Operation Rules Instruction Manual Version 160306 - … Rules Instruction Manual Version 160306...
Transcript of Operation Rules Instruction Manual Version 160306 - … Rules Instruction Manual Version 160306...
Page 1/43, Operation Rules version 160306
Operation Rules
Instruction Manual
Version 160306
Name: BIOCEV, SO 001 and SO 002
Location: Biocev, Průmyslová 595, 252 42 Vestec
Operator: The Institute of Molecular Genetics of the ASCR and Charles
University, Prague
Supplier: LINEQ s.r.o., V Horce 178, 252 28 Černošice
Date of creation: 23 November 2015
Contents:
Operation Rules ................................................................................................................ 1
1. Operation Layout ............................................................................................................. 2
2. List of Documentation ...................................................................................................... 2
3. Technological Diagram, Location: ...................................................................................... 3
4. Operation of the Source of CO2 ......................................................................................... 7
4.1. The A30 Dry Ice Machine ............................................................................................ 8
5. Operation of the Source of Gaseous Nitrogen: ..................................................................... 9
5.1 GN2 Main Source, Main Valve ....................................................................................... 9
5.2 GN2 Distribution System ............................................................................................. 10
5.3 Assembly Specifications .............................................................................................. 10
5.4 The Main Principles for Operation, Filling, Maintenance and Service .................................. 10
6. Operation of the Source of Liquid Nitrogen: ....................................................................... 11
6.1 Main source of LIN, the Main Valve ............................................................................... 11
6.2 The LIN Distribution System ........................................................................................ 12
6.3 Assembly Specifications .............................................................................................. 13
6.4 The Main Principles for Operation, Filling, Maintenance and Service .................................. 13
6.5 Filling Points in Building 001 ........................................................................................ 14
6.6 Cryobank in Buildings 001 and 002 .............................................................................. 16
6.6.1 The Functions of Controllers on the Main Switchboard ............................................... 17
6.6.2 The Operation of Storage Containers....................................................................... 18
6.6.3 Operating the LIN distribution system in the cryobank .............................................. 19
6.6.4 Manual Filling of Dewar Vessels in the Cryobank Room .............................................. 19
6.6.5 The MaR and functions of the MaR controller ............................................................ 20
7. MaR .............................................................................................................................. 32
8. The Kryolab Web Interface............................................................................................... 32
9. Faults and Emergencies ................................................................................................ 34
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9.1 A Drop in Oxygen Levels in Filling Areas........................................................................ 34
9.2 Uncontrolled leakage of liquid nitrogen from the distribution piping container and filling points
..................................................................................................................................... 34
9.3 A Loss of Vacuum in Containers, the VIP Distribution System and Filled Dw and MZ ........... 34
9.4 Solenoid Valve Malfunction .......................................................................................... 35
9.5 MaR Malfunction ........................................................................................................ 35
9.6 Lack of Liquid Nitrogen in the System ........................................................................... 35
9.7 A Lack of Gaseous Nitrogen in the System .................................................................... 35
9.8 Gas Contamination ..................................................................................................... 35
10.1 Liquid and Gaseous Nitrogen ........................................................................................ 35
10.2 Solid, Liquid and Gaseous Carbon Dioxide ...................................................................... 36
11. Training, Maintenance, Inspections, Service and Emergency .............................................. 37
12. An Overview of the Estimated Useful Life of Equipment and a List of Expected Supply Materials
........................................................................................................................................ 42
13. Operational Safety ........................................................................................................ 44
14. Warranty ..................................................................................................................... 46
15. Successive Regulations and Documents ........................................................................... 46
16. Contact Information ...................................................................................................... 46
1. Operation Layout
The operation rules/instruction manual describes the requirements for operating the
facility as per the Agreement dated 30 July 2015: Central cryotechnology SO 001
(Central cryotechnology module) and cryotechnology SO 002 (Transgenic and archiving
department module) II.
The facility is composed of sources of liquid and gaseous nitrogen, CO2, distribution
system, delivery points, and MaR system.
Tanks are dedicated pressure equipment, the distribution system and filling points are
dedicated gas equipment, and MaR is a piece of dedicated electronic equipment. A
detailed description and documentation are parts of the actual construction
documentation. Operations forms an integral unit that may be operated only by trained
personnel and serviced while maintaining the guarantees of the supplier that is
authorised by the subject. Outputs from the MaR system are shared with the server and
available via the Kryolab web interface.
The facility can be divided into three subsystems: The source of liquid nitrogen, applied
in buildings 001 and 002; the source of gaseous nitrogen, connected to building 001 and
the source of CO2 for building 001. The MaR system is centralised into the RBB.01.1
located in the control room of building 001, including GSM gateway and a server on
which the web application of Kryolab is running.
The additionally ordered manufacture of dry ice is also included in the operation.
2. List of Documentation
Documentation of the actual state, press release, drawings
Manuals for parts of the system
Manual for vertical tanks VT9, VTC7, PC1000 and PC230
Manual for air vaporisers
Manual for vacuum-isolated piping
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Manual for storage containers
Manual for product heaters
Manual for Dewar vessels
Manual for solenoid valves
Manual for reduction stations
Manual for the A30 dry ice machine
Declaration of Conformity, certificates, testimonials, attestations
Revised reports of gas, pressure equipment and electrical equipment
A record of personnel training and operator testing
Protocol for operator training
3. Technological Diagram, Location:
The disposition of technology in SO01
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The disposition of technology in SO02
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The disposition on the motherboard:
The technological diagram of the motherboard
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The technology diagram of SO01
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The technology diagram of SO02
Diagrams and dispositions are part of the Documentation of the actual construction
4. Operation of the Source of CO2
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The CO2 source has an administrator who is responsible for the operation, maintenance
of the logbook, performance of the prescribed inspections and revisions, and the training
of operators.
Monitored data are assessed in the main MaR switchboard, and displayed via the Kryolab
web interface. Adjustments of alarm and emergency limits and damping are performed
by the user via the touchscreen on the main switchboard or the touchscreens in
cryobanks in SO01 and SO02.
Wiring Diagram:
Diagrams and dispositions are part of the Documentation of the actual construction
Operation of the reduction station is described in the manual.
The Main Principles of Operation:
The equipment must be fully functional, without defects, with the most current revisions
and must be operated by trained personnel. The manual, diagrams and operating
instructions are provided in the VTC7 manual.
The main gas shutoff valve for the VTC tank is the V9 valve and VT6 for building
14307.
4.1. The A30 Dry Ice Machine
The A30 dry ice machine is located in room R1.002.
Its description, operating instructions, safety information and schedule for inspections
and repairs are provided in a separate manual.
The A30 dry ice machine may be operated only by authorised and trained personnel (with
a valid operator’s certification).
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The CO2 tank, distribution system and generator are designated equipment and must be
secured against use by unauthorised personnel.
The operator must wear appropriate protective equipment.
The managing body appoints a responsible person who, each day, provides a visual
inspection, including an inspection of the pressure and contents on the tank’s gauges. In
case of permanent icing, leakage or any other defects, this person should also secure
professional maintenance service.
The responsible person is responsible for carrying out inspections, revisions and training
at intervals specified in Article 11, and maintaining a logbook.
It is forbidden to operate the tank if there is a malfunction or without a valid revision.
Furthermore, the tank cannot be operated for purposes or manners other than those
described in this document.
The output of gas into the distribution system is opened/closed by the V9 valve – Gas
withdrawal.
5. Operation of the Source of Gaseous Nitrogen:
5.1 GN2 Main Source, Main Valve
The V10 valve acts as the main gas shutoff valve for the PC1000 tank, whereas
V22 is the main shutoff valve for tank P230
The source of gaseous nitrogen consists of main tank PC1000 and auxiliary tank P230.
Properties, operation and filling is described in detail in the separate manual for PC1000
and PC230.
The main source is set to an operating pressure of 18 bar with a maximum pressure of
24 bar.
The auxiliary source is set to an operating pressure of 14 bar with a maximum pressure
of 22 bar.
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Both sources are connected to the output with backflow preventers and thus,
automatically, the source with higher pressure is used.
Connection to liquid nitrogen is carried out through separate backflow preventers and
therefore, refilling is performed only for the tank in which the pressure drops below the
pressure in the liquid nitrogen tank/distribution system (2 bars).
The RV0403 reducing valve is set to 8 bar.
Unreduced piping is protected by 25 bar relief valves. Distribution behind the reduction
into the building is protected at 10 bar.
The heater is described in the manual and works automatically.
The following equipment is installed on the GN2 source: equipment for measuring
pressure differences and recording supplied and taken amounts of LN2; equipment for
measuring operating pressure in the tank and the distribution system. Recorded data are
written into the Kryolab application database.
