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Equipment Manual

CRYO 102 & 204 Freeze Kits

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IMPORTANT : For your own safety, before assembling and operation of the Cryolator Pipe Freeze Kits, read the Equipment Manual completely.

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102 & 204 Pipe Freeze Kits

Table of Contents

Terms and Conditions. . . . . . . . . . . . . . . . . . . . . . . 1.0

Liquid Nitrogen Information. . . . . . . . . . . . . . . . . . . 3.0 Installation Details. . . . . . . . . . . . . . . . . . . . . . . . . 4.0 Freeze Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 Additional Service Brochures. . . . . . . . . . . . . . . . . . 6.0

This equipment manual guide is for information only and is based on general pipe freeze practices. CRYOLATOR PIPE FREEZE PRODUCTS warrants only the components of this pipe freeze kit and is not responsible for any damages due to the use of this pipe freeze equipment. Please see our Terms & Conditions section 1.0.

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Please call toll free (866) 452-0448 for any technical support questions. You may also submit questions via email info@cryolator.com.

CRYOLATOR EQUIPMENT MANUAL 2010

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COPYRIGHT 2010

General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 2.0

102 & 204 Pipe Freeze Kits


Offer, Governing Provisions This writing constitutes an offer or counter-offer by M.T. Ingram & Company, Inc. (Seller) to sell the products described herein in accordance with these terms and conditions, is not an acceptance of any offer made by buyer, and is expressly conditioned upon assent to these terms and conditions. Seller objects to any additional or different terms contained in any purchase order or other communication previously or hereafter provided by buyer to Seller. No additional or different terms or conditions will be binding upon Seller unless specifically agreed to in writing. Prices and Payment All prices are subject to change without notice. Seller will in good faith honor all written equipment quotes and estimates for a period of 30 days. Payment is due in advance upon buyers receipt of Sellers invoice and before Seller will ship order. Seller accepts Master Card or Visa credit cards, certified checks and electronic wire transfer. In some cases Seller will extend 30 day net payment terms. Buyer must be a US Corporation / Company and complete the Sellers credit application and agree to sellers written credit terms. Interest will be charged at the rate of 18% per year (but not more than the highest rate permitted by applicable law) on accounts more than 30 days past due. Taxes, Duty and Other Charges Any manufacturers tax, occupation tax, use tax, sales tax, excise tax, value added tax, duty, custom, inspection or testing fee, or any other tax, fee, interest or charge of any nature whatsoever imposed by any governmental authority, on or measured by the transaction between Seller and buyer (collectively, taxes and other charges) shall be paid by buyer in addition to the prices quoted or invoiced. In the event Seller is required to pay any such taxes and other charges, buyer shall reimburse Seller therefore. Delivery, Claims and Force Majeure Delivery of products to a carrier at Sellers plant or other loading point shall constitute delivery to buyer. Order shipments initiated by the Seller will be insured for the invoiced order amount at the expense of the buyer. Buyer has the option to coordinate their own shipping arrangements and buyer shall bear all risk of loss or damage in transit. Seller reserves the right to make delivery in installments, unless otherwise expressly stipulated herein; all such installments to be separately invoiced and paid for when due per invoice, without regard to subsequent deliveries. Delay in delivery of any installment shall not relieve buyer of its obligations to accept remaining deliveries. Claims for shortages or other errors in delivery must be made in writing to Seller within 10 days after receipt of shipment and failure to give such notice shall constitute unqualified acceptance and a waiver of all such claims by buyer. Claims for loss or damage to goods in transit should be made to the carrier and not to Seller. All delivery dates are approxi-

Terms & Conditions


mate. Seller shall not be liable for any damage as a result of any delay or failure to deliver due to any cause beyond Sellers reasonable control, including, without limitation, any act of God, act of buyer, embargo or other governmental act, regulation or request, fire, accident, strike, slowdown, war, riot, delay in transportation, or inability to obtain necessary labor, materials or manufacturing facilities. In the event of any such delay the date of delivery shall be extended for a period equal to the time lost because of the delay. Buyers exclusive remedy for other delays and for Sellers inability to deliver for any reason shall be rescission of this agreement. Changes Seller may at any time make such changes in design and construction of products as Seller deems appropriate, without notice to buyer. Seller may furnish suitable substitutes for materials unobtainable because of priorities or regulations established by governmental authority or non-availability of materials from suppliers. Warranties M.T. Ingram & Company, Inc. warrants to the original end-user of this CRYO Pipe Freeze Kit product: (1) Each CRYO Pipe Freeze Chamber Housing is covered against any workmanship / material defects found in the course of normal product operations for a (60) month period after the date of purchase. (2) All other hardware components (feed hoses, fittings & fasteners) are covered against any workmanship / material defects found in the course of normal product operations for a (24) month period after the date of purchase. If any covered defect is discovered during the warranty period, M.T. Ingram & Company, Inc. will repair or (at its option) replace the affected parts. Such repair or replacement shall be the sole liability of M.T. Ingram & Company, Inc., and the sole remedy of the purchaser, in connection with a defect in this product. All shipping and handling charges associated with any such warranty repair or replacement shall be paid by the Seller and the Seller maintains at its option of the mode of shipment. If during the warranty period, it appears that this product contains a defect covered by this warranty, contact the dealer from which you purchased the product. This warranty does not cover product failure attributable to anything other than a defect in materials and workmanship, including but not limited to product failure caused by improper operation or care, improper installation, abuse, misuse, alteration, accident, or damage from improper shipping or servicing. Ordinary wear and tear shall not be deemed a defect in materials or workmanship. No employee, agent, dealer or distributor is authorized to extend or expand the coverage of this warranty. THIS WARRANTY IS PROVIDED IN LIEU OF ALL OTHER EXPRESS OR IMPLIED WARRANTIES. EXCEPT FOR THE WARRANTY PROVIDED ABOVE, M.T. INGRAM & COMPANY, INC. SPECIFICALLY DISCLAIMS ANY AND ALL OTHER EXPRESS WARRANTIES WITH RESPECT TO THIS PRODUCT, AND ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

