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USER MANU AL
CeraClean Instal lat ion and start -up
O R D E R N O . :
S E R I A L N O . :
M A N U A L N O . : M T 5 - 0 7
L A N G U A G E : E N G L I S H
R E V I S I O N : 4
D A T E : 0 1 / 2 0 1 2
ENGLISH TRANSLATION OF THE ORIGINAL GERMAN MANUAL
READ THE INSTRUCTIONS IN THIS MANUAL CAREFULLY BEFORE INSTALLATION AND SERVICE.
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CAPTER 1 INTRODUCTION 1
Read this manual carefully before installing the system and pay attention to the safety information.
SPX Flow Technology Norderstedt GmbH will accept no liability for damages due to non-
observance of this manual. Rights under the warranty may also be forfeited.
Rights under the warranty will also be forfeited if spare parts are used which are not supplied by
SPX Flow Technology Norderstedt GmbH.
Information in this manual is subject to change without notice and does not represent a commit-
ment on the part of SPX Flow Technology Norderstedt GmbH.
No part of this manual may be reproduced or transmitted in any form or by any means, electronic or
mechanical, without the prior written permission of SPX Flow Technology Norderstedt GmbH.
Where manuals are translated into several languages, the German language text is considered as
the original.
Copyright 2012, SPX Corporation. All rights reserved.
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CAPTER 1 INTRODUCTION 3
INDEX
INDEX ............................................................................................................................... 3
TABLE OF FIGURES ....................................................................................................... 5
1. INTRODUCTION ........................................................................................................ 6
1.1 Conventions used in this manual ......................................................................................... 7
2. SAFETY INFORMATION ........................................................................................... 9
2.1 General safety information................................................................................................... 9
2.1.1 Intended use ..................................................................................................................... 9
2.1.2 Sources of danger and behavior in case of emergency ................................................... 10
2.1.3 Workplace ....................................................................................................................... 10
2.1.4 Operating personnel ........................................................................................................ 11
2.2 Rules for handling reagents ............................................................................................... 11
2.3 Marking of hazardous substances ..................................................................................... 13
2.3.1 Hazard symbols and descriptions .................................................................................... 13
2.3.2 R and S phrases ............................................................................................................. 14
2.4 Disposal ............................................................................................................................ 14
2.5 Safety data sheets and operating instructions ................................................................... 15
3. DESCRIPTION OF THE UNIT .................................................................................. 16
3.1 Overview ........................................................................................................................... 16
3.2 Introduction to Microfiltration .............................................................................................. 16
3.3 Construction and mode of operation .................................................................................. 16
3.4 Description ........................................................................................................................ 19
3.5 Specification ...................................................................................................................... 20
4. INSTALLATION ........................................................................................................ 21
4.1 Overview ........................................................................................................................... 21
4.2 Workplace design .............................................................................................................. 21
4.3 Operating conditions.......................................................................................................... 22
4.4 Installing the filtration unit .................................................................................................. 22
4.5 Installing the Submersible Pump ....................................................................................... 24
4.6 Connection between the submersible pump and microfiltration system ............................. 24
4.7 Connection to the cleaning solution container ................................................................... 25
4.8 Sample back flow .............................................................................................................. 25
4.9 Connections between the MF and the On-line Monitor ...................................................... 25
4.10 Electrical installations ........................................................................................................ 26
5. COMMISSIONING AND DECOMMISSIONING........................................................ 27
5.1 Overview ........................................................................................................................... 27
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4 CHAPTER 1 INTRODUCTION
5.2 General commissioning ...................................................................................................... 27
5.3 Commissioning the filtration with Bran+Luebbe analyzers .................................................. 27
5.4 Adjusting the filtrate pump .................................................................................................. 28
5.5 General decommissioning .................................................................................................. 28
5.6 Decommissioning the filtration with Bran+Luebbe analyzers .............................................. 29
6. MAINTENANCE AND CARE .................................................................................... 30
6.1 Overview ............................................................................................................................ 30
6.2 Important notice for using the filter tubes ............................................................................ 30
6.3 Maintenance the filter tube ................................................................................................. 31
6.3.1 Causes of blockage, and how to clean the filter tubes ..................................................... 31
6.3.2 Filter tube cleaning, controlled by the analyzer ................................................................ 33
6.3.3 Adjusting the cleaning sequence ..................................................................................... 33
6.3.4 Mechanical cleaning of the filter tube ............................................................................... 34
6.4 Replacing the filter tube ..................................................................................................... 34
6.5 Oil replacement in the submersible pump .......................................................................... 36
7. FILTRATE PUMP ..................................................................................................... 37
7.1 Description ......................................................................................................................... 37
7.2 Specification ...................................................................................................................... 37
7.3 Maintenance and inspection ............................................................................................... 38
7.4 Troubleshooting ................................................................................................................. 38
7.5 Disassembly ...................................................................................................................... 39
8. SPARE PART LIST .................................................................................................. 40
APPENDIX A INDEX ..................................................................................... A-1
APPENDIX B TECHNICAL DATA ................................................................. B-1
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TABLE OF FIGURES
Fig. 2.1: Hazard symbols ..................................................................................................... 13
Fig. 3.1: CeraClean flow chart .............................................................................................. 18
Fig. 4.1: Dimensional drawing of the Microfiltration system .................................................. 23
Fig. 6.1: Picture of a standard microfiltration ........................................................................ 35
Fig. 6.1: Picture of a POROSET microfiltration with 80 m steel filter .................................. 35
Fig. 7.1: Membrane pump .................................................................................................... 37
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6 CHAPTER 1 INTRODUCTION
1. INTRODUCTION
The Bran+Luebbe microfiltration systems of CeraClean type are used to provide a continuous stream of purified sample, typically from waste water or sewage treatment plants. They are the connection between sample extraction from the sample basin and the On-line Monitor. Microfiltra-tion systems remove certain materials, as for example bacteria, from the water so that these ma-terials will not interfere in the On-line Monitor operation. Dissolved substances such as phos-phate, nitrate, nitrite, or ammonia, pass through to the On-line Monitor and may be analyzed con-tinuously.
