Bladder Damper PP/PVC

Transcription

1 Operating instructions Bladder Damper PP/PVC EN Please carefully read these operating instructions before use. Do not discard. The operator shall be liable for any damage caused by installation or operating errors. The latest version of the operating instructions are available on our homepage. Part number BA MOZ /17 EN

2 Supplemental directives Supplementary information Fig. 1: Please read! Read the following supplementary information in its entirety! Should you already know this information, you will benefit more from referring to the operating instructions. The following are highlighted separately in the document: Enumerated lists Operating instructions ð Outcome of the instructions - see (reference) Information This provides important information relating to the correct operation of the unit or is intended to make your work easier. Safety Information Safety information is identified by pictograms - see "Safety Chapter". 2

3 Table of contents Table of contents 1 Product Identification Safety Chapter Users' qualifications General Safety Information Storage and Transport Installation Start Up Maintenance and Repair Troubleshooting Decommissioning and Disposal Technical Data Spare Parts Dimensional Drawing Calculations Principles for Design Volume Manufacturer's declaration

4 Product Identification 1 Product Identification The type name on the nameplate is as follows: Bladder Damper 0.5 l DN15 PP1 - B Bladder Damper 0.5 l DN15 PP1 - V Bladder Damper 1.0 l DN20 PP1 - B Bladder Damper 1.0 l DN20 PP1 - V Bladder Damper 2.5 l DN25 PP1 - B Bladder Damper 2.5 l DN25 PP1 - V Bladder Damper 5.0 l DN40 PP1 - B Bladder Damper 5.0 l DN40 PP1 - V Description Volume Connector Housing material* * PP1: PP material ** B: Butyl - V: FKM Material of bladder** Order No. Bladder Damper 0.5 l DN15 PC1 - B Bladder Damper 0.5 l DN15 PC1 - V Bladder Damper 1.0 l DN20 PC1 - B Bladder Damper 1.0 l DN20 PC1 - V Bladder Damper 2.5 l DN25 PC1 - B Bladder Damper 2.5 l DN25 PC1 - V Bladder Damper 5.0 l DN40 PC1 - B Bladder Damper 5.0 l DN40 PC1 - V Description Volume Connector Housing material* * PC1: PVC material ** B: Butyl - V: FKM Material of bladder** Order No. 4

5 Safety Chapter 2 Safety Chapter Explanation of the safety information The following signal words are used in these operating instructions to identify different severities of a hazard: Signal word WARNI NG Denotes a possibly hazardous situation. If this is disregarded, you are in a life-threatening situation and this can result in serious injuries. CAU TION Meaning Denotes a possibly hazardous situation. If this is disregarded, it could result in slight or minor injuries or material damage. Warning signs denoting different types of danger The pulsation dampers are not intended for use with gaseous media (exception: the requisite cushion of air), flammable media or solids! Do not use the pulsation dampers with feed chemicals, which corrode the materials (refer to ProMinent resistance list in the latest product catalogue or at Never use the pulsation dampers beyond the specified ambient and operating conditions! Only allow qualified personnel to operate the pulsation damper. It is essential that you adhere to the information contained in the operating instructions! Carefully read the operating instructions before commencing installation and commissioning. The following warning signs are used in these operating instructions to denote different types of danger: Warning signs Type of danger Warning danger zone. Intended use The pulsation dampers are used to dampen pulsations, which an oscillating metering pump generates in the feed chemical in a pipe system. Only use the pulsation dampers for liquid media! Any other uses or modifications to the system are prohibited! 5

