Hydro Instruments VPH-10000-2 Series Manual
1
Series VPH-10000-2
Vaporizer
Instruction and Operation Manual
VPH-10000-2 Rev. 5/7/15
2
Hydro Instruments VPH-10000-2 Vaporizer
Table of Contents
I. Introduction............................................................................................................ 3
1. Safety Information
2. System Size, Capabilities, and Specifications
3. Units of Measurement
II. Installation.............................................................................................................. 5
1. Installation of the Vaporizer
2. Installation of Chlorine Pressure Piping
3. Installation of Auxiliary Components
1. Electronic Pressure Reducing Valve
2. Pressure Relief Valve Assembly
3. Expansion Chamber Assembly
4. Electrical Installation
1. Connecting the Main Power
2. Wiring Relays and Alarm Outputs
3. Modbus Information
III. Operation.............................................................................................................. 14
1. Leak Testing
2. Initial Start-Up
3. System Start
4. System Shut Down
1. Short Term Shut Down
2. Long Term Shut Down
5. Navigating the Controller
1. Explanation of Main Controller Screens
6. Operating Controls and Components
1. Chlorine Gas Temperature Thermocouple
2. Chlorine Gas Pressure Transmitter
3. Water Tank Temperature
4. Water Level Control
5. Water Re-Fill Solenoid
6. Cathodic Protection System
7. Water Heater
7. Alarms and Features
IV. Maintenance......................................................................................................... 23
1. Yearly Maintenance
1. Chlorine Pressure Chamber Cleaning
2. Alarms and Switches Testing
3. Component Preventative Maintenance
2. 5-Year Chlorine Pressure Chamber Cleaning and Inspection
V. Troubleshooting ................................................................................................... 26
VI. Important Figures, Parts and Dimensional Drawings
1. Wiring Diagrams ...................................................................................... 10-12
2. Assembly Diagrams ................................................................................. 28-30
3. Vapor Pressure Curves.............................................................................. 31-33
3
I. INTRODUCTION
The contents of this manual are intended to provide information regarding the installation, operation,
maintenance and troubleshooting of Hydro Instruments’ VPH-10000-2 vaporizer. It is critically important
to read and become familiar with the contents of this entire manual before proceeding to install or operate
the unit. If you have any questions please consult Hydro Instruments.
In certain instances throughout this manual, reference may be made specifically to chlorine. However,
the information may also apply to sulfur dioxide and ammonia systems. Please consult with Hydro
Instruments if using this product for a chemical other than chlorine.
For more information on chlorine safety and handling practices, please refer to the following documents
from the Chlorine Institute:
The Chlorine Manual, Sixth ed. Washington: The Chlorine Institute, Inc., 2000.
Pamphlet 1: Chlorine Basics, Seventh ed. Washington: The Chlorine Institute, Inc., 2008.
Pamphlet 6: Piping Systems for Dry Chlorine. Fifteenth ed. Washington: The Chlorine Institute, Inc.,
2005.
Pamphlet 155: Water and Wastewater Operators Chlorine Handbook, Second ed. Washington:
The Chlorine Institute, Inc., 2008.
1. Safety Information
Warning
• Chlorineisahazardouschemicalthatcancauseinjuryanddeathifnothandledproperly.Itis
critically important to take all necessary precautions when handling. This manual is not intended
to replace or limit safety procedures in your facility.
• Safetyproceduresmustbedesignedinaccordancewithallgovernmentalregulationsandnational
safety codes, after giving full consideration to the specific needs of the facility involved. Under no
circumstances should the information in this manual be construed as substituting or superseding
any local, state, or federal laws and regulations.
• HydroInstrumentscannotanticipatethespecicsafetyproceduresrequiredateveryfacility.
Accordingly, Hydro Instruments does not guarantee that safety procedures designed in accordance
with this manual will completely eliminate hazards and thus assumes no liability for accidents that
may occur in your facility.
• Readthisentiremanualandbefullyfamiliarwithyourequipmentandyourentiresystemsothat
the safety procedures you establish will meet the needs of the employees in you facility. Reading
only part of the manual will not help you analyze the needs of your facility. Contact your chlorine
supplier, the chlorine institute, and other similar organizations to obtain MSDS sheets and more
information.
• Allinformationinthismanualwascurrentattimeofprinting.Pleasenotethedateofprinting
and possible obsolescence of material as a result of scientific and medical developments after the
date of publication. This applies to all materials you review in the course of developing safety
procedures for use at your facility.
