Nalco ACT Feed System and Accessories Specification SPEC-478 Nalco ACT Feed System and accessories provide continuous feed of Advanced Condensate Treatment products to improve your boiler program s effectiveness. Uninterrupted feed of Nalco ACT is key to preventing acid and oxygen induced corrosion in condensate systems. Lower total system operating costs Maximize equipment reliability Minimize downtime and maintenance costs The Nalco Corrosion Monitor provides on-line assurance that your boiler system is optimized and protected using real time data. Hands-Free Delivery Nalco s certified delivery specialists are trained to handle Nalco ACT products safely in your plant. Our environmentally friendly PORTA-FEED delivery system eliminates the hassles and expense associated with the delivery of chemical in drums. Zero Defect Delivery Your inventory is managed to maximize the effectiveness of the Nalco ACT products in your process. Fresh product is especially important in food grade applications. Description Nalco ACT Advanced Condensate Treatment is a revolutionary condensate corrosion program that combines patented technology, state-of-the-art monitoring, field-proven equipment and Nalco s onsite service. The following information contained in this bulletin describes the key components required to obtain the best results from your Nalco ACT program. Nalco ACT Feed System Your inventory is managed to maximize the effectiveness of the Nalco ACT products in your process. A switchbox device (patent pending) ensures that you always have a continuous supply of fresh product available for your process. The Nalco ACT feed system comes with our PORTA-FEED unit complete with bag outlet valve assembly, four-way valve and bracket assembly and the switchbox assembly. These items are shipped assembled when you order a new PORTA-FEED base tank. The entire system is completely assembled to make your start-up quick and trouble-free. Your Nalco certified delivery specialist will make the final bag connection at the time of your first Nalco ACT feed system delivery.
Nalco ACT Chemical Feed Pump The Nalco ACT chemical feed pump, PULSAtron Series E Plus pump 0-3 gpd, 300 psi, comes with on/off controls. It includes a 5-function valve that has a built-in pressure relief and bleed valve to assist in priming the pump (Nalco Part Number 121-P01200.88). Additional chemical metering pumps with higher capacity and increased pressure capability are available with an array of control features. Please contact your Nalco representative.in North America, you can also contact the Equipment Solutions Technical Support Group at 800-323-8483. Nalco ACT Chemical Injection Properly dispersing Nalco ACT in the boiler system is key to ensuring optimum performance. Use the Nalco retractable injector with a cut and slotted stinger and a check valve for each application point (Figure 1 on page 3). Some installations may require multiple application points to ensure complete system protection. The following two NALQUILL models are available: Part Number 231-P4634.88 231-P4694.88 Description NALQUILL retractable injector with cut and slotted 18-inch stinger. NALQUILL extended length retractable injector with cut and slotted 28-inch stinger. The retractable injectors allow you to inspect/clean the nozzle without shutting down the boiler. Choose the retractable injector that will allow you to introduce chemical feed into the center of the steam header. Keep in mind that you not only have to consider the pipe diameter but also the retractable injector must pass through the isolation assembly (typically pipe nipple, bushing and a 1-1/4 or larger gate valve not included with the injector.) Refer to Figure 2 for installation information. Selecting the Correct NALQUILL Retractable Injector Maximum Part Number Injector Size Insertion Length 231-P4634.88 18 inches 7-1/2 inches 231-P4694.88 28 inches 17-1/2 inches Size injector to position stinger in the center of the pipe. Total length of fittings (nipple, tee, gate, valve, coupling) plus 1/2 diameter of the pipe must be less than the maximum insertion length. Fittings are not included with NALQUILL injector. Example Pipe Diameter: 18 Nipple: 1 ea 1-1/4 diameter, 4 long Valve: 1 ea 2-1/2 long Tee: 1 ea 2 long Insertion length required = 1/2(18 ) + 1(4 ) + 1(2-1/2 ) + 1(2 ) = 17-1/2 The correct part would be 231-P4694.88 with a 17-1/2 maximum insertion length. For installations (Figure 2) that do not permit Retractable Injectors use the following NALQUILL Injectors: Maximum Part Number Injector Size Insertion Length 231-P4610.88 6 inches 3 inches 231-P4612.88 18 inches 15 inches Refer to Figure 6 for installation. Nalco ACT Sample Conditioning To ensure accurate and reproducible results, sampling technique is critical. Be sure to use stainless steel sample lines and valves. Use a Nalco Sample Cooler (Part Number 500-531062.88) when sampling for metals or when temperatures/pressures exceed 350 F/1000 psi. 2
