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Operating Instructions Gas Odorization System GOE-SO-1P

RMG Messtechnik GmbH Otto-Hahn-Str. 5 P.O.Box 280

35510 Butzbach (Germany) 35502 Butzbach (Germany)

Tel.: +49 (0)6033 897-0 Fax: +49 (0)6033 897-130

Status: 06/2006 Serving the Gas Industry WORLDWIDE


Table of Contents

TABLE OF CONTENTS 1 INTRODUCTION .................................................................................................... 3 2 FUNCTIONAL DESCRIPTION............................................................................... 3 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10

ODORIZATION SYSTEM ..................................................................................................................... 3 EQUIPMENT ..................................................................................................................................... 4 CONTROL UNIT ................................................................................................................................ 4 ODORANT TANK ............................................................................................................................... 5 ACTIVATED CARBON FILTER .............................................................................................................. 5 LEVEL INDICATOR............................................................................................................................. 5 PROPORTIONING PUMPS................................................................................................................... 5 FLOW MONITOR TYPE FS-01 FOR [EEX I] .......................................................................................... 6 LEVEL MONITORING FOR [EEX I] IN THE ODORANT TANK...................................................................... 6 HIGH-PRESSURE FLUSHING AND VENTING DEVICE .............................................................................. 6

3 INSTALLATION ..................................................................................................... 7 3.1 3.2 3.3

PLACE OF INSTALLATION................................................................................................................... 7 MECHANICAL INSTALLATION .............................................................................................................. 7 ELECTRICAL INSTALLATION ............................................................................................................... 8

4 START-UP ............................................................................................................. 9 4.1 4.2 4.3 4.4 4.5

FILLING THE ODORANT TANK ............................................................................................................. 9 VENTING AND FLUSHING – PROPORTIONING PUMPS (6) (ODORANT PART) WITH INJECTION PIPE SYSTEM ..................................................................................................................................................... 10 VENTING THE PROPORTIONING PUMPS MH 6-47 / 6-65 (6) (HYDRAULIC PART) .................................. 11 VENTING THE PROPORTIONING PUMPS MH 15-50 / MH 15-70 (6) (HYDRAULIC PART)........................ 11 SETTING THE DISPLACEMENT ON THE PROPORTIONING PUMP............................................................ 12 STARTING UP THE CONTROL UNIT .................................................................................................... 14

5 OPERATION ........................................................................................................ 15 5.1 5.2 5.3 5.4 5.5

SERVICE SETTINGS ........................................................................................................................ 15 REMOVING OR INSTALLING THE SUCTION AND DISCHARGE VALVES OF THE PUMP HEAD ....................... 15 CHECKING THE OUTPUT OF THE PROPORTIONING PUMP .................................................................... 15 SHUTTING DOWN THE ENTIRE SYSTEM ............................................................................................. 16 SHUTTING DOWN THE PROPORTIONING PUMP .................................................................................. 16

6 MAINTENANCE AND FUNCTIONAL CHECKS .................................................. 16 6.1 6.2

FUNCTIONAL CHECKS ..................................................................................................................... 16 MAINTENANCE WORK ..................................................................................................................... 16

7 TROUBLESHOOTING ......................................................................................... 17 7.1 7.2 7.3 7.4

TROUBLESHOOTING TABLE ............................................................................................................. 17 INITIAL OUTPUT OF THE PROPORTIONING PUMP IS NO LONGER ACHIEVED.............................................................. 17 FAULT – PULSE COMPARISON ................................................................................................................. 17 LEVEL DETECTOR (13) OF THE ODORANT TANK REPORTS MINIMUM LEVEL; THE ODORANT TANK IS EMPTY (CONTENTS ≤ 10 LITRES) ........................................................................................................................................... 17

8 ANNEX ................................................................................................................. 18 8.1 8.2 8.3 8.4

INSTALLATION INSTRUCTIONS FOR SWAGELOK FITTINGS ............................................................... 18 SECTIONAL DIAGRAMS – PROPORTIONING PUMP MH-6-47 / 6-65 ..................................................... 19 SECTIONAL DIAGRAMS – PROPORTIONING PUMP MH-15-50-M11 / 13 .............................................. 20 SECTIONAL DIAGRAMS – PROPORTIONING PUMP MH-15-70-M11 / 13 .............................................. 21

