Instruction Manual O-Ring Ejector Chlorine & Sulfur Dioxide to 500 PPD (10 kg/h)

Transcription

1 Instruction Manual O-Ring Ejector Chlorine & Sulfur Dioxide to 500 PPD (10 kg/h) 100 PPD (2 kg/h) Maximum 250 PPD (5 kg/h) Maximum 500 PPD (10 kg/h) Maximum

2 These instructions describe the installation, operation and maintenance of the subject equipment. Failure to strictly follow these instructions can lead to an equipment rupture that may cause significant property damage, severe personal injury and even death. If you do not understand these instructions, please call Severn Trent Water Purification (STWP), Inc. for clarification before commencing any work at and ask for a Field Service Manager. Severn Trent Water Purification, Inc. reserves the rights to make engineering refinements that may not be described herein. It is the responsibility of the installer to contact STWP Inc. for information that cannot be answered specifically by these instructions. Any customer request to alter or reduce the design safeguards incorporated into STWP Inc. equipment is conditioned on the customer absolving STWP Inc. from any consequences of such a decision. STWP Inc. has developed the recommended installation, operating and maintenance procedures with careful attention to safety. In addition to instruction/operating manuals, all instructions given on labels or attached tags should be followed. Regardless of these efforts, it is not possible to eliminate all hazards from the equipment or foresee every possible hazard that may occur. It is the responsibility of the installer to ensure that the recommended installation instructions are followed. It is the responsibility of the user to ensure that the recommended operating and maintenance instructions are followed. Severn Trent Water Purification, Inc. cannot be responsible for deviations from the recommended instructions that may result in a hazardous or unsafe condition. STWP Inc. cannot be responsible for the overall system design of which our equipment may be an integral part of or any unauthorized modifications to the equipment made by any party other that STWP Inc. STWP Inc. takes all reasonable precautions in packaging the equipment to prevent shipping damage. Carefully inspect each item and report damages immediately to the shipping agent involved for equipment shipped F.O.B. Colmar or to STWP Inc. for equipment shipped F.O.B Jobsite. Do not install damaged equipment. SEVERN TRENT WATER PURIFICATION INC., COLMAR OPERATIONS COLMAR, PENNSYLVANIA, USA IS ISO 9001: 2000 CERTIFIED

3 TABLE OF CONTENTS 1 INTRODUCTION General Warranty Specifications OPERATION General Installation Ejector Vacuum Piping Vacuum Connections START-UP Vacuum Check SHUTDOWN SERVICE Nozzle Cleaning O-Ring Replacement Diaphragm Replacement Functional Test Recommended Torque Values TROUBLESHOOTING CHART FIGURES 1 Gas Feeder System Flow Diagram PPD (2 kg/h) Ejector PPD (5 kg/h) Ejector PPD (10 kg/h) Ejector

