Operating Manual
APOLLO® 50
- 1,3 bar
APOLLO® 100 - 1,3 bar
APOLLO® 150 - 1,3 bar
Contents
Page
Table of Contents
1 Introduction
1.1 Symbols in the Manual
1.2 Principle
1.3 Delivery
1
1
1
1
2 Vessel
2.1 Main Components
2.2 Specifications of the Vessel
2.3 Specifications of the Safety Valve
2.4 Examination of Safety Valve
2.5 Assembly of Safety Valve
2.6 Wrong Installation / Operating Errors
2.7 Combined Positive Pressure Relief and Seal-off
Device
2.8 Siphon with Small Flange Connection Type EK
2.9 Transfer Hose
2.10
Level Indicator
2.11
Pressure Build-up Control System
2.12
Spare Parts / Accessories
2
2
2
2
3
3
3
4
4
5
6
8
9
3 Safety
3.1 How to handle liquid Nitrogen
3.2 General Safety Instructions
3.3 Proper Use according to the Regulations
3.4 Safety Data Sheet “Nitrogen refrigerated“
3.5 Accident Leaflet „suffocating Gases”
3.6 Labelling
10
10
10
10
11
15
16
4 Transportation and Assembly
4.1 General Transportation
4.2 Assembly
17
17
17
5 Operation
5.1 Initial Commissioning
5.2 Assembly and Disassembly of the EK Siphon
5.3 Assembly of the Transfer Hose
5.4 Filling of the Vessel
5.5 Withdrawal of liquid Nitrogen
5.6 Pressure Build-up
5.7 Pressure Relief
5.8 Putting out of Operation
5.9 Operating Instructions
18
18
18
19
19
21
22
23
23
23
6
24
Maintenance / Repair
7 Faults
7.1 General Faults
7.2 Possible Faults
25
25
26
8
27
Warranty
I
Introduction
Appendix:
II
name plate
Certificate/Declaration of Conformity
List of pressure device and equipment
Introduction
1
Introduction
The APOLLO® Vessel is a vacuum super insulated pressure
vessel made of corrosion-resistant stainless steel. It is
intended exclusively for storing nitrogen (cryogenic liquid
nitrogen).
The APOLLO® Vessel acc. to Directive for Pressure Devices
97/23/EG
Category I Module A., with CE - marking
This sign points out to dangerous situations
resulting in possible
• injury to persons
• damage to the environment
• damage to devices
1.1 Symbols in the Manual
This sign refers to
• recommendations
• explanations
• supplements
1.2 Principle
The APOLLO® Vessel may only be operated according to
this operating manual.
1.3 Delivery
Immediately after receipt of the vessel, the delivery has to
be examined with regard to
•
•
completeness
damage
In case of any shipping damage, contact
•
•
•
the shipping insurance
the shipping company
the supplier
1
Vessel
2
Vessel
2.1 Main Components
•
•
•
•
•
•
2.2 Specifications of the Vessel
Coaxial arrangement of the pressure vessel in the outer
vessel with neck suspension and vacuum super insulation
Pressure build-up device arranged in the vacuum room
Chassis
Safety valve
Pressure gauge
Dismountable siphon, Type EK®
Manufacturer
Cryotherm
GmbH & Co. KG
APOLLO® APOLLO® APOLLO®
50
100
150
- 1,3 bar
-1,3 bar
-1,3 bar
Type
Total height, cm
Outside diameter, cm
Total width, cm
Immersion depth, cm
A
B
C
D
80
50
76
58,5
114
50
76
92
146
50
76
122
Neck diameter, mm
50
50
50
Weight empty, kg
44
62
79
Weight full, kg
85
145
204
49,5
99,2
149,5
2
1,2
1
1,3
1,3
1,3
Geometrical capacity, l
Static rate of evaporation,
% / day
Operating pressure, bar
2.3 Specifications of the Safety
Valve
Type
Blow-off pressure
2
max.
06002
1,3
bar
Vessel
2.4 Examination of Safety Valve
Examination
Seat tightness and set pressure of the safety valve may only
be examined by means of the bubble method outlined below.
Contamination and corrosion of the valve mechanics are thus
avoided. The set pressure is indicated on the type plate of the
safety valve.
