Header lines
DN 10 / DN 15
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
English (GB) Installation and operating instructions
Caution
Note
English (GB)
Original installation and operating instructions.
CONTENTS
1. Safety instructions
1.1 Symbols used in this document
1.2 Safety advice for handling chlorine
1.2.1 Hazards of chlorine gas
1.2.2 Hazards of liquid chlorine
1.3 Qualification of the users
1.4 Responsibilities of the owner
1.5 Maintenance and service personnel
1.6 Protective equipment
1.6.1 Personal protective equipment
1.6.2 Obligations of the operating authority
1.6.3 Storage of the protective equipment
1.7 First aid in case of accidents
1.7.1 First aid after inhaling chlorine
1.7.2 First aid after chemical burn of skin
1.7.3 First aid after chemical burn of eyes
1.7.4 First aid after internal chemical burn
1.8 Handling chlorine containers
1.8.1 Steel cylinders
1.8.2 Chlorine drums
1.8.3 Basic rules
1.8.4 Valid regulations
1.9 Chlorine rooms
1.9.1 Regulations for chlorine rooms
1.9.2 Labelling of chlorine rooms
2. Product description
2.1 Correct usage
2.2 Inappropriate usage
2.3 Identification
2.3.1 Nameplate
2.4 Warranty
3. Technical data
3.1 Header line for chlorine gas cylinders
3.1.1 Connections
3.1.2 Weights
3.1.3 Materials
3.2 Header line for chlorine gas drums
3.2.1 Connections
3.2.2 Weights
3.3 Header line for ammonia and sulphur dioxide drums
3.3.1 Connections
3.3.2 Weights
3.4 Dimensions
3.4.1 Header line for 3 cylinders
3.4.2 Header line for 5 drums
3.5 Physical and chemical data of chlorine
4. Construction and function
4.1 Description of the device
4.2 Function
5. Startup
5.1 Installation
5.1.1 Assembling the header line
5.1.2 Tightening the connection valve
5.2 Checking the tightness
5.2.1 Checking the tightness of a large system
5.2.2 Checking the tightness of parts leading chlorine gas or
sulphur dioxide
5.2.3 Checking the tightness of parts leading ammonia
5.3 Start-up
6. Operation
6.1 Container exchange
7. Maintenance
7.1 Replacing the flexible lines
7.1.1 Flexible copper lines for chlorine
7.1.2 Flexible stainless-steel lines for ammonia and sulphur
dioxide
Page
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12
7.2 Retrofitting old header lines
7.2.1 Assembly with Loctite
7.2.2 Assembly with hemp
7.3 Maintenance of connection valve
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7.4 Maintenance of the shut-off valve
8. Spare parts
9. Fault finding
9.1 Leakage at the connection valve
9.2 Leakage at the shut-off valve
10. Decommissioning
10.1 Short-term decommissioning (up to 2 weeks)
10.2 Long-term decommissioning (more than 2 weeks)
11. Disposal
Warning
Prior to installation, read these installation and
operating instructions. Installation and operation
must comply with local regulations and accepted
codes of good practice.
1. Safety instructions
These installation and operating instructions contain important
information for the user of the product:
• Technical data
• Instructions for commissioning and use
• Safety instructions
If you require further information, or if problems occur that are not
described in detail in this manual, please contact Grundfos.
1.1 Symbols used in this document
This manual contains the following standardised safety
instructions about possible residual risks:
Warning
If these safety instructions are not observed,
it may result in personal injury.
If these safety instructions are not observed,
it may result in malfunction or damage to the
equipment.
Notes or instructions that make the job easier
and ensure safe operation.
1.2 Safety advice for handling chlorine
Country-specific local laws, regulations, and standards apply for
the handling of chlorine.
1.2.1 Hazards of chlorine gas
Warning
Toxic by inhalation.
Irritating to eyes, respiratory system and skin!
• Causes whooping cough, dyspnoea and lacrimation.
• Has a slight paralysing effect to the central nervous system.
• Concentrations of more than 10 ppm chlorine gas in the
respiratory air mean an acute danger to life.
• Inhaling air with a high concentration of chlorine gas for a long
time is lethal.
12
12
12
13
14
14
14
14
14
15
15
15
15
2
1.2.2 Hazards of liquid chlorine
• Causes burns of skin.
• Causes reddening and blistering of skin.
• Rules of conduct
• Change chlorine containers only with gas mask.
• Enter contaminated rooms only with protective suit and
compressed-air respirator.
• In case of flight wear gas mask, if possible. Observe wind
direction.
1.3 Qualification of the users
Based on his professional training and experience, the user must
have a good knowledge of the operation of chlorine gas dosing
systems. He must be so familiar with the relevant laws and
regulations governing safety in the workplace and accident
prevention, and with the recognised standards of good practice,
that he is able to judge the safe working condition of a chlorine
gas dosing system.
The user is responsible for operation and monitoring of the
product at the installation site.
The responsibilities of the user:
• Observe the safety data sheets from the chemicals supplier.
• Be trained by qualified Grundfos personnel in the operation of
the product
• Observe the relevant regulations governing safety in the
workplace and accident prevention
• Wear appropriate protective clothing in accordance with
national regulations for the prevention of accidents when
operating the system and handling chemicals.
1.4 Responsibilities of the owner
The operator of the product is responsible for the following:
• Ensure that this manual is kept clearly accessible in the
immediate vicinity of the system for the entire service life.
• Meet the installation requirements specified by the
manufacturer (environmental conditions, required water
connections and fittings, electrical connection, protective pipe
for dosing line if necessary, audible or optical warning device if
necessary).
• Ensure that water lines and armatures are regularly checked,
serviced and maintained.
• Obtain official approval for storing chemicals, if necessary.
• Train users in the operation of the system.
• Ensure that the regulations for the prevention of accidents are
observed in the installation site.
• Provide all users and service personnel with protective
clothing (e.g. face mask, gloves, protective apron) in
accordance with the national regulations.
1.5 Maintenance and service personnel
The product may only be maintained and serviced by personnel
authorised by Grundfos.
1.6 Protective equipment
1.6.1 Personal protective equipment
The operating authority of a chlorine gas dosing system has to
provide respiratory equipment (full-sight gas mask), personally
fitted, labelled by name, with an effective chlorine filter (B2P3)
and at least 1 spare filter per gas mask, for each operator.
