1/4/2014 1 vacuum regulator gas feed systems: theory and maintenance thom digeronimo thom @...

04/10/23www.OperatorSchool.com1

Vacuum Regulator Gas Feed Systems: Vacuum Regulator Gas Feed Systems: Theory and MaintenanceTheory and Maintenance

Thom DiGeronimowww.OperatorSchool.comThom @ OperatorSchool.Com

All Text, drawings and photographs Copyrighted 2005 by T DiGeronimo


Seminar Highlights Seminar Highlights

Gases and PropertiesThe Vacuum Regulator / EjectorElement theory and functionDifferences by manufacturersWork and safety practicesPersonnel & Equipment Safety

History of the Vacuum Regulator 1History of the Vacuum Regulator 1

www.OperatorSchool.com

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.

History of the Vacuum Regulator 2History 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.

04/10/235


Chlorine Gas PropertiesChlorine Gas Properties

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


Sulphur Dioxide Gas PropertiesSulphur Dioxide Gas Properties

Gas & Liquid Expands many Times Corrosive Non Flammable Poisonous @ 3PPM Heavy Gas will Flow CGA makes rules

Overfilled Tanks can explode !!!


Liquid to Gas PropertiesLiquid 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 !!


Safety “Equipment” RequiredSafety “Equipment” Required

SCBA / Face Mask FilterSCBA / Face Mask FilterGas Leak DetectorGas Leak Detector

Leak Repair Kit A or BLeak Repair Kit A or B

Properly Trained Haz-Mat PeopleProperly Trained Haz-Mat People

A PLANA PLAN

Safety is ALWAYS FIRST !!!Safety is ALWAYS FIRST !!!

OBEY

YOUR

SAFETY

RULES



Tank Valves & Fusible Plugs for 150’sTank Valves & Fusible Plugs for 150’s

w/ Fusible plug -- Flex Connector Yoke -- Manifold Valve


Valves & AccessoriesValves & Accessories


Approved 150 lb Cylinder StorageApproved 150 lb Cylinder Storage

Straps & Blocks - NO CHAINS - Straps & RackValve Covers on When NOT Being Used


Un-ApprovedUn-Approved 150 lb Cylinder Capture 150 lb Cylinder Capture


Ton Cylinder Fusible Plugs & ValvesTon Cylinder Fusible Plugs & Valves3 3/4 “ Fusible Plugs on Both Ends of Cylinders

Valve Safety Cover Gas & Liquid Valves


Ton Cylinder ValvesTon Cylinder Valves

Gas Valve (TOP) to the Right

Liquid Valve (BOTTOM) to the Left

Ton Cylinder Eductor TubesTon Cylinder Eductor Tubes


Safety – IT IS YOUR JOB !!Safety – IT IS YOUR JOB !!



Proper Materials used ProperlyProper Materials used Properly

Body Plastics Metals / Hardware O rings / Gaskets Tubing Piping Valves Safety & Function


Basic Vacuum Regulator BodyBasic Vacuum Regulator Body

Two Parts Separated by a Diaphragm Front is Vent Cavity Back is Vacuum Regulation Inlet Valve Mounting


Vacuum Regulator DiaphragmVacuum 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


Standard Hydro RegulatorStandard Hydro Regulator


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


Inlet Valve DetailInlet Valve Detail

Vent Seat

Vent Plug

Valve Spring Assy

Inlet Seat

Inlet Plug

Inlet Filter

NXT 3000NXT 3000Parts Parts

BreakdownBreakdown



Hydro 100 PPD Latching RegulatorHydro 100 PPD Latching Regulator

•Vent Connection•Switchover knob•Rotameter•Gas Connection


Quick Tour around theQuick Tour around theHydro 100 PPD RegulatorHydro 100 PPD Regulatorw/ Switchoverw/ Switchover

•Vent Connection•Switchover knob•Rotameter•Gas Connection

NXT-3000NXT-3000LatchingLatchingRegulatorRegulator

ArmArmLatchLatchPositionsPositions



PivotPivotLatchLatchLift ArmLift Arm



DiaphragmDiaphragmLift EyeLift Eye



DiaphragmDiaphragmLift EyeLift EyePivot PlatePivot Plate



LatchingLatchingLift ArmLift Arm



Auto-Switchover ValveAuto-Switchover Valve


Quick Tour around theQuick Tour around theHydro 100 PPD RegulatorHydro 100 PPD Regulator


