881 HERSEY STREET ST. PAUL , MN 55 114 PHONE (651) 646-1 646-1177 177 FAX (651) 646-1676
Installation Example
Vaporizer Installation Best Practices The following sketch depicts a typical vaporizer installation. The vaporizer system, when piped as shown, will provide long trouble free vapor service. The vaporizer can be isolated for maintenence or repair without interrupting the load. Although some of the components such as the vapor bypass regulator, the burner supply line and the oil separator are optional, they are all highly recommended as "Best Practice Piping" for direct fired vaporizers. Vapor Bypass Regulator
Supplemental Relief Valve
Storage Tank
G O W 0 0 6
Burner Supply Line
600WOG
600WOG
Liquid
Notes All piping must follow the guidelines of NFPA 58. The liquid tank opening shows an internal valve allowing two-way liquid flow. The boiling liquid and expanding vapor in the vaporizer chamber requires this two-way flow capability. The system has a first stage regulator on the discharge of the vaporizer and a vapor bypass regulator on the tank vapor outlet valve. The bypass regulator is normally set slightly lower and only delivers vapor to the system if the vaporizer quits functioning. The vaporizer burner supply line is optional but highly recommended. Pulling cold vapor directly from the storage tank greatly alleviates clogged controls, pilots etc. in the vaporizer from oily heavy ends.
Vaporizer Repair and Maintenance Guide
Oil Separator
Vapor To Load
First Stage Regulator
The oil separator shown piped in after the first stage regulator removes the oily mist from the vapor stream before it can enter the load piping. To avoid recondensation of the propane vapor, the separator must be piped after the first stage regulator. The supplemental relief valve shown is required to protect the downstream system from overpressure conditions and liquid formation in the first stage piping. Because most industrial first stage regulators do not provide adequate relief protection, this relief is nearly always mandatory. Distances from vaporizer Storage tank 10 feet Storage shutoffs 15 feet Point of transfer 15 feet Buildings 25 feet
Maintenance Schedule
FLAMMABLE GAS
Vaporizers and ancillary equipment should be serviced ONLY by trained and fully qualified personnel. This equipment operates with LP gas which is flammable and under pressure. Inherent hazards exist and a thorough understanding of the equipment is required for safe maintenance.
Monthly Check List Items to Service Monthly Strainer
Service to Perform Remove screen and clean.
Pilot Burner Assembly
Inspect pilot for proper flame.
Main Burner Assembly
Inspect for proper flame.
Relief Valves
Enclosure
Check for signs of corrosion and replace any missing caps. Check entire enclosure, louvers and vent cap for debris.
Annual Check List Items to Service Annually Thermostat
Thermocouple
Liquid Inlet Valve
Capacity Control Valve
Heat Exchanger
Main Burner
Service to Perform Check thermostat for proper operation. Replace if needed. Check thermocouple position in pilot and verify proper millivolt output. Replace valve seat, spring and O-ring using Kit # 3-0016. Clean piston and replace the spring and O-ring using Kit # 3-0017. Check flues for holes or excessive scale. Remove debris. Check bottom of the heat exchanger for pitting. Replace if the pitting is in excess of 0.125". Check for proper flame. Clean debris and check air supply. Clean orifices as needed.
Regular scheduled maintenance on vaporizers is a must for trouble free operation. The suggested schedules listed above should be used as a guide. Certain installations and situations will require more stringent inspection and repair.
Vaporizer Repair and Maintenance Guide
40/40 Parts
Repair Parts for Algas 40/40 Vaporizer The Algas 40/40 vaporizer has undergone major improvements and revisions since 2002. The burner assembly, burner regulator and associated supply lines as well as the thermostat control have been updated for more reliable and better performance. Most of these improvements can readily be incorporated to existing models in the field during maintenence and repair servicing. The following parts breakdown lists the Pre 2002 and Post 2002 parts with graphics to depict the differences.
Description Capacity Control Valve Capacity Control Piston Capacity Control Kit
Vaporizers Built To Oct 2002 40C68 40C66 3-0017
Vaporizers Built Post Oct 2002 40C68 40C66 3-0017
2 2
Relief Valve Relief Valve Cap
3129G 3129-40P
T3131G 3131-54
3
Regulator Supply Tube
3-0776
3-0776
4 4
Burner Regulator Kit Regulator Only
41045 920V
41045 920V
5 5
Thermostat Thermostat Cover
3-3540 1501-5015-02
3-3540 1501-5015-02
6
Thermostat Supply Tube
3-0787
3-0787
7
Burner Supply Tube
3-0782
41022
8
Pilot Tube
3-0777
41024
9
Thermocouple
1980-36
1980-36
10 10
Pilot Assembly Pilot Orifice
3-0631 BA-718 .018
3-0631 BA-718 .018
11
Burner Manifold
40C39A
1502-4006
12
Burner Jet
40C14
33581
13
Flue
3-0529
451-506-01
14
Inlet Valve Gasket
40C37
40C37
15 15
Liquid Inlet Valve Inlet Valve Kit
3-4150 3-0016
3-4150 3-0016
16
Loading Tube
3-0778
3-0778
17
Vapor Out Nipple
3-0549
3-0549
1
16
17
Key 1 1 1
2 3
15 4
5 14 6
13
7 8
12 11
10
9
New Burner Regulator Assy 41045 Kit - Upgrades to 920V regulator with shutoffs, tubing assemblies and drip leg. 920V - Regulator only.
