Limpieza de Catdos 03H07200-4-VEN-7813-13-R1 Trans1

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CHEMET~CS
ANODICALLY PROTECTED
SULPHURIC ACID COOLERS
ISSUED TO:
PLANT:
PROJECT No.:
DATE:
SOUTHERN PERU
COPPER CORPORATION
110, Peru
Sulphuric Acid Plant No.2
03H07200 I 04A-618
January 2005
I
DESCRIPTION:
OPERATING
Drying Acid Cooler SIN 04-618

Absorber Acid Cooler SIN 04-619
Product Acid Cooler SIN 04-620
& MAINTENANCE
MANUAL
This manual is issued by Chemetics with the understanding that all information contained herein is of a confidential nature and is not
to be circulated indiscrfminately.
All drawings and specifications relating to the Chemetics' anodic protection system and all
information contained in this manual are to be considered the property of Chemetics and are not to be used or reproduced without
permission, except by the purchaser for his own internal use. Acceptance of this manual implies acceptance of the above conditions
by the purchaser.
CHEMETICS
ACID COOLER OPERATING & MAINTENANCE MANUAL
ANOTROL 2000 SYSTEM
TABLE OF CONTENTS
Chapter 1
Introduction
fI
Chapter 2
System Description
Chapter 3
Anotrol 2000 System
Chapter 4
Operating
Chapter 5
Routine Maintenance
Chapter 6
Performance
Chapter 7
Special Installation
Chapter 8
Troubleshooting
~~~
Appendix
Drawings
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Operating & Maintenance Mal1uai
Procedures
Monitoring
and Maintenance
Procedures
CHEMETICS
CHAPTER 1
INTRODUCTION
Purpose
Guarantees
Proprietary Rights
Anotrol"
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Operating & ~!iaintenaflce Manual
Chapter 1-:1
Introduct~on
INTRODUCTION
PURPOSE
The purpose of this manual is to provide the end user of Chemetics Anodically
Sulphuric Acid Coolers with the information
cooler(s) and the associated Anotrol"
Protected
necessary to operate, maintain, and troubleshoot the
2000 Anodic Protection Equipment.
Plant Supervisory, Operating and Maintenance personnel involved with the day-to-day
operation
and maintenance of the cooler(s) should become completely familiar with the contents of this
Manual in order to gain the maximum benefits.
GUARANTEES
The Performance Guarantee and Mechanical Warranty
provided
conditional
on the cooler(s) being operated and maintained
instructions
provided herein.
for the acid cooler(s)
are
in accordance with the specific
Failure to comply with or observe the recommended
procedures
will cancel all guarantees.
PROPRIETARY RIGHTS
All
information,
specifications
including
but
not
limited
to,
relating to the design, operation,
descriptions,
maintenance,
procedures,
drawings,
or troubleshooting
and
of the acid
cooler(s) and associated equipment provided in the manual are the sole property of Chemetics
and must not be reproduced or divulged to any third party without the express written consent
of Chemetics.
ANOTROL
The name Anotrol" used throughout this manual is a registered trademark of Rohrback Cosasco
Systems Inc.
The Anotrol"
equipment supplied with the acid cooler(s) has been designed to
Chemetics specifications and is marketed and serviced solely by Chemetics to the sulphuric acid
industry.
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Operatirllig &. Ma~l1tenal1aa ~"~anuai
Chapter 1- 2
Introduction
CHEMETICS
CHAPTER 2
SYSTEM DESCRIPTION
Acid Cooler
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Operatir~g & rllairrtenance Mantia!
Chapter 2-1
System Description
CHEMETICS
SYSTEM DESCRIPTION
The acid cooling system removes the excess heat generated from the drying, absorption, and
gas cooling that takes place in the acid towers.
Each acid plant has a unique process
arrangement requiring that the acid coolers be designed to handle the specific heat duty
generated within the plant.
ACID COOLER
The Chemetics acid cooler, which transfers the excess heat from the acid to the cooling water,
is a stainless steel shell and tube heat exchanger with acid flowing through the shell space
being cooled by water flowing through the tubes.
Located within the shell of the cooler are the baffle plates, which support the tubes and divert
the acid around the tubes to promote heat transfer.
Acid Out
The Acid and Water Piping, which deliver acid and cooling medium to and from the cooler, are
an integral part of the acid cooling system.
All metallic surfaces in contact with acid within the cooler, i.e. the tubes, shell, tubesheets,
baffles, and acid nozzles are fabricated from stainless steel. Corrosion of these components is
controlled
by the application of the anodic protection
system, which generates a protective
oxide film on the acid wetted surfaces.
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Chapter 2 -:2
System Description
CHAPTER 3
ANOTROL 2000 SYSTEM
Power Supply
Main AC Power Configuration
Controller
CIPS Board Configuration
Hardware Fail Safe
Fuses and Connections
Remote Display Unit (RDU)

Overview Screen
Event Log Screen
Configuration Mode
Detail Screen
Adjusting Labels, Set Points and Alarm Values
Operational Alarms
Low Alarm
High Alarm
Process Page 1
Process Page 2
Process Data
RDU Software Setup
PC to RDU Data Transfer
RDU Shutdown Procedure
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Controller/Power Supply (C/PS)
CIPS Activation and Shutdown

Activation via RDU
Activation from C/PS
CIPS Shutdown from RDU
CjPS Shutdown from C/PS
Communication Failure
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CHEMETICS
ANOTROL
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2000 SYSTEM
The Anotrol 2000 system is comprised of a Remote Display Unit (RDU) plus a dedicated
Controller/Power Supply (C/PS) for each acid cooler or storage tank. A maximum of six
ReferenceElectrodesand up to twelve process inputs per C/PSmay be monitored.
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The C/PS is the main functional unit of the Anotrol'" 2000 system as it contains both the
hardware to supply the power to the Cathode(s) and the microprocessor, which measures the
anodic potentials and adjusts the current output from the power supply to achieve and
maintain the passivefilm.
The C/PS is designed to accept either 115 or 230 VAC (field selectable) which is supplied to the
system at the terminal strip on the rear panel of the chassis. This AC power is supplied to the
Power Transformer via Fuse Fl and the internal stabilized Power Supply for the
microprocessors via FuseF2.
Before applying power to the Anotrol system, check to ensure that the line
voltage is correct, the power wiring at the terminal strip is in accordance with the
labels and that the main PC Board Voltage Selector Switch and Station Number
Selector are properly set.
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Operating &: Maintenance Manual
C/PS
Chapter 3 - 2
Anotrof19 2000 System
CHEMETICS
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CONTROLLER I POWER SUPPLY (C/PS)

Power Supply
The AC voltage is reduced to the required level by the
Power Transformer located at the top of the chassis,
before being full-wave rectified by the steering Diodes:
Dl and D2, located on the right-hand internal heat sink.
Anodic current flow is controlled by MOSFETs: Ql and
Q2, located on the left-hand internal heat sink. Heat
dissipated by the steering Diodes and MOSFETs is
distributed by the internal heat sinks, which are
thermally coupled to the sides of the enclosure. The
controlled output voltage is supplied to the vessel via
two terminals marked Cathode and Anode.
Main AC Power Configuration
Both the C/PS and the RDU are set up at the factory in accordance with the specifications for the
project site.
The RDU is capable of operating from an AC power supply of between 90/264 VAC, 50/60 Hz.
The C/PS AC power is adjusted by way of jumpers located on the rear panel of the chassis. The
diagram of the jumpers indicates their proper connection. The PC Board has an internal Voltage
Selector Switch, which must be set for the correct AC power being supplied.
All of the connections discussed above are checked and adjusted by a Chemetics Technical
Service Representative during commissioning.
Controller
The microprocessor-based Controller is located in an internal enclosure in the lower portion of
the C/PS. The Controller PC Board Assembly is mounted to the back plate of the C/PS enclosure
using two screws and is a complete replaceable assembly (including the aluminum box).
Except for initially setting the configuration of the Station Number for
communication to the RDU and Voltage Selector Switch, the controller box should
not be removed for any reason as there are no fuses or replaceable parts inside.
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Chapter 3 - 3
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CHEMETICS
The Controller PC Board Assembly has four connectors that interface the wiring to external
circuitry .
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The connector P2 provides the AC power to the Assembly. Selection of 115 VAC or 230 VAC is
made with a Voltage Selector Switch that is on the underside of the PC Board and is only
accessible when the Board is removed from the box. It is set at the factory in accordance with
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the specifications for the project site .
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The connector Pi provides the signal from the current measuring shunt and the signals to the
MOSFETs.
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The connector TBl labeled ELECTRODES provides the interconnection points for the RS-422
digital communication, Cathode Voltage input, Control Electrode and up to five Reference
Electrodes. Any Reference Electrode inputs that are unused should have jumpers
installed.
The connector TB2 labeled PROCESS provides the interconnection
for up to twelve 4-20 rnA
process input signals. Each input is supplied with 24 volts to power a Process Transmitter. Each
pair of channels is over-current protected to prevent the failure of the 24-volt internal stabilized
Power Supply in the event of an external short circuit.
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Anotrol
Chapter 3 ~4
2000 System
CHEMETICS
CONTROLLER POWER SUPPLY (C/PS)
(PIN 079650)
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VAC Power
& Jumpers
Fuses
F1 & F2
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Operating & Maintenance
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Anotrot"
Chapter 3 ~ 5
2000 System
C/PS Board Configuration

Each
C/PS is independently configured to operate as part of a total anodic protection system.
Each
C/PS has it's own specific address within the system and can be configured to display
different values dependant on the set up of the acid cooler, storage tank or acid piping system
to which it is connected.
If it is necessary to change a CIPS Board for any reason, the configuration of the board must be
set to correspond to the address and service of the unit.
The Station Number of a C/PS can be changed by resetting the Station Number Selector Sl
located on the PC Board as follows:
First remove AC power to the C/PS.
Disconnect all plug-in connectors from the Controller PC Board Assembly.
Remove the two screws securing the Controller PC Board Assembly to the C/PS
rear panel and remove box from
C/PS.
Remove the six cover mounting screws and carefully lift the PC Board Assembly
from its support box to allow access to the Station Number Selector located in the
center of the board (see Fig. 3.1 at the end of this chapter).
Examine the position of the four dip switches on the Station Number Selector.
Reposition these switches of the new PC Board to correspond to the required
binary address for the Station Number assigned to the CjPS.
Confirm Voltage Selector Switch is set for correct AC power supplied.
Install new PC Board Assembly in C/PS and connect all plug-in connectors.
Activate power to the
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C/PS.
Hardware Fail Safe

In case of a microprocessor failure, a backup hardware Fail Safe is provided on the
The hardware
screwdriver.
NOTE:
Fail Safe setting
is only field selectable,
requiring
a voltmeter
CIPS Board.
and a small
The unit Fail Safe is factory set at a 600 mV set point.
Two test points are provided on the top of the PC Board inside the C/PS enclosure. The test
paints are labeled:
FAIL SAFE VOLTAGE
+
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Chapter 3 - 6
AnotrofS) 2000 System
The Fail Safe set point adjustment is made by a trim pot, accessed through the cover labeled:
SETPOINT ADJUST.
WARNING:
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If both the red and green status lights are illuminated, stop the unit or
turn the green light off. Once the control millivolt signal drops below
Fail Safe set point, the Fail Safe may be reset. The C/PS will then return
to Idle mode, and the unit may be restarted from the C/PS or RDU.
Fuses and Connections
L1... ._,
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There are two fuses associated with the primary power wiring circuits:
1) The Power Transformer
F1
2) The Controller PC Board
F2
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Operating Sa. Maintenance Manual
Chapter37
Anotrofv 2000 System
CHE~JlETICS
II
REMOTE DISPLAY UNIT (RDU)
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The RDU is a fully functional PC with a touch

screen that interfaces the PC electronics with
each C/PS through an RS-422 communications
channel .
The RDU is the operator's interface with each
functional C/PS and is used to:
1) Display the anodic film status for each
anodically protected vessel.
2) Adjust set points and alarm parameters.
3) Start and stop the anodic current output from the C/PS.
4) Display to the process parameters for each acid cooler.
5) Download data to a DCS via the RS-232 communication channel.
6)
Troubleshoot individual anodic protection
system.
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7) Connect a remote alarm to relay through TB3.

The RDU is connected to each C/PS by a dedicated two-wire shielded communication cable.
The screen uses a color LCD with an integral touch screen. The touch screen is used for all
operator interface functions. It also provides the operator with a read out of either the status
of the operating acid cooler/tank or the set point and alarm settings for the microprocessor.
Overview Screen
When the RDU is first powered up, it automatically loads the Windows 2000 operating
system and the RDU program. At the conclusion of the start-up sequence, the Overview
screen is displayed. This screen displays up to twelve acid cooler and/or tank icons and four
function keys. The function keys are About, Log, Config and Exit.
About
The About key, when pressed, will indicate the version of software and the technical assistance
phone and fax numbers along with the e-mail address for technical assistance.
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Chapter 3 - 8
Anotrol 2000 System
CHEMETICS
Log
The Log key, when pressed, will display the Event Log screen for the cooler/tank selected.
Config
( ' ....
The Config key gives access to the Configuration mode, it is password

protected.
L.
Exit
The Exit key, when pressed, will allow the RDU to exit the program and return to the Windows@
program. If changes were made, you will be prompted to save them.
The RDU will scan for active C/PS units as seen on the Overview screen. Any units not in
Active mode or in an alarm state will be red. Active units will indicate a solid green display
along with the name of the operating cooler/tank. The cursor below the icons will move
between each unit
in operation.
Event Log Screen

The Log key gives access to the Event Log screen for the cooler selected. It indicates the
date, time, unit number, and a brief description of any occurrence with the unit on display.
Six keys on the right side allow the user options as follows:
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PgUp
This key is used to page up through the Event Log screen, one page at a time.
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Operating &. ~1aintenance Manual
Chapter 3 - 9
Anotrof@ 2000 System
CHEPJlETICS
Up arrow
This key moves the cursor up one item at a time.
Down arrow
This key moves the cursor down one item at a time.
PgOn
This key is used to page down through the Log Screen, one page at a time.
Clear Log
This key is used to clear Log Screen of all stored data. It is password protected.
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This key returns user to the Overview screen.
The Config key on the Overview

screen is password protected, this
limits access to the Configuration
mode. Enter the correct password
and touch OK. This is the channel
configuration screen and allows the
configuration of up to 12 C/PS units
to be displayed. Seven keys on the
right side allow entry to further set
up operations as follows:
Back
Configuration Mode
New Passwd
This key is used to enter a second
password. Press key. Enter new
password, up to 20 characters and touch OK.
Save Config
This key is used to configure which unites) is in operation. When all units have been accepted,
(cursor indicated below icon(s)), press the Save Config key to accept this configuration. During
operation the cursor moves between all icons in use, skipping those not configured.
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Anotrori!l 2000 System
M
CHE~JiETICS
Defaults
This key clears the history and loads default settings of the displayed unit. Press "Yes" to
continue or "No" to return to the Overview screen.
WOO
Watch dog timer disabled.
Run
This key is used to return to the Overview screen.
Exit
This key is used to exit the program and return to the Windows 2000 program. If changes were
made you will be prompted to save them. This operation is password protected.
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Detail Screen
=-
To bring up one of the units in operation, touch the icon on the Overview Screen to enter the
Detail screen, for that unit. The top left box indicates the name of the operating vessel, the top
right box indicates the status of the unit, and the right side boxes are function keys.
This page will reveal the status of the Anotrol system and show the following data plus any
alarm conditions within the Anotrol system.

Cathode Current
Amperage being sent to the cooler/tank.
Cathode Voltage
Actual DC voltage applied at the Cathode.
Control Potential
DC millivolt Signal from the Control Electrode
located at the acid inlet area of the cooler.
Outlet Potential
DC millivolt signal from the Reference
['
Electrode located at the acid outlet area of the

cooler.
t ...,...
Reference A - 0
DC millivolt signal from up to four other Reference Electrodes on line.
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Chapter
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Anotrorv 2000 System
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CHE~JlETICS
On the right side of the screen the following function keys are available:
Start
The Start key will activate the unit being displayed and the red Idle unit # icon will change to
Active green. This will allow flow of DC current to the vessel provided the Control Potential is
below its set point and there are no high alarms.
Stop
The Stop key will de-activate the unit being displayed and the green Active unit # icon will
change to Idle red. DC current will be discontinued.
History
The History key will load History screen, which indicates the selected parameter history. Keys are
included on this screen to change the time base and to turn the Control Electrode Data on or off.
The Back key returns user to the Detail screen.
Config
The Config key is password protected to limit access to the Channel Configuration screen. Enter
the correct password and touch OK. This screen allows the configuration of the unit on display.
History Screen
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Chapter 3 - 12
Anotro(B) 2000 System
CHEMET!CS
Adjusting Labels, Set Points and Alarm Values
These values are pre-set at the factory, checked, and adjusted by the Chemetics Technical
Service Representative during commissioning.
Adjustment
of the programmed
values should only be done under the instruction of
Chemetics.
Random adjustment or incorrect setting of these values may result in serious

damage/corrosion to the cooler/tank.
If it is necessary to modify the channel configuration:
1 !
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1)
Call up the C/PS to be modified from the Overview screen.
2)
Select the Channel Configuration screen from the Display screen, by touching the Config
key. The Configuration screen is password protected. Enter the correct password and
touch OK (obtain code from Chemetics, Technical Service Department).
3)
From the Channel Configuration screen, select the item to be modified.
Cooler Name
Using the touch screen, insert or change the title of the unit in service. Up to 20 characters may
be entered. When completed the OK key should be pressed and you will return to the previous
page.
Serial Number
Using the touch screen, insert the serial number of the equipment in service. Up to 20 characters
may be entered. When completed the OK key will return you to the previous page.
Description
Using the touch screen, insert the description of the equipment in service. Up to 20 characters
may be entered. When completed the OK key will return you to the previous page.
Set Point Alarms
Using the Select Slider key move through the set point and alarms to be changed. The Up and
Down arrows will adjust the set point to the required setting (review the recommended settings
in chapter 4 page 11). After all changes have been entered, the OK key will return you to the
previous page.
System Type
Using the touch screen, select cooler or tank.
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Chapter 3 - 13
Anotrol'Si 2000 System
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CHEMETICS
Cooler Type
Using the touch screen (Up & Down arrow keys), select the number of electrodes not
counting the Control Electrode being used. Cathode current can be changed between 60 and
100 amps (most coolers are set for 60 amps, tanks to 100 amps). Une frequency can be
changed from 50 to 60 Hz. Graphic display Down arrow will cycle through different cooler
and tank drawings, select the one required and press the OK key to return to the Channel
Configuration screen.
Proc Parameters
This page is used to enter the data for the set up of the actual process parameters, which are
to be displayed at the RDU. On/Off key activates or removes the parameters from the
circuit. Parameters key allows entry to the Parameter: Labels, Scale 1&2, and Alarms 1&2
pages. Once all settings have been entered, the OK key returns you to the Channel
Configuration screen.
Proc Calculations
This page is used to enter the design data (2 pages) for the unit in operation. Once all data
has been entered, the OK key returns you to the Channel Configuration screen.
Defaults
The Defaults key on the Channel Configuration screen clears the history and resets
parameter default values for this unit.
4)
key.
When all changes/values have been entered, press the Save
The changes will be entered into memory and the screen will return to the Detail screen.
NOTE:
Set points may be edited with C/PS in Idle or Active
mode.
Operational Alarms
To alert the operator of a situation within the Anotrol" System, the system has a series of alarm
points programmed into the C/PS.
An alarm indicates to the operator that the anodic film is becoming unstable and that some
adjustment may be necessary. Most often, the adjustment required should be to the process
and not to the Anotrol" electronics.
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CHEMETICS
& Maintenance Manual
Chapter 3 - 14
Anotrol(& 2000 System
CHEMETICS
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When an alarm value is reached, an audible alarm within the ROU will sound to draw attention
to the situation.
Low Alarm
A Low Alarm indicates that the potential across the anodic film at the Acid Inlet region (Control
Potential) of the vessel has dropped to a level indicating lack or loss of the anodic film required
to control the corrosion within the vessel.
This condition will normally be encountered when the Anotrol" system is first activated at startup when there is no anodic film present and may also occur during major process changes
where the anodic film is being eroded away faster than it is being restored by the Anotrol"
system.
If a Low Alarm occurs, the CIPS will continue applying current to the vessel and the RDU will:
Sound an alarm
Flash the icon on the Overview screen corresponding to the CIPS in alarm.
Cause the Control Potential, unit Active # and the Channel Number to flash red.
L........
Press Control Potential on the screen to silence the alarm.

When the Low Alarm condition is corrected the red LED's will turn green. If alarm is audible, it
will silence automatically.
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High Alarm
A High Alarm prevents the potential from entering the TRANSPASSIVE REGION where the
protective film becomes unstable, indicating that the anodic potential has climbed above the
High Alarm set point. If this high voltage condition continues the anodic film becomes highly
soluble in the acid and corrosion takes place at an accelerated rate.
If a High Alarm occurs, the
C/PS anodic current will automatically shut down and the RDU will:
Sound the internal alarm

Flash the icon on the Overview screen to indicate which unit is in alarm
Detail screen will indicate which value caused the alarm
Pressing the flashing label on the Detail screen will silence the audible alarm.
To reactivate the C/PS from a high alarm shutdown on the Control Electrode press the Start key.
Reactivation of the C/PS from a high alarm shutdown on the Outlet Electrode can only be done
locally at the C/PS.
WARNING:
The C/PS will not automatically restart after

re-activated manually.
a high alarm.
It must be
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Chapter 3 - 16
Anotro' 2000 System
Process Page 1
This page is activated from the Channel Configuration screen and a key to this page can be
displayed
on the Detail screen. This page will
reveal the status of the Acid and Water
Temperature readings along with any alarms related to temperature.
Process Page 2
displayed on the Detail screen. This page will reveal status of other input data and alarms if
required. Example: acid/water flow, water pH, filter status, water pressure, acid strength.
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CHEMETICS
Process Data
displayed on the Detail screen. This page will allow for Cooler Calculation. The Design and
Operating data for the cooler(s) are entered by user and several calculations may be obtained:
e.g. fouling, heat load, velocity etc. The Back key returns to the previous page viewed.
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Chapter 3 - 18
Anotrol@ 2000 System
RDU Software Setup
1)
Copy the RDU software package (Setup.exe,

panel PC:
a) Using network connection.
Setup. 1st, RDU1.cab, RDU8.cab) in the
Connect keyboard, mouse and network cable to the panel PC. Setup and log into
the network (ask the network administrator for details). Create directory
c:\RDUlnst and copy the RDU software package files into this folder.
b) Using serial port communication.
