Spectron spectrocem BE55-1 Bedienungsanleitung
User manual
Pressure control panel
BE55-1
05/2020
Table of contents Spectron Gas Control Systems GmbH
ii GES_BE55-1_0520
Table of contents
1 Introduction.................................................................................................................................................. 4
2 Description................................................................................................................................................... 5
2.1 Intended use ......................................................................................................................................... 5
2.2 Misuse .................................................................................................................................................. 5
2.3 Identification / label ............................................................................................................................... 5
2.4 Environment.......................................................................................................................................... 6
2.4.1 Temperatures............................................................................................................................. 6
2.4.2 Degree of cleanliness ................................................................................................................ 6
2.4.3 Emissions................................................................................................................................... 6
2.5 Standards and laws .............................................................................................................................. 6
3 Safety............................................................................................................................................................ 8
3.1 Basic information on the safety instructions ......................................................................................... 8
3.2 Safety instructions ................................................................................................................................ 9
3.3 Emergencies and safety devices .......................................................................................................... 11
3.4 Qualification of the operating and maintenance personnel................................................................... 11
4 Design and function .................................................................................................................................... 13
4.1 Design................................................................................................................................................... 13
4.2 Functional description........................................................................................................................... 14
4.3 Technical data ...................................................................................................................................... 15
4.4 Boundaries and interfaces .................................................................................................................... 15
5 Installation.................................................................................................................................................... 16
5.1 General information .............................................................................................................................. 16
5.2 Installation work .................................................................................................................................... 16
5.2.1 Installation.................................................................................................................................. 16
5.2.2 Connecting the incoming and outgoing lines ............................................................................. 18
5.3 Checking the system ............................................................................................................................ 18
5.3.1 Pressure test with purge gas ..................................................................................................... 18
5.3.2 Helium leak test ......................................................................................................................... 18
6 Commissioning............................................................................................................................................ 20
6.1 Preparations for commissioning ........................................................................................................... 20
6.2 Procedure for commissioning ............................................................................................................... 20
6.2.1 Connecting the process gas source........................................................................................... 20
6.2.2 Flushing in the process gas to the process................................................................................ 21
7 Operation...................................................................................................................................................... 22
7.1 General information on operation ......................................................................................................... 22
7.2 Gas supply interruption......................................................................................................................... 22
7.2.1 Interruptions to operation for less than 48 hours ....................................................................... 22
7.2.2 Interruptions to operation for more than 48 hours...................................................................... 22
7.2.3 Putting the pressure control panel into a safe condition ............................................................ 22
7.3 Exchanging the process gas source..................................................................................................... 22
8 Maintenance, cleaning and repairs............................................................................................................ 24
8.1 General information on maintenance.................................................................................................... 24
8.2 Flushing the process gas into the pressure control panel .................................................................... 25
8.3 Regular maintenance work and cleaning.............................................................................................. 26
Spectron Gas Control Systems GmbH Table of contents
GES_BE55-1_0520 iii
9 Repair ........................................................................................................................................................... 27
9.1 General information on repair work ...................................................................................................... 27
9.2 Troubleshooting and fault rectification .................................................................................................. 28
10 Decommissioning and recommissioning ................................................................................................. 29
10.1 Decommissioning ................................................................................................................................. 29
10.2 Recommissioning ................................................................................................................................. 29
11 Dismantling and disposal ........................................................................................................................... 30
11.1 General information on dismantling ...................................................................................................... 30
11.2 Returns ................................................................................................................................................. 31
11.3 Disposal ................................................................................................................................................ 31
1 | Introduction Spectron Gas Control Systems GmbH
4 GES_BE55-1_0520
1 Introduction
This user manual is the original user manual for the Pressure control panel BE55-1 from Spec-
tron Gas Control Systems GmbH (Fritz-Klatte-Str. 8, D-65933 Frankfurt), referred to as Spec-
tron.
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.
Spectron Gas Control Systems GmbH Description | 2
GES_BE55-1_0520 5
2 Description
2.1 Intended use
The intended use of the Pressure control panel BE55-1 is the expansion of a gas from a gas
source and the distribution of the gas with adjustable outlet pressure.
Pressure control panels of type BE55-1 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.
Purge gas purging is recommended when using corrosive or toxic gases.
The permissible gas types and pressure ranges are each specified on the label (see "Identifica-
tion / label [}5]").
The pressure control panel is equipped with a process gas valve and an exhaust gas valve on
each side.
The equipment versions of the Pressure control panels without electrical components may be
used in an explosion hazard zone as they do not have separate ignition sources (ignition hazard
assessment according to DIN EN ISO 80079-36).
Pressure control panels with electrical components that are suitable for use in an explosion haz-
ard zone are marked on the label according to EU Directive 2014/34/EU.
To be able to use the Pressure control panels 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 Pressure
control panels. The danger zone changes depending on the system status and use.
2.2 Misuse
Any improper use constitutes misuse. Pressure control panels may only be used for the spe-
cified gases and in the specified pressure range. Pressure control panels with electrical com-
ponents without marking according to EU Directive 2014/34/EU may not be used in an explo-
sion 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 Pressure control panel.
The label provides the following details:
Details Example
Project number PROJECT
Article description BE55-1-200-10-M-M-…
Inlet pressure P1 200 bar
2 | Description Spectron Gas Control Systems GmbH
6 GES_BE55-1_0520
Outlet pressure P2 10 bar
Gas type GAS TYPE
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)
Spectron Gas Control Systems GmbH Description | 2
GES_BE55-1_0520 7
DGUV Regulation 1 German Trade Association Principles of Pre-
vention
DGUV Rule 113-001 German Trade Association Rules on Explosion
Protection
EIGA documents
3 | Safety Spectron Gas Control Systems GmbH
8 GES_BE55-1_0520
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.
Spectron Gas Control Systems GmbH Safety | 3
GES_BE55-1_0520 9
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.
3 | Safety Spectron Gas Control Systems GmbH
10 GES_BE55-1_0520
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.
Inhaltsverzeichnis
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