Installation, Operation and

Safety Manual

Models VWP – 145 & VWP - 180

 TABLE OF CONTENTS
Lifting and Moving…………………………………………………………………………..…………………
3

Installation…………………………………………………………………………………..……………………
4

Connections………………………………………………………………………………….…………………… 4
Water/Glycol Mixture Inlet………………………………………………………………… 4
Water/Glycol Mixture Return…………………………………………………………………… 6
Liquid Nitrogen Inlet and Gaseous Nitrogen Discharge………………………… 6
Leak Check…………………………………………………………………….. 6

Operation………………………………………………………………………………………………………. 6
Initial Start-Up………………………………………………………………… 6
Operating Proceedures……………………………………………………………………
6
Maintenance…………………………….…………………………………………………. 6

Important Safety Precautions………………………………………………………………..…………………7

Hot/Cold Surfaces Warning………………………………………………………………………
7
High Pressure Precautions…………………………………………………………7

Cryogenic Safety Instructions……………………………………………………………..…………………… 7

Introduction…………………………………………………………………………. 7
General Safety Precautions…………………………………………………………. 8
Handling…………………………………………………………………………….. 8
Protective Clothing…………………………………………………………………. 8
Ventilation…………………………………………………………………………... 9
Correct Equipment………………………………………………………………….. 9
Correct Identification……………………………………………………………….. 10
Correct Transfer Equipment………………………………………………………... 10
Installation and Maintenance of Equipment………………………………………... 10
Liquid Oxygen…………………………………………………………………….... 11
Use of Liquid Oxygen Equipment………………………………………….. 12
Fighting Fires Involving Liquid Oxygen…………………………………....
12
Liquid Nitrogen……………………………………………………………………... 12
Good Ventilation……………………………………………………………. 12
Entering Large Liquid Nitrogen Storage Tanks……………………………..
13
First Aid Notice……………………………………………………………... 13
Exposure to the Atmosphere………………………………………………... 13
Medical Treatment of Cryogenic Burns……………………………………………. 13

Cryogenic Industries Service Centers……………………………………………………………..……………

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 LIFTING AND MOVING

Place skid with the vaporizer in a position where a crane or fork lift has easy access to the unit.
Unbolt the unit from the shipping pallet and/or remove any shipping straps. After the VWP is
unbolted from the pallet do not attempt to lift the unit by fork lifting the pallet, as the unit can tip.
When lifting the vaporizer, use one strap securely fastened to the shell of the unit, as shown in
Figure 1. A threaded cap with an eye bolt through it is recommended as a secure lifting point.
When using an eye bolt and cap, only lift from the water/glycol connection on the shell of the
vaporizer.

Figure 1: Lifting Diagram

The VWP weighs approximately 400 lbs, so be certain to use a fork lift with sufficient lift
capacity and qualified personnel for the job. The head of the vaporizer is the heaviest portion of
the unit, so be certain to take this into consideration when lifting.

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INSTALLATION

The VWP vaporizer can be mounted either vertically or horizontally. When mounting the
vaporizer horizontally, a cradle should be used and the VWP should be strapped securely to it.
When mounting vertically, use of a vertically mounted cradle is also recommended, but can be
installed using legs depending on your requirements. Consult the factory if you have special
installation requirements. If any vibration is expected, the VWP vaporizer should be shock
mounted using appropriate shock absorbing mounts. Be certain to use lock washers and thread
seizing compound to prevent loosening under vibration, especially if the unit is to be used in a
mobile application. The VWP vaporizer is not intended to support external piping loads.

CONNECTIONS

After securing the VWP there are several connections which must be completed in order to
prepare the VWP for operation. Figure 2 illustrates the general location of each of the
connections. Refer to Table 1 for the standard connection schedule for the VWP vaporizer.
Your connections types and sizes may vary depending on options ordered. Refer to the outline
drawing for specific size and type of connections.

Figure 2: Connection Diagram, VWP 145

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 Table 1: Connection Schedule

Standard Connection Schedule

Nozzle Service Size Type
N1 LN2 Inlet 1" 1GR5
N2 GN2 Outlet 1" 1GR5
N3 Water/Glycol Mixture Inlet 2 1/2" M.P.T.
N4 Water/Glycol Mixture Return 2 1/2" M.P.T.
N5 Drain with Plug 1/2" F.P.T.