6 Safety Chapter 2.1 Users' qualifications WARNING! Danger of injury with inadequately qualified personnel! The operator of the plant / device is responsible for ensuring that the qualifications are fulfilled. If inadequately qualified personnel work on the unit or loiter in the hazard zone of the unit, this could result in dangers that could cause serious injuries and material damage. All work on the unit should therefore only be conducted by qualified personnel. Unqualified personnel should be kept away from the hazard zone Training Instructed personnel Trained user Trained qualified personnel Electrician Definition An instructed person is deemed to be a person who has been instructed and, if required, trained in the tasks assigned to him/her and possible dangers that could result from improper behaviour, as well as having been instructed in the required protective equipment and protective measures. A trained user is a person who fulfils the requirements made of an instructed person and who has also received additional training specific to the system from ProMinent or another authorised distribution partner. A qualified employee is deemed to be a person who is able to assess the tasks assigned to him and recognize possible hazards based on his/her training, knowledge and experience, as well as knowledge of pertinent regulations. The assessment of a person's technical training can also be based on several years of work in the relevant field. Electricians are deemed to be people, who are able to complete work on electrical systems and recognize and avoid possible hazards independently based on his/her technical training and experience, as well as knowledge of pertinent standards and regulations. Electricians should be specifically trained for the working environment in which the are employed and know the relevant standards and regulations. Electricians must comply with the provisions of the applicable statutory directives on accident prevention. Customer Service department Customer Service department refers to service technicians, who have received proven training and have been authorised by ProMinent to work on the system. 6

7 Safety Chapter Note for the system operator The pertinent accident prevention regulations, as well as all other generally acknowledged safety regulations, must be adhered to! 2.2 General Safety Information WARNING! WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious injuries. Please ensure when handling hazardous substances that you have read the latest safety data sheets provided by the manufacture of the hazardous substance. The actions required are described in the safety data sheet. Check the safety data sheet regularly and replace, if necessary, as the hazard potential of a substance can be re-evaluated at any time based on new findings. The system operator is responsible for ensuring that these safety data sheets are available and that they are kept up to date, as well as for producing an associated hazard assessment for the workstations affected. Operating faults! Possible consequence: Fatal or very serious injuries. Ensure that the device is only operated by adequately qualified and technically expert personnel Please also observe the operating instructions for sensors and fittings and any other units which may be fitted, such as sample water pumps... The operator is responsible for ensuring that personnel are qualified 7

8 Storage and Transport 3 Storage and Transport Protect the bladder damper from frost. Protect the bladder damper from direct sunlight and other sources of UV. Drain the bladder damper before storing or transporting it, referring to the material safety data sheets for the feed chemicals. Seal the openings so that no foreign bodies can penetrate. Storage and transport temperature: C (frost-free) 8

9 Installation 4 Installation Fig. 2: Installation example of a pulsation damper 1. Metering pump 2. Pulsation damper 3. Manometer 4. Shut-off valve 5. Bleeder valve 6. Relief valve WARNING! 5 P_MOZ_0053_SW Ensure that the pulsation damper is easily accessible at all times for operation and maintenance. Do not obstruct or block access routes. Carefully read the operating instructions before commencing installation and commissioning. Install the pulsation dampers in accordance with the applicable regulations (for example governing pressurised vessels). First check whether the pulsation damper matches the stroke volume of the metering pump. The pulsation damper can still contain residual water following testing. Drain water out of the pulsation dampers or flush them with a suitable medium if you are using feed chemicals, which may not come into contact with water. Never use the pulsation dampers with media which could corrode their materials. Protect the pulsation damper from direct sunlight and other sources of UV. Preferably install the pulsation damper as close as possible to the metering pump. Pulsation dampers only work effectively with a specific stable back pressure. Therefore install a back pressure valve or an injection valve with low or fluctuating back pressure. Provide a connecting option for a manometer close to the pulsation damper to check the pressure conditions in the pipe system. Install a shut-off valve and a bleeder valve to depressurise the pulsation damper to atmospheric pressure. Insert the bleeder valve into the storage tank or another suitable vented vessel. 9

10 Installation Install a relief valve to protect the pulsation damper from rupturing in the event of a fault. Avoid oscillations. Fix the pulsation damper firmly in place using the wall bracket. Connect the pipelines to the pulsation damper so that no forces act between them, e.g. caused by shifting, weight or expansion of the line. The connector size of the pulsation damper should preferably match the connector of the pipework. At most they may vary by a nominal width. Keep a suitable union nut to hand for connection. Lay the metering line straight with the connection nominal width of the pulsation damper to avoid unnecessary loss of output. 1. Screw the wall bracket to a stable base surface, remembering the washers. 2. Fit the pulsation damper onto the metering line. 3. Fix the pulsation damper in place with the wall bracket. Make sure that the pulsation damper and pipes do not oscillate. 10