The protective equipment must be stored easily accessible
outside the chlorine rooms.
• For systems with chlorine drums at least 2 protective suits with
compressed-air respirators must be available.
1.6.2 Obligations of the operating authority
• Introducing the operators to handling the protective
equipment.
• The operators must use the personal protective equipment
regularly, or carry out exercises with it at least every 6 months.
• The gas mask filters must be replaced regularly
– after the expiry of the date of durability
– at least 6 months after opening (note the opening date on
the filter)
– after contact with chlorine.
• Observe employing prohibition according to the local laws!
1.6.3 Storage of the protective equipment
• Outside the chlorine rooms
• Well visible
• Easily available at any time
• Protected from dust and moisture.
1.7 First aid in case of accidents
1.7.1 First aid after inhaling chlorine
1. Keep calm.
2. Remove injured persons from the dangerous area.
3. Helpers must pay attention to personal protection.
4. Remove contaminated clothes.
5. Calm down injured persons, and keep them warm with
blankets.
– Supply fresh air, use oxygen respirator, if possible.
– No mouth-to-mouth resuscitation!
6. Call medical aid or transport to hospital
– lying
– sitting in case of difficulty in breathing.
– State chlorine as the cause.
1.7.2 First aid after chemical burn of skin
1. Keep calm.
2. Remove contaminated clothes.
3. Rinse skin with plenty of water.
4. Bandage the wound aseptically.
5. Seek medical aid.
– State chlorine as the cause.
1.7.3 First aid after chemical burn of eyes
1. Keep calm.
– Rinse eyes with plenty of water while the patient is lying.
– Protect healthy eye, if necessary.
– Spread eyelids widely, let the eye move to all sides.
2. Seek ophthalmologist.
– State chlorine as the cause.
1.7.4 First aid after internal chemical burn
1. Keep calm.
2. Drink water in short sips.
– If possible, take medical charcoal.
3. Seek medical aid.
– State chlorine as the cause.
English (GB)
3
1.8 Handling chlorine containers
2
1
3
5
3
1
4
2
English (GB)
Chlorine is stored in grey steel cylinders or drums in lockable
chlorine rooms. Due to safety precautions, chlorine containers
are only filled up to 95 % of their capacity.
Kind of gas, weight, owner, producing date and date of the last
testing have to be noted clearly on the container.
Observe the following:
• Store chlorine containers fireproof.
• Protect chlorine containers from heat and sunlight.
• Chlorine containers should not be modified or repaired by the
user.
• Keep full and empty containers closed.
1.8.1 Steel cylinders
• Contents: 50 kg or 65 kg
• Extract chlorine gas from the upright standing cylinder via the
valve.
1.8.3 Basic rules
Warning
Handling of chlorine containers only by
experienced personnel.
Observe safety regulations for chlorine
containers.
• Treat containers carefully, do not throw!
• Protect containers from turning over or rolling away, e.g. with
chains or clips.
• Protect containers from direct sunlight and temperatures over
50 °C.
• Transport containers only with valve protection nut and
protective cap.
Warning
These rules apply for both full and empty
containers, as empty containers still contain
rests of chlorine and therefore are under
pressure.
1.8.4 Valid regulations
Warning
Local laws and regulations for handling,
transport and storage of chlorine must be
observed!
• Regulations for accident prevention with process instructions.
• Regulations concerning places of work
• Technical rules for pressurized gases
• Chlorine gas dosing systems for water treatment
• Chlorine for the treatment of water for the human use (EN 937)
1.9 Chlorine rooms
Chlorine rooms are rooms, where a chlorine gas dosing system
and/or chlorine containers are located. The chlorine in these
TM04 8943 1813
Fig. 1 Design of a cylinder
Pos. Description
1 Protective cap
2Valve
3 Holding clip for securing the cylinder
1.8.2 Chlorine drums
• Contents: 500 kg or 1000 kg
• Extraction of chlorine gas via the riser pipe valve.
• Extraction of liquid chlorine via the dip pipe valve.
Fig. 2 Design of a drum
Pos. Description
1 Riser pipe for chlorine gas extraction
2 Valve for chlorine gas extraction
3 Valve for liquid chlorine extraction
4 Dip pipe for liquid chlorine extraction
5Tyre
6 Mark for adjustment of drum
rooms is under pressure.
1.9.1 Regulations for chlorine rooms
According to the German regulations for accident prevention
"Chlorination of water", chlorine rooms have to meet the following
requirements:
• They should not have connections to other rooms, and must
be separated gas-tight and fire-resistant.
• They must be at ground level, dry and air-conditioned.
The recommended room temperature is 18-20 °C. It should be
neither lower than 0 °C nor higher than 50 °C.
• Overpressure lines of dosing equipment must not end in the
open air.
• Ventilation openings leading into the open air must be limited
to 2 x 20 cm
2
.
• Appropriate exhaust devices with downstream adsorption
systems must be installed.
• Chlorine gas must not get into lower-lying rooms, shafts, pits,
canals or aspirating holes of ventilation systems.
• Chlorine rooms must be equipped with a water sprinkling
system to precipitate the escaping chlorine gas.
– The sprinkling system must have a run-off with air trap.
TM04 8940 1813
– Operation must be possible manually from outside the
chlorine rooms.
• A chlorine gas warning system must be installed
– with optical and acoustical alarm device,
– with connection to the water sprinkling system,
– with a warning system that reactivates automatically after
switch-off (e.g. for container exchange).
4
• The floor of a chlorine room must be even, the exit not below
✓
✗
✗
✓
ground level and not higher than a possible loading ramp.
Fig. 3 Requirements of chlorine rooms
• Chlorine rooms must have a direct exit to the open air.
• Doors must be lockable, open outwards, and it must be
possible to open the doors without a key from inside the room.
• Chlorine rooms must not be dedicated for the permanent stay
of people.
• Eating, drinking, or storing food in chlorine rooms is prohibited
1.9.2 Labelling of chlorine rooms
In Germany, the following warning signs must be installed outside
the entrance of a chlorine room:
Fig. 4 Warning sign and supplementary sign "Chlorination
plant: Access only for instructed persons"
Inside a chlorine room, the mandatory sign "Use the gas mask"
and the "Instruction sheet for first aid in case of chlorine gas
intoxications" must be installed.
