Mankenberg AS 2 Installation instructions
Original operating manual
Separator
Originalbetriebsanleitung
Abscheider
AS
AS-4.X.222 Issue 19.07.2022 www.mankenberg.com
2
AS-4.X.222 Issue 19.07.2022 www.mankenberg.com
Table of contents EN
1 Introduction................................................................................................................................................. 4
2 Intended use ............................................................................................................................................... 4
3 Marking of the fitting .................................................................................................................................. 5
4 Safety instructions ..................................................................................................................................... 5
4.1 General precaution .............................................................................................................................. 5
4.2 Special safety instructions for the plant operator................................................................................. 5
4.3 Special hazards ................................................................................................................................... 6
5 Transport and storage ............................................................................................................................... 6
6 Installation................................................................................................................................................... 7
6.1 General notes ...................................................................................................................................... 7
6.2 Installation preparations....................................................................................................................... 7
6.3 Installation steps .................................................................................................................................. 8
7 Pressure testing the pipeline section....................................................................................................... 9
8 Initial start-up.............................................................................................................................................. 10
9 Normal operation........................................................................................................................................ 10
10 Maintenance................................................................................................................................................ 11
11 Troubleshooting help................................................................................................................................. 12
12 Information on REACH and RoHS ............................................................................................................ 14
12.1 Declaration on the REACH Regulation 1907/2006.............................................................................. 14
12.2 Declaration on the RoHS Directive 2011/65/EU .................................................................................. 14
13 Further information .................................................................................................................................... 14
Inhaltsverzeichnis DE
1 Einleitung .................................................................................................................................................... 15
2 Bestimmungsgemäße Verwendung.......................................................................................................... 15
3 Kennzeichnung der Armatur ..................................................................................................................... 16
4 Sicherheitshinweise ................................................................................................................................... 16
4.1 Allgemeiner Sicherheitshinweis ........................................................................................................... 16
4.2 Spezielle Sicherheitshinweise für den Betreiber.................................................................................. 16
4.3 Besondere Gefahren ........................................................................................................................... 17
5 Transport und Lagerung............................................................................................................................ 17
6 Einbau.......................................................................................................................................................... 18
6.1 Allgemeines ......................................................................................................................................... 18
6.2 Vorbereitung zum Einbau .................................................................................................................... 19
6.3 Schritte beim Einbau............................................................................................................................ 19
7 Druckprüfung des Rohrleitungsabschnitts ............................................................................................. 20
8 Erste Inbetriebnahme................................................................................................................................. 21
9 Normalbetrieb ............................................................................................................................................. 21
10 Wartung ....................................................................................................................................................... 22
11 Hilfe bei Störungen..................................................................................................................................... 23
12 REACH- und RoHS-Auskunft .................................................................................................................... 25
12.1 Erklärung zur REACH-Verordnung 1907/2006.................................................................................... 25
12.2 Erklärung zur RoHS-Richtlinie 2011/65/EU ......................................................................................... 25
13 Weitere Informationen................................................................................................................................ 25
3
AS-4.X.222 Issue 19.07.2022 www.mankenberg.com
Original operating manual
Separator AS
4
AS-4.X.222 Issue 19.07.2022 www.mankenberg.com
1 Introduction
This manual is intended to assist users of a MANKENBERG separator during installation, operation and
maintenance. Read the manual thoroughly before installing or putting this valve into service.
caution
Failure to follow the following instructions – particularly the cautionary and warning
notes – may lead to hazards and may invalidate the manufacturer's warranty.
MANKENBERG is at your servíce for any assistance and queries.
See section Further information [}14] for the addresses.
Technical information is also available at www.mankenberg.de
2 Intended use
A MANKENBERG separator AS is intended to automatically separate liquids (condensate, also with small
amounts of solids) from gas or steam leading pipelines.
This is an automatic function (no need of any additional electrical/pneumatic energy), achieved by using the
cyclone principle: The separated liquid is collected in the body bottom section.
Depending on the liquid level, a float controls the drainage of the condensate from the body of the separator.
