Shell & Tube. JATCO Inc. Operating Manual

Transcription

1 Shell & Tube JATCO Inc. Operating Manual 1

2 System Operation Operating Instructions System P&ID System Drawing Starting Procedure Shutting Down Service & Maintenance Trouble Shooting Guide Recommended Spare Parts JATCO Tank Service Spec Sheet Manual Reset Valve Actuated 3-Way Ball Valve F3002 Humphrey INDEX Page 3 Page 4 Page 5-7 Page 8-14 Page 15 Page 16 Page 17 Page 18 Page 19 Page Page 23 Page 24 & 25 Page Page 40 1/4" Humphrey Valve Page 41 JATCO Low Pressure 2" Liquid Separator High Liquid Level Shut Down Spud-In Adapter Compound Injector Burner Deflagration Flame Arrestor Micro Valve Vapor Relief Glycol Relief Warranty Page 42 Page 43 Page 44 Page 45 Page 46 & 47 Page Page 51 Page 52 & 53 Page 54 Disclaimer Page N.W. 111 th St. Oklahoma City, Oklahoma / / Fax 2

3 SHELL & TUBE SYSTEM OPERATION The JATCO BTEX ELIMINATOR is designed to condense the emissions from the still column of glycol dehydrators. The hot vapors are routed through the heat exchanger, reducing the temperature and volume of the steam and hydrocarbons produced by the dehydration process. The liquids condensed are routed by gravity into a small tank placed at the base of the condenser. The tank dumps these liquids automatically, and must be connected to a holding tank. The vapors remaining uncondensed are routed through a separation and filtering media, then to either the main burner of the dehydrator, or to the exhaust stack. All V.O.C. s are either condensed into liquids which may be separated and sold, or are burned. 244 N.W. 111 th St. Oklahoma City, Oklahoma / / Fax 3

4 Shell & Tube Operating Instructions JATCO BTEX ELIMINATOR Systems See P&ID: The V.O.C. s are routed from the condenser through an actuated 3-Way ball valve then manual valve (BA-001), and the gas liquid separator (SP-1100). Then though a filtering and separating medium (ME-1101), the flame arrestor (FA-1101), then either to the burner or to the exhaust stack through a second actuated 3-way ball valve. The actuated 3-way ball valve (ABV-1100) is controlled by a relay valve (PY-1101) that receives its pilot signal from the output of the main burner fuel supply valve (SDV-Main Fuel Gas Supply) this is controlled by the temperature controller (TC). During normal operation, when the thermostat (TSH) supplies pressure to operate the burner supply valve (SDV-Main Fuel Gas Supply), the main burner fuel pressure also gives positive signal to the pilot side of (PY-1101) to allow supply gas to actuate the 3-way ball valve. When actuated the condenser residual vapors are routed to main burner. A JATCO air mixer adaptor allows the drift of fuel gas to mix the vapor with primary air in the main burner. When the set temperature of the glycol in the re-boiler is reached, the thermostat removes pressure from the valve, allowing the waste vapors to be diverted into the exhaust stack, where they are mixed with hot air being drafted into the fire tube and stack and ignited. An over temperature controller (TSH) supplies pressure to the thermostat (TC) to operate the control valves. This pressure is also used to operate an actuated 3-way ball valve (ABV-1200) mounted on the heat exchanger. This valve (ABV-1200) allows the vapors to be vented to the atmosphere during start up and automatic shutdown. It will open automatically in the event the over temperature control (TC) or the high level shut down (LSH-1000) is tripped. 244 N.W. 111 th St. Oklahoma City, Oklahoma / / Fax 4

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15 SHELL & TUBE STARTING PROCEDURE See P&ID: The glycol pump should be stopped before beginning the starting sequence. All gas and waste vapors must be allowed to clear from the fire tube and exhaust stack before lighting the pilot. When lighting the pilot, the system should be bypassed by closing valves (BB-001) and (BA-001). Set the thermostat (TC) to desired glycol temperature. When the glycol reaches temperature, start the glycol pump and begin circulation through the contactor and re-boiler tank. The BTEX ELIMINATOR is designed to handle the vapors generated under normal conditions. If the glycol is saturated with water, it will be necessary to allow the excess water to dissipate before opening valves (BA-001) and (BB-001). 244 N.W. 111 th St. Oklahoma City, Oklahoma / / Fax 15

16 SHELL & TUBE SHUTTING DOWN SEE P&ID: The BTEX ELIMINATOR may be isolated from the burner and exhaust stack at any time by closing valves (BB-001) and (BA-001). This allows the vapors to vent through the Actuated 3-way ball valve. The dehydrator may then be serviced or operated normally. NORMAL OPERATION: It is important to keep the glycol flow to the minimum necessary to achieve the desired dew point of the gas stream. Any excess in flow rate will cause additional hydrocarbons to be absorbed by the glycol in the contactor. These hydrocarbons must then be condensed or burned. If a two or three phase separator is used in the wet glycol stream, the load on the condenser is greatly reduced. If no separator is used, any excess glycol flow rate may cause an over rich fuel mixture, smoking or flames from the exhaust stack. 244 N.W. 111 th St. Oklahoma City, Oklahoma / / Fax 16

