ProMinent DULCODOS Ammonia User manual

Ammonia water dilution and metering system
DULCODOS® Ammonia
Operating instructions
EN
Original operating instructions (2006/42/EC)981962 BA DD 037 02/19 EN
Please carefully read these operating instructions before use. · Do not discard.
The operator shall be liable for any damage caused by installation or operating errors.
The latest version of the operating instructions are available on our homepage.

Read the following supplementary information in its entirety! You
will benefit more from using the operating instructions should you
already know this information.
The following are highlighted separately in the document:
nEnumerated lists
Instructions
Information
This provides important information relating to the
correct operation of the unit or is intended to make
your work easier.
Safety information
Safety information is identified by pictograms - see "Safety
Chapter".
These operating instructions conform to current EU regulations
applicable at the time of publication.
This document includes notes and quotes from German guidelines
relating to the system operator's scope of responsibility. This infor‐
mation does not discharge the operator from his responsibility as
an operator and is intended only to remind him or make him aware
of specific problem areas. This information does not lay claim to
being complete, nor applicable to every country and every type of
application, nor to being unconditionally up-to-date.
Supplementary information
Fig. 1: Please read!
Validity
Notes for the system operator
Supplemental directives
2

Table of contents
1List of other applicable documents....................................... 4
2 Type list with performance data............................................ 5
3 About the product.................................................................. 6
4 Safety chapter....................................................................... 7
5 Storage, transport, unpacking............................................. 12
6 Overview of equipment and control elements..................... 14
7 Functional description......................................................... 16
8 Assembly............................................................................ 17
9 Installation........................................................................... 19
9.1 Installation, hydraulic.................................................. 19
9.2 Installation, electrical.................................................. 21
10 Start up............................................................................... 23
10.1 Checking for leak-tightness...................................... 23
10.2 Setting....................................................................... 24
10.3 Functional test with dilution water............................. 25
11 Operation............................................................................ 27
12 Maintenance....................................................................... 33
13 Repair................................................................................. 35
14 Troubleshooting.................................................................. 37
15 Decommissioning and disposal.......................................... 38
15.1 Decommissioning..................................................... 38
15.2 Disposal.................................................................... 38
16 Technical data..................................................................... 40
16.1 Technical data for the complete system................... 40
16.2 Materials and properties of the components............. 42
17 Spare parts and accessories.............................................. 44
17.1 Spare parts............................................................... 44
17.2 Accessories.............................................................. 45
18 Dimensional drawings......................................................... 46
19 Declaration of Conformity for Machinery............................. 48
20 Index................................................................................... 49
Table of contents
3

1 List of other applicable documents
Title
Operating Instructions for Solenoid Metering Pump Beta® b BT4b
and BT5b
Wiring diagram for the terminal box for ammonia water with up to
25% w/w:
Document no. 82_05-401_00_05-44
Dependent on your order, you will find
the following applicable documents in
the appendix to these operating
instructions:
List of other applicable documents
4

2 Type list with performance data
Tab. 1
Dosing tank
volume, nom‐
inal
Dosing tank
volume,
usable
Metering
vessel, usable
Metering
pump
Capacity
Transfer
pump
Delivery
height
Transfer
pump
Pump
capacity
Order no.
l l l l / h bar l / h
130 120 2 7 4 approx. 15 1039192
250 250 5 7 2 approx. 36 1039193
Ammonia water metering systems
DULCODOS® Ammonia
Type list with performance data
5

3 About the product
The metering system DULCODOS® Ammonia is used for the gas-
tight transfer and dilution of ammonia water to common metering
concentrations and for automatic metering into the feed water.
Ammonia (NH3), or diluted in water: Ammonium hydroxide
(NH4OH) is used for the alkalising and binding of free carbonic acid
in boiler water and condensate.
Common stock solutions: from 5% to 25% NH3 (% w/w) (ammonia
water).
The usual metering concentration is 0.1% ... 2.5% NH3 (% w/w).
About the product
6

