Download - ALphagaz CLMA1
-
ALPHAGAZ ML - ML1 - CLSA1
User Manualwww.airliquide.com
-
EN
OP 206 ML-ML1-CLSA1 08/2013 v.1.0 1
WarningTo preserve the quality of our product throughout its usage in the best safety conditions, please read this manual carefully and strictly follow the instructionsthat it contains. Non-compliance with these instructions or modification of the product may result in serious accidents or bodily injuries. AIR LIQUIDEshall not be held responsible in case of non approved usage of the product.Air Liquide reserves the right to make all necessary modifications to the specifications described hereafter without notice.
-
OP 206 ML-ML1-CLSA1 08/2013 v.1.0
ML1300-16-8
ML1300-10-50
ML200-200-30
CLSA1
-
EN
OP 206 ML-ML1-CLSA1 08/2013 v.1.0 3
Contents
1. Domain of usage and Characteristics............................. 41.1 Functions..............................................................................................41.2 Technical characteristics....................................................................... 41.3 Gas compatibiliy table.......................................................................... 4
2. AIR LIQUIDE commitments............................................ 72.1 Conformity ...........................................................................................72.2 Cleaning .............................................................................................. 72.3 Inspections ..........................................................................................72.4 Warranty ..............................................................................................7
3. Assembly - Activation.................................................... 83.1 Safety................................................................................................... 83.2 Precautions before assembly................................................................83.3 Assembly..............................................................................................83.4 Options.................................................................................................93.5 Checking the tightness of connections................................................. 93.6 Activation............................................................................................10
4. Usage...........................................................................114.1 Use.....................................................................................................114.2 Cylinders or Bundles change .............................................................114.3 After use.............................................................................................11
5. Maintenance.................................................................125.1 Troubleshooting.................................................................................. 125.2 Maintenance....................................................................................... 135.3 Spare parts.........................................................................................14
-
OP 206 ML-ML1-CLSA1 08/2013 v.1.04
1. Domain of usage and Characteristics
1.1 Functions
The ML1 & CLSA1 gas manifolds are used to:
connect one or several cylinders or bundles topipe network,
reduce a high-pressure conditioned gas (200 or300 bar at 15C) in cylinder or bundle.
ModelConnection on
Cylinders / BundlesContinued
supply
Continuouslycylinderschange
Adjustableoutlet
pressure
Gas panel ML - ML1 1x1 1x2 no no yes
Automatic changeover with reset
CLSA 1 2x1 2x2 yes yes no
The operation of the CLSA1 automatic change-over with reset is based on the assembly of twoopposing pressure regulators connected to twogas sources and adjusted to obtain a slightlydifferent pressure between the pressure regulatorinto operation and pressure regulator in the reserve.Since these two reducers have a commonoutlet, only the regulator set to the higher
pressure delivers gas to flow. When the source inservice is nearing exhaustion, the pressure dropcauses the commissioning of the second regulatorautomatically.The technician operates to switch the lever towardsthe new source to restore full operating pressure(hence the term "automatic with reset "), and thento replace the empty cylinders or bundles.
1.2 Technical characteristics
Operating temperature : -20C to + 50C
Leakage rate (Int/Ext.) : < 10-7 mbar.l/s helium.
1.3 Gas compatibiliy table
The gas manifold are mainly designed for theimplementation of pure gases and mixtures withpurity < N50 thus ALPHAGAZ 1.
IMPERATIVE: check the gasescompatibility of this equipment byreferring to the "Gas CompatibilityTable".
Legend :Suitable up to a working pressure of XXXbar at 15C.Not suitable.
