CHART Perma-Cyl MicroBulk 1500 ZX VHP User manual
Part Number 20966041 Rev. B
© 2016 Chart Inc.
Designed and Built by:
Chart Inc.
1300 Airport Dr.
Ball Ground, GA 30107 USA
(800) 400-4683
Product Manual
Perma-Cyl®MicroBulk Storage System
1500 ZX VHP
iii
Product Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System
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 Decient Atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Oxygen Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Oxygen Enriched Atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Nitrogen and Argon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Personal Protective Equipment (PPE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Tank Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
System Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Handling the Perma-Cyl 1500 ZX VHP Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Shipping the Perma-Cyl 1500 ZX VHP Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Initial Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
First Fill/Purge Procedure, ASME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Purging and First Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Filling the Tank After the Cool Down Process is Complete . . . . . . . . . . . . . . . . . . . . 10
Primary Plumbing Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
(Refer to Figure 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Build . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Liquid Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gas Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Safety Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Vent/Full Trycock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Other Piping Circuits and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Phase Lines and Liquid Level Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Four-Way Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Vacuum Evacuation Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Calibration Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Bench Setting a Pressure Building Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Bench Setting an Economizer Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Rebuilding the Rego Operational Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
iv
Table of Contents Product Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System
Revision Log
Revision Level Date Description
A 11/24/2015 Original product manual
B 11/14/2016 Update description in Preface, add vacuum evacuation port in Introduction
section, add gas ow capacity and update part numbers and description in
Specications section.
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Controls and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
EXT PB Circuit - Top Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
EXT Gas Use Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
EXT PB Circuit - Bottom Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
External Vaporizer Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Safety Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FlexFill™ Piping Option Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Economizer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Chart Packaged Gas Products Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1
Product Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System
General
The Perma-Cyl 1500 ZX VHP MicroBulk Storage Systems
are designed and built with a rugged internal support system
for mobility within its protective metal pallet. The Perma-Cyl
1500 ZX VHP cylinder features a top and bottom ll system
with an internal ullage tank. The internal ullage tank design
allows for a single hose, ventless delivery with auto shuto
when lled with a Chart Orca™MicroBulk Delivery vehicle.
With the on-board external aluminum heat exchanger, the
Perma-Cyl 1500 ZX VHP cylinder is rated at a ow rate of
3000 SCFH while sustaining 420 to 450 psig. The vessel
is bolted to a dedicated metal pallet for full protection and
transportability with a forklift. The portable design makes the
Perma-Cyl 1500 ZX VHP cylinder the ideal quick-response
solution for demanding industrial gas applications, like laser-
assist gas.
Product Highlights
• Perma-Cyl system is equipped with top and bottom ll
(FlexFill™ Piping Option) for accurate pressure control
during delivery.
• High ow external aluminum vaporizer and pressure
builder system provides up to 3000 SCFH at 420 to 450
psig
• Separate pressure build and economizer regulators with
isolation valves
• Dual relief valves and rupture discs with diverter valve
• Provides safe, single hose, no loss, auto shuto ll when
lled with Orca MicroBulk Delivery System
• Metal pallet incorporates forklift slots while protecting
plumbing and tank during transportation and application
use
• Pallet has durable exterior coating for maximum
corrosion resistance
Product Manual
This product manual describes the specications, installation,
operation and maintenance of the Perma-Cyl 1500 ZX VHP
cylinder model. Included within this manual is information
regarding the safe operation and handling of liquid nitrogen,
argon, and oxygen within the cylinder. It should be
thoroughly read and understood by anyone that operates the
equipment. If there are any questions regarding the operation
of the Perma-Cyl 1500 ZX VHP cylinder, contact Chart
Technical Service at 800-400-4683.
The schematic, piping illustrations and parts list in the
Specications section show a reference number for each
component used on the cylinders. The reference numbers
will be used throughout this manual to draw specic
attention to a component while describing its function,
operation, or repair.
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 section discusses the general design of the
tank and outlines the responsibilities of the distributor and
the ller of the tank. Information on handling the tank and
shipping is also included in this section.
In the Operation section there is information on the initial
inspection, purging the tank, lling the tank, and gas and
liquid withdrawal. This section also includes specications
and calibration charts.
The Troubleshooting section contains a table of issues and
remedies that may arise in the use of the Perma-Cyl 1500 ZX
VHP cylinder.
Please refer to the Maintenance section for general
maintenance instructions and identication of various parts
on the Perma-Cyl 1500 ZX VHP cylinder.
Preface
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Preface Product Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System
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
BAR Pressure (Metric)
CGA Compressed Gas Association
DOT Department of Transportation
H2O Water
Kg Kilogram
LAR Liquid Argon
LIN Liquid Nitrogen
LOX Liquid Oxygen
N2Nitrogen
NFPA National Fire Protection Association
O2Oxygen
PB Pressure Builder
PN Part Number
PSI Pounds per Square Inch
PSIG Pounds per Square Inch (Gauge)
SCFH Standard Cubic Feet/Hour
3
Product Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System
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 1500 ZX VHP
cylinder and safe operations are anticipated, it is essential
that the customer carefully read and fully understand all
Warning and Caution notes listed below.