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Terms & Conditions | 1.0

102 & 204 Pipe Freeze Kits


Patents, Trademarks and Copyrights Seller will, at its own expense, defend any suits that may be instituted by anyone against buyer for alleged infringement of any United States patent, trademark or copyright relating to any products manufactured and furnished by Seller hereunder, provided buyer shall have made all payments then due hereunder and shall give Seller immediate notice in writing of any such suit and transmit to Seller immediately upon receipt all processes and papers served upon buyer and permit Seller through its counsel, either in the name of buyer or in the name of Seller, to defend the same and give all needed information, assistance and authority to enable Seller to do so. Notwithstanding the foregoing, Seller shall not be responsible for any compromise or settlement made without its written consent. The foregoing states the entire liability of Seller for infringement, and in no event shall Seller be liable for consequential damages attributable to an infringement. As to any products Seller furnishes to buyer manufactured in accordance with drawings, designs or specifications proposed or furnished by buyer, Seller shall not be liable, and buyer shall indemnify Seller and hold Seller harmless from and against any and all loss, liability, damage, claim and expense (including but not limited to Sellers reasonable attorneys fees and other costs of defense) incurred by Seller as a result of any claim of patent, trademark, copyright or trade secret infringement, or infringement or any other proprietary rights of third parties.

Terms & Conditions


Technical Information Any sketches, models or samples submitted by Seller shall remain the property of Seller, and shall be treated as confidential information unless Seller has in writing indicated a contrary intent. No use or disclosure of such sketches, models and samples, or any design or production techniques revealed thereby, shall be made without the express written consent of Seller.

Consequential Damages and Other Liability; Indemnity Except as otherwise agreed in writing, Sellers liability with respect to the products sold hereunder shall be limited to the warranty provided in section 6.0 hereof, and, with respect to other performance of any contract with buyer, shall be limited to the contract price. SELLER SHALL NOT BE SUBJECT TO ANY OTHER OBLIGATIONS OR LIABILITIES, WHETHER ARISING OUT OF BREACH OF CONTRACT, WARRANTY, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES OF LAW, WITH RESPECT TO PRODUCTS SOLD OR SERVICES RENDERED BY SELLER, OR ANY UNDERTAKINGS, ACTS OR OMISSIONS RELATING THERETO. Without limiting the generality of the foregoing, Seller specifically disclaims any liability for property damages, penalties, special or punitive damages, damages for lost profits or revenues, cost of capital, cost of substitute products, or for any other types of economic loss, or for claims of buyers customers or any third party for any such damages. SELLER SHALL NOT BE LIABLE FOR AND DISCLAIMS ALL CONSEQUENTIAL, INCIDENTAL AND CONTINGENT DAMAGES WHATSOEVER. Buyer shall indemnify Seller against any and all losses, liabilities, damages and expenses (including, without limitation, attorneys fees and other costs of defending any action) which Seller may incur as a result of any claim by buyer or others arising out of or in connection with the products and/or services sold hereunder and based on product or service defects not proven to have been caused solely by Sellers negligence.

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Returned Goods Policy A Returned Goods Authorization (RGA) number must be assigned by a M.T. Ingram & Company, Inc. Representative prior to returning any merchandise. Returned merchandise will be inspected upon receipt. If the merchandise is found to be of acceptable condition, a credit will be issued less a 15% restocking charge. NO CASH REFUNDS WILL BE GIVEN. The customer is responsible for all freight charges (collect shipments will not be accepted). Governing Provisions THESE TERMS AND CONDITIONS SHALL CONSTITUTE THE ENTIRE AGREEMENT BETWEEN SELLER AND BUYER, AND SHALL BE GOVERNED BY AND SHALL BE CONSTRUED ACCORDING TO THE LAWS OF NORTH CAROLINA AND THE U.S. (WITHOUT REFERENCE TO PRINCIPLES OF CONFLICTS OF LAWS). THERE ARE NO CONDITIONS AFFECTING THIS AGREEMENT WHICH ARE NOT EXPRESSED HEREIN. THE RIGHTS AND OBLIGATIONS OF THE PARTIES HEREUNDER SHALL NOT BE GOVERNED BY THE 1980 U.N. CONVENTION ON CONTRACTS FOR THE INTERNATIONAL SALE OF GOODS. Relationship There is no relationship of partnership, joint venture, employment, franchise, or agency between the parties, and (Customer) or (Buyer) is not authorized to act or attempt to act, or represent himself or herself, directly or by implication, as an agent of the (Company) (Seller) or in any manner assume or create or attempt to assume or create any obligation or responsibility, express or implied, on behalf of, or in the name of, the (Company) (Seller) or to bind the (Company) (Seller) in any manner. (Customer) (Buyer) acknowledges that CryoLator executes all agreements with its clients as an independent contract and that CryoLator is not an employee of its clients. Terms & Conditions | 1.1

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Brochures Any and all brochures, manuals, warnings or the like concerning the products supplied hereunder are supplied as an aid to buyer and are not represented to be accurate, complete or sufficient. Buyer will indemnify and hold harmless Seller against all liabilities and expenses (including attorneys fees) arising out of the use of the products by buyer or a third party in any case where buyer fails to make available adequate warnings and instructions concerning the proper and normal use of the products.

102 & 204 Pipe Freeze Kits


General Design Criteria CRYO Pipe Freeze Kits are recommended for use on fluids such as water, water solutions with simple anti-corrosion and/ or anti-bacterial treatments with system pressures no greater than 300 psi and temperatures less than 110F. CRYO Pipe Freeze applications on fluids other than water and/or with pressures greater than 300 psi and temperatures greater than 110F should never be attempted by an inexperienced person. Please consult our technical support for alternatives. Nominal Pipe Sizes & Types Both CRYO 102 & 204 Pipe Freeze Kits are recommended for use on most all nominal pipe size ranges from 1/2 through 4.0. The CRYO 102 Pipe Freeze Kit is specifically designed for nominal pipe size ranges from 1/2 through 2.0 as well as 2-1/2 copper pipes. The CRYO 102 Pipe Freeze Kit is specifically designed for nominal pipe size ranges from 2-1/2 through 4.0. Both kits are intended for use with most all type of pipe material in the 1/2 through 4.0 size range. It is recommended that the applicator consult with the each pipe manufacturer for information regarding the effects pipe freeze applications to each individual pipe material. Pre-Job Safety Meeting Every CRYO Pipe Freeze application should be preceded by a pre-job project / safety meeting. It is important to plan out all aspects of the project between the pipe freeze applicator and the project foreman.