WATER/GLYCOL MIXTURE INLET

The water/glycol mixture inlet connection should be made using 2 1/2” piping and fittings rated
to a minimum of 200 psig. Supply a 180 to 190 °F 50/50 mixture of ethylene glycol and water
(engine jacket coolant) at 150 psig and 200 gallons per minute to this connection. A boost pump
(not supplied) is typically required. It is the responsibility of the Purchaser to provide pressure
relief devices to ensure that shell does not exceed its maximum allowable working pressure of
200 psig.

The high flow rate of coolant through the shell ensures high fluid velocity across the heat transfer
coil, resulting in ice-free operation. Never supply cryogenic fluid to the vaporizer without
sufficient flow of engine coolant as ice formation on the tube bundle may severely damage the
unit.

WATER/GLYCOL MIXTURE RETURN

This should be the same rating as the water/glycol mixture inlet connection. This nozzle returns
the coolant to the engine.

LIQUID NITROGEN INLET AND GAS DISCHARGE

The LN2 inlet and GN2 outlet connections are “as ordered” by the purchaser. Refer to the outline
drawing for specific size and type of connections. The delivery line should be rated for
cryogenic temperature at 10,000 psig continuous service.

ATTENTION

It is important that all connections to the VWP be of sufficient size and capacity for the service,
whether for engine coolant, or nitrogen. An insufficient size in either of these may significantly
reduce the capacity of the vaporizer and can possibly cause it to be unsafe to operate. Refer to
the outline and this manual for more specific details of sizes and types of connections required.

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LEAK CHECK

After making the required connections, inspect all fittings for leaks.

OPERATION

This equipment must not be operated under conditions that exceed those specified on the name
plate.

INITIAL START-UP

Before the initial start-up of the vaporizer, be sure that all components of the system are clean
and free of dirt and debris. Under some conditions, the use of strainers in the piping to the unit
may be required. Place the unit in service by first filling the shell and associated piping with a
50% water, 50% ethylene glycol mixture from the heat source, typically a diesel engine.
Open all vents on the engine jacket and surge tank to purge air from all passages of the system.
Be sure to add coolant mixture to the surge tank as the air is displaced rom the system.
Once the system is purged, close the engine coolant system vents. Inspect the system for leaks.

OPERATING PROCEDURES

Start the flow of engine coolant to the VWP vaporizer shell before allowing cryogen flow to the
tube bundle as ice may form resulting in severe damage the vaporizer. Ensure that there is
sufficient engine coolant flow and that the engine coolant temperature is at an acceptable level.
Begin to flow cryogen to the tube bundle slowly to prevent excessive thermal shocks to the unit.

To shut down the unit, stop flow of the cryogen to the tube bundle first. Allow the engine
coolant to continue to circulate for several minutes after stopping flow of the cryogen. This will
ensure that the engine coolant mixture does not freeze which may result in severe damage to the
unit and/or the engine.

MAINTENANCE

Although the VWP vaporizer has been designed to give many years of trouble free operation,
periodic preventative maintenance is required to maintain optimal heat transfer. At regular
intervals, or as frequently as experience indicates, an examination of the interior and exterior
condition of the unit should be made. When disassembling the unit, protect the gasket mating
surfaces from nicks and scratches. Never pry the two sealing surfaces apart as they may not seal
upon reassembly.

Before reassembly of the tube bundle to the shell, inspect the gasket mating surfaces for
scratches or nicks. Always use a new gasket when reassembling the bundle to the shell. Inspect
the new gasket for defects that could cause leaks upon reassembly.

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Inspect the exterior of the unit for damage such as cracks, leaks or signs of corrosion. Inspect the
interior for fouling of the heat transfer surfaces and for damage to the tube bundle components.
Reverse flushing of the shell side of the vaporizer will help remove deposits. Circulating hot
wash oil or light distillate through the shell side of the vaporizer at high velocity will effectively
remove sludge or similar soft deposits. Commercial cleaning products are available to remove
sludge or scale provided hot wash oil, light distillates, or water provides unsatisfactory results.
Major reconditioning should be performed at the factory, and the unit should be pressure tested
before being returned to service.

IMPORTANT SAFETY PRECAUTIONS, READ AND UNDERSTAND!

HOT/COLD SURFACES WARNING

All metal surfaces on the VWP should be considered potentially hot or extremely cold and direct
contact with these surfaces should be avoided. Keep all personnel clear of the vaporizer while in
operation and allow surfaces to return to ambient temperatures before performing maintenance.
Refer to the cryogenic safety instructions in this manual.

HIGH PRESSURE PRECAUTIONS

Consider the following:

Engine Jacket Coolant- 150 psi at 170 to 210 °F
Nitrogen coil- 8000 to 10,000 psi at -320 °F

These are very typical hose and piping pressures connected directly at the VWP. Be certain to
wear appropriate protective clothing at all times near this equipment. In addition to ear and eye
protection wear long sleeve work coveralls, gloves, safety shoes, and hard hat.

