Related Manuals for Beko CLEARPOINT V 80
Summary of Contents for Beko CLEARPOINT V 80
- Page 1 Installation and Operation Manual Activated Carbon Tower CLEARPOINT ® Model 80 – 800 READ MANUAL BEFORE INSTALLATION AND OPERATION...
-
Page 2: Table Of Contents
Contents 1. SAFETY AND SYSTEM PRECAUTIONS 1.1 Definition of the Safety Symbols 1.2 Operational Warnings 2. INSPECTION AND TRANSPORTATION 3. TECHNICAL SPECIFICATIONS AND GENERAL FUNCTION 3.1 Technical Data by Model Size 3.2 Correction Factors 3.3 General Function 3.4 Flow Diagram 4. INSTALLATION 4.1 Design and Use of the Activated Carbon Tower 4.2 Location and Installation 4.3 Optimal Installation Diagram 5. ACTIVATED CARBON TOWER OPERATION 5.1 Start-Up 5.1.1 Verification Prior to Start-up 5.1.2 Activated Carbon Fill Procedure 5.1.3 Start-up Procedures... - Page 3 6. MAINTENANCE AND SERVICE 6.1 Maintenance and Service Information 6.1.1 Routine Maintenance 6.1.2 Activated Carbon Replacement 6.2. Maintenance and Spare Parts 6.2.1 Required Maintenance Parts 7. TROUBLESHOOTING GUIDE 8. DISMANTLING OF THE ACTIVATED CARBON TOWER 9. GENERAL DESCRIPTION OF PARTS For technical product support please call +1 (800) 235-6797 and select Option 2 CLEARPOINT V Series Activated Carbon Tower ®...
-
Page 4: Safety And System Precautions
SAFETY AND SYSTEM PRECAUTIONS 1.1 Definition of the Safety Symbols Before attempting any General Warning: Electrical Hazard: Warning: Warning: Warning: service, please read the Risk of damage or Possibility of electro- Under pressure High temperature Non-breathable air manual injury cution Warning: Warning: Warning: Warning: Warning: Operations that can be Do not operate if parts All work to be per- Water cannot be used Machine level noise Personal pro- performed by qualified... -
Page 5: Inspection And Transportation
INSPECTION AND INSTALLATION 2.1 Incoming Inspection and Transportation All adsorbers are tested and inspected at the factory prior to shipping. Thoroughly inspect and verify the integrity of the packaging upon receipt and note any damage on the freight bill. Place the unit as close as possible to the installation point before unpacking the contents and inspect for concealed damage. Freight claims are to be filed with the carrier immediately and the manufacturer’s technical service department notified thereafter. To move the packaged unit, we suggest the use of a suitable crane or forklift. We do not recommend moving the unit by any hand operated or manual mechanism. Handle with care. Heavy blows could cause irreparable damage. Even when packaged, keep the machine protected from severe weather. The packaging materials are recyclable. Each material must be properly disposed in a manner complying with the rules and regulations of the local municipality government. TECHNICAL SPECIFICATIONS AND GENERAL FUNCTION 3.1 Technical Data by Model Size CLEARPOINT V... -
Page 6: Correction Factors
Unit ratings adhere to the following inlet conditions per ISO 7183, Table 2, Option A2: + Inlet Compressed Air Temperature 100 °F (38 °C) + Inlet Compressed Air Pressure 100 psig (7 bar) + Maximum Ambient Air Temperature 100 °F (38 °C) + Inlet Compressed Air Relative Humidity 100% (Saturated) SCFM is defined as the volume of free air in cubic feet per minute measured at 14.696 psia (1.013 bara) at 68 °F (20 °C) temperature with 0% relative humidity (0 WVP). Correction Factors Correction Factors 60 psig 70 psig 80 psig 90 psig 100 psig 110 psig 120 psig 130 psig 140 psig 150 psig correction 1.20 1.25 1.29 0.65 0.74 0.83 0.91... -
Page 7: General Function
General Function The CLEARPOINT® V activated carbon towers use a single pressure vessel, filled with an Adsorption material (1/8” activated carbon as standard) to remove oil aerosol and oil vapor from the compressed air system. As the compressed air flows across the activated carbon, oil aerosol and oil vapor adsorb onto the surface and pores thus removing it. During this process, there is no regeneration of the activated carbon. As a result, it will become saturated over time and must be replaced as it will no longer function to remove oil. To achieve maximum effectiveness of the activated carbon, pretreatment of the compressed air is required. Oil aerosols must not exist in high concentration above 0.01 mg/m and, the compressed air should be pre dried with a relative humidity not exceeding 30%. Other conditions that may affect the operating life of an activated carbon tower are: + Higher volume flow + Higher concentration of oil aerosols + Increased operating pressure + Increase relative humidity During operation, there is a possibility for activated carbon solid particles (as fine powder) to be released, that are particularly abrasive and can be extremely damaging to downstream components and