MANKENBERG planning documents are available to give users precise assistance in selecting and designing
the appropriate fitting, e.g.:
In the section
<KA: Level control valves>:
<Type sheet AS 2>
with technical data and tables of the separation capacity and the dimensions.
MANKENBERG valves are supplied as standard for screw-mounted or flange-mounted pipeline/tank
connections – also for special connections if required.
The upper limit of the permitted operating data for pressure and temperature is permanently marked on each
fitting supplied.
Original operating manual
Separator AS
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AS-4.X.222 Issue 19.07.2022 www.mankenberg.com
3 Marking of the fitting
Each fitting bears the following markings as a minimum:
For Marking Remark
Manufacturer MANKENBERG See section Further information [}14] for the address
Fitting design Separator + type Design name as per accompanying MANKENBERG data sheet
Nominal
diameter
e.g. DN or G and
numerical value
Numerical value for DN in [mm], for G in [inches]
Nominal
pressure
PN or Class and
numerical value
Numerical value for PN in [bar], for Class in [lbs/square inch]
pressure data are displayed as overpressure above the
atmospheric pressure
Max. permitted
temp.
Temperature and
numerical value
Temperatures above 50 °C entail a reduced pressure
resistance. This must be considered for the corresponding
material in accordance with the DIN EN 1092 standard
Body material e.g. CrNiMo steel CrNiMo steel = high-alloy austenitic steel
Flow direction indicated by an arrow
The markings (in the case of fittings made of deep-drawn stainless steel, they are etched into the body) should
neither be covered nor painted over, so that the fitting remains identifiable.
4 Safety instructions
4.1 General precaution
The same safety regulations apply to a fitting as to the system into which it is installed. These instructions only
give those safety recommendations that have to be additionally observed for the fitting.
4.2 Special safety instructions for the plant operator
The following requirements for the intended use of a fitting are not the responsibility of the manufacturer but
have to be guaranteed by the user.
» The fitting may only be employed for the purpose described in section Intended use [}4].
» Only competent specialist personnel may install, operate and service the fitting. Competent as defined in
these instructions refers to persons who, because of their training, specialist knowledge and professional
experience, are capable of correctly assessing and properly executing the work with which they are
entrusted and of recognizing and rectifying hazards.
» The pipeline system must be properly designed and installed so that the fitting can be mounted and
operated without any tension.
» The fitting must be properly installed in the correct mounting position (condensate outlet at the bottom).
» The separator is only applicable for gases / steam with a solid content clearly lower than the liquid content.
This fitting is not a dust separator.
» The drainage of the condensate from the separator must be provided by the customer.
» The usual flow rates should not be exceeded in the pipeline section during continuous operation, and
abnormal operating conditions such as vibrations, unusually high flow rates, etc. should be avoided or – if
unavoidable – clarified with the manufacturer in advance.
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Separator AS
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AS-4.X.222 Issue 19.07.2022 www.mankenberg.com
» The prevailing operating conditions must comply with the limits of the design data stated in the
MANKENBERG order confirmation.
» The corrosion protection for the fitting must be adapted to the local environmental conditions.
» The fitting must not be coated with thermal insulation.
Detailed notes are provided on some of these prerequisites in the following sections.
4.3 Special hazards
danger of
fatalities
Before a fitting is removed from the system or before a fitting is dismantled but partially
remains in place, the pressure in the system on both the inlet and outlet side must be
completely reduced so that there is no uncontrolled flow of the medium out of the system.
In the case of toxic or hazardous media, the system must be completely drained before the
fitting is removed. Caution is required with residues that might continue flowing.
caution
If a fitting is removed from a system with a toxic medium and is taken out of the plant:
it must be properly decontaminated before repair.
5 Transport and storage
A fitting must be handled, transported and stored with care:
» The fitting must be transported and stored in its protective packaging until it is installed.
note
The fitting has moving internal parts.
Even packaged fittings should be transported smoothly without any shocks.
caution
In the case of a fitting that can no longer be transported by hand, the lifting gear must be
attached to a suitable position on the housing (branches).
Under no circumstances may the lifting gear be affixed to any other point.
