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1. 6 4 Electrical Connection and Grounding Electrical Board Connection dravving Vaporizer Grounding s s ee ven cvoobvasceuscanveccseesdesetoeasevsssvwscssescduceansvecccccssssveees Typical Installation Configuration 9 Test the Systemfor Gas 9 7 Vaporizer Start Up and Shut Down 10 Starfing the Direct Fired 2 8 DER EO EE DO mo DOS 10 Control Settings for On Going 25 ss nenne m E e nas 10 APPENDIX A TELEPHONE AND INTERNET SUPPOR T ss rasnon sat sen sos a en sa s s 11 APPENDIX B TROUBLE SHOOTING and 222 11 Mechanical Failure 11 Eledtrica sFailurete 9 8 8 18 90 9 213 25 2 T EE Rom P3 2 SUS 038 228 08 12 Routine enclosure test report amp 8 B B A e eee 2 Boned 13 Routine INFORMATIONS FOR CUSTOMERS This service manual is designed for all customers and users of NEBIMAK LPG FEED BACK LPG VAPORIZERS series NBHXX We recommend to become familiar with the present manual before proceeding to2. NEB MAK LPG FEED BACK VAPORIZER NBH XX SER ES USER MANUAL 2G Ex d IIA T3 capacity Kg h Power 400V AC AC 17 2BAR 2 BAR dac M SANE iNBH X 50 75 aoovac PN4O 172 SERIES Capacity 20 30 50 Kg h Number of Pages 14 Date 04 08 2010 Signature TABLE CONTENTS I INFORMATION FOR eo Sea En e ea aano asas RE nasus TOME RUE NAE 3 2 DENOTATION THE FUEL 15 5 2 22 sos senses eno sone sesh c EIN dcr PRECAUTION E LP GaS EPG 0 0 AE aE E NE E EEE EAE a A 000 Precaution S e EE 4 PRE INSTALLATION INSPECTION 5 YOUR VAPORIZER 5 1 Function of the Feed Back 5 5 2 Features of the Feed Back Vaporizer 5 5 3 Components of the Feed Back Vaporizer 2 a aE aaa aaa ia 6 Cutaway drawing of the Direct Fired etra anas ases enne aa 6 6 INSTALLATION E AR 6 6 1 Unpacei and Anch r UNIE 7 6 2 Stall THE Outlet PIPING 6 3 Install the Inlet Piping
3. or other related equipment 4 Keep all other vehicles gasoline engines and electrical motors avvay from the storage tanks transport trucks and related equipment A running engine or motor can provide the spark needed to cause a fire or explosion DO NOT remove plugs or caps on connections if shut off valves leak e Make sure all unloading connections are tight e Make sure you understand the purpose and operation of all valves and other equipment before using DO NOT tamper with relief valves Open any valve SLOWLY NEVER place your face head hands or any other part of your body over safety relief valves DO NOT overfill LP Gas storage containers DO NOT allow LP Gas to touch your skin or clothing The gas evaporates very quickly and can cause freezing 4 Pre Installation Inspection Before beginning installation a thorough inspection of the installation site and all equipment should be completed to ensure that all equipment valves fittings connectors and lines are prepared and safe The following general steps should be taken during the inspection Conduct both a visual and physical using soap solution or gas detector inspection for leaks on and around any storage tanks pumps unload stations vaporizers mixers and the like Open all valves in line with pressure measuring devices Observe and record any available temperature pressure level or other gauge readings Ch
4. Install a shutoff valve with a minimum rating of PN25 and connect pipe to the feed back vaporizer LPG inlet Either a globe valve or a ball valvemay be used 6 3 Install the Outlet Piping Install a shutoff valve with a minimum rating of PN25 Either a globe valve or a ball valve may be used to the gas phase out of the vaporizer Connect pipe back to the tank Please be sure of that tank return line from vaporizer gas outlet of the vaporizer SHOULD BE connected to the gas phase of the LPG tank 6 4 Electrical Connection and Grounding All Nebimak vaporizers are shipped with 20 meters of energy cables 4X2 5 mm and 20 meters of control cables 4 X 1 5 mm already connected at the factory A If 20 meter length is not enough extending the cables only to be serviced by personnel furnished with requisite authorisation according to national regulations All cables must get through from an 3 4 indivudial protected underground steel pipe to protect cables You can find electric board connection details on next page ELECTRIC CONNECTION DETAILS POWER BOX CONNECTION DIAGRAM NON HAZARDOUS AREA HAZARDOUS AREA POWER CONTROL BOX LPG VAPORIZER F IDTCCTIDN TYPE DOK POWER CABLE 3 0 KW 42 5 mm 3 5 KW 4x2 5 mm 5 5 KW 4x25 mm 7 5 Kev 4 2 5 mm 1x4 mm grounding cables must be used for grounding vaporizer and grounding value must be lower than 3 ohm
