Instruction manual for the pressuree control panels of the BM55-2A series BM55-2A
Contents Contents... 2 1. Introduction... 3 1.1 General... 3 1.2 Description of the pressure control panels of the BM series... 3 1.3 Intended use... 4 1.4 Personnel equirements... 5 2. For your safety... 5 2.1 Symbols used... 5 2.2 Essential safety information... 5 2.3 Safety features... 6 3. Description... 8 3.1 Overview of the pressure control panel... 8 3.2 Functional description... 10 3.3 Technical data... 11 3.4 Connection options... 11 4. Operation... 11 4.1 Labelling... 11 4.2 Installing the pressure control panel... 11 4.3 Putting the pressure control panel into operation... 12 4.4 Changing the cylinder... 13 4.5 Taking the equipment out of operation... 13 5. Problems... 14 6. Maintenance, cleaning and repairs... 15 6.1 Regular maintenancee work and visual inspections......... 15 6.2 Regular cleaning... 15 6.3 Repair information... 15 6.4 Returns... 15 2 GES_BM55-2A_1115.docx
1. Introduction 1.11 General Validity This operating manual is valid for the following pressure control panels: BM55-2A series Manufacturer Spectron Gas Control Systems GmbH Fritz-Klatte-Straße 8 D-65933 Frankfurt Deutschland / Germany Phone: +49 69 38016-0 Fax: +49 69 38016-200 Email: info@spectron.dee Internet: www.spectron.de Publication date November 2015 Retention and completeness This operating manual forms part of the BM55-2A pressure control panel, must be kept with the equip- ment at all times and made available to thee relevant authorized persons. Under no circumstances should chapters be removed from this operating manual. If the operating man- be ual is lost or if any chapters are missing inn particular the "For your safety" chapter it or they must replaced without delay. Copyright This operating manual contains information that is protected by copyright. It must not be photocopied, reproduced, translated or copied onto data carriers, either in full or in part, with- can be made to this operating manual without further notification. 1.2 Description of the pressure control panels of the BM seriess Spectron pressure control panels are availablee in BM and BE versions. BM pressure control panels are suitable for combustible gases, non-combustiblee gases and oxygen up to a out prior authorisation. All rights reserved. Updates No update service is provided for this operatingg manual by Spectron Gas Control Systems GmbH. Changes purity grade of 6.0. BE pressure control panelss are suitable, in addition, for use with corrosive gases. In addition, there is a distinction between pressure control panels withh single-stage pressure reduction from the inlet pressure to the desired outlet pressuree (type code: 55) and two-stage pressure reduction (type code: 56). While two-stage pressuree reduction ensures an extremely constant outlet pressure throughout the entire inlet pressure range (from "full" gas cylinder to almost "empty" gas cylinder), with single-stage pressure reduction the outlet pressure can varyy within a certain range. GES_BM55-2A 1115.docx 3
1. Introduction In the case of single-stage pressuree control panels with an operating and a reserve side, on switchover to the reserve side, the outlet pressuree is returnedd to the level on what was w previously the operating side, when the gas cylinders were full. This is not thee case on pressure control panelss with two-stage pressure reduction. Here, the outlet pressure remains largely constant. BM55-2A pressure control panels described in this manual are double-sidedd pressure control panels with a fully automatic change-over unit. When a pressure limit definedd by the configuration of the respective change-over unit is reached, the unit changes the supply side without interruption. BM55-2A pressure control panels are equipped with a waste gass valve on each side. Optionally, con- tact pressure gauges, pressure transducers and pneumatically operated valves can also be included in the configuration. 