Use service program to copy the software package in the panel PC via the serial
port. The default folder of this communication
program
2)
Install the RDU program:

Start, Run C:\RDUlnst\Setup.exe
3)
is C:\HTBuffer\
(see the Service
description for details).
OK (Start, Run C:\HTBuffer\Setup.exe,
Modify the Windows startup procedure (new system logo screen,

application).
Run, Browse (C:\Program Files\RDU\RDUsetup.bat), OK.
Create New Shortcut to C:\ProgramFiles\RDU\RDU,exe in the Desktop.
OK)
Accept the default values in all Install dialog boxes.

and startup
Copy the RDU Shortcut in the folder.

C:\ Windows\AIIUsers\StartMenu\Programs\Startup.
4)
Test the RDU installation: Start/Shut Down/Restart/Ox.
5)
Disable the power savings functions:

Control Panel, Power Management, Power Schemes tab.
6)
Power Schemes: Always On.
Turn off monitor: Never

Turn off hard disks: Never.
Disable Network connection and User profiles.
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Chapter 3 ~ 19
Anotrof1v 2000 System
CHEMETtCS
PC to RDU Data Transfer
Since the standard panel PC configuration does not include floppy or CD devices, information
between the panel PC and other systems can be exchanged via the network or serial ports. The
most convenient way is to use the network functionality.
compatible 10-Base T Ethernet (RJ4S) interface.
The panel PC provides a NE 2000
If a network connection is not available, the data between the panel PC and remote PC can be
exchanged via the serial ports. The operating system Windows 2000 provides appropriate tool
for COM port communications - HyperTerminal.
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Data Transfer Using the Panel PC Service Program

First install Service program on the panel PC:
1)
Connect keyboard, mouse, and network cable to the panel pc.

Setup and log into the network (ask the network administrator for details).
2)
3)
Create directory C:\ServInst and copy the Service software package files into this folder.
(Setup.exe, Setup.lst, Servic1.cab and Service2.cab).
4)
Install the Service program:
5)
Start, Run, Browse (C:\ServInst\Setup.exe),
OK.
Accept the default values in all Install dialog boxes.
Create New Folder C:\HTBuffer.
Like all general purpose programs the HyperTerminal is designed for working with mouse and
keyboard. To make the HyperTerminal usage with panel PC more convenient, a small external
touch screen interface program is provided. This program starts and sets the HyperTerminal in
file transfer mode (Receive) using the Zmodem protocol.
Step 1:
Disconnect the serial cable from the multiplexer box and connect the cable to the COMl
(COM2) port of the remote PC.
Step 2:
Setup the HyperTerminal session on the remote PC with the following parameters:
ina I
Start/Programs/ Accessories/Communications/HyperTerm
Double click Hyperterm.exe icon - "Connection Description" dialog appears.
Enter the Connection Name (for example RDUcon). Click OK - "Connect to" dialog
appears.
Add Cooler
Chapter
J - 20
Anotrol 2000 System
CHEMETiCS
Select Direct to COMl
(Direct to COM2). Click OK -
COM1 "Properties"
dialog
appears. Select:
Baud Rate:
115200
Data Bits:
Parity:
Stop Bits:
None
Flow Control:
Hardware
Click OK
Step 3:
Start the Service program on the panel PC (double click the Service icon or use Start/Run
dialog (the executable file is in C:\Program Rles\Service folder). The Service program
window appears in the upper left corner of the screen.
Step 4:
Press the Open HyperTerminal command button. The HyperTerminal window appears on
the screen.
Step 5:
Start the HyperTerminal session on the remote PC:
Select Transfer, Send File on the main window - the Send File dialog appears on the
screen.
Select Protocol = Zmodem.

Use the Browse function to select the name of the file you are going to transfer. Now
both the panel and the remote PC are prepared for communication.
Step 6:
Press Start Receiving button on the Service program window. The Zmodem window
appears on the screen.
Step 7:
Press the Send button on the remote pc. The Zmodem window appears on the remote
PC too. The data transfer begins and the progress bar indicates the activity. After the
transfer is completed, the Zmodem windows on both computers are closed.
Step 8:
Press Close HyperTerminal and Exit on the Service program window. Select No button on
the dialog box question "Is the Zmodem window closed?"
Step 9:
Close the HyperTerminal on the remote PC.
Add Cooler
I
Manual
Chapter 3 - 21
Anotrol's 2000 System
t_
CHEMETICS
Oata Transfer without
Service Programme
Step 1:
Disconnect the serial cable from the multiplexer box and connect the cable to the COM1
(COM2) port of the remote PC. Connect the keyboard to the panel Pc.
Step 2:
Setup the HyperTerminal session on the remote PC with the following parameters:
Start/Programs/Accessories/Communications/HyperTerminal
Enter the Connection Name (for example RDUcon). Click OK - "Connect to" dialog
appears.
Select Direct to COM1 (Direct to COM2). Click OK - COM1 Properties dialog appears.
Select:
Baud Rate:
115200
Data Bits:
Parity:
Stop Bits:
Flow Control:
None
Hardware
Click OK.
Step 3:
Setup the HyperTerminal
parameters:
session on the
panel
PC computer
with
the
following
Start/Programs/Accessories/Communications/HyperTerminal
Enter the Connection name (for example RDUcon). Click OK - "Connect to" dialog
appears.
Select Direct to COM1 (Direct to COM2). Click OK - COM1 "Properties"
dialog
appears. Select:
Baud Rate:
115200
Data Bits:
Parity:
None
Stop Bits:
Flow Control:
Hardware
Click OK.
Add Coeler
Manual
Anotrol
Chapter 3 - 22
2000 System
Step 4:
Start the HyperTerminal session on the panel pc:

Select Transfer, Receive File on the main window - the Receive File dialog appears
on the screen.
Use the Browse dialog, select a receiving folder.
Step 5:
Start the HyperTerminal session on the remote pc.

Select Transfer, Send File on the main window - the Send File dialog appears on
the screen.
Use the Browse function to select the name of the file you are going to transfer.
Now both - the panel and the remote pc are prepared for communication.
Step 6:
Press Receive button on the panel PC - Zmodem window appears.

Step 7:
Press the Send button on the remote PC. The Zmodem window appears on the remote
PC too. The data transfer begins and the progress bar indicates the activity. After the
transfer is completed, the Zmodem windows on both computers are getting dosed.
Step 8:
Close the HyperTerminal on the panel and remote PC.
RDU Shutdown Procedure

From the Overview screen press the Exit key.
Answer Yes to exit the program.
Press Windows Start key.
Press Shut Down key.
Press OK key to shut down the computer.
Tum off AC power when screen displays
OK.
Acid Cooler
Chapter 3 - 23
C/PS ACTIVATION AND SHUTDOWN

The
CIPS can be activated or stopped either from the RDU or locally.
When AC power is first applied to the
CIPS, the system will power up in the Idle mode. In this
mode, the Controller will monitor all input signals from the Reference Electrodes and Process
data. No current will be applied to the vessel. Alarm status will be indicated in red or green for
all units in service. Cursor will move between all units in operation, skipping those that are not
used.
Activation via RDU

Select unit to be started. The Detail screen is opened.
This screen will show the Anotrol Page along with current values of the active Reference
Electrode inputs. A low alarm may be indicated in three ways: the flashing red unit #, flashing
Control Reference reading, and the red flashing Channel Number box.
.....
Press the Start key. Unit # Idle (red) goes Active (flashing red or steady green):
Red
Alarm condition
Green
No alarm condition
The unit is now active and current will begin to flow to the vessel, providing the Control Potential
is below the Control set point and there is no High Alarm.
The current will increase in value to a maximum of 60 amps (100 amps for tank systems). Once
the Control Potential rises above the Control Low Alarm set point, the red LED's will turn green.
When the Control Potential nears the Control set point, the current would reduce automatically
and gradually according to the proportional Band setting, to maintain passivation.
-'-'
Activation from C/PS

To activate directly from the CIPS, locate the ACTIVE and FAIL SAFE lights (LED's) and switches
which are situated on the top of the Controller PC Board Assembly.
In the Idle mode, both LED's will be off.
Add Cooler
Chapter 3 - 24
Anotro'@ 2000 System
To start the unit, press the ACT/MaN switch; the green Active light will come on indicating that
anodic current will soon be starting, should the Control Potential be below it's set point.
The output current can be monitored via the Shunt Voltage terminals on the PC Board (25mV
for
100~amp avg.).
P""")
!
I
'
j1.........;1,
..
Pressing the ACT/MaN switch again will shut down the C/PS output and return the C/PS to the
Idle mode. The green Active light will go out and the RDU channel will go into Idle red mode.
The C/PS may be run completely independently of the RDU. However, no changes can be made
to set points and no alarms will be monitored.
C/PS Shutdown from RDU
I
!,\!
From the Overview screen select unit to be stopped. The Detail screen is opened.
Press Stop key. The C/PS anodic current will stop. The green Active and green Channel will
turn red, the green Active light will also return to Idle mode.
C/PS Shutdown from C/PS

The ACT/MaN switch on top off the Controller PC Board Assembly will stop the unit. Pushing
this switch will stop the anodic current and the green light will go off.
COMMUNICATION FAILURE
If communication is lost between the RDU and anyone of the CIPS units connected to it
Channel
# on the Overview screen of the RDU will turn red Comm.
Err.
If this situation should occur, an instrument technician familiar with the system should
investigate. When the condition causing the alarm is cleared, communications will be reestablished and the alarm will reset automatically.
Add Cooler
Operating & Maintenance Manua'
Chapter
3 - 25
Fig 3.1
F"1
L;,
[J
ANOTROL2000
STATION NUMBEIt & SYSTEM CONFIGURATION INSTRUCTIONS
FOR CfPS CONTROLLER ASSEMBLY PH: 07i&66
CAUTION: REMOVE A.C. POWER TO THE CONTROLLER

ASSEMal Y BEFORE ADJUSTING OR RECONFIGURING THIS UNIT.
When replacing a CIPS Controller Assembly, you mUSt configure the unit for the desired
Station Number and proper voltage prior to in~tallation in the enclosure cabinet
TO'access the adjustments, remove the (6) cover rT\9Unting screws. Carefully lift the cover
up and If.Y bottom side up on a clear, flat surface. Be carefull NOT to disturb any of the
components on the PC board. Make settings as indicated below.
I
STATION NUMBER
SELECTOR
(51 )
VOLTAGE
SELECTOR
(115V I 23OV)
STATION NUMBER SELECTION
SWITCH
NUMBest
, ..
CIP S STATION
5
I
OFF ON OFF ON OFF ON
OFF ON
ON OFF OFF ON ON
..
CoRR?RO C()1jPANr~. ROHRBACK COSASCO SYST~
.,
NUMBE R
7
. 10
11
11
OFF ON
OFF ON
OFF ON
ON
OFF
OFF oN
ON ON
ON OFF OFF OFF OFF ON
ON
ON
ON
ON ON
ON ON ON
OFF OFF OFF OFF
OFF
ON
ON
OFF
OFF
07Q65 R!Y He
Add Cooler
Manual
AnotrorSl
Chapter 3 - 26
2000 System
,
,.'
CHEMETICS
CHAPTER 4
OPERATING
..1,.
PROCEDURES
General
Acid Side Considerations

Temperature Limitations
Causes and Effects of Weak Acid
Water Side Considerations

Water Flow Rates
Water Filtration and Treatment
pH and Conductivity of the Water
Maintenance of the pH Monitors
Freeze Protection
Particular Operating Considerations

Energy Recovery Acid Coolers
Water Quality
Prevention Against Creating Boiling Water Conditions
pH Monitoring
Brackish and Seawater Coolers
Seawater
Seawater Filtration
Seawater Treatment Against Biofouling,
Etc. pH Monitoring
Summary of Operating Instructions

The Cooler Rating Sheet(s)
The Water Flow Diagram
Start-up Procedures
Data Collection
Normal Operating Conditions
Shutdowns
Short Term Plant Shutdowns -less than 24
hrs long Term Plant Shutdowns
Emergency Shutdown
Emergency Shutdown for Cooler Tube Leaks
Preparation of the Cooler Shell Side for Extended Shutdown
Anotrol Readings
LJ
I
I
.
Acid Cooler
Chapter 4 -1
Operating Procedures
OPERATING PROCEDURES FOR ACID COOLERS

GENERAL
This chapter details the operating principles for the Chemetics acid coolers. It is important that all the
procedures detailed in this chapter are clearly understood by all operating personnel. The
recommendations are based upon sound engineering considerations and extensive operating
experience.
The various operating considerations, detailed in the following sections, form the basis for the
operating procedures. These procedures are summarized later in the chapter.
I
I
'~",""
'1
>
1
ACID SIDE CONSIDERATIONS

Temperature
Limitations
Anodic protection significantly increases the temperature limits for which stainless steel can be used
in acid service without the initiation of corrosion. Safe design limits have been established and should
not be exceeded during operation. The maximum operating temperature is a function of the acid
concentration. Lower acid concentrations correspond to lower maximum temperature limits. These
limiting temperatures are plotted against acid concentration, as shown in the following figure .
;.,:.
I
.,;
The summary sheets at the end of this chapter define the specific operating temperature limits for
this application.
Fig. 4.1
140
It is important to
note that if during
120
operation the acid 0
o ~ 100
strength
should
Q)
"drop,
then
the
acid
~ 80
temperature
must
be lowered secordingly.
Do
not
operate in the nonshaded area above
the line.
Q)
0.60
E
Q)
"""40
20
91
92
93
94
95
96
97
98
% H2S04
Under no circumstances must the acid concentration be allowed to fall below 900/0
unless the equipment has been designed for this lower strength duty.
99
Acid Cooler
Chapter 4 ~ 2
Causes and Effects of Weak Acid

If the acid concentration is allowed to fall, then it may be difficult, or indeed impossible, to
establish a stable passive film on the acid wetted surfaces of the cooler. If the cooler is in
operation, then the established passive film may be lost. Continued operation of the plant under
these conditions is extremely detrimental, not only to the cooler, but also to the associated
pumps and piping.
The causesof weak acid formation are
Erratic control of water addition.
Defective strength analysis equipment which controls water addition to the circuit.
Accidental water dilution during shutdown caused by a valve being stuck in the open position.
Dilution of the circulating acid by moisture absorption during start up while the plant is being
dried out.
A tube failure will cause the cooling water to flow into the circulating acid if the water
pressure is more than the acid pressure (see section 4).
During a plant turnaround, acid may be drained from the cooler and the shell opened to
atmosphere. Sufficient moisture can be absorbed to ditute the acid remaining in the cooler to
extremely corrosive concentrations. The weak acid formed will accumulate at the low point of
the cooler. It is therefore essential, that the main and expansion joint drain valves remain
open during the period when the cooler is empty and that acid side openings be covered with
plastic to minimize moist air ingress.
Weak acid run-off from the tower during shutdown of extended duration.
Acid Cooler
Chapter 4 - 3
I
. .
"
tU
o
I
CHEMETICS
WATER SIDE CONSIDERATIONS
F;
nJ
Water Flow Rates

The coolers have been designed for a high velocity water flow through the tubes. This high velocity
minimizes hard water scale formation and ensures that tube wall temperatures are maintained as
cool as possible. During operation, design or greater water flow must be maintained. Temperature
control of the acid must be made using the acid by-pass around the cooler.
Throttling the water

temperature.
I
I
flow
to the cooler must never be used to control
the acid
The easiest method of monitoring water flow through the cooler(s) is by measurement of the
waterside pressure drop across the cooler. If the pressure drop is above the specified differential in
the operating summary, the water flow will be adequate providing there is no fouling or tube
blockage.
Water Filtration and Treatment

Fine sand and other small particulate material should not present any problems in the operation of
the coolers. In fact, their presence could be beneficial in retarding scale formation of the tube bores
due to their scouring action. However, It is possible, particularly on once through water systems,
I
I
that pieces of debris and fibrous material may also be present. This material could lead to partial or
complete blockage of some tubes. If this should occur, the stagnant water In the tube will rise to the
temperature of the surrounding acid which would, in some cases, reach the boiling point. This
condition may result in stress corrosion cracking and ultimately tube failure.
It is therefore,
extremely Important that tube blockage be avoided.
Operating experience indicates that water treatment is usually required for cooling
tower systems.This need should be carefully assessedand implemented before start-up.
'''''I
..;:J
On all cooling systems, it is mandatory that adequate filtration be provided to prevent tube blockage.
This can be accomplished in a number of ways; basket type filters, rotating drum filters, etc. The
filtering systems must be designed to ensure that full water flow is present at all times. The mesh
size of any filter shall be less than the bore of the cooler tubes in this way, only small pieces of debris
will be present and will safely carry through the tubes.
Acid Cooler
Chapter 4 - 4
rm
CHEMETICS
P!
tJ
pH and Conductivity of the Water

There are several good reasons for installing a pH monitor/alarm system:
If the cooling water is re-circulating (e.g. cooling tower), a pH control system is usually part of
the water treatment program. To ensure that the pH never drops below 6.0, it is advisable that a
pH alarm is set at 6.5, and in some cases, automatic neutralizing of the circuit can also be
activated. This is especially useful if acid gases from the plant are drawn into the cooling tower
water, thus forcing the pH down to serious levels.
For coolers having acid to water leak path (acid pressure higher than water pressure - the
preferred case), a pH monitor/alarm in the discharge water line of each cooler will provide timely
detection of a tube leak after which immediate stoppage of the plant can be accomplished, thus
restricting the amount of cooler damage to one leaking tube.
For closed loop (demineralized water) systems or boiler feed water applications, conductivity may
also be required to assure that good quality water is being used. Alarms can also be set to
automatically activate isolation and bypass valves at the cooler plus drain any acid contaminated
water out of the cooler. This will minimize damage to the cooler, plus any other equipment
downstream, should an acid-to-water leak develop.
Occasionally, the cooling water supply can become acidified for reasons external to the plant
(e.g. inadvertent dumping of acid into the water). The presence of acid in the cooling water could
initiate pitting in the tubes: If the pH of the inlet cooling water should drop, then it is mandatory
that the coolers be neutralized using a 5% caustic solution as soon as the water conditions have
returned to normal and the plant shut down. Chemetics should be notified of this occurrence (see
chapter 7 - Neutralizing Waterside of a Cooler after a Tube leak).
I
W
Maintenance of the pH Monitors
pH electrodes can lose their sensitivity

as a consequence of dirt accumulation
on the probes. If this occurs, then it will
often require an extremely low pH in the
water to first clean the electrodes prior
to sounding the alarm. Fig. 4.2 shows
the
pH
monitoring
system
recommended
by Chemetics. This
system enables the electrodes to be
tested weekJy by the addition of a few
drops of acid to the sample pot. The
electrodes should be cleaned when their
response is found to be slow.
I
Water sampling system for pH measurement
L
Weekly_on
oIacld to teet reapon ..
of pH monhoring
eyt.t.m
r
t
.
.
Pertoratod s.s, Tube """'"

Pipe eent.rtiM with two row. of
5116" diameter hoM. on n~'"
1
UN 254SMO Of equivalent
materitJ for Seawater.
pH probe
Fig. 4.2 Sample Pot.
Acid Cooler
f
'
'
Leeet ampllll9 poJrd r .IIsonabltl

distance away from cooler
di.charge and .tter .tbawa to
........
good milling.
Chapter 4 - 5
!
t
f!
~
:
CHEMETICS
L,
As a further check, use litmus paper to verify the reading from the sample pot(s) at least twice
per shift (samples should not be taken from the water channel drain or vent valves because a
leak could bypass these points). Similarly, litmus paper should always be used to ensure that a
low pH alarm is in fact valid and not an instrument malfunction.
f""
"
Freeze Protection
It must be realized that a tube bore plugged with debris, rust, etc., will not be self-draining
during shutdowns. A tube filled with water will rupture upon freezing. It is imperative
therefore that all the tube bores be prevented from plugging or that they be prevented from
freezing. Steam injection in the waterside of the cooler can be used.
I
I
.
CAUTION:
care should be taken to prevent the condensate from freezing in the

cooler.
I
I
Acid Cooler
Chapter 4 - 6
CHEMETICS
PARTICULAR OPERATING CONSIDERATIONS
Energy Recovery Acid Coolers
Demineralized water must be used as the cooling medium, when the acid cooler forms part of an
energy recovery system. This type of cooler normally operates with a Closed Loop water circulating
system at elevated water temperatures resulting in high metal (tube wall) temperatures. The design
of an Energy Recovery cooler is optimized to make the best possible use of available cooling water to
promote efficient heat transfer. Some coolers may be designed to use smaller diameter tubes
because of the low water flow available.
t ..:
The very high Tube Wall Temperature associated with this type of cooler requires that chlorides
present in the water be controlled to minimal levels to prevent possible failure from stress corrosion
cracking of the tubes.
Water Quality
Demineralized water or condensate circulated in the closed loop system must be maintained at a
specification of less than 1 mg/litre (1 ppm) cr at a pH not lower than 6.5.
The initial charge of water must be analyzed to ensure that the maximum chloride content does
not exceed 1 mg/litre (1 ppm) cr.
The water should also be deaerated to minimize dissolved oxygen. Where carbon steel water
piping is used, an oxygen-scavenging agent should be added to the water loop to minimize the
scale formation.
Precaution must be taken to ensure that debris or additional chlorides do not enter the system.
The loop water should be checked for pH and chloride content regularly.
Prevention against Creating Boiling Water Conditions

To prevent the possibility of water boiling within the acid cooler, the coolers must operate with
sufficient backpressure to ensure that boiling of the Circulating demineralized water cannot occur in
the tubes.
This is readily achieved by placing the demineralized water make-up/head tank at appropriate
elevation in the demineralized water loop. Ensure that the water pressure at the outlet of the coolers
is maintained at a minimum of 1.0 kg/cm2 (15 psig). This pressure will prevent boiling of the water
for a corresponding acid temperature of 120C (250 OF).
Acid Cooler
Chapter 4 -7
I'
I1
i
CHEMETICS
pH Monitoring
This is an important consideration for closed loop systems and the instructions in the previous section
must be strictly followed.
Brackish and Seawater Coolers

.'_""''
{...
'
"
:~J
Brackish and seawater cooled acid coolers (i.e. coolers operating with greater than 1000 ppm
chlorides in the water) require an upgrade in the materials of construction on the waterside.
