Hydrochloric Acid Recovery System

Conduit re-commissioning (1998 system)

Operation Manual

Beta Control Systems, Inc.

6950 SW 111th Ave.
Beaverton, OR 97008 U.S.A.
phone: (503) 646-3399
fax: (503) 627-0888

Note: Read Appendix B first!

11/30/2017
© 2017. All rights reserved. No part of this publication may be reproduced, stored in a
retrieval system, or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior permission of Beta Control
Systems, Inc. This manual is for authorized personnel at the job site only and may not
be removed from the premises.

Beta Control Systems, Inc.

6950 SW 111th Avenue, Beaverton, OR 97008 U.S.A.
Email: contact@betacontrol.com, Website: www.betacontrol.com
Phone: 503.646.3399, Fax: 503.627.0888

1
1.0 Introduction ................................................................................................................. 4

1.1 Theory of Operation ...................................................................................................... 4

2.0 Screens ....................................................................................................................... 5

2.1 Initial Screen ................................................................................................................... 5

2.2 Operation Screen .......................................................................................................... 7
2.3 History Screen................................................................................................................ 8
2.4 Alarm List and Alarm History Screen ......................................................................... 9
2.5 Trend Screen................................................................................................................ 10
2.6 Display Selection ......................................................................................................... 11
2.7 Analog Alarm Screen .................................................................................................. 12
2.8 Digital Alarm Screen ................................................................................................... 13
2.9 Setpoints Screen ......................................................................................................... 14
2.11 Override ...................................................................................................................... 16
2.12 Manual Screens ......................................................................................................... 19
2.13 Confirmation – E-Stop .............................................................................................. 20

3.0 Operation .................................................................................................................. 21

3.1 Initialization and Login ................................................................................................ 21

3.2 Start System – Check list ........................................................................................... 24
3.3 System Mode –Emergency Stop, Shutdown, Manual, and Stand By/Start ....... 25

4.0 Maintenance Schedules ......................................................................................... 30

4.1 Daily Maintenance ....................................................................................................... 30

4.2 Weekly or As Needed Maintenance ......................................................................... 30
4.3 Annual Maintenance ................................................................................................... 31

5.0 Troubleshooting Guide ........................................................................................... 32

5.1 Analog Alarms .............................................................................................................. 32

5.2 Digital Alarms ............................................................................................................... 34

2
Appendix A: Quick Start Procedure ............................................................................ 35

Appendix B: Quick Shut Down Procedure ................................................................. 36

Appendix C: Installation/Modification Instructions and Warnings ........................... 37

Electrical Instructions and Warnings ............................................................................... 37

Mechanical Instructions and Warnings ........................................................................... 39
Civil Instructions and Warnings ........................................................................................ 40
Chemical Instructions and Warnings .............................................................................. 41

3
1.0 Introduction
1.1 Theory of Operation

Spent pickling acid is pumped (Figure 1) through a prefilter into the Separator Tank where it is
heated to boiling. The water and hydrochloric acid vapors travel through pipes into
condensers, which condense the vapors into liquid acid.

As more vapor is boiled away, the concentration of the remaining dissolved metal in the
separator vessel increases. This leads to an increase in the boiling point of the concentrate.
The solution is monitored, and when it rises above a threshold level, metal concentrate is
removed as a final product.

Additional spent acid is continuously added to replace the vapor and removed product. After a
time, a balance is achieved in which the rate of spent acid fed into the system is matched by the
amount of concentrate removed and vapor generated. The system is now in a steady state of
operation.
Figure 1: Flow Diagram

4
2.0 Screens

The system is controlled by the screens on the PanelView. The function keys do different things
depending on which screen is displayed.

There are two other ways to send commands to the system. One is by pressing the emergency
stop button which shuts off all motors, valves, etc., except the Cooling Tower pump and fan.
These are left on to remove heat from the system. The other way to control the system is the
power switch on the main electrical box.

2.1 Initial Screen

Be sure all manual valves are in their correct position for start up. Check there is enough room
in the Concentrate Tank to hold the product that will be made when the system is running. Be
sure the Separator Pump has a constant minimum of 30 psi clean water to protect the seal.
Refer to Appendix A for a Quick Start Guide.

Turn the power switch from the OFF position to the ON position. After a few minutes, the
INITIAL screen will be the first screen displayed during power up. (Note: The power may be left
on at all times, unless maintenance or repair work is being done.)

