Welker CSVC Installation, Operation And Maintenance Manual

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INSTALLATION, OPERATION, ANDMAINTENANCEMANUAL

WELKER®CYLINDERSTEAM&VACUUMCLEANER

MODEL

CSVC

DRAWING NUMBERS

AD881CA AD881CB

MANUALNUMBER

IOM-128

REVISION

Rev. B, 3/16/2016

Page 2

TABLEOF CONTENTS

SAFETY 3

1. PRODUCT INFORMATION 4

1.1 Introduction 4

1.2 Product Description 4

1.3 Safety Warning 4

1.4 Important Information 4

1.5 Specifications 5

1.6 Equipment Diagrams 6

2. INSTALLATION & OPERATION 11

2.1 Before You Begin 11

2.2 Installation 12

2.3 Operation 13

3. MAINTENANCE 19

3.1 Before You Begin 19

3.2 Maintenance 20

APPENDIX 21

A: Referenced or Attached Documents 21

Welker®, Welker Jet®, WelkerScope®, and OdorEyes® are Registered Trademarks owned by Welker, Inc.

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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SAFETY

IMPORTANTSAFETYINFORMATION

READALLINSTRUCTIONS

Notes emphasize information and/or provide additional information to assist the user.

Caution messages appear before procedures that could result in damage to equipment if not observed.

Warning messages appear before procedures that could result in personal injury if not observed.

This m anual is intended to be used as a basic installation and operation guide fo r the Welker® Cylinder Steam & Vacuum Cleaner, CSVC. For comprehensive instructions, please refer to the IOMManua ls for each individual component. A list of relevant component IOM Manuals is provided in Appendix A of this manual.

The information in this manual has been ca refully checked fo r accuracy and is intended to be used as a guide for the installation, operation, and maintenance of the Welker® equipment described in this manual. Correct installation and operation, however, are the responsibility of the end user. Welker reserves the right to make changes to this manual and all products in order to improve performanc e and reliability.

BEFOREYOUBEGIN

Read t hese instructions completely and carefully.

IMPORTANT - Savethese instructions for l ocal inspector's use.

IMPORTANT - Observeall governing codes and ordinances.

Note to Installer - Leavethese instructions with the end user.

Note to End User - Keep these instructions for future reference.

Installation of this CylinderSteam & Vacuum Cleaner is of a mechanical and electrical nature.

Properinstallation isthe responsibility of the installer. Product failure due to improperinstallation isnot covered underthe warranty.

If you received a damaged CylinderSteam & Vacuum Cleaner, please contact a Welker®representativeimmediately.

Phone: 281.491.2331 Address: 13839West Bellfort Street

Sugar Land, TX 77498

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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SECTION 1: PRODUCTINFORMATION

1.1 Introduction

We appreciate your business and your choice of Welker® products. The installation, operation, and maintenance liability for this equipment becomes that of the purchaser at the time of receipt. Reading the applicable Installation, Operation, and Maintenance (IOM) Manuals prior to installation and operation of this equipment is required for a full understanding of its application and performance prior to use.*

If you have any questions, please call Welker at 1-281-491-2331.

*The following proc edures have been written for use with standard Welker® pa rts and equipment. Assemblies that have been modified may have additional

requirements and specifications that are not listed in this manua l.

1.2 Product Description

The Welker® CSVC Cylinder Steam & Vacuum Cleaner is an effective cleaning system that utilizes heat from saturated and superheated steam to clean sample cylinders. Unlike hot water, steam evenly distributes heat to all surfaces. Moisture content of steam can be quickly and easily controlled by regulating the inlet pressure. The use of a steam separator will reduce moisture in saturated steam to less than one percent (1%). This system does not require any chemicals, saves on water usage, and facilitates the simultaneous cleaning of multiple cylinders. In short, the CSVC is an efficient, environmentally-friendly system for removing contaminants inside sample cylinders.

Welker may custom design the CSVC to suit the particular application and specifications of each customer.

1.3 Safety Warning

1. Steam may be dangerous if the proper precautions are not taken. Hot surfaces and release of live steam may cause

serious bodily injury. Follow safety and correct operating procedures when working with steam. When operating the

system, wear appropriate personal protective equipment (PPE), which could include gloves that cover the forearms.

2. Exposure to steam is hazardous. If not properly controlled, steam may cause serious bodily injury and/or property

damage.

