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

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

History of the Vacuum Regulator 1 Before 1960, when James Haskett, Chlorinators Inc. founder, designed and patented the cylinder-mounted all-vacuum-operated gas chlorinator, most chlorinators worked essentially the same way. Pressure from the tanks forced the gas through one line to an ``ejector“ where it was mixed with water. Water pressure then forced the chlorine/water solution through another line to the ``diffuser" that injected it into the water or wastewater being treated. If either line failed, gas would escape unimpeded. Failure of any of the many valves these systems employed would also cause gas to escape. Haskett's design -- mounting the chlorinator on the cylinder and using a vacuum to pull the gas to the ejector -- eliminated the gas pressure line. This design makes it very difficult for chlorine to escape. If any part of the equipment should fail, the flow of chlorine is immediately -- and automatically -- shut off. The problem of corrosion, which contributed to the difficulties of the pressure systems, is also significantly reduced by Mr. Haskett's design, and the pressure line, the most serious source of corrosion in gas chlorination equipment, is eliminated. www.OperatorSchool.com

History of the Vacuum Regulator 2 In Mr. Haskett‘s design, chlorine gas bubbles immediately enter the main stream, and are quickly dissolved. Further, beginning with the regulator, the gas is never under pressure, and it is mixed with water in the ejector under vacuum conditions. Another important point: laws prohibiting the use of chlorine gas could be costing you a lot of money, because chlorine gas is far more economical than either sodium or calcium hypochlorite. The tank contains 100% chlorine, which can never lose strength. Calcium hypochlorite has only 65-70% total weight chlorine available, and sodium hypochlorite only 10% or less by the time it is used. You need 1.5 pounds of calcium hypochlorite, or 1.2 gallons of sodium hypochlorite (average 10%) to equal a pound of liquid (gas) chlorine. Both calcium and sodium hypochlorite lose strength in storage. Although the initial cost of gas chlorination equipment may be higher than that required for calcium or sodium hypochlorite, the savings in material costs quickly make up the difference. www.OperatorSchool.com 3/25/2017

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Chlorine Gas Properties Amber Gas & Liquid Expands 460 Times Corrosive Non Flammable Poisonous @ 3PPM Heavy Gas Will Flow Chlorine Institute www.OperatorSchool.com 3/25/2017

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

Liquid to Gas Properties Coefficient of expansion Needs minimum headroom With a FULL TANK Liquid expansion at any temperature can cause the tank to fail or explode !! www.OperatorSchool.com 3/25/2017

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

Safety is ALWAYS FIRST !!! OBEY YOUR SAFETY RULES www.OperatorSchool.com 3/25/2017

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

Valves & Accessories www.OperatorSchool.com 3/25/2017

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

Un-Approved 150 lb Cylinder Capture www.OperatorSchool.com 3/25/2017

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

Ton Cylinder Valves Gas Valve (TOP) to the Right Liquid Valve (BOTTOM) to the Left www.OperatorSchool.com 3/25/2017

Ton Cylinder Eductor Tubes www.OperatorSchool.com 3/25/2017

Safety – IT IS YOUR JOB !! www.OperatorSchool.com 3/25/2017

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

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

Vacuum Regulator Diaphragm Flexured Plastic Material Separates Body Cavities Front has pin for Indication and Control Back has Vent Valve Can be Spring Loaded to Inlet Valve Uses Vacuum / Barometric Pressure to Open Inlet Valve www.OperatorSchool.com 3/25/2017

Standard Hydro Regulator www.OperatorSchool.com 3/25/2017

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

Inlet Valve Detail Vent Seat Vent Plug Valve Spring Assy Inlet Seat Inlet Plug Inlet Filter www.OperatorSchool.com 3/25/2017

NXT 3000 Parts Breakdown www.OperatorSchool.com 3/25/2017

Hydro 100 PPD Latching Regulator Vent Connection Switchover knob Rotameter Gas Connection www.OperatorSchool.com 3/25/2017

Quick Tour around the Hydro 100 PPD Regulator w/ Switchover Vent Connection Switchover knob Rotameter Gas Connection www.OperatorSchool.com 3/25/2017

NXT-3000 Latching Regulator Arm Latch Positions www.OperatorSchool.com 3/25/2017

NXT-3000 Latching Regulator Pivot Latch Lift Arm www.OperatorSchool.com 3/25/2017