II
The high chlorides in this type of cooling media requires that all materials in contact with the water
be upgraded to withstand attack from the high chlorides, which would cause pitting and lead to early
failure of the cooler. Chemetics Seawater Cooled Acid Coolers are fabricated using aRAM~
austenitic stainless steel for the tubing, tubesheets, channel barrels, channel nozzles, and the liner on
the channel cover. CIRAM~
has an outstanding resistance to chloride pitting at elevated
temperatures and is highly resistant to hot sulphuric acid when anodically polarized (anodic
protection).
fijI
~
Seawater Filtration
It is imperative that blockage of the tubes in a seawater or brackish water cooler be prevented at all
times, as many of the problems associated with corrosion from high chlorides can be traced to
stagnant or low water flow conditions. It is therefore essential that a good water filter be installed to
ensure that any particles passing to the cooler will not become lodged in the tubes.
The incoming seawater should be screened through an 8-mm maximum dimension mesh filter.
Preferably, this should be a self-cleaning type of strainer but a simple basket type may also be used.
If the latter type is used, then two units should be provided in parallel with a suitable switchover
device, which is automatically activated by a differential pressure system. Chemetics recommends an
inline strainer, similar to that shown in Chapter 5 Fig. 5.3.
Seawater Treatment Against Biofouling, etc.

All coolers are designed to ensure high water velocities through the tubes to minimize the likelihood
of fouling by marine life. However, it is possible, that crustaceans and other marine life could
accumulate in the less turbulent regions of the supply pipe work and the water boxes. Also, in some
regions of the world seawater can contain certain species of Anaerobic Bacteria, which have proven
to be detrimental to the use of stainless steels and other materials. Presence of these bacteria and
other marine organisms must be controlled by the addition of a suitable biocide.
Chemetics has extensive experience in the area and can provide assistance is testing
recommendation of a suitable programme.
CIRAMET
is a registered trademark
Acid Cooler
and
of Chemetics and was developed specifically for use in high chloride water.
Operating
& Maintenance Manual
Chapter 4 * 8
CHEIV1ETiCS
j '\
t ...,.:.
For more information on Chlorination Guide Lines contact
Technical Service Department

CHEMETICS
77 Railside Road
Toronto, Ontario
CANADA M3A 1B2
Switchboard:
(416) 447-5541
Fax:
(416) 391-1637
24 Hour Voice Mail:
(416) 447-0071
e-mail
technical.services@akerkvaerner.com
pH Monitoring
It is essential that the pH monitoring equipment be in good working order at all times. An acid/sea
water mixture is highly corrosive and will lead to extensive damage to a cooler. Any suspected tube
leakage must be immediately investigated and if confirmed, the plant must be shut down
immediately to allow proper repairs of the cooler before extensive damage is done.
WARNING: Failure to obsesv this condition

warranty on the acid cooler.
will invalidate
any and all remaining
I':
L_.
Acid Cooler
Chapter 4 - 9
CHEMETICS
SUMMARY OF OPERATING INSTRUCTIONS
The following sections are intended to provide a quick reference for operation of the Chemetics acid
cooling system:
tJ
The Cooler Rating Sheet(s)

The cooler rating sheet(s) specifies the process design conditions and outlines the major
mechanical details of each cooler. These may be found on the following pages.
The Water Flow Diagram

A water flow diagram showing the process flow arrangement may be found following the
cooler rating sheet(s).
Start-up Procedures
The remaining sections of this chapter summarise the procedures for start-up, normal
operation, and shutdown.
These sections must be completely understood by all operating personnel.
Data Collection
Plant operators must routinely check key cooler operating parameters to ensure proper
operation. To help in possible troubleshooting of the coolers Acid and Cooling Water
Temperatures and Pressures plus the Anotrol readings should become part of the normal
Plant Data Logging Routine.
Chemetics recommends taking aata every 2 hours but not less that every 4 hours.
This data will be invaluable if troubleshoot of cooler performance or Anotrol system becomes
necessary.
Acid Cooler
Chapter 4 - 10
CHEMETICS
NORMAL OPERATING CONDITIONS
Maintain temperatures and pressures within the limits given in the table below.
Record the following on a regular basis as per plant schedule:
-
f-'~
acid and water temperatures and pressures in and out of cooler.

ANOTROL values
cooling water pH (set low alarm at 6.0 minimum)
Drying Tower
Acid Cooler
Absorber
Tower Acid
Cooler
Product Acid
Cooler
75.1
112.0
104.1
kPa
87.6
73.8
91.1
24.0
24.0
24.0
OPERATING PARAMETERS VERSUS

COOLER DUTY
L_~
(A) Acid Inlet Temperature
Normal operating upper

limit:
(8) Acid Pressure Drop
Through Cooler
Ensure ilP does NOT
exceed:
(C) Water Inlet

Temperature
Normal operating upper

limit:
Ensure ilP is maintained at

or above
(E) ANOTROL 2000 Settinas
kPa
94.5
75.9
LG
78.0
I
(see chapter 3)
980/0 ACID
COOLER
a) Readout from the Remote Display Unit CRDU):

Control Set Point
300
mV Control High Alarm
450
mV
Control Low Alarm
150 mV
Outlet Potential RA"'RD High Alarm
650mV
Band
100 mV
b) Reading at the Controller/Power Supply COPS):
Fail Safe
600 mV
NOTE:
930/0 TO 970/0 ACID

& OLEUM COOLERS
200mV
350mV
SOmV
550 mV
100mV
(1
600mV
The settings shown above may be changed by the Chemetics Representative

for coolers operating under different conditions.
l.
Add Cooler
_,
i '
(D) Water Pressure Drop

Through COOler
Manual
Chapter 4 - 11
,
I
i
..~. ,._
..
i.. .
CHEMETICS Equipment
A Division of Aker Kvaerner Canada
HEAT EXCHANGER SPECIFICATION SHEET
".,...
,-. :
.,;,;.j
Job No.: 04A-618

SOUTHERN
PERU
COPPER
CORPORATION
Ref. No: 03B90111
1 Customer:
PLANT #2, ILO, PERU
Cust. PO. No:03H07200-407 -R 1
2 Plant Location:
DRYING TOWER ACID COOLER
Date:
6-0ct-03
3 Service of Unit:
Type:
Item:
7813H
4 Size:
1041 - 9144
NEN -1
Surf.lShell:
454
sq/m.
5 Surf / Unit:
454
eff.sq/m. Shells/Unit: ONE
Position:
HORIZONTAL
ONE
6 No. of Units:
7
PERFORMANCE of one UNIT
SHELL SIDE
TUBE SIDE
8
Fluid
Circulated
96.0%
SULFURIC
ACID
SEAWATER
9
1,551.0
Cu.m/hr,
679.3
10 Total Fluid Quantity
11
kg/hr
1,206,061 I 1,206,061
1,587,570 I 1,587,570
12
Liquid (in/out)
13
14
15 Sp. Gravity / Molecular Weight
cp
16 Viscosity
W/m*K
17 Thermal Conductivity
kJ/kg*K
18 Specific Heat
. 19 Temperature (in/out)
24.0 I 33.1
deg.C
. 75.1 I 45.0
kPa(A)
722.6
308.1
20 Inlet Pressure
ONE
ONE
Passes per Shell
21 Number
mls
Vw=0.94
Vx=O.80
3.05
22 Velocity (mean)
kPa
100.0
I
87.6
100.0
I 94.5
23 Pressure Drop - alc
m2*K/W
TOTAL = 0.000264
24 Fouling Resistance
15.9812
MW
C.L.M.T.D.:
30.3 deg.C
25 Heat Exchanged:
1,161.7
Clean:
1,671.9
W/m2*K
26 Transfer Rate, Service:
CONSTRUCTION of each SHELL
27
Design
Pressure
kPa(g)
1034
290
28
kPa(g)
29 Hydro Test Pressure
PER CODE
PER CODE
30 Design Temp. MIN. I MAX.
deg C
135
95
O.D.: 15.875 mm
BWG: 18 avg.
Length: 9,144 mm
31 Tube No:
1007
1,041.4 mm
Tube Mat'l: CIRAMET
32 SheIlI.D.:
Shell
Mat'l:
SA-240-304L
33
Channel Cover Mat'l: SA-S16-70N cIw CIRAMET lin er
34 Channel Mat'l (2): CIRAMET
-- _ ._----
of
o/
_.
35
36
37
38
39
40
41
42
43
44
45
300 SERIES 58
Baffle Mafl:
Tubesheet Mat'l (2): CIRAMET
Flow Arrangement: COUNTER - CURRENT
1.5mm
Corrosion Allowance - Shell Side:
Gylon Fawn 3500
Channel:
Gaskets - Shell:
Connections - Shell
Inlet 18"
Outlet:
Channel
Inlet: 18"
Outlet:
Code:
ASME & Provo Of Ontario
TEMA:
Shipping:
12,520
Weight I Shell
Remarks:
Cathode:
Tube Side: 0.0 mm
Durlon Green 8500
18"
Rating:
18"
Rating:
cust. Spec:
C
Flooded:
o/
TWO
150# RF. SO.

150# RF. SO.
Chemetics
22,050
46
47
48
49
Rev.No:
Date: 20 October 2004 - Design pressure, nozzle units, weight.
kg.
~j
CHEMETICS Equipment
..
SOUTHERN PERU COPPER CORPORATION

PLANT #2, ILO, PERU
ABSORBER TOWER ACID COOLER
Type:
NEN -1
1753 - 9144
1,048
eff.sq/m. Shells/Unit: ONE
ONE
SHELL SIDE
8
98.5% SULFURIC ACID
9 Fluid Circulated
10 Total Fluid Quantity
Cu.mlhr.
2,664.8
11
4,675,140 I 4,675,140
12
Liquid (in/out)
kg/hr
13
14
15 Sp. Gravity I Molecular Weight
16 Viscosity
cp
17 Thermal Conductivity
W/m'*K
18 Specific Heat
kJ/kg'*K
deg.C
112.0 I 75.0
19 Temperature (in/out)
kPa(A)
716.1
20 Inlet Pressure
21 Number of Passes per Shell
ONE
Vw=1.06
Vx=0.95
22 Velocity (mean)
mls
kPa
100.0 I 73.8
23 Pressure Drop - a/c
24 Fouling Resistance
m2*K/W
TOTAL =
75.6414
25 Heat Exchanged:
MW
1,331.7
Clean:
2,052.2
26 Transfer Rate, Service:
27
1034
28 Design Pressure
kPa(g)
kPa(g)
29 Hydro Test Pressure
PER CODE
30 Design Temp. MIN. I MAX.
deg C
I 135
31 Tube No:
2342
0.0.: 15.875 mm
BWG: 18avg.
Length:
32 Shell 1.0.:
1,752.6 mm
Tube Mat'l:
33 Shell Mat'l:
SA-240-304L
34 Channel Mat'l (2): CIRAMET
Channel Cover Mat'l: SA-516-70N
~-,,--,,----35 Baffle Mat'l:
300 SERIES S8
36 Tubesheet Mat'l (2): CIRAMET
37 Flow Arrangement:
CO -CURRENT
Cathode:
38 Corrosion Allowance - Shell Side:
1.5mm
Tube Side: 0.0 mm
Gylon Fawn 3500
Channel: Durlon Green 8500
39 Gaskets - Shell:
40 Connections - Shell
Inlet: 32"
Outlet: 32"
Rating:
41
Channel
Inlet: 26"
Outlet: 26"
Rating:
42 Code:
ASME& Prov. Of Ontario
TEMA: C
Cust. Spec:
43 Weight I Shell
Shipping:
28,000
Flooded:
1
2
3
4
5
6
7
Customer:
Plant Location:
Service of Unit:
Size:
Surf I Unit:
No. of Units:
Job No.: 04A-619

Ref. No: 03B90111
Cust. PO. No:03H07200-407 -R 1
Date:
6-0ct-03
Item:
7823H
Surf.lShell:
1,048
sq/m.
Position:
HORIZONTAL
TUBE SIDE
SEAWATER
3,234.8
3,311,220 I 3,311,220
24.0 I 44.6
308.1
ONE
2.75
100.0 / 75.9
0.000264
C.L.M.T.D.:
44
45
,i
46
47
48
49
9,144 mm
CIRAMET
c/w CIRAMET liner
FOUR
150# RF. SO.

150# RF. SO.
Chemetics
57,200
Remarks:
Rev.No:
deg.C
290
PER CODE
0/95
54.2
W/m2*K
Date: 20 October 2004 - Design pressure. nozzle units, weight.
kg.
CHEMETICS Equipment
';
~i
I ~-~
r' "
1.: ....
;.
i
\,/ ...,.
0
.
"
"
"
1
2
3
4
Customer:
Plant Location:
Service of Unit:
Size:
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
Surf/Unit:
No. of Units:
49
Rev.No:
SOUTHERN PERU COPPER CORPORATION

PLANT #2, ILO, PERU
PRODUCT ACID COOLER
Type:
NEN -1
521 - 9144
eff.sq/m. Shells/Unit ONE
132
ONE
(in/out)
Sp. Gravity I Molecular Weight

Viscosity
Thermal Conductivity
Specific Heat
Temperature (in/out)
Inlet Pressure
Number of Passes per Shell
Velocity (mean)
Pressure Drop - a/c
Fouling Resistance
Heat Exchanged:
4.3785
Transfer Rate, Service:
kg/hr
cp
W/m"K
kJ/kg"K
deg.C
kPa(A)
mls
kPa
m2*KNJ
TUBE SIDE
SEAWATER
407.7
158,223 I 158,223
417,300 I 417,300
104.1 / 40.0
684.7
ONE
Vw=0.71
Vx=0.60
24.0 / 33.5
308.1
ONE
2.76
100.0 / 78.0
100.0 I 91.1
TOTAL = 0.000264
C.L.M.T.D.:
36.8
901.4
Clean:
1,182.9
W/m2*K
kPa(g)
1034
290
kPa(g)
PER CODE
PER CODE
deg C
o I 135
I 95
15.875 mm
BWG: 18 avg.
Length: 9,144 mm
Tube Mat'l; CIRAMET
MW
Design Pressure
Hydro Test Pressure
Design Temp. MIN. / MAX.
0.0.:
Tube No:
292
Shell 1.0.:
520.7 mm
Shell Mat'l:
SA-240-304L
Channel Cover Mat'l: SA-5i6-70N
Channel Mat'l (2): CIRAMET
_'''''Baffle Mat'l:
300 SERIES SS
Tubesheet Mat'l (2): CIRAMET
Flow Arrangement: COUNTER - CURRENT
Cathode:
Corrosion Allowance - Shell Side:
i.5mm
Tube Side: 0.0 mm
Gaskets - Shell:
Gylon Fawn 3500
Channel: Durlon Green 8500
Connections - Shell
Inlet: 6"
Outlet: 6"
Rating:
Channel
Inlet: 10"
Outlet 10"
Rating:
Code:
ASME& Provo Of Ontario
TEMA: C
Cust. Spec:
Shipping:
3,675
Flooded:
Weight / Shell
Remarks:
Surf.lShell:
132
sq/m.
HORIZONTA~Position:

SHELL SIDE
98.5% SULFURIC ACID
Cu.mlhr.
89.8
Fluid Circulated
Total Fluid Quantity
Liquid
Job No.: 04A-620

Ref. No: 03B90111
Cust.PO.No:03H07200-407-R1
6-0ct-03
Date:
Item:
7876H
deg.C
clw CIRAMET liner
ONE
150# RF. SOF.

150# RF. SOF.
Chemetics
5,895
kg.
Date: 20 October 2004 - Design pressure, nozzle units, weight.
AKER KVAERNER~
Start up Procedure
CHEMETICS
HORIZONTAL SEAWATER
BRACKISH WATER COOLER
PRESSURE SIDE OF ACID PUMP

LEAK PATH: ACID TO WATER
(A)
Check that the acid strength is within 0.5% of design. If the acid strength is below this
level, observe the maximum concentration I temperature limits shown in Fig. 4.1.
(8)
Open all water channel drain valves to check for acid leakage when Circulationstarts.
(C)
Close all acid side drains and open acid bypass valve if installed. Orculate acid and check
for leaks around cooler flanges and piping.
(0)
Using litmus paper check for low pH (acid leakage) at water drain valves
(E)
Close water channel drain valves if no leakage observed.
(F)
Orculate seawater I brackish water through cooler(s) and check for leaks at cooler flanges
and piping.
(G)
Confirm that the add pressure exceeds the water pressure at both ends of the cooler by a
2
minimum of 5 to 15 psig (0.3 to 1.0 kg/cm ).
(H)
Check the pH of exiting water and confirm that the automatic pH and conductivity monitors
are functioning correctly.
(I)
and
When the acid inlet temperature to the cooler reaches 50C (122 oF) for 98% acid coolers
35 C (95 oF) for 93-96% acid coolers, switch on the ANOTROL.
(J)
Ensure that the add flow through the cooler does not exceed the design rating - refer to
Normal Operating Conditions in this chapter.
(K)
Ensure that the water flow through the cooler is at I or above the design rating - refer to
Normal Operating Conditions in this chapter.
(l)
Adjust the acid by-pass valve to achieve the desired add temperature to the tower. Acid
temperature must be controlled by using an acid by-pass valve and never by throttling back
on the water flow.
NOTE: Monitoring the seawater pH is the preferred method of leak detection. Test and
recaJibrate the pH monitor weekly.
Where presence of harmful bacteria has been confirmed, test for effectiveness of
biocide treatment at least once per month.
..
..
:: .. ; :":' .:
::: .. ::.:,: ...,::::.::::........
: :
:::::.:.::.:
.. :.:.::'
::
:::::~.
::: .. :::
:.: .. ::::: .. ::-.:::::-::
-:.:
:.:::":.:.:.::'::::::7/::::::.'.:;:::~:
.:::;:.:.:~.:.::::.:
:.:.:
.:.:.<:
CHEMETiCS
SHUTDOWN PROCEDURES
ALL COOLERS
SHUTDOWNS
Short Term Plant Shutdowns - Less Than 24 Hours
(a)
Switch off ANOTROL system when the add temperature to the cooler falls below:
50 C (122 OF) for 98% acid or
35 C (95 OF) for 93 - 96% acid.
I
I
i
I
(b)
Stop water circulation.
(c)
Open all water channel drain valves and check the pH of the water.
(d)
Water channel drain valves must remain open during the shutdown.
NOTE:
If both water and add flow is to be maintained for a short term shutdown,
monitor acid strength and cooling water pH as normal (see Short Term
Shutdown).
WARNING: On coolers using water of 1000 ppm CI or more (e.g. sea or

brackish water), after draining the cooling water, immediately fill
and flush the water side using potable low chloride water. Never
aI/ow stagnant high chloride water to stand in coolers during
shutdown. Drain the water and leave the drain valves open.
Long Term Plant Shutdowns

(a)
Follow steps (a) to (c) in Short Term Plant Shutdown.
Keep the shell side flooded with
strong acid.
(b)
Blank the add nozzles to prevent weak add run off from the tower from entering the
cooler.
(c)
If it is not possible to blank the acid nozzles, do a laboratory analysis of the acid in the
cooler and circulate the acid once a day to avoid pockets of weak acid developing. Ensure
that the acid does not get weaker than 90% at ambient temperature.
Acid Cooler
Chapter 4 - 12
CHEMETICS
Emergency Shutdown
(Power Failure, Loss of Acid or Water Flow)
(a)
Open all water channel drain valves immediately.
(b)
If shutdown is to be extended, refer to long term shutdown procedure above.
Emergency Shutdown for Cooler Tube Leaks

It is imperative that the plant is shut down as soon as possible after a leak is
detected. (a)
(b)
Stop water circulation.
Open water channel drain valves immediately.
WARNING:
cooler.
Under no drcumstances should water remain in the
(c)
Stop acid circulation.
(d)
Refer to cooler repair section (chapter 7).
Preparation of the Cooler Shell Side for Extended Shutdown

It is preferable to fill the cooler shell with 98% acid and blank the acid lines rather than to empty the
cooler. Draining of the cooler should be undertaken only for repairs or maintenance work. In such a
case, refill the cooler with 98% acid upon completion of the work. If this is not possible, neutralize
the cooler shell side and leave acid nozzles blanked until start-up, then re-introduce strong acid
circulation (see chapter 7). If ambient temperatures during the shutdown are such that there is a risk
of freezing the 98% acid (F.P. -4 C/25 OF), then the cooler shell should be filled with 96% (F.P. -13
0Cj 9 OF) or 93% acid (F.P. -33 C/-27 oF) and the acid lines blanked.
WARNING:
When working on the towers or acid lines, ensure that weak acid
caused by washing cannot enter the coolers. The coolers should be
blanked off or the piping disconnected and plastic covers applied.
Always drain the water from the cooler and leave the drain valves
open. Under no circumstances should stagnant water or neutralising
solution
be left in the cooler.
Acid Cooler
Chapter 4 - 13
I';'
[Il
CHEMETICS
ANOTROL READINGS
Under normal operating conditions, the Anotrol system will be stable. Occasionally variations may
occur in the readings, and these can usually be attributed to fluctuations in the plant operating
conditions. In some cases they may also give a warning that something is not quite right. Once
operating parameters have been verified, and if no irregularities have been found, then the Anotrol
system should be checked.
Some Causes for Increase in Cathode Current Output:
I
I
(a) Increase of the acid inlet temperature - observe maximum temperature

(b) High acid flow
(c) Weak acid
Some Causes of a Change in Outlet Potential:
(a)
(b)
(c)
(d)
Change in acid temperature.

Change in acid flow.
Change in acid strength.
Incorrect pin cathode exposure (where installed).
To Change Outlet Potential
Readings if Process Conditions
(a) For double-ended cathode coolers:

To Increase Outlet Potential:
(1) Ensure cathode(s) are connected at
(2) Electrically disconnect cathode(s) at
cooler. To Decrease Outlet Potential:
(1) Ensure cathode(s) are connected at
(2) Electrically disconnect cathode(s) at
are Normal:
acid outlet end of cooler.

acid inlet nozzle end of
acid inlet end of cooler.
acid outlet end of cooler.
(b) For single-ended cathode coolers with pin cathode at acid inlet nozzle
end: To Increase Outlet Potential:
(1) Electrically disconnect pin cathode.
To Decrease Outlet Potential:
(2) Electrically connect pin cathode.
(c) For single-ended cathode coolers with pin cathode at acid outlet nozzle
end: To Increase Outlet Potential:
(1) Electrically connect pin
cathode. To Decrease Outlet
Potential:
(2) Electrically disconnect pin cathode.
NOTE:
The Control Electrode should be at the acid inlet and Outlet Potential at the
acid outlet end of the cooler.
Acid Cooler
Chapter 4 - 14
CHAPTER 5
ROUTINE MAINTENANCE
Preparation for Cooler Turnaround
Shell Side Inspection
.
