WCF Pall Filter Training

c

TVA Pall Filter Training for HLP22

Operations Continuing Training

Tennessee Valley Authority

TVA

2 Pall Filter Training for HLP22

Table of Contents TABLE OF CONTENTS ..................................................................................................................

LIST OF FIGURES ....................................................................................................................... 3

STUDENT OBJECTIVES .............................................................................................................. 4

Controls and Gauges .....................Gauge Observations ...

...............................................................................................................................................................5 ..................................................................................................................................................................................6

Connecting the Supply Voltage.............................................................................................................................................................8 Motor Rotation Check..............................................................................................................................................................................10

Air Flow PaOil Flow Path..........................................................................................................................................................................11

Prestarth.................................................... ...................................................................................................................................... 12

Energizitup ...................................................................................................................................................................................................13 ng ..........................

Starting....................................................................................................................................................................................................... 15

Running and Adjust..................................................................................................................................................................................18 ing..........................................................................................................................................................................2

Gauge Observations.................................................................................................................................................................................1

Heater............. 22

Heater Set Po..........................................................................................................................................................................23int..

Stopping Unit...........................................................................................................................................................................24 ...........

Draining Purifier..................................................................................................................................................................................27

............Theory of Operation............

....................................................................................................................................................................28

.........Component Identificat

............................................................................................................................................................29

Vacuum Pump Relief Vion.....................................................................................................................................................................30 alve...

Maintenance Schedule.......................................................................................................................................................................31

Replacing the Inlet Breath....................................................................................................................................................................32 er........................

Cleaning the Inl.......................................................................................................................................32

Investigating thet Strainer...................................................................................................................................................................33 e Alarms and W

Major Alarm #1...................................arnings.......................................................................................................................................33

Dirty Filter Warn........................................................................................................................................................36

Service the Vacuing/Shutdown........................................................................................................................................................37 um Pu

PLC Battery mp Soon........................................................................................................................................................38

Dirty Filter WLow..........................................................................................................................................................................................39

HMI Screens...arning 2.............................................................................................................................................................................39

Menu Page #...............................................................................................................................................................................................40

Menu Page #1..............................................................................................................................................................................................41 2

Tower Level..................................................................................................................................................................................................42 ..............................................................................................................................................................................................43

Alarm History..............................................................................................................................................................................................44 ........................................................................................................................................................


List of Figures Figure 1 Controls .....

Gauges ...................................................................................................... 5 ............................................................................................... 6

Figure 2 Figure 3 Vacuum Gauge .......................................................................................... 7 Figure 4 Power Cabinet ............................................................................... 8 Figure 5 Main Disconnect ........................................................................................ 9 Figure 6 Major Alarm #1 ........................................................................................ 10 Figure 7 Oil Flow Path ............................................................................... 11 Figure 8 Air Flow Path ................................................................................ 12 Figure 9 Vacuum Pump Gear Oil Level ..................................................... 13 Figure 10 Drains and Vents ..................................................................................... 14 Figure 11 Plugged Breather ..................................................................................... 15 Figure 12 Power Switch ........................................................................................... 15 Figure 13 Boot Screen ............................................................................................. 16 Figure 14 Purifier Ready Screen .............................................................................. 17 Figure 15 Purifier Ready Screen .............................................................................. 18 Figure 16 Control Panel Stopped............................................................................. 19

Figure 17 Control Panel Started ............................................................................. 20 Figure 18 HMI Screen Running ............................................................................... 20 Figure 19 Running and Adjusting............................................................................. 21 Figure 20 Gauges 2 ................................................................................................. 22 Figure 21 Heater Controls ........................................................................................ 23 Figure 22 HMI Heater SetPoint.................................................................................24 Figure 23 HMI Heater Setpoint 2...................................................................,,,,,,.....26 Figure 24 Control Panel Stopped......................................................................,,,,,,.27

Figure 25 HMI Purifier Draining..........................................................................28 Figure 26 Front View..........................................................................................30