4 1 INTRODUCTION 1.1 General The ADVANCE ejectors are expertly engineered and carefully tested to assure yearsof satisfactory operation. They are constructed of the finest materials available for gas service. Correct installation and proper care will ensure best operation. Read instructions carefully and save for future reference. This instruction manual only covers our standard O-Ring ejector (Reference ). If another ejector is used, reference one of the following: Diaframless , Anti-siphon , Variable Orifice and NOTE: The Series 200 O-Ring ejectors are designed for use with Series 200 gas feeders. 1.2 Warranty See Bulletin for the ADVANCE equipment warranty. 1.3 Specifications Gas Flow Capacity Vacuum Tubing Size Inlet Nozzl e Outlet Diffuser 100 PPD (2 kg/h) 3/8" 1/2" 5/8" 1" hose/universal 3/4" thread Universal - 3/4" NPT male thread, spray or open-end, or 1" hose, 3/4" hose 250 PPD (5 kg/h) 1/2" 5/8" 1 1/4" thread 1 1/2" hose 1 1/4" thread 1 1/2" hose 500 PPD (10 kg/h) 5/8" 1 1/4" thread 1 1/2" hose 1 1/4" thread 1 1/2" hose Different inlet nozzle and diffuser combinations are available for the ejectors. Your particular combination was chosen for your application. a. A universal diffuser can be used four different ways; spray diffuser, open-end diffuser, 3/4" threaded connection, or 1" hose connection. Choose the type suited for the installation (spray is recommended for good mixing). If other than spray is desired, modify by cutting off the closed end. b. The ejector (nozzle and check valve assembly) may be located near the vacuum regulator. A wall mounting bracket is available for field assembly, and the universal diffuser can be modified for a pipe or hose connection. c. The entire diffuser-ejector assembly may be submersed in an open channel or tank. d. Diffuser tubes with corporation stops can be supplied for either close-coupled or remote ejectors. e. Corporation stops are recommended for high pressure pipeline applications and perforated pipe diffusers are recommended for good mixing in open tanks or channels Back Pressure Maximum back pressure at the point of application is 19 psig (1.3 bar). High pressure systems 20 to 140 psig (1.4 to 10 bar) can be accommodated with a high pressure ejector. Consult factory if higher than 140 psig (10 bar) back pressures are required

5 2 OPERATION 2.1 General The ejector is designed to complement Severn Trent Services Series 200 vacuum regulators. The ejector is the heart of the system providing the vacuum necessary to operate the vacuum regulator. The diaphragm ejector is to be used in continuous feed applications. 2.2 Installation - Figure 1 The ejector may be installed in any position, since the check valve is spring actuated. (However, downward water flow may cause cavitation and poor vacuum). The point of injection should be carefully chosen so the water pressure into which the gas is fed, is aslow as possible. If the ejector is installed in a pipe, the ejector-diffuser should not be installed in the top of the pipe where gas may discharge and collect in an empty area of the pipe. Diffuser penetration into the pipe should not exceed 1/3 of the diameter of the pipe. Proceed as follows to install pipe mounted close-coupled diffuser and ejector Unscrew the diffuser from the assembly. Do NOT install the ejector with the diffuser attached, or damage may occur Put Teflon tape on the diffuser pipe threads and screw the diffuser into the pipe by hand. Tighten carefully with pliers. (Make sure that the holes in the spray tube diffuser are in the main stream.) The end of an open- end type diffuser should not allow strong chemical solution to come in contact with pipe or fittings. (This will cause serious corrosion. Figure 1 - Gas Feed System Flow Diagram

6 2.2.3 Reconnect nozzle and check valve assembly to diffuser. The nozzle may extend through the assembly from either side. A gasket should be on each side. Screw the nozzle into the diffuser HAND TIGHT. (The check valve assembly may be installed in any position.) Other types of diffuser and ejector installations may be desired for certain applications: a. The ejector (nozzle and check valve assembly) may be located near the vacuum regulator. A wall mounting bracket is available for field assembly, and the universal diffuser can be modified for a pipe or hose connection. b. The entire diffuser-ejector assembly may be submersed in an open channel or tank. c. Diffuser tubes with corporation stops can be supplied for either close-coupled or remote ejectors. 2.3 Ejector Vacuum The ejector creates a vacuum only when sufficient pressure differential exists between the ejector inlet water versus the water outlet pressure. For example, if the diffuser were discharging into an empty basin (zero back pressure), the supply pressure to the nozzle requires about 25 psig (2 bar) to create enough vacuum to operate a 50 PPD (1 kg/h) vacuum regulator. A lower supply pressure or a higher back pressure would reduce the gas flow rate. Then for each 1 psig (0.07 bar) of back pressure above zero, the supply pressure must be increased about 2 to 3 psig (0.1 to 0.2 bar) above 25 psig (2 bar). A back pressure of 10 psig (0.7 bar) would therefore require about 55 psig (4 bar) supply pressure in order to operate the 50 PPD (1 kg/h) vacuum regulator. Also, the water supply line to the nozzle must be large enough to allow sufficient water flow (3/4" or larger pipe is recommended) and minimize friction losses. 2.4 Piping For most installations, the ejector water supply line should be brought to within 4-6 ft. (1-2 m) of the nozzle with rigid copper or iron pipe. A shutoff valve followed by a Y-strainer, and a hose adapter or pipe union should be installed to allow removal for service. A pressure gauge between the Y-strainer and the ejector can be a useful service tool. If the hose is used, connect the hose between the hose adapter or pipe union and the ejector nozzle. Clamp the hose securely at both ends with single or double clamps. 2.5 Vacuum Connections - See Figure 1 and Introduction, Gas Flow section Table A. Black polyethylene tubing is normally used for the vacuum line between the vacuum regulator and ejector. Use enough length for each line to allow vacuum regulator movement from one cylinder to another Remove the connector nut from the vacuum regulator connection and slip onto the tubing. Push the tubing onto the connector and tighten connector nut HAND TIGHT

