The Butler Gas Products microbulk system reduces costs, increases safety, and maximizes efficiency. The basic idea behind microbulk is replacing cylinders with one, or a few, larger tanks. These tanks are piped into the facility so the gas is available at its points of use. Our truck stops and fills the tank; there’s no cylinder exchange.
Cost reduction is made possible because the system eliminates residual gas loss, reduces the labor costs associated with moving dangerous cylinders, and creates more profitable space in the workplace. This gas system eliminates the residual waste that normally gets sent back in cylinders, allowing more product to be used. The microbulk customer does not have to worry about moving and changing out heavy cylinders, nor does a microbulk user have to dedicate half of the workspace to cylinder storage.
Microbulk System Standards
We hold our microbulk system to a high standard when it comes to technology. The microbulk tanks are built to more advanced specifications and offer much better insulation than DOT cylinders. The thermal characteristics keep the gas from blowing off into the atmosphere, keeping in more of the product.
Mode Change Process
We offer microbulk and bulk supply solutions in nitrogen, oxygen, argon, and CO2.
After conducting a site visit and learning more about your gas consumption, our sales and engineering consultants will collaborate with your operations team to determine the best, most efficient asset package for your application. Full-sized bulk (300 gallons and larger) is surely not designed for all applications and often requires large upfront investments for tank placement and installation. Microbulk (230 – 3000 liters) mimics the benefits of bulk but minimizes the investment, creating the perfect medium for the business who wants an efficient customized solution.
The Butler Gas Products team has full installation capabilities for microbulk applications. Utilizing telemetry technology, we monitor your tank levels remotely, automatically dispatching trucks to fill the tank as needed. The days of monitoring your packaged gas inventory and scrambling to place emergency cylinder deliveries disappear with a microbulk solution from Butler Gas Products.
We install and fully service microbulk systems for nitrogen, argon, oxygen, and carbon dioxide. Our sales and engineering team works with our customers to design, install, preventatively maintain, and service systems of all shapes and sizes.
Our Top 10 Service FAQs and Troubleshooting Tips for Perma-Cyl Microbulk Tanks:
1. No gas to gas-use equipment or insufficient pressure to gas-use equipment
Possible causes include (1) the Perma-Cyl tank is empty; (2) Gas Use Valve to final line regulator is closed or other valves downstream are closed; (3) Pressure builder is not building sufficient pressure; (4) Final line pressure regulator is set too low or malfunctioning; or (5) An inappropriate type of final line regulator was installed and is not able to supply sufficient gas flow. Contact Butler Gas for additional technical support regarding corrective action.
2. Frost or ice on sides, bottom, top-center and/or plumbing of tank
This is a normal condition during and following gas use, liquid use, or filling. If the tank is being used for a continuous flow application and is not receiving sufficient ambient heat to melt the frost or ice, the tank may need to be moved to a warmer location or be paired with a switchover system to allow the tank to rest and warm up when not in use. If frost is present on the tank after an extended period of time with no gas or liquid use, there could be a leak. Ventilate the area and contact Butler Gas. If condensation or sweating is noticed over the entire outer shell, this is a sign of a vacuum issue; please notify us.
3. Routinely low pressure in the tank
Ensure that the pressure builder valve is open and that the regulator is properly adjusted to allow pressure to build. In the event that the gas or liquid withdrawal rate exceeds the tank specifications, the pressure builder will be unable to maintain pressure demands. If withdrawing gas, an external vaporizer may be needed. For gas or liquid applications, a larger tank can also be installed. Contact your Butler Gas sales representative for more information. Routinely low pressure can also be the sign of a large leak. Ventilate the area and contact us as soon as possible.
4. Gas supply to gas-use equipment is too cold
Either the ambient temperature surrounding the Perma-Cyl is too cold or the gas withdrawal rate exceeds the capacity of the tank’s ambient vaporizer. The tank can be moved to a warmer location. We can install a freestanding ambient vaporizer on the gas supply line in a warmer location or an in-line gas heater. A larger tank with a greater withdrawal rate capacity can also be an option.
5. Routinely high tank pressure
This is a normal occurrence when little or no gas has been used for several days. However, this can also be a sign that the pressure building function on the regulator is set too high or that the regulator is malfunctioning. In this case, reduce the pressure setting by turning the adjustment knob counter-clockwise to the desired pressure setting and continue normal gas use until the pressure drops.
6. Hissing sounds or evidence of gas leaking near tank, gas lines, or gas-use equipment
Evacuate the area if the tank is not located in a well-ventilated space. If safe to do so, observe and locate the leak to help identify if its source is a relief valve or a larger leak from elsewhere in the system. Contact us to coordinate a service technician visit.
7. High gas usage
Our hope is that this is caused by your successful and booming business! However, if there have been no changes in your application’s running time, this could be a sign of a leak or frequent venting due to high tank pressure. Refer to the sections on leaks and pressure, and contact us for additional support.
8. Perma-Cyl does not shut off properly
Butler Gas offers full piping installations to provide hassle-free compressed gas solutions. In some instances, we may need to reroute existing piping to prevent pressure drop. System pressure drop can be the culprit behind the Perma-Cyl not shutting off properly, caused by insufficient pipe diameter and/or unnecessary or restrictive bends.
9. Liquid withdrawal contains high level of gas
This occurs when the saturated liquid pressure in the Perma-Cyl is too high. The temperature or energy level of the contents is too high due to excess pressure. The tank must only be filled with low pressure cryogenic product and a secondary lower pressure relief valve may need to be installed to reduce saturated pressure of liquid in the future.
10. Vacuum pump-out port and/or vacuum plug are open or damaged
To prevent damage caused by tampering, we recommend enclosing and securing all microbulk tanks. For logistics ease, we ask that you please provide us with a copy of the key. In the event of damage or tampering, contact us immediately to arrange a service technician visit.
Please note this is a troubleshooting guide and not a comprehensive list. For full technical support, contact us at 800-860-2427.
Source: Chart Industries