Taylor-Wharton EF-1500 User Manual

BT-481 REV. B

Express fill 1500

Installation and Operation 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-481 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
Internal Vaporizer, External Vaporizer Inlet, and Economizer 13
Safety Devices 14
Instrumentation Circuits 15

INSTALLATION 16

Receiving Inspection 16
Handling 16
Vessel Installation Guidelines 16
Fill Box Installation Guidelines 16

OPERATION 19

Filling by Pressure Transfer 19
Filling by Pump Transfer 19
Withdrawing Product 20
Withdrawing Liquid 20
Changing Gas Service 20

MAINTENANCE 21

Leak Test 21
Globe Valves 21
Regulators 22
Instruments 23
Vacuum 23
Trouble-Remedy Guide 24
Replacement Parts 25

APPENDIXES 26

Appendix 1 – Express fill 1500 General Arrangement 26

BT-481 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; 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 possi bl e cont act wi t h li qui d oxy gen. 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 consi dered safe for at least 30 m inutes.

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

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BT-481 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 norm al at mospheri c 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 driveway s 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.

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BT-481 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 liqu id 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 Hi ghway, Arlingt on, 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, especiall y i f there is a possibi l i t y of
liquid ejection or if cold gas may issue forcefully from equipm ent. 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.

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BT-481 REV. B

INTRODUCTION

This manual provides information for the operation and maintenance of Taylor-Wharton's line of Express Fill 1,500
cryogenic gas supply systems. These products store cryogenic liquid and dispense it as a warm pressurized gas. The
Express Fill 1,500 is designed for applications requiring nitrogen, argon, or oxygen gas. These products are ideal for on­site filling with Taylor-Wharton’s Express cryogenic liquid d elivery vehicle. An external vaporizer (order separately)
may be used with this product.

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 1,500 consists of a cryogenic liquid vessel, piping, internal vaporizer, and external pressure builder.

The system vessel has an approximate gross capacity of 1,500 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 cont ents is provi ded by the di fferential pressure gauge.

The Express Fill 1,500 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 pressure building coil is an
external aluminum finned extrusion attached to the outer jacket.

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Specifications

Model EF-1500VHP
Part Number V15LOCO2-EZ/V15L0C03-EZ
Dimensions
Cylinder Diameter inches 48
Height inches 91
Empty Weight lbs 2,950

BT-481 REV. B

Capacity, Gross

gallons 414

(liters) 1,567
MAWP psig 500
Design Specification ASME Section VIII, Division I
Safety Devices
Pressure Relief Valve psig 500
Inner Container Bursting Disc psig 750
Pressure Control Devices
Economizer Setting psig 425
Pressure Building Setting psig 400
Gaseous Capacity NPT1
Nitrogen cu. ft. 31,400
Oxygen cu. ft. 39,500
Carbon Dioxide2 cu. Ft. 26,330
Argon cu. Ft. 38,700
Full Weight of Contents1
Nitrogen lbs 5,230
Oxygen lbs 6,220
Carbon Dioxide2 5,962
Argon lbs 6,950
Gas Delivery Rate scfh 1,350
NER (Percent of capacity per day O2) 1.0%

1

Based on liquid at full trycock saturated @ 0 psig.

2

Based on liquid at full trycock saturated @ operating pressure.

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BT-481 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.

CN-4

­CN-3
CN-2
CN-1

V-3
V-2

-

CV-1

PCV-2

-

SV-2

SV-3

V-6

CN-6

R-2

V-9

PI-1

LI-1

V-8 V-10

CN-5

-

-

SV-1

­FSV-1*

PBC-1

PCV-1

V-7

SV-4

Legend

CN-1 Connection, Pump / Top Fill V-10 Valve, Liquid Phase Isolation
CN-2 Connection, Full Trycock & Vent V-11 Valve, Gas Use
CN-3 Connection, Liquid Fill / Withdrawal CV-1 Check Valve, Pump / Top Fill
CN-4 Connection, Vaporizer Inlet (External) LI-1 Liquid Level Gauge
CN-5 Instrument Connection, Liquid Phase PI-1 Pressure Gauge
CN-6 Instrument Connection, Vapor Phase PBC-1 Pressure Building Coil
CN-7 Connection, Vaporizer Outlet (Internal) PCV-1 Pressure Building Regulator
V-1 Valve, Pump / Top Fill PCV-2 Economizer Regulator
V-2 Valve, Full Trycock / Vent SV-1** Safety Valve
V-3 Valve, Liquid Fill / Withdrawal SV-2 Relief Valve
V-4 Valve, Vaporizer Inlet SV-3 Relief Valve
V-5 Valve, Economizer Isolation SV-4 Relief Valve
V-6 Valve, Pressure Building Outlet R-1** Inner Container Safety Disc
V-7 Valve, Pressure Building Inlet R-2 Outer Casing Safety Disc
V-8 Valve, Vapor Phase Isolation FSV-1* Fill Stop Valve
V-9 Valve, Equalization

* Functions with delivery vehicle equipped with automatic filling system, i.e. Taylor-Wharton Express Cryogenic Delivery System.
** Option for Dual Safeties/Rupture Disc with Diverter Valve.

Figure 1: System Piping Schematic

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BT-481 REV. B

Fill and Vent Circuits

The liquid valve (V-3) communicates with the bottom of the vessel. 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. Th e 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%.

V-3

CN-3

Figure 2: Fill and vent circuits highlighted in blue.

V-2

CN-2

Express Fill Circuit

The Express Fill circuit may be used for filling from the Taylor-Wharton Exp ress Cryogenic Delivery System or for top
filling by a cryogenic pump. A ball valve (V-1) and a check valves (CV-1) 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

V-1

CN-1

Figure 3: Express Fill circuit highlighted in blue.

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