4
When working with Chlorine
• Ensurethatapproved,self-containedbreathingandsafetyequipmentarealwaysavailableand
ready for use and personnel are properly trained for its use.
• Safetyequipmentshouldbeinspectedandmaintainedinaccordancewiththemanufacturer’s
instructions.
• Ensurethatallwarningsignsandplacardsareintheirappropriateplaceandcanclearlybe
displayed.
• Intheeventofaleak,usepropersafetyequipmentandtrainedpersonneltorespondtotheleak
immediately. Evacuate all personnel from dangerous areas to a safe space. If breathing has
stopped perform respiration immediately. If heart has stopped perform CPR.
• Knowledgeabledesignpersonnelshouldoverseeandapproveequipmentinstallationandsuitability
of the system for which it is intended. Qualified personnel should also perform routine equipment
checks and maintenance in accordance with manufacturer’s recommendations and instructions.
2. System Size, Capabilities and Specifications
Overall height: 64" (163 cm)
Clearance space required: 24" (61 cm) on all sides. 12' (3.7 m) floor to ceiling.
Chlorine pressure chamber dry weight: roughly 360 lb (163 kg)
Water tank dry weight: roughly 430 lb (195 kg)
Total assembled dry weight: roughly 790 lb (358 kg)
Rated working pressure: 560 psi (38.6 bar) - hydrostatically tested to 825 psi
(56.9 bar)
Supply pressure: 38 – 210 psi (2.6 – 14.5 bar) Cl2and SO2
48 – 210 psi (3.3 – 14.5 bar) NH3
Maximum capacity: 10,000 PPD (200 kg/hr) Cl2
8,000 PPD (150 kg/hr) SO2
2,500 PPD (50 kg/hr) NH3
Maximum heater output: 18 kW
Power consumption: Single phase power: 120 VAC or 240 VAC
Three phase power: between 240 VAC (44 A max)
and 480 VAC (22 A max)
Ambient temperature: 50-122ºF (10-50ºC)
Recommended torque for
pressure chamber flange bolts: 275 lb-ft (3802 N-m)
3. Units of Measurement
For convenience, common measurement values (temperature, pressure, length, mass, torque) will be
given in both English and equivalent Metric units. Throughout this manual, pressure values will be
shown in units of psi (bar) and denote gauge pressure (zero-referenced against atmospheric pressure.)
5
II. INSTALLATION
1. Installation of the Vaporizer
The VPH-10000-2 is supplied completely assembled. The user should install the vaporizer in a
location that has at least 12 ft. (3.65 m) of space from floor to ceiling. A lifting crane should also be
available at the location and should have a minimum lifting capacity of 2 tons. Additional overhead
space should be factored in for the lifting crane. The lifting crane can be used to connect to the two
1" eyebolts located on the top flange to remove the pressure chamber or move the entire vaporizer
assembly. To access the eyebolts the user must remove the fiberglass cabinet. Once in position, the
vaporizer should be bolted to the floor by the use of four, 5⁄8" concrete anchor bolts through the bottom
plate. If installing multiple vaporizers, Hydro Instruments recommends leaving at least 2 feet of
clearance space between each vaporizer for ease of access.
If using automatic water control, a ½" water pipeline should be installed to the water solenoid valve.
The water should have a minimum supply pressure of 15 psi (1 bar) and not exceed 60 psi (4 bar).
Drain ports from the vaporizer consist of a 1.5" drain valve, a 1¼" water overflow pipe and a 1¼" vent
pipe. For convenience all drain pipes are located on the rear side of the unit and must be plumbed on
site.
Inlet and outlet connections to the vaporizer are made through 1" NPT ammonia type unions. The
inlet connection is made through the center of the top flange. Improper installation of the inlet and
outletpipingcanleadtoseriousmalfunctionoftheunitandpossiblepersonalinjury.Theliquid
chlorine inlet port is on the center of the top flange and the chlorine gas outlet port is off center. For
added convenience, the ports are also stamped “IN” for the liquid inlet and “OUT” for the gas outlet.
2. Installation of Chlorine Pressure Piping
Connections to the vaporizer are made through the use of 1" ammonia type unions. Chlorine pressure
piping should be made of seamless schedule 80 carbon steel, and fittings must be 3000 lb forged type.