5.2 GN2 Distribution System
GN2 is distributed through a DB32 stainless steel distribution system into building 001
through main valve 12702.
5.3 Assembly Specifications
Tank volume: 1000 l / 230 l
Maximum pressure: 24 bar / 22 bar
Operating pressure: 18 bar / 14 bar
Preset alarm condition for pressure in the tank: 8 bar minimum
Preset alarm condition for pressure in the distribution system 8 bar minimum
Preset alarm condition for contents of the tank: 120 kg minimum
Preset emergency condition for pressure in the tank: 7 bar minimum
Preset emergency condition for contents of the tank: 90 kg minimum
5.4 The Main Principles for Operation, Filling, Maintenance and Service
LN2 tanks – Sources of GN2 can be operated only by authorised and trained personnel
(with a valid operator’s certification).
The tank, distribution system and filling points are designated equipment and must be
secured against use by unauthorised personnel.
The operator must wear appropriate protective equipment.
The managing body appoints a responsible person who, each day, provides a visual
inspection, including inspection of the pressure and contents on the tank’s gauges. In
case of permanent icing, leakage or any other defects, this person should also provide
professional service.
The responsible person is responsible for carrying out inspections, revisions and training
at intervals specified in Article 11, and maintaining a logbook.
It is forbidden to operate the tank if there is a malfunction or without a valid revision.
Furthermore, the tank cannot be operated for purposes or manners other than those
described in this document.
The output of gas into the distribution system is opened/closed by the V9 valve
– Gas withdrawal.
Caution: reduced gaseous nitrogen is a source for driving the master valves
MV1 and MV2 for building SO01 and SO02. When closed or when pressure drops
below 3 bar, the MV1 and MV2 valves are automatically shut off.
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Filling the tanks:
Filling must be carried out only by trained personnel. A detailed filling procedure is
described in the manual for the tank.
6. Operation of the Source of Liquid Nitrogen:
6.1 Main source of LIN, the Main Valve
The V20 valve acts as the main liquid nitrogen shutoff valve on tank VT9.
Distribution for buildings 001 and 002 are closed by pneumatic valves 11204
and 11205. These valves are controlled via the main switchboard panel in
cryobank 001.
The VT9/18 tank is the source of liquid nitrogen. The V20 valve is the main shutoff valve
of the tank, followed by the VIP distribution system and two pneumatic-driven valves.
The properties, operation and filling are described in detail in the separate manual for
VT9/18.
The tank is set for an operating pressure of 2 bar. The maximum pressure is 18 bar. The
operating pressure is maintained by an RG2 exhaust generator. For proper operation,
the V26 valve must be permanently opened.
The VIP piping is protected by 8 bar relief valves.
The tank is provided with telemetry by the gas supplier.
The following equipment is installed on the LIN source: equipment for measuring
pressure differences and recording supplied and taken amounts of LN2; equipment for
measuring the operating pressure in the tank and the distribution system. Recorded data
are written into the Kryolab application database.
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Diagram:
The diagram and dispositions are part of the Documentation of the actual construction
6.2 The LIN Distribution System
The LIN is distributed through the V20 main valve of the VIP distribution system
DN60/15 to pneumatically operated valves 11204 and 11205 and the VIP distribution
system into the building 001 and 002.
11204, or MV1, closes the distribution of LIN into building 001. Normally, this valve is
opened. In case of emergency in building 001, it is closed.
11205, or MV2, closes the distribution of LIN into building 002. Normally, this valve is
opened. In case of emergency in building 002, it is closed.
Two buttons for each valve are located on the right side of the cabinet door of the RBB.1
switchboard in the control room. The buttons are backlit so it is possible to observe the
system’s reaction when pressing the relevant driver.
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The white “Ventil LIN-X AUT” button is used to set the valve in the relevant section into
automatic mode. This is indicated by a continuous light behind the button.
The red “Ventil LIN-X VYP” button is used to force close the valve of the relevant section.
This is indicated by a continuous red light behind the button after the valve is closed.
Pressing the “Ventil LIN-X AUT” opens (and sets to automatic mode) the valve again.
In the event of an accident in any section, the valve is closed when in automatic mode.
This is followed by flashing of the “Ventil LIN-X AUT” button’s backlight. After the cause
of the emergency is remedied and the monitored values are back within normal ranges,
the valve is automatically opened.
The main valve of the SO001 section is automatically closed in case of the following
states of emergency: “Oxygen extralow” and “Temp100 extralow” for objects of “Ambient
Values1”, “Ambient Values FS 1”, “Ambient Values FS 2”, and “Ambient Values FS 3”,
and during “Emergency Extrahigh Level Dw1”.. Dw10.
The main valve of the SO002 section is automatically closed in case of the following
states of emergency: “Oxygen extralow” and “Temp100 extralow” for object “Ambient
Values 2” and for “Emergency extrahigh level” of objects Dw20.. Dw26.
Both valves are NC (normally closed), which means they are closed in case of a shortage
of power or power for the pneumatic drive.
The pneumatic drive is carried out via the reduced branch of the GN2 distribution system,
position 1001, through valve V0405. Open valve 12704 and pressure in distribution
system 12705 at a minimum of 5 bar are mandatory for the proper functioning
of MV1 and MV2. In case of lower pressure, these valves are closed.
Branch 002 is fitted with a gas separator (Cryovent, described in detail in the manual).
The separator is located in cryo-storage 002.
During operation, the gas separators must be inspected at least once per month.
The VIP distribution system, its properties and manner of operation are described in
detail in the manual.
6.3 Assembly Specifications
Tank volume: 9000 l
Maximum pressure: 10 bar
Operating pressure: 2 bar
Preset alarm condition for pressure in the tank: 1 bar minimum
Preset emergency condition for pressure in the tank: 0.5 bar minimum
Preset emergency condition for pressure in the tank: 1 bar minimum
Preset alarm condition for contents of the tank: 1200 kg minimum
Preset emergency condition for contents of the tank: 600 kg minimum
6.4 The Main Principles for Operation, Filling, Maintenance and Service
LN2 tanks – Sources of GN2 can be operated only by authorised and trained personnel
(with a valid operator’s certification).
The tank, distribution system and filling points are designated equipment and must be
secured against use by unauthorised personnel.
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The operator must wear appropriate protective equipment.
The managing body appoints a responsible person who, each day, provides a visual
inspection, including an inspection of the pressure and contents the tank’s gauges. In
case of permanent icing, leakage or any other defects, this person should also provide
professional service.
The responsible person is responsible for carrying out inspections, revisions and training
at intervals specified in Article 11.
It is forbidden to operate the tank if there is a malfunction or without a valid revision.
Furthermore, the tank cannot be operated for purposes or manners other than those
described in this document.
The output of gas into the distribution system is opened/closed by the V20 valve.
Filling the Tank:
Refilling must be carried out only by a supplier of LN2 with the consent / knowledge of
the responsible person or appointed operator. A detailed filling procedure is described in
the manual for the tank.
6.5 Filling Points in Building 001
A filling point is used for filling unpressurised Dewar vessels and the minitank.
The diagram, dispositions and specifications are part of the Documentation of actual
construction
A Description of Valves and Control Elements:
Type Function
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Solenoid exhaust valve Used for removing excess L2N before filling from the
L2N distribution system
Solenoid for the LN2
supply valve
Used for supplying LN2 for filling purposes
Depressurisation valve of
the filling hose
Used for depressurising the filling hose before
disconnecting it from the filled minitank
Manometer Measures pressure in the filling hose
Power supply signal lights Indicate the presence of power supply voltage and
the functionality of power supplies of other necessary
voltages
AUT Master Valve signal
light
Indicates the function of the master valve of the
SO001 MV1 object (see paragraph 6.2)
Exhaust on/off buttons Used for controlling exhaust
Filling on/off buttons Used for controlling the supply of LN2
Opto-acoustic signalisation Optically and acoustically indicates and alarm and
fault conditions at the filling point
Electronic chip reader Before filling, the operator logs into the system with
an electronic chip, which activates the filling point’s
controls.
Registration indicator Signal the login status of the registered user and
activation of the filling point
Acknowledgement button Used for bypassing acoustic signalisation
General Rules:
Only authorised and properly trained personnel may operate the equipment.
The equipment must be in proper working condition.
The operator must wear appropriate protective equipment and observe all safety
measures.
Only unpressurised Dewar vessels and minicontainers may be filled.
Minicontainers must meet the following criteria:
Transport minicontainers must have proper documentation
They must be in good condition
The containers must have an endpoint compatible with the filling system
Before filling, pressure in the containers must be lower than 0.5 bar
The operator must be present during filling and observe the process and stop the filling
when done.
In case of emergency, stop the filling immediately!
