SENTRY Dampeners 300 PSI Metal and Plastic User Manual

SENTRY Dampeners 300 PSI Metal and Plastic User Manual

SENTRY™ dampeners are pressure vessels containing a flexible bladder or bellow inside that separates an inert pressurized gas (air or Nitrogen) from a system fluid in the lower chamber. Depending on how dampeners are configured, they are used as Pulsation Dampeners, Inlet Stabilizers, or Surge Suppressors to control pressure fluctuations and spikes in liquid piping systems. Dampeners work on the principle that volume is inversely proportional to pressure (P1V1=P2V2). Compressed air or Nitrogen (never Oxygen) is introduced into the non-wetted side of the dampener.

The gas charge is contained by the bladder or bellows preventing contact between the system fluid and the gas. When the dampener is sized correctly, properly installed, and charged according to the instructions provided it will greatly reduce the damaging effects of pressure variations in piping systems and significantly improve the efficiency of transferring liquids. All dampeners manufactured by BLACOH use pressure bodies made in the USA to ensure quality. Prior to shipment, each and every dampener is factory pressure tested to ensure proper function and leak-free operation.

SAFETY Warnings

General Safety 

• Observe all safety symbols in installation and operation instructions.
• The internal dampener pressure will equal the maximum fluid pressure of the system in which it is installed.
• DO NOT exceed the maximum allowable working pressure (MAWP) specified on the dampener serial tag or marked on the dampener. If missing, DO NOT use a dampener without consulting a distributor or factory for maximum pressure rating.
• Always make sure safety shutoff valves, regulators, pressure relief valves, gauges, etc. are working properly before starting the system or assembly.
• Verify the dampener model received against the purchase order and the shipper.
• Before starting a system or assembly make certain the discharge point of the piping system is clear and safe, and all persons have been warned to stand clear.
• DO NOT put your face or body near the dampener when the system or assembly is operating or the dampener is pressurized.

Equipment Misuse Hazard

Any misuse could result in serious bodily injury, death, fire, explosion, or property damage.

Over-Pressurization
Never exceed the maximum pressure rating for the dampener model being used. Maximum allowable working pressure (MAWP) is specified on the dampener serial tag or marked on the dampener. Maximum allowable working pressure (MAWP) is rated at 70°F (21°C).

Temperature Limits
DO NOT exceed the operating temperature limits for the body and/ or elastomer materials being used. Excessive temperature will result in dampener failure. For temperature limits, refer to the “Temperature Limits” section of this Manual. Temperature limits are stated at zero psi/bar. Installation and Startup Hazards Install the dampener before charging or pressurizing. DO NOT start the system or assembly without first charging or pressurizing the dampener. Failure to charge may result in damage to the bladder or bellows.

DO NOT operate a dampener that is leaking, damaged, corroded, or otherwise unable to contain internal fluid, air, or gas pressure. DO NOT pump incompatible fluids through the dampener. Consult a distributor or factory if you are not sure of the compatibility of system fluids with dampener materials.

• Dampeners are designed to operate with compressed air or clean dry Nitrogen only. Other compressed gases have not been tested and may be unsafe to use.
• Always shut off the air supply, remove the internal dampener pressure, and shut the dampener isolation valve before performing dampener maintenance or repair.
• Remove all pressure from the dampener AND pumping system before disassembly, removal, or maintenance.
• Static spark can cause an explosion resulting in severe injury or death. Ground dampeners and pumping systems when pumping flammable fluids or operating in flammable environments.

Installation Notes

Dampening of flow pulsations can only be effective if a minimum of 5 to 10 psi (0.4 to 0.7 bar) back pressure downstream of the dampener is available. A BLACOH back pressure valve may be required downstream of the dampener, except when the dampener is used as an inlet stabilizer for the inlet side of the pump. It is recommended that a BLACOH pressure relief valve be installed in all pump systems to ensure compliance with pressure limits on system equipment.

To avoid possible damage to bladder/bellows from a system pressure test: Adjustable and Chargeable models — charge dampener to 80% of the system test pressure prior to test. Automatic model — prior to test, dampener must be equipped with a constant source of compressed air with pressure equal to or greater than system test pressure. Inlet Stabilizer model — maximum pressure test 30 psi (2.0 bar), charge to 20 psi (1.3 bar) for system pressure test.

