Intek RheoVac CMS User Manual

CONDENSER

MONITORING SYSTEM

with

RheoVac® and Rheotherm® Instruments

Installation & Operation Manual

Intentionally left blank

TABLE OF CONTENTS

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

1.1 INTEK’S POWER INDUSTRY SERVICES ................................................................................................................ 1

1.2 PURPOSE AND FUNCTION ....................................................................................................................................... 2

1.3 TECHNICAL SPECIFICATIONS – check custom page to determine which components apply to your CMS .......... 3

1.3.1 Main Electronics (SCADA, RTU and HMI) ......................................................................................................... 3

1.3.2 RheoVac Multi-Sensor Probe (MSP) .................................................................................................................... 3

1.3.3 Rheotherm Cooling Water Flow and Fouling (CWFF) Meters ............................................................................. 4

1.3.4 Pressure/Temperature (PT) Probe ......................................................................................................................... 4

1.3.5 Thermocouple (TC) Temperature Sensors and Arrays ......................................................................................... 4

1.3.6 High Spatial Density Temperature Sensors and Arrays ........................................................................................ 5

1.4 WARNINGS , PRECAUTIONS AND RECOMMENDATIONS ........................................................... 6

SECTION 2 - INSTALLATION .................................................................................................................7

2.1 HARDWARE INSTALLATION .................................................................................................................................. 7

2.1.1 RheoVac Multi-Sensor Probes .............................................................................................................................. 7

2.1.2 PT Probes ............................................................................................................................................................ 10

2.1.3 Rheotherm CWFF Meters and Temperature Sensors .......................................................................................... 10

2.2 ELECTRICAL CONNECTIONS................................................................................................................................ 11

2.2.1 Main Electronics – contains the SCADA and HMI components ........................................................................ 12

2.2.2 Satellite Electronics (only provided with systems that have several instruments) .............................................. 13

2.2.3 Distribution Box (see Figure 6) – For distributing RS485 communication and 24VDC .................................... 13

2.2.4 4-20mA Transmitter Box (optional) – For driving eight (8) remote 4-20 mA analog signals ............................ 14

2.2.5 RheoVac MSP and PT Probe Connector Assembly ............................................................................................ 16

2.2.6 Rheotherm CWFF Meters and Temperature Sensors Connections ..................................................................... 17

SECTION 3 - USER INTERFACE AND DATA RETRIEVAL ..............................................................18

3.1 MENUS ....................................................................................................................................................................... 18

3.1.1 Compressing Data (to USB Stick) ...................................................................................................................... 18

3.1.2 Change Line Size (i.e., pipe diameter) ................................................................................................................ 20

3.1.3 Reboot ................................................................................................................................................................. 21

3.1.4 Cancel ................................................................................................................................................................. 21

3.2 UPLOADING TO INTEK’S SECURE FTP SITE FOR DATA EVALUATION ...................................................... 22

SECTION 4 - COMMUNICATION METHODS .....................................................................................24

4.1 ANALOG OUTPUT ................................................................................................................................................... 24

4.2 MODBUS .................................................................................................................................................................... 24

4.2.1 Modbus TCP ....................................................................................................................................................... 26

4.2.2 Serial Modbus ..................................................................................................................................................... 26

4.2.3 Modifying the Modbus Configuration File ................................................................................................ ......... 28

4.2.4 Modbus Troubleshooting .................................................................................................................................... 29

4.3 OPC – (OLE for Process Control) ............................................................................................................................... 30

4.3.1 Connecting .......................................................................................................................................................... 30

4.3.2 Adding Process Variables ................................................................................................................................... 30

SECTION 5 - TROUBLESHOOTING .....................................................................................................31

5.1 COMMON ISSUES .................................................................................................................................................... 33

SECTION 6 - MAINTENANCE GUIDE..................................................................................................34

6.1 WATERBOX INSTRUMENTS .................................................................................................................................. 34

6.2 CALIBRATION .......................................................................................................................................................... 34

6.3 SOFTWARE UPDATES ................................................................ ................................................................ ............. 34

6.4 ADDING/REPLACING SENSORS/INSTRUMENTS .............................................................................................. 34