2. Product description
2.1 Correct usage
Header lines connect several chlorine gas cylinders or chlorine
gas drums with the components of a gas dosing system.
Header lines must be used exclusively for the applications
described in this manual and with the gas they are approved for.
The usage is limited to industry, water treatment and waste water
treatment.
2.2 Inappropriate usage
Operational safety is only guaranteed, if the product is used
correctly. All operating methods conflicting with correct usage are
not permitted, and lead to the expiry of all liability claims.
TM04 8941 1813
2.3 Identification
The header line can be identified by the connection type of the
T-piece (cemented or welded), and the material of the flexible line
(copper or stainless steel).
Identification of the header line
T-piece
Flexible
line
2.3.1 Nameplate
TM04 8939 1813TM06 1198 4114
The indications on the nameplate are:
• product number
• serial number
2.4 Warranty
A guarantee claim in accordance with our general terms of sale
and delivery is only valid if the following requirements are fulfilled:
• The product is used in accordance with the information within
this manual.
• The installation, startup, operation and maintenance is carried
out by authorised and qualified staff.
Warning
Unauthorised structural modifications to the
product may result in serious damage to
equipment and personal injury.
cemented header line for cylinders
welded header line for drums
copper header line for chlorine gas
stainless
steel
header line for ammonia or sulphur
dioxide gas
English (GB)
Fig. 5 Mandatory sign
5
3. Technical data
Caution
English (GB)
The values stated in the technical data must be
adhered to.
3.1 Header line for chlorine gas cylinders
The vacuum regulator is directly connected to the DN 15 header
line. Depending on the chosen header line, up to 8 cylinders can
be connected.
Line pressure max. 16 bar
Ambient temperature 0 °C to +40 °C
Capacity of gaseous chlorine max. 200 kg/h
Capacity of liquid chlorine max. 600 kg/h
3.1.1 Connections
Cylinder connection: 1", G 3/4, G 5/8, 1.03"-14, M 26x3, 1 1/4",
closed yoke (USA), 15/16-8 RH, G 1/2
Vacuum regulator connection: 1", G 3/4, M 26x3
3.1.2 Weights
Number of
cylinders
Weight [kg] 1 3.4 5.1 6.8 8.5 10.2 11.9 13.6
* without collector pipe (only connection valve and copper line)
3.1.3 Materials
Collector pipe
Flexible lines Copper, tin-plated
Valve body Brass, nickel-plated
Valve piston Hastelloy C
Gasket of pressure
connection and gasket of
copper pipe
Packing PTFE
O-rings FKM
1*2345678
Seamless drawn steel pipe,
painted, T-piece screwed in and
cemented
Aramid fibres with NBR
3.2 Header line for chlorine gas drums
DN 15 and DN 25 header lines collect gas or liquid from several
drums. Depending on the chosen header line, up to 8 drums can
be connected.
Line pressure max. 16 bar
Ambient temperature 0 °C to +40 °C
3.2.1 Connections
Drum connection: 1", G 3/4, G 1/2, G 5/8, M26x3, 1 1/4", 1.03"14, closed yoke (USA), 15/16-8 RH
Connection flange of outlet: DN 15 or DN 25
3.2.2 Weights
Materials
Collector pipe
Flexible lines Copper, tin-plated
Body of connection valve Brass, nickel-plated
Body of shut-off valve Grey cast iron, painted
Valve piston Hastelloy C
Connection gaskets Aramid fibres with NBR
Packing PTFE
O-rings FKM
Seamless drawn steel pipe,
painted, connections welded
3.3 Header line for ammonia and sulphur dioxide
drums
DN 15 and DN 25 header lines collect gas or liquid from several
drums. Depending on the chosen header line, up to 8 drums can
be connected.
Line pressure max. 16 bar
Ambient temperature 0 °C to +40 °C
3.3.1 Connections
Pressure connection: 1", G 3/4, G 5/8, W 21.8x1/14
Connection flange of outlet: DN 15 and DN 25
3.3.2 Weights
Number of drums
1* 1.4 1.4
211.5 17.5
3 14.3 21.5
4 18.5 28
522 32
6 24.5 35.5
729 42
832 45.5
* without collector pipe (only connection valve and copper line)
Materials
Collector pipe
Flexible lines
Body of connection valve
Body of shut-off valve Grey cast iron
Valve piston Hastelloy C
Connection gaskets Aramid fibres with NBR
Packing PTFE
O-rings EPDM
DN 15 DN 25
Seamless drawn steel pipe,
painted, connections welded
Stainless steel 1.4571
Weight [kg]
Number of drums
1* 1.3 1.3
211 17
313.8 21
418 27.5
521 31
623.5 34.5
728 41
831 44.5
* without collector pipe (only connection valve and copper line)
DN 15 DN 25
Weight [kg]
6
3.4 Dimensions
350
350
bar 16
0
l = 160 (DN 25, G 1”)
500 1000 500
1000 1000 500
500
3000
2000
l = 130 (DN 15, G 1/2”)
l
NH
3
*
2
SO
2
Cl
*
3.4.1 Header line for 3 cylinders
Fig. 6 Dimensions of header line for 3 cylinders
3.4.2 Header line for 5 drums
English (GB)
TM04 8637 4112
Fig. 7 Dimensions of header line for 5 drums
TM04 8608 4112
7
3.5 Physical and chemical data of chlorine
Temperature [°C]
0
4
8
12
16
20
-50
-30
-10
0
10
30
50 70
Pressure [bar]
10
30
50
70
90
2
6
14
0
10
Temperature [°C]
Solution [g/l]
Caution
bar16
0
7
4
3
1
2
6
5
English (GB)
Under normal conditions of pressure and temperature, chlorine is
a yellowish green gas with a pungent odour, which exists as Cl
molecule.
It is not flammable, but can promote the flammability of metals,
hydrocarbons, etc.