For more information on chlorine pressure piping and vaporizer piping design tips please see Chlorine
Institute’s pamphlet 6 and Hydro Instruments’ Vaporizer Piping Guide EVP-002-CL2.
3. Installation of Auxiliary Components
3.1 Electronic Pressure Reducing Valve
The electronic pressure reducing valve is an integral part of any vaporizer system. The electronic
pressure reducing valve is the device that will stop chemical feed in the event of an alarm condition.
This will prevent liquid chemical from contacting and damaging downstream equipment.
Hydro Instruments’ vaporizer allows the user to install two electronic pressure reducing valves into
the main controller. One is for operation, and the other for standy-by which can be switched to using
the main controller (see Section III.5). The electronic pressure reducing valve must be installed
downstream of the vaporizer, after the pressure relief valve assembly and filter but before the vacuum
regulator. Available in either 120 VAC or 240 VAC single phase power, the hot wire (black) should be
wired into N.O. 1 (CB-8RELAY) and the neutral wire (white) should be wired into the neutral bar in
the relay connections box, with the green wire going to ground. If using a second electronic pressure
reducing valve use N.O. 5 (CB-8RELAY). Ensure that power is disconnected from the vaporizer
before installation. Further information is available through Hydro Instruments’ electronic pressure
reducing valve instruction manual.
6
3.2 Pressure Relief Valve Assembly
The pressure relief valve assembly is a critical component to any chlorine vaporizer system and
is required by ASME code for operation. This mechanical safety device limits the pressure of the
chlorine pressure chamber to a maximum value. The rupture disc must be properly installed into the
rupture disk holder prior to installing the rupture disk assembly onto the pipe. Installation to the gas
pipeline is made through the use of 1" Ammonia type unions. The pressure relief valve assembly
should also be installed as close as possible to the vaporizer gas outlet of the pressure chamber. No
other interferences can be installed between the outlet of the vaporizer and the rupture disc of this
assembly. This assembly must be installed horizontally and in the upright position. Piping coming out
of the relief valve must be 1.5" schedule 80 seamless carbon steel and slope downward outside or to
another safe location with an insect screen on the outside end.
The pressure relief valve assembly also includes a pressure switch that may be wired into the signal
output connections box of the vaporizer for Modbus indication of rupture disc failure. It will be wired
into the V- and DI4 input terminals.
3.3 Expansion Chamber Assembly
The expansion chamber assembly is a mechanical safety device used on liquid chemical lines to
prevent pipe rupture in the event of an over pressure condition. Thus, an expansion chamber assembly
must be installed everywhere that the liquid has the potential to become trapped in the pipe. This
includes sections of pipe that could become isolated through ball valves. In any section of pipe that
an expansion chamber is installed on, it must be located at the highest point of this pipe section. The
volume of the expansion chamber must also be sized so that its volume is not less than 20% of the pipe
volume it is protecting. Supports should also be provided to the expansion chamber assembly.
The expansion chamber assembly comes with a pressure switch that may be wired into the signal
output connections box of the vaporizer for Modbus indication of rupture disc failure. It will be wired
into the V- and DI3 input terminals.
7
4. Electrical Installation
4.1 Connecting the Main Power:
The VPH-10000-2 requires three phase power. All power connections are made through the heater
control box.
Warning: Electrical shock hazard. Ensure all power is disconnected from the source before
proceeding. Ensure that only qualified personnel are working on this equipment.
a. Turn the single phase power switch off.
b. Turn the three phase disconnect switch to the off position. This will allow access to the heater
control box.
c. Unscrew the four screws on the front of the heater control box.
d. Feed the three phase cable and conduit through the 1" conduit fitting on the left side of the heater
control box. Ensure fitting is air tight.
e. Connect the three phase power into the appropriate terminals (Figure 1a-b). Be sure to tie the
ground wire to the ground block. The three phase power is for the heater, which is a delta wiring
arrangement and thus no neutral wire is needed.
f. Close the heater control box and insert screws.
g. Connect power to main source.
h. Ensure that the manual contactor override switch is in the enable position.
i. Turn the single phase and three phase disconnect switches on.
4.2 Wiring Relays and Alarm Outputs
Warning: Electrical shock hazard. Ensure all power is disconnected from the source before
proceeding. Ensure that only qualified personnel are working on this equipment.