,
Cathode Inspection
Cathode Life Expectancy
I
I
Tubeside Inspection
Hydroblasting of Tubes
Anodic Protection System

Controller/Power Supply (C/PS)
Field Wiring
Spare Parts
Anotrol@ System Spare Parts
Chemetics Anotrol Defective Component
Report
Acid Cooler
Chapter 5-1
Routine Maintenance
:.:::::: :~.:.:.::-~:::.--:::
..,'..::::.:
.::::.-_-.-::::.:
.. :-:.:::.: ....; .._.::-:
,'
CHEMETICS
p"l
ROUTINE MAINTENANCE
U
Chemetics anodically protected acid coolers will provide many years of reliable and trouble free
service if the basic Operating and Maintenance Procedures are routinely followed.
The coolers are designed to withstand the normal variations in day-to-day plant operation without
the need for constant adjustments or maintenance.
However, there is a need for routine maintenance, which is normally performed during the main plant
turn-around. At this time, many clients enlist the assistance of a Chemetics Technical Service
Representative to ensure that these essential fundamental checks and necessary adjustments are
made.
The focus of the turnaround inspection is to detect any deterioration in the performance or change in
the physical condition of the cooler, including the anodic protection system, since the last inspection.
Determine possible causes for such a condition and to make the appropriate adjustments to correct
the situation.
There are 3 main areas which require inspection:
Shell side of the Cooler

Waterside of COoler
PREPARATION FOR COOLER TURNAROUND
I
"
",)
The Special Maintenance Procedure PREPARATION OF COOLERS PRIOR TO TURNAROUND

INSPECITON [G-lOO-O] in chapter 7 of this manual, outlines the procedures, precautions,
equipment and tools required to complete a successful turnaround inspection
While scheduling for a major cooler turnaround, it is essential to ensure that adequate mechanical &
electrical spare parts are on-hand in case they are required. The need of some of these items cannot
be determined until the cooler is out of service.
A complete listing of all Mechanical and Electrical Spare Parts can be found later in this chapter.
Acid Cooler
Chapter 5 - 2
Routine Maintenance
SHELL
INS_PECTION
SIDE
The shell of the acid cooler contains the sulphuric acid. Extreme precaution must be taken to ensure
that ALL AOD IS FULLYDRAINED prior to beginning any of these procedures.
The prime focus of an internal inspection of the shelf of an acid cooler is to verify that there is no
foreign materials which may cause blockage and/or restriction of the acid as it enters into the tube
bundle and to confirm the effectiveness of the anodic protection system in controlling corrosion from
the hot acid.
Typical Horizontal Acid Cooler
Main Acid Drain Valve
NOTE:
Expansion Joint Drain
The small acid drain valve on the cooler expansion joint (if installed) may require
cleaning out to remove a sulphate blockage. Use complete acid suit protection when
doing this operation.

Although the acid drain valves are open and acid has stopped flowing out, there may be an acid hold
up inside. Before inspection plates can be opened at the side of the cooler:
1. Tap the side of the cooler with a large metal bolt or Similar, to hear if the vessel is empty.
2. By removing a reference electrode (slowly screwing the unit out and watching for signs of acid at
the threads as the tapered thread gets progressively loose), it is also possible to safely witness
whether a cooler is drained.
3. Drains that are piped into another line should be closed firmly after draining acid to avoid
accidental back filling.
4. Expansion joint drain should be disconnected from the drain line and left open.
The purpose of this procedure is to ensure safety when opening the cooler's acid side inspection
ports for observation and measurement.
Add Cooler
Operating & MaintenanceManual
Chapter 5 - 3
Routine Maintenance
Internal inspection of the shell of an acid cooler should, where possible, be delayed until the last few
days of the maintenance shutdown to minimise the time period when acid is drained from the cooler.
During periods when there is no acid in the cooler, if moist air is allowed to enter the shell, weak acid
will be produced in crevices between baffles and tubes etc., which can under extreme conditions lead
to localised corrosion in those areas.
[l'
During a shell side inspection, the following checks should be made:
1. Measure the 00 of the tubes and try to determine if there has been any metal loss since the last
inspection (corrosion/erosion damage).
2.
Look for any visual signs of corrosion and, if found, review the operational log sheets including
the Anotrol readings to see if anything historical can be found which may pinpoint the reason
for such damage.
3.
Look for any deposits or coatings on the external tube surface that may be a possible detriment
to heat transfer. A thin soft sulphate coating is normal unless the deposit has developed to the
point where blocking the flow area between the tubes and restricting acid flow.
Excessive
sulphates or a harder silica scale will require the vessel to be cleaned (see instructions in chapter
7) to restore full heat transfer ability. If this is the case, the waterside must also be cleaned to
ensure low tube wall temperatures.
4.
Observe tubes surface closely as clean surfaces may indicate corrosion. Investigate the Plant Log
and other recorded data to determine what may have caused the problem if corrosion is found
..
A thorough check of the anodic protection system will be made later.
5. Inspect the acid inlet region through the Inspection Openings on the shell of the cooler for
accumulation of debris from the tower or pump tank. If necessary, remove inlet acid piping and
remove debris by hand or clean mechanically by vacuum.
.
6. Remove reference electrodes for cleaning and inspection. See procedure later in this chapter for
inspection and cleaning procedures.
7. Remove main cathodes and pin cathodes (if present) for inspection and replacement as required,
as described later in this chapter.
8. If inspection or previous experiences indicate that the tubes may be severely corroded, nondestructive eddy current test of the entire tube bundle should be considered.
Before embarking on this procedure be sure to calibrate the test equipment with an identical piece
of tube material. Contact Chemetics to purchase a sample tube for testing purposes.
Add Cooler
Chapter 5 - 4
Routine Maintenance
Cathode Inspection
Main cathode inspection must be carried out during the period when the acid is drained from the
cooler. Each cooler contains one or more main cathode assemblies and on some coolers a pin
cathode. The actual cathode arrangement for a cooler is indicated on the specific cooler Setting Plan
ji
(see Appendix A).

cathodes rods are the sacrificial component of the anodic protection system and will require
replacement after a period of time. cathodes must be checked on a routine basis (see chapter 7 for
specific procedures), as the life will vary dependant the operating conditions. Cathodes life may be
anywhere from 1 to 10 years. For this reason, it is essential that a "First cathode Inspection" be
done within the first 12 to 18 months of service and that a complete set of cathode assemblies for
each cooler be on site.
Typical
Sulphuric
Acid
Figure 5.1. Cooler with two Double-Ended
Cooler
Main Cathode Assemblies.
The main cathode assembly

comprises the Cathode Rod,
Insulating Sheath, Bushing,
Flat Washer and Inner
Gland. In most instances
when the Cathode Rod
requires replacement the
Cathode
Sheath,
Main
Bushing and Gland can be
reused.
However, since the condition of these components cannot be determined without disassembly it is
essential that a complete complement of replacement parts be available before the inspection is
made.
Acid Cooler
ChapterS - S
Routine Maintenance
l.
CHEMETICS
Fig. 5.2 shows a cooler with two Single-Ended Main cathode Assemblies and a Pin cathode (at the
opposite end to where the Main cathodes enter).
'..'1,
[. j
.J
Fig. 5.2. Cooler with

two Single-Ended
Main Cathode
Assemblies.
~"'
I
I
A complete Parts Ust of Main and Pin cathode Assemblies can be found in the cooler drawings (see
Appendix A).
Cathode Life Expectancy

The useful life of an individual cathode rod may vary from cooler to cooler depending on a number of
factors. Acid concentration, temperature, velocity and impurities in the acid all have an influence on the
life of the cathodes (and pin cathodes, where installed).
The key factor, in determining if
the cathode rod is reusable is the
rate of deterioration from a new
condition or the last inspection.
I
"';
Generally, a cathode rod should

be replaced when it reaches 0.400
inches [10 mm] in diameter.
Reinstalling a cathode below this
point may cause severe damage
to the cooler.
".J
The replacement of component parts

of each cathode assembly should be
made as experience dictates.
Cathodes are spedfic to one cooler and can seldom be used in a different cooler. When a cathode
is replaced as a complete assembly, it is essential to note the serial number stamped into the
sheath and to ensure that the assembly is being installed matches the serial number of the
_;
cooler, otherwise severe corrosion of the cooler may result.
See relevant Special Maintenance Procedure in Chapter 7.

Acid Cooler
Chapter 5 - 6
Routine Maintenance
CHEMETICS
TUBESIDE INSPECTION
One of the most important
preventative maintenance items is
to ensure that no tubes are
blocked by debris, especially over
316L wire mesh with
5/16"
(Bmm) max opening
an extended period of time. A
Direction of Water Flow
Use 254 SMO tor seawater
blocked tube with little or no
water flow operates at very high
tube wall temperatures and is
therefore, under stress. In the
presence of chloride-containing
water, a blocked tube will
eventually fail by a phenomenon
of stainless steel called stress
Fig. 5.3. Inline
corrosion cracking. Having an
Water Strainer.
adequate strainer upstream of the
cooler will go a long way in preventing this unnecessary problem from occurring. Fig. 5.3 shows the
design of an inline strainer that can be blown down to clean while in use,
Within the first three months from the date of initial operation, it is strongly recommended to open
the small water side inspection plate (or remove the water channel cover) at the water inlet end of all
coolers to inspect for blocked tubes, then clean if necessary.
Fig. 5.4 shows a cooler with water channel cover
removed (refer to chapter 7 Channel Cover Removal
When Main Cathode Is Present).
If the plant cooling water is of reasonably good
quality and the water flow to the cooler is
maintained at, or above design rates, the likelihood
of tube fouling from hard water deposits (e.g. scale)
or bio-problems (e.g. slime) are minimised.
However/ where the water quality is poor and/or the
water treatment programme is loosely controlled,
serious tube fouling can develop, neceSSitating a
shutdown for cleaning.
Fig 5.4
Acid Cooler
Chapter 5 - 7
Routine Maintenance
CHEMETICS
There are several ways to determine whether a cooler is fouled:
1. The acid temperatures are progressively getting hotter, even with cold cooling water
temperatures and good water flow.
'
2. The acid bypass valve is being closed more and more to get extra cooling ability from the
cooler. Soon, the bypass valve is closed all the way and acid temperatures keep going up.
,,,,I
3. During an inspection, when looking down the bore of the tubes and observing a light at the
other end, no characteristic stainless steel shine is observed; a deposit is on the tubes.
4. When observing the water outlet end of the tubes, a filmy mineral deposit may be seen and
you can carefully scrape it off with a knife. In this event, take a sample and get it analysed.
It is probably calcium carbonate (hard water scale) deposits. If it is slimy, a biological
problem exists.
Hydroblasting of Tubes
When hard water scale or slime/mud are present, the
preferred method for cleaning is hydroblasting (see
chapter 7 for the recommended procedure).
Rg. 5.5
shows a typical operational
spray head from
a
hydroblasting flexible lance (spray head pressures of
5,000"'20,000 psig (335"'1,335 bars) as needed to
remove the deposits.
Fig. 5.5
}
'I"
~
Contact your Chemetics Technical Representative for advice, if required.
.j
For seawater-cooled equipment, the possibitity of biological attack or blockage by crustaceans is a

potential threat. Appropriate bio test kits can be purchased to run tests and determine the potential
for this type of problem. In cases where bio-fouling organisms are detected, chlorine addition to the
seawater may be required. Contact Chemetics Technical Service Department for advice.
During the inspection, pay particular attention to appearance and condition welds, e.g. tube to tube
sheet, channel to nozzle, pressure connection to nozzle, etc. and under the gasket that seals the
channel cover to the channel where crevice corrosion may be occurring.
Contact Chemetics for advice if this type of corrosion is observed.

Acid Cooler
Chapter 5 - 8
Routine Maintenance
CHEMETICS
ANODIC PROTECTION SYSTEM
r-'.
The Anotrol system as described lnChapter 3 generally requires very little maintenance. However,
since the life of the cooler is highly dependant on the effectiveness of the total anodic protection
system it is essential that the operation of the Anotrol be checked and the various control and alarm
points be verified.
The Reference Electrodes are one of the most
critical parts of the anodic protection system.
Each acid cooler will have a minimum of 2
electrodes, which, under normal operation will
require minimal attention.
During the
maintenance shutdown, all Electrodes should
be removed and inspected for physical damage
or contamination and either cleaned, adjusted
and reinstalled or replaced if deemed unfit for
further service.
t ... ,
I
Fig 5.6
Following are special considerations when inspecting the Reference Electrodes:
Breakage of the platinum element must be avoided. Generally, breakage can only happen when
being mishandled. Avoid bending the green-coated platinum wire at sharp 900 angles or twisting
it when removing the electrical ConaXhousing.
Acid leakage can develop after being exposed to

flow with time and the 7/8" hex-head packing
operating conditions. To simulate hot conditions,
hot water for a minute before making the packing
Debris entering the acid inlet of the cooler can, in some instances, touch the reference electrode
tip and short out the reading. As these weak millivolt signals are critical to the operation of the
anodic protection system, many clients install a spare reference electrode at a second location,
usually at the acid inlet end. In this way, a quick swap of wires can be made during cooler
operation and without shutting down the plant.
If the reference electrodes are removed for cleaning, always loosen the packing gland nut and
move the platinum wire to ensure that it is not broken internally.
hot add. The glass-filled Teflon insulator can

gland nut needs to be tightened under hot,
try heating the electrode assembly in a pot of
gland nut tight to 20 ft-lb (3 kg-m).
1. Ensure that the platinum exposure is 1/4" (6 rnrn).

2. Use PTFEtape on the threads.
3. Degrease the platinum tip just before inserting into the cooler [use alcohol, acetone or
non-residue contact cleaner spray].
Acid Cooter
Chapter 5 - 9
Routine Maintenance
'- ...
CHEMETICS
Replacement electrodes can be ordered as a bare electrode only P/N-78853-4 (see Fig. 5.6), or can
be supplied with a protective Conax housing P/N-78854-4.
Reference Electrode is installed on the
cooler through a coupling located at
strategic points with respect to the
formation of the anodic film.
Electrodes are maintained in good

It is very important that the Reference
working order at all times, as they
are the sensors by which the
Anotrol System functions.
Mounted in S12
coupl
..... .
Threads
protected
with TeflonOb
PIN 079610
The ROU is the operator's communication interface with up to 12 individual anodic protection
systems or CjPS's. Although the functionality of the system is designed to be operated from the
ROU, an ROU failure will not prevent the C/PS from maintaining a passive film within its respective
cooler.
Fig. 5.7 shows the front
display.
I
~
I
.
.-.'~
"
Fig.S.7
There is essentially no routine maintenance to be performed on the RDU with the exception of
verifying the tightness and deanliness of all external wiring connections.
The RDUwill be used to verify and/or reset the specific control and alarm values for the individual CjPS
units that are connected to the various acid coolers.
CHEMETICS
Acid Cooler
Chapter 5 - 10
Routine Maintenance
Controller I Power Supply (C/PS)
PIN 079610
(100 Amps Maximum DC Output)
The CIPS, which is selt-contained in an integral NEMA 4 or 4X enclosure, is usually mounted

outside, adjacent to its respective acid cooler. Although in some acid plants, this may be a harsh
environment, if the unit is installed as per specification and the front panel is properly
secured
except
for maintenance access, the internal components will require little routine
maintenance.
.....,
I,:
"
'",'
The unit is designed for ease of maintenance with all components located behind an Acrylic Safety
Shield. The Controller Assembly is supplied in a secondary enclosure and is designed to be replaced as
an assembly.
Routine maintenance for a CjPS is normally limited to ensuring cleanliness and tightness of all wiring
contacts and petiorming a series of system checks to ensure that the system set point; alarms and
control functions are properly adjusted. An Operational System test should also be made to ensure
proper operation.
Chapter 3 of this manual describes the set-up procedures for the microprocessor controller board and
adjustments where necessary.
Field Wiring
The physical condition of the wiring that links all the anodic protection system components together is
very important. Rg. 5.8 shows a simplified basic electrical system with ROU, CIPS and its cooler. A
copy of the Anotrol System Wiring Diagram can be found in Appendlx A. Many acid plants have a
corrosive environment, which in time may degrade the physical condition of the field wiring. During the
normal major plant maintenance period, it is recommended that the entire Anotrol Wiring System be
fully inspected and tested to ensure trouble free operation.
Reid splices in Anode and Cathode wires should be thoroughly inspected for contact cleanliness and
insulation.
Particular attention should be taken of the condition of the cable trays or conduits and fittings to ensure
that all drain points are free and open. Damaged components should be repaired or replaced. All
wiring and flexible conduits immediately adjacent to the cooler should be carefully inspected to ensure
that sensitive instrument wiring is duly protected.
Acid Cooler
Chapter 5 - 11
Routine Maintenance
Simplified Anotrot" Wiring Diagram

Remote Display Unit
(RDU)
Controller I Power Supply (CIPS)
!"j
Anode Wire
I
I
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I
I
I
I
~-+--~------------~~I----------------------------:~~:~_~~~
J :I
Cathode Voltage Wire
Fig 5.8
Spare Parts
To ensure the continued reliable operation of the acid cooler, it is essential to have an adequate
and
complete set of spare parts on-hand, especially when scheduling a major turnaround
inspection.
Most acid cooler system ship with a minimal set of electronic Start-up Spares, which are intended
to address minor upsets during commissioning of the acid coolers.
Chemetics strongly recommends that a more comprehensive set of Mechanical and Electronic Spare
Parts be purchased to provide to necessary security of
operation.
Anotrol System Spare Parts

The minimal Start up Spares Parts Kit, where provided, is only intended to address minor
upsets which may occur during the commissioning phase of the acid coolers.
Replacement Electronic Spare Parts can normally be shipped within 2 working days of order.
However, in more distant or remote locations where overnight shipping is not possible, it is highly
recommended that a more comprehensive supply of parts be on-hand.
Add Cooler
Operating
&. Maintenance Manual
Chapter 5 - 12
Routine Maintenance
A comprehensive list of Recommended Anotrol Spare Parts is detailed

below.
(""\
i
!
A) Reference Electrodes
PIN C78853~4 (Reference Electrode only)

PIN C78854-4 (Reference Electrode c/w housing)
B) Anotrol 2000
;.
"
RDU (PIN 079610)

Part Number
079620
098003~13
Description
PC Board Assembly
0.5 Amp Fuse, 250 VAC Sio Blo Fuse
C/PS (PIN 079650 with NEMA 4 or PIN 079651 with NEMA 4X enclosure)
Part Number
009200
079665
092000~lXFN340N07
09200 1~440CMQ030
092073-V275LA40B
098015
094053-20
094055-15
094055-20
094265
NOTE:
Damaged or suspect Controller PCB Assembly

Chemetics for testing and repair.
Description
RFI Filter (1 Amp)
Controller PC Board Assembly
Power MOSFET Kit
Diode, Schottky Rectifier
MOS Varistor 230 VAC
F1 (Fuse) lOA 230 VAC (Delay)
F1 (Fuse) 20A 115 VAC (Delay)
F2 (Fuse) V2 Amp 230 VAC (Delay)
F2 (Fuse) lAmp 115 VAC (Delay)
Power Transformer
PIN 079665 can be returned to
Please refer to Fig 5.9 for instructions.
C) Mechanical Spare Parts (please see cathode drawings in Appendix A)

for main cathodes
Part Number
101
103
c/w
Description
cathode Rod
102
Acid Cooler
Operating & MaintenanceManual
Plug c/w Rivet
Chapter 5 - 13
Routine Maintenance
Part Number
104 c/w 102, 103
104 cjw 105
I~
104 - 1
105
..j:
201 c/w 206
Sheath (SE) cjw Rivet, Plug

Sheath (DE) c/w Sleeve
Adapter for Sheath Repair
cathode Sleeve
Inner Gland c/w Gland Sleeve
209
Outer Gland
Flat Washer
Bushing (in two parts 209-1, 209-2)
210
211
Outer Packing
Stud
212
Nut
204
207
I
I
Description
For pin cathodes
Part Number
101- K
102 - K
201 - K C/W 206 - K
202 - K c/w 210 - K
202 - KX
207 - K
209 - K
Description
cathode Rod
Sheath
Packing Gland c/w Gland Sleeve
Stuffing Box c/w Flange
Stuffing Box to Fit Coupling
Flat Washer
Bushing (in two parts 209-1K, 209-2K)
Common mechanical spares
Part Number
101 - 4 c/w 101 - 1 &3
208
Description
Connector Cc/w Lock Nut and Set Screw)
Stick Packing
".,J
Acid Cooler
:~.'::--::'-,"".:':"::.:'::.-'
.-_ ...:.::.::: ....:.--.-.-.-...
....
Chapter 5 - 14
Routine Maintenance
(3
CHEMETICS
ANOTROL
DEFECTIVE
COMPONENT
REPORT
I
,,,
..
Company
Project:
Name:
Iloo
Address:
"0
<
o
Plant Number:
Cooler Serial Number & Duty
t/)
Start-Up Date:
(1)
.c
DEFECTIVE
COMPONENT
>0-
Part Number:
1::
a..
Description Of Failure:
(1)
Report Submitted By:
en
Complete This Report And Send With Defective Component To:
{!.~
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a:I -
c~
Chemetics
c/o Rohrback
0,
a:
0..
:E
en
Cosasco Systems
11841 East Smith Ave.

Santa Fe Springs, California,
en
~
Date:
90670
U.S.A.
Address:
..lIC:.
0
---".~",.~~~--~
.Q~
_cC
Attention:
a:
NOTE:
ANOTROL parts may be returned for repair. Warranty repairs are at no charge.
repair is applied you will be notified and a purchase order requested.
If a charge for
In any case, returns to the USA must be done through your country's Customs Office to obtain
the necessary papers for re-entry following repair. Normally, duty will only apply to the repaired
cost (Le. warranty repair is Duty Free).
Failure to follow this procedure may result in Duty being charged on the full value of the part.
Acid Cooler
Oper
ating
&.
Maintenance Manual
Fig. 5.9
Chapt
er 5 -
15
Routin
e
Maint
enanc
e
[.
11
CHEMETICS
CHAPTER 6
PERFORMANCE MONITORING
Data Collection
Data Correction
Flow Calculation (simplified)
Calculating Cp (specific heat) for Acid
Thermal Performance
If
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Acid Cooler
:.','
.. ::: .._.:.--"::.'
.::_
_-:
::: ..,',::::._:.::_-:.::.:::~.:::.-: ..::.-:::.;.\: ::..:--
: -..
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..;
..