Figure 2: Initial

5
2.1.1 Diagnostics

A diagnostic banner will appear for hardware related problems such as the following:

1. Initial start up
2. Program failed to load correctly
3. Network failed to connect
4. Data is not recording

Figure 3: Diagnostic Banner

When a diagnostic banner appears do the following in order:

1. Clear the banner by pressing F2 “Clear All”

2. Close the banner by pressing F5 “Close”

6
2.2 Operation Screen

The OPERATION screen is the primary screen for most functions. The OPERATION screen
provides a graphic layout of the system with dynamic functionality to indicate the current
system state. The upper left corner indicates System Mode operation: Automatic Stand By,
Automatic Start, Manual Mode, Shutting Down (normal/abnormal), Shutdown
(normal/abnormal), and Emergency Stop.
Color Codes
PUMP: Green = ON Gray = OFF Red = DIGITAL INPUT PROBLEM
PIPE/VALVE/TANK: Blue = WATER PRESENT Lt Blue = AIR PRESENT Red = ANALOG/ DIGITAL INPUT PROBLEM

System Mode

Figure 4: Operation

Function Name Description

F1 SB/START Starts and stops the system in Automatic Mode.

F2 ACID Empties the Recovered Acid Tank (T-311)

F3 H2O Empties the Water Collection Tank (T-411)

F4 MAN 0-7 Manual operation of digital outputs

F5 SHUTDOWN Shuts down the system and discharges the concentrate

F6 AUTO/MAN Switches the system between Automatic and Manual Mode

F7 DISPLAY Changes the display of the HMI

F8 SETPOINT Displays the Setpoint screen (sufficient rights required)

F9 MAN 8-15 Manual operation of digital outputs

F10 E-STOP Emergency Stop - Turns off all Analog and Digital Outputs

7
2.3 History Screen

The History screen displays the average, standard deviation, and total of all analog inputs that
the system records.

Figure 5: History - Analog

8
2.4 Alarm List and Alarm History Screen

The Alarm List screen lists the current state and “acknowledge” state of all alarms. Alarms
under current selection are highlighted in blue.

Figure 7: Alarm List

Function Name Description

F1 Acknowledge Alarm Acknowledges the currently selected alarm
F2 Acknowledge All Acknowledges all the alarms
F3 Clear All Clears the Alarm List
F4
F5 Close Returns user to previous screen

In the event of an alarm, follow the procedure below to properly identify and respond to all
that occur.

1. Read the red Alarm Banner that appears across the screen.
2. Press “Ack” (F1) to acknowledge and clear the alarm currently displayed
3. See the Troubleshooting Guide. Respond to Alarms in the order in which they occur.
Some alarms trigger subsequent alarms and may be resolved by fixing the first.
4. If the problem associated with the alarm is not listed in the Troubleshooting Guide or
the alarm occurs frequently, contact Beta Control Systems, Inc. for further instruction.

9
2.5 Trend Screen

The TREND screens are graphs that display the data recorded so far. Data is displayed in 30
minute increments. Scroll using the left and right arrows on the directional pad.

NOTES: The RESUME (F1) resets the graph to the current time interval. The graph is selected
when there is NO visible green select box. The boxes labels MIN and MAX control Y-axis values.
The values listed below the graph indicate the current value of the corresponding analog input.
Values are color coded to match their representation on the graph.

Figure 8: Trend Analog

10
2.6 Display Selection

The DISPLAY SELECTION screen is a means of accessing other screens when there is insufficient
space for a standard Screen Select Box.

NOTE: THE RETURN BUTTON WILL RETURN THE USER TO THE PREVIOUS SCREEN.

Figure 10: Display Selection

11
2.7 Analog Alarm Screen

The Analog Alarm screen has different input components, a Reset button, and an
Enable/Disable button.

Figure 11: Analog Alarm

The six input components are as follows:

