WATER CONTROL PANEL - Webshop, Gas Analysis Technology

WATER CONTROL PANELUSER MANUALRev.: 0 / 07-01-09Drawing no: 48849-WCP-450-110

Unit Operation InstructionWater Control PanelTABLE OF CONTENTSWATER CONTROL PANEL......................................................................................................11.1 APPENDIX...........................................................................................................21.2 SERIAL NUMBERS..................................................................................................22 PREFACE ..................................................................................................................32.1 DOCUMENT MAP...................................................................................................32.2 DEFINITIONS AND TERMS........................................................................................32.2.1 GENERAL .................................................................................................... 32.2.2 UNITS AND CONVERSION FACTORS ..................................................................... 42.2.3 WATER CONTROL PANEL.................................................................................. 42.3 HOW TO READ THIS MANUAL ....................................................................................42.4 WARNING...........................................................................................................42.4.1 WARNING – HAZARDOUS VOLTAGES!................................................................... 42.4.2 WARNING – TOXIC, EXPLOSIVE GASES ................................................................. 52.4.3 WARNING - ACIDS......................................................................................... 52.4.4 WARNING - BURNS ........................................................................................ 52.4.5 WARNING - PRESSUREE................................................................................... 52.4.6 WARNING – MOVING MACHINERY ....................................................................... 63 TECHNICAL INFORMATION WATER CONTROL PANEL ...............................................................73.1 PHYSICAL DISTANCE BETWEEN EQUIPMENT ...................................................................83.2 GENERAL INFORMATION WATER CONTROL PANEL ...........................................................84 INSTALLATION OF WATER CONTROL PANEL .........................................................................94.1 BEFORE INSTALLATION ...........................................................................................94.1.1 TRANSPORT ................................................................................................. 94.1.2 UNPACKING................................................................................................. 94.2 INSTALLATION OF WATER CONTROL PANEL...................................................................94.3 CONNECTION OF PIPES ...........................................................................................94.4 CONNECTION OF WATER SUPPLY ................................................................................94.5 CONNECTION OF WATER DRAIN .................................................................................94.6 CONNECTION OF PIPE LINES FOR COOLING WATER.........................................................104.7 INSTALLATION OF CABLES......................................................................................105 SAFETY INSTRUCTION.................................................................................................116 FUNCTION DESCRIPTION OF WATER CONTROL PANEL ...........................................................126.1 UNIT OVERVIEW.................................................................................................126.2 PARTS P&I........................................................................................................136.3 CIRCUIT BREAKERS .............................................................................................136.4 CONTROL OF WATER CONTROL PANEL.......................................................................136.4.1 WATER FLOW ..............................................................................................136.4.2 WATER LEVEL CONTROL..................................................................................146.4.3 WATER TEMPERATURE CONTROL........................................................................146.5 COMMISSIONING OF WATER CONTROL PANEL..............................................................146.6 CLOSING DOWN THE WATER CONTROL PANEL .............................................................147 OPTIONS................................................................................................................157.1 LOW TEMPERATURE CONFIGURATION.........................................................................157.2 ULTRA LOW TEMPERATURE CONFIGURATION................................................................158 MAINTENANCE .........................................................................................................168.1 GENERAL .........................................................................................................168.2 SPARE PARTS ....................................................................................................168.3 MAINTENANCE WATER CONTROL PANEL.....................................................................16Rev.: 0 / 07-01-09 / LHS Page 1 of 20

Unit Operation InstructionWater Control Panel8.3.1 FILTER FOR MAKE-UP WATER............................................................................168.3.2 WATER TANK...............................................................................................168.3.3 HEAT EXCHANGER.........................................................................................168.3.4 WATER PUMP ..............................................................................................178.4 DISMOUNTING OF THE WATER CONTROL PANEL ...........................................................178.5 MAINTENANCE OF WATER CONTROL PANEL.................................................................179 TROUBLE SHOOTING ..................................................................................................1810 CONTACT INFO.........................................................................................................1911 DOCUMENT REVISION ................................................................................................191.1 APPENDIX(Appendix is found directly after this operating instruction)• Drawings according to “Document list: Drawings”• Circuit diagrams• Cable list• Part list1.2 SERIAL NUMBERSThis manual is specifically related to the following unit serial numbersThis manual covers all serial numbers from48849-01 and forwardThe serial number follows the terms like: 5xxxx-yy where 5xxxx indicates serial lot number. The “yy”is a unique unit number(Documents revision history versus serial numbers is found in section 0)The serial number is tagged on each unit with a stainless steel plate on front of frame orsimilar.Rev.: 0 / 07-01-09 / LHS Page 2 of 20