Warning! Excess accumulation of oxygen
creates an oxygen enriched
atmosphere (dened by the
Compressed Gas Association
as an oxygen concentration
above 23 percent). In oxygen
enriched atmospheres ammable
items burn vigorously and
could explode. Certain items
considered noncombustible in
air may burn rapidly in such an
environment. Keep all organic
materials and other ammable
substances away from possible
contact with oxygen; particularly
oil, grease, kerosene, cloth,
wood, paint, tar, coal, dust and
dirt which may contain oil or
grease. DO NOT permit smoking
or open ames in any area where
oxygen is stored, handled or
used. Failure to comply with this
warning may result in personal
injury.
Warning! Nitrogen and argon vapors in air
may dilute the concentration of
oxygen necessary to support or
sustain life. Exposure to such
an oxygen decient atmosphere
can lead to unconsciousness and
serious injury, including death.
Warning! Before removing cylinder parts
or 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 the 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! The Perma-Cyl 1500 ZX VHP
cylinder should be moved using
a fork truck that lifts the cylinders
from beneath the pallet. The
Perma-Cyl 1500 ZX VHP cylinder
must be used and stored in a
vertical position. Do not lay,
store, or ship a liquid cylinder on
its side. Failure to comply with
these procedures may result in
damage to the liquid cylinder.
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 (www.cganet.com).
Safety
4
5
Safety SafetyProduct Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System Product Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System
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
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-certication.
In the event of known or suspected container vacuum
problems (even if extraordinary circumstances such as those
noted above have 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
decient 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 Decient 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 decient atmosphere
can lead to unconsciousness and
serious injury, including death.
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 Teon tape should be used on
threaded ttings. All new piping joints should be leak tested
with an oxygen compatible leak-test solution.
Oxygen Enriched Atmospheres
An oxygen-enriched atmosphere occurs whenever the normal
oxygen content of air is allowed to rise above 23%. While
oxygen is nonammable, 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 conned 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.
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 decient
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 decient 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.
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 sucient
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 suering 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-o gas contacts worker’s skin or eyes,
the aected 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.
6
Safety Product Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System
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
• Cuess trousers worn over closed shoes
7
Product Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System
Tank Design
The Perma-Cyl 1500 ZX VHP cylinder is a vacuum insulated
cylinder that is designed to furnish liquid and gaseous
oxygen, nitrogen or argon on a reliable, economical basis.
The tank holds 1500 liters of cryogenic product. The tank is
pressure rated at 500 psig and has both internal and external
pressure build and process vaporizers.
The insulation system is comprised of multiple layers of foil
and paper that are incorporated with a very low vacuum.
The vacuum is factory sealed and with the aid of internal
molecular sieve it should remain low for the life of the
container. This insulation system coupled with design of the
support system minimizes the pressure rise when the tank
is left idle. If product is left in the container for a period of
time, the pressure will build and eventually vent through the
safety relief valve. However, if the container is used in gas
withdrawal service after pressure has built, the economizer
system will automatically reduce the head pressure in the
container without loss of product.
The design and construction of the Perma-Cyl 1500 ZX VHP
cylinder is aimed at building the most durable tank available
today. The inner vessel is constructed of stainless steel and
designed to the applicable pressure vessel code. The outer
container is constructed of stainless steel to make the Perma-
Cyl 1500 ZX VHP cylinder a maintenance free container.
The unit is mounted on a painted carbon steel pallet frame.
The inner pressure vessel is protected from over-
pressurization by a safety relief valve. The Perma-Cyl 1500
ZX VHP cylinder pressure is set at 500 psig with a rupture
disc set at 700 psig. The outer container of vacuum space is
protected by a reverse buckling rupture disc that is set at a
maximum of 25 psig.
System Design
The Perma-Cyl 1500 ZX VHP MicroBulk Storage System
cylinder is the newest addition to the Perma-Cyl family
of liquid cylinders, designed for high pressure, high ow
industrial gas applications. With the on-board, heat-
exchanger system, the Perma-Cyl 1500 ZX VHP cylinder
is rated at a ow rate of 3000 SCFH while sustaining 420
to 450 psig. Flows over 3000 SCFH can be achieved with
reduced duty cycles and added vaporization.
The Perma-Cyl 1500 ZX VHP cylinder is contained
completely within a 61.8" deep x 61.8" wide x 92.8" high
pallet. The pallet system can be moved by fork truck. The
portable design makes it a quick-response solution for
demanding industrial gas applications, such as industrial
laser-assist gas.
The piping uses industry proven valves and components.
The operation of the system is simple and is modeled after a
standard liquid cylinder.
Responsibilities
The responsibilities of the Distributor and the Filler of the
Perma-Cyl 1500 ZX VHP cylinder are stated below:
1. The cylinder must be in a safe condition before lling.
The ller is responsible for conrming that the Perma-
Cyl 1500 ZX VHP to be lled is in its proper working
condition. This includes:
• Has an ASME Data Plate
• An appropriately sized and marked primary relief
valve
• There is no visible structural damage to the cylinder
• All required labeling is in place and legible
2. Do not overll.
The Perma-Cyl 1500 ZX VHP cylinder is not to be
lled beyond the recommended lling limits described
in this manual.