Atomic weight 35.453 u
Molecular weight 70.906 u
Boiling point -34 °C
Melting point -101 °C
Degree of purity according to EN 937 99.5 %
TLV (Threshold Limit Value) 0.5 ml/m
3
(1.5 mg/m3)
4. Construction and function
2
4.1 Description of the device
A header line connects several gas containers with the
components of the gas dosing system. A header line consists of
connection valves (5) for connection of the container to the
flexible line (3), a T-piece (2) and a rigid collector pipe (1).
The connection valves (5) can be closed in case of container
exchange.
The installation location must be protected from
direct sunlight and rainfall.
The admissible temperatures must be observed
and excessive temperature variations must be
avoided.
Fig. 8 Vapour pressure curve of chlorine
Fig. 9 Solubility of chlorine gas in water
TM04 0691 0908TM04 0692 0908
Fig. 10 Assembled header line
Pos. Description
1 Collector pipe
2T-piece
3 Flexible line
4 Lock nut
5 Connection valve
6 Connection for the gas container
7 Vacuum regulator
4.2 Function
When several gas containers are connected to a header line, the
gas extraction quantity in the gas dosing system increases by the
number of connected containers.
The maximum extraction quantity must not exceed 1 % of the
container filling quantity. Otherwise the gas will liquefy during
extraction.
If a gas container is empty, it can be exchanged. Before container
exchange, the connection valve must be closed by fastening the
lock nut (4) as far as it will go.
TM04 8612 4112
8
5. Startup
9
bar16
0
4
7
1
2
8
3
6
10
5
11
12
13
43.5
4
32
1
Header lines are a part of a gas dosing system. Before start-up,
the tightness of header lines must be checked together with the
corresponding gas dosing system.
5.1 Installation
5.1.1 Assembling the header line
After unpacking, assemble the header line strainless as soon as
possible, in order to avoid penetration of humidity. Observe that
no foreign matter gets into the header line.
1. Fix the collector pipe (1) to the wall with the enclosed pipe
clips.
2. Connect the vacuum regulator (7) to the collector pipe (1).
3. Place the cylinders or drums correctly and fix them.
Fix cylinders with support clips.
4. Screw the flexible lines (3) to the T pieces (2) of the collector
pipe.
5. Insert the gaskets into the connection valves (4). Screw the
connection valves to the cylinder valves.
6. Screw the flexible lines (3) to the connection valves (4).
English (GB)
Fig. 11 Gas dosing system with header line
Pos. Description
1 Collector pipe
2T-piece
3 Flexible line
4 Connection valve
5 Lock nut
6 Pressure gauge
7 Vacuum regulator
8 Adsorption cylinder
9 Gas sensor
10 Dosing regulator
11 Empty indication display unit
12 Gas warning device
13 Water apparatus with injector
TM04 8611 4112
5.1.2 Tightening the connection valve
Before start-up of the header line, the connection valves must be
tightened.
1. Unscrew the lock nut (1) of the connection valve
2. Tighten the gland (3) with a torque of 15 Nm.
3. The installation dimension from the spindle end to the valve
body must be 43.5 mm.
TM04 8610 4112
Fig. 12 Connection valve: installation dimension of the spindle
Pos. Description
1 Lock nut
2 Spindle
3Gland
4 Valve body
4. Screw in the lock nut (1) as far as it will go.
The connection valve is closed.
9
5.2 Checking the tightness
Note
NH
3
NH
3
!
NH
3
English (GB)
After an exchange of containers or flexible copper lines, the
tightness of the header line must be checked.
1. The tightness of large systems can be checked with a
nitrogen rinsing device.
2. The tightness of parts leading chlorine gas or sulphur dioxide
can be checked with ammonia. The tightness of parts leading
ammonia can be checked with sulphur dioxide.
5.2.1 Checking the tightness of a large system
This is a rough tightness check, which can only
be done with a nitrogen rinsing device.
In addition, the fine checking has to be done
independently.
Checking the tightness with nitrogen
1. Close all chlorine container valves.
2. Open container connection valves and all shut-off valves up to
the chlorine gas dosing system.
3. Open the connection valve of the nitrogen cylinder.
4. Slowly open the valve of the nitrogen cylinder, until the lines
have a pressure of about 10 bar (read at the pressure gauge
of the vacuum regulator).
Warning
Maximum nitrogen pressure 16 bar.
Danger of damages and leakages when being
exceeded.
5. Apply soap water to all components under pressure.
– If bubbles form and/or pressure drops at the pressure
gauge, the pressure lines are leaky.
6. Depressurise the system.
7. Eliminate the leakage.
8. Repeat the tightness check.
9. If no bubbles form, and the pressure at the pressure gauge
does not drop significantly within one hour, the pressure lines
are tight.
5.2.2 Checking the tightness of parts leading chlorine gas or
sulphur dioxide
Even very small leakages become evident with ammonia vapour,
which reacts with chlorine gas forming white mist.
Warning
Ammonia is very toxic for water organisms!
Liquid ammonia must not come in contact with
lines or parts of the system, because it is very
corrosive.
Remove drops immediately with a dry cloth.
Checking the tightness with ammonia
1. Open the container valve and connection valve until the
pressure has reached 3-4 bar, and immediately close it again.
2. If the pressure does not remain constant, there is a leakage.
3. Open the ammonia water bottle.
4. Gently swing the open bottle, until the ammonia vapour
comes out. Slowly move the open ammonia bottle along the
gas leading parts.
TM04 8654 4212TM04 8636 4212
5. If white mist forms, the header line is leaky.
6. Immediately close the container valves.
7. Depressurise the system: Continue operating the system, until
the measuring tube on the dosing system shows no more gas
flow.
8. Switch off the motive water pump.
9. Eliminate the leakage: For instance tighten the gland in the
connection valve, see 9.1 Leakage at the connection valve, or
tighten the connections of the copper line.
10. Repeat the tightness check.
11. If no white mist forms, the header line and pressure
connection are tight.
Fig. 14 Header line without leakage
12. Open all container valves.
13. Switch on the motive water pump and start the system.
See the Installation and Operating Instructions of the gas
dosing system.
Checking the tightness of the gas dosing system
The tightness of the entire gas dosing system has to be checked.
See the Installation and Operating Instructions of the gas dosing
system.
Leakages
Due to the heavy corrosiveness of humid chlorine gas, leakages
increase quickly. Therefore, even the smallest leakage must be
eliminated immediately.