users. For the above reasons, it is required that the compressed air system before and after the carbon tower, be equipped with the following: + 30% RH or better pre-dryer; achieved with either a refrigeration or desiccant dryer + 0.01 micron filtration grade coalescing pre-filter with differential pressure gauge and float drain (automatic drain optional) + 1.0 micron filtration grade particulate post-filter (differential gauge optional) and manual drain The purpose of the carbon tower is the separation of oil aerosol and oil vapor in compressed air. It is not intended to separate other contaminants that are present in compressed air. The compressed air output from this unit cannot be used for respiration purposes of any kind. -
Page 8: Flow Diagram
3.4 Flow Diagram Number Name Number Name 0.01µm Pre-filter with Float Drain Vessel Pressure Gauge Pressure Relief Valve 1.0 µm Post-Filter with Manual Drain INSTALLATION 4.1 Design and Use of the Activated Carbon Tower The CLEARPOINT V activated carbon tower has been designed, manufactured and tested to be used only to ® separate oil aerosol and oil vapor contained in compressed air; any other use is improper. The manufacturer is not responsible for any problems arising from the improper use of this machine. The end user, in any and all cases, is responsible for any resulting damages. Moreover, the correct use of this machine requires the verification of certain installation conditions, in particular: + Pressure, temperature, flow rate and chemical composition of the incoming compressed air + Ambient temperatures The carbon tower is supplied with the only operations left for the end user to: fill the tower with activated carbon and connect to the plant with the instructions given in this manual. CLEARPOINT V Series Activated Carbon Tower ® (Rev. D) -
Page 9: Location And Installation
Location and Installation Serious consideration should be given when selecting the installation site for the carbon tower, as an improper location could directly affect the proper operation of the carbon tower. This unit is not suitable to be used in explosive atmospheres, where risk of fire could exist, in the presence of gaseous or solid pollutants or in outdoor applications or areas exposed to the elements. Do not use water to extinguish fire on the unit or in the surrounding area. Machine level noise at the area of installation could be higher than 85 dBA. Install the unit in a dedicated area where people are not normally present. The installer and/or end user is responsible to install proper safety signs at the installation site. Technicians servicing the carbon tower in an area with excessive noise must wear hearing and eye protection. Each employee must select a proper personal protection device (PPD) hearing protector such as earmuffs, ear canal caps, or earplugs in order to prevent permanent hearing damage or loss. Minimum Installation Requirements: + Select a clean, dry room that is free of dust and protected from atmospheric disturbances. + The foundation must be smooth, horizontally level, able to bear the weight of the carbon tower and be vibration free + The location area must fall within the ambient conditions as listed in section 3 + Allow a clearance of at least 3ft on all sides of the carbon tower in order easily facilitate all maintenance needs + While recommended, the carbon tower is not required to be anchored to the supporting surface + An upstream dryer and filtration must be installed + The location of an air receiver tank will vary depending on compressor type and application Incorrect installation may void warranty. NOTE: All piping connections should be inspected prior to installation to ensure they have maintained their integrity during shipping and locating the unit. First, make the initial connections as follows: Coalescing Pre-filter Inlet piping including an isolation valve Outlet piping including an isolation valve Particulate post-filter CLEARPOINT V... - Page 10 Inlet air entering the carbon tower must be pretreated. Oil aerosols must not exist in high concentration above 0.01 mg/m and, the compressed air should be pre dried with a relative humidity not exceeding 30%. Not following this practice will lead to overloading the carbon tower, permanently reduce the capacity, and cause rapid deterioration of the activated carbon material. It is required that the compressed air system before and after the carbon tower, be equipped with the follow- ing: + 30% RH or better pre-dryer; achieved with either a refrigeration or desiccant dryer + 0.01 micron filtration grade coalescing pre-filter with differential pressure gauge and float drain (automatic drain optional) + 1.0 micron filtration grade particulate post-filter (differential gauge optional) and manual