1. HH Alarm – High High alarm triggers an alarm banner when the corresponding analog
input device is above this value. Depending on the Alarm, it can initiate an emergency
stop.
2. H Alarm – High alarm triggers an alarm banner when the corresponding analog input
device is above this value.
3. L Alarm – Low alarm triggers an alarm banner when the corresponding analog input
device is below this value.
4. LL Alarm – Low Low alarm triggers an alarm banner when the corresponding analog
input device is below this value. Depending on the Alarm, it can initiate an emergency
stop.
5. DURATION – Duration any of the four alarm conditions must maintain before
automated action is taken, whether it be an alarm banner, alarm beacon (if equipped
with a beacon), alarm horn, or emergency shutdown.
6. DEADBAND – Deadband value for all four alarms. The deadband is a “±” value added to
each alarm. For LOW or LOW LOW, the respective alarm will latch when the
corresponding input value is equal to the HIGH plus DEAD or HIGH HIGH plus DEAD. For
HIGH or HIGH HIGH, the respective alarm will unlatch when the corresponding input
value is equal to the HIGH minus DEAD or HIGH HIGH minus DEAD. Alarm latching for
LOW and LOW LOW is the inverse method of HIGH and HIGH HIGH. (continued next pg)

12
 a. ANALOG INPUT > HIGH + DEADBAND → Latch Alarm
b. ANALOG INPUT > HIGH HIGH + DEADBAND → Latch Alarm
c. ANALOG INPUT > HIGH - DEADBAND → Unlatch Alarm
d. ANALOG INPUT > HIGH HIGH - DEADBAND → Unlatch Alarm
e. ANALOG INPUT > LOW + DEADBAND → Unlatch Alarm
f. ANALOG INPUT > LOW LOW + DEADBAND → Unlatch Alarm
g. ANALOG INPUT > LOW - DEADBAND → Latch Alarm
h. ANALOG INPUT > LOW LOW - DEADBAND → Latch Alarm

2.8 Digital Alarm Screen

Digital Alarms are a series of On/Off switches. When the switch is in the OFF position, the
alarm will not trigger any automatic events, alarm banners, or emergency stops. When the
switch is in the ON position it will trigger automatic events, alarm banners, or emergency stops
based on the digital input’s current state.

NOTE: THE RESET BUTTON WILL RETURN THE DIGITAL ALARM SWITCHES TO THEIR DEFAULT
POSITIONS.

F1

F9

Figure 12: Digital Alarm #0-3

13
2.9 Setpoints Screen

The SETPOINTS screens contain the variable input parameters for operating the system. These
are the values the system will attempt to maintain through automated equipment (e.g.
Air/Motor operated valves, Pumps, Motors, Variable Frequency Drives.)

NOTE: CONSULT BETA CONTROL SYSTEMS, INC. BEFORE CHANGING ANY SETPOINT VALUES.

Set points that end with the letters “DB” are Deadband values for the respective set points.
Deadband values for set points add a “dead zone” where automated equipment employed to
maintain the set point will halt any changes. Deadbands allow the system to delay operation
and minimize cycle times on various components. Components that cycle too often will wear
out faster than designed.

NOTE: DEADBAND VALUES SHOULD ALWAYS BE GREATER THAN ZERO.

2.9.1 Setpoints

Figure 13: Setpoints

1. TT-211: The temperature (TT-211) of the Separator tank (T-211) at which the
Concentrate Discharge Valve (AV-611) will open.
2. TT-211 DB: The deadband value of the temperature (TT-211) of the Separator
Tank (T-211).
3. TT-212: The temperature (TT-212) exiting the Main Exchanger (E-211). The
Steam Valve (AV-551) will open and close to maintain the temperature.
4. TT-212 DB: The deadband value of the temperature (TT-212) exiting the Main
Exchanger (E-211).

14
5. LT-211: The level (LT-211) of the Separator Tank (T-211) which the system will
maintain by turning on the Feed Pump (P-111).
6. LT-21 DB: The deadband value of the level (LT-211) of the Separator Tank (T-
211) which the system will maintain by turning on the Feed Pump (P-111).
7. DELAY FLUSH: The time after the Concentrate Discharge Valve (AV-611) cycles
closed before the system automatically purges the concentrate line with water
(SV-641). Note: If the Concentrate Discharge Valve (AV-611) cycles open before
time has expired, the time will reset.
8. H2O FLUSH: The duration the Concentrate Water Purge Valve (SV-641) will
remain open to clean the concentrate line after the Concentrate Valve (AV-611)
cycles closed.
9. SHUTDOWN: The time before a critical error causes the system to enter
automatic shutdown mode.
10. PUMP LEVEL: The level (LT-211) the Separator Tank must achieve before the
Separator Pump (P-211) turns on.
11. PUMP LEVEL DB: The deadband value of the level (LT-211) the Separator Tank
before the Separator Pump (P-211) turns on.
12. STEAM: The level (LT-211) the Separator Tank must achieve before the Steam
Valve Opens (AV-551).
13. STEAM DB: The deadband value of the level (LT-211) the Separator Tank must
achieve before the Steam Valve opens (AV-551).
14. DISCHARGE: The level (LT-211) the Separator Tank will rise to when discharging
concentrate.
15. DISCHARGE DB: The deadband value of the level (LT-211) the Separator Tank
when discharging concentrate.

