CONVERTING HORIZONTAL CLASS C FILTER/SEPARATORS TO INSIDE/OUT FLOW ACI-6XX01LTB AQUACON CARTRIDGES

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1 CONVERTING HORIZONTAL CLASS C FILTER/SEPARATORS TO INSIDE/OUT FLOW ACI-6XX01LTB AQUACON CARTRIDGES 1. Remove all coalescer elements. 2. Remove separators, separator tie rods and mounting adapters. (We recommend removal of separators to avoid inspection problems. Check with your quality assurance department for your company s policy on this matter if in doubt.) 3. The ACI-6XX01LTB threaded base Aquacon cartridges will be installed in place of the threaded base coalescers. If open-end coalescers were previously used, install one each 6000T adapter per ACI-6XX01LTB. If open-end ACI-6XX01L cartridges are desired to be installed, see page 3. GENERAL GUIDELINES 1. Flow rates, prices, and the coalescers they replace are shown on the next page for the ACI-6XX01LTB screw base Aquacon cartridges. 2. Determine maximum operating flow rate for the F/S vessel. Determine which size ACI- 6XX01LTB will be used. Then divide F/S operating flow rate by the flow rate of the applicable ACI-6XX01LTB. Round up to the next full number of cartridges if a decimal amount occurs (i.e. - if 3.42, round up to 4). Example: a. FCS N11 will flow at a maximum 550 USGPM. b. x each ACI-62901LTB will be used in place of the 7 installed I-62887TB coalescers. c. Quantity of ACI-62901LTB = = 5.5, round to 6. Thus, 6 each ACI-62901LTB will be installed. d. Blind the top most open stool with one P/N blind cap (see #3 below). 3. In general, there will be the same amount or less ACI-6XX01LTB cartridges versus the coalescers. When installing the ACI-6XX01LTB, be sure to install on the bottom-most stools, so that water will not build up on the opposite side of the bulkhead. Blind the top stools, if blinding is necessary. NOTE When converting a mobile filter/separator vessel to ACI cartridges, it is recommended that the water defense system be removed. If not removed, an airline inspector may still require the quarterly water defense system check. Velcon can supply new sump cover plates with water drain connections to replace the bottom-mounted float controls. Page 1 of R8 10/02

2 Model No. ACI-6XX01LTB Aquacon Cartridges Maximum Recommended Flow Rate (USGPM) Overall Length (Not including 1 Bolt) Replaces ACI-61401LTB CA14-3SB I-61487TB ACI-62201LTB CA22-3SB I-62287TB ACI-62901LTB /16 CA28-3SB I-62887TB ACI-63301LTB CA33-3SB I-63387TB ACI-63801LTB CA38-3SB I-63887TB ACI-64401LTB CA44-3SB I-64487TB ACI-65601LTB /16 CA56-3SB I-65687TB RECOMMENDED OPERATING PROCEDURES A. Drain the upstream side of the vessel daily to drain any water that might be present. This will prolong element life. This may require adding an upstream drain valve on a filter/separator vessel converted to inside-to-out flow ACI Aquacon cartridges in place of coalescers. B. Daily drain upstream storage tanks to remove accumulated dirt and water. Recirculation of the system upstream of the vessel early in the morning may be recommended if water can condense out of the fuel due to lowering fuel temperatures (a consideration in hydrant systems with underground pipes, or even in above-ground systems with lots of exposed piping). C. Replace the cartridges based on Cartridge Changeout Curves (Form 1846 for fuels without anti-icing additives and Form 1896 for fuels with anti-icing additives. See page 4, 5.) after 2 years service, or if there is a reduction in flow rate or differential pressure, whichever occurs first. D. In converted filter/separator vessels where the deckplate or manifold strength does not meet the 15 bar (220 psi) strength required by the IP Monitor spec., a differential pressure limiting device, set from psid, should be installed across the vessel. Velcon recommends using Gammon Technical Products (GTP) differential pressure limiting adjustable pilot valve as shown on attached sketch GTP- 8813, page 8. This device can easily be installed as shown on attachment GTP Sketch # SK-595, page 9. See also Gammon article, The Gammon DP-Pilot Valve: How Does it Work? on pages 6 7, and Sketch # SK-494, page 10. Additionally, if your current differential pressure gauge is set for 0-15 psi reading, then this should be converted to 0-30 psi reading. GTP can supply a kit which includes: new scale, O rings, and spring. The part number for this conversion is GTP E. Have a spare set of water absorbing cartridges on hand for the unexpected plug-up. Page 2 of R8 10/02

