CHART Orca MicroBulk CO2 Series Product Manual

Product Manual
CO2 Series
Designed and Built by:
Chart Inc.
407 7th Street NW New Prague, MN 56071 USA (800) 400-4683
Part Number 21235568 Rev. D
© 2018 Chart Inc.
Product Manual - Orca™ CO2 Series MicroBulk Delivery System
Contents
Revision Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Product Highlights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Product Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Acronyms / Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Compatibility and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety Bulletin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Oxygen Decient Atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Oxygen Enriched Atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Nitrogen, Argon & Carbon Dioxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Personal Protective Equipment (PPE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Safety — CO2 Specic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Carbon Dioxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
iii
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Terminology of Cryogenics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Cryogenic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Cryogenic Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
States of Matter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Saturation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Equilibrium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Saturation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Subcool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Two-Phase Liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Vaporization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Vapor Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Condensation and the Perma-Cyl® MicroBulk Storage System . . . . . . . . . . . . . . . . . . 10
Stratication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Depressurization Flash Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Entrainment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Liquid Growth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Drop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Orca CO2 — First Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fill Orca CO2 from Bulk Tank Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fill Orca CO2 from Onboard Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Filling Levels - MC-338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Current Saturation of Liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Build: Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Pressure Build: Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Pressure Delivery: Hose Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pump Delivery: Bulk Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Receiving Tank Commission: Hose Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Table of Contents Product Manual - Orca™ CO2 Series MicroBulk Delivery System
iv
Receiving Tank Commission: Bulk Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hydraulic Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Methods to Stop Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Trailer Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Start Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
End Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Methods to Stop Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Components & Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Plumbing Cabinet - Roadside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Plumbing Cabinet - Top Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Plumbing Cabinet - Bottom Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Plumbing Cabinet - Curb Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Plumbing Cabinet - Other Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Anti-Tow Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Ticket Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Bluetooth Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Metering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Meter Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Dierential Pressure Transmitter (DP Transmitter) . . . . . . . . . . . . . . . . . . . . . . . . 29
RTD - Resistance Temperature Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Flowcom Flow Meter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cabinet Power - Truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Work Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Dash Controls - Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Hydraulic System - Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Motor and CO2 Pump Rotation Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Grease Fitting Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pressure Build Heater and Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Trailer System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Top Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Roadside Frame Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Overview of Operation Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Error Codes & Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Overview of Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Overview of Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Daily Observation Checks by Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Beginning of the Day Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
During PTO (Power Take O) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
During Deliveries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Weekly Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Plumbing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Power Take O & Hydraulic System Inspection. . . . . . . . . . . . . . . . . . . . . . . . . .43
Every Three Months Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Electrical Connection Inspection (12V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Every Six Months Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Table of ContentsProduct Manual - Orca™ CO2 Series MicroBulk Delivery System
Tank-to-Frame Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Carbon Dioxide Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Yearly Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Every Five Year Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Vacuum Integrity Check (as required) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Preventive Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Piping Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Truck Electrical System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Trailer Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Truck Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Trailer Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Pressure Build Heater Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Warranty Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Chart Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Chart Purchased Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Workmanship and Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
v
Table of Contents Product Manual - Orca™ CO2 Series MicroBulk Delivery System
vi
Revision Log
Revision Level Date Description
A 2/21/2018 Original
B 3/8/2018 Added parts and specs update
C 6/18/2018 Specs change, added preventive maintenance log
D 10/15/2018 Inclusion of Trailer components
Product Manual - Orca™ CO2 Series MicroBulk Delivery System
Preface
1
General
Chart’s MicroBulk delivery system has revolutionized the gas industry by making on-site distribution for smaller
accounts a protable reality. The Orca CO2 Series delivery unit has been designed to ow up to 500 pounds-per-minute
with minimal pump cooling or product loss under normal conditions. Fill termination with Sure-Fill eliminates lost
product associated with overlling. In total, the Chart CO2
MicroBulk system increases asset utilization, reduces labor
costs and maximizes distribution eciency.
Chart oers the complete MicroBulk CO2 delivery system as a solution to reliably and eortlessly manage a diverse range
of applications. The Orca CO2 Series delivery unit oers fast, reliable and accurate on-site delivery to Perma-Max and Carbo Series storage vessels or small bulk tanks. The Perma-
Max line oers the widest range of sizes and piping options and the greatest exibility with accommodations for indoor
and outdoor installation.
Product Highlights
Fast on-site lling of the Perma-Max storage system
Fast-lling of Carbo-Max and Carbo-Mizer
• Flowcom® Flow Meter System
• National Institute of Standards & Technology (NIST) and California Weights and Measures approved metering system
• Large cabinet with removable access panels for ease of maintenance and servicing
Product Manual
The CO2 Series Product Manual is designed to be used in conjunction with Orca CO2 Series models. It should be thoroughly read and understood by anyone who operates or is exposed to this equipment. If there are any questions regarding the operation of the tank, contact Chart’s Technical Service division at 1-800-400-4683.
