Home

Installa tion and Opera tions Manual 2520 High

Contents

1. 43 5 1 Electrostatic Discharge 43 5 2 L brication REED S EP es 43 5 3 Oil filled Ga ges isciieu EEA EE Eal E RES 44 5 4 Inspection dis ete Gals LR Re RET RE E er ERE ET 45 5 5 Changing Dial Plates 45 5 6 Maintenance and Repair 46 6 51 6 1 Common 51 6 1 1 Dials do not respond when check knob 52 6 1 2 Calibration repeatability unstable 53 7 SPECINCAIONS cd evecare shat etat tb ag s MA NM ds 55 7 1 Genetal icone been eve eis queer niunt ds 55 7 2 Environmental tox RR RE Rr Er ERE TER RT 55 7 3 Mechanical 5 55 7 4 Certifications and 55 8 Ordering 1 57 8 1 Order Codes cx ieee Ret Ie a beso eee icr es 57 viii Installation and Operations Manual High Pressure Automatic Tank Gauge 1 Introduction 1 1 Using this Manual This manual is designed to assist the user in the installation operation maint
2. b kae LAM LO RM tA 7 341 General Preparation 7 3 2 Planning the 1 5 8 3 3 Spheres and Cylinders to 16 Feet Diameter Grade Level Installation 11 3 3 1 Zeroing the display sem Re mrt yk Rm xx 18 3 3 2 Initial calibration sue RR Re OE EG Pe ERR RR TRU RR RR n 18 3 3 3 Auxiliary 21 3 3 4 1 21 3 3 5 Installation quality 22 3 3 6 Reassembly 4 4 ek gan beeen ae RR RERO Ue Baie RTR DR Rer 22 3 3 7 Pressure test the system 22 3 4 Spheres to 48 Feet Diameter Grade Level Installation 24 3 4 1 Zeroing the display 27 3 4 2 lniitial calibration eae ee bap teed at RERO REDE RE RR 27 3 4 3 Auxiliary 28 3 4 4 1 28 3 4 5 Installation quality 28 3 4 6 Reassembly 28 3 4 7 Pressure test the system 29 3 5 Spheres to 60 Feet Diameter Grade Level Installation 30 3
3. Measurement Units 05 English 220 psig 15 bar g 06 Metric 220 psig 15 bar g Tank Type 05 Tank Spheres to 16 ft Diameter or Horizontal Cylinder Tanks TO6 Tank Spheres to 48 ft Diameter T07 Top Mounting on Tank Sphere or Horizontal Cylinder Tanks T08 Tank Spheres to 60 ft Diameter or Horizontal Cylinder Tanks Plug Valve 0 Plug Valve Not Used 1 1 2 0340 300 psig 15 bar g Gauge Plug Valve Viton A plug Transmitter Adapter 0 Transmitter Adapter Not Used 2581 Transmitter Adapter N2520 Example Order Code N2520 06 T05 1 1 Table 8 3 2520 Automatic Tank Gauge ATG 220 psig 15 bar g ATEX Class 1 Zone 1 Ex Il 2G T5 220 psig 15 bar g 58 Installation and Operations Manual Document Code IOM015GVAE4011 Varec Inc 5834 Peachtree Corners East Norcross Atlanta GA 30092 USA Tel 1 770 447 9202 Fax 1 770 662 8939 www varec com 2006 Varec Inc All Rights Reserved This document is for information purposes only Varec Inc makes no warranties express or implied in this summary The names of actual companies and products mentioned herein may be the trademarks of their respective owners
4. Check the part number on the roll of perforated tape to be sure that it is long enough for the tank At the elbow on the tank entry pipe unroll one or two turns of the perforated tape and start to feed it into the horizontal pipe Leave the tape in the box and continue to unroll it several turns at a time until it enters the gaugehead Spread a clean ground cloth below the gaugehead and remove the lower hole plug Continue to unroll the tape several turns at a time feeding it through the gaugehead and lower tape hole and onto the ground from the tank entry pipe elbow until the tape is unrolled Make sure that the tape on the ground does not become kinked or dirty At the elbow on the tank entry pipe lower the end of the tape through the pipe to the tank bottom Let several inches fall on the tank bottom Remove the product specific gravity tag from the float cluster and save it for future reference Attach the tape to the float with the furnished fastener Feed the other end of the tape over the sheave in the elbow above and make sure that it is seated on the pulley See Figure 3 5 on page 19 and attach the furnished installation crank to the tape storage gaugehead tape storage sheave The negator spring motor delivered with the gaugehead was selected by the user s specification of the tank depth of the installation Use the installation crank Wind the motor clockwise the number of turns shown in Table 3 2 on page 14 then tighten the thu
5. No noticeable binding friction in the mechanism Installation cleanliness moana Dp True vertical gauge piping Warning Make certain that the tank is empty and not in service Ensure that the tank has been leak and pressure tested as appropriate for the liquid to be stored Observe appropriate safety precautions in flammable or hazardous liquid storage areas Do not enter a tank that has contained hydrocarbons vapors or toxic materials until a gas free environment is certified Carry breathing equipment when entering a tank where oxygen may be depleted with carbon dioxide nitrogen or other gases Warning The mechanical connections between the guide cables the float the tape and the gaugehead provide an electrical resistance path to ground that is adequate for the safe electrical drain of electrostatic charges that may accumulate in the tank and the product Worker activity and worker clothing may accumulate electrostatic charges on the body of a worker Care should be used in flammable environments to avoid the hazard The user provides the 1 l 2 inch pipe that carries the perforated tape The user must perform the welding tasks and install the necessary mounting The user must drill holes in the tank as needed Assemble the necessary tools and equipment at the work site Table 3 1 on page 9 lists typical tools and equipment that may be needed Use the drop cloth to maintain tool equipment and installation kit cleanliness Vare
6. 10 Replace the counter cover and gasket 20 Installation and Operations Manual High Pressure Automatic Tank Gauge Figure 3 6 shows display adjustments in English fractional and metric hd eer Ti zn uml C ENGLISH FRACTIONAL METRIC Figure 3 6 Display Adjustments 3 3 3 Auxiliary equipment If auxiliary equipment is to be installed remove the cap from the back cover The hole size and bolt pattern mates with Varec auxiliary options Each mating auxiliary unit has a coupling that engages the magnetic drive assembly Use the cap screws to attach the auxiliary unit adapter to the back cover Refer to the manual for the auxiliary unit for operational checkout after it is installed Note The use of auxiliary units not manufactured or supplied by Varec will void any Varec warranty and will relieve Varec of any obligation to service the product under warranty 3 3 4 Initial lubrication Apply LPS 2 to the elbow sheave If the gaugehead is not going to be filled with oil apply LPS 2 to the tape sprocket and storage sheave If the gaugehead is to be filled with oil perform the following reassembly then fill with oil Refer to Chapter 5 Maintenance on page 43 for the details For most service Varec recommends filling the gaugehead with oil to prolong the life Note Before the gaugehead is filled with oil the NPT plug on the counter side that has a hole to drain condensation must be replaced with a solid NPT plug
7. 71 C Date Of Mfr 30 F Ta lt 160 F Reference the opens Q9 C Manual for Details Made in USA 4 16 013139 RevA Le 5834 Peachtree Corners m Noes Atlanta Georgia 30092 USA 300 psig 20 6 bar g 4 P 2520 j Automatic Tank Gauge 220 psig 15 bar g Model No C lt 12675 Serial No 34 C lt lt 71 Date Of Mfr 30 F lt Ta lt 160 F e qeu T 29 A Made in USA GE 16 013138 Rev A 5834 Peachtree Corners East Aliens Georgia 30092 USA 9 220 psig 15 bar g Figure 2 1 2520 High Pressure Automatic Tank Gauge Labels Varec Inc Identification 6 Installation and Operations Manual High Pressure Automatic Tank Gauge 3 Installation 3 1 General Preparation Read Chapter 1 Introduction on page 1 Determine the feature and option codes of the unit to be installed Use Table 8 1 Table 8 2 and Table 8 3 on pages 57 and 58 to determine the appropriate installation figure in this user s manual These are typical installations All situations may not be covered Contact Varec if additional information is needed It is paramount that the user monitors the quality of the installation to assure long term accurate performance If the quality is compromised inferior operation may result Particularly important are Accurate measurements referenced to the tank benchmark Clean interior of the gauge piping No kinks in the tape cable
8. FASTENER BOTTOM ANCHOR MOUNTING BRACKET SHEAVE ELBOW 90 SHEAVE ELBOW 30 GUIDE CABLE 14 50_ TK NOZZLE BY CUSTOMER 15 7150 OR TK NOZZLE BY CUSTOMER NOZZLE LAYOUT IN TANK Ti PECIFY TANK HEIGHT C DIMENSION amp H DIMENSION 14 F1G 275 RUBBER Pi T A QPTIONAL Note 150 flanges for 150 psig models 300 flanges for 220 psig amp 300 psig models Note 220 psig and 300 psig are the same dimensions 50 _ 516 5 50 4 75 5 50 5 62 TOP ANCHOR DETAIL Figure 3 9 Typical Grade Level Installation for Spheres to 60 Feet Diameter Varec Inc 31 Installation 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Install a 30 degree pipe in the bracket and attach it to the 30 degree elbow then attach the second 30 degree elbow Attach the second 30 degree pipe to the bracket and elbow Attach the last 30 degree elbow to the pipe Attach the vertical pipe to the 30 degree elbow Make certain that dimensioning remains as indicated Remove the housing nipple and cap from the top cable anchors and hang plumb lines from them at the center to mark the position where the bottom cable anchors will be welded Mark the plumb bob string at the height of the tank bench mark This will assure that the plumb bob just touches the bottom when the reference is made fr
9. Figure 3 6 on page 21 and loosen screws A until the dial plate and gear rotate freely and independently of the hub Check that the float cluster is at the bottom of the tank with the tape taut Rotate dial and gear H until counter drums all display zero Initial calibration These instructions apply to systems that use a float cluster The float cluster is shipped with six weights attached Table 3 3 on page 20 lists the submersion depth of the cluster for products having specific gravity ranging between 45 and 69 and the quantity of the weights that are required The product specific gravity tag removed from the float cluster should be saved for future reference Note During manufacturing lead shot may be added to the interior of each sphere to make the equator depth submerged displacement equal to 402 12 cu in when the specific gravity is beyond the standard range between 45 and 69 Determine the specific gravity of the product to be stored Refer to Table 3 3 on page 20 and remove the required number of weights Pull up on the dial and gear H to disengage them from the counter pinion then rotate the dial to indicate four inches 102 mm for products with specific gravity between 51 and 69 at 60 degrees F For product of specific gravity of 48 set the dial and drums to indicate four and 1 8 inches 104 8 mm For product of specific gravity of 45 set the dial and drums to indicate
