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Algas SDI Direct Fired F6-ASME Operation & Maintenance Manual

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151 South Michigan Street, Seattle, Washington, USA 98108
Tel: 206-789-5410
This manual covers units built after August 2009
FILE: MANUAL PN 54000 rev 09-23-2019
...Innovative liquid vaporizing and gas mixing solutions
LP-Gas Vaporizer: 160H - 800H
Operations & Maintenance 
Manual 
Fax: 206-789-5414
2019.09.2
6
16:24:07
-07'00'
 
Web: www.algas-sdi.com
After S/N: 09160185

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Summary of Contents for Algas SDI Direct Fired F6-ASME

  • Page 1 ...Innovative liquid vaporizing and gas mixing solutions LP-Gas Vaporizer: 160H - 800H Operations & Maintenance  Manual    151 South Michigan Street, Seattle, Washington, USA 98108 Tel: 206-789-5410 Fax: 206-789-5414 Web: www.algas-sdi.com This manual covers units built after August 2009 After S/N: 09160185 2019.09.2 16:24:07 FILE: MANUAL PN 54000 rev 09-23-2019...
  • 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, Copyrights and Approvals  WARRANTY    Algas-SDI International, LLC (ASDI) warrants that the equipment is free of defects in materials and workmanship under normal use and service. ASDI agrees to repair or replace, at our option, without charge f.o.b. factory, any part which has proven defective to the satisfaction of Algas-SDI International, LLC within one (1) year from the date of the original installation or within 18 months from the date of shipment, whichever is earlier.
  • Page 4 This page left intentionally blank...
  • Page 5 IMPORTANT WARRANTY NOTICE: The Algas-SDI warranty period for equipment is 18 months after shipment from our facility or 12 months after installation. See our warranty statement at the beginning of this manual for the complete text. A warranty registration card has been provided with this manual so that you may register the date of installation for warranty purposes.
  • Page 6 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.
  • Page 7  ...

  • Page 8: Table Of Contents

    Table of Contents  Options  Auto Re-igniter Contaminant Separator / Filtaire Economy Kit Inlet and Outlet Hand Valves Pipeaway Adapter 1st Stage Regulator Introduction  Description/Overview Figure 1 – Direct Fired Vaporizer System - Basic Features How the vaporizer works Direct fired vaporizer specifications Installation ...
  • Page 9 Operation  Direct Fired Vaporizer start up procedure Figure 6– Temperature control dial in “RUN” position Figure 7 – Pilot button pressed down and ignitor switch on Direct Fired Vaporizer setpoint adjustment Figure 8 – Rotating temperature control dial counter-clockwise to desired setpoint Direct Fired Vaporizer shutdown procedure Figure 9 –...
  • Page 10   This page left intentionally blank...

  • Page 11: Options

      Options Auto Re‐igniter  160H, Auto Re-igniter System 115/230 VAC 50/60Hz, Use P/N: 3-8683, Quantity 1 per unit See Page 14 for Details   Contaminant Separator / Filtaire  160H, Filtaire Model F6 - ASME, Use P/N: 20540 or 20540-ASME, Quantity 1 per unit See Page 9 for Details  ...

  • Page 12: Introduction

      1  Introduction    Description/Overview  Congratulations on your purchase of an Algas-SDI Direct Fired vaporizer. Algas- SDI is an ISO 9001 registered company and your new vaporizer was manufactured under strict accordance with ASME, UL and PED requirements and carries 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 13: 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 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 14: Direct Fired Vaporizer Specifications

      Introduction  Direct Fired Vaporizer specifications:  BURNER INPUT: 160H 176,900 BTU’s/Hr (51.8 kW) per burner GAS CONSUMPTION: 1,000 BTU’s per gallon of propane vaporized THERMOSTAT SUPPLY REGULATOR PRESSURE (BURNER ON)*: 15-18” w.c. (37.3 – 44.8 mbar) BURNER PRESSURE**: 9” w.c. (22.4 mbar) PILOT BURNER: 2,200 BTU’s/hr (644 W) 140 to 160 F (60 to 71ºC) NOMINAL OPERATING TEMPERATURE***:...

