KINNEY OIL MIST ELIMINATORS

Transcription

1 KINNEY OIL MIST ELIMINATORS Models: A B, B1 & B2 C1 D & D1 Instruction Manual Revision 12/01

2 TABLE OF CONTENTS DESCRIPTION... 1 OPERATION... 1 ELEMENTS... 2 OIL RETURN METHODS... 3 DIRECT DRAIN TO THE OIL RESERVOIR... 3 SUCKBACK TO THE GAS BALLAST VALVE... 3 AUTOMATIC SUCKBACK ON LOW PROFILE PUMPS... 3 SUCKBACK TO THE SUCTION PORT... 3 SEPARATE OIL DRAIN... 3 OME STYLES... 4 STYLE A... 4 STYLE B... 4 STYLE B1...4 STYLE C1...4 STYLES D AND D BUILT-IN OIL MIST ELIMINATORS... 6 LOW PROFILE PUMPS... 6 VERTICAL PUMPS... 6 OME SPECIFICATIONS FOR PISTON PUMPS... 7 OME SPECIFICATIONS FOR LIQUID RING & CLOSED COUPLE SYSTEMS... 8 OME DIMENSIONS TROUBLESHOOTING OIL MIST VISIBLE OIL SMOKE TROUBLESHOOTING TABLE

3 Description Oil Mist Eliminators (OME) filter out oil entrained in mechanical vacuum pumps. When air and oil are expelled through the pump s discharge valves, the oil is separated by baffles. The oil then drains into the pump reservoir shown as (1) in Figure 1. The discharge gas retains some oil in the form of smoke. At high suction pressures the smoke is composed of fine oil droplets that are then filtered out by the OME, increasing pump efficiency and reducing oil loss. Oil mist eliminators eliminate 99.95% of oil droplets from pump discharge. OMEs are recommended for use with all oil-sealed mechanical vacuum pumps. Operation MANUAL , Tuthill Vacuum & Blower Systems The oil mist eliminator works on a two-stage principle. The first stage (agglomerator stage) intercepts the mist and smoke particles, and merges them into larger droplets. The second stage filters these larger droplets from the gas stream, allowing them to drain by gravity. Standard OMEs contain elements composed of a dual layer of glass fibers impregnated with phenolic resin. The elements are equipped with end caps suitable for use with standard pump oils. Note: Consult TVS for special materials. The element s inner shell of glass fibers (2) are tightly packed, building up oil mist droplets larger than 0.2 micron until gravity forces them to travel down the fibers, saturating the element s lower portion (3). This process may take several hours. The element s fiber outer shell (4) has larger gaps and more binder, which adds strength. As the height of the saturated zone grows, pressure rises, causing the oil to flow through the outer shell, where it builds up at the bottom of the OME housing (5). An oil drain (6) allows the oil to drain back into the pump via the tubing connected to the gas ballast valve. Small pumps are equipped with an automatic valve which drains the oil that collects in the OME back to the pump when the pump is stopped, or when it is operating close to blank-off. In larger pumps, an optional automatic oil return kit is available. Gas leaving the oil mist eliminator through the OME discharge connection (8) contains invisible oil which can only be removed by condensation or sorption traps; in most cases, this invisible oil can be piped outside. When operating correctly, no smoke should be visible in the OME discharge connection. Visible smoke from a correctly sized OME indicates that the element may be damaged or improperly seated. OME discharge connection (8) Fiber outer shell (Element) (4) Saturated zone (3) { Oil collects at bottom (5) Pressure gauge or pressure relief valve Oil mist from the pump (1) Check valve (7) Oil return connection Top cover gasket Fiber inner shell (Element) (2) Oil drain connection Oil drain (6) Alternative to the pump oil reservoir or gas ballast valve Figure 1 1

