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1/4/2014 1 Vacuum Regulator Gas Feed Systems: Theory and Maintenance Thom DiGeronimo OperatorSchool.Com.

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Presentation on theme: "1/4/2014 1 Vacuum Regulator Gas Feed Systems: Theory and Maintenance Thom DiGeronimo OperatorSchool.Com."— Presentation transcript:

1 1/4/ Vacuum Regulator Gas Feed Systems: Theory and Maintenance Thom DiGeronimo OperatorSchool.Com All Text, drawings and photographs Copyrighted 2005 by T DiGeronimo

2 1/4/ Seminar Highlights Gases and Properties The Vacuum Regulator / Ejector Element theory and function Differences by manufacturers Work and safety practices Personnel & Equipment Safety

3 History of the Vacuum Regulator 1 Before 1960, when James Haskett, Chlorinators Inc. founder, designed and patented the cylinder-mounted all-vacuum-operated gas chlorinator, most chlorinators worked essentially the same way. Pressure from the tanks forced the gas through one line to an ``ejector where it was mixed with water. Water pressure then forced the chlorine/water solution through another line to the ``diffuser" that injected it into the water or wastewater being treated. If either line failed, gas would escape unimpeded. Failure of any of the many valves these systems employed would also cause gas to escape. Haskett's design -- mounting the chlorinator on the cylinder and using a vacuum to pull the gas to the ejector -- eliminated the gas pressure line. This design makes it very difficult for chlorine to escape. If any part of the equipment should fail, the flow of chlorine is immediately -- and automatically -- shut off. The problem of corrosion, which contributed to the difficulties of the pressure systems, is also significantly reduced by Mr. Haskett's design, and the pressure line, the most serious source of corrosion in gas chlorination equipment, is eliminated.

4 History of the Vacuum Regulator 2 1/4/ In Mr. Hasketts design, chlorine gas bubbles immediately enter the main stream, and are quickly dissolved. Further, beginning with the regulator, the gas is never under pressure, and it is mixed with water in the ejector under vacuum conditions. Another important point: laws prohibiting the use of chlorine gas could be costing you a lot of money, because chlorine gas is far more economical than either sodium or calcium hypochlorite. The tank contains 100% chlorine, which can never lose strength. Calcium hypochlorite has only 65-70% total weight chlorine available, and sodium hypochlorite only 10% or less by the time it is used. You need 1.5 pounds of calcium hypochlorite, or 1.2 gallons of sodium hypochlorite (average 10%) to equal a pound of liquid (gas) chlorine. Both calcium and sodium hypochlorite lose strength in storage. Although the initial cost of gas chlorination equipment may be higher than that required for calcium or sodium hypochlorite, the savings in material costs quickly make up the difference.

5 1/4/2014 5

6 6 Chlorine Gas Properties Amber Gas & Liquid Expands 460 Times Corrosive Non Flammable 3PPM Heavy Gas Will Flow Chlorine Institute

7 1/4/ Sulphur Dioxide Gas Properties Gas & Liquid Expands many Times Corrosive Non Flammable 3PPM Heavy Gas will Flow CGA makes rules Overfilled Tanks can explode !!!

8 1/4/ Liquid to Gas Properties Coefficient of expansion Needs minimum headroom With a FULL TANK Liquid expansion at any temperature can cause the tank to fail or explode !!

9 1/4/ Safety Equipment Required SCBA / Face Mask Filter Gas Leak Detector Leak Repair Kit A or B Properly Trained Haz-Mat People A PLAN


11 1/4/ Tank Valves & Fusible Plugs for 150s w/ Fusible plug -- Flex Connector Yoke -- Manifold Valve

12 1/4/ Valves & Accessories

13 1/4/ Approved 150 lb Cylinder Storage Straps & Blocks - NO CHAINS - Straps & Rack Valve Covers on When NOT Being Used

14 1/4/ Un-Approved 150 lb Cylinder Capture

15 1/4/ Ton Cylinder Fusible Plugs & Valves 3 3/4 Fusible Plugs on Both Ends of Cylinders Valve Safety Cover Gas & Liquid Valves

16 1/4/ Ton Cylinder Valves Gas Valve (TOP) to the Right Liquid Valve (BOTTOM) to the Left

17 Ton Cylinder Eductor Tubes 1/4/

18 Safety – IT IS YOUR JOB !! 1/4/

19 1/4/ Proper Materials used Properly Body Plastics Metals / Hardware O rings / Gaskets Tubing Piping Valves Safety & Function

20 1/4/ Basic Vacuum Regulator Body Two Parts Separated by a Diaphragm Front is Vent Cavity Back is Vacuum Regulation Inlet Valve Mounting