3 CONVERTING HORIZONTAL CLASS C FILTER/SEPARATORS TO INSIDE/OUT FLOW ACI-6XX01L OPEN-END AQUACON CARTRIDGES Enclosure (1) CONVERSION CHART Coalescer Length Per Stack (in.) Typical Installed Coalescers Equivalent I/O Tie Rods (1) Aquacon 3/8 1/2 Part No. Part No. Part No. 14 CC-N11, I ACI-61401L T T CC-K21, I ACI-62201L T T CC-N21, I ACI-62901L T T CC-K31, I ACI-63301L T T CC-N31, I ACI-64401L T T CC-N41, I ACI-65601L T T (1) In a side-opener, the stack may be a total of 28 high, for example: 2 each CC-N11 cartridges. In these cases, use 2 each ACI-61401L cartridges. OPEN-END HARDWARE ASSEMBLIES (one per tie rod) A. Per 3/8 Tie Rod - Part No. S This assembly does not include a mounting adapter. This assembly is for vessels with manifolds (HV-14 and HV-16). B. Per 3/8 Tie Rod - Part No. S This assembly includes a mounting adapter. It is used in flat deckplate vessels (HVS, HV-22, HV-28). C. Per 1/2 Tie Rod - Part No. S This assembly includes a mounting adapter. It is used in Facet/Fram flat deckplate vessels. SPACERS (when stacking ACI cartridges in side-opener vessels) A. For 3/8 Tie Rod - Part No K B. For 1/2 Tie Rod - Part No T Page 3 of R8 10/02

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6 The Gammon DP-Pilot Valve It is really true. This simple pilot valve will absolutely insure that you will never exceed a differential pressure limit that is pre-set. How Does It Work? CAUTION! To use this pilot you must have a flow control valve in your system. It must be the type that uses pilot flow to control pressure or flow rate. Control valves that are made by Cla-Val, Whittaker (formerly Thiem), Watts, Oil Capital (OCV), Brooks, etc. are entirely compatible. Spring balanced piston valves with no pilot circuit are not compatible because our DP-Pilot operates in the pilot flow circuit. We have been asked: Will the Gammon DP-Pilot in any way keep our control valve from performing its normal functions? Answer: Absolutely not. The control valve will do what it was designed to do, such as closing if water is detected in the filter/separator sump, limiting flow rate, controlling pressure or acting as a check valve. Our DP-Pilot simply adds another function. How does the Gammon DP-Pilot measure the differential pressure on my filter/separator? Answer: Tubing connections are made at the upstream and at the downstream sides of the filter/separator, just as is done to connect a differential pressure gauge. See Figure 1. Page 6 of R8 10/02

7 What does the Gammon DP-Pilot actually do? Answer: It compares the upstream and downstream pressures across a spring balanced piston. Normally, pilot flow passes straight through the DP-Pilot but if its piston moves because it has sensed a preset differential pressure, it moves slightly to partly block flow rate through the pilot system of the control valve. Creating this back pressure in the pilot system causes the control valve to close, but only enough to reduce the flow rate through the filter/separator. By reducing the flow through the filter/separator, the differential pressure across the element stays steady, not exceeding the preset pressure. We use monitor elements instead of coalescers in our filter/separators. Will the DP- Pilot prevent excessive differential across the vessel deckplate if a slug of water suddenly stops flow? Answer: Definitely, yes. Flow rate through the control valve is stopped very rapidly because the DP-Pilot acts directly to stop pilot flow. Will the DP-Pilot permit me to extend the operating life of coalescer elements? Answer: Absolutely not. The only function of the DP-Pilot is to prevent your system from operating in the dangerous condition of a differential pressure that is greater than the recommended limit. When you have reached the manufacturer s recommended differential pressure limit, you must replace the elements. Also, if you continue to operate, the time to refuel an aircraft necessarily becomes longer. Figure 2 shows that when the preset limit of differential pressure is reached (normally 15 psi for coalescers or 25 psi for monitor elements), the differential pressure will always stay at that limit if the maximum recommended flow rate is taking place. Note that the maximum flow rate through the system necessarily is reduced automatically to keep the differential pressure from exceeding the limit. Page 7 of R8 10/02

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