Bello Zon CDVa CDVb Repair Instructions
Contents
1. 5 3 1 1 Safety Requirements Safety Instructions 5 3 2 Decommissioning indt RULES ia E BE 6 341 2 2 Required Materials 6 3 143 SFIUSHING 6 3 1 3 1 System without Flushing Assembly 6 3 1 3 2 System with Flushing Assembly 6 4 Replacing The Reactor e 7 4 1 Safety Requirements Safety 7 4 2 Required Materials 2 5 rri si iba en E Dei Fe gx C RE dpa 7 4 3 Chemical Requirements 8 4 4 Expansion of the Existing Reactor ssessssssssssseseeeeenneen enn 8 4 5 Detoxication of Reactor 7 4 6 Installation of new Reactor nennen nennen 8 4 7 Disposal of Spent Parts sceau eee caved etre edes Doe 9 BRecommissioninge eU EIE 9 Technical Details 2000000090000 ere DES 9 What to do inrantEmergency EE 10 ProMinent Page 3 Transportation Handling and Storage Description of Design and Function Page 4 1 Transportation Handling and Storage The Bello Zon 0 4 CDVb reactors are wrapped in a cardboard surrounding package which is designed either as a sealed disposable wrapper or is transported2. quantity of toxic explosive CIO gas to form Never place both suction lances into the same bucket together or one after another gt This will cause a large quantity of toxic explosive CIO gas to form Do not adjust vent taps as chemicals could be drawn to these outlets gt Corrosive chemicals could then leak out CAUTION Evenif the bypass line is at atmospheric pressure the area between the reactor intake valves and the discharge valve will be at a pressure of approx 1 5 bar Depressurise this area by slowly unscrewing the compression spring centre Page 5 Information about Decommissioning the Chlorine Dioxide System Page 6 NOTE The compression springs and the valve lifters of the discharge valve can be removed easily after unscrewing the compression spring centre when the Bello Zon system and the bypass line are at atmospheric pressure It is then almost impossible for liquid to escape and run through the system 3 1 2 Decommissioning To replace the reactor you need to decomission the Bello Zon system First flush the entire system with water If fitted use the flushing assembly bypass line If no flushing assembly is fitted flush the system using an adapter on the discharge valve upper cross piece outlet 3 1 2 2 Required materials 1 Adapter for cross piece with approx 3 m hose systems with cross piece and no flushing valve 3 1 3 Flushing 3 1 3 1 System without flushing assembly e Dep
3. 20 ml hydrogen peroxide 30 Perhydrol per litre is required This requires use of the following individual components System type Tank Water Caustic soda Hydrogen peroxide Reactor contents with tower packing CDV 201 5l 27 ml 8 ml 0 2 0 4 15 120 CDV 801 201 130 ml 37 ml 1 81 220 600 instead of hydrogen peroxide 3096 H O you can use a dessert spoonful of sodium perborate Na BO H O H O 4 4 Disassembly of spent reactors Before screwing on the union nuts 429 and 5 switch on the suction to continuous operation Disassemble the 4 hexagonal nuts 10 see step 2 Screw both union nuts 429 onto the reactor intake valves see step 2 Detach the union nut 5 from the discharge valve see step 2 Lift the reactor 6 out of the reactor housing and using the appropriate protective equipment lower it into the tank fill this with as much water as is necessary to completely cover the reactor and rapidly place both outdoors or at an exit There you should unscrew the reactor intake valve under water and lift the reactor up and down to transfer the contents into the tank 4 5 Detoxifying reactor contents First add caustic soda and then hydrogen peroxide to the tank contents until the solution is colourless e Let the reactor empty out over the tank and if necessary rinse again with water When the reactor is completely empty the contents must be diluted 10 1 in the neutralisation tank Whils
4. Repair Instructions ProMinent Chlorine Dioxide Systems Bello Zon Replace CDVa reactor with CDVb Pr Minent 3 82 Lu _ uu IMPORTANT The repair manual is valid only when used in conjunction with the appropriate operating manual and or CDVa and CDKa operating instructions manual NOTE The repair manual contains instructions for replacing the reactor with the spare reactor the subsequent tightness check and for recommissioning the chlorine dioxide system Part No 987012 ProMinent Dosiertechnik GmbH 69123 Heidelberg Germany AL BEZ 018 10 03 GB Publishing Details Page 2 Publishing Details Repair Instructions ProMinent Chlorine Dioxide Systems Bello Zon Replace CDVa reactor with CDVb ProMinent Dosiertechnik GmbH 2003 ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5 11 69123 Heidelberg Germany info prominent de www prominent de Subject to revision Printed in the Germany ProMinent Table of contents Transport Handling and Storage essere 4 2 Description of Design and Function 4 2 1 DOSIQN nup derit Gs do doi ER 4 3 Information about Decommissioning the Chlorine Dioxide System 5 3 1 Decommissioning the Chlorine Dioxide System