1.4 Important Information

1. Cylinders must be completely emptied and drained before being connected to the CSVC.

2. A damaged steam hose may result in serious personal injury and/or property damage.

3. Never transport a cylinder with pressure exceeding DOTregulations as established in 49 C.F.R. In cases where the

cylinder may be exposed to varying temperatures, do not allow the cylinder to exceed its maximum allowable

operating pressure (MAOP).

4. Handle the cylinder with care. Protect the cylinder and valves during transport.

5. Once analysis is complete, the cylinder should be emptied safely and placed in a safe area.

Welker recommends cleaning and leak testing the cylinder after each use. Refer to the Installation, Operation, and

Maintenance (IOM) Manual for the Welker® SC Single Cavity Sample Cylinder for instructions.

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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1.5 Specifications

The specifications listed in this section are generalized for this equipment. Welker can modify the equipment according t o your

company's needs. Please note that the specifications may vary depending on the customizations of your

equipment.

Table 1: CSVC Specifications

Application

Maximum Allowable Operating Pressure

Steam Temperature Range

Connections

Cleaning of Sample Cylinders

90 psig (6.2 barg)

212 °F to 331 °F (100 °C to 166 °C)

½" FNPT (Standard) ¾" FNPT

Utility Requirement Water Supply: Up to 100 psig (6.8 barg)

Electrical Connection

AC 120 V AC 480 V, 3 Phase

300 cc (Standard)

Cylinder Volume

500 cc 1000 cc

Up to 6 Cylinders (Standard)

System Cylinder Capacity

Up to 12 Cylinders Up to 24 Cylinders

Blowdown Separator Insulated Tubing Steam Generator

Features

Steam Traps Swagelok® Quick-Connects Thermostatically Controlled Heater Vacuum Pump

FasMate® Quick-Connects

Options

Water Pump Welker® SG-3 Sight Glasses

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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1.6 Equipment Diagrams

Figure 1: CSVC Schematic

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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Figure 2: CSVC Connections Diagram (Shown With Optional FasMate® Quick-Connects)

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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Figure 3: CSVC Valve Diagram (Shown With Optional FasMate® Quick-Connects)

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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Figure 4: Steam Header Diagram (Shown With Optional FasMate® Quick-Connects)

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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Figure 5: Collection Header Diagram (Shown With Optional FasMate® Quick-Connects)

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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2.1 Before You Begin

SECTION 2: INSTALLATION & OPERATION

After unpacking the unit, check the equipment for compliance and any damage that may haveoccurred during shipment.

Immediately contact a Welker®representative if you received damagedequipment.

When sealing fittings with PTFE tape,refer to the propersealing instructions for the brand used.

The Cylinder Steam & Vacuum Cleaner will shipskid-mounted and "hard-tube" connected with manufacturer-supplied fittings

and hardware.However,the customerwill need to supply some tubing and fittings in orderto complete the installation of the

system.

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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2.2 Installation

1. Install the CSVC in the desired location.

Welker recommends the CSVCbe install ed in a location whereaccess to valves, cylinders, auxiliary equipment, and utilities is not

restricted and where relief valves can be safely vented to prevent potential injury.

Ensure that all valves are closed (Figure 3).

Set the relief valve on the steam header to the appropriate pressure (Figure 4). Refer to the Installation, Operation, and

Maintenance (IOM) Manual for the Welker® RV-1 Relief Valve for instructions on setting the relief.

Set the relief valve on the collection header (Figure 4). This relief should be set approximately 10 psig below the relief

valve on the steam header. Refer to the Installation, Operation, and Maintenance (IOM) Manual for the RV-1 for

instructions on setting the relief.

Setting the relief on the collection headerto a pressurelowerthan that of the reliefon the steam headerensures proper

functioning of the steam traps.

If desired, use ½" tubing to connect from the relief valves to an appropriate venting location (Figure 2).

Using ½" tubing, connect from system drain valve J to an appropriate container (Figure 2).

Using the provided ½" steam hose, connect from the steam generator to the steam inlet (Figure 2).

Using the provided ½" vacuum hose, connect from the vacuum pump to vacuum valve H (Figure 2).

Connect the customer-supplied water supply to the inlet on the steam generator (Figure 1).

There is a 10 psig pressure drop across the steam generator from the water inlet to the steam outlet.

10.

Connect the customer-supplied cold water supply to the inlet on the blowdown separator (Figure 1).

