Intek RheoVac SENTRY User Manual

TABLE OF CONTENTS

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

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

1.2 BENEFITS ....................................................... - 1 -

1.3 USES ........................................................... - 2 -

1.4 PRINCIPLE OF OPERATION ....................................... - 2 -

1.5 TECHNICAL SPECIFICATIONS ..................................... - 3 -

1.6 PRECAUTIONS .................................................. - 4 -

SECTION 2 — INSTALLATION ................................................ - 5 -

2.1 SYSTEM CONFIGURATION ....................................... - 5 -

2.2 RheoVac SENTRY INSTALLATION/SITE SELECTION .................. - 5 -

2.2.1 Probe Site Selection .......................................... - 5 -

2.2.2 CPU/Distribution Box Site Selections ............................ - 6 -

2.3 HOT TAP INSTALLATION ......................................... - 7 -

2.4 PROBE INSTALLATION ........................................... - 7 -

2.5 ELECTRICAL CONNECTIONS ..................................... - 9 -

SECTION 3 — OPERATION .................................................. - 13 -

3.1 GENERAL INFORMATION ....................................... - 13 -

3.2 OUTPUT PARAMETERS ......................................... - 13 -

3.3 RheoVac SENTRY PROBES ........................................ - 13 -

3.4 CPU TOUCH SCREEN ............................................ - 14 -

3.5 ETHERNET or MODEM OUTPUT .................................. - 18 -

3.6 SEARCHING FOR LEAKS WITH MULTI-PROBE SYSTEM ............ - 20 -

SECTION 4 — MAINTENANCE ............................................... - 22 -

4.1 GENERAL MAINTENANCE ....................................... - 22 -

4.2 CALIBRATION .................................................. - 22 -

4.3 SPARE PARTS .................................................. - 22 -

4.4 TROUBLE SHOOTING ........................................... - 22 -

SECTION 5 — CUSTOMER SERVICE ......................................... - 24 -

5.1 QUESTION ON EXISTING HARDWARE ............................ - 24 -

5.2 TROUBLE SHOOTING ........................................... - 24 -

5.3 FACTORY AND FIELD SERVICE .................................. - 24 -

5.4 QUESTIONS ON NEW EQUIPMENT ................................ - 24 -

SECTION 6 — CUSTOM INFORMATION ...................................... - 25 -

6.1 UNIT IDENTIFICATION .......................................... - 25 -

6.2 CONFIGURATION ............................................... - 25 -

6.3 SPECIAL INSTRUCTIONS ........................................ - 25 -

©Intek, Inc. 2004

I:\OFFICE\WPMAN UAL\SENTRY\RVSentryRev. A.wpd

Manual no. RVSentry Rev. A

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.

Intek’s instruments are manufactured under United States patent numbers
4,255,968, 4,942,763, 4,949,578, 5,445,018 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

In 1994, Intek Inc. introduced the RheoVac® air in-leak monitor for continuously measuring condenser
air in-leakage. This monitor was the first and only instrument to measure all of the necessary fluid
properties in the condenser exhaust line to provide an accurate, reliable air in-leakage measurement:

— the RheoVac

®

Air In-Leak Monitor*

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

The next generation instrument, the RheoVac SENTRY, uses the same proven sensor configuration, but
brings new capabilities consistent with the industry’s need for local as well as centralized and remote
monitoring.

The RheoVac technology was developed with the help of power plant engineers, to overcome the
deficiencies of existing air in-leakage and condenser performance measurement instrumentation and to
create a powerful, complete condenser system analysis tool. No single product provides power plant
engineers with as much diagnostic information related to the condenser as the RheoVac SENTRY System.
In addition to providing reliable, real time indication of condenser air in-leakage, the SENTRY System
provides valuable information that can be used to analyze problems associated with vacuum system
components, thereby improving plant efficiency, reducing downtime and increasing maintenance
effectiveness.