Unit Operation InstructionWater Control Panel2 PREFACEThis operating instruction is called a unit manual. The operating instruction covers only thisparticular unit with respect to technical data, installation, use etc. This specific unit is a partof a complete system. Control and interaction in the specific system may vary according tosystem demands.The Water Control Panel is a basis instrument air unit to handle, regulate and distributecleaning and control air for the FLSmidth Airloq analysis system. The Water Control Panelcomprises a frame, piping, air tank and valves among others.The system interaction of the Water Control Panel is described in the system manual. Thedocument overview is to be found in section 2.1.The whole analysis system is to be operated and maintained as described in the systemmanual. If not, the efficiency and lifetime of the system will be reduced. An alarm mustalways be corrected at once. Qualified and trained personnel must perform themaintenance.2.1 DOCUMENT MAPThis manual is to be considered as part of the complete system documentation. A completeset of system documentation for an FLSmidth Airloq A/S gas analysis system may comprise:• User manuals (Binder) (all project specific drawings, list etc.) includingo System datasheets covering project specific data.o System operation instructionso Unit operating instructions (this document among others)o Drawings, lists etc.• Data sheets (Binder)o Sub supplier’s manuals and datasheets2.2 DEFINITIONS AND TERMS2.2.1 GENERALSystem (analysis system)System manualSystem datasheetUnit manualGMUCUBETrained/qualified PersonnelThe complete analysis system which includes this unit amongothersThe manual covering system function and interaction with thisunitOverall system data where all technical data and units areidentifiedAn operating instruction for a specific unit (Part of completesystem. E.g. for a Probe)Gas Monitoring Unit: Cabinet or housing comprising analysisparts, power distribution and control.FLSmidth Airloq A/S analysis housing insulated, heated, cooledand with GMU installed.Indicates personnel that is not only certified to work on theplant according to all local and national regulations, butpersonnel who also has specific training from e.g. FLSmidthAirloq in use and maintenance of gas analysis systems.Rev.: 0 / 07-01-09 / LHS Page 3 of 20

Unit Operation InstructionWater Control Panel2.2.2 UNITS AND CONVERSION FACTORSAll units in FLSmidth Airloq documentation are SI-units except from:Pressure:BarTemperature:°C (degrees Celsius)For general use the following approximations can be used for conversion:Length: mm to inch factor 0.04Pressure: Bar to PSI (US) factor 14.5Temperature: °C to °F °F = °C × 1.8 + 322.2.3 WATER CONTROL PANELWCPWLWS1WD1Water Control PanelWater line. Cooling water for probe.Water Supply to WCPWater drain (Note cooling media may contain glycol and must be disposedaccording to environmental demands.)2.3 HOW TO READ THIS MANUALRead the instructions in this manual carefully before installing the system.FLSmidth Airloq A/S cannot accept any liability for damages due to nonobservanceof this manual.Sign:Before doing anything to the system, read warnings in section 2.4.This manual must be used in conjunction with the appendix. The document map in section2.1 shows an overview of the complete gas analysis system. This document covers theWater Control Panel only. For e.g. electrical wiring, the reader must use the appendix“Circuit diagram”. All issues related to system performance must be found in the systemmanual.No part of this manual may be reproduced or transmitted in any form or by any means,electronic or printed, without the prior written permission of FLSmidth Airloq A/S. If thismanual is translated, the English version is to be considered as the original one.2.4 WARNING2.4.1 WARNING – HAZARDOUS VOLTAGES!Sign:All electrical installations must be in accordance with national and local regulations, andqualified personnel who are aware of these regulations must perform the electricalinstallation.Voltage must not be applied to the system until all electrical connections have been madeand checked and then only by qualified personnel who are aware of the risks involved.Rev.: 0 / 07-01-09 / LHS Page 4 of 20

Unit Operation InstructionWater Control PanelAny disconnection of the earthed conductor inside or outside the device or the release of theearthed conductor connection can make the device hazardous to life. Deliberatedisconnection is inadmissible/prohibited.All connections must be made in accordance with the drawings in this manual.2.4.2 WARNING – TOXIC, EXPLOSIVE GASESSign:Be sure to observe the safety regulations for the respective gases (sample gas and testgases/span gases) and test gas cylinders! The gas outlet should be led to ambient air toavoid danger to operators.Inflammable or explosive gas mixtures must not be introduced into the analysis systemunless the system is designed for the application.To avoid danger to operators by explosive, toxic or unhealthy gas components, flush thegas lines with ambient air or nitrogen before cleaning or exchange parts of the gas paths.2.4.3 WARNING - ACIDSSign:To avoid danger to operators by acid droplets build up in gas lines, first flush the gas linesbefore cleaning or exchange parts of the gas paths.Always use skin and eye protection before cleaning or exchanging parts of the gas pathsincluding condensate trap.2.4.4 WARNING - BURNSSign:To avoid the danger of operators getting burned due to high temperatures of probe andother components, the demands of occupational health regulations should be followed.Always plug the hole to the process when the probe is removed from the flange. The plugmust be secured with the lock pin. The water in WCP, water lines or probe can be hot; donot dismantle any part until the water is below 30 °C.2.4.5 WARNING - PRESSUREESign:To avoid danger to operator the hoses must be without pressure before dismounting of anyconnections or hoses.Rev.: 0 / 07-01-09 / LHS Page 5 of 20

Unit Operation InstructionWater Control Panel2.4.6 WARNING – MOVING MACHINERYSign:Do not remove covers from Extraction Device with compressed air pressure to ExtractionDevice.Rev.: 0 / 07-01-09 / LHS Page 6 of 20

Unit Operation InstructionWater Control Panel3 TECHNICAL INFORMATION WATER CONTROL PANELPower supply:Power supply: (From GMU)Power supply heater 1Dimension:Dimensions l x w x h:Dimensions seaworthy package l x w x h:Foundation:Weight:Weight, dry:Weight seaworthy package gross dry:3x380V - 3x480 V 50/60 Hz, 1.5 kVA.24 V DC, 25 W110-230 VAC, 200W1360 x 800 x 1956 mm.1500 x 950 x 2180 mm.4xØ12mm for 12mm expansion boltsApp. 350 kg.App. 500 kg.Temperatures:Ambient temperature: -10°C to 55°CT amb