Install dampener inline as close to the pump discharge/inlet or quick closing valve as possible. Dampener installation should be no more than ten pipe diameters from the pump discharge/inlet or quick closing valve. It is recommended that an isolation valve be installed between the dampener and system piping.

Maintenance

Remove all pressure from the dampener AND pumping system before disassembly, removal, or maintenance. Dampeners require very little maintenance. There is no need for lubrication with bladders or bellows. Elastomeric bladder replacement should be part of a preventive maintenance program. Dampeners used in conjunction with diaphragm pumps should have the bladders replaced at least every second time the diaphragms in the pump are replaced.

As with any pumping system, wear is dependent on many factors including material, temperature, chemicals, fluid abrasiveness, and system design. This suggested maintenance program may need to be adjusted according to specific applications. Periodic inspection of the dampener and fasteners should be conducted to visually check for signs of over-pressurization, fatigue, stress, or corrosion. Body housings and fasteners must be replaced at the first indication of deterioration.

CAUTION!

Replace nut and bolt fasteners at each reassembly with fasteners of equal grade/strength value. DO NOT reuse old nuts and bolts.

After the initial torque of fasteners, bolts may lose strength when re-torqued. Failure to replace both nuts and bolts upon each vessel reassembly will void the product warranty given by the manufacturer and the manufacturer will have no liability whatsoever for any vessel failure or malfunction.

Where dampeners are used in corrosive environments, nut, and bolt fasteners should be regularly inspected and replaced with nut and bolt fasteners of equal grade/strength value if corrosion is observed. Failure to conduct such regular inspections and replacements will void the product warranty given by the manufacturer and the manufacturer will have no liability whatsoever for any vessel failure or malfunction.

IMPORTANT!
After maintenance or disassembly, use new fasteners and torque fasteners according to the specification on the dampener tag. If missing, consult the distributor or factory for specifications. DO NOT use a dampener if the fasteners (nuts and bolts) are corroded. Check for fastener corrosion frequently, especially in atmospheres containing salt or corrosive chemicals, or if dampener leakage has occurred.

Temperature Limits

Operating temperatures are based on the maximum temperature of the wetted dampener components only. Non-wetted dampener components may have a lower temperature limit. Temperature and certain chemicals may reduce the maximum allowable working pressure (MAWP) of the dampener. CAUTION! Plastic (non-metallic) body materials lose strength as temperature increases, which reduces the maximum pressure sustainable by the material. All plastic materials must have an appropriate derating factor applied when working at elevated temperatures above 73.4°F (23°C) to determine maximum allowable working pressure (MAWP).

Installation & Operation Instructions

• DO NOT use plastic models as Surge Suppressors at quick-closing valves. Use metal Surge Suppressors for water hammer or quick closing valve applications. Consult the factory for options.
• ATEX models must be grounded (earthed) before operation.
• Turn the pump off and remove all pressure from the system prior to dampener installation.
• Remove all pressure from the dampener AND pumping system before disassembly, removal, or maintenance.
• Use compressed air or clean dry Nitrogen to charge the dampener. DO NOT USE OXYGEN.
• DO NOT exceed the maximum allowable working pressure (MAWP) specified on the dampener serial tag. If missing, consult the distributor or factory for specifications.
• Always wear safety glasses and other appropriate safety equipment when installing, charging, or repairing dampeners.
• Read and observe all safety warnings and instructions in this Manual before installation, operation, or repair.
• IMPORTANT! After maintenance or disassembly, use new fasteners and torque fasteners according to the specification on dampener tag. If missing, consult the distributor or factory for specifications.
• Before performing a system pressure test, the dampener must be charged with 80% of the system test pressure to avoid possible damage to the bladder/bellows.

Pre-Charge Notes

The following pre-charge notes are for all plastic dampener models; and, metal dampener models with a maximum pressure rating up to 300 psi (20.6 bar). NOTE: Dampeners can be pre-charged with compressed air up to a maximum pressure of 150 psi (10.3 bar). If the maximum pressure exceeds 150 psi (10.3 bar), the dampener must be pre-charged with Nitrogen only. DO NOT USE OXYGEN.