Figure 27 Rear View...........................................................................................30 Figure 28 Relief Valve........................................................................................31 Figure 29 Breather Replacement.......................................................................32

Figure 30 Cleaning Strainer...............................................................................33 Figure 31 AlarmInvestigation..............................................................................35 Figure 32 Relay Settings....................................................................................36 Figure 33 Dirty Filter Indications.........................................................................37 Figure 31 AlarmInvestigation..............................................................................35 Figure 32 Relay Settings....................................................................................36 Figure 33 Dirty Filter Indications.........................................................................37 Figure 34 Vacuum Pump Indications.................................................................38 Figure 35 HMI Screens......................................................................................40 Figure 36 Menu Page #1....................................................................................41 Figure 37 Menu Pge #2......................................................................................42 Figure 38 Tower Alarm.......................................................................................43 Figure 39 Alarm History.....................................................................................44


Student Objectives

To review the components of the Pall Filter H

o review the correct operation of the Pall Fil

LP22....................................................................

ter HLP22...........................................................

..

T To understand the oil flow path of the Pall Filter HLP22............................................................... To understand the air flow path of the Pall Filter HLP22........................................................... To identify the major and minor alarms associated with the Pall Filter HLP22................... To be able to bring up and review the alarm history for the Pall Filter HLP22....................


Controls and Gauges A = HMI (human machine interface) B = Main Disconnect C = Alarm Beacon D = Start Button ** E = Stop Button **

on sure Door Locks

F = Heater Enable/Disable Switch G = Alarm Reset ButtH = Electrical Enclo

Figure 1


Gauge Observations

= Inlet Pressure = Tower Vacuum Gauge

= Oil Temperature Gauge = Differential Pressure Gauge olishing filter)

123 = Outlet Pressure Gauge 45(P6 = Vacuum Pump BackpressureGauge

Figure 2


Figure 3


Connecting the Supply Voltage

order for Pall Corporation to meet the needs of all end-users the Purifier electrical enclosure not provided with a supply voltage “knock out” port. The end-user must drill a hole in the lectrical enclosure for delivery of the supply voltage. he supply voltage should be connected where shown below. The electrical panel is suitable for YE configured electrical service only. Contact factory if Delta configuration is desired. The

nd-user must provide supply voltage with adequate ground fault and circuit breaker protection ns

IniseTWein accordance with Federal, State, Local and plant regulatio

Figure 4


.

Figure 5


Motor Rotation Check The Purifier will automatically detect if the sequence of the supply voltage has been properly connected. There is no need to bump start the motors to check for rotation. If the supply voltage is out of sequence the purifier will alert the operator with an alarm as shown below. Refer to section 11.1 to correct the situation.

Figure 6


il Flow Path

oil will pass through the Oil Purifier as indicated by the gold arrows. are identified with numbers which correspond directly to the number

und on the hydraulic schematic drawing.

valve (#22) and returned to the oil reservoir.

O During normal operationKey system componentsfoOil is drawn into the Purifier via the pump/motor group (# 4 / 6). The fluid passes the inlet gate valve (#31) and inlet strainer (#1). Fluid travels through the check valve (#7), dissolved water sensor (#8), heater (#9), sight glass (#10), and delivered to the vacuum tower (#15). Oil is removed from the vacuum tower via a second pump/motor group (#18&18a). Oil is passed through a polishing filter (#20), check

Figure 7


ir Flow Path

hortly after starting the Oil Purifier the vacuum pump & motor (#25 & #26) will start and air ithin the vacuum tower will be exhausted. Ambient air will be drawn into the vacuum tower rough the inlet breather filter (#11) and vacuum adjustment valve (#13). Filtered air will travel

here.

A Swthupwards through the vacuum tower (#15) and into the vacuum pump (# 26). Air leaves the vacuum pump, travels through the heater exchanger (#5), into the coalescer (#29), through theknock out tank (T), and exhausts to atmosp

Figure 8


re-Startup Checks

heck vacuum pump gear oil level (photo below, see maintenance section for oil type and fill

ance section for change-out procedure).

