CHART 1000 User manual

Part Number 20918023 Rev. B
© 2016 Chart Inc.
Designed and Built by:
Chart Inc.
1300 Airport Dr.
Ball Ground, GA 30107 USA
[phone]
Product Manual
Perma-Cyl®Medical MicroBulk Skid
1000/1500/2000/3000

iii
Product Manual - Perma-Cyl®Medical MicroBulk Skid
Contents
Revision Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Product Highlights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Product Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Product Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Denitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety Bulletin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Oxygen Decient Atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Oxygen Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Oxygen Enriched Atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Nitrogen and Argon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Personal Protective Equipment (PPE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Primary Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Reserve Manifold and Backup Storage Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Primary Storage Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
System Pressure Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Tank and System Piping and Purging Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pre-Fill Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tank Purging (change of grade) and Filling Procedure . . . . . . . . . . . . . . . . . . . . . . 13
System Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Primary Tank LL Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Reserve Low - PS-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Reserve In Use - PS-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Verication and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Illustration & Parts Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Final Line Pressure Manifolds Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Parts Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Appendix 1 - Quality Control Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Appendix 2 - Drawing D-20810866 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Appendix 3 - Alarm Panel Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Appendix 4 - Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Appendix 5 - MicroBulk Skid Tank Sizing Specications . . . . . . . . . . . . . . . . . . . . . . . . 41
Appendix 6 - Perma-Cyl Spec Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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Table of Contents Product Manual - Perma-Cyl®Medical MicroBulk Skid
Revision Log
Revision Level Date Description
A 09/30/2015 Original
B 03/07/2016 Major wording changes throughout manual, Update Form in Appendix 1,
Update Drawing in Appendix 2, add Appendix 4, 5 & 6.

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Product Manual - Perma-Cyl®Medical MicroBulk Skid
General
The Medical MicroBulk Skid is designed to store and
deliver liquid oxygen or nitrogen to medical facilities. The
skid is designed to accept Perma-Cyl®MicroBulk Storage
System tanks for primary liquid storage in sizes of 1000,
1500, 2000, and 3000 liters. It can also accommodate up
to 16 high pressure cylinders for the back-up supply. All
manifolds and alarm switches are mounted on the skid,
connected to a central termination box, preset, and tested at
the manufacturer. Field wiring from the skid to the hospital
alarm panel is easy and efcient. An optional local alarm
panel is also available and can be specied if required. The
only piping required to be run in the eld is the nal tie-in
from the Medical MicroBulk Skid to the medical facility
source valve.
The Medical MicroBulk Skid is a perfect solution for a
turnkey package to serve critical medical facilities such as
surgery centers, nursing homes, small hospitals, clinics, long
term care facilities, veterinary facilities, and dental ofces.
Product Highlights
• Designed in accordance with NFPA 99, NFPA 55, and
CGA M-1
• Available in Perma-Cyl tank sizes from 1000 to 3000
liters
• High ow capable, up to 2000 SCFH
• Utilizes a WIKA analog gauge with adjustable low level
alarm set point.
• Maintains residual liquid level in Perma-Cyl tanks for no-
loss ll and purity integrity
• Optional external PB and process vaporizer packages
available
• Integrates with most alarm panels in medical facilities
• Suitable for outdoor installation
• Dimensions of 84” wide x 95.5” long x 90.25” high
(without storage tank)
Product Advantages
• Drop-in solution where everything is cleaned and pre-
piped at the factory, eliminating the need for costly and
time consuming eld medical piping
• Alarms are prewired into one electrical termination
point making it very easy to tie in the alarms to the main
medical facility alarm panel
• Local alarm panel is optional
• All switches and regulators are pre-set and tested at the
factory which greatly simplies eld verication
• Tanks can be easily upgraded and changed out with
minimal shutdown time
Product Manual
The purpose of this manual is to provide a procedure for new
medical installations and to provide minimum performance
criteria identied by industry consensus for Medical
MicroBulk System installers. It should be thoroughly read
and understood by anyone that installs and operates the
equipment.
The safety requirements for installing and operating the
Medical MicroBulk Skid as well as the safe handling of
liquid nitrogen and oxygen are outlined in the safety section.
Read this section prior to installing the equipment.
The remaining sections describe the various components of
the medical skid and how to inspect, install and commission
the skid per FDA requirements.
References
(use editions currently in effect)
• Applicable State Building Codes
• International Building Code
• National Fire Protection Association 99 / Standard for
Healthcare Facilities
• National Fire Protection Association 55 / Standard for
the Storage, Use and Handling of Compressed Gases and
Cryogenic Fluids in Portable and Stationary Containers,
Cylinders, and Tanks
• Current Editions CGA-M1 Guide for Medical Gas Supply
Systems at Consumer Sites
Preface