The safety requirements for operating the tank and handling or transporting extremely cold liquid products are shown in the Safety section. It is imperative that all persons having contact with the Orca delivery system become thoroughly familiar with all maintenance, safety precautions, and procedures contained in this product manual.
The Introduction section discusses the general features of the tank and the theory of operation.
For detailed information on how to operate the Orca system,
refer to the Operations section. Here are various lling,
pressure dispense and pump dispense instructions.
The Components & Systems section contains photos and descriptions of all working parts of the Orca system.
The Troubleshooting section will become an invaluable tool for answering various possible questions that may arise while using the Orca system.
Reference the Preventive Maintenance section for a schedule of maintenance to follow to keep your Orca system running smoothly.
Please refer to the Specications section for a complete
listing of part numbers, drawings and other technical information.
• Pressure transfer for small delivery
• Optional pump transfer for bulk deliveries; pump can also
be used to ll Orca CO
• Calibrated meter system with no moving parts for minimal maintenance
• Vessel designed with robust inner support system for rugged road conditions
• Stainless steel plumbing with stainless steel and brass valves for long service life and reliability
• Stainless steel inner vessel eliminates damage due to icing
2
Preface Product Manual - Orca™ CO2 Series MicroBulk Delivery System
2
Terms
Throughout this manual safety precautions will be designated as follows:
Warning! Description of a condition that
can result in personal injury or death.
Caution! Description of a condition that
can result in equipment or component damage.
Note: A statement that contains information
that is important enough to emphasize or repeat.
Acronyms / Abbreviations
The following acronyms / abbreviations are used throughout this manual:
ASME American Society of Mechanical Engineers
BAR Metric Unit of Pressure
BARG Metric Unit of Gauge Pressure
CGA Compressed Gas Association
CO
2
DOT Department of Transportation
NER Normal Evaporation Rate
GAWR Gross Axle Weight Rating
GPM Gallons Per Minute
GVWR Gross Vehicle Weight Rating
LAR Liquid Argon
LN2/LIN Liquid Nitrogen
Carbon Dioxide
LOX Liquid Oxygen
LPM Liters Per Minute
MAWP Maximum Allowable Working Pressure
NIST National Institute of Standards and Tech.
NPSH Net Positive Suction Head
OEM Original Equipment Manufacturer
PB Pressure Builder
PN Part Number
PSI Pounds per Square Inch
PSIA Pounds per Square Inch Absolute
PSIG Pounds per Square Inch Gauge
PSID Pounds per Square Inch Dierential
PTO Power Take-O
RV Relief Valve
RTD Resistance Temperature Device
SS Stainless Steel
VAC Voltage - Alternating Current
VDC Voltage - Direct Current
VFD Variable Frequency Drive
Product Manual - Orca™ CO2 Series MicroBulk Delivery System
Safety — General Orca
3
Safety Summary
While every possible safety precaution has been taken to ensure safe operation and maintenance of the Orca CO Series delivery system, it is imperative that all persons having contact with the Orca delivery system become thoroughly familiar with all maintenance, safety precautions, and procedures contained in this product manual. If for any reason any part or parts of this manual become confusing or the information provided is not completely understood contact a Technical Service Representative at Chart Inc. 1-800-400-4683 before proceeding with the operation or repair of the vessel.
2
Compatibility and Cleaning
Always keep the Orca delivery system clean and free from grease and oil. Use care when cleaning with high-pressure water or steam cleaning equipment. DO NOT direct the cleaning nozzle into the electronic components. When replacing components, use only parts which are considered compatible with liquid oxygen. Do not use regulators,
ttings, or hoses, which were previously used in compressed
air or carbon dioxide environments. Use only oxygen compatible sealants on threaded connections. All new joints should be leak tested with an oxygen compatible leak test solution at a minimum of 35 psig. Failure to comply with these instructions may result in serious personal injury, death, or damage to the container.
Caution! Before removing any parts or
loosening of ttings empty the
cryogenic container of liquid contents and release any vapor pressure in a safe manner.
External valves and ttings
can become extremely cold. Personnel must wear protective gloves and eye protection whenever removing parts or
loosening ttings. Failure to do
so may result in personal injury due to the extreme cold and tank pressure. Accidental contact of liquid gases to skin or eyes may cause a freezing injury similar to a burn.