,:-,-- ..,-_
--_
Chapter 6 -1
Performance Monitoring
CHEMETICS
PERFORMANCE MONITORING
During normal operation, it is recommended that regular temperature and pressure surveys be
conducted to monitor the thermal performance of the cooler. These surveys are instrumental in
providing an early indication of the onset of formation of a fouling deposit that could limit the cooling
capabilities of the cooler or even lead to the onset of stress corrosion cracking or other potential
problems.
When a cooler is operating under design conditions, i.e. at design capacity with design cooling water
flow, a quick semi qualitative assessment can be made by checking the position of the acid by-pass
valve. If the by-pass valve is open, then the cooler still has additional cooling capacity indicating that
excess surface area is still available in the cooler.
However, if the by-pass valve is in the fully closed position when the plant is operating at design
capacity or the cooling water temperature is below the design maximum temperature, this could
indicate that the cooler has or is becoming fouled and that cleaning or other actions may be required
to restore design performance and reduce the risk of other potential problems.
For any performance evaluation to be meaningful, care must be exercised in the collection of the
operating data.
The calibration of ALL temperature and pressure gauges to be used in the plant survey should be
verified and adjustment made to the readings to compensate for slight differences.
calibrated thermometers should be accurate to within
0.5F/
0.3C.
Where possible, it is recommended to use a single pressure gauge to eliminate measurement errors.
Move the gauge from point to point, making note of height difference between measuring points.
(e.g. water in/out, acid in/out)
Gauges with a large scale range should be avoided, as this will reduce the accuracy of the readings.
Surveys performed using permanently installed instrumentation seldom prove to be worthwhile, as
the calibration of the instruments is always in question.
Add Cooler
Chapter 6 - 2
CHEMETICS
DATA COLLECTION
85 Thermowell
Connection
It is recommended that a survey only be taken after the plant rate has
stabilized for a minimum of 2 hours (where possible).
Do not adjust setting of bypass valve(s), water or acid flow rates

before or during the survey.
Acid and cooling water temperatures should be measured at the thermowell connections
provided on the respective cooler nozzles.
carefully remove thermowell shipping caps and fill the thermowells with light oil, glycerin
or other viscous fluid.
Allow 5 minutes to ensure that the thermometers stabilize at the correct temperature
before taking readings.
Work on one cooler at a time.

possible (1 - 2 minutes).
Take one complete set of temperature and pressure readings and repeat after five
minutes.
Take temperature readings within as short a period as
DATA CORRECTION
Before using the data for calculation, the acid and

water pressure readings must be adjusted to take into
account any difference in elevation between the
measuring points.
Differential
Static Head
If the cooler has a bottom inlet or is a vertical cooler, then an adjustment for the static head must be
applied.
If the measurements are taken at the pressure connection on the respective nozzles of a horizontal
cooler where acid inlet and outlet are both on tOPI usually no adjustment is required.
The following factors can be used for pressure adjustment:
Differential
Acid
Water
1 foot
1 meter
0.772 psi
2
0.1786 kg/cm
0.4335 psi
2
0.1003 k_gjcm
Acid Cooler
Chapter 6 - 3
I .....
\
L!
Iii
!
t
1
"
f
.
CHEMETICS
FLOW CALCULATION (SIMPLIFIED)
Actual acid and water flow through the cooler can be calculated using the following formula:
~P(a)
Actual flow = Design flow x
Where
~P(d)
~P(a) is the corrected actual measured pressure loss

LlP(d) is the design pressure loss as stated on the Specification Sheet
Design flow is the mass in Ibjhr or kgjhr as stated on the Specification Sheet
Once the actual acid and water flows have been calculated, these values can then be used to
calculate the heat load using the formula:
Q
Where
= Actual Flow x Cp x dT
L\T is the measured temperature difference between the Inlet and Outlet
Cp is the specific heat for either acid or cooling water.
For practical purposes the specific heat of water can be taken as 1.00 BTUjlboF (kcal/kgC).
CALCULATING Cp (SPECIFIC HEAT) FOR ACID

Specific heat of acid varies with temperature and concentration. For the purpose of preliminary
calculation, use the values in BTUjlboF (kcaljkg'C) in the following table for the average acid
temperature:
% H2SO4
Average
Temperature,
OF
ee)
140 (60)
149 (65)
158 (70)
167 (75)
176 (80)
185 (85)
194 (90)
203 (95)
93
0.385
0.387
0.390
0.392
0.394
94
0.376
0.379
0.381
0.384
0.386
0.397
0.399
0.402
0.389
0.391
95
0.394
0.370
0.373
0.375
0.378
96
0.364
0.367
0.369
0.372
0.380
0.383
0.385
0.388
0.374
0.377
0.379
97
0.359
0.362
0.364
0.382
0.367
0.369
98
0.355
0.358
0.372
0.374
0.377
0.360
0.363
0.365
0.368
0.370
0.373
99
0.352
0.355
0.357
0.360
0.362
0.365
0.367
0.370
Heat loads calculated from acid and water data should agree within 5% to give a meaningful analysis
of cooler performance.
Acid Cooler
Chapter 6 - 4
Performance MonitOring
THERMAL PERFORMANCE
Once the cooler heat load has been established, the calculated value can be used to determine
the heat transfer rate within the cooler using the formula:
Q
Where
= Area
.,:
r ....
x HTC x LMTD
Area is the heat transfer surface as stated on the acid cooler Specification
Sheet.
HTC is the heat transfer coefficient
LMTD is the calculated logarithmic mean temperature difference.
Using the measured temperatures of acid and water, calculate the LMTD as follows:
T1
T3
T2
Acid In
Acid Out
T4
I
Calculate the temperature difference at each end of the cooler.
Start with the Acid Inlet temperature and the corresponding water temperature at the same end
of the cooler:
Similarly, calculate the temperature difference at the Acid Outlet end. This value will be LlT2.
Using these values, calculate the LMTD with the formula:
1
\
LMTD
.J
=
In
j
l, "
Acid Cooler
Chapter 6 - 5
The HTC can now be calculated:
HTC
Area x LMTD
At design production rate, if the calculated value of the HTC is greater than the value shown on the
Acid Cooler Specification Sheet, the cooler can be assumed to be clean, that is operating with no
significant accumulation of a fouling deposit.
If the calculated value is less than the design value and the cooler bypass valve is closed, this
indicates that the cooler is fouled and requires cleaning. In this case, contact Chemetics Equipment
for confirmation of calculations and instruction for safe operating conditions (see chapter 7 for
cleaning instructions).
Chemetics Equipment provides a monthly Technical Assistance Program (TAP) follow-up service to all
clients. The first three months of service are included in the contract price of the acid cooler(s).
Ongoing service is provided on an annual basis and can be tailored to meet the specific needs of the
client.
Further information about the TAP can be obtained from Chemetics Equipment.
Acid Cooler
Chapter 6 - 6
. CHEMETICS
CHAPTER 7
SPECIAL INSTALLATION AND MAINTENANCE
PROCEDURES
Procedure
Number
Preparation of Coolers Prior to Turnaround Inspection
G 100-0
Mothballing an Acid Cooler for Extended Shut Down
G 110-0
How to Balance Acid Reference Electrode Readings During
E 100-0
E 110-0
Operation
How to Test the Anotrol System When the Cooler is Not Flooded With Acid
Channel Cover Removal
M 100-0
Main Cathode Removal (Double-ended Style)
M 110-0
Main Cathode Removal (Single-ended Style)

Rebuilding a Main Cathode Assembly
M 120-0
M 130-0
M 140-0
How to Remove a Broken Main Cathode from a Cooler
M 150-0
How to Remove and Rebuild a Pin Cathode
M 160-0
Reference Electrode Maintenance Procedure
M 170-0
Cleaning (Water Side)
C 100-0
C 110-0
C 120-0
How to Separate the Main Cathode Rod from its Sheath
Cleaning (Acid Side)

Neutralizing the Water Side of a Cooler After a Tube
Leak
Neutralizing Acid Side of a Cooler Prior to Welding Repairs
C 130-0
Setting Up Communication with a DCS
C 200-0
Inspection of the Tubes on the Acid (Shell) Side
I 100-0
Tube Plugging Procedure

How to Pressure Test the Cooler Following a Leak Repair
R 100-0
R 110-0
Iron Addition to Force the Passivation of a Difficult-to-Passivate Cooler
P 100-0
Acid Cooler
Chapter 7 - 1
Special Installation and
Maintenance Procedures
CHEMETICS
Special Maintenance Procedure
PREPARATION OF COOLERS PRIOR TO TURNAROUND

INSPECTION
Procedure No. G 100-0
Page 1 of 2
PURPOSE
By completing the following tasks prior to the inspection of the acid coolers, you will ensure
personnel safety plus cooler protection will be maintained:
1. When the acid temperature drops (below 122 of/50C
for 98% acid; below 95 of/35C
for
93% acid), switch the Anotrol system off.

2. Drain all the water out of the cooler. Keep water drain valves open during the turnaround.
Shut off the acid pump but keep the coolers full of acid (unless they are self-draining).
3. Disconnect water dilution lines to prevent accidental dilution of acid in the acid circulating
system.
4. To prevent corrosion by weak acid, blank off the cooler(s), especially if it is necessary to wash
the tower(s) or jf the plant will be inoperative for a long period of time (e.g. over two weeks).
Weak acid draining from the tower can corrode the coolers. The acid in gravity acid flow coolers
should be sampled daily. Ideally these coolers should be isolated from the tower with blanks
installed if the shutdown will exceed two weeks.
5.
Pump acid out of non-self draining coolers (with Anotrol system off) just before opening for
inspection. Vertical coolers require the lower tubesheet drain to be opened to remove the acid
trapped above the tube sheet. Be sure these drain lines are not plugged with sulfate. Horizontal
coolers require expansion joint drain opened to remove the acid trapped inside. The small drain
line is sometimes plugged with sulfate.
6.
Disconnect the main and pin cathode wires at the cooler. Reference electrodes should not be
touched until the day of inspection as they can be physically damaged.
7.
Remove the water box covers, being careful not to bend cathode support pipe(s). The covers
should be moved well away from the water channel flange before lifting or lowering.
8.
Remove all but 2 bolts for the acid side inspection ports (located on shell side of cooler).
9.
If debris is found inside the pump tank or tower material is suspect to be lodged inside the
cooler, remove the section of pipe from the cooler acid inlet nozzle. Cover this opening with
heavy plastic to prevent moisture from entering the cooler. This should be done prior to
inspection, if possible.
AKER kVJERNER-
CHEMETICS
PREPARATION OF COOLERS PRIOR TO TURNAROUND

INSPECTION
Page 2 of 2
10. If the waterside is deemed dirty, arrange for a hydroblasting crew to be on site for
hydroblasting the bore of the tubes. The hydroblasting should be done with 5,000 - 10,000 psig
(330 rv 670 bar) pressure up to 20,000 psig (1330 bar) if scale is very hard.
r-
L,..
({
11. If shell side cleaning is required, arrange to have soda ash available on site to obtain a 20% wt.
solution. Steam heat is also required to obtain a 160 tv 170<>F(71
77C) temperature of the
i.
...... :
re-circulating solution made with potable water. Refer to cleaning instructions in this chapter.
12. Ensure that adequate spare parts are on site including reference electrodes, pin cathodes, main
cathodes, stick packing, etc. Contact Chemetics for advice.
13. Electrical and Mechanical trade's personnel are required to assist Chemetics Technician during
the equipment inspection.
14. Tools & equipment needed:
1/1 OD Micrometer for measuring Cathode Rods.
500 volt Megger for testing Cathode and Reference Electrode Wires.
Main Cathode withdrawal support such as scaffolding or crane (as required).
All safety apparel and equipment.
15. Safety.
Safety goggles, face shield, rubber gloves and suit, hard hat, operational safety showers, and
acid pump(s) lockout system.
l_
,;'
{
\
.
_ ..'
l
'-
AKER kV,fERNER~
.... :::.':::::: ';::.:..:.:-:..:._-:=:::: ..:
CHEMETICS
Special Maintenance
Procedure
MOTHBALLING AN ACID COOLER

FOR EXTENDED SHUT DOWN
Page 1 of 1
MOTHBALLING AN ACID COOLER FOR EXTENDED SHUT DOWN

The major concern during an extended shut down is the prevention of weak acid corrosion of
the stainless steel acid cooler. Chemetics recommends utilising one of the two following
methods, depending on how the acid plant is to be laid up:
1. Wet Lay Up (i.e. the plant is ready for start up at some future, unknown date).
I
.
In some cases it is desirable to circulate acid over the towers once a day. This is acceptable
for the Chemetics acid cooler provided strong acid is maintained at all times and the cooler
remains flooded when the acid pump is shut off. Obviously, it is imperative to do a strength
analysis on a regular basis and change out the acid if the strength gets down to 93%. Even
more desirable, a range of strength from 96
99% is less corrosive at ambient
temperatures and less likely to form pockets of weak acid corrosion.
fV
Should the Chemetics acid cooler be self-draining or become partially filled with acid when
the acid pumps are shut off, then blinds should be installed at both acid nozzles to keep the
moisture out. Even more desirable, proceed to section 2 below and neutralise the shell side
after the cooler is blinded and drained on the acid side.
WARNING:
For seawater coolers it is recommended to neutralise water side

according to the Procedure C 120-0, flush several times with fresh
water, drain and leave water drain valves open.
2. Neutralisation of All Acid
If the Chemetics acid cooler is taken out of service for storage, shipping or repair, both acid
side and waterside must be neutralised to prevent weak acid formation and internal
corrosion. Please refer to the procedures C120-0 and C110-0. As explained in Cleaning
(Shell Side), water and/or moist air should never enter the shell side of the cooler,
otherwise weak acid corrosion can rapidly take place.
After neutralisation blinds may be removed to allow for inspection or repair. However, for
long-term protection use a vacuum pump to dry acid side thoroughly. The blinds should be
left in place c/w rubber gaskets. Under severe climatic conditions (e.g. shipping by sea),
both shell and tube side must have a nitrogen pad c/w pressure gauges fitted to witness
positive and effective internal pressure, ,....,5psig (35 kPa).
AKER kVJERNER~
Special Maintenance
CHEMETICS
Procedure
HOW TO BALANCE ACID INLET & OUTLET REFERENCE

ELECTRODE READINGS DURING OPERATION
Procedure No. E 100-0
1
f..,.:..1.
The day-to-day operation of the acid coolers would normally require no adjustment to the anodic
protection system. Control (acid inlet) and Monitor A (also known as Rl) (acid outlet) reference
f."': '
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electrode (RE) readings will be more or less all right. The Control RE tries to reach the set point
(usually 100-300 mY) and the other monitoring RE reading(s) float around, changing with the
process. Some special applications may even use other monitor electrodes, R2 thru R5 and they
may be around Set Point 350 mV (this is normal).
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When process changes are extreme (especially at start up or following plant rate changes),
temperatures, flow rates and strengths of acid are unstable and make it difficult for the anodic film
to be established on the acid-wetted surfaces of the cooler. During these periods of change, it is
quite possible that alarms may occur, such as Low Alarm on Control or High Alarm on R1 (Monitor
A). A Low Alarm requires only acknowledgment by the Operator and will re-set itself when
conditions return to normal. However, when the acid outlet RE goes high on potential and causes
an anodic current trip-off, the anodic protection system will have to be re-started to resume
passivation, possibly later after conditions have become more favorable.
There are times when a continual High Alarm on R1 (Monitor A) or R2 thru RS, (if installed)
becomes a nuisance to the operator. If this happens more than a few times per day, adjustments
may be required as follows:
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Page 1 of 2
A}
Single-Ended Style Of Main Cathode{s) With Pin Cathode At Opposite End To Main
Cathode Entry
If the Control (acid inlet) RE is located close to the Pin cathode (acid inlet nozzle), ensure that
power is coming to the Pin cathode. To lower Rl RE reading on the opposite end of the cooler,
more Pin cathode exposure is required at the inlet nozzle. This can be done during the next
shut down after acid has been drained. If inspection of the pin cathode proves that it has
corroded away, replace the road. If the rod is already fully pushed into the acid stream, then
there may be some other reason for the imbalance in RE readings. Check the inlet tube bundle,
......;
acid inlet nozzle, to see if debris has entered the cooler. Also, check to see if Control RE is in
contact with debris inside the cooler, thus shorting the platinum element signal.
,)
If the Rl (acid outlet) RE is located close to the Pin cathode (acid outlet nozzle), disconnect the
Pin cathode's power cable to render it powerless and this should lower the Rl RE reading close
to it. If this lowers the Rl reading too much, an adjustment of the Pin cathode rod exposure
will be required during the next shut down, following pumping out the acid from the cooler. By
shortening the rod exposure, the reading should decrease but not as much as by disconnecting
it entirely.
AKER KV.JERNER~
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CHEMETICS
HOW TO BALANCE ACID INLET & OUTLET REFERENCE

ELECTRODE READINGS DURING OPERATION
f"':
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Procedure No. E 1OO~O
Page 2 of 2
8) Split Flow Acid Coolers With Single-Ended Style Of Cathode(s), One Pin Cathode At
Acid Inlet (Center) Nozzle And One Or Two Pin Cathode(s) At The Acid Outlet Nozzle
Located At The Opposite End To The Main Cathode Entry
NOTE:
In this configuration, Monitor B (or R2) RE is a third electrode at the far end
from the Main cathode entry and Monitor A (Rl) RE is at the Main cathode entry
end. Control is in the acid inlet (middle) nozzle, as usual.
The Control (central acid inlet) RE will be located close to the primary Pin Cathode (acid inlet
nozzle) which is almost always required to balance out the 3 RE readings. Sometimes this Pin
Cathode becomes corroded and no longer delivers adequate voltage and current to the inlet
area, thus causing a defiCiency at the Control and High Alarms at either of Rl (Monitor A) or R2
(Monitor 8). Check that the power cable is also connected.
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Secondary Pin Cathodes (2) are usually located at the acid nozzle at the far end of the cooler
from where the Main cathodes enter. Both are usually required to keep the R2 (Monitor B) RE
reading up. If the reading is too high and alarms are occurring, disconnect one (or both) power
cables to lower the potential.
C) Double~Ended Main cathode Coolers
If the acid outlet RE reading (Rl or Monitor A) is too high and the High Alarm is occasionally
tripping, disconnect the power cable feeding the Main Cathode(s) on that end of the cooler.
This should result in an immediate reduction in reading.
Sometimes a Pin Cathode is also installed on these coolers. Try running without it hooked up
as it should rarely be required.
NOTE:
If the readings get worse following the use of the above mentioned procedures,
the Control and Rl (Monitor A) RE readings may be reversed. Check the field
wiring at the Controller/Power Supply (C/PS).
AKER KVA:RNER~
CHEMETICS
HOW TO TEST THE ANOTROL SYSTEM WHEN THE

COOLER IS NOT FLOODED WITH ACID
Procedure No. E 110-0
Page 1 of 1
When a cooler is drained of acid, the reference electrodes will not emit millivolt signals and current
will not pass from cathode to anode (cooler). Both of these need to happen if the anodic protection
system is to be thoroughly tested out.
1. To generate a millivolt signal to fool the system with false electrode readings, a variable millivolt
DC supply will be required with capability of from -400 mV to
+ 2 VDC.
2. To create a load on the power section to see if it will perform at 100% when needed, the
cathode wire needs to be securely shorted to the cooler (anode) using a c-damp, vice grips,
etc. Do this before powering up the CjPS.
3. Although reference electrodes will be giving no actual signals during this test, their cables may
need to be connected to provide a return ground source for the Controller. In older systems,
the signal ground wire performs this function.
4.
Connect the variable DC millivolt source to the terminal strip connections for the Control, Rl
(Monitor A), cathode Voltage (Monitor B), and any other R-values that you want to be tested.
Set the value at +300 mV and if a display of the readings is not present, attach a separate
millivolt meter to see what the readlnqsare,
5. Turn the AC power ON for the anodic protection system.
6. The Remote Display Unit (RDU) should be powered up and proper channel selected to see what
readings are being displayed. For a 300 mV input, the Control, Rl and R2 thru RS (if being
tested) will all read 300 mV 2 mV. The cathode Voltage should read 0.3 volts.
7.
Start the CIPS (press Reset & Set) from the RDU or depress the AGlMON
to turn the green LED on.
switch at the CIPS
8. Decrease the 300 mV input to 200 mV (l.e. below the Control Set Point) and wait to see if
Cathode amps start to be introduced to the cooler. This may take up to 60 seconds to begin.
9. If the Band is 100 mV wide, then a control input of 100 mV below set point should yield 100 %
CjPS cathode Current (either 60 or 100 amps, depending on Dip Switch #7 setting).
10. Further adjust Control input up & down to test all alarm set points.
AKER KVA:RNER~
CHEMETICS
CHANNEL COVER REMOVAL

Procedure No. M 100-0
Page 1 of 1
PURPOSE
This procedure is provided to detail the steps necessary to remove the channel cover(s) from an
acid cooler to guard against damaging the Cathode Pipe(s) which extend from the tubesheet
through the cover and isolate the main cathode(s) from the cooling water.
Figure 7.1 shows a cooler with 2 main cathodes and the
channel cover removed.
Figure 7.2 is a sketch showing the components, which make
up the seal between the cooling water and the outside of the
cooler. These components are referenced in the procedure
and should be retained for reinstallation.
PIN 204
Main Cathodes
Fig. 7.1
212
Fig.7.2 Outer Gland Assembly
PROCEDURE
1. Ensure that cooling water has been drained from the cooler and that the drain valves are left
open.
2. Remove the Cathode Cover and loosen 4 nuts PIN 212 securing the Outer Gland PIN 204 by
approx 2 - 3 turns counter clockwise. It is not necessary to remove the nuts or the Outer
Gland.
3. Loosen nuts securing the Channel Cover to the flange on the water box.
4. Support the weight of the channel cover, with a crane, hoist or other means and remove all
nuts securing the cover to the main flange.
5. Pull cover straight back and away from the water box for approx 12 in (30 cm) and carefully
place in secure area.
6. Inspect the gasket for possible reuse and protect from damage.
The water box is now ready for inspection.
Reinstallation of the cover is done by preparing the gasket and reversing steps 3 through 5.
AKER KV)ERNER~
CHEMETICS
MAIN CATHODE REMOVAL (DOUBLE ENDED STYLE)

Page 1 of 3
NOTE: a) Refer to Fig.7.2 for part numbers and description.

b) Before installing any new cathode assembly, lay new rod assembly alongside the
removed assembly to insure sheath configuration and that the overall length matches.
Each cathode assembly is made for a specific cooler, normally having the cooler serial
number stamped on the sheath close to the threaded end.
CAUTION:
Do not install the wrong cathode assembly!
