Intek RheoVac 940 User Manual

TABLE OF CONTENTS

SECTION 1 — GENERAL INFORMATION ....................................... - 1 -

1.1 INTRODUCTION ................................................. - 1 -

1.2 PRINCIPLE OF OPERATION ....................................... - 2 -

1.3 TECHNICAL SPECIFICATIONS ..................................... - 2 -

1.4 PRECAUTIONS .................................................. - 2 -

SECTION 2 — INSTALLATION ................................................ - 4 -

2.1 INTRODUCTION ................................................. - 4 -

2.2 RheoVac MONITOR INSTALLATION/SITE SELECTION ................ - 4 -

2.2.1 Transducer Site Selection ..................................... - 4 -

2.2.2 Electronics Unit Site Selection ................................. - 4 -

2.3 MOUNTING HARDWARE INSTALLATION .......................... - 6 -

2.4 TRANSDUCER INSTALLATION .................................... - 6 -

2.5 ELECTRICAL CONNECTIONS ..................................... - 8 -

2.6 RheoVac MONITOR GROUNDING ................................. - 13 -

SECTION 3 — OPERATION .................................................. - 15 -

3.1 GENERAL INFORMATION ....................................... - 15 -

3.2 SYSTEM START-UP ............................................. - 15 -

3.3 OUTPUT SIGNALS .............................................. - 15 -

3.4 IBM-PC SOFTWARE ............................................. - 16 -

3.4.1 SOFTWARE INSTALLATION ............................... - 17 -

3.4.2 SOFTWARE OPERATION .................................. - 17 -

3.4.3 DATA PROCESSING ....................................... - 18 -

3.5 CUSTOM SOFTWARE ........................................... - 19 -

SECTION 4 — MAINTENANCE ............................................... - 21 -

4.1 GENERAL MAINTENANCE ....................................... - 21 -

4.2 CALIBRATION .................................................. - 21 -

4.3 SPARE PARTS .................................................. - 21 -

4.4 TROUBLE SHOOTING ........................................... - 21 -

SECTION 5 — CUSTOMER SERVICE ......................................... - 25 -

5.1 QUESTION ON EXISTING HARDWARE ............................ - 25 -

5.2 TROUBLE SHOOTING ........................................... - 25 -

5.3 FACTORY AND FIELD SERVICE .................................. - 25 -

5.4 QUESTIONS ON NEW EQUIPMENT ................................ - 25 -

SECTION 6 — CUSTOM INFORMATION ...................................... - 26 -

6.1 UNIT IDENTIFICATION .......................................... - 26 -

6.2 CONFIGURATION ............................................... - 26 -

6.3 SPECIAL INSTRUCTIONS ........................................ - 26 -

©Intek, Inc. 1999

Manual no. RVAC Rev. D

I:\OFFICE\WPMANUAL\RHEOVAC\RHEOVAC.RVD

WARRANTY

Intek, Inc. warrants each RheoVac product to be free from defects in
material and workmanship under normal use and service, Intek's
obligation under this warranty being limited to making good any part or
parts thereof which shall, within one (1) year after delivery of such
product to the original purchaser, be returned to Intek with transportation
charges prepaid and which Intek's examination shall disclose to its
satisfaction to have been thus defective; this warranty being expressly in
lieu of all other warranties, express or implied and all other obligation or
liabilities on Intek's part. The purchaser will assume all responsibility
and expense for removal, decontamination and reinstallation of
equipment.

Rheotherm instruments are manufactured under United States patent numbers
4,255,968, 4,942,763, 4,949,578, 5,485,754 and 5,752,411. Intek, Rheotherm,
Rheovec, Rheomax, RheoVac and RheoSmart are registered trademarks of Intek,
Inc.

Intek, Inc.

751 Intek Way

Westerville, Ohio 43082-9057

Phone [phone] – Fax [phone]

web site – www.intekflow.com

e-mail – [e-mail]

SECTION 1 — GENERAL INFORMATION

1.1 INTRODUCTION

For the first time, all necessary properties of the fluid in the condenser exhauster line are directly
measured to provide an accurate determination of air in-leakage. These properties are measured to
provide the power industry with the most advantageous and complete product for condenser system
diagnostics:

— the RheoVac

®

Air In-Leak Monitor System*

*USPNs 5,485,754; 5,752,411

The RheoVac air in-leak monitor system consists of multiple sensors configured in a single probe head
and an electronic signal conditioner and digital signal processor (DSP) unit. The sensing probe is
installed in the vacuum line between the condenser and the exhauster. The RheoVac monitor is superior
to all other methods in that it makes no assumptions about the dynamic condenser and vacuum line

®

environment. The sensor head employs the patented Rheotherm

technology to provide an accurate flow
measurement. Additionally, temperature, pressure and water vapor relative saturation measurements are
made using a high accuracy platinum resistance temperature detector (RTD), a strain gauge pressure
sensor and a specially configured and calibrated water vapor saturation sensor.

