< Previous8 Filtration Systems | Installation, Operating and Safety Manual for Liquid Filter Housings and Filter Media • Vent Ports, Drain Ports and Gauge Ports are standard on all Filtration Systems Housings. Install auxiliary Valves and Gauges in the appropriate ports at this time: A Vent Valve should be installed in the Vent Port on the Lid(s). Pressure Gauges, used to monitor differential pressure, should be installed in the Gauge Ports on the Lid and the Filter Vessel Body of each Housing. Drain Valves should be installed in the Drain Ports on the Bottom Head of the Housing and on the Body for the collection of residual liquid. • Seal all unused Vent, Drain or Gauge Ports prior to start-up (user-furnished). • Confirm that the O-Rings have been properly installed in the Lid or Body of each Housing. • If the Housing or System is to be used with Filter Bags, install a Perforated Support Basket in each Housing. Follow instructions for INSTALLING FILTER MEDIA. • If the Housing is to be used with a Lined Basket or Strainer Basket, install it with the appropriate sealing gasket. WARNING Always check chemical and thermal compatibility of Housing Material, O-Rings, Gaskets, Valves, Gauges, Flanges, Plugs and Filter Media with the fluid being filtered. Consult a liquid compatibility guide. Fluid compatibility includes all materials in contact with the liquid under elevated pressures and temperatures.Filtration Systems | Installation, Operating and Safety Manual for Liquid Filter Housings and Filter Media 9 NOTICE Improper Filter Bag installation can result in Filter Bag breakage. To facilitate Filter Bag installation, a Filter Bag Insert (sold separately) will eliminate the need for technicians to reach into the Bag during installation. 1 Take the housing “off-line” (follow the SHUT DOWN PROCEDURES in the OPERATING Section). After draining and venting the Housing, loosen the four Bar Knob Assemblies from the Lid, and lay them back through the slots provided. Open the Vessel Lid using the Lid Handle, and tilt it back completely to the Lid Stop. Remove the used Filter Bag (follow procedures for FILTER BAG REMOVAL). 2 Be certain that a Perforated Support Basket is in place. The use of a Support Basket is mandatory with Filter Bags. 3 Select the appropriate Accufit® or Ultrafit® welded Liquid Filter Bag. Check chemical and thermal compatibility of the Filter Media to be used in an application. 4 Remove the Filter Bag from the plastic packaging. Removing Filter Media from packaging may produce static electrical sparks. To avoid risk of combustion or explosion, never open static packaging in or around areas containing potentially flammable or explosive materials, liquids or gases. 5 Insert the Filter Bag into the Support Basket. The round bottom of the Filter Bag is designed to conform to the shape of the Support Basket. Be certain the Filter Bag is fully extended and supported by the Basket, completely and evenly. Push down on the Bag Collar so it sits flush with the top of the flanged lip of the Support Basket. Note: By design, our Filter Bags are larger in diameter and longer than the Support Basket, promoting ‘blousing’ with the extra fabric. Therefore, under pressure in all directions the Filter Bag remains fully supported mechanically by the Basket during use. Installing Large Diameter, High-Capacity, Drop-In Cartridge Filter Elements 1 Select the appropriate APX® Cartridge Filter Element and Sealing Gasket. Remove the Element from the plastic packaging. 2 If there is a Perforated Support Basket or specialty basket installed, remove it from the Filter Housing. The drop-in design of the APX Element does not require the use of a Support Basket. 3 Insert the APX Element by lowering it into the Filter Housing until the Element is supported by the counterbore of the housing. INSTALLING FILTER MEDIA NOTICE Filtration occurs by capturing particles throughout the depth of the media. As a result, single-use filter media is disposable and cannot be washed or reused. WARNING Removing Filter Media from packaging may produce static electrical sparks. To avoid risk of combustion or explosion, never open static packaging in or around areas containing potentially flammable or explosive materials, liquids or gases. Installing Filter Bags10 Filtration Systems | Installation, Operating and Safety Manual for Liquid Filter Housings and Filter Media OPERATING PROCEDURES Lid Sealing Procedure 1 Confirm that the appropriate O-Rings and Filter Media have been installed properly. 