  • Page 15: 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 16   Operation  Figure 2 – Vaporizer Dimensions 1” VAPOR OUTLET 3/4 “FNPT LIQUD INLET CONNECTION HEAVY ENDS DRAIN Figure 3 – Installation – 160H vaporizers Algas-SDI Operation and Maintenance Manual – P/N – 54000...

  • Page 17: Vapor Distribution Line

      Operation  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 18: Vapor Bypass Line (Optional)

      Operation  1. Install a UL listed shut-off valve with a Minimum 250 psig gas pressure rating. 2. Install a thermometer after the vaporizer shut-off valve. 3. Install the first stage regulator as close to the vaporizer as possible, but not further than 24”...

  • Page 19: Economy Installation (Optional)

      Operation  The liquid pressure to the inlet of the vaporizer must be a minimum of 6PSI higher than desired discharge pressure. If tank pressure cannot meet this requirement, install a pump in the liquid line under the storage tank to maintain the minimum pressure.

  • Page 20: Leak Test

      Operation  A complete system consists of inlet and outlet connections, a blow- FILTAIRE down drain (5), a pressure gauge (4), a vent which is normally plugged (6), and a bypass valve system for cleaning (1, 2, and 3). The bypass valves enable the system to continue operating when the is removed for cleaning FILTAIRE...

  • Page 21: Check Regulator Pressures

      Operation  NOTE    If using direct fired vaporizers in mobile or temporary applications, leak test must be performed each time vaporizer has been moved or re-located.     CHECK REGULATOR PRESSURES See Adjusting the Regulator page 21. NOTE    For installations or locations in Canada it may be required to vent the integral pressure relief of the burner supply regulator.

  • Page 22: Operation

      Operation  3  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 23: Direct Fired Vaporizer Setpoint Adjustment

      Operation  Figure 7 –Pilot button pressed down and ignitor switch ON WARNING    If pilot light goes off after releasing dial, 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 24: Direct Fired Vaporizer Shutdown Procedure

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

  • Page 25: Direct Fired Vaporizer Purge Procedure

      Operation  Direct Fired Vaporizer purge procedure  If the vaporizer is not going to be used for a long period of time, it should be purged. The information contained below is a step by step procedure on how to purge Algas-SDI direct fired vaporizer. This procedure should be followed anytime a vaporizer needs to be maintained, serviced, relocated or shut down for any other reason.

  • Page 26: Maintenance

      4  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 27   Maintenance  Table 4 – Annual Maintenance Requirements Annual Maintenance Items Strainer Remove the plug and clean the screen. Replace screen if tears or holes are present. 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 28   Maintenance  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. Check bottom head of the heat exchanger for pitting and/or scaling.

  • Page 29: Direct Fired Vaporizer Maintenance 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 30: Replacing Reignitor Battery

      Maintenance  Replacing reignitor battery  1. Turn the reignitor switch OFF. Use Phillips screwdriver to 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 reignitor switch ON.

  • Page 31: Adjusting The Regulator

      Maintenance  ADJUSTING THE REGULATOR 1. Close the supply valve to the Thermostat Supply Regulator and vent lines. 2. Using a 3/8” FNPT barb fitting and hose, connect a 0-30” manometers (or similar pressure indicating device) to the pressure tap port at the bottom of the drip leg and at the pressure port at the inlet to the burner.
  • Page 32   Maintenance  Liquid inlet valve maintenance procedure  Use Repair Kit P/n: 3-0016 (see repair kit section for kit details) NOTE: Vaporizer must be purged and empty of all liquid and vapor prior to performing maintenance on the liquid inlet valve. 1. Loosen the four bolts to remove liquid inlet valve cover on the outside of the vaporizer cabinet.

  • Page 33: Liquid Inlet Valve Maintenance

      Maintenance  14. 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. 15. Once the internal components of the valve are replaced perform a “water test”...

  • Page 34: Capacity Control Valve Maintenance

      Maintenance  Capacity control valve maintenance procedure  Use Repair Kit p/n: 3-0017 (see repair kit section for kit details) 1. 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 35   Maintenance  This page intentionally left blank. Algas-SDI Operation and Maintenance Manual – P/N – 54000...