9 SCHEMATIC DIAGRAM ...................................................................................... 22

2

Operating Instructions for the GOE-SO-1P


Introduction, Functional Description

1 Introduction Due to the fact that natural gas by its very nature is odourless or can hardly be smelled, it is essential to odorize it in order to ensure that accidentally escaping gas is detected in time before an explosive gas-and-air mixture can form. In accordance with Code of Practice G 280 of the German Association of Gas and Water Technology (DVGW), all gases as per DVGW Code of Practice G 260 which are used in public gas supply and have no sufficient inherent smell (warning smell) must be odorized. Odorization means adding to the gas an odorous substance what is called an odorant. Special proportioning methods are necessary to add the odorant to the natural gas. On the one hand, a safe and constant odour intensity is desired, but on the other hand, adding too much odorant must be avoided to prevent unnecessary and unpleasant smells. In order to achieve this purpose, the injection method has become widely accepted. With this method, precisely proportioned quantities of odorant are added to the natural gas. To do this, the volume pulses from a volumetric meter, e.g. a volume corrector, are used which are proportional to the gas quantity. This ensures an absolutely constant odorant concentration which is independent of the variations of the gas flow rate.

2 Functional Description 2.1 Odorization system The odorization system operates according to the injection method and is fitted with a stationary odorant tank (1). The complete system has been designed for use with the odorants THT or mercaptan (option: sulphur-free odorant). The odorant flows directly to the pump by gravity. By the additional admission with a pressure of max. 0.5 bar the formation of bubbles in the odorant (e.g. at high ambient temperatures or volatile odorants like Mercaptane or S-free) is prevented. In addition the pressure is used for filling the stationary tank. The level indicator (12) is fitted with both a scale showing the odorant level in litres and a measuring burette for checking if the set proportioning quantity is delivered. The odorization system can be fitted with up to three proportioning pumps (6) and injection pipes for odorizing three separate gas pipes. Solenoid-actuated proportioning pumps (reciprocating diaphragm pumps) are used to inject the odorant into the gas flow. Volume-proportional pulses from a meter measuring the volume at base conditions which are processed by a control unit cause the proportioning pump to perform strokes. To protect the non-return valves (suction and discharge valves) of the proportioning pumps and injection nozzles, a common fine filter sized 50 Âľm (7) is installed in the suction pipe upstream of the proportioning pumps. A flow monitor (8) installed in the injection pipes monitors the correct functioning of the proportioning pumps.

Operating Instructions for the GOE-SO-1

3


Functional Description

In the case of maintenance or repair work to be done, the odorization system can be flushed and vented from the filter (7) up to the injection nozzles with the flushing and venting device (9) using a flushing agent (e.g. spirit, benzine, methanol) up to a maximum back pressure of 80 bar. The activated charcoal filter (5) ensures that during an exhaust no emission of odorant vapour occurs. The whole piping is equipped with SWAGELOK fittings. For any work to be done on parts of the piping, the enclosed installation instructions (see 8.1) must be followed.

2.2 Equipment 2.2.1 2.2.2

Odorant tank (1) with drain connection and ball valve (19) Pressurization armature (37) with pressure regulator (15) at the stationary tank and pressure regulator (29) for the pressure for filling with odorant 2.2.3 Filling armature (38) with hose (3), ball valves (26 and 27) and odorant filter (11) 2.2.4 Level switch (12) with measuring burette, scale and ball valve (20) 2.2.5 Level detector (13) in the odorant tank for [EEx i] 2.2.6 Proportioning pump I MH- .... (6) and control valve (14) 2.2.7 Odorant filter sized 150 µm (11) in the filling pipe 2.2.8 Odorant filter sized 50 µm (7) in the suction pipe upstream of the proportioning pumps 2.2.9 Odorant filter sized 50 µm (11) in the discharge pipe downstream of the proportioning pumps 2.2.10 Activated carbon filter (5) of 1000 grams with ball valve (28) 2.2.11 High-pressure flushing and venting device (9) and ball valves (22) 2.2.12 Flow monitor for [EEx i] (8) in the injection pipes 2.2.13 Injection nozzle (34) with shut-off valve (35) and non-return valve (36) in the gas pipes

2.3 Control unit A control unit belongs to every odorization system. There are six design variants available: a) Wall-mounting unit → Type 7IG4 b) 19“ rack-mounting unit → Type 7EU4 c) Ex-d case, protected against explosions → Type 7IG4 Exd (For further information, please see the enclosed operating instructions for the 7IG4 / 7EU4.) d) Wall-mounting unit → Type OSG 2000-W-P 3.2 e) 19“ rack-mounting unit → Type OSG 2000-E-P 3.2 f) Decentralized installation → Type OSG 2000-M-P 3.2 with the program versions P1, P2 and P3.2. (For further information, please see the enclosed operating instructions for the OSG 2000.)