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Preface Product Manual - Perma-Cyl®Medical MicroBulk Skid
• U.S. Food and Drug Administration / 21 Code of Federal
Regulations / Parts 210 and 211
• ASSE/APMO/ANSI Series 6000 Medical Gas Systems
Personnel
• Product Manual Perma-Cyl w/FlexFill™ Piping Option
PN 20930593
• Manufacturers QC Checklist
• Manufacturers O2 Certication
• Manufacturers literature on individual components
(regulators, switches, excess ow valves)
• Chart specication drawing D-20810866
Terms
Throughout this manual safety precautions will be designated
as follows:
Warning! Description of a condition that
can result in personal injury or
death.
Caution! Description of a condition that
can result in equipment or
component damage.
Note: A statement that contains information
that is important enough to emphasize or
repeat.
Denitions
AHJ Authority Having Jurisdiction
ASME American Society of Mechanical Engineers
BAR Pressure (Metric)
CGA Compressed Gas Association
DPOR Design Professional of Record
Kg Kilogram
MAWP Maximum Allowable Working Pressure
N2Nitrogen
Nm3 Normal Cubic Meters
NER Normal Evaporation Rate
NFPA National Fire Protection Association
O2Oxygen
PB Pressure Builder
PN Part Number
PRV Pressure Relief Valve
PSI Pounds per Square Inch
PSIG Pounds per Square Inch (Gauge)
RPD Rupture Disc
RV Relief Valve
SCF Standard Cubic Feet
SCFH Standard Cubic Feet/Hour
SCM Standard Cubic Meters
UFC Uniform Fire Code
Third Party Verication: Any individual who tests and
veries the operation of bulk medical gas at health care
facilities. Must be qualied per ASSE standard 6035.
Medical Bulk Installation (current edition): An assembly
of equipment, such as bulk or microbulk tanks, pressure
regulators, vaporizers, manifolds, and interconnecting
piping that has a storage capacity of more than 20,000
SCF of gas including unconnected reserves on hand at
the site. The bulk system terminates at the point where
product, introduced at service pressure, rst enters the
distribution pipeline at the source valve. The tanks can be
stationary or portable, and the product can be stored as
gas or liquid.
Note: Bydenition,thebulkinstallationis
classiedwithacapacitymorethan20,000
SCF.

3
Product Manual - Perma-Cyl®Medical MicroBulk Skid
General
While Chart equipment is designed and built to the most
rigid standards, no piece of mechanical equipment can
ever be made 100% foolproof. Strict compliance with
proper safety and handling practices are necessary when
using a cryogenic manifold device or other compressed
gas equipment. We recommend that all of our customers
re-emphasize safety and safe handling practices to all their
employees and customers. While every possible safety
feature has been designed into the Perma-Cyl®Medical
MicroBulk Skid and safe operations are anticipated, it
is essential that the customer carefully read and fully
understand all Warning and Caution notes listed below.
Warning! The Perma-Cyl tank (liquid
cylinder), with its stainless steel
support system is designed,
manufactured, and tested to
function normally for many
years of service. It is never safe
to drop a liquid cylinder or let
it fall over in oxygen or any
cryogenic service. In the event
a liquid cylinder is inadvertently
dropped, tipped over, or abused,
slowly raise it to its normal
vertical position and immediately
open the vent valve to release
any excess pressure in a safe
manner. As soon as possible,
remove the liquid product from
the tank in a safe manner. If the
tank has been used in oxygen
service, purge it with an inert gas
(nitrogen). If damage is evident
or suspected, return the unit
to Chart prominently marked
“LIQUID CYLINDER DROPPED,
INSPECT FOR DAMAGE”.
Warning! Any welding that is done on the
outside of the Perma-Cyl System
can cause loss of vacuum and
will VOID any warranty on the
unit.
Warning! Before removing cylinder parts
or loosening ttings, be sure that
all pressure has been released
and the section has been
properly isolated by closing the
appropriate valves. If isolation
valves do not exist, it might be
necessary to either blow the
pressure off the entire tank or
to drain it. External valves and
ttings can become extremely
cold and may cause painful
burns to personnel unless
properly protected. Personnel
must wear protective gloves
and eye protection whenever
removing parts or loosening
ttings. Failure to do so may
result in personal injury because
of extreme cold and pressure in
the cylinder.
Caution! Only use replacement equipment
which is compatible with liquid
oxygen and has been cleaned
for oxygen use. Do not use
regulators, ttings, hoses, etc.,
which have been previously
used in compressed air service.
Failure to comply with these
instructions may result in serious
damage to the liquid cylinder and
personal injury.
Caution! All valves on an empty Perma-
Cyl system should always be
kept closed to protect the inner
tank and plumbing from being
contaminated.
Safety Bulletin
Portions of the following information are extracted from
Safety Bulletin SB-2 from the Compressed Gas Association,
Inc. Additional information on oxygen, nitrogen, argon, and
cryogenics is available from the CGA.
Cryogenic containers, stationary or portable, are from time
to time subjected to assorted environmental conditions of
an unforeseen nature. This safety bulletin is intended to call
attention to the fact that whenever a cryogenic container
is involved in any incident whereby the container or its
Safety