1.2 BENEFITS

The following are some of the unique benefits of the RheoVac SENTRY System:

• Distinguishes between air flow and water vapor flow

• Measures exhauster capacity

• Measures vacuum quality

• Allows operators to distinguish between air in-leakage and pump failure

• Continuous monitoring provides event time stamp

• Provides high resolution, range and accuracy of data

• Retrievable on-board data storage

• Provides data for condenser performance diagnostics

• Provides centralized access to the data from all of the RheoVac probes installed in the system

• Provides easy access to individual probe’s data as well as on-screen review of selected
common data from all of the probes for performance analysis

• Graphic representation of monitored data gives visual indications of performance changes

• Provides easy review of “before” and “after” data through the diagnostics screen to evaluate
the effect of system changes

• Portable remote measurement (optional feature) of air-in-leak changes through the use of a
hand-held display unit – used to locate leaks

- 1 -

1.3 USES

The RheoVac SENTRY System can be used for a multitude of performance related subjects, such as:

• Continuous air in-leak monitoring

• Vacuum pump performance testing

• Operating with zero excess back pressure

• Load dependent air in-leak isolation

• Optimizing condenser performance

• Scheduled preventive maintenance

• Leak detection during hogging operation

• Minimizing heat rate

• Optimizing condensate/water chemistry

• Understanding condenser performance

1.4 PRINCIPLE OF OPERATION

The RheoVac technology utilizes multiple primary sensors configured in a single probe head and an
electronic signal conditioner and digital signal processor unit. The sensing probe is installed in the
vacuum line between the condenser and the exhauster. The RheoVac instrument 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. The principal features of the RheoVac sensor are shown in Figure 1.

Figure 1 RheoVac Probe Sensor Monitor

- 2 -

At the heart of the RheoVac probe is the Rheotherm 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 water vapor/air mixture.
From the other three measurements, the RheoVac SENTRY electronics converts the total 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 probe is fully calibrated at the factory under dynamic fluid conditions identical to those within
the power plant vacuum line. No field adjustments are required.

In the RheoVac SENTRY System, multiple RheoVac probes are installed at pre-determined condenser
vacuum line locations to provide the most appropriate measurement data for the condenser system.
Depending on the plant configuration, sometimes a single SENTRY System can be configured to monitor
more than one generating unit. The probes are connected to the SENTRY CPU, which processes the
measured data and provides the system output data. The SENTRY System, in add ition to data processing,
display and graphing, also communicates the data, through 10Base-T Ethernet, to the plant control room,
engineer’s office, and/or Intek via modem or internet.

1.5 TECHNICAL SPECIFICATIONS

Primary Calibration Accuracy:

±1% of reading

Repeatability:

±0.5% of reading

Operating Temperature:

Electronics: 32 to 100°F
Probe: 40 to 160°F

Never subject probe 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
pipe for hot tap installation)

Wetted Surface:

300 Series SS and engineering plastic

NEVER allow RheoVac probe heads to
be immersed in liquid water or be
exposed to live steam

Local Display:

touch screen display of all parameters
from each probe, with graphing capability

Input Power:

115 Vac, 50/60 Hz (+10%/!20%)

Signal Output:

Ethernet (10Base T) RJ45
4-20mA (optional)

Storage Temperature:

!20 to 120°F

Storage Pressure:

15 psig (maximum)

Maximum number of probes/SENTRY CPU: 12

- 3 -

1.6 PRECAUTIONS

• Read the entire manual before installing and operating the RheoVac probes and SENTRY
System.

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

• Use reasonable care in handling the sensing probe(s) — the sensing components are delicate.
Take care not to bend the probes, damage the tips, or otherwise obstruct the sensing ports.
When a probe is taken out of line, always place it in the protective sheath which is shipped
with probes from the factory.

• Use proper input power.

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

• 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.

. . WARNING . .

