Taylor-Wharton EF-450 User Manual

Express Fill 450

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

aintain this equipment. If you do not understand these instructions, contact your supplier for additional information. m

booklet (TW-202) for handling cryogenic material. Do not permit untrained persons to use or

Table of Contents

WARNING 3

Safety Precautions for Liquid Oxygen 3 Safety Precautions for Liquid Nitrogen 4

INTRODUCTION 5

System Description 5 Specifications 6

PIPING CIRCUITS 7

Fill and Vent Circuits 8 Express Fill Circuit 9 Pressure Building Circuit 10 Gas Withdrawal Circuit 11 Economizer Circuit 12 Safety Devices 13 Instrumentation Circuits 14

OPERATION 15

Receiving Inspection 15 Handling 15 Customer Installed Equipment/Piping 15 Filling by Pressure Transfer 15 Filling by Pump Transfer 16 Filling for Road Transport 16 Withdrawing Gas 16 Withdrawing Liquid 17 Changing Gas Service 17

MAINTENANCE 18

Leak Test 18 Globe Valves 18 Regulator 19 Instruments 19 Checking Vacuum 20 Trouble-Remedy Guide 22 Replacement Parts 23

APPENDIXES 24

Express Fill 450 General Arrangement

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 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 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.

INTRODUCTION

This manual provides information for the operation and maintenance of Taylor-Wharton's line of Express Fill 450 cryogenic gas supply systems. These products store cryogenic liquid and dispense it as a warm pressurized gas. The Express Fill 450 is 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 450 consists of a cryogenic liquid vessel, piping, internal vaporizer, and an internal pressure builder.

The system vessel has an approximate gross capacity of 450 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. Models are available designed and constructed in accordance with DOT-4L or ASME Section VIII. The DOT-4L vessels may be legally transported by truck in the United States while containing product.

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.

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 differential pressure gauge instrument lines are constructed of copper tube.

The Express Fill 450 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.

Specifications

Model EF-450-DOT EF-450HP DOT EF-450VHP DOT EF-450 EF-450HP

Part Number M4500C03-EZ H4500C03-EZ V4500C03-EZ M4500C01-EZ H4500C01-EZ

Dimensions

Footprint inches 31 x 31 31 x 31 31 x 31 31 x 31 31 x 31

(mm) 787 x 787 787 x 787 787 x 787 787 x 787 787 x 787

Cylinder Diameter inches 30 30 30 30 30

(mm) 762 762 762 762 762

Height inches 74 74 74 74 74

(mm) 1,880 1,880 1,880 1,880 1,880

Empty Weight lbs 640 730 885 730 950

(kg) 290 331 401 331 431

Capacity, Gross gallons 118 117 115 117 115

(liters) 448 443 437 442 436

MAWP psig 250 350 500 250 350

(kPa) 1,724 2,413 3,448 1,724 2,413

Design Specification DOT 4L ASME Section VIII, Division I

Safety Devices

Pressure Relief Valve psig 250 350 500 250 350

(kPa) 1,724 2,413 3,448 1,724 2,413

Inner Container Bursting Disc psig 356 525 750 356 525

(kPa) 2,455 3,620 5,171 2,455 3,620

Road Relief Valve psig 22 22 22 NA NA

(kPa) 152 152 152 NA NA

Pressure Control Devices

Economizer Setting psig 200 325 420 200 325

(kPa) 1,379 2,241 2,896 1,379 2,241

Pressure Building Setting psig 175 300 400 175 300

(kPa) 1,207 2,069 2,758 1,207 2,069

Gaseous Capacity NPT1

Nitrogen cu. ft. 9,250 8,750 7,687 9,798 9,660

(cu. M) 262 248 218 277 274

Oxygen cu. ft. 11,400 11,000 10,208 12,100 11,900

(cu. M) 323 312 289 343 337

Argon cu. ft. 11,000 10,700 9,947 11,900 11,700

(cu. M) 312 303 282 337 331

Weight of Contents1

Nitrogen lbs 670 634 557 710 700

(kg) 304 288 253 322 318

Oxygen lbs 946 907 845 1,001 987

(kg) 429 411 383 454 448

Argon lbs 1,134 1,102 1,028 1,223 1,206

(kg) 514 500 466 555 547

Gas Delivery Rate cfh 450 450 450 450 450

(cu. M/h) 12.7 12.7 12.7 12.7 12.7

NER (Percent of capacity per day O2) 1.0%

Based on liquid at full trycock for ASME designs and maximum liquid weight for DOT designs.

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.

SV-1

PI-1

CN-1

V-3

LI-1

PCV-1

V-5

SV-2

V-1

R-2

V-2

CV-2

CN-2

VC-1

FSV-1

PBC-1

Legend

CN-1 Connection, Liquid Fill / Withdrawal LI-1 Liquid Level Gauge CN-2 Connection, Full Trycock & Vent PI-1 Pressure Gauge CN-3 Connection, Pump / Top Fill PBC-1 Pressure Building Coil CN-4 Connection, Gas Withdrawal VC-1 Vaporizer Coil V-1 Valve, Liquid Fill / Withdrawal PCV-1 Pressure Building Regulator V-2 Valve, Full Trycock / Vent SV-1 Safety Valve V-3 Valve, Gas Withdrawal SV-2 * Safety Valve, 22 psig V-4 Valve, Pressure Building R-1 Safety Disc V-5 * Valve, Isolation R-2 Outer Casing Safety Disc CV-1 Pump / Top Fill Check Valve FSV-1 Fill Stop Valve CV-2 ** Secondary Pump / Top Fill Check Valve

Notes:

* Featured on DOT models only. ** 500 psi vessels feature a ball valve, ½” FNPT instead of the check valve.

Figure 1: System Piping Schematic

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-1

CN-1

V-2

CN-2

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 Truck 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 Taylor-Wharton 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

CN-3

Figure 3: Express Fill circuit highlighted in blue.

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