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

Lp-gas vaporizer
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LP-Gas Vaporizer: 40/40H, 80/40H & 120/60H
Operations & Maintenance
151 South Michigan Street, Seattle, Washington, USA 98108
Tel: 206-789-5410
This manual covers units built after August 2009
FILE: MANUAL PN 52642 DIRECT FIRED 11_12_13.DOC
...Innovative liquid vaporizing and gas mixing solutions
Manual
Fax: 206-789-5414
After S/N:
2013.11.1
2 09:47:39
-08'00'
Web: www.algas-sdi.com
40/40H – A13J20003627
80/40H – A13J40007352
120/60H – A13J60002719

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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: 206-789-5410 Fax: 206-789-5414 Web: www.algas-sdi.com This manual covers units built after August 2009 After S/N: 40/40H –...
  • 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.
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  • 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.
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  • Page 9: Table Of Contents

    Table of Contents Options Auto Re-igniter Contaminant Separator / Filtaire Economy 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 Unpacking and Initial Assembly...
  • Page 10 Operation Direct Fired Vaporizer start up procedure 3-13 Figure 8 – Temperature control dial in “RUN” position 3-13 Figure 9 – Pilot button pressed down and ignitor switch on 3-14 Direct Fired Vaporizer setpoint adjustment 3-14 Figure 10 – Rotating temperature control dial counter-clockwise to desired setpoint 3-14 Direct Fired Vaporizer shutdown procedure 3-15...
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  • Page 12: Pipeaway Adapter

    Options Auto Re-igniter 40/40H, 80/40H & 120/60H, Auto Re-igniter System 115/230 VAC 50/60Hz, Use P/N: 3-8683, Quantity 1 per unit See Page 3-16 for Details Contaminant Separator / Filtaire 40/40H, 80/40H, Filtaire Model F4, Use P/N: 20536 or 20536-ASME, Quantity 1 per unit 120/60H, Filtaire Model F6, Use P/N: 20540 or 20540-ASME, Quantity 1 per unit See Page 2-9 for Details Economy Kit...

  • Page 13: Introduction

    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 and UL 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 14: 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 15: Direct Fired Vaporizer Specifications

    Introduction Direct Fired Vaporizer specifications: BURNER INPUT 40/40H 53,792 BTU/hr per burner 80/40H 47,440 BTU/hr per burner 120/60H 61,854 BTU/hr per burner GAS CONSUMPTION: 1000 BTU’s per gallon of propane vaporized TOTAL BURNER INPUT 40/40H: REGULATOR GAS PRESSURE*: 11” W.C. 53,792 BTU/hr THERMOSTAT PORT PRESSURE**: 10”...

  • Page 16: 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 17 Installation Figure 2 – Vaporizer Dimensions (shown in inches) 40/40H Vaporizer 80/40H and 120/60H Vaporizers Model “A” “B” “C” 40/40H 35” 29” 20” 80/40H 35” 29” 20” 120/60H 44 ¼” 37 ¾” 28 ¾” Algas-SDI Operation and Maintenance Manual – P/N – 52642...

  • Page 18: Vapor Distribution 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 19: Liquid Inlet

    Installation pressure at lowest expected temperature; this may require periodic adjustment. 4. The second stage (or low pressure) regulator should be installed as close to the consuming equipment as practical. 5. A line relief valve may be installed (optional) to protect the regulators from excessively high pressure.

  • Page 20: Liquid Pump (Optional)

    Installation 4. Connect the supply line from the first stage regulator to the burner regulator at the vaporizer. Make sure that the supply is sized properly to handle maximum input rating of the vaporizer burner(s). See Figure 1. 5. For the 40/40H, 80/40H and 120/60H Thermostat Supply Regulator pressure adjustments please refer to page 1-3.

  • Page 21: Contaminant Separator - Filtaire (Optional)

    Installation CONTAMINANT SEPARATOR – FILTAIRE (OPTIONAL) FILTAIRE is a filtering device designed to trap heavy hydrocarbons commonly present in LPG gas vapor. It also traps other materials, which may be in the gas due to storage conditions and internal condition of the equipment. Impurities are collected in the system and periodically removed through the system blow down drain.

  • Page 22: Installing Multiple Units In Parallel

    Installation INSTALLING MULTIPLE UNITS IN PARALLEL Piping should be equal distance on both inlet and outlet piping for balanced performance. Figure 6 – Installing Multiple Units in Parallel AN OVERSIZED INLET AND OUTLET MANIFOLD MAY BE USED TO BALANCE THE FLOW. Figure 7 –...

  • Page 23: Check Burner Input Pressure

    Installation CAUTION The entire installation must be leak tested prior to operating the system. 1. Close outlet valve. 2. Slowly open inlet valve and allow pressure to equalize in the vaporizer. 3. Apply a liberal amount of soap/water solution to ALL internal and external flanged, threaded and tubing connections.
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  • Page 25: 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 26: Direct Fired Vaporizer Setpoint Adjustment

    Operation Figure 9 –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 27: 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. If the vaporizer is below -10°F (-12°C) the main burner may continue to operate for an additional 30-40 seconds until thermocouple cools down.

  • Page 28: 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.
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  • Page 30: Maintenance

    Maintenance Maintenance Recommendations Vaporizers, just like any other LP gas equipment, should be maintained periodically. The following maintenance scheduled may be used as a guideline. This maintenance schedule includes items that must be inspected and the type and frequency of maintenance to be performed. Although the following schedule is the minimum recommended type and frequency of maintenance, the conditions in your area and quality of the LP gas liquid may dictate a more stringent maintenance program.
  • Page 31 Maintenance Table 4 – Recommended annual maintenance and inspections 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 32 Maintenance scaling. Should heat exchanger head thickness be less than 0.156” (5/32”) the heat exchanger should be removed from service. Nominal wall thickness 0.250” (¼”). An Ultrasonic thickness tester can be used to determine wall thickness. 4. Check heat exchanger for heavy ends accumulation inside the vessel.

