Doc No. : I , Satyam Ind. Estate, Subhash Road,

Transcription

1 Page : Page 1 of 19 Basket STRAINERS TABLE OF CONTENTS

2 Page : Page 2 of 19 Sr No Detail Page No Product Warranty 3 Disclaimer of Warranties 4 Limitation of Sellers s Liability 4 Terms of Use About this Manual Introduction System Description Available Models Standard Materials of Construction Standard Strainer Size & Specifications Strainer Pressure & Temperature Specifications Receiving Inspection Installation Effects of Related Piping Installation Positions Operation Pre-Operational Check Hydrostatic Pressure Test Operating Maintenance Preventive Maintenance Maintenance Procedure Shut down Procedure When to clean the Element Element Removal Cleaning & Replacement Troubleshooting Removal / Disassembly / Reassembly Disassembly Reassembly Telephone Assistance Spares Storage European Declaration of Conformity Exploded View 19 TABLES Table No Details Page No 1 Available Models 5 2 Standard Materials of Construction 6 3 Standard Strainer Size & Specifications 6 4 Strainer Pressure & Temperature Specifications 7 5 Troubleshooting 14 PRODUCT WARRANTY

3 Page : Page 3 of 19 C- TRU PROCESS EQUIPMENTS warrants its products as designed and manufactured to be free of defects in material and workmanship for a period of 18 months from the date of dispatch or 12 months from the date of commissioning whichever is earlier subject to the use in the manner as stated by C-TRU C-TRU will at its option, replace or repair any product or the defective part of any product, which fails during the warranty period due to defective material or workmanship on FOR Works basis within 60 days of receipt of product by C-TRU Prior to submitting any claim for warranty service, the owner must submit proof of purchase to C-TRU and obtain written authorization from C-TRU to return the product. Thereafter, the product shall be returned at the cost and liability of the customer to C-TRU in Kansari, Khambhat, Gujarat with freight prepaid. This warranty shall not apply if the product has been disassembled, tampered with, repaired or altered outside of C-TRU factory, or if it has been subjected to misuse, neglect or accident or used in a manner other than as stipulated by C-TRU Other than to repair, replace, or refund, as described above the purchaser agrees that C- TRU PROCESS EQUIPMENTS shall not be liable directly or indirectly for any losses, costs, expenses, charges or damages of any kind arising out of the product, its use, installation or replacement, labeling instructions, information or technical data of any kind, description of product use, sample or model warnings or lack of foregoing. No other warranties written or oral, expressed or implied, including the warranties of fitness for a particular purpose and merchantability, are made or authorized. No affirmation of fact, promise, description of product use or sample or model shall create any warranty from C-TRU PROCESS EQUIPMENTS unless signed by its Chief Executive Officer or General Manager. None of our products are manufactured, sold or intended for personal, family or household purposes or for any purpose other than as specifically stipulated by us in writing. Disclaimer of Warranties

4 Page : Page 4 of 19 The Terms & Conditions of Sale on the website of C-TRU and the offer sent by C-TRU states the entire obligation of C-TRU. The contents of this document shall not become part of or modify any prior or existing agreement, commitment or relationship between C-TRU and the buyer, save and extent to the extent that it limits the liability of C-TRU. There are no express or implied warranties set out in this document. The only warranties that apply between C-TRU and the Buyer are those stated in the above cited documents. C-TRU products have not been tested by C-TRU under all possible operational conditions and C-TRU may not have all the data relative to your application.. The information in this document is not all inclusive and does not and cannot take into account all unique situations. Consequently the user should review this document in view of his/her application. Limitation of C-TRU s Liability In the event that a court holds that this document created some new warranties, C-TRU s liability shall be limited to replacement or repair under the standard warranty clause. Terms of Use The information provided in this document is provided as is without warranty of any kind. C-TRU disclaims all warranties, either express or implied, including the warranties of merchantability and fitness for a particular purpose. In no event shall C-TRU or its suppliers be liable for any damages whatsoever including direct, indirect, incidental, consequential, loss of business profits, punitive or special damages even if C-TRU or its suppliers have been advised of the possibility of such damages. Use of parts/spares/components that are not manufactured or supplied by C-TRU OR THE USE OF THE PRODUCT(S) OTHER THAN AS INDICATED BY C-TRU voids any C-TRU warranty and relieves C- TRU of any obligation to service the product under warranty. C-TRU recommends the use of only C-TRU manufactured or supplied parts to maintain or service C-TRU products. 1.0 ABOUT THIS MANUAL This manual has been prepared as an aid and guide for personnel involved in installation / operation and maintenance. All instructions must be read and understood thoroughly before attempting any installation / operation / maintenance.