Unit Operation InstructionWater Control PanelThe following values of the water quality shouldnot be exceededNever use:de-mineralized water orde-ionized water ordistilled waterAntifreeze protection of water systemTo protect system against frost damage andcorrosion it is recommended to add anti freezeto cooling waterHardness:10 dH*.Chloride:1000 mg/litre.Total salt conc.: 3000 mg/litre.(evaporation residue.)Free CO 2 :20 mg/litre.Suspended solids : 5000 mg/litre.Silica (SiO 2 ):50 mg/litre.Sulphate (SO 4 ): 680 mg/litre.Algae growth:NOT ALLOWED.pH: 5 – 7.*1 dH = 10 mg CaO/litre or 7.14 mg MgO/litre.Anti freeze may be added by e.g. GLYCOL(monoetylenglykol) or similar:Dilution ratio (glycol:water)1:2 gives approx. -18°C protection1:1 gives approx. -35°C protectionNOTE: Dilution may vary and the specific datamust be read carefully on product datasheetbefore use!!3.1 PHYSICAL DISTANCE BETWEEN EQUIPMENTThis information is covered by the system manual.3.2 GENERAL INFORMATION WATER CONTROL PANELThe purpose with the Water Control Panel is to supply cooling water to the KilnLoq probe.The Water Control Panel is a steel frame containing a 200 liters water tank, watercirculation pump, heat exchanger and a stainless control cabinet. The water is cooled downto set point, the water flow is monitored and the water level in the tank is monitored. TheWater Control Panel has its own control built into a cabinet which is mounted in the frame.Rev.: 0 / 07-01-09 / LHS Page 8 of 20

Unit Operation InstructionWater Control Panel4 INSTALLATION OF WATER CONTROL PANELSee layout drawing “System View”4.1 BEFORE INSTALLATION4.1.1 TRANSPORTAll transport must be carried out according to local regulations. Transport may be doneeither with equipment in transport box or unpacked. When equipment is still in a box, itmay be moved by standard fork lift.When unpacked, the WCP frame is equipped with 4 lifting eyes on top of panel. Panel mustbe lifted and secured by the 4 lifting eyes during transport or lifting.It is highly recommended to unpack equipment as close as possible to installation point toprotect against damage during storage and transport.4.1.2 UNPACKINGBefore installation equipment must be unpacked, the wood box must be opened with acrowbar, or e.g. a circular saw (buzz saw) may be used to open the seaworthy box. The sawmust be carefully adjusted to a cutting dept of max. 2 mm though wood panels to avoiddamage of equipment.4.2 INSTALLATION OF WATER CONTROL PANELThe Water Control Panel can be located at the same deck as the probe or it can be locatedat decks below or above the probe. The maximum lengths of the water pipes form the WCPto the probe is 30 m equivalent pipe length, including bending and angles. Maximumvertical distance between WCP and probe 10 m. The WCP must be bolted to the foundationwith 12mm expansion bolts or similar. There must be 0.5 m free space above WCP in orderto open water tank lid.4.3 CONNECTION OF PIPESFour 1” steel pipes have to be connected to the Water Control Panel. Always flush waterpipes with water until it is clean before connecting them. This has to be done to avoid anydirt coming into the closed cooling water loop. If flax/hemp or similar is use for sealing ofjoints the flax/hemp must only be applied on the treads. When pipes are connected andflushed close all valves on Water Control Panel.4.4 CONNECTION OF WATER SUPPLYFor more information regarding required water quality see section 3.From constant available water supplyFrom constant available water supplyTo Water Control Panel1” union labeled “WS1”4.5 CONNECTION OF WATER DRAINFrom Water Control PanelTo Drain1” union labeled “WD1” To pressure free drain systemRev.: 0 / 07-01-09 / LHS Page 9 of 20

Unit Operation InstructionWater Control Panel4.6 CONNECTION OF PIPE LINES FOR COOLING WATERFrom Probe/Extraction DeviceTo Water Control Panel1” union labeled “WL1” 1” union labeled “WL1”1” union labeled “WL2” 1” union labeled “WL2”4.7 INSTALLATION OF CABLESThe stainless cabinet is equipped with cable gland for needed cable. The cable are describedin WCP cable list description. Cable must be connected according to system “Cable list”.Rev.: 0 / 07-01-09 / LHS Page 10 of 20

Unit Operation InstructionWater Control Panel5 SAFETY INSTRUCTIONNOTE warnings in section 2.4Safety procedure before work on WCPIssue:Procedure:Stop systemStop system according to the system manual.Shut off water supply Close water supply valve V3.1Stop the water circulation Turn off main switch 1Q1 and circuit breaker 2F1Close valve 3.2Empty the WCP from water Open valve V3.3 and let all the water run outClose valves V3.3Rev.: 0 / 07-01-09 / LHS Page 11 of 20

Unit Operation InstructionWater Control Panel6 FUNCTION DESCRIPTION OF WATER CONTROL PANELSee layout drawing “P&I Diagram”6.1 UNIT OVERVIEWWCPWS1V3.1C3.1B3.1C3.2ElectricalcontrolcabinetV3.2B3.2B3.3B3.4V3.3WL1WL2WD1Figur 1 WCP parts overviewHeatexchangerandWaterpumRev.: 0 / 07-01-09 / LHS Page 12 of 20