2 Close the Lid of the Vessel using the Lid Handle, being careful not to drop it. 3 Bring the four Bar Knob Assemblies up into position. Hand-tighten bolts in a diagonal pattern, then torque to specification in the same manner. To ensure a secure seal, we recommend 30-50 ft./lbs. of torque on the Bar Knob Assemblies. Start Up Procedure 1 Open the Vent Valve. 2 Gradually fill the Vessel with liquid by opening the Inlet Valve slowly. As liquid enters the Vessel, air is allowed to escape through the Vent Valve to prevent an air pocket from forming. 3 At the first sign of liquid immerging through the Vent Valve, immediately close the Vent Valve and open the Outlet Valve, allowing liquid to flow through the Filter Housing. This begins the filtration process. 4 Monitor the Upstream and Downstream pressure with Gauges, when the Filter Vessel is “on-line”. The difference between the two readings is known as the “pressure differential”, measured across the Filter Bag. Increased upstream pressure indicates “blinding”, and the need for Filter Bag replacement. Follow the Filter Bag manufacturer’s recommendation for maximum allowable differential pressure. Shut Down Procedure 1 Stop the flow of liquid to the Vessel by closing the Inlet Valve. 2 Close the Outlet Valve to isolate the Housing from the liquid flow. 3 Observe the pressure and temperature closely. WARNING Proceed to Step 4 only if the parameters are within safe limits. Safeguards should be taken to wear personal protective equipment (PPE) suitable for the material being handled. 4 The Vessel is still in a pressurized state. Slowly open the Downstream Drain Valve located at the bottom of the Filter Vessel, and capture the liquid in an appropriate container (i.e. suitable for the filtered material that you are evacuating). 5 Open the Vent Valve located on the top of the Filter Vessel Lid. This will promote faster gravity drainage when used in conjunction with the Downstream Drain Valve. 6 Open the upstream Drain Valve located on the Body. If there is any unfiltered residual liquid, collect it in a suitable container. 7 Loosen the four Bar Knob Assemblies from the Lid, and lay them back through the slots provided. Open the Vessel Lid using the Lid Handle, and tilt it back completely to the Lid Stop. The Media may now be removed for replacement (follow procedures for FILTER MEDIA REMOVAL).Filtration Systems | Installation, Operating and Safety Manual for Liquid Filter Housings and Filter Media 11 FILTER MEDIA REMOVAL WARNING Wear personal protective equipment (PPE) suitable for the material being handled. NOTICE Filter Media must be changed at or before the maximum differential pressure, recommended by the manufacturer. If the Filter Media is not changed on a timely basis, it will become “blinded” and will not drain. Filtration occurs by capturing particles throughout the depth of the media. As a result, single-use filter media is disposable and cannot be washed or reused. Filter Bag Removal 1 Be certain the liquid has been drained from the Housing and Filter Bag (see SHUT DOWN PROCEDURES). 2 Grasp the Filter Bag Handles and pull the Collar inward to loosen the upper section of the Bag. Twist the Collar in a circular motion to release the cloth that may be embedded in the perforations of the Support Basket. 3 Anchor the Support Basket Flange while pulling the Filter Bag out of the Basket. If the Bag does not come loose easily, twist the Collar in a circular motion when pulling up. Large Diameter, Drop-In Cartridge Filter Element Removal 1 Be certain the liquid has been drained from the Housing and Cartridge Element (see SHUT DOWN PROCEDURES). 