air ejector

The Unique VIP Service Advantage Value, Integrity, Professionalism and Service

MODEL No. 62C32C CONDENSER AIR REMOVAL HOLDING SYSTEM


FOREWORD

This manual is designed to provide the system owner/operator with detailed information on the proper installation, operation, maintenance, and troubleshooting of a Steam Ejector Vacuum System. Your system is one of many thousands of similar units provided by Unique Systems, and the original developer of this technology, the Elliott® Turbomachinery Company. In 1985, Unique Systems purchased the Process Equipment Product Lines from Elliott®, and your system is an end product of almost 100 years of ejector testing and development work. This manual is written for and to be used with the following equipment:

SYSTEM MODEL 62C32C CONDENSER AIR REMOVAL HOLDING SYSTEM 15 SCFM HOLDING CAPACITY (PER ELEMENT)

SERIAL No. 09-1138

This system serial number is extremely important. It is the means by which Unique Systems, the designer and manufacturer of this equipment, can identify all information about your system. Please refer to this number on all communications with Unique.

*** CAUTION *** This system has been designed in accordance with applicable U.S. Codes and Standards. It is a piece of process equipment that utilizes high pressure/high temperature steam, high pressure cooling water, and (on some models) electrical components that can cause severe injury or death if misused, operated improperly, or operated in excess of design conditions. DO NOT operate this equipment other than in accord with these instructions. Particular care should be taken when operating this equipment, as surface temperatures in excess of 120 øF are present and may cause severe burns if touched with bare skin. USE EXTREME CAUTION when manually operating steam valves. Improper closing of isolation valves before or during operation may cause safety relief valves to ‘pop open’. Notice is hereby given that it is the responsibility of the installation contractor to pipe relief valves away from operator areas and vent to a safe location. In no case should maintenance be attempted while the system is in operation or while the steam supply is ‘on’ or the header is under supply pressure. All manual and automatic steam isolation valves must be locked closed and ‘tagged’ prior to any ejector component maintenance or removal.


STUDY THIS MANUAL!!

All operations and maintenance personnel are strongly encouraged to read and understand the contents of this manual. It includes detailed information on many system components (including component I&O manuals), drawings, and performance data that will be needed in the routine operation and maintenance of this equipment. Note that it is not possible to cover in this manual every conceivable operational contingency that may occur. If circumstances develop or problems occur that cannot be diagnosed and solved with the information in this manual, contact Unique Systems directly for assistance.

*** WARNING *** This equipment has been designed and manufactured for the process and utility conditions specified by the purchaser. It is warranted by Unique Systems for operation under those conditions. The user is hereby advised that making any changes to the design, materials, dimensions, or configuration of any component(s) may result in improper performance or hazardous conditions. Any changes or alterations to this equipment made without the express, written consent of Unique Systems Inc. will void the system warranty.

PERMISSION TO MAKE COPIES OF THIS MANUAL

Permission is hereby granted to the owner of the equipment described and referenced herein by Serial Number, to make copies of the contents of this manual sufficient for operation and maintenance needs. This manual is considered PROPRIETARY by Unique Systems Inc., and copies may not be made or distributed for persons or organizations for whom it is not intended, or used in a manner detrimental to the interests of Unique Systems, or it’s OEM customers.

© 2008 by Unique Systems Incorporated

The Unique VIP Service Advantage • Value, Integrity, Professionalism and Service •

TABLE OF CONTENTS

INTRODUCTION SECTION 1

Air Removal Systems – The Application Ejectors – General Principles of Operation Ejectors – Single & Multistage Operation SHIPPING & RECEIVING INSPECTION SECTION 2

Shipping Information Receiving Inspection Storage – Recommendations for On-site Cleaning & Touch-up

INSTALLATION SECTION 3

Foundation Requirements Piping Connections Suction Cooling Water

Vent Steam Drains & Traps

System Installation & Check-Out Mechanical Electrical

OPERATION SECTION 4

Typical Air Removal System Start-up Procedure Steam Pressure & Temperature System Shut Down Procedure

Normal System Operation – Continuous and Cyclical ROUTINE MAINTENANCE SECTION 5

System Component Checks Replacement Parts QuickCheck® Nozzles


TABLE OF CONTENTS

TROUBLESHOOTING & TESTING SECTION 6

Is it the Ejector System? Ejector Problems – Symptoms & Corrections Methods Poor Vacuum – Motive Steam Conditions Poor Vacuum – Mechanical Condition of Ejector Components Poor Vacuum - Improper Drainage Poor Vacuum – Excess Air Leakage & Testing System Component Problems Erratic Hogger Performance

GETTING HELP SECTION 7

Calling & Online Support Field Service Engineering

SPARE PARTS SECTION 8

Ejector Bills of Material Recommended Spare Parts List

SYSTEM DESIGN SPECIFICATIONS SECTION 9

Data Sheets Performance Curves DRAWINGS SECTION 10

CATALOG CUTS & COMPONENT MANUALS SECTION 11

SPECIAL INSTRUCTIONS SECTION 12 FORMS – RECEIVING & STORAGE INSPECTIONS SECTION 13 WARRANTY & CLAIMS SECTION 14 QC DOCUMENTATION SECTION 15


SECTION 1

INTRODUCTION

AIR REMOVAL SYSTEMS – THE APPLICATION Steam ejectors have been employed for removing air from steam surface condensers since the beginning of the ‘industrial revolution’ and the advent of steam power. They are the simplest, most reliable method known of pumping gases. In the air removal application, ejectors and condensers are employed to evacuate air (and any other non-condensable gases) from the steam space of the main condenser that services a steam turbine. This gas removal is done for the purpose of eliminating the ‘insulating’ effect that non-condensable gases have on the transfer of heat from steam through the tubes to the cooling medium. Without a vacuum system, air would severely reduce the efficiency of the heat transfer, resulting in the condenser surface area increasing many times for a given steam load. An ‘Air Removal System’ is designed to do just that – remove air. It does NOT ‘create’ the vacuum in a condenser. The condensation of steam from a vapor to a liquid actually creates the vacuum (a volumetric reduction on the order of 30,000:1 from 1” HgA to 30” HgA). This is an important point for the operator to understand. The ejector system is designed to remove air, plus water vapor of saturation at the point called the ‘air vent temperature’, which is typically sub-cooled 7.5 degrees F below the saturation pressure of the main condenser by a special ‘sub-cool’ tube bundle in the condenser. System capacity is usually determined by the recommendations given in the Heat Exchange Institute “Standards for Steam Surface Condensers” (latest edition), which gives recommended venting system capacities based on steam load, number of shells, and number of main openings in the main condenser shell. It should be noted that these ‘recommendations’ are not always followed by every condenser manufacturer, and the actual capacity of your specific system is listed on the ‘Ejector System Data Sheet” under SECTION 9 of this manual. A typical Air Removal System for steam condenser service consists of two major components – a ‘rapid evacuator’ ejector (often called a ‘hogger’), and a multi-stage, multi-element ‘holding system’. The ‘hogger’ is a single stage ejector of relatively large capacity that is designed to quickly evacuate the air from the condenser shell prior to steam being introduced to the turbine. Typical evacuation times are on the order of 30 minutes to 10” HgA (see the HEI Standards table for ‘Hogger Capacities’). Hogger ejectors are often designed based on the steam space volume and specified ‘pump-down’ time, which can result in rather large ejectors and high steam consumption for large wet surface condensers, and especially for ‘Air Cooled’ main condensers. Due to the very high generated noise levels of these ejectors, a discharge silencer is almost always included for noise attenuation. The hogger is always vented to atmosphere, since the relatively short operating cycle does not result in the wasting of large amounts of condensate. Note that hoggers are not always included in every air removal system. On smaller systems (less than 7.5 SCFM), it is common to evacuate the condenser using only the second stage ejector for this duty.

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The ‘holding system’ typically consists of two elements with two ejector stages for each element. It is designed to remove air that ‘leaks into’ to the condenser from various sources during normal turbine operation. These two stages are separated by an intercondenser, and the second stage discharges into an aftercondenser for noise attenuation and condensate recovery. Each two stage element is sized (usually) for 100% of the specified air removal capacity as recommend by HEI (or as required by the client’s engineer). Both elements can be mounted on a common inter/after condenser, or on separate condensers. There are a number possible configurations, but the most common is as shown in Figure 1 below.

FIGURE 1 Typical Two Stage/Twin Element Ejector Air Removal System

The first stage ejector draws air and vapor from the condenser sub-cool bundle air off-take, compresses it from design pressure to an ‘interstage pressure’. Steam is condensed in the intercondenser, and the second stage compresses the gases from this point up to atmospheric pressure. Typical system design requires only one element at time to operate, and the condensers are sized accordingly. It is not uncommon, however, for the system to be designed such that both elements can be operated simultaneously (see the ‘Ejector System Data Sheet’ for specific details on your system). Be sure to check the Ejector Spec Sheet to confirm that simultaneous operation is possible BEFORE attempting to do so.

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STEAM EJECTORS OPERATING PRINCIPLES Steam jet ejectors operate on a mass-velocity principle. The propelling steam expands isentropically through a divergent nozzle, converting its pressure energy into velocity energy (ranging from 2,500 to 5,000 ft/sec). The mass of high-velocity steam is discharged from the nozzle in a directed flow through an air chamber and into a convergent-divergent diffuser. As the steam passes through the air chamber it comes in contact with, and entrains, a definite mass of the vapors to be evacuated. It imparts to this mass a portion of its own velocity, and the resultant total mass at reduced velocity enters the diffuser where its velocity energy is, in the greater part, converted into pressure, thus permitting the resultant mass to be discharged at a pressure considerably higher than the pressure in the air chamber. The entrained mass is thus compressed from a low absolute pressure to some higher absolute pressure. SINGLE- & MULTI-STAGE EJECTORS When all of the desired compression is accomplished in a single diffuser, the unit is known as a single-stage ejector. A limited amount of compression may be accomplished more economically in a single-stage ejector than in a multi-stage unit. As with other gas compression apparatus, energy may, in some cases, be saved by affecting compression in several stages. Where the vacuum is high, the discharge pressure high, or the steam pressure low, multi-stage compression is desirable. In a multi-stage ejector, the total amount of compression desired is accomplished by dividing between two or more ejectors operated in series. The ejector which the entrained gases first enter is called the first stage, and subsequent stages are numbered in succession. It is usually desirable to connect a small condenser to the discharge of each diffuser primarily for the purpose of reducing all condensable gases to the liquid state, thus imposing on subsequent stages the work of compressing only those gases which are non-condensable. The condensers so employed are known as intercondensers. A condenser connected to the diffuser discharge of the final stage is known as an aftercondenser. Inter- and aftercondensers may be either direct-contact (barometric) or shell & tube (surface) condensers. A single-stage ejector requires no intercondenser, but an aftercondenser may be used, if desired. A two-stage ejector usually has an intercondenser between stages, and an aftercondenser may be employed, if desired. Where the capacity required is small, or the steam consumption is not important, or where space limitations will not permit installing an intercondenser, a two-stage ejector may be non-condensing with the discharge of the first stage connected to the suction of the second stage. Please see Figure 2 & 4. A three-stage ejector, except in unusual cases, employs two intercondensers, and an aftercondenser may be used, if desired. For unusually high vacuum and small capacity or where the temperature of the condensing water is relatively high the intercondenser between the first and second stages of a three-stage ejector may be omitted and the discharge of the first stage connected directly to the suction of the second stage. For very small capacities or where steam consumption is of little importance both intercondensers may be omitted. A four-stage ejector is used for very high vacuum. It does not have an intercondenser between the first and second stages. A five-stage ejector is used for extremely high vacuum. It does not have an intercondenser between the first and second stage or between the second and third stages.

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An intercondenser operates at pressures less than atmospheric; or, in other words, under vacuum. It is therefore necessary to provide means for draining the mixture of condensing water and condensed steam from a direct-contact (barometric) intercondenser, or the condensed steam only from a shell & tube (surface) intercondenser. An aftercondenser operates at atmospheric pressure and is provided with a vent to allow the air and non-condensable gases to escape. The aftercondenser does not improve the economy of an ejector and is used to recover the heat of the steam, to recover condensate, or to condense the steam from the final stage in order to prevent its being a nuisance.

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SECTION 2

SHIPPING, RECEIVING INSPECTION AND STORAGE SHIPPING INFORMATION The ejector system was prepared for delivery (typically via flatbed truck) at the factory. It was hydrotested for leaks and inspected in accordance with Unique Systems QC procedures (certificate is attached to this document, and sent with the shipping documentation). Digital photos are taken of the equipment before and after loading on the truck for record purposes. The unit(s) were drained thoroughly and all drain connections plugged. All openings were covered, and flange faces were coated with a corrosion inhibitor. A copy of this manual was also sent attached to the skid (usually on a CD-ROM). Please read carefully the instructions that follow relative to inspection and recording of any shipping damage. Every shipment for which Unique Systems is responsible (FOB,CIF, etc jobsite) will be fully insured for the replacement value of the equipment. All valves are shipped in the ‘OPEN’ position. All electrical panels or valve actuators were shipped ‘sealed’ and locked. Please note the instruction below, and in the actuator manuals (attached) instructions regarding energizing of space heaters for moisture control. Some components on the system may have been partially disassembled and attached to the skid. Appropriate ‘match-marks’ are made to facilitate re-assembly on site. A drawing showing final assembly configuration has also been attached to the skid. A number of components (such as drain traps, gauges, etc) are commonly shipped loose for field installation. A spray can of each paint used on the equipment is also included for ‘touch-up’ of minor paint damage that may occur during shipping and unloading. RECEIVING INSPECTION Immediately on receipt of the equipment, BEFORE UNLOADING, a careful inspection of the equipment must be done to note and record any shipping damage. A Unique Systems “SHIPPING AND RECEIVING INSPECTION REPORT” form is attached to the equipment, and a copy is also included with the shipping paperwork. This form MUST be completed and returned to Unique Systems if any claim is to be made for shipping damage. It is also required that digital photographs be taken of any damage, and sent with the Inspection Report Form. We strongly recommend that photos be taken of the equipment both before and after unloading for record purposes, even if no damage is noted. The Bill of Lading must be signed by an authorized person at the site, and a copy sent to Unique Systems with any damage claim.

*****NOTICE*****NOTICE*****NOTICE*****NOTICE***** Notice is hereby given that any claim for shipping damage made to Unique Systems will be rejected unless the SHIPPING AND RECEIVING INSPECTION REPORT FORM , a signed Bill of Lading noting damage, and supporting digital photographs are sent to Unique Systems within one week of the delivery date to the jobsite.