General Guidelines of Freeze Plug Applications


During pipe examinations pay close attention to the bottom area of the pipe since corrosion is often found on pipes which have been insulated or buried. Some scaling or light rust may be acceptable but be careful to avoid severe pitted or corrosive areas of piping. In rare instances pipe walls have been known to have serious defects within the internal wall material. If there is any reason to suspect that a potential freeze plug location might hide such defects, the customer should conduct an NDT inspection or other applicable testing method to assure that the pipe wall is sound. It is NOT recommended to perform a freeze plug procedure on pipes which have a wall thickness less than manufacturers listed design. Chamber Placement: Recommended Recommended placement of the CRYO Pipe Freeze Chamber should be on a clear and unobstructed length of piping no closer than 1-1/2 x the CRYO Pipe Freeze Chamber Length from any pipe obstructions such as pipe welds or fittings. The CRYO Pipe Freeze Chamber should NEVER be placed directly on top of welds, pipe fittings or joints of any kind. (ie: CRYO 102 Pipe Freeze Chamber is 5 long therefore 1-1/2 x 5 = 7-1/2) (Fig. 2). Chamber Placement: Dead Head Obstructions In regions that are prone to very cold winter months you may find domestic piping systems that experience damage when exposed to extreme cold temperatures. This type of pipe damage is usually caused directly from the hydraulic forces created by an unintentionally formed freeze plug as it expands internally against a dead headed restriction such as a closed valve. This uncontrolled lateral freeze plug growth up against a dead headed obstruction may over pressure the piping fluid to a point where it could possibly damage the pipe. It is recommended that CRYO Pipe Freeze Chambers NOT be placed any closer than 15 x the Pipe OD of any closed valves, blind

Recommended Area of Pipe Inspection

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General Pipe Conditions & Examinations When selecting the section of piping for the freeze plug area it should be thoroughly examined for possible defects. CRYO Pipe Freeze Kits should only be used on sections of piping which are in good to excellent condition. Examinations should be done on a minimum length of pipe of 3 x the CRYO Pipe Freeze Chamber Length and the chamber should be placed in the center of the examined area (Fig. 1).

Multiply CRYO Chamber Length By Three

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Fig. 2

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From Welds & Pipe Fittings 7-1/2

Recommended Chamber Placement


7-1/2

This illustration shows a CRYO-102 chamber which is 5 long. (3 x chamber length = 15)

This illustration shows a CRYO-102 chamber which is 5 long. (1-1/2 x chamber length = 7-1/2)

Fig. 1

General Guidelines | 2.0

102 & 204 Pipe Freeze Kits

General Guidelines of Freeze Plug Applications


flanges, pipe caps or any type of dead headed obstruction. (ie: Pipe OD of 1-3/8 x 15 = 20-5/8) (Fig. 3). However, if there is no other available option on the piping system within the recommended placement distance of 15 x the Pipe OD the applicator may utilize a pressure control apparatus such as a hot tap saddle / nozzle equipped with a valve. Most any pressure control point on the piping system should allow any pressure buildup to be relived in a controlled manner (Fig. 4). Chamber Placement: Flowing Headers / Branch Pipes CRYO Pipe Freeze Chambers should not be placed closer than 15 x the Pipe OD from any active flowing pipe. Performing CRYO Pipe Freeze applications closer than the recommended distance may result in the failure of the CRYO freeze plug to establish. This is due to the fluid movement in the mouth of the branch pipe created from flow turbulence generated by the flowing pipe. This placement distance from flowing headers is only a recommendation and may vary with each application (Fig. 5). Heat Convection Heat Convection flow currents are created inside pipes with a constant source of heat. Heat Convection flow currents are most always associated with vertical freeze plug applications. However, when there is a constant source of heat available to a horizontal pipe application it can play a critical factor in the freeze plug formation. The heated fluid within the horizontal pipe literally rises to the high point and is drawn into the cooling formation of a developing freeze plug, cools down and then falls to the low point of the pipe. This hot / cold reaction creates a convective flow resulting in a constant heat transfer that will prevent or greatly slow the freeze plug formation (Figs. 6 & 6.1).

Effects of Dead Head Pressure


MP MP

LP

HP

LP

HP

pipe length w/more than 15 Pipe ODs

pipe length w/less than 15 Pipe ODs

CRYO Plug Outward Expansion

Closed Valve

Fig. 3

Loosen Flange Joint

Vent Valve

Pressure Buildup

Hot Tap Saddle & Valve

When installing a CRYO Pipe Freeze Chamber on a dead headed section of pipe having less than the recommended length, certain steps can be taken to eliminate the potential of pressure damage. A pressure control point can be utilized by using an existing vent valve, periodically loosening a flange, stroking a downstream block valve or installing a hot tap saddle all of which will allow a controlled means to relieve the increased pressure created from the expanding CRYO Freeze Plug. These orifices may also make good controlled drain down ports as well as re-refill ports upon completion.

Fig. 4

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Plug Expansion
Stroke Block Valve
Main Header
Flow Direction Flow Direction Flow Direction

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Loosen Flange Joint

Pressure Relief Points

Branch Pipe Turbulence

Branch Pipe

Closed Valve

Fig. 6

Fig. 5

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Fig. 6.1

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Heat Convection

Hydraulic Pressure Buildup

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102 & 204 Pipe Freeze Kits

General Guidelines of Freeze Plug Applications


Typical Flow Effects

Fig. 8

Fig. 7

Fig. 7.1

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Chamber Placement: Torch / Flame Cuts or Field Welds A recommended distance for torch cuts and field welds from freeze plugs should be no less than 3 x the CRYO Pipe Freeze Chamber Length (Fig. 7). In some applications the distance can be reduced (Fig: 7.1). However, close attention should be given to the freeze plug and both the frost bands and temperature readings should always be monitored during the repair process.