4

Operating Instructions for the GOE-SO-1P


Functional Description

2.4 Odorant tank

♦ ♦ ♦ ♦ ♦ ♦

The odorant tank (1) has been designed as a stationary container which is replenished via the filling pipe. There are the following connections available at the odorant tank: 1 G 1/2“ with SWAGELOK fitting, dia. 12 mm, for the upper connection of the level indicator 1 G 1/2“ with SWAGELOK fitting, dia. 12 mm, for the filling armature 1 G 1/2“ with SWAGELOK fitting, dia. 12 mm, for the pressurization armature 1 NPT 1/2“ with relief valve (4) with 2.4 bar opening pressure 1 G 1½“ for level detector (13) The drain connection with ball valve (19) is located at the bottom of the tank.

2.5 Activated carbon filter The activated carbon filter (5) prevents odorant vapours from escaping into the atmosphere.

2.6 Level indicator The level indicator (12) consists of a measuring burette with scale division. The measuring burette is used to check the quantity delivered by the pump. A minor scale line corresponds to a volume of 100 mm³ (= 100 mg with THT). The contents between two broad scale lines corresponds to a volume of 1,000 mm³. Next to the measuring burette, there is a scale showing the odorant level (residual contents) in litres.

2.7 Proportioning pumps Explosion-protected [Ex e G4] solenoid-actuated (200 VDC) reciprocating diaphragm pumps are used as proportioning pumps (6). Please refer to the data plate with the technical data of the solenoid actuators. A stainless steel diaphragm separates the odorant compartment from the hydraulic compartment. The setting of the delivery rate in mm³/stroke is made through a continuous stroke adjustment feature by means of a scale or counting mechanism. The materials used are resistant against the standard odorants used, such as tetrahydrothiophene and mercaptans. If resistance against sulphur-free odorants is required, there is a special pump design available (option).

Operating Instructions for the GOE-SO-1P

5


Functional Description

Technical data Pump type

Pump data Max. pump pressure [bar,g]

MH–6–47 MH–6–65 MH–15–50–M11 MH–15–50–M13 MH–15–70–M11 MH–15–70–M13

40 20 50 80 25 40

Solenoid data

DisplaceMax. stroke Pulse ment frequency length [mm³/ [pulses/h] [s] stroke] 10 ... 80 15 ... 150 30 ... 280 30 ... 280 60 ... 550 60 ... 550

7200 7200 5000 4300 5000 4300

0.35 0.35 0.55 0.66 0.55 0.66

Interpulse period [s] 0.15 0.15 0.16 0.16 0.16 0.16

2.8 Flow monitor type FS-01 for [EEx i] The flow monitor (8) is installed vertically in the injection pipe downstream of the proportioning pump. It monitors the pulses from the control unit to the pump by means of the pulses returned by the flow monitor. In the case of a pulse difference of 5 pulses (value set in the factory), an alarm will be outputted (”Fault – Pulse Comparison”). This alarm will persist until it is acknowledged by activating the reset function.

2.9 Level monitoring for [EEx i] in the odorant tank The level detector / level switch for monitoring the odorant level (13) is installed in the odorant tank. Please see the enclosed operating instructions for the technical data. If the amount of odorant falls below 10% of the volume of the odorant tank an alarm message is generated at the control unit.

2.10 High-pressure flushing and venting device This device (9) is used to flush the suction and injection pipes including the valves and fittings installed (e.g. proportioning pump with suction and discharge valves, odorant filter, flow monitor and injection nozzle)1) and to vent the proportioning pump. All conventional flushing agents (e.g. spirit, benzine or methanol) can be used. 1)

6

Note: The flushing process reduces odours e.g. when removing or reinstalling valves or fittings in the case of revision work.

