BT-472 Rev. B
Express Fill 700 & 1000
Instruction Manual
Do not attempt to use or maintain these units until you read and understand these instructions. Refer to the TaylorWharton’s Safety First
maintain this equipment. If you do not understand these instructions, contact your supplier for additional information.
booklet (TW-202) for handling cryogenic material. Do not permit untrained persons to use or
BT-472 Rev. B
Table of Contents
WARNING 3
Safety Precautions for Liquid Oxygen 3
Safety Precautions for Liquid Nitrogen 4
Safety Precautions for Liquid Carbon Dioxide 4
Safety Precautions for Liquid Nitrous Oxide 5
INTRODUCTION 6
System Description 6
Specifications 7
PIPING CIRCUITS 8
Fill and Vent Circuits 9
Express Fill Circuit 9
Pressure Building Circuit 10
Gas Withdrawal Circuit 11
Economizer Circuit 12
Safety Devices 12
Instrumentation Circuits 13
INSTALLATION 14
Receiving Inspection 14
Handling 14
Vessel Installation Guidelines 14
Fill Box Installation Guidelines 14
OPERATION 17
Filling by Pressure Transfer 17
Filling by Pump Transfer 17
Withdrawing Gas 18
Withdrawing Liquid 18
Changing Gas Service 18
MAINTENANCE 19
Leak Test 19
Globe Valves 19
Regulators 20
Instruments 21
Checking Vacuum 21
Trouble-Remedy Guide 23
Replacement Parts 24
APPENDIXES 25
Appendix 1 – Express Fill 700/1000 General Arrangement 25
BT-472 Rev. B
WARNING
The following safety precautions are for your protection. Before installing, operating, or maintaining this unit read and
follow all safety precautions in this section and in the reference publications. Failure to observe all safety precautions
can result in property damage, personal injury, or possibly death. It is the responsibility of the purchaser of this
equipment to adequately warn the user of the precautions and safe practices for the use of this equipment and the
cryogenic fluid stored in it.
CAUTION: When installing field fabricated piping, make certain a suitable safety valve is installed in each
section of piping between shut-off valves.
For more detailed information concerning safety precautions and safe practices to be observed when handling cryogenic
liquids consult CGA pamphlet P-12 "Handling Cryogenic Liquids" available from the Compressed Gas Association,
1235 Jefferson Davis Highway, Arlington, VA 22202.
Safety Precautions for Liquid Oxygen
Oxygen is a colorless, odorless, and tasteless gas that can be condensed into a liquid at the low temperature of 297
degrees below zero Fahrenheit (-183°C) under normal atmospheric pressure. Approximately one-fifth of normal air is
oxygen. As a liquid, oxygen is pale blue in color. Oxygen is non-flammable but, however it vigorously accelerates the
burning of combustible materials.
Keep Combustibles Away from Oxygen and Eliminate Ignition Sources
Many substances that do not normally burn in air require only a slight spark or moderate heat to set them aflame in the
presence of concentrated oxygen. Other substances, which are only moderately combustible in air, can burn violently
when a high percentage of oxygen is present.
Do not permit smoking or open flame in any area where liquid oxygen is stored, handled, or used. Keep all organic
materials and other flammable substances away from possible contact with liquid oxygen. Some of the materials that
can react violently with oxygen are oil, grease, kerosene, cloth, wood, paint, tat, and dirt that contains oil or grease.
Under certain conditions flammable materials that have become permeated with liquid oxygen are impact sensitive and
can detonate if subjected to shock.
Keep Area and Exterior Surfaces Clean to Prevent Ignition
As normal industrial soot and dirt can constitute a combustion hazard, all equipment surfaces must be kept very clean.
Do not place oxygen equipment on asphalt surfaces, or allow grease or oil deposits to remain on benches or concrete
surfaces in the vicinity of the oxygen equipment. Use cleaning agents, which will not leave organic deposits, on the
cleaned surfaces. Equipment to be used in contact with liquid oxygen should be handled only with clean gloves or hands
washed clean of oil.
Maintain Adequate Ventilation
Enclosed areas containing oxygen equipment should be ventilated to prevent accumulations of oxygen and thereby
minimize combustion hazards.
Extreme Cold - Cover Eyes and Exposed Skin
Accidental contact of liquid oxygen or cold issuing gas with the skin or eyes may cause a freezing injury similar to
frostbite. Handle the liquid so that it won't splash or spill. Protect your eyes and cover the skin where the possibility of
contact with the liquid, cold pipes and equipment, or the cold gas exists. Safety goggles or a face shield should be worn
if liquid ejection or splashing may occur or cold gas may issue forcefully from equipment. Clean, insulated gloves that
can be easily removed and long sleeves are recommended for arm protection. Cuffless trousers should be worn outside
boots or over the shoes to shed spilled liquid. If clothing should be splashed with liquid oxygen or otherwise saturated
with the gas, air out the clothing immediately, removing it if possible. Such clothing will be highly flammable and easily
ignited while the concentrated oxygen remains, and should not be considered safe for at least 30 minutes.
Replacement Parts Must be Suitable for Oxygen Service
Many materials, especially some non-metallic gaskets and seals, constitute a combustion hazard when in oxygen service,
although they may be acceptable for use with other cryogenic liquids. Make no substitutions for recommended spare
3
BT-472 Rev. B
parts. Also, be sure all replacement parts are thoroughly "Cleaned for Oxygen Service" in accordance with Compressed
Gas Association (CGA) Pamphlet G-4.1 "Cleaning for Oxygen Service" or equivalent industrial cleaning specifications.
Observe Safety Codes When Locating Oxygen Equipment
Before locating oxygen equipment, become thoroughly familiar with National Fire Protection Association (NFPA)
Standard No. 50, "Bulk Oxygen Systems", and with all federal, state and local safety codes. The NFPA Standard covers
the general principles recommended for the installation of bulk oxygen systems on industrial and institutional consumer
premises.
Safety Precautions for Liquid Nitrogen
Nitrogen is an inert, colorless, odorless, and tasteless gas making up four-fifths of the air you breathe. Liquid nitrogen is
obtained by cooling air until it becomes a liquid and then removing the oxygen. Air is roughly one-fifth oxygen. Liquid
nitrogen is at a temperature of -320°F (-196°C) under normal atmospheric pressure.