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Chamber Placement: Pipe Orientation CRYO Pipe Freeze Chambers can be installed on pipes in either a horizontal or vertical position. However the preferred recommended installation position favors a horizontal section of piping due to the possible effects of heat convection found in vertical pipe applications. This is especially true when the fluid temperature is in the higher ranges. Flow Freeze plug applications require that ZERO FLOW be obtained in the system prior to the start of the freeze plug application. Attempting to achieve a workable freeze plug with any amount of flow is extremely difficult and/or impossible (Fig. 8). Impact or Strain Generating Work Activities When repair work is initiated in close proximity of the freeze plug location it is recommended that the planned work on the piping system not produce impact or strains such as bending or twisting action to the pipe. When possible the freeze plug application should be located a safe distance from the work area and well supported. Never place excessive weight on a freeze plug area. Always support the pipe. Project Preparation As much maintenance or pipe repair work should be completed prior to starting any pipe freeze project. This may include such steps as exercising old flange bolts, pre-assembly of pipe components and having all necessary items staged. Each pipe freeze application is different and the applicator should coordinate with the project foreman to complete any pre-project preparation. Work Area Safety Perimeter The applicator should erect a sufficient Safety Perimeter around all pipe freeze projects including the general work area, liquid nitrogen tanks and equipment. Only pertinent project personnel familiar with the project should be allowed access.

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General Guidelines | 2.2

102 & 204 Pipe Freeze Kits


PPE The applicator should consult the area safety manager for site specific PPE requirements. Also see General Liquid Nitrogen Safety for additional recommended PPE requirements. Liquid Nitrogen Supply Recommended liquid nitrogen tanks used in both CRYO 102 and 204 pipe freeze applications should be LN-160 or LN180 Low Pressure (22psi) Dewar Tanks. Please consult your local area Welding Supply Company for availability, pricing and pertinent safety information. Liquid Nitrogen Vapors: Job Site Ventilation Liquid Nitrogen Vapors are generated by most typical pipe freeze operations utilizing Liquid Nitrogen. Liquid Nitrogen Vapors are heavier than air and CAN displace the oxygen in the area if proper ventilation is not maintained. Area ventilation can be maintained using one or multiple fans to keep fresh air moving through the work area. The applicator should contact their Liquid Nitrogen supplier directly for a current MSDS and pertinent safety information. Also contact your safety manager and/or OSHA for recommended safety guidelines. Liquid Nitrogen Vapors: Below Ground Excavations Areas which may not be defined as a confined space area (e.g., very shallow ditches or immense excavations) may not require special ventilation. However general work practices caution that low areas or exceptionally still air areas could have hazardously reduced oxygen levels. It is recommended to use force air ventilation. Please consult with your safety department, oxygen monitor manufacturer, liquid nitrogen supplier and/or OSHA for specific safety details.

General Guidelines of Freeze Plug Applications

Fig. 9

Liquid Nitrogen Vapors: O2 Monitors It is HIGHLY recommended during all aspects of a pipe freeze plug applications that area worksite oxygen levels be monitored continuously by an OSHA approved oxygen monitor. According to OSHA guidelines the breathable air should never be less than 19.5%. Please consult with your safety department, oxygen monitor manufacturer, liquid nitrogen supplier and/or OSHA for more details. Halon, Smoke & Flame Detectors Be aware of halon and smoke detectors in the immediate area. Nitrogen vapors have similar characteristic as smoke and will activate these devices. Also be aware of fire/flame detectors and be careful not to upset them during the procedure. If necessary you may want to consult with the project site coordinator to de-activate these devices.

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Temperature Monitoring Equipment It is HIGHLY recommended to utilize temperature monitoring equipment on all freeze plug procedures. CRYOLATOR Pipe Freeze Products has developed a Freeze Plug Temp Monitoring Kit specifically for pipe freeze applications. (part # ACL-6001015-C). Please consult our sales staff for additional information (Fig. 9). Confirmation of Freeze Plug Once both the Frost Band and Temperature criteria have been meet it is time to check the integrity of the newly formed Freeze Seal Plug. Open a controlled means of drain on the drain down side of the Freeze Seal Plug. (i.e: controlled means may be a valve or other mechanical means which can be isolated as needed) (Fig. 10). SIGN OF GOOD PLUG: During the drain down process the Pipe End Thermocouples Temperature readings maintain temperature reading of no less than -35F and continue to drop as the fluid is drained. SIGN OF GOOD PLUG: During the drain down process the Frost Band growth distance continues to maintain and/or grow in length as the fluid is drained. Normal Frost Band growth is 1-1/2 to 2-1/2 in length out from the chamber end (Fig. 11). SIGN OF GOOD PLUG: During the drain down process the calculated fluid drain amount is completely emptied from the piping system. SIGN OF BAD PLUG: During the drain down process the Pipe End Thermocouples Temperature readings start to increase and continue to increase beyond the recorded drain down temperature start points. Immediately stop the drain down and DO NOT proceed. The plug is not solid or workable.

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General Guidelines | 2.3

102 & 204 Pipe Freeze Kits

General Guidelines of Freeze Plug Applications


SIGN OF BAD PLUG: During the drain down process the Frost Band growth distance starts to melt and shorten from the established start points inward to the chamber ends. Immediately stop the drain down and DO NOT proceed. The plug is not solid or workable (Fig. 12). SIGN OF BAD PLUG: During the drain down process the calculated fluid drain amount is exceeded and fluid continues to drain.

NOTE: If at any time during the drain down process (1) of the (3) BAD PLUG SIGN criteria is noted the drain down SHOULD BE STOPPED and the situation be evaluated by the applicator.
Fig. 10

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Equalization & Warm-Up Before a freeze plug is allowed to thaw it is highly recommended that the downstream piping section be refilled and if possible the pressure equalized to the upstream side. This practice may prevent possible system damage which may occur from the sudden release of a downstream freeze plug. System crossover piping or hose-jumped hot taps may be utilized to equalize the pressure across the freeze plug. Additional caution should be given to the possible pipe travel of a loosened/thawed plug once it has released from the internal pipe wall. A flowing freeze plug could damage downstream pipeline pumps and equipment. To accelerate the thawing process of a freeze plug the applicator may remove the CRYO Pipe Freeze Chamber and using a commercial heat gun to apply direct heat across the freeze plug to accelerate the thawing process. All flexible feed hoses and CRYO Pipe Freeze Chambers should be warmed above 0* F before being removed and flexed. Final Responsibility CRYOLATOR Pipe Freeze technical personnel may at times conduct preliminary telephone, email, off site project assessments and project evaluations for our clients. However the customer is responsible for all pipe inspections, potential freeze plug locations and any damage caused to their piping systems as a result of pipe freeze applications.

Fig. 11

Fig. 12

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NOTE: All (3) of the GOOD PLUG SIGN criteria should be met before proceeding.

