ProMinent DULCODOS Ammonia Operating Instructions Manual

Brand: ProMinent

Model: DULCODOS Ammonia

Type: Operating Instructions Manual

Ammonia water dilution and metering system

DULCODOS

Ammonia

Operating instructions

Original operating instructions (2006/42/EC)981962 BA DD 037 02/19 EN

Please carefully read these operating instructions before use. · Do not discard.

The operator shall be liable for any damage caused by installation or operating errors.

The latest version of the operating instructions are available on our homepage.

Read the following supplementary information in its entirety! You

will benefit more from using the operating instructions should you

already know this information.

The following are highlighted separately in the document:

n Enumerated lists

Instructions

Information

This provides important information relating to the

correct operation of the unit or is intended to make

your work easier.

Safety information

Safety information is identified by pictograms - see "Safety

Chapter".

These operating instructions conform to current EU regulations

applicable at the time of publication.

This document includes notes and quotes from German guidelines

relating to the system operator's scope of responsibility. This infor‐

mation does not discharge the operator from his responsibility as

an operator and is intended only to remind him or make him aware

of specific problem areas. This information does not lay claim to

being complete, nor applicable to every country and every type of

application, nor to being unconditionally up-to-date.

Supplementary information

Fig. 1: Please read!

Validity

Notes for the system operator

Supplemental directives

Table of contents

List of other applicable documents....................................... 4

2 Type list with performance data............................................ 5

3 About the product.................................................................. 6

4 Safety chapter....................................................................... 7

5 Storage, transport, unpacking............................................. 12

6 Overview of equipment and control elements..................... 14

7 Functional description......................................................... 16

8 Assembly............................................................................ 17

9 Installation........................................................................... 19

9.1 Installation, hydraulic.................................................. 19

9.2 Installation, electrical.................................................. 21

10 Start up............................................................................... 23

10.1 Checking for leak-tightness...................................... 23

10.2 Setting....................................................................... 24

10.3 Functional test with dilution water............................. 25

11 Operation............................................................................ 27

Maintenance....................................................................... 33

13 Repair................................................................................. 35

14 Troubleshooting.................................................................. 37

15 Decommissioning and disposal.......................................... 38

15.1 Decommissioning..................................................... 38

15.2 Disposal.................................................................... 38

16 Technical data..................................................................... 40

16.1 Technical data for the complete system................... 40

16.2 Materials and properties of the components............. 42

17 Spare parts and accessories.............................................. 44

17.1 Spare parts............................................................... 44

17.2 Accessories.............................................................. 45

18 Dimensional drawings......................................................... 46

19 Declaration of Conformity for Machinery............................. 48

20 Index................................................................................... 49

Table of contents

1 List of other applicable documents

Title

Operating Instructions for Solenoid Metering Pump Beta

b BT4b

and BT5b

Wiring diagram for the terminal box for ammonia water with up to

25% w/w:

Document no. 82_05-401_00_05-44

Dependent on your order, you will find

the following applicable documents in

the appendix to these operating

instructions:

List of other applicable documents

2 Type list with performance data

Tab. 1

Dosing tank

volume, nom‐

inal

Dosing tank

volume,

usable

Metering

vessel, usable

Metering

pump

Capacity

Transfer

pump

Delivery

height

Transfer

pump

Pump

capacity

Order no.

l l l l / h bar l / h

130 120 2 7 4 approx. 15 1039192

250 250 5 7 2 approx. 36 1039193

Ammonia water metering systems

DULCODOS

Ammonia

Type list with performance data

3 About the product

The metering system DULCODOS

Ammonia is used for the gas-

tight transfer and dilution of ammonia water to common metering

concentrations and for automatic metering into the feed water.

Ammonia (NH

), or diluted in water: Ammonium hydroxide

(NH

OH) is used for the alkalising and binding of free carbonic acid

in boiler water and condensate.

Common stock solutions: from 5% to 25% NH

(% w/w) (ammonia

water).

