K-Patents DD-01 User Manual
WARNING
INSTRUCTION MANUAL
FOR DD-01
DIGITAL DIVERT CONTROL SYSTEM VERSION 4.1.
WITH MAIN PROGRAM 8.5 OR HIGHER
The process medium may be hot or otherwise hazardous. Precautions when removing the sensor from
the process line:
Make sure that the process line is not under pressure. Open a vent valve to the atmosphere. For a retractor/isolation valve the line pressure should be within specifications.
For a prism wash system, close a hand valve for the wash medium and disable the wash valve. Loosen the clamp or flange bolts cautiously, be prepared to tighten again. Be out of the way of any possible splash and ensure the possibility of escape.
Use shields and protective clothing adequate for the process medium. Do not rely on avoidance of contact with the process medium.
After removal of the sensor, it may be necessary to mount a blind flange for security reasons.
Document/Revision No. IMD 1/5 Effective: June 20, 2005
This product manual is delivered to the end-user with a K-Patents product. Information in this manual is
subject to change without notice. The latest manual version is freely available at http//www.kpatents.com/.
You can also contact manuals@kpatents.com.
THE PASSWORD FOR PR-01-S IS 7 8 4 5 1 2 IN PROGRAM VERSIONS 4.0 AND HIGHER.
K-PATENTS OY
Postal address:
P.O. Box 77
FIN-01511 Vantaa, Finland
Tel. + 358-9-825 6640
Fax +358-9-825 66461
E-mail: info@kpatents.com
http://www.kpatents.com/
K-PATENTS OY
Street address:
Elannontie 5
FIN-01510 Vantaa, Finland
Tel. + 358-9-825 6640
Fax +358-9-825 66461
K-PATENTS,INC.
1804 Centre Point Circle,
Suite 106,
Naperville, IL 60563
Tel. 630-955 1545
Fax 630-955 1585
E-mail: info@kpatents.com
http://www.kpatents.com/
1
1. TABLE OF CONTENTS
1 TABLE OF CONTENTS........................................................................................................................1
2 GENERAL INFORMATION .................................................................................................................2
2.1 Digital divert control system DD-01 .................................................................................................2
2.2 Operator panel...................................................................................................................................3
2.3 Alarms...............................................................................................................................................4
2.4 Prism wash ........................................................................................................................................4
2.5 Master divert control unit..................................................................................................................5
2.6 Indicating transmitters.......................................................................................................................6
2.7 K-Patents digital divert control unit specifications............................................................................7
3 MOUNTING...........................................................................................................................................8
3.1 Wiring ...............................................................................................................................................8
4 START-UP ...........................................................................................................................................12
4.1 Divert control unit start-up ..............................................................................................................12
4.2 Divert control system trimming.......................................................................................................12
5 CALIBRATION....................................................................................................................................13
5.1 Refractometer concentration measurement .....................................................................................13
5.2 Refractometer activation for divert control .....................................................................................13
5.3 Signal difference alarm ...................................................................................................................14
5.4 Low alarms......................................................................................................................................14
5.5 Refractometer malfunction alarm....................................................................................................14
5.6 Prism wash ......................................................................................................................................14
5.7 Divert decision rules........................................................................................................................15
6 MAINTENANCE .................................................................................................................................17
6.1 Information flow..............................................................................................................................17
6.2 Divert control circuit boards ...........................................................................................................18
6.3 Diagnostic messages........................................................................................................................23
6.4 Diagnostic lights..............................................................................................................................23
6.5 Push-button assembly......................................................................................................................24
6.6 Fuses................................................................................................................................................24
7 DIVERT CONTROL LOGIC...............................................................................................................25
7.1 Block diagram.................................................................................................................................25
7.2 Logical diagrams.............................................................................................................................26
7.3 Safety Decision Logics....................................................................................................................28
8 OPTIONAL CONFIGURATIONS.......................................................................................................30
8.1 Remote divert control unit...............................................................................................................30
8.2 Equipment .......................................................................................................................................30
8.3 Remote divert control unit in the control room ...............................................................................31
8.4 Wiring and mounting.......................................................................................................................32
8.5 Serial output ....................................................................................................................................34
8.6 Current output signal.......................................................................................................................34
8.7 External DC power supply ..............................................................................................................34
9 DIVERT CONTROL UNIT PARTS LISTS.........................................................................................35
9.1 Divert control unit and optional remote divert control unit.............................................................35
9.2 Remote divert control unit...............................................................................................................36
INSTRUCTION MANUAL FOR DD-01 DOCUMENT/REVISION: IMD 1/5
Effective: June 20, 2005
2
2. GENERAL INFORMATION
The K-Patents Digital Black Liquor Divert Control System DD-01 provides a divert signal preventing black
liquor with dangerously low solids to reach the black liquor burners. The system is built strictly according to
the principles of Recommended Good Practice "Safe Firing of Black Liquor in Black Liquor Recovery Boilers" (BLRBAC August, 1982 and revisions April, 1991, and March, 2001).