The major advantages of the Microfiltration systems are the low maintenance requirement and the long lifetime of the filter.
This manual provides you with the necessary instructions for installing, commissioning and de-commissioning and maintaining your CeraClean filtration unit. We assume that operators have a basic technical knowledge.
Read this manual carefully before installing and commissioning the system. The manual must be kept close to the unit and be available at all times.
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The manual is divided into the following chapters:
CHAPTER 1 INTRODUCTION
CHAPTER 2 SAFETY INFORMATION
CHAPTER 3 DESCRIPTION OF THE UNIT
CHAPTER 4 INSTALLATION
CHAPTER 5 COMMISSIONING AND DECOMMISSIONING
CHAPTER FEHLER! VERWEISQUELLE KONNTE NICHT GEFUNDEN WERDEN. MAINTENANCE AND CARE
CHAPTER 7 FILTRATE PUMP
CHAPTER 8 SPARE PART LIST
APPENDIX A INDEX
APPENDIX B TECHNICAL DATA
If you have any questions or if problems occur, you can contact our customer service hotline at any time:
HOTLINE TELEPHONE: ++49 (0)40/52202-505
HOTLINE FAX: ++49 (0)40/52202-592
If commissioning and/or the supply of reagents have been agreed, these services can be redeemed against a voucher which is sent by SPX Flow Technology Norderstedt to the initial customer (e.g. project engineering office or OEM).
1.1 Conventions used in this manual
The following designations are used:
Capital letters are used to indicate operating modes and functions, e.g. CALIBRATION.
Bold letters are used to indicate the on the touch screen.
The following types of safety information are used:
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Danger: Used when non-observance could result in serious injury or death.
Warning: Used when non-observance could result in minor injuries or serious material damage.
Caution: Used when non-observance could result in minor material damage.
The information arrow is used for additional information or recommendations which relate to practical use of the equipment and which are important for trouble-free operation.
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2. SAFETY INFORMATION
This unit may only be used for the purpose for which it is intended. The owner must ensure that the unit is only operated by technically suitable and trained personnel. The safety information must be observed.
2.1 General safety information
Danger: This unit contains electrical circuits, devices and modules operating under dangerously high voltages. Contact with these components may result in electric shock and severe or fatal injury.
Observe the following general precautions:
All connection, maintenance and repair work which requires the control section to be opened may only be performed by a qualified electrician.
Ensure that the protective conductor for the unit is connected.
Check the mains cable for damage before commissioning. Do not switch on the unit if there is any damage to the mains cable or if the mains cable is worn.
Switch the unit off before starting maintenance, repair or cleaning work in the control and an-alyzer section. Make sure there is no liquid in the hoses.
Never spray or wash down the unit, as no water may enter the interior.
Protect the unit from unidirectional heat radiation, direct sunlight and vibration. It must be in-stalled in a dry, dust-free room. Additional protective measures are required in environments with corrosive gases and vapors or where there is the risk of explosion.
Do not place or lay objects on top of the unit.
2.1.1 Intended use
The CeraClean filtration units are used for the filtration of undissolved substances in aqueous so-lution. The units may only be used for this purpose. The units are intended for commercial use and are only permitted for this usage.
The units may not
be used with other reagents than those which are intended for use, or
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modified without permission. Any liability on the part of the manufacturer/supplier for damage resulting from unauthorized modifications shall be excluded.
2.1.2 Sources of danger and behavior in case of emergency
The Bran+Luebbe CeraClean units comply with the statutory safety requirements.
The hazards emanating from the units have been minimized by engineering design. Residual risks (electrical, mechanical, thermal, chemical or biological dangers) due to transport, installa-tion, service and maintenance work or in operation cannot be completely excluded however.
IMPORTANT! Be sure to observe the warning and safety information on the units and in this user manual.
In case of emergency it must be possible to shut down the unit immediately. An emergency exists whenever human life is endangered and/or other general risks are present. The source of danger may be the unit itself or it may have some other origin.
To switch off the unit in case of emergency pull out the mains plug. Free access to the mains plug must therefore be ensured at all times. If this is not possible, an emergency stop switch must be provided in the vicinity of the unit.
IMPORTANT! An emergency stop switch is not included with the PowerMon or PowerMon S as standard.
Rectify the fault.
In case of fire use only appropriate extinguishing media.
Warn the other staff of any danger, even if it is only suspected.
Keep calm.
After an emergency the unit may only be restarted when the fault has been rectified and it has been ensured that the unit has not been damaged.
2.1.3 Workplace
When operating the unit or carrying out service and maintenance work, the area around the unit and the unit itself must be looked upon as a workplace.
Reagents, some of which require to be marked in accordance with the Hazardous Substances Ordinance, are needed to operate the units. The operator must ensure that operating manuals specific to the equipment and to the material in accordance with the EU directives, and the nec-essary safety devices are provided in the vicinity of the workplace. If the system is installed with-
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out housing, it must also be ensured that working areas below the unit are protected from drip-ping reagents.
IMPORTANT! Refer also to the information in chapter 4 Installation, in particular 4.2 Workplace design.
2.1.4 Operating personnel
Only persons that are authorized and instructed by the user may work on the unit. Trainees may only work on the unit under supervision. The operator is responsible for third parties in the work-ing area.
The user must
make this user manual, the operating manual for the operating software, and the operating instructions specific to the units and to the material accessible to the operator, and
satisfy himself that the operator has read and understand these manuals.
All persons who, as a result of their specialist training and experience, have sufficient knowledge to fulfill the requirements for operating this unit, are regarded as competent, trained and qualified operating personnel. Furthermore, these persons must be familiar with the generally acknowl-edged rules of technology as well as the appropriate industrial safety and accident prevention regulations. This applies also and in particular to the rules for the handling of reagents. This is addressed separately in the two chapters 2.2 Rules for handling reagents and 2.3 Marking of hazardous substances.
2.2 Rules for handling reagents
Danger: {When handling sodium hypochlorite (bleach) and hydrochloric acid, avoid contact with skin and eyes.