4 Elements A new element contains no oil and has a very low pressure drop. It may take several hours for oil to saturate the element, until it begins to drain out, during which the pressure drop increases to about 2 psi at the rated flow rate. See 1 in Figure 2. In normal operation, oil trapped by the fibers drains out the bottom of the element at the same rate that it comes in. This will continue until the spaces between the fibers become obstructed with material other than oil. This can happen as a result of dust or dirt in the gas steam, or products of breakdown like gum or varnish. See 2 in Figure 2. When the gap between fibers clogs up with dirt or oil breakdown products, the pressure drop rises. When the pressure drop reaches 5 or 6 psi (see 3 Figure 2) the internal pressure causes the fibers to separate or rip apart, creating a weak section with large gaps between the fibers. When oil mist travels through the weak section, the pressure drop becomes very low. See 4 in Figure 2. High pressure existing inside the coalescing element will cause it to rupture, allowing smoke to penetrate the element s torn fibers. A ruptured element may also be due to constant cycling pressure. If smoke travels through the filter media and the pressure drop is very low at the rated flow, the element has split and must be replaced Pressure Drop at rated flow (psi) Saturation Normal Operation Clogging Rupture Smoke Blows Through the Element Time Figure 2 2

5 Oil Return Methods Returning oil to the pump reduces oil loss from the pump. Oil trapped by the OME drains through the element and collects at the bottom of the element housing. An oil drain connection is provided so that oil may be drained in a way suitable for the oil to return to the pump. If the oil is not drained, the oil level rises up the wet zone and up the element, reducing the area available for gas flow and increasing the internal pressure. Eventually the high pressure will split the element, allowing oil mist to blow through the fibers. There are several methods of draining oil, as follows: Direct Drain to the Oil Reservoir The most common method of draining oil is to have a direct drain to the oil reservoir. Oil mist eliminators Styles A and B shown in the Table on page 7 employ this method. Style A and B OMEs are equipped with a rubber disc located below the element end plate. This disc drops by gravity into a holder under the plate when the pump is stopped, or when the pressure drop through the element is very low. Style C1, D, and D1 OMEs are equipped with a tube connection from the drain through tubing connected to the gas ballast valve, (rotary piston pumps). For Style A and B, oil is able to drain back into the oil reservoir under the static pressure of collected oil when the pump is stopped, or running at very low pressure. At higher suction pressures, significant amounts of oil mist are generated and the pressure drop through the element holds the drain closed. Suckback to the Gas Ballast Valve When a pump operates continuously at high pressures, the direct drain is unable to return oil to the pump. In this situation it is necessary to use the gas ballast connection to suck the oil back into the pump. This can either be done continuously by leaving the gas ballast needle valve slightly open, or periodically by manually opening and closing the valve. Most oil mist is created at high suction pressures when the gas ballast valve operates partially opened; this won t affect pump performance, and is a highly practical solution to return oil to the pump. Automatic Suckback On Low Profile Pumps In Low Profile pumps the OME is located alongside the oil reservoir. There is no static pressure to return oil to the pump, and very little oil can be accommodated in the OME housing. In this case a float valve is used, to allow oil to be sucked back to the gas ballast valve when a certain amount of oil is collected. Suckback to the Suction Port In most cases, suckback to the gas ballast valve is the preferred method since gas and oil are sucked into a pumping chamber after it has closed, minimizing the effect on pumping speed. At high suction pressures over 200 Torr, air and oil can enter the suction port directly. Separate Oil Drain Vapors may condense in the OME. To prevent the vapors from returning to the oil reservoir, connect the drain valve to a separate container. Warning Oil level in the pump must be maintained by topping it off to the correct level. 3