3. Dispense only to knowledgeable users.
The ller must determine that the user is knowledgeable
about the general characteristics of the product and
proper safety precautions for its use.
4. Dispose of cylinders properly.
To eliminate the risk of injury from the improper reuse
of cryogenic (vacuum jacketed) cylinders, before
disposal, destroy the cylinder's pressure retaining
capability.
We Recommend:
• Purge the cylinder's contents.
• Drill multiple holes through the cylinder and its
vacuum casing or otherwise puncture the inner
vessel. Make sure this is done before the scrap
dealer takes possession.
Introduction
8
Introduction Product Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System
Handling the Perma-Cyl 1500 ZX
VHP Cylinder
The Perma-Cyl 1500 ZX VHP storage vessel is mounted on
a painted carbon steel pallet. The preferred handling method
is a forklift that lifts the pallet-mounted tank from beneath
the pallet. Lifting of the Perma-Cyl 1500 ZX VHP cylinder
should be performed only with equipment rated for the
weight of the cylinder, pallet and contents combined (see
Specications section of this manual).
This container should remain upright at all times. Never lay
the unit on its side to move or transport it. Careless handling
can cause damage to the support system and internal
plumbing, which may result in serious personal injury.
Shipping the Perma-Cyl 1500 ZX
VHP Cylinder
The Perma-Cyl 1500 ZX VHP has a pressure strengthened
inner vessel. It is not permitted to ship this tank with product
in it.
9
Product Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System
Initial Inspections
When the container is rst received it should be inspected for
shipping damage. Never ll a damaged container.
The Perma-Cyl 1500 ZX VHP cylinder is shipped with
nitrogen gas. For this reason any container that is to be put
into oxygen or argon service should be thoroughly purged
with the applicable gas.
First Fill/Purge Procedure, ASME
Note: The Perma-Cyl 1500 ZX VHP cylinder
is shipped with nitrogen gas. Purging is
necessary prior to lling. During rst ll,
only ll the vessel to 75% full to allow for
liquid expansion experienced with a new
(warm) tank. Each ll thereafter can be
lled to 100% full. All valves on an empty
Perma-Cyl cylinder should always be
kept closed to prevent the inner vessel and
plumbing from being contaminated.
Purging and First Fill Procedure
1. Attach the source of liquid purge to the ll connection
of the Perma-Cyl 1500 ZX VHP cylinder.
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 purge valve, if so
equipped, or by loosening the ll connection until vapor
ows from the connection and then retighten. Use the
hose drain on the tank piping if equipped as such.
3. If the Perma-Cyl 1500 ZX VHP is pressurized, open the
vent valve and blow down to 5 psi. To prevent drawing
atmospheric contaminants back into the tank during the
purging operation, a positive pressure of at least 5 psig
should be maintained in the tank.
4. Partially ll the Perma-Cyl 1500 ZX VHP with 3000
standard cubic feet of product.
Let liquid build pressure close to safety setting.
Leak check all plumbing circuits while the tank is under
maximum pressure.
While vent gas is still warm and tank is under pressure,
move the four-way valve to the ‘Equalization’ position
and 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 is no visible signs of moisture. Tighten
ttings to stop the ow of gas. Move the four-way valve
to the ‘Normal Operation’ position.
Vent all product out of the liquid valve and close before
pressure drops below 5 psig.
5. Fill the Perma-Cyl ZX VHP with 3000 standard cubic
feet of product. Primarily use the bottom ll on a
FlexFill piping option tank. Make sure some product is
also routed through the top ll lines 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. When liquid is out of the
tank and pressure is still high, open the vent and gas use
valves.
If a nal line manifold is already connected to the
gas use valve, purge through the manifold to ensure
that there is a ow through the gas use circuit and any
moisture is purged out before liquid is introduced into
this circuit.
Once pressure is blown down to approximately 5 psig,
close the liquid, vent and gas use valves.
6. Fill the Perma-Cyl ZX VHP cylinder with 3000
standard cubic feet of product and let the liquid in the
tank build pressure close to the safety setting. Insure the
product is owing through and purging the economizer
lines. Control the pressure by opening the gas use and
vent valves. Once pressure is blown down to 5 psig,
close the gas use and vent valves.
7. Fill the Perma-Cyl ZX VHP with 3000 standard cubic
feet of product and let the liquid in the tank build
pressure close to the safety setting. Once the desired
psig has been reached, open the gas use and vent valves.
Once pressure is blown down to 5 psig, close the gas
use and vent valves.
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.
A new, warm tank should go through a
minimum of four or ve purge cycles
before lling with liquid.
Operation
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Operation OperationProduct Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System Product Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System
Filling the Tank After the Cool Down
Process is Complete
1. If equipped with a bottom ll valve, the bottom ll
valve and the tank vent valve are the valves to be used
to ll a warm 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 to control the pressure.