Wear safety glasses or goggles. Wear gloves and protective clothing.
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Danger: Never allow sodium hypochlorite and hydrochloric acid to mix or come in con-tact with each other. If they do, poisonous chlorine gas will be produced.
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2.3 Marking of hazardous substances
Some of the reagents used for the CeraClean are hazardous substances. These reagents are subject to the regulations of the Hazardous Substances Ordinance in accordance with European law which contains the appropriate European ordinances that have been implemented.
Hazardous substances are substances or mixtures of substances which can be injurious to hu-man health. These may be solid, liquid or gaseous and can enter the human body by inhalation, swallowing or by contact with the skin.
If the reagents used with your analyzer are classed as hazardous substances, they will be marked as follows:
Hazard symbols. You will find an explanation of these in Section 2.3.1.
The relevant R and S phrases (safety and hazard information). You will find a complete list of the R and S phrases in Section 2.3.2.
2.3.1 Hazard symbols and descriptions
The following hazard symbols and danger labels can be found on the reagent containers:
Fig. 2.1: Hazard symbols
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The danger labels have the following meaning:
Danger label Hazard
F+ Extremely flammable
F Highly flammable
O Oxidizing
T+ Very toxic
T Toxic
Xn Harmful
C Corrosive
Xi Irritant
N Environmentally harmful
E Explosive
2.3.2 R and S phrases
Along with the hazard symbol, the hazard information (R phrases) and the safety information (S phrases) give more detailed information on the characteristics of the hazardous substance. The phrases applicable to a reagent are printed in words on the reagent container in each case. The R and S phrases are likewise listed in the safety data sheets (see 2.5).
The R phrases contain information relating to special hazards; the S phrases contain safety ad-vice.
2.4 Disposal
Anybody who works with chemicals is obliged to dispose of them. Acids and bases may be poured into the waste water system after they have been neutralized. Toxic substances, heavy metals, solvents etc. must be disposed of in special incinerators or by recycling companies. In special cases, more detailed information can be found in the safety data sheets (see 2.5) or the instructions for use specific to the material.
If you have any problems with disposal or if you are unsure of anything, you can obtain assis-tance from SPX Flow Technology Norderstedt customer service.
If a unit is disposed of by the user, he is responsible for ensuring that this is carried out properly and in compliance with the applicable regulations.
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2.5 Safety data sheets and operating instructions
A safety data sheet is available for every reagent. If the data sheet was not supplied with the rea-gent, you can request it from SPX Flow Technology Norderstedt. It contains the following infor-mation:
Chemical characteristics of the substance or substance mixture
Physical and safety-related data
Transport codes
General specifications
Protective measures, storage, handling and disposal
What to do in case of accident or fire
Toxicology data
Environmental data
According to applicable EU Directives, the employer must also provide information to his employ-ees with the help of operating instructions. These operating instructions should clarify the hazards in the workplace due to reagents as briefly and clearly as possible. They contain information such as
Hazardous substance designation
Risks for human beings and the environment
Protective measures and behavioral rules
What to do in an emergency
First aid measures
Proper disposal
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3. DESCRIPTION OF THE UNIT
3.1 Overview
This chapter contains information about
Introduction to Microfiltration (section 3.2)
Construction and mode of operation (section 3.3)
Description (section 3.4)
Specification (section 3.5)
3.2 Introduction to Microfiltration
Microfiltration describes the process of removing solids of a particular size from a mixture of solid and liquid, using a filter membrane whose pores are small enough to allow liquids and dissolved materials to pass through but which retain solids, colloids and bacteria.
The liquid to be filtered flows at high speed through the filter tube parallel to the membrane sur-face. The high speed prevents solids from settling on the surface.
In waste water treatment plants Microfiltration systems are used to remove bacteria and turbidity from the waste water. These materials would otherwise interfere with the measurement of the On-line monitors that measure the concentration of ammonia, nitrate, and phosphate, in the waste water.
3.3 Construction and mode of operation
In Bran+Luebbe Microfiltration systems, waste water is pumped from various sampling points through the filter tubes of the Microfiltration.
The filter tube consists of ceramic (SiC or Al2O3). On the inside, the filter tube has a membrane, which allows particles with a molecular weight of less than about 20,000 to pass through, for ex-ample water, nitrate, phosphate, and other dissolved materials. Bacteria and other small particles are retained.
Most of the sample flows right through the tube and is returned to the sampling point or basin.
The filtered liquid, or filtrate, collects in the space between the membrane filter and the outer tube. A filtrate pump pumps it to the monitor.
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Most of the sample flows right through the tube and is returned to the sampling point or basin. It is important that the sample flows quickly through the tubes (with a speed of at least 3 or 4m/s) to prevent solids from building up on the membrane.
Material such as fat, chalk and iron hydroxide slowly accumulate in the membrane pores, and liv-ing bacteria may colonize the For this reason, the filter tube has to be cleaned frequently. In the Bran+Luebbe CeraClean Microfiltration system, the filter tube can be cleaned and rinsed auto-matically.
The filter tube is rinsed with filtrate. Once a week, the filter tube is automatically cleaned during the calibration of the On-line Monitor.
Figure 3.1 shows the flow chart of a Microfiltration system and the associated components.
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1. To monitor
2. Submersible pump
3. Reflow
4. Filter tube
5. Filtrate pump
6. Baseplate
7. Rinsing connection
8. Cleaning solution
Fig. 3.1: CeraClean flow chart
A Bran+Luebbe Microfiltration system comprises the following modules:
Baseplate
1
6
5
4
3
2
7
8
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All major components are mounted on this plate, which is designed for wall mounting. It is designed for wall mounting.
1 Filter tube
A filter tube is mounted through which the sample is pumped from bottom to top. The filter tube consists of ceramic (SiC or Al2O3) and processes the chemical, mechanical, and ther-mal cleaning.
Filtrate Pump
The filtrate collects in the space between the filter tube and the membrane. A metering pump pumps it to the connected On-line monitor.
Cleaning Solution Container
The CeraClean Microfiltration system is equipped with a cleaning solution container.