4
Safety Product Manual - Perma-Cyl®Medical MicroBulk Skid
safety devices are damaged, good safety practices must be
followed. The same holds true whenever the integrity or
function of a container is suspected of abnormal operation.
Incidents which require that such practices be followed
include: highway accidents, immersion of a container in
water, exposure to extreme heat or re, and exposure to most
adverse weather conditions (earthquake, tornadoes, etc.).
Under no circumstances should a damaged container be left
with product in it for an extended period of time.
Prior to reusing a damaged container, the unit must be
tested, evaluated, and repaired as necessary. It is highly
recommended that any damaged container be returned to
Chart for repair and re-certication.
In the event of known or suspected container vacuum
problems (even if extraordinary circumstances such as
those noted above has not occurred), do not continue to use
the unit. Continued use of a cryogenic container that has a
vacuum problem can lead to embrittlement and cracking.
The remainder of this safety bulletin addresses those adverse
environments that may be encountered when a cryogenic
container has been severely damaged. These are oxygen
decient atmospheres, oxygen enriched atmospheres, and
exposure to inert gases.
Caution! Before locating oxygen
equipment, become familiar
with the NFPA standard No.
55 “Compressed Gases and
Cryogenic Fluids Code” (www.
nfpa.org) and with all local safety
codes.
Oxygen Decient Atmospheres
Warning! Nitrogen and argon vapors in air
may dilute the concentration of
oxygen necessary to support or
sustain life. Exposure to such
an oxygen decient atmosphere
can lead to unconsciousness and
serious injury, including death.
The normal oxygen content of air is approximately 21%.
Depletion of oxygen content in air, either by combustion
or by displacement with inert gas, is a potential hazard and
users should exercise suitable precautions.
One aspect of this possible hazard is the response of humans
when exposed to an atmosphere containing only 8 to 12%
oxygen. In this environment, unconsciousness can be
immediate with virtually no warning.
When the oxygen content of air is reduced to about 15
to 16%, the ame of ordinary combustible materials,
including those commonly used as fuel for heat or light,
may be extinguished. Somewhat below this concentration,
an individual breathing the air is mentally incapable of
diagnosing the situation because the onset of symptoms
such as sleepiness, fatigue, lassitude, loss of coordination,
errors in judgment and confusion can be masked by a state of
“euphoria,” leaving the victim with a false sense of security
and well being.
Human exposure to atmosphere containing 12% or less
oxygen leads to rapid unconsciousness. Unconsciousness can
occur so rapidly that the user is rendered essentially helpless.
This can occur if the condition is reached by an immediate
change of environment, or through the gradual depletion of
oxygen.
Most individuals working in or around oxygen decient
atmospheres rely on the “buddy system” for protection -
obviously the “buddy” is equally susceptible to asphyxiation
if he or she enters the area to assist the unconscious partner
unless equipped with a portable air supply. Best protection
is obtainable by equipping all individuals with a portable
supply of respirable air. Life lines are acceptable only if the
area is essentially free of obstructions and individuals can
assist one another without constraint.
If an oxygen decient atmosphere is suspected or known to
exist:
1. Use the “buddy system.” Use more than one “buddy” if
necessary to move a fellow worker in an emergency.
2. Both the worker and “buddy” should be equipped with
self-contained or airline breathing equipment.
Oxygen Cleaning
When replacing components, only use parts which are
considered compatible with liquid oxygen and have been
properly cleaned for oxygen service (Refer to CGA Bulletin
G-4.1 “Equipment Cleaned for Oxygen Service”). Do not
use regulators, ttings, or hoses which were previously
used in a compressed air environment on these tanks. Only
oxygen compatible sealants or Teon tape should be used on
threaded ttings. All new piping joints should be leak tested
with an oxygen compatible leak-test solution.
Caution! Failure to comply with these
instructions may result in serious
damage to the system and
personal injury.