15
2.11 Override

The ANALOG OVERRIDE and various DIGITAL OVERRIDE screens provide a method to input false
values to the PLC. When an analog input is overridden, the corresponding value on the
OPERATION screen will blink yellow around its border.

NOTE: OVERRIDES ARE FOR SIMULATION PURPOSES ONLY AND SHOULD NOT BE USED
WITHOUT THE EXPRESS CONSENT FROM BETA CONTROL SYSTEMS, INC.

2.11.1 Analog Override

Values displayed on the ANALOG OVERRIDE screen are the current values until the
corresponding Override button is activated. The override buttons are at the bottom of the
screen and controlled by the “F” buttons.

A red button indicates the corresponding value has been overridden. A green value indicates
the corresponding value is current. Overridden values can be modified; current values cannot.

NOTE: RESET DISABLES ALL OVERRIDE BUTTONS AND RETURNS THE VALUES TO THEIR
CURRENT STATE.

Figure 15: Analog Override

16
2.11.2 Digital Override

Values displayed on the DIGITAL OVERRIDE screen are the current values until the
corresponding Override button is activated. The override buttons are at the bottom of the
screen and controlled by the “F” buttons. The “F” buttons open a pop-up screen for the
corresponding digital input. The Override Button, “F1” turns ON or OFF the override feature
while the Control Button, “F5” will modify the state of the digital input as observed by the PLC.
The yellow light indicates the digital input value observed by the PLC, regardless of whether the
digital is overridden or not.

Figure 17: Digital Overrides #0-3

A red button at the bottom of the screen indicates the corresponding value has been
overridden. A green value indicates the corresponding value is current. Overridden values can
be modified; current values cannot.

Figure 18: Digital Overrides #4-7

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 Figure 19: Digital Overrides #8-11

Figure 20: Digital Overrides #12-15

(All four Digital Override screens may not exist on every system.)

NOTE: RESET DISABLES ALL OVERRIDE BUTTONS AND RETURNS THE VALUES TO THEIR
CURRENT STATE.

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2.12 Manual Screens

The MANUAL Screens are pop-up screens that turn ON and OFF digital output devices while the
system is in Manual Mode. Green indicates that the corresponding digital output is currently
ON. Gray indicates that the corresponding digital output is OFF.

F1

F9

Figure 21: Manual Switch #0-7

Figure 22: Manual Switch #8-15

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2.13 Confirmation – E-Stop

A variety of functions require confirmation before automated action is taken. These actions
include user activation of an Emergency Stop or a Shutdown. All confirmation screens ask the
question “ARE YOU SURE?” in reference to the proposed action. All actions on confirmation
screens are performed by “F1”.

Figure 23: Confirm - Emergency Stop

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3.0 Operation
3.1 Initialization and Login

The system power may be left on at all times, unless maintenance is being done. See Appendix
A for quick start up instructions. A minute or two after power up, the “INITIAL” Screen will
appear.

Figure 24: Initial Screen on Power Up

Function Name Description

F1 EXIT
F3 LOGIN See Login Screen.
F4 ESPAÑOL Choose language for screen displays. (OPTIONAL)
F6 EXIT
F8 LOGOUT
F9 ENGLISH Choose language for screen displays. (OPTIONAL)
F10 SHUTDOWN Ordered shutdown of the system.

3.1.2 Login/Logout

User Accessible Screens

Default (not logged in) INITIAL, OPERATION, HISTORY, ERROR - ANALOG, ERROR - DIGITAL,
TREND, DISPLAY, ALARM LIST, ALARM HISTORY, UNIT, DATE AND
TIME
1 (normal user) All the above + SETPOINT, SETTINGS, ANALOG ALARMS, PID, HORN
BEACON DISABLE
2 (administrator) All the above + RANGES, DIGITAL ALARMS, DIGITAL OVERRIDE,
ANALOG OVERRIDE, CONFIG

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3.1.3 Login Procedure

NOTE: IN ORDER TO RUN THE SYSTEM, LOGGING IN IS RECOMMENDED BUT NOT NECESSARY.
To login, first access the “LOGIN” screen from the “INITIAL” screen by pressing F1. Then press
F1 to begin inputting the username and password. A screen will appear as shown below.