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Carefully check all packaging, crates, and boxes for parts and documentation before discarding for disposal. Documentation may be attached directly on the skid, or in some cases placed in a waterproof container or box strapped to the skid. If an electrical panel is part of the scope of supply, electrical drawings and documentation will be placed inside the panel. Any BOM items on the shipping documentation that are ‘missing’ must be noted on the signed Bill of Lading and receiving inspection form and transmitted to Unique Systems within one (1) week of delivery. Digital photographs of the equipment PRIOR TO UNLOADING, and after unloading, must be submitted with any claim. Unique Systems will maintain complete records and photographs of exactly what was included with each shipment. While documentation attached to the skid may not be complete, comprehensive, or even the ‘final’ or latest revision, it is extremely important that all such documentation be collected and secured in a safe location. This manual MUST be read by all on-site personnel that will be involved with the installation and start-up of the equipment. STORAGE The equipment has been prepared for on-site storage for up to six (6) months, PROVIDED that the following instructions are followed. It is highly recommended that the instructions given below under “CLEANING AND TOUCH-UP” be followed and performed BEFORE placing the equipment into on-site storage. All opening and connection points have been covered and flange surfaces coated with rust inhibitor. DO NOT remove covers unless there is reason to suspect damage or some other major problem. If any covers are removed, they must be replaced, in like fashion, prior to placing the equipment in storage. For ‘short-term’ storage (up to 6 months), equipment should be stored indoors whenever possible. It should be covered with a tarp and placed in an area where frequent moving and handling will not be required. If outdoor storage is the only option, the equipment must be covered with a waterproof tarp. The skid must be elevated at least 6” above the ground to allow for air circulation underneath. It must be protected from flooding, high winds, or direct sunlight. Careful attention must be given to electrical components (if any). In particular, motor actuators will have internal space heaters that MUST be energized at all times during storage. FAILURE TO COMPLY WITH THIS REQUIREMENT WILL VOID ANY PRODUCT WARRANTY FROM THE MANUFACTURER OR UNIQUE SYSTEMS. Instructions for required power supply and connection to the actuators is given in the attached Actuator documentation. Under no circumstances should actuator housings be removed and left off the actuator. ALWAYS replace the housing covers and secure according the instruction manual for that item. Some skid mounted control panels and junction boxes also contain space heaters for condensation control. If so, this will be noted on the panel face, and these items must also be energized for the duration of the storage. Instructions for electrical hook-up are noted on the drawing inside the panel. The panel face (door) must be secured and ‘locked’ after connections are made. All valves are shipped in the ‘OPEN’ position, and should be left in this position during storage. For some valves, a manual ‘open/close’ schedule may be required to prevent binding and seat decay. This will be noted in the ‘Special Instructions’ section (SECTION 12) of this manual if applicable.

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The equipment MUST be inspected at least once each month. An ‘ON-SITE STORAGE INSPECTION LOG’ report form included with this manual is provided for use in recording these monthly inspections. Any damage, paint failures, or other signs of trouble must be recorded on this form. Note that any claim for warranty repair or service during or after storage must be supported by transmittal of this log sheet to Unique Systems, which includes the date the damage was first noticed and the extent of the problem. Digital photographs must be taken to support any claim. Note that minor problems with rust, dirt, etc. are NOT considered a valid warranty item, as these can usually be prevented and/or corrected by the customer during storage or installation. For ‘long-term’ storage (durations longer than 6 months), INDOOR STORAGE IS MANDATORY, unless special provisions have been made part of the order for securing and protecting the equipment for extended outdoor storage. Whenever possible, the equipment should be stored in the same container or crate it was delivered in. Additional required protective measures (if any) will be noted under the ‘Special Instructions’ section of this manual (SECTION 12). Failure to follow these instructions, with supporting inspection report logs and digital photographs, will void any warranty by component manufacturers and Unique Systems. CLEANING AND TOUCH-UP It is common that equipment will arrive at the jobsite ‘dirty’, with dust, mud, etc. from the road trip. If the equipment will be put into ‘long-term’ storage, it must be cleaned prior to securing for storage, using a water spray and mild soap detergent to remove ‘road debris’. The unit should be carefully inspected (see above) for any signs of rust or paint failure, and these areas must be ‘touched-up’ immediately. Instructions for minor ‘touch-up’ are given under the ‘Special Instructions’ (SECTION 12) in this manual. Touch-up paint for each color and paint type is included on the skid for this purpose. DO NOT REMOVE RUST INHIBITOR COATINGS ON MACHINED SURFACES OR FLANGE FACES PRIOR TO INSTALLATION!! If these coatings appear to be partially removed from whatever cause, they must be re-coated prior to placing the unit in storage. Recommended coatings are given under the ‘Special Instructions’ section (SECTION 12) of this manual.

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SECTION 3

INSTALLATION

FOUNDATION The ejector system is designed to be mounted on any foundation material commonly used for heavy equipment in a process plant, and which will provide rigid support to the full area of the ‘load bearing’ members of the skid base. Details of the foundation dimensions and anchor bolt type, size, and location are shown on the equipment General Arrangement Drawing. If the equipment is mounted on a concrete foundation built on solid ground, each anchor bolt should be surrounded by a pipe sleeve 2 to 3 times the diameter of the bolt. The sleeves should be held rigidly by the concrete, yet allowing the bolts to be moved as required to conform with the holes in the skid base. Note that Unique Systems does not normally include anchor bolts or sleeves in the skid scope of supply. The equipment must be level and plumb in all directions. Shims may be used at anchor bolt locations if needed, but kept to a minimum. Tighten all nuts and bolts as required, and grout as required in accordance with common practice and local building codes. If the unit is to be mounted directly on structural steel framing, or on another piece of equipment (such as the main condenser shell), it should be located directly over, or as near as possible, to main structural members. If vibration transmission from nearby equipment is possible, consideration should be given to vibration isolation pads between the foundation and the skid support base. ‘Lock’ type washers are recommended for each bolt when mounting on structural steel foundations. PIPING CONNECTIONS SUCTION PIPING Good piping system design practice dictates that suction piping between the ejector system and the condenser or vessel must be kept as short as possible, with as few turns as possible. In no case should the diameter of the connecting piping be less than the inlet connection diameter of the suction connection on the ejector system. Any pipe runs longer than 100’ equivalent length require special consideration, and should be checked for pressure drop, as larger diameter pipe may be indicated. Under no circumstances should suction piping include any vertical u-bends, or loops, as this will result in ‘trap’ formation which will fill with condensate, thus severely restricting the inlet and causing serious performance problems. If, due to space or location circumstances a ‘trap’ is unavoidable, these low points must be automatically drained using a condensate drainer. Careful design of the drain piping and drainer location is essential to proper functioning of the drainer. All suction piping MUST be independently supported. In no case must the allowable forces and moments on the ejector system suction connection be allowed to exceed the value given on the equipment General Arrangement drawing, as this may cause damage and possible misalignment of the critical ‘nozzle-diffuser’ concentricity necessary for proper functioning of the ejectors. Piping, valves, strainers, etc. in the suction piping must NOT be supported off the ejector inlet manifold or connection nozzles of the ejector system.

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COOLING WATER PIPING Cooling water piping into and out of the condenser(s) must be of the same diameter as the condenser inlet/outlet connections. Flange ratings on the piping connections must also be the same as on the condenser(s). All piping must be independently supported, and forces and moments must not exceed the values listed on the ‘F&M” table on the General Arrangement drawing. EXHAUST (VENT) PIPING Vent piping from the ‘hogger’ ejector (if part of the system) must be discharged in a ‘safe’ direction, away from other equipment or areas where personnel may locate. It is HIGHLY RECOMMENDED that vent piping be directed vertically through the roof whenever possible. Horizontal discharge is NOT recommended. Consideration should be given to rainwater entering the piping system, with a ‘rain cap’ if necessary. The hogger silencer includes a drain connection that should be piped to a drain valve or automatic ‘drainer’ to remove water from the silencer and piping system. All vent piping must be independently supported, with careful design consideration given to thermal expansion criteria, and in no case should the allowable loads on the ejector system connection exceed the value given in the ‘F&M’ table on the GA drawing. The piping must be as short and straight as possible. Total vent piping pressure drop MUST NOT exceed 1 psi from the silencer discharge to the atmospheric outlet, based on the design flow rate of air and steam from the hogger ejector. UNDER NO CIRCUMSTANCES SHOULD A VALVE OR OTHER RESTRICTIVE DEVICE BE PLACED IN THE VENT PIPING OF AN ATMOSPHERIC EJECTOR. THIS WILL CAUSE A SERIOUS SAFETY HAZARD, AS THE EJECTOR AND SILENCER ARE NOT ‘PRESSURE VESSELS’, AND WILL BE DAMAGED IF EXCESSIVE BACKPRESSURE IS ALLOWED TO OCCUR. The atmospheric vent from the system aftercondenser must also be run to a ‘safe’ location, preferably outdoors. A silencer is NOT needed for this vent, as the aftercondenser itself provides adequate sound attenuation. The vent line must NOT have any valve or restriction that can isolate the discharge from atmosphere. Piping of at least the same diameter as the vent discharge connection on the ejector system must be used. Piping must be as short as possible, with as few turns as possible. It must be independently supported, and in no case should the allowable loads on the ejector system connection exceed the value given in the ‘F&M’ table on the GA drawing. STEAM PIPING The longevity and performance of an ejector will be seriously affected by the design and installation of the steam piping serving the unit. A poorly designed system will have a negative impact on the pressure and capacity the ejector can produce, and may cause erosion of the nozzle and diffuser such that they must be replaced on a ‘frequent’ basis. All steam piping must be independently supported, and the loads imposed on the skid piping connection must not exceed the value given in the ‘F&M’ table of the GA drawing. Careful consideration must be given to the steam supply piping to the ejector system, as the unit has been designed based on a specific supply pressure and temperature at the ejector system interface connection point. Pressure drop through the skid piping has been allowed for in the design of the ejector nozzles, but it is essential that the specified steam conditions are available at the system connection point. Any steam ejector is a ‘single point’ design as far as motive steam conditions are concerned, and any deviation -0% or +10% beyond this specified design point may cause improper operation of the ejectors (see below under ‘Troubleshooting’ for details). In some cases, a pressure regulating valve is included in the skid piping, and this device must be calibrated and adjusted properly to provide a constant pressure to the ejector nozzles, per the system design specifications. If variable pressure control is provided by others, it is essential that the regulator device be set to provide the supply pressure indicated on the design sheets.

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If the steam supply is less than +25 øF above the saturation temperature for the specified pressure (based on the design supply conditions at the conditioning station), consideration must be given to the installation of a moisture separator and trap. This circumstance often occurs when the ejector system is located at or near the end of a steam supply piping system. ‘Wet’ steam is a major cause of operational problems, and also causes severe damage to the internals of the ejector. Steam piping manifolds included with Unique Systems ejector systems include a ‘strainer’ that is designed to prevent particles large enough to cause damage or plug the nozzles from getting into the steam nozzles. The ‘blow-down’ of the strainer must be piped to a safe location. All steam supply piping to the ejectors (including the piping manifold on the ejector skid, if any) MUST be insulated for personnel protection, preferably after the equipment is installed on its permanent foundation. Temperatures well in excess of 350 øF are common, and will cause severe injury if accidentally touched. Insulation will also help prevent heat loss and the formation of condensation in the steam supply to the ejector nozzles. CONDENSATE DRAINS & TRAPS Drain piping is, by far, the most common source of start-up and operational problems associated with ejector systems. The inter and after condenser drain lines must be of the same size as the fitting on the unit, and NOT reduced in size or combined together to the discharge location. The ideal intercondenser drain configuration is a ‘loop seal’, which is essentially a trap that maintains a barometric leg between the intercondenser and the drain collection point (most commonly the main condenser hotwell or a condensate collection tank that operates at the same pressure as the main condenser). IC/AC Drain Trap Installation Drawing 502293 shows the required minimum dimensions required to insure proper operation of a loop seal, or a ‘float - type’ drainer configuration. Refer to the drawing section (SECTION 10) of this manual. All drain lines must be kept as short and straight as possible. Design of the piping runs MUST allow for a minimum slope of ¼” per foot of horizontal length. All vertical turns in the drain line should be vented back to the condenser shell, or if no fitting is available, to a ‘tee’ in the drain line located just below the condenser drain connection. Traps should also be vented to the same location, using a minimum ¼” diameter tubing. Drain lines for loop seals should be run to a connection BELOW the ‘low water’ level in the hotwell or condensate tank. Drain lines for traps should be run to a connection ABOVE the ‘high water’ level in the hotwell or condensate tank. Traps must be installed in the proper orientation or they will not function. This is usually noted on the trap body, and also in the documentation for this item included in the manual (SECTION 11). It is very important that the drain and vent lines from the inter and after condensers be kept completely separate, and not combined or connected in any way. Cross-connected drain or vent lines will cause flooding, ‘short-circuiting’ of air, and operational problems with the ejector system.

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SYSTEM INSTALLATION AND CHECK-OUT Using the above ‘general precautions’ as a guide, installation of the ejector system is a straight-forward process. Take care to lift the system by the method shown on the GA drawing only. Note in particular the cautions regarding piping connections and design. If, due to constraints of a particular installation very long runs of pipe are required for suction or vent piping, or if many ‘twists and turns’ are required, Unique Systems should be consulted prior to fabrication or installation of piping connections. Excessive pressure drop will result in overall ‘condenser-vacuum system’ performance that will not meet expectations. The same care should be used in drain piping design (see above). When installing the unit on the foundation and before connecting piping, all flange faces must be cleaned of rust inhibitor. Use a solvent as recommended by the inhibitor manufacturer (see SECTION 12). Carefully check flange faces for any damage, including nicks, scratches, etc. Use of the proper gasket material is critical to obtaining a proper seal. For most flange connections, non-asbestos ‘impregnated fiber’ type gaskets (BG-3000, for example) is adequate. In some cases, such as for high pressure cooling water connections, a recessed or ‘o-ring’ type gasket may be required. When applicable, this will be noted on the GA drawing. For flanged connections in the motive steam line, a graphite impregnated gasket is recommended. Certain connections will require ‘flexitalic’ gaskets (metal bound), which will be noted on the BOM. It is of vital importance that all piping systems connected to the ejector system be thoroughly cleaned prior to final assembly. Although ejector systems are not nearly as susceptible to debris damage as rotating machinery, some components, such as resilient seated valves, can be damaged by metallic debris. Fine particulates will cause problems by clogging nozzles, strainers, and drain trap orifices. MECHANICAL The installed system should be checked for mechanical operation of all valves. All bolts should be tightened to the recommended torque. NEW GASKETS ONLY should be used on all flanged connections, if for any reason a flanged connection is broken during installation (or any other time). All strainers should be inspected and cleaned, if necessary, before start-up. If large quantities of particulates are found in the system, it should be flushed thoroughly before start-up, as this debris will cause problems during the start-up process if left in the system. Before installing insulation on steam piping (or any other system component), be sure to carefully inspect the condition of the paint on all surfaces. Field touch-up should be done where necessary to remove any rust or areas where the paint has been damaged during the installation work. BE CERTAIN that all safety relief valves are piped in accordance with applicable codes, and that all vents are located so as prevent accidental injury in the event the valve(s) open. Each relief valve should be ‘opened’ using the manual lift lever to insure it is not ‘stuck’ in the closed position prior to start-up. There are three different ‘pressure design zones’ on a typical ejector system: the steam piping, the tube side of the inter/after condensers, and the ‘shell side’ or process side of the system. Each was hydrotested at the factory in accordance with applicable codes and quality control procedures (hydrotest certificates are included under SECTION 15, and with a “QC” document package submitted after shipment to the customer). If for any reason the factory installed piping or component must be removed at the jobsite, the client must determine, based on local codes and insurance regulations, whether the unit should be re-hydrotested. Hydrotest pressures are indicted on the GA drawing. Contact Unique Systems if any assistance is required.