5 Page : Page 5 of INTRODUCTION FLOCLEAN Model 424 & 425 Basket Strainers are devices installed in a pipeline to remove sediment and debris from fluids. Straining is accomplished by directing the fluid through sized openings in the element. Once sediment and debris is collected in the screen, fluid flow is interrupted while the screen is removed for cleaning. 2.1 SYSTEM DESCRIPTION Model 424 & 425 fabricated Basket Strainers consist of six basic components: Basket Pipe: provides an in-line attachment capability for the connection pipes to which the line process flanges are eventually welded. In addition, element baffle plate or seat is welded to provide for element fitment. Pipe Closures provided at the top are either the bolted types or the quick opening types as specified. Basket Pipe selected is based on the ratio and is undoubtedly the factor on which the strainer price is determined. Connection Pipe: provides an in line attachment capability as the process flanges are welded to the same. Basket Pipe Covers: are provided with a recess or an O ring groove for the gasket and an effective method of compressing and sealing gaskets. The cover also compresses the element handle through a bolt to eventually ensure that there is no by-pass through the element. Element: Placed on the baffle plate or element seat and is compressed by the cover under bolting loads. The element handle is sized to ensure that it does not rotate under bolting loads thus ensuring zero-particle by pass..elements are manufactured in materials compatible to the flowing fluid and the openings provided are based on the degree of filtration requested. Sealing Gaskets: the sealing gasket is placed in the recess / O ring provided in the covers and are compressed by the bolts and nuts to effectively seal the gap and prevent leaking between the body pipe and the cover plate. A variety of materials ensure that the gaskets are compatible to the fluid passing through the Strainer. Bolt Nuts : compress the gaskets between the body and the cover plate. 3.0 AVAILABLE MODELS Model Flanged Ends In Line Off Line Specified Degree Orientation Filtration 424 h h 40 mesh 425 h h 40 mesh 425-OL h h 5 micron of Table 1

6 Page : Page 6 of STANDARD MATERIALS OF CONSTRUCTION Standard Materials OL Carbon Steel h h h STS 304 h h h STS 316 h h h Table STANDARD STRAINER SIZE & SPECIFICATION Model Size Range Style of Unit mm Flanged Ends Class 150, Class 300 # mm Flanged Ends Class 150, Class 300 # 425 OL mm Flanged Ends Class 150, Class 300 # Table STRAINER PRESSURE AND TEMPERATURE SPECIFICATION

7 Page : Page 7 of 19 Never exceed the design ratings or application data limits. Exceeding design ratings or application data may cause severe personal or property damage. Body Material Carbon Steel 316 Stainless Steel Temperature Rating to At At At At to to to to to At At At At PTFE ASBESTOS GRAFOIL NEOPRENE BUNA N Table RECEIVING INSPECTION 1) Upon receipt of the strainer check all components for damage incurred in transit. If damage is evident or suspected do not attempt installation. Notify carrier immediately and request damage inspection. 2) Remove any preservatives with solvent damped cloth. Exercise care when using solvent and follow solvent manufacturer s instructions. 3) Verify that the rating of the strainer is greater than or equal to the maximum pressure on the installation. 4) Inspect the strainer by checking for and removing any foreign or loose material that could be carried downstream when fluid is introduced in the strainer. 5.0 INSTALLATION