Warning! If cryogenic liquid or cold boil-
o gas contacts a worker’s skin or eyes, the aected tissues should be promptly ooded or
soaked with tepid water (105-
115°F; 41-46°C). DO NOT USE
HOT WATER. A physician should examine cryogenic burns that result in blistering or deeper tissue freezing promptly.
Warning! Do NOT use open ame in or
around the plumbing cabinet. Use warm water if thawing of components is necessary.
Safety Bulletin
Portions of the following information are extracted from Safety Bulletin SB-2 from the Compressed Gas Association, Inc. Additional information on oxygen, nitrogen, argon, and cryogenics is available from the CGA at www.cganet.com.
Cryogenic containers, stationary or portable, are from time to time subjected to assorted environmental conditions of an unforeseen nature. This safety bulletin is intended to call attention to the fact that whenever a cryogenic container is involved in any incident whereby the container or its safety devices are damaged, good safety practices must be followed. The same holds true whenever the integrity or function of a container is suspected of abnormal operation.
Good safety practices dictate the contents of a damaged or suspect container be carefully emptied as soon as possible. Under no circumstances should a damaged container be left with product in it for an extended period of time. Further, a
damaged or suspect container should not be relled unless the unit has been repaired and re-certied.
Incidents which require that such practices be followed include: highway accidents, immersion of a container in
water, exposure to extreme heat or re, and exposure to most
adverse weather conditions (earthquake, tornadoes, etc.) As a general rule, whenever a container is suspected of abnormal operation, or has sustained actual damage, good safety practices must be followed.
Safety Product Manual - Orca™ CO2 Series MicroBulk Delivery System
4
In the event of known or suspected container vacuum problems (even if an extraordinary circumstance such as those noted above has not occurred), do not continue to use the unit. Continued use of a cryogenic container that has a vacuum problem can lead to embrittlement and cracking. Further, the carbon steel jacket could possibly rupture if the unit is exposed to inordinate stress conditions caused by an internal liquid leak.
Prior to reusing a damaged container, the unit must be tested, evaluated, and repaired as necessary. It is highly recommended that any damaged container be returned to
Chart for repair and re-certication.
The remainder of this safety bulletin addresses those adverse environments that may be encountered when a cryogenic container has been severely damaged. These are oxygen
decient atmospheres, oxygen enriched atmospheres, and
exposure to inert gases.
Oxygen Decient Atmospheres
Warning! Nitrogen, argon and carbon
dioxide vapors in air may dilute the concentration of oxygen necessary to support or sustain life. Exposure to such an oxygen
decient atmosphere can lead
to unconsciousness and serious injury, including death. Nitrogen, argon and carbon dioxide are colorless and odorless and can replace the oxygen in the
air when released in conned
areas.
The normal oxygen content of air is approximately 21%. Depletion of oxygen content in air, either by combustion or by displacement with inert gas, is a potential hazard and users should exercise suitable precautions.
One aspect of this possible hazard is the response of humans when exposed to an atmosphere containing only 8 to 12% oxygen. In this environment, unconsciousness can be immediate with virtually no warning.
When the oxygen content of air is reduced to about 15
to 16%, the ame of ordinary combustible materials,
including those commonly used as fuel for heat or light, may be extinguished. Somewhat below this concentration, an individual breathing the air is mentally incapable of diagnosing the situation because the onset of symptoms such as sleepiness, fatigue, lassitude, loss of coordination, errors in judgment and confusion can be masked by a state of “euphoria,” leaving the victim with a false sense of security and well being.
Human exposure to atmosphere containing 12% or less oxygen leads to rapid unconsciousness. Unconsciousness can occur so rapidly that the user is rendered essentially helpless. This can occur if the condition is reached by an immediate change of environment, or through the gradual depletion of oxygen.
Most individuals working in or around oxygen decient
atmospheres rely on the “buddy system” for protection ­obviously the “buddy” is equally susceptible to asphyxiation if he or she enters the area to assist the unconscious partner unless equipped with a portable air supply. Best protection is obtainable by equipping all individuals with a portable supply of respirable air. Life lines are acceptable only if the area is essentially free of obstructions and individuals can assist one another without constraint.
If an oxygen decient atmosphere is suspected or known to
exist:
1. Use the “buddy system.” Use more than one “buddy” if necessary to move a fellow worker in an emergency.
2. Both the worker and “buddy” should be equipped with self-contained or airline breathing equipment.
Oxygen Enriched Atmospheres
An oxygen-enriched atmosphere occurs whenever the normal oxygen content of air is allowed to rise above 23%. While
oxygen is nonammable, ignition of combustible materials
can occur more readily in an oxygen-rich atmosphere than in air; and combustion proceeds at a faster rate although no more heat is released.
