CARRARO DC1525 User manual

I N S T R U C T I O N S
For the installation and maintenance of DC1525 - DC1550
desuperheaters
IMI0049E.doc
Rev.0 20/08/14
20090 SEGRATE (MI)- via E.Fermi
EMAIL: [email protected]
TEL.[phone] - FAX.[phone] Page 1 of 16

I N S T R U C T I O N S
For the installation and maintenance of DC1525 - DC1550
desuperheaters
IMI0049E.doc
Rev.0 20/08/14
20090 SEGRATE (MI)- via E.Fermi
EMAIL: [email protected]
TEL.[phone] - FAX.[phone] Page 2 of 16
MAIN INDEX
Pag.
1 General information ............................................................................................3
2 Guarantee ...........................................................................................................3
3 Validity of instructions..........................................................................................3
4 Safety indications.................................................................................................4
5 Safety warnings...................................................................................................5
6 Safety precautions...............................................................................................6
7 Transport, handling and storage..........................................................................7
8 Inst. and ass. instructions for DC1525 - DC1550
8.1 Cross-section drawings .....................................................................................8
8.2 Removing the packaging ...................................................................................9
8.3 Installation.........................................................................................................9
8.4 Start-up..............................................................................................................12
9 Maintenance........................................................................................................12
9.1 Removal ..............................................................................................................13
9.2 Disassembly........................................................................................................13
9.3 Spray cylinder......................................................................................................13
9.4 Body extension....................................................................................................14
9.5 Piston assembly...................................................................................................14
9.6 Packing gland......................................................................................................14
9.7 Re-assembly........................................................................................................14
9.8 Welding................................................................................................................15
9.9 Re-installation......................................................................................................15
10 Replacement parts...............................................................................................16
10.1 Inspection procedure ...........................................................................................16
10.2 Storage................................................................................................................16
11 Repairs................................................................................................................17
1. GENERAL INFORMATION:

I N S T R U C T I O N S
For the installation and maintenance of DC1525 - DC1550
desuperheaters
IMI0049E.doc
Rev.0 20/08/14
20090 SEGRATE (MI)- via E.Fermi
EMAIL: [email protected]
TEL.[phone] - FAX.[phone] Page 3 of 16
1.1. - RIGHT TO MAKE MODIFICATIONS AND "COPYRIGHT"
The regulations, standards etc. quoted in these instructions are valid at the time of preparation of this
document and are not subsequently updated. It is the duty of the user to take full responsibility for
applying the most up-to-date version of the standards and regulations in question.
The supplier reserves the right to make changes and technical improvements to data and information
whenever it sees fit to do so. The user shall on no account be entitled to claim a right of modification or
improvement in relation to desuperheaters already supplied.
2. GUARANTEE
The extent and duration of the guarantee are defined in the manufacturer's “General Conditions of Sale”.
The applicable conditions are those stipulated in the most up-to-date version in existence at the time of
delivery.
The guarantee does not cover, amongst other cases, damage to valves caused by the following:
°Ignorance of or non-compliance with these instruc tions for use!
°The work of personnel insufficiently qualified to undertake fitting, use or maintenance;
°Normal wear;
°Erroneous or negligent use of the desuperheaters.
The guarantee shall not be valid and the manufacturer shall accept no responsibility in the event of:
°Non-compliance with regulations for the preventio n of accidents and/or safety standards;
°Imperfect installation, poor commissioning and in correct use;
°Improper or incorrect use, inappropriate applicat ion or work conditions differing from those agreed.
The user shall bear sole responsibility in the event of physical and/or material damage deriving from
failure to observe the above.
3. VALIDITY OF INSTRUCTIONS
These instructions relate to variable area desuperheaters:
•DC1525 - DC1550 S
EE P ARAGRAPH 8) (Fig.1)

I N S T R U C T I O N S
For the installation and maintenance of DC1525 - DC1550
desuperheaters
IMI0049E.doc
Rev.0 20/08/14
20090 SEGRATE (MI)- via E.Fermi
EMAIL: [email protected]
TEL.[phone] - FAX.[phone] Page 4 of 16
4. PRODUCT SAFETY INDICATIONS AND TAG SYSTEM
If and where appropriate, safety indications have been put inside tags on the sides of the pages of this
manual.
These rectangular tags are placed vertically (as shown in the following examples) and contain four
different messages communicating:
- The level of risk;
- The nature of the risk;
- The effects of the risk on people or products;
- Instructions, if necessary, on how to avoid the risk.
The box at the top contains a warning word (DANGER – WARNING – CAUTION – ATTENTION) which
indicates the level of risk.
The box in the middle contains a drawing indicating the nature of the risk and its possible effects on
people and property. In some cases, the drawing may suggest what preventive measures can be taken,
such as wearing safety clothing.
The box at the bottom may contain a message with instructions on how to avoid the risk. In the event of
risks for people, the message may also contain a more precise definition of the risk and its effects on
people.
1) DANGER – Immediate risk which will certainly cause serious
injury or death.
2) WARNING – Risk or hazardous behaviour which may cause
serious injury or death.
3) CAUTION – Risk or hazardous behaviour which may cause
minor injury.

