Professional Documents
Culture Documents
3.10 Ej 4396 Sjae
3.10 Ej 4396 Sjae
Date : 14.11.2019
Operation & Maintenance Manual of SJAE
Work Order No. : EJ 4396
INDEX OF MANUALS
1 O & M Manual of Gland Steam Condenser ‐‐‐‐‐
2 Globe Valves / Gate Valve STEEL STRONG
4 Ball Valve AUDCO (L&T)
5 Ball Float Steam Trap PENNENT
6 STRAINER PENNENT
7 SRV & TRV FAINGER
8 Rotameter KABIR
9 Instruments (PG/VG) GIC
10 Instruments (TG) GIC
OPERATION
AND
MAINTENANCE MANUAL
FOR
EJECTOR SYSTEM
NEW FIELD
1
ORGANISATION SERVED : SIEMENS LTD
NEW FIELD
MANUFACTURED BY
2
MULTI STAGE EJECTOR
After receipt of Ejector system along with its accessories and packed components - the same
shall be stored properly, after verification with packing slip.
For prolonged storage, the Ejector system shall be stored in proper condition without dismantling
any components or unpacking any material from boxes. This will ensure that all the necessary
parts are not misplaced during the storage duration.
1. Cleaning Shell side of Inter condenser and After condenser by water for removing dirt,
Foreign particles for repetitive cleaning of ball float trap.
2. Tube of inter and after condenser. Should be kept clean on water side.
6. Cleaning of loop line and trap line by water flushing before installation/ erection.
EJECTOR is very simple equipment which operates on the momentum transfer principle.
1. Check all Nozzle joints and steam chest joints for Leak Tightness.
2 Take a leak test of system for ensuring the system leak tightness of the Complete System
Which is to be operated under Vacuum.
For leak test put blind over Nozzle Vapor header, Steam header, Hogger out let, after
condenser vent, & Rotameter vent connections.
3
Keep open all valve of Ejector vapor (suction) side, Ejector discharge Valve, Ejector
Steam Inlet valve.
Fill water from bottom connection that is from bypass valve of after condenser atoms drain &
Remove entrapped air from the system by venting different location like high points of inter
Condenser, after condenser, vapor header & steam header.
It is Advisable to blow off the Steam line with help of Motive Steam at rated pressure to
remove any dirt, slag etc which could clog the Steam Nozzles.
Steam supply pipe must be of proper size, to pass correct quantity at design pressure.
The Ejector inter condenser condensate Loop line keep 2.7 met lg straight & from loop
line there should not be any restriction of flow of the condensate to the Flash Tank.
Ball float steam trap shall be installed as per in condensate trap line of after condenser.
STARTING
For starting new installation, steam line should be blown from the steam nozzles to the
atmosphere & Opening the steam side valve.
For ejector servicing power plant as venting equipment, when not enough condensate from
the main turbine is available to condense the motive steam and cool the air in the ejector
condensers, circulating water from an outside source must be used.
4
Check and Ensure the Correct Steam pressure & Steam Temperature at ejector steam
header and keep all Steam Valves in closed condition.
The drain valve if any should be in open condition during start up the pre- heating the
steam piping as well the steam header and also to remove any condensate in the line.
Start circulating the cooling Condensate through the tube side of the Ejector Inter and
After condensers making sure that there is sufficient flow water coming from Condensate
Extraction Pump a Water pressure should be sufficient working pressure Ejector inter
condenser water inlet.
For starting Hogger Ejector open Motive steam in let valve and by maintaining correct
steam pressure & temp open the Vapor side (suction) valve
With the help of Hogger Ejector, the system will be evacuated to attain a Vacuum of 70%
within 30 minutes.
For taking one pair of service ejector in operation, open Discharge valve of Z stg Ejector
& Open Motive steam valve of Z stg ejector.
Open discharge valve of Y stg Ejector & open Vapor (suction) valve of Y stg Ejector.
5
Open the condensate line valve of loop seal of Ejector Inter Condenser and condensate trap
line valve of the After Condenser before & after the Steam trap to allow condensate to
flow to the hot well.
6
Inter Condensate Loop Assembly
7
Once the service Ejector is taken into operation, close shut down the hogger ejector. For
closing Hogger ejector, close vapor (suction) valve of Hogger Ejector & then close the
Motive steam valve of Hogger ejector.