3. As the lling proceeds and the tank gets cooler, you
should be able to pinch o and, in some cases, close the
vent valve. We recommend that you do not ll the tank
to the full trycock on the rst ll. Fill to 75% in order to
allow for liquid expansion as the tank contents absorb
heat while the metal continues to cool down over time.
Caution! Pressure should be allowed to
escape from the transfer hose
before it is completely removed.
A hose drain and relief valve
should be installed in all transfer
lines.
Primary Plumbing Circuits
(Refer to Figure 1)
Fill
The Perma-Cyl w/ FlexFill has a top and bottom ll circuit
so the driver can control the tank pressure while lling
the Perma-Cyl MicroBulk Storage System. The ll circuit
consists of a top ll valve (V-1), a bottom ll valve (V-2),
a ll check valve (CV-1), and a hose drain valve (V-4). The
ll line check valve has a service tting on the inlet side that
provides the sole connection for the liquid delivery vehicle.
The hose drain valve (V-4) can be used to both purge the ll
hose before lling the tank or to depressurize the ll hose
after lling the tank.
The driver controls the pressure in the vessel during the ll
process by adjusting the ow through the top and bottom ll
valves. Product owing into the bottom of the tank will raise
the pressure and product owing into the top of the tank will
lower the pressure. Adjusting each valve properly will allow
the driver to hold a consistent pressure in the tank throughout
the entire delivery.
During a rst ll, only ll the vessel to 75% full to allow
liquid expansion experienced with a new "hot" tank. Each
ll there after can be lled to 100% full. Please refer to
the Installation section of this manual for detailed lling
procedures.
Caution! If liquid can be trapped in the
transfer system, a suitable relief
valve must be installed to prevent
over pressurization.
Caution! Before making a liquid transfer
either into or out of this
vessel, be sure that protective
eyeglasses and gloves are being
worn. If the transfer is being
made to an open top vessel, the
transfer pressure should be as
low as possible and a phase
separator should be used to
eliminate splashing and hose
whip.
Pressure Build
The pressure build circuit is used to build pressure back in
the vessel after a delivery or to maintain pressure as liquid
is withdrawn from the vessel. The vessel pressure is set by
adjusting the PB regulator (PCV-1). Standard PB set point is
450 psig.
As the tank pressure drops below the PB set point, the
regulator opens and allows liquid to ow o the bottom of
the tank, through the PB vaporization coils, and back into
the gas phase of the tank. The pressure build circuit can be
isolated by closing valve V-7 and V-9.
Economizer
The economizer circuit allows for the customer to utilize
the natural heat leak that occurs in every cryogenic storage
vessel. When the pressure is above the setpoint of the
economizer regulator, the economizer regulator (PCV-2)
opens. This allows gas to be withdrawn directly o the
headspace of the tank and travel through the vaporization
coils, in order to warm the cold gas, and out the gas use
valve. This will result in lowering the pressure of the tank.
Valves V-10 and V-11 can be used to isolate the economizer
regulator.
Note: The economizer circuit will only work if
the customer is using product out of the
vessel.
Liquid Use
The liquid use circuit can be used for both a liquid
application or a high ow gas use application. This circuit
draws liquid directly up the dip tube and out through the
liquid use valve (V-3).
Gas Use
The gas use valve leverages either the internal or external
vaporizer on the Perma-Cyl system to supply gaseous
product to the end user. Gas use valve V-15 is tied to the
internal process vaporizer. Gas use valve V-17 is tied to the
external process vaporizer.
The internal and external vaporizers can support specic
ow rates. Flow is limited when used at the same time. The
line size connected to the gas use should be sized properly
for the pressure and ow rate that is desired.
The Perma-Cyl tank will deliver gas at various ow rates and
temperatures for dierent applications. The equipment that
is being supplied gas from the Perma-Cyl tank controls the
ow rate. Higher ow rates may provide very cold gas that
could damage the equipment to which they are attached. To
supply gaseous product, follow this step by step procedure.
1. Connect the proper regulator/regulating manifold to the
liquid cylinder's gas use outlet.
Figure 1 - Schematic for 1500 VHP Flex Fill
Color Code:
Relief Circuit
Liquid Use Circuit
Fill Circuit
PB Circuit
Economizer Circuit
Gas Use/Final Circuit
12
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Operation OperationProduct Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System Product Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System
2. Connect the proper piping between the nal line
regulator and the receiving equipment.
3. Open the pressure building valve (V-7, V-9).
4. Allow pressure to build to the operating pressure (refer
to gauge).
5. Open the gas use valve (V-17 or V-15).
6. Adjust the gas use regulator for the proper delivery
pressure.
Caution! All valves on an empty Perma-
Cyl tank should always be kept
closed to protect the inner
vessel and plumbing from being
contaminated.
The operator should review the safety precautions found
in the Safety section before conducting a gas or liquid
withdrawal operation. Protective eyeglasses and gloves
should always be worn.
At low ow rates, the Perma-Cyl tank is capable of
delivering warm gas through the line regulator. As the ow
rate increases, the temperature of the gas decreases. If the
cold temperature becomes a problem at a desired ow rate,
an additional external vaporizer can be added. Attach this
vaporizer directly in series with the gas use connection and
place the line regulator at the exit of the vaporizer.