Operating Instructions for the GOE-SO-1P


Installation

3 Installation 3.1 Place of installation For installation of the mechanical parts, it is essential to observe the national guidelines (e.g. DVGW Codes of Practice G 280 in Germany or IGS in Iran). Odorization systems must be installed in separate rooms with sufficient ventilation. They must not be installed in controller rooms which are normally explosionprotected for explosion zone 2 only. The requirements for zone 1 hazardous areas apply to the place of installation of the odorization system. The control unit must be installed in an area free from explosion hazards (exception: type 7IG4-Ex-d, since it is mounted in a Ex-d case with explosion-proof enclosure). The Ex-d case must not be opened in Ex-zone 1! The ambient temperature must be in a range from -29oC to +60oC, otherwise the functioning of the pump can be affected.

3.2 Mechanical installation The complete odorization system has been installed on the collector and tested for leaks and correct functioning in the factory. The following parts must be installed on site: ♦ Auxiliary pressure pipe (16) (max. auxiliary pressure: 80 bar at pos. (16) ♦ Injection nozzle (34) with shut-off valve (35) and non-return valve (36). If possible, installation should be made vertically from above in a horizontal gas pipe. ♦ Injection pipes between the odorization system and the injection nozzle 3.2.1 The pressure regulator (29) at the barrel has been adjusted so that the maximum output pressure is 0.25 bar at an input pressure (16) of 6 bar. The pressure regulator (15) at the odorization system has been adjusted so that the maximum output pressure is 0.5 bar at an input pressure (16) of 6 bar. The output pressure values will slightly change in the case of a change of the input pressure. In this case adjust the pressure regulators (15) and (29) to the output presure values of 0.5 bar and 0.25 bar. The blow-off valves are set to 0.7 bar. The blow-off outputs must not be closed! For adjustment use the attached instructions from TESCOM for the pressure regulators of type 44-2200 3.2.2 After the whole installation has been terminated, the injection pipes are to be tested for leaks. Important: If sulphur-free odorants such as "GASODOR S – Free" are used, all sealants, ball valves, etc., used must be suitable for sulphur-free odorant. 3.2.3 The ball valves are equipped with a lock and can be opend or closed if the lock is released (draw the lock upward).

Operating Instructions for the GOE-SO-1P

7


Functional Description

3.3 Electrical installation The odorization compartment is subject to explosion hazards of “zone 1– temperature class T4”. As to the electrical installation, the applicable regulations of the country where the odorization system is used must be complied with. The standards VDE 0100, VDE 0165 (EN 60079-14) and VDE 0170/0171 (EN 50014, EN 50019, EN 50020) apply to the installation of the electrical equipment. Cable connections are to be made in accordance with the electrical connection diagram.

8

Operating Instructions for the GOE-SO-1P


Start-up

4 Start-up Initial state: ♌ All shut-off valves of the odorization system and the injection nozzle (35) are closed. ♌ All automatic circuit breakers in the distribution box are switched on. ♌ All control units are switched off.

4.1 Filling the odorant tank 4.1.1 Screw the filling armature (38) into the odorant barrel (G2"). Subsequently connect the filling armature with the hose at the quick-coupler (31). 4.1.2 Screw the pressurization armature (37) with pressure regulator into the odorant barrel (G3/4"). Subsequently connect the pressurization armature with the hose at the quick-coupler (32). 4.1.3 Connect the auxiliary pressure pipe (16) to the odorant filter (39). 4.1.4 Open ball valves (19) and (20) as well as (23, 24, 26, 27 and 28). Now the filling level can be read on the measuring burette when odorant2) is filled in and/or is still present. 4.1.5 Set the pressure at the pressure regulator (29) to max. 0,25 bar. Then the odorant flows from the barrel into the odorant tank. During the fueling the ball valve must be closed (25). 2)

Important:

For safety reasons, the operating staff must monitor the odorant level during the time the odorant tank is filled up. This also applies if there is a limit shut-off feature operated by a solenoid valve.

4.1.6 After filling close the ball valves (23, 24, 26, 27 and 28). The hoses (3) at the quick-couplers (31 and 32) can be removed. Filling armature with riser and pressurization armature can be unscrewed from the steel barrel.