Unit Operation InstructionWater Control Panel6.2 PARTS P&ITag number Type FunctionA3 WCP Water Control panel (Default unit tagno.)WS1 Water supply 1 From constant available water supplyV3.1 Shut-off valve Manual shut-off valve for water supplyC3.1 Filter Separate coarse particles and iron particles form watersupplyY3.1 Solenoid valve Controlled by level switches and used for mark up waterlevel in tankC3.1 Water tank Water tank works as a buffer to ensure sufficient coolingwater in systemV3.2 Shut-off valve Manual shut-off valve for water to pumpM3.1 Pump Centrifugal pump, circulate the cooling water trough thesystemE3.1 Heat exchanger Air to water heat exchanger with electrical fan, which iscontrolled by water temperatureB3.1 PressuremeasurementPressure sensor used to check if there is flow troughcooling loopC3.2 PressureRestrictor to ensure pressure sensor functioncylinderV3.3 Shut-off valve Manual shut-off valve for draining the tankB3.2 High level Maximum water level switch, closes solenoid valve Y3.1switchB3.3 Low level switch Minimum water level switch, opens solenoid valve Y3.1and gives low level alarm after a delay in case refill doesnot occur.B3.4 Pt 100TemperaturesensorMeasures temperature in water tank and therebycontrols heat exchanger fan6.3 CIRCUIT BREAKERS1Q1 Main switch Switches of 3 phase power to WCP, not the 24 VDC2F1 Circuit breaker Switches of 24 VDC in WCP1F5 Thermal breaker Overload protection of pump1F7 Thermal breaker Overload protection of fan in heat exchanger5K1TemperaturecontrollerControls start and stop of fan on heat exchanger andgives high temperature alarm. The actual temperature inwater tank can be read on front of controller.6.4 CONTROL OF WATER CONTROL PANEL6.4.1 WATER FLOWThe water runs from water tank C3.1 through valve V3.2 to the pump M3.1. The pumppress the water through the KilnLoq probe, and back through the heat exchanger E3.1 tothe tank. The pump runs whenever power is on. The valves V3.1 and V3.2 have to be openduring normal operation. The drain valve V3.3 has to be closed during normal operation.Pressure switch B3.1 gives Unit alarm “B3.1_PAL” if the flow and thereby pressure dropacross C3.2 is insufficient. Pressure limits and flow curves for C3.2 are found in data sheetNo. 102823. The actual pressure is shown on the display of B3.1. Parameter settings forB3.1 are found in data sheet No. 102799.Rev.: 0 / 07-01-09 / LHS Page 13 of 20

Unit Operation InstructionWater Control Panel6.4.2 WATER LEVEL CONTROLThe water level is monitored by two level switches B3.2 and B3.3. If the water level is belowB3.3 solenoid Y3.1 opens for make-up water until the level reaches B3.2. If the water levelis below B3.3 more than 100 seconds Unit alarm “B3.3_LAL” is activated and the KilnLoqprobe is extracted from the process. The level sensors have a small LED turning red for dryand green for wet.NOTE: In case of using a Glycol mixture for antifreeze protection: When the Y3.1 auto fillfunction are enabled the cooling media will be diluted, and overtime the antifreezeprotection is void with risk of damage on system during stops etc. The auto fill function issimply disabled by closing valve V3.1.6.4.3 WATER TEMPERATURE CONTROLThe water temperature in the tank is monitored and controlled by temperature controller5K1 located in the control cabinet of the Water Control Panel. If the water temperature isabove the set point the controller starts the fan on heat exchanger E3.1. If the actualtemperature is above the alarm limit the Unit alarm “B3.4_TAH” is activated and the KilnLoqprobe is extracted from the process. Parameter settings for 5K1 are found in data sheetNo. 103095.6.5 COMMISSIONING OF WATER CONTROL PANELCheck following items: Mechanical installation (foundation, position etc.) Installation of pipe lines for cooling water according to 4.3 Installation of signal and power cable according to 4.7Carry out following items: Switch on power supply to Water Control Panel in the Gas Monitoring Unit. See circuitdiagram for GMU. Switch on “Main switch” on Water Control Panel Switch on all breakers except for 1F7 (water pump) in the control cabinet Close V3.2 and V3.3 and open inlet valve V3.1 – the tank is filling up. Open valve V3.3 in a couple of minutes to drain the tank for dirt. Open V3.2 and start water pump M3.1 on breaker 1F7 Check rotation for pump M3.1 and change two phases on the main power supply to theWater Control Panel if necessary. Open brass purge valve on pump M3.1 to empty pump for air. Add Glycol if needed.6.6 CLOSING DOWN THE WATER CONTROL PANELIf the WCP is going to be closed down follow the below:Issue:Procedure:Stop systemStop system according to the system manual.Shut off water supply Close water supply valve V3.1Stop the water circulation Turn off Thermal breaker 1F5Close valve 3.2Empty the WCP from water Open valve V3.3 and let all the water run outClose valves V3.3Rev.: 0 / 07-01-09 / LHS Page 14 of 20

Unit Operation InstructionWater Control Panel7 OPTIONSWater control Panel can be equipped with following options according to system data sheet.All options are to be ordered separately when system is configured.7.1 LOW TEMPERATURE CONFIGURATIONIn case of low ambient temperatures, the cabinet can be installed with a thermostatcontrolled heater. The heater is to be supplied externally from GMU according to cable list.Heater temperature is set from factory to 10°C by default.7.2 ULTRA LOW TEMPERATURE CONFIGURATIONIn case of extreme ambient conditions the complete WCP can be equipped with Lowtemperature shield and heating. Please referrer to separate datasheet according to systempart list for further details.Rev.: 0 / 07-01-09 / LHS Page 15 of 20

