KAYDON FILTRATION Mobile Lube Oil Purifier Model Number S-20-60H Project: Quarayyah 2000MW CCCPP SGT6-5000F(5) INSTRUCTION AND OPERATIONAL MANUAL Volume 1 ‘aydon Custom Filtration Corporation 1571 Lukken Industrial Drive West LaGrange, Georgia 30240 16-884-3041 phone 906-683-6199 fox www.kaydonfiltration.com PRINTED INTHE USA (© 2012 Kaydon Fivation, Al Fights ReservedKaydon Filtration Model S-20-60H / Instruction and Operational Manual 4 Table of Revision Revision | Description Introduction / Preface ‘The Model S-20-60H is a portable turbine oil purification system designed to capture particulate and remove water from turbine oii. The primary system component s consists of: Pump/Motor assembly with suction strainer (flow rate = 21 gpm) Pre-Filtration Vessel with filtration element Coalescer (water removal) vessel with coalescer element and separator element Inlet/Outlet isolation valves Oil Heater (15 KW) with flow switch protection Control Panel with ON/OFF switch, indicator lights and alarm lights Hoses with quick connect couplings The system purification stages include following 1 Stage - Pump Suction Strainer (16 mesh) 2" Stage — Pre-Filtration - rated at 5.1 micron (99.9% efficient) 3 Stage - Water Removal ad Final Filtration — water removal to less than 200 ppm and final filtration rating of 4.2 micron (99.9% efficient) ‘The performance of the system is as follows: Particulate Cleanliness: iSO 16/14/12 with influent not exceeding ISO 22/20/18 Water Contamination: 200 ppm with influent not exceeding 5,000 ppm Prinedin the USA Mode 520-608 [May / 2012 Revision 0 (©2012 kaydon Frain. Al Rights Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 2 Table of Contents — O and M Manual item Page 11 Safety Requirements during Operating and Maintenance = Pictograms / Waming Notices 5 = General Requirements, 5 = Health and Safety Regulations 5 2 Product Description 2:4 System Documents. é = _ System Description 6 = System Flowchart / Gireuk (ow) Diagram 7 Zz Description of System / Components g = Description of Component Parts 8 = Design Data 8 = Technical Data 8 = Thermal and Acoustic Insulation 3 = Materials 3 23 Operating Manual 11 = Startup Procedure (Commissioning) 11 = Operation of Piant and Plant Sections — not applicable 23 = Shutdown Procedure 23 4 Maintenance Manual 24 = Regular Maintenance Instructions including Safety Waring 24 = Inspection and Service Plan 27 = Spare Paris List 34 = Operating Materials (Consumables) 34 = Lubrication Chart = not applicable, 34 25 Troubleshooting 35 3 Electrical and Instrumentation and Control Equipment Documentation: Instrumentation B = Control Cabinet Allocation Pians (intemal and external) 45. = Arrangement of Devices Allocated Externally of Control Cabinet 45 = Electrical Circuit Diagram 45. = Equipment Documentation 46. = Connections or Terminal Connection Diagrams: 46. = Functional Diagrams or Program Listings for PLC 46 dices “471 Table of Contents of Appendices ar 4.2. Manufacturer Documents, Catalogs ~ Teted in Appendix Section ~ separate fle 48 = _ Mechanical Components listed in Appendix Section — separate fle a8. = Electrical, Instrumentation, Control Equipment listed in Appendix Section ~ separate fle | 48 43 Further Appendices (on demand) — no further appendices a8 5 Drawings: ‘51 List of Drawings — (Grawings shown after page 49) ae 5.2 Drawings (arrangement Drawing, Flow and Electrical Diagrams, Control Panel Layout) 48 Printed inthe sa Morel 20-60H / May / 2012 Revisor O (©2012 Kaydon Fieation, ARN Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 3 Hem: Page: @ Quality Control File a 3.2 Erection Manual — not applicable a 3 Erection Manual — not applicable wa ‘@ Supporting Technical Specifications wa “= Descriptions of Equipment Paris See 0 and M Manual (section 2.2 and 3) va, “2 Electrical and Instrumentation and Control Equipment Documentation vay ‘See O and M Manual (section 2.2 and 3) la © On-Site Quality Assurance Plan not applicable Wa 6 Time Schedule — not applicabie wa, 7 Erection Drawings — See Section 5 Drawings a = _ Arrangement Drawing with Detailed Mechanical Fastening and Electrical installation wa @ Commissioning Manual 8.1 Pre-Commissioning Checklist a 8.2 Inlial Star-Up Procedure - instructions 48 = Inia Start-Up Measures 43. = Run-Up and Functional Checks 49 Printed inthe USA Modes 20-604 May 2012 Revion 0 (©2012 KaydonFtzation. Al Rights Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 4 List of Abbreviations and Acronyms/Symbols Flow jallons per minute liters per minute Pressure psig = pounds per square inch (gauge) psid = pounds per square inch (siferentia) kglem*” kilogram per square centimeter bar = bar (1 bar = 15.5 psig = 1.02 kg/cm") Power KW= kilowatt HP = horsepower Electrical VAG = Voltage ~ Alternating Current PH-= Phase Hz = Frequency RPM = Revolutions per Minute Acronyms and Symbols * = inch #= number or pounds ISO = International Standards Organization om = parts per million 'SSU = Saybolt Seconds Universal Pred inthe usa Mode! 520-608 / May /2012/ Reviion 0 (©2012 Koydon Filion Aight Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 5 4 Safety Requirements during Operating and Maintenance - Pictograms / Warning Notices QRUUPENSINTINT SD) sete: pxrsty nce tan whi fot avoded cui erle in death or senous ny. Indicates a potentially hazardous situation which, if fot avoded; may resuk a mnar or moderate uy TE may als be uted to alert appinetUneatepracees. ~ General Requirements Kaydon's Is responsible for transiation. ual into the ni Element change-out intervals must be observed to minimize element by-passing o ing, Filter elem be char lal terminal differential ef ner, lly water removal, sed elements can be an environmental hazard, so they must be drained and disposed of properly according to local disnosal codes and reaulations, [TERRI - ‘cavdon’s customer is responsible for using proper procedures and safe handling methods ‘when unloading, moving and instaling equioment {TERE — bo nt onen vessels or close system inlet valve or system outlet valve while system isin - Health and Safety Regulations (TREES - when and if required, customer is responsible for instalina safety pressure relief device. TERRE, Ie ait heater surtace coud be no. so cauton should be exercise at altimes when inthe ‘Vicinity of the heater, DERE - 2ecau jon hazard, co q remain ‘slosed at all times during system operation, TERI - clement cnange-out presents hazardous conditions, such es slipping and lifting of heaw. Wetelements. These safety issues must be addressed by end user. Printed in the USA Mode! S20-60 Jay / 2012 / Revision 0 (©2012 Koyon Fitton, Al Rghs ReservedKaydon Filtration Model S-20-60H / Instruction and Operational Manual 6 2 Product Description 2.1 System Documents = System Description The $-20-60H Turbine Oil Purification System removes particulate and water from mineral base turbine lube oil (ISO 32, ISO 46 or ISO 68). The system consists of: ‘+ Pump Protection ‘© Basket Strainer (SB) © Pump Vacuum Gauge (VG) and Pump Vacuum Switch (VS) © Pump Discharge Pressure Gauge (PG) = OilPump ‘© 20GPM @ 150 SSU (ISO 32) @ 1750 RPM with 90 psig relief valve © Viton® Mechanical Seal ‘© Looking from fan end of motor, inlet is on left © Manufacturer: Haight Mode! 24UR © 3HP/460 VAC/3 PH/60 Hz/ TEFC / 182TC Frame ‘© Manufacturer: Leeson G130326.10 + Check Valve (1-122 inch) + OilHeater o 15KW (© Process Thermocouple (TC1) and High Temperature (Overtemp) Thermocouple (C2) * Oil Sampling Ports ‘© Inlet (SP1) and Outlet (SP2) + ASME Code Pre-Filter Pressure Vessel © Differential Pressure Gauge and Switch (DPS1) ‘© Oi Drain Ball Vaive (3/4 inch) ~ connected to common oil drain port (3/4 inch FNPT) © Air Eliminator (AV) with Manual isolation Ball Valve (4 inch) ‘+ ASME Code Coalescer Pressure Vessel Differential Pressure Gauge and Switch (DPS2) il Drain Ball Valve (3/4 inch) ~ connected to common oil drain port (3/4 inch FNPT) Sight Glass (SG) Pressure Relief Valve (PRV) - set at 150 psig Air Eliminator with Manual Isolation Ball Vaive (%4 inch) ‘Automatic Water Drain Assembly + Level Switch (LS) * Solenoid Valve (S) with Isolation Ball Valve (3/4 inch) + Water Meter (WM) ‘+ Mounting Skid ‘0. Drip Pan with 2 inch (50.8 mm) Drip Lip. Includes Fork Lif Access and Lifting Lugs Exterior Coaling - Epoxy Control Panel © ON/OFF Switch © Alarm Light indicators ‘+ Heater ON Light + Pre-ilter and Coalescer Element Terminal (change-out) Light ‘+ “Tow flow” and diy “strainer Alarm Lights + Temperature Controller ‘© Disconnect Handle + Portability Kit ‘© Casters, Tow Bar, and Hoses 00000 Printed inthe USA ‘More S20-60H / May / 2012 Revision 0 (©2012 Kaydon Fitvation Al ght Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 7 - System Flowchart / Circuit (Flow) Diagram [oq wo logy way on manual air eliminator solenoid sight glass (upper and lower a | Flow Diagram Printed inthe USA Medes 20-604 May 2012 Revision (©2012 Kaydon Fitton, ll Rahs Reserved.Kaydon Filtration Model S-20-6QH / Instruction and Operational Manual 8 2.2 Description of System / Components = Description of Component Parts ‘See Section 4 Appendices (all major component data sheets with descriptions are listed in Appendix section) - Design Data The design criteria for a turbine oil purification system {s to provide oil cleanliness to less than ISO cleanliness code 18/16/13 and reduce water content fo less than 200 ppm. The design data target for cleanliness and water content are met with the Model S-20-60H turbine oil purification system, ‘The filtration pressure vessel design data is per ASME Code section VIll. Welding Procedures/Welders Qualifications are in accordance with ASME Section IX_ Weld Fabrication/Examination/inspection is in accordance with ASME Section Vil, Division 1, Latest Edition ~ 2007, - Technical Data Filtration Element Technical Data Model K1400 val Technical Tested and Rated per ISO 16889 — “Evaluation of Hydraulic Oil Filter Element” Rating: 99.9% efficient at 5.1 micron (Bs; = 1000) Goalescer Element Technical Data Model K2100 Particulate Removal Technical Data ‘Tested and Rated per ISO 16889 — “Evaluation of Hydraulic Oil Filter Element” Rating: 99.9% efficient at 5.1 micron (Bs = 1000) Separator Element Technicat Data Model K3100 culate Removal ‘Tested and Rated per ISO 16889 - “Evaluation of Hydraulic Oil Filter Element” Rating: 99.9% efficient at 4 2 micron (42 = 1000) Water Removal Technical Data Model K2100 and K3100 Combination 1. Element and Separ al Tech Tested and Rated per Kaydon Filtration Testing Protocol Water Removal Efficiency: 98% Printed inthe USA Model 20:60 / May / 2012 /Revsion (©2012 Kaydon tration. Al Righs Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 9 5,000 ppm influent water concentration 100 ppm effiuent water concentration - Thermal and Acoustic Insulation Thermal Insulation: none used (not applicable) Acoustic Insulation: none used (not applicable) ~ operation does not exceed 85 decibels - Materials Vessels Carbon Steel Top Head, Shell Flange and Bottom Head = SA 516 Grade 70 Shell = SA-53 Grade B Vessel Ratings Maximum Allowable Working Pressure = 150 psig @ 250 F Process Piping Schedule 40 SA-53/106 grade B Flanges - SA-105, 150# Couplings - SA-105, 3000# 94" NPT SA-105 3000# couplings (oil/water drain) Drain Lines 2%" carbon steel tubing ASTM-A-179 °° compression tube fittings Valve Material List Key Temperature Valve Kayden | size | Qty.