10. P031 03 1642 KIT INSTRUCTIONS MAINT 2520 33 08848 GASKET COUNTER HOUSING 2500 B6287 071 2520 O RING RETAINER B7411 005 DIAL GEAR ENGLISH B8235 040 DIAL ENGLISH B8218 001 SLOTTED SHIM 010 P031 29 1883 COUNTER COVER GASKET 2500 B7720 071 SHEAVE ASSY MOTOR 70 ALUM BA17725 SPRING GAUGE CHECK 2500 B7796 005 GAUGE CHECK ASSY 2520 BA11566 HUB DIAL PLATE B9668 001 POST 2500 B6547 005 GASKET BACK COVER 300 GA B7293 046 RETAINING RING 5 16 SS P10 2 O RING 11 16X1 2 VITON A P14 148 DELRIN PINION GEAR P25 16 RETAINER DIAL 2500 B8234 001 ENGLISH COUNTER ASSY 2500 BM18849 100 0 RING 38IDX 500DX 06 VITON P14 146 GASKET CAP 2500 B5059 071 PHMS 8 32X1 4 SS P031 01 1719 HSSS 10 24 X 1 2 CUP PT P31 657 TAPE KEEPER SPRING 2500 B7300 005 BINDING HD MACH SCREW 10 24 1 P31 669 WASH SHIM 562X 316 313X 005SS P31 13 Varec Inc 47 Maintenance Part Name Metric Part Number 13 08785 2500 CRANK ASSY BM3784 TAPE MET PERF 316 SST X 180 B10538 606 FHMS 10 24 X 3 8 304 SS P031 03 1642 HSSS 10 24 X 1 2 CUP PT P31 657 KIT INSTRUCTIONS MAINT 2520 33 08848 GASKET COUNTER HOUSING 2500 B6287 071 2520 O RING RETAINER B7411 005 DIAL GEAR METRIC B8327 040 COUNTER COVER GASKET 2500 B7720 071 DIAL PLATE METRIC 30 CM GRAD B8325 001 SHEAVE ASSY MOTOR 70 ALUM BA17725 SPRING GAUGE CHECK 2500 B7796 005 WASH SHIM 562X 316 313X 005SS P31 1
11. four and 4 inches 107 9 mm Re engage the gear and pinion Tighten screws Loosen the thumbscrew lock Observe the operation of the drums and dial while slowly cranking the float cluster to the top of the tank and then lowering it to the bottom The drums and dial should rotate freely and return to the calibrated indication when the float cluster touches the tank bottom Varec Inc 33 Installation 7 Use the chart furnished with the float cluster Mark the float cluster for the submersion depth for the particular product to be stored in the tank 8 With the float cluster on the bottom measure the distance from the tank bottom to the sub mersion depth mark Use this distance to reset the dial and counter drums for an empty tank 9 Tighten the screws after resetting the drums and dial 10 Replace the counter cover and gasket 3 5 3 Auxiliary equipment If auxiliary equipment is to be installed remove the cap from the back cover The hole size and bolt pattern mates with Varec auxiliary options Each mating auxiliary unit has a coupling that engages the magnetic drive assembly Use the cap screws to attach the auxiliary unit adapter to the back cover Refer to the manual for the auxiliary unit for operational checkout after it is installed Note The use of auxiliary units not manufactured or supplied by Varec will void any Varec warranty and will relieve Varec of any obligation to service the product under
12. page 44 to determine the appropriate oil Fill the counter side separately Before filling the counterside substitute a solid NPT plug for the NPT plug with the condensation draining hole by reversing the top and bottom plugs Table 5 2 lists typical gaugehead oils Temperature Degrees Typical Oil c F 0 32 and above Light weight uncompounded low pour mineral oil 32 22 to 0 32 LPS 2 52 62 to 30 22 Low viscosity synthetic base Mil L 7808D 8B or equivalent Table 5 2 Typical Gaugehead Oils 44 Installation and Operations Manual High Pressure Automatic Tank Gauge 5 4 Inspection It is recommended that the first inspection after the unit has been placed in service be made at the end of the first thirty day period Subsequent inspections should be made every 90 days see Table 5 1 on page 44 The user may adjust the schedule for his own convenience and safety depending upon the product Varec maintenance service contracts are available for 90 day periods at a substantial savings Caution Do not release the checker knob and allow the springs to return the mechanism Over time the springs may break and jam the gauge 1 Check the operation of the gauge and calibrate 2 Check for pipe corrosion Interior corrosion of the pipe carrying the tape may become deposited in the mechanism and affect the accuracy 3 Check for leaking oil in oil filled gaugeheads 4 Check for leaking product 5 5 Changing Dial Pla
13. pass over the top of the tank shell close to a stairway platform to facilitate inspection and service of the gauge system Provide the roof holes shown in Figure 3 10 on page 37 centered on this position The guide cable holes are centered 8 50 inches 216 mm each side of the center of the cluster of floats The tape pipe is centered on a 17 00 inch 432 mm diameter The plug valve is also centered on this dimension Weld a1 112 inch ANSI 150 Ib or 300 Ib flanged nozzle into the top pipe center hole Make certain that it is welded in true vertical position Hold it plumb while welding Failure to place the flanged nozzle in a true vertical position may affect the accuracy of the gauge Make sure that the interior of all flanges and pipes are clean and corrosion free Weld the top cable anchor 1 114 inch flanged nozzles into their respective holes Make cer tain that they are welded in a true vertical position Check with a plumb line prior to welding and maintain the plumb position during welding Make sure that the interior of the flanges remain clean and corrosion free Install the Varec plug valve if it is to be installed and install the top pipe Note Failure to place the pipe in a true vertical position may affect the accuracy of the gauge Center the base of a top cable anchor in its hole Hold it plumb while welding it to the roof Do the same for the other top cable anchor Remove the housing nipple and cap from the top cabl
14. service the product under warranty Varec Inc 39 Installation Initial lubrication The gaugehead that is mounted on top of a tank cannot be filled with oil Apply LPS 2 to the tape sprocket and storage sheave Installation quality check It is essential that the user recheck the quality of the installation and then double check it before pressurizing the tank There is no easy method of correcting installation error after the tank is filled If the float cluster travel is stuck due to cables that are not parallel and plumb or if the tape cable travel is impaired repair cannot be accomplished until the product pressure is removed from the tank 3 6 6 Reassembly Remove the installation crank If auxiliary equipment was not installed replace the back cover and its gasket Using the torque sequence shown in Figure 3 7 on page 23 torque the bolts to 30 ft Ibs 41 Nm If auxiliary equipment was installed seat the magnetic coupling with the auxiliary adapter coupling and replace the back cover with the auxiliary unit adapter attached Check the operation of the auxiliary unit as appropriate 1 Replace the gaskets covers and bolts on the elbows 2 Torque the bolts as shown in the Figure 3 7 on page 23 3 Close the tank manholes and inspection covers 3 6 7 Pressure test the system Perform a pressure test of the vessel with the gauge and piping installed Proof test to 1 50 times the normal maximum pressure Thi
15. spring Replace the housing nipple and cap Warning Whenever the back cover of the gaugehead is removed make certain that pressure has been bled from the gaugehead and piping then stand back as the last bolt is removed If the negator motor spring is broken the broken pieces may cause injury when the cover is removed Remove the back cover and gasket from the gaugehead see Figures 3 2 and 3 3 on pages 15 and 16 Attach the gaugehead to the vertical pipe Position it for convenient reading The pipe supports the weight of the gaugehead Tilt the float cluster on edge and slip the guide cables through the loops on the inside of the tank Set it on the tank bottom with the tape connection up Remove the product specific gravity tag and save it At the gaugehead entry pipe lower one end of the tape through the pipe to the tank bottom Attach the tape to the float cluster with the furnished fastener see Figure 3 4 on page 17 See Figure 3 5 on page 19 and attach the furnished installation crank to the tape storage gaugehead tape storage sheave with the thumbscrew Warning Use a firm grasp on crank while winding motor Tighten thumbscrew before releasing grip The rapid unwinding of the spring could result in the crank spinning and striking the operator The negator spring motor delivered with the gaugehead was selected by the user s specification of the tank depth of the installation Use the installation crank Wind the motor clo
16. the flanged nozzle in a true vertical position may affect the accuracy of the gauge Make sure that the interior of all flanges and pipes are clean and corrosion free Weld the top cable anchor 1 1 4 inch flanged nozzles into their respective holes Make certain that they are welded in a true vertical position Check with a plumb line prior to welding and maintain the plumb line during welding Make sure that the interior of the flanges remain clean and corrosion free Install the plug valve if it is to be installed and install the top sheave elbow Note Varec recommends that a plug valve be installed to facilitate gauge maintenance Use of parts that are not manufactured or supplied by Varec voids any Varec warranty and relieves Varec of any obligation to service the product under warranty Weld the side support brackets in place Construct the gaugehead support stanchion and weld the gaugehead support bracket in place Make certain that it is plumb and positioned as shown Install the tankside vertical pipe in the bracket Make certain that it is plumb Install the horizontal pipe in the 90 degree tank top elbow and bracket 10 Install a 30 degree elbow on the horizontal pipe 30 Installation and Operations Manual High Pressure Automatic Tank Gauge Figure 3 9 shows a typical grade level installation for spheres to 60 feet in diameter DESCRIPTION GAUGEHEAD TAPE TOP ANCHOR PIPE SUPPORT BRACKET FLOAT TAPE
17. the spring Replace the housing nipple and cap Warning Make certain that pressure is removed from the gaugehead and piping whenever the back cover of the gaugehead is removed Also stand back as the last bolt is removed If the negator motor spring is broken the broken pieces may cause injury when the cover is removed Remove the back cover and gasket from the gaugehead see Figures 3 2 and 3 3 on pages 15 and 16 Remove the bolts covers and gaskets from the other elbows Mount the gaugehead on the bracket and attach the pipe and flanged nipple to the top Tilt the float cluster on edge and slip the guide cables through the loops on the inside of the tank Set it on the tank bottom with the tape connection up Check the part number on the roll of perforated tape to be sure that it is long enough for the tank At the elbow on the tank entry pipe unroll one or two turns of the perforated tape and start to feed it into the horizontal pipe Leave the tape in the box and continue to unroll it several turns at a time until it enters the gaugehead Spread a clean ground cloth below the gaugehead and remove the lower hole plug Continue to unroll the tape several turns at a time feeding it through the gaugehead and lower tape hole and onto the ground from the tank entry pipe elbow until the tape is unrolled Make sure that the tape on the ground does not become kinked or dirty At the elbow on the tank entry pipe lower the end of the
18. using appropriate industry or military safety procedures Lubricate moving parts of the tape elbow sheaves at regular intervals Use LPS 2 4 Ifthe gaugehead is not oil filled lubricate the moving parts at regular intervals with LPS 2 Varec Inc 43 Maintenance 5 3 Oil filled Gauges Note Some oils may cause the numbers on the counters and dial to flake after long term exposure A maintenance kit is available from Varec to correct the problem The counter side is sealed from the pressure at the back It may be separately filled with oil The NPT plug with the hole for draining condensed moisture must be replaced to fill the counter side with oil Switch the positions of the top and bottom plugs Table 5 1 lists the suggested periodic maintenance routine Routine 90 Days Remarks 10 Years Operation check X Guide cables Lubricate Leak check X Change oil Calibration Corrosion check Sediment check Deformation check X Refurbish X Table 5 1 Suggested Periodic Maintenance Routine Fill the tape sheave compartment of the gaugehead with oil to protect it from corrosion by vapors from the product in the tank Do not use a condensate reservoir Use a 1 1 2 inch NPT plug in the lower tape entry port Check that this drain plug is firmly in place Fill through the top NPT plug see Figures 3 2 and 3 3 on pages 15 and 16 Use Table 5 2 on