Unit Operation InstructionWater Control Panel8 MAINTENANCEBefore any maintenance or other work is performed on the WCP please referrer tosection 2.4 Warning and 5 Safety instruction8.1 GENERALThe analysis system must be maintained and checked daily, the following sections containsmaintenance sheets for each unitTo ensure optimal drift and highest possible run time, the equipment should be serviced byan authorised service engineer. The service interval can vary from 1-4 times pr. year.Please contact us at the email address or telephone mentioned below for: Proposal for a specific service agreement for the present equipment, 24h or normalcontract Preventive maintenance according to technical documentation Technical support Immediate service at breakdown8.2 SPARE PARTSWear parts and recommended spare parts are listed in a section of the parts list. To ensurethat the correct part is delivered when ordering spare parts, please provide FLSmidth withthe project number which is found on the “System Data Sheet” and the FLSmidth Part No.(6 digit) or Parts Id / Int. No.8.3 MAINTENANCE WATER CONTROL PANEL8.3.1 FILTER FOR MAKE-UP WATERClean filter C3.1 monthly or when required. C3.1 consists of a particle filter and a magneticpart.Issue:Procedure:Close for the water supply Close valve V3.1Clean the filter Clean filter C3.1Open water supply Open valve V3.18.3.2 WATER TANKDrain of sediment from water tank monthly or when required.Issue:Visual checkDrain the water tankProcedure:Open cover to tank and check for sediments on bottom of watertankOpen valve V3.3 for two minutes8.3.3 HEAT EXCHANGERClean cooling surfaces of E2.1 every month or when required.Issue:Procedure:Clean cooling surfacesUse compressed air very gently to cleanRev.: 0 / 07-01-09 / LHS Page 16 of 20

Unit Operation InstructionWater Control Panel8.3.4 WATER PUMPClean cooling surfaces and respirator fan of M3.1 every month or when required.Issue:Clean cooling surfacesClean respirator fanProcedure:Use compressed air very gently to cleanUse compressed air very gently to clean8.4 DISMOUNTING OF THE WATER CONTROL PANELIssue:Procedure:Stop systemPress “Start Off” on the HMI. See system operation manual forHMI operation.Shut off water supply Close water supply valve V3.1Power supply (local)Switch off power supply on “Main switch” on the Water ControlPanel and 24 VDC by switching off 2F1Power supply externSwitch off breaker for Water Control Panel at the feeding endCablesDisconnect power and signal cableDrain water tank Open V3.3 until the tank is empty. Close V3.3Pipe linesDisconnect all water lines (WL1, WL2, WS1 and WD1)Water Control PanelDismount Water Control Panel mechanically8.5 MAINTENANCE OF WATER CONTROL PANELRefer to section 8.3, to get instructions on how to do the maintenance in the following table.Date /Initials Maintenance program D W M YPipe connectionsXCheck the water pipes visually for leakage.CabinetXClean the inside of the cabinet. Use a vacuum cleaner toclean inside the cabinet. Never use compressed air.Drain the water tank:XDrain the water tank for sedimentClean heat exchanger surfaces E3:1XClean surfaces of water pump M3.1XFilter C3.1XDismantle, clean and replace any damaged parts.Anti freeze protection of water systemCheck that protection in appropriate according to localenvironment temperatures. Weekly or before stopsXRev.: 0 / 07-01-09 / LHS Page 17 of 20

Unit Operation InstructionWater Control Panel9 TROUBLE SHOOTINGAlarms may vary according to implementation in the system.FaultB3.1_PALB3.3_LALB3.4_TAHAlarmtypeUnitalarmUnitalarmUnitalarmMeaning Probable cause SolutionThere is nocooling waterflow throughKilnLoq probeThe water levelis below switchB3.3The watertemperature is10°C above setpoint1. Circuit breaker topump is off2. A valve is closed3. No power to WCP4. Pump is defect1. Make-up valve V3.1closed2. No extern watersupply3. Drain valve V3.3open4. Water pipe leakage.5. Probe leakage6. Filter C3.1 blocked7. Valve Y3.1 defect1. Heat exchanger notworking2. Temperature sensordefect1. Switch it on2. Check valve V3.2 isopen.3. Call skilled personal4. Replace pump1. Open valve V3.12. Establish watersupply3. Close valve V3.34. Tighten water pipes.5. Extract probe andcheck it for leakage6. Clean filter7. Replace valve1. Clean radiator. Checkfan is running2. Replace sensorRev.: 0 / 07-01-09 / LHS Page 18 of 20

Unit Operation InstructionWater Control Panel10 CONTACT INFOFLSmidth A/SGas Analysis TechnologyKlostermarken 6 · DK-9550 Mariager · DenmarkTel.: +45 7010 2277 · Fax: +45 7010 2288Main e-mail: gas@flsmidth.comService e-mail: gas-service@flsmidth.comCVR-No. DK 1502 8882www.flsmidth.com/gas11 DOCUMENT REVISIONRev. Date Author Description Serial numberscovered0 07-01-2009 LHS New doc. 48849 and forwardOldRev.: 0 / 07-01-09 / LHS Page 19 of 20