1. Admission of Test Pressure
For the admission of the test pressure, a suitable testing
device has to be used. With safety valves which shall not be
dismantled, the test may be executed by the vessel pressure.
Do not carry out examinations with oxygen or combustible as
well as corrosive gases.
2. Examination of Seat Tightness
Increase the test pressure to 90 % of the set pressure. The
valve has to remain tight.
3. Examination of Set Pressure
Slowly increase the test pressure to 100 %. The safety valve
will blow off.
The set pressure may deviate from the nominal value +/10%.
Full-flow safety valves do open abruptly! Possibly,
set pressure and opening pressure are identical.
2.5 Assembly of Safety Valve
Wrap PTFE – tape on the R1/4“ connection and screw it tight
in the connection thread.
Caution! Be careful, that no parts of PTFE peel away
into the medium tube, which will cause malfunction of
the safety valve
2.6 Wrong Installation /
Operating Errors
The application of the following means and tools to
the safety valve are prohibited:
• pliers
• striking tools
• lubricating spray
• hemp
• open flame
• vapour
• leak indicating spray
• lees
3
Vessel
2.7 Combined Positive Pressure
Relief and Seal-off Device
Caution! The positive pressure relief and seal-off
device
protects
the
vacuum
room
from
overpressure. Re-evacuation may only be carried
out by
• manufacturer’s skilled staff
The protective cover (2) intercepts the valve insert
(1), when there is overpressure existing in the
vacuum room.
• Do not remove the protective cover (2).
• Protect the valve from heat as well as cooling, as
brittleness results in the loss of the operating
vacuum.
2.8 Siphon with Small Flange
Connection
Type EK
Structure of the Siphon
Item
1
2
3
4
5
6
Description
Waste gas/overflow line
Basic body with small flange connection
DN 50
Waste gas/overflow valve G 1/2”
Filling/withdrawal valve G 3/8”
Connection screwing
(double nipple ring R 3/8” - 3/4-16 UNF)
for flexible transfer hose
Filling/withdrawal line
The siphon serves for the filling and withdrawal of liquid
nitrogen.
Special designs (e.g. single / triple withdrawal) are available
on request.
Ball Valve Positions:
A - closed
B - open
4
Vessel
2.9 Transfer Hose
Structure of the Standard Transfer Hose
Item
1
2
Description
Flexible corrugated hose with a
corrosion-resistant stainless steel
braiding
Phase separator for ensuring the
splash-free transfer of liquid nitrogen
Exchange damaged hose
Protect transfer hose from
• bending when in a cold condition
• being twisted
• being pulled
• buckling
• impacts
5
Vessel
2.10 Level Indicator
Structure of the Level Indicator
Determination of the Vessel Filling Level
• by reading the scale of the level indicator
•
•
by determining the filling level by means of a dip rod and
comparing with the filling level curve
the black area marks 25% of residual contents
Prior to the disassembly of the level indicator:
• relieve pressure from the vessel
• close the shut-off valve (2)
6
Vessel
APOLLO 50, 100, 150 Filling
Level Curve
drawing 78202700
7
Vessel
2.11 Pressure Build-up Control
System
Automatic Pressure Build-up Control System
(Option)
Item
1
2
3
Description
Pressure build-up line
Pressure build-up valve
Pressure build-up control valve
The automatic pressure build-up valve controls the pressure
in the vessel.
It is recommended with continuous withdrawal operation.
Close the pressure build-up valve (2) prior to filling,
relieving pressure or transporting.
Pressure Build-up Control
• Switch on by opening the pressure build-up valve (2),
Position A.
• Switch off by closing the pressure build-up valve (2),
Position B.
Changing the Operating Pressure
• Turning the regulating screw of the pressure build-up valve
in clockwise direction causes the pressure to increase.
• Turning the regulating screw of the pressure build-up valve
in counter clockwise direction causes the pressure to
decrease.
Automatic Pressure Build-up Control Valve Mode of
Operation:
• The pressure build-up control valve (3) will open when the
pressure in the tank drops.
• The liquid nitrogen is introduced into the pressure build-up
line (1) at the vessel bottom, it evaporates and is returned
to the tank.
• The pressure in the tank rises to the adjusted operating
pressure.