19. 1 2 inch ANSI 150 Ib or 300 Ib flanged nozzle into the top pipe center hole Make certain that it is welded in true vertical position Hold it plumb while welding Failure to place the flanged nozzle in a true vertical position may affect the accuracy of the gauge Make sure that the interior of all flanges and pipes are clean and corrosion free Weld the top cable anchor 1 1 4 inch flanged nozzles into their respective holes Make certain that they are welded in a true vertical position Check with a plumb line prior to welding and maintain the plumb position during welding Make sure that the interior of the flanges remains clean and corrosion free Install the plug valve if it is to be installed and install the top sheave elbow Note Varec recommends that a plug valve be installed to facilitate gauge maintenance Use of parts that are not manufactured or supplied by Varec voids any Varec warranty and relieves Varec of any obligation to service the product under warranty Weld the side support bracket in place Construct the gaugehead support stanchion and weld the gaugehead support bracket in place Make certain that it is plumb and positioned as shown Install the tankside vertical pipe in the bracket Make certain that it is plumb Install the tankside 90 degree sheave elbow and the horizontal pipe to the other elbow Make certain that dimensioning remains as indicated Remove the housing nipple and cap from the top cable anchors a
20. 2X 316 313X 005SS P31 13 0 RING 38IDX 500DX 06 VITON P14 146 GASKET CAP 2500 B5059 071 PHMS 8 32X1 4 SS P031 01 1719 HSSS 10 24 X 1 2 CUP PT P31 657 TAPE KEEPER SPRING 2500 B7300 005 BINDING HD MACH SCREW 10 24 1 P31 669 WASH SHIM 562X 316 313X 005SS P31 13 Table 5 4 Refurbishing Overhaul Maintenance Kit 2 50 Installation and Operations Manual High Pressure Automatic Tank Gauge 6 Troubleshooting 6 1 Common Problems Friction is a common problem that affects gauge accuracy Some liquids produce corrosion in the mechanism Periodic inspection and maintenance provided by an Varec service contract can prevent problems from occurring Periodic cleaning lubrication and replacement of worn parts stops trouble before it starts Warning The product stored in the tanks that are gauged is under pressure of 30 to 300 psig It is most probably a flammable product such as butane or propane The gaugehead and piping are under pressure Do not open them without first closing the plug valve and then carefully bleeding the product pressure from the gaugehead and piping If there is no Varec plug valve installed no maintenance can be performed unless the tank is empty and not under pressure Varec Inc 51 Troubleshooting 6 1 1 Dials do not respond when check knob rotated Possible Cause Action Tape broken Yes No Go Caution Broken negator spring may cause injury Stand clear of
21. 3 GAUGE CHECK ASSY 2520 BA11566 HUB DIAL PLATE B9668 001 POST 2500 B6547 005 GASKET BACK COVER 300 GA B7293 046 RETAINING RING 5 16 SS P10 2 O RING 11 16X1 2 VITON A P14 148 DELRIN PINION GEAR P25 16 2500 COUNTER ASSY METRIC BM18850 100 0 RING 38IDX 500DX 06 VITON P14 146 GASKET CAP 2500 B5059 071 PHMS 8 32X1 4 SS P031 01 1719 SLOTTED SHIM 010 P031 29 1883 RETAINER DIAL 2500 B8234 001 TAPE KEEPER SPRING 2500 B7300 005 BINDING HD MACH SCREW 10 24X1 P31 669 Table 5 3 Basic Maintenance Kit 1 48 Installation and Operations Manual High Pressure Automatic Tank Gauge Table 5 4 lists the Refurbishing Overhaul Maintenance Kit 2 Part Name English Part Number 13 08786 2500 CRANK ASSY BM3784 TAPE ENG PERF 316 SST X 180 B10537 606 FHMS10 24X 3 8 304 SS P031 03 1642 KIT INSTRUCTIONS MAINT 2520 33 08848 GASKET COUNTER HOUSING 2500 B6287 071 2520 O RING RETAINER B7411 005 DIAL GEAR ENGLISH B8235 040 DIAL ENGLISH B8218 001 SLOTTED SHIM 010 P031 29 1883 COUNTER COVER GASKET 2500 B7720 071 SHEAVE ASSY TAPE STORAGE ALUM BA7761 SHEAVE ASSY MOTOR 70 ALUM BA17725 SPRING GAUGE CHECK 2500 B7796 005 GAUGE CHECK ASSY 2520 BA11566 HUB DIAL PLATE B9668 001 POST 2500 B6547 005 GASKET BACK COVER 300 GA B7293 046 COUNTER COVER ASSY DA4044 RETAINING RING 5 16 SS P10 2 O RING 11 16X1 2 VITO
22. 5 1 Zeroing the 33 3 5 2 Initial calibration aa Led Re Repo RUE epus 33 3 5 3 Auxiliary 34 3 5 4 Initial lUbricatiOn iv eae eae es nhe YR 34 3 5 5 Installation quality 34 3 5 6 Reassembly wae RR eg a Pe eed Fae GE eon Y 34 3 5 7 Pressure test the system 35 3 6 Top Tank Reading Installation for Spheres and Cylinders 36 3 6 1 Zeroing the display 39 3 6 2 Initial calibration 5 ue BS ee ER eee ee baie we be 39 3 6 3 Auxiliary 39 3 6 4 Initial lubrication RE eR ERR ex ERE ER nh 40 3 6 5 Installation quality 40 Varec Inc vii Contents 3 6 6 Heassembly Re RR ee RR iw ee eae Re 40 3 6 7 Pressure test the system 40 A Operations cec seer nbi damen heb 41 4 1 Initial 41 4 2 Norimal Operations isubexurhbbei4a gH BIG BS Wi E ni 42 4 3 Calibration and Volume 42 5
23. 8 1 Order Codes Measurement Units 01 English 150 psig 10 3 bar g 02 Metric 150 psig 10 3 bar g Tank Type TOI Tank Spheres to 16 ft Diameter or Horizontal Cylinder Tanks T02 Tank Spheres to 48 ft Diameter T03 Top Mounting on Tank Sphere or Horizontal Cylinder Tanks T04 Tank Spheres to 60 ft Diameter or Horizontal Cylinder Tanks Plug Valve 0 Plug Valve Not Used 1 1 2 DN40 150 psig 10 3 bar g Gauge Plug Valve Viton A plug Transmitter Adapter 0 Transmitter Adapter Not Used 2581 Transmitter Adapter N2520 Example Order Code N2520 01 T01 0 0 Table 8 1 2520 Automatic Tank Gauge ATG 150 psig 10 3 bar g ATEX Class I Zone 1 Ex Il 2G T5 150 psig 10 3 bar g Measurement Units 03 English 300 psig 20 6 bar g 04 Metric 300 psig 20 6 bar g Tank Type 05 Tank Spheres to 16 ft Diameter or Horizontal Cylinder Tanks T06 Tank Spheres to 48 ft Diameter T07 Top Mounting on Tank Sphere or Horizontal Cylinder Tanks T08 Tank Spheres to 60 ft Diameter or Horizontal Cylinder Tanks Plug Valve 0 Plug Valve Not Used 1 1 2 0340 300 psig 20 6 bar g Gauge Plug Valve Viton A plug Transmitter Adapter 0 Transmitter Adapter Not Used 2581 Transmitter Adapter N2520 Example Order Code N2520 03 T05 1 1 Table 8 2 2520 Automatic Tank Gauge ATG 300 psig 20 6 bar g Varec Inc 57 Ordering Information
24. A networks data from a tank farm It can scan a large tank farm in less than five minutes and provide rapid status display and command and control over tank farm activity Varec accessories may be attached to the gaugehead These telemeter status and command information are used by Varec data acquisition systems Figure 1 2 on page 3 illustrates the 2581 High Pressure Gauge to Transmitter Adapter that is needed to couple these accessories See Section 8 1 Order Codes on page 57 in Tables 8 1 8 2 and 8 3 on pages 57 and 58 for details on standard configurations Special order options are available but this manual may not cover all of the details of a special order 4 Installation and Operations Manual High Pressure Automatic Tank Gauge 2 Identification 2 1 Device Designation 2 1 4 Nameplate The following technical data are give on the instrument nameplate of the 2520 High Pressure Automatic Tank Gauge 2520 Automatic Tank Gauge 150 psig 10 3 bar g Model No C 2G T5 Serial No 34 C lt Ta lt 71 Date Of Mfr 30 F lt Ta lt 160 F e P mm cw 29 A Made in USA 16 013137 Rev 5834 Peachtree Corners an Nae lenis Georgia 30092 USA 150 psig 10 3 bar g d 2520 Automatic Tank Gauge 300 psig 20 6 bar g Model No A Serial No 34 C lt Ta lt
25. IOM015GVAE401 1 2520 High Pressure Automatic Tank Gauge Mechanically operated float and tape gauge for continuous liquid level measurement in bulk storage tanks T mmh D D 5 9 3 2 oO 9 r T D D Automation Solutions for oil amp gas defense and aviation applications Copyright All rights reserved Printed in the United States of America Except as permitted under the United States Copyright Act of 1976 no part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of the Publisher Varec Inc 5834 Peachtree Corners East Norcross Atlanta Georgia 30092 Phone 770 447 9202 Fax 770 662 8939 Trademarks Acknowledged Varec Inc recognizes all other trademarks Trademarks of other products mentioned in this manual are held by the companies producing them FuelsManager TankView TacFuels Varec and FuelsManager IntoPlane are registered trademarks of Varec Inc BestoLife 270 is a registered trademark of BestoLife Corp Dallas TX Loctite is a registered trademark of Loctite Corp Newington CT Delrin is a registered trademark of E I du Pont de Nemours Co Inc Wilmington DL Dow Corning is a registered trademark of Dow Corning Inc Midland MI Dow Corning RTV 732 is a registered trad
26. N A P14 148 DELRIN PINION GEAR P25 16 RETAINER DIAL 2500 B8234 001 ENGLISH COUNTER ASSY 2500 BM18849 100 MAGNETIC DRIVE ASSY ENGLISH including O Ring BM6874 101 0 RING 38IDX 50O0DX 06 VITON P14 146 GASKET CAP 2500 B5059 071 PHMS 8 32X1 4 SS P031 01 1719 HSSS 10 24 X 1 2 CUP PT P31 657 TAPE KEEPER SPRING 2500 B7300 005 BINDING HD MACH SCREW 10 24X1 P31 669 WASH SHIM 562X 316 313X 005SS P31 13 Varec Inc 49 Maintenance Part Name Metric Part Number 13 08787 SHEAVE ASSY MOTOR 70 ALUM BA17725 2500 CRANK ASSY BM3784 TAPE MET PERF 316 SST X 180 B10538 606 FHMS10 24X 3 8 304 SS P031 03 1642 WASHER 9 16X21 64X1 16 SS P31 1 KIT INSTRUCTIONS MAINT 2520 33 08848 GASKET COUNTER HOUSING 2500 B6287 071 STOP PIN 2500 B5274 005 2520 O RING RETAINER B7411 005 DIAL GEAR METRIC B8327 040 MAGNETIC DRIVE ASSY METRIC including O Ring BM8645 101 SLOTTED SHIM 010 P031 29 1883 COUNTER COVER GASKET 2500 B7720 071 DIAL PLATE METRIC 30 CM GRAD B8325 001 SHEAVE ASSY TAPE STORAGE ALUM BA7761 SPRING GAUGE CHECK 2500 B7796 005 GAUGE CHECK ASSY 2520 BA11566 HUB DIAL PLATE B9668 001 POST 2500 B6547 005 GASKET BACK COVER 300 GA B7293 046 RETAINING RING 5 16 SS P10 2 O RING 11 16X1 2 VITON A P14 148 DELRIN PINION GEAR P25 16 RETAINER DIAL 2500 B8234 001 2500 COUNTER ASSY METRIC BM18850 100 WASH SHIM 56
27. N2520 05 T05 and N2520 06 T05 Proceed to place the system in operation 22 Installation and Operations Manual High Pressure Automatic Tank Gauge Figure 3 7 shows the torque sequence 30 35 FT LBS TORQUE 41 47 NT M TORQUE SEQUENCE AS SHOWN 150 LB SHEVE ELBOW COVER 300 LB SHEVE ELBOW COVER Torque 50 55 FT LBS TORQUE 50 55 FT LBS 68 75 NT M 68 75 NT M TORQUE SEQUENCE AS SHOWN TORQUE SEQUENCE AS SHOWN Figure 3 7 Torque Sequence Varec Inc 23 Installation 3 4 Spheres to 48 Feet Diameter Grade Level Installation For spheres to 48 feet diameter with the gaugehead located on the side near grade level see Figure 3 8 on page 25 for feature option installation kit codes N2520 01 T02 N2520 02 T02 N2520 03 T06 N2520 04 T06 N2520 05 T05 and N2520 06 TO6 Refer to Table 8 1 Table 8 2 and Table 8 3 on pages 57 and 58 for details Make certain that after the installation is completed it is checked and then doubled checked for proper installation After the tank is pressurized the user will have no easy method of correcting the errors that cause a float cluster to stick and the tape and cables to bind 1 Determine the position on the tank roof beneath which the center of the float cluster will rise and fall Note The position should be located where gauge piping will pass over the top of the tank shell close to a stairway platform to facilitate inspection and service of the gauge s
