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CHEMET~CS

ANODICALLY PROTECTEDSULPHURIC ACID COOLERS

ISSUED TO:

PLANT:

PROJECT No.:

DATE:

DESCRIPTION:

SOUTHERN PERUCOPPER CORPORATION110, Peru

Sulphuric Aci Pl!"# No.$

0%H0&$00 I 0'A()1*

J!"u!r+ $00

Dr+i"- Aci Cooler SIN 04-618 A /or er Aci Cooler SIN 04-619Pro uc# Aci Cooler SIN 04-620

OPERATIN 2AINTENANCE 2ANUAL

This manual is issued by Chemetics with the understanding that all information contained herein is of a confidential nature and is notto be circulated indiscrfminately. ll drawings and s!ecifications relating to the Chemetics' anodic !rotection system and allinformation contained in this manual are to be considered the !ro!erty of Chemetics and are not to be used or re!roduced without!ermission" e#ce!t by the !urchaser for his own internal use. cce!tance of this manual im!lies acce!tance of the abo$e conditionsby the !urchaser.


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CHE2ETICS

ACID COOLER OPERATIN & 2AINTENANCE 2ANUAL

ANOTROL $000 SYSTE2

TA3LE O4 CONTENTS

%" Cha!ter & Introduction

~Cha!ter System (escri!tion

Cha!ter ) notrol* +++ System

Cha!ter , -!erating rocedures

Cha!ter / 0outine Maintenance

Cha!ter 1 erformance Monitoring

Cha!ter 2 S!ecial Installation and Maintenance rocedures

Cha!ter 3 Troubleshooting

!!endi# (rawings

Add Cooler -!erating & Maintenance Mal&uai


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CHEMETICS

CHAPTER 1

INTRODUCTION

4 ur!ose

4 5uarantees

4 ro!rietary 0ights

4 notrol6

I

i

dd Cooler -!erating 7 ~8iaintenaflce Manual

Cha!ter &9:&Introduct~on


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INTRODUCTION

PURPOSE

The !ur!ose of this manual is to !ro$ide the end user of Chemetics nodically rotected

Sul!huric cid Coolers with the information necessary to o!erate" maintain" and troubleshoot the

cooler s; and the associated notrol6 +++ nodic rotection E


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CHEMETICS

CHAPTER $

SYSTE2 DESCRIPTION

6 Aci Cooler

I

cm Cooler -!eratir~g 7 rllairrtenance Mantia8

Cha!ter 2-1System Description


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CHEMETICS

SYSTE2 DESCRIPTION

The acid cooling system remo$es the e#cess heat generated from the drying" absor!tion" and

gas cooling that ta?es !lace in the acid towers. Each acid !lant has a uni


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CHAPTER %

ANOTROL $000 SYSTE2

ControllerD ower Su!!ly CD S;

ower Su!!lyMain C ower Configuration

Controller CIPS oard ConfigurationHardware >ail Safe

>uses and Connections

0emote (is!lay Bnit 0(B;

-$er$iew ScreenE$ent @og ScreenConfiguration Mode(etail Screen

dFusting @abels" Set oints and larm Galues-!erational larms

@ow larmHigh larm

rocess age &rocess age

rocess (ata0(B Software Setu!

C to 0(B (ata Transfer 0(B Shutdown rocedure

CIPS cti$ation and Shutdown

cti$ation $ia 0(B cti$ation from CD SCIPS Shutdown from 0(BCF S Shutdown from CD S

4 Communication >ailure

dd Cooler -!eratlng 7. i'~&ainte8&anceManua~


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H

CHEMETICS

-T0-@ " +++ SJSTEM

'K#.#

"

The notrol* +++ system is com!rised of a 0emote (is!lay Bnit 0(B; !lus a dedicatedControllerD ower Su!!ly CD S; for each acid cooler or storage tan?. ma#imum of si#0eferenceElectrodesand u! to twel$e !rocess in!uts !er CD Smay be monitored.

1 The CD S is the main functional unit of the notrol'6 +++ system as it contains both thehardware to su!!ly the !ower to the Cathode s; and the micro!rocessor" which measures theanodic !otentials and adFusts the current out!ut from the !ower su!!ly to achie$e andmaintain the !assi$efilm.

The CD S is designed to acce!t either &&/ or )+ VAC field selectable; which is su!!lied to thesystem at the terminal stri! on the rear !anel of the chassis. This C !ower is su!!lied to the

ower Transformer $ia >use >l and the internal stabiliAed ower Su!!ly for themicro!rocessors $ia >use> .

efore a!!lying !ower to the notrol* system" chec? to ensure that the line$oltage is correct" the !ower wiring at the terminal stri! is in accordance with thelabels and that the main C oard Goltage Selector Switch and Station umber Selector are !ro!erly set.

ROU

dd Cooler -!erating &:Maintenance Manual

C/PS

Cha!ter ) 9

notrof 1

+++ System


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CHEMETICS

CONTROLLER I PO7ER SUPPLY (C/PS)

Po8er Suppl+

The C $oltage is reduced to the reETs: l and" located on the left9hand internal heat sin?. Heat

dissi!ated by the steering (iodes and M-S>ETs isdistributed by the internal heat sin?s" which arethermally cou!led to the sides of the enclosure. Thecontrolled out!ut $oltage is su!!lied to the $essel $iatwo terminals mar?ed Cathode and node.

2!i" AC Po8er Co"9i-ur!#io"

oth the CD S and the 0(B are set u! at the factory in accordance with the s!ecifications for the

!roFect site.

The 0(B is ca!able of o!erating from an C !ower su!!ly of between N+D 1, G C" /+D1+ HA.

The CD S C !ower is adFusted by way of Fum!ers located on the rear !anel of the chassis. Thediagram of the Fum!ers indicates their !ro!er connection. The C oard has an internal GoltageSelector Switch" which must be set for the correct C !ower being su!!lied.

ll of the connections discussed abo$e are chec?ed and adFusted by a Chemetics TechnicalSer$ice 0e!resentati$e during commissioning.

Co"#roller

The micro!rocessor9based Controller is located in an internal enclosure in the lower !ortion of the CD S. The Controller C oard ssembly is mounted to the bac? !late of the CD S enclosureusing two screws and is a com!lete re!laceable assembly including the aluminum bo#;.

E cep# 9or i"i#i!ll+ /e##i"- #he co"9i-ur!#io" o9 #he S#!#io" Nu; er 9or co;;u"ic!#io" to #he RDU !"


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! CHEMETICS

HC

"6F

LO

The Controller C oard ssembly has four connectors that interface the wiring to e#ternalcircuitry .

The connector !ro$ides the C !ower to the ssembly. Selection of &&/ G C or )+ G C is

made with a Goltage Selector Switch that is on the underside of the C oard and is onlyaccessible when the oard is remo$ed from the bo#. It is set at the factory in accordance withthe s!ecifications for the !roFect site .

The connector i !ro$ides the signal from the current measuring shunt and the signals to the

M-S>ETs.

The connector T l labeled ELECTRODES !ro$ides the interconnection !oints for the 0S9,digital communication" Cathode Goltage in!ut" Control Electrode and u! to fi$e 0eference

Electrodes. A"+ Re9ere"ce Elec#ro e i"pu#/ #h!# !re u"u/e /houl h!=e >u;per/

i"/#!lle .

The connector T labeled PROCESS !ro$ides the interconnection for u! to twel$e ,9 + rn!rocess in!ut signals. Each in!ut is su!!lied with , $olts to !ower a rocess Transmitter. Each!air of channels is o$er9current !rotected to !re$ent the failure of the ,9$olt internal stabiliAed

ower Su!!ly in the e$ent of an e#ternal short circuit.

Acid Cooler -!erating 7. Maintenance Manual

Cha!ter ) ~, notrol* +++ System


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CHEMETICS

CONTROLLER PO7ER SUPPLY ?C@PS?PIN 0&B) 0

G C ower 7 um!ers

>uses)1 7 )2

dd Cooter -!erating & Maintenance Manual

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C/PS 3o!r Co"9i-ur!#io"

Each C/PS is inde!endently configured to o!erate as !art of a total anodic !rotection system.

Each C/PS has it's own s!ecific address within the system and can be configured to dis!laydifferent $alues de!endant on the set u! of the acid cooler" storage tan? or acid !i!ing system

to which it is connected.

If it is necessary to change a CIPS oard for any reason" the configuration of the board must beset to corres!ond to the address and ser$ice of the unit.

The Station umber of a C/PS can be changed by resetting the Station umber Selector Sllocated on the C oard as follows:

. .

>irst remo$e C !ower to the CD S.

(isconnect all !lug9in connectors from the Controller C oard ssembly.0emo$e the two screws securing the Controller C oard ssembly to the CD Srear !anel and remo$e bo# from C/PS.0emo$e the si# co$er mounting screws and carefully lift the C oard ssemblyfrom its su!!ort bo# to allow access to the Station umber Selector located in thecenter of the board see >ig. ).& at the end of this cha!ter;.E#amine the !osition of the four di! switches on the Station umber Selector.0e!osition these switches of the new C oard to corres!ond to the re


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The >ail Safe set !oint adFustment is made by a trim !ot" accessed through the co$er labeled:SETPOINT ADJUST.

WARNING: If both the red a d !ree "tat#" $%!ht" are %$$#&% ated' "to( the # %t or

t#r the !ree $%!ht off) * +e the +o tro$ &%$$%,o$t "%! a$ dro(" be$o .a%$ Safe "et (o% t' the .a%$ Safe &a be re"et) he C/PS %$$ the ret#rto Id$e &ode' a d the # %t &a be re"tarted fro& the C/PS or R )

4u/e/ !" Co""ec#io"/

There are two fuses associated with the !rimary !ower wiring circuits:

&; The ower Transformer >&

; The Controller C oard >

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o

~ CHE~ lETICSI

RE2OTE DISPLAY UNIT ?RDU

The 0(B is a fully functional C with a touchscreen that interfaces the C electronics with

each CD S through an 0S9, communicationschannel .

The 0(B is the o!erator's interface with eachfunctional CD Sand is used to:

OC&; (is!lay the anodic film status for each

anodically !rotected $essel.

; dFust set !oints and alarm !arameters.

); Start and sto! the anodic current out!ut from the CD S.

,; (is!lay to the !rocess !arameters for each acid cooler.

/; (ownload data to a (CS $ia the 0S9 ) communication channel.

1; Troubleshoot indi$idual anodic !rotectionsystem.

2; Connect a remote alarm to relay through T ).