Extreme Cold - Cover Eyes and Exposed Skin
Accidental contact of liquid nitrogen or cold issuing gas with the skin or eyes may cause a freezing injury similar to
frostbite. Handle the liquid so that it won't splash or spill. Protect your eyes and cover the skin where the possibility of
contact with the liquid, cold pipes and equipment, or the cold gas exists. Safety goggles or a face shield should be worn
if liquid ejection or splashing can occur or cold gas can issue forcefully from equipment. Insulated gloves that can be
easily removed and long sleeves are recommended for arm protection. Trousers without cuffs should be worn outside
boots or over the shoes to shed spilled liquid.
Keep Equipment Area Well Ventilated
Although nitrogen is non-toxic and non-flammable, it can cause asphyxiation in a confined area without adequate
ventilation. Any atmosphere not containing enough oxygen for breathing can cause dizziness, unconsciousness, or even
death. Nitrogen, a colorless, odorless, and tasteless gas, cannot be detected by the human senses and will be inhaled
normally as if it were air. Without adequate ventilation, the expanding nitrogen will displace the normal air resulting in
a non-life-supporting atmosphere.
Dispose of Waste Liquid Nitrogen Safely
Dispose of waste liquid nitrogen out-of-doors where its cold temperature cannot damage floors or driveways and where
it will evaporate rapidly. An outdoor pit filled with clean sand or gravel will evaporate liquid nitrogen safely and
quickly.
NOTE: Argon is an inert gas whose physical properties are very similar to those of nitrogen. For handling of
liquid argon, follow the safe practices described for the handling and use of liquid nitrogen.
Safety Precautions for Liquid Carbon Dioxide
WARNING: CARBON DIOXIDE CAN CAUSE ASPHYXIATION AND DEATH IN CONFINED, POORLY
VENTILATED AREAS.
COLD GAS CARBON DIOXIDE CAN CAUSE SEVERE FROSTBITE TO THE EYES OR SKIN. DO NOT
TOUCH FROSTED PIPES OR VALVES. IF ACCIDENTAL EXPOSURE TO THESE GASES OCCURS,
CONSULT A PHYSICIAN AT ONCE. IF A PHYSICIAN IS NOT READILY AVAILABLE, WARM THE AREAS
AFFECTED BY FROSTBITE WITH WATER THAT IS NEAR BODY TEMPERATURE.
Keep Equipment Area Well Ventilated.
Carbon dioxide affects the important acid-base balance in the body. Carbon dioxide is formed in normal functioning
within the body, but the body can tolerate increased amounts of carbon dioxide only in limited concentration. This is
recognized in OSHA standards where a Threshold Limit Value of 5,000 parts per million by volume (0.5 percent
concentration) has been adopted. For safety, concentrations above this level should not be permitted; increased
concentrations can
cause bodily harm or death. Additionally, carbon dioxide can cause asphyxiation
by displacing oxygen resulting in dizziness, unconsciousness or death.
4
BT-472 Rev. B
Ten percent carbon dioxide in air can be endured for only a few minutes; twelve to fifteen percent
soon cause unconsciousness; twenty five percent may cause death if exposure lasts for several
hours. Carbon dioxide cannot be detected by the human senses and will be inhaled like air. Carbon
dioxide is heavier than air and will accumulate in low lying areas. Carbon dioxide concentrations
will be greater in these areas. If adequate ventilation is not provided, carbon dioxide may displace
normal air without warning that a life-depriving atmosphere is developing.
COVER EYES AND SKIN.
If released to atmosphere, liquid carbon dioxide will turn to carbon dioxide snow. Accidental contact of carbon dioxide
snow or cold gas with the eyes or skin may cause severe frostbite. Handle liquid so that it will no vent or spill. Protect
your eyes with safety goggles or a face shield, and cover the skin to prevent contact with snow or cold gas, or with cold
pipes and equipment. Protective gloves can be quickly and easily removed and long sleeves are recommended for
protection.
GROUND ALL PIPING.
The rapid discharge of liquid carbon dioxide through a line which is not electrically grounded will result in a buildup of
static electricity. Contact with this electrical charge could be startling and potentially dangerous to operating personnel.
Such lines should, therefore, be grounded before use.
NOTE: For additional information on properties of carbon dioxide and proper handling refer to CGA pamphlets G-6,
"Carbon Dioxide" and G-6.1, "Standard for Low Pressure Carbon Dioxide Systems at Consumer Sites". These
publications are available from the Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA, 22202.
Safety Precautions for Liquid Nitrous Oxide
Nitrous oxide is a gas which has no color, no odor, and practically no taste. It is obtained by thermal decomposition of
ammonium, which yields nitrous oxide and water. Due to the toxic impurities produced in this process, the water is
condensed out and the gas is passed through scrubbing towers to remove impurities.
Due to the difficulty of detecting nitrous oxide's presence, there is imminent danger of loss of consciousness and
physical inability to function if exposed to low levels of this gas, and death by asphyxiation if exposed to medium or
high levels. Since nitrous oxide is a non-toxic gas, these hazards are created when life-supporting oxygen is displaced
and diluted. It is imperative to maintain a well-ventilated work environment to minimize the danger from a leaking
system or activated safety relief device.
Accidental exposure or contact with skin or eyes can cause severe frostbite. Avoid contact with cold piping and
equipment as this can also cause personal injury. Protect eyes with goggles or shield, especially if there is a possibility
of liquid ejection or if cold gas may issue forcefully from equipment. Keep skin covered at all times.
Nitrous oxide is non-flammable but, as with oxygen, ignition of combustible materials may occur more readily in a
nitrous oxide-enriched atmosphere than in air with combustion proceeding at a faster rate. Open flame and smoking are
strictly prohibited.
For more detailed information concerning safety precautions and safe handling of nitrous oxide, consult CGA pamphlet
G-8.1, "Standard for Nitrous Oxide at Consumer Sites", and CGA pamphlet G-8.2 "Common Specification for Nitrous
Oxide". These publications are available from the Compressed Gas Association, 1235 Jefferson Davis Highway,
Arlington, VA 22202.
5
BT-472 Rev. B
INTRODUCTION
This manual provides information for the operation and maintenance of Taylor-Wharton's line of Express Fill 700 and
1000 cryogenic gas supply systems. These products store cryogenic liquid and dispense it as a warm pressurized gas.
The Express Fill systems are designed for applications requiring nitrogen, argon, or oxygen gas. These products are
ideal for on-site filling with Taylor-Wharton’s Express cryogenic liquid delivery vehicle.
