User manual
Pressure control panel
BM55-2U
07/2020
Страница 1: ...User manual Pressure control panel BM55 2U 07 2020 ...
Страница 2: ...allation work 16 5 2 1 Installation 16 5 2 2 Connecting the incoming and outgoing lines 18 5 3 Checking the system 18 5 3 1 Pressure test with purge gas 18 5 3 2 Helium leak test 18 6 Commissioning 20 6 1 Preparations for commissioning 20 6 2 Procedure for commissioning 20 6 2 1 Connecting the process gas source 20 6 2 2 Flushing in the process gas to the process 21 7 Operation 22 7 1 General info...
Страница 3: ...leaning 27 9 Repair 28 9 1 General information on repair work 28 9 2 Troubleshooting and fault rectification 29 10 Decommissioning and recommissioning 30 10 1 Decommissioning 30 10 2 Recommissioning 30 11 Dismantling and disposal 31 11 1 General information on dismantling 31 11 2 Returns 32 11 3 Disposal 32 ...
Страница 4: ... the facility WARNING Incorrect operation Incorrect operation of the system e g due to instruction errors can lead to personal injury or damage to the system a Access to the user manual by the operating and maintenance personnel must be absolutely ensured at all times b A copy of the system documentation including the user manual must therefore be kept either on the system or in a suitable and acc...
Страница 5: ...ical components that are suitable for use in an explosion haz ard zone are marked on the label according to EU Directive 2014 34 EU To be able to use the Pressure control panels as intended all persons working with it must comply with the specifications of the relevant user manual The area in which hazards can occur when used as intended is the area around the Pressure control panels The danger zo...
Страница 6: ...te gas line or a burst disc line must not end in areas where the escaping process gas poses a hazard to persons or the environment Further emissions in the form of vibrations radiation vapours dusts and waste water do not oc cur in the regular operation of the product 2 5 Standards and laws The design and construction of the pressure control panel is subject to the following standards and directiv...
Страница 7: ... 7 TRBS 1111 2152 3145 3146 Technische Regeln Betriebssicherheit Tech nical Regulations on Operational Safety DGUV Regulation 1 German Trade Association Principles of Pre vention DGUV Rule 113 001 German Trade Association Rules on Explosion Protection EIGA documents ...
Страница 8: ... to the system which result in a change in function b It is not possible to outline and cover in this manual all hazards arising from the environment or unforeseeable operating conditions of the system In the Safety Instructions chapter Users are informed regarding hazards residual risks and measures for risk reduction The presentation of the safety instructions and the symbols is explained Basic ...
Страница 9: ...ing and naked flame are strictly prohibited DANGER Intended use Operation of the product with gases other than those specified or outside the limits may result in dangerous reactions in the system Incorrect use poses considerable risks to operating person nel and the environment a Only use the product for gases for which it was designed b Only use the product in the specified limit values for pres...
Страница 10: ...able risk of injury a Never work on the product unattended or unannounced b Observe the site safety rules and permission procedure WARNING Maintenance Incorrect maintenance or maintenance work performed at the incorrect time can result in dam age to the system or injury to persons a To avoid static charges do not clean the product using dry cloths Use damp cotton cloths b The maintenance intervals...
Страница 11: ...ndard with an integrated relief valve to protect the armatures except for variants with outlet pressures 100 bar The user must ensure there is a suitable safety device installed downstream if not already included with the equipment as standard NOTICE The pressure relief valve or the burst disc are used to blow out gas that must be conveyed away via a non permitted pressure rise They do not functio...
Страница 12: ...s Safety data sheets on the process gas used Personal protective equipment In addition operators must have the requisite physical and mental skills to operate and maintain the equipment Persons who do not meet this requirement e g visitors must not remain alone in the overall system Operating personnel must use appropriate personal protective equipment for the activities to be performed and the as...
Страница 13: ...gnation Short name Connection 1 Process gas source valve 2 Cylinder connection incl plug Cylinder connection see label 3 High pressure process gas shut off valve HPI 4 Pre pressure gauge PG P1 5 High pressure waste gas valve HPV 6 Pressure regulator PR 7 Outlet pressure gauge PG P2 8 Process line isolation on low pressure side PLI 9 Waste gas connection NPT female 10 Process gas connection NPT fem...
Страница 14: ...ntrol panels are two sided pressure control panels with a switching mechan ism 2U The switching mechanism switches automatically from the side that is currently in op eration to the reserve side when the gas supply situation requires it The lever position of the switching mechanism indicates which side is the operational side and which the reserve side You select which side of the pressure control...
Страница 15: ...ional side and at the same time reduces the outlet pres sure of what has been the operational side up to now As a result it becomes the reserve side In the case of two stage switching panels the fall in the outlet pressure as a result of the switchover is barely noticeable The outlet pressure is kept largely constant by means of the second regulating stage All single stage automatic switching pane...
Страница 16: ...stems It is essential to observe the legal regulations and trade association regulations and the information in the safety data sheets Familiarise yourself with the necessary work steps see Installation work 16 and prepare the necessary tools See also 2 Functional description 14 5 2 Installation work 5 2 1 Installation The Pressure control panel can be mounted into a gas cylinder cabinet or on the...
