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Algas SDI Direct Fired 40/40H Operation & Maintenance Manual

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...Innovative liquid vaporizing and gas mixing solutions
LP-Gas Vaporizer: 40/40H, 80/40H & 120/60H
Operations & Maintenance
Manual
151 South Michigan Street, Seattle, Washington, USA 98108
Tel: +1 206-789-5410
Fax: +1 206-789-5414
Web: www.algas-sdi.com
FILE: MANUAL PN 52642 DIRECT FIRED 5-10-21
Samuel Oyen
2021.05.07 17:33:46 -07'00'

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  • Page 1 ...Innovative liquid vaporizing and gas mixing solutions LP-Gas Vaporizer: 40/40H, 80/40H & 120/60H Operations & Maintenance Manual 151 South Michigan Street, Seattle, Washington, USA 98108 Tel: +1 206-789-5410 Fax: +1 206-789-5414 Web: www.algas-sdi.com FILE: MANUAL PN 52642 DIRECT FIRED 5-10-21 Samuel Oyen 2021.05.07 17:33:46 -07'00'...
  • Page 2 WARNING Read the OPERATION MANUAL before operating this equipment. ■ NOTE: Algas-SDI reserves the right to use alternate manufacturers’ components as vendor delivery applicability dictates. Literature contained in the Operation Manual has been supplied by vendors. Please check to be sure supplied data matches your configuration.
  • Page 3 Warranty Registration A Warranty Registration Card is located on the last page of this manual. Fill it out and send a copy either by mail to the address shown at the bottom of the form or submit via email to sales@algas-sdi.com. Warranty, Copyrights and Approvals WARRANTY Algas-SDI International, LLC (ASDI) warrants that the equipment is free of...
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  • Page 5 Symbols and Conventions Special symbols are used to denote hazardous or important information. You should familiarize yourself with their meaning and take special notice of the indicated information. Please read the following explanations thoroughly. GENERAL WARNING OR CAUTION Indicates hazards or unsafe practices which can result in damage to the equipment or cause personal injury.
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  • Page 7: Table Of Contents

    Table of Contents Direct Fired Vaporizer Options Auto Reigniter Contaminant Separator / Filtaire Economy Valve Kit Inlet and Outlet Hand Valves Pipe away Adapter 1st Stage Regulator Introduction Description/Overview Figure 1 – Direct Fired Vaporizer System - Basic Features How the vaporizer works Direct Fired vaporizer specifications Installation General...
  • Page 8 Operation Direct Fired Vaporizer start up procedure 3-13 Figure 7 – Temperature control dial in “RUN” position 3-13 Figure 8 – Pilot button pressed down and igniter switch on 3-14 Direct Fired Vaporizer setpoint adjustment 3-14 Direct Fired Vaporizer shutdown procedure 3-15 Figure 9 –...
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  • Page 10: Pipeaway Adapter

    Direct Fired Vaporizer Options Electronic Auto Reigniter Auto Reigniter System 115/230 VAC 50/60Hz, Use P/N: 3-8683, Quantity 1 per unit FILTAIRE Contaminant Separator A contaminant separator is recommended for all Direct Fired Vaporizer installations. To properly size the FILTAIRE contact Algas-SDI with total connected load and high pressure (first stage) regulator setting.

  • Page 11: Introduction

    Introduction Description/Overview Algas-SDI is an ISO 9001 registered company. Direct Fired Vaporizers are manufactured under strict accordance with ASME, UL and PED requirements and carry the associated marks and the ASME "U" stamp. A Direct Fired vaporizer, as the name implies, is one in which heat is furnished by an open flame directly applied to the heat exchange surface, which in turn contacts the LP Gas liquid that is to be vaporized.

  • Page 12: How The Vaporizer Works

    Introduction HOW THE VAPORIZER WORKS When the shut-off valve in the liquid supply line is opened, liquid is forced into the heat exchanger by the pressure in the storage tank. As the liquid level rises, some of the liquid boils off until it matches the pressure coming from the tank. The flow of liquid into the heat exchanger will stop when the rising liquid forces the float ball upward, closing the liquid inlet valve, or when the pressure in the heat exchanger is the same as the pressure coming from the storage tank.

  • Page 13: Direct Fired Vaporizer Specifications

    Introduction DIRECT FIRED VAPORIZER SPECIFICATIONS: BURNER INPUT 40/40H 51,360 BTU/hr (15 kW) per burner 80/40H 51,360 BTU/hr (15 kW) per burner 120/60H 77,040 BTU/hr (22.5 kW) per burner GAS CONSUMPTION: Approximately 1,000 BTU/hr (0.3 kW) per gallon (3.79 liters) of propane vaporized TOTAL BURNER INPUT THERMOSTAT PORT PRESSURE*: 10”...

