Flowserve OR 52-5 User Manual

OR 52-5 OR 52-6

Installation Instructions 810731-01

Oil & Turbidity Detector OR 52-5, OR 52-6



Component Parts

Key

Nipple with threaded ends

Ball valve ¾“ BSP (DIN ISO 228)

Upper cover flange

Light receiver with tube

Ball valve ¾“ BSP (DIN ISO 228) for purging

Vent nipple

Drying cartridge

Cleaning plunger

Hexagon-head screw M8x30 EN 24017

Lower flange

Support for cleaning ring

Cleaning ring (wiper)

Ring

Retaining ring 19x1.2

Screw

Connector for light emitter / light receiver

Light emitter

Tube

Turbidity standard

Housing

Glass cylinder

O-ring 25x3

O-ring 30x2

O-ring 37x2

Mounting bracket

Y Z

Screwed union

Contents

Page

Important Notes

Usage for the intended purpose.......................................................................................6

Safety note.......................................................................................................................6

Warning............................................................................................................................7

Explanatary Notes

Scope of supply ...............................................................................................................8

Application .......................................................................................................................8

Function ...........................................................................................................................9

Technical data................................................................................................................10

Installation

Measuring sensor ORG 12, ORG 22 .............................................................................13

Measuring transducer ORT 6.........................................................................................17

Wiring

Measuring sensor ORG 12, ORG 22 .............................................................................18

Measuring transducer ORT 6.........................................................................................18

Tools ..............................................................................................................................19

Wiring diagram ORG 12, ORG 22, ORT 6.....................................................................19

Wiring diagram ORG 12, ORG 22, ORT 6 with three-way valve ...................................20

Functional Elements

Measuring transducer ....................................................................................................21

Commissioning Procedure

Factory settings..............................................................................................................22

Start-up procedure .........................................................................................................23

0% calibration ................................................................................................................23

100% calibration ............................................................................................................24

Oil / turbidity curves .......................................................................................................25

Detection and indication of various contaminants..........................................................25

Adjusting limit value alarm 1 ..........................................................................................26

Adjusting limit value alarm 2 ..........................................................................................26

Adjusting time delay for alarm 1.....................................................................................27

Adjusting time delay for alarm 2.....................................................................................27

Setting decimal point......................................................................................................28

Establishing actual value output ....................................................................................28

Contents

Page

Operation

Start ...............................................................................................................................29

Alarm 1 and 2 ................................................................................................................29

Maintenance

Functional check............................................................................................................30

Functional test of relays for alarm 1, alarm 2 and malfunction ......................................30

Malfunctions...................................................................................................................30

Error code – Indication...................................................................................................31

Error Code – Table ........................................................................................................31

Exchanging glass cylinder .............................................................................................33

Cleaning glass cylinder..................................................................................................34

Replacing cleaning plunger ...........................................................................................34

Replacing drying cartridge ............................................................................................. 34

Replacing glow lamp......................................................................................................35

Replacing fuse ...............................................................................................................35

Tools ..............................................................................................................................35

Spare parts ....................................................................................................................36

Annex

Declaration of conformity ............................................................................................... 37

Certificate of type approval ............................................................................................ 40

Type approval certificate................................................................................................44

Updates .........................................................................................................................45

Important Notes

Usage for the intended purpose

Use oil & turbidity detector OR 52 only for monitoring transparent liquids to detect any ingress of light-scattering and insoluble foreign matter.

Chemical and corrosive influences have to be taken into account and the equipment must only be used within its rated pressure and temperature limits. Before installation and operation make sure that the equipment is resistant to the medium in the operational conditions that will exist.

Any type of use differing from the usage described above is considered as improper. The resulting risk will have to be borne by the user alone. The manufacturer hereby expressly rejects any claims for any resulting damage.

Safety note

The equipment must only be installed, removed, commissioned, operated and serviced by qualified staff.

Qualified staff are those persons who - through adequate training in electrical engineering, the use and application of safety equipment in accordance with regulations concerning electrical systems and circuits, and first aid & accident prevention – have achieved a recognised level of competence appropriate to the installation and commissioning of this device.

For installation, removal, commissioning, operation and maintenance, every person who works with the equipment must have read and understood the complete installation manual. Furthermore, responsibilities must have been defined clearly and unambiguously and must be adhered to.

Usage of the equipment for the intended purpose includes compliance with the rules and notes in this installation manual for installation, removal, commissioning, operation and maintenance.

The operating company must ensure that, whenever the equipment is being operated, it is in perfect condition.

Working methods that jeopardise safety must not be used.

Important Notes

Warning

Danger

If the measuring transducer and sensor are used in an inexpert or improper manner by unqualified staff, they can cause danger to life and limb for the user or for third parties, possibly resulting in death.

During operation, the sensor is under pressure. In this condition, screws, nuts or bolts must not be slackened. Hot water or steam could flow out and could cause severe scalding over the entire body.

The sensor might be hot during operation. If it is touched when in the operational condition, severe burns are possible.