Thisunit requires a col d water connection. Welker recommends that the inlet to the blowdown separator be lower than the

sight glass of the steam generator to ensuresafe drainageduring blowdown.

The blowdown separator reducestemperatures and pressuresto safe l evels for dischargeto the drain or sewer.During

blowdown, the blowdown separator separatesliquid from vapor to prevent live steam discharge to city drains.

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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2.3 Operation

Steam Generator

To ensure safe operation of the steam generator, follow all manufacturerinstructions, including PPE recommendations and

safety instructions. Referto the Installation, Operation, and Maintenanc e (IOM) Manual for the steam generator for operating

instructions.

Ensure that all valves are closed (Figure 3).

Close the drain valve and steam outlet valve on the steam generator, and then turn on the customer water supply. Allow the water level to rise approximately halfway up the steam generator sight glass before operating the steam generator. This may take several minutes.

Connect an appropriate electrical supply to the steam generator. Refer to the Installation, Operation, andMaintenance (IOM) Manual for the steam generator for the manufacturer's wiring instructions.

Set the thermostat to the desired steam temperature, and then turn ON the boiler switch to start the steam generator (Table 2). Allow at least thirty (30) minutes for the steam to reach the desired temperature.

Table 2: Steam Temperature Settings

Water Inlet Pressure (psig) Steam Temperature (°F) Water Inlet Pressure (psig) Steam Temperature (°F)

0 1 2 3 4 5 6 7 8 9

212 30 216 35 219 40 222 45 224 50 227 55 230 60 232 65 235 70 237 75 240 80 250 85 259 90 267 –

274

281

287

292

298

303

307

312

316

320

324

328

331

–

Once the steam has reached the desired temperature, open the steam outlet valve on the steam generator.

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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Steam System

Failureto properly follow the manufacturer'srecommended proceduresfor the care, maintenance, and storageof the steam

hoses may result in serious bodily injury and/or property damage.

Only specially trained personnel should engage in operating or testing procedures that requireparticular skills and/or training.

Failureto comply may result in damage to the hoses,other property damage,and/or serious bodily injury.

10.

11.

12.

13.

14.

Ensure that the steam has reached the desired temperature.

Connect the inlet of the customer-supplied Welker® SC Single Cavity Sample Cylinder to the quick-connect on the steam header (Figure 4).

Connect the outlet of the customer-supplied SC to the flex hose with quick-connect on the collection header (Figure 5).

When connecting the outlet of the SC to t he coll ection header, Welkerrecommends positioning the flex hose so that access to

the collection headervalves is not restricted.

Open both valves on the SC.

Open system drain valve J on the collection header (Figure 3 or Figure 5). If the CSVC is equipped with a second collection header, open system drain valve J on the second collection header as necessary. Open steam outlet valve E for the installed SC (Figure 3 or Figure 4).

Open steam inlet valve D for the installed SC (Figure 3 or Figure 4).

As necessary, repeat steps 7-12 for any additional SCs.

Open steam header isolation valve C and collection header isolation valve I (Figure 3 or Figure 4).

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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Wet Cycle

15.

Manually turn the handle on cycle selector valve B so that the arrow on the handle points away from the steam separator (Figure 6). This will open the valve to the wet cycle.

Figure 6: Cycle Selector Valve B Orientation

16.

17.

18.

19.

Open collection header wet cycle inlet valve F for all installed SCs (Figure 3 or Figure 5).

Open steam inlet valve A to start the wet cycle (Figure 3). Saturated contaminants will drain to the container connected to the drain.

During the wet cycle, the steam generator generates saturated steam, which dissolves and flushes cont aminants from the

sample cylinders.

Allow the wet cycle to run for the appropriate amount of time.

The time requiredto completely clean the sample cylindersis dependent on the set temperature of the steam generator, the

water inlet pressure, the t ype of contaminant(s), and the number of sample cylinders.

Once the sample cylinders are free of visible contaminants or considered clean in accordance with the end user's specifications, close steam inlet valve A (Figure 3). This ends the wet cycle.

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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DryCycle

20.

21.

22.

23.

Manually turn the handle on cycle selector valve B so that the arrow on the handle points toward the steam separator (Figure 6). This will open the valve to the dry cycle.

Cycle selector valve B will be HOT.

Open collection header dry cycle inlet valve G and close collection header wet cycle inlet valve F for the installed SCs (Figure 3 or Figure 5). Open steam inlet valve A to start the dry cycle (Figure 3).