Ambient Monitoring:
The ambient concentration of oxygen in the air is monitored around the filling points.
Additionally, for filling point FS2 in room R1.002, the concentration of CO2 is also
monitored due to the dry ice machine placed there.
In case of activation of the opto-acoustic signalisation system, it is necessary to
immediately leave the endangered area – filling point at FS1 or the room at FS2 and FS3
– and inform the cryo-storage administrator as soon as possible.
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Procedure for Filling Dewar Vessels (Hereinafter DW) Without Pressure
- Screw the adaptor with the phase separator onto the end of the filling hose.
- Log into the system using the individual chip. The login is valid only for a limited
period of time – after this, the operator must login again.
- The operator may exhaust excess GN2 into the LN2 distribution system. The filling
valve is operated by pushing the green exhaust button. The exhaust is closed
automatically after LN2 is detected in the exhaust piping, or after the set time
runs out, or after pressing the red exhaust button.
- The filling valve is opened by pressing the green filling button.
- The filling hose is inserted into the filled DW and the container neck needs to be
visually checked.
- As soon as the gas forms drops of LN2, filling must be stopped by pressing the red
filling button.
- Logging out from the filling process can be done by holding down the red filling
button until the green registration indicator switches off.
The Procedure for Filling Minicontainers (hereinafter MZ).
- Make sure that pressure in the MZ is lower than 0.5 bar.
- Connect the filling hose to the filling connector of the MZ, and the exhaust hose to
the exhaust of the MZ.
- Log into the system using the individual chip. Login is valid only for 10 minutes –
after this the operator must log into the system again.
- The operator may let out excess GN2 into the LN2 distribution system. The filling
valve is operated by pushing the green exhaust button. The exhaust is closed
automatically after LN2 is detected in the exhaust piping, or after the set time
runs out, or after pressing the red exhaust button.
- Open the exhaust valve of the MZ and the valve for liquid in the MZ.
- The filling valve is opened by pressing the green filling button.
- Visually inspect the filling process, look out especially for pressure, volume or any
leakages.
- As soon as the MZ is full, perform the following operations in the indicated order:
press the red filling button
close the valve for liquid in the MZ
close the exhaust valve of the MZ
open the exhaust hose valve until the pressure in the filling branch is 0 bar
remove the filling hose
- Logging out from the filling process can be done by holding down the red filling
button until the green registration indicator switches off.
6.6 Cryobank in Buildings 001 and 002
The cryobank administrator is responsible for its operation.
Personnel working in the cryobank must be properly trained.
The cryobank administrator provides a logbook into which data about the operation and
any malfunctions, repairs and inspections are recorded.
Before entering the space, it is necessary to check whether the red light in the hallway is
on. If the light is on, the amount of oxygen within the cryobank is below 19% (see
parameter adjustment of the cryobank). If the light is flashing, the amount of oxygen
within the cryobank is below 18% (see parameter adjustment of the cryobank). In this
case, do not enter the cryobank and inform the administrator.
The cryobank doors are equipped with an entrance and exit chip card reader. The MaR
system thus monitors the comings and goings of authorised personnel. According to
currently logged-in chips, the rights for conducting operations in the cryobank are set
(input of individual DW, nitrogen pumping, etc.).
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If there is a regular (duty cycle of 1:1) flashing of the red light on the right side of the
entrance door from the inside during the presence of operators, the amount of oxygen in
the cryobank is below 18%. Leave the cryobank area immediately. In case of an
uncontrollable outpouring of liquid nitrogen from the filling points, or any other similar
emergency, leave the cryobank area immediately and, if possible, press the emergency
escape button on the right side of the door, and inform the administrator. Pressing the
emergency escape button closes all valves in the liquid nitrogen distribution system. In
order to restore the operation of the valves, you must reactivate the emergency escape
button with a special tool and reactivate the power circuit for solenoid valves on
switchboard RBB.1 (switch the circuit breaker with trip coil J13 upwards).
Flashing at a duty cycle of 1:4 indicates the need to calibrate the oxygen sensor. During
this condition, although the concentration of oxygen is monitored, the signalisation
indicates an urgent need for service.
6.6.1 The Functions of Controllers on the Main Switchboard
The main switchboard RBB.1 is located in the R1.004 control room of building 001. The
main control elements of the cryobank system and the signalisation of important
operational voltages are located on the switchboard.
LEDs and controllers:
230VAC LED – white - indicates a proper power supply from the mains of the
building to the MaR switchboard.
24VAC LED – white - indicates the proper functioning of the 24VAC source for the
operation of solenoid valves for the distribution of LIN.
24VDC LED – white - indicates the proper functioning of the 24VDC source in the
control system power supply.
During normal operation, all indicators must be lit. The lack of lighting of any LED is an
indication of abnormal system operation and a fix must be provided immediately.
FAULT ACKNOWLEDGEMENT – the red button is used for shutting down the
acoustic signalisation and the acknowledgement of a system fault in cases where
the acknowledgement is necessary.
STOP – this red button is used for shutting down the power supply into the MaR.
Pressing this button shuts down the main power supply to the switchboard. The
control system, server and touchscreen remain powered due to power supply from
the internal UPS system.
Indicators and controllers for main LIN valves:
Two buttons for each valve are located on the right side of the cabinet door of the
RBB.1 switchboard in the control room. Therefore, these buttons are for MV1 and
MV2. MV1 shuts off the supply of LIN into building SO001, while MV2 shuts off the
supply to SO002. The buttons are backlit so it is possible to observe the system’s
reaction when pressing the relevant driver.
Ventil LIN-X AUT Button – white - used to set the valve of the relevant section
into automatic mode. This is indicated by a continuous light behind the button.
Ventil LIN-X VYP Button – red - used to force close the valve of the relevant
section. This is indicated by a continuous red light behind the button after the
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valve is closed. Pressing the “Ventil LIN-X AUT” opens (and sets to automatic
mode) the valve again.
In the event of an accident in any section, the valve is closed when in automatic
mode. This is followed by flashing of the “Ventil LIN-X AUT” button’s backlight.
After the cause of the emergency is remedied and the monitored values are back
within normal ranges, the valve is automatically opened.
The RBB.2 switchboard for the SO002 cryobank is located in cryobank SO002. The
switchboard is linked with switchboard RBB.1 in cryobank SO001. With the exception of
buttons for LIN master valves, this switchboard is equipped with the same indicators and
controllers as the RBB.1 switchboard. The LIN master valves buttons are placed only on
the RBB.1 switchboard in the control room.
6.6.2 The Operation of Storage Containers
Storage containers are described in their respective manual.
Storage containers are connected to distribution piping and the measuring and regulation
system. Each container is equipped with a control panel, see below. Inside the containers
are elements for storage of samples. If a particular container is switched off, it is only
monitored. If a container is switched on (in individual, step-by-step or group mode), it is
monitored, automatically refilled and all functions of the control panel are active. See
section 6.6.5 “Operation of MaR and functions of the MaR controller” for switching on, off
and setting the mode, ranges and other parameters.
The cryobank administrator determines which storage containers are switched on, and in
which mode, and determines adjustable parameters.
The Main Principles for Operating the Storage Containers:
- Loading and unloading can be performed only by trained and authorised personnel.
- The operator must use appropriate protective equipment.
- Cell samples must be stored only in cryogenic boxes designed for LIN. Cryogenic boxes
must be placed in appropriate slots and properly labelled.
- Loading and unloading must be recorded.
- In case you notice a fault, or something falls into the container, inform the
administrator immediately.
- Remove stands from the containers for a period of time that is as short as possible!
- Each day, the operator should perform a visual inspection of the containers (level,
temperature, function).
- Once per week, the operator should measure the level of LIN inside the container using
a ruler, and make an entry into the logbook. With the ruler, measure from the platform
on which the racks are standing. Under the platform the level of LIN for LABS 40 and 80
are: 134 and 146 mm.
- At least once per month, the administrator should perform an evaluation of all
operating conditions, as well as for refilling and alarm and emergency states. If
evaporation is suspected, the administrator should determine the degree of evaporation
from the container.
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The Control Panel of Dewar Vessels
Each Dewar vessel is equipped with a control panel of the storage container. The panel
consists of a backlit display and four buttons with different colours. See section 6.6.5,
paragraph “Controller of DW vessels, description and function” for a detailed description.
6.6.3 Operating the LIN distribution system in the cryobank
The LIN distribution system is described in a separate manual.
The LIN distribution system is a dedicated gas equipment.
Solenoid valves for the filling of storage containers and operating pressure are monitored
within the LIN distribution system.
If the master valve is closed, the distribution piping is protected by an 800 kPa (8 bar)
relief valve.