5. ated while replacing the reactor e Any leaked chemicals must be safely removed e g presence of water supply and floor drain IMPORTANT Auser manual and or operating instructions manual must be made available before commencing operation 12 1 5 describes the personal safety equipment that must be provided for operators b Observe the ordinance on hazardous operating substances Arb StoffV version issued 11th February 1982 BGBI p 145 Additional safety instructions WARNING Before all maintenance operations when replacing parts etc flush the Bello Zon system with water until it and above all the reactor no longer contain any chemicals In the worst case the undiluted CIO solution can be subjected to underpressure in the reactor e g due to a leak in a line downstream The reactor may then explode Empty all contents of the reactor before opening the cabinet Press the Extract button water for extraction must be flowing Keep full and empty chemical containers closed Switch off the chlorine dioxide system throughout maintenance operations Depressurise the discharge valve parts before disassembly Open the ball check valve at the reactor outlet bypass Never mix the contents of the component containers gt This will cause a large quantity of toxic explosive CIO gas to form Never pour the contents of the ventilation bottles into the component containers gt This will cause a large
6. da protective goggles rubber gauntlets gas mask rubber apron n the event of contact with one of these chemicals rinse immediately with plenty of cold water consult a doctor if necessary Observe national and local directives The disassembly of an unrinsed reactor is risky because air can get into the solution as it drains out which can quickly produce explosive CIO gas This measure is therefore acceptable only in an emergency and also only if the reactor volume does not exceed 3 litres Only recommission the system and bypass line under pressure if the compression spring centre is tightly screwed into the stop CAUTION e ifa reactor cabinet is present before dismantling the intake valves on the bottom of the reactor press the Suction button to extract the remaining CIO gas from the reactor cabinet NOTE Always add alkaline flushing water to the neutralisation tank for neutralisation Only ProMinent service technicians should carry out repairs to the Bello Zon system 4 2 Materials required approx 3m water hose 1 open tank for neutralising 1 bottle caustic soda 50 1 litre C irritant 1 bottle hydrogen peroxide 3096 1 litre Xi irritant 1 pH meter ideally pH paper but is bleached by CIO Potable water see table ProMinent Page 7 Replacing the Reactor 4 3 Chemicals required e For neutralising and detoxifying reactor contents approx 70 ml caustic soda 50 and
7. e discharge valve holder 324 then tighten see step 7 e Lightly screw the union nut 429 onto the valve body 344 then tighten f hoses 11 are too long adjust to the required length Pull the union nut and clamping ring over the line then push the hose end extended as required right over the nozzle stretch the mouth of the hose if necessary The clamping action is now achieved by tightening the nut whilst pressing against the hose You will obtain a tight hose connection if you briefly pull the line connected to the reactor and then firmly twist the union nut again WARNING Do not mix up the connections IMPORTANT You should use only the appropriate hoses pinch rings and hose sockets otherwise durability and tightness of the connection is not guaranteed gt gt 4 7 Disposal of spent parts WARNING First rinse the reactor thoroughly with water Otherwise chlorine dioxide CIO could be left in the reactor IMPORTANT Observe regulations applying to your own working area gt gt 5 Recommissioning Recommissioning the system after work has finished Check the system for leaks Check safety features are functioning Recommissioning takes place in accordance with the associated operating instructions manual You should follow all safety requirements safety instructions detailed here 6 Technical Data In accordance with the relevant user manual operating instructions manual ProMinen
8. ifter 3 are only dismantled after rinsing e Switch off the system using the START STOP button Connect a hose to the purge valve of the flushing assembly Insert the hose into a tank containing neutralising solution the hose must be immersed below the liquid level Depressurise the bypass if possible Close the stopcock upstream from the Bello Zon system and downstream from the flushing assembly ProMinent Information about Decommissioning the Chlorine Dioxide System Replacing the Reactor Open the purge valve Place each suction lance in a separate bucket filled with clean water Press the Startup button set both metering pump stroke lengths to 10096 e Run the Bello Zon system until the pump s liquid ends the reactor and lines up to the flushing assembly are completely filled with water during disassembly this will prevent chlorine dioxide solution from flowing out of the reactor Disconnect the system from the mains power supply 4 Replacing the Reactor only to be carried out by service technicians 4 1 Safety requirements safety instructions Personal protective equipment e Facial protection e Rubber or plastic boots Protective gauntlets CIO proof design Protective apron Respirator full mask 1 spare filter per respirator WARNING e Wear suitable protective equipment for CIO gas CIO solution hydrochloric acid sodium chlorite and caustic so
9. ntrated chemicals and metering pumps have not yet begun to pump Switch the Bello Zon system immediately to Metering OFF Start Stop button Place each suction lance in a separate bucket filled with water and fill the chemical drum with dilute chemicals Dispose of concentrated chemicals appropriately Also see leaflet Characteristics of chlorine dioxide and notes Appendix List of documentation drawings Replace reactor 0 41 CDVa 81 01 401 00 18 04 Sheet 1 2 ProMinent Appendix Ausbau des alten Reaktors RQ SW GA Z NI Ti LER SN SX WGA Wl Disassembling of the old reaktor OQ i D Page 11 ProMinent Ausbau des alten Reaktors Disassembling of the old reaktor Appendix AN 7 Schritt B 2 AN 7 Pm jl YES 5 Schritt Step ProMinent Step _ 6 Al 11 Page 12