Document List:Unit ManualRevision List: Unit ManualCustomer Drawing No.:S-GENERI--1-000-50Rev. Date. Ini. Remarks0 27-08-2009 RBNWCP: P&I DiagramCustomer Drawing No.:S-GENERI--1-100-10Rev. Date. Ini. Remarks0 27-08-2009 RBNWCP: Water Control PanelCustomer Drawing No.:WCP: Component LayoutCustomer Drawing No.:Circuit diagram: WCP-BASICCustomer Drawing No.:S-GENERI--1-190-10S-GENERI--1-190-30S-GENERI--1-220-1Rev. Date. Ini. Remarks0 27-08-2009 RBNRev. Date. Ini. Remarks0 27-08-2009 RBNRev. Date. Ini. Remarks0 27-08-2009 RBNPart listCustomer Drawing No.:S-GENERI--1-300-10Rev. Date. Ini. Remarks0 27-08-2009 RBNFLSmidth Airloq A/SKlostermarken 69550 MariagerTlf: +45 70102277FLS Airloq Project : Generic documentationProject No. : S-GENERIAnalysis system : For serial no 48849 and forwardCustomer:End Customer:Rev. Date. Ini. Remarks.0 27-08-2009 RBNDrawing number:S-GENERI--1-000-501 / 1The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be duplicated, disclosed, or utilized without written consent from FLSmidth

A3WCPB3.1C3.2Y3.1C3.1V3.1WS1Water supplyE3.1PIB3.1PALB3.2B3.3B3.4B3.3LALTIV3.3V3.2B3.4TAHsM3.1pWL2WD1WL1FLSmidth Airloq A/SKlostermarken 6DK 9550 MariagerDenmarkProject / Plant name:basis V1_5 -Drawing title:WCP: P&I DiagramDrawing number (FLS Airloq):48849-WCP-100-10Drawing number (Customer):Drawing scale: Drawing units: Revision: Initials: Date:Nonemm 0 RBN 27-08-09The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be duplicated, disclosed, or utilized without written consent from FLSmidth

Eye bolt for liftingWS1: Water supply301956WL1: Water outlet to sample probeWD1: Water drainWL2: Water return from sample probe1360390Lid for water tank8004xØ13 for mountingFLSmidth Airloq A/SKlostermarken 6DK 9550 MariagerDenmarkDrawing title:WCP: Water Control PanelDrawing number (FLS Airloq):48849-WCP-190-10Project / Plant name:Drawing number (Customer):- For serial no 48849 and forwardDrawing scale: Drawing units: Revision: Initials: Date:1:16mm 0 RBN 07-01-09The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be duplicated, disclosed, or utilized without written consent from FLSmidth

6K45K44K13K53K25K31F71F52F15K1X00 10 1X35X36X37X38X39X34FLSmidth Airloq A/SKlostermarken 6DK 9550 MariagerDenmarkDrawing title:WCP: Component LayoutDrawing number (FLS Airloq):48849-WCP-190-30Project / Plant name:Drawing number (Customer):- For serial no 48849 and forwardDrawing scale: Drawing units: Revision: Initials: Date:1:4mm 0 RBN 07-01-09The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be duplicated, disclosed, or utilized without written consent from FLSmidth

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Part listWater Control Panel 104363Part ID Pcs. Part description Part No.Remarks / Part S/N FLS No ManufactorManual1F5 1 Thermal breaker, 0,9-1,25 A 3RV1011-0KA10 100792 SIEMENS1F7 1 Thermal breaker, 0,9-1,25 A 3RV1011-0KA10 100792 SIEMENS1Q1 1 Main switch, 25A 3P 194E-E25-1753/B 100783 ALLEN BRADLEY2F1 1 Circuit breaker, 1 pol C 6A 5SY4106-7 4001869206936 105198 SIEMENS3K2, 3K5, 4K1, 5K4,6K43K2, 3K5, 4K1, 5K4,6K455Relay, 2 pole, 24VDC G2R-2-SND-24DC(S)NEW 100264 OMRONSocket, 2 pole P2RF-08-E 100265 OMRON5K1 1 Controller, temperature, 24VDC E5CN-Q2TDU AC/DC24V For 11 pole socket103943OMRON5K1 1 Socket,11 pole,E5CN,DIN mount P2CF-11-E+ 103944 OMRON5K3 1 Contactor, 24VDC, 3P, 4kW 3RT1016-1BB41 100789 SIEMENSA3 1 Water Ctl. Panel, 50Hz, galv 104363 FLSMIDTH AIRLOQA3.1 1 Rack, galv, WCP 104362 FLSMIDTH AIRLOQA3.2 1 Tank, SS WCP 2162029 102821 FLSMIDTH AIRLOQA3.3 1 Cabinet, 600*600*210, SS (WCP) DK5222024 1010600+5499998 Prepared with holes 102161 RITTALB3.1 1 Plug, M12 with cable 438 680 F 102806 BÜRKERT-CONTROMATICB3.1 1 Switch, pressure 0-2 bar ½" 8311 / 439 908 H NPN/PNP, 12-30 VDC, Display102799BÜRKERT-CONTROMATICFLSmidthKlostermarken 69550 MariagerTlf: +45 70102277FLSmidth Project : Generic documentationProject No. : S-GENERIAnalysis system : WCPCustomer:End Customer:Rev. Date. Ini. Remarks.0 03-03-2010 RBNDrawing number:S-GENERI--1-300-101 / 7The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be duplicated, disclosed, or utilized without written consent from FLSmidth