2 When a Drop-In Cartridge Element is fully loaded, debris will accumulate within the Element, eliminating the need to clean the Housing during change-out. 3 Remove the Cartridge Element from the Housing by grasping the built-in Handle and pulling it up and out of the Filter Housing. WARNING Disposal of Filter Media: A Filter Bag or Cartridge that has been used with a hazardous liquid may contain residual amounts of this material and should be handled with the same safeguards that would be used in handling any hazardous and/or toxic material. It is the user’s responsibility to dispose of all Filter Media in accordance with Federal, State, and/or Local laws or requirements.12 Filtration Systems | Installation, Operating and Safety Manual for Liquid Filter Housings and Filter Media MAINTAINING YOUR FILTER HOUSING O-Rings “O-Rings” are subject to wear and should be checked for dirt, cuts, or swelling each time the Filter Vessel is opened. Replacement of O-Rings should be done prior to pressurization of the Filter Vessel. Be certain that the O-Ring material is both chemically and thermally compatible with the fluid being filtered (see page 20 for replacement O-Rings). Lid Hardware Lid Sealing Hardware should be checked each time the Filter Vessel is opened. Inspect the Eyebolts for elongation or thread wear, due to excessive tightening. Check all components of the Bar Knob Assembly for corrosion and replace if necessary (see page 15 for replacement Hardware). Ball Valve Maintenance Filtration Systems Valved Housings are constructed with S/S, Three-Piece, Full-Port Ball Valves, with Teflon Seals and Gaskets. Periodically flush the system to prevent build-up of particulate in the body of the Valve. Replace worn Seals when necessary (see page 19 for replacement Valves & Seals). WARNING Changing Hardware or Ball Valves may produce sparks. Properly ground equipment as required. TROUBLESHOOTING Housing Leaks All Filtration Systems Vessels are hydrostatically tested at our factory to assure the integrity of the Housing. If a Housing leaks: • Confirm that the O-Rings are in place, and properly installed. Check O-Rings for dirt, cuts or swelling and replace, if necessary. • Check the Lid Sealing Procedure; apply the recommended torque pressure and reseal the Housing. • Make sure that both the Inlet and Outlet Shut-Off Valves are open for filtering. • Check all threaded connections; use a threading compound product, as required. • Check plumbing connections. • Check the Housing Body to determine if it was bent out of line during installation. Apply a straight edge over the machined face of the Housing Body from front to back. The straight edge should sit flush on the Body, without gaps. Ball Valves • If the Ball Valve is leaking, identify the leak origin and replace the Seals and Packing. • If the Valve is difficult to open and close, remove the Valve Body and check for obstructions inside the Valve. After removing any debris, reinstall the body of the Valve. • Check the Valve Handle for straightness. Our Valves have built-in ‘Stops’. If the Handle is bent it will give a false ‘Stop’ position. The Valve may appear closed, when it remains slightly open. If this occurs, replace the Valve Handle. • If the Valves don’t fully open or close, the ‘Stop’ or the Handle Slot engaging the Valve Stem may be misshapen, due to excessive force. Remove the Valve Handle and check the ‘Stop’ and the Machined Slot for distortion. If either is distorted replace the Handle. Surface Stains Stains may occur on stainless steel Housing surfaces, due to either process or atmospheric conditions. If surface staining occurs, it can be easily removed with a clean stainless steel wire brush or an aluminum oxide grinding wheel.Filtration Systems | Installation, Operating and Safety Manual for Liquid Filter Housings and Filter Media 13 Abnormally Short Filter Bag Life • Check the position of the Filter Bag in the Support Basket. Be certain that the Filter Bag is fully extended and supported by the Basket. • Check if the Filter Bag has been ripped or torn. • Excessive flow rates may require the user to increase the number of Filter Bags and Filter Housings operating in parallel. As