Yoke & Inlet Valve AssemblyYoke & Inlet Valve Assembly

Mounts the Regulator Inlet Valve Seals to Bottle Lead Washer Gasket


Hydro Ton Mount RegulatorHydro Ton Mount Regulator

•Inlet is the same•Yoke turned to right•Drip leg added•25 W Heater added


Flowmetering w/ Ecometrics @ 500 PPDFlowmetering w/ Ecometrics @ 500 PPD

Rotameter Metering Valve


Ejector DesignsEjector Designs

ABS / PVC Body - Viton / Buna N Gaskets & O Rings


Ejector Sizing ChartsEjector Sizing ChartsProper Inlet & Outlet PressuresProper Installation / Position


Ejector Application by DiffuserEjector Application by Diffuser

Must Not Back Up FlowMust “Diffuse” the Solution in Flowstream


Typical Systems 1 -- Capital ControlsTypical Systems 1 -- Capital Controls


Typical Systems 2 -- Capital ControlsTypical Systems 2 -- Capital Controls


Typical Chlorine – Sulfur Dioxide RoomTypical Chlorine – Sulfur Dioxide Room

Liquid Cl2Liquid Cl2

DamageDamage

# 1 # 1


Liquid Cl2 Damage # 2Liquid Cl2 Damage # 2


NXT3000

Back Body\

$350.00 …

Look on Boss

PRICELESS !!

Liquid Cl2Liquid Cl2

DamageDamage

# 3 # 3


Liquid Cl2 Damage Liquid Cl2 Damage # 4# 4


Main Diaphragm “Melted” / Deformed


Liquid Cl2 Damage # 5

Liquid Cl2 Damage # 6Liquid Cl2 Damage # 6


Also Caused By

Wrong Lubes

Water in System

Condensation

Intervals

Basic Regulator / Ejector MaterialsBasic Regulator / Ejector Materials

Cl2 Regulator Bodies – ABS PlasticsCl2 & SO2 Ejector ABS & PVC PlasticsTubing – Polyethylene & Teflon – KynarO-Rings & Gaskets Viton & Buna NInlet Block – Hastelloy Alumina-Bronze & KynarInlet Valve – Silver, Hastelloy & Stainless SteelScrews – Monel or Titanium


Cleaning MaterialsCleaning Materials

Dish Soap & WaterAlcohol on MOST PlasticsLacquer Thinner on Teflon & Metals SoakingLacquer Thinner “Flash” Wipe on Plastics

*** Caution – This WILL Melt Plastics ***

Vinegar or Muriatic Acid for Corrosion Removal3-M Pads for Plastic Abrasion“00 – Fine” Steel Wool for Metal Abrasion


Maintain Equipment Properly # 1 LubesMaintain Equipment Properly # 1 Lubes




Maintain Equipment Properly # 3 Lubes

Maintain Equipment Properly # 5Maintain Equipment Properly # 5


Maintain

Equipment

Properly &

Routinely

LiquidLiquid

TrapsTraps


Liquid Trap Avoidance # 2Liquid Trap Avoidance # 2


Custom

Made

Flex

Connector

30 Inches

ModifiedModifiedDrip LegDrip Leg

LiquidLiquidTrapTrap



Service Systems 1Service Systems 1 www.OperatorSchool.com www.Start-UpService.com www.PVC-Creations.com


Service Systems 2Service Systems 2 www.OperatorSchool.com www.Start-UpService.com www.PVC-Creations.com


Where to Get More InformationWhere to Get More Information

Chlorine InstituteA.W.W.A. ManualsManufacturers Manualswww.OperatorSchool.comwww.Start-UpService.com

1/4/2014 1 vacuum regulator gas feed systems: theory and maintenance thom digeronimo thom @...

Documents

t digeronimo slide

maintenance thom digeronimo

function differences

seminar highlights gases