The following procedure assumes that the cathode removal end is known. If it is in
question, refer to "Questionable Cathode Removal End" located at the end of this
procedure.
REMOVAL PROCEDURE
1. Before work is to begin on the cooler, ensure it has been drained of acid and water and that all
valves are closed and locked out. Turn Anotrol power off and lock out fuse boxes / breakers to
Controller/Power Supply (C/PS).
2. From the cathode removal end (see Setting Plan of cooler listed in the Drawing Section at the
end of this manual), disconnect the cathode wire from the connector (PIN 101-4) by loosening
the Set Screw (PIN 101-3). Remove Connector (PiN 101-4) and Lock Nut (PIN 101-1).
3. Remove the Inner Gland (PIN 201), clean and inspect thread condition and Gland Sleeve (P/N
206) for damage. Set aside.
4. Using a stick packing removal tool, (4-6/i long, flat screwdriver is suitable), remove and clean
stuffing box of all stick packing and discard old packing.
5.
From opposite end of cooler, repeat steps 2, 3 and 4 if full inspection is desired. However, the
option to leave this end packed is available provided the stick packing is in good condition
(remove gland nut only in this case, steps 2 & 3). Complete step 4 only if the packing is black
and saturated with acid.
6.
From cathode removal end, re-install Nut and Connector (PIN's 101-1 I 101-4), locking the
connector to the rod with the nut. Use a steel rod or screwdriver inserted into the connector's
hole and pull Main cathode Assembly (rod & sheath) from its support pipe. With the assistance
AKER kV.JERNER
CHEMETICS
Special Maintenance
Procedure

Page 2 of 3
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from two other people wearing rubber gloves, pull the cathode assembly completely out of the
cooler and rest it on support stands. Nut and connector may now be removed.
7. If cathode sheath is in clean condition and holes are free of fouling, refer to item 8 below. If
holes are fouled, they can be cleaned by high-pressure steam/water. Be sure to wear protective
clothing.
8. If notches are located on the sheath (inlet and outlet positions), use the 111 micrometer to
measure the cathode rod diameter through these notches. If no notches are found, use a
sharp knife to make them by carefully cutting away a small piece of sheath between two holes,
lengthwise along a single row. If 00 measurement is less than 0.400 inches (10 millimeters),
the rod should be replaced. Be sure to inspect the rod along its entire length for evidence of
corrosion or breakage.
9.
If sheath condition is good and it can be removed from the corroded cathode rod, it can be
installed on a new rod that was designed for this cooler.
10. Once the cathode has been deemed to be in good condition or replacement has been decided,
the assembly is ready for re-installation.
11. From the opposlte end of the cooler and only if item 4 was done, use a wire with a hook on the
end and remove the flat washer, bushing and cathode sleeve for examination.
12. Ensuring that the inner gland threads are clean and with the help of two other persons, slide
the assembly into the cathode support pipe and through the many baffle clearance holes inside
the cooler, until the inner Bushing (P/N 209-2) bottoms out inside the stuffing box.
13. Insert Flat Washer (P/N 207) over cathode rod (threaded end), and push into stuffing box flush
with Bushing (PIN 209). The flat washer has a slight taper to it; install with the widest side
facing you.
14. Insert six to seven pieces of Stick Packing (P/N 208 (see NOTE below) into stuffing box and
tighten packing gland nut. This may take two steps by inserting three or four pieces, installing
packing gland and compressing packing, then remove packing gland, insert remaining stick
packing and re-tighten gland nut.
NOTE:
Only approved stick packing should be used in the stuffing box.

Apply "Never Seize" lubricant to packing gland threads.
AKER kV.lERNER~
I:
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CHEMETICS
Special Maintenance
Procedure

15. Install Nut/Electrical Connector (PIN's 101-1/101-4)
rod.
Page 3 013
using nut to lock connector onto cathode
16. Repeat items 13 thru 15 at the coolers opposite end after the short Cathode Sleeve (PIN 105),
Bushing (PIN 208), and Flat Washer (PIN 207) have been re-inserted.
17. After water box covers have been installed, attach cathode wires and ensure that the outer
gland seals are watertight to prevent water from leaking out and shorting cathode to ground.
QUESTIONABLE CATHODE REMOVAL END

The double ended style main cathode can be removed ln.elther direction but the procedure is
different. If the cathode assembly has been installed in reverse to the Setting Plan (see Drawing
Section) or, if you wish to remove the cathode in reverse to the natural direction, then attempting
to do so in the regular manner (described in this manual) will cause thread damage to the sheath
where the Bushing (PIN 208) is screwed on. This bushing must first be removed from the sheath
before the assembly can pass in the opposite direction; i.e. you must first push the assembly in the
correct direction, remove the Bushing (PIN 208) and then reverse the removal direction.
Obviously, if you do not know which is the correct direction to first push the assembly out, then the
packing gland at each end must first be thoroughly cleaned out to allow for free movement of the
assembly. With gently pushing in one direction or pulling in the other, the assembly should be
extractable in the correct manner. However, if the assembly is solidly fixed and will not move the
PTFE Flat Washer (PIN 207) on each end will first have to be cut in half and removed as it has likely
expanded inside the housing. This may be accomplished by using a hammer and sharp, flat
screwdrlver/chisel to do the cutting.
WARNING: Use face shield as acid may spray out when using the hammer!
NOTE:
Should the threaded end of the main cathode sheath break, refer to the main cathode
drawing, sheath repair details in the upper right comer. Re-thread a new section of
sheath with a 7/8" NF-14 die nut (not a pipe thread) and attach the repair Adapter (PIN
104-1) to regain the correct total sheath length clw threaded end where Bushing (PIN
209) can be re-attached.
AKER KVA:RNER~
Special Maintenance
CHEMETICS
Procedure
MAIN CATHODE REMOVAL (SINGLE ENDED)

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Page 1 of 3
NOTE: a) Refer to Fig. 7.8 for part numbers and description.

b) Before installing any new cathode assembly, lay new rod assembly along side the
removed assembly to insure sheath configuration and overall length match.
Each
cathode assembly is made for a specific cooler, normally having the cooler serial
number stamped on the sheath close to the threaded end.
CAUTION:
Do not install the wrong cathode assembly!
During turnaround inspection of acid coolers, the Main and Pin Cathode assemblies will require
removal for inspection and possible replacement.
TOOLS AND EQUIPMENT NEEDED
Main cathode withdrawal support, (wooden sawhorses, scaffolding or crane as required).

Wrench to fit Nut/Connector (9/16',).
Steel rod 3/8" dia. x 12" long.
1- 1/2" deep socketjT bar.
Stick packing removal tool (flat screwdriver).
1" micrometer for measuring the cathode rod.
All safety apparel and equipment.
REMOVAL PROCEDURE
1. Before work is to begin on the cooler, insure that it has been drained of acid and water. Ensure
all valves are closed and locked out. Turn Anotrol power off and lock out fuse boxes / breakers
to Controller/Power Supply (C/PS).
2.
-"
Disconnect the cathode wire from the Connector (101-4) by loosening the Set Screw (101-3).
Remove Connector (101-4) and Lock Nut (101-1).
3. Remove the Inner Gland assembly (201), clean and inspect it's thread condition, and gland
sleeve for damage. Set aside.
_!
4. Using a stick packing removal tool, (4-6" long flat screwdriver is suitable), remove and clean
stuffing box of all stick packing and discard old packing.
AKER KVJERNER~
,..71
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Page 2 of3
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5.
Re-install Nut and Electrical Connector (101-1 / 101-4), locking the connector to the rod with
the nut. Using a steel rod passing through the hole in the connector, pull the Main cathode
from the cathode pipe. With help from two other people wearing rubber gloves, pull the
cathode assembly completely out of cooler and rest on support stands. Nut and connector may
now be removed.
F"".~
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6. If cathode sheath is in clean condition and holes are free of fouling, refer to item 7 below. If
holes are fouled they can be cleaned by high pressure steam/water. Be sure to wear protective
clothing and face shield.
7.
If notches are located on the sheath (inlet and outlet positions), use a 1" micrometer to
measure the cathode rod diameter through these notches. If no notches are found,
knife to make them by carefully cutting away a small piece of sheath between
lengthwise along a single row. If 00 measurement is less than 0.400 inches (10
the rod should be replaced. Be sure to inspect the rod along its entire length for
corrosion or breakage.
use a sharp
two holes,
millimeters),
evidence of
B. If sheath condition is good and it can be removed from the cathode rod, it can be installed on a
new rod designed for this cooler.
9. Once the cathode has been deemed to be in good condition or a replacement has been
obtained, re-install.
NOTE:
Before installing a new cathode assembly, lay it along side a removed assembly
to ensure sheath configuration and length matches.
10. Ensuring the stuffing box and inner gland threads are clean.
With the help of two other

persons, slide the assembly into the stuffing box through the cathode cover pipe and through
the baffle clearance holes until the Inner Bushing (209-1) bottoms out inside the stuffing box
(metal side facing inside of cooler).
11. Insert Flat Washer (207) over cathode rod (threaded end), and push into stuffing box, flush
with Bushing (209). The flat washer has a slight taper to it; install with the wider side facing
you.
12. Insert six to seven pieces of Stick Packing (20B) (see NOTE below) into stuffing box and
tighten the packing gland nut. This may take two steps by inserting three or four pieces,
installing packing gland and compressing packing, then remove packing gland, insert remaining
stick packing and re-tightening gland nut.
AKER KVJERNER~
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NOTE:
Page 3 of 3
Only approved stick packing should be used in the stuffing box. Apply "Never
Seize" lubricant to packing gland threads.
13. Install Nut/Connector (101-1/
101-4) using nut to lock connector onto cathode rod.
14. After water box covers have been installed, attach cathode wires, and ensure that the outer
gland seals are water tight to prevent water from shorting cathode to ground.
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AKER KV)ERNER~
CHEMETICS
HOW TO SEPARATE THE MAIN CATHODE ROD FROM ITS

SHEATH
Page 1 of 2
A) If the cathode rod is severely corroded along its entire length, then the extraction of the rod
from the sheath should be quite easy.
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Thoroughly wash the entire length of cathode assembly with water using a spray hose.
Remove the flat washer and bushing from the sheath (use acid resistant gloves for personal
protection from any remaining acid).
Re-attach the connector and lock nut to the cathode rod, insert a screwdriver through the hole
of the connector and arrange three other people (wearing rubber gloves) to grasp the Teflon
sheath at the two ends and middle while you pull on the rod.
With a twisting action, pull on the screwdriver while the three assistants keep the sheath
stationary.
After separating the sheath from the rod, wash the sheath again, check its entire length for
defects and if satisfactory, insert a new rod that was specifically made for this cooler/cathode
assembly.
Remove the electrical connector and lock nut from the old rod and set aside.
Re-install the bushing and washer with the tapered ends facing inwards in this manner [><].
B) Difficulty in getting the rod to separate from the sheath:
If the bushing is removed and it is found that the PTFE threads of the sheath are restricting the
removal of the large part of the rod, a small amount of thread should be cut off to expose the
large part of the cathode rod.
If the sheath has sulfated itself to the rod, use of some special vice grips (mechanical pliers
with angle iron welded to the tips, allowing for gripping of sheath over an extended length) is
required to hold the sheath at several places while the rod is Simultaneously twisted and pulled
out.
If the sheath is sulfated over the entire length, then up to 6 persons with special vice grips
(mentioned above) will be needed to hold the sheath firmly while twisting and pulling the rod.
AKER KVJERNER~
r
1:
CHEMETICS
Special Maintenance
Procedure
HOW TO SEPARATE THE MAIN CATHODE ROD FROM ITS

SHEATH
CAUTION:
Page 2 of 2
[Jl
When twisting the rod inside the sheath, be careful that the sheath is
not being damaged from the vice grips or that it is not wrapping
around the rod and breaking.
Severe sulphating can be "melted or softened" by using a long pipe (like the original shipping
container) and a steam hose. Insert the cathode assembly into the pipe and steam it for 5
minutes; then remove it and again try the procedure above.
If a rod has broken inside the sheath (single ended style of cathode), remove the small stainless
steel rivet & plug at the far end of the sheath and push a new cathode rod inside to drive the
broken piece out.
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AKER KVA:RNER~
r""
REBUILDING A MAIN CATHODE ASSEMBLY

Page 101 1
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Deterioration of the main cathode rod is expected to occur over a period of time. Factors such as
acid temperature, velocity, strength, and contamination as weI! as cathode material of construction
all enter into the equation of life expectancy of this sacrificial element.
Generally speaking, a cathode operating in acid strengths of 93",96% range and temperatures of
up to 160F (70C) will last many more years than one in 98.5% acid (or some oleum strengths)
and/or higher temperatures of 200F (90C) or more.
The PTFE sheath is an important component in the main cathode assembly. Its function is to keep
the cathode rod insulated from the anode (cooler) wherever it passes through the hole in each
baffle inside the cooler. Furthermore, the sheath is perforated with holes between each baffle to
allow the acid to touch the rod and to conduct electricity between cathode and anode. The undrilled full insulation sections of sheath are required wherever there are baffles inside the cooler.
Since baffle spacing varies from cooler to cooler, each cathode is made specifically for its cooler and
is not normally interchangeable with other coolers. For this reason, spare main cathode assemblies
are required to be kept on hand for each working cathode in each cooler.
Main Cathode Assembly

Flat Washer (207\
Good Threads
Cathode Rod (104)
Inner Gland Assembly
(201, 206)
Fig. 7.3
The sheath is re-usable provided the PTFE(Teflon@) is not wearing at the baffles or broken. Should
the threads at the cathode removal end become damaged, a spare part (PIN
rebuild the sheath.
104-1) is available to
AKER I<VJERNER~
i,
s
HOW TO REMOVE A BROKEN MAIN CATHODE FROM A

COOLER
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Page 1 of 2
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A) Horizontal Coolers (Double Ended Style Main Cathode(s

1. If a cathode rod becomes broken due to excessive wear, it usually can be pulled out simply by
removing it together with the sheath.
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2. However, the sheath may become broken inside the cooler and hang up so as to prevent its
removal.
3. If there is only one break on the sheath (l.e, 2 pieces of cathode, only), then they may be
removed by pulling the individual pieces in their respective directions (i.e. from either end of
the cooler).
4. If there are more than 2 pieces to remove, remove the end pieces then shine a strong beam of
light inside the cathode support pipes from either end to determine which end to push the
piece(s) out.
S. Passing a second, new cathode rod into one end may edge out the one or more piece(s) in the
middle.
6. In the event that a piece of sheath (Teflon'") only remains inside, a small hook wire on the end
of the new cathode rod may allow for connecting and extraction.
7. Failing that, a long rod with a drill bit attached to the end will be required to break up the
Teflon sheath into small pieces to clear a way for the new cathode assembly.
NOTE:
Depending on cooler size and configuration, at least one working cathode

assembly is required to achieve passivation .
.....:
::1
B) Horizontal Coolers (Single Ended Style Main Cathode(s
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jj
1. A single ended style of cathode limits the removal of a broken rod or sheath.
Steps 6 & 7
mentioned above are about the only methods available.

2. If the cooler has only one cathode, the situation becomes desperate. In this case, it may be
considered to drill a 1" hole in the back tube sheet to allow for extraction of the piece(s) or to
clear a route for the new main cathode assembly. If this method is required! contact Chemetics
Equipment for further advice.
AKER KV~RNER-
.J
HOW TO REMOVE A BROKEN MAIN CATHODE FROM A

COOLER
Page 2 of 2
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C) Vertical Coolers (Single Ended Style Main Cathode(s
(""")
.
1 :
1. This cooler configuration is even more difficult than the horizontal unit. Please see 1 & 2 in
paragraph B) above.
2. Should Option 2 in the previous section not be desired, measure the maximum depth that a
cathode can be inserted and then shorten a cathode to allow at least a partial cathode to be
inserted. If the bottom acid inlet nozzle has more than one Sl1 Cleaning Connection, insert a
second pin cathode in case it is needed to get more anodic amperage into the hot acid inlet
area.
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CHEMETICS
HOW TO REMOVE AND REBUILD A PIN CATHODE

Page 1 of 1
Not every cooler has a pin cathode (example, double-ended cathode coolers). However, when
installed, the pin cathode, like the main cathode, is a sacrificial element that requires inspection
during each turnaround to see if replacement is necessary. Refer to the figure below when
performing the following work:
Pin Cathode Assembly

Paoldng Gland
PIN 201-K
[CIW 206-KJ
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PROCEDURE
. 1. Shut off the anodic protection
system, disconnect the cathode wire
from the pin cathode and drain the
acid from the cooler.
2. Remove the 4 bolts from the pin
cathode's 511 flange and the whole pin
cathode assembly will be easily
removed, including the housing.
StIck Packing (208)
Fig. 7.4
3. Wash all acid exposed areas with

copious amounts of water.
4. The following inspection should now be done in a shop having a large bench vice:
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Check that the sheath is not cracked or broken at the threaded end.
Check that the acid packing is not leaking. Re-pack if necessary using new stick packing.
Measure and record the exposure of the rod from end to the sheath.
Measure and record the 00 of the rod. Replace the rod if it is 0.400 in. (10mm) or less, or if an
extended campaign of more than 1 year will be required.
Adjust the exposure of the rod to balance reference electrode readings (check previous
inspection report for correct length).
5. If the unit is satisfactory, the gasket may require replacement before re-installing.
6. Re-connect the pin cathode wire inside the 2" T-piece before re-commissioning the anodic
protection system.
NOTE:
The rod exposure within the acid directly influences the Rl Reference Electrode
reading.
Rod adjustment
may be required.
Refer to Data Log sheets to
determine if adjustment is required and change accordingly while cooler is empty

of acid.
AKER KY)ERNER~
CHEMETICS
Special Maintenance
Procedure
REFERENCE ELECTRODE MAINTENANCE PROCEDURE

Page 1 of 3 _
PROCEDURE FOR INSTALLATION OF NEW REFERENCE ELECTRODES (RE)

The reference electrodes (RE) are mounted on the shell of the cooler with a platinum element
wire projecting into the acid (see Fig 5.3 b). The electrodes are the sensing devices for
obtaining the millivolt potential of the acid-wetted metal surfaces and are key to the success
of the anodic protection system.
Remove RE from its shipping box and carefully remove protective shrink
wrap.
1.
2. Refer to Fig. 7.5 to identify the various parts of the

RE.
REFERENCE ELECTRODE
I
Fig. 7.5
3. Mount the large stainless steel body of the RE in a bench vice with the wires facing up.
4. Remove the packing gland nut (white colored ground wire is attached to it) counter clockwise.
5. Ensure threads of gland nut are coated with silicon or apply Teflon tape (gland nut removed
in step 4) and re-install. Before tightening, place assembly in hot water to simulate
process conditions, re-install in bench vice, then re-tighten gland nut. Ensure white (ground)
wire has
conductance to electrode body.
---_ .._----------_-----_
.._--
-~~.-
.... -..---.- ..-.~--
6. Remove RE from vice and apply Teflon tape to both sets of threads on the body of the RE.
JlKER RVJERNER"
CHEMETICS

Procedure
7.
No. M 170-0
Page 2 of 3
If it is a new cooler to be commissioned, remove the plugs from coupling 512 on the
cooler (sometimes, 513 or 514 positions are used; see Cooler Setting Pian). Clear away any
loose tape inside the coupling. Measure the depth inside the cooler to the first tube and
compare to the RE to ensure that the platinum tip will not touch a tube.
8. Just before installing the RE in the cooler, degrease the insulator and platinum tip with alcohol,
acetone, or a non-residue contact cleaner.
9.
Screw the new RE into the coupling on the cooler shell and tighten to prevent leakage:
(60 ft'lb /81 N'm), install housing and rewire. (Use of quick connectors for wire
attachment is permissible at the RE, do not solder or make permanent connections at
electrodes)
10. Ensure white (ground) wire has conductance to cooler shell.

11. carefully screw-on the housing cover, making sure not to twist the wire leads inside. If
drain hole exist in the housing, ensure it point down.
NOTE:
To ensure that the wire run is suitable, Megger Test each wire according to the
enclosed Megger Test Procedure. Only "infinity" resistance to ground and
adjacent wires is acceptable for RE signal wiring.
PROCEDURE FOR REMOVING AND INSPECTING OPERATING REFERENCE

ELECTRODES (RE)
1. Drain all of the acid from the cooler and lock out acid pump(s).
2. Unscrew the cap of the RE's housing (without twisting the housing, as the wires inside may be
damaged).
3. carefully separate the RE wires from the incoming Belden wires, removing the latter so
that the RE& housing are free to be removed from the cooler.
4. Using an adjustable wrench, unscrew the RE assembly from the cooler.
CAUTION: As the tapered threads become loose, observe if any acid is coming out at
the RE's threads. Stop removing the RE if acid is seen. Ensure that the
cooler is drained. If necessary, suit up with acid proof protective gear.
I
.
CHEMETICS
rL,~
Page 3 of3
...,j
[1 ::
5. After removing the RE from the cooler, carefully wash the acid wetted surface with copious
amounts of water .
6. Inspect the platinum tip and Teflon insulator for damage. If damaged, replacement is
necessary.
,
,
I
I
7. If replacement is required refer to Fig. 7.5 and follow steps (3) thru (10) of this previous section
for replacement.
8. An older cooler may have debris wedged inside the REfs 512 fitting. Shine a light through the
hole to make sure the entry is clear for the RE. If not, clear the path. Also, clear away any loose
Teflon tape inside the coupling.
9. Using a screwdriver or other suitable object, measure the depth inside the cooler to the nearest
tube and compare to the RE to ensure that the tip will not touch.
10. Before installing a used RE in the cooler, degrease the insulator and platinum tip with alcohol,
acetone, or a non-residue contact cleaner.
I
I
I
1
.:
"1
";
",
11. Screw the RE into the coupling on the cooler shell and tighten to prevent leakage: (60 ft1b / 81
N'm). Install housing and rewire (use of quick connectors for wire attachment is permissible at
the RE; do not solder or make permanent connections at electrodes). If drain hole exist in
housing ensure it points down.
12. Ensure white (ground) wire has conductance to cooler shell.
13. carefully screw-on the housing cover, making sure not to twist the platinum wire leads.
NOTE:
To ensure that there is no faulty wiring, Megger test each RE wire according to the
enclosed Megger Test Procedure. Only "infinity" resistance to ground and adjacent
wires is acceptable for RE wiring.
AKER KVJERNER-
CLEANING (WATER SIDE)

Procedure No. C 100-0
CAUTION:
Page 1 of 2
Many chemical cleaning solutions can damage stainless steel. Their use, in
general, is not recommended. Chemetics should be contacted prior to
introducing any chemical solution into a cooler other than those specified in
this procedure.