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SafetyProduct Manual - Perma-Cyl®Medical MicroBulk Skid
Oxygen Enriched Atmospheres
An oxygen-enriched atmosphere occurs whenever the normal
oxygen content of air is allowed to rise above 23.5%. While
oxygen is nonammable, ignition of combustible materials
can occur more readily in an oxygen-rich atmosphere than
in air; and combustion proceeds at a faster rate although no
more heat is released.
It is important to locate an oxygen system in a well
ventilated location since oxygen-rich atmospheres may
collect temporarily in conned areas during the functioning
of a safety relief device or leakage from the system.
Oxygen system components, including but not limited to,
containers, valves, valve seats, lubricants, ttings, gaskets
and interconnecting equipment including hoses, shall have
adequate compatibility with oxygen under the conditions
of temperature and pressure to which the components may
be exposed in the containment and use of oxygen. Easily
ignitable materials shall be avoided unless they are parts of
equipment or systems that are approved, listed, or proven
suitable by tests or by past experience.
Compatibility involves both combustibility and ease of
ignition. Materials that burn in air may burn violently in pure
oxygen at normal pressure, and explosively in pressurized
oxygen. In addition, many materials that do not burn in
air may do so in pure oxygen, particularly when under
pressure. Metals for containers and piping must be carefully
selected, depending on service conditions. The various steels
are acceptable for many applications, but some service
conditions may call for other materials (usually copper or
its alloy) because of their greater resistance to ignition and
lower rate of combustion.
Similarly, materials that can be ignited in air have lower
ignition energies in oxygen. Many such materials may
be ignited by friction at a valve seat or stem packing, or
by adiabatic compression produced when oxygen at high
pressure is rapidly introduced into a system initially at low
pressure.
Warning! If clothing should be splashed
with liquid oxygen it will become
highly ammable and easily
ignited while concentrated
oxygen remains. Such clothing
must be aired out immediately,
removing the clothing if possible,
and should not be considered
safe for at least 30 minutes.
Nitrogen and Argon
Nitrogen and argon (inert gases) are simple asphyxiates.
Neither gas will support or sustain life and can produce
immediate hazardous conditions through the displacement
of oxygen. Under high pressure these gases may produce
narcosis even though an adequate oxygen supply sufcient
for life is present.
Nitrogen and argon vapors in air dilute the concentration
of oxygen necessary to support or sustain life. Inhalation
of high concentrations of these gases can cause anoxia,
resulting in dizziness, nausea, vomiting, or unconsciousness
and possibly death. Individuals should be prohibited from
entering areas where the oxygen content is below 19%
unless equipped with a self-contained breathing apparatus.
Unconsciousness and death may occur with virtually no
warning if the oxygen concentration is below approximately
8%. Contact with cold nitrogen or argon gas or liquid can
cause cryogenic (extreme low temperature) burns and freeze
body tissue.
Persons suffering from lack of oxygen should be
immediately moved to areas with normal atmospheres.
SELF-CONTAINED BREATHING APPARATUS MAY BE
REQUIRED TO PREVENT ASPHYXIATION OF RESCUE
WORKERS. Assisted respiration and supplemental oxygen
should be given if the victim is not breathing. If cryogenic
liquid or cold boil-off gas contacts worker’s skin or eyes,
the affected tissue should be ooded or soaked with tepid
water (105-115ºF or 41-46ºC). DO NOT USE HOT WATER.
Cryogenic burns that result in blistering or deeper tissue
freezing should be examined promptly by a physician.
Personal Protective Equipment
(PPE)
The following personal protective equipment is
recommended when working around cryogenic liquid:
• Safety glasses with side shields to prevent cryogenic
liquid from splashing into the eyes
• Chemical / Liquid resistant gloves to prevent cryogenic
burns on exposed hands
• Long sleeve shirts to protect the arms
• Cufess trousers worn over closed shoes