TheVPH-10000-2comeswithtwopre-wiredjunctionboxesforwiringrelays,contactsand4-20mA
outputswithouthavingtoaccessthemaincontroller.Thejunctionboxlabeled“RelayConnections”
containstheterminalsforwiringalltherelaysandalarmcontactoutputs.Thejunctionbox
labeled “Signal Connections” contains the terminals for wiring the 4-20 mA outputs and Modbus
communication. The terminal designations can be seen in Table 1 and Table 2.
8
TABLE 1: Relay Designations for Vaporizer Alarms and Relays
Parameter Terminal Range
Gas Pressure AO1 0 - 300 psi (21 bar)**
Gas Temperature AO2 0 - 121°C (32 - 250°F)
Superheat Temperature AO3 0 - 121°C (32 - 250°F)
Control Water Temperature AO4 0 - 121°C (32 - 250°F)
NOT USED IN MODEL VPH-10000-2 AO5 -
Expansion Chamber Switch DI3 closed = alarm
Pressure Relief Valve Switch DI4 closed = alarm
* Wired from the factory.
TABLE 2: 4-20 Output Designations
NOTE: All outputs must also be wired to the appropriate V- (GND) terminal.
**Pressure range can be adjusted but must match the pressure transducer's specifications.
4.3 Modbus Information
The VPH-10000-2 can communicate with a SCADA system using Modbus RS-485 communication.
The baud rate, node number and data format of the VPH-10000-2 must match that of the master
SCADA system. See Section III.5 for information on how to access and edit these features. A table
of Modbus integers and their corresponding parameters can be seen in Table 3. For more information
on configuring Hydro Instruments equipment onto SCADA systems, please refer to the Modbus
Installation and Instruction manual.
Vaporizer Alarm/Relay Board Number Relay Number Recommended Wiring
Electronic Pressure
Reducing Valve 1 CB-8RELAY 1 N.O.
*Refill Solenoid CB-8RELAY 2 N.O.
Not used CB-8RELAY 3 -
*Magnetic Contactor CB-8RELAY 4 N.O.
Electronic Pressure
Reducing Valve 2 CB-8RELAY 5 N.O.
Superheat Alarm CB-8RELAY 6 N/A
High Pressure Alarm CB-8RELAY 7 N/A
Water Level Alarm CB-8RELAY 8 N/A
Low Water Temperature Alarm CB-2RELAY 1 N/A
High Water Temperature Alarm CB-2RELAY 2 N/A
9
TABLE 3: Modbus Information
Name Type Address Register
Value Feature
Gas Temperature Integer 1
Gas Pressure Integer 2
Gas Pressure Span Integer 3
High Pressure Alarm Level Integer 4
Superheat Temperature Integer 5
Superheat Alarm Set Point Integer 6
Control Water Temperature Integer 7
Water Temperature Set Point Integer 8
High Temperature Alarm Set Point Integer 9
Low Temperature Alarm Set Point Integer 10
NOT USED IN MODEL VPH-10000-2
Integer 11
Water Level Integer 12
0 Normal
1 High
2Low
3 Low Low
Heater Power Output (kW) Integer 13
Heater Power Output (%) Integer 14
Heater Element Temperature Integer 15
Temperature Units Integer 16 0 Celsius
1 Fahrenheit
Pressure Units Integer 17 0 PSI
1 Bar
Alarm Status Integer 18
0 Normal
2Low Water Temperature
3High Water Temperature
4Heater Over Temperature
5Superheat Alarm
6High Water Alarm
7Low Water Alarm
8 PRV Burst Disc
9 EXP Burst Disc
10 High Pressure
10
FIGURE 1: Heater Control Box Diagram for Power
3PH
Power In
11
FIGURE 2: Main Controller Wiring
PRESSURE RELIEF VALVE PRESSURE SWITCH
EXPANSION CHAMBER PRESSURE SWITCH
MB181 MB122 MB140 MB114
NOT USED
12
FIGURE 3: Relay Output Box
MB108
MB123
Low Water Temp Alarm
High Water Temp Alarm
Water Level Alarm
Superheat Alarm
Optional PRV #2
Heater Contactor
Not Used
Solenoid
PRV #1
High Pressure Alarm
Ground (Green)
Line 1 (Black)
Connect
PRV #1 Here
Line 2 (Red)
Solenoid
Line 2
Contactor
Line 2 (Red)
Line 2 (Red)
Line 2 (Red)
13
FIGURE 4: Vaporizer Controller
MAIN CONTROLLER
CATHODIC PROTECTION
CONTROL & AMMETER
HEATER
CONTROL BOX
MANUAL CONTACTOR
OVERRIDE
WATER LEVEL
INDICATOR
THREE PHASE
DISCONNECT SWITCH
CONTACTOR INDICATOR
STATUS (ON = ENERGIZED)
SINGLE PHASE
DISCONNECT SWITCH
FIGURE 4: Vaporizer Controller
14
III. OPERATION
1. Leak Testing
Please refer to and follow the leak testing procedure outlined in this section before performing the
initialstart-up,ifthepipinghasbeenchanged,ifthevaporizerhasjustbeencleaned,orforother
situations in which air/moisture has been allowed to enter the system.