Any installation or removal work may only be performed when the equipment is at zero pressure and has cooled down. When such work is to be done, the pressure in the pipes upstream and downstream must have been reduced to zero and the sensor must have cooled down sufficiently.

The terminal strips of the measuring transducer are live during operation. This presents the danger of electric shock. Cut off power supply before opening the cover or mounting/removing the terminal strips.

It must be ensured that during the work the system section in which pressure has been reduced to zero cannot be accidentally put back into operation. The shut-off valves needed for this purpose must be separately secured and marked. The connection to the energy supply must be disconnected and must be secured to prevent it from being operated accidentally. One or more warning notices, for example containing the text "DO NOT SWITCH ON" must be displayed in a clearly visible manner at each operating element.

continued

Explanatary Notes

Scope of supply

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1 Measuring transducer ORT6,



1 Measuring sensor ORG12 or ORG 22 (depending on order),

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3Ball valves,

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3 Screwed unions and nipples with threaded ends,

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1 Vent nipple (screwed in ORG),

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1 Turbidity standard 20ppm (supplied but not fitted),

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1 Drying cartridge (supplied but not fitted),

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1 Installation manual,

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Type approval certificates (according to order)

Application

The oil & turbidity detector consists of the measuring sensor ORG 12 or ORG 22 and the measuring transducer ORT 6 (operating and display unit). The type of measuring sensor depends on the fluid to be used.

The oil & turbidity detector OR 52-5/-6 is used for monitoring transparent liquids to detect any ingress of insoluble foreign matter. The equipment is mainly used for industrial processes and in the foodstuff industry where high level of reliability and ease of maintenance are required.

The equipment combination can be used for marine applications in order to monitor microfiltering equipment in accordance with IMO (International Maritime Organization) resolution MEPC.60(33) and EC directive 96/98/eec (MED) as 15 ppm oil content alarm. In steam boiler plants condensate and feedwater can be monitored for oil and grease contamination (according to TRD 604 sheet 1 paragraph 2.1.1 with 3/5 ppm). In addition, the oil & turbidity detector is well suited for raw water monitoring and water treatment (sand filters, demineralization plants, reverse-osmosis plants) as well as waste-water monitoring.

The OR 52 is also used in breweries and the beverage industry (filtration, monitoring of wort, quality assurance etc.) and in the salad oil production for monitoring filtering processes.

Note

When using the equipment as 15 ppm oil content alarm acc. to IMO please take the following into consideration: Microfilter installations usually consist of an oil/water separator followed by a filter, the so-called coalescer. Gravity coalescer systems cannot split up stable water/oil emulsions, which are formed with certain cold cleaning agents and then accumulate in the bilge. We therefore recommend suitable fast-separating cold cleaning agents which will not produce stable water-oil emulsions.

Explanatary Notes

continued

Function

The measuring sensor is a photometric measuring device consisting of a light source (light emitter ) and a light receiver equipped with two photosensitive elements.

A constant light beam passes through the transparent liquid. Insoluble foreign matter scatters the light, which is then measured using the 15° forward light scattering method. The light intensity is transformed into an electric current which will be used by the measuring transducer to determine the concentration of foreign matter. The actual turbidity value is continuously compared with the adjusted setpoint and the result will be indicated visually and - if required - acoustically.

The measuring transducer is the operating and indicating unit for signal evaluation and the control of the measuring sensor. It serves as visual display unit for the measuring results and the adjustment of the measuring equipment, indicating the actual value, tripping the limit alarms ALARM 1 and ALARM 2 and releasing messages in the event of a malfunction in the measuring sensor. The measuring transducer is designed for setting and indicating the limit values.

ORT 6

ppm

cal

OIL

sec

ALARM

Test

ORG 12/22

Fig.1

Typical application of an oil & turbidity detector type OR 52-5/-6

Explanatary Notes

Technical Data

Measuring sensor ORG 12, ORG 22

continued

Nominal pressure PN 10 bar

Nominal size DN 10, screwed “ ¤§8 BSP to DIN ISO 228

Flowrate 0.5– 50 l/ min

Pressure drop

Corrosive resistance Water, condensate, beverages, etc.

Max. pH value of fluids

Fluid temperature range

Approx. weight 6.8 kg

Housing 0.6025 galvanized 0.6025 galvanized

Cover 0.6025 galvanized 1.4580

Wetted parts 0.6025 galvanized 1.4580

Ball valves Brass 58 1.4436

Screwed unions Steel 1.4571

Glass cylinder Duran 50 Duran 50

Gaskets Silicone Silicone

Cleaning disc EPDM EPDM

0–60 °C

(with drying cartridge)

Materials ORG12 ORG22

g (145 psi g)

5 mbar

10.5

60– 120 °C

(with vent nipple)

Light emitter

Light receiver

At a flowrate of 2 l/min and V-shaped flow through the sensor with a pipe length of 1 m

Glow lamp 12V / 10W BA 15 s

Protection IP 65

2 silicon-type photo-electric cells

Protection IP 65

(DN 10) and 4 bends, ζ=6.1.