During the dry cycle, saturated steam is diverted to t he steam separator,which removes up to 99.8%of moisture.A steam trap

downstream of the sample cylindersdischarges condensate without allowing t he escapeof live steam. The steam trap and

continued input of heat allow steam to be contained, increasing the temperature at which the cylindersare maintained.The

cycle further heats the system to facilitate "baking" of any residueremaining in the sample cyl inders.

Allow the dry cycle to run until the SCs are clean.

The time requiredto completely clean the sample cylindersis dependent on the set temperature of the steam generator, the

water inlet pressure, the t ype of contaminant(s), and the number of sample cylinders.

24.

25.

26.

27.

Once the sample cylinders are considered clean in accordance with the end user's specifications, close steam inlet valve A (Figure 3). This ends the dry cycle. Open collection header wet cycle inlet valve F and close collection header dry cycle inlet valve G for the installed SCs (Figure 3 or Figure 5).

The sample cylinders must be drained prior to disconnecting t he quick-connects. Failure to drainthe sample cylinderspriorto

disconnecting t he quick-connects may result in damage to the equipment and/or injury to the operator.

Close steam header isolation valve C on each steam header used (Figure 3 or Figure 4).

If a vacuum will not be pulled on the SCs, continue to step 28. If a vacuum will be pulled on the SCs, proceed to step

35.

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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Vacuum System

No Vacuum

The SCs will be HOT.Allow t he SCs to cool prior to proceeding.

28.

29.

30.

31.

32.

33.

34.

Turn OFF the thermostat to the steam generator.

Close steam inlet valve D and close steam outlet valve E on the flex hose for all installed SCs (Figure 3 or Figure 5).

Close both valves on eachSC.

Disconnect the SCs from the CSVC. If applicable, install the quick-connects to the corresponding quick-connect rests (Figure 5).

The flex hoses will be HOT.

Open steam header isolation valve C and steam inlet valve A to relieve pressure in the steam header (Figure 3 or Figure

5). Once pressure has been relieved from the steam header, close steam inlet valve A (Figure 3 or Figure 4).

Welker recommends a daily blowdown of the steam generator. Refer to the Installation, Operation, and Maintenance (IOM) Manual for the steam generator for instructions.

Power must be OFFwhen the steam generator is drained.

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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Pulling a Vacuum

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

Turn OFF the thermostat on the steam generator.

Close steam outlet valve E on the flex hose for all installed SCs (Figure 3 or Figure 5).

Close collection header isolation valve I (Figure 3 or Figure 5).

Close the bottom valve on all installed SCs.

Turn ONthe vacuum pump.

Open vacuum valve H to pull a vacuum on the SCs (Figure 3). The steam header pressure gauge will display how much vacuum has been pulled on the SCs.

The time requiredto pul l the desired vacuum is dependent on the sample cylinder volume.

If desired, close the top valve on the SCs to maintain the vacuum on the SCs.

Close vacuum valve H (Figure 3 or Figure 4).

Turn OFF the vacuum pump.

Close steam inlet valve D (Figure 3 or Figure 5).

Disconnect the SCs from the CSVC. If applicable, install the quick-connects to the corresponding quick-connect rests (Figure 5).

The flex hoses will be HOT.

46.

47.

48.

49.

Open collection header isolation valve I (Figure 3 or Figure 4).

Open steam header isolation valve C and steam inlet valve A to relieve pressure in the steam header (Figure 3 or Figure

4). Once pressure has been relieved from the steam header, close steam inlet valve A (Figure 3 or Figure 4).

Welker recommends daily blowdown of the steam generator. Refer to the Installation, Operation, and Maintenance (IOM) Manual for the steam generator for instructions.

Power must be OFFwhen the steam generator is drained.

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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3.1 Before You Begin

SECTION 3: MAINTENANCE

Welker recommends that the unit have standard yearly maintenance under normal operating conditions.

In cases of severe service, dirty conditions, excessive usage, or other unique applications that may lead to excess wear

on the unit, a more frequent maintenance schedule may be appropriate.

2. Prior to maintenance or disassembly of the unit, it is advisable to have a repair kit available for repairs of the system in

case of unexpected wear or faulty seals.

New seals supplied in spareparts kits should be lightly lubricated before being installed to ease the installation of the seals and

reducethe risk of damage when positioning them on parts. Wipe excess lubricant from the seals, as it may adversely affect

analytical instrument results.