17 SHELL & TUBE SERVICE AND MAINTENANCE SEE P&ID: The JATCO BTEX ELIMINATOR system has very few moving parts. Maintenance of the JATCO tank is covered in the service instructions. A pressure gauge is provided to assist in determining operation of the actuated 3-way ball valves (ABV-1100 & ABV-1200). This pressure gauge will indicate any blockage or restriction of flow in the filtering media or flame arrestor. Operation of the vent valve (ABV-1200) can be confirmed by either a drop in system pressure, or if manual valve (BA-001) is closed briefly, no increase in pressure. 244 N.W. 111 th St. Oklahoma City, Oklahoma / / Fax 17

18 SHELL & TUBE TROUBLE SHOOTING GUIDE If the vapor relief valve (PSV-1100) at inlet is relieving pressure, first close valve (BB-001) which will switch the 2 actuated 3-way ball valve (ABV-1200) system by-pass vent to atmosphere. If switching valve (ABV-1200) to by-pass relieves pressure from vapor relief valve, then either mist eliminator (ME-1101) or flame arrestor (FA-1101) may be clogged or obstructed. If switching 2 system by-pass valve (ABV-1200) does not relieve pressure from vapor relief valve, first check operation of JATCO tank. If the tank is dumping by depressing manual dump plunger, check bottom headers, outlets, and tubing for blockage. If the JATCO tank will not dump completely or at all, check for adequate pressure (40 psi) directly at instrument supply inlet of tank. For better performance turn pressure up to (100 psi) max. Also check all downstream lines of the tank for blockage. 244 N.W. 111 th St. Oklahoma City, Oklahoma / / Fax 18

19 RECOMMENDED SPARE PARTS FOR SHELL & TUBE JATCO BTEX ELIMINATOR Qty. Item # Description 1 JM5001X 3 way micro valve for JATCO tank 1 JM5008X ¼ Pilot Valve for JATCO Tank 1 AM100 2 x 6 Stainless Mesh Mist Pad 1 CC01 K-Dyne Manual Reset Valve 1 HQ2 ¼ 3 Way low Pressure Pilot Valve 1 HQ3-R F3002 Humphrey Pilot Valve Repair kit 1 INV F1-B 3 way Micro-Valve for High Level Control 1 ASP19 ½ Actuator Repair Kit 1 ASP29 2 Actuator Repair Kit Contact JATCO Inc. for replacement parts 244 N.W. 111 th St. Oklahoma City, Oklahoma / / Fax 19

20 Service Guide JATCO J-5000CX Environmental Tanks Listed below are a series of steps to follow if the JATCO tank fails to dump properly. Be sure there is an adequate supply of gas pressure ( psi), to the inlet connection on the micro valve. If there is enough pressure at the inlet connection, press down on the manual dump plunger. This should cause the tank to dump, then vent when the cycle is complete. If the JATCO tank fails to dump manually, remove connector tubing to pilot valve (10) to test for pilot pressure from 3 way micro valve (1). If the 3 way micro-valves are not sending pressure to pilot valve when depressing manual dump plunger (#4), removal and or inspection of micro-valve will be necessary and proceed to step #2. If pressure is present but pilot valve fails to operate, removal inspection, and or replacement may be necessary. To remove the micro-valve, remove the top vent tube connector and the bottom gas supply connector to allow access and removal of the two hex socket cap screws. Remove the cap screws and the micro-valve from the valve body. Inspect the inlet port to see if any obstruction has lodged in the orifice which could clog the micro-valve. If no obstruction is visible, apply gas pressure to the inlet port and operate the toggle spring. Flipping the toggle up should allow gas to flow out center ¼ npt port. If operating the toggle does not allow gas to flow, the micro-valve must be replaced. To re-install the micro-valve and mounting plate assembly on the 2 valve body, flip the toggle to the down position and insert toggle spring through the center hole in the valve body. Reinstall the two mounting cap screws, the vent connector, and the gas supply connectors. Check system by depressing manual dump plunger. To remove the install 2 valve body: Remove micro valve as previously described. Remove manual dump plunger. Loosen hex nut on top of valve body and tap down pivot pin. This allows the float arm assembly to swivel while turning valve body out of tank. Remove float assembly carefully to avoid bending the float arm. To install valve body, insert float arm into the tank with the float toward the gauge cock end of the tank. Hold the float pivot with a screwdriver, keeping the slot on the pivot positioned ninety degrees to the float arm. Tighten the 2 valve body into the tank, positioning the machined surface toward the gauge cock end of the tank, while holding the float pivot with a screwdriver; tighten the hex nut to lock the float arm in place. Re-install manual dump plunger and depress it while observing the trip lever through the toggle hold on valve body. The trip lever should be visible and centered. Re-install gasket and micro-valve. 244 N.W. 111 th St. Oklahoma City, Oklahoma / / Fax 20