In order switch over from one side (Operating) Service Ejector to Another side (Standby)
Service ejector, open Discharge valve of Y stg & Z stg standby Ejectors.
Open Motive steam valve of Y stg and Z stg Ejector & Open Vapor (suction) valve of Y
stg and Z stg Ejector.
Then close vapor (suction) valve of Y stg and Z stg Ejector and then close motive steam
valve, close discharge valve.
First steam valve to be closed first Y stg and Z stg ejector whichever is in operation.
Then close all isolating valve of both stages of vapor side Valve of ejector discharge side
Valve.
Close condensate line valve of loop seal and condensate trap line valve.
8
Close the after condenser vent Rota meter line valve.
Then circulating water valve to be closed. In the case where ejector operates on condensate
from a surface condenser as the cooling medium for the inter and after condensers shut off
Condensate pumps and then close valve in re-circulating time.
DO NOT DO.
Do not open drain valve of inter condenser loop drain while system is in operation.
Do not open ball float steam trap without isolating system side down stream valve.
Do not kept open Hogger Vapor (Air/Suction) Valve while Motiv Steam valve of Hogger
Ejector in close condition & System in operation.
Do not open Vapor (Air/Suction) Valve for initial vacuum pulling till Motive Steam
Pressure and Temp reach design parameters.
Do not operate Vacuum system without achieve desire design parameters at steam header.
Do not kept open any valve of vacuum system while starting the system.
Leaky Tube:
By replacing defective tube. If a leaky tube is discovered is the condenser, the operating
requirement may not permit sufficient shut down time to allow for removal of the tube.
In this case a wooden plug may be driven in both end of the tube. Until you get time to
replace the tube.
9
By cleaning tubes by wire brush or by blowing with air or steam or by turbine type
cleaner or by proper solvent cleaner for a hard scale.
Check vapor/air coming out of the vent of blower if seal may not be there you found air
shucking from out let Conn of blower, at the same time one should isolate ball float trap
from the system & allow to go condensate in atmosphere & by cleaning ball float trap re
fixed up & took in operation in system.
Check on line in system with smoke /candle light if one found smoke/candle light going
in side of joint it seem that there is leakage from that joint. By taking shut down that joint
should be replaced.
Correct C.E. Pump discharge pressure at Cooling Water in let connection of ejector
water in let nozzle.
Lower pressure of steam than design pressure. Correct steam pressure at design pressure.
In this case one found ejector suction body heat up & less vacuum for this open steam in
let nozzle of that ejector & apply sufficient packing between nozzle & adopter joint &
tight them faultlessly.
At that time one should take shut down & replace defective tube.
10
Breaking of the loop seal between the inter condenser and main condenser.
If it observed that the inter condenser & main condenser vacuum will be same, then
primary cause would be the breaking of loop seal in U loop between the Ejector Inter
Condenser and the Main Condenser. In order to Seal the loop line again in running
system close valve condensate valve for 4 to 5 min & allow to accumulate condensate in
inter condenser & then open valve for sealing loop line.
At the time of chocking ball float trap isolate inlet & out let valve of the trap line & allow
to condensate go to atmosphere, by cleaning the trap fit up in line & took in operation.
11
INSTALLATION, OPERATION AND
MAINTENANCE MANUAL FOR
AIL SINCLE PIECE & TWO PIECE
FULL BORE BALL VALVES
2.0 INSTALLATION
2.1 GENERAL
3. 0 OPERATION
3.1 GENERAL
3.2 MANUALOPERATION
REMOTEOPERATION
4.0 MAINTENANCE
4.1 GENERAL
4.2 STEMLEAKAGE
4.4 REFURBISHING
4.5 SAFETYPRECAUTIONS
Sloc P'r
3:3nd Nu:: -
Berle!:lje v"r3hers
Gi?na
GiandPac(ing-
_-bs
5
iirenc\ ;rx'nE Eoli
i'irenct Fead
Siaqc fiul
Lrcki4g Clip
3land Nui
Slco ind,calor
Gl3nd
Clandoac(nE
Siea Lmatioi Ring Bodv:cnnectol
Seccidan/ Sten Seal 3c'ew
Seat Rrng
- Sail
Seal Rilg
Slefl:hrrsl
Seal
Sler
With ther.alvesecurelyclamped(r'crtically,insertside
f-acing thetop)andin theopenposition.undothe insert
usingtheappropriatedrive adaptor.It may benecessary
to use a heavy n-ralleton the tommy bar of the insert
tool to breakthemetalto metalsealandmovethe insert
initially.