Warning: When performing this step, ensure that all protective equipment is available.
Warning: Before beginning the leak test ensure that all appropriate measures have been taken
to remove any cutting oils and/or unwanted residue from the piping system. These residues can
cause accelerated pipe corrosion and result in a leak.
NOTE: Before performing this step, be sure to read Hydro Instruments “Nitrogen Purging” document
for further information.
a. Individually leak test all expansion chamber assemblies and pressure relief assemblies before
beginning this test procedure. Also, test the operation of the pressure switch in each expansion
chamber assembly and pressure relief assembly before beginning this procedure.
b. Ensure that piping is installed correctly and securely. Also check to ensure that all the chlorine
container valves are closed and that no chlorine is in the manifold piping.
c. Connect a dry air or nitrogen supply to the end of the chlorine manifold through a ball valve
suitable for chlorine manifold service. Make sure that required pressure controls are installed to
ensure that the nitrogen or dry air pressure entering the manifold cannot exceed 150 psi (10 bar).
d. Purge the system piping with a supply of dry air or nitrogen to remove any moisture or debris (for
more information, refer to the Chlorine Institute’s pamphlet 6).
e. Once the system has been adequately purged, pressurize the piping to 150 psi (10 bar) using dry
air or nitrogen. Then close the air or nitrogen supply valve and record the pressure reading. Watch
to ensure that the pressure reading does not drop. Any drop in pressure indicates the presence of a
leak that must be identified and corrected before proceeding further.
f. Check the entire manifold for leaks using soapy water all the way up to the regulator. If bubbles
form there is a leak. The piping must be re-worked and steps d and e must be repeated.
g. Lower the nitrogen/dry air pressure to slightly below the chlorine gas pressure, and seal off the
nitrogen/dry air connection to the chlorine manifold with a valve or connection that is rated for
chlorine manifold service. Then connect the manifold to the chlorine container gas valves (do not
connect to the chlorine container liquid valves). Ensure that no moisture has been allowed to enter
the system. Close all the valves in the pipeline.
h. Open one chlorine gas container valve and its isolation valve and then quickly close them. Check
for leaks on the manifold one section at a time using a 26 Baume solution of ammonia. If white
smokeappears,thereisaleak.Ifthereisaleak,evacuatethesystemusingtheejectorandcorrect
the leak. Then repeat steps d through h. Correct all leaks before moving to the next step.
i. Open all manifold valves (but, keep the isolation valves and the chlorine container valves closed).
Evacuatethesystemusingtheejector.Openonechlorinecontainergasvalvebrieyandthen
close the valves quickly to reintroduce chlorine gas into the system. Then check for leaks one
section at a time all the way up to the regulator using a 26 Baume solution of ammonia.
j. Withthechlorinegascontainervalvesandisolationvalvesstillclosed,evacuatethesystemby
operatingtheejectoruntilthepressurereads(andholdsat)0psi(0bar).
15
2. Initial Start-Up
Only refer to the start-up procedure outlined in this section if the previous Section III.1 leak test has
already been completed and you are now performing the initial start-up, the piping has been changed,
thevaporizerhasjustbeencleaned,orinanyothersituationinwhichair/moisturehasbeenallowedto
enter the system.