  • Page 14: Installation

    Installation GENERAL • Install the system so it complies with all governing codes and regulations. • Make up all threaded pipe connections with a sealing compound that is approved and listed for LP gas service. • All above ground lines should be adequately supported. •...
  • Page 15 Installation Figure 2 – Vaporizer Dimensions (shown in inches) 40/40H Vaporizer 80/40H and 120/60H Vaporizers “A” “B” “C” Model 35” (0.89 m) 29” (0.74 m) 20” (0.51 m) 40/40H 35” (0.89 m) 29” (0.74 m) 20” (0.51 m) 80/40H 44 ¼” (1.12 m) 37 ¾”...

  • Page 16: Liquid Supply Line

    Installation Figure 3 – Installation – 40/40H, 80/40H, and 120/60H vaporizers CAUTION The entire installation must be leak tested prior to operating the system. NOTE Do not connect this vaporizer to a storage tank that has been used in vapor withdrawal service until the tank has been emptied and all sediment and heavy ends have been cleaned from it.

  • Page 17: Liquid Inlet

    Installation 1. Install a UL listed shut-off valve with a minimum 250 psig (17.24 bar) gas pressure rating. 2. Install a 0-300 psig (0-20.7 bar) pressure gauge (or provisions for one) ahead of the 1 stage regulator. 3. Install the first stage regulator as close to the vaporizer as possible, but not further than 24”...

  • Page 18: Burner Supply Line (Optional)

    Installation BURNER REGULATOR SUPPLY LINE (OPTIONAL) Vaporizer burners are supplied with vapor from the outlet of the vaporizer where the least possibility of condensation will take place. In regions where there is a problem with a high content of heavy ends in the LP gas, a separate vapor supply line to the burner regulator on the vaporizer may be installed.

  • Page 19: Installing Multiple Units In Parallel

    Installation Figure 4 – Filtaire Operation BY PASS VALVE (NORMALLY CLOSED) 1ST STAGE REGULATOR OUTLET VALVE “FILTAIRE” OIL DEMISTER VAPOR FROM VAPORIZER VAPOR LINE INLET VALVE PIPE 5 DRAIN STAND VALVE VAPOR TO LOAD To properly size the FILTAIRE contact Algas-SDI with total connected load and high pressure (first stage) regulator setting.
  • Page 20 Installation AN OVERSIZED INLET AND OUTLET MANIFOLD MAY ALSO BE USED TO BALANCE THE FLOW. Figure 6a – Installing Multiple Units in Parallel, Oversized Manifolds with side inlet/outlet Figure 6b– Installing Multiple Units in Parallel, Oversized Manifolds with center inlet/outlet Algas-SDI Operation and Maintenance Manual –...

  • Page 21: Leak Test

    Installation ENCLOSURE AIR REQUIREMENTS If vaporizer must be housed inside an enclosure or other enclosed area, the following requirements for fresh air intake and exhaust outlet area must be met. Failure to do so will result in improper operation and damage to the equipment. Table 4 –...

  • Page 22: Installation Safety Requirements

    Installation Installation Safety Requirements NOTE Burner supply regulator 1 and 2 stage vents shall be piped away from vaporizer if required by local codes and regulations, or when installed in a building, enclosure, or other situation with potential to accumulate flammable gases. Ensure that vent piping is adequately supported to prevent damage to regulator.

  • Page 23: Operation

    Operation Direct Fired Vaporizer start up procedure 1. Before starting the vaporizer, close the outlet valve in the vapor service line. 2. Fill the vaporizer with LP gas liquid by slowly opening the liquid supply line valve between the storage tank and the vaporizer. If this valve is opened too quickly, the excess flow valve in the tank may close.

  • Page 24: Direct Fired Vaporizer Setpoint Adjustment

    Operation Figure 8 –Pilot button pressed down and igniter switch ON WARNING If pilot light goes off after releasing the pilot button, turn control dial to "OFF", wait 5 minutes and repeat step 4. 6. Turn temperature control dial counter clockwise until burner(s) cycle on. 7.

  • Page 25: Direct Fired Vaporizer Shutdown Procedure

    Operation Direct Fired Vaporizer shut down procedure (See Figure 9) 1. Turn temperature control dial to “OFF” position. Pilot flame should immediately extinguish. 2. Once the pilot flame has extinguished turn the igniter switch to “OFF”. 3. Close the isolation valve ahead of the burner regulator on the side of the vaporizer.

  • Page 26: Automatic Re-Ignition Operation

    Operation 2. Close outlet shut-off valve at the exit of the vaporizer. 3. Start burner per Direct Fired Vaporizer startup procedure and turn the thermostat temperature control dial to the highest setpoint (7). 4. After the burner cycles off, turn thermostat temperature control dial to “OFF”...

