Intek RheoVac 950 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 INSTALLATION ................................................. - 4 -

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

2.2.1 Probe Site Selection .......................................... - 4 -

2.2.2 Electronics Unit Site Selection ................................. - 5 -

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

2.4 PROBE INSTALLATION AND ORIENTATION ........................ - 6 -

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

SECTION 3 OPERATION .................................................. - 14 -

3.1 GENERAL INFORMATION ....................................... - 14 -

3.2 SYSTEM START-UP ............................................. - 14 -

3.3 PORTABLE USB DATA STORAGE DEVICE/Warranty ................. - 14 -

3.4 DISPLAY ....................................................... - 15 -

3.5 COMMUNICATIONS ............................................ - 15 -

3.6 DATA PROCESSING ............................................. - 16 -

3.7 CUSTOM SOFTWARE ........................................... - 17 -

SECTION 4 MAINTENANCE .............................................. - 18 -

4.1 GENERAL MAINTENANCE ....................................... - 18 -

4.2 CALIBRATION ................................................. - 18 -

4.3 SPARE PARTS .................................................. - 18 -

4.4 TROUBLESHOOTING ............................................ - 18 -

4.5 HARDWARE AND SOFTWARE MODIFICATIONS AND UPGRADES . . . - 20 -

SECTION 5 CUSTOMER SERVICE ......................................... - 21 -

5.1 QUESTIONS ON EXISTING HARDWARE ........................... - 21 -

5.2 TROUBLESHOOTING ............................................ - 21 -

5.3 FACTORY AND FIELD SERVICE .................................. - 21 -

5.4 QUESTIONS ON NEW EQUIPMENT ............................... - 21 -

5.5 CONDENSER SERVICES ......................................... - 21 -

SECTION 6 CUSTOM INFORMATION ...................................... - 22 -

6.1 UNIT IDENTIFICATION .......................................... - 22 -

6.2 CONFIGURATION ............................................... - 22 -

6.3 SPECIAL INSTRUCTIONS ........................................ - 22 -

Appendix A - RheoVac Model 950 User Interface Software
Appendix B - RheoVac Model 950 Networking

Intek, Inc. 2007

Manu al no. RV950 Rev. D

I:\OFFICE\WPMANU AL\RV950 Rev D.wpd

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.

RheoVac instruments are manufactured under United States patent numbers
4,255,968, 5,485,754, 5,752,411 and 6,526,755. Intek, Rheotherm, Rheovec,
Rheomax, RheoVac and RheoSmart are registered trademarks of Intek, Inc.

Windows is a registered trademark of Microsoft Corporation in the United States and other countries.

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 gases in the condenser exhauster line are directly
measured to provide an accurate determination of air in-leakage and condenser performance related
parameters. These properties are measured to provide the power industry with the most advantageous
and complete product for condenser system diagnostics:

the RheoVac®System*

*USPNs 4,255,648; 5,485,754; 5,752,411; 6,526,755

A model 950 RheoVac system consists of one, two or three probes reporting to a central signal
conditioner and processor unit. The sensing probe, consisting of multiple sensors configured in a single
probe head, is installed in the vacuum line between the condenser and the exhauster. The RheoVac
system 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
an accurate mass 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.

®

technology to provide

Figure 1 RheoVac Model 950

- 1 -

1.2 PRINCIPLE OF OPERATION

The principal features of the RheoVac system are shown in Figure 1. At the heart of the RheoVac
system is the Rheotherm mass flow transducer, which uses the same patented thermal sensing technique
employed in all precision flow instruments manufactured by Intek. Two temperature sensors 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 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 gaseous water vapor/air
mixture. From the other three measurements, the RheoVac electronics converts the total gas mass flow
signal from the probe 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 system 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:

±5% Total Mass Flow

Repeatability:

±0.5% of reading

Operating Temperature:

Electronics: 40 to 120°F (5 to 49°C)
Probe: 40 to 160°F (5 to 71°C)

Never subject probe to temperatures
above 210°F (99°C)

Operating Pressure:

0.5 to 30 inches Hg absolute
15 psi maximum

Process Connection:

Hot tap assembly
(1½” thread-o-let must be welded to
pipe for hot tap installation)

Wetted Surface:

300 Series SS and engineered plastic

1.4 PRECAUTIONS

Read the entire manual before installing and operating the RheoVac system.