• The pressure build-up control valve (3) closes.
8
Vessel
2.12 Spare Parts / Accessories
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
*
Designation
Lettering APOLLO
Cryotherm logo
Level Indicator MGI WIKA
Ball valve 3/8"
Ball valve ½”
EK Siphon, complete
Safety valve, 1.3 bar
Pressure gauge
0-2.5 bar
Chassis
Castor with locking lever
Castor without locking
lever
Double nipple R 3/8"3/4-16 UNF
Transfer hose, 1.5 m
Straining ring, DN 50
Centering ring, DN 50
complete
O-ring for KF 50
(separate)
Phase separator G 3/8"
complete
Safety glasses
Transport stopper DN 50
Protective insulating
leather gloves
Rating plate (adhesive
film)
Operating instructions
(adhesive film)
Operating manual
GGVS / ADR - Labelling
Cryogenic liquid nitrogen
GGVS adhesive label
no. 2
GGVS adhesive label ↑↑
no.11
Connection tube
Option
Instead of pos. 23
Pressure regulator
Subject
number
APOLLO®
50 – 1,3
bar
78202700
77031445
79406985
78202720
Subject
number
APOLLO®
100 – 1,3
bar
78202701
77031445
79406985
78202720
Subject
Number
APOLLO®
150 – 1,3
bar
78202702
77031445
79406985
78202720
0346570
0793058
78202711
78212669
78202716
0346570 0346570
0793058 0793058
78202712 78202713
78212669 78212669
78202716 78202716
78202740 78202741 78202742
78210302 78210302 78210302
78210301 78210301 78210301
0793576
0793576
0793576
79229957 79229957 79229957
0792277 0792277
079227
0793045 0793045 0793045
0793060
0793060
0793060
79404217 79404217 79404217
0794189 0794189 0794189
78202417 78202417 78202417
0794111 0794111 0794111
78201604 78201604 78201604
79406614 79406614 79406614
78211688 78211688 78211688
78400571 78400571 78400571
0358193 0358193 0358193
0356199
0356199
0356199
78202718 78202718
0366006
0366006
9
Safety
3
Safety
3.1 How to handle liquid Nitrogen
Caution when handling liquid nitrogen!
Observe the following documents and procedures:
• Leaflet „How to handle nitrogen“
• Safety data sheet: “Nitrogen refrigerated”
• Accident leaflet "cryogenic liquefied gases:
suffocating“
• When setting up in rooms, ensure good ventilation
(TRB 610)
• Operation may only be carried out by persons
instructed correspondingly (TRB 700)
• Regulation for the Prevention of Accidents „gases“
BGV B 6 (VBG61)
• Regulation for Pressure Devices
3.2 General Safety Instructions
For safe operation:
• Additional aggregates for filling/withdrawal have to be
adjusted to the operating conditions of the tank.
• Test the tightness and function of the fittings at
regular intervals.
• Use original spare parts.
• Employ suitable tools.
• Do not operate valves abruptly or jerkily.
• Protect lockable rooms from exceeding of the
maximum operating overpressure by means of a
safety valve.
• Have adjustment, maintenance and repair work
done only by authorized skilled personnel.
• Do not carry out any mechanical and thermal work at
the vessel (loss of vacuum).
• Do not transfuse contents with foreign gas.
• Do not overcharge the tank.
• Protect safety valves from splash water and lees.
• Wear gloves and safety glasses.
• Loosen the screwings only in unpressurized
condition.
3.3 Proper Use according to the
Regulations
Company Cryotherm GmbH & Co. KG does not assume
any liability, if the tank is changed or adapted without
approval given by the manufacturer.
Company Cryotherm GmbH & Co. KG does not assume
any liability, if the tank is not properly used according to
the regulations.
10
Safety
3.4 Safety Data Sheet
“Nitrogen refrigerated“
11
Safety
12
Safety
13
Safety
14
Safety
3.5 Accident Leaflet
„suffocating Gases”
ACCIDENT LEAFLET FOR ROAD TRANSPORTATION
ADR/GGVS Class 2
CRYOGENIC LIQUEFIED GASES: suffocating
non-toxic, non-caustic, non-inflammable, non-oxidizing –
designation of the medium is indicated on the next page
HAZARDS
Heating results in pressure increase – danger of bursting.