The high water velocity maintained through the tubes keeps scale and sludge formation to a
minimum. However, when the tube bores require cleaning, hydroblasting with potable water is
recommended.
Tube Bore Cleaning

Reid experience has shown that the most efficient hydroblasting method is obtained with the use of
a self-propelled jet-style cleaning head mounted on a flexible hose. Example: For 3/4" OD cooler
tubes having 0.610" ID, use a 1/2" OD (12.7 mm) cleaning head. Fig. 7.6 shows the spray action of
such a cleaning head.
Equipment for Hydroblasting the Tubes
For satisfactory results, a minimum water pressure of

5,000 psig (350 bar) is required. The self-propelled jet
must be activated at the very edge of the tube bore and
must remain active through the entire length of the tube
bore. Care must be taken to ensure that each and
every tube has been cleaned.
Forgotten tubes or
sections of tubes would operate undetected at a higher
tube wall temperature than the adjacent tubes and
failure by stress corrosion cracking could ultimately
result.
Fig. 7.6
The easiest and surest method to prevent the "forgetting" of the tubes requires the "moving along"
of markers such as two welding rods. One rod is temporarily inserted into the last row of tubes
already cleaned and the other rod into the tube bore of the last tube that has "just been"
hydroblasted.
If the substance coating the tube bores is difficult to remove, it is recommended that the jet be
passed twice through these tubes and/or cleaning pressure be increased to 10,000-20,000 psig
(670 1,335 bar). If hydroblasting proves inadequate, mechanical turbining is required (using nylon
N
or copper brush to avoid scratching the tube bores). Never use a stainless steel brush as this will
scratch the tube walls and set up the possibility of crevice corrosion thereafter.
AKER kV..ERNER*
CHEMETICS
Special Maintenance
Procedure
CLEANING (WATER SIDE)

Page 2 of2
The Special Procedures that are found in this chapter are in general, adaptable to all Chemetics acid
coolers. If a question should arise, please call your Chemetics Equipment Technical Service
Representative at 1 (416) 447~5541 or fax your question to 1 (416) 391~1637.
CAUTION:
When possible, the waterside should be cleaned first prior to cleaning the
acid side, this will prevent the water fouling layer being hardened onto the
tube bores by the heat of the alkaline cleaning solution (water side fouling
normally does not apply to demineralized water acid coolers).
CAUTION:
Do not add sand or any other abrasive material for hydroblasting.

sandblast.
Do not
Tube Inspection After Hydroblasting

Ensure that the bore of each and every tube has been cleaned and is dear of debris. A light
positioned at the opposite end of the Cooler must be seen through the bore of each tube. In cases
where the light cannot be seen through the tube because of a sag in the tube, confirmation of an
open bore must be obtained by a full-bore passage of water through these tubes.
Water Channel Cleaning
For carbon steel water channels and covers, a norust condition or a thin layer of rust indicates that
the water treatment
is effectively preventing
corrosion.
In this case, cleaning of the water
channel wall and cover is not necessary, If; on
the contrary, there is a large layer of rust or large
rust tubercles on the wall and cover of the water
channel; then this rust should be removed in
order to prevent blockage of tubes resulting from
the eventual loosening up of the layer of rust. In
these cases the water treatment program should
be improved. Fig. 7.7 shows a typical acid cooler
water channel & tubesheet.
Fig. 7.7
AKER KVA:RNER~
Special Maintenance
CHEMETICS
Procedure
CLEANING (ACID SIDE)

r1
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It
Page 1 of 3
On the shell side of the cooler, the flow of sulphuric acid normally results in negligible fouling. In
instances where a form of silica/organic fouling occurs, the following procedure has been effective
in removing this deposit:
CAUTION:
Do not introduce water into the shell side of the cooler.
Do not introduce water, even for flushing out the remaining acid in the cooler prior to the
introduction of the cleaning solution. Water and acid form a weak acid solution that is corrosive
and potentially dangerous to the stainless steel cooler.
The shell side of the cooler must pass directly from the specified circulating H2S04 strength
condition to a strongly basic condition obtained by Circulating a 20% wt. soda ash solution.
Similarly after cleaning, the shell side must remain basic until the Circulating acid is reintroduced into the cooler at/or above the specified strength.
In conclusion, the simple rule to follow is:
I
I
PASS RAPIDLY AND DIRECTLY FROM STRONGLY ACIDIC TO STRONGLY BASIC

AND VICE VERSA.
When possible, the water side should be cleaned first in order to prevent the water fouling layer
being hardened onto the tube bores by the heat of the alkaline cleaning solution (not normally
applicable for demineralized water coolers).
Schematic for Shell Side
Cleaning or Neutralization
Fig. 7.8
AKER KVA:RNER~

Page 2 of 3
EQUIPMENT AND MATERIAL REQUIRED (see Fig. 7.8)
One mixing tank with a capacity larger than the cooler.
One circulating pump with a capacity of about 100 GPM (450 litres/rnln).
Two 2" (N50 mm) hoses with flanges for connection to the 1-1/2", 150 Ib FF Cooler 511 Chemical
Cleaning Connections.
5team hose sparger pipe.
An overflow stack for the 511 connection; when needed.
Ir
A 20% wt. soda ash solution made using potable water with a chloride content of less than SO
ppm as cr. To calculate the amount of soda ash required, refer to the Cooler Setting Plan and
use the following formula:
[(Operating Weight - Flooded Weight)(1.25)1
+ Weight
of Water In The Circulating Loop
PROCEDURE
1.
Ensure that all acid has been drained from the Cooter, including the acid trapped in the
expansion joint (horizontal coolers) or lower tube sheet (vertical coolers). Be aware that these
small drains may be plugged with debris or sulphates and require rodding out.
CAUTION: Use complete acid suit protection when cleaning these drains.
2.
In many Cooler installations, blanking of the acid nozzles is not necessary. It is mandatory
however to ensure that the cleaning solution does not rise into the acid lines to the point where
it would overflow into the pump tank or another Acid Cooler. This can be prevented by
temporarily positioning a "stack" on one of the 511 flange connections. The top of this stack
should be well below the invert of the lowest acid line leading into or away from the Acid
Cooler.
NOTE: Orculation of the cleaning solution should be achieved without overflow through this "stack".
3. The use of the "overflow stack" provides the safety required and reduces the time needed to
clean the Coolers by eliminating the necessity for blinding nozzles.
4. Connect the hoses to the 1~1/2", 150 lb. FF chemical cleaning flanges 511 on the Cooler.
Return one hose to the pump tank (this should be the hose from the top nozzle when the acid
nozzles are on opposite sides of the Cooler) and connect the other hose to the pump.
AKER K.VA:RNER~

5. Mix the 20%
Page 3 of 3
wt. soda ash solution by steam sparging.
6. Use the pump to fill the cooler with the mixed solution.
7. Fill the cooler rapidly and circulate promptly. Ensure that the mixture does not back up into the
acid lines or pump tank; the mixture should not overflow at the "stack" installed on the 511
connection.
I
I
8. Continue steam sparging to heat the circulating mixture up to 160F (IV 70C). Circulation of the
hot solution should be maintained for a minimum of two hours (four hours is preferable).
9.
Drain the cooler thoroughly, including the expansion joint (Horizontal Coolers) or lower
tubesheet (Vertical Coolers).
SHELL SIDE INSPECTION

Inspect the shell side for cleanliness through
provided.
the acid nozzles or the inspection openings
The silica/organic coating and/or sulphate build-up should be completely removed or "loose"
enough to be flushed out by the force of the acid flow upon start-up of the acid pump. A rustcoloured coating is normal and represents no problem when acid is re-introduced.
IF THE COOLERS ARE NOT BEING IMMEDIATELY FILLED AND CIRCULATED WITH
STRONG H2S04, THEN BLINDS MUST BE INSERTED TO AVOID WEAK ACID
ENTERING FROM THE ACID PIPING.
AKER K.V.A:RNER~
CHEMETICS
NEUTRALIZING THE WATER SIDE OF A COOLER AFTER A

TUBE LEAK
Page 1 of
21
In cases where acidified water has entered a Chemetics cooler, it is mandatory to neutralise the
cooler in order to prevent the possible initiation of, or continuation of pitting.
EQUIPMENT AND MATERIAL REQUIRED
.
J.
One mixing tank with a capacity larger than the cooler.
One circulating pump with a capacity of about 100 GPM (450 tltres/mmute).
Two 2" (50 mm) hoses complete with flanges for connection to the cooler chemical cleaning
connections, T3 & T4.
Steam hose and sparger pipe.
An overflow stack for the upper cooler flange connection (when needed).
A 2% wt. caustic soda solution made using potable water with a chloride content of less than
-50 ppm
cr.
PROCEDURE
I
I
1. Crean and inspect the bore of the tubes as described in the procedure for cleaning (waterside),
thus ensuring the neutralising solution enters into the bore of all the tubes. If tube(s) were
leaking, perform the Tube Plugging Procedure before continuing with the neutralisation of the
cooler tubes. Re-install the water channel covers.
".
2. In many cooler installations, the blanking of the water nozzles is not necessary. In cases
where the neutralising solution might rise into the water lines to the point of overflowing into
adjacent
equipment; it is recommended to use an "overflow stack" (Fig. 7.8).
3. Connect the hoses to the connections shown. Return one hose to the chemical cleaning tank
(this should be the hose from the highest water nozzle when the nozzles are on opposite sides
of the cooler) and connect the other hose to the pump.
4. Mix the 2%
wt. caustic soda solution using steam sparging.
5. Use the pump to fill the cooler with the solution and continue circulation.
6. Ensure that the mixture does not back up into adjacent equipment.
overflow at the "stack".
The mixture should not
AKER KVA:RNER~
TUBE LEAK
Page 2 of 2
7. Continue steam sparging to heat the circulating mixture up to 160F ( 70C). Circulation of
the hot solution should be maintained for a minimum of two hours (four hours is preferable).
1V
8. Drain the cooler thoroughly.
Schematic for Neutralization

of the Tube Side
Connect Return to
T4 Vent Connection
on Nozzle
'I'
I
Caustic Soda Solution
at 70C
Fig. 7.8
AKER KYJERNER~
CHEMETICS
NEUTRALIZING ACID SIDE OF A COOLER PRIOR TO

WELDING REPAIRS
Page 1 of 1
As explained in Cleaning (Shell Side), water should never enter the shell side of the cooler,
otherwise weak acid corrosion can rapidly take place. Review that procedure before proceeding
here.
I
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I
case #1:
When making a tube-to-tube sheet weld or a plug-to-tube sheet weld repair, the heated
area during the welding process tends to draw acid moisture into the weld puddle, thus
contaminating the weld. To avoid this problem, the acid side should be neutralized first.
(see instructions earlier in this chapter).
case #2:
If water entry into the shell side has occurred as a result of a tube leak or during a
period when the plant is down for repairs and water or weak acid entered the vessel,
then this acidified water should be drained immediately and if possible strong acid
should be Circulated immediately through the cooler. If strong acid cannot be circulated,
the cooler should be neutralised using the Cleaning (Shell Side) procedure described
earlier in this chapter, with the following modification:
Use a 20/0 wt. caustic soda in potable water solution instead of

a 200/0 wt. soda ash in water solution.
AKER KVA:RNER-
CHEMETICS
Procedure
SETTING UP COMMUNICATION WITH A DeS

Page 1 of 4
The Remote Display Unit of the Anotrol 2000 system automatically records and stores the anodic
protection parameters and can record and store up to 12 process values where these are input as 4
- 20 mA signals onto the PC Board.
The stored data is used by the RDU to display trends on the screen when this feature is selected.
The stored data can also be output to a DCS using the MODBUS interface programme, which
runs
on the RDU, but independently of the RDU control programme.
Each C/PS connected to the RDU will be viewed by MODBUS as one of up to twelve devices each
having a distinct address [0 through 11].
The MODBUS programme can be installed either via one of the USB ports or by a serial
communication link to another computer.
Communication between the DCS and RDU should be verified before the RDU releases any data.
Settings on the RDU and DeS must be set to match.
set-up of the MODBUS programme is as follows.
I
I
ANOTROl 2000 - DCS SERIAL COMMUNICATION SPECIFICATION

1.1. Serial interface
1.1.1. RS-232
1.1.2. Baud Rate:
1.1.3. Parity:
1.1.4. Data bits:
1.1.5. Stop bits:
9600 bps
(user selectable)
No
8
2
(user selectable)
1.1.6. Time out:

2000 ms*
1.1.7. Silent interval: 200 ms*
1.2. Communication protocol Modbus:
1.2.1. Message format ASOI (RTU *) (user selectable)
1.2.2. Master/Slave: Master - DCS, Slave - RDU
1.3. Data and Control functions
Read Input Registers
1.4. Poll interval: 5 sec*
(values with * may require to be modified dependant on the DCS in use)
AKER KVA:RNER~
CHEMETICS
Procedure
SETTING UP COMMUNICATION WITH A DCS

Page 2 of 4
The active screen for the MODBUS module is shown below:
..J
I
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I
The left side of the program window is used to setup the serial interface.
~
The right side is used to setup C/PS data.
DATA STRUCTURE
MODBUS protocol views the Anotrol@ 2000 system as a set of up to 12 devices with addresses
ranging from 0 to 11, representing channels 1 through 12 on the RDU.
f'
I
The drop down box in the top right hand side of the screen allows you to select the relative C/PS
address.
I" ..
L._
MODBUS views each device as having 20 Image Registers (IR), each storing the relevant values
of the anodic and process data, as listed in the table below.
AKER KV,ERNER'
'-'
I
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Special Installation Procedure
CHEMETICS
SETTING UP COMMUNICATION WITH A DCS

G~
Page 3 of 4
Anotrol Name
IR Values range
Phvs. Value Scale
IRO:
Control Electrode
-1000 to + 1000
-1000 to +1000 mV
IR1:
Ref. Electrode 1
-1000 to +1000
-1000 to +1000 mV
IR2:
Ref. Electrode 2
-1000 to +1000
-1000 to +1000 mV
IR3:
Ref. Electrode 3
-1000 to + 1000
-1000 to +1000 mV
IR4:
Ref. Electrode 4
-1000 to + 1000
-1000 to +1000 mV
IRS:
Ref. Electrode S
-1000 to + 1000
-1000 to +1000 mV
IR6:
cathode Voltace
-1000 to + 1000
-10.00 to +10.00 V
IR7:
cathode Current
o to +1000
IR8:
Process Par 1
-1000 to +1000
IR9:
Process Par 2
-1000 to +1000
IR10:
Process Par 3
-1000 to + 1000
IR11:
Process Par 4
-1000 to + 1000
IR12:
Process Par S
-1000 to + 1000
IR13:
Process Par 6
-1000 to + 1000
IR14:
Process Par 7
-1000 to + 1000
IRIS:
Process Par 8
-1000 to + 1000
IR16:
Process Par 9
-1000 to + 1000
IR17:
Process Par 10
-1000 to + 1000
IR18:
Process Par 11
-1000 to + 1000
Process Par 12
-1000 to + 1000
Register
"7:
[
"
'"
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IIR19:
* The
o to +100.0
dimensions and scales of the Process Parameters depend on the specific application. These
are user defined in the RDU and must be redefined in the DCS.
AKE
R
KVJ
ER
NE
R~
Special Installation Procedure
CHEMETICS
SETTING UP COMMUNICATION WITH A DeS

Page4of4
Example
The DCS command (request frame) to get all registers of a Unit 5 CC/PS5) is
Slave Address:
Function:
Starting Address Hi:
Starting Address La:
No of Registers Hi:
No of Registers Lo:
04
03
00
00
00
14
Slave Address:
is the Channel number of the CIPS being interrogated.
Function:
The command specifies the starting register (in two bytes) and
quantity of registers to be read (also in two bytes). Registers are
addressed starting at O.
Starting Address Hi &

Starting Address La
are the two bytes for the starting register address.
No of Registers Hi &
No of Registers La
are the bytes for the quantity.
HARDWARE CONNECTION
Communication between the RDU and the DCS is made using the COM 2 or COM 4 port on the
rear of the RDU. NEVERconnect serial communication cable to the COM 3 port.
The D - Sub 9 pin plug should be configured as follows:
Pins 1 - 4 - 6 apply jumper
Pins 7 - 8 apply jumper
Pin 2
TxD
Pin 3
RxD
Pin 5
GND
AKER KV)ERNER~
CHEMETICS
INSPECTION OF TUBES ON THE ACID (SHELL) SIDE

Procedure No. I 100-0
Page 1 of 2
During turnaround inspection of cooler(s), it is recommended that the tube bundle be inspected for
fouling, debris, blockage, and corrosion. For your reference, new tube sizes are shown below for
various duties of coolers (check your Cooler Rating Sheet):
1. For 3/4" 00 (19.05 mm), 16 AWG (most common tube size), minimum tube wall thickness
0.060" (1.524 mm), typical tube wall thickness = 0.065" (1.651 mm).
2. For 3/4" 00 (19.05 mm), 18 AWG (i.e. seawater coolers using Ciramet" tubes), minimum tube
wall thickness
= 0.049" (1.2446
mm).
3. For 1/2" 00 (12.7 mm), 16 AWG (l.e. energy recovery coolers: closed loop heaters, boiler feed
water heaters, etc.), minimum tube wall thickness = 0.060" (1.524 mm).
4. For 5/8" 00 (15.875 mm), 16 AWG (special application coolers), minimum tube wall thickness
= 0.060" (1.524 mm).
Tube losses of 30-50% are unusual and extreme and probably mean that the cooler requires retubing or replacement. Some tube failures may already have occurred. Please contact Chemetics
Equipment for a quotation.
I
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DETERMINATION OF CORROSION RATE FROM TURNAROUND TO TURNAROUND
1. Insure acid has been drained from the cooler(s).

2.
Normally, all coolers have two inspection ports installed on the shell side of the cooler. Some
smaller coolers may only have one inspection port, usually located at the acid inlet end of the
cooler (see the Cooler Setting Plan, listed in Appendix A of this manual).
3. carefully remove the inspection part flange bolts and lift off the blind flange on 57 or 58,
exposing the tube bundle.
4. Use a thickness slip-on gauge or Vernier caliper to determine the outside diameter of one or
more tubes. Record the reading of each tube.
CAUTION:
Try to do this check as quickly as possible to prevent moisture from

entering the acid-wetted bundle. Re-install the flange with a new gasket
as soon as possible. Cover the flange opening with plastic if danger of
rain or other water is possible.
5. Repeat steps 3 and 4 on the second inspection port (if installed).
AKER kVJERNER~
CHEMETICS
INSPECTION OF TUBES ON THE ACID (SHELL) SIDE

Procedure No. I 100-0
Page 2 of
21
6. Compare these measurements with those from the last inspection (if available), or the new tube
size, to determine the amount of tube loss (if any).
7. With a flashlight, inspect to see if debris can be seen lodged within the tube bundle and remove
the material if possible. If a significant amount of debris is found, it may be necessary to
remove the section of pipe at the inlet nozzle in order to clean debris from the tube bundle (see
procedure in this chapter).
OTHER OBSERVATIONS TO BE RECORDED DURING THE TUBE SIDE INSPECTION
1. Cleanliness of the tube surface, e.g. sulfates, silicates, organic/ etc.
2. Evidence of any localized corrosion on tubes or baffle, e.g. pitting, crevices / tube corrosion at
the baffle etc.
3.
Evidence of any tower ceramic packing, pump tank brick, Teflorr" gasket material, stainless
steel pieces etc.
NOTE:
If the acid inlet or outlet piping is being removed for any reason, this will provide an
alternate area for inspection of the tube bundle. Take care that external water does
not enter a non-neutralized acid cooler (cover openings with plastic to prevent moist
air or water from entering).
REVIEW OF LOG SHEETS TO DETERMINE REASONS FOR CORROSION

Anodically protected coolers experience some of the lowest corrosion rates in the industry. If your
equipment is experiencing excessive corrosion, either haphazardly or regularly, a thorough review
of operating procedures is recommended to find out what may be going wrong. Contact your
Chemetlcs Technical Service Representative in Toronto, canada for further advice.
Chemetics
A division of Aker Kvaerner Canada Inc.
77 Railside Road,
Toronto, Ontario
canada, M3A 1B2
Phone: (416) 447-5541 (switchboard)
Voice Mail: (416) 447-0071 (press # on touch-tone phone or
directory listing)
Fax:
(416) 391-1637
E-mail: technical.services@akerkvaerner.com
AKER RVJERNER~
r
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Special Maintenance
CHEMETICS
Procedure
TUBE PLUGGING PROCEDURE

Procedure No. R 100-0
1)
2)*
I
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3)
4)
5)
6)
7)
8)
9)
10)
11)
PART NUMBER
DESCRIPTION
700
730 A,B
710
Tube Plugging Kit (complete)

Tube Plugs-two pieces (sold in lots of 12)
ToolBox
Air Hose with Connector
Air Tool
Safety Glasses
Allen Key
Silicone Seal
Small Diameter Drift
Large Diameter Extension Drift
Reamer Extension
Reamer (tapered)
Reamer Socket
Reamer Ratchet
Plug Driver Attachment
Stainless Steel Brush
737 A,B
711
712
713
714
715
717
718
719
720
721
722
723
724
12)*
13)*
14)
15)*
16)*
Page 1 of 5
- (733
- (733
- (730
- (730
* Order
IV
IV
IV
737)
737)
737)
737)
to suit tube diameter / plug
I
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Item 2:
A - Plug
B - Plug Drift
Tube Sheet Plu s

Tube Dia.
P. N.
0.500"
730 A, B
0.625"
731 A. B
0.750"
732 A, B
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Tube Dia.
P. N.
0.500"
0.625"
0.625"
0.750"
0.750"
733A. B
18 **
16
18
734A.
735 A,
736 A,
737 A,
...,i
Tube Plugging
Kit (PIN 700)
** Special Order
B
B
B
B
A
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CHEMETICS
Special Maintenance
Procedure
TUBE PLUGGING PROCEDURE I

NOTE:
Page 2 of 5 I
A minor leak is simple to repair. However{ if the plant and cooling equipment are
not shut down quickly and properly (see cnapter 4), a minor leak will lead to more
extensive damage.
The following procedures are recommended after the plant has been shut down and water drained
from the coolers, but prior to stopping the acid circulation.
LEAK DETECTION
1. After stopping acid flow, remove both Channel Covers, taking care not to bend the Cathode
Support Pipe(s).
2. Identify the leaking tube(s) by circulating acid. Record the leaking tube(s) on the tube sheet
layout (see cooler drawings at the end of this Manual).
