Algas SDI VAPORAIRE Series Operation & Maintenance Manual
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Algas SDI VAPORAIRE Series Operation & Maintenance Manual

Lpg-air mixing systems
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Operations & Maintenance
151 S. Michigan Street, Seattle, Washington, USA 98108
Tel: 206-789-5410
MANUAL PN 54264 VAPORAIRE REV 08-26-19
Manual
Fax: 206-789-5414
Digitally signed by
Ana Torres
Date: 2019.08.26
15:28:24 -07'00'
Web: www.algas-sdi.com

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  • Page 1 Operations & Maintenance Manual 151 S. Michigan Street, Seattle, Washington, USA 98108 Tel: 206-789-5410 Fax: 206-789-5414 Web: www.algas-sdi.com MANUAL PN 54264 VAPORAIRE REV 08-26-19 Digitally signed by Ana Torres Date: 2019.08.26 15:28:24 -07'00'...
  • Page 2 WARNING Read the OPERATION MANUAL before operating this equipment. DISCLAIMER Algas-SDI International, LLC (ASDI) shall not be liable for technical and/or editorial errors or omissions in this manual. ASDI makes no warranties, express or implied, including the implied warranties of merchantability and fitness for a particular purpose with respect to this manual.
  • Page 3 WARRANTY REGISTRATION Fill out the Warranty Registration information on the last page of this manual to register your equipment. Then make a photocopy and mail to the address shown at the bottom. 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.
  • Page 4 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 This symbol indicates hazards or unsafe practices, which can result in damage to the equipment or cause personal injury.

  • Page 5: Table Of Contents

    Table of Contents     Introduction ..............................1-1 General ................................1-1   DESCRIPTION ..............................1-1   MIXER OPERATION - LPG-VAPOR/AIR MIXING PROCESS ................1-2   LPG-Vapor/Air Mixing Process ........................1-2     Figure 1 - VAPORAIRE Mixing System Components ................. 1-3  ...
  • Page 6 Shutdown ............................... 4-35   To Restart the System ........................... 4-35   Standby Condition ............................4-35       Maintenance ..............................5-37 Schedule for all Models of Mixers Operated Continuously ................5-37     Table 5 - Maintenance Schedule ....................... 5-37 Schedule for all Models of Mixers Operated on Standby ................
  • Page 7 Options Mixer Options Surge/Accumulator Tank Packages Flare stack Secondary Air Check Assembly Venturi Silencer Assembly Appendix A: Component Information Figure 15 – Inlet Solenoid Assembly Diagram Solenoid Noise Component Specifications Warranty Registration - Refer to the Nameplate on the unit to fill out the product registration. Then photocopy and mail to address shown.

  • Page 9: Introduction

    Introduction GENERAL The VAPORAIRE & VAPORAIRE M-Series mixing systems from Algas-SDI are self-contained units providing a mixture of LPG-vapor and air which can replace natural gas. The VAPORAIRE and VAPORAIRE M-Series are similar except the VAPORAIRE is packaged with a surge/accumulator tank. The customer provides the surge/accumulator tank for the VAPORAIRE M-Series or contact Algas-SDI for surge/accumulator tank options.

  • Page 10: Mixer Operation - Lpg-Vapor/Air Mixing Process

    Introduction MIXER OPERATION - LPG-VAPOR/AIR MIXING PROCESS LPG-vapor from a vaporizer enters the mixing system through a header manifold, which distributes the gas to each venturi. A solenoid valve at the manifold controls the flow of vapor to each venturi and a pressure switch monitors the vapor pressure in the header.
  • Page 11 Introduction Figure 1 - VAPORAIRE Mixing System Components Venturi Components.wmf 1. Inlet safety solenoid valve 11. Surge/accumulator tank drain valve 2. Inlet vapor pressure gauge 12. Venturi manual shut-off valve 3. Venturi vapor solenoid valve 13. Venturi motive pressure gauge 4.
  • Page 12 Introduction Figure 2 - VAPORAIRE with surge/accumulator tank configuration Venturi Mixing Sys.wmf Algas-SDI Operations & Maintenance Manual – P/N - 54264...