| Manufacturer | "2"Precure, | Material Ratings Check Valve | AOIOI8S | 15" | 1 | Flowserve(Voet) | 2000 psig | Carbon Steel ‘Check Valve @ 100F ‘AclO5 Piston Type 1.5" FNPT Class 800 Part No. SW701ZLB. Ball Vahe TosHF |W | 3 | Apollo 70-104-01 | 400psi@ | forged bronze Bal Valve 200F body, teflon 3/4°NPT seat, chrome Lever Type Handle plated brass Full Port ball Solenoid Valve | ADIOI4S |" | 1 | ASCO T30 psigat | brass IKF#210G9S120VAC | 180F 3/4” FNPT, 120 VAC, Type 4X 2-Way Pinegin tn USA Model $.20-608 / ay / 2012 / Revision (©2012 KaydonFtration A ighs Reserve.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 10 Ball Valve 16582 | % | 2 | Apollo 70-103-01 240 psig at | bronze Ball Valve 250F 12" NPT 600 # Bronze Lever Type Handle Ball Valve ‘AoIo06E | [9 | Mazzer A-126-4 D0 psig@ | Chrome Ball Valve 200 plated brass V/s" NPT body & ball, Grip Handle teflon seals Printed the USA Model $-20-60H/ May 2012 Revien 0 (©2012 Kaydon tation, Aleks Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 14 2.3 Operating Manual - Start-Up Procedure (Commissioning) IMPORTANT: If itis known that a large amount of water (greater than 5%) has entered into oil reservoir, itis recommended that the excess free water be drained from the bottom of the oil reservoir before: starting, IMPORTANT: The oll purifier plus piping (hoses) to and from ol purifier wil emove an appreciable ‘amount of ol from reservoir. Be sure to have make-up ol available, in effort to reduce possibilty of triggering oil reservoir “low oil" level alarm. NOTE: Below provides an ilustration of coalescer vessel with number of coalescer elements and separator elements. Filter # 2 - Filter/Separator (Coalescer Vessel) Printed inthe usa Mode s-20-60H (May 2012 Revison0 (©2012 Rayon Firion. A Rghs Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 12 IMPORTANT: Verify elements in Filter No. 1 (orefiter) and Filter No. 2 (coalesce) are installed and element hold-downs are secure. Check tightness of element hold-downs and secure filter id covers on Filter No. 1 (prefiter) & Filter No. 2 (coalesce). Verification Procedure ‘Shutdown System — Turn ON/OFF switch to “OFF" position, MCCB to “OFF* position, and power cord is not installed into an electrical receptacle outlet. (EERIE - Veriry POWER Is OFF BEFORE ANY MAINTENANCE IS ACCOMPLISHED. Use proper Lockout/Tagout procedures. See following example procedure: Lockout/Tagout ‘The Lockout/Tagout Standard was created to help reduce death and injury rate caused by te unexpected energizing or start-up of machines or the release of stored energy, Normal production operations, cords and plugs under exclusive Control and hot tap operations are hot covered. Ths standard apples to energy sources such as electrical, mechenieal, hhydraule, chemical, nuclear, and thermal. Procedures for annlving lockyta ‘Before the shutdown, know the unit and power sources Power dawn equipment (remove power from equipment) Isolate power source(s) ‘ply lock andfor tag (Oge proper techniques, personal protective equipment, and test measuring devices to verity electrical circus e-energized Release residual eneroy [Atermptf0 power up (0 verly power is OFF Procedure for removing lock/teg: 4. Inspect machine and/or equipment 2. Gwe notitestion to personne! 3. Remove lockouttagout device 2. Ifinstalled, close system inlet and outlet valves (system inleVoutlet isolation valve installation is ‘customer responsibilty) Vessel Lid Removal Procedures for Lid Removal for Filter 1 and Filter 2 1, The vessel id fasteners include nuts, boltss, and lockwashers. See ‘Table of Fastener Descriptions and Torque Ratings.” Table of Fastener Descriptions and Torque Ratings. Filter — [Nut Bott ‘Lockwasher Fiter 7 | Part Number 28004 | Part Number 21610 | Part Number 26267 Hex Nut(Heavy) | Hex Head Cap Screw | % inch Black Oxide SA-325 233 inch Wath Block Oxide Piated__| 153 inch Thick. Fiera] Part Number 26007 | Part Number 21735 | Part Number 29272 HexNut(Heay) | Hex Head Cap Serew | % inch Y%inch-1UNC | %inch = 1OUNC At94-2H ‘inches Long SAE Standard Black Oxide SA.325 .233 inch Wath Black Oxide Plated 1183 inch Thick. = Rating Yeinen13UNC | %inch-13UNC 194-24 2 pinch Long SAE Standard Printed ia the USA Model 20:68 / may /2012/ Reson 0 (©2012 Kaydon Fitration- A ighs ReservedKaydon Filtration Model S-20-60H / Instruction and Operational Manual 13 2. Remove bolts, nuts and lockwashers for Filter No, 4 and Filter No. 2 Nuts Bolts Lockwashers Filter No. 1 Prefilter Lid Illustration — Top View Filter No. 2 Coalescer Lid Illustration — Printed inthe USA Top View More -20-604 [May 2012 / Revision (©2012 Kayan Frain. A Rghs Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 14 3. Remove fier id cover(s) to access iter elements ‘a, Filer vessel No. 2 utlizes a davit arm with a lidfting nut. To assist in raising the lid (after bolts, nuts, and lockwashers have been removed); tighten the lid-lifting nut to raise Filer No, 2 id. After Fiter No. 2 lid has clearly been lifted and free to rotate, rotate lid away from vessel to access coalescer and separator elements. 4, Verify iter elements are installed and vessel o-rings are installed. Do not remove elements, only veniy they are installed and hold-downs are secure. 5 Check Hoki Down fortightness. Verify elements are securely sealed by hold-down by twisting hold-down with hand, verifying compression upon element flat gasket. No tools required, hand- ighten only. See Photo 1 and Illustration 1 NOTE: Vessel shown without element installed. Hold Dow ) z uJ ona stand Pie Iilestration 4: Mlustration of Fliter No. 4 and Filter No. 2 hold-down, standpipe and element 6. Replace fiter cover and re-install nuts, lackwashers, and bolts. 2. Tighten bolts, nuts, lockwashers in a criss-cross pattem to help prevent damaging vessel o-fings. Criss-Cross pattern procedure helps create a good seal with ld o-rings, ». Tighten nuts to torque rating listed in “Table of Fastener Descriptions and Torque Ratings" Hose Connections (See Iilustration 2: Hose to System Connection) A female Kamiock® is stalled at end of each hose. Photo 1: Inside Pre-Filter (Fiter No. 1) Ves: ‘An extra set of male NPT mating adaptors (aly. = 2) are shipped with each system, These male NPT ‘mating adaptors are included for installation by customer to turbine oil reservoirs. (See Kamlock and Mating Adaptor data sheet located in *Descnption of Component Parts" section.) Each hose end (suction hose and discharge hose) will be supplied with a Female Kamlock® (633 ‘Coupler = Hose Shank). A companion male NPT mating adaptor (633 F Male NPT) is shipped loose for installation at oil reservoir, These male NPT mating adaptors are installed to provide a connection tot hoses. Customer must install each NPT mating adaptor to the reservoir (strongly recommend an isolation ball valve installed between reservoir and 633 F Male NPT mating adaptor). With this configuration, a ‘connection can be made from the inlet and outlet of each system to the oil reservoir suction and discharge connections. Itis customer's responsibilty to install male NPT mating adaptors to oll reservoir (G08 Illustration 3: Sketch of Hose Installation) Printed inthe USA Mode $20.60 ty 2032 Revision O (©2012 Rayon Firalion A Rights Reserved.Kaydon Fittration Model S-20-60H / instruction and Operational Manual 15, Flange Suction = 2 Inch (part no. 38787) Discharge = 1-1/2 inch (part ne. 14325) Flange Type: 150# Ralsed Face Male NPT Mating Adaptor 4-412 inch (part no. 4900519) 2 inch (part no. A900520) Hever | | Swetion:2 inch (part no. asoosis) a, Discharge: 172 mem (part no ASODS17) — Includes female Karlock on each end. Hose NOTE: Customer must install a Male NPT Mating ‘Adaptor on oll reservoir for connection of hoses. justration 2: Hose to System Connection Printed inthe USA Mede!.20-60H / May 2012 / Revision 0 (©2012 kaydon Frain, ll Rights Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 16 Pre-installed on oil purifier Female outlet, Kamlock® Discharge Oil Pu 1 tose msetiy (1-12 inch) i 1 a Discharge ao > {1-2 inch) Female 4 Komlock® LAR DARD DADA MBVA96 Male NPT Mating Pre-installed on aes Jose and must it purifi (shipy loose and must oil purifier inlet; Female be installed by customer) Kamlock® \ Oil Purifier ~_ \V by ementiy ma Suction - Am 1 (inch) i Suction OU Reservoir Female (2 inch) AW Kamlock® MBVAS7_| jijustration 3: Sketch of Hose Installation VALVE POSITIONS Before starting system, open and close valves according to following (see next page): View Flow Diagram Drawing (Flow Diagram FDS200081-1) Located in Drawings Section (Section 5) © Verify that ALL suction and retum valves are OPEN between the system and oil reservoir. © System Inlet Vaive ~ open (inlet valve supplied by customer) (© System Outlet Valve — open (inlet valve supplied by customer) NOTE: Inle¥Outlet isolation valves are not supplied by manufacturer. Its customer responsibility to install isolation valves. © Oil Drain Valves — closed (Valve 13 and Valve 13) NOTE: Oil drain valves are located at base of fiter vessels NOTE: An oil drain valve is supplied at base of each vessel and these cil drain valves are connected to a ‘common oil drain. All ol drain line valves must be closed during start-up and normal operation. ‘© Automatic Water Drain (AWD) Isolation Valve - closed NOTE: AWD isolation valve located at the base of coalescerfiter vessel, upstream of solenoid valve. Priest the USA Mode! 520-608 / May / 2012 / Revision 0 (©2012 Kayon Fitton, All ghs Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 17 ‘© Water Level Sight Glass — upper & lower valves — closed (drain cock on bottom - CLOSED) ‘© Manval Isolation Air Eliminator Valves (AEV) - open © Verify all other valves are in folowing position: Inlet and Outlet Sample Ports (SP#1 and SP#2)— closed Vacuum Switch (VS) Isolation Valve - open Vacuum Gauge (VG) Isolation Valve - open Pressure Gauge (PG) Isolation Valve — open Differential Pressure Gauge/Switch (DPS#1 and DPS#2) Isolation Valves - open ‘© Verify all other valves in suction and return piping are open. manual air eliminator level sight glass (upper and lower salves) LL. Flow Diagram Printed inthe USA Mode! $20-60H / Mey / 2012 Revision 0 (©2012 KaydonFieation. Aight Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 18 150 psig Pressure Relief Valve (for outdoor use) 450 psig Pressure Relief Valve (PRV) — The 1-1/4" NPT PRV is mounted on the side of coalescer vessel. ‘The PRV should be piped back to the oil reservoir. The PRV releases internal pressures developed due to thermal expansion. Control Panel ‘The control panel is rated NEMA 4X~ corrosion, moisture, and dust proof. Electrical Installation Overview ‘The standard operating voltage is 460 VAC / 3 PHASE / 60 Hz /24 amps REFERENCE: Wiring Diagram / Control Panel Layout (included in DRAWINGS section — section 5) Wiring Diagram: WD950840-Dsc Control Panel Layout Drawing: 0950840-Dsc Verify voltage and hertz rating listed on system nameplate matches plant operating voltage. Total amperage and voltage requirements are shown on electrical cabinet nameplate and electrical drawing located in Drawings Seton (section 8). Determine appropriate siz electial wre requirements to meet applicable local, plant, and country code requiremer Note: The unit is equipped with disconnect (molded case circuit breaker— 35 AMP). 4. When installing system, verify your incoming electrical power is “OFF” and secured. 2. Verify MCCB Handle (located on control panel on upper right hand side) isin “OFF” position. 3. A type SOOW exible electrical power cord is installed and supplied with unit. NOTE: Power cord is not installed with an electrical plug. End user must source and install appropriate plug for use with your power outlet receptacles. ‘Type SOOW Flexible Power Cords are permitted for use as specified by Article 400 and related articles of the 2011 National Electrical Code. Type SOOW Flexible Power Cords are designed for ‘extra hard usage on industrial equipment, heavy tools, battery chargers, portable lights welding leads, marine dockside power, power extensions and mining applications. SOOW Cord = Service Cord (up to 600 Volts) (00 = Oil Resistant both inside insulation and outside jacket W= Weather/water resistance ‘Conductor Size (AWG) = 8/4 Conductor Stranding (WAWG) = 65 x 0159 ‘Nominal Insulation Thickness (inches) = .08 ‘Nominal Jacket Thickness (inches) = .125 ‘Nominal Overall Diameter (inches) = 95 Weight (pounds per 1000 feet) = 616 Ampacity = 35, 4, Verify ON/OFF switch located on control panel is in “OFF” position. Printed in the USA ‘Mariel -2.60H May /2012 Revision 0 (©2012 rayon Filtration, Al Rights Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 19 5. Connect electrical power cord with plug (supplied and installed by end user) to appropriate receptacle. 6. After power cord is inserted into power outlet receptacle, again, verity ON/OFF switch located on ‘control panel is in “OFF” position, and MCCB handle is in “OFF* position 7. Apply your incoming power and turn MMCB handle to “ON position. This provides power to system, but does not start system, DO NOT TURN ON/OFF SWITCH TO “ON” POSITION. 8. Before starting unit, venty temperature controller set point is set at 100F. Process Temperature In Home Page, F willbe Huminated. Sot Point Temperaturg In Home Page, adjusts sat pln. Pros UP or DOWN arrow to adjust. Unless set ‘polnt must be changed for a Specific reason, factory Setting of 100F should not be adjusted, Unless the display Is already st Home Page (the Home Page Is dlaplayod when initally powered), press Inilty bution for two ‘seconds to goto Home Page. At Home page, you will 20 tho Process Temperature (current temperature of ol) and tho Set Point Tomporature lomperature that ol hater will energize, Temperature Controller ‘Temperature Controller Set Point Temperature Verification Verity Set Point is 100F. See above for location of Set Point Temperature on Temperature Controller. UP and DOWN arrows adjust Set Point Temperature. Only adjust if Temperature Controller does not display Set Point Temperature of 100F. il Heater Notes + When heater is operating, the oil temperature rise per pass is approximately 2F-3F. NOTE: Once the power output matches the heat losses, the temperature increase will cease, + When dealing with a specific volume, flow rate does not affect the power requirement because the same number of BTUs is being input to raise oll temperature. Printed in the usa Mores 20-604 [ay] 2012 /Revisond (©2012 Kayan Filtration, Aight Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 20 NOTE: The heater will not operate without ol low through the unit. Once oil flow is confirmed by the flow switch, and the process temperature is below the set point, the heater will energize, TO START SYSTEM ‘At control panel, turn ON/OFF switch to “ON” position. The system will begin pumping oil IMPORTANT: Immediately after starting system, check proper rotation of the pump. ROTATION IS VIEWED FROM THE MOTOR FAN END. Rotation arrow is located on motor. Verify motor is in proper rotation. Hf the motor is operating in reverse, turn ON/OFF switch to *OFF* position and turn MCCB to “OFF” position. Use proper Lockout/Tagout procedures to reverse motor rotation. Use proper Lockout/Tagout procedures. See following example procedure VERIFY POWER IS OFF BEFORE ANY MAINTENANCE IS ACCOMPLISHED. Lockout/Fagout ‘The Lockout/Tagout Standard was created to help reduce death and Injury rate caused by the unexpected energizing or ‘start-up of machines or the relese of stored energy. Normal production operations, cords and plugs under exclusive Control, and hot tap operations are not covered. This standard apples to energy sources such as electrical, mechacica, ‘nydraulte, chemical, nuclear, and thermal Procedures tor anpiving lock/tag: 8. Before the shutdown, know the unit and power sources 9. Power down equipment (remave power from equipment) 10. Isolate power source(s) 11. Apply lode anajor tag 12, Use proper techniques, personal protective equipment, and test measuring devices to verity electrical cuit Is. de-energized 13, Release residual eneroy 14. Atternpt to power up 19 verty power is OFF Procedure for cemavina locktag: 4. Inspect machine and/or equipment 5. Give notincation to personne 6, Remove lockout/taqaut device After performing proper Lockou/Tagout procedure, open control panel and swap any power supply wires (L1, L2, L3) located after MCCB. Repeat the test for pump rotation. After verifying proper motor rotation, restart system (Tum ON/OFF switch to “ON” position). ‘The system wil initially be in @ “low flow’ condition, ‘The LOW FLOW ight will be illuminated. The “LOW FLOW “light should cease illumination after flow ‘switch has sensed oil flow. This normally takes less than 2 minutes for ol flow to reach flow switch. I system continues to operate in ‘low flow" condition ("low flow’ light remains illuminated) for more than 2 ‘minutes, turn ON/OFF switch to *OFF* position, Go to Trouble Shooting section and read Low Oil Flow Light, Low Flow Condition ~ Typical Reasons, or Pump Problems. Printed in the USA ‘Mode 20.504 May /2012 Revision O (©2012 rayon Fitraion, Al Rights Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 21 NOTE: Illumination of the “low flow’ light indicates a low flow condition, and this condition prevents the heater from energizing. The flow switch must sense flow before heater wil operate. Under normal ‘operation, ifthe system enters into a “low flow’ condition, the heater, if operating (depends on heater set point, which is factory set at 100F), will hut down. NOTE: If oil reservoir drops below critical ci level, or breaks siphon, or system outlet valve is closed, the low cil flow alarm (ight) wil illuminate and the system heater will shut down. Correct problem before restarting the system. See Trouble Shooting section and read Low Oil Flow Light, Low Flow Condition Typical Reasons, or Pump Problems. IMPORTANT: The ‘low flow’ light ONLY informs operator of low flow condition, it does not shut down pump. ‘0 When the system has completely filled with oil (should take approximately 7-10 minutes), open upper ‘and lower valves on the water sight glass. Remember, the drain cock on the bottom of the sight glass, remains CLOSED. ‘© As system i filing with oi, place your finger over the automatic air eliminator vaive outlets to verity if air is being displaced from vessels and escaping through the automatic air eliminator vaives. After system thas been in operation for 7-10 minutes, air will cease to escape through automatic air eliminator valves. ‘This is an indication that vessels are completely full. Check all automatic air eliminator valves for leaks. ‘© Manual air isolation valves (located between vessel(s) and automatic air release valve) remain open during system operation. © Pump pressure gauge, located on discharge side of pump, must read 10 