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04/10/23www.OperatorSchool.com1
Vacuum Regulator Gas Feed Systems: Vacuum Regulator Gas Feed Systems: Theory and MaintenanceTheory and Maintenance
Thom DiGeronimowww.OperatorSchool.comThom @ OperatorSchool.Com
All Text, drawings and photographs Copyrighted 2005 by T DiGeronimo
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Seminar Highlights Seminar Highlights
Gases and PropertiesThe Vacuum Regulator / EjectorElement theory and functionDifferences by manufacturersWork and safety practicesPersonnel & Equipment Safety
History of the Vacuum Regulator 1History of the Vacuum Regulator 1
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Before 1960, when James Haskett, Chlorinators Inc. founder, designed and patented the cylinder-mounted all-vacuum-operated gas chlorinator, most chlorinators worked essentially the same way. Pressure from the tanks forced the gas through one line to an ``ejector“ where it was mixed with water. Water pressure then forced the chlorine/water solution through another line to the ``diffuser" that injected it into the water or wastewater being treated. If either line failed, gas would escape unimpeded. Failure of any of the many valves these systems employed would also cause gas to escape. Haskett's design -- mounting the chlorinator on the cylinder and using a vacuum to pull the gas to the ejector -- eliminated the gas pressure line.
This design makes it very difficult for chlorine to escape. If any part of the equipment should fail, the flow of chlorine is immediately -- and automatically -- shut off.
The problem of corrosion, which contributed to the difficulties of the pressure systems, is also significantly reduced by Mr. Haskett's design, and the pressure line, the most serious source of corrosion in gas chlorination equipment, is eliminated.
History of the Vacuum Regulator 2History of the Vacuum Regulator 2
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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.
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Chlorine Gas PropertiesChlorine Gas Properties
Amber Gas & Liquid Expands 460 Times Corrosive Non Flammable Poisonous @ 3PPM Heavy Gas Will Flow Chlorine Institute
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Sulphur Dioxide Gas PropertiesSulphur Dioxide Gas Properties
Gas & Liquid Expands many Times Corrosive Non Flammable Poisonous @ 3PPM Heavy Gas will Flow CGA makes rules
Overfilled Tanks can explode !!!
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Liquid to Gas PropertiesLiquid to Gas Properties Coefficient of expansion Needs minimum headroom
With a FULL TANK Liquid expansion at any temperature can
cause the tank to fail or explode !!
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Safety “Equipment” RequiredSafety “Equipment” Required
SCBA / Face Mask FilterSCBA / Face Mask FilterGas Leak DetectorGas Leak Detector
Leak Repair Kit A or BLeak Repair Kit A or B
Properly Trained Haz-Mat PeopleProperly Trained Haz-Mat People
A PLANA PLAN
Safety is ALWAYS FIRST !!!Safety is ALWAYS FIRST !!!
OBEY
YOUR
SAFETY
RULES
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Tank Valves & Fusible Plugs for 150’sTank Valves & Fusible Plugs for 150’s
w/ Fusible plug -- Flex Connector Yoke -- Manifold Valve
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Approved 150 lb Cylinder StorageApproved 150 lb Cylinder Storage
Straps & Blocks - NO CHAINS - Straps & RackValve Covers on When NOT Being Used
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Un-ApprovedUn-Approved 150 lb Cylinder Capture 150 lb Cylinder Capture
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Ton Cylinder Fusible Plugs & ValvesTon Cylinder Fusible Plugs & Valves3 3/4 “ Fusible Plugs on Both Ends of Cylinders
Valve Safety Cover Gas & Liquid Valves
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Ton Cylinder ValvesTon Cylinder Valves
Gas Valve (TOP) to the Right
Liquid Valve (BOTTOM) to the Left
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Proper Materials used ProperlyProper Materials used Properly
Body Plastics Metals / Hardware O rings / Gaskets Tubing Piping Valves Safety & Function
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Basic Vacuum Regulator BodyBasic Vacuum Regulator Body
Two Parts Separated by a Diaphragm Front is Vent Cavity Back is Vacuum Regulation Inlet Valve Mounting
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Vacuum Regulator DiaphragmVacuum Regulator Diaphragm
Flexured Plastic Material Separates Body Cavities Front has pin for Indication and Control Back has Vent Valve Can be Spring Loaded to Inlet Valve Uses Vacuum / Barometric Pressure to Open Inlet Valve
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Inlet Valve AssemblyInlet Valve Assembly Grooved Body Alumina Bronze ( Better: Hastalloy C) Guts Teflon, Monel ABS / PVC Gaskets / O Rings Viton or Buna N