CRYOGENIC SAFETY INSTRUCTIONS

INTRODUCTION

Handling cryogenic liquids safely is largely a matter of knowing their properties and using
common sense procedures based on that knowledge.

There are a number of general precautions and safe practices, which must be observed because of
the extremely low temperatures and high rated of conversion into gas of all of the liquids
discussed here. There are also certain specific precautions, which must be followed where a
particular liquid may react with contaminants or may present a life hazard.

The user of any cryogenic liquid covered in this manual should be familiar with both the general
and specific precautions outlined in the following pages. He should also be thoroughly familiar
with the instructions provided with any equipment with the liquid.

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If you have any doubt about the safe way to handle one of these liquids in your particular
application, call on an experienced person for advice and assistance.

Note:
This manual does not cover the special precautions required to be taken
when working at deep low temperatures with liquefied helium, hydrogen or
neon.

GENERAL SAFETY PRECAUTIONS

The gases in the atmosphere become liquid under different conditions of pressure and
temperature. Each of these liquids has properties different from those of the others. However,
the potential hazards in handling all these liquefied gases stem mainly from two important
properties they have in common: (1) they are extremely cold, and (2) very small amounts of
liquid are converted into very large amounts of gas. The following general precautions have
been devised to avoid any potential injury or damage resulting from these two characteristics.

HANDLING

Always handle the liquid carefully. At there extremely low temperatures, they can produce an
effect on the skin similar to a burn. When spilled on a surface they tend to cover it completely
and, therefore, cool a large area. The gases issuing from these liquids are also extremely cold
and can produce burns. Delicate tissues, such as those of the eyes, can be damaged by an
exposure to these cold gases which is too brief to affect the skin of the face or hands. Stand clear
of boiling and splashing liquids and it's issuing cold gas. Boiling and splashing always occur
when charging a warm container or when inserting objects into the liquid. Always perform these
operations SLOWLY to minimize boiling and splashing.

Never allow any unprotected part of your body to touch un-insulated pipes or vessels containing
liquefied atmospheric gases: the extremely cold metal may stick fast and tear the flesh when you
attempt to withdraw from it. Use tongs to withdraw objects immersed in liquid, and handle the
tongs and the object carefully. In addition to the hazard of burns, or skin sticking to cold
materials, objects that are soft and pliable at room temperatures usually become very hard and
brittle at the temperatures of these liquids and are very easily broken and/or shattered.

PROTECTIVE CLOTHING

Protect your eyes with a face shield or safety goggles. Always wear dry leather gloves when
handling anything that is or may have recently been in contact with cryogenic fluids. The gloves
should be a loose fit so that they may be readily removed should any liquid spill or splash into
them. Remember that even in gloves one can hold cold equipment only for a short time. It is
also advisable to wear overalls, aprons or similar type clothing, without pockets or turnups so

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that liquid cannot be splashed into them. If possible, trousers should be worn outside boots or
shoes or, in particular, gumboots. Skilled personnel who are aware of the hazards surrounding
the handling of cryogenic liquids may under laboratory conditions exercise some discretion in
the interpretation of the recommendations. It must be remembered, however, that people tend to
learn by example, and what may be "safe" practice in the hands of the skilled may be a hazard to
the unskilled, particularly in the instance where the unsafe methods are the quickest and easiest.

VENTILATION

Always handle cryogenic liquid in well-ventilated areas to prevent excessive concentrations of

gas. Never dispose of liquids in confined areas or places where others may enter. Excessive
concentration of oxygen is a fire hazard. Excessive amounts of other atmospheric gases in the
air reduce the concentration of oxygen and can cause asphyxiation.

Note:
The cloudy vapor that appears when a cryogenic liquid is exposed to the air
is condensed moisture; not the gas itself. The issuing gas is invisible.

CORRECT EQUIPMENT

Use only containers specifically designed for holding cryogenic liquids. Such containers are
made from materials, which can withstand the rapid changes and extreme differences in
temperatures encountered in working with these liquids. However, even these special containers
should be filled as slowly as possible to minimize the thermal shocks which occur when any
material is cooled.

Containers designed for low temperature liquids are built to withstand normal operating
pressures. However, all containers should be open or protected by a vent or other safety device
which permits the escape of vapors. Where a special vented stopper or venting tube is used as on
some small portable containers, check the vent at regular intervals to be sure it is not plugged
with ice formed from water vapor condensed out of the air. Inadequate venting can result in
excessive gas pressure, which can damage or burst a container. Use only the stopper supplied
with the container. Never plug small containers of liquid; cover them (if a cover has been
provided with the container) when not in use to prevent and accumulation of moisture and
plugging of the container outlet with ice. Large storage containers not open to the atmosphere
must be provided with pressure-relieving devices.

