Installation, Operation, and

Maintenance Manual
 

Welker® Steam and Vacuum System

Model
CSVC

Drawing No.: AD881CO, AD881CO-SCHM

Manual No.: IOM-128
 

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 above. Correct operating and/or
installation techniques, however, are the responsibility of the end user. Welker® reserves the right to make changes
to this and all products in order to improve performance and reliability.
 

 
This manual is intended to be used as a basic installation and operations guide for the Welker®
  CSVC Steam and Vacuum  System. For comprehensive instructions, please refer to the IOM
Manuals for each individual component. A list of relevant component IOM Manuals is given in
the Appendix section of this manual.

13839 West Bellfort 
Sugar Land, TX 77498‐1671  
(281) 491‐2331 ‐ Office 
(800) 776‐7267 ‐ USA Only 
(281) 491‐8344 ‐ Fax 
http://www.welkereng.com 
©2011 Welker, Inc. All Rights Reserved. 
 TABLE OF CONTENTS
 

1. SPECIFICATIONS 3
1.1 INTRODUCTION 3
1.2 DESCRIPTION OF PRODUCT 3
1.3 IMPORTANT INFORMATION 3
1.4 SPECIFICATIONS 4
1.5 SAFETY ISSUE WARNING 4
1.6 SYSTEM DIAGRAMS 5
1.7 DEFINITIONS 5

2. INSTALLATION & OPERATIONS 6

2.1 BEFORE YOU BEGIN 6
2.2 INSTALLATION 6
2.3 OPERATIONS: STEAM GENERATOR 6
2.4 OPERATIONS: STEAM SYSTEM 7
2.5 OPERATIONS: VACUUM SYSTEM 8

3. MAINTENANCE 10
3.1 BEFORE YOU BEGIN 10
3.2 MAINTENANCE 10

APPENDIX 11
REFERENCED OR ATTACHED WELKER® IOMS 11
REFERENCED OR ATTACHED BUY-OUT IOMS 11
REFERENCED OR ATTACHED DRAWINGS 11

Welker®, Welker Jet®, and WelkerScope® are Registered Trademarks owned by Welker, Inc. 
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 SECTION 1:
SPECIFICATIONS
 

1.1 INTRODUCTION
We appreciate your business and your choice of Welker® products. The installation, operation, and
maintenance liability for this product becomes that of the purchaser at the time of receipt. Reading
the applicable Installation, Operation, and Maintenance (IOM) Manual 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 1-800-776-7267 (USA) or 1-281-491-2331.

Notes, Cautions, and Warnings

Notes emphasize information or set it off from the surrounding text.

Caution messages appear before procedures that, if not observed, could result
in damage to equipment.

Warnings are alerts to a specific procedure or practice that, if not followed

correctly, could cause personal injury.

*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 DESCRIPTION OF PRODUCT

The Welker® CSVC steam and vacuum system is an effective cleaning method that utilizes latent
heat from saturated and super-heated steam to clean stainless steel 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. Dry-steam vapor improves the quality of the steam
generated. This system does not require any chemicals, saves on water usage as well, and facilitates
the cleaning of multiple cylinders at one time. In short, the CSVC is an efficient, environmentally-
friendly method for removing contaminants inside cylinder.

1.3 IMPORTANT INFORMATION

1. Cylinders must be completely emptied and drained before connecting to the CSVC steam and
vacuum system.
2. A damaged steam hose may result in serious personal injury and/or property damage.
3. Never transport a cylinder with pressure exceeding D.O.T. regulations as established in U.S.
Government CFR49. In cases where the cylinder may be exposed to varying temperatures, do not
allow the cylinder to exceed the maximum allowable operating pressure (MAOP) indicated.
4. Protect the cylinder and quick connects during transport, and handle with care at all times.
5. When 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.
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1.4 SPECIFICATIONS
The specifications listed in this section are generalized for this equipment. Welker® can
modify the equipment according to your company’s needs. However, please note that the
specifications may vary depending on the customization of your product.

Table 1: Overall System Specifications

Water Supply Connection ½” FNPT

Water Supply Pressure: 90 PSI Max.

Steam Temperature: 212° - 331°F (see Table 2: Steam Table)

Power Connection: Heater, 240 VAC Thermostat Control, 120 VAC

Steam Header Relief: 1/2” FNPT, 10 psi less than INLET pressure

Header Relief ½” FNPT, 10 psi less than SHR

Drain: ½” FNPT

Table 2: Steam Table

Gauge Pressure (psig) 0 1 2 3 4 5 6 7 8 9 10 15 20 25
Temperature (oF) 212 216 219 222 224 227 230 232 235 237 240 250 259 267

Gauge Pressure (psig) 30 35 40 45 50 55 60 65 70 75 80 85 90

Temperature (oF) 274 281 287 292 298 303 307 312 316 320 324 328 331

Table 3: Optional Equipment – Blow‐down separator 
The blow-down separator reduces temperatures and pressures to acceptable safe levels for
subsequent discharge to drain or sewer. The separator also separates liquid from vapor
during blow-down to prevent live steam discharge to city drains. This unit requires a cold
water connection and must maintain proper height level to ensure safe drainage during
blow-down. A typical steam system hook-up with blow-down separator is shown in Figure
5. Welker® recommends that the inlet to the blow-down separator be lower than the sight
glass of steam generator.