Additional product specifications, flow diagram, views, and important dimensions are shown on the general arrangement
drawing provided in the appendix of this manual.
System Description
The Express Fill 700 and 1000 consists of a cryogenic liquid vessel, piping, internal vaporizer, and an internal pressure
builder.
The system vessels have an approximate gross capacity between 700 and 1,000 liters. The vessel consists of a pressure
vessel suspended inside a jacket. The space between the pressure vessel and the jacket is evacuated and insulated with a
micro-fiberglass / aluminum foil radiation shield. Both the inner pressure vessel and vacuum jacket are constructed of
type 304 stainless steel. All models are designed and constructed in accordance with ASME Section VIII.
Piping circuits allow the vessel to vent, fill, pressurize, and provide pressurized gas. Piping is type-304 stainless steel.
Valves are brass. Fittings are machined from forged brass and type-316 stainless steel.
Instrumentation consists of a pressure gauge and a differential pressure gauge. The pressure gauge allows the vessel
pressure to be monitored. Accurate measurement of the vessel contents is provided by the differential pressure gauge.
The Express Fill system automatically maintains pressure by vaporizing cryogenic liquid in a controlled fashion. All
energy for building pressure and vaporizing liquid is provided by heat from ambient air. The vaporizer and pressure
builder coils are attached to the inside surface of the outer jacket.
6
BT-472 Rev. B
Specifications
Model EF-700 EF-1000 EF-1000HP EF-1000VHP
Dimensions
Footprint inches 38 x 40 38 x 40 38 x 40 38 x 40
(mm) 965 x 1016 965 x 1016 965 x 1016 965 x 1016
Cylinder Diameter inches 38 38 38 38
(mm) 965 965 965 965
Height inches 69 91 91 91
(mm) 1753 2,311 2,311 2,311
Empty Weight lbs 1,308 1,550 1,750 2,085
(kg) 594 703 794 946
Capacity, Gross gallons 180 268 266 268
(liters) 681 1,014 1,007 1,014
MAWP psig 350 250 350 500
(kPa) 2,413 1,724 2,413 3,447
Design Specification ASME Section VIII, Division I
Safety Devices
Pressure Relief Valve psig 350 250 350 500
(kPa) 2,413 1,724 2,413 3,447
Inner Bursting Disc psig 525 356 525 750
(kPa) 3,620 2,455 3,620 5,171
Pressure Control Devices
Economizer Setting psig 325 200 325 425
(kPa) 2,241 1,379 2,241 2,930
PB Setting psig 300 175 300 400
(kPa) 2,069 1,207 2,069 2,757
Gaseous Capacity NPT1
Nitrogen cu. ft. 15,449 22,370 22,230 22,370
(cu. M) 406 634 584 588
Oxygen cu. ft. 19,135 27,663 27,510 27,660
(cu. M) 503 783 723 727
Carbon Dioxide2 cu. ft. 12,011 19,117 17,755 17,038
(cu. M) 316 502 466 448
Argon cu. ft. 18,738 27,102 26,970 27,100
(cu. M) 492 768 709 712
Weight of Contents1
Nitrogen lbs 1,119 1,621 1,611 1,620
(kg) 508 735 731 735
Oxygen lbs 1,585 2,290 2,277 2289
(kg) 719 1,039 1,033 1,038
Carbon Dioxide2 lbs 1,374 2,186 2,031 1949
(kg) 623 992 921 884
Argon lbs 1,938 2,801 2,787 2802
(kg) 879 1,271 1,264 1,271
Gas Delivery Rate cfh 800 960 960 960
(cu. M/h)
NER (Percent of capacity per day O2)
1
Based on liquid at full trycock saturated at 0 psi.
2
Based on liquid at full trycock saturated at operating pressure.
22.1 15.6 15.6 15.6
1.0%
7
BT-472 Rev. B
PIPING CIRCUITS
The following paragraphs describe the operation of the piping circuits of the system. The descriptions refer to the main
components of each circuit and are grouped by function. Reference the piping schematic below and in the general
arrangement drawing for the component designations. These component and circuit descriptions should be understood
before attempting operation.
Legend
CN-1 Connection, Liquid Fill / Withdrawal CV-1 Check Valve, Pump/Top Fill
CN-2 Connection, Full Trycock & Vent CV-2 Check Valve, In Line
CN-3 Connection, Pump / Top Fill LI-1 Liquid Level Gauge
CN-4 Connection, Gas Withdrawal VC-1 Vaporizer Coil
V-1 Valve, Liquid Fill / Withdrawal PI-1 Pressure Gauge
V-2 Valve, Full Trycock / Vent PBC-1 Pressure Building Coil
V-3 Valve, Gas Withdrawal PCV-1 Pressure Building Regulator
V-4 Valve, Pressure Building PCV-2 Economizer Regulator
V-5 Valve, Pressure Builder Isolation SV-1** Safety Valve
V-6 Valve, Economizer Isolation SV-2 Safety Valve
V-7 Valve, Low Pressure Isolation SV-3 Safety Valve
V-8 Valve, High Pressure Isolation R-1** Inner Container Safety Disc
V-9 Valve, Pressure Equalization R-2 Outer Casing Safety Disc
V-10 Valve, Manual Ball FSV-1* Fill Stop Valve
For use with delivery vehicle equipped with automatic filling system, i.e. Taylor-Wharton
*
Express Cryogenic Delivery System.
** Option available for Dual Safeties/Rupture Disc with Diverter Valve.
8
Figure 1: System Piping Schematic
BT-472 Rev. B
Fill and Vent Circuits
The liquid valve (V-1) communicates with the bottom of the vessel. A stainless steel tag labeled “LIQUID” identifies
the valve and the liquid connection (CN-1). Liquid is added or removed from the vessel through this connection and
valve.
The vent / trycock valve (V-2) is attached to a vertical tube in the upper portion of the vessel. The open end of the tube
is positioned at 90% liquid level based on the vessel volume. Opening the vent valve reduces pressure in the vessel
during filling. It also severs as a “full trycock”, venting liquid from the vessel when the liquid level exceeds 90%. A tag
labeled “VENT” is attached to this valve.
V-2
V-1
CN-2
CN-1
Figure 2: Fill and vent circuits highlighted in blue.