Fig. 13 Handling of ammonia
Warning
Ammonia is irritating to eyes, respiratory system
and skin!
When checking the tightness with ammonia, wear
tight protective goggles, gloves and clothes.
10
TM04 8662 4312
TM04 8653 4212
5.2.3 Checking the tightness of parts leading ammonia
12-13 mm
1
2
3
Even very small leakages become evident with burning sulphur,
which reacts with ammonia forming white mist.
1. Open the container valve and connection valve until the
pressure has reached 3-4 bar, and immediately close it again.
2. If the pressure does not remain constant, there is a leakage.
3. Slowly move a burning sulphur strip along the gas leading
parts.
4. If white mist forms, the header line is leaky.
5. Immediately close the container valves.
6. Depressurise the system: Continue operating the system, until
the measuring tube on the dosing system shows no more gas
flow.
7. Switch off the motive water pump.
8. Eliminate the leakage: For instance tighten the gland in the
connection valve, see 9.1 Leakage at the connection valve, or
tighten the connections of the copper line.
9. Repeat the tightness check.
10. If no white mist forms, the header line and pressure
connection are tight.
11. Open all container valves.
12. Switch on the motive water pump and start the system.
See the Installation and Operating Instructions of the gas
dosing system.
Checking the tightness of the gas dosing system
The tightness of the entire gas dosing system has to be checked.
See the Installation and Operating Instructions of the gas dosing
system.
6. Operation
The header line doesn't have to be operated.
If no faults occur, for uninterrupted gas extraction after start-up
exchange empty gas containers by full ones in good time.
6.1 Container exchange
1. Shut off the respective connection valve by tightening the lock
nut (1) as far as it will go, in order to avoid gas escape from
the header line.
2. Close the cylinder valve or drum valve.
3. Exchange the empty container by a full one.
4. Connect the full container to the connection valve.
5. Open the cylinder valve or drum valve.
6. Open the connection valve by loosening the lock nut (1) until
at least 3 convolutions (12 to 13 mm) become visible between
the lock nut and the valve body.
7. Check the tightness of the header line, see section
5.2 Checking the tightness.
Fig. 15 Connection valve
English (GB)
TM04 8609 4112
5.3 Start-up
Warning
Before starting the header line, have its good
condition checked by an expert, see
1.3 Qualification of the users.
Check the tightness only if the entire system is
ready for start-up.
Danger of chlorine gas leakage!
Start-up of the header line has to be done together with the gas
dosing system. See the Installation and Operating Instructions of
the gas dosing system.
Pos. Description
1 Lock nut
2Gland
3 Valve body
11
7. Maintenance
Note
1
1
2
3
4
3
A
B
English (GB)
Intervals for cleaning and maintenance
• Check the connection valves at least once a year.
• When exchanging containers, but at least once a year:
• Replace the flexible copper lines every two years.
7.1 Replacing the flexible lines
The flexible copper lines have to be replaced every two years.
7.1.1 Flexible copper lines for chlorine
Material Length [m] Product No
Copper
7.1.2 Flexible stainless-steel lines for ammonia and sulphur
Material Length [m] Product No
Stainless steel
1. Depressurise the system.
2. Replace the old flexible lines by new ones.
– Clean the sealing surfaces and holes of the connection
valves
– Replace the gaskets of the connection valves
Warning
Maintenance has to be carried out only by
authorised and qualified personnel.
Before starting cleaning and maintenance work,
switch off the entire system.
The system must be pressureless!
Danger of gas escape!
Put on the required protective equipment.
Warning
Make sure that the system cannot be started
accidentally while working at it.
Warning
Before re-starting, check the tightness.
Danger of gas escape!
1 96688686
2 96690366
dioxide
1 96688690
2 96688691
– Close the container valves while the system is still running.
– Continue operating the system, until the measuring tube on
the dosing system shows no more gas flow.
– Switch off the motive water pump. See the Installation and
Operating Instructions of the gas dosing system.
7.2 Retrofitting old header lines
Old header lines have flanged connection screwings. If your
system is equipped with old header lines, these have to be
retrofitted and the old connection screwings have to be replaced
by new soldered connection screwings.
The connection screwings can be tightened with Loctite or hemp.
Mounting the connection screwings with Loctite
leads to better stability.
TM04 8656 4112
Fig. 16 A: Flanged connection screwing (old)
B: Soldered connection screwing (new)
Pos. Description
1 Flanged connection screwing
2 Copper line, flanged
3 Soldered connection screwing
4 Copper line, soldered
7.2.1 Assembly with Loctite
Required equipment: Loctite 273, screw tap G 1/4, brush
Warning
Observe safety instructions when handling
adhesives!
1. Warm up the joint.
2. Remove the old connection screwing (1).
3. Remove all grease from the joint.
4. Remove adhesive residues from the internal thread with
screw tap G 1/4.
5. Apply Loctite to the thread of the connection screwing (3).
The thread must be fully wetted.
6. Screw in the connection screwing.
7. Let the joint harden for 24 hours.
7.2.2 Assembly with hemp
Required equipment: Hemp, screw tap G 1/4, brush
1. Warm up the joint.
2. Remove the old connection screwing (1).
3. Remove all grease from the joint.
4. Remove adhesive residues from the internal thread with
screw tap G 1/4.
5. Seal the connection screwing properly with hemp and screw
in.
12
7.3 Maintenance of connection valve
Caution
1
2
3
4
6
7
8
9
10
5
11
12
13
14
15
5
16
17
When exchanging containers, but at least once a year, the
gaskets of the connection valves must be replaced.
Maintenance kit for connection valves (gaskets)
Set Valve size Product No
1 1/4" 95702615
5 gaskets for
connection
valves
Required equipment: Hot water (approx. 40 °C) and a soft
brush.
1. Depressurise the system.
2. Dismantle the connection valve.
3. Unscrew the union nuts (16 and 17).
4. Remove the gaskets (10 and 13).
5. Clean and dry the sealing surfaces and holes.
6. Insert new gaskets (10 and 13)
7. Slightly grease the gaskets. No grease may get into the gasleading parts.
8. Connect the flexible line and the gas container.
G 1/2 (copper line) 95717254
1", G 3/4 96681161
1.03" - 14, yoke, closed 95707704
Yoke, open 98026856
G 5/8, W 21.80x1/14 95707417
Danger of corrosion when assembling moist
parts!