a general rule, adding a second Filter running in parallel will give you three times the Filter Bag life as a single filter. Reducing the flow rate to a Housing will allow increased loading capacity and promotes longer Filter Bag life. WARNING Always check chemical and thermal compatibility of Housing Material, O-Rings, Gaskets, Valves, Gauges, Flanges, Plugs, and Filter Media with the fluid being filtered. Consult a liquid compatibility guide. Fluid compatibility includes all materials in contact with the liquid under elevated pressures and temperatures. Bag Breakage Possible causes of Bag breakage: Excessive flow rates or differential pressure Chemical or thermal incompatibility with the Filter Bag Improper Filter Bag installation (i.e. Bag not fully extended in the Basket) Bag floating due to backflow in the system Installation of the Bag before the Housing is fully drained Installation of the Bag without a Support Basket • Check for process changes or changes in the liquid being filtered. • Check chemical and thermal compatibility. • Check proper Filter Bag installation procedures (see INSTALLING FILTER MEDIA). • Check to see if the Filter Bag is dirty and “blinded”. • Do not exceed the Manufacturer’s recommended maximum temperature or flow rate parameters. • Do not exceed the Manufacturer’s recommendations for maximum allowable differential pressure. • Be certain that Gauges are accurate and in proper working order. NOTICE PARTICLE CHARACTERIZATION ANALYSIS Filtration Systems offers Particle Characterization Studies of liquid samples. Particle Analysis provides meaningful data, useful in specifically identifying filtration requirements for the selection of equipment and Filter Media. Please contact Technical Services Department for details.14 Filtration Systems | Installation, Operating and Safety Manual for Liquid Filter Housings and Filter Media PARTS AND ACCESSORIES REPLACEMENT LID SEALING HARDWARE Replacement hardware is available in stainless or carbon steel for Filtration Systems ASME Code and Industrial Grade vessels. Filtration Systems Over-The-Top vessels utilize four swing-bolt assemblies to secure the lid. A hardware assembly consists of four component parts: bar knob, eyebolt, axle bolt, and axle nut. BAR KNOB WRENCH Although no special tools are required to seal our housings, a Bar Knob Wrench is an ideal accessory. This convenient device allows operators to quickly torque or loosen the lid closure nuts (bar knobs) of a filter vessel. This ratchet wrench is fabricated of plated carbon steel and may be used on all Filtration Systems housings. PRESSURE GAUGES All Filtration Systems housings feature two gauge ports (1/4" NPT) to allow users to monitor both the upstream and downstream pressure. The variance between the two readings is called the differential pressure, and is used to determine when a filter bag is “blinding,” requiring change-out. Gauges have a 2-1/2" dial, 1/4" NPT connections and are back-center mounted. They are available in three ranges: 0-100 psi, 0-160 psi and 0-300 psi. All gauges have a stainless steel case, and may be ordered with either brass or stainless internals. AUXILIARY VALVES All Filtration Systems housings feature a vent port in the lid and a drain port at the base of the filter for installation of auxiliary valves. Vent valves may be installed at the top of the lid to remove air pockets from process fluid lines and promote faster gravity drainage, when used in conjunction with the inlet and outlet drain valves. The outlet drain valve allows the collection of filtered liquid after the vessel is taken off-line. During operation, this valve may also be used for sampling filtered liquid. The upstream drain port and valve on our housings, allows sampling of pre-filtered liquid. Ball valves are available in stainless steel or brass, and are supplied with stainless steel nipples. Filtration Systems housings are equipped with the following threaded ports: Vent Port: 1/4" NPT (all housings) Upstream Drain Port: 1/4" NPT (all housings) Downstream Drain Port: 3/4" NPT (#1 & 2 size) 1/2" NPT (#4 & 5 size) ADJUSTABLE