Figure 25: Login Prompt

Begin by pressing F2 to input the username. A keyboard prompt will appear to assist for
username input (shown below).

Figure 26: Keyboard Prompt

22
The top row of the keyboard input is the value to be entered into the respective field after the
ENTER key is pressed. For example, if you pressed F2 for “User” after pressing the
ENTER key, the value in the field at the top of the keyboard input will be the username.

Once the username has been entered, follow the same process for the “Password,” F3.

A successful login will result in the username on the top left hand corner of the screen changing
to the desired login name. (see example in next 2 figures)

Figure 27: Logged Out - Default

Figure 28: Logged In - User #2

The username is located in the same location throughout all the other screens.

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3.2 Start System – Check list

1. Check system utilities

a. Power (480 VAC): Breaker-Power, Breaker-Motors, Fuses
b. Air: 30 psig, Valves open
c. Water: 30 psig, Valves open
2. Check that all manual valves are in correct orientation
3. Verify position of level switches
4. Verify automated valve positioners are clipped into valve stem
5. Start Up Boiler
a. Wait for Boiler to reach operating conditions (See Boiler Specifications NOT
INCLUDED IN THIS MANUAL)
6. Turn on power to main breaker on electrical control box and start program on computer
a. Wait for INITIAL screen to appear
7. Login
8. Go to OPERATION screen. Press START, “F1”

24
3.3 System Mode –Emergency Stop, Shutdown, Manual, and Stand By/Start

There are four different system operational modes. These four modes work in a hierarchy in the
following order:
1. Emergency Stop
2. Shutdown
3. Manual
4. Stand By / Start

This means that when the emergency stop button is enabled, the system will be in Emergency
Stop mode regardless of the state of the Shutdown, Manual, or Stand By/Start buttons.
Likewise, if the Emergency Stop button is disabled and the Shutdown button is enabled, the
system will be in Shutdown mode regardless of the state of the Manual or Stand By/Start
button.

NOTE: THE CURRENT OPERATION MODE IS IN THE UPPER LEFT HAND CORNER OF THE SCREEN.

25
3.3.1 Emergency Stop Mode

Emergency Stop mode can be manually enabled by pressing the “E-STOP” button found on
most screens. Emergency Stop mode is also triggered automatically when either the external
emergency stop button is pressed, a critical alarm occurs on the system, or the main power is
turned off or fails.

Emergency Stop mode turns off all analog and digital outputs immediately.

Figure 29: Operation - Emergency Stop

Figure 30: Initial - Confirm E-Stop

26
3.3.2 Shutdown Mode

Shutdown mode is an automatically controlled discharge (AV-611) of all processed fluids (spent
acid and clean acid) and cools down system components: Evaporator (E-211), Condenser (E-
411). Shutdown turns off pumps/motors: P-211, VP-511, P-421, and M-422. Shutdown also
closes proportional valves gradually, and in the correct order, to avoid stressing the system.
Stage One: “SHUTTING DOWN…” notifies the user the system is in the process of shutting down.
Stage Two: “SYSTEM SHUTDOWN” notifies the user that the shutdown is complete.

Figure 31: Stage One -- in process of shutting down

Figure 32: Stage Two -- shutdown is complete

Shutdown mode can be manually enabled by pressing the “SHUTDOWN” button found on most
screens. Shutdown mode is also triggered automatically when critical alarms occur that do not
indicate a pump, VFD, or automated valve failure. The automatically triggered shutdowns are
called Abnormal Shutdowns and will have the letters “(AB)” next to the current mode.

27
3.3.3 Manual Mode

Manual mode leaves every analog and digital output in the User’s control. Manual mode
overrides any operation that may be regulated by automatic control. No analog or digital
output will respond to any analog or digital input.

IMPORTANT: DO NOT LEAVE SYSTEM UNATTENDED WHILE IN MANUAL MODE.

NOTE: MANUAL MODE SHOULD ONLY BE USED BY QUALIFIED PERSONNEL WHO HAVE BEEN
TRAINED BY BETA CONTROL SYSTEMS, INC.