Operating Instructions for the GOE-SO-1P

9


Start-up

4.2 Venting and flushing – proportioning pumps (6) (odorant part) with injection pipe system Initial state of the valves on start-up (prior to flushing): ♦ Ball valve (22) is closed. ♦ Fill the flushing pump tank with approx. 0.5 litres of flushing agent (see 2.12) or top up the flushing agent. ♦ Open ball valves (19 and 20). ♦ Open the control valve (14). ♦ Open the shut-off valve (35) before the injection nozzle. ♦ Close the ball valves (19 and 20). ♦ Prior to pumping, open the screw cap of the flushing agent tank approx. 1 turn. ♦ All control units are switched off at the mains switch. 4.2.1 Venting using the flushing pump (9) Note: Each proportioning line must be vented individually. ♦ Open the ball valve of the line to be vented (22). ♦ Operate the flushing pump several times3) using the hand lever. 3)

Note:

♦ ♦ ♦ ♦

After venting, close the ball valve of the vented line (22). Perform venting for all available lines. After venting, close the screw cap of the flushing agent tank again. Open ball valves (19) and (20), if you want to start odorization afterwards. Set the control units as described in the operating instructions and switch them on. Now the proportioning device injects the set quantity of odorant through the injection pipe into the gas flow. You can check the functioning if you close stopcock 1 of the odorant tank and observe the measuring burette. The level of the measuring burette falls with each pump stroke. NOTE:

10

Flushing pump (output: approx. 6 cm³/stroke, i.e. depending on the length of the injection line, it is necessary to perform at least the number of strokes below. Examples: ● Pipe dia. 6 × 1 mm / 5 strokes per 1 m of pipe; ● Pipe dia. 12 × 1 mm / 13 strokes per 1 m of pipe; permissible max. gas back pressure: 80 bar,g).

Do not completely empty the measuring burette, otherwise you must repeat the venting process.

Operating Instructions for the GOE-SO-1P


Start-up

4.3 Venting the proportioning pumps MH 6-47 / 6-65 (6) (hydraulic part) Usually, the pump has been vented in the factory. Due to transport, it may be necessary to vent the hydraulic part of the pump again at the place of installation. To do this, please proceed as follows: 4.3.1 Open the venting screw (hexagon socket SW 4) for the hydraulic part approx. 1 turn. 4.3.2 Set the proportioning pump to its maximum output. 4.3.3 Make the following settings on the associated control unit: ♦ Mains voltage “ON” ♦ Pulse generator ”Internal” ♦ The hydraulic oil must come out of the venting screw without any bubbles. If necessary, repeat the venting process after 5 minutes. 4.3.4 Close the venting screw for the hydraulic compartment. 4.3.5 Switch the control unit off at the mains switch and reset the pulse generator to “External”. 4.3.6 Check the oil level → To do this, unscrew the black plastic screw SW 19 and top up oil*) up to the lower edge of the threads.

Venting the proportioning pumps MH 15-50 / MH 15-70 (6) (hydraulic part) 4.3.7 Open the venting screw for the hydraulic part until approx. 2 turns are left. 4.3.8 Set the proportioning pump to its maximum output. 4.3.9 Perform pump strokes by operating the automatic/manual changeover switch (“Manual” position) at intervals of approx. 1 second at maximum output until no more air bubbles are visible. 4.3.10 Make the following settings on the associated control unit (I to III): ♦ Mains voltage “ON” ♦ Pulse generator ”Internal” ♦ The hydraulic oil must come out of the venting screw without any bubbles. If necessary, repeat the venting process after 5 minutes. 4.3.11 Close the venting screw for the hydraulic compartment. 4.3.12 Switch the control unit off at the mains switch. 4.3.13 Tighten the venting screw again when the solenoid is in its discharge position. Check the oil level and, if necessary, top up oil* until the level reaches the middle of the sight glass.

*) Only use special hydraulic oil NDT2, RMG ref. No. 50.27.003.00.

Operating Instructions for the GOE-SO-1P

11


Start-up

4.4 Setting the displacement on the proportioning pump 4.4.1

Calculating the pump setting In order to convert working cubic metres [m³] to standard cubic metres [sm³], it is sufficient if only the absolute operating pressure is used for the following calculations. Density and volume data for the most important odorants: Tetrahydrothiophene (THT):→ Density ~0.99kg/dm³ → 1mg corresponds to a volume of ~1mm³ at 20°C Mercaptan:→ Density ~0.82kg/dm³ → 1mg corresponds to a volume of ~ 1.22mm³ at 20°C GASODOR S-Free: → Density ~0.933kg/dm³→1mg corresponds to a volume of ~1.072mm³ at 25°C

Symbols and conversions used: Qb, max

= Max. gas flow, standard cubic metres [sm³/h] ⇒ sm³/h = m³/h × pa

Qm, max

= Max. gas flow, working cubic metres [m³/h] Input pulse value [sm³/pulse]

I1

:

