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TVA Pall Filter Training for HLP22

Operations Continuing Training   Tennessee Valley Authority  TVA 


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Pall Filter Training for HLP22

Table of Contents

TABLE OF CONTENTS .................................................................................................................. LIST OF FIGURES ....................................................................................................................... 3 STUDENT OBJECTIVES .............................................................................................................. 4 Controls and Gauges ....................................................................................................................................................................................5  Gauge Observations .....................................................................................................................................................................................6  Connecting the Supply Voltage.............................................................................................................................................................8      Motor Rotation Check..............................................................................................................................................................................10  Oil Flow Path..........................................................................................................................................................................11  Air Flow Path.................................................... ...................................................................................................................................... 12  Pre­startup ...................................................................................................................................................................................................13  Energizing ....................................................................................................................................................................................................... 15  Starting............................................................................................................................................................................................................18  Running and Adjusting..........................................................................................................................................................................21  Gauge Observations.................................................................................................................................................................................22  Heater.......................................................................................................................................................................................23  Heater Set Point....................................................................................................................................................................24  Stopping Unit...............................................................................................................................................................................................27  Draining Purifier.......................................................................................................................................................................................28  Theory of Operation.................................................................................................................................................................................29  Component Identification.....................................................................................................................................................................30  Vacuum Pump Relief Valve..................................................................................................................................................................31  Maintenance Schedule............................................................................................................................................................................32  Replacing the Inlet Breather...............................................................................................................................................................32  Cleaning the Inlet Strainer...................................................................................................................................................................33  Investigating the Alarms and Warnings.......................................................................................................................................33  Major Alarm #1...........................................................................................................................................................................................36  Dirty Filter Warning/Shutdown........................................................................................................................................................37  Service the Vacuum Pump Soon........................................................................................................................................................38  PLC Battery Low..........................................................................................................................................................................................39  Dirty Filter Warning 2.............................................................................................................................................................................39  HMI Screens..................................................................................................................................................................................................40  Menu Page #1..............................................................................................................................................................................................41  Menu Page #2..............................................................................................................................................................................................42  Tower Level..................................................................................................................................................................................................43  Alarm History..............................................................................................................................................................................................44 

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Pall Filter Training for HLP22

List of Figures  Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24

Controls .................................................................................................... 5 Gauges ...................................................................................................... 6 Vacuum Gauge .......................................................................................... 7 Power Cabinet ............................................................................... 8 Main Disconnect ........................................................................................ 9 Major Alarm #1 ........................................................................................ 10 Oil Flow Path ............................................................................... 11 Air Flow Path................................................................................ 12 Vacuum Pump Gear Oil Level ..................................................... 13 Drains and Vents ..................................................................................... 14 Plugged Breather ..................................................................................... 15 Power Switch ........................................................................................... 15 Boot Screen ............................................................................................. 16 Purifier Ready Screen.............................................................................. 17 Purifier Ready Screen.............................................................................. 18 Control Panel Stopped............................................................................. 19 Control Panel Started ............................................................................. 20 HMI Screen Running ............................................................................... 20 Running and Adjusting............................................................................. 21 Gauges 2 ................................................................................................. 22 Heater Controls........................................................................................ 23 HMI Heater SetPoint.................................................................................24 HMI Heater Setpoint 2...................................................................,,,,,,.....26 Control Panel Stopped......................................................................,,,,,,.27

Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39

HMI Purifier Draining..........................................................................28 Front View..........................................................................................30 Rear View...........................................................................................30 Relief Valve........................................................................................31 Breather Replacement.......................................................................32 Cleaning Strainer...............................................................................33 AlarmInvestigation..............................................................................35 Relay Settings....................................................................................36 Dirty Filter Indications.........................................................................37 AlarmInvestigation..............................................................................35 Relay Settings....................................................................................36 Dirty Filter Indications.........................................................................37 Vacuum Pump Indications.................................................................38 HMI Screens......................................................................................40 Menu Page #1....................................................................................41 Menu Pge #2......................................................................................42 Tower Alarm.......................................................................................43 Alarm History.....................................................................................44


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Pall Filter Training for HLP22

Student Objectives  To review the components of the Pall Filter HLP22.................................................................... To review the correct operation of the Pall Filter HLP22........................................................... To understand the oil flow path of the Pall Filter HLP22................................................................. To understand the air flow path of the Pall Filter HLP22........................................................... To identify the major and minor alarms associated with the Pall Filter HLP22................... To be able to bring up and review the alarm history for the Pall Filter HLP22....................


