• TABLE OF CONTENTS
• INTRODUCTION
  Basic Features
  Working of Vaporizer
  Components of Water bath vaporizer
• Technical Specifications
• OPERATION
  Initializing the vaporizer
  Shutting Down the System
• OPTIONAL ACCESSORIES
  Pressure Switch
  Solenoid Valve for Automatic water filling
• PERIODIC MAINTENANCE
  Checkup’s
  Leakage test Positions
• TROUBLESHOOTING
  Heating issues
  Gas flow issues
• DO’S & DON’TS
  Do’s
  Don’ts
• EMERGENCY PREPAREDNESS
  Action to be taken when leakage is from cylinder
  Action to be taken when leakage is from manifold/ Pipeline
  Action to be taken during power supply failure
• CRITICAL SPARE PARTS
• FREQUENTLY ASKED QUESTION
• APPENDIX
  ELECTRICAL SPECIFICATIONS TABLE

Introduction

The Vapo-Right WB is an advanced water bath vaporizer designed for efficient conversion of liquefied petroleum gas (LPG) or Propane into vapor. It employs a sophisticated heat exchange mechanism to facilitate vaporization when natural energy levels are insufficient. This technology allows for greater capacities from smaller LPG storage quantities, overcoming code restrictions on cylinder storage in limited spaces.The Vapo-Right WB operates by pulling gases from storage and subjecting them to heat exchange within the water bath, ensuring optimal vaporization efficiency. Its compact design and versatile supply options make it ideal for diverse installation scenarios. All Vapo-Right WB vaporizers are manufactured under rigorous quality standards, including ISO 9001, ISO 45001, and PESO approvals, guaranteeing reliability and performance.

Basic Features

The Vapo-Right WB features a coil-in-vessel heat exchanger with a high heat transfer coefficient, enabling efficient heat transfer and handling of varying pressures and temperatures. Specific water quality requirements are essential to minimize operational issues, with water specifications reducing potential problems by approximately 80%. Compared to traditional shell and tube vaporizers, the coil-in-vessel model consumes less space and relies solely on electricity for heater coil operation.

Components of Vaporizer

• Inlet Ball valve is used to control the flow of LPG into the vaporizer. These ball valve also help to isolate the flow of LPG
• Y-strainer is a filtration device shaped like the letter “Y” and used in piping systems to remove solid particles from flowing fluids. It has a perforated or mesh screen inside a cylindrical body, trapping debris to protect downstream equipment
• Gas Solenoid Valve (NC type) is used to control gas flow in systems. It remains closed (no gas flow) by default and opens when electrical power is applied, allowing gas to pass through. This type is preferred for safety as it automatically shuts off gas in emergencies or power failures
• Heater Coil is a device used to generate heat typically by converting electrical energy into heat energy.
• RTD Sensor, short for Resistance Temperature Detector, is a precise temperature sensor used in various industries. It features a sensing element, often made of platinum, with a known resistance-temperature relationship. As temperature changes, the sensor’s resistance changes in a predictable and linear manner
• Water level sensor is a device used to measure the level of water. It typically includes a probe or sensor element that detects water presence. These sensors are crucial for monitoring water levels ensuring efficient water management and equipment operation
• Safety relief valve (Pop-Action type) is a critical safety device designed to prevent overpressure situations. It automatically opens at a predetermined pressure level to release excess pressure from the system, ensuring safe operation and preventing equipment damage or hazards
• Spiral coils of SS 304 grade stainless steel are durable and corrosion-resistant components.Their spiral design maximizes surface area for efficient heat transfer or fluid flow.
• Outlet Ball valve is used to control the flow of LPG out of the vaporizer.
• Air vent/ breather is located at the top of the vaporizer for breathing action
• Drain Valve is a mechanical device used to remove liquids, gases, or other substances from a system

Optional Accessories:

• Water Solenoid valve (NC type) is used to control water flow in systems. It remains closed (no water flow) by default and opens when electrical power is applied, allowing water to pass through
• Pressure Switch is an electrical device that monitors fluid pressure in a system and activates or deactivates electrical circuits based on preset pressure thresholds.

Working of Vaporizer
The vaporizer initiates operation by checking the water level
A water level sensor ensures that the water level is sufficient for proper functioning
If the water level is below the required mark, a signal is sent to the water solenoid valve to open and maintain the water level( In absence of water solenoid valve manual filling of water will be done)
Once the water level reaches the desired level, the solenoid valve closes
The vaporizer inlet is equipped with a y-strainer to filter contaminations from the liquid LPG, ensuring clean and efficient operation
With the water level stabilized, the heater is activated to start heating the water in the vaporizer
When the water temperature reaches approximately 60 degrees Celsius, the gas inlet solenoid valve opens
Due to the temperature difference, gas flows into the coils within the vaporizer for vaporization
A pressure switch monitors the output pressure
If the output pressure exceeds safe limits, the pressure switch sends feedback to the control panel
Upon receiving feedback from the pressure switch indicating high output pressure, the control panel activates to turn off the gas solenoid valve
This action cuts off the gas supply at the inlet, ensuring safety and preventing overpressure situations
An RTD sensor actively monitors the temperature of the water throughout the process
If the water temperature reaches 80 degrees Celsius, the heater is automatically turned off to prevent overheating
Conversely, when the temperature drops below 75 degrees Celsius, the RTD sensor signals the controller to switch on the heater coils again
The vaporizer is equipped with inlet and outlet ball valves for isolation whenever necessary, allowing for maintenance or troubleshooting without interrupting the entire system
The system operates smoothly when all ball valves are in the open position, allowing for the proper flow of water and gas
A vent pipe located at the top of the vaporizer facilitates air breathing action, ensuring adequate ventilation during operation

Operations

ACTIVATING THE VAPORIZER

1. Switch on using the selector switch the control panel.
2. Make sure that water level indication (blue) is not lit.
3. Make sure the heater indication (Red) is lit.
4. If the heater indication is not on then check the temperature in the indication is above the set level.
5. Make sure the set temperature is at least 60 Deg C.
6. Make sure liquid LPG is flowing through the line up to the vaporiser inlet.
7. Now open the inlet and outlet valve of the vaporiser.
8. Ensure that the temperature is rising by observing the temperature display.
9. Please observe for any abnormal sounds, leaks, or malfunctions.

SHUTTING DOWN THE SYSTEM

1. Shut off the LPG supply from the storage point (cylinders/manifolds/tanks)
2. Empty the LPG in the pipeline by firing the burner till it trips.
3. Now slowly close the inlet and outlet ball valve of the vaporiser.
4. Shut down the vaporizer by turning the knob to ‘off’ position.

PERIODIC MAINTENANCE                      

CHECKUP’S

1. The area where the vaporizer is used should be free of any uncontrolled weed growth and accumulation of waste products.
2. Clean the Y-strainers installed in the line at least once a month.
3. All the jumpers need to checked for damages once a month and resistance needs to checked once in every six months
4. All the safety valves should be calibrated once a year.
5. All the other valves should be checked once a year for full range of movement, positive shut off, mechanical damage, etc
6. Visual check should be done for corrosion or any physical damages to the vaporiser body.
7. Filters need to be changed once in a year.