Gas is having a suffocating effect without any observable
symptoms.
The leaked liquid is very cold and evaporates rapidly.
Liquid causes heavy injuries through frostbite on skin and
eyes.
Together with humid air, it generates fog.
Gas is heavier than air and spreads on the ground.
PROTECTIVE EQUIPMENT
Safety glasses,
protective shoes
protective
gloves
or
face
protection,
EMERGENCY MEASURES: IMMEDIATELY NOTIFY FIRE
BRIGADE AND POLICE
Stop the motor.
Secure the road and warn other road users.
Keep unauthorized persons away from the danger zone.
Stay on wind side.
LEAKAGE LOSSES
If possible, remove leakage losses.
Consult an expert.
Have leaked liquid evaporated.
Warn everyone - danger of suffocating existing in sewerage,
cellars and pits.
FIRE:
In case of fire conditions, cool the tank by means of a water
spray jet.
FIRST AID:
Thaw frozen garments and remove them carefully.
Medical aid is required in case of frostbite symptoms.
ONLY VALID FOR ROAD TRANSPORTATION Dez 96
15
Safety
3.6 Labelling
The tanks have to labelled according to the regulations
for hazardous goods for the respective employment.
Cryogenic liquefied Gases
suffocating, Class 2 Figure and Group 3A
Figure
and
Group
3A
Number, Labelling, Designation of the
Medium
1977
1951
nitrogen, cryogenic liquid
argon, cryogenic liquid
Caution Marks
No. 2
Non-combustible
and non-toxic
gas;
16
No. 11
This side up;
This label has to
be attached with
the arrow heads
pointing
upwards.
Transportation and Assembly
4
Transportation and Assembly
4.1 General Transportation
Transportation of the Vessel
• Observe safety instructions.
• Keep upright.
• Lift and set down carefully.
• Avoid impacts and strong shocks
Transportation in filled condition
• The vessel must be in excellent condition.
• The vessel must be in unpressurized condition with
loosely fitted transport stopper.
• The EK Siphon has to be dismantled.
• Use 2 person for transport over inclines, pitches and
steps
Observe the national regulations during internal and
road transportation with vehicles. At the same time,
protect the vessel from tumbling down, shifting and
damage (by stowing / lashing).
4.2 Assembly
Assembly of the Vessel
• Observe safety instructions.
• Ensure good ventilation.
• Consider place of operation
• Fix castors by means of the locking levers.
17
Operation
5
Operation
5.1 Initial Commissioning
The vessel can be commissioned immediately after delivery.
Caution !
• Observe safety instructions.
• Use filling line with safety valve and pressure relief.
• Wear gloves and safety glasses.
• Protect the vessel from rolling away, tumbling down
and damage.
Note !
• When cooling down the hot vessel to operating
temperature, increased evaporation losses do occur.
5.2 Assembly and Disassembly
of the EK Siphon
In principle, operate the vessel exclusively by means of the
EK Siphon (2).
When opening the waste gas/overflow valve (1),
make sure that it is not directed towards any
persons or devices; cryogenic gas will cause burns
and brittleness.
Note !
• Due to operation, open valves will get covered by ice
during the pressure build-up, waste gas/overflow and
filling/withdrawal.
• Closed valves will thaw eventually.
• Lasting frost formation indicates leakage.
Assembly of the EK Siphon
1. Clean and remove ice from the sealing surfaces (4),
centering ring (5) and O-ring (6) and replace if damaged.
2. Place the centering ring (5) with O-ring (6) on the flange.
3. Close the filling/withdrawal valve (3) at the EK Siphon.
4. Open the waste gas/overflow valve (1) for avoiding
pressure increase.
5. Insert the EK Siphon (2) vertically into the neck.
6. Place the straining ring (9) and tighten the wing screw (8).
7. Close the waste gas/overflow valve (1).
Liquid nitrogen may escape from
gas/overflow valve when the EK
immersed.
18
the waste
Siphon is
Operation
Disassembly of the EK Siphon
Danger of Accidents!
Dismantle the EK Siphon only with unpressurized
vessel.
1.
2.
3.
4.