  • Page 27: Maintenance

    Maintenance Maintenance Recommendations Direct Fired Vaporizers are designed for trouble free and safe operation. Because of the nature of their use, and the severe duty they receive, it is important to provide scheduled maintenance. The maintenance schedule, type and frequency, provided in this manual is the minimum maintenance required for proper and safe operation of your vaporizer.
  • Page 28 Maintenance Table 6 – Annual Maintenance Requirements Annual Maintenance Items Strainer Remove the plug and clean the screen. Replace screen if tears or holes are present (40 – 80 Mesh). If oils or contaminants are present, it may be necessary to use a cleaner to remove all of the contaminants. Thermostat Check thermostat for proper operation per the Start-up procedure.
  • Page 29 Maintenance area between the heat exchanger and flue. High pressure air or a wire brush may be used for removal. A large amount of build- up on the outside of the heat exchanger can lead to a reduced capacity from your vaporizer. 3.

  • Page 30: Direct Fired Vaporizer Inspection Checklist

    Maintenance Use the Direct Fired Vaporizer Inspection & Maintenance Checklist included in this manual to record and keep track of your annual maintenance and inspections. DIRECT FIRED VAPORIZER INSPECTION CHECKLIST Model:_________________ Serial Number:___________________ Maintenance Checklist Items Inspected Replaced or Yes/No Kit Installed? 1.

  • Page 31: Replacing Reigniter Battery

    Maintenance Replacing reigniter battery 1. Turn the reigniter switch “OFF”. Open the battery access door on the bottom right corner of the thermostat housing. Figure 10 – Opening the battery access door 2. Pull out the battery, disconnect it and replace with new 9VDC battery. Push the battery back in the thermostat housing and close the battery access door prior to turning the reigniter switch “ON”.

  • Page 32: Adjusting Burner Input Pressure

    Maintenance Adjusting burner input pressure 1. Close the supply valve to the burner supply regulator and vent lines. 2. Using a 3/8” FNPT barb fitting and hose, connect a 0-30” manometer (or similar pressure indicating device) to the pressure tap port at the outlet of the thermostat.

  • Page 33: Liquid Inlet Valve Maintenance Procedure

    Maintenance Liquid inlet valve maintenance procedure Use Repair Kit P/N: 40764 (see Appendix A for kit details) NOTE: Vaporizer must be purged and empty of all liquid and vapor prior to performing maintenance on the liquid inlet valve. CAUTION Follow the below instructions carefully to prevent hazardous conditions.
  • Page 34 Maintenance Lightly grease and replace the O-ring around the inlet valve cap (large flange nut). Install inlet valve cap (large flange nut) and tighten into valve body. You may apply NEVER-SEEZ compound to the flange nut to allow for easy removal of the flange nut in the future. Once the internal components of the valve are replaced perform a “water test”...

  • Page 35: Capacity Control Valve Maintenance Procedure

    Maintenance Capacity control valve maintenance procedure Use Repair Kit p/n: 40764 (see Appendix A for kit details) Using a 7/16” end wrench or tubing wrench, loosen and remove the capacity control valve sensing line fitting on the top of the capacity control valve and carefully slide tube out of the way in order to remove the large flange nut (capacity control valve cap).

  • Page 36: Troubleshooting

    Troubleshooting 1. PILOT - TROUBLESHOOTING TREES #1 & #2 ◼ The pilot flame is adjusted at the factory to provide a non-blowing blue flame. If the flame is not adequate or the pilot does not stay lit, check the pilot burner to see if it is clear of any obstructions.

  • Page 37: Pilot

    Troubleshooting TROUBLESHOOTING TREE #1 PILOT WILL NOT LIGHT CHECK THE BURNER PRESSURE IS OK PRESSURE IS HIGH/LOW INPUT PRESSURE REFER TO PAGE 1-3 NO PRESSURE REPLACE REGULATOR PRESSURE WILL PRESSURE IS OK NOT ADJUST ADJUST REGULATOR DISCONNECT THE PILOT PRESSURE FUEL LINE FROM THE NO PRESSURE THERMOSTAT AND...
  • Page 38 Troubleshooting TROUBLESHOOTING TREE #2 PILOT LIGHTS BUT WILL NOT HOLD CHECK TO SEE THAT THE PILOT IS OK PILOT IS IMPINGING ON THE PILOT IS LOW THERMOCOUPLE BULB, APPROXIMATELY 3/8” TO 1/2” (9 to 13 mm) SEE TROUBLESHOOTING TREE CHECK THE THERMOCOUPLE SIGNAL TO #1: PILOT WILL NOT LIGHT THERMOSTAT CONTROL VALVE.