Express Fill Circuit
The Express Fill circuit may be used for filling from the Taylor-Wharton Express Cryogenic Delivery System or for top
filling by a cryogenic pump. Two check valves (CV-1 & CV-2) prevent product from escaping the vessel.
A fill stop valve (FSV-1) within the vessel prevents over filling. This device functions when filled by the TaylorWharton Express Truck in automatic fill mode. The fill stop valve will not function when the vessel is filled by a typical
cryogenic pump.
CV-1
CV-2 OR
V-10
CN-3
Figure 3: Express Fill circuit highlighted in blue.
9
BT-472 Rev. B
the outer head in a suitable area.
Pressure Building Circuit
The pressure building circuit serves to build pressure after filling the vessel. The circuit is also used to ensure sufficient
driving pressure during high product withdrawal periods. Opening the pressure building circuit valve (V-4) permits the
circuit to function. A stainless steel tag labeled “P.B.” is attached to the valve. When the pressure inside the vessel
drops below the pressure builder setting, the pressure building regulator (PCV-1) opens. This creates a path from the
liquid in the bottom of the container to the gas space in the top. This path contains an internal pressure building coil
(PBC-1) to vaporize product as it flows from the bottom to the top of the vessel. Liquid is expanded to a vapor and
pressure is increased in the vessel. The pressure building coil is attached to the inside surface of the vacuum jacket.
V-5
SV-2
PCV-1
HEATER INSTALLATION
Make sure the container vessel is at 0
psi. Open the vent valve as a
precaution. Remove the ¾” plug in the
SV-3
V-4
Figure 4: Pressure building circuit highlighted in blue.
When the EF cylinder is placed in Carbon Dioxide service and ambient temperatures are low, an electric heating system
may be required to assist in pressure building. The electric system consists of a heater in the container that is controlled
by a pressure switch in the top of the unit. The pressure switch responds to inner container pressure and turns the heater
current on and off as required to maintain a pressure greater than 125 psi (8.6 bar/862kPa). The following procedures
detail adjustment of the set points (high and low) of the pressure switch.
Field Adjustment Procedure: The set-point of the pressure switch that controls the heater element can be adjusted
from inside the control box located on the top of the container. It is factory set to 125 psi. A ¼” open end wrench is
required.
top flange and attach adapter then insert
the heater. Be sure to use tephlon tape
on all pipe threads and seal off well
assembly with a RTV sealant. Wire the
heater to the control box according to
the schematic provided on page 10. The
heater bracket will need to be welded to
:
10
Figure 4A: Pressure Switch Control Diagram
BT-472 Rev. B
The switch should be set to close at pressure below 125 psi and open after a predetermined pressure rise. To check the
setting, vent the container from a pressure greater than 125 psi where the HEATER lamp is off indicating the switch is
open and the heater is not receiving power. As the container vents, observe the container pressure gauge. At
approximately 125 psi the switch should close and the HEATER lamp will light. Close the vent at this point and allow
the heater to cycle until the pressure rises and the HEATER lamp goes out. Note the pressure rise on the pressure gauge
as well as the time interval between ‘heater on’ and ‘heater off’.
Warning:
The pressure switch/control box contains live 120VAC or 240VAC connections. Always disconnect the power
from the wall receptacle before removing the cover from this box for adjustment or maintenance.
If adjustment is needed, unplug the unit and unscrew four Phillips-head screws on top of the pressure control box. The
clockwise movement of the adjusting screw will raise the ‘heater on’ setting; counterclockwise will lower it. The
amount of pressure rise (or the heater ‘off’ setting) will adjust automatically. Move the set point adjustment a small
increment in the desired direction and repeat the venting procedure to determine the new set point. Repeat the process
as necessary until the set point is 125 psi.
adjustment screw
Figure 4B: Pressure Switch Adjustment Screw
Gas Withdrawal Circuit
The gas withdrawal circuit vaporizes cryogenic liquid and warms it to ambient temperature for use in the final
application. Opening the gas withdrawal valve (V-3) allows liquid, driven by the pressure within the vessel, to flow
through the vaporizer (VC-1). The vaporizer uses heat from the ambient air to convert the liquid into a gas and warm it.
The vaporizer, like the pressure building coil, is attached to the inside surface of the vacuum jacket. The vaporizer is
located in the upper ¾ of the jacket, the pressure builder in the lower ¼.
V-3
CN-4
Figure 5: Gas withdrawal circuit highlighted in blue.
11
BT-472 Rev. B
Economizer Circuit
The economizer circuit reduces product loss due to normal evaporation of the liquid within the vessel. The economizer
regulator (PCV-2) opens when the pressure within the vessel exceeds the economizer setpoint. The economizer setpoint
varies depending on the model. This allows gas from the top of the vessel to flow into the vaporizer circuit. Provided
that gas from the vaporizer is being withdrawn for use, the vessel pressure will be reduced. The primary safety valve
(SV-1) will be prevented from opening, avoiding product loss.
PCV-2
V-6
Figure 6: Economizer circuit highlighted in blue.
Safety Devices
The Express Fill system features a safety valve to prevent over pressurization of the vessel. The safety valve (SV-1)
relieves pressure when it exceeds the maximum operating pressure of the vessel. The valve reseats when pressure drops
below this point. In addition, the primary safety valve is supported by a secondary relief device consisting of a rupture
disc (R-1). The rupture disc requires replacement in the event a safety valve malfunctions and allows vessel pressure to
reach the burst pressure rating of the disc. A diverter valve and dual relief valves along with rupture discs may also be
ordered as an option.
SV-1
R-1
Figure 7: Safety circuit highlighted in blue.
12
BT-472 Rev. B
Instrumentation Circuits
The instrumentation consists of a pressure gauge and differential pressure gauge. The pressure gauge (PI-1) displays the
inner vessel pressure in pounds-per-square-inch and kilopascals. The liquid level gauge (LI-1) measures the difference
in pressure between the top and bottom of the vessel. Product within the vessel creates a higher pressure at the bottom
of the vessel than at the top. Readings on the liquid level gauge are in inches of water. This reading, when compared to
the contents chart attached to the front of the vessel, allows accurate monitoring of the amount of product within the
vessel. A digital gauge is also available that can be ordered fitted to the tank or installed in the field.