7
Product Manual - Perma-Cyl®Medical MicroBulk Skid
Product Description
Primary Manifold
Consists of one microbulk cryogenic main header running
from the bulk storage tank. This header should have
sufcient ow capacity for an average day's supply. Header
is connected to a nal line regulating manifold consisting of
two regulators in parallel that can each be isolated without
interrupting the ow of gas into the medical facility. The
manifold also has a pressure relief system on a diverter valve
installed downstream of the connection of the reserve header
and upstream of the nal line pressure regulating assembly
and is set at 50% above the nominal inlet pressure. Another
pressure relief is installed on the downstream side of the
pressure regulators on a diverter valve and set at 50% above
the outlet pressure. There are pressure indicators on both the
high pressure side and the low pressure side of the nal line
regulators.
Reserve Manifold and Backup Storage
Supply
The reserve manifold and backup storage consists of a
secondary supply of product from high pressure cylinders
with the header connected to the primary manifold assembly
in such a manner that either header can supply the system.
When the primary header is supplying the system, the
secondary or reserve header is prevented from supplying
the system based on a pressure differential between the two
headers. The reserve manifold requires a sufcient number
of gas cylinder connections for an average day’s supply, but
not fewer than three, connected upstream of the nal line
pressure regulators. A header shutoff valve must be located
downstream of the nearest cylinder connection, but upstream
of the point at which the header connects to the central
supply system. A check valve is required at each connection
to the cylinder lead.
Primary Storage Tank
Normally a 1000-3000 liter top and bottom (FlexFill™ Piping
Option) style Perma-Cyl tank. See PN 20930593 Perma-Cyl
w/FlexFill Piping Option Manual for details on the proper
operation of the storage tank. See Appendix 5 - MicroBulk
Skid Tank Sizing Specications for System Specications on
the various size MicroBulk tanks.
Pre-Installation
(see Appendix 4 Installation Checklist)
Note: Ataminimumthesiteshouldbesecured
inaccordancewiththerequirementsofthe
localjurisdiction.Whenthereisnospecic
requirements,thesiteneedstomeetthe
minimumrequirementsfoundinNFPA55,
NFPA99andCGAM-1.
• If required, the equipment that will be installed at
medical facilities shall be approved by the Authority
Having Jurisdiction (AHJ), the owner, and the Design
Professional of Record (DPOR). Only approved
equipment shall be used.
• If a temporary gas system is required, the owner shall
contract with a third party for that service.
• The supervising technician shall establish contact with
the medical facility personnel to clarify the point of
contact who will become the person informed regarding
the installation plan. By doing this, it allows the facility
personnel to provide notice to all affected departments
and personnel so they are aware of the activity and they
can take appropriate actions.
• Depending on the size of tank that is on the medical skid,
it may arrive on-site inside a trailer or on a atbed truck.
The skid can be unloaded with either a forklift (minimum
of 6000 lb with 6' fork extensions) or a small crane.
• Visually inspect the receiving paperwork from the
manufacturer (new tank) to ensure the tank is the correct
product and MAWP.
• Visually inspect the concrete pad and the paperwork (e.g.
drawings) to verify that it is suitable for installation of the
MicroBulk skid.
• When picking up the skid with a crane, pick up the skid
using the four lift points on each corner of the frame
(see Figure 1). DO NOT PICK UP THE ENTIRE SKID
WITH THE LIFTING LUGS FOUND ON THE TOP OF
THE PERMA-CYL STORAGE TANK.
Introduction

8
Introduction Product Manual - Perma-Cyl®Medical MicroBulk Skid
Figure 1 - Lifting points
• Place the skid on the concrete pad in the proper
orientation.
• Remove the protective wrapping from the skid and
inspect for the following:
–No visible damage to the outer shell of the liquid
storage tank.
–Check the plumbing on the storage tank for any
visible signs of damage.
–Check to ensure there is still a positive pressure with
nitrogen on the tank.
–Check the piping on both manifolds for any visible
signs of damage.
–If the skid passes all the above criteria, it is ready to
set up and rst ll.
• Anchor the skid (see Figure 2) to the concrete pad with
either chemical adhesive type anchors or wedge anchors.
Anchors should be a minimum of ½ inch or as dictated by
the local codes or the DPOR.
Figure 2 - Anchoring the skid
• Install any extended ll assembly (if required) and
connect to the bulk tank(s). The ll assembly should not
be more than 25 feet from the tank and have a clear line
of sight to the liquid level and pressure gauges, and clear
access for the driver of the molecule provider.
• If the extended ll assembly is more than 25 feet and/or
there is no clear line of sight, an additional liquid level
gauge and pressure gauge shall be located at the ll point
for all bulk and MicroBulk tank installations. If the driver
cannot safely access the bulk tank, a remote lling system
should be engineered and installed (include valves,
PRV(s) and gauges to safely ll the tank). If the tank is
located more than 25 feet from the delivery unit, a remote
lling system should be considered.
Initial Setup
• The awning covers for the manifolds on each side of
the skid are folded down and bolted in place during
shipment (see Figure 3). Remove the bottom bolts that
are holding the awning in place and swing the awning up
into position. Replace the bolts to hold the awning in the
proper position (see Figure 4).
Figure 3 - Removing bolts on awning
Figure 4 - Replacing bolts on awning
Remove
these bolts to
swing awning
into place.
Swing awning
into place,
line up bolt
holes, replace
with bolts
removed in
Figure 3.
Lifting point
found on
each corner
of MicroBulk
Medical Skid