28. Put the bottom plug on top and the top plug in the bottom Varec Inc 21 Installation 3 3 5 Installation quality check It is essential that the user recheck the quality of the installation and then double check it before pressurizing the tank There is no easy method of correcting installation errors after the tank is filled If the float cluster travel is stuck due to cables that are not parallel or plumb or if the tape cable travel is impaired repair cannot be accomplished until the product pressure is removed from the tank 3 3 6 Reassembly Remove the installation crank If auxiliary equipment was not installed replace the back cover and its gasket Using the torque sequence shown in Figure 3 7 on page 23 torque the gaugehead bolts to 30 ft Ibs 41 Nm If auxiliary equipment was installed seat the magnetic coupling with the auxiliary adapter coupling and replace the back cover with the auxiliary unit adapter attached Check the operation of the auxiliary unit as appropriate 1 Replace the gaskets covers and bolts on the elbows 2 Torque the elbow bolts as shown in Figure 3 7 on page 23 3 Close the tank manholes and inspection covers 3 3 7 Pressure test the system Perform a pressure test of the vessel with the gauge and piping installed Proof test to 1 50 x normal maximum pressure This completes the installation for feature options kit codes N2520 01 T01 N2520 02 TOI N2520 03 T05 N2520 04 T05
29. ached Check the operation of the auxiliary unit as appropriate 1 Replace the gaskets covers and bolts on the elbows 2 Torque the bolts as shown in the Figure 3 7 on page 23 3 Close the tank manholes and inspection covers 34 Installation and Operations Manual High Pressure Automatic Tank Gauge 3 5 7 Pressure test the system Perform a pressure test of the vessel with the gauge and piping installed Test to 1 50 times the normal maximum pressure This completes the installation for feature options kit codes N2520 01 T04 N2520 02 T04 N2520 03 T08 N2520 04 T08 N2520 05 T08 and N2520 06 TO8 Proceed to place the system in operation Varec Inc 35 Installation 3 6 Top Tank Reading Installation for Spheres and Cylinders For tank top reading gaugehead installations see Figure 3 10 on page 37 for codes N2520 01 N2520 02 T03 N2520 03 T07 N2520 04 T07 N2520 05 T07 N2520 06 T07 Refer to Table 8 1 Table 8 2 and Table 8 3 on pages 57 and 58 for details Make certain that after the installation is completed it is checked and then doubled checked for proper installation After the tank is pressurized the user will have no easy method of correcting the errors that cause a float cluster to stick and the tape and cables to bind 1 Determine the position on the tank roof beneath which the center of the float will rise and fall Note The position should be located where gauge piping will
30. anual High Pressure Automatic Tank Gauge ITEM 1 2 3 4 5 6 7 8 o 10 11 12 13 14 15 16 17 18 19 20 21 20 39 6 Figures 3 2 and 3 3 on page 16 show exploded views of a typical gaugehead DESCRIPTION GASKET COUNTER HSG STOP PIN RING RETAINER WASHER TEFLON DIAL GEAR GASKET COUNTER COVER DIAL TAPE STORAGE SHEAVE ASEMBLY MOTOR STORAGE SHEAVE ASSEMBLY SHAFT ASSEMBLY KNOB SPRING GAUGE CHECK GLAND GAUGE CHECK ASSEMBLY DIAL HUB TAPE KEEPER POST BACK COVER GASKET BACK COVER COUNTER HOUSING COUNTER COVER ASSEMBLY GAUGEHEAD CASE DELETED RETAINING RING RING SEAL VITON A PINION GEAR COUNTER DIAL RETAINER ITEM DESCRIPTION 27 28 29 30 31 32 33 34 35 36 37 38 e o SSESERREREE COUNTER ASSEMBLY MAGNETIC DRIVE ASSEMBLY O RING SEAL O RING SEAL CAP BACK COVER GASKET BACK COVER CAP GLAND CAP MOTOR SHEAVE FLANGE BINDING HEAD MACHINE SCREW HEX SOCKET SET SCREW TAPE KEEPER SPRING BINDING HEAD MACHINE SCREW ROUND HEAD MACHINE SCREW SELF TAP SCREW STUD HEX NUT HEX HEAD CAP SCREW NAME PLATE STUD HEX NUT HEX SOCKET SET SCREW SHIM WASHER PIPE PLUG PIPE PLUG FLAT HEAD MACHINE SCREW NUT HEX Figure 3 2 Exploded View of a Typical Gaugehead Varec Inc 15 Installation MEASURING TAPE Figure 3 3 Exploded View of aTypical Gaugehead Install
31. ation and Operations Manual 16 High Pressure Automatic Tank Gauge Figure 3 4 shows a float cluster 17 00 GUIDE WIRE CTR S 432 u 8 00 SPHERICAL DIA NOTE EQUATOR DEPTH SUBMERGED DISPLACEMENT 402 12 CU IN Figure 3 4 Float Cluster Varec Inc 17 Installation 3 3 1 3 3 2 Zeroing the display 1 See Figure 3 2 on page 15 and remove the cover from the counter mechanism of the gaugehead 2 See Figure 2 5 and loosen screws A until the dial plate and gear rotate freely and independently of the hub 3 Check that the float cluster is at the bottom of the tank with the tape taut Rotate dial and gear H until counter drums all display zero Initial calibration These instructions apply to systems that use a float cluster The float cluster is shipped with six weights attached see Figure 3 4 on page 17 Table 3 3 on page 20 lists the submersion depth of the cluster for products having specific gravity ranging between 45 and 69 and the quantity of the weights that are required Refer to the tag removed from the float cluster if this information should needed in the future Note During manufacturing lead shot may be added to the interior of each sphere to make the equator depth submerged displacement equal to 402 12 cu in when the specific gravity is beyond the standard range between 45 and 69 1 Determine the specific gravity of the product to be s
32. ator 0 48 0 1 8 in 3 175 mm below equator 0 51 0 At equator 0 54 At equator 0 57 2 At equator 0 60 3 At equator 0 63 4 At equator 0 66 5 At equator 0 69 6 At equator Table 3 3 Product Specific Gravity verses Weight Chart 9 Note English gaugeheads are shipped with dials indicating measurement in feet inches 1 16 inch Another dial that indicates measurement in 1 10 ft x 1 100 foot is included in the kit The user can install the other dial to suit Refer to Chapter 5 Maintenance on page 43 for dial changing information Dials providing outage readout are no longer available from Varec except in a conversion kit that is ordered separately Contact the company if further information is needed The kit part number is 13 08774 Loosen the thumbscrew lock Observe the operation of the drums and dial while slowly cranking the float cluster to the top of the tank and then lowering it to the bottom The drums and dial should rotate freely and return to the calibrated indication when the float cluster touches the tank bottom Use the chart furnished with the float cluster Mark the float cluster for the submersion depth for the particular product to be stored in the tank With the float cluster on the bottom measure the distance from the tank bottom to the sub mersion depth mark Use this distance to reset the dial and counter drums for an empty tank Tighten the screws after resetting the drums and dial
33. c Inc Installation 3 2 Planning the Installation Installation of high pressure and medium pressure storage vessels for hydrocarbons requires planning that is not the same as that associated with atmospheric and low pressure tank storage Butane and propane are the products most commonly stored At atmospheric pressure and temperature they are gases Butane liquefies at 37 psig at 100 degrees F and is usually stored in spherical vessels Propane liquefies at 175 psig at 100 degrees F and is usually stored in cylinders bullets Once filled these vessels cannot be conveniently opened for repair and maintenance of the elements of the gauging system For this reason Varec suggests consideration of the installation of duplex tank gauges see Figure 1 1 on page 2 Accurate level measurement must be assured at the time of the installation Place a pressure relief device near the gaugehead to bleed pressure when maintenance is required Plan the pipe routing Vertical pipe runs must be plumbed to be perpendicular to prevent the tape from binding inside the pipe Installation and Operations Manual High Pressure Automatic Tank Gauge Table 3 1 lists the typical required tools equipment and materials used when installing the 2520 ATG Tool Equipment Use Wrenches Selected for nuts bolts pipe Screwdrivers Selected for sc
34. ce No Go to 4 4 Tape pipe conduit dirty Yes Remove and clean No Go to 5 5 Guide cables loose kinked or broken Yes Tighten repair or replace No Go to 6 6 Worn Teflon bushings or bearings Yes Refurbish gauge replace Teflon bushings or bearings Special tools may be required Varec Inc 53 Troubleshooting 54 Installation and Operations Manual High Pressure Automatic Tank Gauge 7 Specifications 7 1 General Manufacturer Varec Inc Atlanta GA USA Designation 2520 High Pressure Automatic Tank Gauge ATG Function Mechanically operated float and tape gauge for continuous liquid level measurement in bulk storage tanks 7 2 Environmental Operating Temperature Pressure Parameters From 34 C x Ta x 71 C Ambient From 30 F x Ta x 160 F Ambient 150 psig 10 3 bar g 220 psig 15 bar g 300 psig 20 6 bar g 7 3 Mechanical Construction Enclosure Type Material IP66 WCB Cast Steel Dimensions 16 25 x 12 375 x 6 875 Shipping Weight 70 Ibs 33 kg nominal weight increases with various kits 7 4 Certifications and Approvals ATEX Class I Zone 1 Ex Il 2G T5 150 and 220 psi g Rated Models Varec Inc 55 Specifications 56 Installation and Operations Manual High Pressure Automatic Tank Gauge 8 Ordering Information
35. ckened with the float cluster on the surface it may slip off of the tape storage sheave retainer If this occurs refer to Chapter 6 Troubleshooting on page 51 If the gauge operation is normal continue filling the tank to the desired level If it is not remove the product pressure and correct the problem Varec Inc 41 Operation 4 2 Normal Operation Caution Do not release the checker knob and allow the springs to return the mechanism Over time the springs may break and jam the gauge Use the operation checker knob to check gauge operation Turn it clockwise one quarter turn while observing the display Note If the tape is slackened with the float cluster on the surface it may slip off of the tape storage sheave retainer If this occurs refer to Chapter 6 Troubleshooting on page 51 4 3 Calibration and Volume Measurement Tank gauging measurements provide appropriate inventory checks and a valuable method of checking marine receipts and metered custody transfers Accuracy of measurements requires that a number of factors be considered 1 The density and specific gravity of product 2 The gross volume 3 The temperature of the product 4 Tank bottom deformation It is the user s responsibility to appropriately consider these and other factors in his application For example petroleum product tank capacity tables are calculated for product at 60 degrees F A higher temperature will cause the tank to expa