The usual metering concentration is 0.1% ... 2.5% NH

(% w/w).

About the product

4 Safety chapter

The following signal words are used in these operating instructions

to denote different levels of danger:

Signal word Meaning

WARNING Denotes a possibly hazardous

situation. If this is disregarded,

you are in a life-threatening sit‐

uation and this can result in

serious injuries.

CAUTION Denotes a possibly hazardous

situation. If this is disregarded,

it could result in slight or minor

injuries or material damage.

The following warning symbols are used in these operating instruc‐

tions to denote different types of danger:

Warning symbol Type of danger

Warning of a dangerous area.

Warning of hazardous electrical

voltage.

Warning of a risk of explosion

n The metering system DULCODOS

Ammonia is only intended

for batching ammonia water in common concentrations of up to

max. 25% into standard solutions of 0.1% to max. 2.5% and

metering this into water-steam circuits or into steam and con‐

densate systems.

n The metering system DULCODOS

Ammonia may only be

used after correct installation and start up - according to the

technical data and specifications outlined in these operating

instructions and the operating instructions for the individual

components.

n The metering system DULCODOS

Ammonia is not intended

for other uses.

n In the event of a modification, the operator or the contractor he

has appointed becomes the manufacturer of the modified

system in accordance with EC Regulation 2006/42/EC – with

the corresponding obligations.

Labelling of safety information

Warning symbols denoting different

types of danger

Intended use

Safety chapter

n The metering system DULCODOS

Ammonia is not intended

for metering other chemicals, such as sodium hydroxide solu‐

tion.

n The metering system DULCODOS

Ammonia is not intended

for the metering of gaseous or solid media or other liquid

media.

n You are obliged to observe the information contained in the

operating instructions at the different phases of the unit’s

service life (such as assembly, installation etc.).

n These operating instructions contain a summary of the impor‐

tant functions of each of the components used.

The technical information and operating instructions for the

components used form an integral part of the entire operating

instructions and must be observed.

n Make sure that the metering systems are only operated by

trained and authorised personnel, see table.

Task Qualification

Storage, transport, unpacking Technical personnel

Assembly, installation of the

hydraulic system

Technical personnel

Electrical installation Technical personnel, electrical

technician recommended

Start up Authorised technical personnel

Operation Instructed person

Maintenance Technical personnel

Repair Authorised skilled personnel

proven to have been trained by

ProMinent

Troubleshooting Technical personnel

Decommissioning / Disposal Technical personnel

Electrician

Electricians are deemed to be people, who are able to complete

work on electrical systems and recognise and avoid possible haz‐

ards independently based on his/her technical training and experi‐

ence, as well as knowledge of pertinent standards and regulations.

Electricians should be specifically trained for the working environ‐

ment in which the are employed and know the relevant standards

and regulations.

Electricians must comply with the provisions of the applicable stat‐

utory directives on accident prevention.

Instructed personnel

The instructed personnel have been instructed by the operator in a

training session about the tasks allocated to them and potential

hazards with incorrect and improper conduct.

Technical personnel

Technical personnel are deemed to be people, who are able to

complete the tasks allocated to them and recognise and avoid haz‐

ards independently based on his/her technical training and experi‐

ence, as well as knowledge of pertinent regulations.

Qualification of personnel

Safety chapter

WARNING!

Danger from hazardous substances!

Possible consequence: Fatal or very serious inju‐

ries.

Please ensure when handling hazardous sub‐

stances that you have read the latest safety data

sheets provided by the manufacture of the haz‐

ardous substance. The actions required are

described in the safety data sheet. Check the

safety data sheet regularly and replace, if neces‐

sary, as the hazard potential of a substance can be

re-evaluated at any time based on new findings.

The system operator is responsible for ensuring

that these safety data sheets are available and that

they are kept up to date, as well as for producing

an associated hazard assessment for the worksta‐

tions affected.

WARNING!