4.7 REBUILDING
B e f o r c r c b u i l d i n e .c h e c k t h a t a l l t h e c o r r e c t
componentsare availableand thc,vare fit for the
plrrpose. \\"henrebuildingcleanlincss is essentialto
allow long valve life and provide cost effective
maintenance
10
lnstallation,Operation &
liiaintenanceManualfor
AIL Ball Valves
( 3 - P I E C ED E S I G N )
1, STORAGE OF VALVES
Do not apply tar, paint, grease or any other material inside the
valve or on the stem, as this could impairthe performanceof the
valve.
2. INSTALLATION
General
3. OPERATION
General
AIL Ball Valveshave a long, trouble-freelife, and maintenanceis
seldomrequired. But, when necessaryvalvesmay be refurbished
very easily by using few componenls, which do not require
machiningat site. AIL Ball Valvesare designedfor easy service
and assembly in the field. The following checks would however,
help to extend valve life further,or reduce operationalproblems.
Stem Leakage
I n l i n e l e a ka g e
Leakageat PiPelineioint
Screwed Valves
5. REFURBISHING
6 . SA F ET YPR E C A U T ION S
7. DISMANTLING
8 . R E B U I L D I N G ( R e f e rF i g . 2 l
Fit stem thrust seal to stem and insert stem through body cavity
into stem hole and fully up into body recess. Fit gland packing,
gland and disc springswith their outer edges louching Using
leverto preventstem from turning, fit gland nut and screw down
until disc springs are firmly compressed. Operate stem several
limes and re-adjust. Overtighteningwill only reduce the life of
the assembly. Now fit stop plate, lever, identificationplate and
lever nut to stem assemblyand move leverto the closed position
(leveracross the pipeline). In sizes 112"& 3/4" lever has integral
stopper and there is no separatestop plate.
c o =
? - o
. ! - 2 : < 5
. , " i u c r u
F Y
) = z o -
z < z
ii a zi22
r-
U
z u*
-
O a
6
^
O U
U 6 B H H * H s 3
z - z > z -
d:6 ; ; j j - z ^6 a
P
r
]
r A y Hl
o
<J (A
o o o
J
o
)
c
O
l F * s h ; s ; s B3
_---r__i
body connectorswhen the body is removed or rotated . Also,
with the valve in the open position,the ball is retained by the
stem tang and cannot fall out of the body cavity.
1. Prepareclean workingarea.
1a
5 Place all removed parts in clean and secured position.
9. Fit the ball, ball seats and body seals into the'body.
Test
A test for leak tightnessis recommended.
PS11
'Y'-Strainer
DESCRIPTION:
Strainers for steam, air, oil or water piping, protect
equipment, steam traps, valves etc. from dirt, rust or
scale, and debris, in the pipeline.
FEATURES:
Simple yet sound construction ensures long service life.
A stainless steel strainer screen with a large surface
area ensures minimum pressure drop and requires less
frequent cleaning. Designed for easy in-line cleaning
and maintenance.
A
LIMITING CONDITIONS:
PMA: Max. allowable pressure 40 bar (g)
TMA: Max. allowable temp. 340 ºC
PMA / TMA for cast iron construction 17.5 bar(g) / 220ºC
Cold hydro test pressure twice the Max. allowable pressure C
1
SIZES: DN 15, 20, 25, 40, 50 B
3
CONNECTIONS: Screwed (NPT, BSPT, BSP) /
2
Socket Weld* (* Not Available In CI)
4
Non IBR1 / IBR
IBR - Available only in CS / SS construction
INSTALLATION:
For horizontal installations, the strainer should be
MATERIAL: installed with the screen in the horizontal plane or below
No. PART MATERIAL QTY. (Nos.) the centre-line of the pipe. Ensure accessibility of the
1. Body CS / SS / CI 01 strainer cap for cleaning.
2. Strainer Cap CS / SS 01 MAINTENANCE:
3. Strainer Screen AISI 304 (40 mesh)+ 01 This product can be maintained without disturbing the
4. Gasket CAF / Non CAF 01 piping connections. Complete isolation of the strainer
+
from both supply and return lines is required before any
Strainer Screen of 60 or 100 mesh available on request servicing is carried out.