psig (minimum), Ifless than 10 psig, close outlet vaive (supplied and installed by end user) slightly until it indicates 10-psig (.7 g/cm). If the pressure is greater than 50 psig (3.5 kg/cm), check for unnecessary restrictions downstream of system outlet, ‘The other gauges should indicate as follows: © Inlet Vacuum Gauge = less than 5" Hg (.17 BAR) © Diflerential Pressure Gauge(s) = less than 5 psid (.35 kg/cm) If verifications are consistent with manual, system is operating normally. Next, check automatic water drain assembly. ‘Automatic Water Drain Assembly ‘After water sight glass upper and lower valves have been opened, open AWD isolation water drain valve (located before the solenoid valve) IMPORTANT: After opening AWD isolation water drain valve, verily no ol is being released through the water drain ‘Automatic Water Drain Assembly I the sight glass completely full of water and the Water Meter has not shown movement, stop the system. (See Trouble shooting section). Water Drain Function ‘As water is separated from turbine ol, it will collect in bottom of coalesceriseparator vessel. Water level can be seen in sight glass, located on side of the coalescer/separator vessel. When water level rises to cause float switch to rise, itwill rigger a 30 second timer. When 30-second timer expires, water solenoid valve will open and discharge water. The 30-second delay gives water more time to accumulate before solenoid vaive opens. Printed in the USA Made 20-604 May / 2012 / Revision {22012 Koydon tration. Al lghts ReserveKaydon Filtration Model S-20-60H / Instruction and Operational Manual 22 NOTE: Water wil accumulate in water site glass to approximately 1 full. When automatic water drain releases water, water level wil drop only about 1 inch from original position, so once water has accumulated to fil sight glass % full, it will remain at this approximate level until annual service is. performed, which requires a complete draining of system. float switch (inside! water sight glass solenoid valve. water meter Automatic Water Drain Assembly ‘After check of automatic water drain is performed and verified to be operating correctly, system is ‘operating property. ried nthe USA Model S-20-60H /May/2012/ Revision 0 {©2012 Kayson tration. Al gh Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 23 - Operation of Plant and Plant Sections Not applicable - Shutdown Procedure Warnit valve or system outlet valve whil isin ‘operation, + Tum ON/OFF switch to “OFF” position. © transferring system to another reservoir, tum MCCB handle to "OFF" position and remove power cord plug from receptacle outlet. Wrap power cord unto system using power cord rack. IF STORING SYSTEM OR FOR USE WITH ANOTHER RESERVOIR ‘© Ifthe system will be used for another reservoir or placed in a storage area ‘© Disconnect hoses from system (drain oil from hoses) and store hoses on a hose rack. © Drain vessels completely, using oll drain connections on vessels. (Verify manual air isolation valves are open) © Close system inlet and outlet valves © Remove all elements More $:20-60H ay / 2012 Revision 0 (©2012 Kayan Filtration, Al Rahs Reserved.Kaydon Filtration Model $-20-60H / Instruction and Operational Manual 24 2.4 Maintenance Manual - Regular Maintenance Instructions including Safety Warnings — Element change-out presents hazardous conditions, such as slipping and lifting of heavy, Beara in Tae noucs ral be eacresued Oy te vot. "*Gsmant change ou eras mun bo cheered to mine element by posing or collapsing. Filter elements must be changed when differential reaches terminal differential pressure or when they have been in service for 6-months, Exceeding the 6-month time period can cause poor Sa deacon amacahy waist rao peterson EBERIEE seo ciomens can be on envionmertal hazard, so they must be drained and lsposed of properly according to local, state and federal codes. Element & O-Ring Replacement 1. Shutdown System — Tum ONIOFF switch to “OFF” position and tum MCCB handle to “OFF” position. (TERRIM - verry Power is OFF BEFORE ANY MAINTENANCE IS ACCOMPLISHED. 2. Close inlet and outlet valves. 3. Clean strainer and strainer basket Inlet Strainer Basket Inspection and Cleaning - Inspect and clean strainer basket using this procedure: 1. Close manual air release isolation valve on top of vessel. With the manual air valve closed, the strainer can be serviced without draining the fier vessel NOTE: Strainer Drain does not need to open to perform maintenance. 2. Remove strainer lid by removing strainer nuts from strainer bolts. 3. Aller strainer id is removed, remove strainer basket by grasping strainer basket handle. Lift strainer basket completely out of strainer housing. 4. Inspect strainer basket for cuts, dents, and uniform perforation pattern. 5. Remove any debris that has collected inside strainer housing and on strainer basket. 6. Remove strainer gasket and replace with a new strainer gasket. 7. Re-install strainer baskel, strainer lid, and re-install strainer nuts unto strainer botts. Tighten strainer bolts to 407 Ibs. 4. After strainer is serviced, open manual air release valves on prefilter vessel and coalescer vessel. 5. Open oil drain valves on prefiter and coalescer vessel, A common oil drain line is added, and oil drain valves at vessels and in common oil drain ine must be opened (It is not necessary to drain the fiter vessel(s) completely, just enough to remove the elements. However, once per year each fter must be drained completely and checked for contamination that has settled. Clean out debris found inside vessels.) (GRIER The fitter elements need replacement once every 6 months (never exceed 1 year), or when the differential pressure reaches 25 psid (prefliter) and 15 psid (coalescer). Mechanical assistance is not needed for element change, but is recommended to reduce operator back strain. Approximate weights of wet (used) filter elements are: Prited in the USA Model S.20-60H/ way /2012/ Revision (©2012 KaydonFteation, lg Reserved.Kaydon Filtration Model $-20-60H / Instruction and Operational Manual 25, Approximate Weight of Wet Filter Elements 1100 = 20 pounds each (9.1 KG) K2100 = 25 pounds each (11.3 KG) K3100 = 16 pounds each (7.3 KG) Fitter Element Replacement 1, Remove filter cover(s) to access filter elements. See page 11, 12, 13, and 14 for additional information and guidance. a, The coslescing/separator vessel utiizes a davit arm with a lid-ifting nut. To assist in raising lid (after lid bolts have been removed); tighten lid-ifting nut to raise lid. Once lid has clearly been lifted and free to rotate, rotate lid away from vessel to access the filter elements. 2. Remove element hold-downs. (no tools required) 3. Remove filter elements and o-rings. (elements are heavy, take caution when removing) 4, Properly dispose of the used filter elements and o-rings. (see “Procedure for Removal and Handling of Used Elements) 5. Install new elements, o-ings and reinstall element hold-downs (hand-tighten, no tool required). 6. Replace fter cover and tighten bolts to 50 ft-tbs ~ 75 fl.-tbs. 4, Tighten lid boks ina criss-cross patter to help prevent damaging o-ring and to create a good seal 7. The system is ready for operation. Procedure for Removal and Handling of Used Elements Non-drained used oil fier elements are classified as hazardous material (waste) per Federal EPA law 40 CFR 261.3 (a) (2) (iv) and 40 CFR 262.11 c (2). Federal, Sate, and Local laws all across America and ‘most other countries around the world require that oll be removed from all cil iter elements before disposing. Residual ol generally remains inthe fer as a result of ol saturation inthe fitration media and ‘molecular bonding to the metal. Proper Drainage of Used Oit Used oll must be properly removed from oil fiters prior to disposal. Used oi fiers are required to be hot-drained. There are four distinct methods of hot-daining that can be used: Hot Draining — Draining the ol fiter when the oil is hot compared to when the oil is cold or ambient temperature will aid in the oll draining process. Hot-draining means draining oil close to ‘rat operating temperature. When the filer is removed from the system, it should be placed with ‘gaskel side down in a drain pan or drain containment area. The fiter element should then be allowed to drain for 12-24 hours. ‘Crushing and Draining (optional, but preffered) - Crush the used fiter element by a ‘mechanical, pneumatic, or hydraulic device to squeeze out the used oil and compact the remaining fiter materials. Air Pressure Draining (optional) - Place the fiter element into a device where air pressure forces the used oil out of the filter. NOTE: Many state requirements governing used oil management are often more stringent than federal regulations, Contact your state authorities to find out if there are any additional regulations or recommendations relating to draining of oi iter. Printed inthe USA ‘Moe S 20-604 / May/ 2012 Revision (©2012 KajdonFiration. A Rlghts Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 26 Disposal If recycling is not a viable option, the used filers must be disposed of. Used oil fiters that have been properiy drained may be disposed of as nonhazardous solid waste in any municipal solid waste landfil. However, since some states do not alow the disposal of used olf fiters in solid waste landfls, check with your state authority. Requirements for Cold Conditions Shutdown (Short-Term and Extended Shutdown) + Short Term = less than 90 days [At temperatures below 32 degrees F (0 degress Celcius) and down to -7 degress F (-21 degrees Celcius), unheated oil and filler elements can remain in lube oil conditioner during system downtime. + Extended Shutdown = greater than 90 days ‘At temperatures below 32 degrees F (0 degress Celcius) and down to -7 degress F (-21 degrees Celcius), unheated cil and filter elements must be removed from lube oil conditioner. The system must be completely drained, After draining completely and elements removed, inspect the interior of the vessels, If debris has settled in the bottom, use a Shop-VACA (or equivalent equipment) to