K-Patents DD-23 User Manual
PROCESS INSTRUMENTS
INSTRUCTION
MANUAL
IM-EN-DD23 Rev. 1.42
DIGITAL DIVERT
CONTROL SYSTEM
DD-23
Table of contents
1 Introducon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 The Divert Control System DD-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Divert Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3.2 Green indicator lights: System ok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3.3 Yellow indicator lights: Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3.4 Red indicator lights: Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3.5 White pushbuons: Tesng and reseng . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3.6 Header wash key: Enabling ring header wash . . . . . . . . . . . . . . . . . . . . . . . 6
2.3.7 Emergency divert buon: Manual divert . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3.8 External emergency divert buon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Prism wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Indicang transmiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Mounng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Mounng prism wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2.1 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Switch inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3.1 External Divert switch/push buon - input J8 . . . . . . . . . . . . . . . . . . . . . . 10
3.3.2 External divert reset buon - input J9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3.3 Header wash key - input J10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Remote ethernet connecon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 Divert system pre-startup checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Divert control unit DD-23 startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Configuraon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Calibraon lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Divert decision rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3 Refractometer concentraon measurement . . . . . . . . . . . . . . . . . . . . . . . . 17
5.4 Refractometer acvaon for divert control . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.5 Signal difference alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.6 Low alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.6.1 Solids warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.6.2 Solids alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.7 Refractometer malfuncon alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.8 Prism wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6 Regular maintenance and troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1 Informaon flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 Malfuncons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3 Diagnosc tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.4 Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.4.1 A queson mark (?) on the refractometer display . . . . . . . . . . . . . . . . . . 23
6.4.2 A refractometer refuses to come on-line . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.4.3 No lights come up in the Divert Control Unit . . . . . . . . . . . . . . . . . . . . . . 24
6.4.4 All lights are blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7 Divert control logics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.1 Safety decision logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.2 Divert decision logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.3 In operaon logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.4 Malfuncon logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.5 Reseable alarm logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.6 Refractometer difference logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.7 Wash arbitraon logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.8 Wash check logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8 Remote control interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1 Divert Control Unit IP address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.2 The remote interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.2.1 Main page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.2.2 Instrument pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.2.3 Diagnoscs page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.2.4 Log page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2.5 Parameters page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.3 Data logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9 DD-23 specificaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.1 Divert Control Unit specificaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.2 Divert control unit spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10 Oponal Remote Divert Terminal DD-23-RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.1 Mounng instrucons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.2 Startup and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10.3 Troubleshoong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
A Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1 Introducon
The K-Patents Digital Black Liquor Divert Control System DD-23 provides a divert signal preventingblack 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 April
2010; the document is available at
http://www.blrbac.org/Sept2010Updates/Safe_Firing_of_Black_Liquor_April_2010.pdf).
The system consists of the following parts: Two K-Patents Process refractometers
PR-23-SD (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 two 4–20 mA output signal not used by the
divert control system. These can be used to give % solids output or temperature output signals. The sensors are also equipped with a steam wash nozzles although the
self-cleaning sensor design may eliminate the need for prism wash altogether.
1.1 Warranty
K-Patents warrants that all products made by K-Patents shall be free of defects in material and workmanship. K-Patents agrees to either replace or repair free of charge,
any such product or part thereof which shall be returned to the nearest authorized
K-Patents repair facility within two (2) years from the date of delivery.
1
Before returning a defective product for service or replacement, please contact K-Patents or your nearest K-Patents representative (see http://www.kpatents.com/ for
contact information). For the health and safety of personnel handling your return,
clean the instrument, especially the parts that have been in contact with the process
liquid, before packing it. Ship the cleaned instrument to the address given to you.
1.2 Disposal
When disposing of an obsolete instrument or any parts of an instrument, please observe the local and national requirements for the disposal of electrical and electronic
equipment. The aluminium or stainless steel sensor housing can be recycled with
other metallic waste of the same type.
2
Figure 1.1 Complete Digital Black Liquor Divert Control System DD-23
2 The Divert Control System DD-23
2.1 Overview
The Divert control system DD-23 includes:
− A Divert Control Unit
− Two isolation valves SDI for the refractometers above to allow removal of the re-
fractometers from a pipe with full low and pressure. The isolation valve includes
a prism wash nozzle and two check valves (one for prism wash, one for stufing
box lush).
− A roofed mounting plate to mount the two Indicating transmitters and the Divert
Control Unit together.