  • Page 33: 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 34: Replacing Reignitor Battery

    Maintenance Replacing reigniter battery 1. Turn the reigniter switch OFF. Use Phillips screwdriver to open the battery access door on the bottom right corner of the thermostatic gas control valve housing. Figure 12 – Opening the battery access door 2. Pull out the battery, disconnect it and replace with new 9VDC battery. Push the battery back in the thermostatic gas valve housing and close the battery access door prior to turning the reignitor switch ON.

  • Page 35: Adjusting Burner Input Pressure

    Maintenance Adjusting burner input pressure 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” manometer (or similar pressure indicating device) to the pressure tap port at the outlet of the thermostat.

  • Page 36: Liquid Inlet Valve Maintenance Procedure

    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 37 Maintenance 13. Lightly grease and replace the O-ring around the inlet valve cap (large flange nut). 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.

  • Page 38: Capacity Control Valve Maintenance Procedure

    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).
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  • Page 40: 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 41 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 42 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” SEE TROUBLESHOOTING TREE CHECK THE THERMOCOUPLE SIGNAL TO #1: PILOT WILL NOT LIGHT THERMOSTAT CONTROL VALVE.
  • Page 43 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” TURN THE THERMOSTATIC GAS VALVE SEE TROUBLESHOOTING TREE TEMPERATURE CONTROL DIAL UP TO #1 OR #2 THE HIGHEST SETTING.

  • Page 44: If Vapor Pressure Drops

    Troubleshooting TROUBLESHOOTING TREE #4 VAPOR SERVICE PRESSURE DROPS NOTE: SERVICE PRESSURE WILL DROP IF THE DEMAND EXCEEDS VAPORIZER’S CAPACITY: 40/40H 3.6 MBTU/hr, 80/40H 7.3 MBTU/hr, 120/60H 10.9 MBTU/hr. THE FOLLOWING TROUBLESHOOTING TREE ASSUMES THAT THE LOAD ON THE VAPORIZER IS LESS THAN ITS MAXIMUM CAPACITY.
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  • Page 46: Appendix A: Technical Information

    APPENDIX A TECHNICAL INFORMATION A-34 Algas-SDI Operation and Maintenance Manual – P/N – 52642...
  • Page 47 Appendix A This page intentionally left blank. A-35 Algas-SDI Operation and Maintenance Manual – P/N – 52642...
  • Page 48 Appendix A Figure 14 – 40/40H Vaporizer Replacement Parts 3, 22 5, 23 A-36 Algas-SDI Operation and Maintenance Manual – P/N - 52642...
  • Page 49 Appendix A Figure 15 – 80/40H and 120/60H Vaporizer Replacement Parts NOTE Drawing shown for a 80/40H Vaporizer. 3, 22 5, 23 A-37 Algas-SDI Operation and Maintenance Manual – P/N – 52642...
  • Page 50 Appendix A Figure 16 –Inlet Valve and Capacity Control Valve LIQUID INLET VALVE 23 Capacity control valve o-ring 23 Inlet valve spring 23 Inlet valve seat 23 Inlet valve orifice o-ring 23 Inlet valve gasket Pivot arm gasket CAPACITY CONTROL VALVE 22 Cap o-ring 22 Piston o-ring 21 Piston...
  • Page 51 Appendix A Figure 14, 15 and 16 Descriptions Burner Manifold 40/40H, 60/60H new burner post 10/02 P/N: 1502-4006 Burner tip all models – New burner post 10/02 P/N: 33581 Capacity control valve 1” – All models P/N: 1508-4001 Drip leg kit 40/40H, 60/60H, 80/40H, 120/60H P/N: 40403 Liquid inlet valve –...
  • Page 52 Appendix A Table 5 – Repair Kits and Other Available Replacement Parts 81111: Master rebuild kit 40/40H (#66 orifice) Part number Description 3-0034 40/40H Master repair kit (new burner) 33581 Burner tip #66 orifice 34800 Pressure relief valve ¼” inlet x ½” outlet, twin stage 40631: Master rebuild kit 40/40H (#69 orifice) Part number Description...
  • Page 53 Appendix A 40634: Master rebuild kit 120/60H (#69 orifice) Part number Description 41040 Kit, 120/60H repair 34323 Burner tip #69 orifice 34800 Pressure relief valve ¼” inlet x ½” outlet, twin stage 3-0034: Repair kit 40/40H – new burner post 10/02 Part number Description 3-0014...
  • Page 54 Appendix A 3-0014: Repair kit 40/40H Pilot orifice and thermocouple Part number Description 46-4 Thermocouple for 40/40H and 80/40H – snap in 46-6 Orifice pilot burner 40/40H and old burner 80/40H 3-0013: Repair kit 80/40H Pilot orifice and thermocouple Part number Description 46-4 Thermocouple for 40/40H and 80/40H –...

  • Page 55: Liquid Inlet Valve Pin Gasket Installation Procedure

    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. A-43 Algas-SDI Operation and Maintenance Manual – P/N – 52642...
  • Page 56 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). A-44 Algas-SDI Operation and Maintenance Manual –...
  • Page 57 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 64 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 120/60hDirect fired a13j20003627Direct fired a13j40007352Direct fired a13j60002719

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