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ELECTRICAL If electrical components are included on the system, they will have been tested at the factory for proper operation and wiring. However, it is not uncommon for wire connections to loosen during shipping and installation, and a qualified electrician should thoroughly inspect all connections for tightness. Proper wiring is, of course, essential to correct functioning of the device, and an electrical ‘continuity’ check should be made for all connections. When wiring is complete and power is available, each actuator should be operated across the entire range to insure proper operation and setting of limit and torque switches (see Actuator Instruction Manuals in SECTION 11). For pneumatic actuators, the solenoid valve connections should be checked for proper wiring, and the pneumatic regulator should be set for delivering the correct air pressure. Limit switches should be adjusted as required. For skid mounted electrical panels or junction boxes, be sure to check the setting on any space heaters, timers, safety switches, etc. prior to start-up. A continuity check of all connections from the panel to the plant DCS should be done prior to operating the valves (or other device) electrically. All panel doors must be fully closed and ‘locked’ prior to start-up.

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SECTION 4

OPERATION

TYPICAL AIR REMOVAL SYSTEM START-UP Starting up a ‘new’ plant for the first time (really every time!) is a challenging process. Many pieces of equipment must be brought up to operating condition simultaneously, some of which (such as steam turbines) require a lot of adjustment. During the ‘break-in’ or initial start-up period for a new plant, it is very common that there are many air leaks in the system that must be found and ‘fixed’ before much progress can be made. Volumes have been written on this subject, and it is emphasized that EVERY POSSIBLE source of air leakage must be found and fixed. Additional information on ‘leakage testing’ is given under SECTION 6. A typical start-up process for an ejector system is as follows. Once motive steam is available and the Turbine Gland Seal System is operating, the hogger ejector is started (manually or remotely) by FIRST opening the motive steam isolation valve, and then slowly opening the inlet isolation valve. The unit will begin evacuating air from the condenser and turbine. This will continue until a pressure is reached where it is possible to introduce steam to the turbine (as determined by the turbine manufacturer), typically between 10” and 6” HgA. The condensate (or cooling water, as applicable) pumps are started to provide water to the inter/after condenser(s). When the pressure in the condenser reaches the pre-determined point, the SECOND ejector stage of the holding system (mounted on the aftercondenser) is started, first by opening the steam isolation valve, and then the process isolation valves. In some cases, it is necessary to start both first and second stages simultaneously, which is acceptable as long as cooling water is flowing through the inter/after condenser tubes and the suction pressure is at or below 5” HgA. When holding system operation is stable (usually within a minute or so), the hogger ejector should be shut-down. It must be noted that the hogger ejector provides very little capacity below 6” HgA, and once steam is introduced into the condenser, it is moving mostly water vapor, so it may as well be shut down. CAUTION is indicated if the operation of the hogger is continued below 5” HgA, as the unit can begin to ‘break’ (stop pumping), which can cause live steam to flow back out the hogger ejector suction into the holding system and back into the condenser. This may cause damage to resilient valve seat materials and other components. During new plant start-up it is common to operate both the hogger and holding ejectors simultaneously (necessary due the very high leakage rate typically present), and it is recommended that the system be monitored closely to be sure ‘blow-back’ is not occurring. With the hogger shut-down, the holding system continues to evacuate the condenser down to the pressure where the condenser is operating on its thermal curve, based on load and circulating water temperature. It must be noted that this is the ‘ideal’ condition after air leaks have been plugged and the leakage rate to the vacuum system is below the system capacity. If excess air leakage is present, air will tend to remain in the condenser, and the backpressure will be higher than design.

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When the system stabilizes at the operating point, it is recommended that the air leakage meter on the holding system be used to take occasional readings, especially for new plants or plants that are being started after an extended outage. This should be monitored regularly to be sure new leaks do not ‘spring up’ and reduce the overall system efficiency. The air leakage meter is not intended to be a ‘very accurate’ device; it will give a relative reading on how much air is being pumped by the system. Typical selection of these flow meters will have the system design capacity at the center of the scale of the meter. If the meter is ‘pegged’ against the top, that is a good indication that there is excessive air leakage, and corrective action must be taken. STEAM PRESSURE AND TEMPERATURE As previously indicated, the quality of the motive steam supplied to the ejectors is vital to proper operation. Supply pressure must be within -0% +10% of the specified pressure on the system data sheet, or the capacity and suction pressure capability of the unit will be below specified requirements. Increasing the supply pressure to more than 10% of the system rating WILL NOT increase capacity or improve performance. In fact, this will likely DECREASE capacity and degrade system performance. This is very important for another reason: if the vacuum system is ‘limiting’ the performance of the main condenser, the backpressure will rise, which means that the condensate temperature to the inter/after condensers will increase. If this occurs to the point where the temperature is above maximum design, the AIR handling capacity of the system will decrease as it becomes more and more over-loaded with water vapor. This negative spiral of events will continue until the backpressure increases to the point where the turbine will trip. During every start-up cycle, the motive steam supply condition (pressure and temperature) must be monitored closely until plant operation is stable. This is particularly important for ‘cyclical’ operation, such as is common with Combined Cycle plants, where the steam supply can vary considerably depending on gas turbine/HRSG operating conditions, load to the steam turbine, etc. Steam supply temperature is also critical. If the temperature is too low, wet steam can cause an ejector go ‘unstable’, the capacity will drop dramatically, and possibly stop pumping. If the temperature is too high, it will result in insufficient mass flow through the nozzle (because the specific volume is increasing beyond the design point), which will result in lower ejector capacity. Careful adjustment and monitoring of the steam conditioning system (pressure regulation valves and desuperheating system) is essential to insuring proper ejector system performance. SYSTEM SHUT-DOWN Shutting down the ejector system is a straight forward procedure. Once steam supply to the turbine is stopped, the PROCESS isolation valves on the ejector system can be closed. After a few seconds, the motive steam isolation valves can be closed also. Vacuum in the condenser will decay gradually, or (where applicable) the vacuum breaker valves on the condenser shell can be opened to quickly bring the unit up to atmospheric pressure. The cooling water (typically condensate) system should remain operating until the motive steam supply to the ejectors is off. NORMAL OPERATION – CONTINUOUS & CYCLICAL An ejector air removal system can operate on almost any operating cycle required in a power plant. This ranges from 24/7 for months of un-interrupted operation typical of a ‘base load’ thermal plant, to ‘up and down’ cycling several times a day that can occur in some combined cycle units. Regardless of the nature of plant operations, a ‘well operating’ ejector system will be essential to meeting the plants heat rate requirements and on-line availability guarantees. Once the unit as been started and the steam turbine is operating at the required load, the ejector system does not usually require further operator attention. However, it is very important that key operational data be collected routinely during operation. This will allow analysis of parameters such as potential component wear and maintenance scheduling, plant performance analysis, etc. Typical data that should be collected at some regular intervals during system operation include:

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Pressure (vacuum) level in the condenser Condensate temperature (in and out of the inter/after condensers) Steam turbine load Air leakage test data (from the skid mounted air leakage meter) Motive Steam pressure and temperature Main condenser cooling water supply temperature Recommendations are given under 6 (Troubleshooting) regarding periodic checks of the ejector ‘blank-off’ pressure for evaluating the performance of both first and second stage ejectors. All this data should be stored in a format that can be plotted and presented for analysis. It will be very useful for evaluating plant performance and troubleshooting problems. This becomes all the more critical for ‘cyclical’ operation, common with combined cycle plants, as there are many variables that can effect plant operation from day-to-day, even hour-to-hour. A ‘normally operating’ ejector system (in holding mode) should not exhibit any unusual noise or vibration. Since an ejector has no moving parts, a trained ‘Mark 1 Human Ear’ is the best method of detecting potential operational problems. The operator will quickly become familiar with what ‘normal’ means in this regard, and should be aware of unusual circumstances when they develop. For example, a loud ‘hammer’ noise from the ejectors, which may include a ‘surging’ noise, is indicative that one or more of the ejectors is ‘breaking’, and the process vacuum gauge may show considerable variation in suction pressure. This indicates a potential major problem that must be investigated (see ‘Troubleshooting’). Water droplets or even a flow of water out of the vent is indicative of a flooded aftercondenser, suggesting that the drain trap is not functioning, etc. On some units there is an isolation valve on the discharge of each first stage ejector (the ‘Y’ stage, connected to the process, as opposed to the second stage, which discharges to atmosphere through the aftercondenser). This item is NOT used during normal operation. It is intended only for removal of one first stage ejector for maintenance while allowing operation of the system with the ‘stand-by’ ejector. Closing this valve will result in the ‘popping’ open of the safety relief valve on the first stage ejector body when the motive steam is turned on. While not a ‘hazard’ from the standpoint of safety, it obviously is not ‘normal’ operation, and serves no operational purpose, but only wastes steam.

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SECTION 5

ROUTINE MAINTENANCE

One of the main reasons ejectors are used routinely in power plants is that they are so simple and reliable. It is not uncommon for an ejector system to operate for many years with literally no maintenance. While it happens, it is by no means recommended that the old saw “if it ain’t broke, don’t fix it” should govern a piece of process equipment, no matter how reliable it may be. Proper, regular attention to the ejector system will help insure that it remains reliable, and performs at peak efficiency. The following is offered as a guide only as to what should normally be checked on a ‘regular’ basis. ‘Regular’ means whatever is determined for a given plant, usually based on scheduled outages for a week or more. Ejector system checks and routine maintenance can usually be accomplished in these periods, unless a major problem develops (fortunately this is very rare) that would cause a complete system outage. SYSTEM COMPONENT CHECKS Ejectors should be physically inspected at least yearly to check on the condition of the critical internal geometry, in particular the nozzle throat and the diffuser throat. Most Unique Systems ejectors incorporate our patented QuickCheck® steam chest that makes this task very simple. Instructions for the gage rod are given in the QuickCheck® brochure in SECTION 12 (Special Instructions). If there is any reason to suspect the ejectors have been exposed to wet steam, or have not been visually inspected for a number of years, they should be removed and the condition of the nozzle exit taper and diffuser inlet taper be examined for signs of pitting, wire drawing, severe erosion, etc. Any components showing this type of wear should be replaced. Be sure to use new gaskets when re-assembling an ejector. Inter/after condensers will normally not need any type of ‘routine’ maintenance. The condition of the tubes should be checked after the first 5 years of operation by visual inspection. New gaskets should always be used whenever a piping connection is removed. If a tube should spring a leak, common practice is to insert a ‘plug’ in both ends of that tube. This can normally be done without significantly effecting system performance, but it is not recommended that more than 5% of the total number of tubes be plugged. Should this circumstance develop, an investigation should be made as to the cause of ‘excessive’ tube failure, and these tubes should be replaced. Consideration may need to be given to replacing the entire tube bundle if a significant number of tubes have ‘failed’, as this is not a common occurrence. Cleaning of the condenser tubes is normally done using chemical methods. Mechanical cleaning is not normally required, as this application is one of the ‘cleanest’, with treated condensate as the fluid on both sides of the tubes. Mechanical cleaning is indicated only if sever scaling is present. Valves do not normally require routine maintenance. Any leaks should be investigated, and the packing or seats tightened or replaced as required. The condition of ‘resilient seated’ valves, such as butterfly or ball type, should be checked annually for signs of hardening, cracking, or ‘flaking’ due to excess temperature or chemical attack. If there is any reason to suspect the condition of a valve seat, it should be replaced.

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Valve Actuators on systems which have pneumatics or motors should be checked annually. Catalog cuts and maintenance instructions for the devices on this specific system are included in this manual in SECTION 11 with any special requirements given in SECTION 12. Each actuator should be cycled several times through open/close, and the function of electrical components such as limit switches and solenoid valves checked. Instrumentation should be checked annually for calibration. Many plants have set up ‘calibration centers’ in the maintenance shop for pressure and temperature gauges, or have this done by local contractors. This is very important, as the veracity of the data collected during operation depends on the accuracy of the instrumentation used to collect the information. Any gauge which does not calibrate reliably, or which consistently gives readings that vary significantly from other instrumentation in the same process should be replaced. Transmitters which send a 4-20ma signal to the control system should also be calibrated at least annually. Most such units today are of the ‘smart type’, with modular circuits that allow easy ‘on-line’ calibration or replacement of component boards that will not deliver a consistent, repeatable signal. The accuracy of the data collected is critical to proper operation and plant evaluation, so any component which does not provide reliable operation must be replaced. The air flow meter on the ejector system vent is not intended to be a ‘highly accurate’ device. It will give an indication of the relative amount of air that the ejector system is pumping out of the condenser, which is indicative of the amount of air leaking into the condenser. This device does not require routine maintenance, but should be checked for damage annually. Excessive amounts of liquid water in the form of droplets can damage the unit. Internals of this item are not considered ‘replaceable’, and if indicated, the entire meter should be replaced. Any ‘special’ instrumentation that may be installed for a specific system will have catalog and maintenance instructions included in SECTIONS 11 and 12 of this manual. REPLACEMENT PARTS Replacement parts for any component included with the original scope of supply can be obtained directly from the system supplier. Information needed to identify any component is as follows: System Serial Number (listed in the ‘Forward’ to this manual, and on numerous drawings and data sheets) Part Number or Item Number – as listed on the General Arrangement Drawing or Ejector BOM. In addition, a ‘Recommended Spare Parts List’ is included in this manual under SECTION 8. This list contains items that ‘normally’ require replacement on average every 5 years of operation, although this can vary considerably from plant to plant. Normal delivery times are given to aid in planning what specific items should be kept in stock ‘on-site’. QUICKCHECK® NOZZLES The Unique Systems patented QuickCheck® nozzle system allows an operator to check on the condition of the critical nozzle and diffuser throat diameters in as little as 15 minutes, without disassembling or removing the ejectors or steam piping. This feature includes a Performance Gage RodSM that is a ‘go/no-go’ dimensional check. If the rod passes through the nozzle or the diffuser throat, it is time to replace that component as it has worn past the maximum allowable dimensional tolerance. Operation of the ejectors at this point is ‘marginal’, and it is reasonable to expect that the capacity and vacuum range of the ejectors has diminished at least 10+% from the original ‘new unit’ design. Replacement of the nozzle is quick and easy, as it can be removed without further disassembly of the unit. Replacement of the diffuser will require removing the ejector from the system. Note the QuickCheck® feature is not standard on ejectors larger than 6” in inlet diameter, and it may not be included on every ejector that is part of the system.