clean the interior of vessels. When system is placed back into service, new elements must be installed. NOTE: Extreme hot or cold temperatures can cause oil degradation. Oil additives with poor solubility may precipitate during extend hot or cold storage periods. ‘lt Sampling Requirements and Procedures «Take sample an oil sample container suppied by Kaydon Filtration or another approved source for sampling purposes only. + Take oll sample from designated oil sample port locations while system is in operation, + Allow oil to pass through sample port for 15 seconds into another container to clear the sample port tubing before sample is discharged into approved cil sample container. NOTE: Never take a sample from the reservoir. + Mark Sample bottle carefully, accurately, and immediately upon taking the sample. Be sure to not reverse INLET and OULET samples. + An inlet sample and outlet sample needs to be taken upon intial start-up of the system to determine efficiency. After the initial sample is taken, ONLY take an outlet sample. A representative outlet sample should provide sampling result of ISO 15/13/11 or less and 100 ppm or less water content, + IMPORTANT: To accurately determine your system is providing the needed oil quality, an outlet sample must be taken each month, Failure to implement a regular scheduled oil sample schedule prevents an accurate trend analysis. Printed in the USA Meret 20604 May /2012 Revision 0 (©2012 taydon Fitraion, Al ght Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 27 - Inspection and Service Plan ‘Once per year, annual service and inspections must be performed to provide system longevity and minimize problems during restarts. ‘Shutdown Procedure: ‘Shutdown System — ‘Turn ON/OFF switch to “OFF” position, turn MCCB handle to “OFF” position, and remove power cord from receptacle outlet. (TEESInG - veriry POWER IS OFF BEFORE ANY MAINTENANCE IS ACCOMPLISHED. Close system inlet and outlet isolation valves (supplied by end-user). 1 ~ After following shut down procedure, open isolation valves on automatic air release valves. 2 Verify that oil drain is plumbed to an acceptable container or sludge pond. '3— Open isolation valves ofthe oil drain plumbing and COMPLETELY drain entire system. 4— Remove and manually clean strainer located at inlet port of system. See “Inlet Strainer Basket Inspection and Cleaning” section below. NOTE: DO NOT use any solvents or industrial cleaners on any surface that comes into contact wth turbine oil 5 ~ Open pre fiter and coalescing vessels. Remove and properly dispose of ai fit elements {8 — Using lint free rags or absorbent pads attached to wooden handles such as a broom stick so as not to damage epoxy coating of interior of vessels, swab and clean bottom area of all vessels. 7 = Remove o-rings from vessel lid flanges and thoroughly clean all ol from the o-ring grooves. ‘8 — Replace vessel lids on all vessels and tighten lid bolts in a star pattern 9— Verity that all valves are closed that may be exposed to elements. Such as automatic ar bleeds, ‘sample ports, oll drain valves, water drain valves, and the inlet and outlet isolation ball valves. 10- Upon reactivating system, follow steps outlined in system start up procedure. ‘The following inspections must be performed annually: Inlet Strainer Basket Inspection and Cleaning - Inspect and clean strainer basket using this procedure: 4, STOP System. (tum system off) 2. Close manual air release isolation valves on top of vessels. With the manual air valves closed, the strainer can be serviced without draining the fier vessels. NOTE: Strainer Drain does not need to open to perform maintenance Remove strainer lid by removing strainer nuts from strainer bots, After strainer lid is remioved, remove strainer basket by grasping strainer basket handle. Lift strainer basket completely out of strainer housing Inspect strainer basket for cuts, dents, and uniform perforation pattern Remove any debris that has collected on strainer basket. Remove strainer gasket and replace with a new strainer gasket, Re-Install strainer basket, strainer lid, and re-install strainer nuts unto strainer bots. Tighten strainer bolts to 40 ft-lbs Priged inthe USA Model $-20-60 jay /2012/ Revision {©2012 Kayon Frito. Al Rg Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 28 Strainer Gasket Strainer Bolts, Sight Glass - remove and clean gauge glass NOTE: Before cleaning gauge glass, order two gauge glass rubber bushing seals. (Part Number 03214, ‘quantity required = two)) Procedure: 4. STOP System (turn system off) - Close automatic air release isolation valve at top of coalescer vessel 2. Before closing upper and lower gauge valves on sight glass assembly, allow system to cool and ‘equalize pressure by beginning gauge glass removal operation 30 minutes after system has been turned off 3. Find a bucket that holds at least + gallon. Place underneath sight glass assembly. Open drain cock valve. (Oil will spill as drain is open and gauge glass is removed.) 4. Close hand wheels, 5. Loosen upper and lower gauge glass nuts. 6. Lit gauge glass up from lower gauge valve, and then lower it down from upper gauge valve to free the gauge glass from the assembly. 7. Discard seals. 8. Clean inside of gauge glass with water. (do not use any type of cleaning agent) 9. Re-install glass gauge (with new seals) in reverse order it was removed. Printed inthe USA Model $20-60H / May /2012/ Revision (©2012 Kaydon Farin. A Rights Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 20 10. Hand-tighten upper and lower glass nuts, and after hand tighten, use a wrench and tighten another % tum. 11. Close drain cock valve and open upper and lower gauge valves, 42, Check for leakage. Upper Upper Gauge Gauge Gtass, Nat Hand Wheels Drain Cook Valve (normally closed) Example Sight Glass ~ not exact sight glass on system Printed inthe USA Model $20-60H /May 2012 / Revision 0 (©2012 Kaydon Frain, A Rigs Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 30 ‘Automatic Water Drain Assembly - verify operational condition Solenoid Val disassemble, inspect, and clean - replace if necessary 314” FNPT / Brass Body / 120 AC / Type 4X /2-Way ASCO JKF8210G95-120AC MAINTENANCE INSTRUCTIONS ‘2WAY INTERNAL PILOT OPERATED SOLENOID VALVES: HUNG DIAPRAGM — 28, V2 AND a4 NPT. NORMALLY CLOSED OPERATION a vag Cnet etagencostcat ids Yrage meet Solenoid Valve ER pena 5 Bota nage case le td dean ae, Ree 3 Ste atpfee hd osechpre rn eer (SOUL REPLACEMENT ert ie “rf sce peep nd mens ads Proce the Brass Body " ENPT eae ad aig eaters 420 AC {AUTO Sa be ly eae ho rang od ‘Type 4X YALVEDHEASHEMDLY, (Rater Fut 28083) Bareeaahy tise eave nr re 2-Way $5 Seca eh on cores ASCO JKF8210G95-120AC oc anagrams apace ‘ampic ce Pate Re be om Printed inthe USA Mel S-20-604 / May 2012 / Revision (©2012 Kaydon Fitration. lights ReservedKaydon Filtration Mode! $-20-G0H / Instruction and Operational Manual 31 TAINING CAPA S Bo-terannscur se suerte Ta meine re ran TOE Tonoue swe sene nenesrtog ang ‘iehroncnroows. oe CREWS) purine ontceet emrasmone aeeare wea us we conernna eSrapannacasoe i no bas ne, xoseoex0 shay mnosIaTLY Frornubes rou OF Gono. ‘es rnouvace oust = rec soot GASKET sve sop OTE: naULATNG WAGERS) ARE OMITTED SGinauocdvocon se aan —hccmeten re ra ele pnt tea a de FNM Printed in the USA Model 20-604 / May / 2012 Revision 0 (©2012 ayn Fitration. Al Rights Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 32 Water Meter - clean and verify operation - replace as necessary Model DLJ75CH Epoxy Coated Bronze Maintenance - The register assembly is easily removable and replaceable # needed. The integral strainer on the measuring assembly prevents foreign debris damage and can be removed and flushed clean. System Cleantiness ‘+ Aller system checks are completed, the system must be completely drained, fier housing internals inspected end cleaned thoroughly. ‘+ If debris has settled in the bottom, use a Shop-VAC® (or equivalent equipment) to clean the vessels, New elements must be installed after the complete draining is accomplished. NOTE: It is possible for microbial growth to occur between the oilWwater interface inside the coalescing vessel. An annually drainage, inspection and cleaning reduces microbial growth, ‘O-Rings (filter vessel lid seats) ‘O-rings in the respective filter housings must be replaced annually. Indications that they need replacing ‘are when the o-ring no longer remains within the o-ring groove. Evidence that o-ring may not ft into the ‘o-ring groove correctly include visible Nattening of o-ring, cuts, breaks, or swelling Element Change ‘© Filter elements are to be changed when prefiter reaches 25 psid and/or coalescing filer reaches 15 psid, or when the elements have been in service for six months, whichever occurs first. ‘= Any element that has been installed for a peried of one calendar year should be replaced immediately. ‘+ Itis advisable to have the 6-month element change-out procedure coincide with the annual cleaning of the Turbo-TOC® system. Printed inthe USA ‘Mode 520604 /Moy /2012/ Revision 9 (©2012 Kaycon Filtration. Al Rights Reserve.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 33 ‘These verifications must checked when system is in operation. Refer to Start-Up Procedure (commissioning) for start-up procedures before implementing these annual checks. Inlet and Outlet Sample Port Inspection and Oil Sample Collection - inspect for leaking and ‘operation, plus take oil sample for testing, NOTE: Procedure (must be performed while system is in operation) Inlet Oil Sample Valve ltems needed: ‘© Approved oil sample collection container ‘© Bucket to catch oll while testing and flushing oil sample port 1. With the bucket placed under the oil sample valve, open the valve and allow oil to expel through tube for 5 seconds. 2. After § seconds, close valve. 3. Perform this opening and closing procedure three times. 4. Before the fourth opening of the valve, open the oil sample container. 5. Open the oil samples vaive fourth time, and quickly place oil sample container in oil stream. 