Proceed with plugging the leaking
tube(s) (see procedure below). On horizontal coolers, start at the top leak and work down to
the next one, stopping acid circulation and draining acid prior to plugging.
3. If it is impossible to determine where the leaking tube is located by the acid circulation method,
the cooler must be drained of acid; blinds installed at the inlet and outlet acid nozzles, and air
pressure injected up to 45 psig (3 bar) (see procedure in this Chapter). Ensure that this is
accomplished with safety equipment installed, l.e. pressure relief valves set at 3.5 barg
maximum. By using rubber stoppers at one tube sheet (or wet newspaper covering all the
tubes), a soapy solution may be applied at the other tube sheet to witness air bubbles escaping.
Even after plugging tubes (see Leak Repair following), this liquid soap, air pressure method of
leak detection is very good and ensures that the plugs are also leak-free.
LEAK REPAIR
1. The procedures that follow are given as guidelines only.
Depending on the type of tube

material and the extent of damage, the repair may not be a simple one and you should contact
Chemetics Equipment for further advice and clarification.
2. The Expandable Tube Plug was developed to minimise the amount of welding that would be
required when using tapered plugs. Refer to specific expandable tube plugging instructions on
the pages that follow.
TAPERED TUBE PLUG & WELDING PROCEDURE

1. Inspect the ends of the leaking tube(s) to ascertain their condition.
If the tube bore is "like

new" (or can be made smooth by honing), proceed to (2) below. However, jf the surface is
corroded or there is a cracked tube to tubesheet weld, the repair may be more difficult due to
the possibility of acid contaminating the weld. In this case, the internals of the cooler may have
to be neutralised (see details in this Chapter).
AKER KV.JERNER~
CHEMETICS
Special Maintenance
Procedure

Page 3 of 5
2. Prior to commencing the plugging, drain the cooler of acid, wash the area clean of acid and
then air blow dry. If the leak continues to seep acid from inside the tube bore, plug the bore
with a rubber plug, pushing it inside the tube bore about 2/1 (5 cm).
3. The area of the tube and tubesheet to be affected by the repair weld puddle must be undercut
approximately 0.02" (1/2 mm) in depth (down to new metal) with a steel cutting tool (such as a
Rico Solid Carbide Burr, 1/4" shank 2" GAL, STYLE R-29, R-30 or R-31). Grinding is not
recommended because it contaminates the new metal with residue from the previously ground
surface. The plug and tubesheet area must then be washed with a degreasing agent (alcohol,
acetone, etc.).
I
.
4. The plug can now be inserted and llG welded using the following filler metals: (i) INCa ER316l for 316l tubes used on fresh water Coolers; (ii) ER-625L or ER-686L on Ciramet Tubes
used for brackish or sea water cooling; and (iii) ER-625L or higher alloy material for Alloy 20
tubes (see Chapter 2, Cooler Specification Sheet for tube material specification or refer to
Chapter 5 and contact Chemetics for advice).
S. The weld area must be penetrant dye checked (see recommended procedure enclosed).
Remove any porous or cracked welds, re-weld and dye check again (if required).
I
I
6. Following pressure testing the vessel for the last time (see this Chapter), neutralise the tube
side of the cooler to stop any further pitting that may have been initiated by acidified chloride
containing water.
THIS IS AN EXTREMELY IMPORTANT
PART OF THE REPAIR
PROCEDURE.
7. Proceed to Chapter 4 and restart the plant, paying particular attention to the pH of the acid
cooler's discharged cooling water.
NOTE:
If there is some doubt about a specific part of this repair procedure, please
contact Chemetics Equipment immediately for clarification.
AKER KVJERNER
CHEMETICS
Special Maintenance
Procedure

Procedure No. R 100*0
Page 4 of 5
TUBE PLUGGING KIT INSTRUCTIONS

DRIFT/EXPANSION PLUG (AIR TOOL METHOD)
Parts Ust
Air Hammer; Cleco Model # CL-3 (100 psig (7 bar) air supply required to operate)
Air Hose; 1/2" X 5-1/2' c/w 3/8" Hose Connector for attaching to Air Hammer (another fitting
will be required to fit the hose to your air supply).
2-Piece Shaft Drift Punch
Small Diameter Shaft; 1/2" X 26" c/w Extractor
Large Diameter Extension Shaft; 1" X 26" c/w 1/8" Set Screw to secure Small Diameter Shaft, if
required
Allen Key; 1/8"
Plug Driver Attachment; (size is dependent on tube plug size; for example: 0.683" 00 &
0.506" 00 X 2-1/2", specific for 0.S06" 00 X 18 AWG X 3/4" tube plugs)
Stainless Steel Tube Brush; 3/4"
GE Silicone Seal; Clear, SE 1121, 84 ml tube (or equivalent)
Red Tool Box
Tapered Reamer 8r. Ratchet
t~
iI
Tube Plugging Procedure

1. After determining which tube is leaking, drain the Cooler of acid (or remove air pressure if
pressure testing) and neutralise the ends of the leaking tube. The inside tube bore should now
be cleaned thoroughly using the stainless steel tube brush. Fine grit "emery" paper (not
included) may also be used. Ensure that there are no longitudinal scratches along the tube
bore, if so, these must be removed to reduce the chance of an acid leak after plugging. One
method to consider Is an electric drill with spinning rod, slit on the end of the rod for attaching
the "emery" paper. Use the Tapered Reamer & Ratchet (mentioned above) to ensure tube bore
will receive a plug.
2. Now that the tube bore is neutralised and cleaned, a tube plug of a slightly larger 00 than the
tube ID may now be installed. Before this is done, however, apply some silicone around the
barrel of the plug and between the raised ribs. Besides providing lubrication for the plug when
it is drifted into the tube, the silicone will become a gasket seal to reduce the chance of crevice
corrosion when cooling water is reintroduced.
3. Temporarily remove the tube plug's inner drift plug. Insert the Plug Driver Attachment
(mentioned above) and use the Air Hammer to drift the plug all the way into place. If the
cooler's water channel is too close thus preventing the Air Hammer easy access to the plug,
attach to it the large diameter extension shaft (mentioned above) c/w the Plug Driver
Attachment and drive the plug flush to the tubesheet. Remove the Plug Driver Attachment from
the plug when finished.
4. Apply silicone to the plug's drift piece barrel and insert the drift piece into the plug.
AKER KV)ERNER~
,
I
~.
CHEMETICS
c
"
Page 5 of 5
nt~,J
m
,
,,'/
5. Using the Small Diameter Shaft, Drift Punch and Air Hammer (mentioned above) drive the drift
all the way into the bore of the plug. Ensure that the Small Shaft Drift Punch is kept straight
while driving the drift home. Now fill the drift hole with silicone seal.
6. Plug the other end of the failed tube using procedures 1 - 5 above.
7. Pressure test the vessel again to verify that there is no more leaking tubes or plugs.
I
I
NOTE:
This is a very important step in the leak repair procedure! Make sure there are
no leaks.
8. If the plug should leak when the vessel is air tested, welding the plug to the tubesheet must be
done (refer to the previous section for the welding procedure). In the cleaning of the area
around the plug may be difficult due to the presence of the silicone. According to GE, a suitable
cleaner for their silicone is xylene, paint thinner or mineral spirits. However, once the silicone
has set (about 1/2 hour), cleaning may be greatly impaired.
-c-,
AKER KYJERNER"
CHEMETICS
HOW TO PRESSURE TEST THE COOLER FOLLOWING A

LEAK REPAIR
Page 1 of 2
For detecting medium to large leaks prior to repairs, simply circulate acid to identify a leaking tube
(see Tube Plugging Procedure, this chapter). However, when very small leaks are suspect or you
want to make sure that a tube to tube sheet weld repair has been successful, the air pressure leak
test is far superior over the circulation of acid.
This method does have its drawbacks:
Time consuming due to the need to insert blinds at the acid nozzles
Potentially very dangerous if proper precautions are not taken
This method has many benefits:
Excellent detection of very small leaks

Inexpensive to perform
can be performed in conjunction with a hydro test to re-certify the vessel
can be performed in stages and repairs can be done immediately following removal of the
internal pressure
For those not wanting to use this method for leak detection, the following should be
noted:
A small leak is relatively easy to repair but difficult to find.
Should a small leak not be detected and the cooler is put prematurely back into service, there
will inevitably be another costly shut down.
A slow leak may cause more severe damage and possibly additional good tubes will become
damaged.
Due to the fact that compressed air is being used, Chemetics accepts no liabilities
with the use of this procedure. The end-user uses this procedure at their own risk
and agrees to continue only after review of their in-house Plant Safety Regulations.
AKER KV~RNER~
CHEMETICS
Special Maintenance
Procedure
HOW TO PRESSURE TEST THE COOLER FOLLOWING A

LEAK REPAIR
Page 2 of 2
SETTING UP FOR THE AIR PRESSURE LEAK TEST

1. Blind the acid nozzles and connect a pressure relief valve (preset to 3.5 bar or 50 psig) to the
cooler shell (acid side) via any reference electrode 1/2/1 NPT connection (512) or a suitable
small flange on one of the acid nozzles.
2. At another reference electrode 1/2" connection (512) install an air inlet line
and bleed ball valves.
clw double
block
3. Install a 4 bar (60 psig) pressure gauge on the vessel to monitor the internal air pressure.
4. Introduce up to 1 bar dry instrument air pressure and hold.
5. Mix some liquid dish detergent (soap) in a clean pail of water.
6. Cover one tube sheet with wet newspaper/soap solution using a clean/wide paintbrush and the
liquid soap solution.
7. Now "paint" soap bubbles over the tube holes at the other end of the cooler to witness the
presence of any air leaks.
8. Carefully increase the air pressure up to 3 bar if no leaks were previously found.
NOTE:
Even the smallest air leak can be discovered in this manner by watching for
a tube's bubble slowly growing larger.
AKER KVA:RNER~
Special Maintenance
CHEMETICS
Procedure
IRON ADDITION TO FORCE THE PASSIVATION OF A

DIFFICULT-TO-PASSIVATE COOLER
Procedure No. P 100-0
Page 1 of 1
n!
t. '
b.J
Following is the recommended
procedure for iron addition;
successful in assisting difficult-to-passivate
a method that has been very
coolers to achieve low amperage/corrosion
rates:
1. Measure the background Fe++ content in the Circulating acid. An additional 25 ppm of iron is
required to do a forced passivation at the cooler's design operating conditions.
I
I
2. Calculate how much Ferrous Sulfate Heptahydrate is required to maintain this additional 25 ppm
of iron in the acid for the estimated acid production rate over a 4 to 5 day period.
3. Begin adding small quantities directiy into the pump tank every hour or slowly meter it into the
acid circuit as an aqueous solution as follows:
Add water to a 1000 litre (250 USG) Polymer Tank or suitable container and heat it by steam
sparging to about 50C (120 OF),then add (with agitation) up to 660 kg (1450 Ibs) of Ferrous
Sulfate Heptahydrate.
Using a chemical feed pump, slowly add this solution into the acid circuit, possibly through the
dilution water line of the pump tank or directly into the pump tank.
4. Test the acid Fe++ content every 4 hours until the correct feed rate of solution has been
established. If background Fe++ content was 5 ppm, then you should have a minimum of 30
ppm Fe++in the acid to achieve complete passivation. Over-addition of Fe++does not harm the
system or the forced-passivation process.
5. Observe the increase in anodic current supplied by the Anotrol@ system of each cooler; it should
first peak and then gradually diminish after a few days, even though the iron content in the acid
remains high.
6. Consult Chemetics for advice as to when the iron addition (passivation) is complete.
7. Under normal Circumstances, the passivation film will last for a long time provided that there
are no serious upsets in the plant operating conditions, e.g. weak acid excursions, high acid
temperatures, no or reduced water flow. If the film should become destroyed, however, this
will again result in an increase in amperage, giving a clear indication that corrosion rates have
increased and that the cooler requires re-passivation with ferrous sulfate again.
NOTE:
The use of Ferrous Sulfate Heptahydrate was chosen as it is readily available,

inexpensive and water soluble, especially when heated. If adding directly to the
pump tank, any non-halide ferrous compound may be used (e.g. ferrous oxide,
ferrous hydroxide) as long as it is acid soluble.
AKER KVJERNER~
CHEMETICS
CHAPTER 8
TROUBLESHOOTING
I
I
I
.
Acid Cooler
ChapterS
Troubleshooting
CHEMETICS
f1
[j
TROUBLESHOOTING
ANODIC PROTECTION SYSTEM
This section is provided as a guide to locating the causes of alarms and/or faults. When an
alarm exists, it must be stressed that the Plant Operating Conditions should be reviewed
with the Process Engineer or the Operator before troubleshooting the anodic protection
system. However, if a fault is suspect, proceed to the table below to find the symptom, the
probable cause and how to correct the problem.
The troubleshooting table will identify one or more major components where the cause of a
fault may be located. The main components eM) discussed in this section are identified on
the last page.
NOTE:
Service work within the RDU or C/PS must be performed under the direction of
authorized service personnel, especially during the warranty period. Please
contact your Technical Service Representative at:
Chemetics
77 Railside Road,
Don Mills, Ontario
canada, M3A 1B2
Phone:
(416) 447-5541 (Switch Board)
Voice Mail: (416) 447-0071 (press # on touch tone phone
or directory listing)
Fax:
(416) 391-1637
e-mail:
technical.services@akerkvaerner.com
Abbreviation
P
W
C/PS
,;,.,"
RDU
MC
PC
RE
CR
I COMPONENT
=
=
=
=
=
=
=
=
DESCRIPTION
Process
Wiring
Controller Power Supply
Remote Display Unit
Main Cathode
Pin Cathode
Reference Electrode
Control Reference Electrode
Acid Cooler
ChapterS
Troubleshooting
SYMPTOM
1.
2.
No AC Power to RDU
No AC Power to C/PS
3.
4.
No Output current present &

Reference Electrode potential
not being maintained
Reference
Potential
or
Controller Set Point not being
maintained & output current
present
5.
No response from CjPS at RDU
6.
High Alarm Condition

internally) (General)
7.
High Alarm (For Control)
9.
Low Alarm Condition
11.
12.
13.
PROBABLE CAUSE AND CURE
Power Source Wiring, Circuit Breaker

Fuses FI, F2
Power Source Wiring, Circuit Breaker
W
C/PS
Not Activated (green light "Off")
CjPS
Controller PC Board Assembly
W
Cathode or Anode Wiring disconnected or loose
W
Cathode wiring shorted to giOund or to anode wire
MC
Broken or corroded Main cathode rod(s)
PC
Broken or corroded Pin Cathode rod(s)
CRjRE
Reference Electrode faulty
W
Reference Electrode Wiring faulty
W
Communication wiring reversed or open
RDU
Connected to wrong channel
CjPS
Address incorrect
Channel Selector Switch malfunction (try contact cleaner)
C/PS
Main PC Board power fuse (F2)
C/PS
RDU
Channel I/O Fault on PC Board - Change PC Board
CRjRE
Reference Electrode (broken
W
Open signal Wire (Electrode to C/PS)
CRjRE
Shorted Electrode
Microprocessor malfunction (PC Board Assembly)
C/PS
CRjRE
Control Reference Electrode causing high potentials in
vessel, then RI (or R2, if present) trips off the
anodic current. Check for debris at the cooler add inlet, possibly
touching Control Reference Electrode or causing localized
turbulence. Electrode may also be leaking.
Acid temperatures, strength, flow too high; water
P
temperature too high or flow too low.
No signal generated by Reference Electrode
CR/W
(open circuit).
P
Recent start-up (vessel not yet passivated)
P
Acid temperatures, strength, flow too high; water
temperature too high or flow too low
Low alarm set point too high
C/PS
Controller set point too low
C/PS
W
Wiring to Cathode(s) or Anode is loose, corroded or
undersized
CR
Reference Electrode (internal signal shorted or debris
touching part)
W
Reference Electrode Wiring
MC
Broken or corroded Main Cathode
PC
Broken or corroded Pin Cathode
CRjPS
Distorted signal or no platinum element exposure in add
C/PS
Main PC Board failure
Faulty Controller PC Board Assembly
C/PS
t]
C/PS
High Alarm Condition (for Rl,

the R2, etc.)
8.
10.
Components
C/PS anodic current output

starts up after 6Q seconds or
not at all
NO audible alarm
Audible alarm will not silence
High Alarm wiJl not reset
I
RDU
RDU
RDU
C/PS
RDU
Add Cooler
PC Board failure
PC Board failure
Alarm condition remains
Main PC Board failure
PC Board failure
I
I
I
I
.
L~
ChapterS
Troubleshooting
I~
.....
SYMPTOM
14.
No output
condition
under
low
Components
alarm
CIPS
CjPS
CIPS
CjPs
CIPS
15.
Low output current or voltage
16.
High output current
17.
I, Loss of communication
I
18.
I
I
I
l
I
I
for
Causes
between
Control
Electrode readings
differences
and
Rl
P
P
P
P
PC
MC
I
I
I
I,
I Causes
for
changes
in
Rl
potential
i
20.
21.
l22.
i
I
Incorrect Pin Cathode exposure

Fouled Cathodes
Fouled Reference Electrode
Shell side fouling
Broken Main Cathode rod
Shorted Cathode wire
Acid leak at stuffing box
Acid temperature changes
Increased acid velocity
Changes in water temperatures or flow rate
RE
Me
P
W
MC
W
CIPS
P
I
I
CjPS
I
I
19.
W
W
PROBABLE CAUSE AND CURE

Improper
input wiring
(signal ground
on Control
Electrode)
Fuse (F1) faulty
Power transformer faulty
" Ql or Q2 faulty
D1 or D2 Faulty
PC Board Assembly
I Controller
Cathode or Anode wiring open
Low AC line voltage
i Ql, Q2, D1 or D2 Faulty
I Faulty Cathode I Anode connections
!;
Increase in acid temperature, high acid flow, weak acid
Shorted Cathode I anode wires
i
I
Cathode add packing leaking acid (short to cooler)
Power fluctuations on AC input
PC Board Assembly (cycle AC off at CIPS and turn on 10
seconds later' change PC Board if problem continues)
Hotter than normal acid with very cold acid exiting
Reduced water flow
,
Water side fouling
Increased acid velocity
Decrease in acid strength
Control / Rl readings (zero

I millivolt reading)
Control I Rl readings (always
neoative or little chance)
Codes will not be accepted for
set point or label edit
I
I
P
MC
W
MC
P
P
P
PC
RE
W
REI CR
RDU
Incorrect Pin Cathode exposure

Short at Reference Electrode
Short on wiring
Acid may be leaking out of the gland
RDU PC Board
seal nut
Ct1EMETICS
APPENDIX A
DRAWINGS
Drawing List
Drawings
DRAWING LIST
Drawing Number
Drawing Title
Cooler Drawings
04A-618 A
04A-618 E
04A-618 L
04A-618 Y1
04A-618 Y2
04A-618 CZ
04A-618 W
04A-619 A
04A-619 E
04A-619 L
04A-619 Y1
04A-619 Y2
04A-619 CZ
04A-619 W
04A-620 A
04A-620 E
04A-620 L
04A-620 Yl
04A-620 Y2
04A-620 CZ
04A-620 W
Anotrol" 2000 Drawings

04A-618-l900
Setting Plan
Gasket and Bolting Detail
Thermowell Detail (Shell side)
Layout Viewed from Acid Inlet
End
Layout Viewed from Acid Outlet
End Parts List for Acid Cooler Cathode Thermowell Detail (Water
side)
Setting Plan
End
Layout Viewed from Acid Outlet
End Parts List for Acid Cooler Cathode Thermowell Detail (Water
side)
Setting Plan
End
Layout Viewed from Acid Outlet End
Parts List for Acid Cooler - Cathode
Thermowell Detail (Water side)
04A-618-1901
Remote Display Unit & Controller/Power Supply Installation
Dimensions
04A-618-1902
Anodic Protection Wiring Diagram, for Coolers with
Double-Ended Cathode
~AddCoofer
Operat~rtg&
Anodic Protection Wiring Diagram, for Large Coolers with

Double-Ended Cathodes
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::.

Drying Acid Cooler SIN 04-618

Anotrol 2000 System

necessary to operate, maintain, and troubleshoot the

2000 Anodic Protection Equipment.

on the cooler(s) being operated and maintained

for the acid cooler(s)

in accordance with the specific

Failure to comply with or observe the recommended

will cancel all guarantees.

relating to the design, operation,

equipment supplied with the acid cooler(s) has been designed to

by the application of the anodic protection

system, which generates a protective

oxide film on the acid wetted surfaces.

Remote Display Unit (RDU)

Controller/Power Supply (C/PS)

CIPS Activation and Shutdown

CONTROLLER I POWER SUPPLY (C/PS)

Anotrol(!i) 2000 System

the specifications for the project site .

for up to twelve 4-20 rnA

C/PS Board Configuration

C/PS is independently configured to operate as part of a total anodic protection system.

Hardware Fail Safe

Fail Safe setting

is only field selectable,

The unit Fail Safe is factory set at a 600 mV set point.

FAIL SAFE VOLTAGE

Fuses and Connections

2) The Controller PC Board

REMOTE DISPLAY UNIT (RDU)

The RDU is a fully functional PC with a touch

7) Connect a remote alarm to relay through TB3.

The Config key gives access to the Configuration mode, it is password

Event Log Screen

Operating &. ~1aintenance Manual

This key returns user to the Overview screen.

The Config key on the Overview

alarm conditions within the Anotrol system.

Electrode located at the acid outlet area of the

Anotrorv 2000 System

values should only be done under the instruction of

Random adjustment or incorrect setting of these values may result in serious

If it is necessary to modify the channel configuration:

Call up the C/PS to be modified from the Overview screen.

From the Channel Configuration screen, select the item to be modified.

Using the touch screen, select cooler or tank.

When all changes/values have been entered, press the Save

Set points may be edited with C/PS in Idle or Active

Press Control Potential on the screen to silence the alarm.

Sound the internal alarm

The C/PS will not automatically restart after

on the Detail screen. This page will

reveal the status of the Acid and Water

Temperature readings along with any alarms related to temperature.

RDU Software Setup

Copy the RDU software package (Setup.exe,

Setup. 1st, RDU1.cab, RDU8.cab) in the

Install the RDU program:

(see the Service

description for details).

OK (Start, Run C:\HTBuffer\Setup.exe,

Modify the Windows startup procedure (new system logo screen,