5. This grounding cable can be connected to M10 bolt connected to the vaporizer foot A grounding bar with minimum 0 5 mm CU must be used to finish grounding of the vaporizer you can see grounding connection drawing below Thevaporizer is now ready to be connected to the load for which the heated and vaporized LPG is being provided 8 Typical Installation Configuration TANKAVAPORIZER ASSEMBLY SCHEMA e HE M ET LINE t k RASE OUTLET FROM THE PE RETURN LE mur 1 45 LME FOR COMSIMETICU EN M creme ii m pe vct arada av DEM Test the System for Gas Leaks e Ensure outlet valve LPG inlet pipe of the tank is closed Ensure inlet valve of the tank GAS phase pipe is closed Place a solution of soapy water liberally around all threaded and welded pipe joints tube fittings and the like Check all pipe and tube joint connections for evidence of gas leakage Correct any leakage found before proceeding further 7 Vaporizer Start Up and Shut Dovvn This chapter describes how to start the installed Feed Back Vaporizer It also describes how to set the controls for either on going operation or for long periods of shut down Starting the Feed Back Vaporizer The following describes the procedure for starting the vaporizer Inspect all
6. from the upper flange of the vaporizer is too cold There is some test water left in the system To read the pressure in the tank It could be read from the manometer located on the multivalve It should read 2 5 bars in normal weather conditions 2 ELECTRICAL FAILURE 2 1 2 1 1 2 1 2 2 1 3 2 1 4 2 2 2 2 1 2 2 2 2 2 3 The failure light red is flashing on the electric box The RL25 valve which is located bottom of the tank should stay open If this valve is not open and energy is given to the system the failure light red located on the electric box will flash In this case RL 25 must be switched on and the reset button located on the electric box should be pressed to stop the failure light flashing The ball valve which is located on the gas line connected from the upper flange of the vaporizer to the tank should stay opened May be causing the failure light red to flash when energy is given to the system In this case the ball valve should be opened and the reset button located on the electric box should be pressed The thermostat located in the vaporizer could be damaged The contactor in the electric box could be damaged The outside shell of the vaporizer and the upper shell of the tank is hotter than it should be under normal conditions The thermostat located inside the vaporizer could be damaged The contactor in the electric box could be damaged The thermostat located inside the vaporizer is set too
7. high 12 i NEB M AK Over pressure routine test report REK MLL H T MALAT n5 L s sss sa sept qam sani ve 1031 Product code NBH XX SERIES go NEB MAK ROUTINE TEST REPORT FOR ALUMINUM COVER TUV AUSTRIA Serial number Page 1 1 APPLIED TEST METHODS RESULTS EVALUATION Overpressure Tests and desired values EN 60079 1 Item 15 1 3 1 Enclosures with volume lt 10 cm3 group IIA 10 bar gt 10 cm3 group IIA 15 bar Must be pressurized for min 10 maximum 60 seconds TEST YETK L S TESTED BY KONTROL EDEN CONTROLLED BY 13 NEBIMAK NEB MAK ROUTINE TEST T V MAK NA L K T GAZ MALAT ins REPORT ZALA SANAY ve T CARET LTD STi NBH XX SERIES TS GN GO met 2008 Santfiea He 20 190 1820007 SERIALNUMBER 8 o PAGE 1 1 ROUTINE CONTROL REPORT EN 60079 0 1 m PRODUCT CODE NBH SERIES SERIAL NO Final Quality Control Discord No RELIEF VALVE IS CONNECTEDIEMNIVET VALF TAKI FARTHING BOLT IS IN CONTACT WITH SHELL TOPRAKLAMA V DASI TEMASLI MANOMETER BALL VALVE IS ASSEMBLED KURESEL VANA TAKILI Description 7 CABLES CONNECTED TO HEAT S KABLOLAR ISITICIYA BAGLI 4 THERMOSTAT CABLES CONTROL TERMOSTAT KABLOSU OK 2 5 CHECK LABEL AND WARNING ETIKET VE UYARI TAMAM CABLE GLANS ARE CONNECTED GLENDLER BAGLI BUSHINGS ARE CONNECTED BUSHINGLER BAGLI COV
8. ER KAPAK SHELL GOVDE 2 2 7 3 ELECTRIC BOX DIMENSIONS PANO STEN LEN L DE CONTACTOR CONTROL KONTAKTOR UYGUN 3 CABLES ARE PREWIRED KABLOLAR TAKILI LIGHTS ON WHEN ENERGIZED ENERJI VER LD NDE I IKLAR YANIYOR POWER CHECK ON CLAMP 1 KLEMENS 1 ENERJ L WHEN ENERGIZED POWER IS ON CLAMP 2 ENERJI VER LD NDE 2 NOLU KLEMENSE ENERJ GEL YOR CONTACTOR IS ENERGIZED WHEN CLAMP 1 AND 2 IS CONNECTED 1 VE 2 NOLU KLEMENS K PR LEND NDE KONTAKT R EK YOR z HEATER LIGHT IS ON WHEN CONTACTOR IS ENERGIZED KONTAKTOR EK LD NDE ISITICI LAMBASI YANIYOR ELECTRICAL CONNECTION m 5 FAILURE LIGHT IS ON WHEN CLAMP 3 IS ENERGIZED 3 NOLU KLEMENSE ENERJI VERILDIGINDE ARIZA LAMBASI YANIYOR glir ie ki Functional test made by according to EN 60079 1 5 1 and 5 2 EN 60079 0 Item 29 2 CONTROLLED BY APPROVAL PROCESS CONTROLLED BY QUALITY MANAGER 14 F2 01 15 08 03 07 Rev No 00