* 1,013 bar at 15C, according to ISO 2503P1 Inlet = 2(P2 Outlet) + 1 bar
-
EN
OP 206 ML-ML1-CLSA1 08/2013 v.1.0 5
Par
amet
ers
Mai
n g
ases
:
Outlet pressure(bar)
Pressure of gasin reserve supply
(bar)
Nominal nitrogenflow rate*(Nm3/h)
Calibration of reliefvalve (Bar)
Inerts, Nitrogen
CO2**
CO
Breathable air
Air
Oxygen
Nitrous oxide
Hydrogen
Acetylene
Propane
Propylene
Ethylene
Methane
Ammonia
Fo
r b
reat
hab
le o
xyg
en, c
orr
osi
ve g
ases
, oth
er g
ases
and
mix
ture
s : P
leas
e co
ntac
t A
IR L
IQU
IDE
.M
L -
ML1
Gas
pan
els
ML1
300
-16
-8
168
30
050
300
300
4430
0
ML1
300
-10
-50
1050
30
050
300
300
4430
0
ML
200-
200-
3020
030
20
050
200
200
4420
0
CLS
A1
Sem
i-au
tom
atic
cha
nge
ove
rsC
LSA
1 20
0-10
-10
10
1015
200
50
200
200
4420
0
CLS
A1
200-
10-
5010
5015
200
5020
020
044
200
CLS
A1
200-
20-
5020
50
25
200
5020
020
044
20
0
-
OP 206 ML-ML1-CLSA1 08/2013 v.1.06
Material in contact with gas :
CLSA1CLSA1
200-10-10CLSA1
200-10-50CLSA1
200-20-50
Valve block / Purge Regulators
Body Nickel Plated Brass Nickel Plated Brass
Seat PTFCE Brass
Valve / SpringBrass / PA
Brass / SS 301 Brass + PTFCE / SS
Diaphragm SS 304 Hastelloy
Piston
Filter Bronze Monel Bronze
Pressure gauge Copper Alloy Copper Alloy
Relief valve SS / NBR Brass / NBR
Seal EPDM / PA 6.6 EPDM / PA 6.6 / PTFCE
ML/ML1 ML1 300-16-8 ML1 300-10-50 ML 200-200-30
Valve block / Purge Regulators
BodyNickel Plated Brass Nickel Plated Brass
ChroniumPlated Brass
Seat PTFCE Brass
Valve / Spring Brass / PABrass / Bronze
BrassPTFCE / Bronze
Brass PTFCE
Diaphragm Hastelloy
Piston SS
Filter Bronze Monel Bronze
Pressure gauge Copper Alloy Copper Alloy
Relief valve Brass / NBR Brass / NBR Brass / NBR
Seal EPDM / PA 6.6 EPDM / PA 6.6
NBR / PTFCE /Copper
Seat diameter :
ModelsSeat diameter
(Equivalentdiameter in mm)
ModelsSeat diameter
(Equivalentdiameter in mm)
ML1 300-16-8 1,73 CLSA1 200-10-10 1,73
ML1 300-10-50 3,57 CLSA1 200-10-50 4,67
ML 200-200-30 1,73 CLSA1 200-20-50 4,67
-
EN
OP 206 ML-ML1-CLSA1 08/2013 v.1.0 7
2. AIR LIQUIDE commitments
2.1 Conformity
AIR LIQUIDE certifies that the equipment ismanufactured, tested and controlled, in accordancewith the technical specifications described in thespecifications of AIR LIQUIDE.In addition to technical specifications, a degreasingprocess consistant with oxygen service is applied.It is the responsibility of the end user to ensurethat such equipment are installed and used inaccordance with the current regulations.
2.1.1 Directive 97/23/EC: Pressurisedequipment (PED)
AIR LIQUIDE equipment of DN < 25 (e.g. pressureregulators, valves, non return valves) satisfy torequirement of article 33 of 97/23/EC directiveand at the state of the art. Consequently, theseequipments shall not be "CE" marked as definedin article 15.By design, these equipment may integrate pressurerelief valves or burst disks. In this case, those onesshall neither be CE marked according to paragraph2 of annex II.In other case, pressure relief valves and burst disksshall be CE marked.
2.1.2 Directive 94/9/EC ATEX: Explosiveatmospheres
The ML, ML1 & CLSA1 gas manifolds do nothave their own source of ignition. Consequently,they are excluded from field of application of theATEX 94/9/CE directive and shall not be CEmarked.They can be used in zone 2, according to ATEX1999/92/EC pending on up to date regulations,rules, operating instruction and state of the art arefollowed during installation and use.Every installation including one of those equipmentsin ATEX zone shall comply to the ATEX directive andbe certified. Remark: It belongs to the end user todefine the ATEX zone.