= (Value which is specified by the existing gas volume corrector or directly by the turbine meter, for example.) Pulse value, pump [sm³/pulse]

:

PP

= (Gas flow rate which the pump must supply with odorant with each stroke. This value can be adjusted on the control unit.)

pg

= Operating gauge pressure [bar]

pa

= Absolute operating pressure [bar]

fpump

= Max. stroke frequency of the proportioning pump [pulses/h], see 2.8.1

Vpump

= Max. output of the proportioning pump [mm³/stroke], see 2.8.1

ρ (rho)

= Density of the odorant [kg/dm³] or [mg/mm³]

c

= Desired odorant concentration [mg/sm³]

Vsetting

= Setting of the proportioning pump [mm³/stroke]

12

Operating Instructions for the GOE-SO-1P

pa = p + 1


Start-up

Calculating the output (quantity to be set) Vsetting

c × Pp ρ

=

[mm³/stroke]

Calculating the stroke frequency fpump

Qb Pp

=

[strokes/h]

When you make your calculations, make sure that the maximum stroke setting (Vpump) and the max. stroke frequency (fpump) of the proportioning pump are not exceeded (see 2.8.1). Example 1: ⇒ Odorant – GASODOR S-Free Input pulses from a gas volume corrector Proportioning pump: MH-6-47 Qb

= 25,000 [sm³/h]

I1

= Input pulse value [sm³/pulse] :

Pp

= 8 [sm³/pulse] :

ρ (rho)

= 0.933 [kg/dm³]

c

= 9 [mg/sm³]

fpump, max

= 7,200 [strokes/h]

Vpump, max

= 80 [mm³/stroke], adjustable from 10 to 80mm³.

Calculating the output (quantity to be set) Vsetting

=

c × Pp = ρ

9×8 0.933

= 77.2 [mm³/stroke]

Calculating the stroke frequency fpump

=

Qb Pp

=

25,000 8

= 3,125 [strokes/h]

Example 2: ⇒ Odorant – GASODOR S-Free Input pulses from a turbine meter Proportioning pump: MH-6-65 Qm

= 5,000 [m³/h]

Qb

= Qm × pa = 5,000 × 7.0 = 35,000 [sm³/h]

I1m

= 1.0 [m³/pulse]

I1b

= I1m × pa = 1.0 × 7.0 = 7.0 [sm³/pulse] :

pg

= 6 bar

Operating Instructions for the GOE-SO-1P

13


Start-up

pa

= pg + 1 = 6 + 1 = 7 bar

PP

= 12.0 [sm³/pulse] :

ρ (rho)

= 0.933 [kg/dm³]

c

= 10 [mg/sm³]

fpump, max

= 7,200 [strokes/min]

Vpump, max

= 150 [mm³/stroke]

Calculating the output (quantity to be set) Vsetting

=

C × Pp = ρ

10 × 12 0.933

= 128.6 [mm³/stroke]

Calculating the stroke frequency fpump

=

Qb Pp

=

35,000 12

= 2,916 [strokes/h]

4.5 Starting up the control unit 4.5.1 The parameterization and configuration of the control unit is to be made in compliance with the ”Operating Instructions for the 7IG4 / 7EU4 or OSG 2000”. ATTENTION: Type 7IG4-Exd in explosion-proof enclosure is adjusted in the factory. For safety reasons the cover of the case must not be opened in zone 1 hazardous areas. 4.5.2 After you have inputted or selected the parameters, the start-up process of the entire odorization system has been terminated. ♦ Mains voltage “ON” ♦ Pulse generator ”External” 4.5.3 All the setting data set should be recorded in a list.

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Operating Instructions for the GOE-SO-1P


Operation, Maintenance and Functional Checks

5 Operation 5.1 Service settings 5.1.1 The following shut-off valves are closed: ♦ Ball valves (22, 24, 26 and 28) 5.1.2 The following shut-off valves are open: ♦ Ball valve (19) ♦ Ball valve (20) ♦ Ball valve (25) ♦ Control valve (14) ♦ Shut-off valve at the injection unit (35) 5.1.3 The pressure regulator (15) has to be set to max. 0.5 bar as necessary.