Pre-charge pressure should be checked at least monthly as gas molecules will diffuse through bladders/bellows, the speed of which depends on the material, temperature, and pressure. Checks must occur when no system pressure is present or inaccurate readings will be recorded. If the temperature is above 72°F (22°C) and/or pressure is over 300 psi (20.6 bar), checks should be performed more frequently. To prevent pre-charge loss through the fill valve, always replace the fill valve cap after charging. A proper gas charge is the key to dampener effectiveness and bladder/bellows life.

Pre-Charge Instructions for V Model Air Controls The Chargeable V Model air control assembly has a machined stainless steel charging valve and seal for rugged leak-proof operation in corrosive environments. To pre-charge V Model dampeners, turn the Valve Opening Nut counterclockwise to open for charging. The valve on these dampeners has no valve core to prevent the air charge from escaping. Because there is no valve core, the pressure in the dampener will escape if the valve is not closed prior to removing the charging hose. To close the valve, turn the Valve Opening Nut clockwise.

Installation for Pump Discharge Pulsation

Installation Position
Install the dampener inline as close to the pump discharge as possible to absorb the pulse at its source and before any downstream equipment such as risers, valves, elbows, meters, or filters. Dampener installation should be no more than ten pipe diameters from the pump discharge. If using a flexible connector on the discharge side of the pump between the pump and system piping, the dampener should be installed at the pump discharge manifold.

The flexible connector should be attached to the dampener’s tee and system piping (see FIGURE 1). Since pressure is equal in all directions, the dampener can be installed in a vertical, horizontal, or upside-down position. A vertical installation is recommended for better drainage of the dampener. Limitations for horizontal and upside-down mounting include high specific gravity, high viscosity, settling of solid material, or possible air entrapment which could result in shortened bladder/bellows life and/or reduced dampening performance.

Charging and Startup (see Pre-Charge Notes)

Chargeable models do not require an airline connection. The dampener can be pre-charged with compressed air up to a maximum pressure of 150 psi (10.3 bar). If the maximum pressure will exceed 150 psi (10.3 bar), the dampener must be pre-charged with Nitrogen only. Use a hand pump, Nitrogen tank, or air compressor to charge the dampener. DO NOT USE OXYGEN. Charging kits are available from BLACOH. Prior to starting the pump, pre-charge the dampener to approximately 80% of the expected system pressure and replace the fill valve cap. DO NOT USE OXYGEN.

The pre-charge pressure in the dampener must always be lower than the pump discharge pressure. Generally, pulsation is most effectively minimized when the gas pre-charge is 80% of system pressure. Start the pump to generate system pressure. The dampener charge pressure may need to be adjusted up or down to be most effective in reducing pulsation. NOTE: The most effective method to set the proper dampener charge is to install a pressure gauge downstream of the dampener and adjust the dampener to minimize needle movement on the gauge.

Once system pressure is in contact with the bladder/bellows, the gas charge will be compressed to the system pressure and the dampener gauge will read the system pressure, not the initial charge pressure. Once working pressure is achieved adjustment may be necessary. Gradually increase or decrease the gas charge in the dampener by bleeding or filling through the gas valve. Allow the system to respond to each adjustment (this may take a minute or two) before making further adjustments.

Installation for Surge / Water Hammer

Installation Position
Install the dampener inline as close as possible to and before the device causing the water hammer pressure to spike (see FIGURE 2). For example, if a quick closing valve is causing a water hammer, install the dampener on a tee or elbow as close as possible upstream of the valve. Dampener installation should be no more than ten pipe diameters from the valve. It is advisable to install an isolation valve between the dampener inlet and the mounting tee so maintenance and pressure checks can be done while the system is operating.

Charging and Startup (see Pre-Charge Notes)
Chargeable models do not require an airline connection. The dampener can be precharged with compressed air up to a maximum pressure of 150 psi (10.3 bar). If the maximum pressure will exceed 150 psi (10.3 bar), the dampener must be precharged with Nitrogen only. Use a hand pump, Nitrogen tank, or air compressor to charge the dampener. DO NOT USE OXYGEN. Charging kits are available from BLACOH. The dampener must be pre-charged after installation but prior to system operation.