Figure 33: Operation - Manual Mode

28
3.3.4 Stand By / Start Modes

Stand By mode is an automatic mode which means that the analog and digital outputs will
respond to the various analog and digital inputs. Stand By mode will continue operation of the
Separator Pump (P-211) to keep crystals from settling in the bottom of the Separator Tank (T-
211). It will also turn on the Cooling Tower (CTW-421), pump (P-421), and fan (M-422). The
Steam Valve (AV-251) should be closed and the Feed pump (P-111) and Vacuum pump (VP-511)
will be off throughout Stand By mode.

NOTE: NO FLUID EXCEPT CAUSTIC

SHOULD ENTER/EXIT THE SYSTEM
DURING STAND BY MODE.

Start mode is the primary operational

mode and is an automatic mode which
means that the analog and digital
outputs will respond to the various
analog and digital inputs. In Start
mode, analog and digital output
automatically adjusts to maintain the
Figure 33: Operation - Stand By
system's set points while continuously
feeding new, contaminated rinse water
into the system.

NOTE: MONITOR START MODE ON A REGULAR BASIS TO ENSURE PROPER OPERATION.

Figure 34: Operation - Start

29
4.0 Maintenance Schedules

4.1 Daily Maintenance

Perform a visual check of the system every hour. Look for the following items:
1. Leaks
a. Pumps
b. Tanks
c. Pipe / Valves
2. Listen for unusual noises
a. Pumps
i. Cavitation
ii. Grinding
b. Motors
3. Check Boiler

4.2 Weekly or As Needed Maintenance

1. Inspect seals of pumps

2. Grease motor seals and bearings

3. Inspect compressed air line.

4. Clean flow meter and level switches

5. Recalibrate Level Transmitter (LT-211) and Flow Meter (FT-111)

6. Clean Concentrate Valve (AV-611)

7. Replace Filters (F-111)

8. Check pH of cooling tower water

30
4.3 Annual Maintenance

1. Wash and polish the system’s exterior. Paint any chips or scratches on
framework.

2. Inspect tanks for any cracks or wear on exterior.

3. Drain and clean inside of tanks.

4. Check for corrosion on solenoid valves.

5. (Every 2-3 Years) Replace seal for Separator Pump (P-211).

31
5.0 Troubleshooting Guide

5.1 Analog Alarms

Alarm Probable Cause

LT-211 HIGH HIGH: Level (LT-211) of the Separator tank (T-211) exceeds Operating condition and
Separator Tank System will emergency stop.
Level a) Feed pump will not turn off
b) Feed tank spent acid siphoning through Feed pump
c) Feed water solenoid broken
d) Level probe (LT-211) is not calibrated or is broken
e) Signal wires are shorted out or disconnected
f) PLC has malfunctioned
HIGH: Level of the Separator Tank (T-211) exceeds Operating condition (Minor Alarm).
LOW: Level of the Separator Tank (T-211) is below Operating condition (Minor Alarm).
LOW LOW: Level of the Separator Tank (T-211) is below Operating condition and System
will emergency stop.
a) Tank is filled with low conductivity solution
b) Level probe (LT-211) is not immersed, is not calibrated, or is broken
c) Signal wires are shorted out or disconnected
d) PLC has malfunctioned

PT-212 HIGH HIGH: Pressure out of Main Exchanger (E-211) exceeds Operating condition and
Separator Tank System will emergency stop.
Pressure a) Blockage in Spray Wand or Orifice Plate
b) Separator Pump exceeds output parameters
c) Specific Gravity of solution is higher than expected
d) Pressure transmitter (PT-212) is not calibrated or is broken
e) Signal wires are shorted out or disconnected
f) PLC has malfunctioned
HIGH: Pressure out of Main Exchanger (E-211) exceeds Operating condition (Minor Alarm).
LOW: Pressure out of Main Exchanger (E-211) is below Operating condition (Minor Alarm).
LOW LOW: Pressure (PT-212) out of Main Exchanger (E-211) is below Operating condition
and System will emergency stop.
a) Blockage in Gauge Guard or Gauge Guard not calibrated
b) Specific Gravity of solution is lower than expected
c) Pressure transmitter (PT-212) is not calibrated or is broken
d) Signal wires are shorted out or disconnected
e) PLC has malfunctioned