Safety Circuit
The Perma-Cyl tanks with FlexFill are equipped with dual
spring operated relief valves (RV-1) and dual burst discs
(BD-1). The dual safety manifold with diverter valve (V-12)
is standard on these vessels. This allows for change out of
safety relief devices without the need to empty the tank.
These devices are used to automatically relieve excess
pressure in the vessel and cannot be isolated by use of a
valve. Replacement of these relief devices should only be on
a "like for like" basis. Substitutes should be avoided unless
approved by the manufacturer. Purge valves (V-13) can be
used to relieve pressure before repairing safety valves.
Photo 2
Four-Way Valve
The four-way valve (V-6) is used as the primary isolation
valve between the DP gauge and the phase lines from the
tank. This four-way valve also provides an easy method to
check the zero on the DP gauge. By turning the valve into
the equalization position, the DP gauge can be zeroed and
isolated from the tank pressure for removal or replacement
(see photos 1 & 2).
Pressure Gauge
A single pressure gauge (Pl-1)on the Perma-Cyl tank is also
tied into the low phase line and gives the operator a pressure
reading in the gas phase of the vessel. This pressure gauge
can also be isolated with the four-way valve (see photos 1 &
2).
Vent/Full Trycock
The vent valve is used to relieve excess pressure in the
cylinder. On Perma-Cyl systems the vent valve is a gray
handled globe valve (V-14). When installed indoors, the vent
line should be piped outdoors using 1/2" nominal copper or
the equivalent stainless steel hose. The vent valve also serves
as the full trycock during lling operations. When the Perma-
Cyl tank is lled by trucks other than Orca™MicroBulk
Delivery System trucks, the full trycock must be used to ll
the vessel. When liquid starts to spit out of this valve while
being lled, the lling process should be terminated.
Other Piping Circuits and
Components
Phase Lines and Liquid Level Gauges
The Perma-Cyl tank is equipped with both a low pressure
phase line located on the top of the vessel (G) and a high
pressure liquid phase line located on the bottom of the vessel
(E). These lines are connected to a dierential pressure
gauge (Ll-1) which is used to indicate the amount of product
in the vessel. The standard DP gauge used by Chart is the
Cyl-Tel® Liquid Level Gauge. Customers can specify other
models as options such as the WIKA Analog DP Gauge (see
photos 1 & 2 below).
Photo 1
Four-Way
Valve
Pressure
Gauge
Cyl-Tel®
Liquid Level
Gauge
Four-Way
Valve
Pressure
Gauge
WIKA
Analog DP
Gauge
Vacuum Evacuation Port
Unlike bulk tanks, Perma Cyl storage vessels are normally
not provided with an on-board method of taking a vacuum
reading. The vacuum evacuation port is sealed using a
stainless steel disk with O-rings and a protective cover is
placed over it (see Photo 3). Due to the relatively small
volume of the annular vacuum space, taking vacuum
readings is normally not recommended since the vacuum
level is slightly reduced when taking this reading. The
troubleshooting portion of this manual gives steps on how
to determine if the vacuum might be weak. In the event
that the vacuum does need to be checked, a trained vacuum
technician would have to bring the appropriate equipment
to get this done. In most cases where a vacuum has been
compromised, it is often more economical to swap out the
tank.
Photo 3 - Vacuum Evacuation Port with Cover
Evacuation
Port
14
Operation Product Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System
Calibration Chart
Metric Calibration Chart (for 120 psi saturation pressure)
Perma-Cyl 1500 ZX VHP Cylinder
H2O Oxygen Nitrogen Argon
In Liters Kg Cu Ft Liters Kg Cu Ft Liters Kg Cu Ft
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
2.0 8.28 8 223 16.87 12 359 5.73 7 150
4.0 31.02 31 836 61.06 43 1299 21.71 27 567
6.0 65.03 66 1,753 122.94 86 2615 46.15 56 1,205
8.0 107.15 108 2,888 192.88 135 4,103 77.26 95 2,018
10.0 154.20 156 4,156 263.75 184 5,610 113.25 139 2,957
12.0 203.05 206 5,473 334.62 234 7,118 152.31 186 3,977
14.0 252.00 255 6,793 405.49 283 8,625 192.67 236 5,031
16.0 300.94 305 8,112 476.37 333 10,133 233.14 285 6,088
18.0 349.89 354 9,431 547.24 383 11,640 273.61 335 7,145
20.0 398.83 404 10,751 618.11 432 13,148 314.08 385 8,202
22.0 447.78 453 12,070 688.98 482 14,655 354.55 434 9,259
24.0 496.72 503 13.389 759.86 531 16,163 395.02 484 10,315
26.0 545.67 552 14,708 830.73 581 17,670 435.49 533 11,372
28.0 594.61 602 16,028 901.60 630 19,178 475.95 583 12,429
30.0 643.56 651 17,347 972.47 680 20,685 516.42 632 13,486
32.0 692.50 701 18,666 1,043.35 729 22,193 556.89 682 14,543
34.0 741.45 751 19,986 1,114.22 779 23,700 597.36 731 15,599
36.0 790.39 800 21,305 1,185.09 828 25,208 637.83 781 16,656
