SERIES 50-200 EVAPORATOR FOR CHLORINE - … · The USF/W&T Series 50-200 Evaporator for Chlorine...

SERIES 50-200EVAPORATOR

FOR CHLORINE

BOOK NO. IM 50.200AA UA ISSUE B

IM 50.200AA UA (B/1-01)

50-200 EVAPORATOR FOR CHLORINE

EQUIPMENT SERIAL NO. _________________

DATE OF START-UP _____________________

START-UP BY ___________________________

Prompt service available from nationwide authorized service contractors.

ORDERING INFORMATION

In order for us to fill your order immediately and correctly, please order material by description and part number, as shownin this book. Also, please specify the serial number of the equipment on which the parts will be installed.

WARRANTY

Seller warrants for a period of one year after shipment that the equipment or material of its manufacture is free from defectsin workmanship and materials. Corrosion or other decomposition by chemical action is specifically excluded as a defectcovered hereunder, except this exclusion shall not apply to chlorination equipment. Seller does not warrant (a) damagecaused by use of the items for purposes other than those for which they were designed, (b) damage caused by unauthorizedattachments or modifications, (c) products subject to any abuse, misuse, negligence or accident, (d) products where partsnot made, supplied, or approved by Seller are used and in the sole judgement of the Seller such use affects the products’performance, stability or reliability, and (e) products that have been altered or repaired in a manner in which, in the solejudgement of Seller, affects the products’ performance, stability or reliability. SELLER MAKES NO OTHER WARRANTY OFANY KIND, AND THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,INCLUDING ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS OF THE MATERIAL OR EQUIPMENT FORANY PARTICULAR PURPOSE EVEN IF THAT PURPOSE IS KNOWN TO SELLER. If Buyer discovers a defect in materialor workmanship, it must promptly notify Seller in writing; Seller reserves the right to require the return of such defective partsto Seller, transportation charges prepaid, to verify such defect before this warranty is applicable. In no event shall suchnotification be received by Seller later than 13 months after the date of shipment. No action for breach of warranty shall bebrought more than 15 months after the date of shipment of the equipment or material.

LIMITATION OF BUYER’S REMEDIES. The EXCLUSIVE REMEDY for any breach of warranty is the replacement f.o.b.shipping point of the defective part or parts of the material or equipment. Any equipment or material repaired or replacedunder warranty shall carry the balance of the original warranty period, or a minimum of three months. Seller shall not beliable for any liquidated, special, incidental or consequential damages, including without limitation, loss of profits, loss ofsavings or revenue, loss of use of the material or equipment or any associated material or equipment, the cost of substitutematerial or equipment, claims of third parties, damage to property, or goodwill, whether based upon breach of warranty,breach of contract, negligence, strict tort, or any other legal theory; provided, however, that such limitation shall not apply toclaims for personal injury.

Statements and instructions set forth herein are based upon the best information and practices known to U.S. Filter/Wallace& Tiernan, Inc., but it should not be assumed that every acceptable safety procedure is contained herein. Of necessity thiscompany cannot guarantee that actions in accordance with such statements and instructions will result in the completeelimination of hazards and it assumes no liability for accidents that may occur.

1.010-42D

WALLACE & TIERNAN PRODUCTS1901 West Garden Road, Vineland, NJ 08360

IM 50.200AA UA (B/1-01)


Introd.

!

INTRODUCTION

The USF/W&T Series 50-200 Evaporator for Chlorine described in thisinstruction book changes the state of chlorine from liquid to gas to supplyother gaseous flow control apparatus.

The Series 50-200 Evaporator comprises a steel cylinder immersed in ahot water bath, an external heat exchanger, and associated control de-vices.

WARNING: HAZARDOUS GAS IS PRESENT IN THIS EQUIP-MENT DURING NORMAL OPERATION. TO AVOID POSSIBLESEVERE PERSONAL INJURY OR DAMAGE TO THE EQUIP-MENT THROUGH MISUSE, THIS EQUIPMENT SHOULD BEINSTALLED, OPERATED, AND SERVICED ONLY BY TRAINED,QUALIFIED PERSONNEL WHO ARE THOROUGHLY FAMIL-IAR WITH THE ENTIRE CONTENTS OF THIS INSTRUCTIONBOOK AND THE CHLORINE HANDLING MANUAL.

This instruction book covers two versions of the evaporator: (1) standardversion AAA8639 and, (2) lethal certified version AAA8651.

Both versions have identical subassembly and component parts except forthe pressure cylinder. The cylinder in the “standard” version is fabricatedto meet all requirements of Section VIII of the ASME Code for UnfiredPressure Vessels. The “standard” evaporator is therefore suitable for chlo-rine, sulfur dioxide, or ammonia service (as labeled) in all applications. If,however, the customer requires either a “lethal certified” cylinder or agreater wall thickness for extra corrosion allowance, the “lethal rated”version is provided.

CANADIAN USERS NOTE: Canadian law requires that the ownerof an evaporator have it registered with the local authorities prior tooperating it, as it is a pressure vessel. The evaporator cylinder ismanufactured to ASME codes and is stamped with Canadian Regis-tration Number CRN HO 618-5 or D1429-5.

NOTE: When submitting correspondence or ordering material,alwaysspecify model and serial number of apparatus.

IM 50.200AA UA (B/1-01)


Introd. (Cont’d)

TABLE OF CONTENTS

Very Important Safety Precautions (Chlorine) ......... 1.010-40,-41Very Important Safety Precautions ........................... SP-1,-2,-3Regional Offices ....................................................... 1.010-1Technical Data .......................................................... Section 1Installation ................................................................ Section 2Operation .................................................................. Section 3Service ...................................................................... Section 4Illustrations ............................................................... Section 5Spare Parts List ......................................................... Section 6Literature/Manuals .................................................... Section 7

Chlorine Handling Manual .................................... IM 25.000AA

IM 50.200AA UA (B/1-01)


VERY IMPORTANT SAFETY PRECAUTIONS - CHLORINE

This and the following pages titled “Very Important Safety Precautions” provide, in brief, informationof urgent importance relative to safety in the installation, operation, and maintenance of this equip-ment.

WARNING

TO AVOID POSSIBLE SEVERE PERSONAL INJURY OR EQUIPMENT DAMAGE, OBSERVETHE FOLLOWING:

THIS EQUIPMENT SHOULD BE INSTALLED, OPERATED, AND SERVICE ONLY BY TRAINED,QUALIFIED PERSONNEL WHO ARE THOROUGHLY FAMILIAR WITH THE ENTIRE CON-TENTS OF THIS INSTRUCTION BOOK AND THE CHLORINE GAS HANDLING MANUAL.

CHLORINE GAS IS A RESPIRATORY IRRITANT. EXPOSURE TO CHLORINE GAS IN SUFFI-CIENT CONCENTRATION PRODUCES IRRITATION OF THE MUCOUS MEMBRANES, THERESPIRATORY SYSTEM, AND THE SKIN. IN EXTREME CASES, SUFFOCATION AND DEATHCAN OCCUR.

WHEN CHANGING CHLORINE CYLINDERS, IT IS RECOMMENDED PRACTICE TO HAVEAN APPROVED GAS MASK AVAILABLE THAT YOU HAVE BEEN TRAINED TO USE ANDYOU MUCH BE COMPLETELY FAMILIAR WITH YOUR LOCAL PLANT OPERATING ANDEMERGENCY PROCEDURES AND CHLORINE INSTITUTE RECOMMENDED EMERGENCYPROCEDURES.

DO NOT TOLERATE ANY CHLORINE LEAKS. CHLORINE LEAKS NEVER GET BETTER.CHLORINE LEAKS ALWAYS GET PROGRESSIVELY WORSE IF THEY ARE NOT PROMPTLYCORRECTED. IT IS RECOMMENDED PRACTICE TO HAVE AN APPROVED GAS MASK AVAIL-ABLE WHEN MAKING LEAK CHECKS.

AS SOON AS THERE IS ANY INDICATION OF CHLORINE IN THE AIR, TAKE IMMEDIATESTEPS TO CORRECT THE CONDITION.

IMPORTANT INFORMATION RELATED TO SAFETY OF CHLORINATION EQUIPMENT IN-STALLATION IS PROVIDED IN THE CHLORINE GAS HANDLING MANUAL. IN THE INTER-EST OF SAFE OPERATION, THIS INFORMATION MUST BE READ, UNDERSTOOD, ANDPRACTICED BY EQUIPMENT OPERATORS AND THEIR SUPERVISORS.

AT TIME OF INITIAL INSTALLATION, WHEN CHLORINE SUPPLY LINES HAVE BEEN DIS-CONNECTED FOR ANY REASON AND ON A ROUTINE DAILY BASIS, THOROUGHLY CHECKALL JOINTS, CONNECTIONS, AND EQUIPMENT FOR POSSIBLE CHLORINE LEAKS ANDIMMEDIATELY CORRECT ANY THAT MAY BE FOUND.

1.010-40

IM 50.200AA UA (B/1-01)


VERY IMPORTANT SAFETY PRECAUTIONS - CHLORINE (CONT’D)

WHEN ANY CONNECTION IS BROKEN EVEN FOR A SHORT TIME, IMMEDIATELY PLUGTHE RESULTANT OPENINGS WITH A RUBBER STOPPER OR EQUIVALENT TO PREVENTTHE ENTRANCE OF MOISTURE. MOISTURE MUST BE EXCLUDED FROM ANY PART OFTHE EQUIPMENT THAT IS NORMALLY EXPOSED TO DRY CHLORINE ONLY. WHILE DRYCHLORINE IS NON-CORROSIVE, MOIST CHLORINE IS EXTREMELY CORROSIVE TO COM-MON METALS, SUCH AS BRASS OR STEEL.

THE TWO MOST COMMON CAUSES OF CHLORINE PIPING LEAKS ARE:1. RE-USE OF GASKETS. THIS SHOULD NEVER BE DONE. ALWAYS HAVE AN AD-

EQUATE SUPPLY ON HAND AND ALWAYS USE NEW GASKETS OF THE CORRECTMATERIAL AND SIZE AS IDENTIFIED ON THE EQUIPMENT PARTS DRAWING.

2. IMPROPERLY MADE-UP THREADED PIPE JOINTS. SEE CHLORINE GAS HAN-DLING MANUAL FOR RECOMMENDED PROCEDURE.

EXCEPT IN CASES OF LEAK DETECTION OR CALIBRATION ADJUSTMENTS, THE CHLO-RINE GAS SUPPLY MUST BE SHUT OFF AT THE GAS SUPPLY CONTAINERS AND THE CHLO-RINE GAS IN THE SYSTEM EXHAUSTED BEFORE SERVICING THE EQUIPMENT.

USE ONLY USF/W&T LISTED PARTS, EXCEPT FOR COMMERCIALLY AVAILABLE PARTSAS IDENTIFIED ON THE PARTS LIST. THE USE OF UNLISTED PARTS CAN RESULT IN EQUIP-MENT MALFUNCTIONS HAVE HAZARDOUS CONSEQUENCES.

DO NOT DISCARD THIS INSTRUCTION BOOK UPON COMPLETION OF INSTALLATION.INFORMATION PROVIDED IS ESSENTIAL TO PROPER AND SAFE OPERATION AND MAIN-TENANCE.

ADDITIONAL OR REPLACEMENT COPIES OF THIS BOOK ARE AVAILABLE FROM:

USFILTER'S WALLACE & TIERNAN PRODUCTS1901 WEST GARDEN ROADVINELAND, NEW JERSEY 08360PHONE: (856) 507-9000FAX: (856) 507-4125

NOTE

Minor part number changes may be incorporated into USF/W&T products from time to time that arenot immediately reflected in the instruction book. If such a change has apparently been made in yourequipment and does not appear to be reflected in your instruction book, contact your local USF/W&Tsales office for information.

Please include the equipment serial number in all correspondence. It is essential for effective commu-nication and proper equipment identification.

1.010-41

IM 50.200AA UA (B/1-01)


SP-1

VERY IMPORTANT SAFETY PRECAUTIONS

WARNING

THIS EQUIPMENT IS SUITABLE FOR USE WITH CHLORINE ONLY. DO NOT USE WITH OTHERGASES. SUCH USE CAN RESULT IN MALFUNCTION OR FAILURE OF VARIOUS COMPO-NENTS, CAUSING POSSIBLE SEVERE PERSONAL INJURY.

TO AVOID SEVERE PERSONAL INJURY AS A RESULT OF A CHLORINE LEAK(S), ENSURETHAT THE CHLORINATOR IS READY FOR OPERATION BEFORE CHLORINE IS INTRODUCEDINTO THE EVAPORATOR AND ITS CONNECTING PIPELINES. OPERATION OF THE CHLO-RINATOR MAY BE NECESSARY TO DISPOSE OF CHLORINE TO PERMIT THE REPAIR OFLEAKS. IF THE EVAPORATOR IS USED WITHOUT A CHLORINATOR, PROVIDE AN ALTER-NATE MEANS OF DISPOSAL.

IF THE SUPPLY CONTAINER DOES NOT HAVE ADEQUATE RESERVE CAPACITY TO AC-CEPT THE MAXIMUM CONTENTS THAT ARE BEING FORCED FROM THE EVAPORATORCYLINDER, DO NOT STOP CHLORINATION. INSTEAD, IN ORDER TO PREVENT OVER-FILL-ING AND DEVELOPING EXTREME PRESSURES WITHIN THE SUPPLY CONTAINER, CLOSETHE SUPPLY VALVE AND USE THE CHLORINATOR OR GAS DISPOSAL SYSTEM TO COM-PLETELY EVACUATE THE EVAPORATOR AND ITS CONNECTING PIPELINES.

TO AVOID SEVERE PERSONAL INJURY OR CYLINDER RUPTURE, DO NOT INSTALL AVALVE OF ANY TYPE BETWEEN THE EVAPORATOR DISCHARGE AND THE GAS PRES-SURE RELIEF SYSTEM. RUN THE OUTFLOW FROM THE RELIEF VALVE TO ATMOSPHERE.TERMINATE THE RELIEF LINE IN AN AREA WHERE GAS FUMES CANNOT CAUSE DAM-AGE OR INJURY TO PERSONNEL. DO NOT TERMINATE THE RELIEF LINE AT A LOCATIONROUTINELY USED BY PERSONNEL, SUCH AS WORK AREAS OR PATHWAYS, NOR NEARWINDOWS OR VENTILATION SYSTEM INTAKES. IF AN AREA MEETING THESE REQUIRE-MENTS IS NOT AVAILABLE, REFER TO THE CHLORINE INSTITUTE FOR ALTERNATEMETHODS OF DISPOSAL.

TO AVOID AN OVERPRESSURE CONDITION CAPABLE OF RUPTURING THE PIPING SYS-TEM AND RESULTING IN A DISCHARGE OF GAS FROM THE GAS PRESSURE RELIEF SYS-TEM, DO NOT CLOSE ANY VALVE OR VALVES BETWEEN THE EVAPORATOR AND THECHLORINE SUPPLY WITHOUT FOLLOWING THE EVACUATION PROCEDURE DESCRIBEDIN THIS INSTRUCTION BOOK. LIQUID CHLORINE HAS A HIGH COEFFICIENT OF THERMALEXPANSION. DO NOT CLOSE VALVES IN SUCH A WAY THAT LIQUID CHLORINE MAY BETRAPPED, SINCE DANGEROUS PRESSURES CAPABLE OF RUPTURING THE PIPING SYS-TEM MAY BUILD UP WITH A SMALL INCREASE IN TEMPERATURE.

DO NOT REMOVE THE PRESSURE RELIEF SYSTEM WHILE THE EVAPORATOR IS PRES-SURIZED.

IM 50.200AA UA (B/1-01)


VERY IMPORTANT SAFETY PRECAUTIONS (CONT’D)

TO AVOID A MAJOR RELEASE OF CHLORINE, DO NOT OPEN THE LIQUID LINE PRESSURERELIEF SYSTEM WHILE THE EVAPORATOR IS PRESSURIZED.

THE GAS LINE TO THE REGULATING VALVE MUST BE SHORT WITH A SLIGHT DOWN-GRADE TOWARD THE EVAPORATOR, ALLOWING ANY RELIQUEFIED CHLORINE TO DRAINBACK TO THE EVAPORATOR. THIS WILL PREVENT ANY RELIQUEFIED CHLORINE FROMREACHING AND DAMAGING EQUIPMENT DOWNSTREAM OF THE REGULATING VALVE.

TO AVOID RUPTURE OF THE SUPPLY CONTAINER, CAUSING POSSIBLE SEVERE PER-SONAL INJURY, CLOSE THE SUPPLY VALVE AND USE THE CHLORINATOR OR GAS DIS-POSAL SYSTEM TO COMPLETELY EVACUATE THE EVAPORATOR CYLINDER AND ITSCONNECTING PIPELINES.

ALL TWO-BOLT AMMONIA AND RUPTURE DISC UNIONS ARE ONLY LIGHTLY TIGHT-ENED FOR SHIPPING. TO AVOID SEVERE PERSONAL INJURY FROM A CHLORINE LEAK,FIRMLY TIGHTEN ALL UNIONS AFTER PIPING IS INSTALLED.

TO AVOID THE RUPTURE OF THE EVAPORATOR PRESSURE CYLINDER OR ITS CONNECT-ING PIPELINES, CAUSING POSSIBLE SEVERE PERSONAL INJURY AND EQUIPMENT DAM-AGE, DO NOT ATTEMPT TO DISASSEMBLE OR REPAIR THE RELIEF VALVE. IF IT MAL-FUNCTIONS, REPLACE IT.

SECURELY SUPPORT THE EXPANSION TANK (e.g., WITH A BRACKET) TO AVOID DAMAGETHAT COULD RESULT IN A MAJOR RELEASE OF LIQUID.

USE ONLY WATER TO FILL THE HOT WATER TANK AND HEAT EXCHANGER. DO NOT USEANY SUBSTITUTE FLUID. THE BOILING TEMPERATURE OF WATER PROVIDES A LIMIT ONAN ACCIDENTAL OVER-TEMPERATURE CONDITION, THEREBY LIMITING THE GAS PRES-SURE INSIDE THE EVAPORATOR CYLINDER.

THE TOP OF THE TANK WILL BE HOT (180°F). TO AVOID SEVERE PERSONAL INJURY DUETO HOT SURFACES, DO NOT REMOVE OR REINSTALL CAPLUG WITH BARE HANDS; USEA GLOVE OR OTHER INSULATING MATERIAL.

WHEN DRAINING HOT WATER OUT OF HEAT EXCHANGER, ALLOW WATER TO COOLBEFORE REMOVING PLUG.

TO AVOID SEVERE PERSONAL INJURY FROM BURNS DUE TO HOT WATER IN SIGHTGLASSTUBE, TURN POWER OFF AND DRAIN THE TANK ENOUGH SO THAT NO WATER IS VISIBLEIN THE SIGHTGLASS. ALLOW THE SIGHTGLASS TO COOL BEFORE HANDLING.

SP-2

IM 50.200AA UA (B/1-01)



WHEN HANDLING HAZARDOUS MATERIAL, IT IS THE RESPONSIBILITY OF THE EQUIP-MENT USER TO OBTAIN AND OBSERVE ALL SAFETY PRECAUTIONS RECOMMENDED BYTHE MATERIAL MANUFACTURER/SUPPLIER.

BOLT THE EVAPORATOR SECURELY TO THE CONCRETE PAD.

LIFT THE EVAPORATOR BY A CRANE HAVING NO LESS THAN A ONE-TON CAPACITYRATING.

TO AVOID SEVERE PERSONAL INJURY FROM ACCIDENTAL EXPOSURE TO HIGH VOLT-AGE, THE EVAPORATOR MUST BE SUITABLY GROUNDED TO EARTH BEFORE START-UP.USE THE GROUNDING CONNECTOR PROVIDED.

LINE VOLTAGE IS PRESENT INSIDE THE CONTROL BOX EVEN WHEN THE PANEL POWERSWITCH IS IN THE OFF POSITION. TO AVOID POSSIBLE SEVERE PERSONAL INJURY DUETO ELECTRICAL SHOCK, DISCONNECT THE EXTERNAL POWER SUPPLY BEFORE SER-VICING.

TO AVOID POSSIBLE SEVERE PERSONAL INJURY FROM ELECTRICAL SHOCK, BE CARE-FUL NOT TO TOUCH THE METAL SCREWS ON THE TERMINALS OF THE PRESSURE SWITCH.THESE TERMINALS ARE CONNECTED TO 115 VOLTS.

TO AVOID POSSIBLE SEVERE PERSONAL INJURY DUE TO EQUIPMENT MALFUNCTION,SEMI-ANNUALLY MAKE A COMPLETE ELECTRICAL CHECK OF THE OPERATION OF THETEMPERATURE, WATER LEVEL AND PRESSURE RELIEF ALARM SWITCHES. IF THE AP-PROPRIATE RESPONSE IS NOT OBSERVED, REPLACE THE FAULTY CONTROL UNIT.

THE TWO MOST COMMON CAUSES OF CHLORINE PIPING LEAKS ARE:

1. RE-USE OF GASKETS. THIS SHOULD NEVER BE DONE. ALWAYS HAVE AN AD-EQUATE SUPPLY ON HAND AND ALWAYS USE NEW GASKETS OF THE CORRECT MATE-RIAL AND SIZE AS IDENTIFIED ON THE EQUIPMENT PARTS DRAWING.

2. IMPROPERLY MADE-UP THREADED PIPE JOINTS. SEE CHLORINE HANDLINGMANUAL FOR RECOMMENDED PROCEDURE.

USE ONLY USF/W&T LISTED PARTS, EXCEPT FOR THOSE COMMERCIALLY AVAILABLEPARTS IDENTIFIED BY COMPLETE DESCRIPTION ON THE PARTS LIST. THE USE OF UN-LISTED PARTS CAN RESULT IN EQUIPMENT MALFUNCTIONS CAUSING POSSIBLE SE-VERE PERSONAL INJURY.

SP-3

IM 50.200AA UA (B/1-01)



DO NOT DISCARD THIS INSTRUCTION BOOK UPON COMPLETION OF INSTALLATION.INFORMATION PROVIDED IS ESSENTIAL TO PROPER AND SAFE OPERATION AND MAIN-TENANCE.

ADDITIONAL OR REPLACEMENT COPIES OF THIS INSTRUCTION BOOK ARE AVAILABLEFROM:

USFILTER'S WALLACE & TIERNAN PRODUCTS1901 W. GARDEN ROADVINELAND, NJ 08360PHONE: (856) 507-9000FAX: (856) 507-4125

NOTE

Minor part number changes may be incorporated into USF/W&T products from time to time that are notimmediately reflected in the instruction book. If such a change has apparently been made in your equip-ment and does not appear to be reflected in your instruction book, contact your local USF/W&T salesoffice for information.

Please include the equipment serial number in all correspondence. It is essential for effective commu-nication and proper equipment identification.

SP-4

IM 50.200AA UA (B/1-01)


REGIONAL OFFICES

INSTALLATION, OPERATION, MAINTENANCE, AND SERVICE INFORMATION

Direct any questions concerning this equipment that are not answered in the instruction book to theReseller from whom the equipment was purchased. If the equipment was purchased directly fromUSFilter's Wallace & Tiernan Products (USF/W&T), contact the office indicated below.

UNITED STATES

1901 West Garden RoadVineland, NJ 08360TEL: (856) 507-9000FAX: (856) 507-4125

CANADA

If the equipment was purchased directly from USF/W&T Canada, contact the nearest office indicatedbelow.

ONTARIO QUEBEC

250 Royal Crest Court 243 Blvd. BrienMarkham, Ontario Bureau 210L3R3S1 Repentigny, Quebec(905) 944-2800 (514) 582-4266

MEXICO

If the equipment was purchased directly from USF/W&T de Mexico, contact the office indicated be-low.

Via Jose Lopez Portillo 321Col. Sta. Maria CuautepecTultitlan, Edo. de Mexico54900 MexicoTEL: 525 879 0260FAX: 525 875 2171

1.010-1D

IM 50.200AA UA (B/1-01)



IM 50.200AA UA (B/1-01) 1

SECTION 1 - TECHNICAL DATA

List Of Contents

PARA. NO.

General ...................................................................... 1.1Application ............................................................... 1.2Technical Data .......................................................... 1.3

IM 50.200AA UA (B/1-01)


2

1.1 General

WARNING: THIS EQUIPMENT IS SUITABLE FOR USE WITHCHLORINE ONLY. DO NOT USE WITH OTHER GASES. SUCHUSE CAN RESULT IN MALFUNCTION OR FAILURE OF VARI-OUS COMPONENTS CAUSING POSSIBLE SEVERE PERSONALINJURY.

1.2 Application

The Series 50-200 Evaporator is available for either Indoor or OutdoorService (optional), and in the following chlorine evaporating capacities:

• 6,000 lb/24 hr. maximum capacity with 12 kW heaters.