Warning: When performing this step, ensure that all protective equipment for handling chlorine
gas is available.
a. Ensure that piping is installed correctly and securely and the leak test from Section III.1 has
already been completed successfully.
b. Check to ensure that all the chlorine container valves are closed and that no chlorine is in the
piping.
c. Turn the vaporizer on (both single phase and three phase power). Immediately the low water alarm
will turn on and open the water solenoid valve to allow water into the water tank. At this point
also check to see that the low water temperature alarm, and the low superheat alarm are all on (if
applicable).
d. Once the water has reached operating level, check to see that the alarm condition has cleared and
the solenoid valve is completely closed (ensure that no water is coming out of the drain port).
e. Check to see that the heater is working by monitoring the water temperature. The factory set
operating water temperature of the vaporizer is 180˚F (82˚C). The vaporizer should take 30-
60 minutes to heat up, depending on incoming water temperature. Check that the low water
temperature alarm has turned off once the water temperature has risen to the appropriate set point
value.
f. Adjustthecathodicprotection,usingthepotentiometerabovetheammeter.Operatingcurrent
should be between 50-250 mA. Add ¼ lb (113 g) of sodium sulphate to increase the conductivity
if the requirement cannot be met.
NOTE: Due to the enamel painting of the chlorine pressure chamber, a low/no current reading
may appear during the first 6 months of operation. This is normal and the vaporizer is still being
protected.
g. Connect the manifold to the chlorine container gas valves via flexible connectors/isolation valves.
Open the isolation valves connected to each container. Open one chlorine container gas valve
and quickly close it again. Check for leaks one section at a time using a 26 Baume solution of
ammonia. If white smoke appears, there is a leak. If there is a leak, evacuate the system using
theejectorandcorrecttheleak.Thenretestthepipingtoensurethattherearenoleaksbefore
proceeding to the next step.
h. Withthechlorinegasvalvesclosed,evacuatethesystembyoperatingtheejectoruntilthepressure
transmitter on the vaporizer reads (and holds at) 0 psi (0 bar). Close the isolation valves and
connect them to the liquid chlorine header valves. Also close any valves that are in the liquid
manifold pipeline. If using multiple ton containers and a gas pressure equalization manifold, then
make the connections to this gas pressure equalization manifold and open those valves before
opening the liquid chlorine container valves. Open the liquid chlorine header valves, and slowly
introduce the liquid chlorine into the system by opening one chlorine container liquid valve at a
time. Once all the liquid container valves are open, gradually introduce liquid chlorine into the
rest of the manifold by opening the remaining valves one section at a time. Operate the vaporizer
at 25% of scale until equilibrium is reached (when temperature and pressure readings are constant
over a set period of time).
16
Warning: Ensure that the water tank temperature is 180˚F (82˚C). Liquid chlorine should
never be allowed into the vaporizer without the water tank temperature being in the
operating range.
i. Bring the vaporizer up to 50% and allow the system to reach equilibrium. Do the same at 75% of
scale and 100 % of scale.
3. System Start
This procedure may only be used after the initial start-up has been completed or if restarting the
system and the user is sure that no moisture has been allowed into the system and that no leaks are
present. If unsure, use the start-up procedure outlined in Section III.2.
Warning: When performing this step, ensure that all protective equipment for handling chlorine
gas is available.
a. Ensure that the chlorine container valves are closed and there is no chlorine in the piping. Turn on
the vaporizer, check to make sure that the water has filled up and the water tank temperature is at
operating level. Check that all appropriate alarms have turned off.
b. Connect piping to the chlorine gas container valves and allow chlorine gas into the system. Close
the gas container valves and check for leaks using a 26 Baume solution of ammonia. If white
smoke appears, a leak is present and corrective action must be taken.
c. Runtheejector(s)toremovechlorinefromthepipeline.Closetheisolationvalvesandconnectthe
manifold to the liquid chlorine container valves.
d. Close all valves in the manifold pipeline. Open the isolation valves, and slowly open the liquid
chlorine container valves and introduce liquid chlorine into the manifold piping.
e. Open the remaining valves one by one until they are all open.
f. Operate the vaporizer at 25% of full scale until equilibrium has been reached. Then bring up
to 50%, 75% and full scale making sure equilibrium has been established each time (when
temperature and pressure readings are constant over a set period of time).
Warning: Do not introduce liquid chlorine into the vaporizer without the water tank
temperature at operating conditions.