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SECTION 6

TROUBLESHOOTING AND TESTING

IS IT THE EJECTOR SYSTEM? It is quite normal, when there is an apparent problem with maintaining the required vacuum level in the condenser, to immediately look at the ejector system and assume that the cause of the problem is there. However, without a well thought out plan to troubleshoot the problem in a logical, systematic manner, the operator will spend a lot of time ‘going in circles’ without finding the root cause of the problem. Inadequate vacuum levels can be caused by a number of things that have nothing to do the ejector system, and these must be investigated first. Fortunately, the checks for these causes are relatively simple and straightforward. If an ejector system is operating as designed, it is removing all the air that leaks into the condenser and the condenser is operating on its design curve as a function of steam load and cooling water temperature. It is very common, especially with Combined Cycle plants, that steam loads to the condenser can vary considerably depending on the gas turbine operating condition, how many CT’s are operating, etc. Seasonal and even hourly changes in load can cause wide swings in condenser backpressure at any given time. Before suspecting the vacuum system, the condenser curves should be examined to determine what the actual backpressure should be as function of load and cooling water temperature. In some cases, particularly in colder months, the backpressure may try to drop lower than the minimum design capability of the ejector system (in low partial load cases with cold cooling water). In these cases, the ejector system may indeed by ‘limiting’ in terms of available capacity, but there is no operational problem with the unit. Check the ‘Ejector System Data Sheet’ in SECTION 9 for confirmation of the operational design parameters of your particular system. A common cause of inadequate vacuum in the condenser is excessive air leaks. If the air in-leakage rate exceeds the design capacity of the ejector system, air will tend to ‘accumulate’ in the steam space of the condenser, which acts to insulate the tubes and reduces the efficiency of the heat transfer process. The result is that for a given load and cooling water temperature, the condenser will operate at a higher absolute pressure than indicated on the performance curve. This is NOT due to a problem in the ejector system, but rather in the condenser and/or associated piping system. If the steam turbine gland seals are worn, or the gland steam vacuum system is not functioning properly, excess air will get into the condenser from the turbine. This obvious source of air leaks should be checked if the air flow meter on the ejector system indicates excess leakage. Additional information on checking for air leakage is given below. If all the above has been checked and inadequate vacuum is still a problem, attention should be focused on the ejector system. As indicted, a logical, systematic troubleshooting schedule should be followed based on the indicated problem and the ‘most common’ causes.

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EJECTOR PROBLEMS – SYMPTOMS & CORRECTIIVE METHODS The most common ‘problem’ with an ejector system is basically described as ‘inadequate vacuum’, meaning that the pressure level in the condenser is too high, based on where the condenser curve indicates the unit should be operating for a given load and cooling water temperature. If the ‘most common’ cause is indicated – excessive air leakage – proceed to item “4” below for suggested methods of correction. There are a number of parameters that can cause improper functioning of an ejector system, and each is addressed as follows.

1. SYMPTOM: POOR VACUUM (UNSTABLE OPERATION) - MOTIVE STEAM CONDITIONS

Every steam ejector is designed for a very specific motive steam supply condition (pressure and temperature), and is actually quite sensitive to any changes in the supply conditions. ‘Critical Flow’ ejectors – typically those designed to discharge to atmospheric pressure, are very sensitive, as are ejectors operating at very low absolute pressures (not common on condenser air removal systems). IT IS ESSENTIAL THAT THE DESIGN MOTIVE STEAM PRESSURE AND TEMPERATURE BE MAINTAINED AT THE SYSTEM INTERFACE CONNECTION POINT FOR PROPER EJECTOR OPERATION. For the most reliable operation, Unique Systems recommends that the motive steam pressure supply to the ejector system be maintained with a MAXIMUM tolerance of -0% to +10% of the design pressure listed on the system data sheets. The motive pressure is also stamped on the ejector nameplates. Note, however, that the ‘stamped’ pressure is typically several psi BELOW the system design pressure, as the nameplate rating allows for a calculated pressure drop across the system manifold piping, valves, strainers, etc. It is important that the operator maintain the pressure listed on the system data sheet. a) LOW MOTIVE PRESSURE - If the motive pressure is allowed to drop below the design point, ejector operation may start to go ‘unstable’, characterized by fluctuating vacuum gauge readings, and possibly a ‘hammer’ or ‘surging’ noise from the ejectors. Even if they are not ‘breaking’, the capacity is dropping rapidly, and will reach a point where the ejectors will definitely ‘break’ and stop pumping. When this occurs, all you have is ‘steam blowing through a pipe’, with no compression of the inlet gases. The system capacity is in effect ‘zero’ when this occurs. Solution – Increase motive supply pressure to at least the system design pressure listed on the data sheets. b) HIGH MOTIVE PRESSURE - If the motive pressure is increased beyond 10% of the design point, no actual benefit is obtained in terms of added capacity or compression range. Since the diffuser diameter is ‘fixed’, increasing motive pressure will result in more steam flow through the nozzle, which at some point will ‘choke’ the diffuser, causing a decrease in inlet capacity. If pressure is increased beyond 20% of design, it is likely that the unit will ‘break’ (stop pumping), as the diffuser is choked with too much mass flow, and steam can start to ‘back-flow’ out of the suction connection. Solution – Decrease motive supply pressure to within +10% of the design pressure listed on the system data sheet.

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c) HIGH MOTIVE TEMPERATURE - Motive steam temperature is also critical to ejector performance. The steam nozzle and diffuser geometry design is a function of the specific volume of the mass flow, which is a function of temperature at any given pressure. If the temperature of the steam is too high above design, insufficient mass flow will pass through the nozzle which will reduce the inlet capacity of the ejector. Solution – Adjust the steam conditioning system to maintain the motive supply temperature to within +50 °F of the design temperature listed on the system data sheet. d) LOW MOTIVE TEMPERATURE (WET STEAM) – Caused by the presence of water droplets in the motive supply due to the temperature dropping below the saturation point at a given pressure, is a common and serious problem. Symptoms of wet steam include fluctuating vacuum gauge readings and fluctuating steam pressure gauge readings, which will coincide. Not only does wet steam seriously effect ejector performance, it will also cause major damage to the critical internal geometry of the ejectors, and greatly decrease unit longevity. Solution – Adjust the steam conditioning valve to maintain a minimum 25 °F above the saturation temperature at the supply pressure. On systems where ‘Dry & Saturated’ steam is the design point, check traps and separators in the steam supply to the ejector system for proper operation. It may be necessary to install a separator and trap if they are not in the piping system. They should be located as close to the ejector system as practical. Be sure motive steam lines are insulated.

2. SYMPTOM: POOR VACUUM - MECHANICAL CONDITION OF EJECTOR COMPONENTS

If steam conditions are set correctly but poor vacuum still persists, the next step is to check the condition of the ejector itself. Before removing the ejector and doing major disassembly work, the nozzle should be removed and checked for solids plugging the throat. For ejectors with the QuickCheck® steam chest (documentation in SECTION 12, if applicable), this is a matter of a few minutes time. It is common in new plant start-ups for debris to get into the steam system, and a partially blocked nozzle is a common cause of poor ejector performance. Testing an ejector for performance can be a difficult and time consuming task, and requires special equipment (calibrated orifices, accurate instrumentation, test headers, etc.) which makes it unlikely to be a ‘routine’ option for most operators. However, there is a simple test called the “Blank-Off” check that is easy to perform and will give a good indication of the relative ejector performance when compared to the curve. BLANK-OFF TESTING is done one stage at a time. The performance of the second stage ejector is very critical to overall system performance. If this ejector is not functioning as required, the first stage ejector will also not work properly, since its performance is dependent upon the second stage performance. A blank-off test should be done while the unit is in operation on the condenser. First make sure that the motive steam supply is within specified tolerance. A pressure gauge should be fitted to one of the plugged connections on the ejector suction chamber (if one is not available on the intercondenser shell). Shut down the motive steam supply to the FIRST STAGE EJECTOR ONLY, and then close the inlet isolation valve to the first stage ejector. DO NOT CLOSE THE DISCHARGE VALVE ON THE FIRST STAGE EJECTOR!! After a few seconds, record the suction pressure at the second stage inlet. Then, open the first stage inlet and steam valve (in that order). Next, leaving everything else operating as is, close the inlet isolation valve again and take a reading of the suction pressure on the first stage ejector suction, using a gauge attached one of the spare fittings on the 1st stage body.

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This should be repeated at least twice to be sure of the accuracy of the data. Repeat several times as required to obtain consistent readings. Condenser vacuum levels may fluctuate somewhat (depending on the actual air leakage rate), but the brief time required to do the test should not cause vacuum to rise enough to cause a turbine trip.

Compare the suction pressure readings obtained from the test of the second stage ejector with the ‘blank-off’

pressure shown on the performance curves (where the curve crosses the ‘Y’ axis). If the blank off reading obtained is more than 0.5” HgA higher than the curve value (meaning blank-off is higher in absolute pressure), there is reason to suspect that the ejector is not performing as designed. If the second stage is not ‘blanking-off’ where required, it is unlikely that the first stage will either. If the second stage is within tolerance, but the first stage is not, then the first stage may require attention.

If the blank-off tests do not fall within tolerance, there is reason to suspect that the ejector nozzle and/or diffuser

is worn beyond acceptable limits, has been damaged by wet steam, or has corroded to the point where dimensional tolerances have been exceeded. Removal and inspection of the ejectors is indicated.

If the blank-off tests show that the ejectors ARE within performance tolerance, the problem of poor vacuum is not

likely due to the condition of the steam ejectors. EJECTOR STAGE INSPECTION

The condition of the steam nozzle and diffuser is important to proper ejector performance. Excessively worn diameters, ‘wire-drawing’ in the nozzle and diffuser tapers, pitting, and corrosion are all indicative of problems that must be corrected. While ejectors generally give long, trouble-free service, the will eventually erode, particularly if operated with wet steam. Inspection should focus on the following areas:

DIFFUSERS – Check for build up on the inside surfaces of the diffuser, and clean with a scraper and abrasive cloth. If there are signs of MINOR pitting and grooving, these should be smoothed and blended to give a uniform and clean surface, TAKING CARE TO AVOID REMOVING METAL AS FAR AS POSSIBLE. After cleaning, measurements should be taken of the diameter of the straight section of the diffuser (called the ‘throat’) at several locations along the length and in several radial planes. If there is significant ‘out of roundness’ or taper along the length, or if pitting and grooving cannot be removed without excessive removal of metal, the diffuser must be replaced.

In theory, any increase in the diffuser throat diameter will cause a failure of that stage. In practice, however,

units are designed with some margin, and an increase of 1 - 3% of the original diameter should not cause a significant problem. If measured wear is greater than this, and a replacement is not readily available, operation of the stage may be temporarily restored by increasing steam pressure (no more than 10% above design). If this does not work, the unit must be replaced.

NOZZLES also wear and corrode, but usually not to the extent of diffusers, which is to some degree due to industry standard practice of using stainless steel for this component. Check the throat and outlet taper for grooving and ‘out of round’ dimensions as indicated above. Clean and polish if possible, taking care NOT to remove any metal. The throat CANNOT be re-bored or increased in diameter, as this will increase the motive steam flow which can negatively impact condenser performance. If the nozzle throat is worn beyond 2% of the diameter, the nozzle should be replaced.

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INSPECTION OF CONDENSERS – Involves visually inspecting the condition of the tube ends and surfaces (using

the inlet nozzles once the ejector stages have been removed). Fiber optic devices are sometimes used for this purpose if a broken tube is suspected. If the tubes show significant signs of scale build-up, they should be cleaned either chemically or mechanically. Check the bottom of the condenser shell for build-up of debris, and clean and flush as necessary.

3. SYMPTOM: POOR VACUUM - IMPROPER DRAINAGE

A common problem with ‘new’ systems is flooding of the inter and after condensers. This is caused by several factors, the most common being clogged trap orifices, improper installation of the traps, improper venting of traps and horizontal pipe runs, and ‘cross connecting’ the inter and after condenser drain lines. Flooding of the condenser is usually indicated by poor vacuum levels combined with significant amounts of water droplets (sometimes even steady streams of water) coming out the aftercondenser air vent line from the air flow meter. If this is observed, the aftercondenser drain must be checked immediately. The trap should be disconnected from the AC drain and the condensate allowed to flow out onto the floor. If large amounts of water are observed, it is a good indication of problems with the trap installation or clogging of the trap with debris (common during new plant start-up). With the aftercondenser draining onto the floor the performance of the ejector system should begin to stabilize. SOLUTION – Check the trap for clogged orifice, clean as required. Check the location of the trap against the General Arrangement drawing to be sure adequate vertical distance is allowed from the condenser drain connection. Check to be sure vent lines have been installed per the drawing, and that long horizontal runs have been vented. Check to make sure the AC drain line has NOT been connected to the intercondenser drain lines. Check to make sure that the IC and AC vent lines have NOT been cross connected, and are vented to the proper condenser shell. Check to make sure that the drain lines are piped to the proper level in the main condenser hotwell or condensate collection tank. Note that the AC drain can be piped above the condenser hotwell water level, but the IC drain line must be at least 6” below the minimum hotwell water level. Flooding of the intercondenser can be caused the same conditions, especially clogged trap orifices (where traps are used), or improper venting of the line where drain loops or traps are used. SOLUTION – Check the trap for debris and clean as required. Check vent lines and make sure any long horizontal runs are properly vented. Check for cross connection of drain or vent lines with the aftercondenser drains. Check to make sure the IC drain is piped below the minimum hotwell water level. Check that all horizontal pipe runs are adequately sloped (minimum ¼” per linear foot). Check to make sure the same pipe diameter is used from the intercondenser drain outlet (in no case should the pipe be reduced in diameter between the IC drain connection and the hotwell connection.

4. SYMPTOM: POOR VACUUM - EXCESS AIR LEAKAGE & TESTING

The most common cause of poor vacuum in new plant start-up is excess air leakage. This condition can develop (and worsen) as the plant ages. Air can leak into the condenser from many sources, including the turbine (poor seals or improper operation of the gland steam system), loose flanges, worn and cracked expansion joints, valve packing, etc. Finding and ‘fixing’ leaks is an on-going maintenance task that never really ends. It is absolutely essential that the leakage of air into the condenser be kept as low as possible. In any case, it cannot be allowed to exceed the design capacity of the ejector system.

23


Each Unique Systems Ejector Air Removal System includes an ‘air leakage meter’ on the vent of the aftercondenser that will allow the operator to quickly and easily measure the approximate air leakage being pumped by the vacuum system. The meter is selected such that the specified capacity of the system is at the center of the meter scale. The leakage rate can be measured whenever the holding system is operating in stable condition. This should be checked at regular intervals during normal plant operation. When excess leakage exists, it magnitude is usually such that the meter will be ‘pegged against the top’ of the scale. If this is observed, the operator has no other alternative than to find and fix the leak(s). No other troubleshooting is indicated, as until the leaks are fixed the main condenser will never be able to perform along the design curve. Backpressure on the turbine will always exceed the required value. Troubleshooting other potential system problems will be of little value unless/until the leaks are fixed. SOLUTION – Find and fix the leaks!! Finding leaks is a straight forward process, but by no means easy or simple. It is recommended that the operator consider the services of companies that specialize in this area. They will likely use a Helium or Ultrasonic leak detector to find any significant leaks. This testing is done while the vacuum system is operating. Leakage sources are detected and localized for correction when the plant is down. This process must continue until the measured leakage rate is below the design capacity of the vacuum system. It should be noted that even very small ‘holes’ can be a major source of air leakage. A hole as small as ¼” diameter (either by itself or as a collection of even smaller holes) in a turbine/condenser system can result in too much air for the ejector system to handle, based on typical capacities required for air removal duty in current plant designs. One way to determine if excess leakage is present is to do a ‘Vacuum Drop Test’. To do this, evacuate the condenser using the hogger ejector to around 6” HgA. The turbine gland seal system must be operating, but the steam turbine does not need to be running. When this level is reached, close off the hogger suction and steam isolation valve, and start timing the rise in pressure between 1” HgA intervals until the pressure increases to around 12” HgA. The following formula is used to determine the leakage rate into the system: Leakage (#/hr) = 0.15 x V x PR T Where V = System Volume (including the turbine) PR = Pressure Rise (Inches Hg)

T = Time for PR (minutes)

If the calculated leakage is near or above the specified DRY AIR handling capacity of the vacuum system, corrective action must be taken.

