Welker CSVC User manual

INSTALLATION, OPERATION, ANDMAINTENANCEMANUAL
WELKER®CYLINDERSTEAM&VACUUMCLEANER
MODEL
CSVC
DRAWING NUMBERS
AD881CA
AD881CB
MANUAL NUMBER
IOM-128
REVISION
Rev. B, 3/16/2016

TABLEOFCONTENTS
2IOM-128 MODEL: CSVC REV: B 13839 West Bellfort Street Sugar Land, TX 77498 welker.com Service Department 281.491.2331
Welker®, Welker Jet®, WelkerScope®, and OdorEyes® are Registered Trademarks owned by Welker, Inc.
SAFETY 3
1. PRODUCT INFORMATION 4
1.1 Introduction 4
1.2 Product Description 4
1.3 Safety Warning 4
1.4 Important Information 4
1.5 Specifications 5
1.6 Equipment Diagrams 6
2. INSTALLATION & OPERATION 11
2.1 Before You Begin 11
2.2 Installation 12
2.3 Operation 13
3. MAINTENANCE 19
3.1 Before You Begin 19
3.2 Maintenance 20
APPENDIX 21
A: Referenced or Attached Documents 21

IMPORTANTSAFETYINFORMATION
READALLINSTRUCTIONS
Notes emphasize information and/or provide additional information to assist the user.
Caution messages appear before procedures that could result in damage to equipment if not observed.
Warning messages appear before procedures that could result in personal injury if not observed.
This manual is intended to be used as a basic installation and operation guide for the Welker® Cylinder Steam & Vacuum Cleaner, CSVC. For comprehensive
instructions, please refer to the IOM Manuals for each individual component. A list of relevant component IOM Manuals is provided in Appendix A of this manual.
The information in this manual has been carefully checked for accuracy and is intended to be used as a guide for the installation, operation, and maintenance of
the Welker® equipment described in this manual. Correct installation and operation, however, are the responsibility of the end user. Welker reserves the right to make
changes to this manual and all products in order to improve performance and reliability.
BEFOREYOUBEGIN
Read these instructions completely and carefully.
IMPORTANT - Save these instructions for local inspector's use.
IMPORTANT - Observe all governing codes and ordinances.
Note to Installer - Leave these instructions with the end user.
Note to End User - Keep these instructions for future reference.
Installation of this Cylinder Steam & Vacuum Cleaner is of a mechanical and electrical nature.
Proper installation is the responsibility of the installer. Product failure due to improper installation is not covered under the warranty.
If you received a damaged Cylinder Steam & Vacuum Cleaner, please contact a Welker® representative immediately.
Phone: [phone]
Address: 13839 West Bellfort Street
Sugar Land, TX 77498
SAFETY
3IOM-128 MODEL: CSVC REV: B 13839 West Bellfort Street Sugar Land, TX 77498 welker.com Service Department 281.491.2331

1.1 Introduction
We appreciate your business and your choice of Welker® products. The installation, operation, and maintenance liability for this
equipment becomes that of the purchaser at the time of receipt. Reading the applicable Installation, Operation, and
Maintenance (IOM) Manuals prior to installation and operation of this equipment is required for a full understanding of its
application and performance prior to use.*
If you have any questions, please call Welker at 1-281-491-2331.
*The following procedures have been written for use with standard Welker® parts and equipment. Assemblies that have been modified may have additional
requirements and specifications that are not listed in this manual.
1.2 Product Description
The Welker® CSVC Cylinder Steam & Vacuum Cleaner is an effective cleaning system that utilizes heat from saturated and super-
heated steam to clean sample cylinders. Unlike hot water, steam evenly distributes heat to all surfaces. Moisture content of steam
can be quickly and easily controlled by regulating the inlet pressure. The use of a steam separator will reduce moisture in
saturated steam to less than one percent (1%). This system does not require any chemicals, saves on water usage, and facilitates
the simultaneous cleaning of multiple cylinders. In short, the CSVC is an efficient, environmentally-friendly system for removing
contaminants inside sample cylinders.