9
IntroductionProduct Manual - Perma-Cyl®Medical MicroBulk Skid
• Metal grating for the high pressure cylinders is shipped
with the grating folded up and secured in place with tie
wraps (see Figure 5). Cut the tie wraps and lower the
metal grating. This grating will be used to keep the high
pressure cylinders off the ground.
Figure 5 - Installing metal grating
• Install the appropriate number of high pressure cylinders
onto the skid and secure them in place with the provided
chain restraints (see Figure 6). Do not connect the
cylinders to the manifold at this time, but inspect them for
the following:
–Cylinders must meet DOT testing requirements
–Cylinders must have proper labels and lot number
stickers
–Cylinders must be chained and supported from turning
over
–Cylinders need to be on the metal grating
–Common DOT test dates, common lot numbers, new
and freshly painted cylinders should be installed.
Figure 6 - Chain restraints to secure cylinders
• A qualied electrician hired by the owner should tie in
the alarms from the medical facility alarm panel to the
medical skid. All medical skids are equipped with a
central termination point for all alarms (see Figure 7).
Figure 7 - Alarm connection points
• If the medical skid is equipped with a local signal alarm
panel (see Figure 8), termination points CR1, CR2, and
CR3 are located inside the panel. (See Appendix 3, Alarm
panel electrical schematic) Panel also requires a dedicated
120 VAC, 20 amp circuit that is also connected to the
facility back up electrical generator. Control power source
for the local alarm relays shall be independent of any of
the master alarm panels.
Figure 8 - Optional local signal alarm panel
Cut tie wrap
on each side
and lower
metal grate
until it is
laying on the
concrete pad.
Alarm
connection
points for
central alarm
system in
medical
facility.

11
Product Manual - Perma-Cyl®Medical MicroBulk Skid
Note: Installationandcommissioningofthis
MedicalMicroBulkSkidshouldbedoneby
personnelqualiedtomeetthemandatory
requirementsofCGAM-1orASSE6015.
• Make sure all the valves are closed (Gas use valve on
tank, see Appendix 6 Perma-Cyl Spec Drawings, all V-5s,
V-1 and V-2) (see Figure 9).
• The line on the skid that will be tied into the facility
source valve is capped (see Figure 10). Before attempting
to remove the cap, blow down any pressure that might
be on the line. To do this, close the pressure gauge
isolation valve (V-7) on (PI-3) (see Figure 11). Remove
the 1/8 inch brass plug (see Figure 11) and open valve
(V-7) to relieve all the pressure on the line as veried on
(PI-3). Leave the brass plug out for use as purge port if
requirement is to silver solder the nal tie in piping in
place.
Figure 10 - “Remove 1” source line cap
Installation
Figure 11 - Location of purge port and valve (V-7)
• Cut the cap off of the 1” copper pipe using a tubing cutter
(see Figure 10). Do not ream; deburr using a clean, sharp
deburring tool.
• Use a nylon abrasive pad (typically maroon or green) to
lightly clean the tube ends to remove all oxidation and
surface soils. Wipe off with a clean lint free cloth.
Figure 9 - Final Line Pressure Manifolds
Cut off this
cap in order
to make
nal tie-in
to medical
facility source
valve.
1/8 inch brass
plug in purge
port
Isolation
valve V-7

12
Installation Product Manual - Perma-Cyl®Medical MicroBulk Skid
• Recommend using pre-cleaned type L or type K hard
drawn copper seamless pipe meeting the requirements
of ASTM B-819 to make this tie-in. Copper pipe can
either be brazed in place or it can be installed with ttings
meeting the requirements on NFPA 99.
• If brazed in place, dry t the pipe using the appropriate
ux dependent on the brazing ller metal. Brazing is
permitted on copper to copper joints on the gas side of the
system using BCuP brazing ller metal without ux.
• Brazing must be completed under an NF nitrogen purge
by personnel qualied in accordance with ASME Section
IX certications, until the joint is cool to the touch.
Use 1/8 inch port above valve (V-7) (see Figure 11) for
purging and/or the purge port on the upstream side of the
source valve if so equipped (see Figure 12).
Figure 12 - Purge Ports on Source Valve
• Brazed component should be allowed to cool to a warm
condition. Clean joint with a wire brush.
• Visual inspection of the entire piping system shall be
completed while the source valve remains in the closed/
locked-out position.
System Pressure Testing
(shall be witnessed by the AHJ or third
party verication)
Note: Allthirdpartymedicalveriersshouldbe
ASSE6035certied.
• The entire MicroBulk Medical Skid has been pressure
tested per the provided QC inspection checklist (see
Appendix 1) at the factory. Unless dictated otherwise by
the third party verier, the only requirement is to pressure
check the nal piece of pipe that was installed to tie the
skid into the source valve.
• Have available an NF nitrogen source and regulator with
accurate pressure gauge near the piping system.
• Complete connections to the MicroBulk source
equipment upstream of the purge port with proper
pressure rated, oxygen cleaned hose and ttings.
• Remove and plug the active safety (RV-3A or 3B) (see
Figure 9) on the main gas outlet three way valve (V-6)
and insure that valves (V-5A-D) and (V-7) are closed.
Note: Lockoutsourcevalvepriortointroduction
of nitrogen for pressure testing.
Warning! Connection is being made to the
upstream purge port. Verify that
the connection is upstream of
the source valve.
• Pressure up main gas supply line through the upstream
purge port of the facility source valve if so equipped (see
Figure 12). Pressurize system to a minimum of 1.5 times
the normal working pressure (see Appendix 2, table 1,
Primary Reg-R2) and hold pressure for 10 minutes while
leak checking each joint with an approved leak detection
method.
• Open (V-7) and bleed pressure off of line through the 1/8
inch purge port. Replace plug in purge port above (V-7)
and the plug in the upstream purge port of the source
valve.
Tank and System Piping and
Purging Process
After the third party verication process is complete for the
system piping, the system purging process is started.
Pre-Fill Inspection
• Re-inspect all tank ttings, connections, and extended
ll assemblies (if required) to ensure the components are
clean and suitable for medical service, both in terms of
pressure and product compatibility.
Note: Extendedlllinesandllassembliesshall
bethirdpartyveriedwithNFnitrogen
priortollingthebulktankwithproduct.
• Ensure that the product warning labels and other warning
labels have been applied to the tank as required.
• Visually inspect that all valves positions are closed prior
to starting the lling process.
Healthcare Facility
Downstream
Purge Port
MicroBulk Source
Equipment Upstream
Purge Port