  • Page 13: Major Components Of A Vaporaire M-Series Mixer

    Introduction Figure 3 - VAPORAIRE M-Series Mixing System Components VAPORAIRE M-Series Mixing Sys Comp.wmf MAJOR COMPONENTS OF A VAPORAIRE M-SERIES MIXER 1. Diffuser 2. Nozzle 3. Air inlet screen assembly 4. Venturi motive pressure gauge 5. Venturi assembly 6. Venturi vapor solenoid valve 7.
  • Page 14 Introduction Figure 4 - VAPORAIRE M-Series Configuration VAPORAIRE M-Series Mixing Sys.wmf Algas-SDI Operations & Maintenance Manual – P/N - 54264...
  • Page 15 Introduction Figure 5 - Single Venturi Control Box Single Venturi Control Box.wmf 1. Start switch & boot 7. Terminal strip 2. Stop switch & boot 8. Explosion proof enclosure 3. Mixed gas pressure control switch 9. Flame arrestor (2 places) (Venturi pressure controls switch) 10.
  • Page 16 Introduction Figure 6 - 8100 Sequencer Control Box 8100 Seq Control Box.wmf Algas-SDI Operations & Maintenance Manual – P/N - 54264...

  • Page 17: Control Box Components For Mixers Using The Sequencer

    Introduction CONTROL BOX COMPONENTS FOR MIXERS USING THE SEQUENCER NOTE Component arrangement will vary by model. 1. Explosion proof enclosure 2. Start switch & Boot 3. Stop switch & Boot 4. Ground lug 5. Mixed gas pressure control switch (venturi pressure control switch) 6.
  • Page 18 Introduction Figure 7 - SEQUENCER Diagram 1-10 Algas-SDI Operations & Maintenance Manual – P/N - 54264...
  • Page 19 Introduction Figure 8 - 2080-TRIMPOT6(C), 6 Channel Potentiometer (Pot.) Potentiometers: – Coarse adjustment for mixed gas pressure – Fine adjustment mixed gas pressure – Alarm Delay Timer adjustment 0- 10 minutes for Optional Alarm #1 – Not used – Not used –...
  • Page 20 This page intentionally left blank 1-12 Algas-SDI Operations & Maintenance Manual – P/N - 54264...

  • Page 21: Installation

    Installation WARNING The equipment described in this manual is designed to operate with LP-gas, a flammable fuel under pressure. The nature of the application involves inherent hazards that could result in injury. ONLY a trained and fully qualified person should service this equipment.
  • Page 22 Installation Figure 10 - Typical VAPORAIRE Installation Drawing VAPORAIRE Installation.dxf 2-14 Algas-SDI Operations & Maintenance Manual – P/N - 54264...
  • Page 23 Installation Figure 11 - Typical VAPORAIRE M-Series Installation Drawing VAPORAIRE M-Series Installation.wmf 2-15 Algas-SDI Operations & Maintenance Manual – P/N - 54264...

  • Page 24: Installation Instructions For All Lpg-Air/Vapor Mixers

    Installation INSTALLATION INSTRUCTIONS FOR ALL LPG-AIR/VAPOR MIXERS Refer to the installation diagrams for both mixer series on the previous pages. 1. Algas-SDI mixing systems are normally installed outside of plant buildings on a level concrete pad. for both types Refer to the typical installation diagrams of mixers.

  • Page 25: Mixed Gas Outlet Installation For Vaporaire M-Series

    Installation Mixed Gas Outlet Installation for VAPORAIRE M-Series SURGE/ACCUMULATOR TANK REQUIREMENTS FOR VAPORAIRE M-SERIES MIXERS 1. VAPORAIRE mixers come complete with a surge/accumulator tank. VAPORAIRE M-Series mixers require a surge/accumulator tank (by others) for proper operation. Follow the directions below for proper sizing and installation of a surge/accumulator tank for VAPORAIRE M-Series mixers.

  • Page 26: Surge/Accumulator Tank Sizing

    Installation SURGE/ACCUMULATOR TANK SIZING Provide a correctly sized , suitable for the MIXED GAS SURGE/ACCUMULATOR TANK intended service and pressure. The tank must have a relief valve, drain, pressure gauge, mixed gas inlet and outlet, pressure sensing port and gas sampling port. Refer to Table 4 below for surge/accumulator tank requirements.