4. System Shut Down
4.1 Short Term Shut Down
A short term shut down is defined as any situation where the chemical feed is only temporarily
interrupted, and the heater and all control functions will remain on. Hydro Instruments recommends
the following procedure:
a. If applicable, temporarily stop chemical feed at the vacuum regulator and allow liquid to fill back
into the container.
b. Once equilibrium has been reached (when temperature and pressure readings are constant over a
setperiodoftime),shuttheliquid&gaschlorinecontainervalves.Keepallmanifoldvalvesopen.
c. Runtheejectortoremoveallthechlorinefromthepipelineuntilthechlorinepressurereading
reads zero. Wait for 30 minutes to ensure pressure readings hold at 0 psi and then repeat this step
as necessary.
17
d. Close the isolation valves.
Warning: Ensure that the chlorine containers can handle the amount of chemical going back
into the container. Overfilled containers will result in a chlorine leak.
4.2 Long Term Shut Down
A long term shut down is defined as any situation where the chemical feed is going to be stopped
and the heater and all control functions will also be shut down. Hydro Instruments recommends the
following procedure:
a. If applicable, temporarily stop chemical feed at the vacuum regulator and allow liquid to fill back
into the container.
b. Once equilibrium has been reached (when temperature and pressure readings are constant over a
setperiodoftime),shuttheliquid&gaschlorinecontainervalves.Keepallmanifoldvalvesopen.
c. Runtheejectortoremoveallthechlorinefromthepipelineuntilthechlorinepressuregaugesread
zero. Wait for 30 minutes to ensure pressure readings hold at 0 psi and then repeat this step as
necessary.
d. Purge the system with dry air or nitrogen according to the instructions in the Hydro Instruments
NitrogenPurgingdocument.Thenoperatetheejectoragaintoremoveallgasfromthesystem
until the pressure gauges read zero.
e. Close the isolation valves.
f. Once established that all the chlorine is evacuated (pressure readings hold at zero), disconnect all
power to the vaporizer. Switch to the stand-by unit if necessary.
g. Open the drain valve to allow the water in the water tank to drain.
Warning: The water and vaporizer components/equipment will be very hot, 180˚F (82˚C),
so be careful when handling and/or give the water time to cool before draining.
Warning: Ensure that the chlorine containers can handle the amount of chemical going back
into the container. Overfilled containers will result in a chlorine leak.
5. Navigating the Controller
The vaporizer is provided with a Nema 4x, 2 line alphanumeric display controller that will display and
output all important features and conditions. Navigating the controller is done by the use of four push
button keys. The push button functions are described below.
key: Cycles to the previous screen.
key: Cycles to the next screen.
key: Increases/changes value. Also used to enter screens
key: Decreases/changes value.
Note: When adjusting parameter values, the number displayed is automatically saved upon leaving
the screen. Thus no “enter” button is needed.
Password: All editable features for the VPH-10000-2 are password protected to prevent unwanted
tampering with the values. To access these screens the correct password must be entered to proceed.
The password for the VPH-10000-2 is “100”.
18
FIGURE 5: Operating/Configuration Screens
Cl2T=100F P= 85 psi
Superheat = 32 F
Control Water Temp
180 F
Heater Power
9.0 kW (50%)
Solenoid = Closed
Hold “+” to Open
Alarm Status
Normal
Enter Password
100
Temperature Units =F
Pressure Units = psi
Water Temp Alarm
Low= 160F High= 205F
Gas Pressure Alarm
250 psi
Super Heat Alm Temp
20F (0 = off)
Super Heat Alm Type
Non-latching
Select PRV on Duty
PRV#1/Relay1
Modbus Baud=250000
Node=1 Data=8/N/1
Cl2Pressure Span
300 psi
T180 S=180 O=50 E00
G=3.0 I=1.0 LT=5
Heater Sheath Temp
300 F
Select Gas Type
Cl2
1
2
14*
13
12
11
10
9
8
7
6
5
4
3
17*
16*
15*
* These menus are referred to as hidden
screens and are not visible under normal
operation. To access these screens, go
to screen 13 and with the node number
blinking press and hold the down key
until screen 14 appears. The remaining
screens may be accessed by pressing
the down key after screen 14 appears.
Figure 5. Operating/Configuration Screens
19
5.1 Explanation of Main Controller Screens
1. Operation Screen: This screen displays a live reading of the pressure chamber operating
conditions. These parameters include: gas temperature, gas pressure and superheat.
2. Water Temperature: This screen displays a live reading of the water tank temperature. This is
the temperature reading that is used for PID control of the water temperature and all appropriate
water temperature alarms.