Submersible pump
The optional Bran+Luebbe submersible pump delivers the required sample flow to the Micro-filtration system. There are other pump types that may be applied alternatively.
3.4 Description
SPX offers one type of Microfiltration systems:
Microfiltration System CeraClean
Semi-automatic, with one filter tube and rinsing connection for tap water.
The Microfiltration system CeraClean has a filter tube, which does not need to be removed for cleaning.
The cleaning solution container is usually placed under the MF system. During the cleaning pro-cess, the filtrate pump automatically pumps the cleaning solution into the filter tube.
The rinsing connection serves to rinse the filter tube with clear water before removing it.
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3.5 Specification
Number of filter tubes 1
Filter life ca. 6 - 12 months, longer with appropriate mainte-nance
Filter performance Separates solids, colloids and bacteria with molecu-lar weight >20,000
Chemical resistance pH 1 - 12 (SiC), 1 - 14 (Al2O3), 0 - 14 (glass)
Sample temperature max. 45C*
Sample pressure max. 2 bar**
Sample flow rate 2.5 - 3 m3/h
Sample flow rate: ca. 2 l/h
Surrounding temperature 0 - 45C
Time between cleaning depending on sample
Dimensions: approx. 1000 x.500 x 180 mm
Sample connection PVC tube D25 or flexible PVC tubing (38mm)
Power supply
CeraClean 230 V, 50 Hz
Sample pump (submersible) 400 V, 50 Hz
Power consumption
CeraClean 70 VA
Submersible pump (standard) 1.2 kW
* The sample temperature depends on the applied pump, if the submersible pump is in use, the sample temperature must not exceed 40C.
** The sample pressure depends on the applied pump; if the submersible pump is used, the sample pressure may be max. 2 bars. If a different pump is used, it may be slightly lower.
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CAPTER 4 INSTALLATION 21
4. INSTALLATION
4.1 Overview
This chapter contains information on
Workplace design (see section 4.2.)
Operating conditions (see section 4.3)
Installing the filtration unit (see section 4.4)
Installing the Submersible Pump (see section 4.5)
Connection between the submersible pump and microfiltration system (see section 4.6)
Connection to the cleaning solution container (see section 4.7)
Sample back flow (see section 4.8)
Connections between the MF and the On-line Monitor (see section 4.9)
Electrical installations (see section 4.10)
4.2 Workplace design
Because chemicals are used in the operating area, the following requirements must be fulfilled when designing the workplace:
Good ventilation
The exhaust air must be directed away from the area where people work to prevent them from inhaling harmful substances.
Danger labeling
o Working areas must be labeled by means of:
o Warning signs which indicate dangers
o Mandatory signs for required personal protective equipment
o Prohibition signs (e.g. no smoking or no access)
o Information signs (e.g. first aid or behavior in the event of a fault)
Safety equipment for first aid
Working areas must be equipped with eyewashes (2 bottles are recommended; pay attention to the shelf life) and personal protective equipment. This includes suitable eye protection
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(safety glasses or safety screen), suitable hand protection, a cotton apron and safety shoes. Suitable protective equipment can be seen from the operating instructions specific to the unit and to the material (see Section 2.5).
4.3 Operating conditions
The following precautions and operating conditions are necessary to protect the MF from disturb-ance and to ensure correct operation:
Avoid direct heat or sunlight
Install in a place free from vibration
Surrounding temperature should be between 0 - 45C
Do not install in the open air! Install in enclosed buildings or air-conditioned cabins only. Special cabins are available from SPX
Adequate lighting for maintenance
Special precautions may be necessary in areas subject to a corrosive or explosive atmos-phere
4.4 Installing the filtration unit
Figure 4.1 contains the dimensions of the Microfiltration system with rinse connection.
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Fig. 4.1: Dimensional drawing of the Microfiltration system
The MF is wall-mounted. There are three mounting holes in the baseplate. All major components are mounted on this plate.
Mounting height:
The bottom of the MF should be far enough from the ground to allow easy connection of the inlet and outlet pipes.
Space requirement:
You need at least 1 meter clear space in front of the Microfiltration system for maintenance work.
Warning: The Microfiltration system must be securely mounted using all 3 mounting holes. Bran+Luebbe cannot be responsible for damage caused by insecure mounting.
If the Microfiltration system is to be used to supply several Bran+Luebbe On-line Moni-tors with sample, connect the analyzers in the following order:
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4.5 Installing the Submersible Pump
The optional submersible pump supplies sample from a clarifying basin to the Microfiltration sys-tem. The pump is delivered with a self-coupling L-bend and a chain (3 m) as standard.
Other optional devices are also available, as for example a mounting plate for the side of the sample basin (2.5 m standard) and an air separator for use in aerated sample basins. Please re-fer to SPX for more information about these options.
For detailed installation and safety instructions see separate manual delivered with the pump.
Therefore observe the following:
The submersible pump must always be covered with water. If the water level in the sampling basin varies, the pump should be installed just below the lowest level. Do not install the pump right at the bottom of the basin, otherwise sludge will be drawn into it.
The pump must not run dry or pump a high percentage of air.
The pump must rotate in the right direction, i.e. anticlockwise looking out from the pump. An arrow on the pump housing shows the correct direction. If the pump rotates the wrong way, the delivery will be too low. For detailed installation see separate manual delivered with the pump.
The system needs a sample flow of 1 - 3 m3/h. If the distance from the pump to the MF is too low or the flow resistance is too high, the standard pump will not supply an adequate flow. If in doubt, check with SPX before installation.
4.6 Connection between the submersible pump and microfiltra-tion system
For the connection between the submersible pump to the MF observe the following guidelines:
The direct connection to the pump should be with semi-flexible plastic tubing (e.g. PVC 25 mm i.d.). Do not use rigid pipe, as the pump vibrates.
Sample supply tubing can be either reinforced PVC tubing (25 mm i.d.) passed through a 50mm conduit, or PE tubing (40 mm i.d.). When using PE tubing, always make the connec-tions to the pump and to the MF with PVC tubing. Use appropriate intermediate connectors.