  • Page 27: Startup

    Startup WARNING Some of the adjustments require the control enclosure to be open while the circuits are tested. No LPG vapor must be present around the enclosure when it is open. The electrical arcing that occurs when various switches and relays within the enclosure operate is a possible source of explosive ignition.
  • Page 28 Startup This page intentionally left blank 3-20 Algas-SDI Operations & Maintenance Manual – P/N - 54264...

  • Page 29: Operation

    Operation WARNING The equipment described in this manual is designed to operate with LP-gas, a flammable fuel under pressure. The nature of the application involves inherent hazards that could result in injury. ONLY a trained and fully qualified person should service this equipment.

  • Page 30: Single Venturi Systems

    Operation SINGLE VENTURI SYSTEMS MIXER OPERATION The vaporized LPG rises into the vapor header and exits through the vapor outlet. The vapor pressure will close the Low Vapor Pressure Switch and activate the Mixed Gas Pressure Control Switch. The Mixed Gas Pressure Control Switch will cycle the venturi on and off based on load requirements.

  • Page 31: High Mixed Gas Pressure Safety Switch

    Operation EXAMPLE: If the venturi is on at 4.5 PSIG and the mixed gas pressure setpoint should be 5 PSIG, then the Mixed Gas Pressure Control Switch needs to be adjusted. To increase the pressure setpoint, turn the screw clockwise (in). Continue adjusting as needed until the venturi turns on when the mixed gas pressure is at 5 PSIG.

  • Page 32: Multiple Venturi System

    Operation MULTIPLE VENTURI SYSTEM WARNING The sequencer is mounted in an explosion proof control enclosure. If the enclosure is opened for testing or for adjusting, be sure that no LPG vapor is present around the enclosure. The electrical arcing that occurs when the switches and relays within the enclosure operate is a possible source of explosive ignition.

  • Page 33: Plc Controller Led Indicators And Mode Switch

    Operation PLC CONTROLLER LED INDICATORS AND MODE SWITCH There are LED’s on the PLC for diagnostic and status that indicate the operation of the control system and each venturi solenoid valve. The LED indicators can also show potential problems with the system to help troubleshoot faults. Under normal conditions the POWER and RUN LED’s should always be on.

  • Page 34: Memory Module

    Operation MEMORY MODULE: The Memory Module is factory programmed for the SEQUENCER and is labeled with the program version. The Memory module is in the first slot on the top left. On power up, faults are cleared if any, then the program is loaded. NOTE The software program for controlling the blending operation is set at the factory.

  • Page 35: Discrete Inputs

    Operation DISCRETE INPUTS The PLC uses the 14 discrete inputs to configure and control the mixing system. The discrete inputs are as follows: I-00 – Setup mode enable I-08 – Stop switch I-01 – Pressure Scale range I-09 – Start switch I-02 –...

  • Page 36: Discrete Output

    Operation DISCRETE OUTPUT The PLC uses the 10 discrete outputs to control the mixing system via interposing relays (IR). VAPORAIREs that require more than 8 venturis will have an additional Output Module attached to the PLC. The discrete outputs are as follows: O-0 - (IR1 relay) Mixer run status O-5 - (IR6 relay) Venturi solenoid #4 O-1 - (IR2 relay) Vapor inlet solenoid...

  • Page 37: High Mixed Gas Pressure Switch

    Operation CAUTION The pressure adjustment potentiometers are one turn potentiometers. Do not turn beyond the limits! Table 2 - Mixed Gas Pressure and Setpoint Ranges Pressure Setpoint Coarse Pressure Fine Pressure Pressure Scale Mixer Delivery Range Range Setpoint Range Setpoint Range Pressure Input I-01 Input I-02...

  • Page 38: Low Vapor Pressure Switch

    Operation LOW VAPOR PRESSURE SWITCH The mixer requires a minimum Low Vapor Pressure for the venturi to mix gas. The Low Vapor Pressure Switch is wired normally open and is set to close when there is adequate vapor pressure to operate the venturi. The vapor pressure will close the Low Vapor Pressure Switch and activate the Mixed Gas Operating Pressure Control Switch.