5. SYMPTOM: IMPROPER OPERATION OR COMPONENT FAILURE

While ejector systems are relatively simple units with no moving parts (other than occasional valve actuation), some components require periodic inspection and maintenance.

24


SOLUTION: VALVES - Should be inspected during scheduled maintenance outages. Valves with stem packing (gate, globe, etc.) should be checked for any sign of leakage, and the packing gland tightened or, in cases where the leakage cannot be stopped by reasonable tightening of the gland, the packing should be replaced. For resilient seated valves (butterfly, ball, etc.) the condition of the seat material should be checked for signs of hardening or cracking. In many cases this is not possible without disassembly of some components or piping, but if leaks or obvious indications of a problem exist, the valve seat material should be inspected. ACTUATORS – Require scheduled maintenance and periodic adjustment. Please read the manufacturers recommended maintenance included with this manual. INSTRUMENTATION – Should be inspected in accordance with the manufacturers instructions per the information included with this manual. Periodic calibration is required for some devices, particularly electronic transmitters.

AIR FLOW METER – Should be checked during scheduled outages for signs of damage that may be caused by

water droplets. The indicator ‘paddle’ should move freely, and the orifice should be open and cleaned of any debris.

TRAPS – Should be checked during scheduled outages for debris and cleaned as required. It is recommended

that new gaskets be used when re-assembling the unit. The orifice seat should be examined for signs of pitting or chipping caused by debris and replaced if there is any indication of damage.

6. SYMPTOM: ERRATIC HOGGER PERFORMANCE

Operation of the hogger ejector is simple and straightforward. If the performance of the ejector is ‘erratic’, evidenced by fluctuating steam or vacuum readings, or if unusual noise develops during operation, it is usually indicative of either motive steam pressure or temperature supply outside of design tolerances, or excessive backpressure has developed. SOLUTION – check the motive steam supply to be sure it is set at the design point (see item 1 above). If possible, increase the motive steam pressure to 10 psig above the design pressure and see if this corrects the problem. Critical flow ejectors are very sensitive to motive steam pressure, and especially to wet steam. Motive pressure below the design point, or wet steam, will likely cause unstable operation of a hogger. If the problem persists, the nozzle should be checked per item 2 above. Operation of a hogger at or near ‘blank-off’ pressure may also cause instability, which can result in steam flowing out the inlet nozzle into the process lines back to the condenser. This can damage resilient valve seats and should be avoided. Do not attempt to operate a hogger ejector below 5” HgA suction pressure. The capacity is very low below this level, and will be essentially ‘zero’ around 4” HgA.

25


Excessive backpressure can occur when very long lengths of discharge piping are used to vent the hogger/silencer to atmosphere, or if there are many turns in the piping. If consistent instability is observed in hogger operation, particularly when operating below 10” HgA, the possibility of excessive backpressure should be investigated (once the motive steam conditions are set as required). The silencer should be checked to be sure it is not ‘flooded’ or clogged with debris. The discharge piping from the silencer to atmosphere must be AT LEAST the same diameter as the silencer discharge diameter. Piping runs longer than 50 feet (equivalent length) should be evaluated for pressure drop. Hogger ejectors are typically designed to discharge to barometric pressure at the site, plus 3” HgA to allow for pressure drop across the silencer and discharge piping (please see the System Data Sheet included with this manual). There should be no valves or other means to ‘shut-off’ the hogger discharge to atmosphere. Any piping ‘caps’, bird screens, or other obstructions to flow should be checked to be certain they are clean of any debris. If excessive backpressure is indicated, the design of the hogger may have to be modified, unless the vent piping can modified or re-routed. Consult with Unique Systems.

26


SECTION 7

GETTING HELP

CALLING AND ONLINE SUPPORT Unique Systems provides phone and online support to all it’s customers for assistance in troubleshooting problems and ordering parts. Before calling Unique Systems for assistance, be sure to have the following information available to help us find the appropriate records and provide the most efficient service.

INFORMATION REQUIRED FOR TROUBLESHOOTING ASSISTANCE

• System Serial Number on system or ejector body nameplate • Barometric Pressure • System Pressure (Vacuum) • Actual motive steam pressure and temperature at the system interface • Main condenser load, cooling water temperature, and backpressure (curve) • Air leakage meter reading (recent) • Condensate temperature at system connection point • Condensate temperature rise across the inter/after condenser • Status (Open/Close) of all valves on the P&ID

It is highly recommended that the customer have the system GA drawing and Ejector BOM’s available. Records of recent operational history and problems should be available, along with records of maintenance performed in the last year. Be sure to have a detailed description of the problem(s). If system drainage is an issue, elevation drawings showing the drain piping routing will be very helpful. Digital photographs of the installed system, including photos of the drain traps and piping, may be emailed to Unique Systems and will be of assistance in helping to diagnose problems. All valves are labeled with a tag number on the Unique Systems P&ID. Make a list of the (open/closed) status of each valve and email or fax it to Unique for troubleshooting.

FIELD SERVICE SUPPORT On-site field service is available from Unique Systems for installation inspection, troubleshooting assistance, operator and maintenance training, and warranty support. Contact Unique Systems for Field Service rates, policy, and availability of a qualified Unique Systems Field Service Engineer.

PROCESS VACUUM EQUIPMENT SERVICE ENGINEERING RATES & STANDARD CONDITIONS

BULLETIN # PVS-90021050-SRC PAGE 1 OF 4

The Unique “VIP” Service Advantage Value, Integrity, Professionalism & Service

DATE: EFFECTIVE APRIL 1, 2010 OBJECTIVE: Unique Systems will provide qualified technical assistance and direction upon receipt of a purchase order for the installation, inspection, repair and maintenance of equipment located within the United States, except off-shore & Arctic site locations. 1. RATES: DAILY RATE $1,800.00 STANDARD HOURLY RATE $ 225.00

OVERTIME (RATE "A") $ 337.50 / Hour OVERTIME (RATE "B") $ 450.00 / Hour

These rates are subject to change without notice. Unique Systems will invoice at published rate schedule in effect at the time services are required.

2. DAILY RATE – This rate applies to time worked during a normal eight (8) hour day, Monday thru Friday, except holidays. 3. OVERTIME (Rate "A") – This rate applies to all time worked on weekdays, Monday thru Friday, in excess of eight (8) hours per day. 4. OVERTIME (Rate "B") – This rate applies to all time worked on Saturdays, Sundays and holidays. 5. TRAVEL TIME – Travel time will be billed at the Standard Hourly Rate for Monday thru Friday during a normal eight (8) hour day, Overtime (Rate "A") for time in excess of a normal eight (8) hour day and Overtime (Rate “B”) for travel on Saturdays, Sundays and holidays. 6. TRAVEL & LIVING EXPENSES – These expenses will be billed at cost from the time representative leaves his home base until he returns. Economy rates for transportation and lodging will be utilized when available. In all instances, we invite customer recommendations regarding acceptable travel and lodging arrangements. The cost to upgrade any accommodations beyond the minimum available category will be paid by Unique Systems or its representative. Personal vehicle mileage will be billed at the rate allowed by the Internal Revenue Service (www.irs.gov) on the dates of travel. 7. MISCELLANEOUS EXPENSES – Charges related to items such as photocopies or other reproducible media (ie. blueprint copies, sepias, microfilm, electronic formats, etc.), reproductions from microfilm, shipping charges for tools & testing equipment, postage, phone calls, etc., shall be added to final invoice. 8. MINIMUM BILLING – Four (4) hours for time worked up to four (4) hours; eight (8) hours for time worked in excess of four (4) hours, but less than eight (8) hours.




9. HOME OFFICE RATE (Same as Hourly Rates) – Covers all time required to assemble original design specifications, details and Bills of Material for unit under study; all calculations, preparation of curves and/or sketches specific to the unit and problem under study. 10. STANDBY TIME – Any waiting time when the representative is available to work, up to a maximum of eight (8) hours on any one working day, shall be regarded as time actually worked, even though services are not actually utilized. The rate is not pro-ratable for partial days. 11. DELAYS – Unique Systems shall not be liable for delay in performance when such delay is occasioned by causes beyond its reasonable control, including but not limited to: Acts of God; acts of customer; material shortages; transportation difficulties; flood; strikes; epidemics; war (declared or undeclared); riot; etc. 12. EMERGENCY WORK – The minimum time off for a representative during any twenty-four (24) hour period must be eight (8) consecutive hours. 13. TOOLS & TESTING EQUIPMENT – Our representatives often require specialized tools and/or testing equipment which, due to travel restrictions, must be shipped directly to a designated contact at customer’s site. All such items shall remain the property of Unique Systems and customer agrees to immediately return these items to our office upon conclusion of our representative’s visit. Return shipment must be sent via insured carrier with tracking number. Any items not returned within a reasonable period of time will be billed at replacement cost. 14. TERMS OF PAYMENT – All funds are payable in U.S. Dollars. Domestic Accounts – Payment for services and materials will be due upon presentation of monthly invoice. Standard terms of payment are "Net 30 Days" from date of invoice, with approved credit, at which time the entire payment shall be due absolutely, without the right of "setoff", regardless of the basis for same. Overdue invoices will be charged 1.50% per month (18% per annum) on outstanding balances from date of invoice.

Foreign Accounts – Advance payment via wire transfer or other approved method. Adjustments should be made to compensate for variable exchange rates and fees.

15. SALES & SIMILAR TAXES – The amount of any present or future sales, use or other tax, federal, state or local, which Unique Systems now or hereafter shall be required to pay, either on its own behalf or on the behalf of the customer, or otherwise, with respect to the services furnished, shall (unless such prices are expressly stated to be inclusive of such tax) be added to the prices contained above and paid by customer in the same effect as if originally added thereto.




16. INSURANCE – Unique Systems insurance policy with Excelsior Insurance Co. (Policy # CBP9764022)

applies to: All operations - manufacturing & contracting, including blanket contractual; the Netherlands Insurance Company (Policy # BA2436045) for autos (all owned, non-owned and hired); and, Excelsior Insurance Co. (Policy # CU9768823) for umbrella liability. Subject to policy provisions with the following limits:

Comprehensive General – Bodily injury & property damage: $1,000,000.00 – Single Occurrence / $2,000,000.00 – Aggregate Limit

Automobile Liability – Bodily injury & property damage: $1,000,000.00 – Single Aggregate Limit Umbrella Liability – $4,000,000 Each Occurrence / $4,000,000 Aggregate Limit to provide additional coverage over the above liability limits.

Workmen's Compensation – Policy with the New Jersey Manufacturer's Insurance Co. (Policy # W12491-7-10).

17. RESPONSIBILITY – Unique Systems agrees to indemnify, hold harmless and defend the customer from and against any and all claims for damages, to property or for personal injuries, including death, which result solely from the gross negligence of the representative of Unique Systems while engaged in the services described hereunder.

Any hold harmless clause in the customer's purchase order, or in any of the customer's documents, whether requiring the signature of a Unique Systems employee or not, shall be of no effect, and the hold harmless clause set out herein shall apply with respect to any claims for damages, and Unique Systems responsibility will be limited.

Accordingly: Since it is impossible for the representative to observe and control the execution of all details of the installation, inspection, repair and maintenance, Unique Systems will not be responsible for materials or workmanship of others than Unique Systems, or for damages resulting from acts or omissions of others than Unique Systems representatives.

18. APPLICABLE LAW – These "Rates & Standard Conditions” for Unique Systems personnel shall be the complete agreement between the parties for such service work and shall be construed in accordance with the Laws of the State of New Jersey, United States of America.




19. DAMAGES – Unique Systems shall in no event be liable for any incidental or consequential damages

of a commercial nature, such as, but not limited to, loss of revenue, production or use of any equipment, resulting from any cause.

20. SCHEDULE CHANGES & TRIP CANCELLATION – A specific amount of time has been reserved for

customer’s use which has a direct impact on scheduling and time available for other projects. Our representatives also spend time in preparation for field service work by reviewing engineering files, drawings and other available information. We understand that there are circumstances which may result in unexpected scheduling changes or cancellation. Unique Systems will accommodate any reasonable requests for schedule changes to the best of our ability. Travel expenses incurred, such as airline tickets which are non-refundable or subject to change fees, must be reimbursed by customer and may be billed immediately. Schedule changes resulting in postponements beyond thirty (30) days from original service date, or two (2) consecutive schedule changes, will be considered a cancellation and subject to a minimum charge equivalent to one (1) day at the daily rate indicated above. Cancellations or postponements once our representative has begun travel, or has already reached site, will be considered as “Standby Time” and billed as one (1) day on-site plus travel time & expenses as outlined above.

21. This rate agreement covers only the following products: Steam Jet Ejector, Liquid Ring Vacuum Pump & Hybrid Vacuum Systems, and all parts thereof, in addition to other miscellaneous vacuum products sold by Unique Systems, Inc. THESE SERVICE ENGINEERING RATES & STANDARD CONDITIONS MUST BE SPECIFICALLY REFERENCED & INCORPORATED INTO ANY PURCHASE ORDER OR AGREEMENT COVERING THE WORK DESCRIBED HEREIN.

www.uniquesystems.com


SECTION 8

SPARE PARTS Unique Systems can supply spare parts for any component of your ejector system. We recommend that the user contact the OEM supplier of the ejector system (usually the manufacturer of the main condenser) first when securing spare parts. This will be required if the system is under the original manufacturer’s product warranty. The following information is required when ordering parts to be sure that the correct part is shipped.

• System Serial Number • Part Number (from the Bill of Material on either the Ejector drawing or the GA drawing) • A description of the required part(s)

Spare parts for the individual steam ejectors are shown on the attached BOM’s for each stage. A ‘Recommended Spares List’ is also attached that shows typical spares that the user should consider keeping in local stock, which is based on ‘average’ experience for this application.

S Y

S T

E M

S .

C O

MITEM # PART # PART DESCRIPTION QTY COMMENTS

1 500202-9 CAP (STEAM CHEST) 1

B I L L O F M A T E R I A L

3 502508 QUICKCHECK® STEAM CHEST 1

2 500257-1 GASKET (CAP) 1

5 503043-2 GASKET (NOZZLE HOLDER) 1

4 SWP41V36 REDUCING BUSHING (2" x 1½") 1

7 503012 BODY WELDMENT 1

6 502890-4 GASKET (STEAM CHEST) 1

9 503011 NOZZLE 1

8 500203-2 NOZZLE HOLDER 1

11 4513K324 ½"-3,000# HEX HEAD PLUG 1

10 4513K328 1½"-3,000# HEX HEAD PLUG 2

13 90521A240 ⅝"-11 HEAVY HEX NUT 4

12 98750A210 ⅝"-11 THREADED STUD 4

15

14

17

16

19

18

21 501915 QUICKCHECK® NAMEPLATE 1 (NOT SHOWN)

20

W W

W . U

N I Q

U E

13 13

12

58

4

6

9

7

2

10

11

W W

W .