2.1. DIGITAL DIVERT CONTROL SYSTEM DD-01
Figure 2.10 Complete Digital Divert Control System DD-01
The system consists of the following parts (Figure 2.10): Two K-Patents Process Refractometers PR-01-S (A
& B) are installed in series in the main black liquor line. Each refractometer is complete with a Sensor, an
Indicating transmitter and Interconnecting cables. Each refractometer provides also a 4-20 mA % solids output
signal not used by the divert control system.
The Divert Control Unit DD-01 is contained in one enclosure with the same dimensions as the refractometer
Indicating transmitter enclosure. The control unit includes:
- an operator panel
- control logics
- contact outputs for prism wash, warnings, alarms and black liquor diversion
- Two isolation valves HIMP-2 (optional) for the refractometers above to allow removal of
the refractometers from a pipe with full flow and pressure. The isolation valve includes a
prism wash nozzle and two check valves (one for prism wash, one for stuffing box flush).
- A roofed mounting plate to mount the two Indicating transmitters and the Divert Control
Unit together.
- Two steam valves with steam traps for prism wash (pneumatic + solenoid valves).
- Two hand valves (one for prism wash, one for stuffing box flush).
- One alarm horn (supplied by the customer).
Note. BLRBAC (The Black Liquor Recovery Boiler Advisory Committee) recommends a spare sensor to be
maintained in stock on-site.
INSTRUCTION MANUAL FOR DD-01 DOCUMENT/REVISION: IMD 1/5
Effective: June 20, 2005
3
2.2. OPERATOR PANEL
3
4
5
7
6
Figure 2.20 The operator panel.
The operator panel has a clear layout and the operator can see all information at one glance. The divert decision is controlled from the operator panel which provides doubled security, since all information is simultaneously shown both as LED indication in the Divert Control Unit and as a diagnostic messages in the Indicating
Transmitters (Figure 2.20).
Each refractometer has a green OPERATING light (1), so the operator knows when he can rely on the refractometer measurement. A refractometer will influence the divert decision only when the green OPERATING
light is on. A malfunctioning refractometer is automatically taken out of operation. One green indicator light
SAFE% SOLIDS (2) is based on the two refractometers and the divert decision rules (Section 5.7).
One red DIVERT light (3) that will be switched on when the SAFE% SOLIDS goes off. The DIVERT light
indicates divert status of the divert relay. The divert relay has an output switch contact, for use in the Black
Liquor Firing Tripping Logic. The relay is OFF in the DIVERT position, because a power failure will give a
DIVERT decision.
A lockable OVERRIDE/AUTOMATIC switch (5) and a red OVERRIDE warning light (4) is ON always if
switch in OVERRIDE position. If the SAFE% SOLIDS goes OFF and this switch is in the OVERRIDE position, then the OVERRIDE light is lit instead of the DIVERT light. One RESET push-button (6) for the
DIVERT action. The DIVERT action always has to be manually reset. If the override switch is in Automatic
position and SAFE% SOLIDS is off, the DIVERT action cannot be reset.
One EMERGENCY DIVERT push-button (7) to manually initiate DIVERT in an OVERRIDE or emergency
situation. The DIVERT light is lit also after manual divert action. The EMERGENCY DIVERT button has a
protective hinged cover, to prevent inadvertent use.
Two indicator lights (8) for the divert valve status TO BY-PASS/TO BURNER from microswitches on the
valve. For intermediate valve positions both lights are off.
A row of four alarm lights (9) that indicate black liquor SOLIDS WARNING (at 60%), black liquor SOLIDS
ALARM (below 58%), refractometer reading more than 2% absolute difference and refractometer malfunction.
INSTRUCTION MANUAL FOR DD-01 DOCUMENT/REVISION: IMD 1/5
Effective: June 20, 2005
4
A light test button (10) switches all 11 lights on. An alarm reset button (11) resets the alarm lights. For normal
operation the operator panel has four green lights on (A OPERATING/B OPERATING/ VALVE TO
BURNER/SAFE% SOLIDS).
2.3. ALARMS
The divert control system has four alarms, audible and indicating:
1. Black liquor SOLIDS WARNING, yellow light (60% or below)
2. Black liquor SOLIDS ALARM, red light (58% or below)
3. Refractometers reading more than 2% absolute DIFFERENCE, yellow light
4. Refractometer MALFUNCTION, yellow light
The alarms 1, 2 and 4 are initiated by either refractometer. System contains also optional alarms, see wiring
drawing 3.11.
The operator panel contains four indicator lights and an ALARM RESET button. The reset button will silence
the audible alarm, but the visual indication will remain until the condition has returned to normal.