6 OME Styles For most applications an oil mist eliminator with a capacity rating equivalent to the pump displacement is suitable. The tables on pages 7 and 8 list OME part numbers that correspond to various Kinney pump models. When the pump-down volume in cubic feet is larger than the pump capacity in cfm or if pump downs are very frequent, the next larger size is recommended. A number of OME styles are shown in the drawings on page 11. Dimensions associated with these drawings are given in the table on page 10. Style A Style A OMEs are used on small pumps where the element directional flow is from outside to inside. As oil collects inside the element, a rubber disc is held closed by the pressure drop. This allows the oil to drain at a pressure close to blank-off or when the pump is stopped. The Style A OME is a selfcontained filter housing and element; no oil is stored in the housing. Consult TVS for applications where lengthy operations at high pressure are required. Mounting the OME: Screw the OME into the discharge connection on the top of the pump; hand tighten. Changing the element: Unbolt the flange screws at the center of the OME and lift up the top section. Unscrew the wing nut from the clamping plate; remove and replace the element. Style B Style B OMEs are similar to Style A OMEs, except that oil is stored in the housing. Mounting the OME: Screw the OME into the discharge connection on the top of the pump; hand tighten. Changing the element: Unbolt the flange screws at the top of the OME and lift up the top cover. Unscrew the wing nut from the clamping plate; remove and replace the element. Style B1 Style B1 OMEs are similar to Style A OMEs, but designed specifically for use with pump model KTC- 21/35. Mounting and changing techniques are the same as with Style A OMEs. Style B2 Style B2 OME s are similar to Style B1 OME s, but are designed specifically for use with KC-15 pumps. Mounting techniquies are the same as with Style B1 OME s. Changing the element: Style B2 OME s have three filter elements. Remove the thumbscrews on the top cover. Lift off cover and replace elements. Style C1 Style C1 OMEs are used on larger pumps. Models manufactured before 1995 are equipped with a pressure relief valve which allows gas to escape when the pressure exceeds 4 psi. Smoke blowing from the relief valve indicates the valve has opened, and there is need for an element change. Models manufactured after 1995 are equipped with a pressure gauge. Mounting the OME: Mount the OME to the discharge connection of the mounting kits listed below. The KTC-60 and KTC-112 mounting kits have threaded connections, while the KT-150, KT-300, KT-500 and KT-850 mounting kits have flanged connections. These kits are designed for use with standard pump models. Consult TVS for oversized OMEs. Model Mtg. Kit # KTC-60 KTC-112 KT-150C KTC-225B KT-300C KT-500C KT-850C BM BM BM BM BM BM BM Changing the element: Remove the bolts from the top plate. Remove the cover. Unscrew the seal nuts from the holddown rods and remove the holddown plate; remove and replace the element. 4

7 Styles D and D1 Introduced in 1996, Style D and D1 OMEs have elements which function in the same way as Style C OMEs. The elements have a coalescing glass fiber element where oil drains to the bottom of the element, and drains back to the pump. These styles have a gas flow of inside to outside. IMPROVEMENTS The elements and housings are more compact than Style C1. The elements are pleated, which allows the element media to be folded, reducing its size. The pleats are made in a special proprietary way to avoid compressing of fibers at the bends. This unique design is only available from Kinney. The element is sealed by flat gaskets at each end rather than a molded end cap, providing a more reliable seal and separate replacement if necessary. No separate mounting kit is required, since Style D OMEs have integral mounting elbows. A pressure gauge is installed at the OME inlet, similar to recent Style C1 OMEs but different from earlier OMEs which have a relief valve. Oil draining directly back to the pump is no longer recommended. Oil should drain to the gas ballast connection to suck oil back into the pump, particularly if the pump is operated at pressure higher than 150 Torr. For the KT-500 and KT-850, the casing is a Style D1 with two elements in a rectangular casing. The troubleshooting methods for Styles D and D1 are the same as the troubleshooting method for Style C1, since their modes of operation are identical. The addition of flat gaskets reduces the incidence of sealing problems, making those problems easier to fix. Mounting the OME: The OME mounts to the discharge connection of the pump. A mounting kit is included in all Style D OMEs. Changing the Element Style D: Unscrew the top cover bolts and remove the top cover. Unscrew the seal nuts from the holddown rod; remove and replace the element. Note: The holddown plate is part of the element. Style D1: Unlatch the link lock fasteners and remove the top cover. Unscrew the seal nuts from the center of the holddown rods; remove and replace the element. 5