10. ressurise bypass by opening the bypass ball check valve Do not dismantle any parts prior to this e Press the START STOP button to switch off the system 59 Slowly unscrew the compression spring centre 1 tis easy to remove the spring 2 and the valve lifter 3 of the discharge valve after unscrewing the compression spring centre 1 see 1st step according to drawing Screw adapter into cross piece Connect a hose to the adapter Insert the hose into a tank containing neutralising solution the hose must be immersed below the liquid level Remove each suction lance from the chemical tanks and place each one in a separate bucket filled with clean water Close the stopcock upstream and downstream from the Bello Zon system Open the configuration menu on the control display only possible using access code 1000 nthe Start menu set the start up parameters to a minimum of 60 minutes Press the Startup button set both metering pump stroke lengths to 10096 Run the Bello Zon system until the pump s liquid ends reactor and lines up to the flushing assembly are completely filled with water during disassembly this will prevent chlorine dioxide solution from flowing out of the reactor e Disconnect the system from the mains power supply 3 1 3 2 System with flushing assembly n systems with purge valves the compression spring centre 1 compression spring 2 and the valve l
11. t Page 9 What to do in an emergency Appendix Page 10 7 What to do in an emergency gt If you have come into contact with the acid see leaflet HCI gt If you have come into contact with the chlorite see leaflet NaClO gt If you have come into contact with the CIO solution or with CIO gas see leaflet CIO gt If orange yellow CIO gas is leaking out empty the room immediately and disconnect the power supply e g emergency stop switch Put on full protective gear and suppress the gas by spraying with water Also see leaflet Characteristics of chlorine dioxide and notes gt If orange yellow CIO solution is leaking out empty the room immediately and disconnect the power supply e g emergency stop switch Put on full protective gear and pour sodium thiosulphate solution onto the CIO solution then dilute with plenty of water and rinse down the drain Also see leaflet Characteristics of chlorine dioxide and notes P The Bello Zon system has been charged with concentrated chemicals and metering pumps have already pumped them to the reactor empty the room immediately and disconnect the power supply e g emergency stop switch Call the Fire Service and notify them of the risk of explosion due to concentrated CIO gas CIO gas can still explode after a few hours Also see leaflet Characteristics of chlorine dioxide and notes gt The Bello Zon system has been charged with conce
12. t stirring add the quantity of caustic soda required for neutralising protective equipment Then add the calculated quantity of hydrogen peroxide overdose is uncritical whilst stirring If the yellow green solution does not colour immediately check the pH value it must be more than 8 and can be corrected if necessary by adding more caustic soda CAUTION Add the alkaline flushing water to the neutralisation tank for neutralisation Unscrew the discharge valve holder 6 with ball seat disc 7 O ring 9 and valve ball 8 from the crosspiece see step 3 4 6 Installing a new reactor e Carefully remove the protective cap so that no components fall on the floor Screw the union nut 325 for the adapter onto the spare assembly e Screw the discharge valve holder 324 with ball seat disc 367 ring 840 and valve ball 454 onto the crosspiece see step 5 Insert the valve lifter 3 from above into the crosspiece Assemble the compression spring 2 and the compression spring centre 1 see step 6 Check whether the adapter 325 is screwed right up to the reactor Page 8 ProMinent Replacing the Reactor Recommissioning Technical Data Oring 862 in discharge valve holder 324 see step 7 e Assemble the new reactor 200 in the reactor housing and tighten the 4 hexagonal nuts 10 see step 7 e Push the reactor 200 upwards and lightly screw the union nut for the adapter 325 onto th
13. together with other parts Observe the following ambient conditions for storage of the reactors e g danger of frost UV protection e admissible storage temperature TS 10 to 40 C e admissible transport temperature TS 10 C to 40 C e do not expose reactors to direct sunlight prior to storage and or transportation ensure that the reactor is empty 2 Description of Design and Function 2 1 Design The spare assembly comprises a CDVb CDKb series reactor the reactor intake valves reactor outlet adapter and discharge valve parts The assembly is supplied by PM Heidelberg ready for installation into the Bello Zon chlorine dioxide generating system The reactors are available in the following sizes Spare assembly Part number For system type Spare 0 2 I reactor set TN 1023234 CDVa 7 Spare 0 4 reactor set TN 1021935 CDVa 35 120 The procedure for replacing the reactor and discharge valve parts and the actual construction is shown in drawing 81_01 401_00_18 04 ProMinent Information about Decommissioning the Chlorine Dioxide System ProMinent gt gt 3 Information about Decommissioning the Chlorine Dioxide System 3 1 Decommissioning the chlorine dioxide system 3 1 1 Safety requirements safety instructions IMPORTANT Observe the following regulations a Accident prevention regulations GUV 8 15 and or VGB 65 WARNING e Ensure the operating or installation room is well ventil
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