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Vacuum Regulator Gas Feed Systems: Theory and Maintenance

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Presentation on theme: "Vacuum Regulator Gas Feed Systems: Theory and Maintenance"— Presentation transcript:

1 Vacuum Regulator Gas Feed Systems: Theory and Maintenance
Thom DiGeronimo OperatorSchool.Com All Text, drawings and photographs Copyrighted 2005 by T DiGeronimo 3/25/2017

2 Seminar Highlights Gases and Properties The Vacuum Regulator / Ejector
Element theory and function Differences by manufacturers Work and safety practices Personnel & Equipment Safety 3/25/2017

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
In Mr. Haskett‘s 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. 3/25/2017

5 3/25/2017

6 Chlorine Gas Properties
Amber Gas & Liquid Expands 460 Times Corrosive Non Flammable 3PPM Heavy Gas Will Flow Chlorine Institute 3/25/2017

7 Sulphur Dioxide Gas Properties
Gas & Liquid Expands many Times Corrosive Non Flammable 3PPM Heavy Gas will Flow CGA makes rules Overfilled Tanks can explode !!! 3/25/2017

8 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 !! 3/25/2017

9 Safety “Equipment” Required SCBA / Face Mask Filter Gas Leak Detector Leak Repair Kit A or B Properly Trained Haz-Mat People A PLAN 3/25/2017


11 Tank Valves & Fusible Plugs for 150’s
w/ Fusible plug -- Flex Connector Yoke -- Manifold Valve 3/25/2017

12 Valves & Accessories 3/25/2017

13 Approved 150 lb Cylinder Storage
Straps & Blocks - NO CHAINS - Straps & Rack Valve Covers on When NOT Being Used 3/25/2017

14 Un-Approved 150 lb Cylinder Capture

15 Ton Cylinder Fusible Plugs & Valves
3 3/4 “ Fusible Plugs on Both Ends of Cylinders Valve Safety Cover Gas & Liquid Valves 3/25/2017

16 Ton Cylinder Valves Gas Valve (TOP) to the Right
Liquid Valve (BOTTOM) to the Left 3/25/2017

17 Ton Cylinder Eductor Tubes

18 Safety – IT IS YOUR JOB !! 3/25/2017

19 Proper Materials used Properly
Body Plastics Metals / Hardware O rings / Gaskets Tubing Piping Valves Safety & Function 3/25/2017

20 Basic Vacuum Regulator Body
Two Parts Separated by a Diaphragm Front is Vent Cavity Back is Vacuum Regulation Inlet Valve Mounting 3/25/2017

21 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 3/25/2017

22 Standard Hydro Regulator

23 Inlet Valve Assembly Grooved Body Alumina Bronze ( Better: Hastalloy C) Guts Teflon, Monel ABS / PVC Gaskets / O Rings Viton or Buna N 3/25/2017

24 Inlet Valve Detail Vent Seat Vent Plug Valve Spring Assy Inlet Seat
Inlet Plug Inlet Filter 3/25/2017

25 NXT 3000 Parts Breakdown 3/25/2017

26 Hydro 100 PPD Latching Regulator
Vent Connection Switchover knob Rotameter Gas Connection 3/25/2017

27 Quick Tour around the Hydro 100 PPD Regulator w/ Switchover
Vent Connection Switchover knob Rotameter Gas Connection 3/25/2017

28 NXT-3000 Latching Regulator Arm Latch Positions

29 NXT-3000 Latching Regulator Pivot Latch Lift Arm

30 NXT-3000 Latching Regulator Diaphragm Lift Eye

31 NXT-3000 Latching Regulator Diaphragm Lift Eye Pivot Plate

32 NXT-3000 Latching Regulator Latching Lift Arm

33 Auto-Switchover Valve

34 Quick Tour around the Hydro 100 PPD Regulator

35 Yoke & Inlet Valve Assembly
Mounts the Regulator Inlet Valve Seals to Bottle Lead Washer Gasket 3/25/2017

36 Hydro Ton Mount Regulator
Inlet is the same Yoke turned to right Drip leg added 25 W Heater added 3/25/2017

37 Flowmetering w/ Ecometrics @ 500 PPD
Rotameter Metering Valve 3/25/2017

38 ABS / PVC Body - Viton / Buna N Gaskets & O Rings
Ejector Designs ABS / PVC Body - Viton / Buna N Gaskets & O Rings 3/25/2017

39 Ejector Sizing Charts Proper Inlet & Outlet Pressures
Proper Installation / Position 3/25/2017

40 Ejector Application by Diffuser
Must Not Back Up Flow Must “Diffuse” the Solution in Flowstream 3/25/2017

41 Typical Systems 1 -- Capital Controls

42 Typical Systems 2 -- Capital Controls

43 Typical Chlorine – Sulfur Dioxide Room

44 Liquid Cl2 Damage # 1 3/25/2017

45 Liquid Cl2 Damage # 2 NXT3000 Back Body\ $350.00 … Look on Boss
PRICELESS !! 3/25/2017

46 Liquid Cl2 Damage # 3 3/25/2017

47 Liquid Cl2 Damage # 4 3/25/2017

48 Main Diaphragm “Melted” / Deformed
Liquid Cl2 Damage # 5 Main Diaphragm “Melted” / Deformed 3/25/2017

49 Liquid Cl2 Damage # 6 Also Caused By Wrong Lubes Water in System
Condensation Intervals 3/25/2017

50 Basic Regulator / Ejector Materials
Cl2 Regulator Bodies – ABS Plastics Cl2 & SO2 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 3/25/2017

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 3/25/2017

52 Maintain Equipment Properly # 1 Lubes

53 Maintain Equipment Properly # 2 Lubes

54 Maintain Equipment Properly # 3 Lubes

55 Maintain Equipment Properly # 4 Lubes

56 Maintain Equipment Properly # 5
Routinely 3/25/2017

57 Liquid Traps 3/25/2017

58 Liquid Trap Avoidance # 2
Custom Made Flex Connector 30 Inches 3/25/2017

59 Modified Drip Leg Liquid Trap

60 Service Systems 1

61 Service Systems 2

62 Where to Get More Information
Chlorine Institute A.W.W.A. Manuals Manufacturers Manuals 3/25/2017

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