SECTION 7 - CUSTOMER SERVICE .....................................................................................................35

7.1 TROUBLESHOOTING .............................................................................................................................................. 35

7.2 FACTORY AND FIELD SERVICE ................................................................ ................................ ........................... 35

7.3 CONSULTING SERVICES ........................................................................................................................................ 35

7.4 CONDENSER MANAGEMENT AND RheoVac/CMS TRAINING ......................................................................... 36

SECTION 8 - CUSTOM INFORMATION ...............................................................................................37

8.1 UNIT IDENTIFICATION AND CONFIGURATION ............................................................................................... 37

8.2 SPECIAL INFORMATION ........................................................................................................................................ 37

September 2013 i © Intek, Inc. 2013 Revision D

WARRANTY

Intek, Inc. warrants each Rheotherm, RheoVac and CMS 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 flow meters are manufactured under United States patent numbers 4,255,968, 4,942,763, 4,949,578 and 5,445,018. Rheotherm circulating water flow and fouling meters are patent pending in the USA. RheoVac instruments are manufactured under United States patent numbers 4,255,968, 5,485,754, 5,752,411 and 6,526,755. CMS products incorporate Rheotherm and RheoVac technology as well as technology under US patent numbers 6,526,755, 7,065,970, 7,926,277 and international patents.

Intek, Rheotherm, and RheoVac are registered trademarks of Intek, Inc.

September 2013 ii © Intek, Inc. 2013 Revision D

SECTION 1 - GENERAL INFORMATION

1.1 INTEK’S POWER INDUSTRY SERVICES

Intek manufactures RheoVac condenser and air in-leak monitors, Rheotherm circulating water flow and fouling meters, flow meters, flow switches, as well as specialty temperature and pressure measurement instruments. These specialty instruments for the power industry provide continuous monitoring of critical steam surface condenser parameters important to plant thermal performance and life cycle.

The data from these instruments have been used to gain a unique comprehensive understanding of steam surface condensers and the condensation process. This understanding has enabled Intek to help customers troubleshoot condensers with greater speed and accuracy than ever before. Intek has expanded service offerings and developed an online information website for steam surface condensers, available at www.MyCondenser.com.

Intek has also taken advantage of its aerospace design tools and design expertise for the purpose of retrofitting condensers to maximize performance and improve condensate chemistry. Intek has transformed underperforming condensers into some of the best performing condensers in the world.

The condenser services team under Dr. Joseph Harpster’s leadership has also sought to educate the industry by contributing volumes of material to ASME and EPRI regarding proper condenser measurement and steam flow dynamics. Intek conducts a unique Condenser Operations and Management Workshop for continuing education purposes. Tutorials and case studies are also available at www.MyCondenser.com for registered users.

Intek is The Gateway to

Improved Condenser Performance, Fast Response Maintenance and Optimized Operations

September 2013 1 © Intek, Inc. 2013 Revision D

1.2 PURPOSE AND FUNCTION

The Condenser Monitoring System (CMS) integrates unique instruments allowing comprehensive examination of condenser performance. These unique instruments are specifically designed to provide direct measurement of performance degradation mechanisms and data that exceed the requirements of instrumentation outlined in ASME PTC 12.2. A complete system will provide data used to derive information for quantifying specific degradation mechanisms such as microfouling, macrofouling, cooling water flow, waterbox fill, air binding, low vacuum equipment capacity and condensate inundation. This information can also be used to evaluate the cooling water system changes, fouling control systems, waterbox eductors, vacuum equipment, and new or refurbished condenser commissioning. In essence, this system puts a microscope on your condensing heat exchanger and empowers engineers with direct measurements to organize actionable effort.