U N

I Q

U E

S (NOT SHOWN)

23 QCP-HTLPA HYDROSTATIC (LEAK) TEST 1 TEST @ 22.5 PSIG - NO LEAKS ALLOWED

22 09-1138-YQ1,2 PERFORMANCE GAGE ROD™ 1

HIGH TEMPERATURE

NOTICE OF PROPRIETARY RIGHTS GENERAL NOTES

24 SP-1011-09-1138-6 SURFACE PREP & PAINT 1

NOZZLE OFFSET (DISTANCE FROM NOZZLE OUTLET TO DIFFUSER INLET): 1" OUTSIDE

1. FOR SIDE-MOUNTED MOTIVE STEAM INLET, TYPICAL STEAM CHEST ORIENTATION SHOWN.THIS BROCHURE, DRAWING, OUTLINE OF AND/OR INFORMATION SHOWN IS THE SOLE PROPERTY OF UNIQUE SYSTEMS, INC.RECEIPT OR POSSESSION THEREOF DOES NOT CONFER OR TRANSFER ANY RIGHT TO MAKE, USE, COPY, MANUFACTURE AND/OR SELL 2.THIS OR THESE DEVICES BY METHOD SHOWN.UNIQUE SYSTEMS, ITS LOGO AND QUICKCHECK ARE REGISTERED TRADEMARKS OF UNIQUE SYSTEMS, INC. 3.QUICKCHECK DEVICES ARE PROTECTED BY U.S. AND FOREIGN PATENTS.

5.

PURCHASER: CERTIFIED CORRECT BY:

PURCHASE ORDER #: 360-143-1

PROJECT NAME: PHASE II ASTORIA ENERGY EXPANSION PROJECT

GEA POWER COOLING

THE UNIQUE "VIP SERVICE" ADVANTAGE

REVISION HISTORY NAMEPLATE DATA

© 2008 BY UNIQUE SYSTEMS, INC.4.

VALUE • INTEGRITY • PROFESSIONALISM • SERVICE

PROJECT LOCATION: ASTORIA, NY KENNETH A. ERIKSEN, [email protected]

ORDER INFORMATION

INITIAL ISSUE JAPAPP

EQUIPMENT TAG #: 2ARC-SKD-002A/B

GENERAL ARRANGEMENT DRAWING #: D-502987

OUTLINE DRAWING #:

1

REV # DATE DESCRIPTION BY0 02/15/10

210 PSIG

E S Y S T E M

S . C O

M

PSIAKAE SHOP ORDER #: 09-1138

TYPE 62E STEAM JET EJECTOR (Y-STAGE) SERIAL #: 09-1138-YQ1 & -YQ2MOTIVE TEMPERATURE: 700 °F

BACK PRESSURE:

3 MOTIVE PRESSURE (MIN):2

13 13

12

58

4

6

9

7

2

10

11

TYPE 62E STEAM JET EJECTOR (Y-STAGE) SERIAL #: 09-1138-YQ1 & -YQ2

13 13

12

58

4

6

9

7

2

10

11

B I L L O F M A T E R I A LS

Y S

T E

M S

. C

O M

ITEM # PART # PART DESCRIPTION QTY COMMENTS

W W

W . U

N I Q

U E

1 500211-9 CAP (STEAM CHEST) 1

2 500257-7 GASKET (CAP) 1

3 502697 QUICKCHECK® STEAM CHEST 1

4 SWP41V31 REDUCING BUSHING (1½" x 1") 1

5 503043-8 GASKET (NOZZLE HOLDER) 1


7 430120-2 SUCTION CHAMBER 1

8 500887-7 NOZZLE HOLDER 1

9 503013 NOZZLE 1

10 443409-4 GASKET (DIFFUSER) 1

11 503014 DIFFUSER 1

12 4513K324 ½"-3,000# HEX HEAD PLUG 3

13 4513K324 ½"-3,000# HEX HEAD PLUG 1

14 98750A210 ⅝"-11 THREADED STUD 4

15 90521A240 ⅝"-11 HEAVY HEX NUT 4

16 98750A210 ⅝"-11 THREADED STUD 4

17 90521A240 ⅝"-11 HEAVY HEX NUT 4

18

19

20

21 501915 NAMEPLATE 1 (NOT SHOWN)

22 09 1138 ZQ1 2 PERFORMANCE GAUGE ROD™ 1 (NOT SHOWN)

13

10 16 174

1

3

1415

5

8

6

2 9

11

7 12

W W

W .

U N

I Q

U E

SE S Y

S T E M S . C

O M

22 09-1138-ZQ1,2 PERFORMANCE GAUGE ROD™ 1 (NOT SHOWN)


24 SP-1011-09-1138-6 SURFACE PREP & PAINT 1 HIGH TEMPERATURE SERVICE

NOZZLE OFFSET (DISTANCE FROM NOZZLE OUTLET TO DIFFUSER INLET): ½" OUTSIDE

NOTICE OF PROPRIETARY RIGHTS GENERAL NOTES1. FOR SIDE-MOUNTED MOTIVE STEAM INLET, TYPICAL STEAM CHEST ORIENTATION SHOWN.THIS BROCHURE, DRAWING, OUTLINE OF AND/OR INFORMATION SHOWN IS THE SOLE PROPERTY OF UNIQUE SYSTEMS, INC

RECEIPT OR POSSESSION THEREOF DOES NOT CONFER OR TRANSFER ANY RIGHT TO MAKE, USE, COPY, MANUFACTURE AND/OR SELL 2.THIS OR THESE DEVICES BY METHOD SHOWN.UNIQUE SYSTEMS, ITS LOGO AND QUICKCHECK ARE REGISTERED TRADEMARKS OF UNIQUE SYSTEMS, INC. 3.QUICKCHECK DEVICES ARE PROTECTED BY U.S. AND FOREIGN PATENTS.© 2008 BY UNIQUE SYSTEMS, INC.

4.

ORDER INFORMATION 5.

PURCHASER: GEA POWER COOLING


CERTIFIED CORRECT BY:


PROJECT NAME: PHASE II ASTORIA ENERGY EXPANSION PROJECT VALUE • INTEGRITY • PROFESSIONALISM • SERVICE


EQUIPMENT TAG #: 2ARC-SKD-002C/D

GENERAL ARRANGEMENT DRAWING #: D-502987

OUTLINE DRAWING #:

REVISION HISTORY NAMEPLATE DATAREV # DATE DESCRIPTION BY APP0 02/15/10 INITIAL ISSUE JAP KAE SHOP ORDER #:

MOTIVE PRESSURE (MIN):

09-1138 BACK PRESSURE: 15.7 PSIA1

32

TYPE 32E STEAM JET EJECTOR (Z-STAGE) SERIAL #: 09-1138-ZQ1 & -ZQ2210 PSIG MOTIVE TEMPERATURE: 700 °F

13

10 16 174

1

3

1415

5

8

6

2 9

11

7 12

TYPE 32E STEAM JET EJECTOR (Z STAGE) SERIAL #: 09 1138 ZQ1 & ZQ2

13

10 16 174

1

3

1415

5

8

6

2 9

11

7 12


Y S

T E

M S

. C

O M

ITEM # PART # PART DESCRIPTION QTY COMMENTS

W W

W . U

N I Q

U E

1 503016 BODY WELDMENT 1

2 502742-8 STEAM CHEST 1

3 503015 NOZZLE 1

4 440331-2 NOZZLE SPACER 1

5 446109-5 EXTENSION 1

6 446109-5 EXTENSION 1

7 440331-2 EXTENSION SPACER 1

8 440331-2 EXTENSION SPACER 1


10 SWP41V43 REDUCING BUSHING (2½" x 2") 1

11 4513K326 1"-3,000# HEX HEAD PLUG 1

12 4513K324 ½"-3,000# HEX HEAD PLUG 1

13 98750A210 ⅝"-11 THREADED STUD 4

14 90521A240 ⅝"-11 HEAVY HEX NUT 4

15 SWP41V38 REDUCING BUSHING (2" x 1") 1 (NOT SHOWN)

16

17

18

19

20

21

22 501914 EJECTOR NAMEPLATE 1 (NOT SHOWN)

12

35 7

4

6

8

910

1314

12

11

W W

W .

U N

I Q

U E

SE S Y

S T E M S . C

O M

22 501914 EJECTOR NAMEPLATE 1 (NOT SHOWN)


24 SP-1011-09-1138-6 SURFACE PREP & PAINT 1 HIGH TEMPERATURE SERVICE

NOZZLE OFFSET (DISTANCE FROM NOZZLE OUTLET TO DIFFUSER INLET): ½" OUTSIDE

NOTICE OF PROPRIETARY RIGHTS GENERAL NOTES1. FOR SIDE-MOUNTED MOTIVE STEAM INLET, TYPICAL STEAM CHEST ORIENTATION SHOWN.THIS BROCHURE, DRAWING, OUTLINE OF AND/OR INFORMATION SHOWN IS THE SOLE PROPERTY OF UNIQUE SYSTEMS, INC

RECEIPT OR POSSESSION THEREOF DOES NOT CONFER OR TRANSFER ANY RIGHT TO MAKE, USE, COPY, MANUFACTURE AND/OR SELL 2.THIS OR THESE DEVICES BY METHOD SHOWN.UNIQUE SYSTEMS, ITS LOGO AND QUICKCHECK ARE REGISTERED TRADEMARKS OF UNIQUE SYSTEMS, INC. 3.QUICKCHECK DEVICES ARE PROTECTED BY U.S. AND FOREIGN PATENTS.© 2008 BY UNIQUE SYSTEMS, INC.

4.


PURCHASER: GEA POWER COOLING




PROJECT NAME: PHASE II ASTORIA ENERGY EXPANSION PROJECT VALUE • INTEGRITY • PROFESSIONALISM • SERVICE


EQUIPMENT TAG #: 2ARC-SKD-003

GENERAL ARRANGEMENT DRAWING #: B-502993

OUTLINE DRAWING #:

REVISION HISTORY NAMEPLATE DATAREV # DATE DESCRIPTION BY APP0 02/15/10 INITIAL ISSUE JAP KAE SHOP ORDER #:

MOTIVE PRESSURE (MIN):

09-1138 BACK PRESSURE: 2 PSIA1

32

8" x 8" STEAM JET EJECTOR (DEAERATOR) SERIAL #: 09-1138-DA210 PSIG MOTIVE TEMPERATURE: 700 °F

12

35 7

4

6

8

910

1314

12

11

8 x 8 STEAM JET EJECTOR (DEAERATOR) SERIAL #: 09 1138 DA


Y S

T E

M S

. C

O M

ITEM # PART # PART DESCRIPTION QTY COMMENTSCHAMBER (HOUSING) 1

2 502722 INLET COVER 1

4 502269 COVER GASKET

3 502723 OUTLET COVER 1

6 502725 VALVE STEM

5 502724 VALVE FLOAT 1

8 502727 VALVE SEAT

2

7 502726 VALVE POPPET 1

10 9557K462 O-RING

1

9 90298A537 LIMIT SCREW 1

(NOT SHOWN)

12 92196A542 SOCKET-HEAD CAP SCREW

1

11 9557K477 O-RING 1

14 16055T237 FLOW ARROW

1

13 502347 NAMEPLATE 4

16

16

(NOT SHOWN)

15 4513K324 ½"-3,000# HEX HEAD PLUG 2

18

1

17

20

19

21

W W

W . U

N I Q

U E

1 502721

12

1

5

4

215

10

11

9

7

812

6

W W

W .

U N

I Q

U E

S

DRAINER VALVE ONLY

22 QCP-HTLPA PRESSURE TEST 1

PIPING & ACCESSORIES

REBUILD KIT (INCLUDES ITEMS # 4 THRU 12): 502720-99

TEST @ 22.5 PSIG - NO LEAKS

23 SP-1012 SURFACE PREP & PAINT 1

NOTICE OF PROPRIETARY RIGHTS GENERAL NOTES

24 SP-1013 SURFACE PREP & PAINT 1

1. THIS IS A VARIABLE FLOW CONDENSATE DRAIN TRAP (MAX FLOW: 7,000 #/HOUR).THIS BROCHURE, DRAWING, OUTLINE OF AND/OR INFORMATION SHOWN IS THE SOLE PROPERTY OF UNIQUE SYSTEMS, INC.RECEIPT OR POSSESSION THEREOF DOES NOT CONFER OR TRANSFER ANY RIGHT TO MAKE, USE, COPY, MANUFACTURE AND/OR SELL 2.THIS OR THESE DEVICES BY METHOD SHOWN.UNIQUE SYSTEMS AND ITS LOGO ARE REGISTERED TRADEMARKS OF UNIQUE SYSTEMS, INC. 3.© 2008 BY UNIQUE SYSTEMS, INC.

4.


PURCHASER: GEA POWER COOLING, INC.




PROJECT NAME: PHASE II ASTORIA EXPANSION PROJECT

KENNETH A. ERIKSEN, [email protected]

EQUIPMENT TAG #: 2ARS-M-012 / 2ARS-M-013

GENERAL ARRANGEMENT DRAWING #: D-502987 / B-502925 (DRAINER ARRANGEMENT)

VALUE • INTEGRITY • PROFESSIONALISM • SERVICE

PROJECT LOCATION: ASTORIA, NY

APP

102/15/10 INITIAL ISSUE JAP KAE DRAINERSHOP ORDER #:

OUTLINE DRAWING #: B-502776

REVISION HISTORY NAMEPLATE DATAREV # DATE DESCRIPTION BY

09-1138 VALVE TYPE:

MODEL # 2VCD-20B VACUUM CONDENSATE DRAINER SERIAL #: 09-1138-VCD1 2

0

23 502720 TAG / ITEM #: 2ARS-M-012, -013PART #:

E S Y S T E M

S . C O

M

12

1

5

4

215

10

11

93

7

812

6

MODEL # 2VCD 20B VACUUM CONDENSATE DRAINER SERIAL #: 09-1138-VCD1,2

12

1

5

4

215

10

11

93

7

812

6

09-1138 DATE: DOC NO. 09-1138 -RSPLGEA POWER COOLING REVISION:360-143-1 PROJECT ENGINEER: QUOTE #:PHASE II ASTORIA ENERGY EXPANSION PROJECT CHECKED: PAYMENT TERMS: NET 30 DAYS09-360 QUOTE VALIDITY: FREIGHT TERMS: FOB (FCA) SHIPPING POINT

SYSTEM MODEL #:

Skid "A"

Skid "B"

Skid "C"

Skid "D"

1 EJECTOR NOZZLE2 2 503011 Quickcheck® Nozzle (62E) S/N 09-1138-YQ1,2 2ARC-SJ-002A,002B 2 -$ -$ 3 GASKETS, SPACERS, ETC.4 2 500202-9 Cap, Quickcheck® Steam Chest 2 -$ -$ 5 2 500203-2 Nozzle Holder 2 -$ -$ 6 2 503043-8 Gasket, Nozzle Holder See Note 'A' 4 -$ -$ 7 2 502890-4 Gasket, Steam Chest See Note 'A' 4 -$ -$ 8 2 500257-1 Gasket, Cap (Steam Chest) See Note 'A' 4 -$ -$ 9 17 502657-99 Gasket Set, Target Tee 2 -$ -$ 10 MISCELLANEOUS11 12 0911383000-02 Relief Valve, Ejector Body 2ARC-PSV-001A,001B 2 -$ -$ 12 EJECTOR NOZZLE & DIFFUSER13 3 503013 Quickcheck® Nozzle (32E) S/N 09-1138-ZQ1,2 2ARC-SJ-002C,002D 2 -$ -$ 14 3 503014 Diffuser (Venturi) Z Stage 2 $ $

