Spectron BE55+56-SP User manual

User manual
Purge units
BE55+56-SP
05/2020

Table of contents Spectron Gas Control Systems GmbH
ii GES_BE55+56-SP_0520
Table of contents
1 Introduction.................................................................................................................................................. 3
2 Description................................................................................................................................................... 4
2.1 Intended use ......................................................................................................................................... 4
2.2 Misuse .................................................................................................................................................. 4
2.3 Identification / label ............................................................................................................................... 4
2.4 Environment.......................................................................................................................................... 5
2.4.1 Temperatures............................................................................................................................. 5
2.4.2 Degree of cleanliness ................................................................................................................ 5
2.4.3 Emissions................................................................................................................................... 5
2.5 Standards and laws .............................................................................................................................. 5
3 Safety............................................................................................................................................................ 7
3.1 Basic information on the safety instructions ......................................................................................... 7
3.2 Safety instructions ................................................................................................................................ 8
3.3 Emergencies and safety devices .......................................................................................................... 10
3.4 Qualification of the operating and maintenance personnel................................................................... 10
4 Design and function .................................................................................................................................... 11
4.1 Design................................................................................................................................................... 11
4.2 Functional description........................................................................................................................... 12
4.3 Technical data ...................................................................................................................................... 12
4.4 Boundaries and interfaces .................................................................................................................... 13
5 Installation.................................................................................................................................................... 14
5.1 General information .............................................................................................................................. 14
5.2 Installation work .................................................................................................................................... 14
5.2.1 Installation.................................................................................................................................. 14
5.2.2 Connecting the incoming and outgoing lines ............................................................................. 16
6 Commissioning............................................................................................................................................ 17
6.1 Preparations for commissioning ........................................................................................................... 17
7 Maintenance, cleaning and repairs............................................................................................................ 18
7.1 General information on maintenance.................................................................................................... 18
7.2 Flushing the process gas into the pressure control panel .................................................................... 19
7.3 Regular maintenance work and cleaning.............................................................................................. 20
8 Repair ........................................................................................................................................................... 21
8.1 General information on repair work ...................................................................................................... 21
8.2 Troubleshooting and fault rectification .................................................................................................. 22
9 Decommissioning and recommissioning ................................................................................................. 23
9.1 Decommissioning ................................................................................................................................. 23
9.2 Recommissioning ................................................................................................................................. 23
10 Dismantling and disposal ........................................................................................................................... 24
10.1 General information on dismantling ...................................................................................................... 24
10.2 Returns ................................................................................................................................................. 25
10.3 Disposal ................................................................................................................................................ 25

Spectron Gas Control Systems GmbH Introduction | 1
GES_BE55+56-SP_0520 3
1 Introduction
This user manual is the original user manual for the Purge device BE55+56-SP from Spectron
Gas Control Systems GmbH (Fritz-Klatte-Str. 8, D-65933 Frankfurt), referred to as Spectron.
The user manual is intended to facilitate correct and safe operation for the operating firm, and to
warn against misuse. It is intended for the qualified personnel and the operator of the facility.
WARNING
Incorrect operation
Incorrect operation of the system, e.g. due to instruction errors, can lead to personal injury or
damage to the system.
a) Access to the user manual by the operating and maintenance personnel must be absolutely
ensured at all times.
b) A copy of the system documentation including the user manual must therefore be kept
either on the system or in a suitable and accessible location.
This user manual contains information protected by copyright law. It must not be photocopied,
reproduced, translated or copied onto data carriers, either in full or in part, without prior author-
isation. Spectron retains all further rights.

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2 Description
2.1 Intended use
The intended use of the Purge device BE55+56-SP is the controlled introduction of purge gas
into an expansion station for external gas purge.
Purge devices of type BE55+56-SP are suitable for flammable gases, non-flammable gases,
oxygen and additionally also for use with corrosive and toxic gases and gas mixtures up to gas
quality 6.0.
The permissible gas types and pressure ranges are each specified on the label (see "Identifica-
tion / label").
The equipment versions of the Purge devices without electrical components may be used in an
explosion hazard zone as they do not have separate ignition sources (ignition hazard assess-
ment according to DIN EN ISO 80079-36).
Purge devices with electrical components that are suitable for use in an explosion hazard zone
are marked on the label according to EU Directive 2014/34/EU.
To be able to use the Purge devices as intended, all persons working with it must comply with
the specifications of the relevant user manual.
The area in which hazards can occur when used as intended is the area around the Purge
devices. The danger zone changes depending on the system status and use.
2.2 Misuse
Any improper use constitutes misuse. Purge devices may only be used for the specified gases
and in the specified pressure range. Purge devices with electrical components without marking
according to EU Directive 2014/34/EU may not be used in an explosion hazard zone.
Furthermore, the following operating conditions are regarded as misuse:
– Use for gases in their liquid phase
– Failure to carry out inspection and maintenance work
– Pressurisation in reverse (opposite to the flow direction)
– Operation with gases that are not specified on the label
– Operation outside the permissible technical limit values
– Failure to heed and comply with any applicable legal regulations and other provisions
– Non-observance of the user manual
– Failure to heed the information on the label and in the product data sheet
2.3 Identification / label
The label is located on the on the mounting plate of the Purge device.
The label provides the following details:
Details Example
Article number 63AE0032
Article description BE55+56-SP-…
Inlet pressure P1 300 bar
Outlet pressure P2 300 bar
Gas type GAS TYPE