36. ckwise the number of turns shown in Table 3 2 on page 14 then securely tighten the thumbscrew Lower the remainder of tape on the roll into the tank then thread the tape into the gaugehead Put the first hole in the tape on a pin of the sprocket close to the tape guide Rotate the sprocket clockwise to pull the tape through the guide Pull the tape around the storage sheave Fasten the tape to the tape storage sheave with the sheave pin Wind the excess tape counter clockwise around the storage sheave until the slack is removed Securely tighten the thumbscrew lock Check the tape path between the float and the gaugehead to be sure that it is not kinked or twisted Also check the float guide cables for kinks and that they are parallel At the bottom of the tank pull the tape taut Disconnect float cluster while holding tape taut and cut off the excess tape Reconnect the float cluster Caution Do not allow the float cluster to fall back to the floor of the tank Damage may result Loosen the thumbscrew The spring motor will pull the tape taut Slowly smoothly crank the float to the top of the tank and return it to the floor while observing tape travel through the gaugehead There should be no binding The counters will be zeroed in steps following but they should register during the float travel 38 Installation and Operations Manual High Pressure Automatic Tank Gauge Zeroing the display 1 See Figures 3 2 and 3 3
37. cluster if this information is needed in the future Note During manufacturing lead shot may be added to the interior of each sphere to make the equator depth submerged displacement equal to 402 12 cu in when the specific gravity is beyond the standard range between 45 and 69 Determine the specific gravity of the product to be stored Refer to Table 3 3 on page 20 and remove the required number of weights Pull up on the dial and gear H to disengage them from the counter pinion then rotate the dial to indicate four inches 102 mm for products with specific gravity between 51 and 69 at 60 degrees F For product of specific gravity of 48 set the dial and drums to indicate four and 1 8 inches 104 8 mm For product of specific gravity of 45 set the dial and drums to indicate four and 4 inches 107 9 mm Re engage the gear and pinion Tighten screws Loosen the thumbscrew lock Observe the operation of the drums and dial while slowly cranking the float cluster to the top of the tank and then lowering it to the bottom The drums and dial should rotate freely and return to the calibrated indication when the float cluster touches the tank bottom Varec Inc 27 Installation 7 Use the chart furnished with the float cluster Mark the float cluster for the submersion depth for the particular product to be stored in the tank 8 With the float cluster on the bottom measure the distance from the tank b
38. e anchors and hang plumb lines from them at the center to mark the position where the bottom cable anchors will be welded Hang a plumb line through the center of the top tape pipe to the bottom to mark the float center This should be 8 50 inches 216 mm at the bottom from each of the bottom cable anchor positions When the positioning has been checked weld the bottom cable anchors into place Thread the float cables into the tank through the top anchor fittings Fasten them to the bottom cable anchors with the furnished hardware 36 Installation and Operations Manual High Pressure Automatic Tank Gauge Figure 3 10 shows a typical installation for a top reading roof tank Note 150 flanges for 150 psig models 300 flanges for 220 psig amp 300 psig models 2 d 150 OR 300 TANK NOZZLE BY CUSTOME Note 220 psig and 300 psig are the same dimensions Gasket supplied by Customer Typical CUSTOMER TO SPECIFY 5 62 FOR 150 Ij FIG 275 RUBBER iE 38 FOR 300 PLUG GATE VALVE TOP ANCHOR DETAIL ANSI Flanges Figure 3 10 Top Reading Roof Tank Typical Installation Varec Inc 37 Installation 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Thread the upper end of each guide cable through the top anchor assembly Hand tighten Use the lock nut to lock the cable in place then tighten the adjustment nut until the guide cable is tensioned by the
39. e that it is not kinked or twisted Also check the float guide cables for kinks Make certain that the float cluster guide cables are parallel Caution Do not allow the float cluster to fall back to the floor of the tank Damage may result Loosen the thumbscrew The spring motor will pull the tape taut Slowly smoothly crank the float cluster to the top of the tank and return it to the floor while observing the tape travel through the elbows and gaugehead There should be no noticeable binding The counters will be zeroed in steps following but they should register during the float travel 3 4 4 Zeroing the display 1 See Figures 3 2 and 3 3 on pages 15 and 16 and remove the cover from the counter mechanism of the gaugehead See Figure 3 6 on page 21 and loosen screws A until the dial plate and gear rotate freely and independently of the hub Check that the float cluster is at the bottom of the tank with the tape taut Rotate dial and gear H until counter drums all display zero 3 4 2 Initial calibration These instructions apply to systems that use a float cluster see Figure 3 4 on page 17 The float cluster is shipped with six weights attached Table 3 3 on page 20 lists the submersion depth of the cluster for products having specific gravity ranging between 45 and 69 and the quantity of the weights that are required Refer to the product specific gravity tag removed from the float
40. emark of Dow Corning Inc Midland MI Teflon is a registered trademark of E 1 du Pont de Nemours Co Inc Wilmington DL TRUARC is a registered trademark of Walden Kohinoor Inc Long Island City NY LPS 2 is a registered trademark of LPS Laboratories Tucker GA All other product and service names mentioned are the trademarks of their respective companies Varec Inc Disclaimer of Warranties The contract between the Seller and the Buyer states the entire obligation of the Seller The contents of this instruction manual shall not become part of or modify any prior or existing agreement commitment or relationship between the Seller and Buyer There are no express or implied warranties set out in this instruction manual The only warranties that apply are those in the existing contract between the Seller and Buyer The 2520 High Pressure Automatic Tank Gauge ATG has not been tested by Varec under all possible operational conditions and Varec may not have all the data relative to your application The information in this instruction manual is not all inclusive and does not and cannot take into account all unique situations Consequently the user should review this product literature in view of his or her application If you have any further questions please contact Varec for assistance Limitations of Seller s Liability In the event that a court holds that this instruction manual created some new warranties Seller s liabili
41. enance and troubleshooting of high pressure Varec 2520 Series Automatic Tank Gauges Former 2530 Series gauges for 300 psig service are included within the new feature option series These gauges are for use in 30 psig to 300 psig service Low pressure Varec 2500 gauge installations are covered in the 2500 Automatic Tank Gauge ATG Installation and Operations Manual Proper operation of the gauge requires the serious attention of the user to assure high quality control during the installation Long term satisfactory performance of the gauge can thus be obtained If the installation quality is compromised gauge accuracy and life may be degraded This manual covers installation that is to be performed on tanks that are empty and are not in service Varec service contracts provide the user substantial savings for maintaining and refurbishing the systems Contact product service or marketing for further details 1 2 Consider Redundant Installation Varec urges that the user consider installing a redundant duplicate gauging system in high pressure installations while a tank is empty Even a high quality installation is subject to the possibility of failure in time Operations of U S agencies such as NASA use back up systems in high pressure gas and liquid handling Situations may occur that make it impossible to repair a high pressure gauge system while the tank is under pressure For example the optional plug valve will not permit the in
42. gaugehead and remove back cover Replace tape Check negator motor attachment to storage sheave Check for damaged gauge parts to 2 Negator motor broken Yes No Replace negator Do not redrill or repair Wear gloves Check tape condition Check for damaged gauge parts Go to 3 Tape rewound Yes No Tape detached from float Replace tape and reattach Check for damaged gauge parts Go to 4 Dials stopped Yes No Check for frozen tape sprocket sheave shaft Repair replace Check for frozen accessory shaft Repair replace Check dial gear engagement with pinion gear Adjust replace Check gauge checker for broken spring and damaged ratchet pawl Replace Goto 5 Counter dial wheels stopped dial plate rotates Yes Check for worn broken counter pinion gear and counter wheels Replace Table 6 1 Dials do not Respond when Check Knob Rotated 52 Installation and Operations Manual High Pressure Automatic Tank Gauge 6 1 2 Calibration repeatability unstable Possible Cause Action Dirty gauge housing Caution Broken negator spring may cause injury Stand clear of the gaugehead and remove the back cover Yes Clean with automotive type spray degreaser No Go to 2 2 Tape cable off elbow pulley Remove elbow covers Yes Reseat and lubricate the gauge No Go to 3 3 Elbow pulley shaft bushing worn corroded Yes Repair or repla
43. ge to equipment may result if this precaution is disregarded Warning Direct injury to personnel or damage to equipment which can cause injury to personnel may result if this precaution is not followed Safety Precautions Read this manual carefully and make sure you understand its contents before using this product Follow all instructions and safety guidelines presented in this manual when using this product If the user does not follow these instructions properly Varec cannot guarantee the safety of the system Note Comply with all applicable regulations codes and standards For safety precautions the user should refer to the appropriate industry or military standards Caution Read and understand static and lightning electrical protection and grounding described in API 2003 Make certain that the 2520 High Pressure Automatic Tank Gauge ATG installation operation and maintenance conforms with the practice set forth therein Varec Inc vi Installation and Operations Manual Contents InITOQUETIOTI Oi ae tni ur ewe DU Da E Aa EE E aba 1 1 1 Using this Manual eae eh 1 1 2 Consider Redundant 1 1 3 Getting Acquainted with the Tank Gauge Systems 1 Identification MEER PD PPP rey 5 2 1 Device Designation llleeeeele rn 5 271 1 Nameplate 5 4 Li bd LEER haan ee ens Gah eyed ie 5 Installation
44. he bolts cover and gasket from the other elbow Mount the gaugehead on the bracket and attach the pipe and flanged nipple to the top Tilt the float cluster on edge and slip the guide cables through the loops on the inside of the tank see Figure 3 4 on page 17 Set it on the tank bottom with the tape connection up Check the part number on the roll of perforated tape to be sure that it is long enough for the tank At the elbow on the tank entry pipe unroll one or two turns of the perforated tape and start to feed it into the horizontal pipe Leave the tape in the box and continue to unroll it several turns at a time until it enters the gaugehead Spread a clean ground cloth below the gaugehead and remove the lower hole plug Continue to unroll the tape several turns at a time feeding it through the gaugehead and lower tape hole and onto the ground from the tank entry pipe elbow until the tape is unrolled Make sure that the tape on the ground does not become kinked or dirty At the elbow on the tank entry pipe lower the end of the tape through the pipe to the tank bottom Let several inches fall on the tank bottom Remove the product specific gravity reference tag from the float cluster and save it Attach the tape to the float cluster with the furnished fastener Feed the other end of the tape over the sheave in the elbow above and make sure that it is seated on the pulley 12 Installation and Operations Manual High Pressure Au