Part numbers for these arrangements are provided in Section 5. See Dwg.50.200.000.011.

!


IM 50.200AA UA (B/1-01) 3

1.3 Technical Data

yticapaCenirolhC gnidneped.rh42/bl000,01ot000,6.ezisretaehno

ecruoStaeH taehretawtohderewopyllacirtcelE.regnahcxe

stnemeriuqeRlacirtcelE egatlovlanimontarewopesahP-3gnirudremotsucybdenimretedlevel

egatlovlanimonelbaliavA.redro,V042,V022,V802:erastnemeriuqer

.V055dnaV084,V044,V083

stnemeriuqeRretaW retawytilauqyticmuminimisp01

ylppuSenirolhCdiuqiLerusserP

isp041-03

ETON lanimonehtotgnidnopserrocylppusegatlovremotsuC:foseulavmumixamdnamuminimehtfoegnarehtnihtiwebtsumrewopV511esahpelgniS.1.2elbaT,2noitceSnideificepsegatlov

esahpelgnisniatbotnempiuqednaslortnocehT.deriuqertonsiehtnidetacolremrofsnartAVk1afoesuehthguorhtrewop

.xoblortnoc

detaRrednilyCrotaropavEerusserPgnikroW

isp065

gnitteSevlaVfeileR isp065

retawtoH(thgieWdellatsnI)dellifrednilycdnaknat

)yletamixorppa(.bl0011

IM 50.200AA UA (B/1-01)


4


IM 50.200AA UA (B/1-01) 5

SECTION 2 - INSTALLATION

List Of Contents

PARA./DWG. NO.

General .................................................................. 2.1Unpacking and Base Mounting ............................ 2.2Piping .................................................................... 2.3

Chlorine Gas and Liquid Piping ........................ 2.3.1Water Piping ...................................................... 2.3.2

Evaporator Gas Pressure Relief System ............... 2.4Gas Pressure Relief Valve Discharge Piping..... 2.4.1

Liquid Line Pressure Relief System ..................... 2.5Wiring ................................................................... 2.6

Controls ............................................................. 2.6.1Heat Exchanger .................................................. 2.6.2Hot Water Circulating Pump ............................. 2.6.3Alarm Units ....................................................... 2.6.4Evaporator Gas and Liquid Line Pressure

Relief Systems ................................................ 2.6.5Illustrations

Dimensions ........................................................ 50.200.100.010A&BTypical Installation ............................................ 50.200.110.010A&BInstallation - Evaporator Lifting Method ........... 50.200.110.030Installation Wiring

Evaporator ...................................................... 50.200.130.010Alarm Units .................................................... 50.100.130.011Pressure Relief System-Alarm Switch............ 50.200.130.020

IM 50.200AA UA (B/1-01)


6

WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURYOR DAMAGE TO EQUIPMENT, READ AND UNDERSTANDTHIS ENTIRE PREPARATION PROCEDURE AND FAMILIAR-IZE YOURSELF WITH THE CHLORINE HANDLING MANUALBEFORE PERFORMING ANY WORK. BE SURE THE CHLO-RINE SUPPLY REMAINS OFF UNTIL INSTRUCTED TO TURNIT ON.

2.1 General

NOTE: Reference to optional equipment, such as an individual alarmunit, may be disregarded if such equipment is not a part of yourinstallation.

WARNING: WHEN HANDLING HAZARDOUS MATERIAL, ITIS THE RESPONSIBILITY OF THE EQUIPMENT USER TO OB-TAIN AND OBSERVE ALL SAFETY PRECAUTIONS RECOM-MENDED BY THE MATERIAL MANUFACTURER/SUPPLIER.

The Series 50-200 Evaporator is shipped completely assembled and readyfor installation. For the location of the various evaporator components,see Dwg. 50.200.110.010.

2.2 Unpacking and Base Mounting

a. Unfasten and remove shipping crate.

b. If a back cover (outdoor option) was provided, remove it. Loosenand remove the bolts located at the top of the evaporator where theenclosure sides are fastened together.

c. Loosen the black, quarter-turn screws in the side panels of the enclo-sure.

NOTE: Do not attempt to remove the quarter-turns screws as theyare retained on the reverse side of the panel by grommets.

d. Remove the side panels. Do not replace them until the evaporator isready for operation.

e. Remove top cover and pipe trim.

f. Attach two lifting hooks, each with no less than 1/2-ton capacityrating, to the lifting brackets that extend out a few inches from thegray insulation ring.

!

!


IM 50.200AA UA (B/1-01) 7

g. Chain the lifting hooks together to a hoist or crane.

WARNING: TO AVOID SEVERE PERSONAL INJURY, LIFT THEEVAPORATOR BY A CRANE HAVING NO LESS THAN A ONE-TON CAPACITY RATING. LIFT EVAPORATOR ONLY IN THEMANNER SHOWN ON DWG. 50.200.110.030.

h. Unbolt the evaporator from the wooden base. Lift and lower the evapo-rator onto a concrete mounting pad prepared according to the mount-ing details in Dwg. 50.200.100.010. Bolt the evaporator to the pad.

f. Replace top cover and pipe trim.

WARNING: TO AVOID SEVERE PERSONAL INJURY OREQUIPMENT DAMAGE, BOLT THE EVAPORATOR SECURELYTO THE CONCRETE PAD.

2.3 Piping

2.3.1 Chlorine Gas and Liquid Piping

WARNING: ALL TWO-BOLT AMMONIA AND RUPTURE DISCUNIONS ARE ONLY LIGHTLY TIGHTENED FOR SHIPPING.TO AVOID SEVERE PERSONAL INJURY FROM A CHLORINELEAK, FIRMLY TIGHTEN ALL UNIONS AFTER PIPING IS IN-STALLED.

NOTE: Piping for chlorine should conform to Chlorine Institute rec-ommendations.

An ammonia-type union is furnished to accommodate the one-inch chlo-rine gas outlet (discharge) pipe. The chlorine gas outlet pipe and unionextends upward from the gray insulation ring at the top of the evaporator.The gas pressure relief system and a vacuum regulator-check unit (or gaspressure reducing valve) must be installed in this line. Refer to Dwg.50.200.110.010 for proper installation. The vacuum regulator-check unitis electrically operated. The gas pressure reducing valve can be pilot-operated by air or water or can be electrically operated. Separate instruc-tions are furnished with either valve.

WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURYOR EQUIPMENT DAMAGE, THE GAS LINE TO THE REGU-LATING VALVE MUST BE SHORT, WITH A SLIGHT DOWN-GRADE TOWARDS THE EVAPORATOR, ALLOWING ANYRELIQUIFIED CHLORINE TO DRAIN BACK TO THE EVAPO-

!

!

!

!

IM 50.200AA UA (B/1-01)


8

RATOR. THIS WILL PREVENT ANY RELIQUIFIED CHLORINEFROM REACHING AND DAMAGING EQUIPMENT DOWN-STREAM OF THE REGULATING VALVE.

There are two points at which chlorine liquid can be brought into theevaporator. The top connection may be used as a convenience from apiping standpoint when there is only a single evaporator being used. Thebottom connection is required when manifolding several evaporators forhigh capacity. For single evaporators, the bottom connection provides analternate inlet connection. The bottom connection is also used as a drainwhen cleaning the evaporator in place. Ammonia unions are furnished atboth liquid inlet points.

2.3.2 Water Piping (See Dwg. 50.200.110.010)

In the unlikely occurrence of a leak in the evaporator pressure cylinder,chlorine may be present in the water drain-overflow and vapor vent outletlines.

WARNING: TERMINATE THE VAPOR VENT AND DRAIN/OVERFLOW LINES IN AREAS WHERE NO INJURY TO PER-SONNEL OR DAMAGE TO EQUIPMENT WILL OCCUR.

a. Make a 1-1/4-inch connection to the combination water bath drain-overflow line, and connect it to the appropriate plant piping.

b. Make a 1-1/4-inch connection to the vapor vent outlet and connect itto the appropriate plant piping.

c. Connect a 1/2-inch supply (10 psi min., 135 psi max.) to the watersupply for the purpose of water make-up to the hot water tank.

2.4 Evaporator Gas Pressure Relief System

The Gas Pressure Relief System (see Dwg. 50.202.008.011) is providedas a preassembled unit.

WARNING: TO AVOID SEVERE PERSONAL INJURY OR CYL-INDER RUPTURE, DO NOT INSTALL A VALVE OF ANY TYPEBETWEEN THE EVAPORATOR DISCHARGE AND THE GASPRESSURE RELIEF SYSTEM. RUN THE OUTFLOW FROM THERELIEF VALVE TO ATMOSPHERE. TERMINATE THE RELIEFLINE IN AN AREA WHERE GAS FUMES CANNOT CAUSE DAM-AGE OR INJURY TO PERSONNEL. DO NOT TERMINATE THERELIEF LINE AT A LOCATION ROUTINELY USED BY PER-

!

!


IM 50.200AA UA (B/1-01) 9

SONNEL, SUCH AS WORK AREAS OR PATHWAYS, NOR NEARWINDOWS OR VENTILATION SYSTEM INTAKES. IF AN AREAMEETING THESE REQUIREMENTS IS NOT AVAILABLE, RE-FER TO THE CHLORINE INSTITUTE FOR ALTERNATE METH-ODS OF DISPOSAL.

CAUTION: To ensure proper operation, install the system with therelief valve in a vertical position.

Install the Gas Pressure Relief System in the gas discharge line as shownin Dwg. 50.200.110.010. The purpose of this system is to prevent ruptureof the pressure cylinder or related piping in case of an extreme over-pressure condition. A detailed view of this system is provided in Dwg.50.202.008.011.

2.4.1 Gas Pressure Relief Valve Discharge

NOTE: The relief valve outlet may be either 1-1/2-inch or 1-inch NPTdepending on valve furnished.

To provide for friction losses, use the following pipe sizes:

Discharge line less than 50 feet long: use 1-or 1-1/2-inch, schedule 40carbon steel pipe.

Discharge line 50 to 100 feet long: use 1-1/2-inch, schedule 40 carbonsteel pipe.

The ASME Boiler and Pressure Vessel Code, Section VIII Division 1 UA-356, appendix M, provides guidance for relief system discharge piping.The following is an excerpt from that code:

UA-356 Discharge Lines From Safety Devices.

(a) Where it is feasible, the use of a short discharge pipe or vertical riser,connected through long-radius elbows from each individual device,blowing directly to the atmosphere, is recommended. Such dischargepipes shall be at least of the same size as the valve outlet….

(b) When discharge lines are long … the effect of the back pressure thatmay be developed therein … must be considered ….

(c) All discharge lines shall be run as direct as is practicable to the pointof final release for disposal. For the longer lines, due considerationshall be given to the advantage of long-radius elbow, avoidance of

!

IM 50.200AA UA (B/1-01)


10

close-up fittings, and the minimizing of excessive line strains by ex-pansion joints and well-known means of support to minimize line-sway and vibration under operating conditions.

NOTE: It is recognized that no simple rule can be applied generallyto fit the many installation requirements which vary from simpleshort lines that discharge directly to the atmosphere to the extensivemanifold discharge piping systems where the quantity and rate of theproduct to be disposed of requires piping to a distant safe place.

2.5 Liquid Line Pressure Relief System

If liquid is trapped in the supply pipe between two pipes, liquid expansioncan result in pipe rupture. To avoid this, a means of pressure relief isfurnished. (See the Chlorine Handling Manual.)

The liquid line pressure relief system is provided as a pre-assembled unitand needs only to be installed in the liquid line. (See Dwgs. 50.200.110.010and 50.202.007.011.)

CAUTION: To prevent damage to the rupture disc due to inadvert-ent overpressure, and to permit checking the pressure switch electri-cal alarm wiring, do not install rupture disc until initial leak testingis completed.

CAUTION: To ensure proper operation of the Liquid Line PressureRelief System, install the expansion chamber vertically, with the pres-sure switch on top.

WARNING: SECURELY SUPPORT THE EXPANSION TANK(E.G., WITH A BRACKET) TO AVOID DAMAGE THAT COULDRESULT IN A MAJOR RELEASE OF LIQUID, CAUSING POS-SIBLE SEVERE PERSONAL INJURY.

2.6 Wiring

The components inside the control box and the equipment inside theevaporator enclosure have been factory pre-wired. Customer-made con-nections for power, alarms, and the gas regulating valve are shown onDwg. 50.200.130.010.

CAUTION: Alarm connections on the printed circuit board must bewired to actuate appropriate alarm devices (either customer-sup-plied or supplied by USF/W&T) as shown in the Installation draw-ings.

!

!

!

!


IM 50.200AA UA (B/1-01) 11

Connect alarm devices for low water temperature, high water tempera-ture, and low water level conditions to the unpowered contacts on theprinted circuit board. These contacts are rated for 10 amps at 120 volts acand 30 volts dc. Connect the vacuum regulator-check unit (or gas pressurereducing valve) to the powered contacts on the printed circuit board.(Refer to Figure 2.1.) Run the wiring for these devices through the rigidconduit supplied at the top left of the enclosure. Clamps are providedinside the box for securing these wires (for alarms and the regulatingvalve) neatly to the panel.

Figure 2.1 - Control Enclosure Circuit Board

CAUTION: Improper wiring may damage equipment.

Connect the appropriate three-phase power supply to the disconnect switchlocated in the upper right hand corner of the control box. Connect theground wire of the supply to the grounding connector provided to the leftof the disconnect switch. (Refer to Figure 2.2.) Run these wires throughthe rigid conduit provided at the top right of the enclosure.

!

IM 50.200AA UA (B/1-01)


12

Figure 2.2 - Three-Phase Power Supply and Ground Location

WARNING: TO AVOID SEVERE PERSONAL INJURY FROMACCIDENTAL EXPOSURE TO HIGH VOLTAGE, THE EVAPO-RATOR MUST BE SUITABLY GROUNDED TO EARTH BEFORESTART-UP. USE THE GROUNDING CONNECTOR PROVIDED.(SEE DRAWING 50.200.130.010 FOR LOCATION OF GROUND-ING LUG INSIDE CONTROL BOX.)

CAUTION: The three-phase user power supply must be within theminimum and maximum voltage range corresponding to the nominalvoltage rating label located just above the disconnect switch in thecontrol box. See Table 2.1 for this voltage range. Refer to the actualcontrol box to verify that the nominal voltage rating of the evaporatorcontrols is the same as your power supply.

!

!


IM 50.200AA UA (B/1-01) 13

Table 2.1 - Power Supply Voltage Ranges

egatloVlanimoNgnitaR

ylppuSegatloVresU

muminiM mumixaM

802 291 812

022 491 332

042 212 452

083 633 204

044 983 664

084 424 805

055 684 285

CAUTION: If your power supply does not fall within the properrange, do not connect power. Contact your nearest USF/W&T re-gional office for assistance.

NOTE: Field wiring must conform to local electrical code require-ments.

2.6.1 Controls (Dwg. 50.200.170.010)

The evaporator controls and equipment obtain 115-volt, single-phase powerfrom the secondary side of a transformer, located in the control box. Theprimary side of this transformer is connected to two lines of the three-phase power supply; therefore, a separate 115-volt, single-phase supplyis not required from the user to power the controls.

When the operating handle (located at the front right of the control box)for the disconnect switch is in the off position, power is turned off to theheat exchanger and control equipment. Line voltages for the customer-connected alarms and the three-phase power supply are present inside thecontrol box, however, so observe the following warning when servicingthe controls.

WARNING: LINE VOLTAGE IS PRESENT INSIDE THE CON-TROL BOX EVEN WHEN THE PANEL POWER SWITCH IS INTHE OFF POSITION. TO AVOID POSSIBLE SEVERE PER-SONAL INJURY DUE TO ELECTRICAL SHOCK, DISCONNECTEXTERNAL POWER SUPPLY BEFORE SERVICING.

!

!

IM 50.200AA UA (B/1-01)


14

2.6.2 Heat Exchanger

The heat exchanger nameplate voltage must be within the user voltagesupply range corresponding to the nominal voltage labeled inside thecontrol box above the disconnect switch. See Table 2.1. If this is not thecase, the heater must be exchanged for one of the proper value. If neces-sary, contact your nearest USF/W&T regional office for assistance.

NOTE: For 220 Nominal Voltage Users: If the heat exchanger name-plate voltage rating reads as either 220/240 VOLTS or 240 VOLTS,do not return the heater. This is the proper heater for this evaporatorarrangement.

For 440 Nominal Voltage Users: If the heat exchanger nameplatevoltage rating reads as either 440/480 VOLTS or 480 VOLTS, do notreturn the heat exchanger. This is the proper heat exchanger for thisarrangement.

2.6.3 Hot Water Circulating Pump

A circulating pump is provided and runs continuously while the evapora-tor is working. The controls are designed to shut the pump off in the eventof a low water level condition.

The fractional hp 50/60 Hz motor that drives the pump is a totally enclosedtype, suitable for outdoor use.

2.6.4 Alarm Units

If USF/W&T alarm units are provided, connect as shown in Dwg.50.100.130.011.

2.6.5 Evaporator Gas and Liquid Line Pressure Relief Systems

Wire the pressure switch of each system directly to an alarm device orrelay coil per Dwg. 50.200.130.010.

Every relief system, either liquid line or gas pressure relief, is suppliedwith the appropriate rupture disc, which is to be installed after all initialpressure testing is completed. (See paragraph 3.1, Preparation For InitialOperation.)


IM 50.200AA UA (B/1-01) 15

SERIES 50-200 EVAPORATOR - DIMENSIONS

50.200.100.010AISSUE 0 1-01

NOTE: A NOT FURNISHED BY USF/W&T.

IM 50.200AA UA (B/1-01)


16

SERIES 50-200 EVAPORATOR - DIMENSIONS

50.200.100.010BISSUE 0 1-01

NOTE: A NOT FURNISHED BY USF/W&T.


IM 50.200AA UA (B/1-01) 17

SERIES 50-200 EVAPORATOR - TYPICAL INSTALLATION50.200.110.010A

ISSUE 0 1-01

NOTE: SEE DWG. 50.200.110.010B FOR EXPLANATION OF SYMBOLS.

IM 50.200AA UA (B/1-01)


18

SERIES 50-200 EVAPORATOR - TYPICAL INSTALLATION

50.200.110.010BISSUE 0 1-01

WARNING: TO AVOID PERSONAL INJURY FROM ACCIDENTAL EXPOSURE TO HIGH VOLTAGE, SUITABLY GROUND THEEVAPORATOR TO EARTH BEFORE START-UP.

!!!!! THE RELIEF LINE MUST TERMINATE IN AN AREA WHERE GAS FUMES CANNOT CAUSE DAMAGE OR INJURY TOPERSONNEL. DO NOT TERMINATE THE RELIEF LINE AT A LOCATION ROUTINELY USED BY PERSONNEL SUCHAS WORK AREAS OR PATHWAYS NOR NEAR WINDOWS OR VENTILATION SYSTEM INTAKES. IF AN AREA MEET-ING THESE REQUIREMENTS IS NOT AVAILABLE, REFER TO THE CHLORINE INSTITUTE, INC. OR THE COM-PRESSED GAS ASSOCIATION, INC. FOR ALTERNATE METHOD OF RELIEF DISPOSAL.

NOTES: !!!!! SURFACE TEMPERATURE MAY REACH 212°F.A ACCESSORY ITEM FURNISHED ONLY IF SPECIFICALLY LISTED IN QUOTATION.!!!!! GAS PRESSURE REDUCING VALVE CAN BE FURNISHED BY USF/W&T FOR PRESSURE SUPPLY ARRANGE-

MENTS.""""" USE WHEN TWO OR MORE EVAPORATORS ARE MANIFOLDED. FOR ONE EVAPORATOR, CONNECTION MAY BE

AN ALTERNATE TO TOP INLET.""""" THE SYSTEM MUST BE INSTALLED WITH THE RELIEF VALVE IN A VERTICAL POSITION AND WITH THE CLOSED

END OF THE EXPANSION TANK FACING UP.X ALL PIPING AND FITTINGS TO BE SUPPLIED BY THE CUSTOMER. USE SCHEDULE 80 SEAMLESS CARBON

STEEL PIPE WITH 3000 LB. FORGED STEEL FITTINGS.FOR REMOVAL OF CYLINDER, MINIMUM CEILING HEIGHT MUST BE 10'-0" PLUS LIFTING GEAR. FOR REMOVALOF CABINET, ALLOW 15" MINIMUM SIDE CLEARANCE.


IM 50.200AA UA (B/1-01) 19

EVAPORATOR LIFTING METHOD - INSTALLATION

50.200.110.030ISSUE 2 4-91

WARNING: """"" TO AVOID POSSIBLE SEVERE PERSONAL INJURY AND EQUIPMENT DAMAGE, DO NOTATTEMPT TO LIFT EVAPORATOR BY INLET AND OUTLET CONNECTIONS.

NOTE: X NOT FURNISHED BY USF/W&T.

IM 50.200AA UA (B/1-01)


20

SERIES 50-200 EVAPORATOR - INSTALLATION WIRING

50.200.130.010ISSUE 0 4-88

NOTE: X NOT FURNISHED BY USF/W&T.A ACCESSORY ITEM FURNISHED ONLY IF SPECIFICALLY LISTED IN QUOTATION.

FIELD WIRING (NOT BY USF/W&T) MUST CONFORM TO LOCAL ELECTRICAL CODES.

NOMINAL EVAPORATOR VOLTAGE SPECIFIED BY CUSTOMER AT TIME OF ORDER.IN THE EVENT OF A LOW WATER TEMPERATURE, HIGH WATER TEMPERATURE, OR LOW WATERLEVEL CONDITION, THE "C" AND "NC" TERMINALS ARE CLOSED BY A RELAY TO COMPLETE ACIRCUIT. THEREFORE, CONNECT APPROPRIATE ALARMS TO THESE TERMINALS. THE "C" AND"NO" TERMINALS MAY BE USED TO INDICATE NORMAL OPERATION.


IM 50.200AA UA (B/1-01) 21

ALARM UNITS - INSTALLATION WIRINGWith Switch Powered From Equipment

50.100.130.011ISSUE 2 5-83

NOTE: X NOT FURNISHED BY USF/W&T.A ACCESSORY ITEM FURNISHED ONLY IF SPECIFICALLY LISTED IN QUOTATION.

FIELD WIRING (NOT BY USF/W&T) MUST CONFORM TO LOCAL ELECTRICAL CODES.

WIRING BY USF/W&T.

IM 50.200AA UA (B/1-01)


22

SERIES 50-200 EVAPORATOR - INSTALLATION WIRINGLiquid Line & Pressure Relief System - Alarm Switch

50.200.130.020ISSUE 0 4-88



IM 50.200AA UA (B/1-01) 23

SECTION 3 - OPERATION

List Of Contents

PARA./DWG. NO.

Preparation for Initial Operation ............................... 3.1Controls ................................................................. 3.1.1Leak Testing .......................................................... 3.1.2Cathodic Protection System................................... 3.1.3Enclosure ............................................................... 3.1.4

Operation .................................................................. 3.2Startup .................................................................... 3.2.1Operating Routine.................................................. 3.2.2Shutdown ............................................................... 3.2.3

Theory of Operation ................................................. 3.3Illustrations

Operation-Evaporator Front Panel Indicators ........ 50.200.170.010

IM 50.200AA UA (B/1-01)


24

3.1 Preparation For Initial Operation

3.1.1 Controls

WARNING: FOR YOUR SAFETY AND THE SAFETY OF ALLPLANT PERSONNEL, READ AND UNDERSTAND THIS ENTIREPREPARATION PROCEDURE AND FAMILIARIZE YOURSELFWITH THE CHLORINE HANDLING MANUAL BEFORE PER-FORMING ANY WORK.

a. Turn on the water supply to the solenoid valve.

WARNING: TO AVOID SEVERE PERSONAL INJURY OREQUIPMENT DAMAGE, USE ONLY WATER TO FILL THE HOTWATER TANK AND HEAT EXCHANGER. DO NOT USE ANYSUBSTITUTE FLUID. THE BOILING TEMPERATURE OF WA-TER PROVIDES A LIMIT ON AN ACCIDENTAL OVER-TEM-PERATURE CONDITION, THEREBY LIMITING THE GASPRESSURE INSIDE THE EVAPORATOR CYLINDER.

NOTE: Water supply pressure must be 10 psi minimum.

b. Turn the power switch located on the front of the control box to ON.The solenoid valve in the water supply line will be energized andopened, admitting water to the hot water tank, pump, and heat ex-changer. The LOW WATER LEVEL alarm light on the control boxwill go out when the water level reaches a point just above the bot-tom of the sightglass. At this point, the LOW WATER LEVEL indi-vidual alarm unit, if furnished, will go from red to green and thecirculating pump will switch on. The coil in the contactor for theheat exchanger will be energized, resulting in the raising of the tem-perature of the water bath. When the water level reaches normal op-erating height, 2/3 to 3/4 of the height of the sightglass, the waterlevel control switch will de-energize the solenoid valve and shut offthe water supply.

c. Check to see that the low water temperature alarm switch, labeledTS3-LOW, is set to actuate at 160°F (+10°, -5°). This switch is fac-tory calibrated. No adjustment is necessary.

