SECTION Bypass Oil Sampling Station (B.O.S.S 1000) GENERAL.......................... SAFETY........................... Hazards............................... Personal Protective Equipment........... PRODUCT DESIGN.................. Description............................. Parts Diagram........................... Connection Diagram...................... This Operation Manual is furnished to aid the customer in checking, installing and operating Heat Exchange and Transfer, Inc. s Bypass Oil Sampling Station. It does not, however, replace or modify commonly recognized practices or instructions published by suppliers of heat transfer fluids. Refer to the safety data sheet (SDS) of the thermal fluid that you are using for important information on safe practices and procedures. HEAT s Bypass Oil Sampling Station (B.O.S.S 1000) is a thermal fluid sampling device that enables the operator to safely and accurately capture thermal fluid samples at operating temperatures up to 50 Deg. F. Easy to use, the B.O.S.S 1000 enables the operators to capture hot thermal fluid samples that are isolated from the atmosphere. This not only protects the operator from potential burn hazards, but also results in a more representative fluid sample for analysis. SAFETY DEPENDS ON YOU All HEAT equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. DO NOT INSTALL OR OPERATE THIS EQUIPMENT WITHOUT READING THE SAFETY DATA SHEET (SDS) OF THE THERMAL FLUID THAT YOU WILL BE SAMPLING. PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY UPON RECEIVING. HEAT EXCHANGE AND TRANSFER, INC. 500 Superior Street Carnegie, PA 15106 (41) 6-88 Fax: (41) 6-9 E-Mail: sales@heat-inc.com Web: www.heat-inc.com TABLE OF CONTENTS PAGE 1 GENERAL SAFETY SECTION OPERATIONS MANUAL OM-BOSS June 01 OPERATION........................ Pre-Operation............................. MAINTENANCE......................... ACCESSORIES........................... ADDITIONAL INFORMATION............ PAGE Safe Work Procedures...................... 5 Post-Sample Procedure..................... 6 NOTHING IN THIS MANUAL IS INTENDED TO REPLACE OR MODIFY THE STANDARD LIMITED EXPRESS WAR-RANTY OF HEAT EXCHANGE AND TRANSFER (HEAT) INC. (DESCRIBED ON PAGE 1 OF THIS MANUAL) WHICH IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY, THE WARRANTY OF SUITABILITY OR FITNESS FOR USE AND THE WARRANTY OF FITNESS FOR ANY PARTICULAR PURPOSE OR USE. NO WAR-RANTIES OR REPRESENTATIONS AT ANY TIME MADEBY ANY PERSON (DISTRIBUTOR, SALES REPRESENTA-TIVE OR EMPLOYEE) SHALL BE EFFECTIVE AGAINST HEAT TO MODIFY OR EXPAND THE LIMITED EXPRESS WARRANTY OF HEAT OR TO OTHERWISE OBLIGATE HEAT TO THE CUSTOMER OR TO ANY OTHER PARTY. 4 4
OSHA Hazard Communication Standard Pictograms SAFETY Health Hazard May be fatal if swallowed and /or enters airways Corrosion Skin corrosion/burns Eye Damage Corrosive to metals Flame Hazard Highly flammable liquid and vapor Flame Over Circle Oxidizing Gases, Liquids or Solids Exclamation Mark Irritant (skin and eye) Skin sensitizer Respiratory Tract Irritant Environment Toxic to aquatic life Personal Protective Equipment (PPE) For more information, visit https://www.osha.gov/publications/hazcomm_quickcard_pictogram.html NOTE: It is the responsibility of the end-user to conduct a hazard assessment and create their own required PPE for the task being performed OSHA has adopted new hazardous chemical labeling requirements as a part of its recent revision of the Hazard Communmication Standard, 9 CFR 1910.100 (HCS), bringing it into alignment with the United Nations' Globally Harmonized System of Classification and Labelling of Chemicals (GHS). The new label provides information to the workers on the specific hazardous chemical, such as: - Name, Address, and Telephone of Chemical Manufacturer - Product Identifier (Batch Number, Chemical Name, etc) - Signal Words used to indicate level of severity of hazard - Hazard Statements describing the nature of the hazard - Precautionary Statements to minimize adverse effects In addition to the Safety Data Sheet, it is important that one reads the label of the particular thermal fluid that they will be sampling prior to operation of the B.O.S.S 1000. 