32
TT-211 HIGH HIGH: Temperature transmitter (TT-211) exceeds Operating condition and System
Main Heat will emergency stop.
Exchanger In a) Steam Valve (AV-551) will not close or exceeds design parameters
b) Incoming spent acid is too hot
c) Temperature transmitter (TT-211) is not calibrated or is broken
d) Signal wires are shorted out or disconnected
e) PLC has malfunctioned
HIGH: Temperature transmitter (TT-211) exceeds Operating condition (Minor Alarm).
LOW: Temperature transmitter (TT-211) is below Operating condition (Minor Alarm).
LOW LOW: Temperature transmitter (TT-211) is below Operating condition and System will
emergency stop.
a) Steam Valve (AV-551) is not open or does not have air pressure
b) Incoming spent acid is too cold
c) Y-strainer or Steam trap is clogged
d) Temperature transmitter (TT-211) is not calibrated or is broken
e) Signal wires are shorted out or disconnected
f) PLC has malfunctioned

TT-212 HIGH HIGH: Temperature transmitter (TT-212) exceeds Operating condition and System
Main Heat will emergency stop.
Exchanger Out a) Boiler will not turn off or exceeds design parameters
b) Incoming spent acid is too hot
c) Temperature transmitter (TT-212) is not calibrated or is broken
d) Signal wires are shorted out or disconnected
e) PLC has malfunctioned
HIGH: Temperature transmitter (TT-212) exceeds Operating condition (Minor Alarm).
LOW: Temperature transmitter (TT-212) is below Operating condition (Minor Alarm).
LOW LOW: Temperature transmitter (TT-212) is below Operating condition and System will
emergency stop.
a) Boiler is not turned on
b) Incoming spent acid is too cold
c) Temperature transmitter (TT-212) is not calibrated or is broken
d) Signal wires are shorted out or disconnected
e) PLC has malfunctioned

33
5.2 Digital Alarms

Alarm Probable Cause

OL-211 Overload – Separator Pump (P-211)

OL-421 Overload – Cooling Tower Pump (P-421)

FS-241 No Flow –Seal Water Flow Switch (FS-241)

FS-421 No Flow – Cooling Water Flow Switch (FS-421)

E-STOP Exterior Emergency Stop switch has been activated

34
Appendix A: Quick Start Procedure

1 Check system utilities and power to all external components.

Check all manual valve positions before the system operates:

The following valves must be open: Acid Feed, Feed Return, and Prefiltered Feed.
2
The following valves must be closed: Filter Drain and Filter Air Bleed.
Open/close any additional valves which are not part of the Beta System.

3 Check system for leaks, tighten bolts.

4 Check and/or change filters.

5 Verify Concentrate Tank has adequate capacity for full system discharge.

Ensure temperature sensors, level transmitters/switches, and pressure sensors are

6
operating. Ensure automated valves are responding.

If the power has been shut off, Turn on power to the System. Wait for the HMI
7 screen to turn on, during which time the alarm will sound. Disable the alarm after
full system boot up (see page 9).

Go to the OPERATION Screen to verify the System is in Automatic Mode. (Disable

8
any Emergency Stop if necessary.)

9 Push the Start Button (F1). (see page 29)

Warnings:
1. If there is any acid in the Separator Tank, the Separator Pump seal must receive a
dependable water supply, minimum of 30 psi.
2. If the system is shut down for more than 2 hours, drain the Separator Tank and
all pipes.
3. Insure there is plenty of room in the Concentrate Tank before discharging.
4. Be sure the Steam Valve is closed when the system is not in operation.

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Appendix B: Quick Shut Down Procedure

MAKE SURE THERE IS ADEQUATE ROOM IN THE CONCENTRATE TANK TO RECEIVE

FULL VOLUME OF THE SYSTEM.

Press the “SHUTDOWN” button (F5) on the OPERATION Screen and confirm that
1
you want to shut down the system (F1).

Wait for the system to drain. This may take approximately 30 minutes. The
2
Separator Pump will shut down automatically.

Drain any residual Concentrate from the system manually. (V-211) The Drain valve
3
is a 1/2" PVDF ball valve on the Separator Pump suction spool.

4 Ensure all feed and discharge pipes are drained and/or flushed with water.

5 Close all Acid, Steam and Water valves to and from the system.

6 Turn off the power if the system is to be off for more than 48 hours.

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Appendix C: Installation/Modification Instructions and Warnings

0
3 1

WEAR EYE PROTECTION

Electrical Instructions and Warnings

Most electrical components are housed in the Electrical Control Box. The Electrical Control Box
as well as all electrical components outside of the Electrical Control Box must be rated to meet
or exceed ALL of the following hazardous environments:

 Class I, Division 2 Groups A, B, C, D

 Class II, Division 2 Groups F, G
 Class III
 Ordinary, non-hazardous locations only

The Electrical Control Box houses sensitive electronic equipment which may include, but is not
limited to:

 Programmable Logic Controller(s) (PLC)

 Human Machine Interface(s) (HMI)
 Variable Frequency Drive(s)
 Signal Conditioner(s)
 Pre-Amp(s)
 Power Supplies
 Circuit Breaker(s)
 Motor Starter(s)

For information on these items, please refer to their respective manuals for proper
maintenance and handling.