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2.4 Environment
2.4.1 Temperatures
Normal temperatures expected in a production area are assumed when operating the system:
-20°C to +60°C.
The air humidity must be below 60 % rel. humidity to prevent condensation. The operating tem-
perature depends on the gas used.
2.4.2 Degree of cleanliness
Access to the system and to the escape and rescue routes must not be blocked.
The product should be kept clean (dust-free).
A suitable purge gas must be used, taking into account the quality and properties of the process
gas.
Compressed air must be used for the control air at least class 5 according to ISO 8573-1.
2.4.3 Emissions
The A-rated sound pressure level does not exceed the value of 70 dB(A). It is not necessary to
wear hearing protection.
The waste gas line or a burst disc line must not end in areas where the escaping process gas
poses a hazard to persons or the environment.
Further emissions in the form of vibrations, radiation, vapours, dusts and waste water do not oc-
cur in the regular operation of the product.
2.5 Standards and laws
The design and construction of the pressure control panel is subject to the following standards
and directives:
2006/42/EC Machinery Directive
2014/68/EU Pressure Equipment Directive
2014/34/EU ATEX directives
DIN EN ISO 12100:2010 Safety of Machinery
Safety data sheet for the gases used Process gas and auxiliary media
Various additional laws, regulations and guidelines must be complied with when handling pres-
surised gases. Find out about the laws, regulations and guidelines that apply in your location.
BetrSichV Betriebssicherheitsverordnung (Industrial
health and safety ordinance)
ProdSG Produktsicherheitsgesetz (Product Safety Law)
GefStoffV Gefahrstoffverordnung (Hazardous Substances
Ordinance)
TRGS 400, 407, 500, 720, 721, 722, 727,
745,746
Technische Regeln Betriebssicherheit (Tech-
nical Regulations on Operational Safety)
TRBS 1111, 2152, 3145, 3146 Technische Regeln Betriebssicherheit (Tech-
nical Regulations on Operational Safety)
DGUV Regulation 1 German Trade Association Principles of Pre-
vention
DGUV Rule 113-001 German Trade Association Rules on Explosion
Protection

2 | Description Spectron Gas Control Systems GmbH
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EIGA documents

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3 Safety
3.1 Basic information on the safety instructions
The product complies with the recognised technical regulations. Nevertheless, knowledge of the
media used and their dangers as well as basic knowledge of the pressure control panel are pre-
requisites for safe and accident-free operation.
The user manual must be read and understood by every user. Instruction must be documented
in writing.
The safety instructions are to be regarded as a supplement to the applicable accident preven-
tion regulations and laws. Existing accident prevention regulations and laws must be observed
in all cases.
NOTICE
Hazards from the operating environment of the system can lead to injuries to persons.
a) No changes may be made to the system which result in a change in function.
b) It is not possible to outline and cover in this manual all hazards arising from the environment
or unforeseeable operating conditions of the system.
In the Safety Instructions chapter:
– Users are informed regarding hazards, residual risks and measures for risk reduction.
– The presentation of the safety instructions and the symbols is explained.
– Basic safety instructions to be observed in general are listed. Specific safety instructions are
listed in the relevant chapters.
DANGER
DANGER indicates an imminent danger. If not avoided, death or extremely serious injur-
ies will result.
WARNING
WARNING indicates a potential imminent danger. If not avoided, death or serious injury
could result.
CAUTION
CAUTION indicates a potentially imminent danger. If not avoided, minor or moderate in-
jury could result.
NOTICE
NOTICE indicates a potentially harmful situation. If not avoided, the system or property in
its vicinity could be damaged.