Local Display:

Back-lit LCD
Selectable display of air in-leakage and 6
of the other output parameters

Input Power:

100-250 Vac, 50/60 Hz

Signal Output:

RS-232/RS-422/Serial Modbus, Ethernet
Eight 4-20mA signals (optional)

Data Access:

Ethernet

Storage Temperature:

!20 to 120°F (-29 to 49°C)

Storage Pressure:

15 psig (maximum)

Local Keypad:

Parameter scrolling
Metric/English units

Carefully select the best locations for installation of the probes. Access, installation clearances,
freedom from standing water, and straight-run should all be considered when selecting a probe
location.

- 2 -

Use reasonable care in handling the probe the sensing components are delicate. Do not
bend the probes, damage the tips, or obstruct the sensing ports. If shipping the unit, make sure
the probe is adequately protected from foreign objects and damage.

Use proper input power it must be between 100 and 250 Vac (nominal 120/240 Vac) at
50/60 Hz (60 Hz nominal).

Confirm the line and environmental temperature is always below the probe and electronics
ratings never operate a probe at or subject it to temperatures or pressures beyond its
specified limits. (See Section 1.3)

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

exhauster line where a probe is located. This can happen if steam jet ejectors are
operated incorrectly.

.. WARNING - Do not allow the instrument’s RS sensor (or separate RS probe) to come

into contact with liquid water, water mist, or fog – these conditions may be present in
your condenser vent line due to design configuration. The RS sensor measures relative
saturation up to 100% but may fail under the above wet condition. Intek provides design
services to improve condenser venting and reduce or eliminate entrained liquid water and
excess condenser back pressure.

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 all conduit lines.

.. WARNING - Be sure to power up your RheoVac instrument system and probe(s) for

at least 30 minutes before inserting probes into the vent line hot taps. DO NOT leave
probe in vent line unpowered or when flooding the condenser.

- 3 -

SECTION 2 — INSTALLATION

2.1 INSTALLATION

These instructions cover installation of RheoVac instruments in their standard configuration. Additional
information pertaining to your unit is covered in SECTION 6 CUSTOM INFORMATION . Carefully
read these instructions prior to installing the equipment. Also, see preceding SECTION 1.4.

2.2 RheoVac SYSTEM INSTALLATION/SITE SELECTION

The RheoVac 950 can be configured with one, two or three probes. A three probe system is intended
to be installed so that one probe is in each of the two exhaust lines coming out of the condenser (A side
and B side). The third probe should go in the header pipe that runs to the exhauster(s). Other
installation arrangements of multiple probes should be discussed with the factory.

2.2.1 Probe Site Selection

# The location for each probe should provide the probe sensing area with well-established

smooth flow, uniform system temperature and pressure, and consistent non-liquid phase flow
medium. Pipe sections ahead of a probe, in which water can accumulate, must be avoided.
Refer to Figure 2 and select the most preferred location for each probe. Do not install the
probes 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 special instructions.

Figure 2 RheoVac Probe Insertion Recommendation

- 4 -

# Check installation clearance. Each transducer probe is almost 3 feet (0.9m) long and the hot

tap assembly is approximately 13 inches (0.33m) long, therefore, allow minimum clearance
of 4 feet (1.3m) for probe installation. Be sure there are no obstructions around the vacuum
line that will interfere with probe insertion. Figure 3 shows the proper insertion angle. THIS
ORIENTATION IS IMPORTANT FOR PROPER OPERATION.