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Pall Filter Training for HLP22

    Controls and Gauges    A = HMI (human machine interface) B = Main Disconnect C = Alarm Beacon D = Start Button ** E = Stop Button ** F = Heater Enable/Disable Switch G = Alarm Reset Button H = Electrical Enclosure Door Locks 

Figure 1


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Pall Filter Training for HLP22

Gauge Observations

1 = Inlet Pressure 2 = Tower Vacuum Gauge 3 = Outlet Pressure Gauge 4 = Oil Temperature Gauge 5 = Differential Pressure Gauge (Polishing filter) 6 = Vacuum Pump Backpressure Gauge

Figure 2


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Pall Filter Training for HLP22

Figure 3


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Pall Filter Training for HLP22

Connecting the Supply Voltage In order for Pall Corporation to meet the needs of all end-users the Purifier electrical enclosure is not provided with a supply voltage “knock out” port. The end-user must drill a hole in the electrical enclosure for delivery of the supply voltage. The supply voltage should be connected where shown below. The electrical panel is suitable for WYE configured electrical service only. Contact factory if Delta configuration is desired. The end-user must provide supply voltage with adequate ground fault and circuit breaker protection in accordance with Federal, State, Local and plant regulations

Figure 4


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Pall Filter Training for HLP22

Figure 5

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Pall Filter Training for HLP22

Motor Rotation Check The Purifier will automatically detect if the sequence of the supply voltage has been properly connected. There is no need to bump start the motors to check for rotation. If the supply voltage is out of sequence the purifier will alert the operator with an alarm as shown below. Refer to section 11.1 to correct the situation.

Figure 6


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Pall Filter Training for HLP22

Oil Flow Path

During normal operation oil will pass through the Oil Purifier as indicated by the gold arrows. Key system components are identified with numbers which correspond directly to the number found on the hydraulic schematic drawing. Oil is drawn into the Purifier via the pump/motor group (# 4 / 6). The fluid passes the inlet gate valve (#31) and inlet strainer (#1). Fluid travels through the check valve (#7), dissolved water sensor (#8), heater (#9), sight glass (#10), and delivered to the vacuum tower (#15). Oil is removed from the vacuum tower via a second pump/motor group (#18&18a). Oil is passed through a polishing filter (#20), check valve (#22) and returned to the oil reservoir.

Figure 7


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Pall Filter Training for HLP22

Air Flow Path Shortly after starting the Oil Purifier the vacuum pump & motor (#25 & #26) will start and air within the vacuum tower will be exhausted. Ambient air will be drawn into the vacuum tower through the inlet breather filter (#11) and vacuum adjustment valve (#13). Filtered air will travel upwards through the vacuum tower (#15) and into the vacuum pump (# 26). Air leaves the vacuum pump, travels through the heater exchanger (#5), into the coalescer (#29), through the knock out tank (T), and exhausts to atmosphere.

Figure 8


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Pall Filter Training for HLP22

Pre-Startup Checks

Check vacuum pump gear oil level (photo below, see maintenance section for oil type and fill procedure) • Close all drains and vents (locations indicated below). • Completely open the inlet gate valve (#31). • Open all valves in the oil supply line to the purifier. • Open all valves in the oil return line from the purifier to the reservoir. • Verify condition of inlet air breather (see maintenance section for change-out procedure).

Figure 9


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Pall Filter Training for HLP22

Figure 10


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Pall Filter Training for HLP22

Figure 11

Energizing and Boot-up

Turning the main disconnect to the “ON” position will “boot up” the Oil Purifier. During the bootup process the HMI will display screens as shown below. When the boot-up process is completed the HMI will display the HOME page with the words “PURIFIER READY”.