TRIPOD STANDS Allows the user to raise and lower the Filter Vessel, as required.Filtration Systems | Installation, Operating and Safety Manual for Liquid Filter Housings and Filter Media 15 Replacement Hardware Replacement hardware is available in Plated Carbon Steel or Stainless Steel (S/S) for Filtration Systems ASME Code and Industrial Grade vessels. Filtration Systems Over-The-Top vessels utilize four swing bolt assemblies to secure the lid. Each hardware assembly consists of the following component parts: Bar Knob (Castle Nut) Eyebolt (Swing Bolt) Axle Bolt Axle Nut Component parts are not sold separately. * SA-193-B7 rod end Eyebolt, Zinc Plated Carbon Steel. REPLACEMENT LID SEALING HARDWARE MODELDESCRIPTION H-RS-150 * Bar Knob Assembly for S/S, ASME Housings - 150 psi H-RS-150-S/SS/S Bar Knob Assembly for S/S, ASME Housings - 150 psi H-RS-300 *Bar Knob Assembly for S/S, ASME Housings - 300 psi H-RS-300-S/SS/S Bar Knob Assembly for S/S, ASME Housings - 300 psi H-RC-150 *Bar Knob Assembly for C/S, ASME Housings - 150 psi H-RC-300 *Bar Knob Assembly for C/S, ASME Housings - 300 psi H-RNS * Bar Knob Assembly for S/S, Industrial Grade Housings H-RNS-S/SS/S Bar Knob Assembly for S/S, Industrial Grade Housings H-RNC *Bar Knob Assembly for C/S, Industrial Grade Housings H-RNS-141/151 *Bar Knob Assembly for S/S, Miniature Housings (4" Diameter) H-RNC-141/151 *Bar Knob Assembly for C/S, Miniature Housings (4" Diameter) H-RNS-141/151-S/SS/S Bar Knob Assembly for S/S Miniature Housings BARKNOBWRENCH Bar Knob Wrench (for use with all housings) Quickly torques or loosens lid closure hardware PRESSURE GAUGES, DRAIN VALVES AND VENT VALVES MODELDESCRIPTION H- S/S-GVP-8S/S, Gauge/Valve Package for 8" diameter Housings H- BRASS-GVP-8 Brass Gauge/Valve Package for 8" diameter Housings H- S/S-GVP-4 S/S, Gauge/Valve Package for 4" diameter Housings H- BRASS-GVP- 4Brass, Gauge/Valve Package for 4" diameter Housings H-S/S GAUGE-1001/4" NPT S/S, 0-100 psi range H-S/S GAUGE-1601/4" NPT S/S, 0-160 psi range H-S/S GAUGE-3001/4" NPT S/S, 0-300 psi range H-S/B GAUGE-100 1/4" NPT S/S & Brass, 0-100 psi range H-S/B GAUGE-160 1/4" NPT S/S & Brass, 0-160 psi range H-S/B GAUGE-300 1/4" NPT S/S & Brass, 0-300 psi range H-1/4 S/S VALVE1/4" T-316 S/S Ball Valve with Threaded Nipple H-1/2 S/S VALVE1/2" T-316 S/S Ball Valve with Threaded Nipple H-3/4 S/S VALVE3/4" T-316 S/S Ball Valve with Threaded Nipple H-1/4 BRASS VALVE 1/4" Brass Ball Valve with Threaded Nipple H-1/2 BRASS VALVE 1/2" Brass Ball Valve with Threaded Nipple H-3/4 BRASS VALVE 3/4" Brass Ball Valve with Threaded Nipple ADJUSTABLE TRIPOD STANDS MODELDESCRIPTION H-S/STAND S/S, Adjustable Tripod Stand, for 8" diameter Housings H-C/STANDCarbon, Adjustable Tripod Stand, for 8" diameter Housings Gauge/Valve Package Fully equips auxiliary ports on Filtration Systems Housings. Package consists of: (2) Pressure Gauges (Upstream & Downstream) (2) Drain Valves (Upstream & Downstream) (1) Vent Valve Pressure Gauges T-304 S/S Case, T-316 S/S Internals, 2 1/4" Dial, 1/4" NPT Back Center Connection. T-304 S/S Case, Brass Internals, 2 1/4" Dial, 1/4" NPT Back Center Connection. Auxiliary Valves All Filtration Systems Housings feature a Vent Port in the Lid, a Drain Port at the base of the Filter and an Upstream Drain Port. Vent Port: 1/4" NPT (all housings) Drain Port: 3/4" NPT (#1 & #2 Size), 1/2" NPT (#4 & #5 Size) Upstream Drain Port: 1/4" NPT (all housings) Adjustable Tripod Stands For Filtration Systems #1 & #2 Size Individual Filter Vessels (112 & 122).16 Filtration Systems | Installation, Operating and Safety Manual for Liquid Filter Housings and Filter Media PERFORATED SUPPORT BASKETS Stainless Steel support baskets accommodate filter bag sizes #1, 2, 4 and 5. Filtration Systems’ Support Baskets have a perforated wall, and a solid, hemispherical bottom to fully support our filter bags. This patented design promotes “lateral fluid dispersion”, resulting in increased solids loading capacity, and greater differential pressure capability of the filter bags. Staggered pattern, perforated holes (9/64" diameter) maximize the usable surface