The only method to get an accurate pressure charge in the dampener is to charge it prior to system startup or with a closed isolation valve at the dampener inlet. Pre-charge the dampener with 90% to 95% of the expected system pressure. DO NOT USE OXYGEN. A fill valve similar to a Schrader-type tire valve but designed for suppressors is mounted to the top of the dampener. Replace the fill valve cap after charging the dampener and recheck the dampener charge every month.

Supporting Products

SENTRY™ Bladder Kits
Bladder/bellows kits contain all parts necessary for replacement, including hardware as needed (nuts, bolts, washers). PTFE bellows kits include replacement O-rings; Stainless Steel metal bellows kits include replacement gaskets.

SENTRY™ Charging Kits
For SENTRY™ chargeable air control models, charging kits include 8’ (2.4 m) length of hose with a 1/4” (6mm) NPT male fitting at one end for connection to a regulator at the Nitrogen source, and a charging fitting and gauge at the opposite end.

SENTINEL™ Diaphragm Seals & Gauge Guards

ISOLATE AND PROTECT SYSTEM PROCESS INSTRUMENTATION SENTINEL™ Diaphragm Seals, also referred to as Gauge Guards, employ a chemically resistant diaphragm to effectively isolate process fluids from gauges and other process instrumentation. This durable diaphragm allows SENTINEL™ to accurately transfer process pressure without direct contact with hazardous or corrosive fluids. SENTINEL™ Diaphragm Seals are easily installed, come in a variety of chemically resistant materials, and work in both pressure and vacuum conditions.

SENTINEL™ Back Pressure and Pressure Relief Valves

PROTECT PROCESS SYSTEMS FROM FLUCTUATING PRESSURE OR BLOCKAGE SENTINEL™ Back Pressure Valves enhance system performance by applying continuous back pressure to the pump, while also acting as an anti-siphon valve. Diaphragm back pressure valves apply positive discharge pressure to a metering pump system to improve the consistency of dosage rates by shielding the pump from fluctuating downstream pressure. The diaphragm is held against the valve seat by an internal spring. When the preset pressure is exceeded, the diaphragm is forced up and system fluid flows through the valve to the injection point.

SENTINEL™ Pressure Relief Valves protect pumping systems from over-pressure damage caused by defective equipment or blockage in the pump system line. Diaphragm pressure relief valves operate when the pressure in the pumping system exceeds the preset pressure of the valve. The diaphragm is held against the valve seat by an internal spring. When the preset pressure is exceeded, the diaphragm is forced up and the system fluid flows out of the relief port, back to the system fluid tank or suction side of the pump.

SENTINEL™ Hybrid Combination Dampener & Back Pressure Valve

THE ALL-IN-ONE SMART CHOICE The patented Hybrid Valve™ combines the steady flow control of a pulsation dampener and the regulation of a back pressure valve to deliver the performance and functionality of both. A back pressure valve installed in series with a dampener can negate the dampening effect if the valve is opening and closing before the dampener is able to capture a full pulse. This quick-opening effect can also create too much gain within the back pressure valve resulting in inefficiency and chatter. By combining the dampener and back pressure valve into a single engineered unit, we’ve eliminated the most common issues with installation for a more efficient, simplified system.

SENTRY™ Series Pulsation Dampeners

PULSATION DAMPENERS, SURGE SUPPRESSORS & INLET STABILIZERS Positive displacement pumps create destructive pulsation and hydraulic shock due to the reciprocating nature of their stroking action, potentially damaging piping and system components. SENTRY™ Pulsation Dampeners and Surge Suppressors remove virtually all system shock, enhancing the performance and reliability of fluid flow in municipal, industrial, sanitary, and chemical transfer applications.

SENTRY™ Inlet Stabilizers minimize pressure fluctuations and acceleration head losses by preventing fluid column separation at the pump’s inlet. This improved flow to the pump’s inlet effectively extends the service life of all inlet system components.

REFERENCE LINK

https://shop.andersonprocess.com/blacoh-ct3120t-dampener.html