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 IMPORTANT: The Electrical Control Box is designed to meet the NEMA 4X / IEC IP
66 standard of electrical enclosure.
Any conduit or other utilities installed into the Electrical Control Box should allow
the enclosure to retain a NEMA 4X / IEC IP 66 rating.

NEMA 4X: Enclosures constructed for either indoor or outdoor use to provide a degree of
protection to personnel against access to hazardous parts; to provide a degree of
protection of the equipment inside the enclosure against ingress of solid foreign
objects (windblown dust); to provide a degree of protection with respect to
harmful effects on the equipment due to the ingress of water (rain, sleet, snow,
splashing water, and hose directed water); that provides an additional level of
protection against corrosion; and that will be undamaged by the external
formation of ice on the enclosure.
http://www.nema.org/Products/Documents/nema-enclosure-types.pdf

IMPORTANT: DO NOT CUT OR DRILL HOLE(S) OF ANY KIND INTO THE

TOP OF THE ELECTRICAL CONTROL BOX.

IMPORTANT: FULLY ENCLOSED CODUIT AND JUCTION BOXES SHOULD

BE USED FOR ALL ELECTRICAL CONNECTIONS.

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Mechanical Instructions and Warnings

Mechanical components may include but are not limited to:

 Centrifugal Pump(s)
 Diaphragm Pump(s)
 Heat Exchanger(s)
 Mixer(s)
 Motor(s)
 Air Operated Valve(s)
 Motorized Valves(s)

Take special care when performing maintenance on the components listed above. Many
components have designated torque ratings for bolts, pressure ratings, and voltage ratings.
Maintenance personnel should consult the component manual before performing maintenance
on these devices.

Replacement parts should always be an identical part or a part approved by Beta Control
Systems, Inc. Any material easily affected by corrosion should not be used or should be coated
in an approved anti-corrosion material.

IMPORTANT: COAT ALL BOLT THREADS WITH FEL-PRO OR EQUAL ANTI-

SEIZURE COMPOUND.

IMPORTANT: NEVER OVERTORQUE BOLTS ON PUMPS OR HEAT

EXCHANGERS. CONSULT MANUALS OR CONSTRUCTION DRAWINGS
FOR PROPER TORQUE RATINGS. OVERTORQUEING WILL RESULT IN
PERMANENT DAMAGE.

HEAT EXCHANGER BOLTS SHOULD NEVER EXCEED 65 FT-LBS OF

TORQUE. SOME BOLTS SHOULD NOT EXCEED 20 FT-LBS OF TOQUE.

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PUMP BOLTS SHOULD NEVER BE CHANGED WITHOUT FIRST CONSULTING BETA
CONTROL SYSTEMS, INC. ON PROPER PROCEDURE. MAINTENANCE ON PUMPS
SHOULD ONLY BE DONE BY A CERTIFIED PROFESSIONAL.

ALL BOLTS SHOULD BE TIGHTENED IN 3-STAGE STAR PATTERN.

Civil Instructions and Warnings

The structure supporting our system has been professionally rated. No modifications should be
made that compromise the structural integrity.

IMPORTANT: ALL NUTS, BOLTS, AND WASHERS CONNECTING FRAME

PIECES SHOULD BE IN PLACE, SECURED, AND TIGHTENED. ALL X-
BRACES SHOULD BE IN PLACE, SECURED, AND TIGHTENED. ALL
COMPONENTS SHOULD BE IN PLACE, SECURED, AND TIGHTENED.

40
Chemical Instructions and Warnings

The area surrounding our system is considered a hazardous

0 environment. Precautions should be taken to prevent or control any
3 1 leaks/spills that may occur. The following protection should be worn
at all times around the system.

 Eye Protection
 Safety shoes
 Hard hat
 Long pants
 Long sleeved clothing

CAUTION: HIGH CONCENTRATIONS OF CAUSTIC CHEMICALS ARE

PRESENT.

Emergency Eye wash station is required to be in close proximity and in working order.

41