# Observe the selected sites. They should be convenient for the removal and replacement of

probes at any time for service without building scaffolding or waiting for plant shutdown.

# Check operating conditions. The temperature and pressure limits (see Technical

Specifications; Section 1.3) of the unit should be checked to ensure compatibility with your
application.

# Gases in the air removal line should be free of liquid water, mist or fog. Wetness in the line

will result in erroneous readings from the instrument. If wet conditions exist in the air
removal line, there is either air removal section damage or design flaws which adversely
affect condenser performance. Consult Intek for assistance in evaluating the severity of the
problem and possible remedies.

2.2.2 Electronics Unit Site Selection

The Model 950 typically has two or three electronics enclosures (see Figure 1). The processor
enclosure and other electronics boxes should be installed in a convenient location and should be
kept away from direct sources of heat, such as uninsulated steam lines, or moisture. The
maximum temperature rating of electronics is 120°F; ensure that this temperature will not be
exceeded. Once the wiring connections are made, close and latch down the box lid to protect the
contents from damage and debris. All these enclosures should be located in a dry area and should
be kept clamped shut during normal operation. Do not allow water to get into the enclosures. If
installed outdoors, build a roof over all enclosures to prevent eventual water infiltration.

A. Processor Enclosure: This 12x10 NEMA 4 enclosure houses the display and central

processing unit. Input power (100-250 Vac, 50/60 Hz) is connected inside this enclosure.
This enclosure should be installed in a convenient location and should be kept away from
direct sources of high heat, such as uninsulated steam lines.

B. Distribution Box: This 8x6 NEMA 4 enclosure is typically located near the probe that is

closest to the processor enclosure unit. It is connected to the main processor with an RS-485
bus DeviceNet™ cable, which can be hundreds of feet long. The probe and transmitter RS­485 cable connections are also made within this box. The probe and transmitter cable
lengths should be 15 ft. or less, if possible.

C. Transmitter Box (optional): This 10x8 NEMA 4 enclosure contains terminals for accessing

the eight 4-20mA signals. It can be located in or near the control room so that the 4-20 wires

do not have to be run from the plant floor. An RS-485 DeviceNet cable runs from the
distribution box to the transmitter box. (There are restrictions on how this can be done, so
check manual Section 6, or contact the factory.)

- 5 -

2.3 MOUNTING HARDWARE 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 4).

Be sure location is accessible for probe removal and maintenance.

Ð Check installation clearance. Verify there is a minimum probe insertion clearance of 4 feet

(1.3m) between pipe surface and any obstruction.

Ñ Install the mounting hardware. Drill a 1½” through-hole, center the thread-o-let over the

hole and weld it onto the condenser vacuum pipe (see Figure 4). Thread the hot-tap
assembly into the thread-o-let. Use thread tape or pipe dope to seal the connection.
(Alternate: weld thread-o-let to pipe wall, then drill a 1¼" hole in pipe wall using a hot-tap
drill.)

Ò It may be necessary to apply a force of about 23 lb (102 Newtons) to remove or replace the

probe under plant operating conditions.

2.4 PROBE INSTALLATION AND ORIENTATION

Î Check proper installation direction. Each probe has a directional

arrow on the junction box. Before installing the unit, note proper
flow direction. This is important to instrument operation.

Ï Check serial number (S/N). If more than one RheoVac unit has been

purchased, make sure the first five digits of the serial numbers of the
probe(s) match the first five digits of the serial number of the main
processor unit. The electronics and up to three probes are a matched
set. Mismatched components will not work correctly. The dash
number on the probe S/N is the probe number shown on the display.
Record the probe number and installation location for future
reference.