Illustration of the Condenser Monitoring System (CMS)

Used for comprehensive online continuous heat exchanger performance measurement and monitoring

September 2013 2 © Intek, Inc. 2013 Revision D

1.3 TECHNICAL SPECIFICATIONS – check custom page to determine which

components apply to your CMS

1.3.1 Main Electronics (SCADA, RTU and HMI)

Input Power: 100-250 VAC, 50/60 Hz (UPS recommended) Digital Communication: TCP/IP: Windows File Share (SMB) OPC Modbus Web Interface Wireless (optional) All TCP/IP options are enabled by default Serial: RS-232 (Modbus) (optional) Analog Communication: 4-20mA signals (optional) Temperature Environment: Operating: 40 to 120°F (5 to 49°C) Storage: -20 to 158°F (-29 to 70°C) Local Display (optional): LCD Screen

or 2 x 20 alphanumeric LCD – displays output parameters and diagnostic messages Parameter scrolling Wireless Handheld Tablet (optional)

1.3.2 RheoVac Multi-Sensor Probe (MSP)

Typical Calibration Accuracy: ±5% of total mass flow Repeatability: ±1.5% of reading Operating Temperature: Electronics: 40 to 120°F (5 to 49°C) Probe: 40 to 158°F (5 to 70°C)

Never subject probe to temperatures above 210°F (99°C) (high temperature protection optional, up to 450°F)

Operating Pressure:

0.5 to 10 inches Hg absolute 15 psia maximum Storage Temperature:

-20 to 185°F (-29 to 85°C) Storage Pressure: 15 psig (maximum) Process Connection: Ball valve assembly (1½" thread-o-let must be welded to pipe for installation) Wetted Surface: 300 Series SS and engineered plastic (depending on model)

September 2013 3 © Intek, Inc. 2013 Revision D

1.3.3 Rheotherm Cooling Water Flow and Fouling (CWFF) Meters

Primary Calibration Accuracy: Better than ±2% of reading Flow Range: 2-20 ft/s (extended range optional) Repeatability: ±0.5% of reading Operating Temperature: Electronics: 40 to 120°F (5 to 49°C) Sensor: 40 to 140°F (5 to 60°C) Operating Pressure: 60 psi (1000 psi optional) Storage Temperature:

-20 to 140°F (-29 to 60°C) Storage Pressure: 60 psig (maximum) Wetted Surface: 300 Series SS (material options available) Neoprene, Polyolefin (cable included)

1.3.4 Pressure/Temperature (PT) Probe

Accuracy: ±0.02 inches HgA for pressure ±0.1°F for temperature Repeatability: ±0.5% of reading Operating Temperature: Electronics: 40 to 120°F (5 to 49°C) Probe: 40 to 300°F (5 to 149°C) Operating Pressure:

0.5 to 10 inches Hg absolute 15 psia maximum Storage Temperature:

-20 to 185°F (-29 to 85°C) Storage Pressure: 15 psig (maximum) Process Connection: Ball valve assembly (1½" thread-o-let must be welded to pipe for installation) Wetted Surface: 300 Series SS

1.3.5 Thermocouple (TC) Temperature Sensors and Arrays

Temperature range: 40-175°F (higher temperature components optional) Accuracy: ±0.2°F Repeatability:

±0.1°F Wetted Surface:

300 Series SS and thermoplastics

September 2013 4 © Intek, Inc. 2013 Revision D

1.3.6 High Spatial Density Temperature Sensor Arrays

Operating Temperature: 40 to 185°F (5 to 85°C) Accuracy: ±0.15°F Repeatability:

±0.1°F Wetted Surface:

Proprietary

September 2013 5 © Intek, Inc. 2013 Revision D

1.4 WARNINGS , PRECAUTIONS AND RECOMMENDATIONS

WARNING — Never operate any instruments at or subject them to temperatures or

pressures beyond the specified limits. (See Section 1.3)

Use reasonable care in handling the RheoVac and PT probes. Do not bend the probes, damage

the tips, or obstruct the sensing ports. If moving or shipping the unit, make sure the probe is adequately protected from foreign objects and damage during handling and shipping; save and reuse factory provided custom probe protector and shipping boxes.

Keep the USB memory stick disconnected during normal operations to extend memory lifetime.

All instruments should be serviced on a 1 or 2 year cycle to ensure all instruments are within

specifications and electronics are maintained with appropriate software/hardware updates.

Use the USB stick to retrieve data after the system has been online and flow has been established

for at least 48 hrs. E-mail data to Intek for evaluation.