38.0 839.34 850 22,624 1,255.97 878 26,715 678.30 830 17,713
40.0 888.28 899 23,944 1,326.84 928 28,223 718.77 880 18,770
42.0 937.22 949 25,263 759.24 929 19,827
43.6 1,443.71 1,009 30,709
44.0 986.17 998 26,582 799.71 979 20,883
46.0 1,035.11 1,048 27,902 840.18 1,029 21,940
48.0 1,084.06 1,097 29,221 880.65 1,078 22,997
50.0 1,133.00 1,147 30,540 921.12 1,128 24,054
52.0 1,181.95 1,196 31,859 961.58 1,177 25,111
54.0 1,230.89 1,246 33,179 1,002.05 1,227 26,168
56.0 1,279.84 1,296 34,498 1,042.52 1,276 27,224
58.0 1,328.78 1,345 35,817 1,082.99 1,326 28,281
60.0 1,376.95 1,394 37,116 1,123.46 1,375 29,338
62.0 1,163.93 1,425 30,395
63.1 1,443.71 1,461 38,915
64.0 1,204.40 1,474 31,452
66.0 1,244.87 1,524 32,508
68.0 1,285.34 1,574 33,565
70.0 1,325.81 1,623 34,622
72.0 1,365.89 1,672 35,669
74.0 1,404.01 1,719 36,664
76.3 1,443.71 1,767 37,701
Note: Volumes of LN2/LAR/LOX change as the saturation pressure of the liquid in the container changes. For the
most accurate contents reading, insure that the table above is converted to the correct saturation pressure.
15
Product Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System
Trouble Probable Cause Remedy
No gas to gas-use
equipment.
OR
Insucient pressure
to gas-use equipment
Perma-Cyl tank empty. 1. Switch to emergency gas supply.
2. Call gas supplier for delivery.
Gas-use valve to nal line regulator is
closed or other valves downstream are
closed.
1. Open valve or valves, as needed.
2. Insure there is no obstruction in the line or valve.
Pressure builder is not building sucient
pressure.
1. Open pressure building regulator control valve and
allow pressure to build.
2. Adjust setting on regulator to a higher pressure.
3. If tank pressure fails to rise, see section on low
tank pressure.
Final line pressure regulator set too low
or malfunctioning.
1. Insure gas use valve is open and tank pressure
is at least 25 psi higher than desired working
pressure of nal regulator.
2. Call service technician.
Inappropriate type of regulator (high-
pressure or 2-stage or too small) installed
as nal line regulator and is not able to
supply sucient gas ow.
1. Insure gas use valve is open and tank pressure
is at least 25 psi higher than desired working
pressure of nal regulator.
2. Inspect nal line regulator or its specications to
determine if it has a suitable ow capacity for the
required inlet and outlet pressures.
3. Call appropriate equipment supplier or service
technician.
Gas supply line, hose, or network
contains excessive pressure drop.
1. Check line for sucient diameter.
2. Remove all unnecessary bends, elbows, reducers,
and small diameter valves.
3. Check for leaks in the gas supply line.
Unknown 1. Call service technician
Frost or ice on sides,
bottom, top-center
and / or plumbing of
tank.
Normal condition during and following
gas use, liquid use or lling.
1. None
2. User to check tank for frost / leaks before use.
Tank is being used for continuous ow
application and is not receiving sucient
ambient heat to melt the frost or ice.
(Tank may have heavy ice build-up
continuous ice or frost.)
1. Move tank to a warmer location.
2. Add additional environmental heat and / or warm
airow to warm outer piping, components and
sides of the tank.
3. Add switchover system to allow tank to rest and
warm up when not in use.
Leak in gas supply lines, gas-use
equipment, or tank plumbing. (Frost is
present on tank even after an extended
period with no gas or liquid use.)
1. Evacuate and ventilate room.
2. If possible, locate and correct leak,
3. User to check tank for frost / leaks each morning
before starting gas use.
4. Call appropriate equipment service technician.
Troubleshooting
The following table is arranged in a Trouble/Probable Cause/Remedy format. The probable causes for specic problems are
listed in descending order of signicance. That is, check out the rst cause listed before proceeding to the next.
16
17
Troubleshooting TroubleshootingProduct Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System Product Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System
Trouble Probable Cause Remedy
Frost or ice on sides,
bottom, top-center
and / or plumbing of
tank.
(continued)
Weak vacuum or failed vacuum. 1. Check if tank pressure is routinely high even
during gas use and / or if tank has cold or ice spots
even when not in operation as sign of vacuum
problem.
2. Condensation or sweating is seen over the entire
outer shell as a sign of vacuum problem.
3. Call gas service agent.
Unknown. 1. Call gas service agent.
Routinely low
pressure in tank.
PB shut-o valve is closed.
(If PB is not operating, no frost ring will
appear at the bottom of the tank or an
external PB vaporizer during gas use.)
1. Open pressure building regulator control valve and
allow pressure to build.