1.3 Intended use Intended use BM55-2A pressure control panel describedd in this manual is designed for use with non-corrosivon the type plate. Pressure control panels reduce a variable inlet pressure to an outlett pressure that t is as constant as possible. pressure is introduced exclusively via the distributor block. Appropriate measures mustt be taken to prevent the introduction of pressure to the pressure regulator outlet via v the pipe system. gases of a quality up to 6.0. permissible gases and pressuree ranges aree specified Pressure control panels without electrical components (such as a contact pressure gauge or pressure transducer) may be used in potentially explosive atmospheres, since they do not have a potential ignition source of their own (ignition hazard evaluated in accordance with DINN EN 13463-1). danger of ignition has to be taken into account with pressure control panels with electrical components. It is imperative that this is evaluated on the basis of the documentation of the electrical components, taking into consideration how they are incorporated into the system as a whole, in compliance with directives 2014/34/EU ("ATEX 95 ) and 1999/92/EC (ATEX 137). Foreseeable misuse following operating conditions are deemedd to constitute misuse: Operation with gasess that are not specified on the type plate Use with gases in their liquid state Operation outside of the permissible technical limit values Failure to heed and comply with any applicable legal regulations and a other provisionss valid on-site Failure to follow the instructions in this operating manual Failure to carry out inspection and maintenance work Failure to heed the information on the type plate and in the product data sheet Pressurisation in reverse (against normal flow direction) 4 GES_BM55-2A_1115.docx
1. Introduction 1.4 Personnel requirements Definition of an authorised person An authorised person is a person with technical training who has received technical instruction on the sys- tem as a whole and the associated hazards gas cylinder gas typee gas cylinder valve pressure regu- lator and has successfully completed trainingg in the supply of pressurised gases. Tasks of the operating personnel Operating personnel must identify problems or irregularities and in as far as possible and permissiblee remedy them. Requirements for operating personnel To be able to carry out the assigned tasks, operating personnel must meet the following requirements: operating personnel must have received instruction in the operation of the pressuree control panel from an authorised person and must have read and understood this operating manual in its entirety. 2. For your safety 2.1 Symbols used Important! Warning! Danger! Danger! This symbol warns that there is a "risk of fatal injury" or a health hazard for personnel. 2.22 Essential safety informationn safety information given below iss to be regarded as supplementary information to the rele- reg- vant national accident prevention regulations and legislation. All relevant accident preventionn ulations and legislation must be observed under all circumstances. Various laws, regulations, rules and directives must be complied with when handling pressurized gases. following legislation and publications are applicable (although this is not necessarily a complete list): EU Directive 2009/104/EC (Work Equipment Directive) EU Directive 1999/92/EC (ATEX 137) EU Directive 98/24/EC (Dangerous Substances Directive) Industrial health and safety ordinance (implementationn of Directives 2009/104/EC and 1999/92/EC in German law) Ordinance on hazardous substances (implementation of Directivee 98/24/EC in German law) TRBS (technical regulations on industrial safety and health) publications German technical rules for hazardous substances (TRGS) GES_BM55-2A 1115.docx 5
2. BGR 500 BGR 500 BGR 500 BGR 500 2.26 German trade association rules on welding, cutting and related work procedures 2.31 German trade association rules for working on gas lines 2.32 German trade association rules for the operation of oxygen systems 2.33 German trade association rules for the operation of systems that handle gas BG RCI eaflet M034 EIGA documents Safety data sheets for the gasess used 2.3 Safety features pressure regulator is equipped with an integrated relief valve to protect p the fitting. Possible hazard Risk of fatal injury! If oxygen comes into contact with oil or grease, there is a risk of fire due to a chemical reaction. Risk of fatal injury! Gas escaping into the ambient air can ignite; there is a risk of fire and explosion. Risk of fatal injury! Hazard-prevention measures Keep all parts that come into contact with oxygen free of oil and grease. Smoking and naked flames are strictly prohibited near gas supply equipment pressure control panel may be damaged by unauthor- work ised modifications or conversions and may no longer as intended. re is a risk of the system malfunctioning, catching fire or getting damaged. For your safety TRAS (technical regulations on plant safety) publications BGV A1 German trade association basic accident prevention regulations BGR 104 German trade association rules on explosion protection BGR 132 German trade association rules for the avoidance of ignition hazards resulting