It is important to locate an oxygen system in a well ventilated location since oxygen-rich atmospheres may
collect temporarily in conned areas during the functioning
of a safety relief device or leakage from the system.
Oxygen system components, including but not limited to,
containers, valves, valve seats, lubricants, ttings, gaskets
and interconnecting equipment including hoses, shall have adequate compatibility with oxygen under the conditions of temperature and pressure to which the components may be exposed in the containment and use of oxygen. Easily ignitable materials shall be avoided unless they are parts of equipment or systems that are approved, listed, or proven suitable by tests or by past experience.
SafetyProduct Manual - Orca™ CO2 Series MicroBulk Delivery System
5
Compatibility involves both combustibility and ease of ignition. Materials that burn in air may burn violently in pure oxygen at normal pressure, and explosively in pressurized oxygen. In addition, many materials that do not burn in air may do so in pure oxygen, particularly when under pressure. Metals for containers and piping must be carefully selected, depending on service conditions. The various steels are acceptable for many applications, but some service conditions may call for other materials (usually copper or its alloy) because of their greater resistance to ignition and lower rate of combustion.
Similarly, materials that can be ignited in air have lower ignition energies in oxygen. Many such materials may be ignited by friction at a valve seat or stem packing, or by adiabatic compression produced when oxygen at high pressure is rapidly introduced into a system initially at low pressure.
Warning! If clothing should be splashed
with liquid oxygen it will become
highly ammable and easily
ignited while concentrated oxygen remains. Such clothing must be aired out immediately, removing the clothing if possible, and should not be considered safe for at least 30 minutes.
Nitrogen and argon vapors in air dilute the concentration of oxygen necessary to support or sustain life. Inhalation of high concentrations of these gases can cause anoxia, resulting in dizziness, nausea, vomiting, or unconsciousness and possibly death. Individuals should be prohibited from entering areas where the oxygen content is below 19% unless equipped with a self-contained breathing apparatus. Unconsciousness and death may occur with virtually no warning if the oxygen concentration is below approximately 8%. Contact with cold nitrogen or argon gas or liquid can cause cryogenic (extreme low temperature) burns and freeze body tissue.
Persons suering from lack of oxygen should be
immediately moved to areas with normal atmospheres. SELF-CONTAINED BREATHING APPARATUS MAY BE REQUIRED TO PREVENT ASPHYXIATION OF RESCUE WORKERS. Assisted respiration and supplemental oxygen should be given if the victim is not breathing. If cryogenic
liquid or cold boil-o gas contacts worker’s skin or eyes, the aected tissue should be ooded or soaked with tepid
water (105-115ºF or 41-46ºC). DO NOT USE HOT WATER. Cryogenic burns that result in blistering or deeper tissue freezing should be examined promptly by a physician.
Personal Protective Equipment (PPE)
Nitrogen, Argon & Carbon Dioxide
Nitrogen, argon and carbon dioxide (inert gases) are simple asphyxiates. These gases will not support or sustain life and can produce immediate hazardous conditions through the displacement of oxygen. Under high pressure these gases may produce narcosis even though an adequate oxygen
supply sucient for life is present.
The following personal protective equipment is recommended when working around cryogenic liquid:
• Safety glasses with side shields to prevent cryogenic
liquid from splashing into the eyes
• Chemical / Liquid resistant gloves to prevent cryogenic
burns on exposed hands
• Long sleeve shirts to protect the arms
Cuess trousers worn over closed shoes
• Face shield
Safety
6
Safety — CO2 Specic
Product Manual - Orca™ CO2 Series MicroBulk Delivery System
General
The Orca CO2 Series Tank consists of an inner pressure vessel encased within an outer carbon steel vacuum shell. The container operates under low-to-medium pressure. Safety relief devices are used to protect the pressure vessel and vacuum casing, sized and selected in accordance with ASME standards. They include a dual relieve valve system to protect the pressure vessel, and a lift plate to protect the vacuum casing (outer vessel). The Orca CO2 Series is designed and engineered for safe, reliable operations and are durable enough to provide many years of trouble­free operation. Strict compliance with proper safety and handling practices is necessary when using an Orca CO2. We recommend that all our customers re-emphasize safety and safe handling practices to all their employees and customers. While every possible safety feature has been designed into the unit and safe operations are anticipated, it is essential that every user of the Orca CO2 carefully reads all WARNINGS and CAUTIONS listed and enumerated in this safety section and contained in the manual itself. Also read the information provided in the safety bulletins for Carbon Dioxide gas. Periodic review of this safety summary is recommended.