8 Page : Page 8 of 19 Qualified experienced personnel who are familiar with this equipment and have read and understood all the instructions in this manual should undertake installation. The user should refer to C-TRU PROCESS EQUIPMENTS product proposal to obtain overall dimensional information. 1) Do not proceed with installation of the strainer unless the connections and inside of the strainer have been cleaned and are free of any foreign material. 2) Do not proceed with installation of the strainer till you have reviewed the application and chemical compatibility of the process fluid to the materials of construction of the strainer. 3) Do not proceed with installation unless you have ascertained that sufficient clearance is provided for easy opening of the cover and removal of the basket. 5.1 EFFECTS OF RELATED PIPING 1) Do not impose system-piping loads on the strainers. Unit is not designed to be a load-bearing component. Piping must be supported and aligned with strainer end connections to reduce the possibility of stresses imposed on the unit. Large heavy units must be independently supported to avoid stressing the piping. 2) Locate the strainer where it can be easily accessed for cleaning. 3) When bolting units to adjacent piping, care must be taken to ensure that bolts or studs do not project sufficiently past the flange to strike any part of the strainer thus avoiding potentially stripped flange connections or movement of the preset retainers. 5.2 INSTALLATION POSITION 1) Remove protective wraps before installing the strainer into operation 2) A Basket Strainer has to be installed in a horizontal position.

9 IOM Revision : 00 Page : Page 9 of 19 3) Once again confirm that sufficient clearance is provided for easy opening of the cover. 4) Connect the strainer to the pipeline with a compatible companion flange face. Do not bolt a raised face flange to a flat face flange. Ensure flange gaskets are in place and fasteners are tight. 5) If specified, Basket Strainers have provision to accept gauges. Pressure Gauges near the inlet and outlet are required to determine differential pressure across the strainer and cleaning frequency. Pressure Gauges are essential for the safe operation of a strainer and should be installed using standard piping practices. 6) It is recommended that a compatible valve (and piping as needed) be installed in the cover (blow off) for safe quick clean out (normal blow down cleaning). To protect the operator while draining and clean out, the fluid must be piped to a safe area by using the valve mentioned in 6 above. This requirement is for all fluids and also for water where the temperature is exceeding

10 Page : Page 10 of C. The operator should wear appropriate protective equipment consistent with the process fluid for strainer operation and servicing 6.0 OPERATION The problem of unwanted material in pipelines is a never-ending one. Whatever be the flowing material there is often something present that can cause trouble. Strainers remove foreign particles from the pipeline flow. They are relatively inexpensive compared To the equipment they protect To the down time. Inferior products. Loss of production If they are not installed in the piping system. 6.1 PRE OPERATIONAL CHECK 1) Ensure that all installation procedures have been completed. 2) Check to determine that all connections are pressure tight. 6.2 HYDROSTATIC PRESSURE TEST 1) Take all precautions necessary to handle the possibility of leakage. 2) Pressure test all installations hydrostatically to at least 5 Kg/cm 2, and correct any leakage before proceeding. 6.3 OPERATING 1) Open blow down valve to expel air from the strainer. 2) Slowly allow the fluid to enter the strainer Strainer installations should be brought into service slowly to avoid excessive shock or stress. This is extremely important for steam service

11 Page : Page 11 of 19 3) Close vent when fluid begins to flow. 7.0 MAINTENANCE Qualified experienced personnel who are familiar with this equipment and have read and understood all the instructions in this bulletin should undertake maintenance. Do not proceed with any maintenance unless the strainer has been relieved of all pressure or vacuum, has been allowed to reach ambient temperature and has been drained or purged of all fluids. 7.1 PREVENTIVE MAINTENANCE The user must create maintenance schedules, safety manuals and inspection details for each specific installation. On all installations the user should regularly evaluate the following items for purpose of maintenance: 1) Strainer, for signs of leakage at gaskets or at connections. 2) Strainer, for signs of internal or external corrosion. 3) Clogging of strainer. The user must determine upon evaluation of his or her own operating experience an appropriate maintenance schedule necessary for his or her specific application. Realistic maintenance schedules can only be determined with full knowledge of the services and application situation involved. 7.2 MAINTENANCE PROCEDURES 1) Gaskets: A strainer that leaks at the gasket must be immediately taken out of service. Do not proceed with the operation of a strainer until gaskets have been replaced. 2) Connection Leaks: A strainer that leaks at the connection should be corrected by tightening the bolts at the connection, 3) Corrosion: While we do recommend materials, on request or when the materials requested by the user is ambiguous what we eventually supply is what the user has insisted upon. If internal or external corrosion is present the user as to the cause of the problem should immediately carry out an investigation.