For sample-exposedseals, Welker recommends non-hydrocarbon-basedlubricants, such as Krytox®.

For non-sample-exposed seals, Welker recommends either non-hydrocarbon-based lubricants or silicone-based lubricants, such

as Molykote® 111.

After the seals are install ed, t he outer diameter of shafts and innerdiameter of cylinders may be lubricated to allow smooth

transition of parts.

3. All maintenance and cleaning of the unit should be performed on a smooth, clean surface.

4. Welker recommends having the following tools available for maintenance. Please note that the exact tools required may

vary by model.

a. 10" Adjustable Wrench (Qty. 2)

b. Flat Head Screwdriver

c. Seal Pick

d. Tubing Cutters

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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3.2 Maintenance

1. Routinely inspect the steam separator and steam traps for buildup, clogging, corrosion, and other damage. Refer to the

Installation, Operation, and Maintenance (IOM) Manual for the steam generator and for the steam traps for inspection

and maintenance instructions.

Propersteam separator and steam trap maintenance is essential to a steam system. Faulty steam traps not only waste energy,

but also can contribute t o pipe erosion due t o poor water quality and contaminants allowed to pass downstream. A poor

maintenance program will increase energy losses,decrease reliability, reduce steam quality, and may affect production

downtime.

The frequency of inspection should be determinedby application.

Maintain the steam generator. Refer to the Installation, Operation, and Maintenance (IOM) Manual for the steam

generator for maintenance instructions.

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

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APPENDIX A: REFERENCEDOR ATTACHEDDOCUMENTS

Welker®Installation, Operation, and Maintenance (IOM) Manuals suggested for use with this unit:

l IOM-033: Welker® RV-1, RV-2, RV-2CP, andRV-3 Relief Valves

l IOM-146: Welker® SCSingle Cavity Sample Cylinder

l IOM-172: Welker® SG-3 Sight Glass

Other Installation, Operation, and Maintenance (IOM) Manuals suggested for use with this unit:

l Apollo Valves 76-100 Series Stainless Steel BallValve withMounting Pad 1/4" - 1" (Welker® IOM-V141)

l Ashcroft® BISeries Bi-Metal Thermometers (Welker® IOM-V235)

l Ashcroft® Type 1008S Stainless Steel Case Gauge withStainless Steel System (Welker® IOM-V242)

l Chromalox® Type CMB Electric Steam Generator (Welker® IOM-V049)

l Chromalox® Steam Boilers (Welker® IOM-V052)

l Dekker Vacuum Technologies, Inc. DuraVane Lubricated Rotary Vane Pump forSaturated Air (Wet) Service RVL031W

(Welker® IOM-V246)

l FasTest Inc. FasMate® FN and FX Series Connectors (Welker® IOM-V245)

l McMaster-Carr Supply Company Extra-Flexible Nylon Tubing (Welker® IOM-V248)

l McMaster-Carr Supply Company Red Steam Hose (Welker® IOM-V247)

l McMaster-Carr Supply Company Super High-Pressure CheckValves (Welker® IOM-V251)

l Swagelok® Hose and Flexible Tubing (Welker® IOM-V176)

l Swagelok® One-Piece Instrumentation BallValves 40G Series and 40 Series (Welker® IOM-V085)

l Swagelok® Quick-Connects QC, QF, QM, and QTMSeries (Welker® IOM-V088)

l TLV® Balanced Pressure Thermostatic Steam Trap Model L21S/L32S (Welker® IOM-V249)

l TLV® Balanced Pressure Thermostatic Steam Trap Model LV21 (Welker® IOM-V051)

l TLV® Cyclone Separator Model DC7 (Welker® IOM-V050)

Welker® drawings and schematics suggested for use with this unit:

l Assembly Drawing: AD881CA (For up to 24 Sample Cylinders)

l Assembly Drawing: AD881CB (For up to 6 Sample Cylinders; With Optional FasMate® Quick-Connects and Welker® Sight

Glasses)

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331

Page 22

NOTES

____________________________________________________________________________________________________

13839 West Bellfort Street

Sugar Land, TX77498

Phone: 281.491.2331

welker.com

IOM-128 MODEL: CSVC REV: B 13839 West Bellfort St reet Sugar Land, TX 77498 welker. com Servic e Depart ment 281.491.2331