Warning! Carbon Dioxide vapors in air
may dilute the concentration of oxygen necessary to support or sustain life. Exposure to such
an oxygen decient atmosphere
can lead to unconsciousness and serious injury, including death.
Warning! Before removing any parts or
loosening of ttings empty the
cryogenic container of liquid contents and release any vapor pressure in a safe manner.
External valves and ttings can
become extremely cold and may cause painful burns to personnel unless properly protected. Personnel must wear protective gloves and eye protection whenever removing parts or
loosening ttings. Failure to do
so may result in personal injury due to the extreme cold and tank pressure.
Warning! Accidental contact of liquid or
solid CO2 with the skin or eyes may cause a freezing injury similar to a burn. Handle liquid so that it will not splash or spill. Protect your eyes and cover skin where the possibility of contact with liquid CO2 cold pipe and cold equipment, or cold gas exists. Safety goggles or a face shield should be worn if liquid ejection or splashing may occur or if cold gas may issue forcefully from equipment. Clean, insulated gloves that can easily be removed and long sleeves are recommended for arm protection.
Cuess trousers should be worn
over the shoes to shed spilled liquid.
Caution! Do not use oxygen equipment
that is marked “For Oxygen Use”
in CO2 service. Failure to comply with these instructions may result in serious damage to the container.
Carbon dioxide
Carbon dioxide is a compound formed by the combination of carbon and oxygen atoms in a 1:2 ratio expressed by the chemical symbol CO2. The weight percentages of carbon and oxygen are 27.3% and 72.7%, respectively.
Carbon dioxide is a gas at normal atmospheric temperature and pressure. It is colorless and somewhat pungent, although essentially odorless and is about 1.5 times more dense than air.
Depending on the temperature and pressure to which it is subjected, carbon dioxide may exist in the form of a solid, liquid or gas. At a temperature of 69.9°F (56.6°C) and a pressure of 60.4 psig (417 kPa), CO2 can exist simultaneously in all three phases. This condition is known as the triple point. The phase diagram for CO2 is shown in Figure A.
Product Manual - Orca™ CO2 Series MicroBulk Delivery System
Safety
7
Safety Product Manual - Orca™ CO2 Series MicroBulk Delivery System
8
Product Manual - Orca™ CO2 Series MicroBulk Delivery System
Introduction
9
Theory of Operation
Although the Orca CO2 Series system can have pressure or pump delivery options, all units have the same general functional operating characteristics. They have the ability to
be lled with liquid CO2 and deliver that product to the end customer safely and eciently.
Terminology of Cryogenics
Cryogenic
A product retaining a temperature of -238°F (-150°C) or
colder. Orca delivery systems maintain gases eciently in a cryogenic liquid state. Gases can be most eciently stored as liquids. Gases may be liqueed by compression or cooling
them until they liquefy. In order to be maintained in a liquid state, each gas must be kept at or below their respective boiling temperatures.
Though liquid CO2 is very cold, it cannot exist below
-69.9°F. While it is technically not a cryogen, it is to be handled as such.
Liquid density, temperature, and equilibrium pressure change with the saturation condition of the liquid. Saturation can also be described as an energy state. Liquid molecules at a higher energy state (warmer) take up more space, which is often referred to as liquid growth.
Equilibrium
In a closed vessel the gas and liquid temperatures are the
same. If there is a temperature dierence between the gas
and liquid (with the tank closed), the gas and liquid will change their temperatures until they are equal. In stationary
tanks, stratication can take place, creating a temperature
gradient across the liquid and vapor. However, the temperature at the liquid-vapor interface is the same for both.
Saturation Pressure
Pressure (usually in psig) that is used to describe the current saturation condition of a liquid and gas within a closed container.
Cryogenic Temperatures
The Orca CO2 Series delivery systems employ near­cryogenic temperatures to store the product in its liquid state. CO2 can exist as a liquid down to -69.9°F (60.4 psig saturation). Below that, CO2 becomes solid. CO2 is typically transported and stored above -20°F (200 psig saturation).
States of Matter
Matter can exist as a gas, liquid, or a solid. Two phase liquid is a liquid with gas bubbles or slugs of gas due to lack of pressure (subcool) to maintain equilibrium. Gas and liquid can exist at a range of temperatures.
Saturation
Dened as the point at which liquid and vapor coexist at the
same pressure and temperature.
Subcool
Raising the vapor space pressure above the current boiling pressure of a saturated liquid is called subcool. This contributes to the Net Positive Suction Head (NPSH) to the pump. The higher the subcool, the less susceptible the liquid
will be to two-phase ow and pump cavitation.