The strainer should be disassembled periodically for
DIMENSIONS - Nominal in mm cleaning the screen.
MODEL SIZE A B C Wt. IMPORTANT:
DN15 75 69 91 0.82 kg For new pipelines, ensure that the lines are properly
flushed, prior to fitting the strainer.
DN20 75 69 91 0.77 kg
PS11 DN25 95 87 114 1.6 kg HOW TO ORDER:
DN40 190 157 202 6.850 kg PS11 DN15 BSP NIBR
DN50 190 157 202 6.0 kg ORDERING INFORMATION:
1) Inlet Pressure in bar (g)
AVAILABLE SPARES: 2) Operating Temperature in ºC
Strainer Screen (Packet of 5) 3) Size & Model
4) End Connections.
5) IBR / NIBR
6) Material of construction
Local regulations may restrict the use of this product below the conditions quoted. Limiting conditions refer to standard connections only.
In the interest of development and improvement of the product, we reserve the right to change the specifications without prior notice.
R
USA - 10 Parsonage Road, Suite 312, Edison, NJ, Tel.: 877-597-TRAP(8727) Fax:1-866-682-1244.
Email: info@pennantcorp.com Website: www.pennantcorp.com
August 2010
INDIA - S.No. 116 (New), Gat No. 976 (Old), Wadki, Taluka Haveli, Pune - 412 308, INDIA.
Tel.: +91 (0) 20 2698 9709, Telefax: +91 (0) 20 2698 9470
Email: enq@pennantindia.com Website www.pennantindia.com
FL 549
Assembly of a Spring Loaded Safety Valve Type 549
3
1*= Basic valve assembly
fitted with 2*and 4*
42
Item Part Name
75 1 Inlet Body
2* 2 Outlet Chamber
7 Disc Compl.
90
43 8 Spindle Guide
83 9 Bonnet
80 12 Spindle
1* 14 Split Ring
41 16 Spring Plate
45
79 18 Adjusting Screw
19 Lock Nut
44 50 Name Plate
54 Spring
4* 57 Pin
59 Securing Ring
60 Gasket
61 Ball
61
57
When installing pressure relief valves with threaded All drainage pipes that have been connected must be
connections, use only metal seal washers. Seal materials such free of restriction and the ends easily seen. Care must be
as hemp or PTFE tape should not be used as this type of taken when discharging any drainage to prevent injury
material can break off and enter the valve causing it to leak. to personnel. For example on steam connect a suitable
steam trap.
If valves with open bonnets and/or levers are to be painted
after despatch from the factory, care must be taken to protect Note!
the sliding parts. Otherwise the correct operation of the When valves are supplied with a drain hole that is not
pressure relief valve may be affected. going to be used the plastic plug fitted in the hole must
be removed and replaced by a metal plug.
2. Transport Protection
The inlet and outlet of the pressure relief safety valves are 3.3 Mounting Brackets
protected during transportation with plastic caps. These caps For pressure relief valves with mounting brackets a
should only be removed just before installing the valve. fastening possibility for the brackets should be
provided to withstand the forces of reaction when
The lifting lever of spring loaded pressure relief valves is valve blows off. The bracket holes can be drilled
secured with a wire to the bonnet. This wire should be on request.
removed only after installation. For testing the set pressure or
tightness of the pressure relief valve remove also this wire and 3.4 Insulation
take care that the lever is not engaged with the spindle cap. In case any insulation of the pressure relief valve is
provided, the bonnet must be kept free to avoid
3. Installation/Assembly unacceptable heating up of the spring.
When pressure relief valves with bellows are used with According to DIN specification 4754, Oct. 74 Edition
toxic or inflammable fluids, care must be taken to fit a "Explanations", Para 4.4 pressure relief valves represent the
suitable vent pipe to provide safe venting. For this last step in the line of protection for the vessel, and they should
purpose, the vent can be threaded 1/4" BSP female be able to prevent excess pressure when all other automatic
on request. or pilot operated checking instruments have failed. To
guarantee this function pressure relief valves require, like all
4. Mode of Operation/Maintenance other technical equipment, regular service. How often a
The working pressure of the plant should be at least 5% below valve must be checked, depends on the actual operating
the blow down pressure of the valve to enable a correct conditions, so that no general indications can be given.