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3.2 Safety instructions
The safety instructions are to be observed by all persons working on the system. The rules and
regulations for accident prevention applicable to the place of use are to be observed. The in-
struction of the operating and maintenance personnel on system safety must be documented.
Please pay special attention to this chapter to avoid accidents.
All measures and specifications in the safety data sheets must be implemented and observed.
DANGER
Gas leaks
If gas escapes on the product, contamination of persons, fires or explosions or the displacement
of atmospheric oxygen can occur! Serious or fatal injuries are possible.
a) Do not place pipelines and fittings under mechanical stress. Never use pipelines and com-
ponents as climbing aid or to secure other parts!
b) In the event of leaks, immediately secure the affected area!
c) Smoking and naked flame are strictly prohibited!
DANGER
Intended use
Operation of the product with gases other than those specified or outside the limits may result in
dangerous reactions in the system. Incorrect use poses considerable risks to operating person-
nel and the environment!
a) Only use the product for gases for which it was designed.
b) Only use the product in the specified limit values for pressure and withdrawal quantity.
c) Usage for another type of gas or outside the limit values is prohibited and constitutes mis-
use.
DANGER
Defective product
A defect on the product can result in unforeseeable operating conditions. Persons may be in-
jured.
a) The product may only be operated in technically perfect condition in compliance with all
chapters of the user manual.
b) Environmental protection laws and safety regulations must be observed.
WARNING
Displacement of atmospheric oxygen
In the event of inert gas leaks, displacement of atmospheric oxygen may occur. Danger of suf-
focation!
a) The operator must ensure adequate ventilation and airing in all rooms with gas installations
and monitor the oxygen content.

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WARNING
Repairs
If the product is not used as intended, unpredictable operating conditions may occur. Serious
personal injuries are possible.
a) Repairs may not lead to a change in function. The system may not be tampered with or
modified.
b) Before each repair, the system must be depressurised and flushed through.
c) Repairs are only permitted to be carried out by trained persons.
WARNING
Incorrect operation
Incorrect operation of the system, e.g. due to instruction errors, can lead to personal injury or
damage to the system.
a) Access to the user manual by the operating and maintenance personnel must be absolutely
ensured at all times.
b) A copy of the system documentation including the user manual must therefore be kept
either on the system or in a suitable and accessible location.
WARNING
Working on the product
If an accident occurs when working on the product, there is a considerable risk of injury.
a) Never work on the product unattended or unannounced.
b) Observe the site safety rules and permission procedure.
WARNING
Maintenance
Incorrect maintenance or maintenance work performed at the incorrect time can result in dam-
age to the system or injury to persons.
a) To avoid static charges, do not clean the product using dry cloths. Use damp cotton cloths.
b) The maintenance intervals are to be specified by the system operator as part of its risk as-
sessment.
c) Observe the maintenance intervals and maintenance guidelines from the manufacturer and
the applicable guidelines.
d) Components may only be replaced by spare parts of the same design. The specifications of
the component manufacturers must be complied with during installation.
CAUTION
Pressure relief lines
Discharge of hazardous media at the end of a pressure relief line or exhaust air line.
a) Pressure relief lines may not end in areas where the escaping process gas poses a hazard
to persons or the environment.
b) The position of the pressure relief line must be carefully checked taking into account the ma-
terial properties, main wind direction and other conditions.

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NOTICE
Lighting
Incorrect switching actions or confusion can occur due to inadequate lighting.
a) Ensure sufficient lighting in accordance with the statutory regulations.
3.3 Emergencies and safety devices
The operational local safety regulations of the system operator, such as the alarm plan, fire
safety regulations and the escape and rescue plans, apply in all cases for the operation of the
Purge device.
When handling gases, all specifications from the safety data sheets must be followed. Local
emergency services should be informed of the gases used at the site of the system.
In the event of mechanical damage, the product must be put into a safe operating condition.
3.4 Qualification of the operating and maintenance
personnel
The intended user group is the system operator (user of the system) and the system mainten-
ance personnel.
Every person working on the system must be familiar with the functions and dangers associated
with the overall system. Instruction on the system is to be documented in writing.
Maintenance and repair work should only be carried out by specially trained personnel.
All operators, as well as personnel who regularly enter the area, must be trained on a minimum
of the following topics:
– Alarm rules at the site and conduct in the event of malfunctions and leaks
– Basic functions of the product
– User manual
– System documentation incl. manufacturer documentation
– Position of the safety devices
– Safety data sheets on the process gas used
– Personal protective equipment
In addition, operators must have the requisite physical and mental skills to operate and maintain
the equipment.
Persons who do not meet this requirement (e.g. visitors), must not remain alone in the overall
system.
Operating personnel must use appropriate personal protective equipment for the activities to be
performed and the associated environmental hazards. The operational instructions and the spe-
cifications of the employers' liability insurance associations and the safety data sheets must be
complied with.