The connection via a PVC tube is also possible.
Sample supply tubing must be protected from frost by insulation or laying it below ground level.
The pipework should be as short as possible with as few changes of direction as possible, avoiding right-angle bends to minimize back pressure.
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The sample supply tubing must be secured with clamps when it is connected to the nipples on the Microfiltration system.
The sample supply tubing must be secured with clamps when it is connected to the nipples on the Microfiltration system. Connection to the cleaning fluid container
4.7 Connection to the cleaning solution container
The MF is fitted with a cleaning solution container (20 L). The container should be as close as possible to the MF. The container is connected to the Y56 valve via a 3.2 x 1.6 mm PVDC tubing.
4.8 Sample back flow
The outflow for sample which has passed through the filter tube is normally fitted in the lower right-hand part of the Microfiltration system. The outflow usually returns to the sampling basin. Therefore observe the following:
Caution: The outlet must be free from back pressure!
The connection from the sample outlet to the return point should flow only in a level or downwards direction, going through the side of the basin if necessary.
The return pipe diameter must be at least as large as the inlet.
The pipework should be as short as possible with as few changes of direction as possible, avoiding right-angle bends to minimize back pressure.
4.9 Connections between the MF and the On-line Monitor
Tubing Connection
Use PVDC tubing, 3.2 x 1.6 mm, ca. 3 m. The tubing is usually connected by the Bran+Luebbe service technician who installs the MF system.
If the Microfiltration system is to be used to supply several Bran+Luebbe On-line Monitors with sample, connect the analyzers in the following order:
Microfil
Electrical safety
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For the MF an additional cable connection is required between the connection box of the MF and each Monitor connected. This connection is used to set the Monitor into SERVICE mode be-fore changing a filter tube.
See Terminal Diagram in Appendix B for details.
4.10 Electrical installations
Danger: All electrical connection, repair, or maintenance work must be carried out only by a qualified electrician in accordance with local statutory requirements. . Safety regulations prescribed by EVU and other authorities must be adhered to.
Connect the modules as is shown on the terminal diagrams.
Cables must enter the terminal box through approved grommets. All unused entries must be closed.
The mains voltage for the Microfiltration system is 230V/50Hz.
The mains voltage for the submersible pump system is 400/50Hz.
Danger: Electrical and liquid connections must not be arranged together. 0/4-20 mA signal cables should always be arranged separately.
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CAPTER 5 COMMISSIONING AND DECOMMISSIONING 27
5. COMMISSIONING AND DECOMMISSIONING
5.1 Overview
When the Microfiltration system has been completely installed it may be put into operation.
This chapter describes:
General commissioning (section 5.2).
Commissioning the filtration with Bran+Luebbe analyzers (section 5.3).
Adjusting the filtrate pump (section 5.4).
General decommissioning (section 5.5)
Decommissioning the filtration with Bran+Luebbe analyzers (section 5.6)
5.2 General commissioning
1. Open inlet valve Y1 / Y2.
2. Close outlet valve (Y11) and rinsing valve (Y31).
3. Switch on submersible pump in the sampling basin. The filter tube should now fill from the bottom.
4. Wait until filtrate has reached a certain level inside the filter tube, then switch on the filtrate pump.
5. Wait until filtrate has reached the analyzer. Then start the analyzer.
5.3 Commissioning the filtration with Bran+Luebbe analyzers
Commissioning procedure:
1. Switch on the CeraClean MF system. Switch on the main power switch.
2. Open valve Y1 and close valves Y11 and Y31.
3. Switch on the submersible pump.
4. Filtrate is now being pumped to the Bran+Luebbe analyzer.
When it has reached the analyzer, switch on the analyzer.
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28 CHAPTER 5 COMMISSIONING AND DECOMMISSIONING
The MF can now remain in operation until the tube has to be cleaned. This is described in section 6.3.
Manual Operation
Ball valves must always be operated manually if a filter tube has to be cleaned. .See section 6 "Maintenance and care".
In addition to automatic operation, it is possible to operate the valves manually. There are small switches at the valves that have to be turned.
5.4 Adjusting the filtrate pump
The filtrate pump, mounted on the PVC baseplate, is factory-set for 50% delivery, which is about 2 l/h.
On installation, the output can be reduced depending on the number of monitors applied. Each analyzer needs about 300 ml/h, depending on the application.
Warning: The filtrate pump should not run dry. Only set the output when the submersi-ble pump is running and filtrate is present at the filtrate pump.
The adjustment procedure depends on the type of filtrate pump. Standard delivery contains the DL-PK type pump. See appendix for more information.
Adjusting the Pump Delivery:
1. Remove the black rubber grommet from the filtrate pump.
2. Adjust the potentiometer underneath with a screwdriver.
If one On-line Monitor is connected, a pulse should be visible every 1 to 2 seconds in the tube leading to the pressure buffer. If more Monitors are connected, increase the number of pulses per second accordingly.
3. Put the rubber grommet back on.
5.5 General decommissioning
Switch off the submersible pump in the sample basin.
Close inlet valve Y1
Open outlet valve Y11 to allow waste water to flow out of the filter tube.
If necessary, rinse with clear water (Y31).
Clean filter tube without removing it. (see section 6.2 and 6.2.1)
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Warning: If the Microfiltration system will be out of use for more than 1 day, do not leave the filter tube filled with waste water, otherwise it will become clogged.
5.6 Decommissioning the filtration with Bran+Luebbe analyzers
Switch off the main power switch. The filtrate pump is stopped and the valves are switched off.
Warning: If the Microfiltration system will be out of use for more than 1 day, do not leave the filter tube filled with waste water, otherwise it will become clogged.
Therefore the filter tube has to be cleaned with hypochlorite. (Do not leave reagent 781236 inside the filter tube for more than 1 day).
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30 CHAPTER 6 MAINTENANCE AND CARE
6. MAINTENANCE AND CARE
6.1 Overview
The filter tube has to be carefully maintained and must be cleaned regularly, because deposits gradually build up in the filter pores.
The tubing must also be cleaned periodically.