General Guidelines | 2.4

102 & 204 Pipe Freeze Kits


General Liquid nitrogen is inert, colorless, odorless, non-corrosive, nonflammable, and extremely cold. Nitrogen makes up the major portion of the atmosphere (78.03% by volume, 75.5% by weight). Nitrogen is inert and will not support combustion; however, it is not life supporting. Nitrogen is inert except when heated to very high temperatures where it combines with some of the more active metals, such as lithium and magnesium, to form nitrides. It will also combine with oxygen to form oxides of nitrogen and, when combined with hydrogen in the presence of catalysts, will form ammonia. Health Effects Although nitrogen is nontoxic and inert, it can act as a simple asphyxiate by displacing the oxygen in air to levels below that required to support life. Inhalation of nitrogen in excessive amounts can cause dizziness, nausea, vomiting, loss of consciousness, and death. Death may result from errors in judgment, confusion, or loss of consciousness that prevents selfrescue. At low oxygen concentrations, unconsciousness and death may occur in seconds and without warning. Personnel, including rescue workers, should not enter areas where the oxygen concentration is below 19.5%, unless provided with a self-contained breathing apparatus or air-line respirator.

Liquid Nitrogen Information


Handling and Storage Store and use this product with adequate ventilation. Do not store in a confined space. Cryogenic containers are equipped with pressure relief devices to control internal pressure. Under normal conditions, these containers will periodically vent product. Do not plug, remove, or tamper with any pressure relief device. Never allow any unprotected part of the body to come in contact with uninsulated pipes or equipment that contains cryogenic product. The extremely cold metal will cause the flesh to stick fast and tear when one attempts to withdraw from it. Use a suitable hand truck for container movement. Containers should be handled and stored in an upright position. Do not drop, tip, or roll containers on their sides. Do not remove or interchange connections. Contact the vendor if you experience any difficulty operating the container valve or with the container connections. Discontinue use. Use the proper connection. Use piping and equipment designed to withstand the pressures to be encountered. On gas withdrawal systems, use a check valve or other protective apparatus in any line or piping from the container to prevent reverse flow. To prevent cryogenic liquids or cold gas from being trapped in piping between valves, the piping should be equipped with pressure relief devices. Only transfer lines designed for use with cryogenic liquids should be used. Some elastomers and metals may become brittle at low temperatures and will easily fracture. These materials must be avoided in cryogenic service. It is recommended that all vents be piped to the exterior of the building or to a well ventilated indoor space. NOTE: It is recommended Liquid Nitrogren feed pressure be limited to 22psi. This will prevent the CryoFoam Chamber Gaskets & Pipe Seals from experiencing an LN2 blowout failure.

Fig. 13

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Containers Fig. 13 shows a typical cryogenic liquid cylinder. Cryogenic liquid cylinders are insulated, vacuum-jacketed pressure vessels. They come equipped with safety relief valves and rupture discs to protect the cylinders from pressure build-up. These containers operate at pressures up to 350 psig and have capacities between 80 and 450 liters of liquid. Product may be withdrawn as a gas by passing liquid through an internal vaporizer or as a liquid under its own vapor pressure (Fig. 13).

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Liquid Nitrogen Information | 3.0

102 & 204 Pipe Freeze Kits


Personal Protective Equipment (PPE) One must be thoroughly familiar with the properties and safety considerations before handling a cryogenic liquid and its associated equipment. The eyes are the most sensitive body part to the extreme cold of the liquid and vapors of cryogenic liquids. The recommended personal protective equipment for handling cryogens includes a full face shield over safety glasses, loosefitting thermal insulated or leather gloves, long sleeve shirts, and trousers without cuffs. In addition, safety shoes are recommended for people involved in the handling of containers. Depending on the application, special clothing suitable for that application may be advisable.

Liquid Nitrogen Information


A special note on insulated gloves: Gloves should be loose-fitting so they are able to be quickly removed if cryogenic liquid is spilled on them. Insulated gloves are not made to permit the hands to be put into a cryogenic liquid. They will only provide short-term protection from accidental contact with the liquid. In emergency situations, self-contained breathing apparatus (SCBA) may be required. Material Safety Data Sheet Please contact your local gas supplier to request a copy of the Liquid Nitrogen MSDS.

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Cryo PPE Kit
Cryogenic Apron Cryogenic Gloves Also Recommended: Face Shield & Safety Glasses Protective Clothing Liquid Nitrogen Information | 3.1

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CRYO 102 & 204 Freeze Kit Installation Instructions

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102 & 204 Pipe Freeze Kits

Freeze Kit Packaging Information

CRYO 102S Pipe Freeze Kit


Kit includes the below listed items:

Single freeze plug applications on nominal pipe sizes of 1/2 thru 2.0. (1) CRYO 102 Chamber. . . . . . . . . . . . . . . . . . . . . . . . . Part # ACL-102-CHK (1) CRYO 102 Insert Kit . . . . . . . . . . . . . . . . . . . . . . . . Part # ACL-102-INK Includes: (1) 102 A Insert Set, (1) 102 B Insert Set, (1) 102 C Insert Set & (1) 102 D Insert Set (1) CRYO 102 LN2 Hose. . . . . . . . . . . . . . . . . . . . . . . . Part # ACL-102-LN2

(1) CRYO 102 Hardware Kit. . . . . . . . . . . . . . . . . . . . . . Part # ACL-102-HDK Includes: (1) 1/2 Brass Plug, (1) 1/2 Brass Nipple, (1) Straight Swivel Connector, (2) 90 Swivel Connectors, (1) T-Bolts with Nuts, (1) Bottle to Hose Adapter (ACL-LN2-BH) & (1) 1/8 Allen Key (1) CRYO 102 Single Case. . . . . . . . . . . . . . . . . . . . Part # ACL-102-CASE-S

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CRYO 102D Pipe Freeze Kit

Single or double freeze plug applications on nominal pipe sizes of 1/2 thru 2.0.