22 1/2" : 572 mm (D) 18" : 457 mm (A) 24 1/2" : 622 mm (C) 1" : 25 mm Safety collar 3 3/4" : 95 mm "Stinger" (E) 11 1/2" : 292 mm (B) 1/4" : 6 mm Note: Add 10" : 254 mm to dimensions A, C, and D for extended length injectors Figure 1 Nalco Retractable Injector with cut and slotted stinger Nalco ACT Monitor and Control Monitor the Nalco ACT program using the NCM100 for boilers (Part Number 400-NCM100KB.88). It s a good idea to establish a baseline corrosion rate prior to feeding the Nalco ACT products. An NCM100 Starter Kit for boilers internal data logger with real-time clock captures critical system information that allows you to trend system performance and provides assurance that your boiler system is under control. The Nalco Corrosion Monitor for boilers includes the corrosion monitor, software CD, manual, Smart high temperature probe (250 F/1000 psi maximum) with front and back ferrule, test probe, Swagelock fitting, 1018 MS probe tips (2), high temperature housing kit (tee and reducer) and a 6 foot serial cable. Use the optional WebAlert to monitor the performance of the Nalco ACT program at key points throughout your boiler system. Used along with the NCM100, you can log corrosion rates, trend the information in real time and obtain access from anywhere with your Internet web browser for up to six 4-20 ma isolated inputs. Set the userdefined alarms (email, page or short text message) to warn you about process upsets. Nalco ACT Product Dosage Dosage 5-15 ppm Dosage 10-20 ppm Nalco ACT 52211 Nalco ACT 52214 Nalco ACT 52212 Nalco ACT FG Installation Guidelines Be sure to take a look at the typical installation diagrams (Figures 2, 3, 4, 5 and 6) prior to ordering or installing any equipment. Follow the recommendations to ensure the best program results. 3
To Order The PORTA-FEED Accessory Package for the Nalco ACT Feed System will be provided automatically when you place a base tank order for Nalco ACT products in container package code 37B. Order the required Nalco ACT Advanced Condensate accessories by using the Nalco part numbers listed below. Contact your local Nalco representative or our Nalco Customer Service at 800-288-0879 for further order information. Part Number Description Nalco ACT Metering Pump 121-P01200.88 Nalco ACT Metering Pump Nalco Retractable Injector Select either the 18 or 28 injector: 231-P4634.88 NALQUILL retractable injector with cut and slotted 18-inch stinger. 231-P4694.88 NALQUILL extended length retractable injector with cut and slotted 28-inch stinger. Check valve 991-V00283.88 Check valve (1 required per application point) check valve 304 SS 1/4 x 1/4 FNPT 25 psi Flexible Hose Teflon/304 SS Select one: 991-P09243.88 18 braided hose Teflon/304 SS 1/4 inch MNPT Union 3000 psi, 450 F maximum 991-P09244.88 18 braided hose Teflon/304 SS 1/2 inch MNPT Union 1500 psi, 450 F maximum NCM100 for boilers 400-NCM100KB.88 NCM100 for Boilers If you have a NCM100 for cooling water order the following parts for each sampling point to adapt to a boiler/condensate application. Part Number Description NCM100 Accessories (optional) 400-NCMP6.88 NCM boiler probe 400-NCMAC13.88 Boiler probe housing kit (tee and reducer) 400-NCMAC14.88 500-P6116.88 500-P6113.88 Boiler probe cable Boiler probe replacement tips (2 mild steel) Boiler probe Teflon O-rings Sample Cooler 500-531062.88 Sample cooler 316 SS 1 ft 2 (1 required per metals sampling point or if conditions exceed 350 F/1000 psi) WebAlert (optional) 051-WAEM0000.88 051-WAEMN000.88 WebAlert with Ethernet and modem WebAlert with Ethernet, modem and networking master software. Accessories/ Replacement Parts Part Number Description 991-V00283.88 Check valve 304 SS 1 4 in x 1 4 in FNPT 25 psi 420-C0227.88 Millipore insoluble iron test kit 500-P6116.88 Boiler probe replacement tips (2/pkg 1010 mild steel) 500-P6113.88 Boiler probe Teflon O-rings 