Danger of electric shock

Mains voltage may be present inside the pump

housing and the switch cabinet.

– Immediately disconnect the system from the

mains power supply if the pump housing or

switch cabinet has been damaged. Only return

the pump to service after it has been repaired

by authorised personnel.

CAUTION!

Please also observe the operating instructions for

the metering pump and any other units which may

be fitted.

CAUTION!

Do not climb onto the system or parts thereof - the

metering station cannot support the load, could

leak or topple over.

NOTICE!

Warning of illegal operation

Observe the regulations that apply where the

device is installed.

The following dangers could arise if incorrectly operated or mis‐

used:

Water pollution and damage to health

n Water pollution and damage to health due to escaping liquids.

n Damage to health from the inhalation of ammonia vapours.

n Dangerous reactions due to contact with other chemicals.

Safety information

Potential danger from the system

Safety chapter

Take special precautions with storage and metering. The specific

potential danger and resulting hazards should be taken from the

current material safety data sheet for the substance used.

Danger of explosion

n Risk of explosion due to trapped ammonia-air mixtures.

A potentially explosive ammonia-air mixture (lower explosion limit

15.4 vol.%, upper explosion limit 33.6 vol.%) can form in the inte‐

rior of the metering vessel and also in the interior of the supply

drum via the liquid phase depending on the temperature and con‐

centration of the commercial ammonia water product.

The built-in level switch in the metering vessel is therefore

designed to be intrinsically safe “i” with an explosion-proof design.

Pay attention to any static charge when connecting or replacing a

supply drum!

Turn the Emergency Stop switch to “0” in the event of an emer‐

gency or if liquid escapes from the system during pumping.

Refer to the material safety data sheet for ammonia water supplied

by the chemical supplier in the event of any accidents with

ammonia water.

If ammonia water escapes, evacuate the room, put on protective

equipment, seal the leak and, if necessary, collect the escaped sol‐

ution and dispose of!

Refer to the material safety data sheet for ammonia water provided

by the chemical supplier.

Refer to the material safety data sheet for ammonia water provided

by the chemical supplier.

Keywords when searching for the necessary regulations:

n Ammonia water systems

n Ammonia water

n Storage

n Hazardous substances

n Personal protective equipment

n Water protection

n Air protection

n ...

The “GESTIS Substance Database” published by the IFA Institute

for Occupational Health and Safety of the German Social Accident

Insurance provides valuable information.

Direct contact with ammonia water may occur when changing over

the supply drum and during maintenance work. Observe the

instructions.

Emissions of ammonia gas are not expected due to the gas-tight

design of the storage tanks and the downstream exhaust air

adsorber. This is the case providing the adsorber is regularly

changed.

Information in the event of an emer‐

gency

Health hazards

First aid instructions

Note for the system operator

Emissions

Safety chapter

Sound pressure level LpA < 70 dB according to EN 3746

The system is provided with the following protection equipment,

which prevents large quantities of ammonia from escaping, or the

resulting ignition of an ammonia water-air mixture:

n The level switch in the metering vessel prevents overflowing.

n The system is designed so that the transfer from the storage

tank to the metering vessel is via a vapour recovery line.

n The aeration and venting of the system is through an active

carbon filter, which absorbs the escaping ammonia gas.

n The lid of the dosing tank protects the user from ammonia gas.

It needs to be secured by a seal when operating with ammonia.

n The level switches in the metering vessel and in the dosing

tank are designed to be explosion-proof and intrinsically safe “i”

with an appropriate explosion-proof intrinsically safe “i” switch

amplifier.

Further recommendations, the implementation of which is however

outside our area of responsibility:

n Place the dosing tank in a collecting pan.

Affix workplace labels in line with the current regulations.

They might look like this in accordance with the German regula‐

tions governing printing of the operating instructions:

Warning of caustic substances

Use eye protection

Use safety gloves

Ensure that the warning label is always fitted and legible.

Sound pressure level

Protective equipment

Warning labels

Safety chapter

5 Storage, transport, unpacking

WARNING!