WARNING
READALLINSTRUC TIONS BEF ORE L I GH TI NG
H
I G
H
W O L B E RTSHAW
R O
New Burner Arrangement Post October 2002
Vaporizer Repair and Maintenance Guide
Old Burner Arrangement Pre October 2002
80/40 Parts
Repair Parts for Algas 80/40 Vaporizer The Algas 80/40 vaporizer has undergone major improvements and revisions since 2002. The burner assembly, burner regulator and associated supply lines as well as the thermostat control have been updated for more reliable and better performance. Most of these improvements can readily be incorporated to existing models in the field during maintenance and repair servicing. The following parts breakdown lists the Pre 2002 and Post 2002 parts with graphics to depict the differences. New Burner Arrangement Post October 2002 19
2
1
20
3
18 4
21
Old Burner Arrangement Pre October 2002
5 6
17 WARNING READALLINSTRUCTIONS BEF ORE LIG H TNI G
H
H
G I
W O L R O B E RTSHAW
New Burner Regulator Assy 41045 Kit - Upgrades to 920V regulator with shutoffs, tubing assemblies and drip leg.
7
16 8
15 14
13
12
9 11
920V - Regulator only.
10
Description Vapor Out Nipple
Vaporizers Built To Oct 2002 3-0549
Vaporizers Built Post Oct 2002 3-0549
Description Pilot Assembly Pilot Orifice
Vaporizers Built To Oct 2002 3-0644 BA-718 .023
Vaporizers Built Post Oct 2002 41021 BA-718 .023
2 2 2
Capacity Control Valve Capacity Control Piston Capacity Control Kit
40C68 40C66 3-0017
40C68 40C66 3-0017
13
Burner Manifold Tube
3-0783
3-0783
3
Regulator Supply Tube
3-0779
3-0779
14
Left Burner Manifold
40C39
1504-4004
4 4
Burner Regulator Kit Regulator Only
41045 920V
41045 920V
15
Burner Jet
40C14
33581
16
Left Flue
452-505-01
452-505-01
5 5
Thermostat Thermostat Cover
3-3540 1501-5015-02
3-3540 1501-5015-02
17
Inlet Valve Gasket
40C37
40C37
6
Thermostat Supply Tube
3-0788
1504-5005
18 18
Liquid Inlet Valve Inlet Valve Kit
3-4150 3-0016
3-4150 3-0016
7
Burner Supply Tube
3-0782
41019
19
Loading Tube
3-0786
3-0786
8
Pilot Tube
3-0781
40404
Relief Valve Relief Valve Cap
T3131G 3131-54
T3131G 3131-54
9
Right Flue
1504-5009
1504-5009
20 20
3-0792
3-0792
1980-36
Connector Tube
Thermocouple
1980-36
21
10 11
Right Burner Manifold
80C99
1504-4005
Key 1
Vaporizer Repair and Maintenance Guide
Key 12 12
Kits and Service
FLAMMABLE GAS
CAUTION The vaporizer must be completely blown down before performing service. Be sure all sources of ignition are extinguished within 25 feet of the work area.
Liquid Inlet Valve Remove the plug from the inlet valve and wipe away debris. Use kit # 3-0016 to replace the valve seat, spring and O-ring on the plug.
Capacity Control Kit Disassemble and clean the valve assembly inside the body. Use kit # 3-0017 to replace the spring and O-rings on the piston and plug. Use powdered graphite as a lubricant on the piston and use grease on the plug O-ring.
Main Burner The burner flame should be a non blowing blue flame and evenly distributed over the burner ring. If uneven, clean individual burner jets (#66 drill for new style jet. # 64 drill for old style jet).
Pilot Flame The pilot flame should envelope 3/8" to 1/2" of the thermocouple tip. Clean or replace the pilot if it is too small.
66
Old Style Jet
New Style Jet
40/40 Pilot
80/40 Pilot
Pressure Adjustment Below Thermostat Check At ambient temperatures, rotating the temperature control knob from LOW through HIGH will energize the main seat of the control producing a loud audible click.
ON
PILOT
4
2
READ ALLINSTRUCTIONS BEFORE LIGHTING
The burner gas pressure must be at least 9" W.C. when checked at the pressure tap with the main burner operating. Set the pressure with the adjusting screw located beneath the cap on the Pilot-On-Off knob.
HIGH W O L
ALGAS - SDI
Using a suitable junction block tester, check the thermocouple millivolt output. A reading of 13 to 30 millivolts is acceptable. Turn the gas valve off and observe the millivolt reading at the point when the internal safety magnet drops out with a click. The millivolt drop out should be appreciably lower (at least 5 Mv) than the running millivolt reading.