Active outputs to Dw1 through Dw26 and manual filling valves are controlled
automatically via solenoid valves controlled by the measuring and regulation system. All
solenoid valves are normally closed (NC).
Each working day, the cryo-storage administrator should perform a visual inspection of
the distribution system, and in case of permanent icing, leakages or faults, should secure
professional service.
6.6.4 Manual Filling of Dewar Vessels in the Cryobank Room
The Main Principles:
- Filling can be performed only by trained and authorised personnel.
The operator must wear appropriate protective equipment.
Only unpressurised vessels for storage of liquid nitrogen should be filled.
During filling, the operator must not leave the area and must have access to the filling
valve switch and visually inspect the neck of the filled container.
The filling valve is opened by pressing the green filling button. Before pressing the green
button, you need to login with a chip card (a separate chip card reader next to the filling
control panel). A proper login into the system is indicated by the green Registration LED
on the filling controller.
The filling valve is closed by pressing the red filling button. User logout from the manual
filling is done by placing the chip card onto the chip card reader at the cryobank
entrance. In case the user forgets to logout, they remain logged in, thus making the
pumping of nitrogen available for unauthorised personnel! Logout of a logged in user is
indicated by switching off of the green Registration LED on the filling panel.
During filling, the filling valve may close automatically after the set time for filling runs
out. The operator may continue with the filling process by pressing the green button. To
change the maximum time of filling, contact the cryobank administrator.
Fill only with a filling needle equipped with a phase separator.
When a fault occurs during filling, especially when liquid nitrogen leaks out or the filling
valve does not close, the operator must immediately press the red emergency button
placed on the inside of the cryobank entrance door and inform the cryobank
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administrator about such event. Pressing the red button closes all valves in the liquid
nitrogen distribution system of.
Procedure:
-Attach the chip card to the chip card reader placed next to the filling panel. The green
Registration LED indicates login into the system.
-Start the filling by pressing the green button and exhaust the gas until there is liquid
nitrogen coming out from the separator on the end of the filling hose (be careful not to
damage surrounding objects due to the cold exhausted gas). During this step, prepare
the filling needle and the filling distribution.
- Turn off the filling by pressing the red button and carefully insert the filling needle into
the filled vessel.
- Press the green button to start the filling.
- Visually check the neck of the container.
- Stop the filling by pressing the red button as soon as liquid nitrogen appears above the
neck of the Dewar vessel.
- Remove the filling needle and hang it in the rack.
- Attach the chip to the chip card reader at the cryobank entrance and verify your logout
from the system by checking whether the green Registration LED has switched off.
6.6.5 The MaR and functions of the MaR controller
With the exception of field instrumentation, the measuring and regulation system is
concentrated in the RBB.1 switchboard located in control room R1.004 for cryobank
SO001 and RBB.2 in cryobank SO002.
An AiO computer is located at both switchboards. Current conditions of equipment are
displayed on this computer. Furthermore, system parameters can be set there - see
below. A similar AiO computer is located in cryobank SO001 R1.003 to allow presenting
information on equipment without having to access the SO001 control room.
The MaR Monitoring and Security System
The operating principle is strictly structured. This means that there are events that are
defined that clearly determine the origin and termination of any fault condition. Security
functions and SMS generation are derived from the occurrence of faults. All events are
recorded in individual machines, and consequently written into the database along with
other measured values. The sending of emails is initiated here.
The Functioning of the SMS gateway
Due to poor signal quality in building SO001, the SMS gateway is located inside the RP
control cabinet on the outside of the facility.
Two parameters can be set for each SMS.
SMS damping SMS damping interval, i.e. if the fault condition ceases to
exist during this interval, an SMS is not be sent.
SMS blocking the blocking interval determines the period of time after
which an SMS can be sent again
Both these parameters are adjustable in the range of 1..510 minutes. These parameters
can be set only by service personnel. The default values are as follows: damping = 6
min, blocking = 120 min.
An Overview of Fault Conditions with Examples of Sent SMS’s
Page 21/43, Operation Rules version 160306
For Dw, i.e. for Dw1..Dw10 and Dw20..Dw26, 16 fault conditions emergency for each
Dw.
Name
Functional
consequence SMS Mail
A. Highlevel None Yes
A. Lowlevel None Yes
E. Extrahighlevel Master valve blocked ExHighLevelDwX Yes
E. Extralowlevel None ExLowLevelDwX Yes
A. Hightemperature Disposable QC Yes
E. Extrahightemperature Disposable QC Temp. ExHighDwX Yes
Long fill None E-DwX- longfill Yes
Long open door None Yes
AutoFilloften None Yes
AutoQCoften None Yes
Temp 1 sensor error None
Temp 1 sensor
error Yes
Temp 1 out of range None Yes
Temp 2 sensor error None
Temp 2 sensor
error Yes
Hardware error None Hardware error Yes
Unauthorized
manipulation None Yes
A total of 68 fault (and operational) conditions
Building name Alarm name Functional consequence SMS Mail
Tank LIN Weight low None Yes
Tank LIN Weight extraLow Closes valves of all DW, HF1 and HF2
LIN-ExtraLow Weight
Yes
Tank LIN leakage of LIN None Yes
Tank LIN Press low None Yes
Tank LIN Press extraLow Closes valves of all DW, HF1 and HF2
LIN-ExtraLow Pressure
Yes
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Tank LIN Press High None Yes
Tank LIN Press extraHigh None LIN-ExtraHigh
Pressure
Yes
Ambient values 1 Break 24VAC None, relevant valves are
without power
EXTERNAL STOP
Yes
Ambient values 1 Break230V Closes valves of DW1..DW10, HF1, FS1..FS3
Break 230V Yes
Ambient values 1 Oxygen 1 low Turns on AC (Stage 2), OS continuously lit
Yes
Ambient values 1 Oxygen 1 extralow Closes Master Valve 1, turns on AC (Stage 2), OS flashes, AS is on
Oxygen ExLow _
Yes
Ambient values 1 Oxygen 2 low Turns on AC (Stage 2), OS continuously lit
Yes
Ambient values 1 Oxygen 2 extralow Closes Master Valve 1, turns on AC (Stage 2), OS flashes, AS is on
Oxygen ExLow _
Yes
Ambient values 1 Temp.100low None Yes
Ambient values 1 Temp.100extralow Master valve 1 blocked Temp100 ExLow
Yes
Ambient values 1 Temp.1200low None Yes
Ambient values 1 Temp1200 extralow None Temp1200 ExLow
Yes
Ambient values 1 Temp.1200high None Yes
Ambient values 1 Temp1200 extrahigh None Temp 1200 ExHigh
Yes
Ambient values 2 Break 24VAC None, relevant valves are
without power
EXTERNAL STOP
Yes
Ambient values 2 Break230V Closes valves of DW20..DW26, HF2 Break 230V Yes
Ambient values 2 Oxygen 1 low Turns on AC (Stage 2), OS continuously lit
Yes
Ambient values 2 Oxygen 1 extralow Closes Master Valve 2, turns on VZT (Stage 2), OS flashes, AS is on
Oxygen ExLow _
Yes
Ambient values 2 Oxygen 2 low Turns on AC (Stage 2), OS continuously lit
Yes
Ambient values 2 Oxygen 2 extralow Closes Master Valve 2, turns on AC
(Stage 2), OS flashes, AS is on
Oxygen
ExLow _
Yes
Ambient values 2 Temp.100low None Yes
Ambient values 2 Temp.100extralow Master valve 2 blocked Temp100 ExLow
Yes
Ambient values 2 Temp.1200low None Yes
Ambient values 2 Temp1200 extralow None Temp1200 ExLow
Yes
Ambient values 2 Temp.1200high None Yes
Ambient values 2 Temp1200 extrahigh None Temp 1200 ExHigh
Yes
Ambient values 2 Chanel temp.low None
Ambient values FS1 Oxygen low Turns on AC (Stage 2), OS continuously lit
Yes
Ambient values FS1 Oxygen extralow Closes Master Valve 1, turns on AC (Stage 2), OS flashes, AS is on
Oxygen ExLow _
Yes
Ambient values FS1 Temp.100low None Yes
Ambient values FS1 Temp.100extralow Master valve 1 blocked Temp100 ExLow
Yes
Ambient values FS2 Oxygen low Turns on AC (Stage 2), OS continuously lit
Yes
Ambient values FS2 Oxygen extralow Closes Master Valve 1, turns on AC
(Stage 2), OS flashes, AS is on
Oxygen
ExLow _
Yes
Ambient values FS2 Temp.100low None Yes
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Ambient values FS2 Temp.100extralow Master valve 1 blocked Temp100
ExLow
Yes
Ambient values FS2 CO2 high Turns on AC (Stage 2), OS
continuously lit
Yes
Ambient values FS2 CO2 ExtraHigh Turns on AC (Stage 2), OS flashes, AS is on
CO2 ExtraHigh
Yes
Ambient values FS2 CO2-2 high Turns on AC (Stage 2), OS continuously lit
Yes
Ambient values FS2 CO2-2 ExtraHigh Turns on AC (Stage 2), OS flashes, AS is on
CO2 ExtraHigh
Yes
Ambient values FS3 Oxygen low Turns on AC (Stage 2), OS continuously lit
Yes
Ambient values FS3 Oxygen extralow Closes Master Valve 1, turns on AC (Stage 2), OS flashes, AS is on
Oxygen ExLow _
Yes
Ambient values FS3 Temp.100low None Yes
Ambient values FS3 Temp.100extralow Master valve 1 blocked Temp100 ExLow
Yes
GN2 Weight 1 low None Yes
GN2 Weight 1 extraLow None GN2-1 ExtraLow Weight
Yes
GN2 Weight 2 low None Yes
GN2 Weight 2 extraLow None GN2-2 ExtraLow
Weight
Yes
GN2 Press 1 Low None Yes
GN2 Press 1 extraLow None GN2-ExtraLow Pressure 1
Yes
GN2 Press 2 Low None Yes
GN2 Press 2 extraLow None GN2-ExtraLow Pressure 2
Yes
GN2 Reduced Pressure Low None Yes
GN2 Reduced Pressure
ExtraLow None GN2-
Reduced Pressure ExtraLow
Yes
GN2 Reduced Pressure
ExtraHigh None GN2-
Reduced Pressure ExtraHigh
Yes
CO2 Weight low None Yes
CO2 Weight extraLow None CO2 ExtraLow Weight
Yes
CO2 Pressure High None Yes
CO2 Pressure extraLow None CO2-Pressure
ExtraLow
Yes
CO2 Reduced Pressure Low None Yes
CO2 Reduced Pressure ExtraLow
None CO2- Reduced Pressure ExtraLow
Yes
Clients SO1 Door Open None Yes
Clients SO2 Door Open None Yes
Clients FS2 Door Open None Yes
Page 24/43, Operation Rules version 160306
Setting Parameters through the PC-Touchscreen
An inspection of the cryobank can be performed remotely via the cryolab web application.