Below the tank water temperature of 160°F, the LOW TEMPERA-TURE alarm light on the control box will stay on. When the tempera-ture reaches 160°F (+10°,-5°) the low temperature switch will close,causing the vacuum regulator-check unit (or gas pressure reducing

!

!


IM 50.200AA UA (B/1-01) 25

valve) to open. At this time, the low temperature alarm unit, if fur-nished, will go from red to green.

d. The water bath will reach operating temperature about 45-60 min-utes after start-up, depending on initial water temperature and heatercapacity. The water bath temperature is controlled electronically bythe printed circuit board. The control circuitry has been factory-cali-brated to maintain the water temperature at approximately 180°F;adjustments are not required.

e. The high temperature alarm switch, labeled TS2-HIGH and locatednext to the low temperature switch TS3-LOW, is factory calibrated.No adjustment is necessary.

f. The pressure relief alarm switches are factory preset at 20 psi. Nofurther adjustment of these switches is needed. When power is con-nected, the individual alarm unit, if furnished, will be green.

WARNING: IF ANY OF THE RESPONSES TO THE ELECTRI-CAL CONTROLS IN B, C, D, AND E ARE NOT OBSERVED, AFAULTY CONTROL DEVICE OR WIRING ERROR IS INDI-CATED. IN ORDER TO AVOID POSSIBLE PERSONAL INJURYOR EQUIPMENT DAMAGE, TAKE CORRECTIVE ACTIONBEFORE PROCEEDING. SEE THE TROUBLESHOOTINGGUIDE IN SECTION 4.

3.1.2 Leak Testing

WARNING: TO AVOID SEVERE PERSONAL INJURY AS A RE-SULT OF A CHLORINE LEAK(S), ENSURE THAT THE CHLO-RINATOR IS READY FOR OPERATION BEFORE CHLORINEIS INTRODUCED INTO THE EVAPORATOR AND ITS CON-NECTING PIPELINES. OPERATION OF THE CHLORINATORMAY BE NECESSARY TO DISPOSE OF CHLORINE TO PER-MIT THE REPAIR OF LEAKS. IF THE EVAPORATOR IS USEDWITHOUT A CHLORINATOR, PROVIDE AN ALTERNATEMEANS OF DISPOSAL.

NOTE: Do not install the rupture discs yet; wait until instructed to doso.

a. Connect a supply of dry air or nitrogen to the evaporator supply line.

b. Purge the system with the dry air or nitrogen to remove all moisture.

!

!

IM 50.200AA UA (B/1-01)


26

WARNING: TO AVOID SEVERE PERSONAL INJURY DUE TOA CHLORINE LEAK(S), THE SUPPLY LINE MUST BE COM-PLETELY DRY AND FREE OF OIL OR GREASE. AVOID LEAKTESTING WITH WATER. STEEL PIPING WILL RAPIDLY COR-RODE IF ANY MOISTURE IS PRESENT WHEN CHLORINE ISALSO IN THE PIPE.

c. Pressurize the system with dry air or nitrogen to 50 psi and check thepressure switches for correct operation. When the 50 psi is applied,the pressure relief alarm switch contacts will close and the optionalUSF/W&T alarm unit, if provided, will turn red.

d. Vent the pressure and install the rupture discs, taking care not to letmoisture enter the system.

CAUTION: When installing the rupture discs, ensure that the grooveof the disc fits the mating tongue of the safety head to avoid alteringthe operation level of the rupture disc. Install the disc as per theinstructions that accompany the rupture discs.

WARNING: TO AVOID SEVERE PERSONAL INJURY DUE TOA CHLORINE LEAK(S), INSTALL BOTH PRESSURE RELIEFSYSTEMS’ RUPTURE DISCS FOR LEAK TESTING WITH DRYAIR OR NITROGEN NOW, BEFORE LEAK TESTING WITHCHLORINE LATER.

e. Connect the evaporator inlet connection to the gas valve (rather thanthe liquid valve) on the chlorine supply container. This temporaryconnection is required to minimize the release of chlorine in the eventthat repairs are needed. Do not open the gas valve yet.

f. Pressurize the system with the dry air or nitrogen supply to 150 psiand check for leaks by applying soapy water to the pipe joints. Ifbubbles form, a leak is present and must be corrected. If an alarm ineither or both of the pressure relief systems is actuated, a leak(s) inthe rupture disc(s) is indicated. If the disc is damaged, do not attemptto repair it; replace it with a new one.

WARNING: TO AVOID SEVERE PERSONAL INJURY, BE FA-MILIAR WITH EMERGENCY PROCEDURES RECOMMENDEDBY THE CHLORINE INSTITUTE, INC. AND ANY APPLICABLEPLANT EMERGENCY PROCEDURES FOR DEALING WITHCHLORINE LEAKS THAT DO NOT RESPOND TO NORMALREPAIR PROCEDURES. HAVE AN APPROVED GAS MASKAVAILABLE WHEN TESTING FOR CHLORINE LEAKS.

!

!

!

!


IM 50.200AA UA (B/1-01) 27

g. Reduce the pressure in the system to slightly below the chlorine sup-ply pressure. Open the chlorine container gas valve and allow somechlorine gas to enter the system. Turn off the chlorine, repressurizewith the dry air (or nitrogen) supply to 150 psi, and test for leaks with26° Baume solution of ammonia. If a cloud of white mist forms whenthe ammonia solution is held near a pipe joint, a chlorine leak ispresent and must be corrected. If a leak is discovered, operate thechlorinator to dispose of the chlorine-in-air mixture. (If the evapora-tor is used without a chlorinator, provide an alternate means of dis-posal. See the warning in paragraph 3.1.2.) If no leaks are found,dispose of the chlorine-in-air mixture and proceed to the next step.

h. Close all valves between the evaporator and the source of supply.Then slowly open the gas valve at the chlorine tank car or the toncontainer and test for leaks using the ammonia supplied with theevaporator. Open valves progressively, testing for leaks as each newsection is filled with chlorine. If a leak is discovered, shut off the gassupply immediately, open the gas discharge line of the evaporatorand operate the chlorinator to dispose of the gas. (If the evaporator isused without a chlorinator, provide an alternate means of gas dis-posal. See the gas disposal warning in paragraph 3.1.2.) Repair theleak before proceeding.

Moisture, including atmospheric, when combined with chlorine, formshydrochloric and hypochlorous acids, which are highly corrosive.

WARNING: TO AVOID SEVERE PERSONAL INJURY DUE TOCHLORINE LEAKS, WHEN ANY CONNECTION IN A CHLO-RINE SYSTEM IS BROKEN EVEN FOR A SHORT TIME, PLUGTHE OPENING IN THE SYSTEM IMMEDIATELY TO PREVENTTHE ENTRANCE OF MOISTURE. PLUG THE OPENING OR USEAUXILIARY CONTAINER VALVES TO PREVENT ENTRANCEOF MOISTURE WHEN CONNECTING AND DISCONNECTINGTHE CHLORINE SUPPLY.

i. After the system up to the chlorinator inlet valve has been tested andfound acceptable, close the gas supply valve and run the chlorinatorto exhaust the gas in the evaporator and in the inlet line. When theevaporator pressure gauge reads zero, the evaporator chlorine outletvalve may be closed. If the evaporator pressure gauge shows pres-sure after the outlet valve has been closed for several minutes, repeatthe above procedure until the evaporator pressure gauge holds zero.When this is done, disconnect the piping from the gas valve and con-nect it to the liquid valve on the supply container. With the evapora-tor water bath adequately filled and up to operating temperature (ap-

!

IM 50.200AA UA (B/1-01)


28

proximately 180°F), open the liquid valve slowly and check this newconnection for leaks.

WARNING: ONCE THE LIQUID SUPPLY VALVE HAS BEENOPENED, ALL VALVES IN THE LIQUID SUPPLY LINE MUSTBE LEFT OPEN UNTIL EITHER THE SUPPLY OF LIQUID HASBEEN EXHAUSTED OR THE SUPPLY LINE AND EVAPORA-TOR ARE BEING EMPTIED BY THE CHLORINATOR OROTHER MEANS OF DISPOSAL. FAILURE TO FOLLOW THISPROCEDURE MAY RESULT IN AN OVERPRESSURE CONDI-TION AND DISCHARGE OF GAS FROM THE RELIEF SYSTEM.

3.1.3 Cathodic Protection System

Sodium sulfate is added to the water bath to increase its conductivity, thusaiding in the start of the cathodic protection process. Observe and followthese instructions:

a. Remove the caplug covering the 2-3/4-inch hole in the top of thetank.

WARNING: THE TOP OF THE TANK WILL BE HOT (180°F). TOAVOID SEVERE PERSONAL INJURY DUE TO HOT SURFACES,DO NOT REMOVE OR REINSTALL CAPLUG WITH BAREHANDS; USE A GLOVE OR OTHER INSULATING MATERIAL.

b. Add 1/4 lb. (approximately 1/4 of the bottle provided) of sodiumsulfate to the water bath when starting up for the first time. For bestresults, dissolve 1/4 lb. of sodium sulfate in one or two quarts ofwater and pour this solution into the water tank.

c. Replace caplug (See above warning.)

NOTE: Due to the insulating quality of the chlorine cylinder paintfinish, there may be little or no initial reading on the milliammeter.If a reading is now observed, adjust the potentiometer located next tothe milliammeter on the front of the control box to obtain a readingbetween 25 and 50% on the meter. See Dwg. 50.200.170.010. If theneedle remains on zero, check the cathodic protection system’s elec-trical connections. Before opening the control box to check connec-tions, observe the following warning.

WARNING: LINE VOLTAGE IS PRESENT AT THIS LOCATIONEVEN WHEN THE PANEL POWER SWITCH IS IN THE OFFPOSITION. TO AVOID POSSIBLE SEVERE PERSONAL INJURY

!

!

!


IM 50.200AA UA (B/1-01) 29

DUE TO ELECTRIC SHOCK, DISCONNECT THE EXTERNALPOWER SUPPLY BEFORE SERVICING.

d. If, after six months to one year, the milliammeter shows no reading,add another 1/4 lb. of sodium sulfate. If the water bath is drained,add 1/4 lb. of chemical on refill and adjust for a 25 to 50% reading.

NOTE: One-quarter lb. of chemical is all that is required at eachaddition of chemical. Using more than 1/4 lb. will not increase theefficiency of the cathodic protection system.

CAUTION: Always replace caplug after adding sodium sulfate solu-tion. This will prevent the introduction of foreign objects or sub-stances into the water bath.

3.1.4 Enclosure

Replace the enclosure on the evaporator. The evaporator is now ready foroperation. Refer to Dwg. 50.200.060.030.

3.2 Operation

3.2.1 Startup

When the procedures in paragraph 3.1, Preparation For Initial Operation,are completed, the water bath will be at the operating temperature of180°F. Slowly open the evaporator liquid supply valve. Open the outletvalve of the evaporator and put the chlorinator in service.

3.2.2 Operating Routine

Regular observation of the evaporator function indicators and alarm lightswill enable the operator to verify that the evaporator is working properly.

• EVAPORATOR PRESSURE GAUGE: The gauge indicates the pres-sure inside the evaporator cylinder, which is also the equilibrium pres-sure inside the chlorine supply container corresponding to the tem-perature of the chlorine liquid. If a blockage develops or a valve isclosed while chlorination is stopped, the pressure will increase sub-stantially. Normal operating pressure is 30 to 140 psi. If the pressurerises into the 180 to 200 psi range, take corrective action. Refer tothe Troubleshooting guide, Symptoms Group 2, in Section 4. Thepressure gauge is designed for exposure up to 600 psi without loss ofcalibration.

!

IM 50.200AA UA (B/1-01)


30

• WATER TEMPERATURE METER: The meter indicates the waterbath temperature. Normal operating temperature is approximately180°F.

• CONTROL BOX ALARM LIGHTS: The front of the control boxcontains three alarm lights and one power indicator light. The redHIGH TEMPERATURE alarm lights will go on when the water bathtemperature exceeds 200°F. The orange LOW TEMPERATUREalarm light will illuminate when the water bath temperature dropsbelow 160°F. If the water level drops below the bottom of thesightglass, the red LOW WATER LEVEL alarm light will come on.

NOTE: When the evaporator is turned on after short-term shutdownand the water is at normal operating level, the LOW WATER LEVELalarm light will remain on for several seconds. Then the circulatingpump will turn on. This pause is a part of the normal control opera-tions of the evaporator.

• CATHODIC PROTECTION AMMETER: Refer to paragraph 3.1,Preparation For Initial Operation. The meter may not indicate cur-rent for the first several months of service. Normal operating currentis between 50 and 250 milliamps. If it exceeds this value, it may bereduced by turning counterclockwise the knob located to the right ofthe milliammeter. If the current is allowed to rise above 250 milliamps,the anodes of the cathodic protection system will not last as long asthey would if the reading is maintained. The 50- to 250-milliampsreading assures full protection. More than 250 milliamps unneces-sarily consumes anodes.

• WATER LEVEL SIGHTGLASS: The sightglass provides a directindication of water bath level. If a LOW WATER LEVEL alarm lightor separate alarm actuates, observation of the sightglass will confirmthe low level condition or indicate a low water level switch malfunc-tion. The normal operating level in the sightglass tube, as maintainedby the automatic water level control, is 2/3 to 3/4 full. Low waterlevel is approximately 1/8 full or less.

• OBSERVATION OF NEED FOR CYLINDER CLEANING: A build-up of impurities in the evaporator cylinder will result in gradual lossof heat transfer and loss of evaporating capacity. An obvious indica-tion of this will be a cooling of the pipe coming from the outlet of thevacuum regulator-check unit (or gas pressure reducing valve). Thiscooling can be sensed by touching the pipe or observing condensa-tion of frost on the outlet pipe.


IM 50.200AA UA (B/1-01) 31

WARNING: TO AVOID DAMAGING THE INTERNAL PLASTICCOMPONENTS OF THE CHLORINATOR, OR TO AVOID SE-VERE PERSONAL INJURY CAUSED BY THE RELEASE OFCHLORINE GAS, BE CERTAIN THAT NO LIQUID CHLORINEEXISTS IN CHLORINATOR ROTAMETER TUBE. IF CHLORINELIQUID IS PRESENT IN THE ROTAMETER TUBE, IMMEDI-ATELY SHUT DOWN THE EVAPORATOR BY FOLLOWINGTHE CYLINDER EVACUATION PROCEDURES IN PARA-GRAPH 3.2.3B. REFER TO SECTION 4 FOR CYLINDER CLEAN-ING INSTRUCTIONS.

The need for cylinder cleaning can also be determined by observingthe gas temperature gauge on the front panel next to the pressuregauge. The gas temperature gauge will show a drop in gas temperatureat a given pressure and rate of withdrawal as impurities are depositedinside the chlorine cylinder. With some experience, the operator canuse this indication to determine when the evaporator will need clean-ing. As long as there are no blockages or closed valves between theevaporator and the supply, the pressure within the evaporator cylinderis the same as the pressure in the tank car or ton container, which inturn is a function of the temperature of the liquid chlorine in the tankcar or ton container. By reading the pressure gauge for the evaporatorcylinder, a close approximation of the liquid chlorine temperature canbe obtained by referring to the temperature/pressure scale on the faceof this gauge.

After evaporation at this temperature, the chlorine will pick up heatduring its passage through the evaporator. The additional heat pickedup is called “Superheat”. The amount of superheat at a particular timeis function of the difference in temperatures between the water bathand the liquid chlorine, the efficiency of heat transfer through the wallof the chlorine cylinder and the rate of withdrawal of gaseous chlorine.The face of the pressure gauge is graduated for pressure and the equi-librium (evaporating) temperature at that pressure. Using the gas tem-perature gauge, an approximate value of superheat can be obtained byreading the pressure and gas temperature gauge. For example, thepressure is 85 psi and temperature is 87°F. Reference to the tempera-ture scale on the pressure gauge will show that the equilibrium (evapo-rating) temperature for a pressure of 85 psi is 70°F. Since the actualgas temperature is 87°F, the superheat is 17°F. It will be observed thata decrease in the withdrawal rate will result in an increase in superheat.Likewise, increasing the withdrawal rate will result in a decrease insuperheat.

!

IM 50.200AA UA (B/1-01)


32

In general, as long as there is some superheat, the evaporator is func-tioning properly. By periodically recording the superheat at a givenchlorine feed rate and water bath temperature, the plant operator hasan indication of the condition of the inside of the chlorine cylinder.Contaminants in the liquid chlorine tend to accumulate in the evapo-rator cylinder and deposit on the inside wall, thus reducing heat trans-fer from the water bath. When sufficient impurities have collected toresult in insufficient heat transfer, the superheat will have droppedclose to zero and liquid chlorine will begin passing through the evapo-rator outlet, resulting in a hazardous condition of operation. There-fore, a periodic record of superheat will permit the operator to sched-ule the cleaning of the evaporator well in advance. As noted previ-ously, the evaporator is functioning properly as long as there is somesuperheat. Due to tolerance in gauges, the first cleaning of a newevaporator should be scheduled when the superheat has dropped toabout 10°F. Examination of the interior of the cylinder when the head(upper flange) is removed for cleaning can guide the operator in judg-ing what value of superheat should be used as a criterion for furthercleanings.

NOTE: The specific pressure/temperature values used in this ex-ample were obtained from the Chlorine Manual, published by theChlorine Institute, Inc.

3.2.3 Shutdown

• Short-Term Shutdown.

a. Close the evaporator outlet valve. When the outlet valve is closed,gas will form inside the cylinder, pushing liquid back to the sup-ply container.

b. If the supply container does not have adequate reserve capacityto accept the maximum contents being forced from the evapora-tor cylinder, do not stop chlorination.

WARNING: TO AVOID RUPTURE OF THE SUPPLY CON-TAINER, CAUSING POSSIBLE SEVERE PERSONAL INJURY,CLOSE THE SUPPLY VALVE AND USE THE CHLORINATOROR GAS DISPOSAL SYSTEM TO COMPLETELY EVACUATETHE EVAPORATOR CYLINDER AND ITS CONNECTING PIPE-LINES.

NOTE: The warning above applies if a situation is created, for ex-ample, where a new, capacity-filled supply is connected to the evapo-

!


IM 50.200AA UA (B/1-01) 33

rator and the previous supply is disconnected or closed. If a liquidsupply valve is then closed, after additional liquid is forced into thecapacity-filled supply container, pressures capable of rupturing thecontainer will develop with a slight increase in temperature.

c. If the supply container can accept the maximum contents with-out exceeding its rated capacity, the outlet valve can remain closedthroughout the short-term shutdown; however, do not shut anyvalves in the chlorine supply piping. With the evaporator outletclosed or with chlorination stopped, as long as the inlet valve tothe evaporator and the valves to the ton container or tank cars areopen, the pressure within the evaporator cylinder is limited tonever exceeding the pressure in the ton container or tank car.

WARNING: TO AVOID AN OVERPRESSURE CONDITIONTHAT MAY RESULT IN A DISCHARGE OF GAS FROM THEGAS PRESSURE RELIEF SYSTEM, DO NOT CLOSE ANY VALVEOR VALVES BETWEEN THE EVAPORATOR AND THE CHLO-RINE SUPPLY WITHOUT FOLLOWING THE EVACUATIONPROCEDURE DESCRIBED IN STEP B, BELOW. LIQUID CHLO-RINE HAS A HIGH COEFFICIENT OF THERMAL EXPANSION.DO NOT CLOSE VALVES IN SUCH A WAY THAT LIQUIDCHLORINE MAY BE TRAPPED, SINCE DANGEROUS PRES-SURES CAPABLE OF RUPTURING THE PIPING SYSTEM MAYBUILD UP WITH A SMALL INCREASE IN TEMPERATURE.

d. Re-open the gas outlet valve to resume evaporator operation.

• Long-Term Shutdown.

a. Follow the instruction for Short-Term Shutdown, steps a, b, andc. If the liquid can be safely pushed back to the supply container,shut the evaporator outlet valve for a period of approximately 30minutes. Under these conditions, most of the liquid chlorine willbe forced back to the supply tank through the nipple and remain-ing liquid will be evaporated by the heat of the water bath.

b. At the end of this period, shut the supply valve at the tank car orthe ton container; immediately open the evaporator outlet valveand run the chlorinator to exhaust the gas in the evaporator andthe gas and liquid in the inlet line.

c. When the evaporator pressure gauge reads zero, the chlorine out-let valve may be closed.

!

IM 50.200AA UA (B/1-01)


34

d. If the evaporator pressure gauge shows pressure after the outletvalve has been closed for several minutes, repeat steps a throughc until the evaporator pressure gauge reads zero with outlet valveclosed. Then turn off power to the control box and alarm units.

e. If no standby evaporator is being used, shut down the chlorina-tor.

f. Drain the hot water tank by opening the drain valve at the back ofthe unit.

g. Drain the heat exchanger by removing the 1/2-inch plug at thebottom (underside) of the heat exchanger. A small container maybe used to capture the water (approximately 1/2 gallon) when theplug is removed.

WARNING: TO AVOID SEVERE PERSONAL INJURY WHENHOT WATER DRAINS OUT OF HEAT EXCHANGER, ALLOWWATER TO COOL BEFORE REMOVING PLUG.

h. Replace the plug after the water has completely drained from theheater. Remove the 1/4 NPT plug at the bottom of the pump im-peller housing (Dwg. 50.200.110.010 in Section 2). Allow thepump to drain thoroughly before replacing the plug.

CAUTION: The pump and heat exchanger must be drained to pre-vent corrosion build-up during long-term shutdown.

3.3 Theory Of Operation

Liquid chlorine from the source container is piped to the evaporator chlo-rine cylinder. This cylinder is immersed in a temperature-controlled hotwater bath. Liquid enters the cylinder through the top, but a drop pipeinside carries the liquid almost to the bottom. The alternate inlet connec-tion at the bottom has a riser that terminates at approximately the samelevel as the end of the drop pipe. Thus, the liquid chlorine enters near thebottom of the cylinder and the vapor leaves from a point somewhat belowthe top, as the discharge connection also has a short drop pipe. This ar-rangement limits cylinder pressure to that of the source container andprevents the complete filling of the cylinder with liquid chlorine. The heattransfer surface in the gas-filled portion of the cylinder superheats thechlorine vapor.

!

!


IM 50.200AA UA (B/1-01) 35

When the entering liquid chlorine contacts the hot inner surface of theevaporator cylinder, it boils inside this cylinder. When sufficient gas hasformed to satisfy the demand of the chlorination process, the incomingliquid chlorine flow stabilizes because the pressure in the evaporatorcylinder and supply container have equalized. If too much liquid enters theevaporator cylinder, more gas is formed than is required by the chlorina-tion process. The evaporator cylinder pressure rises above that of thesupply container, causing some liquid chlorine to be forced back into thesupply container until the pressure in the evaporator cylinder and supplycontainer have again equalized. Therefore, as long as the line to the supplycontainer is open, the liquid level in the evaporator cylinder is automati-cally adjusted by the rate of gas used. If no gas is withdrawn, the evapo-rator will empty itself as the gas formed pushes the liquid back to thesupply container. When the liquid level falls below the end of the inletpipe, it is pushed back to the supply container by gas until no liquidremains. Conversely, if more gas is called for than a particular liquid levelis able to generate, the liquid level will rise, causing more liquid to changeto gas to meet the demand.

NOTE: For detailed description of control equipment, refer to Sec-tion 4 - Service.

IM 50.200AA UA (B/1-01)


36

EVAPORATOR FRONT PANEL INDICATORS - OPERATION

50.200.170.010ISSUE 0 4-88


IM 50.200AA UA (B/1-01) 37

SECTION 4 - SERVICE

List Of Contents

PARA./DWG. NO.

