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Algas SDI 160H Operation & Maintenance Manual

Lp-gas vaporizer
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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 12-8-21
...Innovative liquid vaporizing and gas mixing solutions
LP-Gas Vaporizer: 160H - 800H
Operations & Maintenance
Manual
Fax: 206-789-5414
Samuel Oyen
2021.12.10
15:11:28 -08'00'
Web: www.algas-sdi.com
After S/N: 09160185

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  • 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...
  • 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

    Unpacking Initial Assembly Table 1 – Distance from Vaporizer Figure 2 – Vaporizer Dimensions Figure 3 – Vaporizer Dimensions 160H Vaporizer Liquid Supply Line Table 2 – Recommended Liquid Supply Line Size Vapor Distribution Line Table 3 – Recommended Vapor Distribution Line Size...
  • Page 8 Appendix A: Technical Information Figure 11 – 160H Vaporizer Replacement Parts Figure 12 – Liquid Inlet Valve and Capacity Control Valve Table 7 – Repair Kits and Other Available Replacement Parts 160H Liquid inlet valve pin gasket installation procedure Thermowell leak test procedure...
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  • Page 10: Pipeaway Adapter

    Direct Fired Vaporizer Options Electronic Auto Re-igniter Auto Reigniter System 115/230 VAC 50/60Hz, Use P/N: 3-8683, Quantity 1 per unit See Page 3-15 for Details 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 Fire 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 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

    DIRECT FIRED VAPORIZER SPECIFICATIONS: BURNER INPUT 176,900 BTU/hr (51.8 kW) per burner GAS CONSUMPTION: Approximately 1,000 BTU/hr (0.3 kW) per gallon (3.79 liters) of propane vaporized TOTAL BURNER INPUT 160H: 176,900 BTU/hr (51.8 kW) 320H: 353,800 BTU/hr (103.6 kW) 480H: 530,700 BTU/hr (155.4 kW)

  • 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 [MM]) Figure 3 – Installation – 160H vaporizers Algas-SDI Operation and Maintenance Manual – P/N – 54000...

  • Page 16: Liquid Supply Line

    The liquid supply line should be adequately sized for the service. Table 2 – Recommended Liquid Supply Line Size (Nominal Pipe Size) Liquid Line Length Ft. (m) Up to 50 (15) 50-150 (15-36) 150-250 (36-76) 160H Vaporizers 1” (DN25) 1-1/4” (DN 32) 1-1/2” (DN40) 320H Vaporizers 1-1/4”...

  • Page 17: Vapor Bypass Line (Optional)

    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: Liquid Pump (Optional)

    Installation LIQUID PUMP (OPTIONAL) The liquid pressure to the inlet of the vaporizer must be a minimum of 6 PSIG (0.4 bar) 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 19 Installation Figure 4 – Filtaire Operation BYPASS 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: Leak Test

    Failure to do so will result in improper operation and damage to the equipment. Table 4 – Cross-Sectional Inlet/Outlet Air Requirements Outlet Exhaust, Flue Inlet Air, Louver Area Annular Area Vaporizer 160H 89 (574) 27 (174) 320H 177 (1142) 54 (348)

  • Page 21: 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 22: 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 23: Direct Fired Vaporizer Setpoint Adjustment

    Operation Figure 6 – Pilot button pressed down and ignitor 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 24: Direct Fired Vaporizer Shutdown Procedure

    Operation Direct Fired Vaporizer shut down procedure (See Figure 7) 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 25: Automatic Re-Ignition Operation

    Operation 1. Ensure all tank valves are open with no restrictions of flow back to the storage tank. A check valve restricting flow back to the storage tank must never be used in a vaporizer installation. 2. Close outlet shut-off valve at the exit of the vaporizer. 3.

  • Page 26: 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 27 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 28 Maintenance service. Nominal wall thickness 0.375” (9.5 mm). An Ultrasonic thickness tester can be used to determine wall thickness. 4. Check heat exchanger for heavy ends accumulation inside the vessel. Remove the liquid inlet valve and tilt the vaporizer on its side to drain the heavy ends.

  • Page 29: 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 30: Replacing Reigniter Battery

    Maintenance Replacing reignitor battery 1. Turn the reigniter switch “OFF”. Open the battery access door on the bottom right corner of the thermostat housing. Figure 8 – 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 31: 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 port at the inlet to the burner.

  • Page 32: 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 33 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 34: 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 35 Maintenance This page intentionally left blank. Algas-SDI Operation and Maintenance Manual – P/N – 54000 4-25...

  • Page 36: Troubleshooting

    If the pilot flame is too small, clean the pilot burner orifice, or replace the pilot. Each 160H pilot uses #23 pilot orifices.
  • Page 37 Troubleshooting TROUBLESHOOTING TREE #1 PILOT WILL NOT LIGHT CHECK THE BURNER PRESSURE IS HIGH/LOW PRESSURE IS OK 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 LOW PILOT IS OK PILOT IS IMPINGING ON THE THERMOCOUPLE BULB, APPROXIMATELY 3/8” TO 1/2” (9 to 13 mm) SEE TROUBLESHOOTING TREE #1: PILOT WILL NOT LIGHT CHECK THE THERMOCOUPLE SIGNAL TO THERMOSTAT CONTROL VALVE.

  • Page 39: Igniter Will Not Spark

    Troubleshooting TROUBLESHOOTING TREE #3 IGNITER WILL NOT SPARK CHECK BATTERY DEAD BATTERY OK REIGNITER BATTERY CHECK IF ELECTRODE IS CONTACTING HOOD REPLACE BATTERY OR FURTHER THAN 1/8” (3 mm) OUT OF POSITION CHECK IF ADJUST AND 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. THE FOLLOWING TROUBLESHOOTING TREE ASSUMES THAT THE LOAD ON THE VAPORIZER IS LESS THAN ITS MAXIMUM CAPACITY. IS THE BURNER OPERATING? SEE TROUBLESHOOTING TREE #3: MAIN BURNER WILL NOT LIGHT CHECK THE...

  • Page 42: Appendix A: Technical Information

    APPENDIX A TECHNICAL INFORMATION Algas-SDI Operation and Maintenance Manual – P/N – 54000 5-32...
  • Page 43 Figure 11 – 160H Vaporizer Replacement Parts...
  • Page 44 Figure 12 – Liquid Inlet Valve and Capacity Control Valve LIQUID INLET VALVE 17 Inlet valve cap o-ring 17 Inlet valve spring 17 Inlet valve seat 17 Inlet 17 Inlet valve gasket valve orifice o-ring 17 Pivot arm gasket CAPACITY CONTROL VALVE 16 CCV Cap o-ring 16 Piston o-ring...
  • Page 45 Figure 11 and 12 Descriptions 1. Burner Manifold assembly P/N: 41091 2. Burner tip #69 burner jet orifice (qty 32) P/N: 41092 3. Capacity control valve 1” P/N: 1508-4001 4. Drip leg kit P/N: 40450 5. Liquid Inlet Valve P/N: 1501-4001 6.
  • Page 46 Table 7 – Repair Kits and Other Available Replacement Parts 160H through 800H 160H through 800H 40764: Repair kit, Liquid Inlet/Capacity Control Valve Components Description Qty. 3-0016 Liquid Inlet Valve repair kit 3-0017 Capacity Control Valve repair kit 40449: 160H Pilot Assembly kit...
  • Page 47 40480: Master repair kit Components Description Qty. 40764 Repair kit, Liquid Inlet/Capacity Control Valve 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 48 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 49 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 50 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 51 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 58 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:

800h

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