7 3 START-UP 3.1 Vacuum Check The ejector, its water supply and solution lines, must be properly installed and checked before operating the vacuum regulator. Unless the ejector is creating a vacuum, the vacuum regulator will not work Disconnect the vacuum tubing from the ejector Open the ejector water supply valve. The ejector should now be in operation and creating a vacuum Put your finger on the vacuum connector opening and feel the vacuum. There should be no doubt that a vacuum exists. If there is no vacuum, be certain the supply pressure is sufficient and the nozzle or piping is not plugged. Correct the condition and obtain proper vacuum before proceeding with vacuum regulator operation. (Reference vacuum regulator instruction manual) Reconnect the vacuum tubing to the ejector. Leave the ejector running

8 4 SHUTDOWN WARNING Before disconnecting or disassembling the ejector, shutdown the system as described below. Failure to do so may result in serious injury or death. 1. Close the gas supply valve at the pressure source(s) to shut off the gas flow. This is normally the gas cylinder and/or container valve(s) supplying the gas dispensing (regulator) system. The rate valve on the dispensing system meter panel(s) is/are not to be used to shut off the gas flow. The float in the gas flowmeter(s) should drop to the bottom of the flow meter indicating zero (no gas feed) 2. Continue the flow of water through the ejector for a few minutes to remove all gas remaining in the feeder, pressure piping and vacuum tubing. While the ejector continues to operate remove the vacuum tubing from the gas inlet of the ejector to allow air to enter the unit further diluting the residual gas. Stop the ejector water flow and relieve all residual water pressure. Close any water supply and chemical solution valves to isolate the ejector