Small containers should not generally be stored in the open where they may come in contact with
rain or moisture, unless suitable protection from the weather is provided. Even then, excessive
moisture on moving parts such as valves, relief devices and couplings might cause malfunction
due to external ice formation.

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CORRECT IDENTIFICATION

Containers should be clearly identified so that the correct contents may be filled or withdrawn.
Introducing an inert liquid will result in a contaminated product. Mixing liquid oxygen with
another liquefied atmospheric gas may be hazardous; in certain instances the oxygen
concentration may increase as time progresses due to the evaporation of lower boiling point
liquids (i.e. nitrogen, argon, etc.).

Unknown concentrations of oxygen always represent a hazardous condition

If liquid oxygen is introduced into a liquid nitrogen refrigerator, the oxygen may cause and
organic material in the refrigerator to burst into flames.

CORRECT TRANSFER EQUIPMENT

Use a filling funnel whenever you pour liquid into a Dewar flask or other small container. The
top of the funnel should be partly covered to reduce splashing. When it is not safe or convenient
to tilt the container, use a discharge tube to remove liquid.

Insert the discharge tube through the neck of the container and well down into the liquid until the
packing materials or stopper on the discharge tube forms a seal in the neck tube of the container.
Normal evaporation usually produces adequate pressure for withdrawal.

If sustained withdrawal is desired, the container may be pressurized with the gas corresponding
to the liquid product or with an oil-free inert gas. Use no more than just enough pressure to force
the liquid out. Always use a discharge tube to remove liquid from large 50 to 100 liter
containers.

Alternately, liquid nitrogen may be transferred by use of a small submersible pump, which can
pass down the neck of the container. If the pump is driven electrically it may be stopped and
started by level controls in the apparatus being filled.

INSTALLATION AND MAINTENANCE OF EQUIPMENT

OBTAIN AUTHORITATIVE ADVICE. Never install equipment or piping for cryogenic

liquids without consulting someone thoroughly experienced in low temperature work. The
materials used must possess certain physical properties to qualify them for use at these extremely
low temperatures. Ordinary carbon steels, for example loses their ductibility and become
extremely brittle when subjected to the low temperature of any liquefied atmospheric gas.
Certain ferrous alloys and number of non-ferrous materials on the other hand, may safely be
used. Cryogenic temperatures also give rise to unique installation problems and considerations
of expansion and contraction. Dealing with all of these problems and installing the special relief
devices and other equipment to be used requires the advice of a fully experienced person.

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FOLLOW PRESCRIBED PROCEDURES. Always follow all of the procedures prescribed
by the manufacturer for operating and maintaining equipment used with cryogenic liquids.
Everyone who works with these liquids must be properly trained and supervised by someone
with experience in the field. If there is a suspicion that any equipment is faulty (usually
detectable by high boil-off rates or patches of external frost).

RESTRICTED ACCESS TO STORAGE UNITS. Make sure that only authorized personnel
have access to liquid storage units. Even if the supplier retains ownership of the storage unit,
you should be thoroughly familiar with the operation of the equipment. You must know
especially, the positions of the valves and switches to be used when the unit must be shut down
in the case of an emergency.

CONCISE EMERGENCY INSTRUCTION SHOULD BE CLEARLY

DISPLAYED NEAR THE STORAGE UNIT.

LIQUID OXYGEN

In addition to the general precautions for handling all cryogenic liquids observe the following
precautions in handling liquid oxygen.

PREVENT ALL FIRE HAZARDS

Do not smoke or permit smoking or open flames in any area where liquid oxygen is stored,
handled, or use, or where it is loaded or unloaded. Post NO SMOKING signs conspicuously
in all such areas.

Do not permit organic material or flammable substances of any kind to come in contact with
liquid oxygen. Some of the materials that can react violently with oxygen under certain
conditions of pressure and temperature are oil, grease, asphalt, kerosene, cloth, wood, paint, tar,
and dirt which may contain oil or grease. Under certain conditions, mixtures of powered organic
materials with liquid oxygen can detonate.