5.2 Removing or installing the suction and discharge valves of the pump head MAKE SURE THAT YOU WORK UNDER EXTREMELY CLEAN CONDITIONS! 5.2.1 Refer to the relevant sectional drawings to remove or install the valves. 5.2.2 The parts belonging to the discharge valves must not be confused with the parts belonging to the suction valves. 5.2.3 When you install the discharge valves, insert the individual parts centrically into the pump head and then screw in the valve housing. When you screw in the valve housing, make sure that the valve parts do not get out of place.

5.3 Checking the output of the proportioning pump 5.3.1

Switch the control unit on and switch to “Internal Pulse Generator”. See the operating instructions for the 7IG4 / 7 EU4 or OSG 2000. 5.3.2 Close ball valve (19). 5.3.3 Mark the odorant level on the level indicator (e.g. with adhesive tape or a water-soluble felt-tip pen). 5.3.4 Determine the odorant volume in mm³ available in the measuring burette. The volume between two minor scale lines is 100 mm³ and between two broad scale lines 1,000 mm³. 5.3.5 The volume determined in the measuring burette divided by the displacement in mm³ set on the proportioning pump is the number of possible pump strokes. Example: Volume in the measuring burette = 1,600 mm³ (16 minor scale lines) Displacement set on the proportioning pump = 80 mm³ Number of possible pump strokes: 1,600 : 80 = 20 strokes NOTE! Do not completely empty the measuring burette, otherwise it is possible that air enters the proportioning pump.

Operating Instructions for the GOE-SO-1P

15


Start-up

5.3.6 The calculated value should be identical to the set displacement of the proportioning pump. If there is a large deviation, refer to the �Troubleshooting Table�. 5.3.7 After the delivery check has been terminated, reset the initial service settings on the control unit and the shut-off valves in accordance with 5.1.

5.4 Shutting down the entire system 5.4.1 Switch the mains voltage (230VAC) off at the associated control units. 5.4.2 Close shut-off valves (14) and (35) in the injection pipe downstream of the proportioning pump and close ball valve (22) or leave them closed. 5.4.3 Close ball valve (20) of the level indicator. 5.4.4 Close ball valve (19) in the extraction line from the odorant tank.

5.5 Shutting down the proportioning pump This is necessary, for example, if revision work has to be done on a gas line. 5.5.1 5.5.2

Switch the associated control unit off. Close the associated shut-off valves (14) and (35).

6 Maintenance and Functional Checks 6.1 Functional checks 6.1.1 Possible disturbances must be eliminated at once. 6.1.2 Check the delivery of the proportioning pump in accordance with 5.3 (on a monthly basis).

6.2 Maintenance work 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5

Check the odorant level of the odorant tank (once a week). Check the oil level of the proportioning pump (once a month). Change the activated carbon (at one-year intervals or earlier, if necessary). Carry out complete odorization system maintenance (once a year).*) Check the overflow controller (limit transmitter) (10 option) with cut-off function (once a year). 6.2.6 Replace the filter elements (7), (11) and (39) (at one-year intervals or earlier, if necessary). To avoid leakages at the fittings, fix the filter with a wrench while replacing the filter element. *) Such maintenance work is to be carried out by specialist staff only. On request, we will offer you an appropriate maintenance contract.

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Operating Instructions for the GOE-SO-1P


Annex

7 Troubleshooting 7.1 Troubleshooting table Cause

Fault 7.2

Initial output of the proportioning pump is no longer achieved.

7.2.1

Vent the odorant part of the pump head (see 4.2).

7.2.2

Vent the hydraulic part of the pump head (see 4.3).

7.2.3

7.2.4

♦ ♦ ♦

7.3.1

♦ ♦

Check delivery as described in 5.3: If the level rises in the measuring burette during the delivery stroke, the suction valve is leaky. If the displacement set at the proportioning pump is not sucked away during the suction stroke, the discharge valve is leaky. Remove the valves (see 5.2) and replace the parts. Clean or replace the filter element of the filter (7). Clean or replace the filter element of the filter (11 option). Clean or replace the filter element of the filter (39). Adjust the operating point of the flow monitor.

7.3.2

Take measures as described in 7.2.

7.3.3

Disassemble the flow monitor and clean all parts.

7.3.4

♦ ♦

Clean or replace the filter element of the filter (7). Clean or replace the filter element of the filter (11 option). Clean or replace the filter element of the filter (39) Fill up the odorant tank.

Air in the odorant part of the pump head. Air in the hydraulic part of the pump head. Valves of the proportioning pump are leaky.

Odorant filter is soiled.