A special version of the cryolab application is also installed on the touchscreen. There is a
bar in the top section of the application. The actual objects page is the base screen the
touchscreen displays. The page displays all objects, their condition and all currently
measured data, as well as a listing of current fault conditions. This tab is automatically
refreshed every 5 seconds.
The condition of an object is indicated by its colour:
Object OFF - grey
Object turned ON without any fault conditions - green
Object turned ON with a fault - orange
Object turned ON with an emergency - red
Currently measured data are displayed on the screen in detailed windows of individual
objects. They include temperatures, nitrogen level, pressure, humidity, oxygen, etc.
To set or enter a parameter in the following menu, you need to have full access rights -
these rights are initialised with a chip (applies only to chips for the cryobank
administrator) at the entrance card reader. To set parameters, select “set parameters”
and choose the object for which you want to set the parameters
Parameters of “Dewar vessels”. This page can be accessed by pressing the icon of the
related Dw x
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“Control” This parameter can take the following values: OFF – Individual – Group -
StepByStep
o OFF - announces fault conditions of the object and filling is turned off
o Individual - announcement of fault conditions of the object turned on
and individual filling occurs, i.e. with no connection to other Dewar
vessels.
o Group - announcement of fault conditions of the object turned on and
filling within the Group occurs. In this mode, if any object announces
an automatic request for refill, a refilling of all other objects of the
Group is initiated. This option affects the consumption of nitrogen
(refilling of all vessels takes place simultaneously - i.e. the filling
system is cooled just once for refilling the entire group) – and the time
of refilling (more containers take more time to be refilled than just one
- beware of the connection to the LongFill fault condition). A “Group”
always consists of Dewar vessels connected to the same supply pipe.
Therefore, filling takes place only for those vessels physically belonging
to the same group and that are verified in the “Group” mode.
o StepByStep - announcement of fault conditions of the object turned on
and filling in StepByStep mode. In this mode, if any object announces
an automatic request for refill, the refilling of this object is initiated.
After the given vessel is filled, the system gradually starts to fill other
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vessels within the StepByStep group. This option has similar properties
to the Group option, but affects the time for filling less (each Dw is
filled individually, which makes the time for filling of each vessel the
same - the filling takes more time only in case of gradual reduction of
pressure in the nitrogen container). The overall time for filling, of
course, is longer (when compared to the Group option).
TimeLevel This is the interval for bypassing of announcement of “high level” and
“low level” faults. For a short time, a low level (always before filling) and high level
(always after filling) cannot be considered a fault. Therefore, the announcement of
these faults is bypassed by a set interval (a recommended value of 7 200 seconds).
TimeTempHigh and TempHigh are parameters used for announcing a “High
Temperature” fault. If the temperature in the object exceeds the TempHigh value for
a TimeTempHigh, a “High Temperature” fault is announced. When a temperature is
exceeded, a single QC is initiated.
Similarly, TimeTempExHigh and TempExHigh are parameters used for announcing
an “ExHigh Temperature” fault.
TimeFill If the time for opening the valve exceeds the limit set by the TimeFill
parameter, a LongFill fault is given.
TimeOpen If the time for opening the valve exceeds the limit set by the TimeFill
parameter, a LongFill fault is given.
TimeAutoFill If the time between a new request for filling and the last filling is
shorter than TimeAutoFill, an AutoFill Often fault is given. This fault disappears after
the TimeAutoFill timer runs out without a filling request, or this fault can be bypassed
by the button on the RM3.01 main switchboard.
TimeAutoQC If the time between a new request for QC and the last QC is shorter
than TimeAutoQC, a QC Often fault is given. This fault disappears after the
TimeAutoQC timer runs out without a QC request, or this fault can be bypassed by
the button on the RM3.01 main switchboard.
TimeQC Sets the time for opening the filling valve during QC.
Level exlow limit level for announcing a Level exlow
Level low limit level for announcing a Level low
Level high limit level for announcing a Level high
Level exhigh limit level for announcing a Level exhigh
The “confirm” button at the bottom allows the user to enter parameters. If any
parameter is set outside the permissible range, the form is not sent – no changes are
made and incorrect items are highlighted in red.
The parameters of the cryobank and related spaces – select the relevant object on the
“set parameters” tab
OxygenLow, OxygenTime If the level of oxygen in a room is lower than
OxygenLow for a period of time longer than OxygenTime, the Oxygen Low fault is
announced.
Oxygen ExLow If the level of oxygen is lower than OxygenExLow, a Oxygen
ExLow fault is announced.
Temp100Low, Temp100Time If the temperature on the sensor (100 mm above
ground) is lower than Temp100Low, a Temp100 Low fault is announced. If this
condition lasts longer than Temp100Time, a Temp100ExLow fault is announced.
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Temp1200Low, Temp1200Time If the temperature on the sensor (1200 mm
above ground) is lower than Temp1200Low, the Temp1200 Low fault is
announced. If this condition lasts longer than Temp1200Time, a Temp1200ExLow
fault is announced.
Temp1200High, Temp1200ExTime If the temperature on the sensor (1200
mm above ground) is higher than Temp1200Low, a Temp1200 High fault is
announced. If this condition lasts longer than Temp1200ExTime, a
Temp1200ExHigh fault is announced.
PressLow If the pressure in the container is lower than PressLow, a PressLow
fault is announced. The parameter applies to both containers.
Hand Fill Time If the manual filling takes longer than this parameter, the valve is
automatically closed. Manual filling can be started again by pressing the green
Start button.
VZTprolong This parameter determines the run-out time for the airconditioning
unit after a request to run the unit.
Nitrogen Low This parameter sets the limit amount of nitrogen after the
announcement of a Nitrogen Low fault. The parameter applies to both mini tanks.
Nitrogen ExLow This parameter sets the limit amount of nitrogen after the
announcement of a Nitrogen extralow fault.
Fill Door Prolong If the time for opening of filling doors exceeds the time set by
Fill Door Prolong, a Long Open Fill Door fault is given.
Door Prolong If the time for opening of filling doors exceeds the time set by
Door Prolong, a Long Open Door fault is given.
Authorized Time sets the time for which making changes with the door is
allowed since the chip login. After this time is exceeded, an “Unauthorized
manipulation” condition is announced when the doors of the cryobank are
manipulated.
Parameters of cryobanks and related spaces
Screens for adjusting cryobank parameters can be accessed by clicking on the “Ambient
Values1”, “Ambient Values2”, or “LN2” buttons.
