Igema LG40-CS Bedienungsanleitung

Reflex Level Gauge

LG40-CS

D-02-B-31946-EN-0.doc

Ausgabe 07/2017

-Table of contents-

1. Health and safety instructions 4-5

1.1 General health and safety instructions ........................................4

1.2 Unit-specific safety instructions..................................................5

1.3 Exclusion of liability ..................................................................5

2. Important information 6

2.1 Intended use ...........................................................................6

3. Explanations 6

3.1 Scope of supply........................................................................6

3.2 System description ...................................................................6

3.3 Function..................................................................................6

4. Technical data 7-8

4.1 Versions..................................................................................7

4.2 Type of connection ...................................................................8

4.3 Materials .................................................................................8

4.4 Application limits......................................................................8

4.5 Corrosion resistance .................................................................8

4.6 Identification plate / Marking .....................................................8

5. Construction 9

6. Assembly 9-10

6.1 Version with flange...................................................................9

6.2 Version with butt welding end .................................................. 10

6.3 Heat treatment of weld seams ................................................. 10

6.4 Drain piping........................................................................... 10

7. Commissioning 10-11

7.1 Commissioning of unit together with the boiler........................... 10

7.2 Commissioning of unit if boiler is already in operating condition ... 10

7.3 Re-tightening of screws........................................................... 11

8. Maintenance 11-12

8.1 Leakage ................................................................................ 11

8.2 Cleaning of glasses................................................................. 11

8.3 Cleaning and purging of level gauge ......................................... 12

8.4 Exchange of glass................................................................... 12

8.5 Assembly .............................................................................. 12

8.6 Tightening torques.................................................................. 12

9. Shutoff valves 13-16

9.1 General information and operating instructions .......................... 13

9.2 Construction ..................................................................... 14-15

9.3 Commissioning....................................................................... 15

9.4 Maintenance .......................................................................... 16

9.5 Assembly .............................................................................. 16

10. Drain valve 17-18

10.1 Construction .......................................................................... 17

10.2 Assembly .............................................................................. 17

10.3 Commissioning....................................................................... 17

10.4 Maintenance .......................................................................... 18

11. Case of Damage 18

12. Spare parts 18-19

12.1 Reflex level gauge .................................................................. 18

12.2 Shutoff valve ......................................................................... 19

12.3 Drain valve............................................................................ 19

13. Decommissioning 20

13.1 Disposal ................................................................................ 20

14. Supplement 20-22

14.1 Warranty............................................................................... 20

General health and safety instructions

1. Avoidance of danger for persons and property

•Only use unit for intended purpose.

•No additional mountings and modifications on the unit without our approval.

•Adhere to the standards for prevention of accidents and to the plant specific safety

regulations.

•Read and observe installation and operating instructions.

2. Application limits

Only use this unit according to these operating instructions and to the parameters agreed

upon in the delivery contract (see identification plate) including the agreed operating

conditions.

3. Avoidance of danger and damages

•Distribute these mounting and operating instructions to appropriate department “arrival

of goods, works transport, mounting, commissioning and maintenance”.

•When passing the unit to a third party, these mounting and operating instructions must

be enclosed in the national language of this third party.

•Only skilled and qualified personnel with special work order may work on the unit,

which must be free of pipeline stress!

•Carefully read, observe and preserve these mounting and operating instructions.

•Observe and adhere to the precautions marked in bold characters in the

sections of these mounting and operating instructions!

•Avoid shocks and impacts during transport, which could damage the unit.

•In case of intermediate storage take care for a dry and appropriate place where the

unit cannot be damaged.

4. Marking

In these mounting and operating instructions, the safety instructions are specially

marked with the following symbols:

means danger to life and/or serious property damage in case of

non-observance. Never ignore!

Danger

means that you must pay special attention to the technical relationships.

Attention

Unit-specific safety instructions

The fitting is under pressure during operation!

If flange connections, screw plugs or stuffing boxes are unfixed, hot water and steam

will escape.

Carry out assembly and maintenance works only if plant is completely pressureless!

The fitting is hot during operation!

Severe burns on hands and arms are possible.

Wait until the unit has cooled before carrying out assembly and maintenance works!

Severe burns and scaldings on the whole body are possible!

Wait until the unit has cooled. In case of opening and disassembling the unit, residual

medium can escape. Further evaporation is also possible on pressureless plant.

Sharp-edged interior parts can cause cutting damages on the hands!

Always wear work gloves when exchanging packing, valve seat and valve cone!

Exclusion of liability

The IGEMA GmbH Mess- und Regelsysteme does not accept liability when a/m

regulations, instructions and warning indications are not observed and adhered to.

The operator is responsible for modifications on a unit of IGEMA (if they are not explicitly

specified in the mounting and operating instructions).

2. Important information

2.1 Intended use

Reflex level gauge:

The reflex level gauge LG40-CS is a direct water level gauge which can be used

for steam boilers and containers.