21 J-5000cx (A) Inlet Check Valve 1 NPT (B) Discharge Check Valve 1 NPT (C) Supply Gas Inlet ⅜ Compression (D) ¼ Screen Vent (E) Pressure Relief Valve (F) Manual Dump Plunger Assembly (G) Three Way Pilot Valve (H) Vessel Vent ¼ NPT (I) Gauge Cocks & Sight Glass 244 N.W. 111 th St. Oklahoma City, Oklahoma / / Fax 21

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23 JATCO Shell & Tube Steam to Liquid Heat Exchangers Completely constructed with 304 stainless steel. Single pass tube construction. Available in 5 O.D. 304 stainless steel shell. Units can be configured in series to increase cooling capacity. Specifications: Test Pressure: 400 psi Operating Pressure: >1 psi Shell (Vapor Side) / 150 psi Tube Sheet (Glycol Side) Max Operating Temp: 225 F Min Operating Temp: 32 F Max Condenser Vapor Outlet Temp: 10 F Approach to Inlet Glycol of the Condenser Shell: 5" Schedule stainless steel pipe Tubes: ½ Diameter.035 Wall 304 stainless steel Tube Length: 72" - 120" No. of Tube Cooling Model # Passes Diameter Bundle Length Surface S.T " 72" sq. ft. S.T " 120" sq. ft. S.T Duplex 2 5" 120" sq. ft. S.T Triplex 3 5" 120" sq. ft. 244 N.W. 111 th St. Oklahoma City, Oklahoma / / Fax 23

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42 JATCO Low Pressure 2 Liquid Separator A = 5 CAP B = 5 SCH 10 CAP C = CLASS HALF COUPLING D = ½ FULL COUPLING E = 5 x 1/8 FLAT BAR 244 N.W. 111 th St. Oklahoma City, Oklahoma / / Fax 42

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51 JATCO Part #TVT N.W. 111 th St. Oklahoma City, Oklahoma / / Fax 51

52 JATCO Part #TVT N.W. 111 th St. Oklahoma City, Oklahoma / / Fax 52

53 JATCO Part #TVT N.W. 111 th St. Oklahoma City, Oklahoma / / Fax 53

54 WARRANTY JATCO, Inc. warrants its products to be free from defects in materials and workmanship, under normal use and service, for a period of one year from the date of shipment. The sole liability and exclusive remedy is limited to the repair or replacement, at the option of JATCO, Inc., of the product, or any parts thereof, which upon examination by JATCO, Inc., disclose to its satisfaction defects due to faulty material or poor workmanship, and which defects are reported to JATCO, Inc., in writing, during the warranty period. The warranty provision contained herein shall not apply to or cover any defects resulting from normal wear and tear, unauthorized changes, repairs, alterations or modifications to the product: or any other causes beyond the control of JATCO, Inc. JATCO, Inc. neither assumes nor authorizes any other person or business organization to assume for it any other warranty or liability in connection with the sale, use or operation of its products. 244 N.W. 111 th St. Oklahoma City, Oklahoma / / Fax 54

55 JATCO INC. OPERATING MANUAL DISCLAIMER Except as otherwise expressly provided in the Warranty section of this manual, JATCO, Inc. does not warrant that the system or any of its components will work properly in all environments or under all conditions and makes no warranty or representation, express or implied, with respect to the quality, performance, merchantability, or fitness for a particular purpose of the system or its components. This operating manual is not intended as an installation guide for the product. This product is intended to be installed by an installation specialist. For a list of such installation specialists please contact JATCO, Inc. In the event the product is not installed by an installation specialist, the warranty provided in the Warranty section of this manual shall not apply to any defects, damage, or other failure of the product to properly function due to improper installation, and JATCO shall have no liability whatsoever for any loss, damage, injury, cost, or expense of any nature arising out of an installation of the product by anyone other than an installation specialist. The information in this manual is subject to change without notice. JATCO, Inc. makes no representations or warranties with respect to the contents of this manual. JATCO, Inc. reserves the right to revise this manual and to make changes from time to time in the content hereof without any obligation of JATCO, Inc. to notify any person of such revisions or changes. It shall be the user s responsibility to determine whether any changes or revisions to this manual have been made. Neither JATCO, Inc. nor any of its directors, shareholders, officers, employees, or agents shall be liable in contract, tort, or in any other manner whatsoever to any person for any loss, damage, injury, liability, cost or expense of any nature, including without limitation, incidental, special, direct, or consequential damages arising out of or in connection with the use of this manual. This manual is proprietary to JATCO, Inc. and no ownership rights in this manual or its contents are transferred to the user. No part of this manual shall be used, reproduced, translated, converted, adapted, stored in a retrieval system, communicated or transmitted by any means, for any commercial purpose, including without limitation, sale, resale, license, rental or lease, without the prior written consent of JATCO, Inc. Any product or component part names used in this manual that are not property of JATCO, Inc. are the properties of the respective owners of such products or component parts and each of JATCO, Inc. and the user acknowledge such ownership. 244 N.W. 111 th St. Oklahoma City, Oklahoma / / Fax 55