from electro- static charges relief valve allows gas that has to be released as a result of an impermissiblee rise in the out- meets the requirements of the regulations for operators must be incorporated to protect down- stream fittings, pressure vessels andd pipes from excess pressure. Danger! With combustible, toxic, corrosive and other gases that aree harmful to health or the environment, an exhaust pipe must be connected to the relief valve to take the gas away safely. factory setting of the relief valve must not be let pressure to be blown off. It does not function as the safety valve for the entire gas supply system. Important! In the event of the failure of the pressure regulator and its relief r valve, a safety mechanism that altered! No modifications or conversions changes may be made without the written approvall of the manufacturer's author- ised technical personnel. p 6 GES_BM55-2A_1115.docx
2. For your safety Gas that escapes in an uncontrolled manner indoors can reduce the oxygen content of the air and be lifemanner indoors can result in a dangerous rise in the oxygen content of the threatening. Risk of fatal injury! Oxygen that escapes in an uncontrolled air and an increase in the tendency of clothing and other objects to ignite. Risk of fatal injury! use of the pressure control panel with components or accessories that are not rated for the same pressure as the control panel itself can lead to serious damage orr bursting. If the pressure control panel is used outside the specified ambient temperature range, there is a risk of the system malfunctioning, catching fire or getting damaged. Risk of fatal injury! If pressure control panels unsuitable for the relevant gas and pressure range are used, there is a risk of a fire or explosion occurring as a result of a chemical reaction. Risk of fatal injury! If the pressure control panel is used with combustible, toxic or corrosive gases, the respective gas can escape into the surrounding atmosphere when the relief valve is actuated. Risk of fatal injury! If dirt particles get into the pressure regulator of the pres- sure control panel, this can damage it orr cause it to mal- function. If the device is not handled properly and used as intended, this may be dangerous for the user and others and may damage it. If the connecting surfaces or gaskets of the t fittings aree damaged or missing, there is a danger of gas escaping in an uncontrolled manner. pressure control panel must be suitable for the relevant gas and the pressure ranges involved. Only use for the gases indicated on o the device. If there are no gas types specified on the pressure control panel, consult thee manufacturer to find out which gases it can be used with. On no account must the pressure control panel be put into operation withoutt this information. Relief valves of pressure control panels for combustible, toxic or corrosive gases must t have a pipe that routes the gases emitted to a safe recycling device that complies with regulations. Make sure that the outlet end of the blow-off into the open air. In the case of toxic or corrosive gases or gases that are harmful to pipe of sys- tems operated indoors is routed the environment in some other way, dispose of the blown-off gas in accordance with the applicable regulations. Make sure that the outlet end of the blow-off into the open air, and do pipe of oxygen systems operatedd indoors is routed not start a fire or ignite a flame. Read the EIGA document SAG 79/04/E for more infor- mation. Components or accessories a (fittings, pipes etc.) connected to the pressure control panel must be rated for the pressure given on the type plate of the pressure control panel. Do not use in ambient temperatures below -30 C or over +60 C. It must be ensuredd that no dirt particles of any kind can get into the pressure regulator. That is why a filter is incorporated into the process gas inlet of the pressure control panel. Use and handle the pressure control panel only as de- scribed in this operating manual. Check the connecting surfaces for damage, and do not in- are stall if i the connecting surfacess are damaged or gaskets missing. GES_BM55-2A 1115.docx 7
