FuelBar 501
Contents
1. FuelCom 5080 5040 Installation guide Document no 15 CFC08044 Rev B Page 1 of 10 CONTENTS 1 installation ee 3 2 Mak pr parati ns er ee e aS 4 2 1 Gather necessary site Information 4 2 1 1 Situation Map E 2 1 2 Tank informatio DE 2 1 3 Pump hose tank link report from DOS 2 1 4 POS system and versi n sssssssie sriid aa EE E a EE eE ae Ea aia 2 1 5 BO IIe PIP OS geed a EEE E a whee EO aa aiak 2 2 Local authorities and legislations ccccccssssscececessesesneaeceeecesseseeaeseeeeecesseeaaeseeeesseesesseaeeesess 4 2 3 Verify CQUIPMON EE 4 2 3 1 TO be installed vicsesscccsvesceceesssaceceescedeesetacecssanicceesasacuessascccesdesadece sandeveesaaucndevasdedeesetacecesesdevessa 2 3 2 Spare El CC 2 3 3 Ree 3 e e E 5 3 1 DEE 5 3 2 Se re are dpn e e E E E EEE REE AEREA 5 AL J stal Ward wWate AN EN A E E E aesdeer 5 4 1 CADDIES ege erugeet eege Aere e agedeelt eege Ae ee 5 4 2 Controler console arroios ie eege Sea EIA EEE gehE soseesteeres 5 4 3 Calculate tilt an glosses eege dees cade e aee ia Eee EEE Eed ees 5 4 4 lte 6 4 5 Cable grounding EX x szccecssvsscuse vesteteseseetidsogecues ageet SeE eege eege et e ech 6 5 Calibrate height and temperature 6 5 1 Synchronise FuelWin with the controller cccscccccceceesssesseceeceecesseseaeeeeeescesseseaeaeseesseees 6 5 2 Define tanks height parametersl 6 5 3 Get correct height and temperature c ccccccccssssssssceeecececse2. 2 1 Gather necessary site information 2 1 1 Situation map The situation map should illustrate tank location pulling pipes in the ground manhole covers and which tanks that is manifolded This information is useful for planning the installation and verifying the required material 2 1 2 Tank information Get as much information about the tanks as you can This information makes it easier to create an accurate calibration of the system List of relevant tank information Tank size in liters Tank shape Strap table Tank height inner diameter for horizontal cylinders For horizontal cylinders a Diameter b Total length end to end c Cylinder length length of the cylindrical part of the tank d Tilt angle 6 Manifolded tanks Oe Ou 2 1 3 Pump hose tank link report from POS If pump levels are to be reported by the POS Point Of Sale system it is very important to get a report of which pump numbers and hose numbers are connected to which tanks This is called the pump hose tank link report This report must be configured in FuelCom during the installation 2 1 4 POS system and version Different POS systems will be connected in different ways to the FuelCom Most POS systems read level information and delivery reports from the FuelCom and some provides reconciliation pump traffic data as well The type and version of the POS system will determine the requirements for preparing successful communication between the two 2 1 5 P
3. Low level o Possible open circuit o Possible connection fault switched polarity o Possible damage on air tube High level o Possible short circuit o Possible damage on air tube o Check if tank 1 is connected to input 1 tank 2 to input 2 and so on FuelBar 410 probe o Check that level and temperature inputs not are swapped 7 5 2 Small discrepancies Document n Is the tank angle correctly calculated Does the probe reach the tank bottom completely if not adjust Offset Try to adjust Density typically 0 005 FuelBar probe o 15 CFC08044 Rev B Page 9 of 10 8 Tidy up Briefing and acceptance Make sure the site is as tidy as when you entered leaving no garbage behind It is important to brief the customer with the newly installed equipment in order to give him the full benefit The following areas are the most important 8 1 Set alarm limits according to customers needs Make sure the alarm limits on each are set according to the needs of the customer or oil company 8 2 FuelWin main window and reports If installed on site introduce the FuelWin program to the customer and let him understand the importance of letting FuelWin run at all times to collect level and report data to the database Show the aspects of the main window and each of the report types period report delivery report inventory report leakage report 8 3 FuelCom console Show the customer the FuelCom console and how to oper
4. 15 degrees default will be shown if the temperature cannot be read Handle any discrepancies according to sections 7 5 1 and 7 5 2 in this document Document no 15 CFC08044 Rev B Page 6 of 10 4 tech 6 Seal installation When the height calibration of all tanks is verified the installation can be sealed The probe connections should be sealed with the glue joint Again make sure the blue cable grounding shield is NOT connected to the probe cable grounding shield Seal the end of the pulling pipes with gas proof sealant or notify owner if it is not done EX Mount flanges with new flange gaskets Mount the manhole covers 7 Calibrate volume The volume is calculated using the tank height diameter on horizontal tanks and gauge table The measured height is calculated by looking up in this 21 point table The table can be determined in 3 ways Generated from tank shape definition Entered manually Auto calibration only relevant when initial table has proven to be inaccurate In this document we describe how to generate the table from the shape definition of horizontal cylindrical tanks 7 1 Configure volume parameters Determine and enter the following parameters by measurement calculation and existing tank data Total length This is the total length of the tank from end to end Cylinder length This is the length of the cylindrical tank part Reinforcement This is the height of