45. heck It is essential that the user recheck the quality of the installation and then double check it before pressurizing the tank There is no easy method of correcting installation errors after the tank is filled If the float cluster travel is stuck due to cables that are not parallel or plumb or if tape cable travel is impaired repair cannot be accomplished until the product pressure is removed from the tank 3 4 6 Reassembly Remove the installation crank If auxiliary equipment was not installed replace the back cover and its gasket Using the torque sequence shown in Figure 3 7 on page 23 torque the bolts to 30 ft Ibs 41 Nm If auxiliary equipment was installed seat the magnetic coupling with the auxiliary adapter coupling and replace the back cover with the auxiliary unit adapter attached Check the operation of the auxiliary unit as appropriate 1 Replace the covers gaskets and bolts on the elbows 2 Torque the bolts as shown in the Figure 3 7 on page 23 3 Close the tank manholes and inspection covers 28 Installation and Operations Manual High Pressure Automatic Tank Gauge 3 4 7 Pressure test the system Perform a pressure test of the vessel with the gauge and piping installed Test to 1 50 times the normal maximum pressure This completes the installation for feature options kit codes N2520 01 T02 N2520 02 TO2 N2520 03 T06 N2520 04 T06 N2520 05 T06 and N2520 06 TO6 Proceed to place the system i
46. ion The user should comply with all applicable regulations codes and standards For safety precautions the user should refer to the appropriate federal state local industry or military standards 10 Installation and Operations Manual High Pressure Automatic Tank Gauge 3 3 Spheres and Cylinders to 16 Feet Diameter Grade Level Installation For spheres and cylinders to 16 feet diameter with the gaugehead located on the side near grade level see Figure 3 1 on page 13 for N2520 01 T01 N2520 02 T01 N2520 03 T05 N2520 04 T05 N2520 05 T05 and N2520 06 TO05 feature option installation kit codes Refer to Table 8 1 Table 8 2 and Table 8 3 on pages 57 and 58 for details Make certain that after the installation is completed it is checked and then doubled checked for proper installation After the tank is pressurized the user will have no easy method of correcting the errors that cause a float cluster to stick and the tape and cables to bind 1 10 11 12 13 14 15 Determine the position on the tank roof beneath which the center of the cluster of floats will rise and fall Provide the roof holes shown in Figure 3 1 on page 13 centered on this position The guide cable holes are centered 8 50 inches 216 mm each side of the center of the cluster of eight inch diameter floats The tape pipe is centered on a 17 00 inch 432 mm diameter The plug valve is also centered on this dimension Weld a 1
47. lation 10 Install the 45 degree pipe in the bracket and attach it to the 45 degree elbow then attach 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Install 45 degree elbow on the horizontal pipe the second 45 degree elbow Attach the vertical pipe to the 45 degree elbow Apply thread compound as appropriate Make certain that dimensioning remains as indicated Remove the housing nipple and cap from the top cable anchors and hang plumb lines from them at the center to mark the position where the bottom cable anchors will be welded Mark the plumb bob string at the height of the tank bench mark This will assure that the plumb bob just touches the bottom when the reference is made from the bench mark distance to the bottom Open the top sheave elbow and hang a plumb line through the center of the top tape pipe to the bottom to mark the float center This should be 8 50 inches 216 mm at the bottom from each of the bottom cable anchor positions When the positioning has been checked weld the bottom cable anchors into place Thread the float cables into the tank through the top anchor fittings Fasten them to the bottom cable anchors with the furnished hardware Thread the upper end of each guide cable through the top anchor assembly Hand tighten Use the lock nut to lock the cable in place then tighten the adjustment nut until the guide cable is tensioned by
48. mbscrew 32 Installation and Operations Manual High Pressure Automatic Tank Gauge 3 5 1 3 5 2 32 33 34 35 36 37 After the motor is wound and the thumbscrew securely tightened attach the tape to the storage sheave Pull the tape on the ground back through the gaugehead Put the first hole in the tape ona pin of the sprocket close to the tape guide Rotate the sprocket clockwise to pull the tape through the guide Pull the tape around the storage sheave Fasten the tape to the tape storage sheave with the sheave pin Wind the excess tape counter clockwise around the storage sheave until the slack is removed Check the tape path between the float cluster and the gaugehead to be sure that it is not kinked or twisted Also check the float guide cables for kinks Make certain that the float cluster guide cables are parallel Caution Do not allow the float cluster to fall back to the floor of the tank Damage may result Loosen the thumbscrew The spring motor will pull the tape taut Slowly smoothly crank the float cluster to the top of the tank and return it to the floor while observing the tape travel through the elbows and gaugehead There should be no binding The counters will be zeroed in steps following but they should register during the float travel Zeroing the display 1 See Figures 3 2 and 3 3 on pages 15 and 16 and remove the cover from the counter mechanism of the gaugehead See
49. n operation Varec Inc 29 Installation 3 5 Spheres to 60 Feet Diameter Grade Level Installation For spheres and cylinders to 60 feet diameter with the gaugehead located on the side near grade level see Figure 3 9 on page 31 for feature option installation kit codes N2520 01 T04 N2520 02 T04 N2520 03 T08 N2520 04 T08 N2520 05 T08 and N2520 06 TO8 Refer to Table 8 1 Table 8 2 and Table 8 3 on pages 57 and 58 for details Make certain that after the installation is completed it is checked and then doubled checked for proper installation After the tank is pressurized the user will have no easy method of correcting installation error 1 8 9 Determine the position on the tank roof beneath which the center of the float cluster will rise and fall Note The position should be located where gauge piping will pass over the top of the tank shell close to a stairway platform to facilitate inspection and service of the gauge system Provide the roof holes shown in the Figure 3 9 on page 31 centered on this position The guide cable holes are centered 8 50 inches 216 mm each side of the center of the cluster of floats The tape pipe is centered on a 17 00 inch 432 mm diameter The plug valve is also centered on this dimension Weld a 1 1 2 inch ANSI 150 Ib or 300 Ib flanged nozzle into the top pipe center hole Make certain that it is welded in true vertical position Hold it plumb while welding Failure to place
50. nd and the actual volume will be greater than the volume at the standard temperature Refer to appropriate industry standards for volume correction factors Careful reference to the benchmark of the tank will help assure accuracy of the automatic gauge 42 Installation and Operations Manual High Pressure Automatic Tank Gauge 5 Maintenance Warning The product stored in the tanks that are gauged is under pressure of 30 to 300 psig It is most probably a flammable product such as butane or propane The gaugehead and piping are under pressure Do not open them without first closing the Varec plug valve and then carefully bleeding the product pressure from the gaugehead and piping If there is no Varec plug valve installed no maintenance can be performed unless the tank is empty and not under pressure Warning Observe appropriate safety precautions in flammable or hazardous liquid storage areas Do not enter a tank that has contained hydrocarbons vapors or toxic materials until a gas free environment is certified Carry breathing equipment when entering a tank where oxygen may be displaced by carbon dioxide nitrogen or other gases 5 1 Electrostatic Discharge Hazard Warning The mechanical connections between the guide cables the float the tape and the gaugehead provide a resistance to ground that is adequate for the safe electrical drain of electrostatic charges that may accumulate in the tank and the product Worke
51. nd hang plumb lines from them at the center to mark the position where the bottom cable anchors will be welded Mark the plumb bob string at the height of the tank benchmark This will assure that the plumb bob just touches the bottom when the reference is made from the benchmark distance to the bottom Open the top sheave elbow and hang a plumb line through the center of the top tape pipe to the bottom to mark the float center This should be 8 50 inches 216 mm at the bottom from each of the bottom cable anchor positions When the positioning has been checked weld the bottom cable anchors into place Thread the float cables into the tank through the top anchor fittings Fasten them to the bottom cable anchors with the furnished hardware Thread the upper end of each guide cable through the top anchor assembly Hand tighten Use the lock nut to lock the cable in place then tighten the adjustment nut until the guide cable is tensioned by the spring Replace the housing nipple and cap Varec Inc 11 Installation 16 17 18 19 20 21 22 23 24 Warning Whenever the back cover of the gaugehead is removed make certain that internal pressure has been bled Stand back as the last bolt is removed If the negator motor spring is broken the broken pieces may cause injury when the cover is removed Remove the back cover and gasket from the gaugehead see Figures 3 2 and 3 3 on pages 15 and 16 Remove t
52. om the bench mark distance to the bottom Open the top sheave elbow and hang a plumb line through the center of the top tape pipe to the bottom to mark the float center This should be 8 50 inches 216 mm at the bottom from each of the bottom cable anchor positions When the positioning has been checked weld the bottom cable anchors into place Thread the float cables into the tank through the top anchor fittings Fasten them to the bottom cable anchors with the furnished hardware Thread the upper end of each guide cable through the top anchor assembly Hand tighten Use the lock nut to lock the cable in place then tighten the adjustment nut until the guide cable is tensioned by the spring Replace the housing nipple and cap Warning Whenever the back cover of the gaugehead is removed make certain that the pressure has been bled from the gaugehead and piping then stand back as the last bolt is removed If the negator motor spring is broken the broken pieces may cause injury when the cover is removed Remove the bolts back cover and gasket from the gaugehead see Figures 3 2 and 3 3 on pages 15 and 16 Remove the bolts covers and gaskets from the other elbows Mount the gaugehead on the bracket and attach the pipe and flanged nipple to the top Tilt the float cluster on edge and slip the guide cables through the loops on the inside of the tank see Figure 3 4 on page 17 Set it on the tank bottom with the tape connection up