drain Activated carbon dust traveling downstream of the carbon tower may cause contamination and/or accelerat- ed wear to other components and equipment. Therefore, a particulate post-filter should be used to prevent carbon dust from traveling downstream. Activated carbon is considered a nuisance dust and proper precau- tions should be taken during handling (refer to applicable SDS sheet). IMPORTANT! Bypass piping is necessary. Only bubble tight valves should be used. Points of access should be provided upstream and downstream of the carbon tower for pressure and temperature monitoring prior to finalizing the installation. These access points can also serve as periodic monitoring of oil aerosol and oil vapor carryover, to determine whether the carbon tower is performing optimally. We recommend using METPOINT® instrumentation to ensure accurate measurements. All piping must be adequately supported and at least of equal size to the carbon tower connections. Before any attempt is made to operate the carbon tower, the operator must thoroughly read and understand this installation and operation manual. CLEARPOINT V Series Activated Carbon Tower ® (Rev. D)
-
Page 11: Optimal Installation Diagram
4.3 Optimal Installation Diagram Number Name Air Compressor After Cooler CLEARPOINT® Inline Water Separator CLEARPOINT® 5.0 micron (Grade G) Filtration Receiver Tank CLEARPOINT® 1.0 micron (Grade F) Filtration DRYPOINT® XCp Desiccant Dryer (Shown with CLEARPOINT® Pre and Post-Filtration CLEARPOINT® 0.01 micron (GradeF) Filtration Condensate Drainage Points for BEKOMAT®... -
Page 12: Activated Carbon Tower Operation
ACTIVATED CARBON TOWER OPERATION Start Up 5.1.1 Verification Prior to Start Up Verify that the operating parameters match with the acceptable ranges indicated on the data plate of the carbon tower (air pressure, air temperature, ambient temperature, etc.). This is not the same as the ASME UW plate on the vessels and may be lower than what is stamped on the ASME UW plate. Before delivery, each carbon tower completes a quality check for approval. Nevertheless, the unit could be damaged during transportation. Therefore, we suggest checking the integrity of the carbon tower upon arrival (see section 3) and observing the carbon tower during the first hours of operation. The start-up must be performed by qualified personnel only. It is mandatory that the qualified person in charge will verify safe operational conditions complying with the local safety and accident prevention requirements. The same qualified person will be responsible for the proper and safe operation of the carbon tower. Never operate the carbon tower if any component is missing or appears damaged. Service is to be performed by qualified personnel only. The end user is responsible to ensure that the carbon tower will never be operated with pressure that exceeds the maximum pressure rating of the unit. Operating the carbon tower at a pressure higher than the maximum rating could be The inlet air temperature and air flow rate entering the carbon tower must be within the limits indicated on the data plate. 5.1.2 Activated Carbon Fill Procedure The CLEARPOINT V activated carbon tower may be delivered without activated carbon filled in the vessel. ® This is done for the ease of transportation and the higher center of gravity resulting from the carbon tower after it is filled. Activated carbon filling should only be done by an experienced professional. Personal protection equipment (PPE) must be used when filling activated carbon into a carbon tower such as: dust mask, proper full cover eye protection, and protective clothing including gloves. 1. Make sure the carbon tower is properly placed in the installation location. The unit may be bolted down before filling. -
Page 13: Start-Up Procedures
5.1.3 Start-up Procedures During the first start-up or start-up after a long period of inactivity or following maintenance, the technician must comply with the instructions below. The start-up must be performed by qualified personnel only. The employee that operates the machine must wear hearing and eye protection before operating the adsorber. Each employee must select proper personal protection equipment and device(s) (PPE & PPD). Hearing protection such as earmuffs, ear canal caps, or earplugs is needed in order to prevent permanent hearing damage or loss. Start-up Sequence + Please read and understand the entire manual before operating the carbon tower + Verify that all the steps of in the previous chapters relating to installation have been observed + Verify that the connection to the compressed air system is correct + Remove any packaging and other material that might obstruct the area around the carbon tower Before bringing pressure to the activated carbon