Figure 1 RheoVac Air In-Leak Monitor

- 1 -

1.2 PRINCIPLE OF OPERATION

The principal features of the RheoVac monitor are shown in Figure 1. At the heart of the RheoVac
monitor is the Rheotherm flow transducer which uses the same patented thermal sensing technique
employed in all precision flow instruments manufactured by Intek. Two temperature sensor probes are
used — one sensor is in thermal equilibrium with the flow medium and provides a temperature and flow
signal reference, while the second sensor is located near a constant power probe heater so that its
temperature is always above that of the fluid. The temperature of the heated sensor will vary with the
stream velocity of the fluid. Hence, the measured temperature differential between the reference sensor
and heated sensor is a function of flow rate, which is approximately proportional to the logarithm of
mass flow rate (USPN 4,255,968).

The Rheotherm flow sensor is calibrated to measure the total mass flow of the water vapor/air mixture.
From the other three measurements, the RheoVac electronics converts the total mass flow signal from
the transducer into two components, air mass flow rate and water vapor mass flow rate. This unique
measurement method is disclosed in two separate patents (USPN 5,485,754 & 5,752,411).

The RheoVac monitor is fully calibrated in the factory under dynamic fluid conditions identical to those
within the power plant vacuum line. No field adjustments are required.

1.3 TECHNICAL SPECIFICATIONS

Primary Calibration Accuracy:

±1% of reading

Repeatability:

±0.5% of reading

Operating Temperature:

Electronics: !20 to 120°F
Transducer: 40 to 160°F

Never subject transducer to
temperatures above 210°F

Operating Pressure:

0 to 10 inches Hg absolute

Process Connection:

Hot tap assembly
(1½” thread-o-let must be welded to

Wetted Surface:

300 Series SS and engineering plastic

Local Display:

air in-leakage (SCFM)

Input Power:

115 Vac, 50/60 Hz (±15V)
230 Vac, 50/60 Hz (±15V)

Signal Output:

4/20 mA (for 10 parameters)
RS 232/422

Storage Temperature:

!20 to 120°F

Storage Pressure:

15 psig (maximum)

pipe for hot tap installation)

1.4 PRECAUTIONS

• Read the entire manual before installing and operating the RheoVac monitor.

• Carefully select the best location for installation of the transducer probe. Adequate straight
run and freedom from standing water in the line are vital to achieving optimal performance
from the RheoVac monitor (See Figure 2).

• Use reasonable care in handling the transducer — the sensing components are delicate. Take
care not to bend the probes, damage the tips, or otherwise obstruct the sensing ports.

- 2 -

• Use proper input power — check the power select switch position on the electronics. Select
either 115 Vac or 230 Vac before applying power.

• Check the transducer maximum temperature and pressure ratings — never operate a
transducer at or subject it to temperatures or pressures beyond its specified limits.

. . WARNING - Never allow live high temperature steam to flow either direction in

the exhauster line where the probe is located.

• Keep moisture out of the enclosures — once all service connections are made, make sure the
enclosure lids are tightly closed and all gaskets are in place. Seal conduit lines at the
instrument.

SECTION 2 — INSTALLATION

Figure 2 RheoVac Probe Insertion Recommendation

- 3 -

2.1 INTRODUCTION

These instructions cover installation of the RheoVac monitor in its standard configuration. Additional
information pertaining to your unit is covered in SECTION 6 — CUSTOM INFORM A TION.
Carefully read these instructions prior to installing the equipment.