− Wiring to connect the Indicating transmitters with the Divert Control Unit.
− Two steam valves with steam traps for prism wash (pneumatic + solenoid valves).
− Two hand valves (one for prism wash, one for stufing box lush).
− A remote operator panel facility, accessible with a web browser over Ethernet
BLRBAC (The Black Liquor Recovery Boiler Advisory Committee) recommends a
spare refractometer sensor to be maintained in stock on-site.
3
2.2 Divert Control Unit
The Divert Control Unit is contained in an enclosure with the same dimensions as the
refractometer transmitter enclosure. The control unit includes:
− An operator with system state indicators and pushbuttons
− Relay outputs for connecting to the control system
− Contact inputs for external control
− Ethernet interface for remote operator panel
2.3 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 information is shown both as LED indication in the Divert control
unit and as a diagnostic messages in the Indicating transmitters. The same information is also available through the remote operator panel.
4
Red indicator
lights (alarms)
Yellow indicator
lights (warnings)
Green indicator
lights (all well)
White pushbuttons
Red push-button
2.3.1 Overview
Figure 2.1 DD-23 operator panel
The three top rows on the operator panel consist of indicator lights. The green A IN
OPERATION and B IN OPERATION lights are also push buttons used to include the refrac-
tometers in the Divert system. Below the lights there are push buttons and the HEADER
WASH key key used to operate the system.
The indicator lights on the operator panel are arranged like trafic lights: top row is
red for alarm, middle row is yellow for warning and bottom row is green for "system
ok". When the system is running normally, only the row of green lights should be lit.
The white LIGHT TEST button is used to check that all the LEDs behind the indicator
lights are working. It also veriies the data processing system in the control unit. The
other two white push buttons, ALARM RESET and DIVERT RESET can be used to reset
the system back to normal after all problems have been ixed. The HEADER WASH key
enables the use of ring header washing with water, when set to ON.
The big red EMERGENCY DIVERT push button is used to manually initiate divert in an
emergency situation. An external push button can also be connected to a switch input
in the control unit as External Emergency divert button, see Section 2.3.8.
2.3.2 Green indicator lights: System ok
Each refractometer has a green operating light – A IN OPERATION and B IN OPERATION –
to let the operator know when he can rely on the refractometer measurement. A refractometer will only inluence the divert decision and activate warnings and alarms
when it is in divert operation, i.e. when its green operating light is lit.
When DIVERT is effective, the system may be reset to normal operation only when
SAFE SOLIDS is lit.
2.3.3 Yellow indicator lights: Warnings
The SOLIDS WARNING light indicates a black liquor concentration of below warning
limit (by default at 60%). This warning can be activated by either refractometer.
The A&B DIFFERENCE light is lit when the refractometer readings differ by at least 2%.
This warning will only be initiated if both refractometers are operating.
If the yellow MALFUNCTION light is switched on, some part of the system – a refractometer, an indicating transmitter or the control unit – is malfunctioning. A list over
malfunctions and critical malfunctions is given in Section 6.2. If a critical malfunction
occurs in a sensor or transmitter, the malfunctioning refractometer will be automatically removed from divert operation (its operating light will also be switched off).
Check the reason for the malfunction and correct the problem (see Section 6.4) before returning the refractometer back to divert operation.
5
2.3.4 Red indicator lights: Alarms
The black liquor SOLIDS ALARM is lit when the concentration reading goes below alarm
limit (by default below 58%). This alarm can be activated by either refractometer
depending on the operation rule setting.
The DIVERT light will be switched on when the SOLIDS ALARM is activated. The DIVERT
light indicates divert status of the divert relay. The relay is inactive in the divert position, because then a power failure will give a divert decision signal to the system.
The OVERRIDE light is lit to indicate that no automatic divert will happen as long as
the system is in the header wash state (see Section 2.3.6).
2.3.5 White pushbuons: Tesng and reseng
The LIGHT TEST button switches all 12 lights on. The ALARM RESET button resets the
alarm lights.
6
2.3.6 Header wash key: Enabling ring header wash
The header wash key function is a 3-level procedure which can be used when ring
header washing with water is needed. When the HEADER WASH key is switched to ON
position and information from black liquor guns switch inputs connected in series tell
that guns are out from recovery boiler, then a ring header wash can be done without
activating Divert.
Pushing the EMERGENCY DIVERT button will always initiate divert regardless of the
header wash functionality.