Страница 17: ...l at approx imately 2 3 of the cylinder height and in centred posi tion beneath the process gas valves Step 7 Where toxic or combustible gases are used it must be ensured that purge and venting gases are routed off safely For example the corresponding lines can be connec ted to the waste gas valve of the pressure control panel and the relief valve of the pressure regulator via compression fittings...
Страница 18: ...ves PGI and HPI to build up pressure in the system 3 Slowly open the pressure regulator and build up pressure 4 Wait until the pressure has been built up and close the PGI valve 5 Check whether the displays on PG P1 and PG P2 are identical If both pressure gauges show the same pressure release the pressure on the pressure regulator If the values do not match check the pressure regulator setting an...
Страница 19: ...55 2U_0720 19 4 Close valve PGI 5 Disassemble the leak test device and connect the exhaust gas line to valve HPV 6 Relieve the pressure regulator 7 Close all valves The system should now be filled with inert gas approx 1 bar overpressure up to the consumer ...
Страница 20: ...ssembly has been correctly carried out and a leak test has been performed all valves are closed the red marking is visible in the handwheel window the pressure regulator has been depressurised if possible the purge gas supply only standard for SP4 and SP6 is in operation the on site exhaust gas system is functional at all times and is in operation all shut off armatures are checked for loose conne...
Страница 21: ...pen shut off valve on the process Ensure that the process gas can be discharged safely via the process The pressure control panel is now in a condition ready for operation Once it is put into operation both sides of the panel must always be connected Before repla cing a cylinder always turn the switching lever with the In operation display to the side from which gas is currently being drawn The ar...
Страница 22: ...owing steps must be carried out 1 Close all valves 2 Open valve HPV to reduce the pressure 3 Close valve HPV 7 2 3 Putting the pressure control panel into a safe condition In the event of interruptions in operation for more than 5 days or pending maintenance or servi cing the pressure control panel must be put into a safe condition First carry out the steps In terruptions to operation for more tha...
Страница 23: ...zontally the two pressure regulators are set to the same outlet pressure 2 The gas cylinder pressure on the preselected side falls below the outlet pressure of the re serve side the reserve side takes over the job of supplying process gas to the connected consumers without interruption With single stage switching panels the outlet pressure falls markedly when there is an automatic switch from the ...
Страница 24: ...ressure with purge gas process gas 9 Wait until the pressure has been built up and close the process gas source valve again 10 Open valve HPV to build up the pressure and then close it again Repeat steps 8 to 10 depending on the gas type at least 10 times 11 Open the gas source valve to fill the gas connection with process gas 12 Close the process gas source valve 13 Open valve HPI In the case of ...
Страница 25: ...uding the user manual must therefore be kept either on the system or in a suitable and accessible location WARNING Working on the product If an accident occurs when working on the product there is a considerable risk of injury a Never work on the product unattended or unannounced b Observe the site safety rules and permission procedure WARNING Maintenance Incorrect maintenance or maintenance work ...
Страница 26: ...by competent spe cialist companies and persons Maintenance work should be documented by the operator The documentation should indicate who carried out which work and when proof of maintenance It is only permitted to use original spare parts or equivalent spare parts as well as suitable tools The recommended maintenance and test intervals are to be observed Also observe the manu facturer s document...
Страница 27: ...duce the pressure level In this case gas must be removed so that the reduced pressure can be read off 4 After adjusting the pressure level re tighten the threaded pin item 2 screw the switching lever back on and position it to preselect the removal side 8 4 Regular maintenance work and cleaning For components in which the tests reveal wear or even malfunctions repairs or component re placement mus...
Страница 28: ...ther on the system or in a suitable and accessible location WARNING Working on the product If an accident occurs when working on the product there is a considerable risk of injury a Never work on the product unattended or unannounced b Observe the site safety rules and permission procedure CAUTION Injury or damage in the event of incorrect assembly or disassembly Special steps are required for ass...
Страница 29: ...es in the pres sure regulator Pressure regulator faulty Replace pressure regulator Pressure regulator frozen Flow rate too high Reduce flow rate or use gas preheater if possible System pressure cannot be set to the desired value Pressure regulator faulty Replace pressure regulator System pressure outside the intended system pressure Only operate the system at the intended range Flow insufficient o...
Страница 30: ...ciple decommissioning must be carried out in In principle decommissioning must be car ried out in the following order 1 Interrupt gas supply see Gas supply interruption 22 2 Disconnect the process gas source from the pressure control panel 3 Seal all open screw connections tightly e g plug on process gas port 4 Flushing through to the process see Flushing through to the process 5 Close all valves ...
Страница 31: ...p propriately skilled specialist companies and persons b The product is not permitted to be re used following disassembly All components must be disposed correctly NOTICE Lighting Incorrect switching actions or confusion can occur due to inadequate lighting a Ensure sufficient lighting in accordance with the statutory regulations Before dismantling and disposal of the pressure control panel it mus...
Страница 32: ...ww spectron de sites default files 2020 08 Declaration 20of 20decontamination pdf has been duly completed 11 3 Disposal Dismantling and disposal must be carried out in accordance with the official and legal require ments at the site of the system The operator must produce a risk assessment and work instruc tions before dismantling A piece of equipment may only be disposed of when the decontamina t...
Страница 33: ...Spectron Gas Control Systems GmbH Fritz Klatte Str 8 D 65933 Frankfurt Tel 49 0 69 38016 0 Fax 49 0 69 38016 200 info spectron de www spectron de ...
