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 booklet (TW-202) for handling cryogenic material. Do not permit untrained persons to use or maintain this equipment. If you do not understand these instructions, contact your supplier for additional information.
BT-481 REV.
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.
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.
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.
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 delivery vehicle.
BT-481 REV. B Specifications Model EF-1500VHP Part Number V15LOCO2-EZ/V15L0C03-EZ Dimensions Cylinder Diameter inches 48 Height inches 91 Empty Weight lbs 2,950 gallons 414 (liters) 1,567 Capacity, Gross 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.
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.
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. 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.
BT-481 REV. B 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 outlet valve (V-6) and pressure building inlet valve (V-7) permits the circuit to function. When the pressure inside the vessel drops below the pressure builder setting, the pressure building regulator (PCV-1) opens.
BT-481 REV. B Figure 4A: Pressure Switch Control Diagram 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.
BT-481 REV. B 1. Close the pressure builder input (V-7) and output (V-6) Valves. 2. Allow the unit to vaporize the liquid that is in the pressure builder and closed off lines. It may require an hour or longer to vaporize all the residual liquid and vent the gas through the safeties. 3. After all the liquid is vaporized, there will still be pressure on the lines that will not be vented through the safety.
BT-481 REV. B Internal Vaporizer, External Vaporizer Inlet, and Economizer Circuit The Internal Vaporizer circuit vaporizes cryogenic liquid and warms it to ambient temperature for use in the final application. Opening the gas use valve (V-11) allows liquid, driven by the pressure within the vessel, to flow through the vaporizer. The vaporizer uses heat from the ambient air to convert the liquid into a gas and warm it. The vaporizer is attached to the inside surface of the vacuum jacket. .
BT-481 REV. B Safety Devices The Express Fill 1,500 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).
BT-481 REV. B Instrumentation Circuits The instrumentation consists of a pressure gauge and digital liquid level or 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.
BT-481 REV. B INSTALLATION Dimensions and connection data for the Express Fill 1,500 can be found on the General Arrangement Drawing 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.
BT-481 REV. B Vent Line Safety Line Fill Line Figure 8: Typical fill box installation diagram. Recommended components for a typical fill box installation: Fill and Vent Line Vessel Fitting: Compression Fitting, 1/2” Male Pipe Thread x 7/8" O.D. Tube, Brass (2 required) 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.
BT-481 REV. B 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 safety disc must be removed and replaced with an equivalent device featuring outlets with pipe threads. Consult the factory when specifying this component. Thread the compression fittings for the safety line of the vessel (recommended above) into the safety valve and safety disc outlets.
BT-481 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.
BT-481 REV. B Withdrawing Product Internal Vaporizer To withdraw gas from the Express Fill 1,500, connect a suitable line regulator to the gas withdrawal connection (CN-7). Connect the outlet of the regulator to the application. Follow these steps: 1. Open the pressure building valve (V-6). Monitor the pressure gauge (PI-1). When the pressure exceeds the desired delivery pressure, continue. 2. Open the gas withdrawal valve (V-11). 3. Adjust the line regulator to desired delivery pressure.
BT-481 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.
BT-481 REV. B 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.
BT-481 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.
BT-481 REV. B Trouble-Remedy Guide Trouble 1. Low operating pressure. 2. Excessive system pressure. 3. Leaking relief valve. 4. Ruptured pressure vessel rupture disc. Possible Cause a. Safety valve leaking or frozen open. b. Safety disc ruptured. c. Piping leaks to atmosphere. d. Pressure building / economizer regulator malfunction. e. Excessive product withdrawal. f. g. h. Pressure building valve closed. Malfunctioning pressure gauge. Excessive frost on pressure building coils. a. b. c. d. e.
BT-481 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.
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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 99187839 Publication # BT-481 REV.