1. Never allow live high temperature steam to flow in either direction in the
exhauster line where the probe is located.

2. Never flood an exhauster line that has a RheoVac probe in it. Always remove
the probe, or seal off that section of pipe before a hydrostatic leak test is
performed.

- 4 -

SECTION 2 — INSTALLATION

2.1 SYSTEM CONFIGURATION

The system provided consists of:

• a RheoVac SENTRY central processing unit (CPU) in a metal housing. The CPU includes a
touch screen interface, uninterruptible power supply (UPS), modem (optional),
interconnections and controls

• up to twelve (12) RheoVac SENTRY probes (see Custom Information Section)

• one (1) or more distribution box(s), and remote power supply boxes as required, (see Custom
Information Section)

• RS485 cable for connecting the probes and electronics boxes.

A drawing is included in this manual illustrating the general layout of all the SENTRY components.

2.2 RheoVac SENTRY INSTALLATION/SITE SELECTION

2.2.1 Probe Site Selection (IMPORTANT)

# Select the installation site. The location should provide the probe’s sensing area with well-

established smooth flow, uniform system temperature and pressure, and consistent non-liquid
phase flow medium. Refer to Figure 2 and select the most preferred location that fits your
vacuum line configuration.

# DO NOT INSTALL THE PROBE DOWNSTREAM OF 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 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 probe insertion or removal and that there is
sufficient room for flexible conduit.

# OBSERVE the selected site. It should be convenient for removal and replacement of probe(s)

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

# Figure 3 shows the proper insertion angle. THIS ORIENTATION IS IMPORTANT FOR

PROPER OPERATION.

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

to ensure compatibility with your installation point, see Section 1.5.

- 5 -

Figure 2 RheoVac Probe Insertion Recommendation

2.2.2 CPU/Distribution Box Site Selections

# Select the CPU installation sit e. The CPU should be located in a cool, dry area. The

electronics are not protected against condensed liquid water inside the enclosure. The location
should permit easy viewing and access to the touch screen display. Maximum temperature in
the area should not exceed 100°F.

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

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

# Consider the distances to all of the distribution boxes (located near the probes). Distances of

250 feet or more away from CPU may require a remote power supply (depends on number of
probes).

# Distribution boxes are used to split off the RS485 signal to the probes. Distances from the

distribution boxes to the probe, or probes, should be kept to 15 feet or less, if possible. Cable
runs between distribution boxes can be hundreds of feet, although a remote power supply
might be needed.

- 6 -

These instructions cover installation of the RheoVac probes and SENTRY CPU in its standard
configuration. Additional information pertaining to your unit is covered in SECTION 6 — CUSTOM

INFORMATION. Carefully read these instructions prior to installing the equipment.

2.3 HOT TAP INSTALLATION

Î Check installation configuration. Make sure the probe is parallel to the floor (see Figure 4).

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

from the pipe surface.

Ð Install the mounting hardware. Drill a 1½” through hole and weld the thread-o-let 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.

Ñ It should be convenient to apply a restrictive or pulling force of between 9 and 11 lbs to

remove or replace the probes under plant operating conditions.

2.4 PROBE INSTALLATION

Î Check proper installation direction. The probe 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 of the probe. Choose a location for each probe (always reinstall probe

to same location). Custom labeling of the SENTRY screen with probe serial numbers or other
I.D. is possible - see Section 3.3.

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 this stay in place in
order for the probe to be installed correctly and to ensure the end of
the probe does not contact the opposing pipe wall. The clamp’s
location is determined based on the diameter of each pipe, 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 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 probes. Each probe should be mounted through the pipe

wall using a hot-tap assembly. The probe installs so that the two probe
tips (visible in the probe head) are side-by-side across the gas stream.
The probe has a flow directional arrow on the tag. When installing
under vacuum, do not allow the clamp to "slam" against the seal nut
upon opening the valve. Grasp the probe shaft firmly before opening
the ball valve. Allow the probe 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.

- 7 -

Figure 3 Transducer
Stop Clamp