  • Page 39: Lpg/Air Venturi Type Mixers

    Operation LPG/Air Venturi Type Mixers The venturi assembly produces mixed gas. High pressure LPG vapor is introduced into the venturi nozzle. It accelerates through the venturi nozzle forming a vacuum as it exits the nozzle. That vacuum draws in air through the venturi check valve that is then mixed with the LPG vapor.

  • Page 40: Venturi Motive Pressure

    Operation VENTURI MOTIVE PRESSURE The motive pressure for the venturi is stamped on the base on the Venturi housing. This pressure is a starting point for adjustment. This pressure is adjusted using the vapor pressure regulators on each venturi train. Final adjustments should be made with the system in operation, using the pressure gauge on each venturi to adjust the motive pressure per Data Sheet.

  • Page 41: Adjusting The Heating Value Of The Mixed Gas With A Single Regulating Station

    Operation 4. Open the surge/accumulator tank outlet and establish the flow to keep the venturis cycling at 50% on, 50% off. 5. Adjust the mixture by varying the venturi motive pressure ( Refer to the motive pressure adjustment) 6. After the selected venturi is adjusted, close the isolation valve and open the isolation valve of the next venturi to be adjusted.
  • Page 42 Operation Figure 13 - Typical Venturi Performance Curve Venturi Performance Curve.wmf MOTIVE PRESSURE The factory set is the point at which the venturi performance yields the leanest mixture at rated output and discharge pressure, when installed at elevations up to 2000 ft. Increasing the motive pressure beyond the factory setpoint will increase the venturi output, while also putting a greater demand on the vaporizer.

  • Page 43: Shutdown

    Operation SHUTDOWN If the system is to be shut down for extended periods of time, follow these procedures: 1. Close the mixed gas discharge valve on the surge/accumulator tank. STOP 2. Push the switch on the mixer control box. Leave power applied to the mixer so that the heater in the box continues to operate to prevent moisture build-up.
  • Page 44 Operation This page intentionally left blank. 4-36 Algas-SDI Operations & Maintenance Manual – P/N - 54264...

  • Page 45: Maintenance

    Maintenance SCHEDULE FOR ALL MODELS OF MIXERS OPERATED CONTINUOUSLY Use this maintenance schedule if your LPG-vapor/air mixer is used full-time. Table 5 - Maintenance Schedule Description Monthly Every 6 Months Annually Vapor Motive Pressure Check setpoint Check gas quality Heating Value Adjustment (every two months) Mixed Gas Operating Pressure Control Switch Adjustment and...

  • Page 46: Schedule For All Models Of Mixers Operated On Standby

    Maintenance SCHEDULE FOR ALL MODELS OF MIXERS OPERATED ON STANDBY Use this maintenance schedule if your LPG-vapor/air mixer is used only for standby operation. Table 6 - Maintenance Schedule Description Monthly Every 6 Months Annually Vapor Motive Pressure Check setpoint Check gas quality Heating Value Adjustment (every two months)

  • Page 47: Venturi Check Valve Removal And Installation Instructions

    Maintenance VENTURI CHECK VALVE REMOVAL AND INSTALLATION INSTRUCTIONS This instruction set is to be used for the Venturi Check Valve Kit- P/N - 40490. Please refer to the following diagrams when removing and installing the Venturi Check Valve A. Check Valve Assembly B.

  • Page 48: Removal

    Maintenance REMOVAL 1. If individual venturi trains cannot be isolated from the mixed gas surge/accumulator header or tank, it will be necessary to vent all pressure from the system. 2. If individual venturi trains can be isolated from the mixed gas surge/accumulator header or tank, close the valve between the venturi housing and the header or tank.