area of any filter bag and provide greater basket strength than straight-line pattern perforations. Basket bottom has drainage holes and walls have a longitudinal taper to assist with filter bag removal. Perforated Support Baskets are available in T-316 or T-304 Stainless Steel and are offered in size #1, 2, 4 and 5. Support baskets are required when using liquid filter bags. PERFORATED STRAINER BASKETS Heavy-duty Perforated Strainer baskets convert size #1, 2, 4, and 5 filter vessels into high-capacity liquid strainers. When our filter housings are used with strainer baskets they allow heavy dirt loading at high flow rates. Perforated strainers are reusable and may be pressure cleaned, if required. To maximize the usable surface area of the strainer basket, holes are punched in a staggered pattern. Constructed of T-304 stainless steel, strainers have a lift-out handle and a solid, flat bottom. Strainer Baskets are available with the following perforations: 1/2" 3/8" 1/4" 3/16" 9/64" 3/32" 1/16" 3/64" (.500) (.375) (.250) (.1875) (.1406) (.0938) (.0625) (.0469) TRIPLE-WALL, MESH AND MICRON LINED BASKETS These reusable baskets provide liquid straining and filtering at various levels of mesh and micron ratings. The lining specified is embedded between two perforated structural walls, allowing sustained pressure in both directions, and protecting it from harsh brushing or hose spray while cleaning. Fully welded construction assures that no particle bypass occurs around the welded seams. Ideally suited for high temperature applications and/or aggressive service, baskets are constructed of Stainless Steel and include a Buna sealing gasket. Mesh: 20, 30, 40, 50, 60, 70, 80, 100, 150, 200 Industrial Service Micron: 40, 90, 160, 250 Industrial Service 5, 10, 15, 25Light-Duty, Specialty UseFiltration Systems | Installation, Operating and Safety Manual for Liquid Filter Housings and Filter Media 17 * Includes Buna-Gasket Seal SUPPORT BASKETS AND ACCESSORY BASKETS FOR 8" DIAMETER FILTER VESSELS (MODELS 112 & 122) MODELDESCRIPTION A-#1PB-316#1 Size Perforated Support Basket, T-316 S/S 9/64" diameter holes, staggered pattern wall; hemispherical bottom A-#1PB-304 #1 Size Perforated Support Basket, T-304 S/S A-#2PB-316 #2 Size Perforated Support Basket, T-316 S/S A-#2PB-304 #2 Size Perforated Support Basket, T-304 S/S A-#1PB-SANITARY#1 Size, Sanitary Design, Electropolish, Perforated Support Basket, T-316 S/S * A-#2PB-SANITARY#2 Size, Sanitary Design, Electropolish, Perforated Support Basket, T-316 S/S * A-#1PERF-MLB-TW#1 Size Triple-Wall, Mesh or Micron Lined Basket, T-316 S/S * Mesh or Micron Choices: Mesh: 20, 30, 40, 50, 60, 70, 80, 100, 150, 200 (Industrial Service) Micron: 40, 90, 160, 250 (Industrial Service) A-#2PERF-MLB-TW#2 Size Triple-Wall, Mesh or Micron Lined Basket, T-316 S/S * A-#1SMLB-TW#1 Size, Triple-Wall, Small Micron Lined Basket, T-316 S/S * Micron Choices: 5, 10, 15, 25 (Light Duty, Specialty Use) A-#2SMLB-TW#2 Size, Triple-Wall, Small Micron Lined Basket, T-316 S/S * A-#1STRAINER #1 Size, Heavy Duty Perforated Strainer Basket, T-304 S/S *Hole Size: 1/2" 3/8" 1/4" 3/16" 9/64" 3/32" 1/16" 3/64" Decimal:(.500) (.375) (.250) (.1875) (.1406) (.0938) (.0625) (.0469)A-#2STRAINER #2 Size, Heavy Duty Perforated Strainer Basket, T-304 S/S * A-#1PREFILTER#1 Size Pre-Filter, T-316 S/S- Micron Lined Micron Choices: 90, 160 or 250 A-#2PREFILTER#2 Size Pre-Filter, T-316 S/S- Micron Lined A-#1RESTRAINER#1 Size Filter Bag Restrainer, T-316 S/S Keeps filter bag properly seated during filtration A-#2RESTRAINER#2 Size Filter Bag Restrainer, T-316 S/S A-#1MB #1 Size Mesh Basket, T-316 S/S 8 x 8 mesh; cone-shaped bottom A-#2MB #2 Size Mesh Basket, T-316 S/S A-#1CB#1 Size Canister Basket, T-316 S/S Holds granular materials, such as activated carbon. Solid wall; perforated, hemispherical bottomA-#2CB#2 Size Canister Basket, T-316 S/S A-BAG INSERT#1 or #2 Size Filter Bag Insert, T-316 S/S (112 or 122)Allows for easy installation of filter bags A-#1DISPLACER #1 Size, Liquid Displacer, T-316 Stainless Steel A-#2DISPLACER #2 Size, Liquid Displacer, T-316 Stainless SteelNext >