1... 4. Face Shield Face shields complying with ANSI Z8.1-015 should be used when risk assessment indicates this is necessary to avoid exposure to liquid splashes, mists, or gases Safety Glasses Even when wearing a face shield, it is still necessary to wear safety glasses that comply with ANSI Z8.1-015 FR Clothing PPE for the body should be selected based on the task being performend and the risks involved and should be approved by a specialist. Recommendations: Apron or other light protective clothing. If prolonged or repeated contact is likely chemical resistant clothing is recommended. Promptly remove nonimpervious clothing that becomes wet or contaminated and dispose of properly Gloves High temperature, chemical resistant gloves should be worn Footwear Proper footwear should be worn during operation. Consult your safety department for footwear requirements
DESCRIPTION HEAT s Bypass Oil Sampling Station (B.O.S.S 1000) is a thermal fluid sampling device that enables the operator to safely and accurately capture thermal fluid samples at operating temperatures up to 50 Deg. F. Easy to use, the B.O.S.S 1000 enables the operators to capture hot thermal fluid samples that are isolated from the atmosphere. This not only protects the operator from potential burn hazards, but also results in a more representative fluid sample for analysis. SAFE The B.O.S.S 1000 can capture thermal fluid samples at operating temperatures up to 50 deg F. The thermal fluid sample is isolated from the operator in a stainless steel vessel and allowed to cool prior to sample collection. PRODUCT DESIGN SIMPLE Easy to use, the B.O.S.S 1000 can be set up and operated in less than fifteen minutes. It comes in both portable and stationary configurartions and can be used on any size heat transfer system. ACCURATE The B.O.S.S 1000 allows the capture of hot samples that are isolated from the atmosphere. This results in: - Accurate reporting of Flash Point Temperature - Accurate reporting of Particulate Count - Accurate Reporting of Moisture Content Parts & Connection Diagrams The diagram on the left is a parts breakdown for the B.O.S.S 1000 Thermal Fluid Sampling Device. Each part is clearly labeled and identified. These indentifiers will be used in the procedure and installation section (PAGE XX) The diagram on the right is a connection diagram for the B.O.S.S 1000 Thermal Fluid Sampling Device. Each part is clearly labeled and identified. These indentifiers will be used in the procedure and installation section (PAGE XX)
Pre-Operation OPERATION Pre-Operational Checklist: READ and obey all Safety Data Sheets (SDS) and the Safe Work Procedure found on the B.O.S.S 1000 READ the entire Operations Manual before proceeding Only those who have been properly trained may operate the B.O.S.S 1000 Ensure that your workspace has proper ventilation and is free of all unnecessary obstructions WEAR the proper Personal Protective Equipment (PPE) ENSURE ALL VALVES ON THE B.0.S.S 1000 ARE COMPLETELY CLOSED Gather all necessary tools (list can also be found on Safe Work Procedure): /8" Wrench 1 1/" Wrench " Crescent Wrench Fluid Sampling Bottle (provided with B.O.S.S 1000) Catch Basin Spill Kit Fire Extinguisher Safe Work Procedures Safe Work Procedure 1... 4. Double check to ensure that all valves on the B.O.S.S 1000 are in the closed position. Locate high and low pressure connection ports on the Heat Transfer System. Ex: Suction and discharge sides of the pump Using the INLET FLEX HOSE, connect the INLET (B) PORT to the high-pressure port on the Heat Transfer System. Using the OUTLET FLEX HOSE, connect the OUTLET (A) PORT to the low-pressure port on the Heat Transfer System. ENSURE THAT ALL CONNECTIONS ARE TIGHT! If connections are not properly made, thermal spray can occur resulting in a serious burn and/or fire hazard! The above photos show the operator ensuring that the connections are tight 4