Two-Phase Liquid
The mix of liquid and gas due to the pressure dropping below the saturation pressure of the liquid caused by the lack of proper subcool. This can damage the pump and cause meter inaccuracy.
Cavitation
Dened as the formation of vapor bubbles in a liquid, it
manifests as partial or full loss of pump prime due to the lack
of proper subcool. The pressure of the liquid owing to the
pump has dropped below the saturation pressure. Audible changes in the pump often are an indication of partial loss of prime. The pump will stop pumping during full loss of prime. Cryogenic pumps will be damaged by cavitation. Some CO2 pumps can handle small amounts of cavitation, however, cavitation should always be avoided.
Introduction Product Manual - Orca™ CO2 Series MicroBulk Delivery System
10
Vaporization
Changing liquid into vapor by warming the liquid for the purpose of subcooling or for gas use. The Orca CO2 Series delivery system uses a pressure building coil inside of a propylene glycol/water bath heat exchanger in the cabinet.
Vapor Pressure
Pressure of the vapor space within the tank. Measured by reading the tank pressure gauge or the Flowcom® Flow Meter System.
Condensation
The conversion of vapors into liquid by cooling the vapors. The Orca CO2 Series storage vessel pressure during normal operation will rise above the saturation pressure of the liquid. This warmer gas will condense to the colder liquid pressure during transit. The liquid splashes into the gas space during normal movement of the truck/trailer. The splashing condenses the gas and drops the pressure. This is known as "splash-down."
Depressurization Flash Losses
Dropping the vapor space pressure below the saturation pressure of the liquid causing the liquid to boil. During the venting of the tank below the saturation pressure of the liquid, the liquid temperature will drop, the density will increase, weight of the liquid will decrease, and the saturation pressure will drop.
Entrainment
Liquid carried along with venting gas. This can occur during
violent depressurization of a tank and during the top lling
of a tank with the vent valve open. Large product losses will occur during this event.
Liquid Growth
As liquid warms to higher saturation pressures, the volume increases. Warm liquid is less dense. Less dense liquid takes up more volume. Liquid growth is a safety concern if the
liquid is allowed to grow until it lls the storage vessel. This
condition is called liquid full or hydraulically full. During this condition the pressure rises rapidly, the safeties will relieve, and the tank will vent liquid.
Condensation and the Perma-Cyl® MicroBulk Storage System
Pressure Drop
An example of condensation can be seen in the lling theory of a Perma-Cyl tank. Top lling a Perma-Cyl tank without
venting is possible due to condensing warmer gas into liquid.
Pressure lost due to the ow of liquid. The faster liquid ows
through the piping circuit, the higher the pressure drop.
Stratication
Warm liquid is less dense. In a tall vertical tank this less dense liquid will nd its way to the top of the tank. Colder more dense liquid will remain at the bottom. The layering of temperature zones from top to bottom is called stratication.
Product Manual - Orca™ CO2 Series MicroBulk Delivery System
Operations
11
Modes of Operation
Orca CO2 — First Use — 11
Fill Orca CO2 from Bulk Tank Pump — 11
Fill Orca CO2 from Onboard Pump — 12
Filling Levels - MC-338 — 13 Current Saturation of Liquid — 13
Pressure Build: Heater — 13
Pressure Build: Operation — 14
Pressure Delivery: Hose Reel — 15
Pump Delivery: Bulk Hose — 16
Receiving Tank Commission: Hose Reel — 19
Receiving Tank Commission: Bulk Hose — 19
Hydraulic Power Supply — 19
Methods to Stop Pump — 20
Primary — 20
Trailer Operation — 21
I. Orca CO2 First Fill
The Orca CO2 Series delivery system is shipped under pressure with a CO2 atmosphere to keep out moisture. It must be purged prior to use.
1. Remove hoses from storage tubes, set in place and open cabinet doors.
2. Open Vapor Vent (V-5) valve and vent tank until empty.
3. Open Pump Inlet/Fill (V-1), Pressure Dispense (V-4), PB Force Feed (V-16), PB Liquid (V-28) valves.
a. Vapor Balance/PB Isolation (V-13), Inner Vessel
Gauge (V-14), Vapor Phase Isolation (V-31), Liquid Phase Isolation (V-32) valves should already be open, they are only closed for service.
4. From delivery tank connect vapor balance hose to Fill
Line (DC-1) connection. Use size adapters as necessary.
5. Open Bottom Fill (V-17) supply tank vapor balance
valve to pressurize to 50 psig. Close supply tank vapor balance valve.
Note: Cryogenicballvalveshaveaow
direction; the higher pressure must
alwaysbeontheinletsideoftheball valve.Ifthereissignicantlyhigher
pressure on the outlet side, product WILL leak past the ball valve.