RECOMMENDED SPARE PARTS LISTE-Mail: [email protected] • Website: www.uniquesystems.com

UNIQUE SYSTEMS SO#: 9/10/2010CUSTOMER: 0

PROJECT: KAELOCATION: 9/9/2011

CUSTOMER PO#: DSB

Part NumberExtended

Price

GA DWG #: D-502987 62C32C

Line

#

Ope

rati

onal

2-Y

ears

5-Y

ears

GA

BO

M #

CategoryDelivery

(Estimated)

Y-S

TAG

E (6

2E)

Part Description Comments Tag Numbers

Recommended Quantity On-Hand

Unit Price

14 3 503014 Diffuser (Venturi), Z-Stage 2 -$ -$ 15 GASKETS, SPACERS, ETC.16 3 500211-9 Cap, Quickcheck® Steam Chest 2 -$ -$ 17 3 500887-7 Nozzle Holder 2 -$ -$ 18 3 503043-8 Gasket, Nozzle Holder See Note 'A' 4 -$ -$ 19 3 502890-1 Gasket, Steam Chest See Note 'A' 4 -$ -$ 20 3 500257-7 Gasket, Cap (Steam Chest) See Note 'A' 4 -$ -$ 21 3 443409-4 Gasket, Diffuser 4 -$ -$ 22 18 503018-99 Gasket Set, Discharge Manifold 2 -$ -$ 23 DRAINERS, CONDENSATE24 9 502720-99 Vac Cond Drainer Rebuild Kit See Note 'B' 2ARS-M-012,013 2 -$ -$ 25 9 0911382997-38 Ball Valve 2ARC-V-208,209,210,212,213,214 1 -$ -$ 26 9 0911382992-03 Strainer 2ARC-M-018,019 1 -$ -$ 27 HEAT EXCHANGER28 1 09-11382985-01-99 IC/AC Gasket Set S/N 09-1138-IC/AC 2CNM-HEX-003 1 -$ -$ 29 INSTRUMENTATION30 29 0911382999-01 Air Flow Meter 2ARC-FI-0130 1 -$ -$ 31 27 0911382998-03 Pressure Gauge, Steam 2ARC-PI-0201 1 -$ -$ 32 26 0911382998-04 Pressure Gauge, Vacuum 2ARC-PI-0124,0127 1 -$ -$ 33 24 0911382998-06 Temperature Gauge, Steam 2ARC-TI-0201 1 -$ -$ 34 22 0911382998-05 Temperature Gauge, Process 2ARC-TI-0128,0129,0202 1 -$ -$ 35 23 0911382998-01 Thermowell, Temp Gauge 1 -$ -$ 36 MISCELLANEOUS37 31 0911382992-02 2" SW Strainer 2ARC-M-010 1 -$ -$ 38 VALVES, ACTUATED39 4 0911382990-02-99 10"-150# Motorized Buttefly Valve See Note 'C' 2ARC-MOV-0170 1 -$ -$ 40 8 0911382990-03-99 2" Motorized Ball Valve, Complete No Spares Available 2ARC-MOV-0123 1 -$ -$ 41 VALVES, MANUAL42 5 0911382990-05 6"-150# Manual Butterfly Valve 2ARC-V-202A,202B 1 -$ -$ 43 6 0911382997-01 6"-150# Manual Gate Valve 2ARC-V-203A,203B 1 -$ -$ 44 7 0911382992-06 3"-150# Manual Butterfly Valve 2ARC-V-205A,205B 1 -$ -$ 45 10 0911382997-38 2" NPT Ball Valve 2ARC-V-206 1 -$ -$ 46 13 0911382997-29 1" SW Globe Valve 2ARC-V-204A,204B 1 -$ -$ 47 14 0911382997-37 1/2" NPT Ball Valve 2ARC-V-207,211 1 -$ -$ 48 15 0911382991 02 Block & Bleed Valve 2ARC V 0127 0201 0202 1 $ $

8-10 WEEKS / AR

O

Z-ST

AG

E (3

2E)

MIS

CEL

LAN

EOU

S

48 15 0911382991-02 Block & Bleed Valve 2ARC-V-0127,0201,0202 1 -$ -$

SYSTEM MODEL #:

Skid "A"

Skid "B"

Skid "C"

Skid "D"

49 EJECTOR NOZZLE50 1 503015 Nozzle (82E) S/N 09-1138-DA 2ARC-SJ-003 1 -$ -$ 51 GASKETS, SPACERS, ETC.52 1 440331-2 Spacer, Nozzle & Extension 3 -$ -$ 53 1 446109-5 Extension, Nozzle 2 -$ -$ 54 1 502890-4 Gasket, Steam Chest See Note 'A' 2 -$ -$ 55 MISCELLANEOUS56 6 0911383000-01 Relief Valve, Ejector Body 2ARC-PSV-003 2 -$ -$ 57 INSTRUMENTATION58 10 0911382998-03 Pressure Gauge, Steam 2ARC-PI-0204 1 -$ -$ 59 11 0911382998-04 Pressure Gauge, Vacuum 2ARC-PI-0203 1 -$ -$ 60 8 0911382998-06 Temperature Gauge, Steam 2ARC-TI-0203 1 -$ -$ 61 9 0911382998-02 Thermowell, Temp Gauge 1 -$ -$ 62 MISCELLANEOUS63 13 0911382992-01 1" SW Strainer 2ARC-M-011 1 -$ -$ 64 VALVES, ACTUATED65 4 0911382990-04-99 1" Motorized Ball Valve, Complete No Spares Available 2ARC-MOV-0010 1 -$ -$ 66 VALVES, MANUAL67 2 0911382990-07 8"-150# Manual Butterfly Valve 2ARC-V-001 1 -$ -$ 68 3 0911382997-02 8"-150# Manual Gate Valve 2ARC-V-215 1 -$ -$ 69 5 0911382997-29 1" SW Globe Valve 2ARC-V-217 1 -$ -$ 70 7 0911382991-02 Block & Bleed Valve 2ARC-V-0204,0203 1 -$ -$

A.B.C.D.E

Unit Price

GA DWG #: 502993 82E (8" x 8")

Line

#

Ope

rati

onal

8-10 WEEKS / AR

O

DEA

ERA

TOR

(82

E)

Part DescriptionCategory Part Number

NOTESTo avoid steam or air leakage, if seals are broken during maintenance, gaskets MUST be replaced.Vacuum Condensate Drainer Rebuild Kit consists of valve float, stem, poppet, seat, limit screw, o-rings, cover gaskets & cap screws.

2-Y

ears

5-Y

ears

GA

BO

M #

Delivery (Estimated)Comments Tag Numbers

Recommended Quantity On-Hand

Extended Price

Actuated Valve Rebuild Kit consists of EPDM seat only, actuator hardware kit & retaining ring.

E.

A.B.C.D.E.F.G.H.I.J.

Overdue payments shall be subject to interest charges at the rate of eighteen (18%) percent per annum (1.5% per month) or the maximum rate permitted by applicable law, whichever is less.Any purchase order shall be interpreted and governed by the laws of the State of New Jersey and any disputes arising from an order shall be resolved only in that jurisdiction.

All quoted prices are in U.S. Dollars and exclude duties, fees & taxes associated with the export of goods outside the United States which is the responsibility of Purchaser.TERMS & CONDITIONS

WARRANTY & GUARANTEE

A $250 minimum order value (excluding freight charges) applies to all spare part orders.Unless otherwise noted, selling terms for spare parts are strictly FOB (FCA) SHIPPING POINT & NET 30 DAYS (with approved credit). Unique Systems reserves the right to require progress payments.

These Terms & Conditions represent the selling terms of our offer. Notice is hereby given that any terms or conditions contrary to those indicated above are rejected.

Unique Systems warrants that replacement parts and equipment will be free from defects in design, workmanship and material, for a period of one (1) year from the date of shipment, normal wear and tear and corrosion excepted. Any parts or equipment designed and manufactured by others but furnished by us will be repaired or replaced only to the extent of the original manufacturer's guarantee. Our warranty is limited to the cost of repair or replacement of items, and shall not include removal, shipment or re-installation of any items, except to the extent that Unique Systems was required to incur such costs for the original supply of the item. Unique Systems will in no event be liable for any special or consequential damages and our liability is limited to the purchase price of the item affected. Our warranty will not apply to any equipment that has been subject to misuse, negligence, accident, or which has been modified, altered or repaired by anyone except our authorized employees or representatives. We will not be liable in any event for modifications, alterations or repairs, except those made with our prior written consent.

CONFIDENTIALITY NOTICEThis document, including any attachments and supporting details, remains the exclusive property of Unique Systems, Inc. It is for the sole use of the intended recipient(s) or entity for which it was prepared. It may contain information that is proprietary, confidential or constitutes trade secrets. Your use of this information constitutes your agreement to these conditions. If you do not agree with these conditions, you are prohibited from using this information. If you are not the intended recipient, or an employee or agent responsible for delivering this document to the intended recipient, be aware that any review, use, disclosure, dissemination, distribution, storing or copying of this document, or the use of its contents, is not authorized and is strictly prohibited. Unique Systems will take such action as is necessary to protect its interests if this information is misused. If you have received this document and are not the intended recipient, you must notify us immediately and return the entire, original document at our expense.

Title of goods, materials or services shall not pass from Seller to Purchaser until all invoices are paid-in-full.Domestic packaging is included in quoted prices. Export-quality packaging (ie. wood crates, heat-treated lumber, waterproofing, fumigation services, etc.) is available at additional cost.All machined, custom-fabricated and/or special order components are subject to cancellation charges quoted at the time of cancellation.A 25% re-stocking fee applies to stock components which are returned in new, resaleable condition. We cannot accept returns of custom-fabricated, machined or special order items.


SECTION 9

SYSTEM DESIGN SPECIFICATIONS Information in this section is intended to provide the operator with critical information on the ejector system relative to expected performance and original design specifications.

E-Mail: [email protected] • Website: www.uniquesystems.com

1 S.O. #: DATE: 07/19/10 DOC NO. 09-1138 -SDS

2 CUSTOMER: REVISION: 4

3 CUSTOMER P.O.: ENGINEER: DSB

4 PROJECT: CHECKED: WPS

5 PROJECT #:

6 CONTRACTOR:

7 CONTRACT #:

8 LOCATION:

9 SYSTEM MODEL NO. 62C32C10 SYSTEM PROCESS DESIGN 200% CAPACITY 100% CAPACITY

11 CASE A CASE B CASE C CASE D

12 UNITS HEI MAXIMUM --- HEI MAXIMUM --- NOTES

13 TURBINE STEAM FLOW LB/HR --- --- --- --- --- --- ---

14 VACUUM SYS. SUCTION PRESSURE In HgA 1 8 --- 1 8 --- ---

15 SUCTION SUBCOOL °F 7.5 7.5 --- 7.5 7.5 --- ---

16 SUCTION TEMPERATURE °F 71.5 152.2 --- 71.5 152.2 --- ---

17 VAPOR SUCTION LOAD (STEAM) LB/HR 297.0 1652.0 --- 148.5 826.0 --- ---

18 SUCTION LOAD (AIR) LB/HR 135.0 135.0 --- 67.5 67.5 --- ---

19 SUCTION LOAD (DAE) LB/HR 501.7 2200.0 --- 250.8 1100.0 --- ---

20 COOLING WATER SOURCE --- CONDENSATE CONDENSATE --- CONDENSATE CONDENSATE --- SAME MAIN COND.

21 COOLING WATER INLET TEMP. °F 79 157 --- 79 157 --- ---

22 COOLING WATER FLOW LB/HR 1588500 1750000 --- 1588500 1750000 --- ---

23 MAX. COOLING WATER ∆P ALLOWED PSI 5.1 5.1 --- 5.1 5.1 --- NTE

24 AMBIENT TEMPERATURE °F 11 - 95 11 - 95 --- 11 - 95 11 - 95 --- ---

25 AMBIENT PRESSURE In HgA 29.9 29.9 --- 29.9 29.9 --- ---

26

27 UNITS EJECTORS VACUUM PIPING MOTIVE STEAM DRAINS SHELL SIDE TUBE SIDE SILENCER

28 DESIGN TEMPERATURE °F 750 250 750 250 600 250 N/A

29 DESIGN PRESSURE PSIG 15 + F V 15 + FV 250 15 + FV 100 + FV 500 N/A

DESIGN POINTS

MECHANICAL DESIGN

DESIGN POINTS

HOLDING EJECTOR SKID DATA SHEET 09-1138

GEA POWER COOLING

360-143-1

PHASE II ASTORIA ENERGY EXPANSION PROJECT

ASTORIA, NY

09-360

SNC LAVALIN CONSTRUCTOR

0620

29 DESIGN PRESSURE PSIG 15 + F.V. 15 + FV 250 15 + FV 100 + FV 500 N/A

30 TEST PRESSURE PSIG 22.5 22.5 325 22.5 130 650 N/A

31

32 UNITS Y-STAGE Z-STAGE DEAERATOR NOTES

33 NOMINAL DESIGN CAPACITY SCFM 15 15 0.9 PER ELEMENT --- --- ---

34 EVACUATION VOLUME FT3 N/A N/A N/A --- --- --- ---

35 EVACUATION TIME MIN N/A N/A N/A --- --- --- ---

36 SUCTION PRESSURE In HgA 1.00 9.50 2.00 --- --- --- ---

37 SUCTION TEMPERATURE °F 71.5 163.6 120 --- --- --- ---

38 VAPOR SUCTION LOAD (STEAM) LB/HR 148.5 198.0 496 --- --- --- ---

39 VAPOR SUCTION LOAD D.A.E. LB/HR 183.3 244.4 612.3 --- --- --- ---

40 SUCTION LOAD (AIR) LB/HR 67.5 67.5 4.0 --- --- --- ---

41 SUCTION LOAD (OTHER NCG) LB/HR N/A N/A N/A --- --- --- ---

42 SUCTION LOAD (OTHER VAPOR) LB/HR N/A N/A N/A --- --- --- ---

43 SUCTION LOAD (DAE TOTAL) LB/HR 250.8 311.9 616.3 --- --- --- ---

44 DESIGN DISCHARGE PRESSURE In HgA 10.00 32.00 3.00 --- --- --- ---

45 MAX. 2-STAGE OPERATING RANGE In HgA 1 - 8 N/A N/A --- --- --- ---

46 OPER. MOTIVE STEAM PRESSURE PSI 210 210 210 --- --- --- ---

47 OPERATING MOTIVE STEAM TEMP °F 700 700 700 --- --- --- ---

48 MOTIVE STEAM CONSUMPTION LB/HR 945 687 388 --- --- --- ---

49

50

51 STEAM CHEST A106B / A516 SHELL A106B SHELL N/A EJECTOR DI, CI VACUUM SIDE A106B

52 NOZZLE 316 SS TUBES A249 INTERNALS N/A MOTIVE STEAM A106B MOTIVE SIDE A106B

53 SUCTION CHB. A106B / A285C T. SHEETS A516 PIPING N/A VACUUM RELIEF B584 CW SIDE N/A

54 DIFFUSER A285C / C1018 BONNETS A106B EXT. FINISH N/A TUBESIDE RELIEF N/A EXT. FINISH SP-1011

55 EXT. FINISH SP-1011-09-1138-6 BAFFLES A36 AC VENT DI, CI SP-1011-09-1138-6

56 EXT. FINISH SP-1012-09-1139-06 INSTRUMENT SS

57 NOTES

58 1. EXTERIOR FINISH APPLIES TO FABRICATED COMPONENTS ONLY. VALVES, ETC., RECEIVE MFR'S STD TOP COAT.