9. ars in normal vveather conditions VERY IMPORTANT NOTICE In cold weather at weekends and on holidays the multivalve should be closed and the remaining gas should be used or discharged otherwise the gas will become liquid due to the cold weather The vaporizer should be switched on 30 45 minutes before working hours Appendix A Telephone and Internet Assistance If you have any questions regarding this manual or the installation of your vaporizer you may call our technically trained customer service department at 90 216 473 54 04 Our normal office hours are from 8 30 A M to 6 00 P M EST Monday thru Friday Please be prepared to give us the model number and the serial number of your vaporizer when you call You can also submit your question or request for support via e mail The address for this is info nebimak com tr Our website at http www nebimak com contains an updated version of this manual Go to http www nebimak com brochures htm to view and or download the latest version Appendix B Trouble Shooting and Maintanence eThe vaporizers just like any other LP gas equipment should be maintained periodically The conditions in your area and quality of the LP gas liquid may dictate a more stringent maintenance but whatever your schedule remember that maintenance is of paramount importance for trouble free operation of the vaporizer FLAMMABLE 4 GAS EN V VERY IMPORTANT NOTICE e LPG Feed Back Vaporize
10. eck status of all other valves e Inspect all connections to ensure any necessary protective caps plugs are in place 5 Your Vaporizer This chapter describes the function features and specific components of your Vaporizer 5 1 Function of the Feed back Vaporizer The function of all models of the Feed Back Vaporizer is to safely and efficiently take liquid LPG from a container heat it until it reaches a gaseous state and then send it back to the container 5 2 Features of the Feed Back Vaporizer All models of the Feed Back Vaporizer are designed to operate in any climate provide years of service and require minimum maintenance The vaporizer model numbers are NBH 20 NBH 30 and NBH 50 The model number for NBH series the first 2 digits of the model number indicate the kilograms per hour LPG vaporization capacity for each unit All vaporizers are designed and manufactured under the strict quality control procedures set forth by the ATEX Directive 94 9 EC 5 The follovving features are standard on all units Rego 22 setted at 17 2 Bar safety relief valve Rego vent valve to check if there is enough LPG on inlet line and for the removal of accumulations heavy ends Ball valve equipped with a manometer filled with glycerine for easy read out and uninstallation Electric board already connected to vaporizer with 20 meter cables Security and control thermostats already connected and setted 5 3 C
11. fittings and connections for gas leaks Any leakage must be corrected before proceeding any further FLAMMABLE q GAS N VERY IMPORTANT NOTICE LPG Feed Back Vaporizer must be pressurized by means of inert nitrogen etc gas for ventilation before START UP eDo not connect this vaporizer to a storage tank that has been used in vapor withdrawal service until the tank has been emptied and all sediment and heavy ends have been cleaned from it eClean all foreign material from all pipes prior to making final connections Open the liquid inlet valve and gas outlet valve slowly Turn On the power from electric board located inside the room at plant When you see green light it means your vaporizer is heated and gasesous phase is transferring back to the tank Control Settings for On Going Operation Open the valve located under the tank This valve allows the liquid LPG to flow through the pipe line to the feed back vaporizer This valve should stay open all the time to avoid the failure light alerting the user when the power is turned on In this case the failure light can be turned off by pressing the reset button The ball valve located on the pipe line from the top of the vaporizer to the tank should stay open The liquid level of the tank should controlled The order to the gas company should given before the liquid level reaches 2096 The tank should not filled over the 8096 liquid level Over filling can cause seri