Kit includes the below listed items: (2) CRYO 102 Chamber. . . . . . . . . . . . . . . . . . . . . . . . . Part # ACL-102-CHK (2) CRYO 102 Insert Kits. . . . . . . . . . . . . . . . . . . . . . . . Part # ACL-102-INK Includes: (2) 102 A Insert Sets, (2) 102 B Insert Sets, (2) 102 C Insert Sets & (2) 102 D Insert Sets (2) CRYO 102 LN2 Hose. . . . . . . . . . . . . . . . . . . . . . . . Part # ACL-102-LN2 (2) CRYO 102 CryoFoam Kit . . . . . . . . . . . . . . . . . . Part # ACL-102-DS-CFK Includes: (2) Rolls CryoFoam Tape & (18) Sets Chamber Gaskets (2) CRYO 102 Hardware Kit. . . . . . . . . . . . . . . . . . . . . . Part # ACL-102-HDK Includes: (2) 1/2 Brass Plugs, (2) 1/2 Brass Nipples, (2) Straight Swivel Connectors, (2) 90 Swivel Connectors, (2) T-Bolts with Nuts, (2) Bottle to Hose Adapters (Part # ACL-LN2-BH) & (2) 1/8 Allen Keys (1) CRYO 102 Double Case. . . . . . . . . . . . . . . . . . . Part # ACL-102-CASE-D

CRYO 204S Pipe Freeze Kit


Kit includes the below listed items:

Single freeze plug applications on nominal pipe sizes of 2.5 thru 2.0. (1) CRYO 204 Chamber. . . . . . . . . . . . . . . . . . . . . . . . . Part # ACL-204-CHK (1) CRYO 204 Insert Kit . . . . . . . . . . . . . . . . . . . . . . . . Part # ACL-204-INK Includes: (1) 204 A Insert Set, (1) 204 B Insert Set & (1) 204 C Insert Set (1) CRYO 204 LN2 Hose. . . . . . . . . . . . . . . . . . . . . . . . Part # ACL-204-LN2 (1) CRYO 204 CryoFoam Kit . . . . . . . . . . . . . . . . . . Part # ACL-204-DS-CFK Includes: (1) Roll CryoFoam Tape & (9) Sets Chamber Gaskets (1) CRYO 204 Hardware Kit. . . . . . . . . . . . . . . . . . . . . . Part # ACL-204-HDK Includes: (2) 1/2 Brass Plugs, (2) 1/2 Brass Nipples, (1) Straight Swivel Connector, (1) 90 Swivel Connector, (2) 1/2 Brass Elbows, (4) T-Bolts with Nuts, (1) Bottle to Hose Adapter (ACL-LN2-BH) & (1) 1/8 Allen Key (1) CRYO 204 Single Case. . . . . . . . . . . . . . . . . . . . Part # ACL-204-CASE-S Installation Instructions | 4.0

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(1) CRYO 102 CryoFoam Kit . . . . . . . . . . . . . . . . . . Part # ACL-102-DS-CFK Includes: (1) Roll CryoFoam Tape & (9) Sets Chamber Gaskets

102 & 204 Pipe Freeze Kits

Freeze Kit Application Requirements

Minimum application requirements for the Cryolator Freeze Kit.


General Guidelines General Design Criteria Nominal Pipe Sizes & Types No Flow

General Guidelines Pipe Conditions & Examinations Chamber Placement : Recommended Chamber Placement: Dead Head Obstructions Chamber Placement: Flowing Headers / Branch Pipes Chamber Placement: Torch / Flame Cuts or Field Welds Chamber Placement: Pipe Orientation

Basic Safety Information


General Guidelines Work Area Safety Perimeter PPE Liquid Nitrogen Vapors: Job Site Ventilation Liquid Nitrogen Vapors: Below Ground Excavations Liquid Nitrogen Vapors: O2 Monitors

Cryostop has over 27 years of extensive experience and has performed our service procedures worldwide on most all types of pipe and conditions. Cryostop maintains a staff of continually trained and experienced pipe freeze technicians specializing in the Nuclear Power, Pharmaceutical, Medical, Hotel, Education, Financial and most all Sectors as well as both large and highly secured Government Institutions. Please contact Cryostop International 24/7/365 toll free @ (866) 452-0448 or on the web @ www.cryostop.com.

Remember for any applications outside your equipment range, experience level or complex applications, please feel free to contact our Cryostop Service Division and they will be glad to assist in your project.

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Installation Instructions | 4.1

Locate the Cryolator Freeze Application

102 & 204 Pipe Freeze Kits

Freeze Kit Reference Charts


Estimated Minutes to Form Plug 4 to 6 10 to 14 Estimated LN2 To Form Plug Gals 12.5 Gals 15.5 Gals

CRYO-102 Reference Chart


PIPE TYPE Pipe Size inch 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 1/2 3/4 1 1-1/4 1-1/2 2 Pipe Size mm 16mm 22mm 28mm 35mm 41mm 54mm 67mm 21mm 27mm 34mm 42mm 48mm 60mm Chamber Insert Set A B C D D D None A B C D D None CRYOFOAM Pipe Wraps 3 Wraps 4 Wraps 3 Wraps 4 Wraps 3 Wraps 3 Wraps 3 Wraps CRYOFOAM Wraps Length 14 22 16 18 30 28

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18 to 20 21 to 23 4 to 6 27 20 to 23 13 15 10 to 14 18 30 24 28 14 to 16 16 to 18 18 to 20 19 to 21 CRYOFOAM Wraps Length 44 37 43 29 36 41 47 Estimated Minutes to Form Plug 30 to 35 35 to 40 40 to 45 30 to 35 35 to 40 40 to 45 45 to 50

COPPER TUBING TYPE L

3 Wraps 3 Wraps 3 Wraps 3 Wraps 3 Wraps 3 Wraps

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Chamber Insert Set B C A CRYOFOAM Pipe Wraps 4 Wraps B 3 Wraps 3 Wraps 3 Wraps 3 Wraps 3 Wraps 3 Wraps B C None

STEEL & OTHER PIPES

CRYO-204 Reference Chart


PIPE TYPE Pipe Size inch 3 Pipe Size mm 16mm

COPPER TUBING TYPE L

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3-1/2 4 22mm 28mm 2-1/2 3 21mm 27mm 34mm 3-1/2 4 42mm

STEEL & OTHER PIPES

IMPORTANT NOTES Specification data is based on horizontal setups @ <70F inside fluid temperature with <70F outside ambient temperature. Only Low Pressure 22 psi Liquid Nitrogen Tanks should be used. Vertical setups may take approximately 10% additional time & Liquid Nitrogen Refrigerant. Listed Liquid Nitrogen Refrigerant quantities and times are estimates only. Actual times and quantities may vary due to factors such as outside ambient temperatures, fluid temperatures, and fluid type. System flow should be static (no flow) during the pipe freeze procedure. In addition to the listed Liquid Nitrogen quantity estimates additional Liquid Nitrogen should be on hand until the customer / pipe freeze applicator has obtained a proficient experience level and is familiar with each individual size and characteristics of pipe freeze applications. CRYOLATOR 102 & 204 Pipe Freeze Chambers / Equipment should NOT be used on piping systems with pressures greater than 300psi and temperatures greater than 110F. System temperatures and pressures operating beyond these limits should be reduced.