Safe Work Procedures (Continued) OPERATION 6.. 8. 9. 10. 11. 1. Open the valve on the high-pressure port of the Heat Transfer System (check for leaks) Open the valve on the low-pressure port of the Heat Transfer System (check for leaks) Open the INLET (D) VALVE on the B.O.S.S 1000 (check for leaks) It is very important to check for leaks after each valve opening! NOTE: Opening this valve quickly can result in pump cavitation and can shut down your Heat Transfer System Allow the thermal fluid to flow for 5-10 minutes. The reading on the temperature gauge should begin to rise After 5-10 minutes, close the OUTLET (C) VALVE on the B.O.S.S 1000 Next, close the INLET (D) VALVE on the B.O.S.S 1000 Next, close both the high and low pressure port valves on the Heat Transfer System SLOWLY, open the OUTLET (C) VALVE on the B.O.S.S 1000 (check for leaks) NOTE: Once this valve is open fluid will begin to flow through the B.O.S.S 1000 1. Allow the fluid sample to cool until the TEMPERATURE GAUGE reads 140 deg F. THIS CAN TAKE SEVERAL HOURS 14. Once the sample has reached a temperature less than 150 deg F, place the fluid sample container under the SAMPLE COLLECTION PORT (H). 1 Open the VENT (G) VALVE fully. This will prevent the possibility of vapor lock and allow the fluid to flow freely 16. 1. Open the DRAIN (E) VALVE. Fluid will begin to flow into the sample container Fluid is still hot. Use caution Close the DRAIN (E) VALVE once the fluid sample container is full. Place lid on sample container and remove. Close all valves 5
Post-Sample Procedure OPERATION Post-Sample Procedure 1. OUTLET AND INLET FLEX HOSES WILL STILL CONTAIN HOT, PRESSURIZED FLUID. Ensure all valves are closed on both the B.O.S.S 1000 and the Heat Transfer System. To drain the hot, pressurized fluid in the flex hoses, open both the Inlet (D) and Outlet (C) valves on the BOSS. This will allow the fluid in the flex hoses to flow into the collection vessel. This location can be located at either the low-pressure port on the Heat Transfer System or the OUTLET (A) PORT on the B.O.S.S 1000 depending on which connection is lower. 6.. 8. 9. 10. 11. Slowly open the low point fitting on the OUTLET FLEX HOSE. CAUTION: FLUID WILL EMPTY INTO THE CONTAINMENT PAN. Once drained, install plug on low-pressure port on Heat Transfer System. Fully loosen the opposite fitting on the OUTLET FLEX HOSE. Connect the ends of the OUTLET FLEX HOSE so they form a complete circle Repeat this process for the INLET FLEX HOSE Place containment pan under SAMPLE COLLECTION PORT (H) Open DRAIN (E) VALVE and VENT (G) VALVE on the B.O.S.S 1000 to allow any remaining fluid inside of the device to drain completely. Close all valves on the B.O.S.S 1000 and safely store for future use 6
Maintenance Protocol MAINTENANCE Prior to Each Use: 1. Inspect B.O.S.S 1000 and flex hoses for damage. If damaged, DO NOT USE. Ensure threads are clean and free of old pipe tape. Apply new pipe tape before each use 4. Ensure that all valves on the B.O.S.S 1000 are in the closed position Ensure that there is no oil in the base of the B.O.S.S 1000 After Each Use: 1. Inspect the B.O.S.S 1000 and flex hoses for damage. If damaged, replace.. Clean old pipe tape from threads.. Ensure all fluid has been drained from B.O.S.S 1000. 4. If sample contained large amounts of sludge, flush the B.O.S.S 1000 with flushing fluid to remove debris. Clean and store safely Accessory Items Folding Work Stand ($150): Description: Collapsable work table for mounting BOSS 1000. Weight Capacity of 0 lbs. Silver, Black, or Yellow ACCESSORIES Insulated Flex-Hoses Standard: 6 ft ea. Custom: 8 ft +$0 10 ft + $40 1 ft + $60 Operational Spill Kit ($100): Includes: Five gallon bucket, absorbant pads, bag for used pads, 10 ft dam, gloves Fluid Sample Kits ($5): Description: Three additional sample bottles PPE Package ($00): Includes: Duffle bag, face shield, safety glasses, FR clothes, high temp gloves Cleaning Kit ($65) Cleaning kit for spraying flushing fluid into BOSS 1000 ADDITIONAL INFORMATION For more information, please contact us: Website: www.heat-inc.com Email: customerservice@heat-inc.com Phone: 41-6-88 Fax: 41-6-9