NXT-3000 Latching Regulator Diaphragm Lift Eye www.OperatorSchool.com 3/25/2017

NXT-3000 Latching Regulator Diaphragm Lift Eye Pivot Plate www.OperatorSchool.com 3/25/2017

NXT-3000 Latching Regulator Latching Lift Arm www.OperatorSchool.com 3/25/2017

Auto-Switchover Valve www.OperatorSchool.com 3/25/2017

Quick Tour around the Hydro 100 PPD Regulator www.OperatorSchool.com 3/25/2017

Yoke & Inlet Valve Assembly Mounts the Regulator Inlet Valve Seals to Bottle Lead Washer Gasket www.OperatorSchool.com 3/25/2017

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

Flowmetering w/ Ecometrics @ 500 PPD Rotameter Metering Valve www.OperatorSchool.com 3/25/2017

ABS / PVC Body - Viton / Buna N Gaskets & O Rings Ejector Designs ABS / PVC Body - Viton / Buna N Gaskets & O Rings www.OperatorSchool.com 3/25/2017

Ejector Sizing Charts Proper Inlet & Outlet Pressures Proper Installation / Position www.OperatorSchool.com 3/25/2017

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

Typical Systems 1 -- Capital Controls www.OperatorSchool.com 3/25/2017

Typical Systems 2 -- Capital Controls www.OperatorSchool.com 3/25/2017

Typical Chlorine – Sulfur Dioxide Room www.OperatorSchool.com 3/25/2017

Liquid Cl2 Damage # 1 www.OperatorSchool.com 3/25/2017

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

Liquid Cl2 Damage # 3 www.OperatorSchool.com 3/25/2017

Liquid Cl2 Damage # 4 www.OperatorSchool.com 3/25/2017

Main Diaphragm “Melted” / Deformed Liquid Cl2 Damage # 5 Main Diaphragm “Melted” / Deformed www.OperatorSchool.com 3/25/2017

Liquid Cl2 Damage # 6 Also Caused By Wrong Lubes Water in System Condensation Intervals www.OperatorSchool.com 3/25/2017

Basic Regulator / Ejector Materials Cl2 Regulator Bodies – ABS Plastics Cl2 & SO2 Ejector ABS & PVC Plastics Tubing – Polyethylene & Teflon – Kynar O-Rings & Gaskets Viton & Buna N Inlet Block – Hastelloy Alumina-Bronze & Kynar Inlet Valve – Silver, Hastelloy & Stainless Steel Screws – Monel or Titanium www.OperatorSchool.com 3/25/2017

Cleaning Materials Dish Soap & Water Alcohol on MOST Plastics Lacquer Thinner on Teflon & Metals Soaking Lacquer Thinner “Flash” Wipe on Plastics *** Caution – This WILL Melt Plastics *** Vinegar or Muriatic Acid for Corrosion Removal 3-M Pads for Plastic Abrasion “00 – Fine” Steel Wool for Metal Abrasion www.OperatorSchool.com 3/25/2017

Maintain Equipment Properly # 1 Lubes www.OperatorSchool.com 3/25/2017

Maintain Equipment Properly # 2 Lubes www.OperatorSchool.com 3/25/2017

Maintain Equipment Properly # 3 Lubes www.OperatorSchool.com 3/25/2017

Maintain Equipment Properly # 4 Lubes www.OperatorSchool.com 3/25/2017

Maintain Equipment Properly # 5 Routinely www.OperatorSchool.com 3/25/2017

Liquid Traps www.OperatorSchool.com 3/25/2017

Liquid Trap Avoidance # 2 Custom Made Flex Connector 30 Inches www.OperatorSchool.com 3/25/2017

Modified Drip Leg Liquid Trap www.OperatorSchool.com 3/25/2017

Service Systems 1 www.OperatorSchool.com www.Start-UpService.com www.PVC-Creations.com www.OperatorSchool.com 3/25/2017

Service Systems 2 www.OperatorSchool.com www.Start-UpService.com www.PVC-Creations.com www.OperatorSchool.com 3/25/2017

Where to Get More Information Chlorine Institute A.W.W.A. Manuals Manufacturers Manuals www.OperatorSchool.com www.Start-UpService.com www.OperatorSchool.com 3/25/2017