This chapter describes:
"Important notice for using the filter tubes": Important precautions to be followed to protect the filter tube (section Fehler! Verweisquelle konnte nicht gefunden werden.).
"Maintenance the filter tube": Describes cleaning instructions for the filter tube (section 6.3).
"Replacing the filter tube" (section 6.4)
"Oil replacement in the submersible pump" (section 6.5)
6.2 Important notice for using the filter tubes
The filter tube is the most important part of the Microfiltration system and needs special care.
Avoid vibrations
The filter tube for microfiltration consists of ceramic and must thus be protected from strong vibrations or tremors.
Drying out the filter tube
The filter tube must not be kept moist but may dry out as well. Before it may be taken into operation again it should be filled with water for ca. 1 h.
Clean the filter tube regularly
During operation, the filter tubes should be cleaned regularly (see section 6.2.1.).
Continuous use
The tube has the longest life if it is in continuous use without frequent start/stop switching or long intervals out of service.
During long shutdown periods, living bacteria may colonize the filter membrane and thus re-duce the filtering effect. These bacteria can only be removed with strong detergents (see section 6.3.1.)
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Storage
The filter tube is temperature resistant and may be exposed to frost as long as it is dry.
6.3 Maintenance the filter tube
Even when all of the above mentioned precautions are obeyed, the membrane inside the filter tube exhausts because its life span is limited.
The normal life is 18 months, according to sample.
In normal use the filter tubes must be cleaned regularly because the pores slowly become blocked. The frequency of cleaning depends on operating conditions and the cleanliness of the sample.
The normal interval between cleaning is 3 - 30 days. This might be lower in sewage works if for example there is a high concentration of fat in the sample.
The tube should be cleaned once a week with adequate cleaning solution or detergent, even if it is not blocked, to avoid bacteria from colonizing the filter membrane (see section 6.3.1.)
The filter tube in the MF system must be changed if the delivery is less than 1.5 l/h despite regu-lar cleaning, because otherwise the flow of filtrate to the Monitors drops, and the cleaning solution consumption is too high.
The following section describes the causes of blockage and how the tubes may be cleaned. In the section after the following, the steps that have to be taken to clean the filter tube are de-scribed.
6.3.1 Causes of blockage, and how to clean the filter tubes
The membrane inside the filter tube has very small pores that retain bacteria and solids but allow all liquids and dissolved material like phosphate, nitrate, and ammonia to pass through . In nor-mal use, the pores may slowly become blocked.
The following section describes the causes of blockage and how the tubes may be cleaned. The section after the next describes how the filter tube is cleaned.
The following cleaning methods are possible:
Cleaning the Filter Tube with Reagent 781236
This cleaning solution was developed by SPX Flow Technology Norderstedt GmbH and is particularly suitable for analyzers of the Ionometer type and for DiaMon and PowerMon S
Reagent 781236 is a hydrogen peroxide containing solution suitable for various applications.
It kills bacteria and removes blockages caused by them.
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32 CHAPTER 6 MAINTENANCE AND CARE
Reagent 781236 contains PLURONIC which acts as a detergent, so that fat can also be removed.
Lime is removed and prevented from building up again due to hard water.
Cleaning with Hypochlorite Solution
Living or dead bacteria are the most common cause for blockage of the filter tube. That is why the filter tube should always be cleaned with diluted hypochlorite solution first.
Dilute one part commercial hypochlorite (13%) with 10 parts tap water. For example, add 100 ml hypochlorite to a container with one liter tap water. Leave the filter tube in the solution for at least 24 hours. The used solution can be disposed of into waste.
Cleaning with diluted hydrochloric acid (blockage due to chalk or iron hydroxide)
If cleaning with hydrochloric acid is not sufficient, lime or iron hydroxide may be the cause. Chalk deposits may occur in regions with hard water or in water works with chalk precipita-tion Iron hydroxide deposits may occur if iron is used for water treatment.
In this case, clean with hydrochloric acid (HCl). Dilute one part commercial hydrochloric acid (25%) with 99 parts tap water. For example, add 10 ml hydrochloric acid to a container with 1 liter tap water. Always fill in the water first and then the acid!
The acidity of the solution should never be lower than pH 1.
To avoid influence on the continuous operation of the monitors, the filter tube should be removed from the MF system, because the tube should remain in the solution for approx. 12 h.
In case of chalk deposits, clean the filter tube with hydrochloric acid solution first and then with hypochlorite solution to avoid unsolvable deposits in the filter tube.
Cleaning with detergent (blockage due to fat)
If the filter tubes have to be cleaned more frequently, the cause may be a high concentration of fat in the waste water. Fat will also block the membrane.
In this case, clean with a mild detergent. FLAMIL 55E has proved to be suitable. It is to be di-luted 1:10 with hot water, for example, add 100 ml to a container with one liter hot water. Special cabins are available from Bran+Luebbe. Household detergents, diluted in hot water, are also suitable in some cases. If the tubes are very dirty they can also be very carefully cleaned with a long, soft cylindrical sponge (approx. 25 mm).
Warning: The membrane must not come into contact with hard or sharp items, oth-erwise it will be permanently damaged.
Danger: Never allow sodium hypochlorite and hydrochloric acid to mix or come in contact with each other. If they do, poisonous chlorine gas will be pro-duced. Whenever a filter tube has to be cleaned with both hydrochloric acid and sodium hypochlorite, always rinse it thoroughly with tap water in between. Do not store hydrochloric acid and sodium hypochlorite contain-ers in the same room!
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Danger: Avoid contact with hydrochloric acid or hypochlorite solution. Wear protec-tive glasses and gloves.
When a filter tube is out of use for a long time it should be stored in hypo-chlorite solution. The tube can be left in contact with hypochlorite infinitely.
6.3.2 Filter tube cleaning, controlled by the analyzer
A blocking of the membrane cannot be caused only by hydroxides, iron and manganese colloids and microorganisms (fouling) but also by precipitating salts like calcium carbonate, calcium sul-fate, calcium fluoride, barium sulfate and silica (Scaling).