P Cprocedure) • Close all drains and vents (locations indicated below). • Completely open the inlet gate valve (#31). • Open all valves in the oil supply line to the purifier. • Open all valves in the oil return line from the purifier to the reservoir. • Verify condition of inlet air breather (see mainten

Figure 9


Figure 10


Energizing and Boot-up Turning the main disconnect to the “ON” position will “boot up” the Oil Purifier. During the boot-

p process the HMI will display screens as shown below. When the boot-up process is ompleted the HMI will display the HOME page with the words “PURIFIER READY”.

Figure 11

uc

Figure 12


Figure 13


Figure 14


Starting the Purifier Complete sections 7.1, 8.3, & 8.4 first! Ensure all valves connecting the Oil Purifier to the reservoir are 100% open. Only after the Purifier has booted up and the HMI displays “PURIFER READY” can be started. To start the purifier press the “START” button on the front panel. The start button will illuminate immediately after the start button is pressed. After the purifier starts the HMI screen will display “PURIFIER RUNNING”.

Figure 15


Figure 16


Figure 17

Figure 18


Running and Adjusting A few seconds after pressing the start button the inlet and outlet pumps will start (which one starts first depends on the oil level within the tower). Several seconds later the vacuum pump will start and tower vacuum will begin to build. Oil will be seen flowing in the upper sight glass. The oil level within the tower will become stable in the lower sight glass. Shortly thereafter, if the heater is enabled, it may come on depending on the heaters set point in relation to the current temperature. With the purifier running make the following adjustments and observations: Adjust the tower vacuum to approximately 17-18” Hg using the needle valve (#13). Clockwise rotation of the needle valve will increase tower vacuum. Counter-clockwise rotation will decrease tower vacuum. Note: Adjust the tower vacuum to 16” Hg or less if the water content in the oil is above 100% saturation (see the photo below which indicates where to read the % saturation). Caution: When adjusting the needle valve, use only ½-turn (180 degree) or ¼-turn (90 degree) increments. It may take up to 60 seconds for the tower vacuum to stabilize. Do not over adjust. Vent air trapped within the polishing filter housing using the needle valve (32).

Figure 19


Gauge Observations 2 The gauge cluster is shown below. After approximately 60 seconds all gauges should be within the range stated on the placard located below the gauge. If the operator observes a reading outside the stated ranges the Purifier may issue an alarm condition. The operator should turn to the troubleshooting section of this manual for further instructions.

Figure 20


eater

he heater is enabled/disabled using the ON/OFF switch located on the front panel. When the eater is enabled the heater logic determines when to energize the heater. When the heater is nergized the switch will illuminate.

H The

Figure 21


Changing Set Point The heater set point is factory set at 120oF (49oC). The set point is adjustable using the purifier’s HMI (human machine interface). The set point can be changed if the purifier is running or not. From the HMI home, page press F2, which corresponds to “HEA” which is short for “heater”.


hanging Set Point 2

rom the heater control screen press F3 to bring up the heater set point screen. The heater set oint can now be adjusted. Heater control is not password protected. se the F2 & F3 keys to raise or lower the heater set point temperature. ressing the F2 or F3 key one time will adjust the temperature by one degree. ress and hold the F2 or F3 key to scroll the numbers more quickly. hen the desired set point is reached, press F1 to return to the home page.

old Startup Condition - Oil Viscosity Above 1000 cSt (4650 SUS) he Oil Purifier will not run properly with fluids having a viscosity above 1000 cSt. The user hould be aware of cold fluid conditions resulting from hoses lying on cold floors. During colder onths of the year, users are advised to drain fluid from purifier supply line hoses when the oil urifier is not being used. It is especially important to keep fluid supply lines to the oil purifier as hort as possible to minimize the effects of cold fluid introduction.

Figure 22

C FpUPPW CTsmps


Kinematic Viscosity

amed after es

Sometimes expressed in terms St)

Symbol (St) NGeorge Gabriel Stok

of Centistokes. (c

Figure 23


Stopping Unit To stop the Purifier press the “stop” button. The heater and all pumps, motors will stop and the stop button will illuminate as shown below.