To avoid unnecessary alarms the following interlocks are implemented:
- A refractometer can initiate an alarm only when it is operating.
- Alarm 4 can be initiated only if both refractometers are operating.
The parameters (2%, 58% and 60%) are default settings, which can be changed from the Indicating transmitter
keyboard (Sections 5.3 and 5.4). The parameter for 2% can be decreased and the parameter for 58% and 60%
can be increased.
2.4. PRISM WASH
For K-Patents Process Refractometer, the need of prism wash is reduced and even in some cases eliminated.
The prism keeps clean due to the probe design features:
- The prism is flush mounted in a surface deflecting the black liquor main flow, which causes
a strong mechanical cleaning action.
- The prism has the same temperature as the black liquor.
In any case, however, an automatic regular prism wash provides an efficient check that the refractometer reacts. A steam wash of 3 seconds every half hour should be sufficient. Automatic single (one-of-two) diversion
will occur if either of the refractometers is in wash cycle.
The Divert Control Unit contains two relays for prism wash, WASH A and WASH B. To follow the BLRBAC
recommendation not to wash both prisms at the same time, there is an interlock. If both refractometers try to
wash simultaneously, one will display "WAIT" and perform the wash when the other has finished.
K-Patents recommends to use a steam trap instead of preconditioning valve to remove condensate from the
steam line. The wash times can be seen pressing soft keys "Display"/"System configuration"/"Wash times". To
change the wash times, see Section 5.6.
INSTRUCTION MANUAL FOR DD-01 DOCUMENT/REVISION: IMD 1/5
Effective: June 20, 2005
5
2.5. MASTER DIVERT CONTROL UNIT
Figure 2.50 Operator’s panel and functions of the master divert control unit in the field with LED
indications.
1. Black liquor SOLIDS WARNING (at
60%), Black liquor SOLIDS ALARM (below 58%), Refractometer reading more than
2% absolute difference, and Refractometer
malfunction).
2. Each refractometer A and B has an
OPERATING green light, A refractometer
will influence the divert decision only when
the green OPERATING light is on. A malfunctioning refractometer is automatically
taken out of operation.
3. One green indicator light SAFE%
SOLIDS, based on the two refractometers
and the divert decision rules.
4. A red OVERRIDE warning light is on
always if the override switch is switched on.
5. One red DIVERT light that will be
switched on when the SAFE% SOLIDS
goes off. The DIVERT light indicates divert
status of the divert relay.
6. Two indicator lights for the divert valve
status. TO BY-PASS/TO BURNER from
microswitches on the valve. For intermediate valve positions both lights are off.
7. A lockable Override/Automatic divert
switch
8. A DIVERT RESET push-button.
9. An EMERGENCY DIVERT push-button.
10. A light test button switches all 11 lights
on.
11. An alarm reset button resets the alarm
lights.
INSTRUCTION MANUAL FOR DD-01 DOCUMENT/REVISION: IMD 1/5
Effective: June 20, 2005
6
2.6. INDICATING TRANSMITTERS
An Indicating transmitter in a Divert Control System is identical (both hardware and software) to a standard
transmitter described in the PR-01-S Instruction manual.
1
3
2
CONC
PROCESS TEMPERATURE
TEST
109.3
In divert co ntrol operation
Removed
Start
fro m d iv
prism
wash
A
7
4
1
0
C a lib ra te
control
B
8
9
56
2
3
.
-
22.1
A
°C
Display
D
C
K-PTENTS
PROCESS INSTRUMENTS
RESET
ENTER
5
4
Figure 2.60 The Indicating transmitter.
The display, Figure 2.60, will give the following additional information pertinent to the Divert system:
1. A or B in the upper right corner indicates that the
transmitter is OPERATING in the divert system as refractometer A or B, Figure 2.10. If a or b is displayed
instead, the refractometer is removed from divert control operation. (If the upper right corner is empty, see
Section 5.2). For A or B the corresponding green
OPERATING light, Figure 2.20, is on, for a or b it is
off.
If you see a ? in this corner, see Section 5.2.
2. A softkey (B) defined by "Remove from divert control"
or alternatively "Restore to divert control". The visible
effects of pressing "Remove" for refractometer A is
that the soft key changes to "Restore", A switches to a,
and the green OPERATING light goes off. Further the
"Remove" soft key disappears from refractometer B,
because B must not be removed if it is the only refractometer in operation.
Note. Always press "Remove" for a refractometer before making service or switching the power off.
3. The "Normal operation" message is substituted by
"In divert control operation" or "Removed from divert control". Those messages may change to "Solids warning" or "Solids alarm" at low solids. An additional error message may occur: ** Divert control
fault ** combined with a ? in the upper right corner,
see Section 6.3.