3. NOT USED in Model VPH-10000-2.
4. Heater Power: This screen displays the instantaneous heater power/energy output. The value
displayed is based on the 4-20 mA control signal sent to the heater control box. This provides the
current energy consumption and provides some indication that chamber/heater cleaning is required
due to irregularly high consumption.
5. Solenoid Override: This screen displays the current status of the water refill solenoid (either open
or closed). From this screen the solenoid can be overridden from normal operation to open (and
fill the water tank) by pressing and holding the key.
6. Alarm Status: This screen displays any alarm conditions that may currently be active, or displays
“normal” if no alarm conditions exist. If multiple alarms exist, the controller will cycle all
active alarms on this screen every two seconds. For more information on alarm conditions and
preventative actions refer to Sections III.7 and V.
7. Password Screen: This screen allows access to all the editable features of the VPH-10000-2.
To access the configuration screens the correct password must be entered on this screen. The
password for the VPH-10000-2 is “100” and can be entered using the and keys. Once the
correct password is blinking the user may press the key to access the remaining screens.
8. Vaporizer Units:Thisscreenallowstheusertoadjusttheoperatingunitsused.Temperature
values can be displayed in either degrees Fahrenheit (F) or in degrees Celsius (C). Pressure values
can be displayed in either psig (psi) or barg (bar). To change units, press the or key until the
appropriate parameter is blinking, then press the key.
9. Water Temperature Alarm:Thisscreenallowstheusertoadjustthehighandlowwater
temperaturealarmsettings.Duetoinherentsafetyanddesignfeaturestheadjustablerangeofthe
lowwatertemperaturealarmhasbeensetto160–170˚F(71–77˚C)andtheadjustablerangeof
the high water temperature alarm has been set to 195 – 205˚F (91 – 96˚C). To change values, press
the or key until the appropriate parameter is blinking, then press the key to increase or the
key to decrease.
10. Gas Pressure Alarm:Thisscreenallowstheusertoadjustthepressurevalueabovewhichthegas
pressurealarmwillactivate.Thissettinghasanadjustablerangeof250–300psi(17–21bar).
To edit this value, press the and keys when this value is blinking until the appropriate value
is achieved.
11. Super Heat Alarm Temperature:Thisscreenallowstheusertoadjusttheminimumallowable
superheat temperature, below which the alarm and all relevant functions will activate (Section
III.7).Thisvalueisadjustablefrom0–50˚F(0–27˚C)with“0”disablingthealarm.Toeditthis
value, press the and keys when this value is blinking until the appropriate value is achieved.
Recommended superheat alarm values are: 20ºF for chlorine, 30ºF for sulfur dioxide, and 12ºF for
ammonia.
20
12. Super Heat Alarm Type: The superheat alarm has the option of either being in the non-latching
mode, or completely disabled. If disable is chosen then there will be no alarm indication and the
system will not shut down based on a low superheat condition. To change the alarm type, press the
key on this screen until the correct type is blinking.
13. Pressure Reducing Valve Duty/Standby Screen: When using two pressure reducing valves in
the system one must be designated as the duty (active) pressure reducing valve, with the other
inherently in standby. On this screen the user can select whether they want the pressure reducing
valve in relay 1 active or the pressure reducing valve on relay 5 active.
14. Modbus:ThisscreenenablestheusertoadjusttheModbuscommunicationsettingstobeableto
communicate with a SCADA system. Refer to separate “MODBUS Communication Manual” for
details.
15. Pressure Range Screen: If desired, a different scale pressure transmitter may be used to monitor
pressure.Thenewspanmustthenbeadjustedonthisscreentomatchtheincoming4-20mA
signal. Consult Hydro Instruments before changing pressure ranges or pressure transmitters.
16. PID Control Setting:ThisscreendisplaysandallowstheusertoadjustthePIDcontrolsettings
ofthevaporizer.Theusercanadjustthecontrolwatertemperaturesetpoint(S),thegain(G),the
integral (I) and the lag time (LT). Live values are also displayed on this screen such as, control
water temperature (T), heater output (O), and the integral error (E).
17. Heater Element Sheath Temperature: This screen displays the temperature of the heater
elements. It is used for diagnostic purposes only and to trigger disconnection of power to the
heater if the temperature rises too high.
18. Gas Type: This screen allows the user to select the chemical feed type depending on the
application. Choices are between chlorine (Cl2), sulfur dioxide (SO2), and ammonia (NH3).
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