Part listWater Control Panel 104363Part ID Pcs. Part description Part No.Remarks / Part S/N FLS No ManufactorManualB3.2, B3.3 2 Switch, level, VEGASWING 51 SWING51.XXSGATPV for WCP103919VEGAB3.4 1 Sensor, PT100 ½" 90mm KP5751941 104927 KJÆRULFPEDERSENC3.1 1 Filter, magnet 1" 5795349 1" 102285 FLSMIDTH AIRLOQC3.2 1 Pressure-cylinder, WCP 2162047 102823 FLSMIDTH AIRLOQE3.1 1 Heat exch., 380-480VAC 50/60Hz HN43.UWARAB.BKC 103921 GEA HAPPELE3.1-1 1 Cover, heat exch. HN43.UWARAB 2162044 103920 FLSMIDTH AIRLOQM3.1 1 Water pump, 380-415 VAC/50Hz 96516592 CR3-4 AAA-E-HQQE102280GRUNDFOSV3.1, V3.2, V3.3 3 Valve, ball, 1" 5795347 102289 FLSMIDTH AIRLOQY3.1 1 Valve, 2/2,1" Brass NC 24VDC 134 325 102842 BÜRKERT-CONTROMATICWater Control Panel 104364Part ID Pcs. Part description Part No.Remarks / Part S/N FLS No ManufactorManual1F5 1 Thermal breaker, 0,9-1,25 A 3RV1011-0KA10 100792 SIEMENS1F7 1 Thermal breaker, 0,9-1,25 A 3RV1011-0KA10 100792 SIEMENS1Q1 1 Main switch, 25A 3P 194E-E25-1753/B 100783 ALLEN BRADLEY2F1 1 Circuit breaker, 1 pol C 6A 5SY4106-7 4001869206936 105198 SIEMENSFLSmidthKlostermarken 69550 MariagerTlf: +45 70102277FLSmidth Project : Generic documentationProject No. : S-GENERIAnalysis system : WCPCustomer:End Customer:Rev. Date. Ini. Remarks.0 03-03-2010 RBNDrawing number:S-GENERI--1-300-102 / 7The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be duplicated, disclosed, or utilized without written consent from FLSmidth

Part listWater Control Panel 104364Part ID Pcs. Part description Part No.Remarks / Part S/N FLS No ManufactorManual3K2, 3K5, 4K1, 5K4,6K43K2, 3K5, 4K1, 5K4,6K455Relay, 2 pole, 24VDC G2R-2-SND-24DC(S)NEW 100264 OMRONSocket, 2 pole P2RF-08-E 100265 OMRON5K1 1 Controller, temperature, 24VDC E5CN-Q2TDU AC/DC24V For 11 pole socket103943OMRON5K1 1 Socket,11 pole,E5CN,DIN mount P2CF-11-E+ 103944 OMRON5K3 1 Contactor, 24VDC, 3P, 4kW 3RT1016-1BB41 100789 SIEMENSA3 1 Water Ctl. Panel, 60Hz, galv 104364 FLSMIDTH AIRLOQA3.1 1 Rack, galv, WCP 104362 FLSMIDTH AIRLOQA3.2 1 Tank, SS WCP 2162029 102821 FLSMIDTH AIRLOQA3.3 1 Cabinet, 600*600*210, SS (WCP) DK5222024 1010600+5499998 Prepared with holes 102161 RITTALB3.1 1 Plug, M12 with cable 438 680 F 102806 BÜRKERT-CONTROMATICB3.1 1 Switch, pressure 0-2 bar ½" 8311 / 439 908 H NPN/PNP, 12-30 VDC, Display102799B3.2, B3.3 2 Switch, level, VEGASWING 51 SWING51.XXSGATPV for WCP103919BÜRKERT-CONTROMATICVEGAB3.4 1 Sensor, PT100 ½" 90mm KP5751941 104927 KJÆRULFPEDERSENC3.1 1 Filter, magnet 1" 5795349 1" 102285 FLSMIDTH AIRLOQC3.2 1 Pressure-cylinder, WCP 2162047 102823 FLSMIDTH AIRLOQFLSmidthKlostermarken 69550 MariagerTlf: +45 70102277FLSmidth Project : Generic documentationProject No. : S-GENERIAnalysis system : WCPCustomer:End Customer:Rev. Date. Ini. Remarks.0 03-03-2010 RBNDrawing number:S-GENERI--1-300-103 / 7The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be duplicated, disclosed, or utilized without written consent from FLSmidth

Part listWater Control Panel 104364Part ID Pcs. Part description Part No.Remarks / Part S/N FLS No ManufactorManualE3.1 1 Heat exch., 380-480VAC 50/60Hz HN43.UWARAB.BKC 103921 GEA HAPPELE3.1-1 1 Cover, heat exch. HN43.UWARAB 2162044 103920 FLSMIDTH AIRLOQM3.1 1 Water pump, 380-440 VAC/60Hz 96517773 CR3-3 AAA-E-HQQE102828GRUNDFOSV3.1, V3.2, V3.3 3 Valve, ball, 1" 5795347 102289 FLSMIDTH AIRLOQY3.1 1 Valve, 2/2,1" Brass NC 24VDC 134 325 102842 BÜRKERT-CONTROMATICWater Control Panel 104365Part ID Pcs. Part description Part No.Remarks / Part S/N FLS No ManufactorManual1F5 1 Thermal breaker, 0,9-1,25 A 3RV1011-0KA10 100792 SIEMENS1F7 1 Thermal breaker, 0,9-1,25 A 3RV1011-0KA10 100792 SIEMENS1Q1 1 Main switch, 25A 3P 194E-E25-1753/B 100783 ALLEN BRADLEY2F1 1 Circuit breaker, 1 pol C 6A 5SY4106-7 4001869206936 105198 SIEMENS3K2, 3K5, 4K1, 5K4,6K43K2, 3K5, 4K1, 5K4,6K455Relay, 2 pole, 24VDC G2R-2-SND-24DC(S)NEW 100264 OMRONSocket, 2 pole P2RF-08-E 100265 OMRON5K1 1 Controller, temperature, 24VDC E5CN-Q2TDU AC/DC24V For 11 pole socket103943OMRONFLSmidthKlostermarken 69550 MariagerTlf: +45 70102277FLSmidth Project : Generic documentationProject No. : S-GENERIAnalysis system : WCPCustomer:End Customer:Rev. Date. Ini. Remarks.0 03-03-2010 RBNDrawing number:S-GENERI--1-300-104 / 7The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be duplicated, disclosed, or utilized without written consent from FLSmidth