6. Filloll sample container haif full. Close vaive. 7. After sample is taken, close lid on the oil sample container. Send to appropriate lab to test for particle count (ISO Code) and Total Water using Karl Fischer analysis, 8. Inspect oil sample valve for leaks. Perform same procedure for oullet oll sample valve. NOTE: Label samples with time and date, including the sample location (inlet or outlet). Pump - Verity relief setting is 90 psig (+/- 5 psig) Flow Switch - Verify system shutdown in a “no flow" situation ‘The pump relief valve and the flow switch can be tested at the same time. Verify proper setting of pump relief valve and operation of flow switch by folowing this procedure: 4. With system in operation, slowly close the system outlet ball valve. 2. As the outiet bal valve is being slowly closed, fluid pressure will increase. 3, When the pump pressure reaches 90 psig (+/-5 psig), the pump rellef valve will crack open (you will hear a chattering noise from the pump). 4. Continue to close the outlet valve until the system flow switch shuts the system down, 5, After verification, open the outlet valve completely and restart system, Motor- Verily current draw within specification (check motor nameplate) NOTE: Qualified Electrician must perform this verfication. ‘With system in operation, verify with appropriate electrical equipment that the amp draw is below the Full ‘Load Amp (FLA) as written on the motor namepl Printed inthe USA Morel 20-604 May [2012 /Reiiond (©2012 Kayon Filtration. Al its ReservedKaydon Filtration Model S-20-60H / Instruction and Operational Manual 34 - Spare Parts List Part Description ‘Quantity, ‘AS95034 Basket Strainer 4 ‘A080001, Isolation Bail Valve 3 ‘000018 ‘Vacuum Gauge 1 35889 ‘Vacuum Switch 1 ‘Aag7129 ‘PumpiMiotor Assembly 1 ‘A00185 ‘Check Valve 1 ‘Aa00054 ‘Heater with Over-Temperature Thermocouple 1 ‘A407030. Process Thermocouple 1 ‘AASO103 Flow Switch 1 16582 Ball Valve (solation valve for air eliminator) 2 27360 ‘Air Eliminator 2 ‘AA50102 Differential Pressure Gauge with Switch 2 16583 Ball Valve 3 ‘Aa53022 ‘Sight Glass 1 ‘Aa50060 Level Switch 1 ‘A010271 ‘Solenoid Valve 1 ‘A008525. ‘Water Meter 1 ‘A000022 Pressure Gauge 1 8085) Pressure Relief Valve + 300148 “T-Handle “Wing Nut Siyie* Element Hold-downs 4 - Operating Materials (Consumables) Patt, Description, ‘Quantity | 1100 Prefiter Element (K1100) 1 K2100- ‘Coalescer Element (K2100) 2 3100 ‘Separator Element (K3100) 1 ‘A828008 Pre-Filer Vessel O-Ring Seal 1 300958. Goalescer Vessel O-Ring Seal 1 ‘A447 129-SEALKIT | Purip Mechanical Seal 1 ‘A595034-GASKET | Strainer Gasket 1 ‘A595034-BASKET | Strainer Basket 1 - Lubrication Chart Not appicable. Printed inthe usa Mode § 20-604 | May 2012 Revision 0 (©2012 Kayan Frat, A gh Reserved.Kaydon Filtration Model S- -20-60H / Instruction and Operational Manual 35, 2.5 Troubleshooting High Vacuum Reading ~ General Problems Problem ‘Solution, Thiet Valve is Closed ‘Open inlet Valve fo Full Open Hose or Pipe not full of of ‘Make sure hose is completely full of of, Air will create a high vacuum condition Hose is kinked or curled up, ‘Straighten hose. Reservoir is at a lower level than fiiration system Pump has diffculy iting oll. Provide a larger diameter hose or pipe of move system so the ‘elevation difference is not as great Inlet valve is open, hose is straight, and reservoirs at same level as fitration system, but a high vacuum still exits ‘Check connection at reservoir. Ifthe ‘connection is less than system suction ‘connection, this creates a high vacuum, ‘Solution is to find a larger connection Stiihigh vacuum?? ‘Check strainer, may need to be cleaned Low Flow Condition — Typical Reasons Problem ‘Solution ‘Gutlet Vaive is Closed ‘Open Outlet Valve to Full Open. ‘Airis being brought into suction of pump ‘Make sure the suction pipe or hose fs not introducing ai into the system, Make sure suction hose/pige is fully immersed in oi Flow Switch Set Point ‘Adjust set point per procedure (see index for age for flow switch adjustment) High Differentiat Reading ~ General Problems Problem ‘Solution, Diferental greater than 5 psid (35 Kglem) at start-up ‘Open up air bleed al top of vessels and release the trapped air Differenial greater than 5 paid (SB Kglem) at start-up Check oll viscosity. Wollis less than 60F, 6 higher differential pressure can occur. Wait for cil to heat up. Differential is greater than 20 psid (1.4 kg/om’) Elements are clogged with contaminate. Replace elements, Automatic Wator Drain Assembly - Trouble Shooting ‘Symptom, Look For Possible Problem Solution Water Sight Glass is | Water Drain \solation | Water Drain isolation | Open Water Drain greater than % full | Valve Valve is closed Isolation Valve and no water is being discharged There is some Ts water sight glass at_| Trwater sight glass is | Woperation is stil indication that least % full of water? | not atleast % full of | suspected to be Automatic Water water, be patient and_| malfunctioning, go to Drain is not Ifless than % full, be | allow automatic water | Service Screen and functioning patient and wait for | drain to perform. press Water Drain automatic water drain ‘Solenoid Test icon, to perform. {recent oil analysis | NOTE: The Water Drain Solenoid Test icon is a momentary and sight glass does’ | push button, soa not show water {uick touch and accumulation to at__| release allows for a Printed inthe USA ‘Mee s-20-504 ay 2012 Revision 0 (©2012 Kayan Fikration Aight Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 36 Teast 7 full on sight ‘lass, water has not ‘accumulated enough for automatic water drain, ‘quick opening and shutting of the solenoid valve, A longer touch provides for a longer opening of the solenoid valve. Be careful to not open the solenoid valve too long, since it may release oil through the water drain, Water sight glass is greater than % full of water and water has not been released Float Switch 1, Float switch bail float ball is upside down, 2. Float ball is hung ‘on side of iter element and/or float switch stem is crooked 3. Float ball not weighted properly (NOTE: system must be drained before float switch Is inspected) 41, Remove ball ow {rom stem, reverse ball postion 180 degrees, and re- install To verity ball fost is working properly: ‘While system is not ‘operating, but power stil supplied, move float ball up on stem Have another person watch Inpu/Output information screen. if “flow switch” icon does tums Green the float switch is sending signal to PLC to energize solenoid valve to open. 2. (a) Free ball foat by turning ster, 2. (b) Tum float s ‘lem to straight, vertical position. 3. Remove float ball {rom stem and place in bucket of water. Float ball must float in water. Also, place float ballin bucket of turbine oll. Float bal must sink, and not float. Waler sight glass is greater than % full of clogged with debri | solenoid vaive, close water and water has 2, Solenoid Valve —_| water drain isolation riot been released installed backwards. | valve, located 3 Not receiving upstream of solenoid ‘Solenoid Valve 7, Solenoid valve is Before checking Proges inte USA Model 520-604 / way / 2012 / Revision 0 (©2012 Kaydon Fitton. Al ighsRaserve.Kaydon Filtration Model S-20-60H / instruction and Operational Manual 37 ‘electrical signal valve 41. Remove 4 bolts on top of solenoid (be careful to not lose spring). Check inside solenoid valve and remove any lodged debri. 2, Remove solenoid ‘and install correctly. Arrows on solenoid ‘show inietioutiet flow direction, 3, (non-PLC systems) “Jumper-Oul” solenoid valve from inside control panel to determined electrical continuity. As ‘seemed necessary, replair connection or replace solenoid valve. Heater - General Troubleshooting ‘Symptom Look For, Possible Problem ‘Solution: No Heat Temperature Thermocouple is Replace indication is accurate} Open ‘Thermocouple and controler is constantly calling for heat Runaway Heat Temperature Thermocouple leads | Locate short. Check Indication is ambient, | are shorted outside of | to see i thermocouple system is calling for | process area wires are touching heat, Actual ‘grounded objects. temperature is Examples are wires ‘excessive (continues touching TC well head to "runaway" to 180F) ‘or wire insulation is bare and touching each other. Temperature Fauly thermocouple | Type Jthermocouple | Replace indication is has deterioration thermocouple Inaccurate (cause is typically rust) Eralic operation and | Loose thermocouple | Connections are loose | Tighien all display ‘connections somewhere inthe | connections. ‘thermocouple path Oil nat heating to Ts system sized Not enough KWto | Add additional heating desired temperature | correctly for oll heat oil (heater skid). reservoir? Too much heat loss in | Try to eliminate areas Is oileservoirin cold | piping and oi of heat loss. temperature reservoir. ‘environment? Fieater does not seem | Check line vollage To | Wine current is lower,_| Verify wiring is Panta inthe usa ‘eel s-20-60H ay 2012 /Reviion 0 (©2017 Kayden Fitri, A gh Reserved,Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 38 To be delivering much | ensure tis within the heater may be | correct power. specification. Check | wired wrong, full line current if voltage is correct. Motor or Pump Problems Ts this system being operated on the vollage that itis designed for? Confirm itis proper voltage The START button (icon) is pressed, but there is no power? ‘Check for biown fuses or tripped ciroult breaker. Check fuses for recommended size. ‘Check all power source connections. Repair or replace loose, dirty or corroded connections. ‘Check for faulty wiring. Using a voltmeter, ‘check for proper incoming ine voltage, Motor is very hot when itis touched, Possibly a short. Motor may need to be replaced. High amp raw Motor is overloaded. Ts a downstream valve closed? Pump Problems Problem Possible Cause Probable Solution Not Pumping Oil or Low Flow | Pump not primed 7 Thstall priming port on Rate suction side of pump. 2. Open strainer housing and fill strainer housing with oil, 3, Prime from the outlet side. Remove sample port located after discharge side of pump. Pour oil into port. Keep port ‘open and start system. Wait tnt oil begins to discharge, After oil is discharged, shut system off, re-install sample ort, and restart system. Not Pumping Oilor Low Flow Rate ‘Wrong Direction of Rotation Reverse wiring at incoming three-phase power connection in control panel or at motor Not Purnping Oilor Low Flow Rate Thiet or Oullet Valves closed or some other type of obstruction ‘or flow restriction is occurring at either iniet or outlet of Verify all valves fo and from system are fully open. suction fine system. Not Pumping Oifor Low Flow | End of suction pipe in Raise oil level in reservoir Rate reservoir not fully submersed | Install anti-vortex baffles into oil, causing air to enter reservoir NOTE: A low oil level in the reservoir that pulls in air is sometimes indicated by the low flow switch shutting down system. Not Pumping Ollor Low Flow Rate valve) is stuck Foot vaive (antifiow back 1. Foot valve installed improperly. Inlet pipe may be screwad in too far, blocking valve from opening. 