8 Built-In Oil Mist Eliminators The following Series 2000 pump models have mist eliminators built into the housings. These OMEs function as an integral part of the pump. KT-120LP KT-275LP KT-840 KT-170LP KT-190LP KT-505LP KT-1350 Low Profile (LP) models are designed with the OME housing and elements attached horizontally to a separate housing. Models KT-840 and KT-1350 are designed with the OME housing and elements attached vertically. LP models are equipped with an oil reservoir beneath the separator housing. This housing has a float valve that allows the automatic return of filter oil to the pump, via the gas ballast piping. This occurs at pressures up to 150 Torr. Models KT-840 and KT-1350 use Suckback Kit Number BM, which has an external flexible tube connected from the upper box of the OME to the metering valve of the gas ballast assembly. This tube returns oil dropout from the filters to the pump. High Pressure Oil Suckback Kit number BM for LP Pumps, and Oil Suckback kit number BM for KT-840 and KT-1350 pumps, are available from TVS for pumps that are to be run for extended periods of time at pressures above 150 Torr. A pressure gauge is installed in the separator housing, which indicates the back pressure from the OME elements. If the gauge approaches 5 psi, it is probably an indication that the elements need to be changed (see p. 2). Low Profile Pumps Changing the Element: Unbolt the flathead countersunk head cap screw and remove the OME cover located on the side of the pump. Remove the seal nuts at the center of the elements and detach the holddown plates. Remove the filters. When replacing elements, make sure the element is positioned over the alignment screws at the rear of the OME. Insert the element and attach the holddown plate, (the holddown plate may or may not be part of the element.). Screw the seal nuts onto the rod with the elastomer portion facing the plate. The orientation of the sealing nuts is very important. If the nut is facing backwards, the oil mist may leak. Vertical Pumps Warning Changing the Element: Unlatch the link lock fasteners and remove the top cover, the seal nuts and the holddown plates; remove and replace the elements. 6

9 OME Specifications for Piston Pumps The Specifications table lists OME part numbers that correspond to Kinney pump models. Pump Model Cfm Style WT LBS OME Part Number Optional Oil Return Kit Suckback Kit Element Gasket KC-2/3/5/8 (Std/Ref) 8 A C OVIT KC-2/3/5/8 (BF) 8 A C OVIT KC-15 (Std/Ref/BF) 20** B C A000 KS-15/KD-30A 30 B C VIT KTC-21/35 30 B C VIT KD B C VIT KTC-60C 85 D C KDH-65/80 85 C KT-120LP * X B FE B000 KTC-112, 165 D A KT-150C, and D 165 C KDH-130/150B 165 C KT-170LP/190LP 120 * X B FE B000 KT-275LP 150 * X B A000 KTC-225B, KT-300C & D 315 D C KT-500C and D 520 * D *** C KT-505LP (f) 3 and * X B B000 KT-505LP (a) 4 and * X B B000 KT * X A FE A000 KT-850C and D 870 * D ** C *** C KT * X A FE A000 1 LP = Low Profile 2 X = In an X Style Pump, the OME housing is an integral part of the pump and is not shown as a separate style. 3 (f) = Steel fabricated housing 4 (a) = Aluminum housing 5 Conversion kit required ( BM) when replacing filter elements. Remove or and replace with & conv. kit. * = Requires two elements ** = Requires three elements *** = Requires four elements 7

10 OME Specifications for Liquid Ring & Closed Couple Systems The Specifications table lists OME part numbers that correspond to Kinney pump models. Pump Model Cfm Sty WT LBS OME Part Number Optional Oil Return Kit Suckback Kit Element Gasket KLRC-40/75 CC Units KLRC-100/125 CC Units KLRC-200/300 CC Units KLRC-525/526 CC Units KLRC-775/776 CC Units KLRC-950/951 CC Units 85 C BM C BM C BM *** C BM ** C BM *** C BM * Requires two elements / **Requires three elements / ***Requires four elements Note: Oil mist eliminators made before 1984 use the same elements as the current version but, may require different gaskets 8