reseat. When a slight leakage occurs, due to deposits Usually pressure relief valves operating in a corrosive
between the sealing surfaces, surfaces can be cleaned by atmosphere or on laden fluids require service more often than
operating the lifting lever causing the valve to blow off. valves operating clean conditions. This also applies if the
pressure relief valve operates frequently causing a higher
The valve should be closed by sudden release of the lever. If wear out to the seat and disc.
this procedure does not stop the leakage, the valve seals are
probably damaged. Repairs should be carried out at our Special consideration is required if conditions such as
vibration (to be avoided, if possible) pressure pulsation and/or
CAUTION
During all work the spindle has to be secured against twisting in order to prevent damage to the sealing surfaces.
43
44
18
41
19
1. Physical Check;
Following checks are necessary before installation
a) Pointer dislocation
b) Glass broken
c) End nipple loosened
Remedy
a) Ask factory or our nearest branch office for replacement spares. Provide P.O. No. and
instrument No. so that correct spare glass can be provided.
2.3 Fault:. End Nipple Loosened
Remedy
il) Tighten the same firmly along with the asbestos thread by first holding the
Instrument nipple on a rigid vice.(Applicable for Bimetal T.G.only)
3. Calibration Test
3.1 Test:. Check the Dial Thermometer .under test for ambient temp, which should be
measured by Comparision with standard thermometer.
(Std.Thermometer may be glass/RTD/Digital)
Observation :-
The dial thermometer under test must read the temperature within:l: 1% FSD.
•
"ABL
CE
"010
Remedy:-
If the dial thermometer under test deviates from desired value carry out following
adjustment
aj All the instruments are provided with micrometer pointer & external zero if specified.
Set the instrument to std. ref. temp. by rotating the reset nutl screw clockwise or
anticlockwise with the help of spanner/ small screw driver.
Caution: We recommend that maximum Zero reset should be :!: 10.C angular.
'b) The instrument is provided with micrometer pointer, dismantle the inst. Cover after
loosening the same and with the help of small screw driver, rotate the reset screw of
the micrometer pointer clockwise or anti-clockwise, as required to set the instrument to
correct temp.
Caution: Hold other end of the micro pointer firmly between the thumb and finger.
3.2) Test: Check the instrument at two. different temp. 2/3'. of the temp. span by
immersing the sensing length "0" in a wall stirred and controlled temperature bath and
thus compare the temperature shown by the gauge under test, with standard
thermometer. (Std.Thermometer may be glass/RTD/Digitalj .
Observation:
a) Accuracy should within stipulated limits, as above.
INSTRUcnONS FOR CHANGES THE ORIENTATION/ BENDING FOR EVERYANGEL DIAL THERMOMETER
DOCNo~:QR/TECH/050
This Drawing and Design is the property of NEW FIELD INDUSTRIAL EQUIPMENT P.LTD and must not be copied or lent without their permission in writing.
DESIGN DATA
DESIGN CODE ASME Sec VIII DIV 1-2017, Tema 'C & HEI'
FIRST CONDENSER SECOND CONDENSER
DESCRIPTION
X
~1731
~1605
Y
1478.7
1
323 O/D
SPECIFICATION FOR EJECTOR
FIRST CONDENSER
SECOND CONDENSER
460
2
100
X Fixed Support
For M16 Bolt 3215 C/C
1 1095
130
130
65 353
M.O.C OF EJECTOR & HOGGER EJECTOR
INSTRUMENTATION RANGE
PRESSURE GAUGES
TEMPERATURE GAUGES
100
ROTA METER DETAILS
1
NOZZLE THERMAL MOVEMENTS 1 1095
INSTRUMENTS HOOK UP
S. NO TAG NOS. RANGE S. NO TAG NOS. RANGE S. NO TAG NOS. RANGE
2
PG
2
VG
PG
PROCESS CONNECTION
28
65
30 - LIFTING LUG NOTES : P.NO. DESCRIPTION SIZE MATERIAL QTY. TAG NO.
BILL OF MATERIAL
3 3215 C/C
3
610KGS 440KGS
M16
125X125 M16
For M16 125X125 5. PAINTING
75
75
Foundation Bolt
Rev.No Date Desription Pre.by Chd.by App.by
370
320
75
300
370
Foundation
ISMC100
Anchor Bolt