2.2 Cleaning
Each equipment is subject to a grease removal anda high quality cleaning to preserve the purity of gasin the equipment as well as for use with oxygen incompatible equipment.A suitable packaging protects the equipmentagainst exterior pollutions during storage andtransport.Take care to avoid polluting the equipmentduring usage.
2.3 Inspections
Each equipment is inspected and has undergonea leak test (with helium) before packing.
2.4 Warranty
The warranty period for equipment supplied by AIRLIQUIDE is one year, covering faulty material andworkmanship during manufacture. The warrantydoes not cover packing and return transport costs.Excluded from warranty: seals and relief valves.These components are subjected to a natural wear.Warranty is not valid on deterioration resulting fromincorrect or improper use, use of spare parts whichare not marked AIR LIQUIDE or from the nonerespect of this operating instruction.For more information, refer to the general salesconditions of AIR LIQUIDE.
-
OP 206 ML-ML1-CLSA1 08/2013 v.1.08
3. Assembly - Activation
3.1 Safety
First of all, read and respectIMPERATIVELY the safety instructionsdescribed in the document GeneralSafety Instructions delivered with theproduct.
3.2 Precautions before assembly
After opening the packaging, check that theequipment is not damaged and that the contentscorrespond to the delivery notes accompanying theequipment. During assembly, it is important to take extreme
care to ensure cleanliness and avoid pollution. To install the equipment, select a ventilated area,
protected from the effects of bad weather.
3.3 Assembly
3.3.1 Assembly of the gas manifold
Set the manifold (see drawing) The surface on which the manifold will be mounted,must be flat. Any deformation of the plate couldaffect the proper operation of the equipment. Depending of the case, mount and connect the
extension ramps (Options) Fix the racks (in case of cylinder use). Attach the panels "Cylinders/bundles change
procedure" and the "Safety precautions"corresponding to the gas used. They have to bevisible and in close range.
Mount the anti-flapping connectors. Warning!They must be imperatively mounted in a verticalposition. Unused ports must be sealed with blindplugs provided for that purpose.
Place the cylinders in their racks with their safetychains.
Connect the flexible hoses or pigtails as specifiedin their operating instructions.
Attach the safety cables. Use the holes for thatpurpose on the manifold. In case of bundles,attach the anchor cable to a solid anchor point.
In case of CLSA1 used with hydrogen or Helium,install at the outlet the calibrated orifice adaptedto the gas used and delivered with the equipment.
Connect the outlet of the manifold to the pipenetwork.
Install a shut-off valve between the manifold andthe pipeline:-At a distance equal to 20 x internal diameter of
the pipe when used with breathable air. CheckThe compatibility of the seals.
-EFP9 shut-off valve for oxygen (> 20 bar) andhydrogen use
If continuous supply is required, even during themaintenance, install back up cross downstreamthe manifold
If necessary, collect the purges and the reliefvalve (particularly for the combustible gases) andconnect them to exhaust pipes to secure theinstallation. Height > 2,5m.
In case of combustible gases, connect the manifoldto the ground and check the electrical continuitybetween the different components.
3.3.2 Assembly of a compression fitting
Check dimensions and respect materialcompatibility between connection and pipe :Connection and pipe must always be made from thesame material, example: Stainless steel connectionfor stainless steel pipe < Rockwell hardness B90(exception : brass connection with copper pipe).
-
EN
OP 206 ML-ML1-CLSA1 08/2013 v.1.0 9
Connector pre-assembled by hand. After cutting, de-burring and blowing on the tube
(use preferably a tube cutter), pre assemble thenut and the ferrules, following the order and thedirection indicated in the figure.
Introduce the tube inside the connector up to thestop limit on the body.
Clamp the nut completely by hand. Complete the clamping using a wrench by turning
the nut at a 1 1/4 turn.
3.4 Options
To choose the appropriate option, pleaseconsult the AIR LIQUIDE "Product sheet" inmyCatalogue.
For the options assembly, refer to Assembly - Activation chapter of the operating instructions delivered with the options.
3.5 Checking the tightness ofconnections
Even though the different components of theequipment have been carefully checked in thefactory, it is nevertheless necessary to make averification of the sealing of the mounted assemblybefore commissioning .