400-NCMP6.88 NCM boiler probe 400-NCMAC13.88 Boiler probe housing kit (tee and reducer) 400-NCMAC14.88 Boiler probe cable 231-ACT0001.88 Nalco ACT delivery lance complete 231-ACT0002.88 Nalco ACT delivery lance adapter 231-ACT0003.88 Nalco ACT delivery lance disposable hose assembly 231-ACT0004.88 Nalco ACT four-way valve and bracket assembly 231-ACT0005.88 Nalco ACT bag outlet valve assembly 231-ACT0006.88 Nalco ACT switchbox assembly 231-ACT0007.88 Nalco ACT air relief valve assembly 991-05056071.88 Nalco ACT four-way valve brass 1/4 inch 231-T00140.88 Tubing polypropylene 1/4 inch 231-T00141.88 Tubing polypropylene 3/8 inch 991-05056072.88 Nalco ACT check valve brass 1/4 inch 231-P4610.88 NALQUILL 6 - Fixed 231-P4612.18 NALQUILL 18 - Fixed 4
DANGER Multiple feed points may be required to treat entire system. Locate 10 diameters downstream from sample points Cut tip facing flow Locate tip in center of pipe STEAM 1. Burn hazard 2. Pressurized equipment 3. Follow plant lock out and isolation procedures. 4. Wear appropriate personal protective equipment. 5. Safe access required for elevated installations. 6. Use Buddy System. Do not work alone. Steam header Vent valve Tee To process 1-1/4" or larger gate valve Nalco retractable injector Horizontal Flow Stainless steel flexible hose Isolation valve Protect from rain, direct sunlight Check valve To 45 acceptable radius To 120 acceptable radius Metal pipe Ball valve Pump 115 Vac, 15 Amps Level pad Boiler 1 Boiler 2 Boiler 3 Common Steam Header Retractable Injectors Process 1 Process 2 Process 3 Process 4 Process 5 Complicated boiler systems supplying multiple processes require individual Nalco ACT feed points to each process to ensure adequate protection. Figure 2 Nalco ACT installation setup 5
DANGER Steam From process STEAM 1. Burn hazard 2. Pressurized equipment 3. Follow plant lock out and isolation procedures. 4. Wear appropriate personal protective equipment. 5. Safe access required for elevated installations. 6. Use Buddy System. Do not work alone. 10-45 Locate sample tap 10-45 off pipe bottom to minimize contamination 1/2" SS gate valve 1/4" SS sample line Cooling water out 5.0 Corrosion rate, mpy 4.5 4.0 3.5 3.0 2.5 2.0 1.5 Neutralizing amine treatment No treatment Nalco ACT corrosion inhibitor Nalco ACT interrupted Gate valve Sample cooler required for metal studies or when temperature/pressure exceeds, 350 F/1000 psi. 1.0 0.5 0 6-Sep 16-Sep 26-Sep 6-Oct 16-Oct Throttle outlet only To drain Date Internet Cooling water in Remote monitoring Real-time data Emails Datalogs Alarm Notification NCM100 Flush connection for cleaning For accurate, reproducible test results: Sample cooled to less than 75 F Continuous flow Metals analysis requires 5-6 ft/sec flow velocity (2 gpm in 1/4" schedule 40 pipe) Dry contact alarm relay RS 232 Local monitoring Corrosion rate (4-20mA input) High temperature probe 350 F, 1000 psi max Block valve To drain Vent/depressurize line before removing probe Figure 3 Nalco ACT Monitoring and Control Primary sample location 1/2" SS gate valve Condensate receiver tank Pump 1/4" SS sample line Cooling water out Secondary sample location Gate valve Sample cooler required for metal studies or when temperature/pressure exceeds 350 F/1000 psi Throttle outlet only To drain Cooled sample To NCM100 Cooling water in Flush connection for cleaning Figure 4 Alternate sampling points 6
Figure 5 Nalco ACT feed system general arrangement Pipe coupling Pipe nipple Weld CL 1 1/2" A.P.I. pipe Support If you have any questions regarding this specification, please contact your local Nalco representative. In North America, you can also contact the Equipment Solutions Technical Support Group at 800-323-8483. 3 9/16" 6" A.P.I. pipe Weld coupling CL 3 9/16" Figure 6 Fixed NALQUILL installation, used when retractable injector installations are not permitted NALCO COMPANY OPERATIONS North America: 1601 West Diehl Road Naperville, Illinois 60563-1198 USA Europe: Ir.G.Tjalmaweg 1 2342 BV Oegstgeest The Netherlands Asia Pacific: 2 International Business Park #02-20 The Strategy Tower 2 Singapore 609930 Latin America: Av. das Nações Unidas 17.891 6 Andar 04795-100 São Paulo SP Brazil www.nalco.com NALQUILL, PORTA-FEED, Nalco ACT, Zero Defect Delivery NALCO and the logo are Registered Trademarks of Nalco Company WebAlert is a Trademark of Walchem Corporation 2004, 2007 Nalco Company All Rights Reserved 12-07