  • Page 49: Installation

    Maintenance INSTALLATION 1. After the existing Check Valve Assembly (A) has been removed, examine the machined Seating Surface (F) on the Venturi Housing (D) to be sure the surface is clean and without flaws. 2. Screw the Clevis (I) into the Venturi Housing (D), until 3 – 3 1/2 threads are left inside of the housing. Do not use a screwdriver or other prying device to install the clevis.
  • Page 50 Maintenance b) With the Check Valve (M) rotated to the other extreme position around the valve/arm pivot, lowering the Check Valve Arm (K) should cause only the upper part of the Check Valve (M) to contact the Seating Surface (F). Lower the Check Valve Arm (K) a third time, allowing free rotation of the Check Valve (M).
  • Page 51 Maintenance d) If the Check Valve (M) does not contact the Seating Surface (F) as described above, reposition the Clevis (I) in the Venturi Housing (D). At least three threads must be exposed for proper installation of the Acorn Nut (G). 5.

  • Page 52: Leak Check Procedure For Venturi Check Valves

    Maintenance NOTE As with all components containing materials subject to deterioration, the venturi check valves should routinely be checked and replaced as necessary. A minimum annual inspection should be conducted. Test for leaks with the system pressurized. WARNING LPG is heavier than air and LPG vapor either mixed with or without air will “pool”...

  • Page 53: Maintenance For All Mixers Using The Sequencer

    Maintenance MAINTENANCE FOR ALL SINGLE VENTURI MIXERS USING A PRESSURE SWITCH FOR CONTROL 1. No additional maintenance is required for single venturi mixers using a pressure switch. 2. Replacing the pressure switch. a. Turn off all power to the explosion proof control box at the main feed disconnect.

  • Page 54: Sequencer

    Maintenance SEQUENCER SEQUENCER The ASDI is accessed by opening the door of the control cabinet. NOTE Do not attempt to repair the sequencer modules. If the module is defective, the entire module should be replaced. REPLACING TRIMPOT6 (C) AND ANALOG INPUT MODULE (D): Figure 14 - Module Removal &...
  • Page 55 Maintenance 4. Position the replacement plug-in module with the terminal block facing the front of the controller as shown. 5. Snap the replacement module into the module bay. 6. Using a screwdriver, tighten the 10…12 mm (0.39…0.47 in.) M3 self-tapping screw. 5-47 Algas-SDI Operations &...

  • Page 56: Replacing The Relays

    Maintenance REPLACING THE RELAYS  Turn off power at the disconnect.  Remove bus bar jumpers, use a screwdriver on the din rail clamp to remove the relay.  Insert a new relay and re-install bus bar jumpers. CORROSION INHIBITOR TAPE A small synthetic sponge-tape is mounted on the inside top of the explosion proof box to prevent corrosion and absorb moisture.

  • Page 57: General Troubleshooting For All Lpg-Vapor/Air Mixers

    Troubleshooting WARNING Most electrical test operations require the control enclosure to be open while the circuits are tested. At all times make sure that no propane vapor is present around the enclosure. The electrical arcing that occurs when the various switches and relays within the enclosure operate is a possible source of explosive ignition.

  • Page 58: Troubleshooting Guide For Lpg-Vapor/Air Mixers Using The Sequencer

    Troubleshooting TROUBLESHOOTING GUIDE FOR LPG-VAPOR/AIR MIXERS USING THE SEQUENCER SETUP MODE START If all the venturis cycle on and off at once, the mixer is in . Press both the STOP buttons simultaneously or remove the jumper terminal between orange terminal B3 and SETUP MODE terminal 4, to take out of If the mixer has fewer than 7 venturis Table 3 can be used to help troubleshoot the mixer.

  • Page 65: Options

    OPTIONS...
  • Page 66 This page intentionally left blank.
  • Page 67 MIXER OPTIONS SURGE/ACCUMULATOR TANK Contact Algas-SDI international for surge/accumulator tank packages. FLARE STACK Contact Algas-SDI international for Flare Stack Packages. SECONDARY AIR CHECK VALVE ASSEMBLY Secondary Air Check Valve Assembly: ASDI PN: 20120 See Drawing 1302-3002 in Appendix A VENTURI SILENCER ASSEMBLY Venturi Silencer: ASDI PN: 36080...
  • Page 69 APPENDIX A COMPONENT INFORMATION...
  • Page 70 This page left intentionally blank...
  • Page 72 Algas-SDI International, LLC 151 S. Michigan Street Seattle, Washington 98108 Ph.: 1.206.789.5410 Fax.: 1.206.789.5414 www.algas-sdi.com...

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