I N S T R U C T I O N S
For the installation and maintenance of DC1525 - DC1550
desuperheaters
IMI0049E.doc
Rev.0 20/08/14
20090 SEGRATE (MI)- via E.Fermi
EMAIL: [email protected]
TEL.[phone] - FAX.[phone] Page 5 of 16
5. SAFETY WARNINGS
Thorough maintenance operations and overhauls are important for the safe and reliable operation of all
desuperheaters.
The service procedures recommended by CARRARO and described in this manual are effective methods
for carrying out maintenance operations. Please note that this service manual contains various warning
and caution notices which should be read carefully in order to minimise the risk of injury to people or the
possibility of using incorrect work methods which may damage the desuperheaters or make them unsafe.
It is important to realise, however, that these warnings cannot be exhaustive.
CARRARO is unable to know, assess and inform customers or users of all the conceivable methods of
performing maintenance operations and all the risks deriving from the use of such methods.
Consequently, CARRARO has not even attempted to start such a task. Therefore, whoever uses a
service method or piece of equipment which is not recommended by CARRARO must make sure that
neither his own or other people's safety, nor desuperheater safety and performance are jeopardised by
the chosen method.
In case of doubt about the method used, please contact CARRARO.
Take all safety precautions while testing, installing or dismounting the product; these include, wearing ear
plugs, goggles and safety clothing, such as gloves, both in or near the work area.
Given the large number of conditions and circumstances that may arise while working on the products
and the consequent risks deriving from the way this is done, CARRARO is not able to prevent all risks of
injury to people and damage to property and can only help by asking you to take the utmost care and
giving you the following safety suggestions.
Users of CARRARO products are responsible for training the staff that will use the product.
It is most important for these people to acquire a thorough knowledge of the instructions relative to the
product, especially the ones contained in this manual.

I N S T R U C T I O N S
For the installation and maintenance of DC1525 - DC1550
desuperheaters
IMI0049E.doc
Rev.0 20/08/14
20090 SEGRATE (MI)- via E.Fermi
EMAIL: [email protected]
TEL.[phone] - FAX.[phone] Page 6 of 16
6. SAFETY PRECAUTIONS
Always follow the safety regulations applicable to the plant and observe the
following precautions:
° Wear protective clothing. Hot water causes burns and superheated
vapour is invisible.
° Before starting disassembly, make certain that the desuperheater is
isolated from any source of pressure that may exist within the system.
° Carry out checking/maintenance of desuperheaters at least once two
years.
° The outer surfaces of desuperheaters reach temperatures approximately
equal to the temperature of the fluid flowing through them. For this reason,
if fitting a desuperheater in a potentially explosive atmosphere, check that
the explosion point of the atmosphere surrounding the desuperheater is
sufficiently higher than fluid temperature inside the desuperheater itself,
and prevent deposits of dust from forming on its outer surfaces.
° In the connection between the desuperheater and line, ensure the
equipotentiality of the system in order to prevent the accumulation of
electro-static charges on the outer surfaces of the plant, which could act as
an effective trigger in a potentially explosive atmosphere.
° Before carrying out any work on desuperheater components, consult
CARRARO.

I N S T R U C T I O N S
For the installation and maintenance of DC1525 - DC1550
desuperheaters
IMI0049E.doc
Rev.0 20/08/14
20090 SEGRATE (MI)- via E.Fermi
EMAIL: [email protected]
TEL.[phone] - FAX.[phone] Page 7 of 16
7. TRANSPORT, STORAGE AND HANDLING
Transport
Carraro DS desuperheaters are packed with the utmost care in wooden
crates or cardboard boxes so that they are protected during handling and
transport to their place of installation. The connections are protected to
prevent the entry of dirt. Follow any directions marked on the packaging.
ATTENTION!
Personnel assigned to load-handling activities must take
all the necessary safety precautions.
Storage
The desuperheaters must be stored in a dry environment and protected
against atmospheric conditions. They must not be removed from their
crates or packaging until immediately before installation.
The protective materials on the connections must be left in place until the
last minute. Whether packed or not, the desuperheaters must not be
subject to violent impacts.
Whether packed or not, the desuperheaters must always be stored in an
upright position, i.e. never laid on one side, in order to prevent distortion
or damage to internal components.
Handling
When removing desuperheaters from their packaging and removing the
protective materials from the connections immediately prior to installation,
take the utmost care to prevent foreign matter from entering inside the
desuperheater.
ATTENTION!
When handling desuperheaters, keep the work area clear
in order to prevent damage to property
or injury to persons.