The 0(B is connected to each CD S by a dedicated two9wire shielded communication cable.The screen uses a color @C( with an integral touch screen. The touch screen is used for allo!erator interface functions. It also !ro$ides the o!erator with a read out of either the statusof the o!erating acid coolerDtan? or the set !oint and alarm settings for the micro!rocessor.

O=er=ie8 Scree"

=hen the 0(B is first !owered u!" it automatically loads the =indows* +++ o!erating

system and the 0(B !rogram. t the conclusion of the start9u! se


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CHEMETICS

--

Lo-

The @og?ey" when !ressed" will dis!lay the E$ent @og screen for the coolerDtan? selected.

Co"9i-

The Config ?ey gi$es access to the Configuration mode" it is !assword!rotected.

E i#The E#it ?ey" when !ressed" will allow the 0(B to e#it the !rogram and return to the =indows!rogram. If changes were made" you will be !rom!ted to sa$e them.

The 0(B will scan for acti$e CD S units as seen on the -$er$iew screen. ny units not in cti$e mode or in an alarm state will be red. cti$e units will indicate a solid green dis!layalong with the name of the o!erating coolerDtan?. The cursor below the icons will mo$ebetween each unitin o!eration.

E=e"# Lo- Scree"

The @og ?ey gi$es access to the E$ent @og screen for the cooler selected. It indicates thedate" time" unit number" and a brief descri!tion of any occurrence with the unit on dis!lay.

Si# ?eys on the right side allow the user o!tions as follows:

!!!..C :l.~%., ~1!

>Ct f'~C~ ~D ~~t.i>f

~Ie.~~/0

c.~~at.~~

#~~IoIc~

.....a.2rr.

P-UpThis ?ey is used to !age u! through the E$ent @og screen" one !age at a time.

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CHE lETICS

I

I

Up !rro8This ?ey mo$es the cursor u! one item at a time.

Do8" !rro8This ?ey mo$es the cursor down one item at a time.

P-O"This ?ey is used to !age down through the @og Screen" one !age at a time.

Cle!r Lo-This ?ey is used to clear @og Screen of all stored data. It is !assword !rotected.

3!cThis ?ey returns user to the -$er$iew screen.

I Co"9i-ur!#io" 2o eThe Config ?ey on the -$er$iewscreen is !assword !rotected" thislimits access to the Configurationmode. Enter the correct !asswordand touch -U. This is the channelconfiguration screen and allows theconfiguration of u! to & CD S units

to be dis!layed. Se$en ?eys on theright side allow entry to further setu! o!erations as follows:

Ne8 P!//8This ?ey is used to enter a second!assword. ress ?ey. Enter new!assword" u! to + characters and touch -U.

S!=e Co"9i-This ?ey is used to configure which unites; is in o!eration. =hen all units ha$e been acce!ted"

cursor indicated below icon s;;" !ress the Sa$e Config ?ey to acce!t this configuration. (uring

o!eration the cursor mo$es between all icons in use" s?i!!ing those not configured.

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Cha!ter ) M &+ notrori8l +++ System


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CHE~ iETICS

De9!ul#/This ?ey clears the history and loads default settings of the dis!layed unit. ress 6Jes6 tocontinue or 6 o6 to return to the -$er$iew screen.

WOO=atch dog timer disabled.

Ru"This ?ey is used to return to the -$er$iew screen.

E i#

This ?ey is used to e#it the !rogram and return to the =indows* 2555 !rogram. If changes weremade you will be !rom!ted to sa$e them. This o!eration is !assword !rotected.

De#!il Scree"

To bring u! one of the units in o!eration" touch the icon on the -$er$iew Screen to enter the(etail screen" for that unit. The to! left bo# indicates the name of the o!erating $essel" the to!right bo# indicates the status of the unit" and the right side bo#es are function ?eys.

This !age will re$eal the status of the notrol system and show the following data !lus anyalarm conditions within the notrol system.

C!#ho e Curre"#

m!erage being sent to the coolerDtan?.

C!#ho e


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CHE~ lETICS

-n the right side of the screen the following function ?eys are a$ailable:

S#!r#

The Start ?ey will acti$ate the unit being dis!layed and the red Idle unit 8 icon will change to cti$e green. This will allow flow of (C current to the $essel !ro$ided the Control otential isbelow its set !oint and there are no high alarms.

S#op

The Sto! ?ey will de9acti$ate the unit being dis!layed and the green cti$e unit 8 icon willchange to Idle red. (C current will be discontinued.

Hi/#or+

The History ?ey will load History screen" which indicates the selected !arameter history. Ueys areincluded on this screen to change the time base and to turn the Control Electrode (ata on or off.The ac? ?ey returns user to the (etail screen.

Co"9i-

The Config ?ey is !assword !rotected to limit access to the Channel Configuration screen. Enter the correct !assword and touch -U. This screen allows the configuration of the unit on dis!lay.

Hi/#or+ Scree"

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CHEMET8CS

A >u/#i"- L! el/, Se# Poi"#/ !" Al!r;

These $alues are !re9set at the factory" chec?ed" and adFusted by the Chemetics TechnicalSer$ice 0e!resentati$e during commissioning.

dFustment of the !rogrammed $alues /houl o"l+ e o"e u" er #he i"/#ruc#io" o9 Che;e#ic/. 0andom adFustment or incorrect setting of these $alues may result in seriousdamageDcorrosion to the coolerDtan?.

If it is necessary to modify the channel configuration:

&; Call u! the CD S to be modified from the -$er$iew screen.

2 Select the Channel Configuration screen from the (is!lay screen" by touching the Config?ey. The Configuration screen is !assword !rotected. Enter the correct !assword and

touch -U obtain code from Chemetics" Technical Ser$ice (e!artment;.

); >rom the Channel Configuration screen" select the item to be modified.

Cooler N!;eBsing the touch screen" insert or change the title of the unit in ser$ice. B! to + characters maybe entered. =hen com!leted the -U ?ey should be !ressed and you will return to the !re$ious!age.

Seri!l Nu; er Bsing the touch screen" insert the serial number of the e


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CHEMETICS

Cooler Ty!eBsing the touch screen B! 7 (own arrow ?eys;" select the number of electrodes notcounting the Control Electrode being used. Cathode current can be changed between 1+ and&++ am!s most coolers are set for 1+ am!s" tan?s to &++ am!s;. Bne fre


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CHEMETICS& Maintenance Manual Cha!ter ) 9 &,

notrol 7 +++ System


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CHEMETICS

=hen an alarm $alue is reached" an audible alarm within the 0-B will sound to draw attentionto the situation.

@ow larm

@ow larm indicates that the !otential across the anodic film at the cid Inlet region Controlotential; of the $essel has dro!!ed to a le$el indicating lac? or loss of the anodic film re


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Hi-h Al!r;

High larm !re$ents the !otential from entering the T0 S SSIGE 0E5I- where the!rotecti$e film becomes unstable" indicating that the anodic !otential has climbed abo$e theHigh larm set !oint. If this high $oltage condition continues the anodic film becomes highly

soluble in the acid and corrosion ta?es !lace at an accelerated rate.

If a High larm occurs" the C/PS anodic current will automatically shut down and the 0(B will:

Sound the internal alarm>lash the icon on the -$er$iew screen to indicate which unit is in alarm(etail screen will indicate which $alue caused the alarm

ressing the flashing label on the (etail screen will silence the audible alarm.

To reacti$ate the C/PS from a high alarm shutdown on the Control Electrode !ress the Start ?ey.0eacti$ation of the C/PS from a high alarm shutdown on the -utlet Electrode can only be donelocally at the C/PS.

"I

WARNING: he C/PS %$$ ot a#to&at%+a$$ re"tart after a h%!h a$ar&) It "t bere-a+t%,ated &a #a$$ )

dd Cooter Cha!ter ) 9 &1-!erating 7 Maintenance Manual notro'* +++ System

:::: .--5:# ::::~.~$.-:-:~~$::.~%.:::::.-0-:-::::.::.:.#.!.:: .:9.~$.-%:%.:!!::c.:


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Proce// P!-e 1

This !age is acti$ated from the Channel Configuration screen and a ?ey to this !age can bedis!layed on the (etail screen. This !age will re$eal the status of the cid and =ater

Tem!erature readings along with any alarms related to tem!erature.

Proce// P!-e $

This !age is acti$ated from the Channel Configuration screen and a ?ey to this !age can be

dis!layed on the (etail screen. This !age will re$eal status of other in!ut data and alarms if re


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CHEMETICS

Proce// D!#!

This !age is acti$ated from the Channel Configuration screen and a ?ey to this !age can bedis!layed on the (etail screen. This !age will allow for Cooler Calculation. The (esign and

-!erating data for the cooler s; are entered by user and se$eral calculations may be obtained:e.g. fouling" heat load" $elocity etc. The ac? ?ey returns to the !re$ious !age $iewed.

cid Cooler -!erating 7 Maintenance fA&al&uaf

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RDU So9#8!re Se#up

&; Co!y the 0(B software !ac?age Setu!.e#e" Setu!. &st" 0(B&.cab" 0(B3.cab; in the!anel C:a; Bsing networ? connection.

Connect ?eyboard" mouse and networ? cable to the !anel C. Setu! and log intothe networ? as? the networ? administrator for details;. Create directoryc:K0(Blnst and co!y the 0(B software !ac?age files into this folder.

b; Bsing serial !ort communication.Bse ser$ice !rogram to co!y the software !ac?age in the !anel C $ia the serial!ort. The default folder of this communication is C:KHT ufferK see the Ser=ice

program descri!tion for details;.

; Install the 0(B !rogram:4 Start" 0un C:K0(BlnstKSetu!.e#e -U Start" 0un C:KHT ufferKSetu!.e#e" -U;4 cce!t the default $alues in all Install dialog bo#es.

< Modify the =indows* startu! !rocedure new system logo screen" and startu!a!!lication;.4 0un" rowse C:K rogram >ilesK0(BK0(Bsetu!.bat;" -U.4 Create ew Shortcut to C:K rogram>ilesK0(BK0(B"e#e in the (es?to!.

4 Co!y the 0(B Shortcut in the folder.C:K =indowsK IIBsersKStartMenuK rogramsKStartu!.

,; Test the 0(B installation: StartDShut (ownD0estartD-#.

/; (isable the !ower sa$ings functions:Control anel" ower Management" ower Schemes tab.

4 ower Schemes: lways -n.

4 Turn off monitor: e$er 4 Turn off hard dis?s: e$er.

1; (isable etwor? connection and Bser !rofiles.