Isolation valves (V-7 and V-8) allow maintenance of the circuit without emptying and depressurizing the vessel. The
equalization valve (V-9) must be opened before the isolation valves are closed. Two ¼” female pipe thread connections
(CN-5 and CN-6) are provided to allow easy connection of telemetry devices or other differential pressure measurement
instruments. The connections are provided plugged.
V-8
V-7
LI-1
PI-1
V-9
Figure 8: Instrumentation circuits highlighted in blue.
13
BT-472 Rev. B
INSTALLATION
Dimensions and connection data for the Express Fill systems can be found on the General Arrangement Drawings in the
appendix of the manual. System installation is the responsibility of the customer.
Receiving Inspection
Freight and damage claims are the customer’s responsibility. Take time to visually inspect each shipment in the
presence of the carrier’s agent before accepting delivery. If any damage is observed, make an appropriate notation on
the freight bill. Ask the driver to sign the notation before receiving the equipment. Do not accept equipment with
damage that may affect serviceability.
Handling
Each Express Fill system should be handled only by a forklift or crane. Ensure that handling equipment has adequate
rated capacity for the system weight listed on the general arrangement drawing in the appendix. The Express Fill 700
and 1000 is a rugged product intended for years of industrial use. However, take care when moving the unit.
Abuse (dropping or careless handling by forklift) may affect the integrity of the insulation system or damage
piping. Always transport, operate, and store the unit in the vertical position. Never place the unit on its side.
Important: When lifting by crane, use the lift-eyes provided on the top of the jacket. Never lift the unit overhead.
Vessel Installation Guidelines
This section and the “Fill Box Installation Guidelines” section below provide general installation guidelines. Complete
installation specifications, procedures, and applicable codes are beyond the scope of this manual. Designing and
installing a safe cryogenic system is the responsibility of the customer. Consultation, design, and installation services are
available from the factory or one of our authorized repair centers. Contact customer service at the location shown at the
back of the manual for additional information.
Important: Check the regulator codes and license requirements in your area before beginning an installation. When
installing piping, be sure to follow accepted design practices for cryogenic equipment. Use only components
compatible with cryogenic liquids. Be sure to include properly sized pressure relief valves in all piping where liquid
product or cold gas could be trapped between closed valves, regulators, etc. All components must be rated for the
maximum operating pressure of the vessel. If the vessel is in oxygen service, only use components compatible with and
cleaned for oxygen service.
The Express Fill system should be installed on a suitable concrete pad and secured with anchor bolts. The minimum
recommended pad is 4’ by 4’ by 6” thick. Concrete strength of 3 ksi (28 day strength) is recommended. In areas where
frost heaving is a concern, the pad perimeter should be 12” thick. Four 3/8” galvanized steel concrete expansion bolts
are recommended. A heavy-duty rotary hammer will be required to drill the bolt holes in the concrete slab. The holes
may be drilled and the bolts installed with the vessel in place. Where seismic loads are a concern, 1/2” expansion bolts
should be used. When using 1/2” bolts, it is not practical to drill the bolt holes with the vessel in place.
For outdoor installations, the vessel should be installed in a location easily accessible to the delivery vehicle. A chainlink fence with a lockable gate should be installed around the vessel to prevent tampering.
The unit may also be mounted on a steel pallet anchored with four ½” bolts to allow for easy maneuverability around the
customer site using a rated capacity fork lift. The pallet is available from Taylor Wharton.
Fill Box Installation Guidelines
The Express Fill system may be installed inside a building or behind a wall and filled remotely through a fill box.
Indoor installations should only be considered for vessels in argon or nitrogen service. An Express Fill 1000 or 700 in
oxygen service must never be installed indoors. The diagram below shows a typical installation with a fill box.
14
BT-472 Rev. B
.
Recommended components for a typical fill box installation:
Fill Line
Vessel Fitting: Compression Fitting, 1/2” Male Pipe Thread x 7/8" O.D. Tube, Brass
Tubing: Copper, 3/4" Size (7/8” Actual O.D.), Type K (.065” Wall), per ASTM B-88
Fill Box Fitting: Compression Fitting, 1/2” Female Pipe Thread x 7/8" O.D. Tube, Brass
Vent Line
Vessel Fitting: Compression Fitting, 3/8” Male Pipe Thread x 5/8" O.D. Tube, Brass
Tubing: Copper, 1/2" Size (5/8” Actual O.D.), Type K (.049” Wall), per ASTM B-88
Fill Box Fitting: Compression Fitting, 3/8” Female Pipe Thread x 5/8" O.D. Tube, Brass
Safety Line
Vessel Fittings: Compression Fitting, 1/2” Male Pipe Thread x 7/8" O.D. Tube, Brass (2 required)
Relief Valve, 1/2" Inlet x 1/2" Outlet, (Consult with factory for part.)
Safety Disc, 1/2" Inlet x 1/2” Outlet, (Consult with factory for part.)
Compression Union Tee Fitting, 7/8” O.D. Tube, Brass
Tubing: Copper, 3/4" Size (7/8” Actual O.D.), Type K (.065” Wall), per ASTM B-88
Fill Box Fitting: Compression Fitting, 1/2” Female Pipe Thread x 7/8" O.D. Tube, Brass
Warning: It is essential that the lines be connected properly. If the vessel safety line were attached to the fill box fill
line or vent line, the vessel pressure relief devices could be prevented from functioning. This will cause a dangerous
pressure build-up in the vessel and in the lines. Never install a shut-off valve on the safety line.
The fill box should be located such that it is accessible for deliveries 24 hours a day. For safety and efficient filling,
keep the length of the lines as short as possible. Actual length of the lines must not exceed 20 feet. Consult with TaylorWharton when installing longer lines. Use large radius bends and minimize the number of bends. If wrought copper
fittings with slip joints are used in the lines, the joints should be silver brazed. Bag-7 silver braze rod is recommended.
Pipe insulation compatible with cryogenic temperatures (urethane based foam pipe insulation or a rigid cellular-glass
pipe insulation) is recommended. All of the lines (fill, vent, and safety) should be insulated.
Vent Line
Safety Line
Fill Line
Figure 9: Typical fill box installation diagram.
15
BT-472 Rev. B
6
1
2
3
4
5
7
8
9
10
11
Warning: Lines must not be installed such that they are susceptible to damage. A crushed safety line, for example,
could prevent the relief devices from functioning properly. This will cause a dangerous pressure build-up in the vessel
and in the lines.