Warning of hazardous ammonia

Ammonia can escape in the event of damage.

– Make sure that the metering system is free

from ammonia prior to storage or transport.

–

Carefully protect the metering system against

mechanical damage, so that no one can be

endangered by escaping caustic ammonia

during subsequent operation.

WARNING!

Only return metering pumps for repair in a cleaned

state and with a flushed liquid end - refer to

"Decommissioning!

Only return metering pumps with a completed

Decontamination Declaration form. The Declara‐

tion of Decontamination constitutes an integral part

of an inspection/repair order. A unit can only be

inspected or repaired when a Declaration of

Decontamination Form is submitted that has been

completed correctly and in full by an authorised

and qualified person on behalf of the pump oper‐

ator.

The "Declaration of Decontamination” form can be

found at www.prominent.com.

WARNING!

Danger of leakage

The device can be damaged or leak by incorrect or

improper storage or transportation!

– Only store or transport the unit in its original

packaging.

–

The packaged device should also only be

stored or transported in accordance with the

stipulated storage conditions.

– The packaged device should be protected from

moisture and the ingress of chemicals.

CAUTION!

Danger of material damage

The device is top-heavy as long as the dosing tank

is empty.

– Bear this in mind when transporting it.

Safety information

Storage, transport, unpacking

Parameter Value

Minimum storage and transport temperature: 0 °C

Maximum storage and transport temperature: +50 °C

Minimum ambient temperature during operation: 0 °C

Maximum ambient temperature during operation*

at up to 15% ammonia water:

at up to 20% ammonia water:

at up to 25% ammonia water:

35°C

30°C

25°C

Max. temperature of the dilution water: 20°C

Maximum air humidity**: 92% relative humidity

* The higher the starting concentration, the lower the temperature

needs to be.

** non-condensing

Do not allow to stand in direct sunlight.

Ambient conditions

Storage, transport, unpacking

6 Overview of equipment and control elements

P_HYD_0011_SW.svg

Fig. 2: Overview of equipment: metering system DULCODOS

Ammonia

1 Supply drum (not in the scope of

delivery)

2 Suction lance with gas recovery (acces‐

sory)

3 Vapour recovery line

4 Transfer pump (with control elements)

5 Metering pump (for metering; with con‐

trol elements)

6 Injection valve

7 Chemical vapour lock

8 Stopcock (dilution water)

9 Metering vessel with level switch

10 Manual stirrer

11 Stopcock (metering vessel drainage)

12 Dosing tank with sprinkler

13 Suction assembly

14 Dosing tank level switch

15 Stopcock (rinsing water metering vessel)

16 Switch cabinet - see also Fig. 3

Not shown Collecting pan (accessory)

Overview of equipment and control elements

P_HYD_0029_SW

Fig. 3: Switch cabinet control elements(on the side of the system)

1 Main switch with Emergency Stop function

2 “Start filling metering vessel” key

Overview of equipment and control elements

7 Functional description

The DULCODOS

Ammonia system is used for the gas-tight

transfer and dilution to usual metering concentrations and then

automatic metering into the feed water.

The dosing tank (12) needs to be filled with de-ionised water to

batch a diluted usable ammonia water solution. The transfer pump

(4) semi-automatically fills concentrated ammonia water solution

(max. 25%) from the supply drum (1) into a metering vessel (9). An

appropriate amount of this concentrated solution from this metering

vessel needs to be left in the dosing tank to obtain a final concen‐

tration of between 0.1% ... 2.5%.

The manual stirrer (10) mixes the solution until it is homogeneous.

A chemical vapour lock (adsorber) (7) is fitted on the metering

vessel to prevent ammonia vapours from escaping into the envi‐

ronment.

The metering pump (5) meters the ready-to-use ammonia solution

from the dosing tank at the corresponding point of injection (6).

Metering can be provided on-demand using external control of the

metering pump.