Intek recommends using the RJ-45 network connection for all data traffic (as opposed to serial

and 4-20 mA communication).

RheoVac probes and PT probes:

WARNING — Be sure to power up your RheoVac probe(s) for at least 30 minutes before

inserting probes into the vent line. DO NOT leave probe in vent line without power or when flooding the condenser.

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

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

WARNING — Do not allow RheoVac or PT probes to come into contact with liquid water,

including water from condenser flooding (hydro testing) and entrained liquid water. Entrained liquid water is an indicator of poor condenser venting and may be present in your condenser vent line due to design configuration. See EPRI’s “Air In-Leakage and Intrusion Prevention Guideline,” TR 1014125. Intek offers analysis and design services to improve condenser venting and reduce or eliminate entrained liquid water and excess condenser back pressure.

Recalibration every 2 years: RheoVac probes and PT probes should be returned to the factory

for inspection and calibration service every two years.

Rheotherm CWFF and thermocouple sensor arrays:

WARNING — Ensure cleaning crews do not apply lateral pressure, “cock,” to the cleaning

guns; this can damage epoxy cladded tubesheets and the installed meters.

WARNING — Do not attempt to disassemble the meters/sensors – there are no user

serviceable components.

When cleaning condenser tubes, it is recommended to insert projectiles into the CWFF meter.

Inspect the installation on a scheduled basis or as opportunities arise to ensure the epoxy coating

is securely sealing the installed meters/sensors in place. Follow epoxy coating manufacturer’s

(Plastocor, Duromar, etc.) recommendations to touch up coat as required. Intek recommends annual inspections, as a minimum.

SECTION 2 - INSTALLATION

2.1 HARDWARE INSTALLATION

2.1.1 RheoVac Multi-Sensor Probes

2.1.1.1 Selecting a Ball Valve Assembly Location (Hot Tap Compatible)

Figure 1: Recommended ball valve assembly locations

1. Select an easy to access location; location should be accessible for probe removal

and maintenance.

2. Adhere to locations shown in Figure 1.

3. Verify there is a minimum probe insertion clearance of 4 feet (1.3m) between pipe

surface at the tap location and any obstruction, refer to Figure 2.

4. Verify installation site is parallel to the floor, refer to Figure 2.

5. An additional ball valve assembly is required for high temperature model MSPs.

Refer to SECTION 8 -CUSTOM INFORMATION for installation instructions.

2.1.1.2 Ball Valve Installation

1. Be sure location is accessible for probe removal and maintenance.

2. Install 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 2). Thread the ball valve 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).

3. Make sure the probe installs parallel to the floor (see Figure 2).

4. Verify that the probe slides easily through the ball valve assembly and pipe

penetration hole.

Figure 2: RheoVac MSP ball valve assembly installation detail

2.1.1.3 Installing/Removing Probe Instruments – refer to Figure 3

1. Power up your RheoVac MSP for at least 30 minutes before inserting probe into the

vent line ball valves. DO NOT leave probe in vent line without power or when flooding the condenser.

2. Prepare each probe. Verify stop clamp location (see Figure 3). It is important that

the stop clamp is securely in place which determines the position of the multisensor assembly and ensures that the probes do not contact the opposite pipe wall. Contact with the pipe wall could damage the probe. The clamp’s location is set at the factory and is marked with a groove on each probe shaft. This location roughly places the thermal mass flow elements (two metal probe tips) in the center of the pipe. Refer to this mark if a stop clamp is inadvertently moved. Loosen the compression nut on the thermocouple connector of the ball valve assembly and clean the inner surface of the thermocouple connector to ensure it is free of particles that may cause probe damage.

3. Insert probe until the extraction line meets the compression nut and snug the

compression nut.

4. Install each probe. 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.

5. Align the FLOW arrow to the direction of flow and the centerline of the pipe.

6. When removing the probe, loosen the compression nut on the thermocouple

connector of the ball valve assembly and slowly extract the probe until the Extraction Line is visible (see Figure 3). This indicates that the probe is clear of the ball valve. Close the ball valve, then remove the probe from the assembly.

Figure 3: Installing and removing probe instruments

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