6. Open Vapor Vent (V-5) and vent tank under 5 psig. Close Vapor Vent.
7. Open Bottom Fill (V-17) and pressurize to 250 psig.
8. Remove the cap from Vapor Balance (DC-5) connection. Slowly open Vapor Balance (V-44) valve and purge for 1-2 minutes. Close Vapor Balance (V-44) valve and replace cap.
9. Remove the cap from Dispense (DC-2) and Hose Reel Inlet (DC-3) connections. Connect Hose Reel Inlet (DC-3) to Dispense (DC-2) connection.
10. Slowly open Dispense (V-41), Delivery Flex Hose (V-47), Delivery Hose (V-46), and Hose Reel Line Drain (V-6) valves and purge for 1-2 minutes. Close Hose Reel Line Drain (V-6) valve and leave Hose Reel Inlet (DC-3) connected to Dispense (DC-2) connection for hose reel delivery.
11. Slowly open Vapor Vent (V-5) valve 1-2 turns and let purge 1-2 minutes. Close Vapor Vent (V-5) valve.
12. Crack open the compression tting on the Inner Vessel Front of Tank (PI-3) gauge and allow leak for 1-2
minutes. Tighten tting before line frosts. Leak check compression tting.
13. Crack open the compression ttings on the Inner Vessel Level Indicator (LI-1) and Inner Vessel Pressure Indicator (PI-2) manifold gauges and allow leaks for
up to 1 minute. Tighten tting before line frosts. Leak check compression ttings.
14. Close Pump Inlet/Fill (V-1), Pressure Dispense (V-4), PB Force Feed (V-16), PB Liquid (V-28) and Bottom Fill (V-17) valves.
15. Open and close Fill Line Drain (V-9) valve to depressurize connection.
16. Disconnect supply tank vapor balance hose from Fill Line (DC-1) connection and connect to Vapor Balance (DC-5) connection.
17. Follow the rest of the instructions in “II. & III. Fill Orca CO2”.
Operations Product Manual - Orca™ CO2 Series MicroBulk Delivery System
12
II. Fill Orca CO2 from Bulk Tank Pump
1. Remove hoses from storage tubes, set in place and open cabinet doors.
2. Connect supply tank vapor balance hose to Vapor
Balance (DC-5) connection and connect ll hose from
supply tank to Fill Line (DC-1) connection.
3. Open supply tank vapor balance and dispense valves.
a. This assumes supply tank is at a lower pressure than
Orca CO2. If Orca CO2 is at a higher pressure, swap Orca CO2 and supply tank in steps 3 and 4.
4. Open and close Vapor Balance Line Drain (V-45) and Fill Line Drain (V-9) valve to purge air from hoses.
5. Slowly open Vapor Balance (V-44) valve to equalize pressure in tanks.
6. Open Bottom Fill (V-17) and Pump Inlet/Fill (V-1) valve.
7. Start supply tank pump lling and monitor liquid level.
8. When liquid level is getting close to full (3/4 of net capacity), open Vapor Balance Line Drain (V-45) valve.
a. The vapor balance line serves as the 95% full trycock.
9. When liquid exits the Vapor Balance Line Drain (V-45), valve stop the pump and close the Bottom Fill (V-17) valve.
10. Close the Vapor Balance Line Drain (V-45), Pump Inlet/Fill (V-1), and Vapor Balance (V-44), supply tank dispense & vapor balance valves.
11. Open and close the Fill Line Drain (V-9) and Vapor Balance Line Drain (V-45) valves to drain and release all pressure.
Warning! Fast depressurization of liquid
CO2 can cause dry ice to form, holding in pressure that quickly releases when the dry
ice melts. Follow proper safety
procedures for draining and venting liquid CO2 from hoses.
III. Fill Orca CO2 from Onboard Pump
1. In order to minimize pump cavitation and surging:
a. The liquid level in the supply tank must be above the
Orca CO2 pump inlet height. As such, supply tanks should be limited to vertical tanks or horizontal tanks located above the Orca CO2 pump height.
b. Additional subcool in the supply tank will be
benecial.
c. If the Orca CO2 tank pressure is signicantly lower
than the supply tank, causing the supply-tank pressure to drop below the saturation of the supply liquid when vapor balancing, pressure in the supply tank must be added to subcool the liquid.
2. Start truck and engage PTO, turn on cruise control and increase engage speed to set point.
a. Engine must be at low idle speed to engage PTO.
Caution! Engage the PTO when not at
low idle speed will damage the PTO.
b. Engine will go to set speed with one push of the cruise control speed increase button.
