CHART 1000 User manual

Part Number 20930593 Rev. C
© 2016 Chart Inc.
Designed and Built by:
Chart Inc.
1300 Airport Dr.
Ball Ground, GA 30107 USA
[phone]
Product Manual
Perma-Cyl®MicroBulk Storage System
w/ FlexFill™Piping Option
1000/1500/2000/3000/5500

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Product Manual - Perma-Cyl®w/ FlexFill™ Piping Option
Contents
Revision Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Product Highlights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Product Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Acronyms / Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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/Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Initial Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Vacuum Check Procedure - Perma-Cyl 5500 Only. . . . . . . . . . . . . . . . . . . . . . . . . .7
Primary Plumbing Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Pressure Build . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Liquid Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Gas Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Safety Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Vent/Full Trycock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Other Piping Circuits and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Phase Lines and Liquid Level Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Four-Way Valve (see photos 1 & 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Gauge (see photos 1 & 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Vacuum Evacuation Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2000/3000VHP Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2000 and 3000 VHP Primary Plumbing Circuits . . . . . . . . . . . . . . . . . . . . . . . . . 11
5500 MP/VHP Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5500 MP/VHP Primary Plumbing Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Vacuum Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Unloading and Placement of the Perma-Cyl Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation Common Codes and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Conducting a Site Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation Tools and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Additional Required Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Indoor Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Internally Sited / Filled Indoors / Pipe Out Safeties . . . . . . . . . . . . . . . . . . . . . . . . 19
Wall Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation of Hoses and Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Line Connection to Fill Box Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Bolting to Floor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

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Table of Contents Product Manual - Perma-Cyl®w/ FlexFill™ Piping Option
Outdoor Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Externally Sited / Gas Use Indoors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Outdoor Installation Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
First Fill/Purge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Purging and First Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Filling the Tank After the Cool Down Process is Complete . . . . . . . . . . . . . . . . . . . . 23
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Illustrations & Parts Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1000 HP/VHP FlexFill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1500 HP/VHP FlexFill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2000 HP FlexFill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3000 HP FlexFill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2000 VHP FlexFill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3000 VHP FlexFill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5500 VHP FlexFill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5500 MP FlexFill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Revision Log
Revision Level Date Description
A 11/24/2015 Original manual
B 02/22/2016 Add information on thermocouple to the end of 5500 VHP Operation section
C 09/08/2016 Add information for 5500 MP model; update Filling Weight Table

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Product Manual - Perma-Cyl®w/ FlexFill™ Piping Option
General
The new Perma-Cyl FlexFill storage vessel is equipped with
a top and bottom ll circuit in place of the top oat assembly
so the driver can control the tank pressure while lling the
Perma-Cyl® MicroBulk Storage System. The FlexFill option
uses the ullage technology adopted from our LNG fueling
system which allows the inner vessel to safely go liquid full.
Once the meter on the Orca™MicroBulk Delivery System
senses a ow rate reduction, the pump is automatically shut
down. This patented automatic dispensing system simulates
the same process drivers have used for years to safely ll
Perma-Cyl storage tanks without venting.
The FlexFill feature is critical for applications like laser
assist gas and medical gas supply where a signicant drop in
downstream pressure during the Perma-Cyl tank rell could
result in equipment alarms. The new FlexFill feature works
with all Orca delivery unit models, both new and existing
units.
*Perma-Cyl tanks with the FlexFill Piping Option are
presently not approved for service with CO2.
Product Highlights
• Allows top and bottom lling for accurate pressure
control in the Perma-Cyl tank during rell
• Provides the same safe, single hose, no-loss, auto shut-
off ll with the Orca delivery system as the top ll oat
design
• Backward compatible - works with new and existing Orca
delivery units without modications
• Incorporates the lling technology from the LNG vehicle
& dispenser system
• Comes standard with dual relief valves and rupture discs
• Utilizes separate pressure build and economizer
regulators
Product Manual
This manual contains information regarding the safe
operation and maintenance of a Perma-Cyl tank w/ FlexFill
piping option. It should be thoroughly read and understood
by anyone that operates the equipment.
The safety requirements for operating the tank and handling
or transporting extremely cold liquid products are shown
in the Safety section. Use this safety section as a “Safety
Checklist” each time the equipment is being used.
The Introduction/Operation section discusses the general
features of the tank and the theory of operation.
In the Installation section there are illustrations for how to
uncrate and install the tank.
The remaining sections describe the specic tank models
covered by this manual. They contain warranty information,
troubleshooting help, technical specications/illustrations,
and parts lists. They should be reviewed rst and referred to
as the rest of the manual is read.
The Illustrations & Parts Listing section contains schematics,
piping illustrations, and parts list that show a reference
number for each component used on the tank. The reference
numbers may refer to the same functional component
between the various models. The reference numbers will be
used throughout this manual to draw specic attention to a
component while describing its function, operation, or repair.
Preface

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Preface Product Manual - Perma-Cyl®w/ FlexFill™ Piping Option
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.
Acronyms / Abbreviations
The following acronyms / abbreviations are used throughout
this manual:
Ar Argon
ASME American Society of Mechanical Engineers
BARG Pressure (Metric) Gauge
CGA Compressed Gas Association
CO2Carbon Dioxide
DOT Department of Transportation
FPT Female Pipe Thread
ID Inner Diameter
Kg Kilogram
LAR Liquid Argon
MAWP Maximum Allowable Working Pressure
N2Nitrogen
Nm3Normal Cubic Meters
Nm3h Normal Cubic Meters/Hour
NER Normal Evaporation Rate
NFPA National Fire Protection Association
NPT National Pipe Thread
O2Oxygen
PB Pressure Builder
PSI Pounds per Square Inch
PSIG Pounds per Square Inch (Gauge)
SCF Standard Cubic Feet
SCFH Standard Cubic Feet/Hour
UFC Uniform Fire Code

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Product Manual - Perma-Cyl®w/ FlexFill™ Piping Option
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®MicroBulk
Storage System w/ FlexFill™ Piping Option 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, 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 vessel in a safe manner.
If the vessel 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, completely
empty the liquid cylinder of
liquid and release the entire
vapor pressure in a safe manner.
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
vessel 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 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
Safety

4
Safety Product Manual - Perma-Cyl®w/ FlexFill™ Piping Option
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.

5
SafetyProduct Manual - Perma-Cyl®w/ FlexFill™ Piping Option
Oxygen Enriched Atmospheres
An oxygen-enriched atmosphere occurs whenever the normal
oxygen content of air is allowed to rise above 23%. 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