General ...................................................................... 4.1Inspection ............................................................... 4.1.1

Temperature Control and Indication ......................... 4.2High and Low Temperature Switches ...................... 4.3Relief System Pressure Switches .............................. 4.4Automatic Water Level Control and Low Level

Switches ................................................................. 4.5Electrical System Checks ......................................... 4.6

Temperature Switches ........................................... 4.6.1Water Level Switch and Low Level Switch .......... 4.6.2Pressure Switch (Evaporator Relief Systems) ....... 4.6.3

Cathodic Protection System...................................... 4.7Power and Alarm Lights on Control Box ................. 4.8Hot Water Circulating Pump .................................... 4.9Evaporator Pressure Relief System .......................... 4.10Liquid Line Pressure Relief System ......................... 4.11“In-Place” Cleaning of the Evaporator Cylinder ...... 4.12Five Year Inspection of Evaporator Cylinder ........... 4.13Operational Inspection of the Pressure Relief

Systems .................................................................. 4.14Evaporator Gas Pressure Relief System ................ 4.14.1Liquid Line Pressure Relief System ...................... 4.14.2Pressure Alarm Switch .......................................... 4.14.3

Troubleshooting Guide ............................................. 4.15Warning Summary Pages ......................................... 2 PagesCaution Summary Page ............................................ 1 PageIllustrations

Wiring - Cathodic Protection ................................. 50.200.140.010Service

U20208 Drying Kit ............................................. 50.200.150.010Lifting Method .................................................... 50.200.150.060

Schematic WiringLevel and Temperature Control .......................... 50.200.155.020Controls and Equipment ..................................... 50.200.155.010

IM 50.200AA UA (B/1-01)


38

4.1 General

WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURYFROM EXPOSURE TO CHLORINE, REVIEW THE CHLORINEHANDLING MANUAL BEFORE BREAKING ANY CHLORINECONNECTIONS.

Piping leaks are usually caused by either improperly assembling pipejoints or reusing gaskets.

WARNING: LINE VOLTAGE IS PRESENT INSIDE THE CON-TROL BOX. TO AVOID POSSIBLE SEVERE PERSONAL INJURYFROM ELECTRICAL SHOCK, DEACTIVATE EXTERNALPOWER SOURCE(S) BEFORE OPENING THE CONTROL BOX.

WARNING: TO REDUCE THE POSSIBILITY OF CHLORINELEAKAGE, ASSEMBLE ALL THREADED JOINTS IN ACCOR-DANCE WITH THE CHLORINE HANDLING MANUAL. DO NOTREUSE GASKETS; ALWAYS USE NEW GASKETS.

WARNING: TO AVOID SEVERE PERSONAL INJURY, WHENANY PIPING CONNECTION IS BROKEN, EVEN FOR A SHORTPERIOD OF TIME, PLUG THE RESULTANT OPENING IMME-DIATELY TO PREVENT THE ENTRANCE OF MOISTURE.MOISTURE, INCLUDING ATMOSPHERIC, WHEN COMBINEDWITH CHLORINE, IS HIGHLY CORROSIVE TO PIPING. WHENCHANGING CHLORINE SUPPLY CONTAINERS, PREVENTTHE ENTRANCE OF MOISTURE INTO THE CHLORINE PIP-ING BY PLUGGING OPEN ENDS OR USING AUXILIARY TONCONTAINER VALVES.

4.1.1 Inspection

When performing preventive maintenance or servicing of the evaporator,perform the following inspection routine:

a. Check for any physical damage to removed parts (chipped, cracked,damaged threads; excessive corrosion). Replace all damaged com-ponents.

b. Discard and replace all removed gaskets, seals, and O-rings.

NOTE: Refer to Section 6 for a list of approved USF/W&T spareparts.

!

!

!

!


IM 50.200AA UA (B/1-01) 39

4.2 Temperature Control and Indication

The tank water temperature is sensed by an electronic temperature probeimmersed in the water bath. The probe is mounted in the probe housingblock located on the top of the hot water tank. The electronic signal fromthe probe is processed by the printed circuit board to control the operationof the heat exchanger and to indicate the water temperature on the analogmeter on the front of the control box. This circuitry has been factory-calibrated; adjustments are not required. Refer to the TroubleshootingGuide in case of malfunction.

4.3 High and Low Temperature Switches

This is a dual temperature switch that senses the water bath temperaturedirectly at the tank. The low temperature switch (TS3-LOW) is set to160°F; the high temperature switch (TS2-HIGH) is set to 200°F. Theswitches are rated for 10 amperes at 120 VAC and 30 VDC. Alarm con-nections for the switches are located on the printed circuit board inside thebox.

4.4 Relief Systems Pressure Switches

This single-setting pressure sensing device is pre-set for 20 psi at thefactory and requires no readjustment. The switch is rated at 10 amperes for125 or 250 Vac.

Should the pressure switch (U24680) function improperly on either theliquid line pressure relief system (U27615) or the pressure relief system(U25471), proceed as follows:

WARNING: TO AVOID A MAJOR RELEASE OF CHLORINE,CAUSING POSSIBLE SEVERE PERSONAL INJURY, DO NOTREMOVE THE PRESSURE RELIEF SYSTEM WHILE THEEVAPORATOR IS PRESSURIZED. BEFORE ATTEMPTING TOSERVICE THE PRESSURE RELIEF SYSTEM, FOLLOW STEPSA AND B IN PARAGRAPH 4.12.

If after performing step a in paragraph 4.12, the pressure switch remainsactuated, chlorine under pressure is still present in the pressure reliefsystem. This indicates a leaking (not ruptured) rupture disc.

WARNING: TO AVOID SEVERE PERSONAL INJURY DUE TOINHALATION OF CHLORINE GAS, USE AN APPROVED GASMASK AND VENTILATION EQUIPMENT WHEN REMOVINGTHE RUPTURE DISC.

!

!

IM 50.200AA UA (B/1-01)


40

a. Turn off the evaporator controls, alarm unit power supplies, and powerto the alarm circuit being serviced. Ensure that the chlorine supplyvalve will remain closed while work is in progress.

b. Remove the front cover from the pressure switch and disconnect thealarm wiring and electrical conduit from the switch’s terminals.

NOTE: The relief system pressure switch is protected from corrosionby an oil-filled diaphragm capsule.

CAUTION: Do not disturb the threaded connections between thepressure switch and this capsule, as a loss of oil will cause the pressureswitch to malfunction or become inoperative.

c. Remove the pressure switch-diaphragm capsule assembly from thepressure relief system at the point where the diaphragm capsule bot-tom connection and the expansion tank reducing bushing meet. Donot remove the reducing bushing from the expansion tank, as this isa permanent joint.

d. Using the Resistance Mode, connect a volt/ohmmeter across the “C”(Common) and “NO” (Normally Open) terminals.

e. Connect the pressure switch-diaphragm capsule assembly to a con-trolled pressure source. Install a calibrated pressure gauge in the lineto the source.

f. Raise and lower the pressure to determine if the switch is function-ing properly and at what pressure the switch closes.

g. The pressure switch should be able to close repeatedly on a risingpressure at 15 to 20 psi. If it does not, adjust the response point byturning counterclockwise the knurled nut on the switch located be-low the microswitch. Repeat step f and this step to confirm properactuating pressure.

h. Reconnect the alarm wiring and the conduit to the switch and replacethe front cover.

i. Energize the alarm portion of the electrical circuit.

!


IM 50.200AA UA (B/1-01) 41

4.5 Automatic Water Level Control and Low Level Switches

Water level is sensed by four stainless steel probes (one common, one lowlevel, and two differential service) mounted in the probe housing block onthe top of the tank. Two independent switches are actuated by these probes.The differential service probes actuate the Automatic Water Level Con-trol Switch filling the evaporator hot water tank 2/3 to 3/4 of the height ofthe sightglass and will refill the tank when the water level has dropped toabout two inches or more below this position. The Low Water Levelswitch will operate just before the water level drops below the sightglass.The probe lengths are pre-cut and no adjusting is required.

Periodically clean the sightglass tube in the water level indicator on thefront panel so that the water level can be easily seen. The tube is easilyaccessible after removing the plastic indicator cover.

WARNING: TO AVOID SEVERE PERSONAL INJURY FROMBURNS DUE TO THE HOT WATER IN THE SIGHTGLASS TUBE,TURN THE POWER OFF AND DRAIN THE TANK ENOUGH SOTHAT NO WATER IS VISIBLE IN THE SIGHTGLASS. ALLOWTHE SIGHTGLASS TO COOL BEFORE HANDLING.

4.6 Electrical System Checks

Make electrical checks described in paragraphs 4.6.1 and 4.6.2.

WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURYDUE TO EQUIPMENT MALFUNCTION, SEMI-ANNUALLYMAKE A COMPLETE ELECTRICAL CHECK OF THE OPERA-TION OF THE TEMPERATURE, WATER LEVEL, AND PRES-SURE RELIEF ALARM SWITCHES. IF THE APPROPRIATE RE-SPONSE IS NOT OBSERVED, REPLACE THE FAULTY CON-TROL UNIT.

4.6.1 Temperature Switches

The high and low temperature switches are factory calibrated. No adjust-ment is necessary.

4.6.2 Water Level Switch and Low Level Switch

a. Drain the water to below the sightglass and allow it to refill. If levelcontrol is working properly, it will refill automatically and the lowlevel alarm will activate and reset.

!

!

IM 50.200AA UA (B/1-01)


42

b. Close drain tightly when testing is completed.

4.6.3 Pressure Switch (Evaporator Relief System)

a. Remove the switch cover.

b. Using a thin screwdriver, operate the microswitch and observe op-eration of the alarm.

WARNING: TO AVOID POSSIBLE SEVERE PERSONAL INJURYFROM ELECTRICAL SHOCK, BE CAREFUL NOT TO TOUCHTHE METAL SCREWS ON THE TERMINALS. THEY ARE CON-NECTED TO 115 VOLTS.

c. Replace the switch cover when testing is completed.

4.7 Cathodic Protection System

An annual inspection of the cathodic protection anodes will, under normalconditions, show that the anodes are almost expended. Replace the fourmagnesium anodes. On a new evaporator, the anodes normally last wellover a year. After the first replacement, they should be replaced annually.

Before new anodes are installed, it is recommended that the water bedrained from the system and an inspection of the tank and cylinder bemade. Sludge formed by the corrosion of the anodes should be flushedfrom the hot water tank and discharged through the water overflow line.

If the cathodic protection system has been operated in the recommendedrange, little or no corrosion will be found. Add fresh water after the newanodes have been installed. If no reading on the ammeter is obtained,additional sodium sulfate (1/4 lb.) may be added.

4.8 Power and Alarm Lights on Control Box

The lamps inside the power and alarm lights on the control box are ratedfor 5000 hours of life, therefore, they will eventually burn out. See Section6, Spare Parts List, for information on ordering replacement bulbs.

4.9 Hot Water Circulating Pump

This pump is completely sealed; no lubrication or maintenance is re-quired. However, the manufacturer of the pump has made two repair kitsavailable for the pump:

!


IM 50.200AA UA (B/1-01) 43

• Pump housing seal kit

• Shaft seal kit.

Part numbers for these kits are found in the Section 6 - Spare Parts List.

The pump is the end-suction type. If the evaporator is to be shut down foran extended period of time, remove the plug at the bottom of the pumpimpeller housing to fully drain the pump.

CAUTION: Failure to fully drain the pump could lead over time tocorrosion build-up and permanently damage the pump.

Replace plug after draining.

4.10 Evaporator Pressure Relief System

A pressure relief system conforming to ASME Boiler and Pressure VesselCode recommendations is supplied with the evaporator. This pressurerelief system consists of a rupture disc (rupture point 400 psi), a pressureswitch (set at 20 psi), and a pressure relief valve (set at 560 psi). Theevaporator will not, under normal operating conditions, reach these pres-sures, but in abnormal circumstances, such as a closed inlet and outletvalve, these pressures could develop. The alarm actuates when the discruptures or develops a leak. This alarm serves as a signal that conditionsexist that can cause gas to be relieved out of the system. A Pressure ReliefSystem Alarm indicates that the evaporator system requires immediatecorrective attention.

WARNING: TO AVOID SEVERE PERSONAL INJURY, BE FA-MILIAR WITH EMERGENCY PROCEDURES, TROUBLE-SHOOTING PROCEDURES, AND SERVICE SO THAT PROMPTAND EFFECTIVE ACTION CAN BE TAKEN.

Overpressure in the evaporator cylinder can result from a closed outletvalve or stopping of the chlorinator in conjunction with a blockage in theliquid inlet line, a closed valve in the liquid inlet line, or excessive “airpadding” of tank cars. If the pressure relief system alarm actuates, thecause must immediately be determined and corrected. Refer to the Trouble-shooting Guide, Symptom, Group 2, in this section. If an alarm is actuated,observe the evaporator pressure gauge. If it reads normal (30 to 140 psi),the rupture disc may be faulty.

To resume operation after correction of the overpressure problem, replacethe rupture disc. Purge any gas from the pressure relief system piping lines

!

!

IM 50.200AA UA (B/1-01)


44

with dry air, nitrogen, or carbon dioxide as soon as possible after systemactuation. Check the relief valve for leaks using 150 psi pressure. Thevalve must be leak-tight to function properly.

WARNING: TO PREVENT MAJOR RELEASE OF CHLORINE,CAUSING POSSIBLE SEVERE PERSONAL INJURY, DO NOTREMOVE THE PRESSURE RELIEF SYSTEM WHILE THEEVAPORATOR IS PRESSURIZED.

Before attempting to service the relief system, follow step a in paragraph4.12, “In-Place” Cleaning Of Evaporator Cylinder. If, after this step, thepressure switch remains actuated, chlorine under pressure is still presentin the pressure relief system. This indicates a leaking (not ruptured) rup-ture disc.

WARNING: TO AVOID SEVERE PERSONAL INJURY DUE TOINHALATION OF CHLORINE, USE AN APPROVED GAS MASKAND VENTILATION EQUIPMENT WHEN REMOVING THERUPTURE DISC.

If the disc is removed and is not ruptured, a leaking disc is the trouble. Inthis case, a closed valve and/or blockage are not likely to be found. Re-place the rupture disc.

CAUTION: When installing the rupture disc, ensure that the grooveof disc fits the mating tongue of the safety head to avoid altering theoperating level of the rupture disc.

WARNING: TO AVOID THE RUPTURE OF THE EVAPORATORPRESSURE CYLINDER OR ITS CONNECTING PIPELINES,CAUSING POSSIBLE SEVERE PERSONAL INJURY ANDEQUIPMENT DAMAGE, DO NOT ATTEMPT TO DISASSEMBLEOR REPAIR THE RELIEF VALVE. IF IT MALFUNCTIONS, RE-PLACE IT.

CAUTION: Purge the valve of gas as soon as possible after operationbefore moisture can combine with the gas to become corrosive.

4.11 Liquid Line Pressure Relief System

Overpressure in the liquid line is usually the result of a valve closed at thesupply and at the evaporator at the same time. A contaminant blockage inthe inlet line with a valve closed on either side can also cause an overpres-sure problem. The rupture disc will rupture at 400 psi, activating an alarm.If the system activates, as indicated by the alarm switch, the cause must

!

!

!

!

!


IM 50.200AA UA (B/1-01) 45

immediately be determined and corrected. Usually, corrective action willinvolve opening one or more valves. To restore the liquid line pressurerelief system, replace the rupture disc as instructed in the preceding sec-tion.

WARNING: TO AVOID MAJOR RELEASE OF CHLORINE,CAUSING POSSIBLE SEVERE PERSONAL INJURY, DO NOTOPEN THE LIQUID LINE PRESSURE RELIEF SYSTEM WHILETHE EVAPORATOR IS PRESSURIZED.

Before attempting to service the relief system, follow step a in paragraph4.12, “In-Place” Cleaning Of Evaporator Cylinder.

CAUTION: Do not disturb the threaded joints between the alarmswitch and the protective capsule. Any oil loss will result in a faultypressure-gauge reading.

If this rupture disc is removed and is not ruptured, a leaking disc is thetrouble. In this case, closed valves and/or blockage are not likely to befound. Replace leaking rupture disc. If the pressure switch remains actu-ated after performing step a in paragraph 4.12, “In-Place” Cleaning of theEvaporator Cylinder, chlorine is still under pressure in the pressure reliefsystem. This indicates a leaking (not ruptured) rupture disc.

WARNING: TO AVOID SEVERE PERSONAL INJURY DUE TOINHALATION OF CHLORINE, USE AN APPROVED GAS MASKAND VENTILATION EQUIPMENT WHEN REMOVING THERUPTURE DISC.

CAUTION: When installing rupture disc, ensure that the groove ofthe disc fits the mating tongue of safety head to avoid altering theoperating level of the rupture disc.

4.12 “In-Place” Cleaning of the Evaporator Cylinder

The rate of residue buildup varies considerably with the type of impurity,the source of chlorine supply, the rate of usage, and various other factors.The following maintenance cleaning procedure should be implementedevery 12 months, or sooner if a loss in superheat or reduction in chlorinecapacity is observed. These instructions describe a method for cleaningchlorine residue from the evaporator without removing the cylinder. Thespecial accessories required by this procedure for cleaning and drying areavailable in kit form in USF/W&T Part No. U20208. The replacementgaskets required for each evaporator are included in parts kit U28839. Awater supply line of 3/4-inch pipe size at a minimum pressure of 20 psi

!

!

!

!

IM 50.200AA UA (B/1-01)


46

must be available. The hose required is not furnished as part of either kit.If these instructions are carefully followed, the cylinder should be cleanand dry when restored in service.

In some circumstances, it could be desirable to thoroughly review therelative advantages of cleaning versus simply replacing the evaporatorcylinder, thereby eliminating the time and necessary complexities of thecleaning process and enjoying the security and full operating capacityprovided by a new cylinder. This choice would take into consideration thelocal cost and availability of personnel, facilities, equipment, and timerequired for the cleaning process measured against the installed cost of anew cylinder. This comparison can be made only on the basis of individuallocal circumstances.

Under normal operating conditions, deposits will accumulate in the evapo-rator cylinder and, over a period of time, will reduce its operating capacity.For this reason, periodic cleaning is required to remove these deposits.

CAUTION: Refer to the instruction book provided with the equip-ment for complete details on recommended frequency and proce-dures to properly accomplish this cleaning.

To clean the evaporator cylinder “In-Place,” perform the following steps.

WARNING: ANY MOISTURE, INCLUDING ATMOSPHERIC, ISHIGHLY CORROSIVE WHEN COMBINED WITH CHLORINE.TO AVOID SEVERE PERSONAL INJURY AND EQUIPMENTDAMAGE AS A RESULT OF EXTREME CORROSION, THE CYL-INDER MUST BE ABSOLUTELY DRY AFTER CLEANING ISCOMPLETED.

a. With the evaporator controls on, evacuate the chlorine cylinderas follows:

(1) Close the evaporator outlet valve. When the outlet valve is closed,gas will form inside the cylinder, thereby pushing liquid chlorineback to the supply container.

WARNING: IF THE SUPPLY CONTAINER DOES NOT HAVEADEQUATE RESERVE CAPACITY TO ACCEPT THE MAXI-MUM CONTENTS THAT ARE BEING FORCED FROM THEEVAPORATOR CYLINDER, DO NOT STOP THE CHLORINA-TOR. INSTEAD, IN ORDER TO PREVENT OVER-FILLING ANDDEVELOPING EXTREME PRESSURES WITHIN THE SUPPLYCONTAINER, CLOSE THE SUPPLY VALVE AND USE THE

!

!

!


IM 50.200AA UA (B/1-01) 47

CHLORINATOR OR GAS DISPOSAL SYSTEM TO COM-PLETELY EVACUATE THE EVAPORATOR AND ITS CON-NECTING PIPELINES.

(2) If the maximum amount of contents can be forced out of the cyl-inder to the supply without exceeding the rated capacity of thesupply container, the outlet valve can be closed. However, do notshut any valves in the chlorine supply piping.

NOTE: If the evaporator outlet is closed or chlorination is stopped,and if the inlet valve to the evaporator and the valves to the toncontainer or tank cars are open, the pressure within the evaporatorcylinder will not exceed the pressure in the ton container or tank car.

WARNING: TO AVOID AN OVERPRESSURE CONDITION CA-PABLE OF RUPTURING THE PIPING SYSTEM AND RESULT-ING IN A DISCHARGE OF GAS FROM THE GAS PRESSURERELIEF SYSTEM, CAUSING POSSIBLE SEVERE PERSONALINJURY AND EQUIPMENT DAMAGE, DO NOT CLOSE ANYSUPPLY VALVE WITHOUT FOLLOWING THE EVACUATIONPROCEDURE FOR LONG-TERM SHUTDOWN IN PARAGRAPH3.2.3B.

NOTE: Liquid chlorine has a high coefficient of thermal expansion.

WARNING: DO NOT CLOSE VALVES IN SUCH A WAY THATLIQUID CHLORINE MAY BE TRAPPED, SINCE DANGEROUSPRESSURES CAPABLE OF RUPTURING THE PIPING SYSTEMMAY BUILD UP WITH A SMALL INCREASE IN TEMPERA-TURE.

(3) Leave the evaporator outlet valve shut for approximately 30 min-utes. Under these conditions, most of the liquid chlorine will beforced back to the supply tank through the inlet nipple and theremaining liquid will be evaporated by the heat of the water bath.At the end of this period, shut the valve at the tank car or the toncontainer, immediately open the evaporator chlorine outlet valve,and run the chlorinator to exhaust the gas in the evaporator andthe gas and liquid in the inlet line. When the evaporator pressuregauge reads zero, the chlorine outlet valve may be closed. If theevaporator pressure gauge shows pressure after the outlet valvehas been closed for several minutes, repeat the above procedureuntil the evaporator pressure gauge reads zero with outlet valveclosed. Then turn off power to the control system and alarm units.

!

!

IM 50.200AA UA (B/1-01)


48

If no standby evaporator is being used, shut down the chlorina-tor. Remove the enclosure and the associated hardware.

b. Through the port hole located on top of the hot water tank, examinethe visible exterior of the chlorine cylinder with a flashlight. Inspectthe surface. If signs of pitting or corrosion are evident, proceed toparagraph 4.13, Five-Year Inspection.

WARNING: TO AVOID SEVERE PERSONAL INJURY DUE TOINHALATION OF CHLORINE, USE AN APPROVED GAS MASKAND BE PREPARED TO RECONNECT UNION QUICKLY IFTHERE IS ANY SIGN OF PRESSURE IN THE GAUGE LINE.

CAUTION: Do not disturb the threaded joint between the pressuregauge and the protecting oil-filled capsule. Any loss of oil will resultin a faulty indication by the pressure gauge.

c. Remove the temperature gauge bulb, if furnished, from the well inthe cylinder flange. Put on an approved-type gas mask before pro-ceeding. Disconnect the pressure gauge and the chlorine inlet andoutlet piping through the unions on the top of the cylinder.

d. Remove the upper cylinder flange cover plate and attached parts.Note the orientation of the chlorine inlet and outlet pipes.

CAUTION: Do not lose or misplace any of the nuts or brackets whendisassembling the upper flange.

e. Examine the interior of the cylinder. Because residues vary widely, itis not possible to describe exactly what may be found. However, itmay be expected that the upper portion of the cylinder will be linedwith a reddish-brown ferric chloride and the lower portion will con-tain a mixture of ferric chloride and other residue. This mixture maybe solid, liquid, or of some intermediate consistency.

f. Disconnect the ammonia union at the bottom chlorine inlet.

g. Using the flange PC22627 with nipple P6645, run a one-inch hoseline from the bottom chlorine inlet connection to a drain, as shown inDwg. 50.200.150.010.

h. Loosen any residual buildup from the internal walls of the cylinder.

!

!

!


IM 50.200AA UA (B/1-01) 49

i. Remove riser pipe P42718 from the bottom chlorine inlet and flushthe cylinder with water at a minimum of flow of 5 GPM. Continue toflush until the discharge water is clean.

j. Inspect the interior surface for pitting and corrosion. If pitting ex-ceeds 0.125-inch deep, if deep seated corrosion is apparent, or if cyl-inder seems to be of questionable condition, either proceed with thefive-year inspection procedure (paragraph 4.13) or replace the cylin-der and the appropriate components.

k. Thoroughly dry all internal surfaces and items within the cylinder, asany residual moisture will accelerate corrosion once combined withchlorine.

WARNING: ANY MOISTURE, INCLUDING ATMOSPHERIC, ISHIGHLY CORROSIVE WHEN COMBINED WITH CHLORINE.TO AVOID SEVERE PERSONAL INJURY AND EQUIPMENTDAMAGE FROM EXTREME CORROSION, AND POSSIBLEFAILURE OF THE CYLINDER, IT MUST BE ABSOLUTELY DRYAFTER CLEANING IS COMPLETED.

l. Unbolt and remove the bottom chlorine inlet pipe and flange. Re-move as much water as possible from the bottom of the cylinder witha rag or sponge to reduce drying time. Dry the bottom chlorine inletpipe thoroughly by baking or other means.

m. After the cylinder and other parts have been dried thoroughly, re-place the riser pipe and the cylinder flange cover plate using a newgasket P42293. Tighten the bolts uniformly.

NOTE: When replacing the cylinder flange cover plate, it is necessaryto observe the orientation of the inlet and outlet as stamped on the topof the flange and install accordingly.