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Inlet Valve DetailInlet Valve Detail
Vent Seat
Vent Plug
Valve Spring Assy
Inlet Seat
Inlet Plug
Inlet Filter
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Hydro 100 PPD Latching RegulatorHydro 100 PPD Latching Regulator
•Vent Connection•Switchover knob•Rotameter•Gas Connection
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Quick Tour around theQuick Tour around theHydro 100 PPD RegulatorHydro 100 PPD Regulatorw/ Switchoverw/ Switchover
•Vent Connection•Switchover knob•Rotameter•Gas Connection
NXT-3000NXT-3000LatchingLatchingRegulatorRegulator
ArmArmLatchLatchPositionsPositions
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NXT-3000NXT-3000LatchingLatchingRegulatorRegulator
PivotPivotLatchLatchLift ArmLift Arm
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NXT-3000NXT-3000LatchingLatchingRegulatorRegulator
DiaphragmDiaphragmLift EyeLift Eye
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NXT-3000NXT-3000LatchingLatchingRegulatorRegulator
DiaphragmDiaphragmLift EyeLift EyePivot PlatePivot Plate
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NXT-3000NXT-3000LatchingLatchingRegulatorRegulator
LatchingLatchingLift ArmLift Arm
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Quick Tour around theQuick Tour around theHydro 100 PPD RegulatorHydro 100 PPD Regulator
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Yoke & Inlet Valve AssemblyYoke & Inlet Valve Assembly
Mounts the Regulator Inlet Valve Seals to Bottle Lead Washer Gasket
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Hydro Ton Mount RegulatorHydro Ton Mount Regulator
•Inlet is the same•Yoke turned to right•Drip leg added•25 W Heater added
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Flowmetering w/ Ecometrics @ 500 PPDFlowmetering w/ Ecometrics @ 500 PPD
Rotameter Metering Valve
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Ejector DesignsEjector Designs
ABS / PVC Body - Viton / Buna N Gaskets & O Rings
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Ejector Sizing ChartsEjector Sizing ChartsProper Inlet & Outlet PressuresProper Installation / Position
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Ejector Application by DiffuserEjector Application by Diffuser
Must Not Back Up FlowMust “Diffuse” the Solution in Flowstream
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Typical Systems 1 -- Capital ControlsTypical Systems 1 -- Capital Controls
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Typical Systems 2 -- Capital ControlsTypical Systems 2 -- Capital Controls
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Typical Chlorine – Sulfur Dioxide RoomTypical Chlorine – Sulfur Dioxide Room
Liquid Cl2 Damage # 2Liquid Cl2 Damage # 2
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NXT3000
Back Body\
$350.00 …
Look on Boss
PRICELESS !!
Liquid Cl2 Damage # 6Liquid Cl2 Damage # 6
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Also Caused By
Wrong Lubes
Water in System
Condensation
Intervals
Basic Regulator / Ejector MaterialsBasic Regulator / Ejector Materials
Cl2 Regulator Bodies – ABS PlasticsCl2 & SO2 Ejector ABS & PVC PlasticsTubing – Polyethylene & Teflon – KynarO-Rings & Gaskets Viton & Buna NInlet Block – Hastelloy Alumina-Bronze & KynarInlet Valve – Silver, Hastelloy & Stainless SteelScrews – Monel or Titanium
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Cleaning MaterialsCleaning Materials
Dish Soap & WaterAlcohol on MOST PlasticsLacquer Thinner on Teflon & Metals SoakingLacquer Thinner “Flash” Wipe on Plastics
*** Caution – This WILL Melt Plastics ***
Vinegar or Muriatic Acid for Corrosion Removal3-M Pads for Plastic Abrasion“00 – Fine” Steel Wool for Metal Abrasion
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Maintain Equipment Properly # 1 LubesMaintain Equipment Properly # 1 Lubes
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Maintain Equipment Properly # 2 LubesMaintain Equipment Properly # 2 Lubes
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Maintain Equipment Properly # 3 LubesMaintain Equipment Properly # 3 Lubes
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Maintain Equipment Properly # 4 LubesMaintain Equipment Properly # 4 Lubes
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Maintain Equipment Properly # 3 Lubes
Maintain Equipment Properly # 5Maintain Equipment Properly # 5
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Maintain
Equipment
Properly &
Routinely
Liquid Trap Avoidance # 2Liquid Trap Avoidance # 2
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Custom
Made
Flex
Connector
30 Inches
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Service Systems 1Service Systems 1 www.OperatorSchool.com www.Start-UpService.com www.PVC-Creations.com
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Service Systems 2Service Systems 2 www.OperatorSchool.com www.Start-UpService.com www.PVC-Creations.com