-Close the outlet valve.-Verify that the HP shut-off valves (2) and the
purge valves (3) are closed.-Open and then close gradually all valves of
cylinders or bundles (1). The cylinder pressureis read on the high pressure gauges (5).
-Verify that the value indicated on the highpressure gauge does not vary over a sufficientlylong period. Otherwise, there is leakage ona connection. Identify it by using a leakdetector such as the Mille Bulles from AIR
LIQUIDE. After locating the leakage, purge theinstallation, check the state of seals and of theseats of seals, and retighten the connectorsagain.
Always turn valves GRADUALLY.Never retighten a fitting under gaspressure.
In the same way, during the pressurization of theinstallation, check also the tightness of the outputconnections.
-
OP 206 ML-ML1-CLSA1 08/2013 v.1.010
3.6 Activation
Never use the purge valves to purgethe pipeline connected downstreamof the gas manifold (risk polluting theregulators).
3.6.1 1st stage: Flexible hoses purging.
Initial stage: Closed HP shut-off valves (2) and purge valves
(3). Closed low-pressure outlet shut-off valve.Purge all flexible hoses or pigtails, by at leastof 3 compressions-reductions cycles, ie: openthe cylinder/bundle valves (1) and close it beforereaching the pressure of the cylinder (high pressuregauge (5)), wait 1 minute, slowly open the purgevalve (3) and then close it before falling toatmospheric pressure.
3.6.2 2nd stage: function control
Initial stage: Closed cylinder/bundle valves, Closed HP shut-off valves (2) and purge valves (3) Closed low pressure outlet shut-off valve.Indicate the main gas source to use first by usingthe lever (4). (In case of CLSA1): On the right: lever downwards On the left: lever upwards Slowly open all cylinder/bundle valves (1). Slowly open the HP shut-off valves (2) on the mainsource.Note the outlet pressure of the low pressure gauge(6). Adjust the pressure with the handwheel (exceptCLSA1: not adjustable).
Slowly open the HP shut-off valve on the 2nd gassource (In case of CLSA1).Slowly open the outlet shut-off valve.Let the gas flow normally through the manifold andpurge all pipes.Limit the outlet flow during the filling of the pipenetwork to avoid vibrations. Respect the nominalflow.
If necessary, adjuste the outlet pressure (Except withCLSA1: non-adjustable).
3.6.3 3rd stage: verification of theautomatic switchover (In case of CLSA1only)
Close the cylinder/bundle valves of the main gassource in service, the high pressure gauge (5)decreases.When the HP pressure falls below 2 times theworking pressure, the source in reserve must entergradually in service. The LP pressure gauge (6)indicates the pressure of the gas source in reserve.Change the position of the lever, the initial outletpressure is now restored. The previous gas sourcein reserve becames the main gas source inservice.Repeat in reverse the operation, to check that theautomatic switchover works well in both directions.Remark: if during the switchover, the pressuredifference "deltaP" is too disturbing for the user, itis recommended to install one 2nd stage pressureregulator at the outlet.
3.6.4 4th stage: setting in flow
The tested equipment is now ready to use.Slowly open the shut-off valve at the outlet.In the case of the CLSA1, when the gas source inservice is empty, the switchover to the gas sourcein reserve will be automatic. It will be sufficient toswitch over the position of the lever so that the gassource initially in reserve will be in service, at therequired working pressure.Change the empty cylinders or bundles which willbe automatically in reserve.The gas source in service is indicated by the positionof the lever. The arrow on the lever indicates themain source.
Open always the cylinder (orbundle) valves slowly andgradually.
-
EN
OP 206 ML-ML1-CLSA1 08/2013 v.1.0 11
4. Usage
4.1 Use
Adjust the outlet pressure according toyour need with the handwheel (ML1 gas panel only).
4.2 Cylinders or Bundles change
Identify the empty cylinders or bundles.
-1. Push the handle (4) (for semi-automatic gasmanifold only):-Downwards: if empty cylinders are on the
left.-Upwards : if empty cylinders are on the right.
Change of empty cylinders or bundles.
-2. Close the High Pressure shut off valve(2) (empty side) on the gas panel or on theconnection point (in case of use of more than2 bundels).
-3. Close the cylinder or bundle valves (1).-4. Slowly open the purge valve (3) and release
the pressure, then close the valve.The pressuregauge must indicate 0 bar.