.dd Cooler -!erating 7 Maintenance Manual

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CHEMETtCS

C to 0(B (ata Transfer

Since the standard !anel C configuration does not include flo!!y or C( de$ices" informationbetween the !anel C and other systems can be e#changed $ia the networ? or serial !orts. Themost con$enient way is to use the networ? functionality. The !anel C !ro$ides a E +++

com!atible &+9 ase T Ethernet 0 ,S; interface.

If a networ? connection is not a$ailable" the data between the !anel C and remote C can bee#changed $ia the serial !orts. The o!erating system =indows* +++ !ro$ides a!!ro!riate toolfor C-M !ort communications 9 Hy!erTerminal.

(ata Transfer Bsing the anel C Ser$ice rogram

>irst install Ser$ice !rogram on the !anel C:

&;2low Control:

4 Clic? -U

11>255?

one&Hardware

S#ep


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CHEMETICS

-ata Transfer without Ser$ice rogramme

Ste! &:

(isconnect the serial cable from the multi!le#er bo# and connect the cable to the C-M&C-M ; !ort of the remote C. Connect the ?eyboard to the !anel c.

Ste! :

Setu! the Hy!erTerminal session on the remote C with the following !arameters:

4 StartD rogramsD ccessoriesDCommunicationsDHy!erTerminal4 (ouble clic? Hy!erterm.e#e icon 9 6Connection (escri!tion6 dialog a!!ears.4 Enter the Connection ame for e#am!le 0(Bcon;. Clic? -U 9 6Connect to6 dialog

a!!ears.4 Select (irect to C-M& (irect to C-M ;. Clic? -U 9 C-M& ro!erties dialog a!!ears.

Select:

4 aud 0ate:

4 (ata its:4 arity:4 Sto! its:4 >low Control:

4 Clic? -U.

&&/ ++

?one

&Hardware

Ste! ):

Setu! the Hy!erTerminal session on the !anel C com!uter with the following!arameters:

4 StartD rogramsD ccessoriesDCommunicationsDHy!erTerminal4 (ouble clic? Hy!erterm.e#e icon 9 6Connection (escri!tion6 dialog a!!ears.4 Enter the Connection name for e#am!le 0(Bcon;. Clic? -U 9 6Connect to6 dialog

a!!ears.4 Select (irect to C-M& (irect to C-M ;. Clic? -U 9 C-M& 6 ro!erties6 dialog

a!!ears. Select:

4 aud 0ate:

4 (ata its:4 arity:4 Sto! its:

4 >low Control:4 Clic? -U.

dd Coeler -!erating & Maintenance Manual

&&/ ++

?one

&Hardware

Cha!ter ) 9 notrol* +++ System


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S#ep ':

Start the Hy!erTerminal session on the !anel !c:4 Select Transfer" 0ecei$e >ile on the main window 9 the 0ecei$e >ile dialog a!!ears

on the screen.

4 Select rotocol W Vmodem.4 Bse the rowse dialog" select a recei$ing folder.

S#ep >:Start the Hy!erTerminal session on the remote !c.4 Select Transfer" Send >ile on the main window 9 the Send >ile dialog a!!ears on

the screen.4 Select rotocol W Vmodem.4 Bse the rowse function to select the name of the file you are going to transfer.4 ow both 9 the !anel and the remote !c are !re!ared for communication.

S#ep @:

ress 0ecei$e button on the !anel C 9 Vmodem window a!!ears.

S#ep :

S#ep *:

ress the Send button on the remote C. The Vmodem window a!!ears on the remoteC too. The data transfer begins and the !rogress bar indicates the acti$ity. fter the

transfer is com!leted" the Vmodem windows on both com!uters are getting dosed.

Close the Hy!erTerminal on the !anel and remote C.

RDU Shu# o8" Proce ure

>rom the -$er$iew screen !ress the E#it ?ey. nswer Jes to e#it the !rogram.

ress =indows* Start ?ey.ress Shut (own ?ey.ress -U ?ey to shut down the com!uter.

Tum off C !ower when screen dis!lays

-U.

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C/PS ACTI


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To start the unit" !ress the CTDMa switchL the green cti$e light will come on indicating thatanodic current will soon be starting" should the Control otential be below it's set !oint.

The out!ut current can be monitored $ia the Shunt Goltage terminals on the C oard /mG

for &++~am! a$g.;.

ressing the CTDMa switch again will shut down the CD Sout!ut and return the CD Sto theIdle mode. The green cti$e light will go out and the 0(B channel will go into Idle red mode.

The CD Smay be run com!letely inde!endently of the 0(B. Howe$er" no changes can be madeto set !oints and no alarms will be monitored.

C/PS Shu# o8" 9ro; RDU

>rom the -$er$iew screen select unit to be sto!!ed. The (etail screen is o!ened.ress Sto! ?ey. The CD Sanodic current will sto!. The green cti$e and green Channel will

turn red" the green cti$e light will also return to Idle mode.

C/PS Shu# o8" 9ro; C/PS

The CTDMa switch on to! off the Controller C oard ssembly will sto! the unit. ushingthis switch will sto! the anodic current and the green light will go off.

CO22UNICATION 4AILURE

If communication is lost between the 0(B and anyone of the CI S units connected to itChannelY on the -$er$iew screen of the 0(B will turn red Comm.Err.

If this situation should occur" an instrument technician familiar with the system should

in$estigate. =hen the condition causing the alarm is cleared" communications will be re9established and the alarm will reset automatically.

dd Cooler -!erating & Maintenance Manua'

Cha!ter ) 9 / notrol +++ System


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)i4


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CHE2ETICS

CHAPTER '

OPERATIN PROCEDURES

4 5eneral

4 cid Side ConsiderationsTem!erature @imitationsCauses and Effects of =ea? cid

4 =ater Side Considerations=ater >low 0ates=ater >iltration and Treatment!H and Conducti$ity of the =ater Maintenance of the !H Monitors

>reeAe rotection

4 articular -!erating ConsiderationsEnergy 0eco$ery cid Coolers

=ater ualityre$ention gainst Creating oiling =ater Conditions

!H Monitoringrac?ish and Seawater Coolers

Seawater Seawater >iltrationSeawater Treatment gainst iofouling"Etc. !H Monitoring

Summary of -!erating InstructionsThe Cooler 0ating Sheet s;The =ater >low (iagramStart9u! rocedures(ata Collection

ormal -!erating Conditions

4 ShutdownsShort Term lant Shutdowns 9less than ,

hrs long Term lant ShutdownsEmergency ShutdownEmergency Shutdown for Cooler Tube @ea?s

re!aration of the Cooler Shell Side for E#tended Shutdown

4 notrol* 0eadings

cid Cooler -!erating 7 Maintenance Manual

Cha!ter , -1

3peratin4 rocedures


37/173

- E0 TI 5 0-CE(B0ES >-0 CI( C--@E0S

5E E0 @

This cha!ter details the o!erating !rinci!les for the Chemetics acid coolers. It is im!ortant that all the!rocedures detailed in this cha!ter are clearly understood by all o!erating !ersonnel. Therecommendations are based u!on sound engineering considerations and e#tensi$e o!eratinge#!erience.

The $arious o!erating considerations" detailed in the following sections" form the basis for theo!erating !rocedures. These !rocedures are summariAed later in the cha!ter.

CI( SI(E C- SI(E0 TI- S

Tem!erature @imitations

6

.

nodic !rotection significantly increases the tem!erature limits for which stainless steel can be usedin acid ser$ice without the initiation of corrosion. Safe design limits ha$e been established and shouldnot be e#ceeded during o!eration. The ma#imum o!erating tem!erature is a function of the acidconcentration. @ower acid concentrations corres!ond to lower ma#imum tem!erature limits. Theselimiting tem!eratures are !lotted against acid concentration" as shown in the following figure .

The summary sheets at the end of this cha!ter define the s!ecific o!erating tem!erature limits for

this a!!lication.

It is im!ortant to 1;5

note that if during 125o!eration the acid 5

o ~ 155strength should ;

69dro!" then the acid~e?5

)i4. ;.1

tem!erature must Ee lowered secor9

;+. @5E

;

dingly. (o not ;5o!erate in the non9

shaded area abo$e 25

the line. a1 2 < N, > @ ?

K H2S+ ;

Bnder no circumstances must the acid concentration be allowed to fall below N+ 5 L5unless the e


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Acid Cooler -!erating 7 Maintenance Manual

Cha!ter , ~ -!erating rocedures


39/173

C!u/e/ !" E99ec#/ o9 7e! Aci

If the acid concentration is allowed to fall" then it may be difficult" or indeed im!ossible" to

establish a stable !assi$e film on the acid wetted surfaces of the cooler. If the cooler is ino!eration" then the established !assi$e film may be lost. Continued o!eration of the !lant under these conditions is e#tremely detrimental" not only to the cooler" but also to the associated!um!s and !i!ing.

The causesof wea? acid formation are

4 Erratic control of water addition.

(efecti$e strength analysis e


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;

B

o".

CHEMETICS

= TE0 SI(E C- SI(E0 TI- S

=ater >low 0ates

The coolers ha$e been designed for a high $elocity water flow through the tubes. This high $elocityminimiAes hard water scale formation and ensures that tube wall tem!eratures are maintained ascool as !ossible. (uring o!eration" design or greater water flow must be maintained. Tem!erature

= control of the acid must be made using the acid by9!ass around the cooler.

Throttling the water flow to the cooler must ne$er be used to control the acidtem!erature.

The easiest method of monitoring water flow through the cooler s; is by measurement of thewaterside !ressure dro! across the cooler. If the !ressure dro! is abo$e the s!ecified differential inthe o!erating summary" the water flow will be adeiltration and Treatment

I

>ine sand and other small !articulate material should not !resent any !roblems in the o!eration of the coolers. In fact" their !resence could be beneficial in retarding scale formation of the tube boresdue to their scouring action. Howe$er" It is !ossible" !articularly on once through water systems"that !ieces of debris and fibrous material may also be !resent. This material could lead to !artial or com!lete bloc?age of some tubes. If this should occur" the stagnant water In the tube will rise to thetem!erature of the surrounding acid which would" in some cases" reach the boiling !oint. This

condition may result in stress corrosion crac?ing and ultimately tube failure. It is therefore"e#tremely Im!ortant that tube bloc?age be a$oided.