Assembly drawing
English (GB)
TM04 8606 4112
Fig. 17 Connection valve
Pos. Description
1 Lock nut
2 Spindle
3Gland
4 Valve body
5Packing
6Gland
7Packing
8Packing
9 Connection screwing (gas container)
10 Gasket
11 Sliding disk
12 Connection screwing (copper line)
13 Gasket
14 O-ring
15 Support disk
16 Union nut for connection of gas container
17 Union nut for connection of copper line
13
7.4 Maintenance of the shut-off valve
Caution
A
F
H
L
DN
2
1
3a
4
2
5
3
43.5
4
32
1
English (GB)
Every two years, but at least when leakages occur, the gaskets
and packings of the shut-off valve must be replaced.
Set
2 external flat gaskets, 4 internal
packings
Shut-off
valve
DN 15 96688716
DN 25 96688717
Required equipment: Hot water (approx. 40 °C) and a soft
brush.
1. Open the shut-off valve completely.
2. Depressurise the system.
3. Unscrew the nuts at the upper part of body (1).
4. Remove the upper part of body with piston (5).
5. Take the packings (3a) and lantern (3) out of the valve body.
6. Clean the valve body and all other parts. Replace damaged or
worn parts.
Danger of corrosion when assembling moist
parts!
7. Dry all parts well.
8. Insert lantern and new packings.
9. Place upper part of body with piston.
10. Screw on the nuts slightly by hand.
11. Close the shut-off valve.
12. Tighten the nuts with an open-end wrench.
Product No
8. Spare parts
Flexible copper lines for Cl
Material Length [m] Product No
Copper
Flexible stainless-steel lines for NH3 und SO
Material Length [m] Product No
Stainless steel
Connection valves
Set Valve size Product No
1 1/4" 95702615
G 1/2 (copper line) 95717254
5 gaskets for
connection
valves
1", G 3/4 96681161
1.03" - 14, yoke, closed 95707704
Yoke, open 98026856
G 5/8, W 21.80x1/14 95707417
Shut-off valves
Set
2 external flat gaskets, 4 internal
packings
2
1 96688686
2 96690366
2
1 96688690
2 96688691
Shut-off
valve
Product No
DN 15 96688716
DN 25 96688717
9. Fault finding
Possible faults at the header line:
• Leakages at the connecting parts between copper line and
connection valve of the gas container.
• Leakages at the connecting part between copper line and
steel line.
9.1 Leakage at the connection valve
TM04 8607 4112
Fig. 18 Shut-off valve
Pos. Description
1 Upper part of body
2Flat gasket
3 Lantern
3a Packing
4 Pressure disc
5Piston
DN
[mm]F[mm]L[mm]H[mm]A[mm]
15 95 130 105 100 2.5 96706445
Weight
[kg]
Product
number
25 115 150 120 120 4.15 96706446
Fig. 19 Connection valve
Pos. Description
1 Lock nut
2 Spindle
3Gland
4 Valve body
1. Unscrew lock nut (1).
2. Tighten the gland (3) with a torque of 15 Nm.
3. Retighten lock nut.
4. If the leakage still exists, install a new connection valve.
9.2 Leakage at the shut-off valve
See 7.4 Maintenance of the shut-off valve.
TM04 8610 4112
14
10. Decommissioning
Note
Caution
Warning
Decommissioning must be carried out by
authorised and qualified personnel.
Before dismantling, the entire system must be
switched off.
The system must be pressureless.
Danger of gas escape!
Put on the required protective equipment.
If possible flush the system with nitrogen.
10.1 Short-term decommissioning (up to 2 weeks)
1. Close the connecting valves of all drums or cylinders.
2. Start the system and stop it when the variable area flowmeter
indicates no more flow.
3. Close the adjusting valve at the gas dosing unit.
4. Stop the motive water pump or close the solenoid valve.
10.2 Long-term decommissioning (more than 2 weeks)
1. Close the connecting valves of all drums or cylinders.
2. Start the system and stop it when the variable area flowmeter
indicates no more flow.
3. Close the adjusting valve at the gas dosing unit.
4. Stop the motive water pump or close the solenoid valve.
5. Close the shut-off valves of the motive water pump.
6. Close the shut-off valves upstream and downstream of the
injector.
7. Close the shut-off valve of the injection unit.
8. Remove and dismantle the header line.
9. Use warm water to clean the parts that have been in contact
with chlorine.
10. Dry all parts completely.
Seal up the connections and valves to make sure,
that no moisture can ingress!
11. Store all components of the header line.
English (GB)
11. Disposal
This product or parts of it must be disposed of in an
environmentally sound way. Use appropriate waste collection
services. If this is not possible, contact the nearest Grundfos
company or service workshop.
Subject to alterations.
15
161718
Argentina
Bombas GRUNDFOS de Argentina S.A.
Ruta Panamericana km. 37.500 Centro
Industrial Garin
1619 - Garin Pcia. de B.A.
Phone: +54-3327 414 444
Telefax: +54-3327 411 111
Australia
GRUNDFOS Pumps Pty. Ltd.
P.O. Box 2040
Regency Park
South Australia 5942
Phone: +61-8-8461-4611
Telefax: +61-8-8340 0155
Austria
GRUNDFOS Pumpen Vertrieb Ges.m.b.H.
Grundfosstraße 2
A-5082 Grödig/Salzburg
Tel.: +43-6246-883-0
Telefax: +43-6246-883-30
Belgium
N.V. GRUNDFOS Bellux S.A.