4. The softkey "Display" (D) leads via "System configuration" (C) to "Divert control system" (D) which
gives the following information:
Refractometer difference alarm limit in % solids
Solids warning limit in % solids (default
value 60%)
solids alarm limit in % solids (default value 58%)
Divert rule and SW1/SW2 positions (Section 5.7)
5. The softkey "Calibrate" (C) gives possibilities to set
up for divert control and calibration, see Chapter 5.
INSTRUCTION MANUAL FOR DD-01 DOCUMENT/REVISION: IMD 1/5
Effective: June 20, 2005
7
2.7. K-PATENTS DIGITAL DIVERT CONTROL UNIT SPECIFICATIONS
Model: DD-01
Enclosure: IP66 Nema 4X, dimensions 226 x 267 mm (8.91 x 10.5 in)
Supply: 24 V DC, provided by the Indicating transmitters
Ambient temperature: max 45 °C (113 °F)
Accessory: Roofed mounting plate for the Divert Control Unit and 2 Indicating
transmitters, Figure 2.60.
Material: AISI 316, dimensions 916 x 488 mm (36 x 19.2 in)
Figure 2.70 Divert Control Unit Mounting Plate: Dimensions (mm/in)
Figure 2.71 Divert Control Unit and Indicating Transmitter Enclosures: Dimensions (mm/in)
INSTRUCTION MANUAL FOR DD-01 DOCUMENT/REVISION: IMD 1/5
Effective: June 20, 2005
8
3. MOUNTING
For mounting of the process refractometer and the isolation valve, consult the separate Refractometer
PR-01-S(-EX/FM) Manual.
3.1. WIRING
Wiring for the complete system, see Figure 3.10 and Figure 3.11 which describe also all cables and how each
cable is connected.
The cables 1 and 2 are included in the delivery. The terminal strip positions of the Divert Control Unit are
specified in Figure 3.11 and Figure 3.12.
Figure 3.10 Divert Control System Wiring Cables and Connections
INSTRUCTION MANUAL FOR DD-01 DOCUMENT/REVISION: IMD 1/5
Effective: June 20, 2005
9
Figure 3.11 Divert Control System Wiring and Connections
INSTRUCTION MANUAL FOR DD-01 DOCUMENT/REVISION: IMD 1/5
Effective: June 20, 2005
10
Figure 3.12 Cable connections
INSTRUCTION MANUAL FOR DD-01 DOCUMENT/REVISION: IMD 1/5
Effective: June 20, 2005
11
RN1
C43
C1
R2
C2
R3
C3
R4
C4
R5
C5
R6
C6
J1
L1
R1
R14
C18
C19C20
C46
K4
C44
C47
IC30
K-PATENTS PR-7310 Rev.C
F2
C8
IC2
IC1
R15
D2
1A
C7
C45
V1
D1
C48
C49
C9
C10
C23
1
IC11 IC10
IC12
RN4
IC13
RN5
C21
IC14
F1
1A
RE1 RE8RE7RE6RE5RE4RE3RE2
V2
IC15
D15
IC16
D16
V3
IC3
C11
IC5IC4
C24
C22
R16
V4
K7K6K5 K14
DIVERT CONTROL UNIT
RN2
C12
IC6
C13
IC7
C14
X1
R7
C25
C26
D10 D12
K1 K2
C27
IC17
D5
IC8
IC18
D7
C28
C29
R8
C30
IC19
D6
SW
D8
X2
87654321
IC22
SW1
C16 C15
C31 C33
IC23
R10
R9
C17
IC9
IC20IC21
RN7
C37
D13D11
14 1413 1312 1211 1110 109988
D17
D18
D26D25D24D23D22D21D20D19
R24R23R22R21R20R19R18R17
V6
V5 V9
K8 K13
V7
V8
K11K10
K12K9
TP1
+5V
D3
RN3
D4
IC24
J2
RN6
C32
IC27
D14
C35
D9
C52
C39
C34
IC26
C38
K3
1615
EXT24VSERIAL BUS BSERIAL BUS A
D27 D28
C50
R25
R26
D29
D30
D31
63mA 63mA
F3 F4
R28
TP4
D32
TP3
TP2
C36
C40
C41
R12
R13
C42
C51
GND
IC25
R11
SGND
IC28
IC29
R27
SWGND
VALVE
37 403938363534333231302928
BURNERBYPASS
L
N
AC-POWER
27191817 26252423222120
WARN.
SOLIDS
ALARM
NORM.
DIVERT
A
B
SOLIDS
HORNWASH WASH
REF.DIFF.
OVERRIDE
POSITION
DANGER HIGH VOLTAGE
Figure 3.13 Divert control circuit board, layout.
INSTRUCTION MANUAL FOR DD-01 DOCUMENT/REVISION: IMD 1/5
Effective: June 20, 2005
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