3. Description 3.1 Overview of the pressure control panel Drawing of the pressure control panel Elements of the pressure control panel Item. Designation Function 1 2 3 4 5 6 7 8 Pressure regulator Pressure gauge Optional contact pressure gauge Pressure gauge Optional contact pressure gauge Waste gas valve or purge valve Optionally with pneumatic activation Connection block Relief valve Ambimat Back pressure return Reduces the variable inlet pressure to achieve a set outlet pressure level. Indicates the inlet pressure on the respective side. Display and electr. monitoring of the pressure Is opened gas pipe. Connecting point for the t pipe system. Protects the pressure control panel from impermissibly high outlet pressure. Does not function as a safety valve! Indicates the current outlet o pressure of the pressure regula- tor. Display and electr. monitoring of the pressure to remove the t waste gases or vent the process Fully automatic switching unit; gas supply is switched autoa spe- matically from the operating to the reserve side when cific pressure limit is reached. r change-over pressure is based on the inlet i and outlet pressure. Used to increase the change-over pressure. 8 GES_BM55-2A_1115.docx
3. Description Flow chart of gas supply with a pressure control panel GES_BM55-2A 1115.docx 9
3. Description 3.2 Functional description Pressure control panels in the BM555 2A series are double-.sided pressure control panels which reduce an inlet pressure which lies within a specific range to a required outlet pressure. pressure is reduced by the pressure regulator which is fitted behind thee Ambimat (change-over unit). In turn, the Ambimat switches from the side currently supplying the gas (operating side) to the reserve side when the so-called change- Initially, the side first pressurised is in operation. When the supply pressure sinkss towards the change-over pressure which is preset via the pressure control panel configuration,, the Ambimat switchess automatically from the operating to the reserve side. change-over process alsoo completelyy isolates the supply side which has just been taken out of operation from the gas supply. This means thatt a separatee process gas valve is not equired. over pressuree is reached. Selection of the operating side and change-over to the reserve side are a performed completely automatically. shut-off valve (cylinder valve) of the gas vessels (e.g. gas cylinders) which have been taken t out of opvia eration can now be closed and the pressure control panel side which is no longer in operation vented the waste gas valve. New gas cylinders shouldd be connected immediately and the shut-off valve opened so that they are ready for operation when the switching pressure is reached again. change-over pressure always depends on the pressure pending on the two sides of the panel. On the one hand, change-over only takes place when the pressure on the operating side drops to the t change-over pressure or below, while on the other hand, thee pressure on the reserve side must be at a certain minimum level that allows it to function as the actuating pressure for change-over to the reserve side. Under ideal conditions, the gas cylinders will bee full of gas at the pressure P1 listed on the type t plate of the change-over panel. If this is the case, change-over takes place at a pressure p slightly above the pressure P2 indicated on the type plate. If gas vessels with gas below the pressure P1 are connected to the panel, change-over takes place at a pressure below P2. Below a certain pressure limit,, the pressure on the re- serve side is no longer sufficient and change-over cannot take place. pressure control panels can be equipped with contact pressure gauges. se issue a change-over signal when a specific pressure limit is violated or, in the same way as pressuree transducers, supply a current that varies continuously with the pressure (4-20 ma). change-over signal or variable electrical current can bee processedd by means of connected control units, resulting, for example, in the issue of a gas shortage alarm. When these contact pressure gauges or pressure transducers are used in areas where theree is a risk of fire or explosion, special measures have to be taken, as described in directive 2014/34/EU (ATEX 95) and 1999/92/EEC (ATEX 137). Another option is to equip the pressure control panel with pneumaticalp lly operated valves. se require a pneumatic control pressuree of between a minimum of 6 bar and a maximum of 8 bar. 10 GES_BM55-2A_1115.docx