11 Start Up 5 Start Up Note the national regulations when starting up the pulsation damper. In Germany, for example, the operator must currently ensure that pulsation dampers with a volume of 5 litres comply with the national regulation in accordance with EN 2014/38/EU. Furthermore the operator must ensure that the pulsation damper undergoes a handover inspection by an expert in accordance 531 (Technical Regulations Governing Pressurised Tanks) and the national directive in accordance with EN 2014/38/EU at the installation site (arrangement inspection, equipment inspection, installation inspection and handover inspection certification). A manufacturer s declaration should be issued for pulsation dampers with a volume of 5 litres. 1. Check the installation. (Is the relief valve correctly adjusted?) 2. Close the shut-off devices on the discharge side. 3. Increase the charging pressure of the bladder to 40% charging pressure using the bleed valve (based on the operating pressure of the feed chemical). 4. Open the shut-off devices on the discharge side. 5. Start up the metering pump at a low capacity. 6. Monitor whether the threaded connectors and the pulsation damper s bleed valve are air-tight. 7. Slowly increase the capacity to the required value. 8. Increase the charging pressure to %. 9. Check whether the pressure of the bladder remains constant. 10. Check whether all hydraulic components of the system are tight. Check correct installation in accordance with the installation instructions. Take appropriate protective measures if hazardous feed chemicals are being metered refer to the material safety data sheet for the feed chemical. 11

12 Start Up Maximum operating pressure Material version PP1 Volume in l Max. operating pressure in bar Ambient temperature or feed chemical temperature in C 0.5 / / Material version PC1 Volume in l Max. operating pressure in bar Ambient temperature or feed chemical temperature in C 0.5 / /

13 Maintenance and Repair 6 Maintenance and Repair Safety information Repair Wear suitable protective equipment when metering hazardous or unknown feed chemicals. Adhere to the material safety data sheet for the feed chemical. Bleed the pulsation damper at regular intervals! They can rupture or fly through the room with too low a gas cushion. Maintenance intervals Maintain at regular intervals, depending on the feed chemical, installation and operating conditions. Check the following regularly The tightness of the threaded connectors and wall brackets, if fitted The leak-tightness of the pulsation damper (welding seams and adhesive) Vapour effect of the manometer close to the pulsation damper Ensure that the bladder and pulsation damper are at atmospheric pressure. Drain the pulsation damper and, if necessary, flush with a neutral medium. Adhere to the material safety data sheets for the feed chemical! Replacing the bladder: 1. Disconnect the pulsation damper from the system, with regard to pressure. 2. Depressurise the bladder via the air valve: to do so, remove the rubber cap, unscrew the valve cap and press the valve cap onto the tapper in the centre of the valve. 3. Bring the pulsation damper to atmospheric pressure via a bleeder valve in the system. 4. Remove the pulsation damper. 5. Drain the pulsation damper and, if necessary, flush it through with a neutral medium. 6. Loosen the hexagonal head screw on the pulsation damper. 7. Remove the old bladder. 8. Ensure that all sealing surfaces are clean and smooth, including the sealing surface of the new bladder. 9. Reassemble the pulsation damper in reverse order. 10. Re-tighten the hexagonal head screws. 11. Re-install the pulsation damper in its correct position. 12. Start up the pulsation damper again - refer to the "Start Up chapter. 13

14 Troubleshooting 7 Troubleshooting Fault description Cause Remedy The system is beating (increased noise, manometer displays large pressure surges with the pulsation damper, strong vibrations of parts of the system, metering is uneven...) The gas cushion is too low or has disappeared. Immediately stop the metering pump Bleed the pulsation damper - see "Start Up". 14