Welker may custom design the CSVC to suit the particular application and specifications of each customer.
1.3 Safety Warning
1. Steam may be dangerous if the proper precautions are not taken. Hot surfaces and release of live steam may cause
serious bodily injury. Follow safety and correct operating procedures when working with steam. When operating the
system, wear appropriate personal protective equipment (PPE), which could include gloves that cover the forearms.
2. Exposure to steam is hazardous. If not properly controlled, steam may cause serious bodily injury and/or property
damage.
1.4 Important Information
1. Cylinders must be completely emptied and drained before being connected to the CSVC.
2. A damaged steam hose may result in serious personal injury and/or property damage.
3. Never transport a cylinder with pressure exceeding DOTregulations as established in 49 C.F.R. In cases where the
cylinder may be exposed to varying temperatures, do not allow the cylinder to exceed its maximum allowable
operating pressure (MAOP).
4. Handle the cylinder with care. Protect the cylinder and valves during transport.
5. Once analysis is complete, the cylinder should be emptied safely and placed in a safe area.
6. Welker recommends cleaning and leak testing the cylinder after each use. Refer to the Installation, Operation, and
Maintenance (IOM) Manual for the Welker® SC Single Cavity Sample Cylinder for instructions.
SECTION 1: PRODUCTINFORMATION
4IOM-128 MODEL: CSVC REV: B 13839 West Bellfort Street Sugar Land, TX 77498 welker.com Service Department 281.491.2331

1.5 Specifications
The specifications listed in this section are generalized for this equipment. Welkercan modify the equipment according to your
company's needs. Please note that the specifications may vary depending on the customizations of your
equipment.
Table 1: CSVC Specifications
Application Cleaning of Sample Cylinders
Maximum Allowable Operating Pressure 90 psig (6.2 barg)
Steam Temperature Range 212 °F to 331 °F (100 °C to 166 °C)
Connections ½" FNPT (Standard)
¾" FNPT
Utility Requirement Water Supply: Up to 100 psig (6.8 barg)
Electrical Connection AC 120 V
AC 480 V, 3 Phase
Cylinder Volume
300 cc (Standard)
500 cc
1000 cc
System Cylinder Capacity
Up to 6 Cylinders (Standard)
Up to 12 Cylinders
Up to 24 Cylinders
Features
Blowdown Separator
Insulated Tubing
Steam Generator
Steam Traps
Swagelok® Quick-Connects
Thermostatically Controlled Heater
Vacuum Pump
Options
FasMate® Quick-Connects
Water Pump
Welker® SG-3 Sight Glasses
5IOM-128 MODEL: CSVC REV: B 13839 West Bellfort Street Sugar Land, TX 77498 welker.com Service Department 281.491.2331

1.6 Equipment Diagrams
Figure 1: CSVC Schematic
6IOM-128 MODEL: CSVC REV: B 13839 West Bellfort Street Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Figure 2: CSVC Connections Diagram (Shown With Optional FasMate® Quick-Connects)
7IOM-128 MODEL: CSVC REV: B 13839 West Bellfort Street Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Figure 3: CSVC Valve Diagram (Shown With Optional FasMate® Quick-Connects)
8IOM-128 MODEL: CSVC REV: B 13839 West Bellfort Street Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Figure 4: Steam Header Diagram (Shown With Optional FasMate® Quick-Connects)
9IOM-128 MODEL: CSVC REV: B 13839 West Bellfort Street Sugar Land, TX 77498 welker.com Service Department 281.491.2331

Figure 5: Collection Header Diagram (Shown With Optional FasMate® Quick-Connects)
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2.1 Before You Begin
After unpacking the unit, check the equipment for compliance and any damage that may have occurred during shipment.
Immediately contact a Welker® representative if you received damaged equipment.
When sealing fittings with PTFE tape, refer to the proper sealing instructions for the brand used.