Attach the lines to interior walls or secure them to overhead structural members as required by local codes. If damage to
the lines is a possibility, the damage prone sections should be placed inside protective jackets. Jackets may be
constructed from PCV pipe. For heavy-duty protection, construct the jackets from steel pipe.
The vessel safety valve (SV-1) and inner container safety disc (R-1) must be piped to the single fill box safety line. The
existing relief valve and safety disc must be removed and replaced with equivalent devices featuring outlets with pipe
threads. Consult the factory when specifying these components. Thread the compression fittings for the safety line of
the vessel (recommended above) into the safety valve and safety disc outlets. Connect the safety valve and safety disc
fittings to a compression union tee with the recommended tubing. Connect the compression union tee to the fill box with
the same tubing material.
The schematic below shows the components used in the wall mounted fill box. Fill boxes are available from TaylorWharton. The fill box is designed to be mounted on an exterior wall with the pipe stub connections extending through
the wall. Use silicone sealant to weather-tight the fill box against the wall. Do not install the fill box at face height.
Mount the fill box approximately 3 to 4 feet above the ground.
After the installation is complete, perform a pneumatic leak test on the lines (fill, vent, and safety) per ANSI/ASME
B31.3-345.5. Isolate the vent line from the vessel during the leak test by closing the vessel vent valve (V-2). It will be
necessary to test the safety and fill lines while disconnected from the vessel. The vessel connection ends of the lines
should be capped during testing. Check all line connections at reduced pressure with an oxygen compatible bubbleforming leak check solution.
Item # Description
1 Safety Line Connection, 1/2” Male Pipe Stub
2 Vent Line Connection, 3/8” Male Pipe Stub
3 Fill Line Connection, 1/2” Male Pipe Stub
4 Vent Line Relief Valve
5 Enclosure Vent
6 Vent Line Exhaust
7 Fill Line Ball Valve, 1/2” Female Pipe Thread, Fitted with proper CGA
8 Vent Line Shut-Off Valve, 3/8” Female Pipe Thread
9 Vent Line Pressure Gauge
10 Safety Line Baffle
11 Fill Box Enclosure
Figure 10: Fill box detail schematic (side-view).
Legend: Fill Box Detail Schematic
fitting (295 for argon or nitrogen, 440 for oxygen)
16
BT-472 Rev. B
OPERATION
These instructions are for operators experienced with cryogenic equipment. Before operating this product, become
familiar with the safety precautions in this manual and in reference publications. Study this manual and the general
arrangement drawing located in the back of this manual thoroughly. Know the location and function of all components.
Filling by Pressure Transfer
Filling by pressure transfer is accomplished by lowering the pressure in the Express Fill system below that of the source
vessel. Typically the source vessel is a truck-mounted vessel. The pressure is reduced in the Express Fill system by
venting gas through the vent valve (V-2). Liquid is pushed by pressure from the truck-mounted vessel and into the
Express Fill system.
CAUTION: Follow the safety precautions at the beginning of this manual. Accidental contact with liquid or cold gas
can occur during filling.
A cryogenic transfer hose equipped with a relief valve and dump valve should be used to connect the Express Fill
system to the liquid source. Follow the instructions below to fill by pressure transfer:
1. Visually inspect the Express Fill system, transfer hose, and bulk tank piping. Do not attempt to fill the unit
if any components are broken or missing.
2. Connect a transfer hose from the bulk tank to the liquid connection (CN-1).
3. Open the liquid valve (V-1) and vent valve (V-2) to begin the fill.
4. When liquid issues from the vent valve, the vessel is full. A 10% gas head space will remain above the
liquid. Close the liquid valve (V-1).
5. Once liquid stops issuing from the vent valve (V-2), close the vent valve.
6. Close the liquid source supply valve and open the transfer hose dump valve.
7. Disconnect the transfer hose from the liquid connection (CN-1).
Filling by Pump Transfer
When a pump is used to fill the container, the pump / top fill connection (CN-3) should be used. Open the manual ball
valve (V-10) if equipped. Closely monitor the vessel pressure during the fill. If the vessel pressure approaches the relief
valve setting or the pump pressure rating, shut down the pump. Open the vent valve (V-2) to reduce pressure as needed.
When filling using the Taylor-Wharton Express Cryogenic Delivery Vehicle in automatic mode, the fill is stopped at a
level providing an adequate gas head space. Refer to the Express Vehicle instruction manual for details.
When using a traditional pumping system, the vent valve (V-2) should remain open during the fill. Monitor the product
exiting the vent valve closely. When liquid issues from the vent valve(V-2), immediately stop the pump and close the
manual ball valve (V-10) if equiped. Once liquid stops issuing from the vent valve, close the vent valve.
17
BT-472 Rev. B
Withdrawing Gas
To withdraw gas from the Express Fill system, connect a suitable line regulator to the gas withdrawal connection (CN-
4). Connect the outlet of the regulator to the application. Follow these steps:
1. Open the pressure building valve (V-4). Monitor the pressure gauge (PI-1). When the pressure exceeds the
desired delivery pressure, continue.
2. Open the gas withdrawal valve (V-3).
3. Adjust the line regulator to desired delivery pressure.
Withdrawing Liquid
Attach a transfer hose from the receiver vessel to the Express Fill 1000 or 700 liquid connection (CN-1) and open the
adjacent liquid valve (V-1). The pressure in the container will drive liquid product out through the valve as long as the
container pressure exceeds that of the receiver.
Changing Gas Service
The Express Fill system may be used for argon, oxygen, or nitrogen service. Follow these steps to properly change gas
service:
1. Safely empty all liquid from the container.
2. Open the pressure building valve (V-4) and the vent valve (V-2) to vaporize any residual liquid that may
remain in the bottom of the vessel. It may require an hour or longer to vaporize all the residual liquid.
3. To ensure purity, it is recommended that the Express Fill system be evacuated with a suitable vacuum
pump. The ultimate vacuum reading should be at least 20 inches of mercury.
4. Replace the fittings for the vent, liquid, and use connections with the appropriate fittings shown in the chart
below. Use Teflon tape or another suitable thread sealant when threading the fittings into the connections.