9 5 SERVICE It is recommended that the Gas Dispensing System be inspected and serviced a minimum of once per year. More frequent service periods may be required due to: 1) the type, quality and quantity of the gas being handled, 2) the complexity of the gas supply system, 3) the quality and quantity of water or process liquid being used to operate the ejector(s), and 4) operation procedures. More frequent service periods are especially indicated when venting of the VR is occurring during the one year operational period. This is usually indicative of foreign debris holding the inlet valve open or destruction of the inlet valve parts caused by the gas quality not up to industry purity standards. Preventative maintenance kits for each of the assemblies are available from the factory. Each kit contains all the parts and detailed instructions that are required for complete maintenance. All o-rings and gaskets that have been disturbed during the disassembly must be replaced during reassembly in order to insure safe, trouble free operation. Failure to replace these parts could result in a shortened operation period and bodily injury. 5.1 Nozzle Cleaning Refer to Figures 1, 2 or 3 and remove the nozzle as follows: Ejector Disassembly NOTE: After it has been confirmed that all residual gas has been evacuated and water pressure has been relieved, proceed as follows: Remove the connecting hose to the ejector assembly For 100 PPD (2 kg/h) ejectors, rotate the complete ejector body counterclockwise. This loosens the threaded portion of the nozzle from the diffuser, eliminating the need for pliers on the hose connection which may damage the plastic. For 250 & 500 PPD (5 & 10 kg/h) ejectors, remove the two (2) screws and loosen the flange to remove the nozzle. NOTE: Nozzle plugging can be caused by foreign material (pipe scale, stone, dirt accumulation). This can usually be blown out or pushed out with a wire. Build-up of deposits caused by iron, manganese or other material can usually be remove by immersing the nozzle in muriatic acid and rinsing. Some waters may cause an inoperable ejector and require nozzle cleaning every two months To reinstall the nozzle, insert the nozzle through the ejector body and fasten to the diffuser using new gaskets, or o-rings on each side of the ejector body. NOTE: These parts are plastic and excessive tightening may cause breakage. For 100 PPD (2 kg/h) ejectors, tighten only hand tight with the ejector body 90 to the left of its final position, then turn the complete assembly Reinstall the ejector supply hose or pipe and vacuum tubing. 5.2 O-Ring Replacement Ejectors contain an o-ring that should be checked and the o-ring/diaphragm bolt assembly replaced as necessary. 5.3 Diaphragm Replacement - Refer to Figures 2, 3 or Remove the four bolts holding the ejector together to expose the internal parts The diaphragm bolt assembly is tightened at the factory, but can usually be separated by using large, jaw pliers or a vice. All assemblies contain a support diaphragm. In high pressure applications, the assembly includes two thin plastic support diaphragms Replace the diaphragm and reassemble the diaphragm nut and bolt. These must be assembled tightly using jaw pliers or a special tool to tighten. Install the diaphragm assembly in the recess of the top hole, and bolt the two sections together. (Note diaphragm orientation on Figure 2, 3 or 4) No adjustments are necessary, but ensure both ends of the spring are square

10 5.4 Functional Test When the ejector is reassembled, a functional test of the check valve assembly is recommended to check for proper ejector assembly and prevent future flooding of the vacuum regulator Do not connect vacuum tubing to vacuum regulator Turn on water supply Verify vacuum at ejector Turn water supply off for approximately 5 minutes. If ejector is assembled properly, no water will leak from vacuum tubing. 5.5 Recommended Torque Values Torque values of 14 inch pounds for ejector body screws on units up to 500 PPD/10 kg/h are used at the factory, and are recommended guidelines for Reassembly of a repaired unit

11 Figure PPD (2 kg/h) Ejector

12 Figure PPD (5 kg/h) Ejector

13 Figure PPD (10 kg/h) Ejector

14 6 TROUBLE SHOOTING CHART Trouble Probable Cause Corrective Action 1. Insufficient ejector vacuum. a. Y-strainer in water supply dirty. b. Supply pressure too low. c. Back pressure too high. 1. Solution valve, if supplied, not fully open. 2. Solution line, if present, partially blocked. d. Velocity too low (cavitation.) e. Nozzle 1. Flow restricted 2. worn or damaged. f. Incorrect nozzle size. g. Improper installation. 2. Flooded flowmeter a. Dirt on the ejector o-ring. b. Worn or damaged diaphragm c. Improper application a. Clean Y-strainer b and c. Open solution valve; clean solution line; correct back pressure condition. d. Increase pressure to ejector. e-g. Clean nozzle and/or throat. See Service section and bulletin a. Clean or replace ejector o-ring. See Service section. b. Replace worn diaphragm. See Service section. c. See bulletin on hydraulic considerations. d. Use a slow acting solenoid valve. Extend vacuum line, at ejector, a few feet above the ejector to allow the water to empty the next time the ejector is placed in service. 3. O-Ring sealing surface of ejector top body is extruding into diaphram bolt. a. Rare chemical anomaly. a. Replace ejector P/N U top body with Design improvements may be made without notice. Represented by: Severn Trent Services 3000 Advance Lane Colmar, PA United States Tel Fax Web: marketing@severntrentservices.com MAY/ Copyright 2010 Severn Trent Services