4 Safety chapter
The following signal words are used in these operating instructions
to denote different levels of danger:
Signal word Meaning
WARNING Denotes a possibly hazardous
situation. If this is disregarded,
you are in a life-threatening sit‐
uation and this can result in
serious injuries.
CAUTION Denotes a possibly hazardous
situation. If this is disregarded,
it could result in slight or minor
injuries or material damage.
The following warning symbols are used in these operating instruc‐
tions to denote different types of danger:
Warning symbol Type of danger
Warning of a dangerous area.
Warning of hazardous electrical
voltage.
Warning of a risk of explosion
nThe metering system DULCODOS® Ammonia is only intended
for batching ammonia water in common concentrations of up to
max. 25% into standard solutions of 0.1% to max. 2.5% and
metering this into water-steam circuits or into steam and con‐
densate systems.
nThe metering system DULCODOS® Ammonia may only be
used after correct installation and start up - according to the
technical data and specifications outlined in these operating
instructions and the operating instructions for the individual
components.
nThe metering system DULCODOS® Ammonia is not intended
for other uses.
nIn the event of a modification, the operator or the contractor he
has appointed becomes the manufacturer of the modified
system in accordance with EC Regulation 2006/42/EC – with
the corresponding obligations.
Labelling of safety information
Warning symbols denoting different
types of danger
Intended use
Safety chapter
7

nThe metering system DULCODOS® Ammonia is not intended
for metering other chemicals, such as sodium hydroxide solu‐
tion.
nThe metering system DULCODOS® Ammonia is not intended
for the metering of gaseous or solid media or other liquid
media.
nYou are obliged to observe the information contained in the
operating instructions at the different phases of the unit’s
service life (such as assembly, installation etc.).
nThese operating instructions contain a summary of the impor‐
tant functions of each of the components used.
The technical information and operating instructions for the
components used form an integral part of the entire operating
instructions and must be observed.
nMake sure that the metering systems are only operated by
trained and authorised personnel, see table.
Task Qualification
Storage, transport, unpacking Technical personnel
Assembly, installation of the
hydraulic system
Technical personnel
Electrical installation Technical personnel, electrical
technician recommended
Start up Authorised technical personnel
Operation Instructed person
Maintenance Technical personnel
Repair Authorised skilled personnel
proven to have been trained by
ProMinent
Troubleshooting Technical personnel
Decommissioning / Disposal Technical personnel
Electrician
Electricians are deemed to be people, who are able to complete
work on electrical systems and recognise and avoid possible haz‐
ards independently based on his/her technical training and experi‐
ence, as well as knowledge of pertinent standards and regulations.
Electricians should be specifically trained for the working environ‐
ment in which the are employed and know the relevant standards
and regulations.
Electricians must comply with the provisions of the applicable stat‐
utory directives on accident prevention.
Instructed personnel
The instructed personnel have been instructed by the operator in a
training session about the tasks allocated to them and potential
hazards with incorrect and improper conduct.
Technical personnel
Technical personnel are deemed to be people, who are able to
complete the tasks allocated to them and recognise and avoid haz‐
ards independently based on his/her technical training and experi‐
ence, as well as knowledge of pertinent regulations.
Qualification of personnel
Safety chapter
8