3. Description 3.33 Technical data technical data can be taken from the Spectron data sheet for the relevant product. If this is not available, you can view and download it at www.spectro on.de. maximum inlet and outlet pressures and the gas type are a indicated on the type plate. 3.4 Connection options Inlet pressure connection: 1/4NPT femalee thread, usually equipped with a stainless steel compression fitting for 6mm pipes Outlet pressure connection: 1/4NPT femalee thread Relief valve: 1/4NPT femalee thread Extensionn connector: 1/4NPT femalee thread 4. Operation 4.1 Labelling Labelling example Hydrogen (H 2 2) BM55-2A-300-10-M-M-H2 P1: 300 bar P2: 10 bar gas type must be specified on the pressuree control panel! If the gas type is not specified on the type plate, it must be done using the attached gas-typee adhesive labels before the device is put into operation for the first f time. Warning! Only the gas type for which the pressure control panel wass ordered may be specified on it. 4.2 Installing the pressure control panel You can find instructions on how to install the pressure control panel inn the installation manual MA_BM+BE. You can view and download this at www.spectron.de. GES_BM55-2A 1115.docx 11
4. Operation 4.3 Putting the pressure control panel intoo operation Important! Before putting the equipment into operation for the first time, the entire pressure control panel must be purged via the connection block right up to the consumer! It is imperative to adhere to the direction of the gas flow when doing this! You must not purge counter to the usual direction of flow (from the tapping point to the pressure control panel), since this can flush debris resulting from the instal- of lation work, for example, back into thee pressure regulator. connecting thread and connectingg surfaces of the gas cylinder c valves and the sealing rings the manual connectors of the pigtails must be checked to ensure they are in perfect condition. Pigtails with manual connectors are connected to gas cylinder valves without the need for tools. Pigtails with flat faces for tightening (generally for corrosive or o toxic gases) are tightened with a suitable spanner until they are gas-tight. In general but especially for filling the downstream installation the process gas valves must be opened gradually ensuring that any (audible) vibration of thee pressure regulator is avoided. Always turn shut-off valves as far as the stop when opening or closing them! Step 1 2 Activity Ensure that: gas type is specified on the pressure control panel All protective caps have been removed installation has been carried outt properly pigtails and other connecting points have been checked for leakss waste gas valves are closed (the red marking is visiblee in the handwheel window) pressure regulator is released. Pressure-purge the system: Slowly open the gas cylinder valves on the left and right. Slowly close the gas cylinder valves on the left and right. Open the waste gas valve on the leftt and right to relieve the pressure,, and then close it again. Repeat at least three times! If the inlet pressure is low, the process has to be repeated more often. 3 Slowly open the gas cylinder valve on the side which is to go into operation first. 4 5 6 7 Slowly open the gas cylinder valve on the reservee side. Set the pressuree regulator to t the desired outlet pressure by turning the handwheel clockwise. It is essential that no vibrations should be audible when filling thee downstream pipe, since otherwise the pressure regulator can be damaged. Check the entiree pressure control panel and all detachable connections for leakage. Gas can now be drawn. 12 GES_BM55-2A_1115.docx
4. Operation 4.44 Changing the cylinder Important! Step 1 2 3 Once it is put into operation, both sides of the panel must always be connected - except when changing the gas cylinders. Each time you change the cylinder, check that the gasket is in perfect condition and replace it if necessary. Each time you change the cylinder, ambient air gets into the connectingg parts of the system. To prevent the gas and the entire system from being contaminated, the connection must be purged before gas is drawn from the cylinder again. In the case of non-toxic, non-corrosive gases, this can be done by means of multiple pressuree purges with own gas. Activity Close the gas cylinder valve of the emptied gas cylinder. To relieve the pressure completely, open the waste gas valve of the side on which the cylinder is to be changed. Close the waste gas valve again. Loosen the pigtail connection to thee gas cylinder valve, replace the gas cylinder, and connect the pigtail to the new gas cylinder inn accordance with the regulations. Check the cylinder connection and all of the connections you loosened for leakage again. Pressure-purgee the system: Slowly open the gas cylinder valve.. Close the gas cylinder valve. Open the waste gas valve of the side on whichh the cylinder has beenn changed this relieves the pressure. Close the waste gas valve again. Repeat at least three times! If the inlet pressure is low, the process has to be repeated more often. 4 Slowly open the gas cylinder valve. 5 Check the gas cylinder connection and all detachable connections for leakage. 4.5 Taking the equipment out off operationn Taking out of operation or interrupting operation for a short period When interrupting operation for a short period, all you need to do is close c the gas cylinder valve. GES_BM55-2A 1115.docx 13