12 Page : Page 12 of 19 4) Clogging: A differential pressure of 5 10 psig indicate clogging and this requires the basket to be removed and cleaned 7.3 SHUT DOWN PROCEDURE 1) Slowly close the pipeline valves upstream and downstream from the strainer. Ensure that the valves are tightly closed and are not passing any fluid. 2) Relieve fluid pressure in the strainer by first opening the drain and then the vent. The strainer must be drained and internal pressure relieved prior to cleaning. Now proceed to clean the element. 7.4 WHEN TO CLEAN THE ELEMENT A differential pressure increase of 5 to 10 PSI indicates that the strainer is full of debris and needs to be removed. To prevent strainer damage do not permit differential pressure across the strainer to exceed 20 PSI. 7.5 ELEMENT REMOVAL, CLEANING & REPLACEMENT 1) Follow the shut down procedures outlined above. 2) When the strainer s internal pressure is relieved, drain the fluid and remove fasteners. Remove cover (blowoff). 3) Remove the debris laded element.

13 Page : Page 13 of 19 Do not permit the element debris to dry as then it would be difficult to remove and clean the element. 4) Invert the element and wash out debris by directing a stream of water or air against the element exterior. 5) Inspect element at each cleaning for holes or tears. Replace as needed with genuine FLOCLEAN elements. Always keep spare elements and gaskets in stock. 6) Inspect sealing surfaces and cover gasket. Clean sealing surfaces. 7) Place cleaned/new element in basket pipe. Care must be taken to assure that basket ellipse ring rests squarely on the elliptical retaining ring welded in the basket pipe 8) Ensure that the element hold down bolt is sufficiently high to be compressed by the cover. 9) Fasten the covers uniformly. 10) Close the valve if provided and follow OPERATION procedures. 7.6 TROUBLESHOOTING Problem Possible Reason Remedy Strainer leaks at gaskets Damaged gasket Replace the gasket Internal / External Corrosion Strainer material not compatible with the fluid Evaluate for compatibility and replace the strainer with a compatible one.

14 Page : Page 14 of 19 Frequent Clogging of the Strainer Filtration Level too fine Frequent Bursting of Element Unrealistic Maintenance Schedules Replace Element provided with the correct filtration level Install differential pressure gauges and follow above maintenance procedures Table REMOVAL / DISASSEMBLY / REASSEMBLY Do not proceed with the removal or disassembly of a Strainer from connecting pipelines unless it has been relieved of all pressure or vacuum, has been allowed to reach ambient temperature, and has been drained or purged of all fluids 8.1 DISASSEMBLY Basket Strainers should be assembled in line. Ensure that the unit is stable and secure, hold the Strainer firmly and loosen cover nuts. Remove the element and gaskets from the strainer body / cover using appropriate safety precautions. Once a Strainer has been disassembled, all gaskets must be disposed of since they are permanently deformed by compression during service DO NOT under any circumstances reuse gaskets previously in service, since they can cause leaks or high stress points resulting in leakage.