2.2 RheoVac MONITOR INSTALLATION/SITE SELECTION

2.2.1 Transducer Site Selection

# Select the installation site. The location should provide the transducer sensing area with

well-established smooth flow, uniform system temperature and pressure, and consistent non­liquid phase flow medium. Pipe sections ahead of probe, in which water can accumulate,
must be avoided. Refer to Figure 2 and select the most preferred location that fits your
vacuum line configuration. Do not install the probe beyond any “trap” sections as shown in
Figure 2, Configurations B and D. Special installation instructions unique to your unit,
where applicable, will be noted in SECTION 6.3 SPECIAL INSTRUCTIONS. Refer to
this section now to review any special instructions.

# Check installation clearance. The transducer probe is almost 3 feet long and the hot tap

assembly is about 13” long, so allow 4 feet of clearance for probe installation. Be sure there
are no obstructions around the vacuum line that will interfere with transducer insertion.
Figure 3 shows the proper insertion angle. THIS ORIENTATION IS IMPORTANT FOR
PROPER OPERATION.

# OBSERVE the selected site. It should be convenient for removal and replacing probe at any

time for service without building scaffolding or waiting for plant shutdown.

# Check operating conditions. The temperature and pressure limits of the unit should be

checked to ensure compatibility with your application.

2.2.2 Electronics Unit Site Selection

# Select the installation site. The electronics unit should be located in a dry area. The

electronics are not protected against condensed liquid water inside the enclosure.

# Check for input voltage access. The electronics unit should be located in an area with access

to a 115 Vac or 230 Vac single phase, 50-60 Hz input power source.

# Check cable distances. The distances from the transducer to the electronics unit and from

the electronics unit to the control room, or to the receiving equipment serial communications
port or to the analog input device, should not exceed the distances shown in Figure 4.

# Check electronics enclosure mounting area requirements. The RheoVac electronics

enclosure is NEMA 4, measuring 12"×10"×5". A detailed drawing of the mounting interface
is shown in Figure 5 (pg. 7).

# Check for accessibility to setup and use a portable computer (PC) at the site for trouble-

shooting. There should be a place to set up the PC and to open the electronics enclosure.

- 4 -

- 5 -

Transducer Installation Detail

2.3 MOUNTING HA RDWA RE INSTALLATION

Î Check hardware. Verify that the probe slides

through the hot tap assembly.

Ï Check installation configuration. Make sure

the probe is parallel to the floor. (see Figure 3).

Ð Check installation clearance. Verify there is a

probe insertion clearance of 4 feet from the
pipe wall.

Ñ Install the mounting hardware. Drill a 1½”

through hole and weld the thread-o-let onto
the condenser vacuum pipe (See Figure 3).
Thread the hot-tap assembly into the thread­o-let. Use thread tape or pipe dope to seal the
connection.

Ò It should be convenient to apply a force of

about 23 lb to remove or replace the probe
under plant operating conditions.

2.4 TRANSDUCER INSTA LLATION

Figure 4 Maximum Cable Lengths

Î Check proper installation direction. The transducer has a directional arrow on the tag and/or

etched into a metal part. Before installing the unit, note proper flow direction. This is
important to instrument operation.

Ï Check serial number. If more than one RheoVac unit has been purchased, make sure the

complete serial number of the transducer matches the complete serial number of the separate
electronics unit. The transducer and electronics are a matched set. Mismatched components
will result in erroneous readings.

Ð Verify stop clamp location (see Figure 6). A stop clamp is attached to the probe as an

indication of its insertion depth. It is important this stay in place so the sensors are in the
correct location and ensure the probes do not contact the opposite pipe wall. The clamp’s
location was determined based on your pipe diameter, as shown in SECTION 6.2, and is
marked with a groove on the probe’s shaft. Refer to this mark if the stop clamp is
inadvertently moved.

Ñ Inspect the transducer probe tips. Be sure wetted surfaces are clean before installing. If

cleaning is needed, use a damp cloth wetted with alcohol and wipe dry using a soft, lint-free
cloth. Do not immerse probe in liquid alcohol or any other liquids.

Ò Install the transducer. The instrument should be mounted through the pipe wall using the hot-

tap assembly. The transducer installs so that the two probes are side-by-side across the gas
stream. The transducer has a flow directional arrow on the transducer tag and/or marked into
the fitting. When installing under vacuum, do not allow the clamp to "slam" against the seal
nut upon opening the valve. Grasp the transducer shaft firmly before opening the ball valve.
Allow the transducer to slide through the valve by controlling the amount of grip on its shaft.
Special installation instructions, if any, will be noted in SECTION 6.

- 6 -

Figure 5 RheoVac Electronics Enclosure

- 7 -