-!erating e#!erience indicates that water treatment is usually re


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CHEMETICS

!H and Conducti$ity of the =ater

There are se$eral good reasons for installing a !H monitorDalarm system:

4 If the cooling water is re9circulating e.g. cooling tower;" a !H control system is usually !art of

the water treatment !rogram. To ensure that the !H ne$er dro!s below 1.+" it is ad$isable that a!H alarm is set at 1./" and in some cases" automatic neutraliAing of the circuit can also beacti$ated. This is es!ecially useful if acid gases from the !lant are drawn into the cooling tower water" thus forcing the !H down to serious le$els.

4 >or coolers ha$ing acid to water lea? !ath acid !ressure higher than water !ressure 9 the!referred case;" a !H monitorDalarm in the discharge water line of each cooler will !ro$ide timelydetection of a tube lea? after which immediate sto!!age of the !lant can be accom!lished" thusrestricting the amount of cooler damage to one lea?ing tube.

4 >or closed loo! demineraliAed water; systems or boiler feed water a!!lications" conducti$ity may

also be re;SM3 -f e+ui7alentmaterit= for Sea ater. !H proEe

>ig. ,. Sam!le ot.

Cha!ter , 9 /-!erating rocedures


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"

CHE2ETICS

@6

4 s a further chec?" use litmus !a!er to $erify the reading from the sam!le !ot s; at least twice!er shift sam!les should not be ta?en from the water channel drain or $ent $al$es because alea? could by!ass these !oints;. Similarly" litmus !a!er should always be used to ensure that alow !H alarm is in fact $alid and not an instrument malfunction.

4ree e Pro#ec#io"

4 It must be realiAed that a tube bore !lugged with debris" rust" etc." will not be self9drainingduring shutdowns. A #u e 9ille 8i#h 8!#er 8ill rup#ure upo" 9ree i"-. It is im!erati$etherefore that all the tube bores be !re$ented from !lugging or that they be !re$ented fromfreeAing. Steam inFection in the waterside of the cooler can be used.

CAUTION: c!re /houl e #! e" #o pre=e"# #he co" e"/!#e 9ro; 9ree i"- i" #he

cooler.

I

I

Aci Cooler

Oper!#i"- 7 Maintenance Manual

Cha!ter , 9 1

Oper!#i"- Proce ure/


43/173

CHEMETICS

PARTICULAR OPERATIN CONSIDERATIONS

Energy 0eco$ery cid Coolers

(emineraliAed water must be used as the cooling medium" when the acid cooler forms !art of an

energy reco$ery system. This ty!e of cooler normally o!erates with a Closed @oo! water circulatingsystem at ele$ated water tem!eratures resulting in high metal tube wall; tem!eratures. The designof an Energy 0eco$ery cooler is o!timiAed to ma?e the best !ossible use of a$ailable cooling water to!romote efficient heat transfer. Some coolers may be designed to use smaller diameter tubesbecause of the low water flow a$ailable.

The $ery high Tube =all Tem!erature associated with this ty!e of cooler re


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1

06 #'

CHEMETICS

!H Monitoring

This is an im!ortant consideration for closed loo! systems and the instructions in the !re$ious sectionmust be strictly followed.

rac?ish and Seawater Coolers

~= rac?ish and seawater cooled acid coolers i.e. coolers o!erating with greater than &+++ !!mchlorides in the water; reig. /.).

Seawater Treatment gainst iofouling" etc.

ll coolers are designed to ensure high water $elocities through the tubes to minimiAe the li?elihoodof fouling by marine life. Howe$er" it is !ossible" that crustaceans and other marine life could

accumulate in the less turbulent regions of the su!!ly !i!e wor? and the water bo#es. lso" in someregions of the world seawater can contain certain s!ecies of naerobic acteria" which ha$e !ro$ento be detrimental to the use of stainless steels and other materials. resence of these bacteria andother marine organisms must be controlled by the addition of a suitable biocide.

Chemetics has e#tensi$e e#!erience in the area and can !ro$ide assistance is testing andrecommendation of a suitable !rogramme.

CI0 MET* is a registered trademar? of Chemetics and was de$elo!ed s!ecifically for use in high chloride water.

Acid Cooler -!erating


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7 Maintenance Manual Cha!ter , ] 3-!erating rocedures


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CHEIG&ETiCS

>or more information on Chlorination 5uide @ines contact

Technical Ser$ice (e!artmentCHEMETICS22 0ailside 0oadToronto" -ntarioC ( M) &

Switchboard: ,&1; ,,29//,&>a#: ,&1; )N&9&1)2

, Hour Goice Mail: ,&1; ,,29++2&e9mail technical.ser$ices a?er?$aerner.com

!H Monitoring

It is essential that the !H monitoring e


47/173

C

CHEMETICS

SU22ARY O4 OPERATIN INSTRUCTIONS

The following sections are intended to !ro$ide a


48/173

CHEMETICS

NOR2AL OPERATIN CONDITIONS

Maintain tem!eratures and !ressures within the limits gi$enin the table below.0ecord the followingon a regular basis as !er !lant schedule:

9 acid and water tem!eratures and !ressures in and out of cooler.9 -T0-@ " $alues9 cooling water !H set low alarm at @.5 minimum;

OPERATIN PARA2ETERS .1 112.5 15;.1

limit:?* Aci Pre//ure Drop

Throu-h Cooler? a ? .@ 5 mG

255mF)/+mGS-mG

-utlet otential 0 6'0( High larmand

b; 0eading at the ControllerD ower Su!!ly C- S;:

@>5mF155 mG

>>5 mG155mF

>ail Safe @55 mG 1++mG

NOTE: The settings shown abo$e may Ee changed by the Chemetics 0e!resentati$efor coolers o!erating under different conditions.

dd Cooler -!erating & Maintenance Manual

Cha!ter , 9 11

-!erating rocedures


49/173

ii.. 4.


50/173

umber of asses !er Shell - E - EGelocity mean; mls GwW+.N, G#W-.3+ ).+/

H.

*.+

I

CHE2ETICS EFuip;e"#A Di=i/io" o9 A er G=!er"er C!"! !

HEAT E CHAN ER SPECI4ICATION SHEETob o.: +, 91&3

& Customer: S-BTHE0 E0B C- E0 C-0 -0 TI- 0ef. o: +) N+&&& lant @ocation: @ T Y " I@-" E0B Cust. -. o:+)H+2 ++9,+2 90 &

) Ser$ice of Bnit: (0JI 5 T-=E0 CI( C--@E0 (ate: 19+ct9+), SiAe: &+,& 9 N&,, Ty!e: E 9& Item: 23&)H/ Surf D Bnit: ,/, eff.s


51/173

F CHE2ETICS EFuip;e"#

+%A Di=i/io" o9 A er G=!er"er C!"! !

HEAT E CHAN ER SPECI4ICATION SHEETob o.: +, 91&N

& Customer: S-BTHE0 E0B C- E0 C-0 -0 TI- 0ef. o: +) N+&&&lant @ocation: @ T Y " I@-" E0B Cust. -. o:+)H+2 ++9,+2 90 &

) Ser$ice of Bnit: S-0 E0 T-=E0 CI( C--@E0 (ate: 19+ct9+), SiAe: &2/) 9 N&,, Ty!e: E 9& Item: 23 )H/ Surf I Bnit: &"+,3 eff.sluid Circulated N3./[ SB@>B0IC CI( SE = TE0&+ Total >luid uantity Cu.mlhr. "11,.3 )" ),.3&&& @iouling 0esistance m ]UD= T-T @ W +.+++ 1,/ Heat E#changed: 2/.1,&, M= [email protected].(.: /,. deg.C1 Transfer 0ate" Ser$ice: &"))&.2 Clean: "+/ . =Dm ]U2 CONSTRUCTION o9 e!ch SHELL3 (esign ressure ? a g; &+), N+N Hydro Test ressure ? a g; E0 C-(E E0 C-(E

)+ (esign Tem!. MI . I M ^. deg C o I ,40 /50 )& Tube o: ), +.+.: &/.32/ mm =5: &3a$g. @ength: N"&,, mm) Shell &.+.: &"2/ .1 mm Tube Mat'l: CI0 MET)) Shell Mat'l: S 9 ,+9)+,@), Channel Mat'l ;: CI0 MET Channel Co$er Mat'l: S 9/&192+ cDw CI0 MET liner ~9""99""99999)/ affle Mat'l: )++ SE0IES S?)1 Tubesheet Mat'l ;: CI0 MET)2 >low rrangement: C- 9CB00E T Cathode: >-B0)3 Corrosion llowance 9 Shell Side: &./mm Tube Side: +.+ mm)N 5as?ets 9 Shell: 5ylon >awn )/++ Channel: (urlon 5reen 3/++,+ Connections 9 Shell Inlet: ) 6 -utlet: ) 6 0ating: &/+Y 0>. S-.,& Channel Inlet: 16 -utlet: 16 0ating: &/+Y 0>. S-., Code: SME7 ro$. -f -ntario TEM : C Cust. S!ec: Chemetics,) =eight I Shell Shi!!ing: 3"+++ >looded: /2" ++,, 0emar?s:,/

,1,2,3,N 0e$. o: (ate: + -ctober ++, 9 (esign !ressure. noAAle units" weight.


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5

~9~.6

CHE2ETICS EFuip;e"#A Di=i/io" o9 A er G=!er"er C!"! !

HEAT E CHAN ER SPECI4ICATION SHEETob o.: +, 91 +

& Customer: S-BTHE0 E0B C- E0 C-0 -0 TI- 0ef. o: +) N+&&&lant @ocation: @ T Y " I@-" E0B Cust. -. o:+)H+2 ++9,+290&

) Ser$ice of Bnit: 0-(BCT CI( C--@E0 (ate: 19+ct9+)

, SiAe: / & 9 N&,, Ty!e: E 9& Item: 2321H

/ SurfDBnit: &) eff.s


53/173

CHE2ETICS Start u! rocedure

H-0IV- T @ SE = TE00 CUISH = TE0 C--@E0

0ESSB0E SI(E -> CI( BM@E U TH: CI( T- = TE0

A Chec? that the acid strength is within +./[ of design. If the acid strength is below thisle$el" obser$e the ma#imum concentration I tem!erature limits shown in >ig. ,.&.

3; -!en all water channel drain $al$es to chec? for acid lea?age when Circulationstarts.

C Close all acid side drains and o!en acid by!ass $al$e if installed. -rculate acid and chec?for lea?s around cooler flanges and !i!ing.

+; Bsing litmus !a!er chec? for low !H acid lea?age; at water drain $al$es

E; Close water channel drain $al$es if no lea?age obser$ed.

>; -rculate seawater I brac?ish water through cooler s; and chec? for lea?s at cooler flangesand !i!ing.