1.5 SAFETY ISSUE WARNING

Warning: superheated 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. Wear appropriate
Personal Protective Equipment (PPE) when operating the steam system.

Exposure to steam is hazardous. If not properly controlled, steam may cause property
damage or serious bodily injury.

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1.6 SYSTEM DIAGRAMS 
Figure 1: Steam System

Table 4: System Components

Steam Header (Valve A, Figure 3)
Collection Header (Valves B-D, Figure 4)
Steam Separator (Valves E & F, Figure 5)
Three-way Selector Ball Valve (Figure 6)
Vacuum Manifold (Valves H-J, Figure 7)

Figure 2: General Steam System Arrangement

(Typical steam system hook-up with blow-down separator)

REFER TO DRAWINGS AD881BO-A, AD881BO-SCHM, AND FIGURES 1 & 2 THROUGHOUT THIS MANUAL.
1.7 DEFINITIONS
“Wet Cycle” refers to saturated steam generation by the steam generator. Saturated steam
temperature is determined at the steam generator’s exit point and by the water inlet pressure (See
Table 2). This cycle ensures that all sample cylinders reach the saturated steam temperature to
dissolve and flush all contaminants. The time required to clean the sample cylinders completely is
dependent upon the set temperature of the steam generator, the water inlet pressure, the type of
contaminant(s), and the number of cylinders.
“Dry Cycle” refers to the cycle activated when saturated steam is diverted to the steam separator.
The steam separator’s filter removes up to 99.8% of moisture. A steam trap is placed downstream of
sample cylinders to discharge condensate without allowing the escape of live steam. With the steam
trap and the continued input of heat, the saturated steam will be elevated to dry hot steam, which
removes almost 100% of moisture. The purpose of the dry hot steam at this stage is not to clean but
to dry sample cylinders. The dry hot steam is near superheated steam temperature levels.
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 SECTION 2:
INSTALLATION & OPERATIONS
 
2.1 BEFORE YOU BEGIN
After unpacking the unit, check the equipment for compliance and for any damage that
may have occurred during shipment. Claims for damage caused during shipping must
be initiated by the receiver and directed to the shipping carrier. Welker® is not
responsible for any damage caused by mishandling by the shipping company.
When sealing fittings with PTFE tape, refer to the proper sealing instructions for the tape
used.

Recommended Tools
It is advisable to have the following tools available for installation and operation of this unit. Tools
needed may vary depending on the product model.
 Flexible hose or tubing
 10” adjustable wrench
 Tubing cutters
 Small diameter stainless steel tubing
 Appropriate Personal Protective Equipment (PPE) during operation.

2.2 INSTALLATION
1. Connect ½” NPT steam hose from steam generator to ball valve F (Figure 5) on the steam
separator.
2. Close valves, D, E, and F (Figures 4 & 5) when not in use.
3. Set relief valves for steam header and collection header to appropriate pressure. Relief pressure
for steam header must be higher than relief pressure for collection header to ensure proper
function of steam traps.
4. Connect ½” NPT relief valves and pipe relief steam to an approved area.

2.3 OPERATIONS: STEAM GENERATOR

All Chromalox® manufacturer’s instructions, including appropriate PPE and safety
instructions, should be followed when operating the Chromalox® steam generator to
ensure safe operation (Refer to Chromalox® IOM).
1. Connect water supply to steam generator’s inlet. Incoming water supply must be 10 psi greater
than the operating pressure.
2. Close drain valve and steam outlet valve of steam generator and turn on water supply valve.
Water level should be approximately half way up the sight glass before operating steam
generator. This may take several minutes.
3. Connect 240 VAC and 120 VAC to Chromalox® steam generator per manufacturer’s instruction.
4. The steam generator does not have an on/off switch. Turn thermostat to desired steam
temperature to start steam generator.
5. When desired temperature or pressure is reached, open outlet steam valve. It may take
approximately 30 minutes for steam to reach normal operating temperature.