tower, your compressor should be running, your compressed air system pressurized, and the carbon tower bypassed and not yet pressurized. With the adsorber is bypassed and in isolation follow these steps. SLOWLY open the inlet isolation valve allowing compressed air into the carbon tower. It is critical that the carbon tower be pressurized slowly to prevent damage to the activated carbon bed. Keep the outlet isolation valve closed at this time. SLOWLY open the outlet isolation valve. All valves are now in their open positions and compressed air is flowing through the carbon tower and downstream. Close the carbon tower bypass valve. The bypass valve must be bubble tight to prevent any oil vapor from contaminating the dry air outlet from the adsorber. Check all piping for compressed air leaks. 5.2. ISOLATION AND SHUT DOWN PROCEDURES Users operating the machine must wear hearing and eye protection. Each employee must select proper personal protection device(s) (PPD). Hearing protection such as earmuffs, ear canal caps, or earplugs are required to prevent permanent hearing damage or loss. Isolation Open the bypass valve. -
Page 14: Maintenance And Service
To bring the carbon tower back in use, follow the start-up procedure in section 5.1: Start Up MAINTENANCE AND SERVICE 6.1 Maintenance and Service Information 6.1.1 Routine Maintenance The service must be carried out only by a qualified technician. Before any service is carried out, always verify that: + The unit is depressurized and ensure the unit is isolated from the compressed air system Users operating the machine must wear hearing and eye protection. Each employee must select proper personal protection device(s) (PPD). Hearing protection such as earmuffs, ear canal caps, or earplugs are required to prevent permanent hearing damage or loss. DAILY + Check the differential pressure of any installed pre and post filtration + Check that the tower pressure gauge reads full line pressure ANNUALLY + Replace the pre and post filter elements + Check the air quality for oil aerosol and oil vapor content. Replace the activated carbon material in the tower as necessary 6.1.2 Activated Carbon Replacement CAUTION: Activated carbon dust is considered a nuisance dust. Proper precautions should be taken prior to replacing the activated carbon material in the tower. Please refer to the Safety Data Sheet (SDS). Isolate and shut down the carbon tower (see sect. 5.2). Place a suitable container at the edge of the drain port on the bottom of the tower. Open the drain port on the bottom of the tower and catch the activated carbon in the container. Refill the tower with the recommended type, size, and quantity of activated carbon. Only use manufacturer supplied activated carbon, which is high quality, high capacity activat- ed carbon designed and sized for the carbon tower. Replace the drain port using thread sealant. -
Page 15: Maintenance And Spare Parts
MAINTENANCE AND SPARE PARTS We strongly recommend stocking the suggested spare parts to help enable you to promptly carry out any required maintenance and/or replace any parts that may fail without having to wait for the parts to be deliv- ered. If you need to replace any other parts, please contact your local distributor or BEKO Technologies, Corp. Technical Service Department at +1 (800) 235-6797 for assistance. 6.2.1 Required Maintenance Parts Interval DESCRIPTION Order No. Pre-filter Element 0.01 μm 07SX 4038113 10SX 4038149 12SX 4038114 15SX 4038115 18SX 4038150 20SX 4038151 ... -
Page 16: Troubleshooting Guide
TROUBLESHOOTING GUIDE The troubleshooting and the eventual checks must be performed by qualified personnel only. Users or technicians operating or servicing the machine must wear hearing and eye protection. Each employee must select proper personal protection device(s) (PPD). Hearing protection such as earmuffs, ear canal caps, or earplugs are required to prevent permanent hearing damage or loss. COMPONENT TROUBLE POSSIBLE CAUSE and SUGGESTED ACTION Leak Detected in Check each componenet for connection of fitting a component (such as: Refit or replace component Pressure Gauge, PRV, etc...) High Oil Carryover Replace activated carbon DISMANTLING OF THE UNIT If the carbon tower is to be dismantled and disposed of then it must be split into groups of materials of con- struction. Part Material Activated Carbon Material Activated carbon, Oil contaminated Frame and supports... - Page 17 CLEARPOINT V Series Activated Carbon Tower ® (Rev. D)
- Page 18 CLEARPOINT V Series Activated Carbon Tower ® (Rev. D)
-
Page 19: For Technical Product Support Please Call +1 (800) 235-6797 And Select Option 2
For technical product support please call +1 (800) 235-6797 and select Option 2 CLEARPOINT V Series Activated Carbon Tower ® (Rev. D)