The Cylinder Steam & Vacuum Cleaner will ship skid-mounted and "hard-tube" connected with manufacturer-supplied fittings
and hardware. However, the customer will need to supply some tubing and fittings in order to complete the installation of the
system.
SECTION 2: INSTALLATION&OPERATION
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2.2 Installation
1. Install the CSVC in the desired location.
Welker recommends the CSVC be installed in a location where access to valves, cylinders, auxiliary equipment, and utilities is not
restricted and where relief valves can be safely vented to prevent potential injury.
2. Ensure that all valves are closed (Figure 3).
3. Set the relief valve on the steam header to the appropriate pressure (Figure 4). Refer to the Installation, Operation, and
Maintenance (IOM) Manual for the Welker® RV-1 Relief Valve for instructions on setting the relief.
4. Set the relief valve on the collection header (Figure 4). This relief should be set approximately 10 psig below the relief
valve on the steam header. Refer to the Installation, Operation, and Maintenance (IOM) Manual for the RV-1 for
instructions on setting the relief.
Setting the relief on the collection header to a pressure lower than that of the relief on the steam header ensures proper
functioning of the steam traps.
5. If desired, use ½" tubing to connect from the relief valves to an appropriate venting location (Figure 2).
6. Using ½" tubing, connect from system drain valve J to an appropriate container (Figure 2).
7. Using the provided ½" steam hose, connect from the steam generator to the steam inlet (Figure 2).
8. Using the provided ½" vacuum hose, connect from the vacuum pump to vacuum valve H (Figure 2).
9. Connect the customer-supplied water supply to the inlet on the steam generator (Figure 1).
There is a 10 psig pressure drop across the steam generator from the water inlet to the steam outlet.
10. Connect the customer-supplied cold water supply to the inlet on the blowdown separator (Figure 1).
This unit requires a cold water connection. Welker recommends that the inlet to the blowdown separator be lower than the
sight glass of the steam generator to ensure safe drainage during blowdown.
The blowdown separator reduces temperatures and pressures to safe levels for discharge to the drain orsewer. During
blowdown, the blowdown separator separates liquid from vapor to prevent live steam discharge to city drains.
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2.3 Operation
Steam Generator
To ensure safe operation of the steam generator, follow all manufacturer instructions, including PPE recommendations and
safety instructions. Refer to the Installation, Operation, and Maintenance (IOM) Manual for the steam generator for operating
instructions.
1. Ensure that all valves are closed (Figure 3).
2. Close the drain valve and steam outlet valve on the steam generator, and then turn on the customer water supply. Allow
the water level to rise approximately halfway up the steam generator sight glass before operating the steam generator.
This may take several minutes.
3. Connect an appropriate electrical supply to the steam generator. Refer to the Installation, Operation, andMaintenance
(IOM) Manual for the steam generator for the manufacturer's wiring instructions.
4. Set the thermostat to the desired steam temperature, and then turn ON the boiler switch to start the steam generator
(Table 2). Allow at least thirty (30) minutes for the steam to reach the desired temperature.
Table 2: Steam Temperature Settings
Water Inlet Pressure (psig) Steam Temperature (°F) Water Inlet Pressure (psig) Steam Temperature (°F)
0212 30 274
1216 35 281
2219 40 287
3222 45 292
4224 50 298
5227 55 303
6230 60 307
7232 65 312
8235 70 316
9237 75 320
10 240 80 324
15 250 85 328
20 259 90 331
25 267 – –
5. Once the steam has reached the desired temperature, open the steam outlet valve on the steam generator.
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Steam System
Failure to properly follow the manufacturer's recommended procedures for the care, maintenance, and storage of the steam
hoses may result in serious bodily injury and/or property damage.
Only specially trained personnel should engage in operating or testing procedures that require particularskills and/or training.
Failure to comply may result in damage to the hoses, other property damage, and/or serious bodily injury.
6. Ensure that the steam has reached the desired temperature.
7. Connect the inlet of the customer-supplied Welker® SC Single Cavity Sample Cylinder to the quick-connect on the
steam header (Figure 4).