OxygenLow, OxygenTime If the level of oxygen in a room is lower than OxygenLow
for a period of time longer than OxygenTime, an Oxygen Low fault is announced.
Oxygen ExLow If the level of oxygen is lower than OxygenExLow, an Oxygen ExLow
fault is announced.
Temp100Low, Temp100Time If the temperature on the sensor (100 mm above ground) is
lower than Temp100Low, a Temp100 Low fault is announced. If this condition lasts longer than
Temp100Time, a Temp100ExLow fault is announced.
Temp1200Low, Temp1200Time If the temperature on the sensor (1200 mm
above ground) is lower than Temp1200Low, a Temp1200 Low fault is announced. If
this condition lasts longer than Temp1200Time, a Temp1200ExLow fault is
announced.
Temp1200High, Temp1200ExTime If the temperature on the sensor (1200 mm
above ground) is higher than Temp1200Low, a Temp1200 High fault is announced. If
this condition lasts longer than Temp1200ExTime, a Temp1200ExHigh fault is
announced.
PressLow If the pressure in the container is lower than PressLow, a PressLow fault is
announced. The parameter applies to both containers.
PressExLow If the pressure in the container is lower than PressExLow, a PressExLow
fault is announced.
HandFillTime Sets the time after which manual filling is automatically closed. To
continue, a new request must be initiated.
VZTprolong This parameter determines the run-out time for the airconditioning unit
after a request to run the unit. The parameter applies to both containers.
Page 28/43, Operation Rules version 160306
Parameters of HF1, HF2 Manual Fillings
Screens for setting HF parameters can be accessed by pressing the “HF1” or “HF2”
button, respectively.
CO2 Parameters
Screens for adjusting CO2 parameters can be accessed by pressing the “CO2” button.
Parameters and their meaning is the same as the related parameters in the Cryobank
tab.
GN2 Parameters
Screens for adjusting GN2 parameters can be accessed by pressing the “GN2” button.
Parameters and their meaning is the same as the related parameters in the Cryobank
tab.
Controller of DW vessels, description and function
Each container is equipped with a controller with a control terminal. The terminal is used
for maintaining manual control and displaying current values and fault conditions.
Furthermore, the terminal displays a listing of fault conditions and gives an indicative
graphs for temperatures, levels and conditions of the valve and the cover for the last 10
days. The graphs are for guidance only – used for a quick overview on the operation and
use of the container.
Fig. 1 Dw controller turned off
Figure 1 shows a switched-off controller of a Dewar vessel. The terminal indicates such
controller as being “OFF”. In the “OFF” condition, no fault conditions are assessed and
the level and temperature are monitored.
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Fig. 2 Dw controller in “Individual” mode – signals Alarm and Emergency.
Figure 2 shows a controller set to “Individual” mode – the display is backlit. An active
alarm is indicated by a permanently backlit “Alarm”, while an emergency is indicated a
continuously backlit “Emergency”. The current level and temperature inside the container
are shown on the display.
The display is a touchscreen and allows the user to control the Dw and switch between
displays. The display is equipped with a resistive touch sensor that is not as sensitive
(you need to push a little more) as the capacitive sensors of touchscreen phones. This,
however, has the advantage that the display does not need contact with human skin and
can be controlled by someone wearing gloves. To switch between screens, swipe
(gesture) left or right. For the gesture to be accepted, you need to swipe horizontally as
straight as possible. Furthermore, a double-click is assessed (for acceptance you need to
perform it at the same spot). And finally, a long press. The meaning of individual
commands is as follows:
There are four buttons with different colours below the display. From the left:
- double-click When the lid of the Dw vessel is closed, a double-click
initiates filling of the container. When the lid is open, (approximately 10 seconds, see
parameter adjustment) a double-click initiates Defrog – a short filling of nitrogen, used
for cleaning – for transparency of the space inside the Dw.
- long press - stops the filling
- left, right - a repeated gesture shows additional screens, see below. The
screen shown in Fig. 2 is the default – after the keyboard is not active for a minute, this
screen is activated.
Fig. 3 Listing of current fault conditions on the controller terminal.
If any fault conditions of the given object are active (i.e. “Alarm” is lit, or “Emer.” is
flashing on the main display), a listing of faults is available. The listing can be accessed
by swiping right on the screen. If no fault conditions are active, the screen cannot be
accessed and the next screen is shown, see below.
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Fig. 4 Graph of the level for the last 13 days
By continuing to press the grey button on the display, a graph of the level for the last 13
day is displayed. The upper line shows the maximum value, the bottom line shows the
minimum value (in this case, the range of values is zero). Figure 4 shows a constant
value. In reality, there will be a noticeable gradual decrease in the level due to
evaporation and an abrupt increase due to supply of nitrogen. The current condition is
shown on the right. Each point on the horizontal axis represent a two-hour interval.
Fig. 5 Graph of temperature for the last ten days
By swiping right, a temperature graph for the last 13 days is displayed. All graphs are
only approximate. Detailed and valid graphs can be accessed via the web application.
Fig. 6 Graph of opening the valve and lid of the Dw vessel
Swiping right on this screen displays a graph of doors and valves for the last 13 days.
The bottom line shows the history of doors, the upper line shows the history of the
supply valve. Swiping right displays the base screen.
Functional Secondary Bonds
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These are safety functions derived from the occurrence of individual fault conditions.
Functional secondary bonds include:
Triggering of emergency VZT (AC) – VZT (AC) is triggered by the following
events:
Oxygen levels in the cryobank drop below the value of the “OxygenLow” parameter, or
Oxygen levels in the cryobank drop below the value of the “OxygenExLow” parameter
Blocking Dewar vessel valves and manual filling – valves are blocked when
the following conditions occur:
Emergency oxygen exlow
Emergency-LIN-pressureexlow
Emergency-LIN-weightextralow
Emergencytemperature 100mm exlow
Break 230V
Extrahigh level DwX
Respective Master Valve closed
Blocking manual filling valves FS1, FS2, FS3 – valves are blocked when the
following conditions occur:
Emergency oxygen exlow
Emergencytemperature 100mm exlow
Break 230V
Master Valve 1 closed
Applied Software:
All MPCs and MT424s (Dw control panels)
Micropel firmware, part of the Micropel supply, see the declaration of conformity
Application SW by Ing. Jaroslav Kurzweil. SW created in StudioWin free software by
Micropel
A description of SW functions in the MPC, MT424, GSM gateway, entering data into the
database and the record of supplied nitrogen.
- The Functioning of the MPC in the MaR switchboard
All measured signals (temperatures, oxygen, humidity, pressures and constant inputs,
e.g. lids of Dw vessels) are applied to, and assessed in the MPC in the MaR switchboard.
This is the core of the functioning of the entire cryobank – the MPC controls all functions
(filling Dw, fault and emergency announcements, emergency signalisation, fan control,
the record of supplied nitrogen, control of communication and management and sending
of SMS’s). Furthermore, the MPC keeps a record of all events (opening of Dw doors,
opening of valves, announcements of faults and emergencies, changes in Dw controls)
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and data of the cryobank (temperature, humidity, pressure, oxygen and amount of
nitrogen) in the internal memory. After the RS485 data network, the MPC is also
connected to Dw controllers, to which it provides information necessary for their proper
functioning.
- The functioning of terminals – control panels in Dw.
The controller interface terminal consists of MT424. Its function is to control the Dw,
display the current condition and alarms of the Dw, and to display an approximate, ten-
day brief history of the Dw. Data about the relevant Dw are stored in the internal
memory (temperature and level).
- The function of touchscreens
A touchscreen provides the operator with a control interface.
7. MaR
The following equipment is installed on the GN2 and LN2 sources: equipment for
measuring pressure differences and recording supplied and taken amounts of LN2;
equipment for measuring the operating pressure in the tank and in the distribution
system. Recorded data are written into the Kryolab application database.
Data are stored in the cryolab database, which is stored on the server. The server is
located in the MaR switchboard in building SO01.
Data are accessible as a part of the current cryolab web application to all registered
users. Alarm messages are sent to these users via email. Adjustment alarm and
emergency condition parameters is done via the touchscreen interface in the control
room or in C cryobanks. Emails and SMS’s are sent selectively, based on user
requirements.
8. The Kryolab Web Interface
Current values and all events in the cryobank, recorded by the measuring and regulation
system, are stored in the database of the server in switchboard RBB.1 in room R1.004.
The Kryolab Web Interface
The Kryolab application is a part of the cryobank monitoring system. It can be accessed
at the IP address assigned by the network administrator (kryolab). To access it, you need
to enter your user name and password assigned to you by the Kryolab application
administrator. Here you can monitor the current conditions of all monitored objects and
their history.