Close the pressure build-up valve (7).
Close the filling/withdrawal valve (3).
Detach the connected withdrawal line from the EK Siphon.
Open the waste gas/overflow (1) valve for relieving the
pressure of the vessel.
5. Loosen the wing screw (8) and remove the straining ring
(9) from the unpressurized tank.
6. Remove the EK Siphon (2) by pulling it out carefully from
the top and deposit it carefully.
7. Loosely insert the transport stopper.
5.3 Assembly of the Transfer
Hose
Note
• Avoid any heavy mechanical strain.
• Do not carry out any assembly and disassembly
while the vessel is cold.
Assembly of the Transfer Hose
1. Screw the union nut (3) onto the connecting screwing (2) of
the filling/withdrawal valve (1).
2. Tighten the union nut (3) by means of an open-jawed
wrench; in doing so retain the hexagon (2) with a wrench.
3. If necessary, tighten the union nut (3) in cold condition.
5.4 Filling of the Vessel
Caution !
• Observe safety instructions.
• Use filling line with safety valve and pressure relief.
• Wear gloves and safety glasses.
• Protect the vessel from rolling away, tumbling down
and damage.
• The pressure in the supply – vessel must not be
higher than 1,3 bar
Note !
• Additional aggregates for filling and withdrawal have
to be adapted to the operating conditions of the
vessel.
• Filling has to take place outside or in a sufficient
ventilated room
Risk of suffocation
19
Operation
Filling
1. Mount the EK Siphon.
2. Connect the filling line from the tank to the
filling/withdrawal valve.
3. Open the waste gas/overflow valve for causing pressure
relief.
4. Open the filling/withdrawal valve at the EK Siphon.
5. Open the tank valve for filling the vessel.
6. Close the tank valve when liquid nitrogen escapes from the
waste gas/overflow valve .
Caution!
Risk of skin burns
After completion of filling:
Waste Gas/Overflow Valve (3) to leave open.
1.
2.
3.
4.
5.
Close the filling/withdrawal valve (1) at the EK Siphon.
Relief pressure from the filling line (2).
Loosen the filling line (2).
Dismantle the EK Siphon.
Move the tank (with the transport stopper loosely inserted)
to its destination.
6. Remove the transport stopper.
7. Mount the EK Siphon.
Risk of skin burns by escaping nitrogen
Filling without EK-Siphon in open condition
Alternatively to the procedure described above the vessel
may be filled by a hose with phase separator in open
condition. The filling has to be stopped prior the liquid level
reaches the neck tube.
1. depressurise and unmount the EK-siphon
2. let liquid inflow trough the neck tube in open condition
3. stop filling procedure prior liquid level reach the neck tube
(liquid level gauge 5% under max-indicator)
4. mount the EK siphon
(ball valves 1 + 2 closed)
5. open overflow valve 3: overfilled liquid will escape
Caution!
Risk of skin burns by escaping nitrogen
20
Operation
5.5 Withdrawal of liquid Nitrogen
Withdrawal
1.
2.
3.
4.
Move the vessel to the place of withdrawal.
Mount the EK Siphon.
Mount the delivered transfer hose or a relevant filling line.
Open the filling/withdrawal valve in order to withdraw liquid
nitrogen.
5. Adjust the desired withdrawal pressure and open
the pressure build-up valve for this purpose.
Caution !
• Observe safety instructions.
• Wear gloves and safety glasses.
• Protect the vessel from rolling away, tumbling down
and damage.
21
Operation
5.6 Pressure Build-up
The operating pressure in the vessel allows for withdrawing
the liquid gas.
Vessel name
Apollo®
maximum operating
pressure
1,3 bar
The safety valve limits the maximum operating pressure.
Should the pressure in the tank not be sufficient for the
withdrawal operation, it can be increased by opening the
pressure build-up valve.
Prior to pressure build-up:
• Check the EK Siphon for tight seat.
• Adjust the operating pressure only as high as
required.
Pressure Build-up
1.
2.
3.
4.
5.
Close the waste gas/overflow valve.
Close the filling/withdrawal valve.
Slowly open the pressure build-up valve.
Watch the pressure gauge.
Close pressure build-up valve when the desired pressure is
reached.