The filter tube should be cleaned frequently (at least once a week), so that a long life of the filter tube can be guaranteed. Clean the filter tube when the flow of filtrate to the DiaMon drops and the "sample" warning lamp lights.
During the cleaning sequence of the filtration unit no analyzer measurement is performed. The cleaning sequence is controlled and started by the programmed software of the analyzer. At first after switching the valves cleaning solution is pumped from the outer to the inner side of the filter tube. After a residence time the cleaning solution is pumped with sample from the filter tube to the analyzer in order to clean the tubing too and to avoid influences with the next measurement.
The filter tube must be cleaned dismounted, when it is blocked outside the normal cleaning inter-vals.
6.3.3 Adjusting the cleaning sequence
The cleaning cycle is activated daily by the sequence programs of the analyzer (factory-provided).
When this automatic function is not used or the analyzer is not in measuring mode, the cleaning may be activated by a rotary potentiometer (if a PLC is present). The cleaning cycle can be ad-justed between 2 and 72 h.
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By a second rotary potentiometer (in the PLC module) the automatic back flush can be adjusted between 3 and 15 min.
6.3.4 Mechanical cleaning of the filter tube
To remove accumulated pollutions from the membrane, there is the possibility of a mechanical cleaning. Do not proceed mechanical cleanings if a scaling is present.
Use a special sponge brush (cylindrical with 25 mm diameter) for the mechanical cleaning to avoid destroying the inner membrane. If a weak brush is used for cleaning, use it only in one di-rection!
The pyrolysis is an additional possibility to clean the filter. A slow heating up to a temperature of 300 350C combusts the impurities. After a slow cooling down the combustion residue must be removed with water (an addition of a detergent is helpful).
6.4 Replacing the filter tube
The filter tube in the MF system must be changed if the delivery is less than 1.5 l/h despite regu-lar cleaning, because otherwise the flow of filtrate to the Monitors drops, and the cleaning solution consumption is too high.
Warning: Before removing a filter tube, make sure that the system is not in use (see section 5).
Warning: Let the filter tube drain before removing it, otherwise liquid may run out.
The filter tube can be cleaned via the rinsing connection.
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Loosen the connection at the top and the bottom of the filter tube and remove the filtrate connection. Then take out the filter tube.
Remove O-rings and pull out the inner tube.
Insert and align the new filter tube.
Fit new O-rings over the filter tube.
Re-install the filter tube.
Fig. 6.1: Picture of a standard microfiltration
Fig. 6.1: Picture of a POROSET microfiltration with 80 m steel filter
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36 CHAPTER 6 MAINTENANCE AND CARE
6.5 Oil replacement in the submersible pump
Every 6 months you should replace the oil in the submersible pump.
For detailed descriptions refer to the manual delivered with the submersible pump.
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CAPTER 7 FILTRATE PUMP 37
7. FILTRATE PUMP
7.1 Description
This pump PKX MA is used as filtrate pump for the Microfiltration system CeraClean.
1 Power supply
2 Tubing connection pressure side
3 Tubing connection suction side
4 Adjustment of the permeate flow
Fig. 7.1: Membrane pump
7.2 Specification
Pump head material: Polypropylene
Membrane: PTFE
Valves and sealing: Viton
Dimensions: 188 x 106 x 143 mm (H x B x T)
Protection: IP 65
Flow rate 0 5 L/h Max. pressure 5 bar
Stroke frequency 0 120 min-1 Stroke volume 0.69 ml
Weight 1.9 kg
Lift height 2 m
Power consumption 32 W
Power supply 100 or 240 V 50/60 Hz
1
2
3
4
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Warning: This metering pump is a positive displacement pump and must not be run with closed or even partially blocked lines. Before carrying out any maintenance work, flush the pump with an appropriate cleaning solution (especially if used with aggressive liquids) and disconnect it from power.
7.3 Maintenance and inspection
Check for normal operation (sound and vibration)of the pump. Check the delivery volume and pressure.
If degassing of the liquid has caused faulty delivery, release the pressure on the delivery side before re-starting it.
If crystal formation has caused reduced, unstable, or no delivery, delivery/inlet valves must be checked and cleaned.
If the pump has been out of use for more than a month, the parts in contact with liquid must be cleaned by pumping fresh water for 30 minutes.
If the pump has been out of use for a long time, the valves may need to be cleaned before the pump can be started. In this case, all valves must be cleaned.
Danger: Disconnect pump from power supply before disassembling it!
7.4 Troubleshooting
Symptom Cause of malfunction Countermeasures
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Pump drive does not work
damaged or disconnected cables
power loss
faulty electronics board
Reconnect wiring properly
Rectify
Replace
no flow rate air in inlet tube
Missing O-ring or valve seal
valve installed upside down
air in inlet tube
dirty valve(s)
jammed valve(s)
Connect inlet securely
Check
Check
De-gas
Remove, check and clean
Remove, check and clean
fluctuant flow rate
dirty valve(s)
air in inlet tube
pump over-filled
membrane ruptured
Remove, check and clean
De-gas
Install pressure or back-flow valve
Replace
Leakage loose inlet or outlet tube or fittings
loose pump head
membrane ruptured
missing O-ring or valve seal
Tighten inlet or outlet tube or fittings carefully
Tighten bolts tightly and evenly
Check and replace if necessary
7.5 Disassembly
Before disassembling the pump, switch off the power, release pump pressure, empty liquid, and clean the pump.
Do not use excessive force on plastic parts, to avoid damage.
O-ring seats are used, so that sealing tape is not required. After disassembly, all seals must be replaced.
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40 CHAPTER 8 SPARE PART LIST
8. SPARE PART LIST
The following list contains the spare parts that are available for the Microfiltration systems.
Spare parts should normally be ordered from your local Bran+Luebbe Analyzer provider. In case of difficulty, our central service department in Germany has a service hot-line for emergencies.
HOTLINE TELEFON: ++49 40/52202-505
HOTLINE FAXGERT: ++49 40/52202-317
EMAIL: [email protected]
Using non-genuine Bran+Luebbe spare parts will invalidate the guarantee.