Ð Verify stop clamp location (see Figure 3). A stop clamp is attached

to each probe as an indication of its insertion depth. It is important
that the stop clamp is securely in place to position the sensors in the
correct location and to ensure that the probes do not contact the
opposite pipe wall. Contact with the pipe wall could damage the
probe. The clamp’s location was determined based on your
submitted pipe diameter, as shown in SECTION 6.2, and is marked
with a groove on each probe shaft. Refer to this mark if a stop clamp
is inadvertently moved. The two metal probe tips should be in the
middle of the pipe.

Figure 3

Probe Stop Clamp

- 6 -

Figure 4 Transducer Installation Detail

- 7 -

Ñ Inspect the 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 second dry, soft, lint-free
cloth. Do not immerse probes in alcohol or any other liquids. This may damage the probe
sensors.

Ò Be sure to power up your RheoVac instrument system and probe(s) for at least 30 minutes

before inserting probes into the vent line hot taps. DO NOT leave probe in vent line
unpowered or when flooding the condenser.

Ó Install each probe. The probe should be mounted through the pipe wall using the hot-tap

assembly. The probe installs so that the two sensor tips are side-by-side across the gas stream.
The probes have a flow directional arrow on the junction box. When installing under vacuum,
do not allow the clamp to "slam" against the seal nut upon opening the valve. Grasp the probe
firmly, with hand against the seal nut, before opening the ball valve. Allow the probe shaft to
slide slowly through the valve by controlling the amount of grip on the probe shaft. Special
installation instructions, if any, will be noted in SECTION 6.

Ô Prior to inserting probe, loosen the compression nut on the thermocouple connector of the hot

tap and clean the inner surface of the thermocouple connector to ensure it is free of particles
that may cause probe damage.

2.5 ELECTRICAL CONNECTIONS

. IMPORTANT . Inspect and VERIFY these electrical connections carefully. Improper

connection could damage electronic components and sensor function. If additional holes need to
be drilledin the processor enclosure, remove the electronicssubassembly (mounted ona mounting
plate) and temporarily store inside an ESD bag in a safe, clean place. Do not drill with electronics
boards inside the enclosure.

A. Main Processor Unit (see Figure 5)

1. Sensor Power and Communication Line
box using the RS-485 Communications/Power cable. Follow indicated connector color code.
[communications

2. Main Power
circuit. An external disconnect switch should be used for disconnecting power to the

: white (A), blue (B) and shield (SH); power: 24Vdc, red (+), and black (!)]

: Connect main power terminals to a dedicated 100-250Vac, single phase, 15 amp

: Connect the distribution box to this main processor

system during outages. Power connection wires should be at least 18 gauge and comply with
accepted wiring codes. SW1 is used for cycling power to reset.

3. Serial Communication

: Connector JP3 is the RS-232 serial communication interface. This
interface should only be used for distances of 20 feet or less, such as to a laptop computer. A
20 foot serial cable with a DB-9 connector can be shipped upon request (see Figure 9 and

Table I below). An RS-422 serial communication interface is present for long data
communications when configured without 4-20 mA outputs.

Table I RJ-11 to DB-9 Module Adapter

RS-232 CONFIGURATION RS-422 CONFIGURATION

RJ-11 Pin Out DB-9 Pin Out RJ-11 Pin Out DB-9 Pin Out

1 Tx (transmit) 1 N/C 1 Tx+ (transmit+) 1 Rx

2 N/C 2 Tx (transmit) 2 TxS (transmitS) 2 Rx+ (receive+)

3 Rx (receive) 3 Rx (receive) 3 Rx+ (receive+) 3 Tx+ (transmit+)

4 N/C 4 N/C 4 RxS (receiveS) 4 N/C

5 Power (+5V) 5 Ground 5 Power (+5V) 5 Ground

6 Ground 6 Pulled high 6 Ground 6 Tx

7 N/C 7 7 TBD

8 Pulled high 8 8 TBD

9 N/C 9 9 TBD

S (receiveS)

S (transmitS )

- 8 -

Figure 5 Output Connections and Set-up

- 9 -