Figure 12


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Pall Filter Training for HLP22

Figure 13


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Pall Filter Training for HLP22

Figure 14


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Pall Filter Training for HLP22

Starting the Purifier Complete sections 7.1, 8.3, & 8.4 first! Ensure all valves connecting the Oil Purifier to the reservoir are 100% open. Only after the Purifier has booted up and the HMI displays “PURIFER READY” can be started. To start the purifier press the “START” button on the front panel. The start button will illuminate immediately after the start button is pressed. After the purifier starts the HMI screen will display “PURIFIER RUNNING”.

Figure 15


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Pall Filter Training for HLP22

Figure 16


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Pall Filter Training for HLP22

Figure 17

Figure 18


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Pall Filter Training for HLP22

Running and Adjusting A few seconds after pressing the start button the inlet and outlet pumps will start (which one starts first depends on the oil level within the tower). Several seconds later the vacuum pump will start and tower vacuum will begin to build. Oil will be seen flowing in the upper sight glass. The oil level within the tower will become stable in the lower sight glass. Shortly thereafter, if the heater is enabled, it may come on depending on the heaters set point in relation to the current temperature. With the purifier running make the following adjustments and observations: Adjust the tower vacuum to approximately 17-18” Hg using the needle valve (#13). Clockwise rotation of the needle valve will increase tower vacuum. Counter-clockwise rotation will decrease tower vacuum. Note: Adjust the tower vacuum to 16” Hg or less if the water content in the oil is above 100% saturation (see the photo below which indicates where to read the % saturation). Caution: When adjusting the needle valve, use only ½-turn (180 degree) or ¼-turn (90 degree) increments. It may take up to 60 seconds for the tower vacuum to stabilize. Do not over adjust. Vent air trapped within the polishing filter housing using the needle valve (32).

Figure 19


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Pall Filter Training for HLP22

Gauge Observations 2 The gauge cluster is shown below. After approximately 60 seconds all gauges should be within the range stated on the placard located below the gauge. If the operator observes a reading outside the stated ranges the Purifier may issue an alarm condition. The operator should turn to the troubleshooting section of this manual for further instructions.

Figure 20


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Pall Filter Training for HLP22

Heater The heater is enabled/disabled using the ON/OFF switch located on the front panel. When the heater is enabled the heater logic determines when to energize the heater. When the heater is energized the switch will illuminate.

Figure 21


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Pall Filter Training for HLP22

Changing Set Point

The heater set point is factory set at 120oF (49oC). The set point is adjustable using the purifier’s HMI (human machine interface). The set point can be changed if the purifier is running or not. From the HMI home, page press F2, which corresponds to “HEA” which is short for “heater”.


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Pall Filter Training for HLP22

Figure 22 Changing Set Point 2 From the heater control screen press F3 to bring up the heater set point screen. The heater set point can now be adjusted. Heater control is not password protected. Use the F2 & F3 keys to raise or lower the heater set point temperature. Pressing the F2 or F3 key one time will adjust the temperature by one degree. Press and hold the F2 or F3 key to scroll the numbers more quickly. When the desired set point is reached, press F1 to return to the home page. Cold Startup Condition - Oil Viscosity Above 1000 cSt (4650 SUS) The Oil Purifier will not run properly with fluids having a viscosity above 1000 cSt. The user should be aware of cold fluid conditions resulting from hoses lying on cold floors. During colder months of the year, users are advised to drain fluid from purifier supply line hoses when the oil purifier is not being used. It is especially important to keep fluid supply lines to the oil purifier as short as possible to minimize the effects of cold fluid introduction.


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Pall Filter Training for HLP22

Kinematic Viscosity Symbol (St) Named after George Gabriel Stokes Sometimes expressed in terms of Centistokes. (cSt)

Figure 23


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Pall Filter Training for HLP22

Stopping Unit To stop the Purifier press the “stop� button. The heater and all pumps, motors will stop and the stop button will illuminate as shown below.