12. installation and use of this feed back vaporizer 4 VERY IMPORTANT NOTICE This service manual and all other associated documents should be kept during the use of the vaporizer In addition all other materials supplemented during the use should also be kept Preserve this Service Manual and other documents for users in future 4 NOTICE Shall not be liable for any damages or loss due to improper use of this Service Manual In this service manual it is described how to operate the vaporizer properly NBHXX series shall also be not liable for damages to persons and material due to failure in adherence to safety regulations contained in this manual The safety regulations contained herein are to be considered as a supplement of national regulations instead of replacement and therefore should be within the knowledge of personnel that is servicing the vaporizer Before you start to unpack install or use the feed back vaporizer Please read through the whole Service Manual The vaporizer is only to be serviced by personnel furnished with requisite authorisation according to national regulations 4 NOTICE Any repairs and modifications in design are subject to the manufacturer s explicit consent Only parts approved by the manufacturer may be used To prevent electric shock or fire any operation inside the vaporizer shall not be carried out before switching off power supply by the main power switch that is placed in
13. omponents of the Feed Back Lpg Vaporizer The following diagram represents view of a Feed Back Vaporizer This diagram includes all major component designations Please note that this is a concept drawing only not a representation of the actual design 6 Installation Certain procedures should be followed during installation This chapter provides you with the step by step instructions necessary for effective and safe installation Before proceeding with the installation please read the Summary ATEX 94 9 EC Directive 6 6 1 Unpack and Anchor Unit Remove vaporizer from shipping container and take out the packing A IMPORTANT Never use the safety relief valve pipe as a handle to move the vaporizer etc Place the vaporizer on a level concrete platform The vaporizer base has a hole in each corner through which anchoring bolts may be affixed You can check anchoring bolts fixing from typical installation drawing 6 2 Install the Inlet Piping Install a special nozzle to the liquid outlet of the LPG tank equipped with a liquid valve OMECA RL 25 REGO 9300 or equivalent and weld it to the piped according to the directive Install a Y i e pipeline strainer advised NOTE In new pipe installations the strainer should be removed and cleaned after approximately the first hour of operation This is necessary to remove residue and other materials which may accumulate as a result of the new installation
14. ous damage to the customers system All pipelines should be periodically controlled to prevent gas leaking The yellow light on the electric box means that the energy is on and should stay lighted when the energy is given There are two thermostats on the system one is for working the other for security The energy is activated by pressing the on off button In this case the contactor in the electric box will activated the heaters in the vaporizer will begin to heat and the green light will flash on the electric box The green light is connected to the working thermostat in the vaporizer and will flash until the temperature reaches the preset value determined and set by user The green light will turn on and off automatically while the system is on The flashing light indicates the heaters in the vaporizer are working When the green light is off it means that the vaporizer is heated to the preset temperature The red light is connected to the safety thermostat in the vaporizer and it is activated in the case of a failure in the system It should not normally be alight when the system is on The pressure in the outlet of the first stage regulator should be set by the user After allowing the gas through to the suction line any remaining air should be discharged 10 The pressure in the tank can be read from the manometer located on the multivalve The pressure should read max 4 6 bars in hot vveather and 2 2 5 b