Installation Instructions | 4.2

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14 to 16 16 to 18

16.5 Gals 18.5 Gals 20.5 Gals

21.5 Gals 24.5 Gals 12.5 Gals 15.5 Gals 16.5 Gals 18.5 Gals 20.5 Gals 21.5 Gals

Estimated LN2 To Form Plug Gals 27.5 Gals 32.5 Gals 36.5 Gals 27.5 Gals 32.5 Gals 36.5 Gals 44.5 Gals

102 & 204 Pipe Freeze Kits

Installation Instructions

Step 1
Install CRYO Inserts

Note

CRYO Insert

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Installing Insert

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Button Head Location Install Complete

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Installation Instructions | 4.3

Insert Identification stamp will face outward from Chamber Housing. Inserts should fit flush to the Chamber Housing. 1/8 Allen Key included for installation.

Secure Inserts with #10 Button Head found in Chamber Housing.

102 & 204 Pipe Freeze Kits

Installation Instructions

Step 2
Install Chamber Gaskets.

Gasket must be flush with Chamber Body inside edge.

CRYO Chamber Gasket

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CryoClamp = T-Hook (left), Trunion (right)

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CRYO Gasket Install Gasket Install, Complete

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Installation Instructions | 4.4

Note:

Select two CRYO chamber gaskets. Remove paper backing. Apply gaskets to chamber half with trunions.

102 & 204 Pipe Freeze Kits

Installation Instructions

Step 3
Remove Excess Gasket Material.

Note:

CRYO Gasket Trim

CRYO Gasket Before Trim

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CRYO Gasket After Trim

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Installation Instructions | 4.5

Some applications may not require removal of excess gasket material.

Cut flush to current chamber I.D.

102 & 204 Pipe Freeze Kits

Installation Instructions

Step 4
Inspect and Prepare Cryolator Temperature Kit Note:

ACL-90_Temp Kit Includes:

Note:

Replace battery if BAT appears on monitor screen. Properly maintain the monitor and calibrate it regularly.

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Check for damage to monitor, wire insulation, mini-connectors & end probe contact spade. Turn monitor on and set for T-Type thermocouple. Connect end probes and extension leads to monitor and test

Failure to utilize the ACL-90_Temp Kit may result in:

Catastrophic plug failure. Costly, unnecessary repair. Property Damage. Personnel injury

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Calibrated Temp Leads Meet or Exceed Most Nuclear Utility Standards.

(1) Handheld Dual Lead Thermocouple Thermometer (2) Calibrated Temperature End Probes with Mini-Connectors (2) Extension Leads with Mini-Connectors (1) Installation / Operation Instructional Guide (1) Carry Case

Cryolator Temperature Kit

Warning !!!!
Correct usage of the ACL-90_Temp Kit will result in:

Safe Integrity of Cryolator Plug Efficient operation of Cryolator Freeze Kit. Monitoring of Freeze Plug from a safe distance. Troubleshoot Freeze Applications.

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Installation Instructions | 4.6

This will assist in maintaining a uniform placement of the CryoFoam seal tape, temperature monitor leads and chamber housing.

102 & 204 Pipe Freeze Kits

Installation Instructions

Step 5
Apply CryoFoam seal tape and Temp Probes.

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CryoFoam Reference Marks

CryoFoam Side View

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CryoFoam Wrap Example: Cryo Chamber Installed

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Installation Instructions | 4.7

Locate marks at each end of the chamber. Place end probes centered on the reference marks. Center seal tape on reference mark. Wrap pipe OD according to Cryo reference chart.

Improper Chamber Fit Liquid Nitrogen Leaks Freeze Plug Failure Facility Damage Personal Injury

Caution: Failure to review CRYO Reference Chart for the correct number of wraps per application may result in:

102 & 204 Pipe Freeze Kits

Installation Instructions

Step 6
Install T -bolts.

Thread nut onto tee bolt until full thread engagement is achieved.

CRYO-102 uses (2) T-Bolts

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CryoClamp Trunion / T-Bolt Install

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CRYO-204 uses (4) T-Bolts

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Installation Instructions | 4.8

Note:

Insert T-bolt through clamp trunion. Secure with hex nut. Repeat steps for all trunions.

102 & 204 Pipe Freeze Kits

Installation Instructions

Step 7
Install Cryo Chamber

CRYO-102 Chamber Placement

Note:

Caution Both Cryo chambers require a minimum of 1 vent port.

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Tighten nuts equally alternating sides until Chamber Gaskets and Pipe Seals are compressed to about on both sides. Fittings require teflon tape to prevent leaks.

Tighten Cryo 102 T-Bolts

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Tichten Cryo 204 T-Bolts Install Cryo 102 Fittings Install Cryo 204 Fittings

Ensure chamber is centered on CryoFoam seal tape.

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Place Chamber half (with Trunion) on CryoFoam pipe wrap. Hook tee bolts into clamp on opposite half. Tighten hex nuts with deep set socket or equal. Install fittings to meet your freeze seal criteria.

CRYO-204 Chamber Placement

Installation Instructions | 4.9

102 & 204 Pipe Freeze Kits

Installation Instructions

Step 8
Attach liquid nitrogen hose to Chamber and Liquid Nitrogen source.

LN2 Hose & Mesh Tote Bag

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Cryolator Bottle to Hose Connector

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Attach LN2 Hose

Hose to LN2 Tank Connection

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Installation Instructions | 4.10

A Straight or 90* Swivel Adapter may be used. Use the bottle to hose adapter to connect to a standard nitrogen dewar. The bottle to hose adapter is used as a shutoff valve.