13
InstallationProduct Manual - Perma-Cyl®Medical MicroBulk Skid
Tank Purging (change of grade) and Filling
Procedure
(See Appendix 6 for tank valve tag numbers)
Purging the Tank Prior to Filling
1. Attach the source of liquid purge to the ll connection
of the Perma-Cyl tank.
2. If the ll hose has not been kept under pressure since
the last delivery, it will need to be purged. Purge the ll
hose and connector through the hose drain valve (V-3)
on the tank piping until a light frost appears on the
valve. Close the hose drain valve.
3. If the Perma-Cyl tank is pressurized, open the vent
valve (V-9) and blow down to less than 5 psi. To
prevent drawing atmospheric contaminants back
into the tank during the purging operation, a positive
pressure should be maintained in the tank.
First Fill Procedure
1. Partially ll the Perma-Cyl tank with product according
to the Tank Fill Table (shown below). Use truck meter
to verify the amount put into tank.
Let liquid build pressure close to safety setting.
While the vent gas is still warm and tank is under
pressure, move the four-way valve (V-11) to the
‘Equalization’ position. Loosen the ttings on either
side of the liquid level gauge to allow the gauge lines to
purge with gas. Check the gas stream coming out of the
ttings for evidence of moisture. Continue to ow the
gas until lines have been purged and there are no visible
signs of moisture. Tighten ttings to stop the ow of
gas. Move the four-way valve to the ‘Normal Operation’
position. When liquid is out of the tank and pressure is
still high, open the vent valve (V-9). Before blowing
remaining pressure out of the vent valves, this would be
a good time to leak check all connections that are under
pressure.
Vent all product out of the liquid valve and close before
pressure drops below 5 psig.
Tank Fill Table
Tank
Size Amount of Product Oxygen (gal)
Nitrogen
(gal)
1000 L 2000 standard cubic feet 17 21
1500 L 3000 standard cubic feet 26 32
2000 L 4000 standard cubic feet 35 43
3000 L 5000 standard cubic feet 43 54
2. Fill Perma-Cyl tank with product as indicated in the
Tank Fill Table. Primarily use the bottom ll (V-5) on a
FlexFill™ Piping Option tank. Make sure some product
is routed through the top ll lines (V-6) to purge them
prior to totally lling the tank.
Open the PB circuit and set to maximum psi. Insure
liquid is owing through this circuit as indicated
by frosting on the pipes. Let liquid in the tank build
pressure close to safety setting. Once desired pressure is
reached, open liquid valve (V-4). When liquid is out of
the tank and pressure is still high, open the vent valve
(V-9).
Once pressure is less than 5 psig, close the liquid (V-4)
and vent valves (V-9). Maintain positive pressure on the
tank.
3. Fill the Perma-Cyl tank with product (per Tank Fill
Table) and let the liquid in the tank build pressure close
to the safety setting. Remove safety in economizer
unit and ensure the product is owing through the
economizer regulator and purging the economizer lines.
Control the pressure by opening the vent valve (V-9).
Once pressure is less than 5 psig, close the vent valve
(V-9). Maintain a positive pressure on the tank.
4. Fill the Perma-Cyl tank with product (per Tank Fill
Table) and let the liquid in the tank build pressure to
close to the safety setting. Once the desired psig has
been reached, open the vent valve (V-9). Once pressure
is less than 5 psig, close the vent valve.
Note: Thepurgegasshouldbecoolingthetank.
IfthetankventlineisHOT,alwayspurge
untiltheventlineiscoolorevenfrosted.
Note: Whileventingdownthetankeachtime,
ensureapositivepressureremainson
thetanktokeepambientairfromowing
backintothetankandcontaminatingthe
product.
Filling the Tank After the Cool Down Process is
Complete
1. If equipped with a bottom ll valve (V-5), the bottom
ll valve and the tank vent valve (V-9) are the valves to
be used to ll the tank.
2. Have the driver start the pump and slowly deliver the
liquid into the tank. Observe the tank pressure and
control the pressure by venting the tank down or using
the top ll valve (V-6) to control the pressure.