5; Confirm that the add !ressure e#ceeds the water !ressure at both ends of the cooler by aminimum of / to &/ !sig +.) to &.+?gDcm2 .

H; Chec? the !H of e#iting water and confirm that the automatic !H and conducti$ity monitorsare functioning correctly.

I; =hen the acid inlet tem!erature to the cooler reaches /+\C & o) for N3[ acid coolersand

)/ \C N/ o) for N)9N1[ acid coolers" switch on the -T0-@ ".

; Ensure that the add flow through the cooler does not e#ceed the design rating 9 refer toormal -!erating Conditions in this cha!ter.

U; Ensure that the water flow through the cooler is at I or abo$e the design rating 9 refer toormal -!erating Conditions in this cha!ter.

l dFust the acid by9!ass $al$e to achie$e the desired add tem!erature to the tower. cidtem!erature must Ee controlled by using an acid by9!ass $al$e and ne$er by throttling Eac/ on the water flow.

-TE: Monitoring the seawater !H is the !referred method of lea? detection. Test andreca ibrate the !H monitor wee?ly.

=here !resence of harmful bacteria has been confirmed" test for effecti$eness ofbiocide treatment at least once !er month.


54/173

:: .. % : :# .: ::: .. ::.:!: ...!::::.::::........ . : : :::::.:.::.: .. :.:.::# : :: : :::::~. ::: .. ::: :.: .. ::::: .. ::-.:::::-:: -:.: :.::: :.:.:.:$:$#::$:$::: L:::$:::$.#.:%:::~: .:::%:.:.:~.:.::::.: :.:.:.:.:. :


55/173

CHEMETiCS SHBT(-= 0-CE(B0ES @@ C--@E0S

SHBT(-= S

Short Term lant Shutdowns 9 @ess Than , Hours

a; Switch off -T0-@ " system when the add tem!erature to the cooler falls below:

/+ \C & 3) for N3[ acid or

)/ \C N/ 3) for N) 9 N1[ acid.

b; Sto! water circulation.

c; -!en all water channel drain $al$es and chec? the !H of the water.

d; =ater channel drain $al$es must remain o!en during the shutdown.

-TE: If both water and add flow is to be maintained for a short term shutdown"monitor acid strength and cooling water !H as normal see Short TermShutdown;.

WARNING: 9# cooler u i#( %ater of , ' CI or 'ore ;e.(. ea or bracollow ste!s a to c; in Short Term lant Shutdown. Uee! the shell side flooded with

strong acid.

b; lan? the add noAAles to !re$ent wea? add run off from the tower from entering the

cooler.

c; If it is not !ossible to blan? the acid noAAles" do a laboratory analysis of the acid in the

cooler and circulate the acid once a day to a$oid !oc?ets of wea? acid de$elo!ing. Ensure

that the acid does not get wea?er than N+[ at ambient tem!erature.

cid Cooler -!erating &. Maintenance Manual

Cha!ter ; - 12-!erating rocedures


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CHEMETICS

E;er-e"c+ Shu# o8"ower >ailure" @oss of cid or =ater >low;

a; -!en all water channel drain $al$es immediately.

b; If shutdown is to be e#tended" refer to long term shutdown !rocedure abo$e.

E;er-e"c+ Shu# o8" 9or Cooler Tu e Le! /

It is im!erati$e that the !lant is shut down as soon as !ossible after a lea? is

detected. a; Sto! water circulation.

b; -!en water channel drain $al$es immediately.

WARNING: der o dr+#&"ta +e" "ho#$d ater re&a% % the+oo$er)

c; Sto! acid circulation.

d; 0efer to cooler re!air section cha!ter 2;.

Prep!r!#io" o9 #he Cooler Shell Si e 9or E #e" e Shu# o8"

It is !referable to fill the cooler shell with N3[ acid and blan? the acid lines rather than to em!ty thecooler. (raining of the cooler should be underta?en only for re!airs or maintenance wor?. In such acase" refill the cooler with N3[ acid u!on com!letion of the wor?. If this is not !ossible" neutraliAethe cooler shell side and lea$e acid noAAles blan?ed until start9u!" then re9introduce strong acidcirculation see cha!ter 2;. If ambient tem!eratures during the shutdown are such that there is a ris?

of freeAing the N3[ acid ). . 9, \CD / 3) ! then the cooler shell should be filled with N1[ ). . 9&)5CT N 3) or N)[ acid ). . 9)) \CD9 2 o) and the acid lines blan?ed.

WARNING: Whe or3% ! o the to er" or a+%d $% e"' e "#re that ea3 a+%d +a#"ed b a"h% ! +a ot e ter the +oo$er") he +oo$er" "ho#$d beb$a 3ed off or the (%(% ! d%"+o e+ted a d ($a"t%+ +o,er" a(($%ed)

A$ a " dra% the ater fro& the +oo$er a d $ea,e the dra% ,a$,e"

o(e ) der o +%r+#&"ta +e" "ho#$d "ta! a t ater or e#tra$%"% !

"o$#t%obe $eft % the +oo$er)

cid Cooler

-!erating 7. Maintenance ManualCha!ter , 9 &)

-!erating rocedures


57/173

CHEMETICSIl

-T0-@* 0E (I 5S

Bnder normal o!erating conditions" the notrol* system will be stable. -ccasionally $ariations mayoccur in the readings" and these can usually be attributed to fluctuations in the !lant o!eratingconditions. In some cases they may also gi$e a warning that something is not or double9ended cathode coolers:To Increase -utlet otential:

&; Ensure cathode s; are connected at acid outlet end of cooler.2 Electrically disconnect cathode s; at acid inlet noAAle end of

cooler. To (ecrease -utlet otential:

&; Ensure cathode s; are connected at acid inlet end of cooler.2 Electrically disconnect cathode s; at acid outlet end of cooler.

b; >or single9ended cathode coolers with !in cathode at acid inlet noAAleend: To Increase -utlet otential:

&; Electrically disconnect !in cathode.To (ecrease -utlet otential:

2 Electrically connect !in cathode.

c; >or single9ended cathode coolers with !in cathode at acid outlet noAAleend: To Increase -utlet otential:

&; Electrically connect !incathode. To (ecrease -utlet

otential:2 Electrically disconnect !in cathode.

-TE: The Control Electrode should Ee at the acid inlet and -utlet otential at theacid outlet end of the cooler.


Cha!ter , 9 &,-!erating rocedures


58/173

CHAPTER

ROUTINE 2AINTENANCE

4 re!aration for Cooler Turnaround

4 Shell Side Ins!ection

Cathode Ins!ectionCathode @ife E#!ectancy

4 Tubeside Ins!ection

Hydroblasting of Tubes

nodic rotection System

0emote (is!lay Bnit 0(B;ControllerD ower Su!!ly CD S;>ield =iringS!are arts

notrol System S!are artsChemetics notrol* (efecti$e Com!onent0e!ort

Aci Cooler Oper!#i"- 2!i"#e"!"ce 2!"u!l

Ch!p#er (1Rou#i"e 2!i"#e"!"ce


59/173

:.:::::: :~.:.:.::-~:::.--::: .."'..::::.: .::::.-0-.-::::.:.. :-:.:::.:....%.. 0.::-: : : "'


60/173

CHEMETICS

lROUTINE 2AINTENANCE

Chemetics anodically !rotected acid coolers will !ro$ide many years of reliable and trouble freeser$ice if the basic -!erating and Maintenance rocedures are routinely followed.

The coolers are designed to withstand the normal $ariations in day9to9day !lant o!eration withoutthe need for constant adFustments or maintenance.

Howe$er" there is a need for routine maintenance" which is normally !erformed during the main !lantturn9around. t this time" many clients enlist the assistance of a Chemetics Technical Ser$ice0e!resentati$e to ensure that these essential fundamental chec?s and necessary adFustments aremade.

The focus of the turnaround ins!ection is to detect any deterioration in the !erformance or change inthe !hysical condition of the cooler" including the anodic !rotection system" since the last ins!ection.(etermine !ossible causes for such a condition and to ma?e the a!!ro!riate adFustments to correctthe situation.

There are ) main areas which re C--@E0S 0I-0 T- TB0 0-B (

I S ECIT- BU-l33-3V in cha!ter 2 of this manual" outlines the !rocedures" !recautions"e


61/173

SHELL SIDEINS PECTION

The shell of the acid cooler contains the sul!huric acid. E#treme !recaution must be ta?en to ensurethat @@ -( IS >B@@J(0 I E( !rior to beginning any of these !rocedures.

The !rime focus of an internal ins!ection of the shelf of an acid cooler is to $erify that there is noforeign materials which may cause bloc?age andDor restriction of the acid as it enters into the tubebundle and to confirm the effecti$eness of the anodic !rotection system in controlling corrosion fromthe hot acid.

T+pic!l Hori o"#!l Aci Cooler

Main cid (rain Gal$e E#!ansion oint (rain

NOTE: The small acid drain $al$e on the cooler e#!ansion Foint if installed; may re


62/173


63/173

H

Internal ins!ection of the shell of an acid cooler should" where !ossible" be delayed until the last fewdays of the maintenance shutdown to minimise the time !eriod when acid is drained from the cooler.(uring !eriods when there is no acid in the cooler" if moist air is allowed to enter the shell" wea? acidwill be !roduced in cre$ices between baffles and tubes etc." which can under e#treme conditions lead

# to localised corrosion in those areas.l (uring a shell side ins!ection" the following chec?s should be made:

1. Measure the ++ of the tubes and try to determine if there has been any metal loss since the lastins!ection corrosionDerosion damage;.

. @oo? for any $isual signs of corrosion and" if found" re$iew the o!erational log sheets includingthe notrol* readings to see if anything historical can be found which may !in!oint the reasonfor such damage.

). @oo? for any de!osits or coatings on the e#ternal tube surface that may be a !ossible detriment

to heat transfer. thin soft sul!hate coating is normal unless the de!osit has de$elo!ed to the!oint where bloc?ing the flow area between the tubes and restricting acid flow. E#cessi$esul!hates or a harder silica scale will re


64/173

C!#ho e I"/pec#io"

Main cathode ins!ection must be carried out during the !eriod when the acid is drained from thecooler. Each cooler contains one or more main cathode assemblies and on some coolers a !incathode. The actual cathode arrangement for a cooler is indicated on the s!ecific cooler Setting lan

see !!endi# ;.

cathodes rods are the sacrificial com!onent of the anodic !rotection system and will reirst cathode Ins!ection6 bedone within the first 12 to 1? months of ser$ice and that a com!lete set of cathode assemblies 9ore!ch cooler be on site.