2. Call service agent to repair, replace or adjust
regulator.
Pressure builder setting is too low.
(If PB is not operating, no frost ring will
appear at the bottom of the tank or an
external PB vaporizer during gas use.)
1. Adjust regulator to higher pressure and allow
pressure to build.
2. Call service agent to repair, replace or adjust
regulator.
Economizer regulator setting is too low or
economizer regulator is stuck open.
1. Adjust regulator to higher pressure (should be
at least 15 psig above pressure build regulator
setting).
2. Check to ensure regulator is not stuck open.
Relief valve(s) stuck open. 1. Evacuate and ventilate the room.
2. Check exhaust of relief valve to see if gas is
owing at a pressure below the pressure stamped
on the valve.
3. Tap lightly on the side of the relief valve to attempt
to dislodge any obstruction holding valve open.
Repeat several times, if needed.
4. Call gas service technician to replace relief valve,
if necessary.
Large gas leak from tank plumbing or
from gas use system.
1. Evacuate and ventilate the room.
2. If possible, locate and repair leak or call gas
equipment service technician.
Gas or liquid withdrawal rate exceeds the
tank specications.
1. Excess usage will cause tank pressure to
decrease as PB is unable to maintain pressure.
Decrease withdrawal rate to within design
specications.
2. Increase pressure setting on PB regulator.
3. If withdrawing gas, consider: (a) withdrawing liquid
and using external vaporizer, (b) installing larger
tank, (c) installing additional tank(s), or (d) splitting
application.
4. If withdrawing liquid, consider: (a) installing larger
tank, (b) splitting application or (c) installing
additional tank(s).
5. Call gas service agent.
Unknown 1. Switch to emergency gas cylinder.
2. Call gas service technician.
Gas supply to gas-
use equipment is too
cold.
Ambient temperature surrounding the
Perma-Cyl tank is too cold.
1. Move tank to warmer location.
2. Install freestanding ambient vaporizer on gas
supply line in warmer location or install in-line gas
heater.
Trouble Probable Cause Remedy
Gas supply to gas-
use equipment is too
cold. (continued)
Gas withdrawal rate from Perma-Cyl tank
exceeds the capacity of tank’s ambient
vaporizer.
1. Reduce gas withdrawal rate to within specied
parameters.
2. Install freestanding ambient vaporizer on gas
supply line in warm location or install in-line heated
vaporizer on gas supply circuit.
3. Install larger tank with greater withdrawal rate
capacity.
Routinely high tank
pressure.
Normal when little or no gas has been
used for several days.
1. None - Routine use of gas will automatically
reduce the tank pressure.
2. Gas usage must exceed NER of tank, if not,
contact gas supplier for dierent tank model.
Economizer function on regulator is
malfunctioning.
1. If tank is in a mixer application and the usage is
low, consider drawing gas o the vent line, as
the economizer will not work completely in non-
consistent draws.
2. Call gas service technician to clean, repair, or
replace regulator.
Tank is over-lled 1. If tank is lled to or beyond proper ll level,
pressure builds very rapidly and relief valve may
open.
2. Use gas or liquid as soon as possible to reduce
tank contents.
3. Vent tank until no liquid is coming out the vent
valve.
Pressure building function on
regulator is set too high or regulator is
malfunctioning.
1. Reduce pressure setting by turning adjustment
knob counter-clockwise to the desired pressure
setting and continuing normal gas use until
pressure drops.
2. Close PB isolation valve and carefully observe
pressure to ensure tank pressure does not drop
too low during use.
3. Call gas service technician to adjust PB regulator.
Weak or failed vacuum. 1. Observe if condensation and / or frost are present
even during periods of non-use as possible sign of
vacuum problem.
2. Call gas service technician.
Unknown. 1. Call gas service technician.
Hissing sounds or
evidence of gas
leaking near tank,
gas lines, or gas-use
equipment.
Normal for short periods of time from
some regulators and relief valves.
1. Evacuate and ventilate room or area, if necessary.
2. If possible, observe leak. If leak is not large, does
not last long, does not occur frequently and is in
well-ventilated area, no action may be needed.
If in doubt, call appropriate equipment service
technician.
3. If above combined conditions do not exist, call
equipment service technician and observe “Safety”
precautions.
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Troubleshooting TroubleshootingProduct Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System Product Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System
Trouble Probable Cause Remedy
Hissing sounds or
evidence of gas
leaking near tank,
gas lines, or gas-
use equipment.
(continued)
Large leaks, leaks from elsewhere in
the system, sustained leaks, or frequent
leaks (not normal).
1. Evacuate all personnel from aected areas.
Ventilate room / area.
2. If possible, locate the leak and repair it or call gas
service or gas-use equipment service technician.
High gas usage. Unrecognized increase in actual gas use. 1. None for Perma-Cyl tank or gas supplier
2. Gas user to determine reason for increase in gas
use.
Leak in gas supply line or network or in
gas-use equipment or tank plumbing, e.g.
relief valve.
1. Evacuate and ventilate room, if necessary.
2. If possible, locate and repair leak or call gas-use
equipment service agent.