WARNING: IF USER OUTLET PIPING IS CONNECTED TO THEEVAPORATOR INLET PIPE, LIQUID CHLORINE WILL DIS-CHARGE FROM THE EVAPORATOR, CAUSING EQUIPMENTDAMAGE AND POSSIBLE SEVERE PERSONAL INJURY.THEREFORE, ENSURE THAT USER PIPING IS CONNECTEDTO THE EVAPORATOR OUTLET PIPE.

n. Replace the bottom chlorine inlet pipe using a new gasket P12470.Connect the injector U20230 to the bottom chlorine inlet per Dwg.50.200.150.010. Install vacuum gauge U10264.

!

!

IM 50.200AA UA (B/1-01)


50

o. Turn on the evaporator controls and raise the temperature in the tankto 180°F. Pull a vacuum via the injector and maintain for 1/2 hour ata minimum of 22 inches of mercury.

p. Shut off the vacuum line and observe the vacuum gauge. If a vacuumof 22 inches of mercury or more can be held for one minute, and allparts of the system being dried are heated by the 180°F water bath,no further evacuation is necessary. If not, continue to pull a vacuumuntil 22 inches of mercury can be held for 1/2 hour.

q. Disconnect the injector and restore the bottom chlorine inlet piping.Use a new gasket P12470 in the ammonia-type union.

r. Remove the vacuum gauge and reconnect the chlorine pressure gaugeusing a new O-ring PXA26482.

s. Refer to paragraph 4.14, Operational Inspection of the Pressure Re-lief Systems, to test both the gas pressure relief system and the liquidline pressure relief system.

t. Refer to paragraph 3.1, Preparation For Initial Operation, to put theevaporator back into service.

u. Replace the enclosure and put the evaporator into service.

4.13 Five-Year Inspection of Evaporator Cylinder

This inspection is conducted either every five years, after 12 “in-place”cleanings, or when indicated by step j, paragraph 4.12.

NOTE: Canadian owners of evaporators must comply with local regu-lations governing periodic inspection and testing of the pressure ves-sel.

a. Complete steps a through l of the “in-place” cleaning of the evapora-tor cylinder procedure (paragraph 4.12).

b. Open the hot water tank drain valve just above the circulator waterpumps and allow the water to fully drain from the tank.

c. Remove the silicone bead surrounding the cylinder and the hot watertank.


IM 50.200AA UA (B/1-01) 51

d. Install the top flange and lifting brackets back into the evaporatorcylinder. Bolt the brackets securely in place, making sure the brack-ets are 180 degrees apart.

e. Disconnect the four cylinder mounting bolts beneath the evaporatorwater tank. Remove the cylinder from the hot water, using the twolifting brackets (see Dwg. 50.200.150.060).

f. Remove the external scale, etc. Verify that the inside of the cylinderis free of residue.

g. Weigh the cylinder. (Exclude the internal riser, top flange, brackets,bolts, nuts, gaskets, and down-drop pipes.)

h. If the present weight is 10 or more pounds less than the original tareweight (stamped on the cylinder), scrap the cylinder and replace itwith a new one.

NOTE: Exterior corrosion indicates improper maintenance of thecathodic protection system. Interior corrosion usually indicates thepresence of moisture in the cylinder.

i. Clean, inspect, and replace, as necessary, the hot water tank, tem-perature switch sensing bulb, overflow outlet, and cathodic protec-tion anodes. If there is any doubt about any component, replace it.

j. Replace the new or re-tested cylinder into the hot water tank with anew bottom gasket (28, Dwg. 50.200.000.011).

k. Reassemble per steps m through n of the “in-place” cleaning of evapo-rator cylinder procedure (paragraph 4.12).

4.14 Operational Inspection of the Pressure Relief Systems

Perform an operational inspection of the pressure relief system beforecompletely re-assembling the evaporator exterior piping. Make the fol-lowing checks on the pressure relief systems during “in-place” cleaningat the five-year inspection of the chlorine cylinder.

WARNING: TO AVOID THE RELEASE OF CHLORINE INTOTHE ATMOSPHERE, DO NOT REMOVE EITHER PRESSURERELIEF SYSTEM WHILE THE EVAPORATOR IS PRESSUR-IZED. BEFORE ATTEMPTING TO SERVICE THE PRESSURERELIEF SYSTEM, FOLLOW STEP A IN PARAGRAPH 4.12.

!

IM 50.200AA UA (B/1-01)


52

4.14.1 Evaporator Gas Pressure Relief System

a. Carefully remove the rupture disc. Do not damage the surfaces or theremove tape that secures the components together. Check the systemcomponents for signs of internal or external corrosion. Replace asnecessary.

b. Reassemble safety head (union) without the rupture disc.

c. Pressurize the system at rupture disc connection to 150 psi with dryair, carbon dioxide, or nitrogen. Alarm should activate imediatelyand pressure should hold. Check for leaks.

d. Test Farris relief valve @560 ±17 psi.

e. Reinstall the rupture disc and pressurize to 150 psi. Pressure shouldhold. If an alarm sounds or pressure does not hold, replace the discand retest at 150 psi.

4.14.2 Liquid Line Pressure Relief System

a. Carefully remove rupture disc. If any internal or external corrosion isnoted, the expansion chamber must be hydrostatically tested at 840psig (and cleaned and dried) or replaced. Replace other componentsas necessary.

b. Reassemble the safety head (union) wihout the rupture disc.

c. Pressurizethe system to 150 psi with dry air, carbon dioxide, or nitro-gen. An alarm should activate immediately and the pressure shouldhold. Check for leaks.

d. Reinstall the rupture disc and pressurize to 150 psi. Pressure shouldhold. If an alarm sounds or pressure does not hold, replace the discand retest at 150 psi.

4.14.3 Pressure Alarm Switch

If an alarm does not activate during the relief system test, perform thechecks detailed in paragraph 4.4, Relief System Pressure Switches, todetermine whether the switch requires adjustment or replacement.


IM 50.200AA UA (B/1-01) 53

4.15 Troubleshooting Guide

NOTE: All symptoms in any given group occur concurrently unlessotherwise noted.

Table 4.1 - Troubleshooting

MOTPMYS ESUACELBABORP NOITCAEVITCERROC

1PUORG morfdegrahcsidenirolhcdiuqiLfotluserasateltuorotaropave:snoitidnocgniwollofehtfoyna

NIENIROLHCDIUQILROTANIROLHC

.RETEMATOR

rotaropavenodnameD)a(.yticapacngisedsdeecxe

sagrotanirolhcecudeR)a(.etarlawardhtiw

CITSALPROTANIROLHCLAIRETAM

.NOITAROIRETED

ees(hgihooterusserpylppuS)b(.)2puorGniesuaCelbaborP

.erusserprednilycecudeR)b(hgiHrofnoitcAevitcerroCeeS

.2puorGnierusserP

.CITARREROTANIROLHC -RO-

asarefsnarttaehetauqedanInopu-dliubtnanimatnocfotlusertisopedro/dnarednilycfoedisni

.rednilycfoedistuonopu-dliub

etaucave,evlavylppusesolCeeS.nwodtuhsdna,metsys

noitceSninwodtuhSmreT-gnoLdnaroiretnirednilycnaelC.3

gninaelC"ecalP-nI"eeS.roiretxenoitceSnirednilyCrotaropavEfo

.4-RO-

htiwerutarepmethtabretawwoLotgniliafhctiwserutarepmetwol

,)UC-RVro(*VRPGesolclenapetavitcadna,mraladnuos

niesuaCelbaborPeeS(.thgil).5puorG

rofnoitcAevitcerroCeeS.5puorGmotpmyS

dnuoranepossap-yB)c(.)dedivorpfi(*VRPG

.ssap-ybesolC)c(

gnikael)dedivorpfi(*VRPG)d(.evlavssorcaerusserp

etaucave,evlavylppusesolC)d(eeS.nwodtuhsdnametsys

noitceSninwodtuhSmreT-gnoLkoobnoitcurtsni*VRPGeeS.3

.riaperevlavrof

*GPRV - Gas Pressure Reducing Valve; VR-CU - Vacuum Regulator-Check Unit

IM 50.200AA UA (B/1-01)


54

Table 4.1 - Troubleshooting (Cont'd)


2PUORG rotaropaveedisnierusserphgiHehtfoynaoteudrednilyc

:gniwollof

ERUSSERPHGIHLENAPTNORFGNIDAER.)ISP041EVOBA(EGUAG

erusserpylppusdeddapriA)a(.hgihoot

.erusserpgniddapriaecudeR)a(

SEHCAERERUSSERPFI(CSIDERUTPUR,ISP004

FEILERDNATSRUBLLIWERUSSERPMETSYS

EBLLIWMRALA).DETAVITCA

neewtebdesolcevlaV)b(htiwylppusdnatelnirotaropave

rodesolcteltuorotaropave.deppotsnoitanirolhc

.enilylppusnisevlavllanepO)b(

eudenilylppusniegakcolB)c(rotaropavehtiwstnanimatnocot

noitanirolhcrodesolcteltuo.deppots

ot,deriuqersa,sevlavnepO)c(ylppusnidiuqilgnippartdiovatuhsdnametsysetaucave,enil

mreT-gnoLwolloF.nwodnaelC.3noitceSninwodtuhS

.enilylppus

3PUORG enilylppusnierusserpevissecxEgniwollofehtfoynaoteud

:snoitidnoc

ERUSSERPENILYLPPUSEREHW(EGUAG

TADENNIPSI)DEDIVORP.GNIDAERMUMIXAM

owtneewtebdeppartdiuqiL)a(.sevlavdesolc

.enilylppusnisevlavllanepO)a(

ERUSSERPENILYLPPUSMETSYSFEILER

EREHW(**MRALADETAVITCA)DEDIVORP

CSIDERUTPURNEHW.)ISP004TA(STSRUB

rotaropavenideppartdiuqiL)b(taevlavgnisolcybrednilyc

.noitanirolhcgnippotsdnaylppus

tuhsdnametsysetaucavE)b(.csiderutpurecalpeR.nwod

KAELYAMENIROLHCSASGNITTIFMORF

.SESAERCNIERUSSERP

aneewtebdeppartdiuqiL)c(niegakcolbadnaevlavdesolc

.enileht

metsysetaucave,evlavnepO)c(-gnoLwolloF.nwodtuhsdna.3noitceSninwodtuhSmreT

.senilnaelC

**Alarms will not activate if customer power fails.


IM 50.200AA UA (B/1-01) 55



4PUORG

ERUSSERPROTAROPAVEMETSYSFEILER

**MRALAERUSSERPTNORFTUBSETAVITCA

EGUAGERUSSERPLENAPDNA03NEEWTEBSDAER

.ISP041

-RO- .skaelcsiderutpuR nwodtuhSmreT-gnoLwolloFecalpeR.3noitceSnierudecorp

.csidERUSSERPENILDIUQIL

METSYSFEILERTUBSETAVITCA**MRALA

ERUSSERPENILDIUQILNEEWTEBSDAEREGUAG

.ISP041DNA03

*GPRV - Gas Pressure Reducing Valve; VR-CU - Vacuum Regulator-Check Unit

IM 50.200AA UA (B/1-01)


56



5PUORG asaerutarepmetretawknatwoLgniwollofehtfoynafotluser

:snoitidnoc

ERUTAREPMETWOL.NOTHGILLENAP

sdeecxednamedsaG)a(.yticapacgnitaropave

.etarlawardhtiwsagecudeR)a(

ERUTAREPMETWOL)DEDIVORPFI(**MRALA

.SETAVITCA

rospotspmuprotalucriC)b(.noitceridgnorwnisetator

dnarotompmupkcehC)b(ecalperrogniriwtcerroC.gniriw

.tnempiuqeytluaf

WOLEB(GNIDAERWOLLENAPNO)F°061

.RETEMERUTAREPMET

nepokcutsevlavdioneloS)c(.knatotniretawdlocgnittimda

fotuogniwolfeblliwretaW().noitcennocwolfrevo

rofevlavdioneloskcehC)c(.evlavgnimmajrettamngierof

gniriweborplevelretawkcehCecalpeR.tiucriclortnocdna

.ytluaffi,tnempiuqe

)UC-RVRO(*VRPG.DESOLC

roknatfotuognikaelretaW)d(.gnipip

.skaeltcerroC)d(

LANOITIDDAELBISSOP:SMOTPMYS

lioc:eruliafrotcatnocretaeH)e(.tuonrowstcatnocro

.stcatnocdnaliockcehC)e(.tnempiuqeytluafecalpeR

LEVELRETAWWOL)DEDIVORPFI(**MRALA

LEVELRETAWWOLDNA)H(EES;NOTHGILLENAP

.NMULOCTXEN

:noitcnuflamregnahcxetaeH)f(rotuonrubstnemele3llaro2,1

reporpehtfotonsiretaeh.gnitarrewoproegatlov

dnastnemelekcehC)f(ytluafecalpeR.sgnitaretalpeman

.tnempiuqe

yrtiucriclortnocerutarepmeT)g(erutarepmetrodraobtiucricno

sirosliafgnisuoheborpnirosnes.deriwyltcerrocni

ecalperrogniriwkcehC)g(.tnempiuqeytluaf

,noitidnoclevelretawwoL)h(.8puorGniesuaCelbaborPees

rofnoitcAevitcerroCeeS)h(.8puorG,motpmyS

ETON mralaeslafA:ehtfitsixedluownoitidnoc

hctiwsmralaerutarepmetwolaroF°061ottestonsi

hctiwsmralaerutarepmet.sliaf

hctiwserutarepmetecalpeR.ylbmessa

*GPRV - Gas Pressure Reducing Valve; VR-CU - Vacuum Regulator-Check Unit**Alarms will not activate if customer power fails.


IM 50.200AA UA (B/1-01) 57


*GPRV - Gas Pressure Reducing Valve; VR-CU - Vacuum Regulator-Check Unit**Alarms will not activate if customer power fails.


6PUORG asaerutarepmetretawknathgiH:fotluser

ERUTAREPMETHGIH.NOTHGILLENAP

tiucricnolortnocerutarepmeT)a(yltcerrocnisirosliafdraob

.deriw

rotnempiuqeytluafecalpeR)a(.gniriwtcerroc

ERUTAREPMETHGIH)DEDIVORPFI(**MRALA

.SETAVITCA

nirosneslortnocerutarepmeT)b(sirosliafgnisuoheborp

.deriwyltcerrocni

rotnempiuqeytluafecalpeR)b(.gniriwtcerroc

.FFOREGNAHCXETAEH ETON mralaeslafA:ehtfitsixedluownoitidnoc

hctiwsmralaerutarepmethgiharoF°002ottestonsi

hctiwsmralaerutarepmet.sliaf

hctiwserutarepmetecalpeR.ylbmessa

LENAPDNAMRALA(NOHCTIWSYAMTHGILYLLACIDOIREPFFODNA

GNILOOCEHTOTEUDEHTFOGNITAEHERDNA

EHTTUOBARETAW).TNIOPTESHCTIWS

7PUORG asanoitidnoclevelretawwoL:gniwollofehtfoynafotluser

LEVELRETAWWOL.NOTHGILLENAP

rodekcolbylppusretaW)a(.deliaf

erotseR.gnipiptuonaelC)a(.ylppus

LEVELRETAWWOL)DEDIVORPFI(**MRALA

.SETAVITCA

rodeggolcevlavdioneloS)b(.ytluaf

.evlavytluafecalperronaelC)b(

DNAREGNAHCXETAEH.FFOROTALUCRIC

.gnipiproknatni)s(kaeL)c( .)s(kaeltcerroC)c(

)UC-RVRO(*VRPG.DESOLC

roneposievlavniarD)d(.gnikael

.evlavecalperroesolC)d(

THGISNILEVELRETAWTONROWOLSSALG

.LLATAELBISIV

retawcitamotuaroflortnoC)e(seborplevelretawrosliafllifer

.deriwyltcerrocniera

roslortnocytluafecalpeR)e(.gniriwkcehc

LANOITIDDAELBISSOPRETAWWOL:MOTPMYS

**MRALAERUTAREPMETDNA)DEDIVORPFI(

.ETAVITCATHGILLENAP

IM 50.200AA UA (B/1-01)


58



8PUORG fotluserasalevelretawhgiH:snoitidnocgniwollofehtfoyna

FOTUOGNIMOCRETAWNOITCENNOCWOLFREVO

REVOGNILLIPSRO/DNA.ROOLFOTNOPOTKNAT

gnimmajlairetamngieroF)a(.nepoevlavdionelos

.evlavdionelosnaelC)a(

RETAWNISSALGTHGISSIROTACIDNILEVEL

.LLUFYLRAENROLLUF

.evlavdionelosytluaF)b( .evlavecalpeR)b(

LANOITIDDAELBISSOPRETAWWOL:SMOTPMYS**MRALAERUTAREPMET

DNA)DEDIVORPFI(.ETAVITCATHGILLENAP

tiucriclliferretawcitamotuA)c(eborpleveltcerrocniroeruliaf

.gniriw

roslortnocytluafecalpeR)c(.gniriwkcehc

**Alarms will not activate if customer power fails.


IM 50.200AA UA (B/1-01) 59

WARNING LABELS AND TAGS

The following warning labels and tags are attached to the equipment.------------------------------------------------------------------------------------L1967: HAZARDOUS GAS IS PRESENT IN THIS EQUIPMENT

DURING NORMAL OPERATION. TO AVOID POSSIBLESEVERE PERSONAL INJURY OR DAMAGE TO THEEQUIPMENT, READ THE WALLACE AND TIERNANINSTRUCTION BOOK AND THE APPROPRIATE GASMANUAL BEFORE CONNECTING THIS EQUIPMENTTO A SUPPLY OF GAS. OPERATION AND MAINTE-NANCE OF THIS EQUIPMENT MUST BE RESTRICTEDTO TRAINED, QUALIFIED PERSONNEL WHO ARECOMPLETELY FAMILIAR WITH THESE INSTRUC-TIONS.

------------------------------------------------------------------------------------L2716: DO NOT REMOVE THIS TAG. FACTORY ASSEMBLED

UNITS INCLUDE EITHER A PRESSURE RELIEF DE-VICE OR EXPANSION CHAMBER TO SATISFY THEREQUIREMENTS OF ASME CODE, CHLORINE INSTI-TUTE AND/OR RECOMMENDED PRACTICES OF THECOMPRESSED GAS ASSOCIATION. TO MAINTAINPROPER OPERATION OF THESE ASSEMBLIES IT ISESSENTIAL THAT THE FOLLOWING PRECAUTIONSBE OBSERVED.A. Do not disassemble the protective diaphragm (3) from

pressure switch (4).B. The rupture disc (5) is pressure rated for its particular

service. Should replacement be necessary, an identicalunit must be ordered & installed.

C. See the USF/W&T Instruction Book furnished for partsordering information and for further detailed operatinginstructions.

------------------------------------------------------------------------------------L2016: TO AVOID POSSIBLE SEVERE PERSONAL INJURY

FROM ELECTRICAL SHOCK TURN POWER OFF BE-FORE SERVICING.

------------------------------------------------------------------------------------L2257: TO AVOID POSSIBLE PERSONAL INJURY FROM

ELECTRICAL SHOCK, TURN POWER OFF BEFORESERVICING.

------------------------------------------------------------------------------------

IM 50.200AA UA (B/1-01)


60

WARNING LABELS AND TAGS (CONT'D)

------------------------------------------------------------------------------------L3397: LINE VOLTAGE PRESENT AT THIS LOCATION EVEN

WHEN THE PANEL POWER SWITCH IS IN THE OFFPOSITION. TO AVOID POSSIBLE SEVERE PERSONALINJURY DUE TO ELECTRICAL SHOCK, DISCONNECTEXTERNAL POWER SUPPLY BEFORE SERVICING.

------------------------------------------------------------------------------------L2833: TO AVOID POSSIBLE SEVERE PERSONAL INJURY

DUE TO HIGH TEMPERATURE CAUSING BURNS,DISCONNECT POWER AND ALLOW TO COOL BE-FORE HANDLING.

------------------------------------------------------------------------------------L2720: CHLORINE, WHICH IS A HAZARDOUS CHEMICAL,

IS PRESENT IN THIS EQUIPMENT DURING NORMALOPERATION. TO AVOID POSSIBLE SEVERE PER-SONAL INJURY OR DEATH, YOU MUST OBSERVETHE FOLLOWING PRECAUTIONS:1. When changing chlorine supply containers you must be

completely familiar with your local plant operating andemergency procedures including the location and use ofa gas mask. Recommended emergency procedures canbe obtained from your chlorine supplier, the ChlorineInstitute, Inc., or similar organization.

2. Do not open the chlorine supply container valve morethan one complete turn. This will permit maximum dis-charge and can be turned off quickly in the event of aleak.

3. On a routine daily basis, starting at the chlorine supplycontainer(s), thoroughly check all joints, connectionsand equipment for possible chlorine leaks and immedi-ately correct any found. Do not tolerate any chlorineleaks.

4. Chlorine leaks never get better. Chlorine leaks alwaysget progressively worse, if they are not promptly cor-rected.

5. Never re-use gaskets in chlorine piping systems. Al-ways have an adequate supply on hand and always usenew gaskets of the correct size and material as identifiedon the equipment parts drawings.

6. Except in cases of leak detection or calibration adjust-ments, the chlorine supply must be shut off at the supplycontainer valve(s) and the chlorine in the system com-pletely exhausted before servicing the equipment.


IM 50.200AA UA (B/1-01) 61

WARNING LABELS AND TAGS (CONT'D)

7. It is recommended practice to have an approved gasmask available, which you have been trained to use,when making chlorine leak checks and when changingchlorine supply containers.

8. The USF/W&T instruction book provided with thisequipment furnishes complete and detailed instructionsfor its installation, operation and maintenance and mustbe referred to for that detailed information.

9. The USF/W&T instruction book provided with thisequipment also furnishes technical information on thecharacteristics, storage and handling of chlorine, andmust be referred to for that information. Contact yourchlorine supplier, the Chlorine Institute, Inc., or similarorganization to obtain more detailed information.

10. Operation and maintenance of this equipment must berestricted to trained, qualified personnel who are com-pletely familiar with these instructions.

11. Liquid chlorine has a high temperature coefficient ofexpansion. Do not close valves in such a way that liquidchlorine may be trapped since dangerous pressures ca-pable of rupturing the piping system may build up witha small increase in temperature.

To avoid possible severe personal injury from electricalshock, turn power off before servicing this equipment.

DO NOT REMOVE THIS SIGN FROM THIS EQUIP-MENT

------------------------------------------------------------------------------------

IM 50.200AA UA (B/1-01)


62

CAUTION LABELS AND TAGS

The following caution labels and tags are attached to the equipment.------------------------------------------------------------------------------------L2558: FOR CHLORINE USE ONLY.------------------------------------------------------------------------------------L2717: UNDER NORMAL OPERATING CONDITIONS DEPOS-

ITS WILL ACCUMULATE IN THE EVAPORATOR CYL-INDER AND OVER A PERIOD OF TIME WILL REDUCEITS OPERATING CAPACITY. FOR THIS REASON PE-RIODIC CLEANING IS REQUIRED TO REMOVE THESEDEPOSITS. THE INSTRUCTION BOOK PROVIDEDWITH THIS EQUIPMENT PROVIDES COMPLETE DE-TAILS ON RECOMMENDED FREQUENCY AND PRO-CEDURES TO PROPERLY ACCOMPLISH THISCLEANING AND MUST BE REFERRED TO FOR THATGUIDANCE.

------------------------------------------------------------------------------------L2135: DO NOT DISCONNECT THIS SEAL ASSEMBLY FROM

GAUGE. SEAL PROOF PRESSURE 840 P.S.I.------------------------------------------------------------------------------------L2137: DO NOT DISCONNECT THIS SEAL ASSEMBLY FROM

PRESSURE SWITCH. SEAL PROOF PRESSURE 840P.S.I.

------------------------------------------------------------------------------------L3222: TO PREVENT DAMAGE TO EQUIPMENT, ALWAYS

REPLACE COVER AFTER SERVICING.------------------------------------------------------------------------------------


IM 50.200AA UA (B/1-01) 63

SERIES 50-200 EVAPORATOR - WIRINGCathodic Protection

50.200.140.010ISSUE 1 1-90

IM 50.200AA UA (B/1-01)


64

U20208 DRYING KIT FOR SERIES 50-200 EVAPORATOR - SERVICE

50.200.150.010ISSUE 1 12-91


!!!!! PART OF U28839 SPARE PARTS KIT.

""""" PART OF CYLINDER & NOT INCLUDED IN U20208.

""""" PART OF INJECTOR ASSEMBLY U20230, WHICH MAY BE ORDERED SEPARATELY.


IM 50.200AA UA (B/1-01) 65

LIFTING METHOD - SERVICE

50.200.150.060ISSUE 0 4-88

WARNING: """"" TO AVOID POSSIBLE SEVERE PERSONAL INJURY AND EQUIPMENT DAMAGE, DO NOTATTEMPT TO LIFT EVAPORATOR BY INLET AND OUTLET CONNECTIONS.