The following sections are available after login:
“Actual object status” – here you can monitor current conditions of all monitored
objects. Individual object colours (grey, green, yellow, red) indicate
their current conditions (off, normal, alarm, emergency). Therefore, the colour meaning
is the same as the touchscreen on the cryobank switchboard. If an alarm or emergency
occurs on one of the objects – such condition is coloured and its name is written into the
object. Clicking on the object – in minimised overview – displays current values.
“Graph” – this section is for displaying graphs of all monitored objects.
Here you can display graphs of objects, both of default ranges and user-specified ranges.
The items labelled “today”, “last 10 days”, “this month” and “last month” refer to
the interval from the current time backwards. The “user range” item allows entering the
display of the desired range between two times in days.
Page 33/43, Operation Rules version 160306
“Values” – this section displays values in the selected time interval.
The desired time range can be set in the same manner as the “Graph” item. This section
displays values.
“Events” – this section displays events that have occurred within the selected time
interval.
“View Parameters” – this section displays an overview of the objects set on the
touchscreen.
"Print" – used for creating a PDF file containing values and graphs for the selected time.
The desired time range can be set in the same manner as the “Graph” item. After
selecting the desired object and time period, you can select items (“Graphs”, “Values”,
“Events”) that are to be included in the PDF.
In each main section, you need to select an object and time period for which the desired
values/graphs are to be displayed.
Page 34/43, Operation Rules version 160306
List of SW:
OS: Linux 2.6.32-24-generic-pae #43-Ubuntu SMP ThuSep 16 15:30:27 UTC
2010 i686, licence GNU/Linux
Apache v.2.2.14, licence http://www.apache.org/licenses/
PHP, licence GPL
Postgresql v.8.4, licence Open Source license
Postfix v.2.7.0-1, free sw license
Open SSH server, GNU
The above is all open source and parts of GNU/LINUX
Kryolab - (c) author/licence Ladislav Koucký
KryoLabgraph 1.0.00 - (c) author/licence Ing. Miroslav Charvát
Note:
The supplier of the system, LINEQ s.r.o., is also the administrator of the cryobank server.
If the server is accessed by an unauthorised person, the supplier shall not be liable for
any damages caused by such action. Source codes of Kryolab and KryoLabgraph are not
included. The operator may use the Kryolab and KryoLabgraph applications only as a
complete monitoring system of the cryobank. The applications must run on the server in
the cryobank switchboard, and the operator must be a registered user of the Kryolab
application.
9. Faults and Emergencies
9.1 A Drop in Oxygen Levels in Filling Areas
If a red or yellow signalisation is triggered, stop the filling process, leave the area
immediately, or do not re-enter it.
The measuring and regulation system will trigger emergency air conditioning.
If in doubt, do not enter on your own and secure the area against entry by another
person outside of the room.
9.2 Uncontrolled leakage of liquid nitrogen from the distribution piping
container and filling points
Uncontrolled leakage is often accompanied by a large amount of nitrogen vapours
(“beads of nitrogen rolling on the floor”), direct leakage of liquid nitrogen, overflow of
Dewar vessels, “jamming” of opened solenoid valves, massive icing on parts of the
distribution system and similar extreme phenomena.
This event is often manifested by a low temperature at 100 mm, oxygen levels below
18%, etc. This, however, is not a mandatory result, and these values may not be
affected at all. Close valves on all containers, valve no. 10 on the GN2 source and no. 21
on the LN2 source in front of the building immediately! Do not forget to report such event
to a responsible person.
9.3 A Loss of Vacuum in Containers, the VIP Distribution System and Filled Dw
and MZ
If a loss of vacuum in the isolation layer occurs, there will be a quick evaporation of liquid
nitrogen. This is manifested by condensation or icing on the outer shell of the containers.
If you suspect a loss of vacuum, investigate the situation immediately and inform a
responsible person. Do not use vessels without vacuum.
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9.4 Solenoid Valve Malfunction
Solenoid valves may malfunction and stay in an open or closed state.
Open state: leakage of liquid nitrogen occurs. Immediately close valve 21 of the liquid
branch on the container and report this event to a responsible person.
Closed state: Loss of functionality, report this event to a responsible person.
9.5 MaR Malfunction
Manifested by system behaviour disorder. Report this event to a responsible person.
9.6 Lack of Liquid Nitrogen in the System
Prevented by daily inspections.
In case of a lack of nitrogen, order a delivery from the supplier.
9.7 A Lack of Gaseous Nitrogen in the System
This may endanger operation in building A. Prevented by daily inspections of the pressure
and contents inside the container.
In case of a lack of nitrogen, order a delivery from the supplier.
9.8 Gas Contamination
This may endanger operation in buildings A and C.
Order LN2 only from a supplier who guarantees purity and can document it with a
protocol for each batch. During filling, the supplier must comply with the regulations and
technological requirements.
The distribution piping and active parts must be kept under pressure. In case of
depressurisation, the system must be thoroughly flushed with gas before resuming
operation.
10.1 Liquid and Gaseous Nitrogen
Properties and effects are included in the Safety Data Sheet, which is a part of the
documentation.
The Basic Characteristics of LN2:
Product Name: Nitrogen
Chemical Formula: N2
Chemical Characteristics: inert, non-toxic, non-flammable, low chemical reactivity
Form: liquid (deeply refrigerated gas)
Colour: colourless
Odour: Odourless
Important Thermodynamic States:
Triple Point: (0.1246 bar) - 210.0 °C
Boiling Point: (1.013 bar) - 195.8 °C
Liquid Density: (- 195.8°C; 1.013 bar ) 0.809 kg/l
Gas Density: (15°C; 1 bar ) 1.170 kg/m3
Saturation Vapour Pressure: (- 195.8°C; ) 1.013 bar
Viscosity: (- 195.8°C; 1.013 bar ) 0.158mPas
Solubility in Water: (15°C; 1 bar ) 0.0214 g/l
Thermal Decomposition: none
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Hazardous Decomposition Products: none
Further Information: Gaseous nitrogen is lighter than air (relative density at 15 °C is
0.967).
Toxicity: non-toxic, in concentrations higher than 80% in
air, it may kill due to the low concentration of oxygen!
10.2 Solid, Liquid and Gaseous Carbon Dioxide
Properties and effects are included in the Safety Data Sheet, which is a part of the
documentation.
The Basic Characteristics of CO2:
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11. Training, Maintenance, Inspections, Service and Emergency
Training, inspections, revisions, calibration and maintenance should be done as described
below.
In case of malfunctions or an emergency, the operator should secure a supplier-
authorised (during warranty period) service supplier.
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Object Type of action Interested
persons
Term Record
L2N and VIP
container, filling
points
Visual inspection Authorised
personnel
Once per
working day
Operational log
L2N and VIP
container,
storage filling
points
Main functions
check
Authorised
personnel
Once per
month
Operational log
L2N and VIP
container,
storage filling
points
Inspection Service Once per 6
months
Inspection record
Ambient
temperature
sensors
Inspection Service Once per
year
Inspection record
Measurement of
oxygen
concentration in
the cryobank
Calibration,
inspection
Service Once per
year
Calibration list
LN2 container –
GN2 source,
distribution
system
Visual inspection Authorised
personnel
Once per
working day
Operational log
LN2 container –
GN2 source,
distribution
system
Main functions
check
Authorised
personnel
Once per
month
Operational log
LN2 container –
GN2 source,
distribution
system
Inspection Service Once per 6
months
Inspection record
Source and
distribution of
CO2
Visual inspection Authorised
personnel
Once per
working day
Operational log
Source and
distribution of
CO2
Main functions
check
Authorised
personnel
Once per
month
Operational log
Source and
distribution of
CO2
Inspection Service Once per 6
months
Inspection record
MaR Inspection Service Once per 6
months of
operation
Inspection record
VPZ, VTZ, VEZ,
MaR
Revision Revision report Once per 3
years
Revision report
VPZ, VTZ, VEZ,
MaR
Training,
examination
Operators and
tutor
Once per 3
years
Protocol
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List of revisions
Source of gaseous and liquid
nitrogen, distribution system, filling
points and cryobank term
Revision of dedicated pressure equipment
At least Once per 3
years
Revision of dedicated gas equipment
At least Once per 3
years
Revision of dedicated electric equipment
At least Once per 3
years
List of
Inspections and
Maintenance
Schedule
Source of gaseous and liquid
nitrogen, distribution system, filling
points and cryobank term
Revision and maintenance of dedicated
pressure equipment
At least Once per 6
months
Revision and maintenance of dedicated
gas equipment
At least Once per 6
months
Inspection and maintenance of the MaR
At least Once per 6
months
Inspection and maintenance of the web
application
At least Once per 6
months
Inspection and maintenance of the GMS
gateway
At least Once per 6
months
Inspection and maintenance of the
database
At least Once per 6
months
Inspection and maintenance of MaR, PLC
and data concentrators
At least Once per 6
months
Inspection and maintenance of the web
application
At least Once per 6
months
Inspection and maintenance of the GMS
gateway
At least Once per 6
months
Inspection and maintenance of the
database
At least Once per 6
months
Training List
Training for operating pressure
equipment, examination, issuance of
certificates for operators
At least Once per 3
years
Training for operating the monitoring
system, training report
At least Once per 2
years
Calibration Oxygen sensor, 7 pieces Once per year
Software update
of the web
application
Sources of gas and LIN, cryobank,
filling points Once per 6 months
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An Overview of Inspection and Service Activities for the Dry Ice
Machine
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12. An Overview of the Estimated Useful Life of Equipment and a List of
Expected Supply Materials
DESIGNATION PART Service Life Note
1
Source of
LN2
at least 10
years
With the exception of consumables, gaskets,
safety valves, valves and fittings. Their
service life depends on operating conditions
and their replacement is determined during
inspections and revisions.