Figure 24


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Pall Filter Training for HLP22

Draining the Purifier Considerations Prior to Draining: The Oil Purifier is equipped with an automatic draining feature. To maximize the effectiveness of the drain mode, the user should disconnect the fluid supply line from the inlet of the purifier. This will prevent additional fluid from being drawn into the purifier and allow for better drainage overall. If the above-mentioned procedure is followed the purifier will have approximately 1 gallon of fluid still left on board. If more draining is desired, the user should manually drain the heater, vacuum tower and polishing filter using the manual ball valves located at the bottom of each of these components. Enabling Drain Mode: The operator should read and understand the section above: “Considerations Prior to Draining”. • To activate the drain mode the purifier must be stopped and the power energized. • Press and hold the stop button for 5 seconds. After 5 seconds the HMI screen will display the screen below and the user can release the stop button. • The user can now start the automatic drain mode by pressing the start button. At that time the inlet pump will run for 45 seconds, and the outlet pump for 90 seconds. The operator will see the seconds counting down on the screen. • The user may also start and stop either the inlet or outlet pump individually. Pressing and holding the F1 key will start the inlet pump; pressing the F4 will start the outlet pump • When draining is complete, exit to the “Home Page” by pressing F2 (HOME)

Figure 25


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Pall Filter Training for HLP22

Theory of Operation Oil contaminated with water, gas, and particulate is purified on-board the Purifier. Dry air in the tower is obtained by expansion: Ambient air is drawn into the tower by the vacuum pump, and expanded to approximately 4 times its former volume (depending on vacuum set point). As the inlet air volume expands 4-fold, the relative humidity of that air decreases 4- fold. The resulting air inside the tower has effectively been dried. The contaminated oil is drawn into the purifier via the inlet fluid pump. The oil passes through the heater and enters the top of the tower. The oil cascades from the top of the tower to the bottom via gravity, passing through a column of stainless steel rings in the process. While the contaminated oil travels down the column, water trapped in the oil converts from a liquid phase to a gaseous phase. The gasses trapped in the oil will expand as per Boyles Law. As the oil travels down the column the vacuum pump maintains airflow through the tower. Water vapor and expanded gases are removed through the top of the tower by the vacuum pump and are discharged to atmosphere downstream of the vacuum pump. Dry, degassed oil at the bottom of the tower is drawn out via the fluid pump and passed through the absolute rated filter before returning to the reservoir.

Boyle's Law, a principle that describes the relationship between the pressure and volume of a gas. According to this law, the pressure exerted by a gas held at a constant temperature varies inversely with the volume of the gas. For example, if the volume is halved, the pressure is doubled; and if the volume is doubled, the pressure is halved. The reason for this effect is that a gas is made up of loosely spaced molecules moving at random. If a gas is compressed in a container, these molecules are pushed together; thus, the gas occupies less volume. The molecules, having less space in which to move, hit the walls of the container more frequently and thus exert an increased pressure.


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Pall Filter Training for HLP22

Component Identification

Front View A = Gauge Cluster B = Electrical Enclosure 3 = Inlet Pressure Sensor 7 = Inlet Check Valve 15 = Vacuum Tower 15A = Demisting Pad 16 = Fluid Level Sight Glass 24 = Vacuum Pump Relief Valve ** 26 = Vacuum Pump 27 = Coalescer Backpressure Sensor 28 = Vacuum Pump Back Pressure Gauge

Figure 26

Figure 27

Rear View 1 = Inlet Strainer 4 = Inlet Fluid Pump 5 = Exhaust Air Cooler 6 = Inlet Pump Motor 9 = Heater 10 = Flow Sight Glass 11 = Inlet Air Breather Element 15 = Vacuum Tower 18 = Outlet Pump Motor 20 = Polishing Filter 22 = Check Valve (outlet) 23 = Check Valve 25 = Vacuum Pump Motor 29 = Coalescing Filter (air) 31 = Inlet Gate Valve T = External mounted variable frequency drive (VFD)


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Pall Filter Training for HLP22

Vacuum Pump Relief Valve The vacuum pump relief valve is factory set and should not be adjusted. The valve is properly set by rotating the knob clockwise until the stop is reached. The valve requires no service or adjustment.