Optional fault indicating relays on the pumps can report faults on a

control panel.

Functional description

8 Assembly

WARNING!

Warning of hazardous ammonia

Ammonia can escape if the system is not handled

correctly.

– Store and transport the metering system in its

original packaging. Take special precautions to

ensure that the metering system is protected

against mechanical damage

–

Select a suitable installation site for the

ammonia water metering system.

WARNING!

Danger of severe eye injuries

Immediately rinse the eyes in the event of

ammonia coming into contact with them.

– Provide an eye shower (with water connection)

directly adjacent to the installation site.

WARNING!

Warning of explosive atmospheres

An explosive air-ammonia mixture can form with

high concentrations of ammonia water – particu‐

larly above 15% w/w – or also at high ambient tem‐

peratures (at over 30 °C above 10% w/w).

– Note the current regulations and technical reg‐

ulations dealing with ammonia and ensure ade‐

quate ventilation.

CAUTION!

Observe the material safety data sheet

Observe the current material safety data sheet for

ammonia water.

The following must be available at the installation site:

n Water connector with eye shower (refer to the material safety

data sheet)

n Water connector for deionised water (dilution water and rinsing

water). Properties - refer to "Technical data" chapter

n Prevent the installation site from unauthorised access.

n Mains connection 230 V / 50 Hz for the system.

n An appropriate exhaust air duct for an exhaust air line from the

chemical vapour lock.

n Recommendation: There needs to be a gas detector fitted

n brick or masonry, leak-tight tray provided on site around the

installation site or a collecting pan with ribs on the inside (on

request).

n A horizontal, level and stable surface must be available for the

installation.

Safety information

Requirements for the installation site

Assembly

n The system must be secured against possible damage from

people, objects and mobile equipment, such as fork-lifts or

pallet trucks.

n There needs to be 1 metre clearance around the system for

maintenance purposes.

n The installation site must have continuous effective ventilation.

n Depending on the actual conditions on site, the installation site

for the system and supply drum may need to fulfil other

requirements in line with the applicable regulations and tech‐

nical rules!

n Take appropriate measures if any of the following chemicals

are stored at the installation site: phosphorus oxides, acids,

oxygen bottles, hydrogen sulphide (H

S), strong oxidising

agents, hydrogen peroxide (H

), zinc, nitric acid, ethylene

oxide, strong alkalis, chlorates, mercury, silver or hydrogen

bromide (HBr).

Assembly

9 Installation

9.1

Installation, hydraulic

WARNING!

Warning of hazardous ammonia solution

Ammonia solution will escape if the metering line

comes off or tears.

– Only fit lines of sufficient strength.

–

Note the resistance of the line material.

– Prevent the metering line from coming off

caused by back pressure or tearing. You may

wish to install a relief valve.

WARNING!

Warning of hazardous ammonia solution

Liquid from the application could press back

through the metering pump.

– Use an injection valve or vacuum breaker.

Personnel:

Technical personnel

P_HYD_0012_SW

Screw together the units supplied for the metering system

DULCODOS

Ammonia as shown - see A:

1. - Chemical vapour lock

2. - Fastening bracket. Use it to screw the chemical vapour

lock to the metering vessel.

3. - Hand crank

Installation

2. Make the internal piping connections - see B:

1. - “Transfer pump” (f) suction line to the suction lance for

the storage tank. Use hose clips!

2. - Vapour recovery line from the metering vessel to the

suction lance for the storage tank. Use hose clips!

P_HYD_0033_SW

3. Make the external pipe connections - see

Fig. 4:

1. - “Metering pump” (d) metering line to the installed injec‐

tion valve

2. - De-ionised water feed connector to fill the dosing tank

3. - Chemical vapour lock exhaust air line to the respective

exhaust air duct

Installation

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ProMinent DULCODOS Ammonia Operating Instructions Manual

ProMinent DULCODOS Ammonia Operating Instructions Manual

ProMinent DULCODOS Ammonia Operating Instructions Manual

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