11 OME Dimensions The dimensions in the following chart correspond to the OME figures on the following page. Dimensions (in inches) PUMP MODEL Sty A B C D E F G H J K L M N P R KC-2/3/3R A /2 1-5/16 3 1/16 1/2 3/4 KC-5/8/8R A 6-7/16 5-1/4 6-1/2 1-1/8 3-1/16 1/2 3/4 KC-15 B2 6-3/4 5-1/4 9-3/16 15/ /2 KS-15/KD-30A B 9 7-5/8 13-1/16 2-1/2 8-3/ /4 1/2 1 KTC-21/35 B1 8-7/8 7-3/4 6-3/4 2-5/ /2 KD-50 B 11-3/4 10-1/4 16-7/8 2-5/ /2 1-1/4 3/4 2 KTC-55, KTC-60C and D, KDH-65/80 C1 D 10-3/ / /8 13-5/ /2 7-7/8 9-1/2 9-1/4 12-1/2 1-1/2 1-1/2 1-1/4 5-1/4 3/8 KT-120LP 1 X 2 KTC-90/112 KT-150C KDH-130/150B C1 D 14-1/2 10-1/ / / / /16 9-3/4 15-1/4 1-1/ /4 3/8 KT-170/190LP 1 X 2 KT-275LP 1 X 2 KTC-225B KT-300C and D C1 D / /4 19-1/4 19-7/8 4-1/2 5-1/8 13-5/ / /8 KT-500C KT-500D C1 D /4 4-1/2 2-3/ /4 14-1/2 17-1/ / /8 6 KT-505LP 1 X 2 KT-840 VFP 1 X 2 KT-850C KT-850D D1 C /2 23-3/8 3-1/ / /8 24-1/ /8 24-1/2 23-1/8 6 KT-1350 VFP 1 X 2 1 LP = Low Profile 2 X = In an X Style pump, the OME housing is an integral part of the pump and is not shown as a separate style. 9

12 OME Styles Style A Style B Style B1 Style B2 Style C1 Style D Style D1 10

13 Troubleshooting When operating correctly, no smoke should be visible in the OME discharge. Oil Mist Visible Possible causes of oil mist visible in the discharge valve: The element has been removed from the casing, or an unsuitable element has been installed. Refer to 1 in Figure 3. There are gaps at the top or bottom of the element or because the element has moved or settled in transit. The seal materials have lost their resilience. Refer to 2 in Figure 3. Mist is leaking around the holddown nut and threads. A great deal of smoke can filter through a tiny gap. Refer to 3 in Figure 3. Smoke may be coming through the element because of over-tightening the holddown nut. Refer to 4 in Figure 3. The element may have ruptured because of excessive pressure drop. Refer to Elements on page 2. Oil Smoke To locate the cause(s) of oil smoke: Caution: Wear safety glasses! 1. Remove the top cover. 2. Start the pump at blank-9off. 3. Let some air into the suction port or open the gas ballast valve. 4. Look into the canister with a flashlight. Determine which problem(s) listed in the Oil Mist Visible section above applies Figure 3 5. If the leak is at the endcap: Gently turn the holddown screws a half turn at a time. If there are three nuts, rotate each a half turn at a time. Warning Overtightening may cause crushing of the element. 6. If smoke appears to be coming straight through the element, replace the element

14 Troubleshooting Table Refer to page 12 when attempting to determine the source of problems with the OME. Problem Cause Remedy Oil smoke is present in the exhaust. Smoke is coming from the relief valve. Element is not seated properly. Leaks at the holddown nuts or washers. Smoke blows straight through the element. Smoke blows straight through a new element. The canister is filled with oil. Pressure in the OME is too high. Relief valve is damaged. Remove the cover to locate cause. Refer to page 12 for determining the source. Reseat the element if possible, or replace element. Seal threads with Kinseal or RTV. Use a flat seal under washer. Replace the element. Check that the element is the correct type. Drain the oil and install a suitable drain line. Replace element. Replace the relief valve. OME fills with oil. Check valve is stuck closed. Replace the check valve. Oil smoke in the exhaust is visible in bright light. Haze accumulates indoors. A continuous high pressure operation is required. This is normal. Inadequate ventilation. Drain the oil to the gas ballast valve, or suction port. Very bright light makes dust and other extremely small particles visible. Improve the ventilation, or duct the OME exhaust outside. 12