IM 50.200AA UA (B/1-01)

50-200 EVAPORATOR FOR CHLORINE 50-200 EVAPORATOR FOR CHLORINE

IM 50.200AA UA (B/1-01)66

LEVEL AND TEMPERATURE CONTROL - SCHEMATIC WIRING

50.200.155.020ISSUE 2 4-91

67

IM 50.200AA UA (B/1-01)

50-200 EVAPORATOR FOR CHLORINE 50-200 EVAPORATOR FOR CHLORINE

IM 50.200AA UA (B/1-01)

SERIES 50-200 EVAPORATOR - SCHEMATIC WIRINGControls and Equipment

50.200.155.010ISSUE 3 4-91

68 69

IM 50.200AA UA (B/1-01)


70


IM 50.200AA UA (B/1-01) 71

SECTION 5 - ILLUSTRATIONS

List Of Contents

DRAWING NO.

PartsEvaporator - Basic Components ........................ 50.200.060.010A-EWater Level and Temperature Control Probes .. 50.200.000.020A&BAAA8723 Controls Enclosure ........................... 50.200.060.020A-CAAA9083 Enclosure.......................................... 50.200.060.030A&BU27615 Liquid Line Pressure Relief System .... 50.202.007.011U25471 Gas Pressure Relief System ................. 50.202.008.011Line Valves ........................................................ 50.150.005.011

IM 50.200AA UA (B/1-01)


72

AAA8693 - STANDARD CYLINDER;AAA8651 - "L" CERTIFIED CYLINDER

SERIES 50-200 EVAPORATOR - PARTS

50.200.060.010AISSUE 1 1-01

NOTES: FOR DETAILS, SEE DWG. 50.200.060.010B.FOR PARTS LIST, SEE DWGS. 50.200.060.010C,D&E.


IM 50.200AA UA (B/1-01) 73

AAA8693 - STANDARD CYLINDER; AAA8651 - "L" CERTIFIED CYLINDERSERIES 50-200 EVAPORATOR - PARTS

50.200.060.010BISSUE 1 1-01

NOTES: FOR PARTS LIST, SEE DWGS. 50.200.060.010C,D&E.

IM 50.200AA UA (B/1-01)


74

AAA8693 - STANDARD CYLINDER; AAA8651 - "L" CERTIFIED CYLINDERSERIES 50-200 EVAPORATOR - PARTS LIST

50.200.060.010CISSUE 0 12-97

.ONYEK .ONTRAP .YTQ NOITPIRCSED1 68195P 1 NOITALUSNI2 88195P 1 TROPPUSNOITALUSNI3 29525DXP 2 PARTS4 33171P 2 TPN"¼-1)NORI(WOBLE°095 27105P 2 .GL"¾xEPIP04.HCS"¼-1)NORI(ELPPIN6 60735P 1 TPN"¼-1)NORI(GNILPUOC7 52682U 5 )REPPOC(PUCREDLOS"¼-1x)NORI(TPN"¼-1,NOINU8 69574P 1 REDLOS"¼-1)REPPOC(EET9 9932P 3 )SSARB(PUCREDLOS"1x)NORI(ELPPINESOLC01 21032U 4 )SSARB(PUCREDLOS"1x)NORI(TPN"1,NOINU11 38451P 3 REDLOS"1)REPPOC(WOBLE°0921 386P 1 .GL"2xEPIP04.HCS"½)NORI(ELPPINESOLC31 31032U 2 REDLOS"½x)NORI(TPN"½,NOINU41 70932U 1 EVLAVDIONELOS"½51 99574P 2 TPN"½xPUCREDLOS"½)SSARB(RETPADA61 22032U 1 )SSARB(PUCREDLOS"¾x)NORI(TPN"¾,NOINU71 81422U 1 POTSNOISSERPMOC,EVLAV"¾81 19195P 1 C"¼-1xC"¾xC"¼-1)REPPOC(EET91 4894CU 3 AINOMMA"1,NOINU02 92374CP 1 TPN"1)LEETS(WOBLE°0912 31195P 1 ETALPKCIK22 87575P 02 TUNGNIDAERHT-FLES32 05185AXP 2 .GL"½-3x11-"8/5)LEETSETALP.DAC,.DH.XEH(TLOB42 74215P 1 KCOLBWOBLE52 07421P 1 TEKSAG62 558CP 4 .GL"¼-1x31-"½)LEETSETALP.DAC,.DH.XEH(TLOB72 1901CP 4 REHSAW82 43224P 1 TEKSAG92 89092U 1 KNATROTAROPAVE03 15452U 1 )9368AAANODESU(REDNILYC

RO91672U 1 )1568AAANODESU(DEIFITREC'L',REDNILYC

13 92574P 1 C"1xGTF"1)SSARB(WOBLE°0923 968CP 4 .GL"1x61-"8/3)LEETS,.DH.XEH(TLOB33 0901CP 61 )LEETS(REHSAW"8/343 4338P 8 )LEETS(REHSAWKCOL"8/353 888CP 8 61-"8/3)LEETS(TUNGNIPMALC63 07653P 2 TPF"¼xTPM"¼)NORI(WOBLETEERTS°0973 31942U 2 TPN"¼xEBUT"½)YLOP(ROTCENNOC83 96682U 2 TPN"8/1xEBUT"½)YLOP(ROTCENNOC93 9174CP 02 .GL"¾x02-"¼)LEETS,.DH.XEH(TLOB04 9801CP 6 )LEETS(REHSAW"¼14 7336P 61 )LEETS(REHSAWKCOL"¼24 02844P 4 TIUDNOC"¼-1,TUNKCOL34 36722U 2 TIUDNOC"¼-1,GNIRLAES44 85284P 2 TIUDNOC"¼-1,GNIHSUB54 19495CP 2 TIUDNOC"¼-1,ELPPIN64 59284P 2 TPN"¼-1)TIUDNOC(GNILPUOC74 37531CP 1 TPN"1ELPPIN84 2601CP 01 )LEETS(REHSAW"61/505 34422U 21 81-"61/5)LEETS(TUNGNIPMALC15 3674CP 01 )LEETS(REHSAWKCOL"61/5

WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS.


IM 50.200AA UA (B/1-01) 75


50.200.060.010DISSUE 0 12-97

.ONYEK .ONTRAP .YTQ NOITPIRCSED35 478CP 41 .GL"1x81-"61/5)LEETS,.DH.XEH(TLOB55 8992CP 4 .GL"8/3x61-"8/3)LEETS,.DH.XEH(TLOB65 79995P 4 LENNAHCTROPPUS75 17195P 1 GULPAC85 97224P 1 81-"8/5xTPN"¼,RETPADANOINU95 18224CP 1 TPF"¼xTPM"¼)LEETS(WOBLETEERTS°0916 8468AAA 1 ELGNATROPPUSDNAH-TFEL26 59195P 4 ROTALUSNI36 54195P 2 LENNAHCTROPPUS46 37682U 1 TINUEBUT56 28462AXP 2 DO"2/1xDI"8/3,NOTIV)210(GNIR-O

RO" 28462P 2 )YLNOESUAINOMMAROF(DO"2/1xDI"8/3,N-ANUB)210(GNIR-O

" 66 30813P 1 TEKCARBEGUAG" 76 88154P 2 ).S.S(REHSAWKCOL01#" 86 7852EP 2 23-01#)SSARB(TUN

96 42095P 1 TEKCARBEGUAG07 7852EP 2 23-01#)SSARB(TUN17 88154P 2 ).S.S(REHSAWKCOL01#27 5468AAA 1 ELGNATROPPUSDNAH-THGIR37 ---- 1 )020.000.002.05.GWD.FER(STNENOPMOCLORTNOCLEVELRETAW47 7902L 1 LEBALTELNI57 15682U 1 YDOBRETAEH67 39982U 1 HCTIWSERUTAREPMET87 65351P 1 TPN"1)NORI(WOBLE°0997 38372P 2 TPN"¼-1)NORI(ELPPIN08 26674P 1 C"1)REPPOC(WOBLE°0918 41195P .TF7 NOITALUSNIEPIP28 42295P 1 DRAUGPMUP38 83043CP 2 .GL"8/3x42-01).DH,.DR,LEETS(WERCS.HCAM48 68582U 1 PMUPLAGUFIRTNEC58 62784P 1 C"¼-1)REPPOC(WOBLE°5468 8902L 1 LEBALTELTUO

" 78 21952U 1 )YLNOESUENIROLHC(EGUAGERUSSERPSAGRO

21952AXU 1 )YLNOESUEDIXOIDRUFLUS&AINOMMA(EGUAGERUSSERPSAG88 87195P 2 TEKSAG98 57195P 1 EUQALPEMAN09 37195P "61/31-7-'8 REBBURDEDURTXE,LENNAHC"U"19 70092U 1 RETEMEGRUP39 6278AAA 1 )020.060.002.05.GWD.FER(ERUSOLCNELORTNOC49 9275AAA 1 REPPU,LENAPTNORF,OGOL59 5375AAA 1 REWOL,LENAPTNORF69 51285P 1 KSAM79 21891U 1 EGUAGERUTAREPMETSAG

!# 89 2202L 1 LEBALGNINRAW!# 99 2223L 1 LEBALNOITUAC!# 001 3382L 2 LEBALGNINRAW


IM 50.200AA UA (B/1-01)


76


50.200.060.010EISSUE 0 12-97

.ONYEK .ONTRAP .YTQ NOITPIRCSED" 101 83682AXU 1 )PMA06,STLOV802(REGNAHCXETAEH

RO83682BXU 1 )PMA06,STLOV042/022(REGNAHCXETAEH

RO83682CXU 1 )PMA03,STLOV083(REGNAHCXETAEH

RO83682DXU 1 )PMA03,STLOV084/044(REGNAHCXETAEH

RO83682EXU 1 DCP000,8)PMA03,STLOV055(REGNAHCXETAEH

RO83682FXU 1 )PMA06,STLOV802(REGNAHCXETAEH

RO83682GXU 1 )PMA06,STLOV042/022(REGNAHCXETAEH

RO83682HXU 1 )PMA03,STLOV083(REGNAHCXETAEH

RO83682JXU 1 )PMA03,STLOV084/044(REGNAHCXETAEH

RO83682KXU 1 DCP000,01)PMA03,STLOV055(REGNAHCXETAEH

RO83682LXU 1 )PMA03,STLOV084/044(REGNAHCXETAEH

RO83682MXU 1 )PMA03,STLOV803(REGNAHCXETAEH

! 201 75284P 1 GNIHSUBTIUDNOC"1! 401 71825P 1 TEKSAG# 501 87982U 1 REVOCRETAEH# 601 49795P 1 ELGNAROTCENNOCRETAEH# 701 7792CP 1 .GL"¾x31-"½)LEETS,.DH.XEH(TLOB# 801 99035P 1 .GL"2/1X01#)LEETS.DHLAVO(WERCSLATEMTEEHS# 901 39795P 1 ETALPREVOC

011 06703P 4 TEMMORG111 76991U 4 BONK211 5665CP 41 )LEETS(REHSAW"¼311 85703P 4 )SSARB(REHSAW411 46703P 4 EDONA511 45095P 1 )RAER(NOITALUSNIKNAT611 35095P 1 )THGIR(NOITALUSNIKNAT711 55095P 1 )TFEL(NOITALUSNIKNAT811 51621CP 2 )LEETS(REHSAWKCOL01#911 14181CP 2 )LEETS(REHSAW01#021 77495P 2 TEMMORG121 29195CP 3 .GL"¼-9EPIP08.HCS"1)LEETS(ELPPIN221 81284P 1 REVOCTIUDNOC321 02284P 1 TEKSAGTELUDNOC421 61161U 1 NOINUETITLAES"½521 06722U 5 TIUDNOCRENIATERDNAGNIR-O621 33602U 5 TIUDNOCELBIXELF"½,WOBLE°54721 47991U 2 ROTCENNOC"½821 40284P 1 TIUDNOCTELTUOYDOB"½921 68172P 1 .GL"8/1-1TIUDNOC"½)DEZINAVLAG(ELPPIN031 75284P 2 "1TIUDNOCGNIHSUB231 66812U 2 TIUDNOCELBIXELF"1,WOBLE°54

NOTE: """"" PART OF G678.! PART OF G2343.# PART OF G2344." NOT PART OF AAA8639 OR AAA8651.

ALL STEEL PIPING IS 1” (SCHEDULE 80) AS PER ASTM 1-106, GRADE B.ALL POLYPROPYLENE TUBING IS 1/2” O.D. x 1/16” WALL (WORKING PRESSUE: 250 PSI).ALL COPPER TUBING IS ½”, ¾”, 1”, OR 1-¼” (SEAMLESS, TYPE M) AS PER ASTM B-88 OR EQUIVALENT.ALL FLEXIBLE CONDUIT IS ½” OR 1” (STEEL, LIQUID TIGHT) WITH APPROPRIATE CONNECTORS AND FITTINGS (MEETS JIC REQUIRE-MENTS).


IM 50.200AA UA (B/1-01) 77

WATER LEVEL AND TEMPERATURE CONTROL PROBES - PARTS For Series 50-200 Evaporator

50.200.000.020AISSUE 0 4-88

NOTE: FOR PARTS LIST, SEE DWG. 50.200.000.020B.

IM 50.200AA UA (B/1-01)


78

WATER LEVEL AND TEMPERATURE CONTROL PROBES - PARTS LIST For Series 50-200 Evaporator

50.200.000.020BISSUE 0 4-88



IM 50.200AA UA (B/1-01) 79

AAA8723 CONTROLS ENCLOSURE - PARTS

50.200.060.020AISSUE 0 12-97

NOTES: FOR PARTS LIST, SEE DWGS. 50.200.060.020B&C.

IM 50.200AA UA (B/1-01)


80

AAA8723 CONTROLS ENCLOSURE - PARTS LIST

50.200.060.020BISSUE 0 12-97

.ONYEK .ONTRAP .YTQ NOITPIRCSED1 62682U 2 DER,THGILROTACIDNI

" 2 92682U 4 PMAL3 72682U 1 REBMA,THGILROTACIDNI5 29582U 1 RETEMPMET6 97195P 2 TEKSAG7 39582U 1 RETEMMA8 82682U 1 NEERG,THGILROTACIDNI9 02752U 1 ELDNAHGNITAREPO01 91682U 1 RETEMOITNETOP11 49802U 1 BONK21 6278AAA 1 XOBLORTNOC31 95195P 1 LENAPGNITNUOMREMROFSNART41 64573P 4 .GL"2/1x81-"61/5).S.S,.DH.DR(WERCS.HCAM51 61622P 8 ).S.S(REHSAW"61/561 36351P 8 ).S.S(REHSAWKCOL"61/571 48582U 1 )STLOV084/042(REMROFSNART

RO" 38582U 1 )STLOV044&,022,055,083,802(REMROFSNART

81 59504P 4 .GL"1x81-"61/5).S.S,.DHXEH(WERCS.HCAM91 06195P 1 ETALPGNITNUOM02 18195P 1 ETITKCOL,ROTCENNOC

" 12 5923L 1 )V802(REKRAMRO

9923L 1 )V022(REKRAMRO





7923L 1 )V055(REKRAM22 02682U 1 HCTIWSTCENNOCSID32 24924P 6 .GL"8/5x02-"4/1).S.S,.DHXEH(WERCS.HCAM42 88891P 6 ).S.S(REHSAW"4/152 53641P 6 ).S.S(REHSAWKCOL"4/1

NOTE: """"" PART OF KEY NUMBERS 1, 3 OR 8.""""" NOT PART OF AAA8723.



IM 50.200AA UA (B/1-01) 81

AAA8723 CONTROLS ENCLOSURE - PARTS LIST

50.200.060.020CISSUE 0 12-97

.ONYEK .ONTRAP .YTQ NOITPIRCSED62 53304P 6 .GL"8/3x42-01#).S.S,.DH.DR(WERCS.HCAM72 04783P 4 ).S.S(REHSAW01#82 91631P 4 ).S.S(REHSAWKCOL01#

! 92 53304P 3 .GL"8/3x42-01#).S.S,.DH.DR(WERCS.HCAM! 03 04783P 3 ).S.S(REHSAW01#

13 84153P 6 .GL"4/3x42-01#).S.S,.DH.DR(WERCS.HCAM" 23 18582U 1 )STLOV055,084/044,083ROFDESU(TIKPILCESUFPMA03

RO28582U 1 )STLOV042/022,802ROFDESU(TIKPILCESUFPMA06

33 88582U 1 KCOLBESUF" 43 22682U 1 )STLOV042/022,802ROFDESU(ESUFRETAEHPMA54

RO75074U 1 )STLOV055,084/044,083ROFDESU(ESUFRETAEHPMA03

RO87625P 3 )STLOV042/022,802ROFDESU(ESUFRETAEHPMA06

" 53 74682U 1 )STLOV042/022,803ROFDESU(ESUFREMROFSNARTPMA7RO

64682U 1 )STLOV083ROFDESU(ESUFREMROFSNARTPMA2/1-3RO

54682U 1 )STLOV055,084/044ROFDESU(ESUFREMROFSNARTPMA363 84682U 2 KCOLBESUF

! 73 91631P 3 ).S.S(REHSAWKCOL01#" 83 32682U 1 )STLOV042/022,802ROFDESU(ROTCATNOCPMA06

RO78582U 1 )STLOV055,084/044,083ROFDESU(ROTCATNOCPMA03

93 39692P 4 .GL"2/1x02-"4/1).S.S,.DH.DR(WERCS.HCAM04 05405P 3 ROTCENNOCDNUORG14 09195P 8 TROPPUSDRAOBTIUCRIC24 23902U 1 KCOLBLANIMRET34 9617CP 2 .GL"1x23-8#)SSARB,.DH.DR(WERCS.HCAM44 1859CP 2 )SSARB(REHSAW8#54 91482U 1 DRAOBLORTNOCLEVEL64 19185P 3 PMALCERIW74 95315P 2 LEBALWORRA84 7933L 2 LEBALGNINRAW94 59154P 1 ).S.S(REHSAWKCOL"8/305 39883P 1 "2/1x23-"8/3)SSARB(TUNGNITNUOM

NOTE: !!!!! PART OF G2343.""""" NOT PART OF AAA8723.


IM 50.200AA UA (B/1-01)


82

AAA9083 ENCLOSURE - PARTS50.200.060.030A

ISSUE 0 12-97

NOTES: FOR PARTS LIST, SEE DWG. 50.200.060.030B.


IM 50.200AA UA (B/1-01) 83

AAA9083 ENCLOSURE - PARTS LIST

50.200.060.030BISSUE 0 12-97


.ONYEK .ONTRAP .YTQ NOITPIRCSED1 07421P 3 TEKSAGDAEL2 59575P 6 PILCHSUP3 66995P 1 REVOC4 75724P 2 .GL"8/7x42-01#).S.S,.DH.NAP(WERCS.HCAM5 04783P 2 ).S.S(REHSAW01#6 91631P 2 ).S.S(REHSAWKCOL01#

! 7 1217AAA 1 ERUSOLCNEEDIS-DNAH-THGIR8 2223L 1 LEBAL

" 9 2223L 1 LEBAL" 01 59575P 52 PILCHSUP" 11 4217AAA 1 LENAPRAER! 21 8117AAA 1 ERUSOLCNEEDIS-DNAH-TFEL

31 5117AAA 1 ECARBRAER41 09995P 6 ELCATPECER51 58195P 41 DUTS61 28195P 41 RENIATER

! 71 9942L 4 )YLNOESUAINOMMA(LEBALRO

8552L 4 )YLNOESUENIROLHC(LEBALRO

8033L 4 )YLNOESUEDIXOIDRUFLUS(LEBAL! 81 9317AAA 1 ERUSOLCNEPOT

91 2468AAA 1 TEKCARB02 94874P 2 .GL"½x42-01#).LTS,FEPYT(WERCSPAT-FLES12 9174CP 4 .GL"¾x02-¼,.DH.XEHTLOB

! 22 0272L 2 )YLNOESUENIROLHC(DRACGNINRAWRO

1272L 2 )LACIMEHCSUODRAZAH(DRACGNINRAW32 7691L 1 LEBAL42 7172L 1 LEBAL52 48195P 8 ELCATPECER62 7663P 4 "¼,KCOL,REHSAW

NOTE: !!!!! NOT PART OF AAA9083.""""" PART OF AAA8624 OPTIONAL PARTS GROUP FOR OUTDOOR USE.

IM 50.200AA UA (B/1-01)


84

U27615 LINE PRESSURE RELIEF SYSTEM - PARTS

50.202.007.011ISSUE 3 12-97

NOTE: X NOT FURNISHED BY USF/W&T.USE LITHARGE AND GLYCERIN CEMENT OR OTHER CEMENT APPROVED BY THE CHLORINEINSTITUTE.WHEN ORDERING MATERIAL, ALWAYS SPECIFY MODEL AND SERIAL NUMBER OF APPARATUS.


IM 50.200AA UA (B/1-01) 85

U25471 GAS PRESSURE RELIEF SYSTEM - PARTS

50.202.008.011ISSUE 2 7-85

NOTE: USE LITHARGE AND GLYCERIN CEMENT OR OTHER CEMENT APPROVED BY THE CHLORINE INSTI-TUTE.


IM 50.200AA UA (B/1-01)


86

LINE VALVE - PARTS

50.150.005.011ISSUE 9 6-88



IM 50.200AA UA (B/1-01) 87

SECTION 6 - SPARE PARTS LIST

QTY. DESCRIPTION PART NO.

1 Spare Parts Kit (replacement gaskets) U28839

1 Cylinder Gasket °P42293

5 Gaskets for Ammonia Type Union °P12470

2 O-ring for Gauge Line (Chlorine gas pressure) °PXA26482

1 Gasket for Water Tank °P42234

1 lb. Sodium Sulfate U23934

1 Drying Kit U20208

1 Rupture Disc (Liquid Line 400 psi) U24910

3* **Fuse, 600V, 30 amp P47057

3* **Fuse, 600V, 45 amp U28622

3* **Fuse, 600V, 60 amp P52678

1 Fuse, Transformer, 3 amp U28645

1 Fuse, Transformer, 3-1/2 amp U28646

1 Fuse, Transformer, 7 amp U28647

1 Wrench P8200

1 Bottle of Ammonia Solutionfor Chlorine Leak Detection U409

1 Complete Pump Repair Kit(minus shaft seal and seat) U28665

1 Shaft Seal and Seat Kit U28664

1 Lamp (replacement bulb) U28629

*Minimum order.**Used for heat exchanger and 3-phase power supply.°Part of Spare Kit U28839.

IM 50.200AA UA (B/1-01)


88

IM 25.000AA UA ISSUE B

Taking care of the world’s water.

Wallace & Tiernan Products1901 West Garden Road

Vineland, NJ 08360856.507.9000 tel.856.507.4125 fax

http://www.wallaceandtiernan.usfilter.com

CHLORINE HANDLING MANUAL

IM 25.000AA UA (B/6-00) PAGE 1


WARNING:

CHLORINE IS A HAZARDOUS CHEMICAL THAT CAN CAUSE INJURYAND DEATH IF NOT HANDLED PROPERLY. THIS MANUAL CONTAINSONLY GENERAL INFORMATION ON THE PHYSICAL PROPERTIES, STOR-AGE, AND HANDLING OF CHLORINE. IT IS NOT INTENDED TO REPLACEOR LIMIT SAFETY PROCEDURES IN YOUR FACILITY.

SAFETY PROCEDURES IN AN INDUSTRIAL SETTING MUST BE DESIGNEDIN ACCORDANCE WITH ALL GOVERNMENTAL REGULATIONS ANDNATIONAL SAFETY CODES, AFTER GIVING FULL CONSIDERATION TOTHE SPECIFIC NEEDS OF THE INDUSTRIAL FACILITY INVOLVED.

U.S. FILTER/WALLACE & TIERNAN (USF/W&T) CANNOT ANTICIPATETHE SPECIFIC SAFETY PROCEDURES REQUIRED AT EVERY INDUS-TRIAL FACILITY. ACCORDINGLY, USF/W&T DOES NOT GUARANTEETHAT SAFETY PROCEDURES DESIGNED IN ACCORDANCE WITH THISMANUAL WILL COMPLETELY ELIMINATE HAZARDS AND THUS AS-SUMES NO LIABILITY FOR ACCIDENTS THAT MAY OCCUR IN YOURFACILITY.