14
Installation Product Manual - Perma-Cyl®Medical MicroBulk Skid
3. As the lling proceeds and the tank gets cooler, you
should be able to pinch off and, in some cases, close
the vent valve (V-9). We recommend that you do not ll
the tank to the full trycock (V-9) on the rst ll. Fill to
80% in order to allow for liquid expansion as the tank
contents absorb heat while the metal continues to cool
down over time.
Insure that PB and economizer regulators are properly
set. For medical oxygen installations, tank should be
set at 125 psig. For medical nitrogen installations tank
should be set at 220 psig.
System Purging
Refer to Figure 9 for valve references in the following
procedure.
Note: Thefollowinginstructionsgivedetails
onalarmandregulatorsetpointsforthe
standardoxygenmicrobulkmedicalskids.
Setpointsfornitrogenandhyperbaric
oxygenskidmodelscanbefoundonspec
drawingD-20810866inAppendix2.
• Connect the pigtails on the high pressure manifold to the
high pressure tanks (see Figure 13). Do not over tighten
the connection nuts on the pigtails (see Figure 14). This
will cause the tting to distort and leak. Be sure the valve
V-1 is closed and then slowly open the valves on each
tank listening for any leaks. Check each tank connection
using an approved leak detection method.
Figure 13 - Pigtail connections
Figure 14 - Connection nuts on pigtails
• Open V-2, all V-5s, V-8 (refer to Figure 9)
• Close V-7 and remove the 1/8 inch plug in the purge port
above valve V-7. Reopen V-7.
• Slowly open V-1 to allow pressure to ow through
R-1. Insure that the pressure on PI-1 reads 65 psig.
(recommended pressures for nitrogen skids and
hyperbaric oxygen skids can be found on spec drawing
D-20810866 in Appendix 2) If pressure is incorrect,
adjust regulator R-1 and then close V-7 and V-2.
• Ensure valves V-10 & V-11 (see Figure 15 & 16) are
closed and slowly open valve V-2.
• Remove plug from V-10 valve (see Figure 15) and slowly
open the valve in order to purge the short instrument line
with oxygen.
Note: Thepurgevalvebelowpressureswitch
PS-1isdirectlyconnectedtothehigh
pressureoxygencylinders.Useextreme
cautionwhenopeningthisvalve.
Once V-10 valve is “burped” with oxygen ow, close the
valve and replace the plug.
• Open valve V-11 (see Figure 16) to apply pressure to
PS-2 and PI-5. Close valve V-11 and allow pressure to
exhaust out of the downstream purge port on the valve.
Repeat this process of opening and closing V-11 three
to four times in order to purge the instrument line. After
purging line, leave valve V-11 open.
Figure 15 - Pressure switch isolation valves
• Close valve V-1.
• If the source valve has an upstream purge port, open V-7
and bleed all the pressure off the manifold and replace
purge port plug above V-7. Open upstream purge port
on source valve. If the source valve does not have an
upstream purge port, use the purge port above V-7 to
complete the remaining purge steps below. SOURCE
VALVE SHOULD REMAIN LOCKED OUT.
Pressure
switch
isolation valve
V-10
Pressure
indicator PI-5
Pressure
switch (PS-1)
1/8 inch purge
port
Do not
overtighten
this tting.

15
InstallationProduct Manual - Perma-Cyl®Medical MicroBulk Skid
• Slowly open gas use valve on tank (see Appendix 6
Perma-Cyl Spec Drawings).
Figure 16 - Pressure valves
• Source gas should now be owing throughout the
entire manifold and out the purge port. Insure that both
regulators R-2A & B (see Figure 9) are adjusted to 50-55
psig (or as called out in spec drawing D-20810866 for
other model skids in Appendix 2).
Pressure
indicator PI-4
• Continue purging the entire system with the source gas.
When purging with oxygen as the source gas, recommend
using an oxygen analyzer at the purge port to verify when
the purge is complete.
• Once purge is complete, cut back purge gas with the gas
use valve on the Perma-Cyl tank and replace the plug in
the port that was being used for purging.
• Completely open gas use valve on Perma-Cyl tank and
leak check all ttings all the way to the source valve
using an oxygen approved leak detection method.
Pressure
switch (PS-2)
isolation valve
V-11