Ty!ical Sul!huric cid Cooler

>igure /.&. Cooler with two (ouble9Ended Main Cathode ssemblies.

The main cathode assemblycom!rises the Cathode Rod!Insulating Sheath" ushing">lat =asher and Inner5land. In most instanceswhen the Cathode 0odre


65/173

CHEMETICS

>ig. /. shows a cooler with two Single9Ended Main cathode ssemblies and a in cathode at theo!!osite end to where the Main cathodes enter;.

>ig. /. . Cooler with

two Single9Ended

Main Cathode

ssemblies.

com!lete arts Bst of Main and in cathode ssemblies can be found in the cooler drawings see !!endi# ;.

Cathode @ife E#!ectancy

The useful life of an indi$idual cathode rod may $ary from cooler to cooler de!ending on a number of factors. cid concentration" tem!erature" $elocity and im!urities in the acid all ha$e an influence on thelife of the cathodes and !in cathodes" where installed;.

The ?ey factor" in determining if the cathode rod is reusable is therate of deterioration from a newcondition or the last ins!ection.

5enerally" a cathode rod shouldbe re!laced when it reaches +.,++inches &+ mm` in diameter.0einstalling a cathode below this!oint may cause se$ere damageto the cooler.

The re!lacement of com!onent !artsof each cathode assembly should bemade as e#!erience dictates.

Cathodes are s!edfic to one cooler and can seldom be used in a different cooler. =hen a cathodeis re!laced as a com!lete assembly" it is essential to note the serial number stam!ed into thesheath and to ensure that the assembly is being installed matches the serial number of the

cooler" otherwise se$ere corrosion of the cooler may result.

See rele$ant S!ecial Maintenance rocedure in Cha!ter 2.Acid Cooler -!erating 7 Maintenance Manual

Cha!ter / 9 10outine Maintenance


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CHEMETICS

TU3ESIDE INSPECTION

-ne of the most im!ortant!re$entati$e maintenance items is

to ensure that no tubes arebloc?ed by debris" es!ecially o$er an e#tended !eriod of time. bloc?ed tube with little or nowater flow o!erates at $ery hightube wall tem!eratures and istherefore" under stress. In the!resence of chloride9containingwater" a bloc?ed tube wille$entually fail by a !henomenonof stainless steel called stresscorrosion crac?ing. Ha$ing anadelow

>ig. /.). Inline=ater Strainer.

cooler will go a long way in !re$enting this unnecessary !roblem from occurring.design of an inline strainer that can be blown down to clean while in use"

>ig. /.) shows the

=ithin the first three months from the date of initial o!eration" it is strongly recommended to o!enthe small water side ins!ection !late or remo$e the water channel co$er; at the water inlet end of allcoolers to ins!ect for bloc?ed tubes" then clean if necessary.

>ig. /., shows a cooler with water channel co$er remo$ed refer to cha!ter 2 Channel Co$er 0emo$al=hen Main Cathode Is resent;.

If the !lant cooling water is of reasonably good


67/173

m

CHEMETICS

There are se$eral ways to determine whether a cooler is fouled:

&. The acid tem!eratures are !rogressi$ely getting hotter" e$en with cold cooling water tem!eratures and good water flow.

. The acid by!ass $al$e is being closed more and more to get e#tra cooling ability from thecooler. Soon" the by!ass $al$e is closed all the way and acid tem!eratures ?ee! going u!.

). (uring an ins!ection" when loo?ing down the bore of the tubes and obser$ing a light at theother end" no characteristic stainless steel shine is obser$edL a de!osit is on the tubes.

,. =hen obser$ing the water outlet end of the tubes" a filmy mineral de!osit may be seen andyou can carefully scra!e it off with a ?nife. In this e$ent" ta?e a sam!le and get it analysed.It is !robably calcium carbonate hard water scale; de!osits. If it is slimy" a biological!roblem e#ists.

Hydroblasting of Tubes=hen hard water scale or slimeDmud are !resent" the!referred method for cleaning is hydroblasting seecha!ter 2 for the recommended !rocedure;. 0g. /./shows a ty!ical o!erational s!ray head from ahydroblasting fle#ible lance s!ray head !ressures of /"+++6' +"+++ !sig ))/6'&"))/ bars; as needed toremo$e the de!osits.

)i4. >.>

Contact your Chemetics Technical 0e!resentati$e for ad$ice" if reor seawater9cooled e


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CHEMETICS

ANODIC PROTECTION SYSTE2

The notrol* system as described lnCha!ter ) generally reEta!e on the threads.

). (egrease the !latinum ti! Fust before inserting into the cooler use alcohol" acetone or non9residue contact cleaner s!ray`.

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CHEMETICS

I~

0e!lacement electrodes can Ee ordered as a bare electrode only D 9233/)9, see >ig. /.1;" or canbe su!!lied with a !rotecti$e Cona# housing D 9233/,9,.

0eference Electrode is installed on thecooler through a cou!ling located at

strategic !oints with res!ect to theformation of the anodic film.

Electrodes are maintained in good

Mounted in S&

cou!l

It is $ery im!ortant that the 0eference

wor?ing order at all times" as theyare the sensors by which the

notrol System functions.

0emote (is!lay Bnit 0(B;

4.4.4.44...444

444444

Threads!rotected

with Teflon 3E

I 5A&@15

The 0-B is the o!erator's communication interface with u! to & indi$idual anodic !rotectionsystems or CF S's. lthough the functionality of the system is designed to be o!erated from the0-B" an 0-B failure will not !re$ent the CD S from maintaining a !assi$e film within its res!ecti$ecooler.>ig. /.2 shows the frontdis!lay.

I

~

)i4.S.A

There is essentially no routine maintenance to be !erformed on the 0(B with the e#ce!tion of$erifying the tightness and deanliness of all e#ternal wiring connections.

The 0(Bwill Ee used to $erify andDor reset the s!ecific control and alarm $alues for the indi$idual CF Sunits that are connected to the $arious acid coolers.


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CHEMETICS

cid Cooler -!erating 7. Maintenance Manual

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71/173

Controller I ower Su!!ly ;C/PS) I 5A&@15&++ m!s Ma#imum (C -ut!ut;

The CIPS, which is selt9contained in an integral EM , or ,^ enclosure" is usually mountedoutside" adFacent to its res!ecti$e acid cooler. lthough in some acid !lants" this may be a harsh

en$ironment" if the unit is installed as !er s!ecification and the front !anel is !ro!erlysecured e#ce!t for maintenance access" the internal com!onents will reield =iring

The !hysical condition of the wiring that lin?s all the anodic !rotection system com!onents together is$ery im!ortant. 0g. /.3 shows a sim!lified basic electrical system with 0-B" CIPS and its cooler. co!y of the notrol System =iring (iagram can Ee found in !!endl# A. Many acid !lants ha$e acorrosi$e en$ironment" which in time may degrade the !hysical condition of the field wiring. (uring thenormal maFor !lant maintenance !eriod" it is recommended that the entire notrol =iring System Eefully ins!ected and tested to ensure trouble free o!eration.

0eid s!lices in node and Cathode wires should Ee thoroughly ins!ected for contact cleanliness andinsulation.

articular attention should Ee ta?en of the condition of the cable trays or conduits and fittings to ensurethat all drain !oints are free and o!en. (amaged com!onents should Ee re!aired or re!laced. llwiring and fle#ible conduits immediately adFacent to the cooler should Ee carefully ins!ected to ensurethat sensiti$e instrument wiring is duly !rotected.

cid Cooler -!erating & Maintenance Manual

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I

Si' lifie$ A#otrot" Wiri#( =ia(ra'

0emote (is!lay Bnit 0(B;Controller I ower Su!!ly CI S;

6F

II

node =ire III

IIIII

~-+--~------------~~I-----------------------------I

:-Cathode Goltage =ire(I

:~~:~0~~~ =I

I S!are arts)i4 >.?

To ensure the continued reliable o!eration of the acid cooler" it is essential to ha$e an ade


73/173

&.Maintenance Manual Cha!ter / 9 &0outine Maintenance


74/173

com!rehensi$e list of 0ecommended notrol S!are arts is detailedbelow.

; 0eference Electrodes

I C233/)~, 0eference Electrode only;

I C233/,9, 0eference Electrode c/w housing;

; notrol* +++

0(B I +2N1&+;

art umber (escri!tion+2N1 + C oard ssembly

+N3++)~&) +./ m! >use" /+ G C Sio lo >use

C/PS I +2N1/+ with EM , or I +2N1/& with EM ,^ enclosure;

art umber (escri!tion++N ++ 0>I >ilter & m!;+2N11/ Controller C oard ssembly

+N +++~l^> ),+ +2 ower M-S>ET Uit+N ++&~,,+CM +)+ (iode" Schott?y 0ectifier

5 24-V 20>A3 ? M-S Garistor )+ VAC +N3+&/ >& >use; l- )+ VAC (elay;

+N,+/)9 + >& >use; + &&/ VAC (elay;+N,+//9&/ > >use; V2 m! )+ VAC (elay;+N,+//9 + > >use; l m! &&/ VAC (elay;

+N, 1/ ower Transformer

-TE: (amaged or sus!ect Controller C ssembly PIN +2N11/ can be returned toChemetics for testing and re!air.

lease refer to >ig /.N for instructions.

C Mechanical S!are arts !lease see cathode drawings in !!endi# ;

for main cathodes

art umber (escri!tion&+& cathode 0od

103 c/w 102 lug c/w 0i$et

cid Cooler Cha!ter / 9 &)-!erating 7 MaintenanceManual 0outine Maintenance


75/173

:

art umber De/crip#io"15; cDw 152! 15< Sheath SE; c+% 0i$et" lug

, 3 c+% , 0 Sheath (E; cDw Slee$e

15; - 1 da!ter for Sheath 0e!air

15> cathode Slee$e251 cDw 25@ Inner 5land cDw 5land Slee$e

25; -uter 5land25 >lat =asher 25 ushing in two !arts 25 -1! 25 -2

215 -uter ac?ing211 Stud

212 ut

4or pi" c!#ho e/

art umber De/crip#io"151- cathode 0od152 - Sheath

251 - CD=25@ - ac?ing 5land cDw 5land Slee$e252 - cDw 215 - U Stuffing o# cDw >lange

252 - U^ Stuffing o# to >it Cou!ling25 - U >lat =asher 25 - ushing in two parts 25 -1 ! 25 -2

Co;;o" ;ech!"ic!l /p!re/

P!r# Nu; er De/crip#io"151 - ; cDw 151 - 1 7)

25?Connector Cc/% @oc? ut and Set Screw; I

Stic? ac?ing


Cha!ter / 9 1!0outine Maintenance

: :99::'9"66.:':6::.:'::.9' . . .-0... :.::.::: ....:.--.-.-.-... .... .