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2.4 OPERATIONS: STEAM SYSTEM (FIGURES 3-6)
Exposure to steam is hazardous. If not properly controlled, steam may cause property
damage or serious bodily injury.
Failure to properly follow the manufacturer’s recommended procedures for the care,
maintenance, and storage of steam hose may result in property damage or serious bodily
injury.
Only specially trained persons should engage in operating or testing procedures that
require particular skills and/or training. Failure to comply may result in damage to the
hose products, other property damage, and/or serious bodily injury.
1. Allow steam generator at least 30 minutes to warm up and generate enough steam to reach
normal operating temperature.
2. Quick connect both ends of the stainless steel sample cylinder to the steam system. The needle
valves on both ends of the stainless steel cylinder must be open.
3. Open valve(s) A (Figure 3) and valve(s) C (Figure 4) and close valve(s) B (Figure 4) for each
connected sample cylinder.
Figure 3: Steam Header

Figure 4: Collection Header

4. Start “Wet-Cycle” steam system by opening ball valve of steam generator’s steam outlet and
valve F (Figure 5).
5. Turn 3-way selector valve E (Figure 5) pointed handle away from steam separator to “pre-soak”
stainless steel cylinders and flush out contaminants with saturated steam.

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 Figure 5: Steam Separator Figure 6: Three-way Selector Ball Valve

6. Slowly open drain valve D (Figure 4) to allow saturated steam to flow out of steam system.
7. Saturated contaminants will drain out to an approved container; connection must be made by end
users.
8. When stainless steel cylinders are free of visible contaminants or determined clean by end users,
turn 3-way selector valve pointed handle toward steam separator to clean cylinders with dry-
steam. Depending on the temperature, the types of contaminants and the number of cylinders to
be cleaned at one time, the time for saturated steam to pass through cylinder(s) must be
determined by end users.
9. Start “Dry-Cycle” steam system to trap steam by first opening valve(s) B, then closing valve(s)
C (Figure 4). The introduction of steam trap(s) raises the temperature even higher than the
“Wet-Cycle” by thermostatically blocking dry hot steam from passing the steam trap(s).
10. When stainless steel cylinders are clean, the “Dry-Cycle” is complete. Depending on the
temperature, the number of cylinders, and the types of contaminants, the time for dry steam to
pass through cylinder(s) must be determined by end users.
11. Open valve(s) C (Figure 4) and close valve(s) B (Figure 4) to allow cylinder(s) to drain. Time
required to drain completely must be determined by end users.
12. Turn off steam generator’s thermostat and steam outlet valve.
13. Close both needle valves of stainless steel sample cylinder and disconnect.
14. Shut down steam system by closing valve(s) A (Figure 3) and valve(s) E & F (Figure 5).
15. Daily blow-down of steam generator is recommended. Power must be off when steam generator
is drained in accordance with Chromalox® steam generator instruction manual (Refer to
Chromalox® IOM).

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2.5 OPERATIONS: VACUUM SYSTEM (FIGURE 7)
A vacuum may be created on up to two cylinders at a time.

1. Begin with valves G, H, and J closed.

2. Connect polyethylene vacuum line tube fitting to valve G.
3. Quick connect top of stainless steel cylinder to vacuum manifold.
4. Open stainless steel cylinder(s) top needle valve(s).
5. Close stainless steel cylinder(s) bottom needle valve(s).
6. Open needle valves H and J.
7. Turn on vacuum pump.
8. Open valve G to pull vacuum on stainless steel cylinder(s).
9. When ready, close stainless steel cylinder(s) top needle valve(s) to maintain vacuum.
10. Close valves G and H.
11. Turn off vacuum pump.
12. Uncouple quick connect of stainless steel cylinder from vacuum manifold.

Figure 7: Vacuum Manifold

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 SECTION 3:
MAINTENANCE
 
3.1 BEFORE YOU BEGIN
1. Welker® recommends that the unit have annual 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 on hand for
repairs of the system in case of unexpected wear or faulty seals.
3. All maintenance and cleaning of the unit should be done on a smooth, clean surface.

3.2 MAINTENANCE
For all maintenance instructions, refer to the maintenance section of the Chromalox® IOM.

Proper steam separator and steam trap maintenance is essential to a steam system. Faulty
steam traps not only waste energy, but 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.

Steam separator and steam traps should be inspected routinely. The frequency of
inspection is often determined by application.

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 APPENDIX

ATTACHED DOCUMENTS:
Welker® Installation, Operation, and Maintenance Manuals suggested for use with this unit:

 IOM-105: Small Welker® Valve NV-1

Other Installation, Operation, and Maintenance Manuals suggested for use with this unit:

 CMB-9, PQ400-9: Chromalox® Steam Generator

 LV21, LV21S: TLV® Steam Traps
 DC7: TLV® Steam Separator
 McMaster-Carr® Hi-temp Check Valve

Welker® drawings and schematics suggested for use with this unit:

 CSVC Assembly Drawing: AD881CO

 CSVC System Schematics: AD881CO-SCHM

13839 West Bellfort

Sugar Land, TX 77498-1671
Phone: (281) 491-2331
Fax: (281) 491-8344
Toll Free: (800) 776-7267
Web Page: www.welkereng.com

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