Boomsesteenweg 81-83
B-2630 Aartselaar
Tél.: +32-3-870 7300
Télécopie: +32-3-870 7301
Belarus
Представительство ГРУНДФОС в
Минске
220125, Минск
ул. Шафарнянская, 11, оф. 56
Тел.: +7 (375 17) 286 39 72, 286 39 73
Факс: +7 (375 17) 286 39 71
E-mail: minsk@grundfos.com
Bosnia/Herzegovina
GRUNDFOS Sarajevo
Trg Heroja 16,
BiH-71000 Sarajevo
Phone: +387 33 713 290
Telefax: +387 33 659 079
e-mail: grundfos@bih.net.ba
Brazil
BOMBAS GRUNDFOS DO BRASIL
Av. Humberto de Alencar Castelo Branco,
630
CEP 09850 - 300
São Bernardo do Campo - SP
Phone: +55-11 4393 5533
Telefax: +55-11 4343 5015
Bulgaria
Grundfos Bulgaria EOOD
Slatina District
Iztochna Tangenta street no. 100
BG - 1592 Sofia
Tel. +359 2 49 22 200
Fax. +359 2 49 22 201
email: bulgaria@grundfos.bg
Canada
GRUNDFOS Canada Inc.
2941 Brighton Road
Oakville, Ontario
L6H 6C9
Phone: +1-905 829 9533
Telefax: +1-905 829 9512
China
Grundfos Alldos
Dosing & Disinfection
ALLDOS (Shanghai) Water Technology
Co. Ltd.
West Unit, 1 Floor, No. 2 Building (T 4-2)
278 Jinhu Road, Jin Qiao Export Processing Zone
Pudong New Area
Shanghai, 201206
Phone: +86 21 5055 1012
Telefax: +86 21 5032 0596
E-mail: grundfosalldos-C N@grundfos.com
China
GRUNDFOS Pumps (Shanghai) Co. Ltd.
50/F Maxdo Centre No. 8 Xing Yi Rd.
Hongqiao Development Zone
Shanghai 200336
PRC
Phone: +86-21 6122 5222
Telefax: +86-21 6122 5333
Croatia
GRUNDFOS CROATIA d.o.o.
Cebini 37, Buzin
HR-10010 Zagreb
Phone: +385 1 6595 400
Telefax: +385 1 6595 499
www.hr.grundfos.com
Czech Republic
GRUNDFOS s.r.o.
Čapkovského 21
779 00 Olomouc
Phone: +420-585-716 111
Telefax: +420-585-716 299
Denmark
GRUNDFOS DK A/S
Martin Bachs Vej 3
DK-8850 Bjerringbro
Tlf.: +45-87 50 50 50
Telefax: +45-87 50 51 51
E-mail: info_GDK@grundfos.com
www.grundfos.com/DK
Estonia
GRUNDFOS Pumps Eesti OÜ
Peterburi tee 92G
11415 Tallinn
Tel: + 372 606 1690
Fax: + 372 606 1691
Finland
OY GRUNDFOS Pumput AB
Mestarintie 11
FIN-01730 Vantaa
Phone: +358-(0)207 889 900
Telefax: +358-(0)207 889 550
France
Pompes GRUNDFOS Distribution S.A.
Parc d’Activités de Chesnes
57, rue de Malacombe
F-38290 St. Quentin Fallavier (Lyon)
Tél.: +33-4 74 82 15 15
Télécopie: +33-4 74 94 10 51
Germany
GRUNDFOS Water Treatment GmbH
Reetzstraße 85
D-76327 Pfinztal (Söllingen)
Tel.: +49 7240 61-0
Telefax: +49 7240 61-177
E-mail: gwt@grundfos.com
Germany
GRUNDFOS GMBH
Schlüterstr. 33
40699 Erkrath
Tel.: +49-(0) 211 929 69-0
Telefax: +49-(0) 211 929 69-3799
E-mail: infoservice@grundfos.de
Service in Deutschland:
E-mail: kundendienst@grundfos.de
Greece
GRUNDFOS Hellas A.E.B.E.
20th km. Athinon-Markopoulou Av.
P.O. Box 7 1
GR-19002 Peania
Phone: +0030-210-66 83 400
Telefax: +0030-210-66 46 273
Hong Kong
GRUNDFOS Pumps (Hong Kong) Ltd.
Unit 1, Ground floor
Siu Wai Industrial Centre
29-33 Wing Hong Street &
68 King Lam Street, Cheung Sha Wan
Kowloon
Phone: +852-27861706 / 27861741
Telefax: +852-27858664
Hungary
GRUNDFOS Hungária Kft.
Park u. 8
H-2045 Törökbálint,
Phone: +36-23 511 110
Telefax: +36-23 511 111
India
GRUNDFOS Pumps India Private Limited
118 Old Mahabalipuram Road
Thoraipakkam
Chennai 600 097
Phone: +91-44 4596 6800
Indonesia
PT GRUNDFOS Pompa
Jl. Rawa Sumur III, Blok III / CC-1
Kawasan Industri, Pulogadung
Jakarta 13930
Phone: +62-21-460 6909
Telefax: +62-21-460 6910 / 460 6901
Ireland
GRUNDFOS (Ireland) Ltd.
Unit A, Merrywell Business Park
Ballymount Road Lower
Dublin 12
Phone: +353-1-4089 800
Telefax: +353-1-4089 830
Italy
GRUNDFOS Pompe Italia S.r.l.
Via Gran Sasso 4
I-20060 Truccazzano (Milano)
Tel.: +39-02-95838112
Telefax: +39-02-95309290 / 95838461
Japan
GRUNDFOS Pumps K.K.
Gotanda Metalion Bldg. 5F,
5-21-15, Higashi-gotanda
Shiagawa-ku, Tokyo,
141-0022 Japan
Phone: +81 35 448 1391
Telefax: +81 35 448 9619
Korea
GRUNDFOS Pumps Korea Ltd.
6th Floor, Aju Building 679-5
Yeoksam-dong, Kangnam-ku, 135-916
Seoul, Korea
Phone: +82-2-5317 600
Telefax: +82-2-5633 725
Latvia
SIA GRUNDFOS Pumps Latvia
Deglava biznesa centrs
Augusta Deglava ielā 60, LV-1035, Rīga,
Tālr.: + 371 714 9640, 7 149 641
Fakss: + 371 914 9646
Lithuania
GRUNDFOS Pumps UAB
Smolensko g. 6
LT-03201 Vilnius
Tel: + 370 52 395 430
Fax: + 370 52 395 431
Malaysia
GRUNDFOS Pumps Sdn. Bhd.
7 Jalan Peguam U1/25
Glenmarie Industrial Park
40150 Shah Alam
Selangor
Phone: +60-3-5569 2922
Telefax: +60-3-5569 2866
Mexico
Bombas GRUNDFOS de México S.A. de
C.V.