5. Remove any decals identifying the previous gas service. Attach new gas service identification decals.
Gas Service Valve Description TW Part Number
Use Fitting CGA 540 x 1/2” NPT 7114-0159
Oxygen
Nitrogen
Argon
Vent Fitting CGA 440 x 3/8” NPT 6514-8992
Liquid & Top Fill Fitting CGA 440 x 1/2” NPT 6514-8990 (2 required)
NA Oxygen Service Decal GL55-9C52
Use Fitting CGA 580 x 1/2” NPT 7114-0160
Vent Fitting CGA 295 x 3/8” NPT 7355-4712
Liquid & Top Fill Fitting CGA 295 x 1/2” NPT 7355-4698 (2 required)
NA Nitrogen Service Decal GL55-9C51
Use Fitting CGA 580 x ½” NPT 7114-0160
Vent Fitting CGA 295 x 3/8” NPT 7355-4712
Liquid & Top Fill Fitting CGA 295 x 1/2” NPT 7355-4698 (2 required)
NA Argon Service Decal GL55-9C53
18
BT-472 Rev. B
MAINTENANCE
Routine inspections of the system are recommended. The need for maintenance usually becomes apparent from
inspection and indications of improper operation. Typical trouble indications include leakage from valves or piping
connections and excessive venting through relief valves. Keep a permanent log of all inspections and repairs performed.
Such a log can be valuable in evaluating performance and scheduling maintenance.
Date Nature of Work (Describe in Full) Remarks Servicemen's Signature
Figure 11: Inspection and Repair Log (Sample Form)
Always observe the safety precautions at the front of this manual and follow the instructions given in this section.
Before working on the system, properly empty the vessel of liquid and relieve pressure on the vessel and piping. Do not
allow unqualified persons to attempt repairs on this equipment. Refer to the Trouble-Remedy Guide in this manual for
assistance in troubleshooting.
Leak Test
After making repairs requiring disassembly or replacement of components, leak test all valves or piping joints that were
taken apart and reconnected. Apply leak detector fluid to the test surface. Large leaks instantly form large bubble
clusters, while fine leaks produce white foam that builds up more slowly. All leaks must be repaired and retested before
the system is returned to service.
Globe Valves
All of the globe valves (V-1, V-2, V-3, & V-4) are easily removable. Tapered pipe thread connections are used at the
inlet and outlet. However, the valves may be rebuilt without removal from the system. All of the globe valves use the
same rebuild kit. The Taylor-Wharton part number for the rebuild kit is 1750-9C35. All valve components, except the
body, are provided in the kit.
19
BT-472 Rev. B
Dump Valve
Regulators
The pressure building regulator may be adjusted without removal from the system. The following procedure describes
the process:
1. Fill the container with liquid product.
2. Open the pressure building valve and allow the container pressure to stabilize for about an hour. Note the
pressure.
3. Loosen the lock nut on the adjusting screw on the top of the regulator. Raise the setpoint by turning the
adjusting screw clockwise; lower the setpoint by turning the screw counterclockwise. When decreasing the
setting, the pressure building valve must be closed and the container vented to a lower pressure. Repeat
step two and observe the change.
For more accurate adjustment it is recommended that the pressure building regulator be removed from the system. A
regulator bench adjustment fixture should be used. The figure below shows a typical setup.
1. Leak test joints between the high pressure cylinder regulator and the dump valve. Joints must be leak free
2. Close the on/off valve and the dump valve.
3. Open the high pressure cylinder valve.
4. Set the high pressure regulator above the desired set point for the pressure builder.
5. Slowly open the on/off valve and observe the downstream pressure gauge.
6. When the regulator under adjustment closes, the P.B. set point is indicated on the downstream pressure
7. Close the on/off valve and open the dump valve.
8. To reset the regulator, loosen the lock nut on the adjusting screw. Raise the setpoint by turning the
9. When reinstalling the pressure building regulators on the system, orient the regulator so the flow arrow
Adjustment of the economizer regulator should be accomplished with the regulator removed from the system. The
regulator bench adjustment fixture shown above should be used.
High Pressure
Cylinder
before proceeding.
gauge.
adjusting screw clockwise; lower the setpoint by turning the screw counterclockwise. After adjustment,
repeat steps 5 and 6 to check the setting before reinstalling the regulator on the liquid container.
points away from the pressure building valve.
Pressure
Gauge
On/Off
Valve
Regulator
Figure 12: Regulator bench adjustment fixture.
Regulator to
be adjusted
Pressure
Gauge
20
BT-472 Rev. B
1. Leak test joints between the high pressure cylinder regulator and the dump valve. Joints must be leak free
before proceeding.
2. Close the on/off valve. Open the dump valve.
3. Open the high pressure cylinder valve.
4. Set the high pressure regulator above the desired set point for the economizer.
5. Slowly open the on/off valve for a few seconds and then close it.
6. When the regulator under adjustment closes, the economizer set point is indicated on the upstream pressure
gauge.
7. To reset the regulator, loosen the lock nut on the adjusting screw. Raise the setpoint by turning the
adjusting screw clockwise; lower the setpoint by turning the screw counterclockwise. After adjustment,
repeat steps 5 and 6 to check the setting before reinstalling the regulator on the liquid container.
8. The economizer regulator should be reinstalled oriented horizontally with the tube compression fitting
threaded into the side port.
Instruments
User adjustment of the pressure gauge or liquid level gauge is not possible. If the gauges are malfunctioning, they must
be replaced. Empty the container of liquid and completely depressurize it before replacing either gauge.
Note that the liquid level gauge may read erratically while the safety valve is venting. This is normal and will stop when
the safety valve reseats.
Checking Vacuum
Cryogenic containers are two containers, one within the other. The space between the containers acts as a highly
efficient thermal barrier including high technology insulation, a vacuum, and a vacuum maintenance system. Each
serves a very important part in the useful life of the container. The high technology insulation is very effective in
preventing radiated heat from entering the inner container. Unfortunately, the perfect vacuum cannot be achieved since
trace gas molecules begin to enter the vacuum space from the moment of manufacture. The vacuum maintenance system
consists of materials that gather trace gas molecules from the vacuum space. The maintenance system can perform its
function for years, but however it has a limited capacity. When the vacuum maintenance system becomes saturated it
can no longer maintain the vacuum integrity of the container. The change will be very gradual and may go unnoticed for
several years. When the vacuum in the insulation space is no longer effective, the following symptoms may appear:
1. With liquid in the container, the outer casing will be much colder than comparative containers.
2. Frost, indicating the liquid level, may be visible on the outer casing of the container.
3. Condensation may form on the container. Note that some icing or condensation is normal around the piping
connections of the vessel. Condensation may also occur on the vessel outer surface as a result of high
humidity.