102 & 204 Pipe Freeze Kits

Installation Instructions

Step 9
Connect Temperature Kit

Temperature Mini-Connectors

Don your Cryo PPE Kit

List:

Cryogenic Apron Cryogenic Gloves


Also Recommended:

Face Shield and Safety Glasses Protective Clothing


Cryo PPE Kit

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Installation Instructions | 4.11

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Cryo Freeze Log

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Connect calibrated end probes to extension wires. Connect extension wires to Dual Temperature Monitor. Record base line temperature readings on the CRYO LOG.

102 & 204 Pipe Freeze Kits

Installation Instructions

CRYO-102 Chamber
Typical CRYO 102 Pipe Freeze Kit installed in a Horizontal Setup.

Cryolator Temperature Kit

Cryolator Temperature Kit

Please see our other quality pipe freeze products at www.cryo-lator.com

Central Warehouse - 1901-A Blue Clay Road - Wilmington, NC 28405 Toll Free (866) 452-0448 - Fax (910) 763-0947 - E-mail info@cryo-lator.com

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One very cool company!
Installation Instructions | 4.12

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Typical CRYO 204 Pipe Freeze Kit installed in a Vertical Setup.

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CRYO-204 Chamber

Freeze Log
102 & 204 Pipe Freeze Kits

Customer: Date: Pipe:

Project ID#: Tech(s):

Service:

LN2 Change

Time Stamp

Action

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#1 Temp

Number of LN2 Dewers: Dewers @ Achieve Plug:

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Type of LN2 Dewers Dewers @ Hold plug:
Freeze Log | 5.0

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#2 Temp

102 & 204 Pipe Freeze Kits

Additional Service Brochures

M.T. Ingram & Company, Inc. M.T. Ingram & Company Specialty Piping Service Solutions Pipe Freeze Services Pipe Freeze Kits & Products Pipe Freeze Pipe Tapping Services Services Line Stop PipeMechanical Freeze Kits & Services Products

Pipe24 Tapping Hours / 365Services Days Routine Schedules & Emergency Service Mechanical Line Stop Services
Toll Free (866) 452-0448

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24 Hours / 365 Days Routine Scheduled & Emergency Service

Toll Free (866) 452-0448


Additional Service Brochures | 6.0

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Speciality Piping Service Solutions

102 & 204 Pipe Freeze Kits

Additional Service Brochures


New Jersey

www.cryostop.com
New York

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Colorado

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Seattle, Washington Washington, DC

M.T. Ingram & Company

Speciality Piping Service Solutions

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New Mexico
Additional Service Brochures | 6.1

Texas

Corporate Offices 105 Oxmoor Place Wilmington, NC 28403

102 & 204 Pipe Freeze Kits

Additional Service Brochures

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Qualified & Trained Pipe Freeze Technicians. Written Technical Procedures and Safety Guidelines. Innovative Pipe Freeze Seal Technology. More Than 31 Years of Diverse Pipe Freeze Seal Experience. Custom CRYO-LATOR Chambers Designed, Engineered & Fabricated For Special Projects.

Typical Fluids

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Service Highlights Modifications performed without complete building or system drain downs. Save time and money by avoiding the replacement of costly chemically treated fluids. Minimize environmental issues by avoiding the possible deposal of wastewater or toxic fluids. Freeze Plugs are a non-intrusive method of developing temporary piping isolations. Service Capabilities 3/8 to 48 Pipe Diameters or larger upon special request Single, Double or Multiple Freeze Plugs Developed Independently or Simultaneously Freeze Plugs Maintained Hours, Days or Weeks. State-Of-The-Art CRYO-LATOR Chambers And Equipment CRYO-LATOR Computer Software Used To Monitor And Data Log Projects

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Fuel Oil Hydraulic Oil

Water Waste Water Sewage Fuel Oils Glycol Solutions

Chill Water Slurries Brine Solutions Polybutene Dielectric Oils Hydraulic Oil

Typical Customers Water Utilities Sewage Treatment Mechanical & Utility Contractors Hospitals Office Buildings Casinos Hydro, Fossil & Nuclear Power Stations Pulp & Paper Chemical & Petrochemical

Additional Service Brochures | 6.2

www.cryostop.com

PIPE TAPS

Our Line Stopping Machines to achieve t an operating pipeline. to plug piping systems Temporary Mechanic with bypass piping aro be repaired, allowing flow. APPLICATIONS

Single Line Stop Double Line Stop with Bypass Pip Single Line Stop with New Pipe Double Line Stop End New Pipe

102 & 204 Pipe Freeze Kits

Additional Service Brochures

PIPE TAPS MECHANICAL LINE STOPS VALVE INSERTS


Our Line Stopping Service uses special Pipe Plugging Machines to achieve temporary mechanical flow stops on an operating pipeline. Mechanical Line Stops can be used to plug piping systems for repair, alterations, or relocations. Temporary Mechanical Line Plugs can also be configured with bypass piping around the plugged section of pipe to be repaired, allowing for uninterrupted product / system flow. APPLICATIONS Single Line Stop Double Line Stop with Bypass Piping Single Line Stop with New Pipe Relocation Double Line Stop_Bottom End New Pipe Relocation

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Prevent shutdowns New construction tie-ins Installation of by-pass lines Thermowell coupling installation Pipe Repair Valve Repair Decommission of piping Isolate pressure vessels

Sewage Brine Solutions Oils Hydraulic Oil

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Additional Service Brochures | 6.3

utions

ge Treatment Contractors

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ildings Casinos

ear Power Stations

mical & Petrochemical

wns. treated fluids. ewater or toxic fluids. g isolations.

Our Hot Tapping Service utilizes various sizes of drilling / pipe tapping machines to perform our procedure of cutting holes in operating pipelines while under pressure allowing for new branch connections on the original piping systems. The process is done without any product leakage or interruption to flow. The components for a typical hot tap application include a fitting designed to contain system pressure, a valve used to control the new connection, and a drilling machine used to make the hot tap. We perform pipe taps on all types of pipe. Special applications are available upon request. APPLICATIONS

multaneously

g Projects

yostop.com

www.mtitaps.com

Professional CRYO-LA prefer to Do-It-Thems wasted time of fluid sys

CRYO-LATOR P

Avoid the expense of company to do somethi Freeze Companies DO ment.

Each kit comes with & operational guide. (P

Each kit purchase com support telephone num

CRYO-LATOR Cha DO NOT use Canvas Collar Kits, Plastic Fee erant or Other Inadeq ment!

All Equipment is eng the identical specificatio in our Professional CR

Do It Yourself pipe

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