Figure 24


Draining the Purifier Considerations Prior to Draining: The Oil Purifier is equipped with an automTo maximize the effectiveness of the drain mode, the user should disconnecline from the inlet of the purifier. This will prevent additional fluid from being purifier and allow for better drainage overall. If the above-mentioned procedpurifier will have approximately 1 gallon of fluid still left on board. If more draining is desired, the user should manually drain the heater, vacuum tower and polishing filter using the manual ball valves located at the bottom of each of these components. Enabling Drain Mode: The operator should read and understand the section above: “Considerations Prior to Draining”. • To activate the drain mode the purifier must be stopped and the power energized. • Press and hold the stop button for 5 seconds. After 5 seconds the HMI screen will display the screen below and the user can release the stop button. • The user can now start the automatic drain mode by pressing the start button. At that time the inlet pump will run for 45 seconds, and the outlet pump for 90 seconds. The operator will see the seconds counting down on the screen. • The user may also start and stop either the inlet or outlet pump individually. Pressing and holding the F1 key will start the inlet pump; pressing the F4 will start the outlet pump

When draining is complete, exit to the “Home Page” by pressing F2 (HOME)

atic draining feature. t the fluid supply drawn into the ure is followed the

•

Figure 25


ation

il contaminated with water, gas, and particulate is purified on-board the Purifier.

es its former volume (depending on vacuum set oint). As the inlet air volume expands 4-fold, the relative humidity of that air decreases 4- fold.

The resulting air inside the tower has effectively been dried. The contaminated oil is drawn into the purifier via the inlet fluid pump. The oil passes through the heater and enters the top of the tower. The oil cascades from the top of the tower to the bottom via gravity, passing through a column of stainless steel rings in the process. While the contaminated oil travels down the column, water trapped in the oil converts from a liquid phase to a gaseous phase. The gasses trapped in the oil will expand as per Boyles Law

Theory of Oper ODry air in the tower is obtained by expansion: Ambient air is drawn into the tower by the vacuumpump, and expanded to approximately 4 timp

. As the oil travels down the column the vacuum pump maintains airflow through the tower. Water vapor and expanded gases are removed through the top of the tower by the vacuum pump and are discharged to atmosphere downstream of the vacuum pump. Dry, degassed oil at the bottom of the tower is drawn out via the fluid pump and passed through the absolute rated filter before returning to the reservoir.

Boyle's Law, a principle that describes the relationship between the pressure and volume of a gas. According to this law, the pressure exerted by a gas held at a constant temperature varies inversely with the volume of the gas. For example, if the volume is halved, the pressure is doubled; and if the volume is doubled, the pressure is halved. The reason for this effect is that a gas is made up of loosely spaced molecules moving at random. If a gas is compressed in a container, these molecules are pushed together; thus, the gas occupies less volume. The molecules, having less space in which to move, hit the walls of the container more frequently and thus exert an increased pressure.


omponent Identification

C

Front View A = Gauge Cluster B = Electrical Enclosure 3 = Inlet Pressure Sensor

24 = Vacuum Pump Relief Valve ** ump

ure

ressure

7 = Inlet Check Valve15 = Vacuum Tower

g Pad 15A = Demistin16 = Fluid Level Sight Glass

26 = Vacuum P27 = Coalescer BackpressSensor 28 = Vacuum Pump Back PGauge

Figure 26

Rear View 1 = Inlet Strainer 4 = Inlet Fluid Pump 5 = Exhaust Air Cooler 6 = Inlet Pump Motor 9 = Heater 10 = Flow Sight Glass 11 = Inlet Air Breather Element 15 = Vacuum Tower 18 = Outlet Pump Motor 20 = Polishing Filter 22 = Check Valve (outlet) 23 = Check Valve 25 = Vacuum Pump Motor 29 = Coalescing Filter (air) 31 = Inlet Gate Valve T = External mounted variable frequency drive (VFD)

Figure 27


Vacuum Pump Relief Valve The vacuum pump relief valve is factory set and should not be adjusted. The valve is properly set by rotating the knob clockwise until the stop is reached. The valve requires no service or adjustment.