Part listWater Control Panel 104365Part ID Pcs. Part description Part No.Remarks / Part S/N FLS No ManufactorManual5K1 1 Socket,11 pole,E5CN,DIN mount P2CF-11-E+ 103944 OMRON5K3 1 Contactor, 24VDC, 3P, 4kW 3RT1016-1BB41 100789 SIEMENSA3 1 Water Ctl. Panel, 60HzHV, galv 104365 FLSMIDTH AIRLOQA3.1 1 Rack, galv, WCP 104362 FLSMIDTH AIRLOQA3.2 1 Tank, SS WCP 2162029 102821 FLSMIDTH AIRLOQA3.3 1 Cabinet, 600*600*210, SS (WCP) DK5222024 1010600+5499998 Prepared with holes 102161 RITTALB3.1 1 Plug, M12 with cable 438 680 F 102806 BÜRKERT-CONTROMATICB3.1 1 Switch, pressure 0-2 bar ½" 8311 / 439 908 H NPN/PNP, 12-30 VDC, Display102799B3.2, B3.3 2 Switch, level, VEGASWING 51 SWING51.XXSGATPV for WCP103919BÜRKERT-CONTROMATICVEGAB3.4 1 Sensor, PT100 ½" 90mm KP5751941 104927 KJÆRULFPEDERSENC3.1 1 Filter, magnet 1" 5795349 1" 102285 FLSMIDTH AIRLOQC3.2 1 Pressure-cylinder, WCP 2162047 102823 FLSMIDTH AIRLOQE3.1 1 Heat exch., 380-480VAC 50/60Hz HN43.UWARAB.BKC 103921 GEA HAPPELE3.1-1 1 Cover, heat exch. HN43.UWARAB 2162044 103920 FLSMIDTH AIRLOQM3.1 1 Water pump, 440-500 VAC/60Hz 96553468 CR3-3 AAA-E-HQQE102796GRUNDFOSV3.1, V3.2, V3.3 3 Valve, ball, 1" 5795347 102289 FLSMIDTH AIRLOQFLSmidthKlostermarken 69550 MariagerTlf: +45 70102277FLSmidth Project : Generic documentationProject No. : S-GENERIAnalysis system : WCPCustomer:End Customer:Rev. Date. Ini. Remarks.0 03-03-2010 RBNDrawing number:S-GENERI--1-300-105 / 7The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be duplicated, disclosed, or utilized without written consent from FLSmidth

Part listWater Control Panel 104365Part ID Pcs. Part description Part No.Remarks / Part S/N FLS No ManufactorManualY3.1 1 Valve, 2/2,1" Brass NC 24VDC 134 325 102842 BÜRKERT-CONTROMATICRecommended spare parts 104663Part ID Pcs. Part description Part No.Remarks / Part S/N FLS No ManufactorManualA3, B3.1 1 Switch, pressure 0-2 bar ½" 8311 / 439 908 H NPN/PNP, 12-30 VDC, Display102799A3, B3.2, B3.3 1 Switch, level, VEGASWING 51 SWING51.XXSGATPV for WCP103919A3, M3.1 1 Water pump, 380-415 VAC/50Hz 96516592 CR3-4 AAA-E-HQQE102280BÜRKERT-CONTROMATICVEGAGRUNDFOSRecommended spare parts 104664Part ID Pcs. Part description Part No.Remarks / Part S/N FLS No ManufactorManualA3, B3.1 1 Switch, pressure 0-2 bar ½" 8311 / 439 908 H NPN/PNP, 12-30 VDC, Display102799A3, B3.2, B3.3 1 Switch, level, VEGASWING 51 SWING51.XXSGATPV for WCP103919A3, M3.1 1 Water pump, 380-440 VAC/60Hz 96517773 CR3-3 AAA-E-HQQE102828BÜRKERT-CONTROMATICVEGAGRUNDFOSFLSmidthKlostermarken 69550 MariagerTlf: +45 70102277FLSmidth Project : Generic documentationProject No. : S-GENERIAnalysis system : WCPCustomer:End Customer:Rev. Date. Ini. Remarks.0 03-03-2010 RBNDrawing number:S-GENERI--1-300-106 / 7The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be duplicated, disclosed, or utilized without written consent from FLSmidth

Part listRecommended spare parts 104665Part ID Pcs. Part description Part No.Remarks / Part S/N FLS No ManufactorManualA3, B3.1 1 Switch, pressure 0-2 bar ½" 8311 / 439 908 H NPN/PNP, 12-30 VDC, Display102799A3, B3.2, B3.3 1 Switch, level, VEGASWING 51 SWING51.XXSGATPV for WCP103919A3, M3.1 1 Water pump, 440-500 VAC/60Hz 96553468 CR3-3 AAA-E-HQQE102796BÜRKERT-CONTROMATICVEGAGRUNDFOSFLSmidthKlostermarken 69550 MariagerTlf: +45 70102277FLSmidth Project : Generic documentationProject No. : S-GENERIAnalysis system : WCPCustomer:End Customer:Rev. Date. Ini. Remarks.0 03-03-2010 RBNDrawing number:S-GENERI--1-300-107 / 7The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be duplicated, disclosed, or utilized without written consent from FLSmidth