7.3

Fault – Pulse comparison

Flow monitor is not properly adjusted. Initial output of the proportioning pump is no longer achieved. Flow monitor is soiled. Odorant filter is soiled.

7.4

Remedy

♦ ♦

7.4.1 Odorant tank is Level detector empty. (13) of the odorant tank 7.4.2 Level detector (13) is ♦ reports defective. minimum level; the odorant tank ♦ is empty (contents ≤ 10 litres)

Check the level detector (13) and the isolating amplifier (transmitter supply unit) → see the technical documentation. Check the electrical connections!

Operating Instructions for the GOE-SO-1P

17


Troubleshooting

8 Annex 8.1 Installation instructions for SWAGELOK fittings

INSTALLATION INSTRUCTIONS FOR TUBE FITTINGS INITIAL INSTALLATION Cut the tubing perpendicularly and remove the fins. Insert the tubing into the tube fitting. Make sure that the tubing rests firmly on the shoulder of the fitting and that the nut is finger-tight.

Before tightening the SWAGELOK nut, scribe the nut at the 6 o’clock position.

Then tighten the nut 1 ¼ turns* until the scribe mark reaches the 9 o’clock position. * For 2, 3, 4 mm or 1/16, 1/8, 3/16 in. size tube fittings, tighten the nut ¾ turn on initial installation.

RETIGHTENING INSTRUCTIONS Fitting shown in the disconnected position.

Insert tubing with preswaged ferrules into fitting body until front ferrule seats. Tighten nut by hand. Then tighten the nut approx. ¼ turn with a wrench.

18

Operating Instructions for the GOE-SO-1P


Annex

8.2 Sectional diagrams – proportioning pump MH-6-47 / 6-65

MH-6-47 / 65 pump head Discharge valve Venting screw for hydraulic part

Oil level

MAX

MIN

Delayed discharge Suction valve

Suction valve

Stainless steel diaphragm

Discharge valve

Delayed discharge valve

Operating Instructions for the GOE-SO-1P

19


20

Oil filler

Stroke adjustment

Section A - B

solenoid actuator

Z

Suction valve Oil level eye

B

A

View Z

Delayed discharge valve

Venting screw for hydraulic part

Proportioning pump Type MH-15-50

Suction valve

Suction valve

Discharge valve

Stainless steel diaphragm

Discharge valve

Annex

8.3 Sectional diagrams – proportioning pump MH-15-50-M11 / 13

Discharge valve

Operating Instructions for the GOE-SO-1P


Annex

8.4 Sectional diagrams – proportioning pump MH-15-70-M11 / 13

Suction valve

Discharge valve

Operating Instructions for the GOE-SO-1P

21


Annex

9 Schematic Diagram 16

Pressure inlet P max. = 80 bar

18

13

36

11

28

39

4

35

9

1

34 26

40 Injection pipe

3

31

22

15

25

21

24

10

33 29

30 10 27

23 32 5

12

8

14

17

37

6 2

7

20

19

1 - Stationary odorant tank 2 - Transporting vessel 3 - Hose 4 - Relief valve 2.3 bar 5 - Activated charcoal filter 6 - Proportioning pump 7 - Odorant filter 50Îźm 8 - Flow switch 9 - Flushing and venting device 10 - Non return valve 11 - Odorant filter 150 Îźm 12 - Measuring burette 13 - Level switch 14 - Regulation valve injection pipe 15 - Pressure regulator 16 - Inlet auxiliary pressure 17 - Push button 18 - Outlet injection pipe 19 - Ball valve odorant supply 20 - Ball valve measuring burette

22

21 - Non return valve 2.75 bar (40 psi) 22 - Ball valve flushing and venting device 23 - Ball valve pressurization transporting vessel 24 - Ball valve pressure pipe 25 - Ball valve pressurization odorization system 26 - Ball valve filling pipe odorization system 27 - Ball valve filling pipe transporting vessel 28 - Ball valve charcoal filter 29 - Pressure regulator transporting vessel 30 - Fast coupling filling pipe transporting vessel 31 - Fast coupling filling pipe odorization system 32 - Fast coupling pressure pipe odorization system 33 - Fast coupling pressure pipe transporting vessel 34 - Injection nozzle 35 - Ball valve injection nozzle 36 - Non return valve 37 - Pressurization armature 38 - Filling armature with riser 39 - Odorant filter 50 Îźm 40 - Non return valve

Operating Instructions for the GOE-SO-1P

38


/goe_so_1p_manual_gb