76/173

B.S. .

-o

.c

a

V

~

::

a:

.-e ~

Com!any

CHEMETICS -T0-@ " (E>ECTIGE C-M - E T 0E -0T I

< ame: roFect:Iloo

5 ddress:6+CRtD; lant umber: Start9B! (ate:

L'

&;

o

Cooler Serial umber 7 (uty

(E>ECTIGE C-M - E TJ5-m1:: art umber:

a..&; (escri!tion -f >ailure:

0e!ort Submitted Wy: (ate:

en O8.~Com!lete This 0e!ort nd Send =ith (efecti$e Com!onent To:

5 c~ ChemeticsiW .8 ~ cDo 0ohrbac? Cosasco Systemsc 5! &&3,& East Smith $e.a: Santa >e S!rings" California" N+12+eIn

9

e ea:+..

..lIC:. ddress:+ 9996.~6".~~~99~XI

. ~:' _cC

en5

ttention:

-TE: -T0-@* !arts may be returned for re!air. =arranty re!airs are at no charge. If a charge for re!air is a!!lied you will be notified and a !urchase order reree;.

>ailure to follow this !rocedure may result in (uty being charged on the full $alue of the !art.

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-!er

ating7.

Maintenance Manual


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)i4. >.

Cha!t

er / 9

&/

& I0outineMaintenance

B.r


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11 CHEMETICS

CHAPTER )

PER4OR2ANCE 2ONITORIN

4 (ata Collection

4 (ata Correction

4 >low Calculation sim!lified;

4 Calculating Cp s!ecific heat; for cid

I "4 Thermal erformance

f

"

I

I0=


Cha!ter 1 9&erformance Monitoring

:.'"' .. ::: .. 0.:.-- ::.# .::0 0-: :::..!#!::::.0:.::0-:.::.:::~.:::.-: ..::.-:::.%.*:::..:-- : : -.. . Q6 ..: .. 0.0 ...L .. !:-!-- ..!-0 --0 .


79/173

CHEMETICS

PER4OR2ANCE 2ONITORIN

(uring normal o!eration" it is recommended that regular tem!erature and !ressure sur$eys beconducted to monitor the thermal !erformance of the cooler. These sur$eys are instrumental in!ro$iding an early indication of the onset of formation of a fouling de!osit that could limit the cooling

ca!abilities of the cooler or e$en lead to the onset of stress corrosion crac?ing or other !otential!roblems.

=hen a cooler is o!erating under design conditions" i.e. at design ca!acity with design cooling water flow" a D +.)\C.=here !ossible" it is recommended to use a single !ressure gauge to eliminate measurement errors.Mo$e the gauge from !oint to !oint" ma?ing note of height difference between measuring !oints.

e.g. water inDout" acid inDout;

5auges with a large scale range should be a$oided" as this will reduce the accuracy of the readings.

Sur$eys !erformed using !ermanently installed instrumentation seldom !ro$e to be worthwhile" asthe calibration of the instruments is always in


80/173

CHEMETICS

&

DATA COLLECTION 3/ ThermowellConnection

It is recommended that a sur$ey only be ta?en after the !lant rate hasstabiliAed for a minimum of hours where !ossible;.

(o not adFust setting of by!ass $al$e s;" water or acid flow rates

before or during the sur$ey.

4 cid and cooling water tem!eratures should be measured at the thermowell connections!ro$ided on the res!ecti$e cooler noAAles.

4 carefully remo$e thermowell shi!!ing ca!s and fill the thermowells with light oil" glycerinor other $iscous fluid.

4 llow / minutes to ensure that the thermometers stabiliAe at the correct tem!eraturebefore ta?ing readings.

4 =or? on one cooler at a time. Ta?e tem!erature readings within as short a !eriod as!ossible & 9 minutes;.

4 Ta?e one com!lete set of tem!erature and !ressure readings and re!eat after fi$eminutes.

DATA CORRECTION

efore using the data for calculation" the acid andwater !ressure readings must be adFusted to ta?e intoaccount any difference in ele$ation between themeasuring !oints.

(ifferentialStatic Head

If the cooler has a bottom inlet or is a $ertical cooler" then an adFustment for the static head must Eea!!lied.

If the measurements are ta?en at the !ressure connection on the res!ecti$e noAAles of a horiAontalcooler where acid inlet and outlet are both on t- I usually no adFustment is re


81/173

CHEMETICS

4LO7 CALCULATION ?SI2PLI4IED

ctual acid and water flow through the cooler can be calculated using the following formula:

ctual flow W (esign flow #~ a

~ d;

=here ~ a; is the corrected actual measured !ressure loss@l d; is the design !ressure loss as stated on the S!ecification Sheet(esign flow is the mass in IbFhr or ?gFhr as stated on the S!ecification Sheet

-nce the actual acid and water flows ha$e been calculated" these $alues can then be used tocalculate the heat load using the formula:

W ctual >low # C p # dT

=here @KT is the measured tem!erature difference between the Inlet and -utletC ! is the s!ecific heat for either acid or cooling water.

>or !ractical !ur!oses the s!ecific heat of water can be ta?en as &.++ TBFlb%o> ?calD?g%\C;.

CALCULATIN C p ?SPECI4IC HEAT 4OR ACID

S!ecific heat of acid $aries with tem!erature and concentration. >or the !ur!ose of !reliminarycalculation" use the $alues in TBFlb%o> ?calF?g'\C; in the following table for the a$erage acidtem!erature:

[ H2S- ; $erage Tem!erature" 3) ee;1;5 @5 1; @> 1>? 5 1@ > 1 @ ?5 1?> ?> 1 ; 5 25< >

< 5. 5. 5.


82/173

THERMALPERFORMANCE-nce the cooler heat load has been established" the calculated $alue can be used to determinethe heat transfer rate within the cooler using the formula:

Z W rea # HTC # @MT(

=here rea is the heat transfer surface as stated on the acid cooler S!ecificationSheet.

HTC is the heat transfer coefficient

@MT( is the calculated logarithmic mean tem!erature difference.

Bsing the measured tem!eratures of acid and water" calculate the @MT( as follows:

T&T) cid In

T cid -ut T,

Calculate the tem!erature difference at each end of the cooler.

Start with the cid Inlet tem!erature and the corres!onding water tem!erature at the same endof the cooler:

Similarly" calculate the tem!erature difference at the cid -utlet end. This $alue will be @lT .

Bsing these $alues" calculate the @MT( with the formula:

@MT( WIn


Cha!ter 1 9 /erformance Monitoring


83/173

The HTC can now be calculated:

HTC 6 rea # @MT(

t design !roduction rate" if the calculated $alue of the HTC is greater than the $alue shown on the cid Cooler S!ecification Sheet" the cooler can be assumed to be clean" that is o!erating with nosignificant accumulation of a fouling de!osit.

If the calculated $alue is less than the design $alue and the cooler by!ass $al$e is closed" thisindicates that the cooler is fouled and re


84/173

. CHEMETICS

CHAPTER &

SPECIAL INSTALLATION AND 2AINTENANCEPROCEDURES

rocedure umber

re!aration of Coolers rior to Turnaround Ins!ection

Mothballing an cid Cooler for E#tended Shut (own

I . . How to alance cid 0eference Electrode 0eadings (uring-!eration

How to Test the notrol* System =hen the Cooler is ot >looded =ith cid

U 155-5

U 115-5

' 155-5E 115-5

Channel Co$er 0emo$alMain Cathode 0emo$al (ouble9ended Style;

Main Cathode 0emo$al Single9ended Style;

How to Se!arate the Main Cathode 0od from its Sheath0ebuilding a Main Cathode ssembly

How to 0emo$e a ro?en Main Cathode from a Cooler

How to 0emo$e and 0ebuild a in Cathode

0eference Electrode Maintenance rocedure

M 155-5

M 115-5

M 125-5M 15-5

M 1@5-5M 1 5-5

Cleaning =ater Side;

Cleaning cid Side;

eutraliAing the =ater Side of a Cooler fter a Tube@ea?

eutraliAing cid Side of a Cooler rior to =elding 0e!airs

C 155-5C 115-5C 125-5C 1ollowing a @ea? 0e!air 0 155-50 115-5

Iron ddition to >orce the assi$ation of a (ifficult9to9 assi$ate Cooler 155-5

cid Cooler

-!erating 7. Maintenance Manual

Cha!ter - 1S!ecial Installation and


85/173

Maintenance rocedures


86/173

CHE2ETICS Speci!l 2!i"#e"!"ce Proce ure

PREPARATION O4 COOLERS PRIOR TO TURNAROUNDINSPECTION

Proce ure No. 100(0 P!-e 1 o9 $

PURPOSE

y com!leting the following tas?s !rior to the ins!ection of the acid coolers" you will ensure!ersonnel safety !lus cooler !rotection will be maintained:

&. =hen the acid tem!erature dro!s below & ofD/+\C for N3[ acidL below N/ ofD)/\C for

N)[ acid;" switch the notrol* system off.

. (rain all the water out of the cooler. Uee! water drain $al$es o!en during the turnaround.Shut off the acid !um! but ?ee! the coolers full of acid unless they are self9draining;.

). (isconnect water dilution lines to !re$ent accidental dilution of acid in the acid circulatingsystem.

,. To !re$ent corrosion by wea? acid" blan? off the cooler s;" es!ecially if it is necessary to washthe tower s; or Ff the !lant will be ino!erati$e for a long !eriod of time e.g. o$er two wee?s;.=ea? acid draining from the tower can corrode the coolers. The acid in gra$ity acid flow coolersshould be sam!led daily. Ideally these coolers should be isolated from the tower with blan?sinstalled if the shutdown will e#ceed two wee?s.