15 Page : Page 15 of REASSEMBLY Refer to the exploded view for component identification, assistance and position 1) Thoroughly clean the element if a new replacement is not envisaged. 2) Place the element in the cavity provided such that it rest firmly on the cavity 3) Carefully remove the gasket from the shipping package and place in a safe area. 4) Clean any material from gasket seating cavity. 5) Place new gasket in the gasket-seating cavity. 6) Place cleaned/new element in basket pipe. Care must be taken to assure that basket ellipse ring rests squarely on the elliptical retaining ring welded in the basket pipe 7) Ensure that the element hold down bolt is sufficiently high to be compressed by the cover. 8) Locate the gasket cavity of the cover plate and place the cover plate over the body. 9) Apply oil or anti seize to threads and screw the nuts to the bolts 10) Tighten bolts and check through the connection openings that the element is located correctly and is fit tight under bolting loads. 11) After 24 hours in service relieve pressure or vacuum, drain the strainer and allow it to return to ambient temperature. Re-tighten the nuts once again. DO NOT re-tighten a Strainer while under pressure. A Strainer in service must be freed of all pressure or vacuum, allowed to reach ambient temperature and be drained or purged of all fluids before re-tightening 9.0 TELEPHONE ASSISTANCE If you are having difficulty with your FLOCLEAN Basket Strainer, notify your local C - TRU distributor or call us direct on / To help us to assist you more effectively, please have as much of the following information when you call: Model # Name of the company from whom you have purchased the Strainer. Invoice # and Date Materials of Construction Serial Number of the Strainer

16 Page : Page 16 of 19 Process Media Operating Temperature Operating Pressure Brief description of the problem Troubleshooting procedures that failed If attempts to solve your problem fail, you may be requested to return your instrument to our factory for intensive testing. You must obtain a Return Authorization ( R A) number from C TRU prior to returning anything. Failure to do so will result in the unit being returned to you, without being tested freight collect. To obtain a R A # the following information in addition to that above is needed: Reason for Return Person to contact at your company Ship To address We recommend that you return the entire unit for testing. There is a minimum charge of Rs. 1500/- for evaluation of non-warranty units. You will be contacted before we repair the unit if there will be any additional charges. If you return a unit that is covered by warranty, but is not defective, the minimum charge will apply SPARES We recommend that a limited number of cover sealing gaskets and elements be held in your maintenance stocks. Our Sales department will provide a spare part recommendation offer. It is critical that replacement component parts are identical in specification to the original component STORAGE Strainer and Spare Component part should be stored carefully in a clean dry area at a temperature preferably above freezing point. REMEMBER FLOCLEAN strainers are the lowest cost insurance that you have provided to protect both your product and your investment. C - TRU PROCESS EQUIPMENTS Head Office: 53 Satyam Industrial Estate Subhash Road, Jogeshwari (East), Mumbai , Maharashtra - India Telephone No: (0) / Fax : (0) sales@arsen-india.com Website:

17 Page : Page 17 of 19 Works: Jasma Industries Compound, Kansari, Khambhat , Gujarat - India 12.0 European Community Declaration of Conformity (Pressure Equipment Directive 97/23/EC) Manufacturer Office Address Factory Address C TRU Process Equipments 53 Satyam Industrial Estate; Subhash Road; Jogeshwari East; Mumbai ; India Jasma Industries Compound; Kansari; Khambhat Gujarat India

18 Page : Page 18 of 19 Products Conformity Assessment Procedures followed Name of the notified body monitoring the Quality System Address of the notified body monitoring the Quality System Name and Address of the notified body that carried out the final inspection: Particulars of Authorized Signatory Sight Flow Indicators Strainers Liquid Level Gauges Flush Bottom Valves Category III ; Module H Eurocert Greece EURO CERT 73 TATOIOY & CHAR, TRIKOUPI STR KIFSA; GREECE ICL CERTIFICATIONS LIMITED # 372 INDUSTRIAL AREA, PHASE 1 PANCHKULA HARYANA EURO CERT 73 TATOIOY & CHAR, TRIKOUPI STR KIFSA; GREECE Mr. Upen Vakil Managing Director C TRU Process Equipments Yours faithfully For C TRU Process Equipments Upen Vakil Chief Executive Officer 13.0 EXPLODED VIEW

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