15 Decommissioning and Disposal 8 Decommissioning and Disposal First ensure that the bladder and pulsation damper are at atmospheric pressure. Thoroughly clean the pulsation damper of chemicals and dirt when decommissioning it. Take appropriate protective measures if hazardous or unknown feed chemicals are being metered. Adhere to the material safety data sheet for the feed chemical. Observe the current applicable regulations in your country governing disposal. 15

16 Technical Data 9 Technical Data Volume Connector Max. operating overpressure Operating temperature for pump stroke volume* Shipping weight l bar C ml kg PP1 0.5 G1-DN G1 ¼-DN G1 ½-DN G2 ¼-DN PC G1-DN G1 ¼-DN G1 ½-DN G2 ¼-DN * A calculation example in the appendix shows which bladder damper is suitable for which stroke volume range. Wetted materials Material version Housing Bladder Seals PP1-B PP RAL7032 Butyl EPDM PP1-V PP RAL7032 FKM FKM 16

17 Technical Data Material version Housing Bladder Seals PC1-B PVC-U RAL 7011 Butyl EPDM PC1-V PVC-U RAL 7011 FKM FKM FKM: Fluorine rubber Wetted parts of the product were bonded using Tangit adhesive. Note the durability of Tangit adhesive. 17

18 Spare Parts 10 Spare Parts Spare parts for PP/PVC bladder damper Spare part 0.5 l 1.0 l 2.5 l 5.0 l Butyl bladder (with PP) FKM bladder (with PP) Butyl bladder (with PVC) FKM bladder (with PVC) Manometer 16 bar Manometer 10 bar Air filling valve LV 1/8" NPT O-rings FKM 22.2 x 3 28 x x x x 5 90 x x x d 40 d 40 d 40 d O-rings EDPM 22.2 x 3 28 x x x x 5 90 x x x d 40 d 40 d 40 d

19 Dimensional Drawing 11 Dimensional Drawing DIN Rp 1/4 L LA 4 x Ø7 D DIN ISO 118 G 1A P_MOZ_0051_SW Fig. 3: Dimensional drawing of bladder damper 19

20 Dimensional Drawing Dimensions of PP bladder damper - dimensions in mm Volume Connector L Ø D LA 0.5 G 1 - DN G 1 1/4 - DN G 1 1/2 - DN G 2 1/4 - DN Dimensions of PVC bladder damper - dimensions in mm Volume Connector L Ø D LA 0.5 G 1 - DN G 1 1/4 - DN G 1 1/2 - DN G 2 1/4 - DN

21 Calculations Principles for Design Volume 12 Calculations Principles for Design Volume With simple metering pumps: Estimation of the design volume V 0 in l for residual pulsation of approx. ±5%: V 0 = 0.8 * F * C * V H with V 0 - Design volume F - Factor for pump construction - see Ä Table 1: Factor F for pump construction on page 21 C - Conversion factor - see Ä Table 2: Conversion factor C on page 21 V H - Stroke volume (l/stroke = * ml/stroke) with mean operating pressure - refer to the pump s performance data Table 1: Factor F for pump construction Pump construction F 1-cylinder pump 26 2-cylinder pump 12 3-cylinder pump 6 4-cylinder pump 6 Table 2: Conversion factor C 1.1 * Pm (system pressure (bar)) C

22 Calculations Principles for Design Volume Example: Output data Pump type: Meta HM , Pump construction, 1-cylinder metering pump System pressure Pm: Stroke volume 1.5 bar ml/stroke or l/stroke Therefore: F = C = 26 (for 1-cylinder metering pumps (see Ä Table 1: Factor F for pump construction on page 21)) 1.43 (for 1.1 * Pm = 1.5 (see Ä Table 2: Conversion factor C on page 21)) V 0 = 0.8 * C * F * V H = 0.8 * 1.43 * 26 * = l Therefore select a pulsation damper with V = 2.5 l. 22

23 Manufacturer's declaration 13 Manufacturer's declaration You can find the Manufacturer s Declaration on our homepage. 23

24 ProMinent GmbH Im Schuhmachergewann 5-11 D Heidelberg Telephone: Fax: Internet: Heidelberg, 1, en_gb 2017