Caution! Supply tank must have a
vapor balance circuit for this functionality otherwise pump damage may occur.
3. Remove hoses from storage tubes, set in place and open cabinet doors.
4. From delivery tank connect vapor balance hose to Vapor
Balance (DC-5) connection and connect ll hose from
delivery tank to Fill Line (DC-1) connection.
5. Slowly open supply tank liquid valve to ll pump supply
hose with liquid.
6. Open Fill Line Drain (V-9) valve until CO2 snow comes
out and close valve. This purges air and lls the hose
with liquid.
12. Disconnect hoses from Vapor Balance (DC-5) and Line (DC-1) connections.
13. Close cabinet doors and stow hoses. Replace all dust caps.
7. Make sure Pump Inlet/Fill (V-1) valve is closed.
8. — If supply tank is higher pressure than Orca CO2:
a. Open Bottom Fill (V-17) valve.
b. Start pump with Switch (SW-1).
c. When supply tank pressure comes within 5 psig
of Orca CO2 tank pressure, open supply tank
OperationsProduct Manual - Orca™ CO2 Series MicroBulk Delivery System
13
vapor balance and Orca CO2 Vapor Balance (V-44) valves.
— If Orca CO2 is higher pressure than supply tank:
a. Open supply tank vapor balance and Orca CO2
Vapor Balance (V-44) valves.
b. Open Bottom Fill (V-17) valve.
c. Start pump with Switch (SW-1).
9. Monitor for pump to catch prime.
a. Pump discharge pressure should be 70 psig higher
than tank pressure (bypass valve factory setting).
b. In recirculation mode, if pump discharge pressure
is less than 50 psig higher than Orca CO2 tank, pump did not catch prime; stop pump and restart or open the Pressure Dispense (V-4) valve to help catch prime.
10. Open Pressure Dispense (V-4) valve and throttle to maintain pump discharge minimum 25 psig higher than Orca CO2 tank pressure.
a. This keeps the pump on the pump curve, maintaining
prime.
b. Too little pressure dierential can cause pump
cavitation.
c. Too much pressure dierential creates a low ow rate.
Close Fill Line Drain (V-9) and Vapor Balance Line Drain (V-45) valves.
Warning! Fast depressurization of liquid
CO2 can cause dry ice to form, holding in pressure that is quickly released when dry ice
melts. Follow proper safety
procedures for draining and venting liquid CO2 from hoses.
17. Disconnect hoses from Vapor Balance (DC-5) and Line (DC-1) connections.
18. Close cabinet doors and stow hoses. Replace all dust caps.
19. Disengage engine speed control and disengage PTO.
Filling Levels - MC-338
The DOT regulations limit the ll levels based on the
tank’s pressure control valve settings. This volume assures that when the pressure control valve discharges the tank is
not liquid full. This ll volume varies with the saturation pressure of the liquid. DOT ll levels are based on the weight of the liquid. Dierential pressure liquid level gauges
are an approximation of the pounds of liquid in the vessel. The true full liquid level should be determined by the full trycock. Both are dependent on the vessel being level.
11. Monitor liquid level and pump pressure.
12. When liquid level is getting close to full (3/4 of net capacity), open Vapor Balance Line Drain (V-45) valve.
a. The vapor balance line serves as the 95% full trycock.
Note: DonotpressurebuildwithOrcaCO
afterllinghasstarted.IfthePBcoil isoverrun,liquidwillenterthevapor
balance/full trycock line, giving a false
indicationthatOrcaCO2 is full.
13. When liquid exits the Vapor Balance Line Drain (V-45) valve stop the pump (SW-1) and close the Bottom Fill (V-17) valve.
14. Close the Pressure Dispense (V-4) valve.
15. Close the Vapor Balance Line Drain (V-45), Vapor Balance (V-44), supply tank dispense & vapor balance valves.
16. Open the Fill Line Drain (V-9) and Vapor Balance Line Drain (V-45) valves to drain and release all pressure.
2
Current Saturation of Liquid
Upon arriving at a delivery site, the Orca tank pressure
indicator (PI-1) will reect the current saturation pressure.
During travel the liquid splashes condensing the warmer vapor. This is referred to as “splash down.” During pressure building operations the tank pressure will rise. This is not an increase in the saturation pressure but an increase in the subcool. During normal deliveries the saturation pressure will remain the same as at arrival.
IV. Pressure Build: Heater
Note: Instructionsarespecictothestandard
heater and programmable controller.
Otherheatersandcontrollersmaybe
used, refer to their respective manuals.
1. Review heater and heater controller manuals for additional operational information.
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