WARNING!
Danger from hazardous substances!
Possible consequence: Fatal or very serious inju‐
ries.
Please ensure when handling hazardous sub‐
stances that you have read the latest safety data
sheets provided by the manufacture of the haz‐
ardous substance. The actions required are
described in the safety data sheet. Check the
safety data sheet regularly and replace, if neces‐
sary, as the hazard potential of a substance can be
re-evaluated at any time based on new findings.
The system operator is responsible for ensuring
that these safety data sheets are available and that
they are kept up to date, as well as for producing
an associated hazard assessment for the worksta‐
tions affected.
WARNING!
Danger of electric shock
Mains voltage may be present inside the pump
housing and the switch cabinet.
– Immediately disconnect the system from the
mains power supply if the pump housing or
switch cabinet has been damaged. Only return
the pump to service after it has been repaired
by authorised personnel.
CAUTION!
Please also observe the operating instructions for
the metering pump and any other units which may
be fitted.
CAUTION!
Do not climb onto the system or parts thereof - the
metering station cannot support the load, could
leak or topple over.
NOTICE!
Warning of illegal operation
Observe the regulations that apply where the
device is installed.
The following dangers could arise if incorrectly operated or mis‐
used:
Water pollution and damage to health
nWater pollution and damage to health due to escaping liquids.
nDamage to health from the inhalation of ammonia vapours.
nDangerous reactions due to contact with other chemicals.
Safety information
Potential danger from the system
Safety chapter
9

Take special precautions with storage and metering. The specific
potential danger and resulting hazards should be taken from the
current material safety data sheet for the substance used.
Danger of explosion
nRisk of explosion due to trapped ammonia-air mixtures.
A potentially explosive ammonia-air mixture (lower explosion limit
15.4 vol.%, upper explosion limit 33.6 vol.%) can form in the inte‐
rior of the metering vessel and also in the interior of the supply
drum via the liquid phase depending on the temperature and con‐
centration of the commercial ammonia water product.
The built-in level switch in the metering vessel is therefore
designed to be intrinsically safe “i” with an explosion-proof design.
Pay attention to any static charge when connecting or replacing a
supply drum!
Turn the Emergency Stop switch to “0” in the event of an emer‐
gency or if liquid escapes from the system during pumping.
Refer to the material safety data sheet for ammonia water supplied
by the chemical supplier in the event of any accidents with
ammonia water.
If ammonia water escapes, evacuate the room, put on protective
equipment, seal the leak and, if necessary, collect the escaped sol‐
ution and dispose of!
Refer to the material safety data sheet for ammonia water provided
by the chemical supplier.
Refer to the material safety data sheet for ammonia water provided
by the chemical supplier.
Keywords when searching for the necessary regulations:
nAmmonia water systems
nAmmonia water
nStorage
nHazardous substances
nPersonal protective equipment
nWater protection
nAir protection
n...
The “GESTIS Substance Database” published by the IFA Institute
for Occupational Health and Safety of the German Social Accident
Insurance provides valuable information.
Direct contact with ammonia water may occur when changing over
the supply drum and during maintenance work. Observe the
instructions.
Emissions of ammonia gas are not expected due to the gas-tight
design of the storage tanks and the downstream exhaust air
adsorber. This is the case providing the adsorber is regularly
changed.
Information in the event of an emer‐
gency
Health hazards
First aid instructions
Note for the system operator
Emissions
Safety chapter
10

Sound pressure level LpA < 70 dB according to EN 3746
The system is provided with the following protection equipment,
which prevents large quantities of ammonia from escaping, or the
resulting ignition of an ammonia water-air mixture:
nThe level switch in the metering vessel prevents overflowing.
nThe system is designed so that the transfer from the storage
tank to the metering vessel is via a vapour recovery line.
nThe aeration and venting of the system is through an active
carbon filter, which absorbs the escaping ammonia gas.
nThe lid of the dosing tank protects the user from ammonia gas.
It needs to be secured by a seal when operating with ammonia.
nThe level switches in the metering vessel and in the dosing
tank are designed to be explosion-proof and intrinsically safe “i”
with an appropriate explosion-proof intrinsically safe “i” switch
amplifier.
Further recommendations, the implementation of which is however
outside our area of responsibility:
nPlace the dosing tank in a collecting pan.
Affix workplace labels in line with the current regulations.
They might look like this in accordance with the German regula‐
tions governing printing of the operating instructions:
Warning of caustic substances
Use eye protection
Use safety gloves
Ensure that the warning label is always fitted and legible.
Sound pressure level
Protective equipment
Warning labels
Safety chapter
11