CAUTION

WHEN ORGANIC MATERIALS, SUCH AS THOSE LISTED ABOVE, ARE

EXPOSED TO LIQUID OXYGEN, THEY WILL BURN VIOLENTLY IF IGNITED
EVEN SEVERAL MINUTES AFTER THEY HAVE BEEN IN CONTACT WITH
THE LIQUID. ANY CLOTHING THAT HAS BEEN SPLASHED OR SOAKED
WITH LIQUID OXYGEN SHOULD BE REMOVED IMMEDIATELY AND AIRED
AWAY FROM SOURCES OF IGNITION UNTIL IT IS COMPLETELY FREE OF
OXYGEN.

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USE OF LIQUID OXYGEN EQUIPMENT

Use only approved lubricants on oxygen equipment, since most hydrocarbons become highly
flammable in the presence of oxygen. Purge all oxygen equipment before making repairs.
Remove all traces of the product oxygen from the equipment, using oil-free dry nitrogen or oil-
free dry air for purging.

ALL OXYGEN STORAGE AREAS SHOULD BE MARKED WITH SIGNS

CAUTION------NO SMOKING

FIGHTING FIRES INVOLVING LIQUID OXYGEN

Since oxygen itself does not burn, there can be no fire unless combustible materials are also
present. In any fire involving liquid oxygen, the oxygen plays the same part as oxygen from the
air in an ordinary fire. However, the presence of additional oxygen will make any fire burn
much faster and more violently. The following fire-fighting procedures should be observed:

T Remove everyone not actively engaged in fighting the fire.

T If possible, shut off the flow of oxygen.

T Use large quantities of water, preferably in the form of a spray, to cool the
burning material below the ignition point. If electrical equipment is involved in the
fire, use carbon dioxide, dry chemicals, or vaporizing liquid extinguisher. DO NOT
USE WATER

LIQUID NITROGEN

In addition to the general precautions for handling all cryogenic liquids observe the following
precautions in handling liquid nitrogen.

GOOD VENTILATION

Store and use liquid nitrogen only in a well-ventilation place. If enough nitrogen gas evaporates
from the liquid in an unventilated space, the percentage of oxygen in the air may become
dangerously low.

When oxygen concentration in the air is sufficiently low, a man can become unconscious without
sensing any warning symptoms, such as dizziness. If he remains in this atmosphere long enough,
there may be fatal results.

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ENTERING LARGE LIQUID NITROGEN STORAGE TANKS

Before entering any large liquid nitrogen storage tank, be sure all pipes to the tank are blanked or
positively closed off. If a check with instruments show that the atmosphere in the tank is normal
air, it should be safe to enter. Unless all lines are blanked, check the atmosphere frequently with
instruments during work. If, for any reason, the supply of fresh air in the tank is doubtful, use
breathing apparatus with its own supply of oxygen of air. Whenever you enter a tank, always
make sure you are equipped with a lifeline and that an observer is stationed outside to check on
your reactions while working, it is a good practice to have ventilating equipment rapidly
changing the air in tanks at all times when personnel are working inside them.

FIRST AID NOTICE

If a person seems to become dizzy or loses consciousness while working with liquid
nitrogen, get him to a well-ventilated area immediately. If breathing has stopped apply
artificial respiration. When a person loses consciousness, SUMMON MEDICAL AID
IMMEDIATELY.

EXPOSURE TO ATMOSPHERE

Liquid nitrogen is colder than liquid oxygen. Therefore, if it is exposed to the ambient air,
oxygen from air the may condense into the liquid nitrogen. If this is allowed to continue for any
length of time, the oxygen content of the liquid nitrogen may become appreciable and the liquid
will require the same precautions required in handling liquid oxygen. However, most liquid
nitrogen containers are entirely closed except for a small neck area and the nitrogen gas issuing
from the surface of the liquid forms a barrier, which keeps air away from the liquid and prevents
oxygen contamination.

MEDICAL TREATMENT OF CRYOGENIC BURNS

If a person is exposed to a cryogenic surface or fluid, SUMMON MEDICAL

AID IMMEDIATELY for the proper treatment of cryogenic burns.

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 VWP
Nitrogen Vaporizer Systems

North American Service Centers

& Parts Sales

Pittsburgh Cryogenic Services, Inc.

Tel: 1.724.695.1910
E-mail: pittcryo@pittcryogenic.com
www.pittcryogenic.com

Cryogenic Industries – Houston

Tel: 1.281.590.4800
E-mail: sales@cihouston.com
www.cihouston.com

CryoCanada, Inc. – Red Deer

Tel: 1.403.852.4436
E-mail: info@cryocanada.com
www.cryocanada.com

CryoCanada, Inc. – Toronto

Tel: 1.416.502.1950
E-mail: info@cryocanada.com
www.cryocanada.com

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