8. Connect the outlet of the customer-supplied SC to the flex hose with quick-connect on the collection header (Figure 5).
When connecting the outlet of the SC to the collection header, Welker recommends positioning the flex hose so that access to
the collection header valves is not restricted.
9. Open both valves on the SC.
10. Open system drain valve J on the collection header (Figure 3 or Figure 5). If the CSVC is equipped with a second
collection header, open system drain valve J on the second collection header as necessary.
11. Open steam outlet valve E for the installed SC (Figure 3 or Figure 4).
12. Open steam inlet valve D for the installed SC (Figure 3 or Figure 4).
13. As necessary, repeat steps 7-12 for any additional SCs.
14. Open steam header isolation valve C and collection header isolation valve I (Figure 3 or Figure 4).
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Wet Cycle
15. Manually turn the handle on cycle selector valve B so that the arrow on the handle points away from the steam separator
(Figure 6). This will open the valve to the wet cycle.
Figure 6: Cycle Selector Valve B Orientation
16. Open collection header wet cycle inlet valve F for all installed SCs (Figure 3 or Figure 5).
17. Open steam inlet valve A to start the wet cycle (Figure 3). Saturated contaminants will drain to the container connected
to the drain.
During the wet cycle, the steam generator generates saturated steam, which dissolves and flushes contaminants from the
sample cylinders.
18. Allow the wet cycle to run for the appropriate amount of time.
The time required to completely clean the sample cylinders is dependent on the set temperature of the steam generator, the
water inlet pressure, the type of contaminant(s), and the number of sample cylinders.
19. Once the sample cylinders are free of visible contaminants or considered clean in accordance with the end user's
specifications, close steam inlet valve A (Figure 3). This ends the wet cycle.
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DryCycle
20. Manually turn the handle on cycle selector valve B so that the arrow on the handle points toward the steam separator
(Figure 6). This will open the valve to the dry cycle.
Cycle selector valve B will be HOT.
21. Open collection header dry cycle inlet valve G and close collection header wet cycle inlet valve F for the installed SCs
(Figure 3 or Figure 5).
22. Open steam inlet valve A to start the dry cycle (Figure 3).
During the dry cycle, saturated steam is diverted to the steam separator, which removes up to 99.8% of moisture. A steam trap
downstream of the sample cylinders discharges condensate without allowing the escape of live steam. The steam trap and
continued input of heat allow steam to be contained, increasing the temperature at which the cylinders are maintained. The
cycle further heats the system to facilitate "baking" of any residue remaining in the sample cylinders.
23. Allow the dry cycle to run until the SCs are clean.
The time required to completely clean the sample cylinders is dependent on the set temperature of the steam generator, the
water inlet pressure, the type of contaminant(s), and the number of sample cylinders.
24. Once the sample cylinders are considered clean in accordance with the end user's specifications, close steam inlet valve
A (Figure 3). This ends the dry cycle.
25. Open collection header wet cycle inlet valve F and close collection header dry cycle inlet valve G for the installed SCs
(Figure 3 or Figure 5).
The sample cylinders must be drained prior to disconnecting the quick-connects. Failure to drain the sample cylinders prior to
disconnecting the quick-connects may result in damage to the equipment and/or injury to the operator.
26. Close steam header isolation valve C on each steam header used (Figure 3 or Figure 4).
27. If a vacuum will not be pulled on the SCs, continue to step 28. If a vacuum will be pulled on the SCs, proceed to step
35.
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Vacuum System
No Vacuum
The SCs will be HOT. Allow the SCs to cool prior to proceeding.
28. Turn OFF the thermostat to the steam generator.
29. Close steam inlet valve D and close steam outlet valve E on the flex hose for all installed SCs (Figure 3 or Figure 5).
30. Close both valves on eachSC.
31. Disconnect the SCs from the CSVC. If applicable, install the quick-connects to the corresponding quick-connect rests
(Figure 5).
The flex hoses will be HOT.