59 2. MOTIVE STEAM CONDITIONS REQUIRED AT CUSTOMER STEAM INTERFACE CONNECTION SPECIFIED ON GA DWG.

60 3. MECHANICAL DESIGN TEST PRESSURE PER ASME CODE WHERE APPLICABLE.

DESIGN POINTS

MATERIALS OF CONSTRUCTION

EJECTORS CONDENSERS SILENCER VALVES PIPING

EJECTOR PERFORMANCE

Page 1 of 1

1 S.O. #: 09-1138 DATE: 10/09/09 DOC. NO. 09-1138 -PCY2 CUSTOMER: GEA POWER COOLING REVISION: 2 SYSTEM MODEL NO. 62C32C3 CUSTOMER P.O.: 360-143-1 ENGINEER: DSB4 PROJECT: CHECKED: PWL5 PROJECT #: 09-3606 CONTRACTOR:7 CONTRACT #: 06208 LOCATION: ASTORIA, NY

9 EJECTOR SERIAL NO. 09-1138-YQ10 OPERATING CONDITIONS11 MOTIVE STEAM PRESSURE: 210 PSIG12 MOTIVE STEAM TEMPERATURE: 700 ºF13 DESIGN DISCHARGE PRESSURE: 10.00 IN. HgA


Y-STAGE EJECTOR PERFORMANCE CURVE


SNC LAVALIN CONSTRUCTOR

9

10

11

12

13

14

15

Discharge Pressure Curve

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

200 400 600 800 1000 1200

Pres

sure

-In

. HgA

Capacity - Lbs/Hr D.A.E.

Suction Pressure Curve


DESIGN POINT: 250.8 LB/HR @ 1" HGA

Page 1 of 1

1 S.O. #: 09-1138 DATE: 10/09/09 DOC. NO. 09-1138 -PCZ2 CUSTOMER: GEA POWER COOLING REVISION: 2 SYSTEM MODEL NO. 62C32C3 CUSTOMER P.O.: 360-143-1 ENGINEER: DSB4 PROJECT: CHECKED: PWL5 PROJECT #: 09-3606 CONTRACTOR: SNC LAVALIN CONSTRUCTOR7 CONTRACT #: 06208 LOCATION: ASTORIA, NY

9 EJECTOR SERIAL NO. 09-1138-ZQ10 OPERATING CONDITIONS11 MOTIVE STEAM PRESSURE: 210 PSIG12 MOTIVE STEAM TEMPERATURE: 700 ºF13 DESIGN DISCHARGE PRESSURE: 32 IN. HgA


Z-STAGE EJECTOR PERFORMANCE CURVE


25

30

35


0

5

10

15

20

25

30

35

300 400 500 600 700 800

Pres

sure

-In

. HgA




DESIGN POINT: 311.9 LB/HR @ 9.5" HGA

Page 1 of 1

1 S.O. #: 09-1138 DATE: 10/08/09 DOC. NO. 09-1138 -PCD2 CUSTOMER: GEA POWER COOLING REVISION: 2 SYSTEM MODEL NO. 62C32C3 CUSTOMER P.O.: 360-143-1 ENGINEER: DSB4 PROJECT: CHECKED: PWL5 PROJECT #: 09-3606 CONTRACTOR: SNC LAVALIN CONSTRUCTOR7 CONTRACT #: 06208 LOCATION: ASTORIA, NY

9 EJECTOR SERIAL NO. 09-1138-DA10 OPERATING CONDITIONS11 MOTIVE STEAM PRESSURE: 210 PSIG12 MOTIVE STEAM TEMPERATURE: 700 ºF13 DESIGN DISCHARGE PRESSURE: 4 IN. HgA


DA FORWARDING EJECTOR PERFORMANCE CURVE


20

25


0

5

10

15

20

25

600 700 800 900 1000 1100

Pres

sure

-In

. HgA




DESIGN POINT: 616.3 LB/HR @ 2" HGA

Page 1 of 1


SECTION 10

DRAWINGS This section contains copies of drawings submitted to the purchaser during the ‘Engineering Stage’ of the project. They are included in this manual to assist the user in operation, maintenance, and troubleshooting the equipment.

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SECTION 11

CATALOG CUTS AND COMPONENT MANUALS Catalog cuts for components are attached to aid the user with operation, maintenance, and troubleshooting where applicable. OEM manuals are included for special components as necessary per specific project requirements. The operator is advised to carefully study the attached manuals for information on the proper operation and maintenance of critical system components. Depending on the specifics of the order, however, none may be required. Consult Unique Systems for detailed questions or concerns regarding specific component operation not addressed in this section of the manual.


SECTION 12

SPECIAL INSTRUCTIONS QUICKCHECK EJECTORS

Unique’s patented Quickcheck Ejectors are designed to facilitate component inspections with minimized system downtime. With the Quickcheck design the operator can quickly gauge critical ejector geometry parameters, namely steam nozzle throat and diffuser throat diameters, without taking apart the system or removing the ejector from the skid. Reference the Quickcheck figures in the following pages for detailed instructions on assembly and disassembly of Quickcheck ejectors. To determine if your system was supplied with Quickcheck Ejectors refer to the Ejector Bills of Materials in SECTION 8 of this manual. If your ejectors are not Quickcheck contact Unique Systems for assistance with the disassembly procedure for your particular system. TOUCH-UP PAINTING

Touch-up painting may be required from time to time, especially if the unit is installed outdoors. For outdoor installations routine maintenance should include periodic checks on paint integrity. When small amounts of paint (6” sq. or less) flake or chip exposing the bare metal underneath, rusting will occur and repairs should be made immediately. To repair the rust spot first use a wire brush or a small power tool to scrape away rust leaving only the clean metal surface. Apply two coats of primer as directed by the paint specifications included with this manual (SECTION 15). Then apply one coat of finish paint. If rusting or painting damage is severe contact Unique Systems for recommendations particular to your system and ambient conditions. RUST INHIBITORS

Rust inhibitor is applied to all flanged connection faces and exposed threaded pipe connections at Unique’s factory. However, should the need arise where another application of inhibitor is required we recommend using the following coatings. Follow the manufacturer’s directions for specific instructions and product details.

1. Rust Veto 344 E. F. Houghton & Co.

2. Industrial SP-400 03282 CRC Industries

When cleaning is required the following solvents are recommended for use with the rust inhibitor coatings listed. Follow the manufacturer’s directions for specific instructions and product details.

1. Dykem Remover

2. Paint Thinner

3. Mineral Spirits


SECTION 13

FORMS The attached forms are provided for the user to assist with various requirements of installation, storage, spare parts ordering, and problem troubleshooting. Included are the Receiving Inspection & On-Site Storage Inspection forms. Please contact Unique Systems if you have any questions or need assistance completing a required form.

QC FORM 1020RI RECEIVING UNIQUE SYSTEMS, INC. INSPECTION1 Saddle Road • Cedar Knolls, NJ 07927-1998 (USA)Phone: (973) 455-0440Fax: (973) 455-7214Email: [email protected]

CUSTOMER:

Please note below any shortages, damage, or other problems with this delivery.

QTY. ACCEPTED/REJECTED

NOTES:

Attach signed BOL, digital photographs, and any other Completed By:applicable documentation to prove claim.

This form and associated documentation must be returned to Unique within one (1) week of delivery or claims may be rejected. Date Completed:

SERIAL #

PURCHASE ORDER #

SHIP DATE

SHIP DATE

SHIPPING DIM'S

SHIPPING WEIGHT

REC. INSPECTOR

UNIQUE SHIPPING INSPECTOR

ITEM # PART NUMBER DESCRIPTION OF DAMAGE OR SHORTAGE

DELIVERY DATE:

QC FORM 1030SI STORAGE UNIQUE SYSTEMS, INC. INSPECTION LOG1 Saddle Road • Cedar Knolls, NJ 07927-1998 (USA)Phone: (973) 455-0440Fax: (973) 455-7214Email: [email protected]

STORAGE LOCATION

MONTHLY INSPECTION IS REQUIRED TO MAINTAIN WARRANTY VALIDITY

INSP BY CORRECTIVE ACTION

NOTES:

Note any damage or other problem immediately. Date RemovedDigital photographs required for record and warranty claims.

This form and associated documentation must be kept for record. Signed copy required for warranty and service claims. Installation Date

START DATE:

CONDITIONINSP DATE COMPONENT

COVERED

SPACE HEATERS

STORAGE INSP

INTO STORAGE DATE

SERIAL #

PURCHASE ORDER #

DELIVERY DATE

RECEIVING INSPECTOR


SECTION 14

WARRANTY & CLAIMS

The following documentation is provided for reference regarding Unique’s standard warranty policy. In the case of equipment malfunction, Unique’s warranty coverage is provided to assist the customer with repairs and/or replacement parts per the terms included. Should the need arise, a Warranty Claim Form is attached. All claims to Unique Systems must be accompanied by a completed form. Claims will not be processed without the proper documentation and repairs will not be approved without the explicit written consent of Unique Systems.


01/ 2009

WARRANTY

Unique Systems warrants that all new Process Vacuum Systems & equipment will be free from defects in design, workmanship and material for a period of TWO (2) YEARS from the date of shipment or ONE (1) YEAR from the date of installation, whichever occurs first. Spare parts will be warranted for a period of ONE (1) YEAR from shipment. Any claims for defective products must be made in writing to Unique Systems and the item in question must be returned to our factory for evaluation. Items found to be defective will either be repaired or replaced, at our discretion, free of charge. Shipping terms for all warranty items are “Ex-Works” Factory. The following conditions are not considered to be defects in design or workmanship:

• Normal Wear & Tear

• Improper Handling

• Improper Storage

• Corrosion

• Erosion

• Rubbing

Our warranty will not apply to any equipment that has been subject to misuse, negligence, accident, or which has been modified, altered or repaired by anyone except our authorized employees. We will not be liable in any event for modifications, alterations or repairs, except those made with our prior written consent. Any parts or equipment designed and manufactured by others but furnished by us will be repaired or replaced only to the extent of the original manufacturer's guarantee. Our warranty is limited to the cost of repair or replacement of items, and shall not include removal, shipment or re-installation of any items, except to the extent that Unique Systems was required to incur such costs for the original supply of the item. In such instances, we must have “free & open access” to our equipment for any warranty repairs. Unique Systems, its officers, employees or representatives, shall in no event be held liable for any consequential, incidental, or subsequential damages or expenses arising from the use or misuse of our products. Our liability is limited to the purchase price of the item affected, excluding any emergency premiums or expediting fees.

DOCUMENT #: QCF-590 DOCUMENT TITLE: WARRANTY CLAIM FORM CONTROLLED BY: Alexander J. Sosa, Engineering/Q.A. Manager

Q.C. FILE: Operations/Quality Control/QCF Quality Control Forms


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CLAIM REFERENCE

Date: Claimant Company:

Warranty Claim #: Contact:

Entered By: Phone:

System Serial #: E-mail:

System Type: Site Address:

System Ship Date:

Warranty Exp. Date:

CLAIM DESCRIPTION

[ ] SYSTEM PERFORMANCE [ ] DAMAGED PART

[ ] Poor Vacuum Part Number: [ ] Inadequate Capacity Part Description:

Brief Problem Description:

CLAIM INSTRUCTIONS CLAIM OPTIONS

This portion of the form is intended to be completed by the claimant and returned to Unique Systems. Please review Unique Systems’ Warranty Policy (attached) and check one of the following options: A, B, or C. A purchase order is required for all options. Upon receipt of the damaged part(s) and determination that the damage is covered under warranty Unique Systems will void your P.O.

When requesting replacement parts also check option ‘A’ for Unique Systems on-site supervision of installation if desired by customer. No travel arrangements will be made until a customer P.O is received when on-site services are requested.

After selecting the desired claim option please complete the customer authorization section below.

A [ ] Engineering field service personnel requested on site (at location listed above).

B [ ] Damaged parts to be removed by the User and returned to Unique Systems, freight prepaid, for review prior to replacement.

C [ ] Replacement parts to be sent to and installed by the User prior to return of damaged parts to Unique Systems for review.

DOCUMENT #: QCF-590 DOCUMENT TITLE: WARRANTY CLAIM FORM CONTROLLED BY: Alexander J. Sosa, Engineering/Q.A. Manager

Q.C. FILE: Operations/Quality Control/QCF Quality Control Forms


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Notes

1. Unique Systems considers any complaint by the User and/or the purchaser regarding system performance or damaged parts to be a warranty claim provided that the warranty coverage period is in effect at the time of the call or communication. The validity and extent of said claim will be determined by Unique Systems as governed by Unique Systems’ Warranty policy.

2. A Warranty Claim Form completed in its entirety, including digital photographs, is a prerequisite for claim processing and corrective action by Unique Systems.

3. This form must be returned complete to Unique Systems within 3 calendar days of issue in order to ensure a prompt response and expedient claim processing.

4. After evaluating the warranty claim part(s) received it is determined that part(s) are damaged due to causes not covered by our warranty, or that the part(s) are not defective, Unique Systems will invoice against the purchase order on file. If the warranty claim parts are not received by Unique Systems within 30 days of the User receiving the replacement part(s) the customer forfeits claim rights and the purchase order on file will be charged.

5. All parts being returned must be thoroughly cleaned and totally free of any hazardous material. Parts must be marked with the warranty claim number as shown above and sent freight prepaid.

6. Service personnel rates are portal to portal. Saturdays are billed at time and a half; Sundays and locally observed holidays are billed at double time. Travel and living expenses are charged at cost, based on Economy Class airfare for domestic travel, Business Class for overseas travel. See Unique Systems’ field service rate sheet for current rates and more details.

CUSTOMER AUTHORIZATION

Unique Systems is authorized to proceed with this warranty claim as noted. All terms included are accepted.

[ ] Replacement Parts Required Customer Purchase Order Number: -

[ ] Engineering Field Service Required On Site

Authorized by:

- - -

Name Title Date

Note: A formal P.O. must accompany this completed form in order for claim processing to proceed.

Form Rev. 2 AJS 07/23/10


SECTION 15

QC DOCUMENTATION

Quality documentation is an integral part of every system delivered by Unique Systems. Included in this manual by reference is Unique Systems’ QC Dossier which incorporates a compilation of quality documents required by the purchase order. This document package is provided for ‘permanent record’ purposes, intended to verify scope of supply, materials of construction, testing, etc. However, it is not represented as being a complete listing of all quality related documents associated with the manufacture of this equipment. The QC Dossier is submitted under separate cover as a stand-alone document. Please reference the dossier for all quality related documentation pertinent to this order.

air ejector

Documents

system components

system owneroperator

unique systems

system serial number

steam ejector vacuum

steam valves

following equipment

service model