15. r must be pressurized by means of inert nitrogen etc gas for ventilation before START UP after maintenance for safe operation The equipment described in this manual is designed to operate with LP gas a flammable fuel under pressure The nature of the application involves inherent hazards that could result in injury ONLY a trained and fully qualified person should service this equipment 1 MECHANICAL FAILURE 1 1 There is not enough gas phase for the suction units 1 1 1 The capacity of the goods are bigger than the capacity of the energy which is produced by the vaporizer system The system should be extended to be able to handle the capacity of the suction equipment 1 1 2 excess flow valve in the multivalve is damaged or blocked 1 1 3 There is a heater failure in the vaporizer 11 1 2 1 2 1 1 2 2 1 3 1 3 1 1 3 2 1 3 3 1 3 4 1 3 5 1 3 6 1 4 1 4 1 1 5 1 5 1 1 5 2 The system stops suddenly when suction begins Excess flow valve is blocked or damaged Excess flow valve is shut off due to high suction The suction equipment flame is poor and or yellow The adjustment of the regulator is set too high The mambrane of the regulator is damaged The tank is overfilled Gas remained in the suction line in cold weather The radius of the suction line is incorrect There is liqualization in the suction line The outside shell of the vaporizer is too hot and the gas line which goes to the tank
16. re each becomes a liquid At atmospheric pressure at normal ambient temperatures each is a gas LP Gas is typically stored and distributed in its liquid state in pressurized containers When LP Gas is released from the pressurized container it quickly changes from a liquid to a gas However even in its gaseous state always remember that it is heavier than air If the gas is released in small quantities it will generally mix with the air and harmlessly scatter Released in greater quantities the gas may spread over an area in flammable concentrations You must be careful because a spark or other ignition source can cause a fire or explosion in either case LP Gas is highly flammable and can be extremely dangerous if not handled properly Although colorless and odorless an additive is usually combined with the gas to give it an odor so that leakage can be detected LP Gas is also non toxic however large concentrations can cause oxygen deficiency As a result inhalation can result in asphyxiation The mixture of LP Gas and air make a potentially explosive combination A mixture of LP Gas and air is explosive when as little as 2 1596 and not more than 1096 of the mixture is LP Gas When LP Gas changes from a liquid to a gas it expands its volume by approximately 272 times Precautions You should observe the following general precautions whenever you are working with LP Gas DO NOT SMOKE when you are near storage tanks transport trucks
17. the room for the service personnel of the plant In cases when a failure is encountered immediately switch off the vaporizer and the main power switch that is placed in a room on the plant Contact the manufacturer s Service Department Taking the vaporizer in service shall be conducted by the manufacturer s service or any other authorized service only Any failure in adherence to these requirements entails the loss of warranty for the purchased product In cases when irregular operation of the vaporizer is encountered immediately contact the manufacturer The vaporizer may be installed in explosive areas zone 1 2 defined in EN 60079 10 standard 2 DENOTATION THE FEED BACK VAPORIZER Method of denoting the vaporizer NEB MAK Brut Volume Capacity Povver Design Max of enclosure Brut Volume of enclosure Kg h Kw h Voltage Pressure Pressure Lpg Output Temperature partA part B 1100 cm3 2700 cm3 wo 20 aoovac m o z nn wo 30 ss aoovac pwao 17 268 1100 2700 cmi wax so 75 400V AC PN 40 17 2 BAR 1100 cm3 2700 cm3 NBH XX SERIES Capacity 20 30 50 Kg h 3 LP Gas Precautions This chapter provides general information about LP Gas discusses certain precautions you should take during installation of Nebimak feed back LPG vaporizers installation LP Gas LPG Propane propylene butane and butylene all fall under the general term LPGas Under pressu
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