53. on pages 15 and 16 and remove the cover from the counter mechanism of the gaugehead 2 SeeFigure 3 6 on page 21 and loosen screws A until the dial plate C and gear H rotate freely and independently of the hub 3 Check that the float cluster is at the bottom of the tank with the tape taut Rotate dial C and gear H until counter drums all display zero Initial calibration These instructions apply to systems that use a float cluster The float cluster is shipped with six weights attached Table 3 3 on page 20 lists the submersion depth of the cluster for products having specific gravity ranging between 45 and 69 and the quantity of the weights that are required Keep the product specific gravity tag removed from the float cluster for future reference Note During manufacturing lead shot may be added to the interior of each sphere to make the equator depth submerged displacement equal to 402 12 cu in when the specific gravity is beyond the standard range between 45 and 69 1 Determine the specific gravity of the product to be stored 2 Referto Table 3 3 on page 20 and remove the required number of weights 3 Pull up on the dial and gear H to disengage them from the counter pinion then rotate the dial to indicate four inches 102 mm for products with specific gravity between 51 and 69 at 60 degrees F For product of specific gravity of 48 set the dial and drums to indicate four and 1 8 inches 104 8 mm For prod
54. ottom to the sub mersion depth mark Use this distance to reset the dial and counter drums for an empty tank 9 Tighten the screws after resetting the drums and dial 10 Replace the counter cover and gasket 3 4 8 Auxiliary equipment If auxiliary equipment is to be installed remove the cap from the back cover The hole size and bolt pattern mates with Varec auxiliary options Each mating auxiliary unit has a coupling that engages the magnetic drive assembly Use the cap screws to attach the auxiliary unit adapter to the back cover Refer to the manual for the auxiliary unit for operational checkout after it is installed Note The use of auxiliary units not manufactured or supplied by Varec will void any Varec warranty and will relieve Varec of any obligation to service the product under warranty Initial lubrication Apply LPS 2 to the elbow sheave If the gaugehead is not going to be filled with oil apply LPS 2 to the tape sprocket and storage sheave If the gaugehead is to be filled with oil perform the following reassembly then fill with oil Refer to Chapter 5 Maintenance on page 43 for the details For most service Varec recommends filling the gaugehead with oil to prolong the life Note Before the gaugehead is filled with oil the NPT plug on the counter side that has a hole to drain condensation must be replaced with a solid NPT plug Switch the top plug to the bottom Put the bottom plug on top Installation quality c
55. r activity and worker clothing may accumulate electrostatic charges on the body of a worker Care should be used in flammable environments to avoid the hazard Observe American Petroleum Institute API Recommended Practice 2003 or other appropriate industry or military standard Varec 2520 Series High Pressure Automatic Tank Gauges are designed for long service life Like any other instrument Varec 2520 gauges require regular periodic service to maintain the original performance Table 5 1 on page 44 provides some suggested periodic service Performance of routine maintenance will lengthen the service life Gauge accuracy may be impaired if routine maintenance is not performed Varec provides maintenance service contracts that provide regular periodic inspection and maintenance at substantial savings Some repair tasks may require special tools 5 2 Lubrication Warning The product stored in the tanks that are gauged is under pressure of 30 to 300 psig It is most probably a flammable product such as butane or propane The gaugehead and piping are under pressure Do not open them without first closing the Varec plug valve and then carefully bleeding the product pressure from the gaugehead and piping If there is no Varec plug valve installed no maintenance can be performed unless the tank is empty and not under pressure 1 Close the Varec plug valve 2 Ventthe product pressure in the piping and gaugehead safely to the atmosphere
56. rews Pliers As needed Level Level pipe installation Pipe taps dies Connect pipe segments Vice Hold pipe Pipe cutter Cut pipe Cable cutter As needed Sheet metal shears As needed Electric drill Drill holes Drill bits Selected for hole size Hole cutters Selected for hole size Plumb bob Check vertical plumb Long measuring tape Make required measurements Chalk line Mark lines Chalk Marking String Alignment Compass Centering angle measurement Protractor Centering angle measurement Shovel As needed Pick As needed Welding equipment Weld pipe supports Breathing equipment As needed Tank hand gauge Manual measurement Clean drop cloth Keep dirt off tape tools Loctite 567 Pipe thread compound Dow Corning 4 compound Mil S 8660 white silicon grease Dow Corning RTV 737 Multipurpose sealant Loctite 262 Permanent thread locker LPS 2 Lubricate screws nuts bolts shafts etc Table 3 1 Typical Required Tools Equipment and Materials Note The user must attach the pipe carrying the tape to the tank by welding the supplied brackets If the environment is such that welding cannot be performed the user can con struct a support structure with 3 inch 75 mm pipe or conduit close to the outside of the tank The brackets can be welded to the support structure at another location if necessary and the pipe structure assembled at the tank site Refer to Document 2500 for additional details Varec Inc 9 Installat
57. s completes the installation for feature options kit codes N2520 01 N2520 02 N2520 03 TO7 N2520 04 TO7 N2520 05 TO7 and N2520 06 TO7 Proceed to place the system in operation 40 Installation and Operations Manual High Pressure Automatic Tank Gauge 4 Operation 4 1 Initial Operation Caution Initial filling of the tank must be at a reduced rate of flow until the float travel and dial operation are verified This checks that the installation was correctly made and prevents possible damage to the gauge system The system must have been previously pressure checked to a proof pressure 1 50 times the normal maximum operating The user should review the appropriate industry manual for petroleum products API Chapter 3 and others for details of the handling of the particular product These are general instructions 1 2 Station an observer at the gaugehead Commence tilling the tank to raise the float cluster several feet about three feet or one meter from the bottom Caution Do not release the checker knob and allow the springs to return the mechanism Over time the springs may break and jam the gauge Turn the operation checker knob on the front of the gaugehead a quarter turn clockwise to lift the float cluster slightly Check that the display registers the movement Return the knob slowly to its original position Verify that the float has returned to its original level Note If the tape is sla
58. stallation of a new perforated tape if the installed tape is broken 1 3 Getting Acquainted with the Tank Gauge Systems System consists of the gaugehead see Figure 1 1 on page 2 a cluster of three type 304 stainless steel S S floats perforated tape and the gauge piping which carries the perforated tape Changes in the liquid level in the tank raise or lower the float which moves the tape which drives a sprocket that is connected to the counter mechanism The liquid level in feet and inches or meters and millimeters is displayed on dials that are visible though a glass window on the gaugehead The user may convert the liquid level to units of volume This may be accomplished manually or as is frequently the case Varec s SCADA system performs the task Varec Inc Introduction FUELSMANAGER amp RTU HIGH PRESSURE GAUGE SYSTEM Figure 1 1 Typical Varec Model 2520 Installation 2 Installation and Operations Manual High Pressure Automatic Tank Gauge TEM DESCRIPTION ADAPTER BRACKET COVER DRIVE DISK ASSEMBLY 3 1 DRIVE DISK 3 2 DRIVE PIN 3 3 SOCKET HEAD SET SCREW COVER GASKET GASKET ROUND HEAD MACHINE SCREW HEX HEAD CAP SCREW PIPE PLUG NOTE PART OF ITEM 3 ASSEMBLY D S Ad 4 P f i AUXILIARY UIPM ay a E M T C view INN HIGH PRESSURE GAUGE ACCESSORY ADAPTER Figure 1 2 Varec Gauge Accessories Varec Inc Introduction SCAD
59. sts the number of turns to wind the negator motor Gaugehead Motor Motor Sheave Assembly Number of Turns Extra Strong PI 22 BA17725 47 Table 3 2 Turns to Wind Negator Motor 27 28 29 30 31 32 After the motor is wound and the thumbscrew securely tightened reattach the tape to the storage sheave Pull the tape on the ground back through the gaugehead Put the first hole in the tape ona pin of the sprocket close to the tape guide Rotate the sprocket clockwise to pull the tape through the guide Pull the tape around the storage sheave Fasten the tape to the tape storage sheave with the sheave pin Wind the excess tape counter clockwise around the storage sheave until the slack is removed Check the tape path between the float cluster and the gaugehead to be sure that it is not kinked or twisted Also check the float guide cables for kinks Make certain that the float cluster guide cables are parallel Caution Do not allow the float cluster to fall back to the floor of the tank Damage may result Loosen the thumbscrew The spring motor will pull the tape taut Slowly smoothly crank the float cluster to the top of the tank and return it to the floor while observing the tape travel through the elbows and gaugehead There should be no notice able binding The counters will be zeroed in steps following but they should register during the float travel 14 Installation and Operations M
60. t it is plumb and positioned as shown Install the tankside vertical pipe in the bracket Make certain that it is plumb Install the horizontal pipe in the 90 degree tank top elbow Apply thread compound BestoLife 270 or equal as appropriate 24 Installation and Operations Manual High Pressure Automatic Tank Gauge 1 180 0 300 Tk NOZZLE BY CUSTOMER T NOTE CUSTOMER TO SPECIFY TANK HEIGHT Gaugehead Support 1 Figure 3 8 shows a typical grade level installation for spheres to 48 feet in diameter DESCRIPTION GAUGEHEAD TAPE TOP ANCHOR PIPE SUPPORT BRACKET FLOAT TAPE FASTENER BOTIOM ANCHOR SHEAVE ELBOW 90 GUIDE CABLE MOUNTING BRACKET Note 150 flanges for 150 psig models SHEAVE ELBOW 45 300 flanges for 220 psig amp 300 psig models O 00 40U bh wi Note 220 psig and 300 psig dimensions are the same vom press a Te T2 PSIG 1600 550 5 50 sez 462 3002516 J 25 5 75 5 05 575 et supplied by Customer Typical C DIMENSION R PLUG GATE VALVE OPTIONAL zm d PIPING 8 FLANGES 6 62 SHOWN DOTTED FURNISHED BY L CUSTOMER San ip TOP ANCHOR DETAIL TANK HEIGHT C DIMENSION amp DIMENSION Structure Constructed by CONVENIENT Customer EYE LEVEL Figure 3 8 Typical Grade Level Installation for Spheres to 48 Feet Diameter 25 Instal