5 Storage, transport, unpacking
WARNING!
Warning of hazardous ammonia
Ammonia can escape in the event of damage.
– Make sure that the metering system is free
from ammonia prior to storage or transport.
–Carefully protect the metering system against
mechanical damage, so that no one can be
endangered by escaping caustic ammonia
during subsequent operation.
WARNING!
Only return metering pumps for repair in a cleaned
state and with a flushed liquid end - refer to
"Decommissioning!
Only return metering pumps with a completed
Decontamination Declaration form. The Declara‐
tion of Decontamination constitutes an integral part
of an inspection/repair order. A unit can only be
inspected or repaired when a Declaration of
Decontamination Form is submitted that has been
completed correctly and in full by an authorised
and qualified person on behalf of the pump oper‐
ator.
The "Declaration of Decontamination” form can be
found at www.prominent.com.
WARNING!
Danger of leakage
The device can be damaged or leak by incorrect or
improper storage or transportation!
– Only store or transport the unit in its original
packaging.
–The packaged device should also only be
stored or transported in accordance with the
stipulated storage conditions.
– The packaged device should be protected from
moisture and the ingress of chemicals.
CAUTION!
Danger of material damage
The device is top-heavy as long as the dosing tank
is empty.
– Bear this in mind when transporting it.
Safety information
Storage, transport, unpacking
12

Parameter Value
Minimum storage and transport temperature: 0 °C
Maximum storage and transport temperature: +50 °C
Minimum ambient temperature during operation: 0 °C
Maximum ambient temperature during operation*
at up to 15% ammonia water:
at up to 20% ammonia water:
at up to 25% ammonia water:
35°C
30°C
25°C
Max. temperature of the dilution water: 20°C
Maximum air humidity**: 92% relative humidity
* The higher the starting concentration, the lower the temperature
needs to be.
** non-condensing
Do not allow to stand in direct sunlight.
Ambient conditions
Storage, transport, unpacking
13

6 Overview of equipment and control elements
P_HYD_0011_SW.svg
Fig. 2: Overview of equipment: metering system DULCODOS® Ammonia
1 Supply drum (not in the scope of
delivery)
2 Suction lance with gas recovery (acces‐
sory)
3 Vapour recovery line
4 Transfer pump (with control elements)
5 Metering pump (for metering; with con‐
trol elements)
6 Injection valve
7 Chemical vapour lock
8 Stopcock (dilution water)
9 Metering vessel with level switch
10 Manual stirrer
11 Stopcock (metering vessel drainage)
12 Dosing tank with sprinkler
13 Suction assembly
14 Dosing tank level switch
15 Stopcock (rinsing water metering vessel)
16 Switch cabinet - see also Fig. 3
Not shown Collecting pan (accessory)
Overview of equipment and control elements
14

1
2
P_HYD_0029_SW
Fig. 3: Switch cabinet control elements(on the side of the system)
1 Main switch with Emergency Stop function
2 “Start filling metering vessel” key
Overview of equipment and control elements
15

7 Functional description
The DULCODOS® Ammonia system is used for the gas-tight
transfer and dilution to usual metering concentrations and then
automatic metering into the feed water.
The dosing tank (12) needs to be filled with de-ionised water to
batch a diluted usable ammonia water solution. The transfer pump
(4) semi-automatically fills concentrated ammonia water solution
(max. 25%) from the supply drum (1) into a metering vessel (9). An
appropriate amount of this concentrated solution from this metering
vessel needs to be left in the dosing tank to obtain a final concen‐
tration of between 0.1% ... 2.5%.
The manual stirrer (10) mixes the solution until it is homogeneous.
A chemical vapour lock (adsorber) (7) is fitted on the metering
vessel to prevent ammonia vapours from escaping into the envi‐
ronment.
The metering pump (5) meters the ready-to-use ammonia solution
from the dosing tank at the corresponding point of injection (6).
Metering can be provided on-demand using external control of the
metering pump.
Optional fault indicating relays on the pumps can report faults on a
control panel.
Functional description
16