4. The relief valve will open continuously until the container is empty.
If a loss of vacuum integrity is suspected, the container’s normal evaporation rate (NER) should be checked. The test
procedure explained below measures the actual product lost over time.
1. Fill the container with approximately 400 pounds of liquid nitrogen.
21
BT-472 Rev. B
2. Close the liquid valve and the pressure building valve. Leave the vent valve open for the duration of the
test.
3. Allow the container to stabilize for 24 hours after filling. Weigh the container. Record the weight, date,
and time.
4. Move the container as little as possible during the test. After 48 hours, weigh the container a second time.
Record the weight, date, and time.
The following formula will provide the actual normal evaporation rate in pounds per day. An actual NER that exceeds
40 pounds per day indicates a vacuum problem.
Daily NER = First Weight – Second Weight
Time between weights in hours
If it has been determined that the vessel has a vacuum problem it will be necessary to repair and re-evacuate the vessel.
A skilled service technician should perform vessel repair. Contact Taylor-Wharton customer service at 1-800-898-2657
for assistance in locating the closest service center.
X 24
22
Trouble-Remedy Guide
Trouble Possible Cause Remedy
1. Low operating pressure.
2. Excessive system pressure.
3. Leaking relief valve.
4. Ruptured pressure vessel rupture
disc.
a. Safety valve leaking or frozen
open.
b. Safety disc ruptured. b. Replace disc.
c. Piping leaks to atmosphere. c. Leak test and repair piping.
d. Pressure building / economizer
regulator malfunction.
e. Excessive product withdrawal. e. Check for leaks downstream.
f. Pressure building valve closed. f. Open pressure building valve.
g. Malfunctioning pressure gauge. g. Replace pressure gauge.
h. Excessive frost on pressure
building coils.
a. Extensive shutdown time. a. No remedy.
b. Low withdrawal rate. b. No remedy.
c. Malfunction of pressure building
circuit.
d. Malfunction of pressure gauge. d. Replace gauge.
e. Bad vessel vacuum. e. Perform NER test. Have vessel
a. Dirt or ice in valve. a. Thaw out valve. Replace if
b. Damaged valve seat. b. Replace valve.
a. Excessive vessel pressure. a. Refer to Step 2, this section.
b. Defective rupture disc. b. Replace rupture disc.
c. Atmosphere corrosion and/or
disc fatigue.
d. Interior disc corrosion. d. Blow out safety device line.
e. Relief device failed. e. Replace relief device and rupture
a. Thaw out valve or replace if
necessary.
d. Adjust regulators. Replace if
necessary.
Reduce product use.
h. Thaw pressure building coils.
c. Adjust pressure building
regulators. Replace if necessary.
repaired and re-evacuated if
necessary.
necessary.
Replace rupture disc.
c. Replace rupture disc.
Replace rupture disc.
disc.
BT-472 Rev. B
23
BT-472 Rev. B
Replacement Parts
Order replacement parts from Taylor-Wharton Customer Service at 1-800-898-2657. Refer to the piping circuits section
on Page 8 to identify the components.
ITEM PART NUMBER DESCRIPTION
V-1 6914-4050 Globe Valve, 1/2” FNPT
V-2 2198262 Globe Valve, 3/8” FNPT
V-3 6914-4050 Globe Valve, 1/2” FNPT
V-4 2198262 Globe Valve, 3/8” FNPT
CV-1 6913-9365 Check Valve, Swing, ½” FNPT
CV-2 6913-9370 Check Valve, Ball-Cone, ½” FNPT
LI-1 57143700 Differential Pressure Gauge, 0-80 inches H2O
PI-1, 250 psi Vessel 7702-6196 Pressure Gauge, 400 psig
PI-1, 350/500 psi Vessel 7702-6197 Pressure Gauge, 600 psig
PCV-1, 250 psi Vessel 85368040 Regulator, Pressure Builder, 175 psig
PCV-1, 350 psi Vessel 85368042 Regulator, Pressure Builder, 300 psig
PCV-1, 500 psi Vessel 85368044 Regulator, Pressure Builder, 400 psig
PCV-2, 250 psi Vessel 85362615 Regulator, Economizer, 200 psig
PCV-2, 350 psi Vessel 1706-9C75 Regulator, Economizer, 325 psig
PCV-2, 500 psi Vessel 6999-9017 Regulator, Economizer, 425 psig
SV-1, 250 psi Vessel 85440299 Relief Valve, ½” MNPT, 250 psig
SV-1, 350 psi Vessel 85450298 Relief Valve, ½” MNPT, 350 psig
SV-1, 500 psi Vessel 85450299 Relief Valve, ½” MNPT, 500 psig
SV-2, 250/350 psi Vessel 6913-9072 Relief Valve, ¼” MNPT, 500 psig
SV-3, 250/350 psi Vessel 6913-9072 Relief Valve, ¼” MNPT, 500 psig
SV-2, 500 psi Vessel 6913-9079 Relief Valve, ¼” MNPT, 600 psig
SV-3, 500 psi Vessel 6913-9079 Relief Valve, ¼” MNPT, 600 psig
R-1, 250 psi Vessel M6009C33 Safety Disc, ½” MNPT, 356 psig
R-1, 350 psi Vessel 85163510 Safety Disc, ½” MNPT, 525 psig
R-1, 500 psi Vessel 85163520 Safety Disc, ½” MNPT, 750 psig
R-2 BC04-6C66 Casing Safety Disc
N/A 85449402 Diverter Valve (Optional)
N/A BCO4-9C87 Heater, 208/240 (Optional)
N/A BCO4-9C86 Heater Control (Optional)
N/A BC06-9C71 Well Assembly (Optional)
N/A H4509C10 Adaptor, Heater (Optional)
N/A H4509C20 Bracket, Heater Control (Optional)
N/A Q1KL9C36 Pallet, Steel (Optional)
24
APPENDIXES
Appendix 1 – Express Fill 700/1000 General Arrangement
BT-472 Rev. B
25
4075 Hamilton Blvd.
Theodore, Alabama 36582 U.S.A.
Telephone (251) 443-8680
Fax (251) 443-2250
In U.S. and Canada:
(800) TW TANKS (898-2657)
P/N 99187836
Publication # BT-472 Rev. B
Loading...