3. User to check tank for frost / leaks before
operations.
Tank pressure routinely too high and
venting.
1. See troubleshooting section on routinely high tank
pressure.
High ash or vaporization losses in liquid
use application due to high pressure /
temperature liquid in tank.
1. Vent tank to approximately 25 psi. Follow safety
procedures.
2. In future only rell the Perma-Cyl tank with low-
pressure cryogenic product.
Error in gas delivery or supplier invoice. 1. Check gas usage history / pattern against supplier
invoices.
2. Call gas supplier, if necessary.
Perma-Cyl tank
cannot be lled.
Perma-Cyl tank is full. 1. None
Fill line is blocked or inoperative. 1. Check for obstructions in the ll line. Clear if
necessary.
2. Gently tap on check valve to assure proper
operation.
3. Ensure top & bottom ll valves are open.
4. Call gas service technician.
Orca™ MicroBulk Delivery System is not
functioning properly.
1. Refer to Orca system Troubleshooting.
Transfer hose is obstructed, e.g. hose is
bent excessively, crimped or plugged.
1. Clean obstruction, inspect hose for damage, and, if
everything is satisfactory, continue the lling.
Perma-Cyl tank does
not initiate automatic
ll shut o properly.
Fill line piping created too much pressure
drop.
1. Ensure ll line is piped with 3/4” nominal copper (or
equivalent) with minimal 90° bends.
2. Re-route ll piping.
Improper ll procedure. 1. Review Orca system/Perma-Cyl tank lling
procedure.
2. Ensure that all vent and use valves of the tank are
closed.
Only works with Chart Orca MicroBulk
delivery vehicle. For other type trucks use
full trycock.
N/A
Liquid withdrawal
contains high level
of gas.
Saturated liquid pressure in Perma-Cyl
tank is too high. (Temperature or energy
level of contents is too high due to
excess pressure.)
1. Ensure PB shut-o valve is closed.
2. Open vent valve to allow excess pressure to vent
until desired pressure is obtained. Follow “Safety”
guidelines and procedures for venting.
3. Install secondary lower pressure relief valve to
reduce saturated pressure of liquid in the future.
4. In future only rell the Perma-Cyl tank with low-
pressure cryogenic product.
Trouble Probable Cause Remedy
Vacuum pump-out
port and / or vacuum
plug are open or
damaged.
Pump-out plug or port have been
damaged or tampered with.
1. If possible, transfer any remaining contents to
another tank.
2. Call gas service technician to replace and repair
tank.
Inner vacuum space leak has dislodged
safety pump-out plug.
1. If possible, transfer any remaining contents to
another tank.
2. Cover pumpout port to keep moisture from getting
into the annular space.
3. Call gas service technician to replace and repair
tank.
Warning! Use only parts which are
cleaned and approved
for oxygen service. Chart
recommends the use of only
Chart approved parts.
21
Product Manual - Perma-Cyl®1500 ZX VHP MicroBulk Storage System
Bench Setting a Pressure Building
Regulator
1. Connect the pressure building regulator to a nitrogen
pressure source as shown in the Figure 2 below.
2. Close Valve B.
3. Open pressure source valve (follow appropriate safety
rules).
4. Open Valve C slowly.
5. Pressure Gauge A will indicate the pressure to which the
regulator has been set. The pressure can be increased by
turning the adjusting screw in or decreased by turning
the screw out; however, after each adjustment outward
it will be necessary to open and then close Valve B to
relieve excess pressure.
6. This procedure may be repeated as many times as
necessary to obtain the proper setting.
7. After the proper setting is obtained, secure the lock nut
on the adjusting screw.
Note: Factory setting is 450 psig.
Figure 2 - Pressure Building Regulator
Bench Setting an Economizer
Regulator
1. Connect the inlet of the economizer regulator to a
pressure source as shown in the Figure 2.
2. Open the valve at the pressure source (follow
appropriate safety rules).
3. Slowly open Valve B just enough to allow some gas to
escape.
4. Pressure Gauge A will indicate the setting to which
the economizer regulator is set. This setting may be
increased by turning the adjusting screw in, or lowered
by turning the adjusting screw out.
5. Gas will ow through the economizer regulator when
the pressure of the gas reaches the pre-set setting.
Note: Factory setting is 475 psig.
Rebuilding the Rego Operational
Valves
When a defective valve is suspected, follow this procedure to
repair it. Refer to Figure 3 on the next page for identication
of parts.
1. Open the valve and release any pressure that is in the
container.
2. If the valve to be repaired is the vent valve, allow it to
warm up before it is disassembled.
3. If the valve to be repaired is the pressure building
valve, the container should be emptied of product and
pressure.
4. Remove the valve handle screw (item 3), washer (item
14), retainer cap and spring assembly (items 2, 4, 8, 10
and 13).
5. Remove the valve handle (item 1) and Teon thrust
washer (item 7).
6. Unscrew bonnet (item 5) to remove stem (item 6) and
stem seal.
7. Pick out body insert (item 12) and plug assembly (item
9).
8. Clean seat.
Maintenance
Table of contents
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