Figure 28


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Pall Filter Training for HLP22

Maintenance Schedule

Replacing the Inlet-Air Breather Replacing Inlet Air Breather While running, the Oil Purifier introduces filtered air into the vacuum tower through the inlet air breather. The breather is fitted with a visual indicator. The inlet air breather should be changed upon indication. Note: The HMI screen will not alert the operator when to change the breather; it is the operator’s responsibility to check the indicator on a regular basis (weekly). Note: Do not discard the indicator it can be unscrewed and re-used on the new breather filter.

Figure 29


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Pall Filter Training for HLP22

Cleaning the Inlet Strainer The Oil Purifier is fitted with a strainer to protect the inlet fluid pump. If the inlet strainer becomes blocked a warning will be displayed on the HMI (turn to section 11.5 for details). The inlet strainer should be cleaned and inspected a minimum of 1 time per year.

Figure 30

Investigate Alarms and Warnings The HMI (human machine interface) located on the front panel of the Oil Purifier will alert the operator of current running conditions and alarm or warning conditions. If a “major” or “minor” alarm condition is detected the HMI will change to a red color and flash a message across the screen. When multiple alarms are present the most recent alarm will be displayed. If a “warning” condition is detected the HMI will turn a brown/yellow color and flash a message across the screen.


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Pall Filter Training for HLP22

List of Major Alarms • Section 11.1 Major Alarm #1: Phase Reversal / Low or High Voltage • Section 11.2 Major Alarm #2: High System Temperature Shutdown • Section 11.3 Major Alarm #3: Inlet Pump Motor Contactor Failure • Section 11.4 Major Alarm #4: Vacuum Pump Motor Contactor Failure • Section 11.5 Major Alarm #5: Inlet Pump Cavitation • Section 11.6 Major Alarm #6: Change Exhaust Coalescer • Section 11.7 Major Alarm #7: High Tower Level Shutdown • Section 11.8 Major Alarm #8: Low Tower Level Shutdown • Section 11.9 Major Alarm #9: Outlet Pump Motor / Drive Overload • Section 11.10 Major Alarm #10: Inlet Pump Motor Overload • Section 11.11 Major Alarm #11: Vacuum Pump Motor Overload • Section 11.12 Major Alarm #12: Dirty Filter Warning / Shutdown • Section 11.13 Major Alarm #13: Tower Fluid Level Sensor Signal Loss • Section 11.14 Major Alarm #14: Outlet Pump Motor Drive Fault <###> • Section 11.15 Major Alarm #15: Outlet Pump Motor Drive Comm.Loss List of Minor Alarms • Section 11.101 Minor Alarm #101: Heater Thermocouple Signal Loss • Section 11.102 Minor Alarm #102: High Oil Temperature at Water Sensor • Section 11.103 Minor Alarm #103: High Water Saturation • Section 11.104 Minor Alarm #104: Heater Contactor Failure • Section 11.105 Minor Alarm #105: Condenser Fan Motor Contactor Failure • Section 11.106 Minor Alarm #106 Condenser Fan Motor Overload List of Warnings • Section 11.201 Warning #201: Service Vacuum Pump Soon • Section 11.202 Warning #202: PLC Battery Low….Replace Soon • Section 11.203 Warning #203: Dirty Filter • Section 11.204: Warning #204: Not used • Section 11.205: Warning #205: Water Saturation Probe Signal Loss • Section 11.206: Warning #206: Change Vacuum Pump Exhaust Coalescer Soon


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Pall Filter Training for HLP22

Figure 31


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Pall Filter Training for HLP22

Major Alarm #1 The Oil Purifier will announce the “PHASE REVERAL/LOW/HIGH VOLTAGE” alarm when the supply voltage is out of the expected range. Listed below are the 4 possible causes for this alarm. The HMI does not identify which of the 4 conditions is causing the alarm, only that an alarm condition exists. • Phase Reversal – supply voltage is out of phase, switch 2 of 3 supply voltage legs. • Phase Loss – one or more of the supply voltage legs is not energized • Low Voltage – the voltage supplied to the purifier is below the lower threshold. • High Voltage – the voltage supplied to the purifier is above the upper threshold.

