing Contactor will not close Heater will not heat Dirt, debris or rust on pole pieces. Check frequency of electrical system. Faulty contactor. Low voltage to contactor coil. Open circuit in control circuit. Faulty coil. Faulty contactor. Thermostat set too low. Control circuit has open circuit. Heater failure. Thermostatic switch failure. Disassemble contactor, clean and sand pole pieces, reassemble. Increase frequency if below 50Hz. Replace contactor. Check voltage, increase input voltage, tighten all connections. Check wiring, repair any broken wires. Replace coil. Replace contactor. Reset thermostat. Check circuit and repair any open circuits (including fuse). Replace heater element. Replace thermostat. 19 Chapter 6

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29 Appendix A - Recommended Spares Divex Part No Part Description Quantity/Unit Element Filter 5µm Carbon Block Anode, 1/2" NPT, Zinc Contactor, 16kW, 4pole, 25A (AC1) Element, 4.5 kw, 380V, 1 1/4 BSP, 300 I.M.L C Cartridge, Press Reducing Valve, 3/4" 1 Table A.1 Recommended spare parts 21 Appendix A

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31 Appendix B - Drawings and Part Break Down 23 Appendix B

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37 Appendix C Water Pump 29 Appendix C

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53 Appendix D Water Regulator 45 Appendix D

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59 Appendix E Air Regulator 51 Appendix E

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