Figure 28


aintenance Schedule

eplacing the Inlet-Air Breather

eplacing Inlet Air Breather hile running, the Oil Purifier introduces filtered air into the vacuum tower through the inlet air

reather. The breather is fitted with a visual indicator. The inlet air breather should be changed pon indication. ote: The HMI screen will not alert the operator when to change the breather; it is the perator’s responsibility to check the indicator on a regular basis (weekly). ote: Do not discard the indicator it can be unscrewed and re-used on the new breather filter.

M

R RWbuNoN

Figure 29


Cleaning the Inlet Strainer The Oil Purifier is fitted with a strainer to protect the inlet fluid pump. becomes blocked a warning will be displayed on the HMI (turn to secinlet strainer should be cleaned and inspected a minimum of 1 time p

vestigate d Warnings

The HMI (human machine interface) located on the front panel of the Oil Purifier will alert the operator of current running conditions and alarm or warning cond ajor” or “minor” alarm condition is detected the HMI will change to a red color and cross the screen. When multiple alarms are present the most recent alarm warning” condition is detected the HMI will turn a brown/yellow color and fla e screen.

If the inlet strainer tion 11.5 for details). The er year.

Figure 30

In Alarms an

itions. If a “m flash a message awill be displayed. If a “sh a message across th


mperature Shutdown Section 11.3 Major Alarm #3: Inlet Pump Motor Contactor Failure Section 11.4 Major Alarm #4: Vacuum Pump Motor Contactor Failure

• Section 11.5 Major Alarm #5: Inlet Pump Cavitation • Section 11.6 Major Alarm #6: Change Exhaust Coalescer • Section 11.7 Major Alarm #7: High Tower Level Shutdown • Section 11.8 Major Alarm #8: Low Tower Level Shutdown • Section 11.9 Major Alarm #9: Outlet Pump Motor / Drive Overload • Section 11.10 Major Alarm #10: Inlet Pump Motor Overload • Section 11.11 Major Alarm #11: Vacuum Pump Motor Overload • Section 11.12 Major Alarm #12: Dirty Filter Warning / Shutdown • Section 11.13 Major Alarm #13: Tower Fluid Level Sensor Signal Loss • Section 11.14 Major Alarm #14: Outlet Pump Motor Drive Fault <###> • Section 11.15 Major Alarm #15: Outlet Pump Motor Drive Comm.Loss List of Minor Alarms • Section 11.101 Minor Alarm #101: Heater Thermocouple Signal Loss • Section 11.102 Minor Alarm #102: High Oil Temperature at Water Sensor • Section 11.103 Minor Alarm #103: High Water Saturation • Section 11.104 Minor Alarm #104: Heater Contactor Failure • Section 11.105 Minor Alarm #105: Condenser Fan Motor Contactor Failure • Section 11.106 Minor Alarm #106 Condenser Fan Motor Overload List of Warnings • Section 11.201 Warning #201: Service Vacuum Pump Soon • Section 11.202 Warning #202: PLC Battery Low….Replace Soon • Section 11.203 Warning #203: Dirty Filter • Section 11.204: Warning #204: Not used • Section 11.205: Warning #205: Water Saturation Probe Signal Loss • Section 11.206: Warning #206: Change Vacuum Pu p Exhaust Coalescer Soon

List of Major Alarms • Section 11.1 Major Alarm #1: Phase Reversal / Low or High Voltage • Section 11.2 Major Alarm #2: High System Te• •

m


Figure 31


” alarm when the upply voltage is out of the expected range. Listed below are the 4 possible causes for this larm. The HMI does not identify which of the 4 conditions is causing the alarm, only that an larm condition exists. Phase Reversal – supply voltage is out of phase, switch 2 of 3 supply voltage legs. Phase Loss – one or more of the supply voltage legs is not energized Low Voltage – the voltage supplied to the purifier is below the lower threshold. High Voltage – the voltage supplied to the purifier is above the upper threshold.

o determine which of the 4 possibilities is causing the alarm the operator must open the lectrical panel and view the lights on the sensor.