/. um! acid out of non9self draining coolers with notrol* system off; Fust before o!ening for ins!ection. Gertical coolers re


87/173


PREPARATION O4 COOLERS PRIOR TO TURNAROUND

INSPECTION

Proce ure No. 100(0 P!-e $ o9 $

15. If the waterside is deemed dirty" arrange for a hydroblasting crew to be on site forhydroblasting the bore of the tubes. The hydroblasting should be done with >!555 - 15!555 !sig


88/173

Speci!l 2!i"#e"!"ce Proce ureCHE2ETICS

I

I

I

2OTH3ALLIN AN ACID COOLER4OR E TENDED SHUT DO7N

Proce ure No. 110(0 P!-e 1 o9 1

2OTH3ALLIN AN ACID COOLER 4OR E TENDED SHUT DO7N

The maFor concern during an e#tended shut down is the !re$ention of wea? acid corrosion of the stainless steel acid cooler. Chemetics recommends utilising one of the two followingmethods" de!ending on how the acid !lant is to be laid u!:

1. 7e# L!+ Up i.e. the !lant is ready for start u! at some future" un?nown date;.

In some cases it is desirable to circulate acid o$er the towers once a day. This is acce!table.

for the Chemetics acid cooler !ro$ided strong acid is maintained at all times and the cooler remains flooded when the acid !um! is shut off. -b$iously" it is im!erati$e to do a strengthanalysis on a regular basis and change out the acid if the strength gets down to N)[. E$enmore desirable" a range of strength from N1 fG NN[ is less corrosi$e at ambienttem!eratures and less li?ely to form !oc?ets of wea? acid corrosion.

Should the Chemetics acid cooler be self9draining or become !artially filled with acid whenthe acid !um!s are shut off" then blinds should be installed at both acid noAAles to ?ee! themoisture out. E$en more desirable" !roceed to section below and neutralise the shell sideafter the cooler is blinded and drained on the acid side.

WARNING: .or "ea ater +oo$er" %t %" re+o&&e ded to e#tra$%"e ater "%dea++ord% ! to the Pro+ed#re C 120-0' f$#"h "e,era$ t%&e" %th fre"h

ater' dra% a d $ea,e ater dra% ,a$,e" o(e )

2. Neu#r!li/!#io" o9 All Aci

If the Chemetics acid cooler is ta?en out of ser$ice for storage" shi!!ing or re!air" both acidside and waterside must be neutralised to !re$ent wea? acid formation and internalcorrosion. lease refer to the !rocedures C& +9+ and C&&+9+. As e#!lained in Cle!"i"-?Shell Side;" water andDor moist air should ne$er enter the shell side of the cooler"otherwise wea? acid corrosion can ra!idly ta?e !lace.

fter neutralisation blinds may be remo$ed to allow for ins!ection or re!air. Howe$er" for long9term !rotection use a $acuum !um! to dry acid side thoroughly. The blinds should beleft in !lace cDw rubber gas?ets. Bnder se$ere climatic conditions e.g. shi!!ing by sea;"

both shell and tube side must ha$e a nitrogen !ad cDw !ressure gauges fitted to witness!ositi$e and effecti$e internal !ressure" "...."/!sig )/ ? a;.

AGER/F='R 'R~


89/173


HO7 TO 3ALANCE ACID INLET OUTLET RE4ERENCEELECTRODE READIN S DURIN OPERATION

&!.:..1.

#:~ #6"r.

I

I~:

I

I .....L

";

Proce ure No. E 100(0 P!-e 1 o9 $

The day9to9day o!eration of the acid coolers would normally re


90/173


HO7 TO 3ALANCE ACID INLET OUTLET RE4ERENCEELECTRODE READIN S DURIN OPERATION

Proce ure No. E 133~3 P!-e $ o9 $

* Spli# 4lo8 Aci Cooler/ 7i#h Si"-le(E" e S#+le O9 C!#ho e?/ , O"e Pi" C!#ho e A#Aci I"le# ?Ce"#er No le A" O"e Or T8o Pi" C!#ho e?/ A# The Aci Ou#le# No leLoc!#e A# The Oppo/i#e E" To The 2!i" C!#ho e E"#r+

NOTE: In this configuration" Monitor or 0 ; 0E is a third electrode at the far endfrom the Main cathode entry and Monitor Rl 0E is at the Main cathode entryend. Control is in the acid inlet middle; noAAle" as usual.

4 The Control central acid inlet; R' will be located close to the !rimary in Cathode acid inletnoAAle; which is almost always re


91/173


I

I

HO7 TO TEST THE ANOTROL SYSTE2 7HEN THECOOLER IS NOT 4LOODED 7ITH ACID

Proce ure No. E 110(0 P!-e 1 o9 1

=hen a cooler is drained of acid" the reference electrodes will not emit milli$olt signals and currentwill not !ass from cathode to anode cooler;. oth of these need to ha!!en if the anodic !rotectionsystem is to be thoroughly tested out.

1. To generate a milli$olt signal to fool the system with false electrode readings" a $ariable milli$olt(C su!!ly will be reor a )++ mG in!ut" the Control" 0l and 0 thru 0S if beingtested; will all read )++ mG mG. The cathode Goltage should read +.) $olts.

2. Start the CI S !ress 0eset 7 Set; from the 0(B or de!ress the 5lM- switch at the CI Sto turn the green @E( on.

3. (ecrease the )++ mG in!ut to ++ mG l.e. below the Control Set oint; and wait to see if Cathode am!s start to Ee introduced to the cooler. This may ta?e u! to 1+ seconds to begin.

N. If the and is &++ mG wide" then a control in!ut of &++ mG below set !oint should yield &++ KCF S cathode Current either 1+ or &++ am!s" de!ending on (i! Switch Y2 setting;.

15. >urther adFust Control in!ut u! 7 down to test all alarm set !oints.

A"E# UG :0 E0~


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PURPOSE

CH E@ C-GE0 0EM-G @

rocedure o. M &++9+ age & of &

This !rocedure is !ro$ided to detail the ste!s necessary to remo$e the channel co$er s; from an

acid cooler to guard against damaging the Cathode i!e s; which e#tend from the tubesheetthrough the co$er and isolate the main cathode s; from the cooling water.

>igure 2.& shows a cooler with main cathodes and thechannel co$er remo$ed.

>igure 2. is a s?etch showing the com!onents" which ma?eu! the seal between the cooling water and the outside of thecooler. These com!onents are referenced in the !rocedureand should be retained for reinstallation.

4 I +,

Main Cathodes

I>ig.2. -uter 5land ssembly

PROCE URE

&

)i4. .1

&. Ensure that cooling water has been drained from the cooler and that the drain $al$es are lefto!en.

. 0emo$e the Cathode Co$er and loosen , nuts I & securing the -uter 5land PIN +, bya!!ro# 9 ) turns counter cloc?wise. It is not necessary to remo$e the nuts or the -uter 5land.

). @oosen nuts securing the Channel Co$er to the flange on the water bo#.,. Su!!ort the weight of the channel co$er" with a crane" hoist or other means and remo$e all

nuts securing the co$er to the main flange./. ull co$er straight bac? and away from the water bo# for a!!ro# & in )+ cm; and carefully

!lace in secure area.1. Ins!ect the gas?et for !ossible reuse and !rotect from damage.

The water bo# is now ready for ins!ection.

0einstallation of the co$er is done by !re!aring the gas?et and re$ersing ste!s ) through /.

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2AIN CATHODE RE2Oig.2. for !art numbers and descri!tion.

b; efore installing any new cathode assembly" lay new rod assembly alongside theremo$ed assembly to insure sheath configuration and that the o$erall length matches.Each cathode assembly is made for a s!ecific cooler" normally ha$ing the cooler serialnumber stam!ed on the sheath close to the threaded end.

CAUTION: Do "o# i"/#!ll #he 8ro"- c!#ho e !//e; l+

The 9ollo8i"- proce ure !//u;e/ #h!# #he c!#ho e re;o=!l e" i/ "o8". I9 i# i/ i"Fue/#io", re9er #o M ue/#io"! le C!#ho e Re;o=!l E" M loc!#e !# #he e" o9 #hi/

proce ure.

REMO!ALPROCE URE

1. efore wor? is to begin on the cooler" ensure it has been drained of acid and water and that all$al$es are closed and loc?ed out. Turn notrol* !ower off and loc? out fuse bo#es D brea?ers toControllerD ower Su!!ly CD S;.

. >rom the cathode remo$al end see Setting lan of cooler listed in the (rawing Section at theend of this manual;" disconnect the cathode wire from the connector I &+&9,; by loosening

the Set Screw I &+&9);. 0emo$e Connector i &+&9,; and @oc? ut I &+&9&;.

). 0emo$e the Inner 5land I +&;" clean and ins!ect thread condition and 5land Slee$e D+1; for damage. Set aside.

,. Bsing a stic? !ac?ing remo$al tool" ;3- /i long" flat screwdri$er is suitable;" remo$e and cleanstuffing bo# of all stic? !ac?ing and discard old !ac?ing.

/. >rom o!!osite end of cooler" re!eat ste!s " ) and , if full ins!ection is desired. Howe$er" theo!tion to lea$e this end !ac?ed is a$ailable !ro$ided the stic? !ac?ing is in good condition

remo$e gland nut only in this case" ste!s 7 );. Com!lete ste! , only if the !ac?ing is blac?and saturated with acid.

1. >rom cathode remo$al end" re9install ut and Connector I 's &+&9& I &+&9,;" loc?ing theconnector to the rod with the nut. Bse a steel rod or screwdri$er inserted into the connector'shole and !ull Main cathode ssembly rod & sheath; from its su!!ort !i!e. =ith the assistance

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2AIN CATHODE RE2O


95/173


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QF

2AIN CATHODE RE2Oig. 2.3 for !art numbers and descri!tion.

b; efore installing any new cathode assembly" lay new rod assembly along side theremo$ed assembly to insure sheath configuration and o$erall length match. Eachcathode assembly is made for a s!ecific cooler" normally ha$ing the cooler serialnumber stam!ed on the sheath close to the threaded end.

CAUTION: Do "o# i"/#!ll #he 8ro"- c!#ho e !//e; l+

(uring turnaround ins!ection of acid coolers" the Main and in Cathode assemblies will re


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2AIN CATHODE RE2Olat =asher 25 o$er cathode rod threaded end;" and !ush into stuffing bo#" flushwith ushing 25 .The flat washer has a slight ta!er to itL install with the wider side facingyou.

12. Insert si# to se$en !ieces of Stic? ac?ing 25W see NOTE below; into stuffing bo# andtighten the !ac?ing gland nut. This may ta?e two ste!s by inserting three or four !ieces"installing !ac?ing gland and com!ressing !ac?ing" then remo$e !ac?ing gland" insert remainingstic? !ac?ing and re9tightening gland nut.

AGERUG E0 E0~

8/10/2019 Limpieza de Catdos 03H07200-4-

limpieza de catdos 03h07200-4-ven-7813-13-r1 trans1

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