  • Page 36: Troubleshooting

      5  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: Troubleshooting Tree #1: Pilot Will Not Light

      Troubleshooting  TROUBLESHOOTING TREE #1 PILOT WILL NOT LIGHT CHECK THE BURNER PRESSURE IS HIGH/LOW PRESSURE IS OK SUPPLY REGULATOR PRESSURE. REFER TO PAGE 3 NO PRESSURE REPLACE REGULATOR PRESSURE WILL PRESSURE IS OK NOT ADJUST ADJUST REGULATOR DISCONNECT THE PILOT PRESSURE FUEL LINE FROM THE NO PRESSURE...

  • Page 38: Troubleshooting Tree #2 Pilot Lights But Will Not Hold

      Troubleshooting  TROUBLESHOOTING TREE #2 PILOT LIGHTS BUT WILL NOT HOLD CHECK TO SEE THAT THE PILOT IS LOW PILOT IS OK PILOT IS IMPINGING ON THE THERMOCOUPLE BULB, APPROXIMATELY 3/8” TO 1/2” SEE TROUBLESHOOTING TREE #1: PILOT WILL NOT LIGHT CHECK THE THERMOCOUPLE SIGNAL TO THERMOSTAT CONTROL VALVE.

  • Page 39: Troubleshooting Tree #3: Main Burner Will Not Light

      Troubleshooting  TROUBLESHOOTING TREE #3 MAIN BURNER WILL NOT LIGHT CHECK TO SEE THAT THE PILOT IS IMPINGING ON THE THERMOCOUPLE BULB, APPROXIMATELY 3/8” TO 1/2” SEE TROUBLESHOOTING TREE TURN THE THERMOSTAT CONTROL KNOB #1 OR #2 UP TO THE HIGHEST SETTING. DID THE CONTROL “CLICK”? REPLACE CHECK FOR...

  • Page 40: Troubleshooting Tree #4: Vapor Service Pressure Drops

      Troubleshooting  TROUBLESHOOTING TREE #4 VAPOR SERVICE PRESSURE DROPS NOTE: SERVICE PRESSURE WILL DROP IF THE DEMAND EXCEEDS VAPORIZER’S CAPACITY: 160H - 14.6 MBTU/hr. THE FOLLOWING TROUBLESHOOTING TREE ASSUMES THAT THE LOAD ON THE VAPORIZER IS LESS THAN ITS MAXIMUM CAPACITY. IS THE BURNER OPERATING? CHECK THE BURNER...
  • Page 41   Troubleshooting  This page intentionally left blank. Algas-SDI Operation and Maintenance Manual – P/N – 54000...

  • Page 42: Appendix A: Technical Information

      APPENDIX A TECHNICAL INFORMATION...
  • Page 43 Appendix A  This page intentionally left blank.
  • Page 44 Appendix A  Table 6 – Repair Kits and Other Available Replacement Parts 160H trough 800H 160H trough 800H 3-0016: Liquid Inlet Valve Repair Kit Components Description Qty. 3-4165 Valve seat assembly 3-4172 Spring 40C37 Gasket, liquid inlet valve 8135-101 Gasket, pins 1501-5002 O-ring 9000-25...
  • Page 45 Appendix A  40480: Master repair kit Components Description Qty. 3-0016 Liquid inlet valve repair kit 3-0017 Capacity control valve repair kit 40449 160H Pilot assembly kit 41082 RS to ASDI Thermostat/Thermowell field kit THE0001-00-3 Thermocouple 48” LG. 41091: Burner assembly kit without thermocouple and pilot Components Description Qty.
  • Page 46 Appendix A  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 47 Appendix A  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 of torque (approximately 1/8” full turn).
  • Page 48 Appendix A  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 49 Appendix A  Thermowell leak test procedure 3. REMOVE NUT 1. CLOSE REULATOR SUPPLY VALVE 4. REMOVE FITTING 6 .REMOVE NUT 5. REMOVE THERMOCOUPLE 2. LOOSEN NUT Thermowell leak test procedure: 1. Close regulator supply valve. 2. Allow for burner and pilot to consume any remaining gas in the tubing. 3.
  • Page 50 Appendix A ...
  • Page 51 Appendix A ...
  • Page 52 Appendix A  Algas-SDI International, LLC 151 South Michigan Street Seattle, Washington, 98108 1.206.789.5410 Fax: 1.206.789.5414 www.algas-sdi.com.

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