2.3.7 Emergency divert buon: Manual divert
The EMERGENCY DIVERT push-button is used to manually initiate divert in an emergency situation.
2.3.8 External emergency divert buon
An external (remote) push button can also be connected to an input inside the Control
unit, see Figure 3.3.
External emergency divert button must be normally closed (NC). Opening the circuit
will initiate divert.
2.4 Prism wash
The wash parameters for the sensors are set through each transmitter (Section 2.4).
The transmitters contain a relay for prism wash. To follow the BLRBAC recommendation not to wash both prisms at the same time, the Divert Control Unit implements an
interlock which prevents the instrument from washing both sensors simultaneously.
2.5 Indicang transmiers
Mechanically the Indicating transmitters shipped with a DD-23 are the same than
PR-23 Indicating transmitter DTR. The transmitter will only allow single sensor connection and a special DD-23 transmitter software is used for the Divert system. When
Divert software is 2.01 or newer, Indicating transmitter software version has to be
4.12 or newer.
For more information on the basic functions of an indicating transmitter, please see
the PR-23 manual, chapters 3 and 10.
3 Mounng
For mounting of the process refractometers and the isolation valves, consult the separate process refractometer PR-23 instruction manual.
7
Figure 3.1 Mounng the Divert control system
3.1 Mounng prism wash
K-Patents recommends to use a steam trap instead of a preconditioning valve to remove condensate from the steam line.
8
3.2 Wiring
For wiring for complete system, see Figure 3.2 which shows the connections to the
Indicating transmitters and to steam washing. Figure 3.3 has information of all connections to the Divert control unit.
Figure 3.2 Transmier wiring cables and connecons
3.2.1 Relays
Relay 1 NORMAL/DIVERT information
Relay 2 NORMAL/DIVERT information
Relay 3 SOLIDS WARNING: when one of the refractometers goes lower than the
solids warning limit, typically 60% or higher. See Section 5.6.1.
Relay 4 SOLIDS ALARM: when one of the refractometers goes lower than the solids
alarm limit, typically 58% or higher. See Section 5.6.2.
Relay 5 Refractometer signal difference warning: when the refractometerreadings
have more than 2% difference in concentration. See Section 5.5.
Relay 6 Horn relay: connection to the audible alarm. See Section 7.5.
Relay 7 Header wash key information. See Section 3.3.3.
Relay 8 Refractometer A malfunction information. See Sections 6.2 and 7.4.
Relay 9 Refractometer B malfunction information. See Sections 6.2 and 7.4.
Relay 10 Information on if refractometer A is active in the Divert Control System or
dropped off.
Relay 11 Information on if refractomter B is active in the Divert Control System or
dropped off.
9
Figure 3.3 Divert control unit internal wiring
10
3.3 Switch inputs
3.3.1 External Divert switch/push buon - input J8
An external divert switch can be connected to the DD-23 Divert Control Unit, input J8.
If the external divert switch is not used, a jumper has to be connected across J8. The
unit is delivered with this jumper connected.
3.3.2 External divert reset buon - input J9
If you want to use external Divert reset button, it can be connected max. 200 m (600 ft)
from the DD-23 Divert control unit. Use normal instrument cable 2x0.5 (AWG 20) and
connect cable to DD-23 motherboard input J9.
You must make sure both refractometers A and B are working OK before starting to
use the remote divert button (the remote interface can be used to check on the refractometers, see Chapter 8).
The external reset button connection is normally open (NO).
3.3.3 Header wash key - input J10
Black liquor is injected to the recovery boiler through liquor guns. Occassionally the
header ring needs washing and during that procedure the divert system has to be
by-passed and the liquor guns have to be removed from the furnace. The Digital Divert
Control System DD-23 allows for a safe override of divert logic during header ring
wash.
The override is mounted by connecting the gun micro switches in series to the Header
wash/override key switch input J10, see Figure 3.5.
The Header wash key may be used without the external switch information if a jumper
(dotted line in Figure 3.5) is placed to swith input J10. If the input is left open, the key
does not have any effect.
11
DD-23
Operator panel
OVERRIDE
HEADER WASH
HEADER
WASH
KEY
MICROSWITCH
on each liquor gun or
on liquor gun door
Recovery
boiler
Guns out microswitches
HEADER
WASH
KEY
SWITCH INPUT
J10
Figure 3.4 Header wash key funconality
Figure 3.5 Header wash key connecons
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