-5. Disconnect the flexible hoses or the pigtailsfrom the cylinders or the bundles.
-6. Replace the empty cylinders or bundles andsafely store.
-7. Verify the cleanliness of the cylinders' orbundles' valve outlet.
-8. Connect the flexible hoses or the pigtailsafter change the seals. Do not forget toremount the Safety cable.
-9. Slowly open the cylinder or bundel valves(1) and close them again before to reach themaximum pressure.
-10. Wait about 1 minute..-11. Slowly open the purge valve (3) and
close it again before to reach the atmosphericpressure.
-12. Start twice this cycle from point (9) to (11).(4 to 6 times in case of pure gases).
-13. Slowly open the cylinder or bundel valves(1) at least 2 turns.
-14. Slowly open the High Pressure shut offvalve (2).
Do not allow a flexible hoses to rub against theground or a wall.Fix the chain holding the cylinders in the racks. Inthe case of bundles, make sure that they are onhorizontal surface.All flexible hoses or pigtails must be connectedand safety cables hooked up before opening thecylinders or bundles.In case of combustible gases, make sure that thebundles are connected to the ground, before toconnect them to the gas manifold.* Different positions according to models
4.3 After use
Close all of shut-off valves and cylinder (or bundle)valves.
Open the purge valves, purge the installation andthe flexible hoses (or pigtails). The gauges shallindicate "0".
Close the purge valves again. Dismantle and store carefully the flexible hoses
or the pigtails. Store safely from dust and ofmoisture.
Screw the blind plugs on the "High Pressure" inletports.
-
OP 206 ML-ML1-CLSA1 08/2013 v.1.012
5. Maintenance
5.1 Troubleshooting
FAULT CAUSE REMEDYImpossible assembly of theconnections
Verify the compatibility with gases,inlet and outlet
Impossible assembly
Dammaged connection Change the connectionCross section passage limited bya valve.
Open the valve
Insufficient filled or empty cylinder Change the cylinderNot operating valve Change the cylinderUnder-dimensioned equipment Contact AIR LIQUIDE
Insufficient output of gas
Equipment in output notoperational
Change the equipment
Occasional over consumption Replace by an equipment with alower output
Leakage check out the gas tightness
The gas source in reserve drainswithout being used (Change overonly)
Leakage at the main valve of theregulator
Replace the main valve* or theregulator,
At the same pressure and outputentry, the outlet pressure is notthe same which side you areusing
Disturb regulators Adjust the regulators
Leakage at the flap of theregulator
Replace the regulatorGas comes out of the relief valve
defect relief valve Replace the relief valveToo low working pressure Close the cylinder valve.
Increase the temperature of theequipment above 0C
Frosting
The used gas is argon (Ar),carbon dioxide (CO2) or nitrousoxide (N2O)
Mount an heater at the inlet
The outlet pressure decreases Output flow too high
Respect the regulator flow. Limitthe flow by using a valve or acalibrated orifice.
Vibrations
Presence of a valve with rapidopening on the outlet pipe.
Limit the flow by using a valve or acalibrated orifice.
-
EN
OP 206 ML-ML1-CLSA1 08/2013 v.1.0 13
5.2 Maintenance
Even though the equipment is reliable, it mustbe checked periodically. Since this task requiressome precautions, it must be done exclusively by aqualified technician.
The periodicity of this verification dependsessentially on the usage of the equipment (intensive,moderate, occasional). It can be performed annuallyby AIR LIQUIDE under a maintenance contract(SERVIGAZ).The period will in no case exceed 5years.
Legend Periodically Once a yearEvery
3 years
We suggest the use of the following table toensure an optimum usage of your equipment
V : to verify
C : to change Leakage
Operation
condition of threads
Sealing of closure
Fastening
Appearance
Setting
Safety
Cleanliness
Labelling
Seal
Setting
Filter
Electrical continuity
Flexible hoses / Pigtails V V V V V V C V CSafety cable V V CRacks V VChain V V
Cylinder/Manifoldconnection
Fittings / Filters V V V CSupport plate V V V V VHP Valves V V VRegulators V V V V V VLP Valves V V VRelief valves V V C
Manifold
Pressure Gauges V V V
2nd Stage reducer V V V C V CMonitoring system V V V Others
Pipe network V V V V V V C V
In case of operating accident (insufficient output,leakage, opening of the relief valve or accidentaldamage) : Contact AIR LIQUIDE.