READ THIS ENTIRE MANUAL AND BE FULLY FAMILIAR WITH YOUREQUIPMENT AND YOUR ENTIRE INDUSTRIAL SYSTEM SO THAT THESAFETY PROCEDURES YOU ESTABLISH WILL MEET THE NEEDS OFTHE EMPLOYEES IN YOUR FACILITY. READING ONLY PART OF THEMANUAL WILL NOT HELP YOU ANALYZE THE NEEDS OF YOUR FACIL-ITY. CONTACT YOUR CHLORINE SUPPLIER, THE CHLORINE INSTITUTE,INC., OR SIMILAR ORGANIZATION TO OBTAIN A MATERIAL SAFETYDATA SHEET (MSDS) AND MORE DETAILED INFORMATION ON CHLO-RINE. INFORMATION IS AVAILABLE FROM: THE CHLORINE INSTITUTE,INC., 2001 L STREET, NW, WASHINGTON, D.C. 20036.

PLEASE NOTE THE PUBLICATION DATE AND POSSIBLE OBSOLESCENCEOF THIS MATERIAL AS A RESULT OF SCIENTIFIC AND MEDICAL DEVEL-OPMENTS AFTER THE DATE OF PUBLICATION. THIS APPLIES TO ALLMATERIALS YOU REVIEW IN THE COURSE OF DEVELOPING SAFETYPROCEDURES FOR USE AT YOUR FACILITY.

Table Of Contents

PARA. NO.

Introduction ...............................................................................1Technical Data and Characteristics of Chlorine .......................2Supply Containers ......................................................................3 Maximum Gas Withdrawal Rates ...........................................3.1 Manifolding for Gas Withdrawal ..........................................3.1.1 Maximum Liquid Withdrawal Rate ........................................3.2 Manifolding for Liquid Withdrawal .....................................3.2.1 Container Valves .....................................................................3.3 Pressure Relief Devices ...........................................................3.4 Storage of Containers ..............................................................3.5

IM 25.000AA UA (B/6-00)


PAGE 2

Table Of Contents (Cont’d)

Handling Containers ...............................................................3.6 Using Containers .....................................................................3.7Piping .........................................................................................4 Piping Materials and Joints .....................................................4.1 Gas Piping Installation Requirements ....................................4.2 Liquid Piping Installation Requirements ................................4.3 Pressure Relief and Vent Piping Requirements ......................4.4 Valves ......................................................................................4.5 Pressure Gauges and Switches ................................................4.6 Pressure Relief Devices ...........................................................4.7 Preparation for Use ..................................................................4.8Personnel Safety .........................................................................5 General .....................................................................................5.1 Health Hazards ........................................................................5.2 Safety Precautions ....................................................................5.3 Emergency Action Plans .........................................................5.4 Chemical Disposal Facilities ...................................................5.5

1 INTRODUCTION

This manual discusses the characteristics, storage and han-dling of chlorine used with USF/W&T equipment. Chlorineis used with USF/W&T equipment primarily as a disinfec-tant in water or wastewater treatment.

WARNING:

CHLORINE IS HAZARDOUS. TO AVOID SEVEREPERSONAL INJURY OR DEATH BY SUFFOCATION,READ THIS MANUAL AND THE CHLORINESUPPLIER’S PRECAUTIONS BEFORE HANDLINGOR CONNECTING CHLORINE TO USF/W&T EQUIP-MENT.

WHEN WORKING WITH CHLORINE:ENSURE THAT APPROVED, SELF-CONTAINEDBREATHING APPARATUS IS ALWAYS AVAILABLEAND PERSONNEL ARE PROPERLY TRAINED IN ITSUSE.ENSURE THAT SAFETY EQUIPMENT, SUCH ASVENTILATION FANS AND BREATHING APPARA-TUS, IS INSPECTED AND MAINTAINED IN ACCOR-DANCE WITH THE MANUFACTURER’S INSTRUC-TIONS.ENSURE THAT APPROPRIATE PLACARDS ANDWARNING SIGNS ARE IN PLACE AND PROMI-NENTLY DISPLAYED IN THE AREAS WHERE THEGAS IS STORED.

IN CASES OF ACCIDENT:USE SAFETY EQUIPMENT TO PROTECT THE RES-CUER AND MOVE VICTIM TO FRESH AIR. IFBREATHING HAS STOPPED, START ARTIFICIALRESPIRATION IMMEDIATELY.IF HEART HAS STOPPED, START CPR (CARDIOP-ULMONARY RESUSCITATION) IMMEDIATELY. INALL CASES, OBTAIN MEDICAL ATTENTION ASSOON AS POSSIBLE.

TO AVOID ACCIDENTAL GAS RELEASE:KNOWLEDGEABLE DESIGN PERSONNEL SHOULDOVERSEE AND APPROVE EQUIPMENT INSTALLA-TION AND SUITABILITY OF THE SYSTEM FORWHICH IT IS INTENDED.QUALIFIED PERSONNEL SHOULD PERFORM PE-RIODIC INSPECTION TO ENSURE PROPER MAIN-TENANCE OF THE EQUIPMENT.MONITOR SAFETY PROGRAMS AND CONDUCTPERIODIC TRAINING PROGRAMS, ESPECIALLYON EMERGENCY SITUATIONS. SAFETY PRO-GRAMS ARE AVAILABLE FROM YOUR GAS SUP-PLIER.

LOCAL LAWS:UNDER NO CIRCUMSTANCES SHOULD THE IN-FORMATION IN THIS BOOK BE CONSTRUED ASSUBSTITUTING FOR OR SUPERSEDING ANY LO-CAL, STATE, OR FEDERAL LAWS AND REGULA-TIONS CONCERNING THE STORAGE, HANDLING,OR USE OF CHLORINE.


IM 25.000AA UA (B/6-00) PAGE 3

2 TECHNICAL DATA AND CHARACTERISTICS OFCHLORINE

The following general information on chlorine may be usefulin planning a chlorinator installation; however, a specificapplication may require more information than that includedhere. For further information, consult your chlorine sup-plier, the Chlorine Institute, Inc., or similar organization.

Chlorine in commerce is a liquefied gas under pressure. It isa clear, amber-colored liquid. The gas has a greenish-yellowcolor and a strong, pungent odor. It is an irritant to the skinand respiratory system. In the moisture-free state at ordinarytemperatures, it is relatively non-corrosive. In the presenceof moisture, however, it is highly corrosive. Accordingly,every precaution should be taken to avoid leaks, to stop thempromptly if they occur, and to keep moisture out of valves,tubing, etc., not specifically designed to handle moist chlo-rine. Among the important physical properties of chlorineare:

Specific Gravity, Dry Gas2.48 at 32° F and 1 atm referred to air.

Specific Gravity, Liquid1.47 at 32° F and 53 . 5 psia.

Liquid to Gas volume Ratio1:456.5 at 32° F and 1 atm.

Latent heat of Vaporization123.9 Btu per lb at boiling point, -29.2° F.

Specific Volume, Dry Gas1 lb = 4.99 of at 32° F and 1 atm.

Specific Volume, Liquid1 lb = 0.0109 cf at 32° F and 53.5 psia.

Weight, Dry Gas1 cf = 0.2006 lb at 32° F and 1 atm.

Figure 1 – Chlorine Pressure vs Temperature SO

UR

CE

: TH

E C

HL

OR

INE

MA

NU

AL

, FIF

TH

ED

ITIO

N, P

UB

LIS

HE

D B

Y T

HE

CH

LO

RIN

E IN

ST

ITU

TE

, IN

C.

IM 25.000AA UA (B/6-00)


PAGE 4

Weight, Liquid1 cf = 91.56 lb at 32° F.

Solubility in Water*6.93 lbs./100 gals at 60° F and 1 atm.

Pressure vs TemperatureSee Figure 1

*NOTE: Theoretical values shown. Actual solubility inwater based on chlorinator performance has proven to be3500 ppm or 2.92 lbs/100 gals maximum.

Chlorine is an oxidizing agent and will support combustionbut is not explosive or flammable. Many organic chemicalswill react with chlorine, some violently. Steel will ignitespontaneously in the presence of chlorine at 483° F.

3 SUPPLY CONTAINERS

Table 1 gives details on the supply containers most com-monly used with USF/W&T equipment.

Some large installations that would normally use single unittank cars but are not serviced by railroad facilities use tankmotor vehicles (tank trailers) which usually range in capacityfrom 15 to 22 tons.

All supply containers must conform to appropriate Depart-ment of Transportation (DOT) and Canadian TransportCommission (CTC) regulations. It is the responsibility of thesupply container manufacturer and the chlorine supplier tomeet these requirements.

3.1 RATES

In general, using a remote vacuum type chlorinator, the maxi-mum sustained gas withdrawal rate at which chlorine may betaken from a 100 or 150 pound cylinder is one pound per dayper degree Fahrenheit (1.0 lb/24 hrs/°F). The correspondingrate for ton containers is about 8.0 lbs/24 hrs/°F. At an as-sumed liquid temperature of 70° F (and using a remote vacuumtype chlorinator) the above figures translate into 70 lbs/24hrs for cylinders and 560 lbs/24 hrs for ton containers. Fora direct feed cylinder pressure operated chlorinator theserates become 42 and 336 lbs/24 hrs respectively. These ratescan be increased substantially for brief periods. Do not placecontainers in a water bath or apply direct heat in order topermit higher withdrawal rates.

It is not practical to withdraw chlorine as a gas from tank cars(or tank trailers).

3.1.1 MANIFOLDING FOR GAS WITHDRAWAL

When higher gas withdrawal rates are required, cylinders orthe gas valves (upper) of ton containers may be manifolded.A typical arrangement for manifolding cylinders is shown inFigure 2.

If cylinders or ton containers are manifolded, it is essentialthat all supply containers be at the same temperature to pre-vent the transfer of liquid chlorine from a warmer containerto a cooler container, possibly resulting in a container be-coming overfilled through reliquefaction of chlorine in thecooler container.

NOITAMROFNIRENIATNOCENIROLHC-1ELBATFOEPYT

RENIATNOCTHGIEWTEN THGIEWERAT SSORG

THGIEWEDISTUORETEMAID

HTGNEL

SREDNILYC bl001bl051

bl511-36bl041-58

bl512-361bl092-532

"¾01-"¼8"¾01-"¼01

"11'4-"½3'3"8'4-"5'4

NOTRENIATNOC

bl0002 bl0561-0031 bl0563-033 "6'2 "½01'6-"¾7'6

TINUELGNISSRACKNAT

snot61snot03snot55snot58snot09

-----

-----

"0'21-"5'01"7'31-"½4'21

"1'51-"3'41"1'51-"11'41"1'51-"11'41

"3'33-"2'23"½11'53-"01'33

"0'34-"9'92"0'05-"7'34"2'74-"8'54

.cnI,etutitsnIenirolhCehtybdehsilbup,noitidEhtfiF,launaMenirolhCmorfatadlanoisnemiD

aivytpmerollufdeppihsebyamezisbl051robl001ehtrehtiE.elbaliavaylidaertsomyllarenegsirednilycbl051ehT)1(.sdaolracrokcurtllufnirostolllamsniliarrokcurt

ehtetanimileotredronidedeensaracehtmorfyltceriddedaolnuyllarenegsisraCknaTtinUelgniSmorfenirolhC)2(owT.ylnosgnidisetavirpotdengisnoceradnadoirepsihtgnirudremusnocehtotdesaelerasraC.sknategarotsfoytissecen

nwod-tuhstuohtiwnoitareposuounitnoctimrepotdnasracfognildnahehtetatilicafotdednemmocereraskcartlellarap.dehctiwsgnieberasracelihwsdoirep


IM 25.000AA UA (B/6-00) PAGE 5

Figure 2 – Manifolding Cylinders

3.2 MAXIMUM LIQUID WITHDRAWAL RATE

The generally accepted alternate to manifolding ton contain-ers is to withdraw liquid chlorine from the lower valve anduse an evaporator. By this means, a ton container can beemptied in approximately five hours, which is equivalent to9600 lbs/24 hrs.

Liquid can be withdrawn from tank cars at up to nearly 8,000pounds per hour, or 192,000 pounds per 24 hours.

3.2.1 MANIFOLDING FOR LIQUID WITHDRAWAL

WARNING: IN ACCORDANCE WITH CHLORINE IN-STITUTE RECOMMENDATIONS, DO NOT MANI-FOLD TON CONTAINERS FOR SIMULTANEOUSLIQUID CHLORINE WITHDRAWAL. THISMANIFOLDING CAN CAUSE OVER-PRESSURIZA-TION AND RUPTURE.

3.3 CONTAINER VALVES

Standard cylinder and ton container valves are identical indesign, except that the cylinder valve includes a pressurerelief device. Cylinder valves are shown in Figure 3 and toncontainer valves in Figure 4.

See Figure 5 for captive yoke type auxiliary container valves(valve connection style #820, recognized by the CompressedGas Association as the only acceptable means of connectingto container valves). The external threads on the containervalve are used only for securing the protective cap.

Figure 3 – Standard Cylinder Valve

Figure 4 – Standard Ton Container Valve

Figure 5 – Auxiliary Ton Container Valve

IM 25.000AA UA (B/6-00)


PAGE 6

Cylinders are equipped with one valve that is normally usedfor gas withdrawal. Ton containers are equipped with twovalves, as shown in Figure 6.

Figure 6 – Ton Container Valves

Figure 7 – Standard Angle Valve

The upper valve is used for gas withdrawal and the lowervalve for liquid withdrawal. Tank cars are equipped withfour standard angle valves, as shown in Figure 7.

Outlet is one-inch female ANSI Standard taper pipe thread.The liquid withdrawal valves are located on the longitudinalcenter line of the tank car. The valves on the transversecenter line are connected to the vapor space and are used toobtain chlorine gas under pressure for testing the piping orfor air padding the tank car.

3.4 PRESSURE RELIEF DEVICES

All chlorine supply containers are equipped with some typeof device for relief of pressure. Cylinder valves have a fusiblemetal plug screwed into the body of the valve, as shown inFigure 3. The fusible metal melts when the temperature in-

creases to 158-165° F to relieve pressure and prevent ruptureof the cylinder.

Ton containers are equipped with six fusible metal plugs (seeFigure 8), three of which are in each end, spaced 120 degreesapart.

Figure 9 – Excess-Flow Valve

Figure 8 – Standard Fusible Plug for Ton Containers

Tank cars have an excess-flow valve (see Figure 9) locatedunder each liquid valve. While this valve may close duringa catastrophic pipe line failure, its main function is to closeautomatically if the angle valve is broken off in transit. Tankcars also have a pressure relief device (see Figure 10) lo-cated in the center of the manway. The relief level varieswith the type of car or tank.

3.5 STORAGE OF CONTAINERS

Store chlorine containers of any type under cover and in cool,well ventilated locations protected from fire hazards andadequately protected from extreme weather conditions. Dur-ing the summer months, full containers should be shieldedfrom the direct rays of the sun, otherwise a dangerous build-up of pressure might result (see Figure 1 and Paragraph 3.3).If stored out of doors, keep containers in fenced-off areas forprotection. Avoid storage in subsurface areas because chlo-rine is heavier than air and will not readily rise from subsur-


IM 25.000AA UA (B/6-00) PAGE 7

Figure 10 – Standard Safety Relief Device

face locations should leaks occur. Do not store or use chlo-rine containers near other chemicals or gases.

WARNING: STORE CYLINDERS IN AN UPRIGHTPOSITION. TO AVOID SEVERE PERSONAL INJURYOR EQUIPMENT DAMAGE, SUPPLY CYLINDERSMUST BE SECURED IN SUCH A MANNER (E.G.,CHAIN) AS TO PREVENT THEIR BEING KNOCKEDOVER. TON CONTAINERS MUST BE SECURED INSUCH A MANNER (E.G., CROCKS) TO PREVENTTHEIR ROLLING OUT OF PLACE.

Do not remove the protective cap or hood from cylinders orton containers until they are ready to be put in actual use. Donot store containers in a heavily traveled area where physicalcontact damage could occur.

It is essential that areas used to house chlorine containers orequipment be continuously monitored for the presence ofchlorine in the air. This may be a requirement of applicablelaws and/or regulations.

When containers are moved from a storage area to an areawhere they will be used, allow sufficient time to stabilize thetemperature, and therefore the pressure, of the container andthe chlorine before it is used.

The chlorine inventory depends to a large extent on localavailability. Consult with chlorine suppliers in the area; reviewappropriate fire code requirements concerning storage ofoxidizing materials and other applicable laws and regula-tions.

When planning space for stored containers, sufficient spacemust be allowed for empty containers. The best way to deter-mine the amount of chlorine remaining in a container is toweigh the container continuously on a scale. This also makesit possible to record the amount of chlorine used. Portable ordormant scales in beam, dial, or digital types and with vary-ing platform sizes are available.

WARNING: ALWAYS REMOVE WHEELS AND AX-LES OF PORTABLE SCALES SO THAT THE SCALECANNOT MOVE WHEN CYLINDERS ARE ON THEPLATFORM.

Preferably, scales for cylinders should be installed with theirplatform flush with the floor to eliminate the necessity oflifting the cylinders. Some low profile scales such as theUSF/W&T Two Cylinder Scale (platform 1-1/2 inches abovefloor) are low enough that cylinders can be placed on thescale without lifting. Others are installed with ramps. If scalesare pit mounted, a trapped drain should be provided.

Scales for ton containers are usually installed above the floor,since ton containers are usually handled by overhead con-veyor. Many of these scales do not have platforms since theton containers are usually supported by cradles or trunnions.

Special high-capacity scales are provided at some installa-tions using tank cars. These scales are usually pit mountedbelow the railroad siding with the dial or digital unit housedabove ground beside the track.

Some of the dial or digital scales are equipped with loss-of-weight recording systems providing a permanent record ofchlorine usage.

3.6 HANDLING CONTAINERS

Always handle chlorine containers with utmost care. Toprevent injury or damage, do not drop chlorine containersand do not permit containers to strike each other or otherobjects. To prevent damage to the valve, valve protectingcaps or hoods must always be in place when containers aremoved.

Handle cylinders with a simple two-wheel hand truck of thebarrel pattern. Hand trucks should be well balanced andequipped with chains or clamps to prevent the cylinders fromfalling off the truck.

IM 25.000AA UA (B/6-00)


PAGE 8

WARNING: NEVER LIFT CYLINDERS BY THEVALVE PROTECTING HOOD. THE HOOD MAYSEPARATE FROM THE CYLINDER, CAUSING THECYLINDER TO FALL.

Never lift cylinders by sling or magnetic devices. If lifting isnecessary, use a specially designed cradle. Contact yourchlorine supplier for recommendations or information.

When moving ton containers, due consideration must begiven to the fact that the liquid in the container represents alive load in addition to the dead load of the container and theliquid. The most accepted way of moving ton containers is byoverhead conveyor and lifting beam (see Figure 11).

Figure 11 – Ton Container Handling

THIS DIMENSIONDETERMINED BYREQUIREMENTS OFLIFTING DEVICE

OVERHEAD MONORAIL

HOIST(4000 LB. MIN.)

2’-7”CLEARANCE

LIFTING BAR

13”

2’-6”

2’-8”

1/2”±

6’-10”

Rails or roller conveyors have also been used. Fork lift trucks,in addition to having adequate capacity, must have the con-tainers restrained and be sufficiently stable to prevent tip-ping.

3.7 USING CONTAINERS

If containers have been stored in an area other than that inwhich they will be used, they should be allowed to stabilizeat the new temperature before being used. Containers shouldalways be used in the order in which they are received toavoid unnecessarily long storage and possible difficulty withvalves that have not been opened or closed for too long aperiod.

WARNING: CYLINDERS ARE NORMALLY USED INAN UPRIGHT POSITION FOR GAS WITHDRAWAL.TO AVOID SEVERE PERSONAL INJURY OR EQUIP-MENT DAMAGE, SUPPLY CYLINDERS MUST BESECURED IN SUCH A MANNER (E.G., CHAIN) ASTO PREVENT THEIR BEING KNOCKED OVER. TONCONTAINERS MUST BE USED IN A HORIZONTAL

POSITION WITH THE TWO VALVES IN A VERTI-CAL LINE. TON CONTAINERS MUST BE SECUREDIN SUCH A MANNER (E.G., CHOCKS) TO PREVENTTHEIR ROLLING OUT OF PLACE.

When withdrawing gas from a ton container, connection ismade to the upper valve (see Figure 6). Liquid withdrawal isaccomplished by connecting to the lower valve.

It is recommended that special 3/8-inch square box wrenches,rather than adjustable wrenches, be used for opening cylin-der and ton container valves. Length of the wrench shouldnot exceed eight inches. It is good practice to leave the wrenchin place so the valve can be closed quickly in case of anemergency. Maximum discharge can be accomplished withone full turn of the valve. Excessive force must not be usedin opening valves. Never strike the wrench with anythingother than the heel of the hand. Loosening the packing nuta maximum of 1/2 turn is acceptable, provided the packingnut is tightened after the valve is operated. Contact yourchlorine supplier if these procedures do not permit operationof the valve.

Angle valves on tank cars must be opened fully to aid theoperation of the excess flow valve.

Always test for leaks before putting new containers in ser-vice. The system can be pressurized by opening the containervalve and then closing it. The valve can be opened again afterit is determined that there are no leaks.

WARNING: ALWAYS WEAR PROTECTIVE CLOTH-ING WREN CHECKING FOR LEAKS. REFER TO“PERSONNEL SAFETY” FOR INFORMATION ONHEALTH HAZARDS AND SAFETY PRECAUTIONS.

It is not unusual during humid conditions for condensationto collect on the outside of the container. A buildup of froston the container indicates that withdrawal rates are too highto permit the surrounding air to supply the heat necessary toevaporate the liquid chlorine. Increasing the circulation ofroom temperature air past the container may correct thecondition. Do not apply direct heat to the container in anyway. It may be necessary to shut off the container valve andpermit it to warm up again before putting it back in service.

After emptying the container, the valve must be closed beforedisconnecting to prevent the entry of moisture. After discon-necting, the valve cap and the valve protecting cap or hoodmust be replaced before the container is moved. Empty con-tainers should be segregated from full containers and shouldbe tagged.


IM 25.000AA UA (B/6-00) PAGE 9

Tank cars are unloaded by means of one of the liquid valves.One of the gas valves can be connected to the system topermit pressure testing with gaseous chlorine rather thanliquid. The flexible connection used for tank car unloadingmust be designed for and installed in such a manner to allowfor the significant increase in height as the car unloads. Sincetank car pressure is the only force causing the chlorine todischarge, many cars are padded with dry air by the produceror the user. Reference to Chlorine Institute Pamphlet 66,Chlorine Tank Car Loading, Unloading, Air Padding, Hy-drostatic Testing, should be made for information on user airpadding. It is essential that air padding pressure be kept aslow as possible for satisfactory operation of the chlorinationequipment since excessive air padding pressures can have anegative impact on evaporator performance. The depletionof the liquid chlorine supply in the car is accompanied by asharp drop in tank car pressure.

After the angle valve is closed and the discharge line emp-tied, the piping may be disconnected. The valve outlet plugsshould be replaced and the discharge piping capped imme-diately.

4 PIPING

4.1 PIPING MATERIALS AND JOINTS

If the chlorinator capacity is low enough, the vacuum regu-lator or the complete chlorinator may be mounted directly ona cylinder or ton container valve, totally eliminating pres-sure piping. In this case, reference to the equipment instruc-tion book provides all necessary details.

Pressure connections from all chlorine containers are nor-mally made by means of flexible connections made of coppertubing. Use yoke type connections at container valves. Thechlorinator or vacuum regulator instruction book should bereferred to for details for use of flexible connections alongwith the required auxiliary cylinder or ton container valves,header valves, and auxiliary header valves (if required).

WARNING: ALWAYS REPLACE FLEXIBLE CON-NECTIONS ANNUALLY (OR SOONER IF THERE ISEVIDENCE OF DETERIORATION).

The usual practice for chlorine liquid or gas pressure lines,at the commonly encountered pressures and temperatures atchlorinator installations, is the use of 3/4 or 1.0 inch sched-ule 80 carbon steel seamless pipe with Class 3000 forgedsteel fittings; two-bolt flanges (commonly referred to as ovalammonia unions) are also often used. Both screwed andsocket welded construction are common. Threaded jointsshould be made up using litharge and glycerine for perma-nent joints, white lead or TFE tape for others.

To facilitate maintenance, the number of line valves shouldbe kept to a minimum. Insulation is required only in thosecases where it is necessary to prevent chlorine gas lines frombecoming chilled, or liquid lines from becoming overheated.

More complete details, along with ASTM and ANSI speci-fications, can be obtained by referring to Chlorine InstitutePamphlet 6, Piping Systems For Dry Chlorine.

WARNING: TWO COMMON CAUSES OF CHLO-RINE PIPING LEAKS ARE:1. RE-USE OF GASKETS. THIS SHOULD NEVER BEDONE. ALWAYS HAVE AN ADEQUATE SUPPLY ONHAND AND ALWAYS USE NEW GASKETS OF THECORRECT MATERIAL AND SIZE AS IDENTIFIEDON THE EQUIPMENT PARTS DRAWING.2. IMPROPERLY MADE-UP THREADED PIPEJOINTS. SEE CHLORINE INSTITUTE MANUAL ORPAMPHLET 6 FOR RECOMMENDED PROCEDURE.