Major Alarm #1 The Oil Purifier will announce the “PHASE REVERAL/LOW/HIGH VOLTAGEsaa• • • •

Te

Explanation of LED Light Sequences Normal Operation – Green LED on & Red LED’s off

ing of

& Red Low

Red

Phase Loss – Green LED flashing

Phase Reversal – Alternating flashGreen & Red LED’s Low Voltage – Green LED flashingVoltage LED on High Voltage – Green LED flashing &High Voltage LED on

Figure 32


hutdown

ifferential pressure (dP) r 24 hours, the purifier will

dP warning. The y drops.

n timer from part one reaches ll shut down and issue an alarm on

Dirty Filter Warning/S The status of the discharge filter is constantly monitored for elevated dThe purifier will continue to run. If the high dP condition continues foshut down. Note: Elevated fluid viscosity due to cold oil may trigger the warning may go away if the oil warms and the viscositPart 2: “DIRTY FILTER SHUTDOWN” – When the countdow“0” and the elevated dP condition still remains, the purifier withe HMI (shown above).

Figure 33


Service Vacuum Pump Soon The Oil Purifier will issue a vacuum pump service warning after 8760 hours (365 days) of run time have been logged. The operator should plan on changing the vacuum pump timing gear oil within the next 7 days. Turn to section 10.3 of this manual for instructions on changing the gear oil. After the gear oil is replaced the service timer needs to be reset to 8760 hours. This can be done by pressing the “RST” button and then typing in 8760 as shown below.

Figure 34


LC Battery Low

een

2354 lithium ion. For details regarding how to replace the battery, refer or

hen pressure across the main fluid filter reaches approximill be displayed on the HMI. Review section 11.12 for detailequence.

P The purifiers PLC used an on board battery. When the battery becomes drained the HMI scrwill announce a PLC Battery Low warning. The user should change the battery within 7 days.The battery type is CRto the appendix section corresponding to the PLC which is contained within this operatmanual.

Dirty Filter Warning W ately 35 psid a dirty filter warning

s about the entire filter alarm ws


MI Screens

ome Page

ch F button corresponds to. From any screen the operator can avigate back to the home page by pressing the F key corresponding to HOM.

H HFrom the home page the operator can navigate to all other screens. The home page displays the temperature and % saturation of the oil entering the purifier upstream of the heater. Pall Corporation has chosen to display this information because it most closely represents thecurrent conditions with the customer reservoir. F1 to F4 buttons correspond to the items circled in yellow. For example pressing F1 will navigate the operator to the system run time screens. Similarly, pressing F4 will call up the menu which lists what ean

Figure 35


enu Page #1

enu Page #1

M MF1= Home Page F2 = Run Time Screens F3 = Heater Control F4 = Saturation Sensor (Pall water sensor) F5 = Filter Status F6 = VFD (variable frequency drive) F7 = Tower Level F8 = Vacuum Pump Status F9 = Next (navigates to Menu page #2)

Figure 36


enu Page #2 enu Page #2

MMF1 = Home Page F2 = Alarm History F3 = Contact Information F8 = Exhaust Coalescer Status F9 = Next (navigates to Menu page #1)

Figure 37


ower Level id within the tower and its set-point can be viewed by pressing F7 (Tower Level)

om menu page #1. The operator can toggle from inches to centimeters by pressing F2. This creen is only for reference; the fluid level cannot be adjusted.

TThe level of flufrs

Figure 38


larm History (Menu Page #2)

he purifiers PLC will log alarm conditions as they occur. To view the history of alarms which ave been logged navigate to Menu page #2 then press F2 which corresponds to Alarm History. fter pressing F2 the alarm history will be displayed with the most recent alarm showing in

creen shot below). To exit press “HOME” (F1).

T

A ThAposition 0 (see s

Figure 39



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