Maintenance - Walker 20HP25 Gebrauchs- Und Wartungshandbuch

GB
Stainless Steel High Pressure Filters, 50, 100 & 350
barg (725, 1450 & 5000 psig)
Alloy High Pressure Filters 20 barg (300 psig) 50
barg (725 psig)
Application:-
Walker Filtration design and manufacture a comprehensive range of high pressure
compressed air filters intended for the removal and separation of air borne
contaminants such as oil, water and dirt particles.
The Stainless Steel Filter Range offers 21 models with varying flow rate capacities,
with a maximum working pressure of 350 barg (5000 psig) at a maximum
temperature of 120°C (248°F).
The Alloy High Pressure Filters are manufactured using machined or die-cast
aluminium components. There are a total of 13 models in the 20 barg (300 psig)
range from 1/4" to 3" pipe connections with flow rates up to 4383 Nm3/h (2580
scfm). There are a total of 9 models in the 50 barg (725 psig) range from 1/4" to
2" pipe connections with flow rates up to 3200 Nm3/h (1882 scfm). They have
a recommended maximum temperature of 120°C (248°F).
WARNING: All filter housings operate at high pressures.
Extreme care should be taken. Do not operate filters above
maximum working pressure (mwp) at maximum operating
temperature.
Filter Housing Installation Guidelines:-
High pressure filters should be installed downstream of aftercoolers, receivers, at
the point of lowest operating temperature and as close to the point of application
as possible. Existing or new pipelines should be purged to remove any collected
debris. Filters are best utilised in mainlines and terminal points, avoid by-pass
lines where leaks often occur.
Putting into service:-
1. Select position for filter. It is vital to depressurise new or existing pipework
before installation.
2. Install filter into pipeline observing vertical orientation and direction of flow
arrow marked on the filter housing. On threaded models, PTFE tape or
sealing compound should be used on pipe threads to ensure a good seal.
Max. working pressure and replacement elements are marked on the filter.
3. To allow simple element replacement, ensure adequate space for removal of
filter bowl. See minimum required distance, dimension D on page 10 and 11.
4. All models of High Pressure Filters are supplied with a drain plug. High
pressure drains valves are available. Only drain valves rated to maximum
working pressure should be used. Contact manufacturer for further
information. Note: Standard condensate float drains must not be
used on High Pressure applications.
5. During initial pressurisation of the system, inlet valves should be opened
slowly to reduce inlet velocities until system pressures are stabilised. Check
for leaks before putting filters into operation.
Note: The recommended maximum working pressure for the
Stainless Steel range of high pressure filters is 350 barg (5000 psig).
The recommended maximum working pressure for models 20HP25
to 20HP302 is 20 barg (300 psig).
The recommended maximum working pressure for models 50HP25
to 50HP201 is 50 barg (725 psig).
6. Alloy High Pressure Housings (Models 20HP25 to 20HP302 and
50HP25-50HP201) should not be bolted together. Connecting any one
or more of the above housings in series should be carried out using a nipple
or coupling with the correct thread form for the housing and should be
suitably rated for the operating temperature and operating pressure.

Maintenance

1. General maintenance and routine checks should be carried out to ensure
correct operation and to maintain long-term system reliability.
Filter Element Replacement
Coalescing filter elements should be changed every 12 months. Always complete
the element replacement label and attach to filter.
Grade AC, activated carbon elements will purify compressed air by removing oil
vapour and odours and must be changed to suit specific applications, or at least
every 6 months.
3
WARNING: AC elements do not remove carbon dioxide
(CO2), carbon monoxide (CO) or other toxic gases and
fumes.
Filter Element Installation Guidelines:-
1. Shut off all compressed air supplies to filter housing.
2. Close inlet valve (s), open all outlet valves and ensure system is fully
depressurised before dismantling the filter housing.
3. After all pressure is removed from the filter, grasp the filter bowl firmly. Turn
bowl anti-clockwise to unscrew from the filter head. Strap wrenches can be
used on the bowls if necessary.
4. With the Alloy 20 & 50 barg range of high pressure housings and models
C25 (grade) - C50 (grade) in the Stainless Steel range, remove used element
by pulling downwards and dispose of element properly taking necessary
health and safety precautions.
5. For the remaining models featured in the Stainless Steel range C75 (grade) -
C201(grade) and 100HP24 (grade) -350HP101(grade) tie rods are
incorporated therefore the element must be unscrewed first.
6. Check housing O-ring in filter head. Replace if worn or damaged. Ensure
that O-ring seat is clean.
7. Fit new element with O-rings supplied, check that the O-ring is correctly
positioned in end cap and lightly greased.
8. Clean and lubricate threads on filter bowl with light silicone-free grease. This
allows the bowl to be removed easily during next service.
9. With the Alloy 20 & 50 barg range and models C25 (grade) - C50 (grade) in
the stainless steel range, place filter bowl over element, screw into head and
tighten. Do not over tighten. With tie rod elements tighten nuts where fitted
firmly or screw filter directly onto the rod.
10. Close outlet valves.
11. Close valve on drain valve equipment (if in use).
12. Slowly open inlet valve (s) and re-pressurise system.
depressurise system following earlier instructions and inspect filter housings
and internal O-ring seals. Re-fit the O-ring checking that the seal is clean.
Re-pressurise the system.
ALL FILTER HOUSINGS OPERATE AT HIGH PRESSURES.
EXTREME CARE SHOULD BE TAKEN
ONLY A COMPETENT PERSON SHOULD ATTEMPT TO FIT
FILTER HOUSINGS AND CHANGE FILTER ELEMENTS
SERIOUS PERSONAL INJURY CAN RESULT IF THESE INSTRUCTIONS
ARE NOT FOLLOWED
DO NOT REMOVE REPAIR OR REPLACE ANY ITEM ON VESSEL
WHILST IT IS UNDER PRESSURE
DO NOT OPERATE IF THERE IS ANY EXISTING LEAKS TO VESSEL.
IMMEDIATELY TAKE VESSEL OUT OF SERVICE. CHECK ALL
POTENTIAL LEAK AREAS AND RE-SEAL PRIOR TO RE-INSTALLATION
IT IS RECOMMENDED THAT THE OPERATOR CONTACT THE
MANUFACTURER BEFORE INSTALLING ANY ANCILLARY EQUIPMENT
ON TO THE HIGH PRESSURE FILTERS
DO NOT OPERATE ABOVE MAXIMUM WORKING PRESSURE (M.W.P .)
AT MAXIMUM OPERATING TEMPERATURE.
The ultimate filtration & drying technology
If leaks occur,
WARNING!