8 Assembly
WARNING!
Warning of hazardous ammonia
Ammonia can escape if the system is not handled
correctly.
– Store and transport the metering system in its
original packaging. Take special precautions to
ensure that the metering system is protected
against mechanical damage
–Select a suitable installation site for the
ammonia water metering system.
WARNING!
Danger of severe eye injuries
Immediately rinse the eyes in the event of
ammonia coming into contact with them.
– Provide an eye shower (with water connection)
directly adjacent to the installation site.
WARNING!
Warning of explosive atmospheres
An explosive air-ammonia mixture can form with
high concentrations of ammonia water – particu‐
larly above 15% w/w – or also at high ambient tem‐
peratures (at over 30 °C above 10% w/w).
– Note the current regulations and technical reg‐
ulations dealing with ammonia and ensure ade‐
quate ventilation.
CAUTION!
Observe the material safety data sheet
Observe the current material safety data sheet for
ammonia water.
The following must be available at the installation site:
nWater connector with eye shower (refer to the material safety
data sheet)
nWater connector for deionised water (dilution water and rinsing
water). Properties - refer to "Technical data" chapter
nPrevent the installation site from unauthorised access.
nMains connection 230 V / 50 Hz for the system.
nAn appropriate exhaust air duct for an exhaust air line from the
chemical vapour lock.
nRecommendation: There needs to be a gas detector fitted
nbrick or masonry, leak-tight tray provided on site around the
installation site or a collecting pan with ribs on the inside (on
request).
nA horizontal, level and stable surface must be available for the
installation.
Safety information
Requirements for the installation site
Assembly
17

nThe system must be secured against possible damage from
people, objects and mobile equipment, such as fork-lifts or
pallet trucks.
nThere needs to be 1 metre clearance around the system for
maintenance purposes.
nThe installation site must have continuous effective ventilation.
nDepending on the actual conditions on site, the installation site
for the system and supply drum may need to fulfil other
requirements in line with the applicable regulations and tech‐
nical rules!
nTake appropriate measures if any of the following chemicals
are stored at the installation site: phosphorus oxides, acids,
oxygen bottles, hydrogen sulphide (H2S), strong oxidising
agents, hydrogen peroxide (H2O2), zinc, nitric acid, ethylene
oxide, strong alkalis, chlorates, mercury, silver or hydrogen
bromide (HBr).
Assembly
18

9 Installation
9.1 Installation, hydraulic
WARNING!
Warning of hazardous ammonia solution
Ammonia solution will escape if the metering line
comes off or tears.
– Only fit lines of sufficient strength.
–Note the resistance of the line material.
– Prevent the metering line from coming off
caused by back pressure or tearing. You may
wish to install a relief valve.
WARNING!
Warning of hazardous ammonia solution
Liquid from the application could press back
through the metering pump.
– Use an injection valve or vacuum breaker.
Personnel: nTechnical personnel
1.
P_HYD_0012_SW
1
2
3
Screw together the units supplied for the metering system
DULCODOS® Ammonia as shown - see A:
1. - Chemical vapour lock
2. - Fastening bracket. Use it to screw the chemical vapour
lock to the metering vessel.
3. - Hand crank
Installation
19

2. Make the internal piping connections - see B:
1. - “Transfer pump” (f) suction line to the suction lance for
the storage tank. Use hose clips!
2. - Vapour recovery line from the metering vessel to the
suction lance for the storage tank. Use hose clips!
P_HYD_0033_SW
2
3
1
5
4
fd
3. Make the external pipe connections - see Fig. 4:
1. - “Metering pump” (d) metering line to the installed injec‐
tion valve
2. - De-ionised water feed connector to fill the dosing tank
3. - Chemical vapour lock exhaust air line to the respective
exhaust air duct
Installation
20