61. tape through the pipe to the tank bottom Let several inches fall on the tank bottom Remove the product specific gravity tag from the float cluster and save it Attach the tape cable to the float cluster with the furnished fastener see Figure 3 4 on page 17 Feed the other end of the tape over the sheave in the elbow above and make sure that it is seated on the pulley See Figure 3 5 on page 19 and attach the furnished installation crank to the tape storage gaugehead tape storage sheave The negator spring motor delivered with the gaugehead was selected by the user s specification of the tank depth of the installation Use the installation crank Wind the motor clockwise the number of turns shown in Table 3 2 on page 14 then tighten the thumbscrew 26 Installation and Operations Manual High Pressure Automatic Tank Gauge 30 31 32 33 34 35 After the motor is wound and the thumbscrew securely tightened reattach the tape to the storage sheave Pull the tape on the ground back through the gaugehead Put the fist hole in the tape ona pin of the sprocket close to the tape guide Rotate the sprocket clockwise to pull the tape through the guide Pull the tape around the storage sheave Fasten the tape to the tape storage sheave with the sheave pin Wind the excess tape counter clockwise around the storage sheave until the slack is removed Check the tape path between the float cluster and the gaugehead to be sur
62. tes As indicated in earlier paragraphs the English gaugehead is shipped with a counter wheel assembly for measurement in feet and a dial plate that indicates inches and 1 16 inch that is factory installed A spate dial that indicates measurement of 1 10 inch and 1 100 inch is included in the package To change the dial see Figures 3 2 3 3 and 3 6 on pages 15 16 and 21 respectively 1 Remove the screws attaching the counter cover and remove the counter cover 2 Remove the screws attaching the dial and lift off the dial and the dial retainer 3 Substitute the other dial plate and reassemble in reverse order of disassembly Varec Inc 45 Maintenance 5 6 Maintenance and Repair Kits Varec provides two maintenance and repair kits for either English or Metric 2520 Series Gauges The parts in each are listed in Table 5 3 and Table 5 4 on pages 48 and 50 Kit installation instructions are included in the kits when delivered The casting has been changed on newer gaugeheads Users with the old style 150 psig pressure gauge will use the gasket indicated Table 5 3 on page 48 46 Installation and Operations Manual High Pressure Automatic Tank Gauge Table 5 3 lists the Basic Maintenance Kit 1 Part Name English Part Number 13 08784 2500 CRANK ASSY BM3784 TAPE ENG PERF 316 SST X 180 B10537 606 FHMS 10 24 X 3 8 304 SS
63. tomatic Tank Gauge Figure 3 1 shows a typical grade level installation for spheres and cylinders to 16 feet in diameter DESCRIPTION GAUGEHEAD TAPE TOP ANCHOR PIPE SUPPORT BRACKET FLOAT TAPE FASTENER BOTTOM ANCHOR SHEAVE ELBOW GUIDE CABLE MOUNTING BRACKET if 150 OR soc Tk NOZZLE BY CUSTOMER bs NOZZLE BY Pe 8 50 8 50 NOZZLE LAYOUT IN TANK ROOF Swomyanaon Note 150 flanges for 150 psig models 300 flanges for 220 psig amp 300 psig models Note 220 psig and 300 psig dimensions are the same FIG 275 RUBBER PLUG GATE VALVE OPTIONAL Side Support Bracket DIMENSION BRACKET DETAIL NOTE CUSTOMER TO SPECIFY TANK HEIGHT C DIMENSION DIMENSION Figure 3 1 Typical Grade Level Installation for Spheres and Cylinders to 16 Feet Diameter Varec Inc 13 Installation 25 26 See Figure 3 5 on page 19 and attach the furnished installation crank to the tape storage gaugehead tape storage sheave The negator spring motor delivered with the gaugehead was selected by the user s specification of the tank depth of the installation Use the installation crank Wind the motor clockwise the number of turns shown in Table 3 2 then tighten the thumbscrew Warning Use a firm grasp on crank while winding motor Tighten thumbscrew before releasing grip The rapid unwinding of the spring could result in the crank spinning and striking the operator Table 3 2 li
64. tored 2 Referto Table 3 3 on page 20 and remove the required number of eights 3 Pull up on the dial and gear H to disengage them from the counter pinion then rotate the dial to indicate four inches 102 mm for products with specific gravity between 51 and 69 at 60 degrees F For product of specific gravity of 48 set the dial and drums to indicate four and 1 8 inches 104 8 mm For product of specific gravity of 45 set the dial and drums to indicate four and 4 inches 107 9 mm 4 Re engage the gear and pinion Tighten screws A 18 Installation and Operations Manual High Pressure Automatic Tank Gauge MEM 1 2 3 4 5 6 7 8 9 CAUTION Figure 3 5 shows a tape installation on a low pressure gaugehead TAPE ENTRY TANK SIDE MOUNTED GAGE DESCRIPTION SPROCKET SHEAVE TAPE STORAGE SHEAVE THUMBSCREW LOCK TAPE GUIDE MOTOR STORAGE SHEAVE NEGATOR SPRING REMOVABLE CRANK TURN CLOCKWISE TO LOAD SPRING MOTOR NEGATOR SPRING SCREW SHEAVE PIN ATTACHES TAPE TO TAPE STORAGE SHEAVE DO NOT RELEASE CRANK HANDLE WHEN SPRING IS BEING LOADED AND THUMBSCREW LOCK IS REMOVED TAPE ENTRY TANK ROOF MOUNTED GAGE Figure 3 5 Tape Installation Low Pressure Gaugehead Shown Varec Inc 19 Installation Table 3 3 shows a product specific gravity verses weight chart Special Gravity 60 F Number of Weights Submerged Depth 0 45 0 1 4 in 6 35 mm below equ
65. ty shall be limited to repair or replacement under the standard warranty clause In no case shall the Seller s liability exceed that stated as Limitations of Remedy in the contract between the Seller and Buyer Use of parts that are not manufactured or supplied by Varec voids any warranty and relieves Varec of any obligation to service the product under warranty Varec recommends the use of only Varec manufactured or supplied parts to maintain or service Varec 2520 High Pressure Automatic Tank Gauges Terms of Use The information provided in this document is provided as is without warranty of any kind Varec Inc disclaim all warranties either express or implied including the warranties of merchantability and fitness for a particular purpose In no event shall Varec Inc or its suppliers be liable for any damages whatsoever including direct indirect incidental consequential loss of business profits or special damages even if Varec Inc or its suppliers have been advised of the possibility of such damages This manual is solely intended to describe product installation and functions and should not be used for any other purpose It is subject to change without prior notice This manual was prepared with the highest degree of care However should you find any errors or have any questions contact one of our service offices or your local sales agent Installation and Operations Manual Safety Precaution Definitions Caution Dama
66. uct of specific gravity of 45 set the dial and drums to indicate four and 1 4 inches 107 9 mm 4 Re engage the gear and pinion Tighten screws A 5 Loosen the thumbscrew lock 6 Observe the operation of the drums and dial while slowly cranking the float cluster to the top of the tank and then lowering it to the bottom The drums and dial should rotate freely and return to the calibrated indication when the float cluster touches the tank bottom 7 Use the chart furnished with the float cluster Mark the float cluster for the submersion depth for the particular product to be stored in the tank 8 With the float cluster on the bottom measure the distance from the tank bottom to the submersion depth mark Use this distance to reset the dial and counter drums for an empty tank 9 Tighten the screws after resetting the drums and dial 10 Replace the counter cover and gasket 3 6 3 Auxiliary equipment If auxiliary equipment is to be installed remove the cap from the back cover The hole size and bolt pattern mates with Varec auxiliary options Each mating auxiliary unit has a coupling that engages the magnetic drive assembly Use the cap screws to attach the auxiliary unit adapter to the back cover Refer to the manual for the auxiliary unit for operational checkout after it is installed Note The use of auxiliary units not manufactured or supplied by Varec will void any Varec warranty and will relieve Varec of any obligation to
67. warranty Initial lubrication Apply LPS 2 to the elbow sheave If the gaugehead is not going to be filled with oil apply LPS 2 to the tape sprocket and storage sheave If the gaugehead is to be filled with oil perform the following re assembly then fill with oil Refer to Chapter 5 Maintenance on page 43 for the details For most service Varec recommends filling the gaugehead with oil to prolong the life Note Before the gaugehead is filled with oil the NPT plug on the counter side that has a hole to drain condensation must be replaced with a solid NPT plug Put the bottom plug on top and the top plug in the bottom Installation quality check It is essential that the user recheck the quality of the installation and then double check it before pressurizing the tank There is no easy method of correcting installation errors after the tank is filled If the float cluster travel is stuck due to cables that are not parallel or plumb or if tape cable travel is impaired repair cannot be accomplished until the product pressure is removed from the tank 3 5 6 Reassembly Remove the installation crank If auxiliary equipment was not installed replace the back cover and its gasket Using the torque sequence shown in Figure 3 7 on page 23 torque the bolts to 30 ft lbs 41 Nm If auxiliary equipment was installed seat the magnetic coupling with the auxiliary adapter coupling and replace the back cover with the auxiliary unit adapter att
68. ystem Provide the roof holes shown in the Figure 3 8 on page 25 centered on this position The guide cable holes are centered 8 50 inches 216 mm each side of the center of the cluster of floats The tape pipe is centered on a 17 00 inch 432 mm diameter The plug valve is also centered on this dimension Weld a 1 1 2 inch ANSI 150 Ib or 300 Ib flanged nozzle into the top pipe center hole Make certain that it is welded in true vertical position Hold it plumb while welding Failure to place the flanged nozzle in a true vertical position may affect the accuracy of the gauge Make sure that the interior of all flanges and pipes are clean and corrosion free Weld the top cable anchor 1 1 4 inch flanged nozzles into their respective holes Make cer tain that they are welded a true vertical position Check with a plumb line prior to welding and maintain the plumb position during welding Make sure that the interior of the flanges remain clean and corrosion free Install the plug valve if it is to be installed and install the top sheave elbow Note Varec recommends that a plug valve be installed to facilitate gauge maintenance Use of parts that are not manufactured or supplied by Varec voids any Varec warranty and relieves Varec of any obligation to service the product under warranty Weld the side support brackets in place Construct the gaugehead support stanchion and weld the gaugehead support bracket in place Make certain tha

Download Pdf Manuals

Related Search

Related Contents

Bryant Commercial TSTATBBPCM01-A User's Manual  IShowV3 User Manual  Troubleshooting Step Sheet 4  Instalación del Software Magaya  販売価格 77，000円（ 税抜 ）  PA 9117 FSAMP Lilly Prefilled Insulin Delivery Device User Manual  KitchenAid KGCC506RBL Use and Care Manual  GEIGER-SOLIDline GEIGER-VariousWireless (GU45..F01)  MEMENTO DE SECURITÉ - Ambassade de France  Operating Instructions Bruksanvisning Brugervejledning  

Copyright © All rights reserved. Failed to retrieve file