32. Open steam header isolation valve C and steam inlet valve A to relieve pressure in the steam header (Figure 3 or Figure
5).
33. Once pressure has been relieved from the steam header, close steam inlet valve A (Figure 3 or Figure 4).
34. Welker recommends a daily blowdown of the steam generator. Refer to the Installation, Operation, and Maintenance
(IOM) Manual for the steam generator for instructions.
Power must be OFF when the steam generator is drained.
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Pulling a Vacuum
35. Turn OFF the thermostat on the steam generator.
36. Close steam outlet valve E on the flex hose for all installed SCs (Figure 3 or Figure 5).
37. Close collection header isolation valve I (Figure 3 or Figure 5).
38. Close the bottom valve on all installed SCs.
39. Turn ONthe vacuum pump.
40. Open vacuum valve H to pull a vacuum on the SCs (Figure 3). The steam header pressure gauge will display how much
vacuum has been pulled on the SCs.
The time required to pull the desired vacuum is dependent on the sample cylinder volume.
41. If desired, close the top valve on the SCs to maintain the vacuum on the SCs.
42. Close vacuum valve H (Figure 3 or Figure 4).
43. Turn OFF the vacuum pump.
44. Close steam inlet valve D (Figure 3 or Figure 5).
45. Disconnect the SCs from the CSVC. If applicable, install the quick-connects to the corresponding quick-connect rests
(Figure 5).
The flex hoses will be HOT.
46. Open collection header isolation valve I (Figure 3 or Figure 4).
47. Open steam header isolation valve C and steam inlet valve A to relieve pressure in the steam header (Figure 3 or Figure
4).
48. Once pressure has been relieved from the steam header, close steam inlet valve A (Figure 3 or Figure 4).
49. Welker recommends daily blowdown of the steam generator. Refer to the Installation, Operation, and Maintenance
(IOM) Manual for the steam generator for instructions.
Power must be OFF when the steam generator is drained.
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3.1 Before You Begin
1. Welker recommends that the unit have standard yearly maintenance under normal operating conditions.
In cases of severe service, dirty conditions, excessive usage, or other unique applications that may lead to excess wear
on the unit, a more frequent maintenance schedule may be appropriate.
2. Prior to maintenance or disassembly of the unit, it is advisable to have a repair kit available for repairs of the system in
case of unexpected wear or faulty seals.
New seals supplied in spare parts kits should be lightly lubricated before being installed to ease the installation of the seals and
reduce the risk of damage when positioning them on parts. Wipe excess lubricant from the seals, as it may adversely affect
analytical instrument results.
For sample-exposed seals, Welker recommends non-hydrocarbon-based lubricants, such as Krytox®.
For non-sample-exposed seals, Welker recommends either non-hydrocarbon-based lubricants or silicone-based lubricants, such
as Molykote® 111.
After the seals are installed, the outer diameter of shafts and inner diameter of cylinders may be lubricated to allow smooth
transition of parts.
3. All maintenance and cleaning of the unit should be performed on a smooth, clean surface.
4. Welker recommends having the following tools available for maintenance. Please note that the exact tools required may
vary by model.
a. 10" Adjustable Wrench (Qty. 2)
b. Flat Head Screwdriver
c. Seal Pick
d. Tubing Cutters
SECTION 3: MAINTENANCE
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3.2 Maintenance
1. Routinely inspect the steam separator and steam traps for buildup, clogging, corrosion, and other damage. Refer to the
Installation, Operation, and Maintenance (IOM) Manual for the steam generator and for the steam traps for inspection
and maintenance instructions.
Proper steam separator and steam trap maintenance is essential to a steam system. Faulty steam traps not only waste energy,
but also can contribute to pipe erosion due to poor water quality and contaminants allowed to pass downstream. A poor
maintenance program will increase energy losses, decrease reliability, reduce steam quality, and may affect production
downtime.
The frequency of inspection should be determined by application.
2. Maintain the steam generator. Refer to the Installation, Operation, and Maintenance (IOM) Manual for the steam
generator for maintenance instructions.