I N S T R U C T I O N S
For the installation and maintenance of DC1525 - DC1550
desuperheaters
IMI0049E.doc
Rev.0 20/08/14
20090 SEGRATE (MI)- via E.Fermi
EMAIL: [email protected]
TEL.[phone] - FAX.[phone] Page 8 of 16
8 INSTALLATION AND ASSEMBLY INSTRUCTIONS
DC1525 – DC1550
8.1 Cross-section drawings
• DC1525/IF1 – DC1550/ IF1
Pos. Part name Material
1+ 2 •Spray nozzle assembly AISI 316L
3 •Piston ring Aluminium bronze
4 •Piston AISI 316L
5 •Fastener ring Nitronic 60
6 Bushing Nitronic 60
7 •Stem AISI 316
8 •Plug AISI 316L
9 Body pipe AISI 316L
10 Liquid flange AISI 316L
11•Gasket PTFE + AISI 316L
12 • Packing set PTFE
13 Stud A-193 B8M
14• Follower AISI 316
15 Nut A-194 8M
16 Packing flange AISI 304
17 Nameplate AISI316L
18 Body AISI 316L
19• Seat AISI 316L
20 Cage AISI 316
21• Gasket PTFE +AISI 316L
22• Gasket PTFE + AISI 316L
23 Extension AISI 316L
24• Spacer Aluminium bronze
25 Bonnet AISI 316L
26 Extension AISI 316L
27• Bushing PTFE
28• O-rings Silicone
29 Disc Spring AISI 316L
30 Spacer AISI316L
• RECOMMENDED SPARE PARTS
Fig.1 – section and packing details

I N S T R U C T I O N S
For the installation and maintenance of DC1525 - DC1550
desuperheaters
IMI0049E.doc
Rev.0 20/08/14
20090 SEGRATE (MI)- via E.Fermi
EMAIL: [email protected]
TEL.[phone] - FAX.[phone] Page 9 of 16
8.2 REMOVING THE PACKAGING
Carraro DC desuperheaters are packed with the utmost care in wooden crates or cardboard boxes so
that they are protected during handling and transport to their place of installation. After hydrostatic testing,
the desuperheater is flushed and carefully dried to protect the internal surfaces. Should any damage
occur during transport, however, the transport company or a representative of Carraro must be notified
immediately. Remove the packaging with care, then check that the surfaces of the flanges, threads,
actuators, connection pipes, etc. are not damaged (see Fig. 1).
8.3 INSTALLATION
Before installation, visually inspect the desuperheater, the actuator and any accessories, to make certain
that they are not damaged. Check that the information given in the documentation and on the data plate,
and the tag number correspond to the specifications of the order. Remove the desuperheater from its
package by lifting it with slings (for heavy loads) wrapped round its body. Do not lift the unit by the liquid
inlet connection, the actuator or other accessories. Do not remove the flange coverings until immediately
before installation.
During installation of the desuperheater, use gaskets and fasteners which comply with the appropriate
standards. Position the gasket on the mounting flange and gently insert the nozzle into the secondary
pipe. Before tightening the studs, check that the spray cylinder is directed in the same direction as the
process gas flow (see Fig. 2).
The desuperheater must not be installed in such a way that it is subject to tensions, forces and torque.
- Liquid flange positions -
PFAn PFAe PFAs PFAw
- Handwheel positions -
PVn PVe PVs PVw
Fig. 2
The DC desuperheater has a standard lower body length as specified in the contractual drawings,
whereas the mounting trunk of the process pipe must be made to measure. The length of this secondary
pipe must be such that the central axis of the spray cylinder corresponds with the central axis of the
vapour line (±5 mm). The nominal diameter of the mounting trunk must be as follows: for DC1525 25 m
3
/h

I N S T R U C T I O N S
For the installation and maintenance of DC1525 - DC1550
desuperheaters
IMI0049E.doc
Rev.0 20/08/14
20090 SEGRATE (MI)- via E.Fermi
EMAIL: [email protected]
TEL.[phone] - FAX.[phone] Page 10 of 16
version - 3” (DN 80), with maximum tube schedule of 160; for DC1550 50 m
3
/h version - 4” (DN 100) with
maximum tube schedule of 160.
The minimum length of tube required downstream varies according to application and is specified by
Carraro in the respective quote. This length without bends is necessary to prevent erosion caused by
drops of liquid deposited on the walls of the pipes, the valves and the fittings, and is normally a minimum
of 4, 6 m (a straight length of pipe is not generally necessary upstream). The distance that separates the
desuperheater from the temperature sensor is between 12 and 15 m, although the specific distance for
the application is generally specified in the quote.
Longer distances ensure complete evaporation of the liquid at lower process gas speeds. The
temperature sensor must be located in the top half of the pipe. Avoid fitting branches of the vapour pipe
between the desuperheater and the sensor (see Fig. 3).
1) Temperature sensor
2) Temperature transmitter
3) Temperature control
4) Varicryo
5) Actuator
6) Positioner
7) Filter (Optional)
8) Auxiliary N2
9) Check valve
Fig. 3
The unit can be fitted on either horizontal or vertical pipes. The direction of liquid injection must
correspond to the direction of process gas flow. The desuperheater can be fitted at 90° to the vapour
pipe, regardless of direction of flow. The allowed orientations are outlined in Fig. 4. Vertically downwards
position must be achieved If installed horizontally, the unit must be mounted with a weight-compensation
system.