4.2 GAS PIPING INSTALLATION REQUIREMENTS

Reliquefaction of a gas should be avoided. If liquid chlorineis carried downstream to the chlorinator or vacuum piping,it may soften the plastic components and affect their struc-tural strength. Liquid can wash any collected contaminantsinto the vacuum regulator and can also cause erratic surging,freezing, and pressure release, which can damage the dia-phragm and control valves. Cold conditions in a gas pipe line(cold to the touch, dripping of water condensed from theatmosphere, frost, ice) are an indication that liquid chlorineis present in the line and is flashing to gas. Refer to the properguidelines that follow.

It is important to observe the correct temperature conditionsin conducting chlorine gas under pressure from the locationof the containers to the point of use. To avoid difficulty withreliquefaction of chlorine, pressure piping and control equip-ment receiving gas under pressure should be at a highertemperature than that of the chlorine containers. In general,a difference of 5° to 10° F is recommended.

Pitch pressure lines uphill from the gas source toward thechlorinators if possible.

Install a pressure reducing valve or the chlorinator vacuumregulator close to, but higher than, the source of gas. The useof a chlorine pressure reducing valve is also recommendedin those localities where severe temperature changes are likelyto be encountered during a 24-hour period.

It is preferable to run chlorine pressure gas lines overheadthrough relatively warm areas rather than along the floor orthrough basement areas where lower temperatures may be

IM 25.000AA UA (B/6-00)


PAGE 10

encountered. Do not run these gas lines along exterior wallsthat may be cold in winter months. Do not run pressure gaslines under windows from which cold air descends in wintermonths.

If the source of gas is one or more ton containers connectedto a manifold, install a drip leg of 1.0-inch schedule 80seamless steel pipe approximately 18 inches long in a tee inthe manifold with the lower end capped. Locate the drip legimmediately downstream of the last container connection tointercept the liquid that comes from the ton containers’ gaseduction tubes when initially opened.

Gas may be withdrawn from two or more containers simul-taneously provided all containers are at the same tempera-ture. Refer to Paragraph 3.1.

The installation of chlorine gas strainers in pipe lines up-stream from pressure reducing valves or vacuum regulatorsis a common practice. These strainers can also serve as trapsfor a small amount of liquid chlorine. Figure 12 illustrates atypical strainer.

Figure 12 – Chlorine Gas Strainer

HOUSING

GASKET

SCREENAND COVER

BOLT

4.3 LIQUID PIPING INSTALLATION REQUIRE-MENTS

It is important to avoid conditions that will encourage vapor-ization. Thus it is important to keep liquid chlorine lines ascool as, or cooler than, the containers themselves by elimi-nating restrictive fittings and always operating with fullyopened line valves. Avoid running liquid chlorine linesthrough overheated areas where gasification is likely.

Valves in liquid chlorine lines should be kept to a minimum.It is particularly important to avoid situations where it is easyto close two valves in a line thus trapping liquid that, uponan increase in temperature, will expand and develop higherthan acceptable pressures.

A liquid line pressure relief system (which includes a rupturedisc and an expansion chamber) is required where liquidmay be trapped in the line or where it is necessary to run linesa considerable distance. The relief system is detailed in Fig-ure 13.

Figure 13 – Liquid Line Pressure Relief System

6-5/8”

1/2” FEMALE NPT FOR115 V ELECTRICAL

CONNECTION

PRESSURESWITCH

DIAPHRAGM SEALUNIT

EXPANSIONCHAMBER

SUPPORT BRACKET

WARNING LABEL

LENGTH OF LIQUID LINEPROTECTED PER EXPANSIONCHAMBER SYSTEM

1” CHLORINELINE

UNIONHEAD

RUPTUREDISC

46-1/4”

30”

��

The expansion chamber provides an area for expansion inthe event that valves at both ends of the line are closed.Relief system placement must be based not only on lengthof line but also placement of valves.

4.4 PRESSURE RELIEF AND VENT PIPING RE-QUIREMENTS

All pressure relief vent line systems must be treated as thoughthey contain chlorine. Use the same materials for pressurerelief vent lines as used for chlorine gas piping, unless thevent line is a combination pressure relief/vacuum relief linein which case the material must be suitable for moist chlorinegas (PVC or polyethylene tubing).

Vent lines must be run in such a way that moisture collectingtraps are avoided. A continuous gradient is preferred. Theend of all vent lines must be turned down and screened.

Manifolding of vent lines is an acceptable practice providedonly like vents are manifolded (i.e., evaporator water vapor


IM 25.000AA UA (B/6-00) PAGE 11

Figure 15 – Gas and Liquid Ball Valve

vents must be separate from gas pressure reducing valvepressure vents, etc.). The interior cross sectioned area of acommon vent or pressure relief line should be approximatelyequal to the sum of the cross sectional areas of the individualvent lines.

WARNING: THE VENT LINE AND RELIEF LINEMUST TERMINATE IN AN AREA GAS FUMES CAN-NOT CAUSE INJURY TO PERSONNEL OR DAMAGE.DO NOT TERMINATE THE VENT LINE AND RE-LIEF LINE AT A LOCATION ROUTINELY USED BYPERSONNEL, SUCH AS WORK AREAS OR PATH-WAYS NOR NEAR ANY WINDOWS OR VENTILA-TION SYSTEM INTAKES. IF AN AREA MEETINGTHESE REQUIREMENTS IS NOT AVAILABLE,REFER TO THE CHLORINE INSTITUTE’S CHLO-RINE MANUAL AND PAMPHLET NO. 9 FOR AL-TERNATE METHOD OF RELIEF DISPOSAL.

4.5 VALVES

Yoke type auxiliary cylinder, yoke type auxiliary ton con-tainer, and header valves are described adequately in thechlorinator or vacuum regulator instruction book.

Line valves are used to isolate alternate sources of supply(manifolded banks of ton containers or tank cars), individualevaporators or pressure type chlorinators. Sufficient linevalves should be provided for flexibility of system operationconsistent with the recommended practice of eliminatingredundant or unnecessary valves.

Valves are usually of approximately globe pattern as shownin Figure 14 or ball type as shown in Figure 15.

Care should be taken that only valves designed by the manu-facturer specifically for chlorine service are used. Ball valvesmust include a provision for venting the cavity in the closedposition to the upstream side.

Figure 14 – 3/4- and 1-Inch Line Valves

MACH. SCREWWASHER

PACKING NUT

PACKING GUARD

PACKING BOX

GAP

LEAD GASKET

STEM UNITLEAD GASKET

INLET

HANDLE

PACKING

PACKING RING

CAP SCREW (4)

SEAT

VALVE BODY

4.6 PRESSURE GAUGES AND SWITCHES

Whenever pressure gauges and switches are used in chlorineliquid or gas lines, they must be of the type protected by aflanged diaphragm seal specifically designed for chlorine ser-vice to prevent the entry of chlorine into the gauge or switchmechanism. The fill material must be suitable for chlorineservice. The connection between the seal and the gauge orswitch must not be broken. If the connection is inadvertentlybroken, the complete assembly must be discarded and replaced,unless it can be returned to the manufacturer for repair.

Frequently, valves are installed between chlorine lines andthe gauge or switch diaphragm seal to permit removal with-out taking the line out of service. A means of relieving thepressure in the isolated piping, gauge, or switch is stronglyrecommended.

WARNING: RELEASING EVEN A SMALL AMOUNTOF LIQUID CHLORINE IS DANGEROUS AND RE-QUIRES EXTREME CAUTION TO AVOID SEVEREPERSONAL INJURY. ALWAYS USE PROTECTIVEEQUIPMENT WHEN RELIEVING PRESSURE, EVENIN ISOLATED CHLORINE GAS PIPING.

Since small size line valves for chlorine are not readily avail-able, many times a header valve is used as shown in Figure 16.

Figure 16 – Chlorine Pressure Gauge or Switch Mounted on Header Valve

PRESSURE GAUGE(OR SWITCH) ANDDIAPHRAGM

UNION ADAPTER

UNION NUT

LEAD GASKET

HEADER VALVE

3/4” CONNECTIONIN GAS LINE

RETAINING RING

INDICATOR STOP

BODY SEAL

BALL

BODY CAP

BODY

STEMSEAT

HANDLESTEM NUT

BONNET PLATE

STEM BEARING

STEM SEAL

IM 25.000AA UA (B/6-00)


PAGE 12

4.7 PRESSURE RELIEF DEVICES

There are two types of pressure relief devices in use in chlo-rine piping systems. The first, as shown in Figure 13, isusually employed in liquid chlorine piping to protect thepiping from rupture due to high pressure from thermal ex-pansion of the liquid chlorine. It consists of a rupture discthat ruptures before the pipe line itself can rupture, an expan-sion chamber that allows for relief of the over-pressure con-dition without releasing chlorine to the atmosphere, and apressure switch to warn of the disc rupture.

The second type, as shown in Figure 17, is usually used in gaspiping at the evaporator discharge. This system consists ofa rupture disc that keeps chlorine out of the valve duringnormal operation, a pressure relief valve, and a pressureswitch to warn of disc rupture.

Figure 17 – Evaporator Pressure Relief System

GAS PRESSURE RELIEF VALVE 500 PSIG 1/2” FEMALE NPT FOR 115VELECTRICAL CONNECTION

PRESSURE SWITCH

DIAPHRAGM SEAL UNIT

1” FEMALE NPT INLET

RUPTURE DISC 400 PSI

UNION HEAD

1-1/2” FEMALE NPT RELIEF CONNECTION

WARNING: THE RELIEF LINE MUST TERMINATEIN AN AREA WHERE GAS FUMES CANNOT CAUSEDAMAGE OR INJURY TO PERSONNEL. DO NOTTERMINATE THE RELIEF LINE AT A LOCATIONROUTINELY USED BY PERSONNEL, SUCH ASWORK AREAS OR PATHWAYS, NOR NEAR WIN-DOWS OR VENTILATION SYSTEM INTAKES. IF ANAREA MEETING THESE REQUIREMENTS IS NOTAVAILABLE, REFER TO THE CHLORINEINSTITUTE’S CHLORINE MANUAL AND PAM-PHLET NO. 9 FOR AN ALTERNATE METHOD OFRELIEF DISPOSAL.

4.8 PREPARATION FOR USE

Normal plumbing practices will result in the entry of cuttingoils, greases, and other foreign materials into the piping.

In addition, the line will have been open to the atmosphereduring construction, allowing moisture to enter. It is there-

fore essential that all piping be thoroughly cleaned and driedprior to exposure to chlorine.

WARNING: INCOMPLETE CLEANING CAN RE-SULT IN VIOLENT REACTIONS BETWEEN CHLO-RINE AND THESE MATERIALS.

Steam cleaning is an acceptable method for removal of theabove materials. Provision must be made for removal ofcondensate and foreign materials. For alternate methods ifsteam is not available, refer to Chlorine Institute Pamphlet6, Piping Systems for Dry Chlorine.

After proper cleaning, all chlorine piping should be hydro-statically tested to one and one half times the expected maxi-mum operating pressure. Prior to testing, all gauges, switches,rupture discs, etc., that could be damaged during testingmust be removed and connections plugged. Any moistureabsorbing packing or gaskets left in the system during hydro-static testing must be removed and replaced with new pack-ing or gaskets. After hydrostatic testing, it is essential that allpiping be thoroughly dried with inert gas (e.g., nitrogen) ordry air having a dew point of -40° F or below. The dew pointof the air or gas leaving the piping must be checked anddrying continued until the dew point is at or below -40° F,which may require quite some time.

WARNING: MOISTURE MUST BE REMOVED FROMANY PART OF THE EQUIPMENT THAT IS NOR-MALLY EXPOSED TO DRY CHLORINE ONLY.WHILE DRY CHLORINE IS NON-CORROSIVE,MOIST CHLORINE IS EXTREMELY CORROSIVETO COMMON METALS, SUCH AS BRASS OR STEEL,POSSIBLY RESULTING IN A LEAK AND SEVEREPERSONAL INJURY. ALSO, IF WATER IS TRAPPEDIN A SECTION OF PIPING OR EQUIPMENT, SUBSE-QUENT HEATING OR FREEZING OF THE WATERMAY RESULT IN HIGH ENOUGH PRESSURE TORUPTURE THE PIPING OR EQUIPMENT, POSSIBLYCAUSING SEVERE PERSONAL INJURY.

A very acceptable alternate to hydrostatic testing, if properfacilities do not exist for drying, is to test with nitrogen or dryair having a dew point of -40° F or below. The same provisionof removing equipment that could be damaged by test pres-sure applies.

WARNING: TO AVOID SEVERE PERSONAL IN-JURY, BEFORE PLACING THE PIPING SYSTEMINTO SERVICE, PRESSURE TEST WITH CHLORINEGAS, NOT LIQUID. EACH VOLUME OF CHLORINELIQUID THAT LEAKS AND THEN EVAPORATESRESULTS IN APPROXIMATELY 460 VOLUMES OFCHLORINE GAS.


IM 25.000AA UA (B/6-00) PAGE 13

The chlorine container valve should be opened only slightlyduring this phase of testing or preferably closed again afterpressurizing the system. The piping should be tested in thesmallest sections permitted by the existing valves to mini-mize the discharge of chlorine through any leaks.

WARNING: IT IS ESSENTIAL THAT PROPERBREATHING APPARATUS BE AVAILABLE BEFORECHLORINE IS ADMITTED TO ANY PIPING SYSTEMOR EQUIPMENT. THIS APPARATUS WILL BE DIS-CUSSED FURTHER UNDER “PERSONNELSAFETY”.

Chlorine leaks are best located using a dauber moistenedwith commercial 26° Baume’ aqueous ammonia (householdammonia is not strong enough) . A white cloud will be formedat the site of any leak. A plastic squeeze bottle that directsammonia vapor, not liquid, at the joint being tested may alsobe used.

When a leak is detected, the system must be depressurizedbefore corrective action is taken. The best method of depres-surizing the system is through one of the chlorinators. Atleast one chlorinator must be readily available for this pur-pose before testing with chlorine begins.

5 PERSONNEL SAFETY

5.1 GENERAL

Proper consideration of personnel safety begins with theprovision of properly sized and arranged housing so thatoperating personnel have adequate room to perform theirduties. It is preferable that any room used for chlorine storageor equipment have two doors that open outward and that areequipped with panic bars.

Rooms housing chlorination equipment, and chlorine con-tainers that are “in service” or “in reserve”, should be heatedwhen the room temperature falls below 50° F. Comfortableworking temperatures of 65° to 75° F are recommended forthe chlorine equipment room. The temperature of the chlo-rine container room (if separate) should normally be 5° to10° F lower. All common methods of heating are acceptable,provided that care is taken to prevent overheating of chlorinecontainers. Radiators should not be located adjacent to con-tainers. If space heaters are used, the warm air should bedeflected away from the containers. Outside windows shouldbe located or screened so that the rays of the sun do not falldirectly on chlorine containers.

Natural ventilation may be adequate for a small chlorinatorinstallation in a separate building when windows and doors

can provide cross circulation; however, ventilation by meansof a proper type electric fan is always recommended.

In all cases, installations must comply with appropriate regu-lations.

5.2 HEALTH HAZARDS

Exposure to a sufficiently high concentration of chlorine canresult in difficulty in breathing and, if prolonged, finallydeath through suffocation. Chlorine’s strong pungent odormay result in detection at levels as low as 1.0 ppm and mostpeople will detect it by the time the concentration reaches 3.5ppm. Concentrations of 5 ppm or more are so objectionablethat only those who are unconscious or trapped will normallyremain in the area. Increasing concentrations will produceeye irritation, coughing, throat irritation, vomiting, and la-bored breathing.

Even concentrations below the threshold of smell can resultin minor eye and throat irritation if the exposure is longenough.

Liquid chlorine can cause burns and/or irritation when it isin contact with the skin or eyes.

Medical attention should be obtained immediately for per-sonnel who have sufficient exposure to result in any symp-toms beyond minor irritation. Properly trained and equippedfirst aid personnel are usually the first line of defense. Whilewaiting for their arrival, the exposed individual must beremoved to a safe area and be placed in a comfortable posi-tion. If breathing has stopped, artificial respiration must bestarted immediately. CPR administered by properly trainedpersonnel is required if the heart has stopped.

If the exposed individual has difficulty breathing, oxygenshould be administered only by those adequately trained inthe procedure and the equipment used.

The proper procedure for emergency treatment of clothing orskin contaminated by chlorine is to flush the area with largequantities of water under a shower for at least 15 minutes.While still under the shower, affected clothing should beremoved. No medical treatment or neutralization of the chlo-rine should be attempted except as directed by a physician.

Immediate flushing with tepid water should be administeredif even small quantities of chlorine enter the eye or if the eyehas been exposed to strong concentrations of chlorine. Theeyelids must be parted and thorough flushing continued forat least 15 minutes. As mentioned previously for skin expo-sure, no medical treatment or neutralization should be at-tempted except as directed by a physician.

IM 25.000AA UA (B/6-00)


PAGE 14

The attending physician may wish to refer to a MaterialSafety Data Sheet on chlorine as well as to the ChlorineInstitute’s Chlorine Manual and/or Pamphlet 63, First Aidand Medical Management of Chlorine Exposures.

5.3 SAFETY PRECAUTIONS

The first steps to be taken in providing proper safety precau-tions at any facility are the selection of safety equipment tobe on hand, the proper location of the equipment, and thetraining of all personnel in proper procedures to avoid un-necessary chlorine releases and to deal with releases thatoccur.

Proper respiratory equipment is essential for all facilitiesregardless of size. For maximum safety, it is preferable to useair tank type pressure demand masks that have a self-con-tained air supply and, therefore, are suitable regardless ofchlorine concentration.

All respiratory equipment must meet the requirements of theNational Institute for Occupational Safety and Health. Fol-lowing the respiratory equipment manufacturer’s recommen-dation regarding maintenance and periodic testing is essen-tial. This equipment should be stored outside the area con-taining chlorine or chlorine equipment in a manner protect-ing it from damage of any kind and so as to be readily avail-able.

WARNING: DO NOT LOCK CABINETS OR CLOS-ETS IN WHICH RESPIRATORY EQUIPMENT ISSTORED, AS THE EQUIPMENT MUST BE READILYAVAILABLE.

All personnel with no assigned responsibility for dealingwith a chlorine release should be instructed to leave the area.Those responsible for correcting the situation should donrespiratory equipment before doing so.

Protective clothing is recommended for handling even rou-tine operations involving chlorine. In the event of a substan-tial release, protective clothing is required. Anyone desiringfurther information on protective clothing should refer to theChlorine Institute Pamphlet 65, Protective Clothing forChlorine.

Safety shoes, hard hats, and safety glasses should be used inaccordance with standard plant practice.

Most leaks will occur in piping, valves, connections, and thepressurized portions of chlorine equipment. These leaks willusually be eliminated by tightening packing, replacing gas-kets, or repairing the equipment.

WARNING: REPLACE FLEXIBLE CONNECTIONSANNUALLY, OR SOONER IF THERE IS EVIDENCEOF DETERIORATION.

Emergency kits (meeting Chlorine Institute requirements)are available that can seal off most leaking areas of chlorinecontainers (i.e., valves, fusible plugs, or container wall). Ifthese are on hand they must be used only by personnel thor-oughly familiar with their use. The chlorine supplier shouldbe contacted immediately for information, assistance, andadvice on the disposition of the leaking container. The con-tainer should always be repositioned, if possible, so the leakis gas rather than liquid.

WARNING: NEVER UNDER ANY CIRCUMSTANCESPRAY WATER ON A CHLORINE LEAK. THIS WILLONLY MAKE IT WORSE.

Wall charts are available from most chlorine suppliers thatprovide much of the information contained in this manual.

5.4 EMERGENCY ACTION PLANS

The best emergency plan includes routine practices that aredesigned to minimize emergencies. Proper maintenance ofall equipment associated with the storage, handling, and useof chlorine in accordance with the manufacturer’s instruc-tions is essential.

All equipment and piping containing chlorine under pres-sure must be tested periodically for leaks following proce-dures covered in Paragraph 4.8. Since it is not unusual forareas used for chlorine storage and chlorine equipment to berelatively unattended, it is important for the air in these areasto be monitored continuously with chlorine detectors, so thatwarning of leaks is given as early as possible. As with mostemergencies, the earliest detection helps to minimize thedamage to equipment and personnel. In addition to warningof leaks when the areas are unattended, chlorine detectorsshould warn of the presence of minor amounts of chlorinethat may not be detected by personnel in the area.

Some chlorine leaks are minor but all require immediateattention.

In the event of a major release of chlorine, there should be nodelay in contacting the agency in the community that isresponsible for handling hazardous material releases. Ap-propriate names and telephone numbers must be prominentlyposted.

The chlorine supplier is probably the best source of assistancefor most chlorine users. In addition, the Chlorine Institute’sChlorine Emergency Plan (CHLOREP) can provide vital as-


IM 25.000AA UA (B/6-00) PAGE 15

sistance. In the United States this plan is activated throughCHEMTREC (toll free 800-4249300). In Canada, contactCANUTEC (call collect 613-996-6666). These names andnumbers must also be posted prominently.

The person responsible for making any of the calls listedabove must be sure to give the agency contacted completedetails including facility name, address, telephone number,and the names(s) of personnel to contact for further informa-tion. The description of the emergency should include size ofcontainer, corrective action already taken, local weatherconditions, injuries, proximity to populated areas, and direc-tions for easiest access to the site.

It is vital that the emergency plan include use of the “buddysystem”, i.e., no personnel should be allowed to work alonein an area with a chlorine leak even if the second person isonly standing by. As indicated earlier, all personnel not in-volved in locating and correcting the leak should leave thearea travelling in a crosswind direction to an area that isupwind and above the leak. Since it may not be possible forall personnel to be equipped with respiratory equipment,they should be instructed to use a wet cloth or handkerchiefover the nose and mouth while leaving the area.

Chlorine Institute Pamphlet 64, Emergency Control Plan-ning Checklist for Chlorine Facilities, may be of assistancein preparing the emergency plan. A Material Safety DataSheet for Chlorine, available from the Institute or the sup-plier, should also be consulted.

No emergency plan should be implemented until it is re-viewed by the chlorine supplier and the agency in the com-munity having responsibility for hazardous material han-dling and disposal.

If it is apparent that fire will threaten or is present in achlorine storage area, it is preferable to remove the contain-ers. If this is not possible, the containers must be protectedfrom the heat of the fire by spraying them with water. Do notspray water on any leaking container, however, since waterwill react with the chlorine, forming acids that will make theleak worse.

5.5 CHEMICAL DISPOSAL FACILITIES

Part of the planning for emergencies entails provision fordisposal of any released chlorine. In most cases little can bedone about the chlorine already released to the atmosphereexcept to try to prevent its dissipation into areas where dam-age to equipment and personnel will result.

At some large installations, scrubbers have been installed sothat areas containing chlorine or chlorine equipment can besealed off and the air removed to a process that will absorbthe chlorine. The design of such a system is complex andshould only be attempted by those thoroughly familiar withthe process.

Absorption systems have been provided at some facilities topermit a leaking container to be emptied quickly if this isdeemed essential. One pound of chlorine can be absorbed by1. 4 pounds of sodium hydroxide (caustic soda), 3.7 poundsof sodium carbonate (soda ash), or 1.3 pounds of calciumhydroxide (hydrated lime).

WARNING: TO AVOID SEVERE PERSONAL INJURYWHEN USING CORROSIVE CHEMICALS, OBSERVEALL SAFETY PRECAUTIONS RECOMMENDED BYTHE CHEMICAL MANUFACTURER/ SUPPLIER.

In each case, one pound of the material should be dissolvedin one gallon of water. Lime will actually be suspended in,rather than dissolved in, the water and requires constantagitation.

The tank and other equipment provided for an absorptionsystem must be fabricated of materials suitable for the chemi-cals involved.

Provision must be made for dissolving the chlorine in thealkaline solution in such a way that the solution cannot besucked back into the container.

Actually the safest way of disposing of the chlorine in theleaking container might be through the chlorination process,particularly if the process can absorb the chlorine at higherthan normal rates without creating damage.

It is not generally permissible to ship a container damagedby leak or fire if it contains chlorine. If for some reason thisseems necessary, the chlorine supplier must be contacted.

SERIES 50-200 EVAPORATOR FOR CHLORINE - … · The USF/W&T Series 50-200 Evaporator for Chlorine...

Documents

Transcript of SERIES 50-200 EVAPORATOR FOR CHLORINE - … · The USF/W&T Series 50-200 Evaporator for Chlorine...