A pH value above 10.5 can lead to wear of the glass, depending on the temperature.

Vent nipple screwed in measuring transducer as standard.

Explanatary Notes

continued

Technical Data

Name plate

contiuned

Explanatary Notes

continued

Technical Data

continued

Measuring Transducer ORT 6

Inputs Directly transmitted light (D), scattered light (S)

1 voltage output for light emitter ,

1– 12V pulse-amplitude modulated

3 volt-free change-over contacts

Outputs

(alarm 1 + 2 and malfunction),

Contact material AgNi 0.15

Max. contact rating for switching voltages 24V AC / DC,

115V and 230V AC. Resistive / inductive 4 A

1 current output 0/4 – 20 mA, max. load 500 ohm

Measuring range 0– 25 ppm

Actual value output

Adjustment range Limit value alarm 1 and 2

0/4 mA 0ppm, 20 mA 25ppm

Adjustable between 0 and 15ppm

Other ranges on request

4 membrane keys,

8 LEDs for indicating operating modes and dimensions,

Indicators and adjustors

1 three-digit seven-segment display for actual value,

limit value and fault indication,

3 LEDs for monitoring system voltages

Adjustment range Time delay alarm 1 and 2

0 to 20 sec.

Other ranges on request

230V + 10 / - 15%, 50 – 60 Hz

Mains voltage

115V + 10 / - 15%, 50 – 60 Hz (optional)

24 V + 10 / -15%, 50–60 Hz (optional)

Power consuption 25 VA

Thermal fuse M 0.2A 5x 20 at 230 V

Fuse

Thermal fuse M 0.4A 5x 20 at 115 V

Thermal fuse M 1.0A 5x20 at 24 V

Housing Field case for wall installation

Housing material Die-cast aluminium

Protection IP 65 (DIN EN 60529)

Admissible ambient temperature

0–55

°C

Approx. weight 3.6 kg

Installation

Measuring Sensor ORG 12, ORG 22

It is highly advisable to have the installation work done by qualified staff in the manner described by these installation instructions. The manufacturer will not accept liability for damage resulting from improper installation.

The measuring transducer is designed for wall mounting and should be installed close to the measuring sensor. Install the measuring sensor and lines in accordance with the examples given in figs. 2 to 7.

Provide a throttling point – e. g. a non-return valve (GESTRA type RK 86) in the main line. Mount the measuring sensor in a bypass at a lower level than the main line so that any gas bubbles and flash steam can pass through the main line instead of the sensor. Tap main line at the side from the bottom to prevent air and dirt particles from flowing into the bypass. If the fluid temperature is above the max. ambient temperature: Screw in vent nipple .

If the fluid temperature is below the ambient temperature: Remove the plastic lid from the drying cartridge (blue colour) and screw in the drying cartridge .

If the fluid temperature is very high: Provide a non-insulated pipe upstream of ORG 12/ORG 22 which will allow the fluid to cool down to 120 °C when reaching the sensor.

In the presence of large amounts of gas: Tapping point must be at the bottom of the line – use a welding pocket in accordance with DIN 2618 (see page 14 fig. 5).

If the condensate can be/is highly contaminated: Ensure downward flow of the fluid through the glass cylinder (glass cylinder may be scratched), for installation see page 14 fig. 3.

If this does not help and/or a lot of flash steam builds up ahead of the measuring sensor fit a separator upstream of the equipment (see page 15, fig. 6).

Important

Avoid flashing, outgassing and the presence of air due to a pressure drop upstream of the measuring sensor.

The additional connection of the cover flange must be reserved for the

inlet of either wash water or calibration fluid.

Installation

continued

Measuring Sensor ORG 12, ORG 22

Inlet Outlet

Cleaning device V-shaped

Fig.2

flow through sensor, automatic deaeration

Outlet

Cleaning device

Inlet

Fig.3

continued

Sensor installed in a sample line, e. g. water treatment, beer filtering, permeate downstream of reverse osmosis.

Installation of sensor when the condensate contains suspended solids. If the sensor is installed in acc. with figs. 4 – 6, solids could deposit on the cleaning device and scratch the glass cylinder .

Sensor installed in a bypass of a product line with upward flow.

Fig.4

Fig.5

500

≥

Sensor installed below a product line carrying a slight amount of gas, e. g. sufficiently sized condensate line (flashing) downstream of steam traps.

*) Tap product line at the side (angle of 45°) from the bottom to prevent air and dirt from flowing into the bypass.

Installation

DN>inl

continued

Measuring Sensor ORG 12, ORG 22

Flash steam

Separator DN100-300

250

≥

Condensate

Downward flow of sample if condensate is very contaminated

Fig.6

NRGS 16-1

continued

Installation of sensor in a condensate line with large amount of flash steam

ppm

cal

OIL

sec

ALARM

P E

Test

Fig.7

Schematic layout of oily water separation system for bilge water with the oil and turbidity detector OR 52 as 15 ppm oil content alarm.

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