To determine which of the 4 possibilities is causing the alarm the operator must open the electrical panel and view the lights on the sensor. Explanation of LED Light Sequences Normal Operation – Green LED on & Red LED’s off Phase Reversal – Alternating flashing of Green & Red LED’s Low Voltage – Green LED flashing & Red Low Voltage LED on High Voltage – Green LED flashing & Red High Voltage LED on Phase Loss – Green LED flashing

Figure 32


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Pall Filter Training for HLP22

Dirty Filter Warning/Shutdown The status of the discharge filter is constantly monitored for elevated differential pressure (dP) The purifier will continue to run. If the high dP condition continues for 24 hours, the purifier will shut down. Note: Elevated fluid viscosity due to cold oil may trigger the dP warning. The warning may go away if the oil warms and the viscosity drops. Part 2: “DIRTY FILTER SHUTDOWN” – When the countdown timer from part one reaches “0” and the elevated dP condition still remains, the purifier will shut down and issue an alarm on the HMI (shown above).

Figure 33


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Pall Filter Training for HLP22

Service Vacuum Pump Soon The Oil Purifier will issue a vacuum pump service warning after 8760 hours (365 days) of run time have been logged. The operator should plan on changing the vacuum pump timing gear oil within the next 7 days. Turn to section 10.3 of this manual for instructions on changing the gear oil. After the gear oil is replaced the service timer needs to be reset to 8760 hours. This can be done by pressing the â&#x20AC;&#x153;RSTâ&#x20AC;? button and then typing in 8760 as shown below.

Figure 34


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Pall Filter Training for HLP22

PLC Battery Low The purifiers PLC used an on board battery. When the battery becomes drained the HMI screen will announce a PLC Battery Low warning. The user should change the battery within 7 days. The battery type is CR2354 lithium ion. For details regarding how to replace the battery, refer to the appendix section corresponding to the PLC which is contained within this operator manual.

Dirty Filter Warning When pressure across the main fluid filter reaches approximately 35 psid a dirty filter warning will be displayed on the HMI. Review section 11.12 for details about the entire filter alarm sequence.


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Pall Filter Training for HLP22

HMI Screens Home Page From the home page the operator can navigate to all other screens. The home page displays the temperature and % saturation of the oil entering the purifier upstream of the heater. Pall Corporation has chosen to display this information because it most closely represents the current conditions with the customer reservoir. F1 to F4 buttons correspond to the items circled in yellow. For example pressing F1 will navigate the operator to the system run time screens. Similarly, pressing F4 will call up the menu which lists what each F button corresponds to. From any screen the operator can navigate back to the home page by pressing the F key corresponding to HOM.

Figure 35


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Pall Filter Training for HLP22

Menu Page #1 Menu Page #1 F1= Home Page F2 = Run Time Screens F3 = Heater Control F4 = Saturation Sensor (Pall water sensor) F5 = Filter Status F6 = VFD (variable frequency drive) F7 = Tower Level F8 = Vacuum Pump Status F9 = Next (navigates to Menu page #2)

Figure 36


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Pall Filter Training for HLP22

Menu Page #2 Menu Page #2 F1 = Home Page F2 = Alarm History F3 = Contact Information F8 = Exhaust Coalescer Status F9 = Next (navigates to Menu page #1)

Figure 37


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Pall Filter Training for HLP22

Tower Level The level of fluid within the tower and its set-point can be viewed by pressing F7 (Tower Level) from menu page #1. The operator can toggle from inches to centimeters by pressing F2. This screen is only for reference; the fluid level cannot be adjusted.

Figure 38


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Pall Filter Training for HLP22

Alarm History (Menu Page #2) The purifiers PLC will log alarm conditions as they occur. To view the history of alarms which have been logged navigate to Menu page #2 then press F2 which corresponds to Alarm History. After pressing F2 the alarm history will be displayed with the most recent alarm showing in position 0 (see screen shot below). To exit press â&#x20AC;&#x153;HOMEâ&#x20AC;? (F1).

Figure 39 T


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Pall Filter Training for HLP22

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Pall Filter Training for HLP22

WCF Pall Filter Training