Use only original parts and do not modify theequipment,
Never dismantle any of the equipmentscomponents.
Defective reassembly may causebursting, malfunctioning and/or an
increasing output pressure, which isdangerous for your safety.
-
OP 206 ML-ML1-CLSA1 08/2013 v.1.014
5.3 Spare parts
ManifoldInlet
pressuregauge (5)
Outletpressuregauge (6)
Reliefvalve (7)
Regulator(8)
Shut-off/purge
valvesblock (9)
Designation Code
ML1 300-16-8 16004 152809
ML1 300-10-50 151821
18554
ML 200-200-30 15337 15969 15653
CLSA1 200-10-10 15209 16003 15481
CLSA1 200-10-50 15228
17076
CLSA1 200-20-50 15247
15970
18544
16188
Spare part seals (package of ten):
Designation Code
O-Ring EPDM R6 PC851 for inlet port 16x1,336 SI 17129
Flat seal PTFCE (Kel-F) 14,5x10x2 for outlet port G3/8 AL 17141
Flat seal Alu/ARCAP for gauge M10x1 (Kit of seals, Alu:8,5x5x1, ARCAP:8,5x5x0,3) 17084
Flat seal PA 6.6 for gauge G1/4 151862
Flat seal annealed copper for intet fitting 16x1,336 SI 137203
-
EN
OP 206 ML-ML1-CLSA1 08/2013 v.1.0 15
Other spare parts
Dsignation Code
Plug for orifice 16x1,336 SI in stainless steel 16597
Plug for orifice G 3/8 in stainless steel 16596
Plug for orifice M10x1 in stainless steel 16598
Fitting with non-flapping valve brass/EPDM + filter 16x1,336 SI M - M20x1,5 M 16413
Fitting with non-flapping valve brass/EPDM + filter 16x1,336 SI M - CF10MM 151804
Plastic cover for central 83401
Cylinder/Bundle Change Procedure Panel for CLSA/ML 152662
Multilingual stickers Change procedure for cylinders or bundles CLSA/ML 153663
Hazard panel Oxygen - Nitrous oxide 153687
Hazard panel Combustible Gases 155103
Hazard panel Inert Gases 153689
Choice of the calibrated orifice :
Nitrogen N2 Helium He Hydrogen H2Code Change over Orifice
mmCode
Orifice mm
Code Orifice mm
Code
15209 CLSA1 200-10-10 1,5 155748 0,9 155743 0,8 155742
15228 CLSA1 200-10-50 3,8 155761 2,3 155755 2,0 155752
15247 CLSA1 200-20-50 2,2 155754 1,3 155746 1,1 155745
-
OP 206 ML-ML1-CLSA1 08/2013 v.1.016
1. Drawings
1.1 Dimensions
ML - ML1
L: 135 mmH: 115 mmP: 112 mmWeight: 7-7,5 Kg
CLSA1
L: 530 mmH: 115 mmP: 112 mmWeight: 12,5 Kg
-
FR
OP 206 ML-ML1-CLSA1 08/2013 v.1.0 17
1.2 CLSA1
-
OP 206 ML-ML1-CLSA1 08/2013 v.1.018
1.3 ML-ML1
-
We are present in more than 80 countries.
Contact:AIR LIQUIDEEuropean Platform and ServicesTour Kupka C92039 Paris La Dfense Cedex, Francewww.airliquide.com
www.ai r l iqu ide.com
Air Liquide is the world leader in gases for industry, health and the environment, and is present in 80 countries serving over 2 million customers.Its Industrial Merchant Business Line plays a vital role in helping Air Liquide achieve its goals. We are a network of over 20,000 open-mindedpeople working at 500 facilities, each one committed to inventiveness in moving our customers businesses forward. This means always beingready to adapt, to understand, to recognise opportunities and to innovate, in order to drive long-term performance at every stage of your growth.
OP
206
ML-
ML1
-C
LSA
1 08
/201
3 v.
1.0
A
IR L
IQU
IDE
, G B
oula
y