2. Foot valve stuck from large: Printed in the USA ‘Morel s-20604 / ay 2012 Revisono 122012 Kayo itration. Al RightsReserved.Kaydon ration Model S-20-60H / Instruction and Operational Manual 39 ‘debris. Clean foo! valve. ‘Not Pumping Oil or Low Flow Rate High Vacuum Reading than 10° Hg) il viscosity is too high due to cold oil. Heat oi ‘Not Pumping Oil or Low Flow Rate Pump Bypass Relief Valve Open ‘Check pump relief valve for sticking or build-up of particulate material under valve seat. IF the pressure setting of the safety relief valve is to be checked, the following basic instructions should be followed (Please contact pump manufacturer for specific information) 41. Remove the relief valve ‘cap, which covers the adjusting screw, and loosen the lock nut that locks the adjusting screw. 2. While the pump is in ‘operation, watch the pressure ‘gauge in the discharge tine. 3. The adjusting screw should bee “turned in’ for increasing the pressure or ‘turned out" for decreasing the pressure. 4, Close the outlet valve to 75% closed. With the discharge line valve almost closed the pressure gauge should increase pressure. If it does not, then adjust the adjusting screw to increase pressure (close the by-pass relief valve). The pressure gauge will show the pressure while the pump is in operation, The relief valve should be set for 90 psig. 5. After relief valve setting is corrected, re-install the lock nut and tighten. Re-Install the relief valve cap. Not Pumping Oil or Low Flow Rate ‘ir Leak in iniet Line (automatic air release valves constantly are eliminating air) 1. Tighten threaded and flanged joints. 2. Raise cil level in reservoir. 3 Verify all opening on inlet (Guction side) of pump are closed (sealed) ‘Nat Pumping Oil or Low Fiow Rate irainer Clogged (indicated by the vacuum gauge reading of Remove strainer basket, clean, and reinstall. if basket 10° Hg or greater andlor looks damaged, replace vacuum switch shutting system off Not Pumping Oil or Low Flow | Pump badly worn Repiace internal parts, adjust Rate clearances, or replace pump, Printed nthe usa Model $20:608/ May / 2012 / Revision (©2012 Kaye Firat. A gh Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 40 excessive clearances causes “slip” to pump displacement, “which decreases ow rate) Not Pumping Oil or Low Flow | Loose coupling, high vibration, | 1. Correct coupling - Check Rate misalignment alignment 2. te align pumpimotor assembly NOTE: This does not apply to close coupled pump/motor assemblies. Not Pumping Ollor Low Flow | Pump starvation or cavilation | 1. Increase size of inlet Rate {sounds like “loose marbies’ | (suction line. are trapped in pump) 2. Reduce overall length of inlet line. 3, Simplify inlet piping by reducing unnecessary elbows, valves and any other restrictions. NOTE: This problem is normally indicated by the ‘vacuum switch shutting down the system. Not Pumping Oil or Low Flow | Motor speed (RPM) too low. | 1. Check that motoris wired Rate correctly 2. Check motor RPM. 3. Motor may be overloaded. Check to see if motor overioad has tripped. Excessive Power Hight O1 Viscosity han Reduce speed or heat oi fo ‘Consumption Specified reduce viscosity Excessive Power Discharge Pressure Higher | 1. Check ail outlet valves to ‘Consumption than calculated verify they are all fully open. 2. increase outline line size andlor simply outlet piping by reducing unnecessary elbows, valves and restrictive fittings. Excessive Power Rotating elementin pump or | 1. Correct pump/motor Consumption ‘motor is binding from alignment. ‘misalignment or improper | 2. Check binding of pump due ‘pump-to-piping misalignment | to improper pump-to-piping bending/misalignment Rapid Pump Wear Pump runs dry. Pump stalls | 1. Verity ample supply of due to frictional heat liquid at all times. (may need generated to install foot vaive at end of suction line). Motor Problems Motor fails fo start upon initial installation Possible Cause Corrective Action, © Suppiy voltage Is t00 1ow, too high or is | (1) Check power supply fuses ‘severely unbalanced (one phase is low or | (2) Match motor lead wiring to nameplate missing) connection + Motor leads are wired incorrectly at conduit | diagram and supply voltage box (@) Ensure that steady state supply voltage at motor terminals is within limits. Printed inthe USA Model 20-604 / May /2012/ Revision 0 (©2012 KaydonFitration. All RightsReserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 41 (Verify motor vollage matches actual supply ~ Driven load exceeds motor capacity That motor & pump tum freely + Load is jammed. {@) Disconnect motor from pump & ensure motor shaft turns freely. (3) Verify that motor starts when disconnected from pump (4) Remove excessive / binding iad if present Fan guard is bent and making contact with fan | Replace fan guard & fan (if blades are damaged) VED with power factor capacitors installed ‘Remove power factor correction capacitors iF equipped ‘VED with motor neutral lead grounded Ensure that motor neuiral lead is ungrounded 'VFD programmed incorrectly (1) Verify that VED current fimit and starting boost are set correctly {@) Double-check motor and feedback parameter settings and VED permissives (G) Gonsutt VED supplier. Motor has bean in operation, then slows down, stalis, or fails to restart Possible Cause Corrective Action ‘Supply voltage has droppad or has become | Replace fuse or reset motor cireult breaker, severely unbalanced ‘Aliow motor to cool down before restarting NOTE: Verity that rated and balanced supply voltage has been restored before restarting motor. Measure voltage during restart. Ensure that steady state supply voltage at motor terminals is within limits. . Motors overloaded WARNING: Make sure the power is OFF to the 2. Motor bearings are seized ‘unit before inspection. 3. Load is jammed (1) Check the current for each leg. Remove the pump from the motor 50 that the pump is completely disconnected from the pump. 1. Rotate the pump shaft with your hand, ititeannot be rotated with your hand, then there is some type of binding with the pump. Repair or replace binding component. 2, Tum the motor shaft to see if it wil turn relatively free. ifit does not turn, the motor bearings are seized. Repair or replace motor. 3. While the pump is disconnected, turn the power back ON to the unit 4. Check the amperage readings with an AmProbe for all three legs (3 wires) ‘coming from the bottom of the motor contactor. Each leg should not exceed the F.L. amps. Ifit does, the motor possibly is bad Printed nthe USA ese s-20-604 May / 2012 / Revision 0 (62022 Kayan Frain. A Rights Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 42 (2) Reduce pump load (possibly caused by some type of unnecessary piping restriction). (1) Check fault codes on VED and follow VFD ‘troubleshooting procedures (2) Verify that VFD input voltage is balanced and within timits (3) Remove excessive pump load if present. ‘VFD will not restart motor after tippi ‘Motor takes too Tong to accelerate Possible Cause. Corrective Action Motor leads are not connected correctly Maich motor lead wiring to motor nameplate siagram. ‘Supply wolage has dropped or become (7) Ensure thal steady stale supply voltage at severely unbalanced. rotor terminals is within limits. Correct a5 needed (@) Obtain correct motor to match actual supply voltage. Toad exceeds motor eapabiliy (i) Check pump reliel valve. Must be set at 100 psig (7.03 kg/cm’) — maximum (2) Check discharge piping. An unnecessary restriction may be creating flow resistance. Remove restriction. {2) Motor size is too low for application, Determine correct motor size and contact ‘motor representative to obtain property sized motor. Motor rotates in the wrong direction Possible Cause, Corrective Action Incorrect wiring connection at motor [Three Phase Power] interchange any two power supply (phase) leads. Motor overheats or overioad protector repeatedly trips When the motor averioad trips, the system wil not operate unt the motor overload is reset. The problem that created the motor overload must be corrected if the overload trips more than two times after restarting the system. Possbie Cause Corrective Action: Driven Load is excessive (i) If motor current exceeds nameplate valve, censure that driven load has not increased. Correct as needed. {@) if new motors 2 replacement, veify that the rating is the same as the old motor. If previous motor was a special design, a {general purpose motor may not have the correct performance. “Ambient temperature too high ‘Most motors are designed to operate in an ambient up to 40. (1) Ifa 60C ambient motor is required, and your motor nameplate states 40C, motor must be replaced with a 60C motor. {@) If area is poorly ventilated or is installed ‘next to high operating temperature equipment, ‘additional fan cooling or heat dissipation ventilation may be required or re-install system to a new location with a lower ambient temperature. olor cooling fins andlor vent openings (1) Remove foreign materials - clear vent Ped inthe USA ee s:20-60H | May /2012/ Revision (©2012 Kaydon Frat. AU ght Reserved.Kaydon Fiitration Mode! S-20-60H / Instruction and Operationa| Manual 43, Blocked ‘openings, fan quard air inlets and frame fins, ‘Supply volage fo Tow, to0 high, or unbalanced ‘See "Motor fails to start upon initiat instaitation” Ts motor overload set correctly? ‘Motor overioad should be set at of below full load amp (FLA) of rating of motor. If overload is et at FLS and motor stil trips, took at the motor nameplate and find the service factor. If service factor 's greater than 1. then you may increase the overload ainperage setting to eliminate the overload trip. Most motors have a service factor of 1.15. Ifthe motor has been subjected to adverse moisture conditions you should have someone ‘check the insulation resistance of the winding with a mega ohm meter. It the resistance 's lower than one mega ohm, the motor windings should be dried in an oven. ‘or with heat lamps not to exceed 80 degrees C nti insulation resistance becomes constant Motor Vibrates Possible Cause, ‘Corrective Action ‘Motor misaligned fo pump (not applicable for close coupled pump/motor assembiies) Realign pumpimotor assembly ‘Pump out of balance Ensure that motor shat is straight Remove motor from pump and inspect motor shatt. Verify motor shaft is not bent. A 0.002" (05 mm) out-of-round for shafts extension lengths up to 3.00" (76 mm), Add 0.0005" (0127 mm) per every additional inch of shaft length beyond 3.00" (76 mm). Divan load operaling at resonant point7 natural frequency. ‘A De-energize motor and record vibration as {oad coasts from 100% speed to 0 RPM. If vibration drops immediately, vibration source is electrical. (1) Redesign system to operate below the resonant point (2) On VED-driven pumps, adjust program to skip frequencies to bypass resonant points B. If levels do not drop immediately, source is mechanical (misalignment or out of balance) ‘VED torque pulsations Drive may be unstable at light load. increase pump oullet pressure to 25 psig (1.76 Kgicm’). Motor wired incorrecily Match motor lead wiring to nameplate connection diagram. Uneven, weak or loose mounting support. ‘Shim, strengthen or tighten where required: Motor out of balance Disconnect motor from pump. Set motor on rubber pads on solid floor. Secure key in shaft keyway and energize from balanced power supply @ rated voltage. Record vibration levels and compare with Printed in the USA rel S:20-60H / May 2012 / Revision 0 (©2012 Kaydon Fitton. Al gh ReservedKaydon Filtration Model S-20-60H / Instruction and Operational Manual 44 ‘appropriate standards. If excessive vibration persists contact motor manufacturer, Bearings repeatedly fail Possible Cause, Corrective Action: Motor bearings defective Remove motor from pump and test motor. If bearings are bad, unusual noise will be created. Possibie solution: add grease per motor manufacturer lubricating instructions. IW noise persists contact motor manufacturer warranty service. Toad to motor may be excessive or unbalanced | (1) Check pump on motor shaf. An unbalanced ‘pump will also cause the bearings to fail (2) Check dimensions of mating components, such as @ C-face and pump flange. Bearings contaminated Motor enclosure not suitable for environment. Replace with correct enclosure construction, Tacorrect grease of bearings for ambient ‘Check to determine if motor needs a 60C rating extremes for ambient operating conditions, Motor, at star up, makes a loud rubbing, grinding, or squealing noise Possible Cause Corrective Action Contact between rotaling and stationary (1) Verity that supply voltage is within traits ‘components (2) Ensure that motor iead wiring matches nameplate connection diagram (3) Isolate motor from load. {4) To locate point of contact turn motor shaft by hand. (©) If point of contact is not located contact motor service shop. Printed in the USA Model 20604 / May /2012 Revision 0 ‘©2012 taydon Fitration Al hts Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 45 (Electrical andl inetramentation|® (Control Equipment Documentation - Instrumentation See Equipment Documentation, Cable Lists - Control Cabinet Allocation Plans (internal and external) ‘See Control Panel Layout Drawing in Drawings Section (Section 5) Drawing Number D950840-Dsc (Title: Panel Layout) = Arrangement of Devices allocated externally of Control Cabinets ‘See Outline Drawing in Drawings Section (Section 5) Drawing Numiber SD920081-1 (Title: Quarayyah 2000MW CGPP SGT6-5000F(5) PROJECT) ‘See Flow Diagram Drawing in Drawings Section (Section 5) Drawing Number FD92006 1-1 (Tile: FLOW SCHEMATIC Quarayyah 2000MW CCPP SGT6-5000F(6) PROJECT) - Electrical Circuit Diagrams ‘See Wiring Diagram in Drawings Section (Section 5) Drawing Number WD950840-DSC (Title: Electrical Panel ~ 460V) ‘See Control Panel Layout Drawing in Drawings Section (Section 5) Drawing Number D950840-Dsc (Title: Panel Layout) Printed inthe USA ‘Mose 20.601 / May /2012 Revision O (©2012 rayon irae. Al RightsReserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 46 = Equipment Documentation, Cable Lists [[egya Part Numbers Description a Sa 1 AdB9091 Molded Case Circuit Breaker (Power Disconnect) — 35 amps. | aas0008 ‘Control Voltage transformer (460 VAC to 120 VAG) 7 [A489033-LED_{ Green Pilot Light | Aa89108 Timer. [500326 Motor Contactor — @ amps | Aa0306% Motor Protection Circuit Breaker (Range = 4 amp—6.3 amp) 2 [ad70013 Fuse 1 amp 4_[Aa7001s Fuse—2 amp 7 [A489033 2 position selector switch (green Mluminated) 7 [Aa73036. Circuit Breaker — 30. amp {71 Taao3048 Heater Contactor — 37 amp 4 aa07034 “Temperature Controller “4 _[-A455065-AMB | Amber Pilot Light 2 | Aas6040 Control Reta 6 | Aa63054 “Terminal Biock (quad) | a407030 “Thermocouple (Type J) 7 [Aas0103. Flow Switch (120 VAC) 7 [-A450099-ADT | Flow Switch Adapter [467020 Flow Switch Cable 7_[ 35889 ‘Wacuum Switch +_[aao0054 Oil Heater “_['Aa3047 “Terminal Block 1 Aa63048 “Terminal Block End | A455079 Contact Block [489086 Molded Case Circuit Breaker Handle and Rod 2 | Aa55065-RED_| Red Pilot Light [500350 Motor Overload Cable Lists: not applicable = Connections or Terminal Connection Diagrams ‘See Wiring Diagram in Drawings Section (Section 5) Drawing Number WD950840-DSC (Title: Electrical Panel ~ 460V) - Functional Diagrams or Program Listings for PLC ‘See Flow Diagram Drawing in Drawings Section (Section 5) Drawing Number FD920081-1 (Title: FLOW SCHEMATIC Quarayyah 2000MW CCPP SGTE-5000F(5) PROJECT) NOTE: PLC not utilized with this mobile oil purifier. Printed inthe USA Modes 20-604 / May 2012 / Revision 0 (©2012 KaydonFtvation. All RightsReserved.Kaydon Filtration Model $-20-60H / Instruction and Operational Manual 47 (4 Appendices =m 4.4 Table of Contents of Appendices - See Appendix Section (separate file) Part Description ‘Appendix Number: ‘A595034_| Basket Strainer 4 ‘A080001 | Isolation Ball Valve 2 ‘A000078_| Vacuum Gauge _ 3 35889 | Vacuum Switch 4 "A447129 _| Pump/Motor Assembly 5 ‘010185 | Check Valve 6 ‘A400063 | Heater with Over-Temperature Thermocouple T ‘A407030__| Process Thermocouple 8 ‘A450103 | Flow Switch 9 16582___| Ball Valve (isolation valve for alr eliminaton) 10 727360_—_| Air Eliminator tt “Aa50102 | Differential Pressure Gauge with Switch 2 16583 | Ball Valve 13 "Aa53022 _| Sight Glass 14 ‘4450060 | Level Switch 15. ‘A010271 | Solenoid Valve 16. ‘009525 _| Water Meter 17 ‘000022 __| Pressure Gauge: 18 18085 | Pressure Relief Valve 19 ©300749_| T-Handle “Wing Nut Style" Element Hald-downs 20, ‘A489091 | Molded Case Circuit Breaker (Power Disconnecl) — 35 amps. 21 ‘A460008__| Control Voltage Transformer (460 VAC to 120 VAC) 22 ‘Aa69105_| Timer 23 500326 | Motor Conlactor=9 amps 24 ‘403067 _| Motor Protection Circuit Breaker (Range = 4 amp 6.3 amp) 25 ‘Aa70013 | Fuse—1 amp 26 ‘A470015_| Fuse —2 amp 26 ‘A489033 | 2 position selecior switch (green Wuminated) 27 ‘A473036 | Circuit Breaker ~ 30 amp 28 ‘Aa03049 | Healer Contactor ~ 37 amp 28 ‘A407034_ | Temperature Controller 30 ‘Aa56040_| Control Relay _ 31 ‘Aa63054 | Terminal Block (quad) 32 ‘A407030__| Thermocouple (Type J) 33 ‘Ad50103 | Flaw Switch (120 VAC) 34 ‘Aa00083_| Oil Heater 35 ‘463047 _| Terminal Block 32 ‘Aa63048_| Terminal Block End 32 ‘455079 _| Contact Block 36 “489086 | Molded Case Circuit Breaker Handle and Rod 37 "500350 __| Motor Gvertoad 38 Printed inthe USA Model $20-60/ May / 2012 Revision O {©2012 aydon Fiat. Al Fights Reserve.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 48 4.2. Manufacturer Documents, Catalogs = Mechanical Components ‘See Appendices - Electrical and Instrumentation and Control Equipment ‘See Appendices 4.3 Further appendices (on demand) No further appendices. 5) Drawings 3 ie 5.1 List of Drawings — List after page 49 Outline Drawing Drawing Number SD920081-1 (Title: Quarayyah 2000MW CCPP SGT6-5000F(5) PROJECT) Flow Diagram Drawing Number FD920081-1 (Title: FLOW SCHEMATIC Quarayyah 2000MW CCP SGT6-S000F(5) PROJECT) Controt Panel Layout Drawing Drawing Number D950840-Dsc (Title: Panel Layout) Wiring Diagram Drawing Number WD950840-DSC (Title: Electrical Panel - 460V) 5.2 Drawings (Component General Arrangement Drawings, Arrangement Drawings) See following pages. Q Quality Control File — not applicable 3.2 _ Erection Manual - not applicable Erection Manual - not applicable Supporting Technical Specifications - not applicable On-Site Quality Assurance Plan — not applicable Time Schedule — not applicable Erection Drawings — not applicable Noose Printed inthe USA Mode 520-604 say 2012 Revision O (©2012 Kaydon Firatio. A Rights Reserved.Kaydon Filtration Model S-20-60H / Instruction and Operational Manual 49 [8) Commissioning Manual” = aE aS a 8.1 Pre-Commissioning Checklist ‘See Start-Up Procedure (Commissioning) 8.2 Initial Start-Up Procedure — Instruction - Initial Start-Up Measures ‘See Start-Up Procedure (Commissioning) - Run-Up and Functional Checks See Start-Up Procedure (Commissioning) 4,0 APPLICABLE DOCUMENTS Not applicable Printed inthe us Modes 20-60H / May 2012 Revision O (©2012 Kayan Firation, Al Rights Reserved.= \sonmvaa aodSL meg, [Be “siroug (ehecos-aiod mana} BS=