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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


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


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


The disposition of technology in SO02


The disposition on the motherboard:

The technological diagram of the motherboard


The technology diagram of SO01


The technology diagram of SO02

Diagrams and dispositions are part of the Documentation of the actual construction

4. Operation of the Source of CO2


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).


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.


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




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.


at intervals specified in Article 11, and maintaining a logbook.




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.


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.


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.


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





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



at intervals specified in Article 11.




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


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.


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.).


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


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.


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


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.


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


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


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


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


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 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


Yes

Ambient values 2 Oxygen 1 extralow Closes Master Valve 2, turns on VZT (Stage 2), OS flashes, AS is on

Oxygen ExLow _

Yes


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.100extralow Master valve 2 blocked Temp100 ExLow

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


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.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


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.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


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


“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


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.


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.


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.


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.


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


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)


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.


“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.


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.

http://www.apache.org/licenses/


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


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:


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.


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


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


months

Inspection record

Source and

distribution of

CO2


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


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


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


An Overview of Inspection and Service Activities for the Dry Ice

Machine


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


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.


safety valves, valves, fittings, flex hoses

and vacuum insulation. Their service life

depends on operating conditions and their

replacement is determined during


4

Exhaust of

Filling Points

at least 10

years


safety valves, valves, fittings and flex

hoses. Their service life depends on



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.







6

Filling point

2

at least 10

years

The oxygen

measurement

converter

and sensors

for

temperature

and humidity








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.







8

Exhaust of

Filling Point

at least 10

years






revisions.

9

GN2 source at least 10

years


safety valves, valves and fittings. Their

service life depends on operating conditions

and their replacement is determined during


10

LN2

Distribution

at least 10

years






revisions.

11

GN2

Distribution

at least 10

years






revisions.

12

CO2

Distribution

at least 10

years






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 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


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



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


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


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


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

mailto:[email protected]