In the sight opening, the water level is indicated dark and the steam light.

The product corresponding to the EU 2014/68/EU.

Applied standards as per EN 13445 / EN 12952 / EN 12953 / AD 2000 or ASME-

Boiler.

3. Explanations

3.1 Scope of supply

LG40-CS:

The unit is delivered as complete unit (see page 9):

1 level gauge (1)

1 upper shutoff valve (2)

1 Lower shutoff valve (3)

1 drain valve (4)

3.2 System description

The reflex level gauge in different versions is used to detect the water level of

containers and steam generators.

3.3 Function

The level gauge works according to the physical law of the communicating

tubes.

It is equipped with a longish sheet glass with prismatic grooves on the surface

turned to the medium. The water space is indicated dark and the steam space

light due to the different reflection (refraction) of the light.

Steam

Water

4. Technical Data

4.1 Designs

One sight opening design

On top of each other

sight opening design

*L=dependent from process connection

T=26mm (dead space)

*L=dependent from process connection

*Using an A140-CS valve, dimension are differently. Different dimensions see on data sheet D-09-D-36387-EN

Sight openings standard designs:

One sight

opening

Size

Sight lenght

200

230

260

300

320

350

Sight opening on

top of each other

2ü

426

486

546

626

666

726

3ü

652

742

832

952

1012

1102

4ü

878

998

1118

1278

1358

1478

5ü

1104

1254

1404

1604

1704

1854

6ü

1330

1510

1690

1930

2050

2230

7ü

1556

1766

1976

2256

2396

2606

8ü

1782

2022

2262

2582

2742

---

9ü

2008

2278

2548

---

10ü

2234

2534

2834

---

View show the left sided model

Valves:

Valves

Type

Shut-Off valves

A120-CS; A140-CS

Drain valves

AV100

4.2 Type of connection

Standard : flanges according to DIN EN 1092-1

On request : flanges as per ASME

Butt welding ends according to DIN or ASME

Socket Welding ends according to DIN or ASME

4.3 Materials

Components in contact with the medium and pressure-holding components are

made of C steel or stainless steel according to DIN or ASME.

4.4 Application limits

Max. allowable pressure PS

[bar]

Max. allowable temperature TS

[°C]

239

4.5 Corrosion resistance

The safety of the unit is not influenced by corrosion if it is used as intended.

4.6 Identification plate / Marking

The following data are indicated on the identification plate:

* marking depending on the realization

ADate of manufacture

BType of unit

CMax. allowable pressure

DMax. allowable temperature

ENominal pressure

FNominal diameter

5. Construction

for example: one sight design

(1) Glass holder (7) Screw holder

(2) Upper shutoff valve (8) Locking

(3) Lower shutoff valve (9) Sealing

(4) Drain valve (10) Glass

(5) Plug (11) Sealing

(6) Pressure screw (12) Pressure plate

6. Assembly

6.1 Version with flange

•Respect installation position!

•Remove protecting caps from connection flanges. Caps only serve as

transport protection.

•Ensure that sealing surfaces are clean and undamaged.

•Mount reflex level gauge.

6.2 Version with butt welding end

•Respect installation position!

•Remove protecting caps from connection flanges. Caps only serve as

transport protection.

•Assembly only by using welding process 111 and 141.

6.3 Heat treatment of weld seams

Supplementary temper tests of weld seams are not required!

6.4 Drain piping

•Close valves (D1, D2, W1, W2) after mounting.

•Mount drain piping on drain valve (4) (to be provided by the customer).

Ensure that drain piping has free outlet to atmosphere and is

protected from pressure peaks!

7. Commissioning

7.1 Commissioning of unit together with the boiler

Check specifications of material, pressure and temperature!

•Close drain valve / plug.

•Fully open shutoff devices (D1, D2, W1, W2).

7.2 Commissioning of unit if boiler is already in operating

condition

•Close shutoff device (D2, W2).

•Fully open shutoff device (D1,W1) (if exists)and drain valve (4).

•Slightly open upper shutoff device (D2), carefully heat up glass holder with

steam until operating temperature is reached.

•Closed drain valve.

•Slowly open upper shutoff device (D2) and lower shutoff device (W2) as far

as it will go. Wait for alignment of water level. (If water level is not visible,

see special operating instructions shutoff valves / drain valve)

(If water level is not visible, see 9.1 General information and operating instructions “self-

closing ball”)

7.3 Re-tightening of screws

All screw connections except pressure screws

•Before commissioning of level gauge, check all screw connections: plugs,

valve and flange connections and screw caps of shutoff valves / drain valve

(see special operating instructions shutoff valves / drain valve.

•We suggest to observe the level gauge especially during first days after

commissioning.

•Re-tighten firmly screw connection where leakage appears.

Pressure screws

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