4. Operation Taking out of operation or interrupting operation for a longer period Step Activity 1 Close all valves on the connected pressure cylinders. 2 Open the waste gas valves. 3 Any gas in the system flows out of thee waste gas pipe. 4 Close the waste gas valves. 5 pressure in the pressure control panel must be released by allowing the gas to t flow away via the consumer. It must be ensured that the indicators of the two t pressure gauges are on zero [0] visual check! 6 Relieve the pressure regulator 5. Problems Problem/cause Remedy Gas is released from the relief valve. Close all valves immediately. Impermissiblee increase in the outlet Have the pressure control panel inspected pressure. immediately by the manufacturer or an authorised specialist com- com- pany. pressuree regulator is making noises. Close all valves immediately. This indicates a defect. Have the pressure control panel inspected immediately by the manufacturer or an authorised specialist pany. pressuree regulator is frozen. Reduce the amount of gass drawn or This indicates that too much gas is being if technically, chemically, physically possible drawn. install an upstream gas preheater. re is a leak. Close all valves immediately. This indicates a defect in a pressure Have the pressure control panel inspected regulator component. immediately by the manufacturer or an authorised specialist com- the pany. outlet pressure level is unstable and Reduce the amount of gass drawn. is not adhering to the usual range of vargas pressure control panel must be checked by the manufactur er or It is also possible that there is dirt in the inlet filter. In this case, iation. This indicates that too much is being drawn. an authorised specialist company. Switchover from the operating to the re- at which does not have the required minimum pressure for switch- too low a pressure. over connected on the reserve side. re may be an empty pressure cylinder or a pressure cylinder serve side is not effected or is effected Connect a pressure cylinder with the pressure rating P1 indicated on the type label. 14 GES_BM55-2A_1115.docx
6. Maintenance, cleaning and repairs 6.1 Regular maintenance work and visual inspections Regular maintenance work To ensure the pressure control panel remains in perfect working order and a constantly highh level of opera- tional safety and reliability is maintained, the pressure control panel should s be checked once a year by a specialist. Regular visual inspections Visual inspection of all Interval parts for Damage Regular inspections at intervals of 12 months m and each time the t device is put Function into operation make an important contribution to the cost-effectiveness and Leaks preservation of the value of the fittings. Integrity/stability Corrosion If you find defects during the visual inspection, do not put the pressuree control panel into opera- tion! Have the pressure control panel inspected immediately by the manufacturerr or an author- ised specialist company. 6.2 Regular cleaning Warning! Detergents or disinfectants can corrode and ruin gaskets inside the fittings. Do not use deter- clean gents or disinfectants! If the equipment gets very dirty, this can interfere with operation. If it becomes necessary to the pressure control panel, use only a damp, lint-free cloth. Safe and reliable operation can only be guaranteed if original spare parts are used. 6.3 Repair information Important! Repairs may only be carried out by specialist personnel in authorised repair workshops. After re- inspection instructions. pairs, the entire pressure control panel must be checked inn accordance with the original Spectron manufacturer accepts no liabilityy for damage resulting from unauthorised repairs or modifica- tions carried out by the user or third parties without the express writtenn approval of the manufac- turer. 6.4 Returns If the pressuree control panel is returned to the manufacturer for testing, maintenance or repair, and it has been in contact with corrosive and toxic gases,, it is imperative that it is purged with inert gas. GES_BM55-2A 1115.docx 15
Spectron Gas Control Systems GmbH Fritz-Klatte-Straße 8 D-65933 Frankfurt Deutschland / Germany Phone: +49 69 38016-0 Fax: +49 69 38016-200 Email: info@spectron.de Internet: www.spectron.de