Details of guarantee conditions are included in our general conditions of business.
Description Material no. CeraClean
Filter module (PVC) complete without Filter tube BL844024 1
Filter module (PVC) complete with POROSMET 80 m BL844016 1
Filter housing (PVC) BL821933 1
Inner tube , ceramic 0,4 m BL844038 1
Inner tube , ceramic 0,4 m (long service life) BL844018 1
Inner tube , ceramic 0,8 m (long service life) BL844019 1
Inner tube , steel 80 m BL844037 1
O-ring for filter tube connection BL811246 2
Adapter D32 1" (top) BL810032 1
screw connection NW 4/ 6 BL849167 3
Adapter D32 1" (bottom) BL810031 1
O-ring for screw connection filter module (GF) BL080471 2
Ball valve Y1, Y2 BL823268 per 1 x
Ball valve Y11 BL823267 1
Ball valve Y31 BL823269 1
Solenoid valve Y55, Y56, Y57 (24V AC) BL834125 per 1 x
Filtrate pump M1 / 110 V BL841177 1
Filtrate pump M1 / 230 V BL841185 1
Tubing 3.2 x 1.6 mm (filtrate) BL801122 4.0 m
Tubing PE 4 x 1 BL801109 2 m
T-connector (filtrate) BL822626 1
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APPENDIX A INDEX A-1
Appendix A Index
B
Behavior in case of emergency 10
C
Care 30
Cleaning filter tubes 31
Cleaning solution container
Connection to Microfiltration 25
Commissioning 27, 29
General 27
Conventions 7
D
Danger labels 14
Decommissioning
General 28
Description of the unit 16
Disposal 14
E
Electrical installations 26
F
Filter tube
Cleaning 31
Replacement 34
Filter tubes
Important notice 30
Filtrate pump
Adjusting the filtrate pump 28
Filtration
Commissioning 27, 29
G
General safety information 9
H
Hazard symbols 13
Hazardous substances
Marking 13
I
Installation 21
Intended use 9
M
Maintenance 30, see Cleaning filter tube
Microfiltration
Description 19
dimensional drawing 23
Picture 35
Types 19
Microfiltration system
Installation 22
O
Oil replacement
Submersible pump 36
On-line Monitor
Connection to the microfiltration system 25
Operating conditions 22
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A-2 APPENDIX A INDEX
Operating instructions 15
Operating personnel 11
P
Pumpe
PKX MA 37
R
R phrases 14
Reagent 781236 (cleaning) 32
Reagents
Safety information 11
S
S phrases 14
Safety data sheets 15
Safety equipment 21
Safety information
General 9
Reagents 11
Symbols for 7
Spare part list 40
Specification 20
Submersible pump
Oil replacement 36
Submersible Pump
Installation 24
U
Use
intended 9
W
Warning information
Symbols for 7
Workplace 10
Workplace design 21
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APPENDIX B TECHNICAL DATA B-1
Appendix B Technical Data
The technical data for your Bran+Luebbe CeraClean filtration unit are shown in detail below. Among other things, the documents are used as a reference in the event that a service is re-quired. Changes to the unit should be noted on the relevant drawings.
Terminal diagram
Circuit diagrams
Additional information (if any)
PowerMon PowerMon S
U s e r m a n u a l
S P X F l o w T e c h n o l o g y N o r d e r s t e d t G m b H
W e r k s t r a s s e 4 , D 2 2 8 4 4 N o r d e r s t e d t
P o s t B o x 1 3 6 0 , D - 2 2 8 0 3 N o r d e r s t e d t
P : + 4 9 ( 0 ) 4 0 - 5 2 2 0 2 - 0
F : + 4 9 ( 0 ) 4 0 - 5 2 2 0 2 - 4 4 4
E : b r a n l u e b b e @ s p x . c o m
The SPX Corporation shall be entitled to incorporate the newest construction and
material changes without further notice and liability on this.
Design arrangements, material and dimensions as described in this document are
only for information. All data are without obligation, unless they are confirmed in
writing. For the availability in your region please contact a local representative. For
more information please visit our website www.spx.com.
The green > is a brand of the SPX Corporation, Inc.
ISSUED 12/2011 MT5-13-EN-05
COPYRIGHT 2011 SPX Corporation
IndexTable of figures1. Introduction1.1 Conventions used in this manual
2. Safety information2.1 General safety information2.1.1 Intended use2.1.2 Sources of danger and behavior in case of emergency2.1.3 Workplace2.1.4 Operating personnel
2.2 Rules for handling reagents2.3 Marking of hazardous substances2.3.1 Hazard symbols and descriptions2.3.2 R and S phrases
2.4 Disposal2.5 Safety data sheets and operating instructions
3. Description of the unit3.1 Overview3.2 Introduction to Microfiltration3.3 Construction and mode of operation3.4 Description3.5 Specification
4. Installation4.1 Overview4.2 Workplace design4.3 Operating conditions4.4 Installing the filtration unit4.5 Installing the Submersible Pump4.6 Connection between the submersible pump and microfiltration system4.7 Connection to the cleaning solution container4.8 Sample back flow4.9 Connections between the MF and the On-line Monitor4.10 Electrical installations
5. Commissioning and decommissioning5.1 Overview5.2 General commissioning5.3 Commissioning the filtration with Bran+Luebbe analyzers5.4 Adjusting the filtrate pump5.5 General decommissioning5.6 Decommissioning the filtration with Bran+Luebbe analyzers
6. Maintenance and care6.1 Overview6.2 Important notice for using the filter tubes6.3 Maintenance the filter tube6.3.1 Causes of blockage, and how to clean the filter tubes6.3.2 Filter tube cleaning, controlled by the analyzer6.3.3 Adjusting the cleaning sequence6.3.4 Mechanical cleaning of the filter tube
6.4 Replacing the filter tube6.5 Oil replacement in the submersible pump
7. Filtrate pump7.1 Description7.2 Specification7.3 Maintenance and inspection7.4 Troubleshooting7.5 Disassembly
8. Spare part list