  • Page 39: Igniter Will Not Spark

    Troubleshooting TROUBLESHOOTING TREE #3 IGNITER WILL NOT SPARK CHECK BATTERY OK BATTERY DEAD REIGNITER BATTERY CHECK IF ELECTRODE IS CONTACTING HOOD REPLACE BATTERY OR FURTHER THAN 1/8” (3 mm) OUT OF POSITION ADJUST AND CHECK IF CHECK ELECTRODE OPERATION IS WET WIPE ELECTRODE DRY OR LIGHT...
  • Page 40 Troubleshooting TROUBLESHOOTING TREE #4 MAIN BURNER WILL NOT LIGHT CHECK TO SEE THAT THE PILOT IS IMPINGING ON THE THERMOCOUPLE BULB, APPROXIMATELY 3/8” TO 1/2” (9 to 13 mm) TURN THE THERMOSTATIC GAS VALVE TEMPERATURE CONTROL DIAL UP TO SEE TROUBLESHOOTING TREE THE HIGHEST SETTING.

  • Page 41: If Vapor Pressure Drops

    Troubleshooting TROUBLESHOOTING TREE #5 VAPOR SERVICE PRESSURE DROPS NOTE: SERVICE PRESSURE WILL DROP IF THE DEMAND EXCEEDS VAPORIZER’S CAPACITY: 40/40H 3.6 MMBTU/hr (1,055 kW), 80/40H 7.3 MMBTU/hr (2,139 kW), 120/60H 10.9 MMBTU/hr (3,195 kW). FOLLOWING TROUBLESHOOTING TREE ASSUMES THAT THE LOAD ON THE VAPORIZER IS LESS THAN ITS MAXIMUM CAPACITY.

  • Page 42: Appendix A: Technical Information

    APPENDIX A TECHNICAL INFORMATION...
  • Page 43 Figure 13 – 40/40H Vaporizer Replacement Parts...
  • Page 44 Figure 14 – 80/40H and 120/60H Vaporizer Replacement Parts NOTE Drawing shown for an 80/40H Vaporizer.
  • Page 45 Figure 15 – Inlet Valve and Capacity Control Valve LIQUID INLET VALVE 23 Inlet valve cap o-ring 23 Inlet valve spring 23 Inlet valve seat Inlet valve orifice 23 Inlet valve gasket 23 Inlet valve orifice o-ring 23 Pivot arm gasket CAPACITY CONTROL VALVE 22 Capacity control valve Cap o-ring...
  • Page 46 Figure 13, 14 and 15 Descriptions Burner Manifold – 40/40H P/N: 1502-4020 Burner tip #69 burner jet orifice – All models P/N: 34323 Capacity control valve 1” – All models P/N: 1508-4001 Drip leg kit – All models P/N: 40403 Liquid inlet valve –...
  • Page 47 Table 7 – Repair Kits and Other Available Replacement Parts 40631: Master rebuild kit 40/40H Part number Description 3-0034 40/40H Repair kit 34323-10 Burner tip #69 orifice (qty 10) 34800 Burner supply regulator 40633: Master rebuild kit 80/40H Part number Description 3-0035 80/40H Repair kit...
  • Page 48 3-0014: Repair kit 40/40H Pilot orifice and thermocouple Part number Description 37050 Thermocouple for all models 46-6 Orifice pilot burner 40/40H, #18 3-0013: Repair kit 80/40H Pilot orifice and thermocouple Part number Description 37050 Thermocouple for all models 37510 Orifice pilot burner 80/40H & 120/60H, #23 41041: Repair kit, 120/60H Pilot orifice and thermocouple Part number Description...
  • Page 49 Liquid inlet valve pin gasket installation procedure 1. Clean pivot screw hole opening from any residue. 2. Apply blue (medium strength) Locktite 243 or Permatex to threads on the liquid inlet valve body or pivot screw.
  • Page 50 3. Slide pin gasket (P/N 8135-101) over the pivot screw (P/N 3-4169) threads as shown in the picture. 4. Screw in pivot screw to the inlet valve body and apply 8 in-lbs (0.9 Nm) of torque (approximately 1/8 full turn).
  • Page 51 5. Align valve stem with pivot screw and repeat the same step with the pin gasket and pivot screw on the opposite side of the liquid inlet valve. 6. Verify there is no damage to the pin gasket. Set inlet valve assembly aside for an hour to allow Locktite to properly dry before reinstalling valve assembly back on the vaporizer.
  • Page 56 Algas-SDI International, LLC 151 South Michigan Street Seattle, Washington, 98108 1.206.789.5410 Fax: 1.206.789.5414 www.algas-sdi.com.

This manual is also suitable for:

Direct fired 80/40hDirect fired 120/60h

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