» When the fitting is stored prior to installation, it should be kept in closed rooms and protected against
harmful influences such as dirt, moisture and frost.
» In special cases, the fitting is supplied free of oil, grease or silicone and is marked accordingly. A fitting such
as this must not come into contact with oil/grease/silicone during storage and handling (particularly when
subsequently unpacked).
» A MANKENBERG fitting generally has functional and/or sealing parts made of elastomer materials. These
cannot be stored for an unlimited period.
note
ISO 2230 describes the storage conditions for elastomers in detail and specifies the
permissible storage period.
Functional and sealing parts must be replaced well before the storage period expires.
They are available from MANKENBERG as a “service set”. See also section Troubleshooting
help [}12].
Original operating manual
Separator AS
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AS-4.X.222 Issue 19.07.2022 www.mankenberg.com
note
MANKENBERG fittings of small and medium nominal diameters are largely made of stainless
steel (high-alloy CrNiMo steel).
If, under exceptional circumstances, fittings are stored in a unpacked state, they must be
protected against ferritic dust to avoid corrosion.
note
The fitting - especially with higher nominal diameter - is generally not capable of standing
alone:
Handle with care so that the fitting does not tip over during transport/storage..
6 Installation
6.1 General notes
The same installation regulations apply to a fitting as to the system into which it is installed. The following
additional notes apply:
» section Transport and storage [}6] should also be observed during transport to the installation site.
» The installation site to allow perfect functioning of a fitting should be a section of pipe without any flow
disruptions, without any angles and without any restrictors or shut-off devices close to the fitting, either
upstream or downstream (optimum distance = 10 x DN). If this does not apply, the installation situation
should be checked with the plant operator and/or MANKENBERG.
» The statics of the pipeline must be designed so as to take account of the weight of the fitting – particularly
those with an eccentric mass. If required, the pipeline may have to be properly supported on both sides next
to the fitting (or at the fitting itself) – particularly in the case of fittings with a substantial mass and especially
if vibrations are to be expected in the system.
» When the fitting is supported, it is important to check that all functioning parts (levers, floats) remain capable
of moving freely and are not blocked.
» The fitting must not be coated with thermal insulation.
caution
A fitting that is operated at a medium temperature above 130°C needs undisrupted removal of
heat if it is to function perfectly.
Failure to observe this instruction may cause damage to the fitting and hence in the
pipeline system as well.
6.2 Installation preparations
» It is necessary to ensure that a fitting is not installed unless its matches the operating conditions in terms of
function, pressure and temperature, range, body material as well as connection type and dimensions.
danger of
fatalities
No fitting may be operated that does not have a sufficient pressure and temperature range for
the operating conditions – see section Intended use [}4] and markings on the fitting.
The manufacturer MANKENBERG should be consulted in the case of any applications outside
of this range.
Failure to observe this regulation may mean danger to life and limb and may cause
damage to the pipeline system.
Original operating manual
Separator AS
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AS-4.X.222 Issue 19.07.2022 www.mankenberg.com
» Newly installed tanks and pipeline sections must be thoroughly rinsed and cleaned before commissioning.
» The corrosion protection for the fitting must be adapted to the local conditions:
important
note
As a general rule, the separator must be installed so that the cylindrical body lies vertical
(condensate outlet at the bottom). See also the picture in the MANKENBERG data sheet.
Failure to observe this instruction may cause malfunction of the fitting.
6.3 Installation steps
» Fittings should only be finally unpacked at the installation site and inspected for damage prior to assembly.
Damaged fittings must not be installed.
» It is necessary to ensure that the covers have been removed from all the connection branches before
installation.
» The fitting should be inspected to ensure that it is clean. Interior parts must be free of liquid (e.g.
condensate): if necessary, connecting branches should be cleaned before installation with clean
compressed air.
» The type and dimensions of the line or tank connections must match the fitting to be installed and be flush
with the connecting surfaces of the fitting as well as in a parallel plane to the fitting itself.
» The drainage of the condensate from the lower body branch must be provided by the customer.