2
Distribution
of LN2
at least 10
years
With the exception of consumables, gaskets,
safety valves, valves, fittings and vacuum
insulation. Their service life depends on
operating conditions and their replacement
is determined during inspections and
revisions.
3
1st floor
filling point
at least 10
years
The oxygen
measurement
converter
and sensors
for
temperature
and humidity
have a
service life of
a maximum
of 5 years.
With the exception of consumables, gaskets,
safety valves, valves, fittings, flex hoses
and vacuum insulation. Their service life
depends on operating conditions and their
replacement is determined during
inspections and revisions.
4
Exhaust of
Filling Points
at least 10
years
With the exception of consumables, gaskets,
safety valves, valves, fittings and flex
hoses. Their service life depends on
operating conditions and their replacement
is determined during inspections and
revisions.
5
Filling point
1
at least 10
years
The oxygen
measurement
converter
and sensors
for
temperature
and humidity
have a
service life of
a maximum
of 5 years.
With the exception of consumables, gaskets,
safety valves, valves, fittings, flex hoses
and vacuum insulation. Their service life
depends on operating conditions and their
replacement is determined during
inspections and revisions.
6
Filling point
2
at least 10
years
The oxygen
measurement
converter
and sensors
for
temperature
and humidity
With the exception of consumables, gaskets,
safety valves, valves, fittings, flex hoses
and vacuum insulation. Their service life
depends on operating conditions and their
replacement is determined during
inspections and revisions.
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have a
service life of
a maximum
of 5 years.
7
Filling point
3
at least 10
years
The oxygen
measurement
converter
and sensors
for
temperature
and humidity
have a
service life of
a maximum
of 5 years.
With the exception of consumables, gaskets,
safety valves, valves, fittings, flex hoses
and vacuum insulation. Their service life
depends on operating conditions and their
replacement is determined during
inspections and revisions.
8
Exhaust of
Filling Point
at least 10
years
With the exception of consumables, gaskets,
safety valves, valves, fittings and vacuum
insulation. Their service life depends on
operating conditions and their replacement
is determined during inspections and
revisions.
9
GN2 source at least 10
years
With the exception of consumables, gaskets,
safety valves, valves and fittings. Their
service life depends on operating conditions
and their replacement is determined during
inspections and revisions.
10
LN2
Distribution
at least 10
years
With the exception of consumables, gaskets,
safety valves, valves, fittings and vacuum
insulation. Their service life depends on
operating conditions and their replacement
is determined during inspections and
revisions.
11
GN2
Distribution
at least 10
years
With the exception of consumables, gaskets,
safety valves, valves, fittings and vacuum
insulation. Their service life depends on
operating conditions and their replacement
is determined during inspections and
revisions.
12
CO2
Distribution
at least 10
years
With the exception of consumables, gaskets,
safety valves, valves, fittings and vacuum
insulation. Their service life depends on
operating conditions and their replacement
is determined during inspections and
revisions.
Expected Consumables
Seal kit including a Rego 1/2" stopper
Seal kit including a Rego 3/8" stopper
Seal kit including a Herose DN15 stopper
Seal kit including a Herose DN20 stopper
Seal kit including a Herose DN25 stopper
Seal kit for Solenoid ACO, 1/4" and 3/8"
O-ring for VIP DN15/60
Light source for opto-acoustic signalisation
Flex stainless steel hose DN10/2000
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Flex stainless steel hose DN12/1600
Filling aerator LIN, 3/8"
Safety valve ¼“, 3 bar
Safety valve ¼“, 10 bar
Safety valve 1/2“, 25 bar
Safety valve 1/2“, 8 bar
Safety valve 1/2“, 18 bar
Backflow valve ½“
Variogard oxygen measurement converter
Variogard CO2 measurement converter
Pt100 temperature sensor
Pressure sensor
Pressure difference sensor
Humidity sensor
Exhaust regulator
Reducing valve
AP30 spare kit including hydraulic oil
Liquid nitrogen, purity 5.0
Liquid carbon dioxide
13. Operational Safety
The Main Principles:
Comply with Decrees no. 18/1979 Coll., 21/79 Coll., 3/2010 Coll., 85/1978 Coll.,
551/1990 Coll. and 378/2001
Observe all operating rules and manuals.
The operator must be familiar with the nitrogen safety data sheet.
Observe the dates of training, inspections and revisions listed in Article 7.
Keep the equipment and its surroundings in good condition and address any faults or
emergencies immediately.
Servicing and modifications may be performed only by authorised and qualified service
personnel.
The operating personnel must be qualified and have good knowledge of the equipment,
connections and hazards
The operating personnel must wear protective equipment: for work with LN2, they must
wear hand and face, or eye protection
Air conditioning at the filling points must operable. If it is out of order, substitute
ventilation must be provided.
Hazards:
1. Hazards due to pressure: LN2 may evaporate and cause an explosion in
enclosed spaces.
Examples: a section of piping or hose without a safety valve
a closed container without any safety elements
2. Hazards due to low temperature: During normal pressure, LN2 has a
temperature of - 196 °C. Supercooled LN2 and supercooled GN2 exhaust are
especially dangerous. Risk of severe frostbite.
Examples: the supercooled surface of non-insulated distribution system
of LN2
LN2 gushing or dripping due to leakage
the emission of supercooled GN2 from exhaust
3. Risk due to low amounts of oxygen: an increased concentration of N2 can be
deadly.
The Effects of O2 concentration
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O2
(%)
Effects and symptoms
18-21 No recognisable symptoms
in persons. Risk assessment
must be carried out so
that the causes are understood,
and then to decide whether it is safe
to continue work.
11-18
Reduced physical and mental
performance without the knowledge
of the affected.
8-11
Possible fainting after
several minutes with no prior warning.
Risk of death at concentrations below 11%
6-8
Fainting occurs after a short time.
Resuscitation is possible if performed
immediately.
0-6
Almost immediate fainting.
Brain damage even in the case of
a rescue.
The Effects of CO2 concentration
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14. Warranty
The work performed shall be considered free of defects if its installation, startup and
operation corresponds to the intended result described in the supplier contract.
The warranty period and conditions are subject to the contract with the supplier.
The warranty is conditioned by:
- proper operation in accordance with operational rules, manuals and regulations in force
- operation by qualified personnel with valid training, examination and certification
(issued by the contractor of the work)
- compliance with dates of inspections, revisions and training
- servicing, any possible modifications and inspections are to be carried out by the
supplier or a supplier-authorised supplier.
15. Successive Regulations and Documents
ČSN EN1251 – ČSN EN1253 - The operation of vacuum insulated containers
ČSN 690012 - Stable pressure vessels
Reg. No. 85/78 and 21/79 Coll.
ČSN EN 13 480 – operation of air conditioning equipment
Directive 97/23/EC
ČSN 07 8304 Pressure vessels for gas – Operation Rules
Collection of Laws No. 378/2001 regarding the requirements for safe operation.
Operational requirements of Reg. 18/1979 Coll. as amended by Decree 551/1990 Coll.,
which addresses dedicated pressure equipment and imposes certain conditions to ensure
their safety.
Collection of Laws No. 378/2001 regarding the requirements for safe operation.
Nitrogen Safety Data Sheet
Documentation of the actual construction with all instruction manuals, declarations of
conformity, drawings, etc.
16. Contact Information
Workplace Contact e-mail telephone
Operator
Administrator
Page 47/43, Operation Rules version 160306
Supplier Lineq s.r.o.
[email protected] 724 115 290
Supplier of liquid
N2
Supplier of liquid
CO2
Fire department
150
Emergency
medical service
155