Boulevard TLC No. 15
Parque Industrial Stiva Aeropuerto
Apodaca, N.L. 66600
Phone: +52-81-8144 4000
Telefax: +52-81-8144 4010
Netherlands
GRUNDFOS Netherlands
Velu we zoom 35
1326 AE Almere
Postbus 22015
1302 CA ALMERE
Tel.: +31-88-478 6336
Telefax: +31-88-478 6332
E-mail: info_gnl@grundfos.com
New Zealand
GRUNDFOS Pumps NZ Ltd.
17 Beatrice Tinsley Crescent
North Harbour Industrial Estate
Albany, Auckland
Phone: +64-9-415 3240
Telefax: +64-9-415 3250
Norway
GRUNDFOS Pumper A/S
Strømsveien 344
Postboks 235, Leirdal
N-1011 Oslo
Tlf.: +47-22 90 47 00
Telefax: +47-22 32 21 50
Poland
GRUNDFOS Pompy Sp. z o.o.
ul. Klonowa 23
Baranowo k. Poznania
PL-62-081 Przeźmierowo
Tel: (+48-61) 650 13 00
Fax: (+48-61) 650 13 50
Portugal
Bombas GRUNDFOS Portugal, S.A.
Rua Calvet de Magalhães, 241
Apartado 1079
P-2770-153 Paço de Arcos
Tel.: +351-21-440 76 00
Telefax: +351-21-440 76 90
Romania
GRUNDFOS Pompe România SRL
Bd. Biruintei, nr 103
Pantelimon county Ilfov
Phone: +40 21 200 4100
Telefax: +40 21 200 4101
E-mail: romania@grundfos.ro
Russia
ООО Грундф ос
Россия, 109544 Москва, ул. Школьная
39
Тел. (+7) 495 737 30 00, 564 88 00
Факс (+7) 495 737 75 36, 564 88 11
E-mail grundfos.moscow@grundfos.com
Serbia
GRUNDFOS Predstavništvo Beograd
Dr. Milutina Ivkovića 2a/29
YU-11000 Beograd
Phone: +381 11 26 47 877 / 11 26 47 496
Telefax: +381 11 26 48 340
Singapore
GRUNDFOS (Singapore) Pte. Ltd.
25 Jalan Tukang
Singapore 619264
Phone: +65-6681 9688
Telefax: +65-6681 9689
Slovakia
GRUNDFOS s.r.o.
Prievozská 4D
821 09 BRATISLAVA
Phona: +421 2 5020 1426
sk.grundfos.com
Slovenia
GRUNDFOS d.o.o.
Šlandrova 8b, SI-1231 Ljubljana-Črnuče
Phone: +386 1 568 0610
Telefax: +386 1 568 0619
E-mail: slovenia@grundfos.si
South Africa
Grundfos (PTY) Ltd.
Corner Mountjoy and George Allen Roads
Wilbart Ext. 2
Bedfordview 2008
Phone: (+27) 11 579 4800
Fax: (+27) 11 455 6066
E-mail: lsmart@grundfos.com
Spain
Bombas GRUNDFOS España S.A.
Camino de la Fuentecilla, s/n
E-28110 Algete (Madrid)
Tel.: +34-91-848 8800
Telefax: +34-91-628 0465
Sweden
GRUNDFOS AB
(Box 333) Lunnagårdsgatan 6
431 24 Mölndal
Tel.: +46 31 332 23 000
Telefax: +46 31-331 94 60
Switzerland
GRUNDFOS ALLDOS International AG
Schönmattstraße 4
CH-4153 Reinach
Tel.: +41-61-717 5555
Telefax: +41-61-717 5500
E-mail: grundfosalldos-CH@grundfos.com
Switzerland
GRUNDFOS Pumpen AG
Bruggacherstrasse 10
CH-8117 Fällanden/ZH
Tel.: +41-44-806 8111
Telefax: +41-44-806 8115
Taiwan
GRUNDFOS Pumps (Taiwan) Ltd.
7 Floor, 219 Min-Chuan Road
Taichung, Taiwan, R.O.C.
Phone: +886-4-2305 0868
Telefax: +886-4-2305 0878
Thailand
GRUNDFOS (Thailand) Ltd.
92 Chaloem Phrakiat Rama 9 Road,
Dokmai, Pravej, Bangkok 10250
Phone: +66-2-725 8999
Telefax: +66-2-725 8998
Turkey
GRUNDFOS POMPA San. ve Tic. Ltd. Sti.
Gebze Organize Sanayi Bölgesi
Ihsan dede Caddesi,
2. yol 200. Sokak No. 204
41490 Gebze/ Kocaeli
Phone: +90 - 262-679 7979
Telefax: +90 - 262-679 7905
E-mail: satis@grundfos.com
Ukraine
Бізнес Центр Європа
Столичне шосе, 103
м. Київ, 03131, Україна
Телефон: (+38 044) 237 04 00
Факс.: (+38 044) 237 04 01
E-mail: ukraine@grundfos.com
United Arab Emirates
GRUNDFOS Gulf Distribution
P.O. Box 16768
Jebel Ali Free Zone
Dubai
Phone: +971-4- 8815 166
Telefax: +971-4-8815 136
United Kingdom
GRUNDFOS Pumps Ltd.
Grovebury Road
Leighton Buzzard/Beds. LU7 4TL
Phone: +44-1525-850000
Telefax: +44-1525-850011
U.S.A.
GRUNDFOS Pumps Corporation
17100 West 118th Terrace
Olathe, Kansas 66061
Phone: +1-913-227-3400
Telefax: +1-913-227-3500
Uzbekistan
Grundfos Tashkent, Uzbekistan The Representative Office of Grundfos Kazakhstan in
Uzbekistan
38a, Oybek street, Tashkent
Телефон: (+998) 71 150 3290 / 71 150
3291
Факс: (+998) 71 150 3292
Addresses revised 21.05.2014
Grundfos companies
98401778 1114
ECM: 1105371
www.grundfos.com
The name Grundfos, the Grundfos logo, and be think innovate are registered trademarks owned by Grundfos Holding A/S or Grundfos A/S, Denmark. All rights reserved worldwide. © Copyright Grundfos Holding A/S
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