» If the fitting is marked with an arrow on the housing, the flow in the pipe section must match the marked
direction of flow.
caution
If installed in the opposite direction to the arrow, the fitting will not perform its intended
function.
» The fitting mist be installed without any tension. In the case of an already installed system, the geometry of
the pipeline must match the face-to-face length of the fitting.
note
It is necessary to ensure that even under operating conditions no tension from the pipeline
is transferred to the fitting.
note
A MANKENBERG fitting made of "high grade" or "high grade pure" stainless steel (austenite,
e.g. 1.4404 or 1.4435) does not need any surface protection for normal environmental
atmosphere and for normal weather conditions.
External parts of the fitting made of low-alloy or non-alloy materials that are supplied ex-works
with a primer have to be provided with a suitable coating by the customer.
Caution:
Never paint over the marking(s) of the fitting (either etched into the body or on nameplate).
Original operating manual
Separator AS
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AS-4.X.222 Issue 19.07.2022 www.mankenberg.com
In addition, the following applies to the pipeline connection:
With flanges:
note
The sealing surfaces on the body of the fitting are formed in accordance with the
MANKENBERG order confirmation. The accompanying flange seals are generally not
included in the MANKENBERG supply schedule.
» During installation, centre the fitting by means of the flange screws on the mating flange before the screws
are tightened.
With screw-mountings:
note
The connecting surfaces on the body of the fitting are formed in accordance with the
MANKENBERG order confirmation. The required seals are generally not included in the
MANKENBERG supply schedule.
7 Pressure testing the pipeline section
The fitting has already been pressure-tested by the manufacturer. The following points should be observed
when conducting a pressure test on a pipeline section with a separator installed:
» According to EN 12266-1, the test pressure may under no circumstances exceed 1.5 times the value
indicated on the body with “PN” or “Class”.
caution
To protect the fitting against damage by pressure surge, the pipeline section has to be filled
slowly.
Failure to observe this instruction may cause damage to the fitting.
note
When the housing is filled with water, the separator is not sealed. During the pressure test it
may be necessary to shut off the drain pipe.
If any leakage occurs on the fitting, section Troubleshooting help [}12] should be observed.
note
If the pipe section is flushed and/or dried after assembly or pressure testing, it is necessary to
make sure that the fitting has not been damaged by corrosion or excessively high temperature.
Original operating manual
Separator AS
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AS-4.X.222 Issue 19.07.2022 www.mankenberg.com
8 Initial start-up
danger of
fatalities
No fitting may be operated that does not have a sufficient pressure and temperature range for
the operating conditions – see section Intended use [}4] and markings on the fitting. The
manufacturer MANKENBERG should be consulted in the case of any applications outside of
this range.
Failure to observe this regulation may mean danger to life and limb and may cause
damage to the pipeline system.
caution
After the initial start-up:
Check the seals on screw-mounted parts of the body and reseal if necessary.
Ask MANKENBERG for tightening torque, if necessary.
Observe the relevant notes in section Troubleshooting help [}12].
9 Normal operation
A properly designed separator works automatically and does not need any form of auxiliary energy.
MANKENBERG is at your servíce for any assistance and queries, for the addresses see section Further
information [}14].
note /
danger
Shortly after start-up it has to be checked on separators equipped with drain screws whether
dirt has accumulated during installation or longer standstill.
Open drain screw only at low pressure in the fitting.
The drain flow must not be directed at persons.
Open carefully when handling hot or toxic media, use protective gloves!
danger of
fatalities
It is necessary to ensure that the materials selected for the parts of the fitting in contact with
media are suitable for the media in use. The manufacturer accepts no liability for any damage
due to corrosion by aggressive media on parts made of unsuitable materials.
Failure to observe this regulation may mean danger to life and limb and may cause
damage to the pipeline system and to the fitting.
caution
The fitting has functional parts that have to remain capable of moving easily. Make sure that
parts in contact with the medium cannot freeze nor become blocked by dirt or deposits.
Observe the maintenance intervals.
Failure to observe this instruction may cause damage to the pipeline system and to the
fitting.
It is recommended that the fitting should be inspected to ensure that it is functioning correctly after each new
start-up.
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