Continuous Withdrawal under constant Pressure
1. Slightly open the pressure build-up valve.
2. Close the pressure build-up valve when the desired
pressure is reached.
3. When starting with the withdrawal, watch the pressure drop
at the pressure gauge.
4. Open the pressure build-up valve is such a way that the
desired pressure remains constant.
Note
• Avoid blowing-off of the safety valve.
• Frost formation on the vessel bottom is operational.
Close the pressure build-up valve prior to finishing
the withdrawal process.
A pressure control valve is recommended for
continuous withdrawal. This item has to be indicated
separately on the purchase order. Retrofitting is
possible.
22
Operation
5.7 Pressure Relief
Open the waste gas/overflow valve, until the operating
pressure at the pressure gauge will be achieved.
Subsequently, close the valve again.
Do not direct the opening of the waste gas/overflow
valve towards any persons or devices, as cryogenic
gas causes burns and brittleness.
5.8 Putting out of Operation
When putting the vessel out of operation, it has to be
completely emptied out, warmed up and stored under slight
gas overpressure, in order to avoid condensation of humidity.
5.9 Operating Instructions
Note !
The operating instructions
• are firmly attached to the outer vessel.
23
Maintenance / Repair
6
Maintenance / Repair
•
•
•
•
•
•
24
With conventional use, the vessel does not require any
special maintenance or attendance.
Regular examinations with regard to operativeness and
tightness of the fittings and screwings are recommended.
Every two years, the safety valves have to examined with
regard to function and set pressure. The pressure gauge
indicates the set pressure.
With conventional use, the vessel does not require any
special maintenance or attendance.
Regular examinations with regard to operativeness and
tightness of the fittings and screwings are recommended.
Every two years, the safety valves have to examined with
regard to function and set pressure. The pressure gauge
indicates the set pressure.
Faults
7
Faults
7.1 General Faults
Immediately put the vessel out of operation, in case
that
• the fittings are leaky.
• the safety valve does blow off intensively.
• the rate of evaporation is too high.
• The outer cylinder is thawed / iced-up, which
indicates loss of vacuum.
In case of nitrogen escaping,
• there exists the danger of suffocation.
• open windows and doors.
• leave closed rooms.
Vessels with vacuum loss are useless and have to
be returned to the manufacturer for examination /
repair.
In case of any queries, please indicate
• type of vessel
• maker’s number
• year of construction
25
Faults
7.2 Possible Faults
Fault
Cause
Iced-up valve
This is operational
with opened valve.
-
The valve is not
closed completely.
Close the valve (it
thaws).
The valve is leaky.
Tighten the
screwings / seat.
If required, rinse /
exchange the
valve.
Pressure build-up
valve is open.
Close pressure
build-up valve.
Pressure raising
controller is too
highly adjusted.
Lower adjust the
opening pressure
of the pressure
raising controller.
Filling pressure is
too high.
Decrease the
filling pressure of
the withdrawal
tank.
Pressure build-up
valve is open
Open waste gas
overflow valve.
Level indicator is
defective.
Close shut-off
valves of the level
indicator,
exchange level
indicator.
Vacuum loss
Examination / reevacuation by the
manufacturer
Safety valve blows
off.
Frost formation on
the vessel
• at the outer
vessel
•
at the bottom
Positive pressure
relief and seal-off
device released,
vessel extremely
iced-up
26
Operational
pressure build-up
Trouble
shooting
-
Vacuum loss within Empty out the
the vacuum room
vessel / put it out
of operation
Examination /
repair at the
manufacturer’s
works
Warranty
8
Warranty
Our warranty requires the proper use of the device according
to the regulations. When exchanging parts, only original
spare parts have to be used. Wear parts are not subject to
warranty.
Extent and duration of our warranty comply with the regulation
indicated in our terms of delivery.
27
Cryotherm GmbH & Co. KG, certified according to DIN EN ISO 9001
Article No. :• 78211688 Ÿ 0067
Subject to changes
©Cryotherm GmbH & Co. KG
® registered Trademark
Cryotherm GmbH & Co. KG Germany
Euteneuen 4
D-57548 Kirchen (Sieg)
Tel.: (0049-2741) 9585-0 • Fax (0049-2741) 6900