21 1/4/ Vacuum Regulator Diaphragm Flexured Plastic Material Separates Body Cavities Front has pin for Indication and Control Back has Vent Valve Can be Spring Loaded to Inlet Valve Uses Vacuum / Barometric Pressure to Open Inlet Valve

22 1/4/ Standard Hydro Regulator

23 1/4/ Inlet Valve Assembly Grooved Body Alumina Bronze ( Better: Hastalloy C) Guts Teflon, Monel ABS / PVC Gaskets / O Rings Viton or Buna N

24 1/4/ Inlet Valve Detail Vent Seat Vent Plug Valve Spring Assy Inlet Seat Inlet Plug Inlet Filter

25 NXT 3000 Parts Breakdown 1/4/

26 1/4/ Hydro 100 PPD Latching Regulator Vent Connection Switchover knob Rotameter Gas Connection

27 1/4/ Quick Tour around the Hydro 100 PPD Regulator w/ Switchover Vent Connection Switchover knob Rotameter Gas Connection

28 NXT-3000 Latching Regulator Arm Latch Positions 1/4/

29 NXT-3000 Latching Regulator Pivot Latch Lift Arm 1/4/

30 NXT-3000 Latching Regulator Diaphragm Lift Eye 1/4/

31 NXT-3000 Latching Regulator Diaphragm Lift Eye Pivot Plate 1/4/

32 NXT-3000 Latching Regulator Latching Lift Arm 1/4/

33 1/4/ Auto-Switchover Valve

34 1/4/ Quick Tour around the Hydro 100 PPD Regulator

35 1/4/ Yoke & Inlet Valve Assembly Mounts the Regulator Inlet Valve Seals to Bottle Lead Washer Gasket

36 1/4/ Hydro Ton Mount Regulator Inlet is the same Yoke turned to right Drip leg added 25 W Heater added

37 1/4/ Flowmetering w/ 500 PPD Rotameter Metering Valve

38 1/4/ Ejector Designs ABS / PVC Body - Viton / Buna N Gaskets & O Rings

39 1/4/ Ejector Sizing Charts Proper Inlet & Outlet Pressures Proper Installation / Position

40 1/4/ Ejector Application by Diffuser Must Not Back Up Flow Must Diffuse the Solution in Flowstream

41 1/4/ Typical Systems 1 -- Capital Controls

42 1/4/ Typical Systems 2 -- Capital Controls

43 1/4/ Typical Chlorine – Sulfur Dioxide Room

44 Liquid Cl2 Damage # 1 1/4/

45 Liquid Cl2 Damage # 2 1/4/ NXT3000 Back Body\ $ … Look on Boss PRICELESS !!

46 Liquid Cl2 Damage # 3 1/4/

47 Liquid Cl2 Damage # 4 1/4/

48 Main Diaphragm Melted / Deformed 1/4/ Liquid Cl2 Damage # 5

49 Liquid Cl2 Damage # 6 1/4/ Also Caused By Wrong Lubes Water in System Condensation Intervals

50 Basic Regulator / Ejector Materials Cl 2 Regulator Bodies – ABS Plastics Cl 2 & SO 2 Ejector ABS & PVC Plastics Tubing – Polyethylene & Teflon – Kynar O-Rings & Gaskets Viton & Buna N Inlet Block – Hastelloy Alumina-Bronze & Kynar Inlet Valve – Silver, Hastelloy & Stainless Steel Screws – Monel or Titanium 1/4/

51 Cleaning Materials Dish Soap & Water Alcohol on MOST Plastics Lacquer Thinner on Teflon & Metals Soaking Lacquer Thinner Flash Wipe on Plastics *** Caution – This WILL Melt Plastics *** Vinegar or Muriatic Acid for Corrosion Removal 3-M Pads for Plastic Abrasion 00 – Fine Steel Wool for Metal Abrasion 1/4/

52 Maintain Equipment Properly # 1 Lubes 1/4/

53 Maintain Equipment Properly # 2 Lubes 1/4/

54 Maintain Equipment Properly # 3 Lubes 1/4/

55 Maintain Equipment Properly # 4 Lubes 1/4/ Maintain Equipment Properly # 3 Lubes

56 Maintain Equipment Properly # 5 1/4/ Maintain Equipment Properly & Routinely

57 Liquid Traps 1/4/

58 Liquid Trap Avoidance # 2 1/4/ Custom Made Flex Connector 30 Inches

59 Modified Drip Leg Liquid Trap 1/4/

60 1/4/ Service Systems 1

61 1/4/ Service Systems 2

62 1/4/ Where to Get More Information Chlorine Institute A.W.W.A. Manuals Manufacturers Manuals

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