5. add the height of the reinforcement plate if the is one Measure the heights this before the probe is mounted and note the two heights measured Measure height at end point add height of reinforcement plate if any Measure height at mid point Measure the distance between the two point Angle INV TAN End point height Mid point height Distance between points Example Height end point 100cm height of reinforcement plate 1 5cm 101 5cm Height mid point 99 5cm Distance between points 220cm Angle INV TAN 101 5 99 5 220 Angle 0 521 Document no 15 CFC08044 Rev B Page 5 of 10 4 4 Probes Please refer to the FuelCom technical description under Planning Probe Installation Actions Take note of the probe spans e g 0 250mBar g for each probe and tank combination Mount each of the probes in the tanks according to the probe user manual Ifthe FuelBar has been delivered with aluminium pipes the pipes have to be tightened at each connection with a pipe tong See picture Make sure the probes are only connected to the cables using ShotchLocks yet and wait with the glue joint until the height is calibrated and verified 4 5 Cable grounding EX Please refer to the FuelCom technical description under FuelCom grounding bar Actions The screen of the blue installation cable shall not be connected to the probe cable screen If a grounding kit is required
6. ate it Most important points are The meaning of the values on the front panel How to switch between the different tanks How to reset alarm sound How to reset alarms 8 4 FuelWin If the FuelWin software is to be installed at site make sure to test the functionality and demonstrate the functionality for the customer 8 5 Certificates and declarations EX ATEX EX legislation requires that you have to leave certificates of the installed equipment on the site The customer must be made aware of this and handed copies of necessary certificates and declarations A paper copy is included in the delivery and requires that they are filled out and delivered to the station owner Installation overview diagram Safety calculation form with values documented Certificates for all relevant ATEX certified parts Declaration of Conformity CE The relevant declarations and forms are stored on the FuelCom CD 8 6 Customer acceptance Make sure the customer accepts the installation by signing the installation report 9 Write report Write a full report of the installation as documentation to your employer including the customer acceptance Document no 15 CFC08044 Rev B Page 10 of 10
7. d in Figure 1 The following chapters describe each activity in more detail FuelCom 5080 is intended for Ex installations like petrol station etc while FuelCom 5040 is for NON Ex installations like oil diesel stations etc For full details of the products involved please refer to the following documents FuelWin User Manual Doc no 15 SFW08043 FuelCom 5080 Installation amp User manual Doc no 15 CFC09026 FuelCom 5040 Installation amp User manual Doc no 15 CFC09023 AD424 Installation amp User manual Doc no 15 CFC09029 PT100 Installation amp User manual Doc no 15 CFC09030 RE202 Installation amp User manual Doc no 15 CFC09031 FuelBar 410 420 P44 Installation amp User manual Doc no 15 CFC09027 MiniBar Installation amp User manual Doc no 15 CFC09028 Figure 1 Main installation workflow Preparations Install hardware don t seal Calibrate height using FuelWin Seal installation Calibrate volume using FuelWin Tidy up gt W Briefing and acceptance oN ww gt Write report Document no 15 CFC08044 Rev B Page 3 of 10 2 Make preparations Please make sure to make as many of the preparations in this chapter as you can in the office before driving to the site Failing to do so may result in unnecessary high installation costs and time
8. ing FuelCom 5040 in a NON Ex environment 3 Arrive at site Notify the customer and the local authorities if required of your arrival and start analysing the site 3 1 Risk analysis In order to reduce the total risk of the installation a risk evaluation form should be filled out on site 3 2 Secure area Make sure the installation area is secured and properly marked before starting the installation 4 Install hardware 4 1 Cables Please refer to the FuelCom technical description under Planning Probe Installation Actions Measure the required cable lengths Perform EX energy calculation if required Pull the cable through the pulling pipes Mark the cable ends with tank numbers 4 2 Controller console Please refer to the FuelCom technical description under Installing of the control unit Actions FuelCom 5080 in Ex environment Install the FuelCom controller in the safe area according to the user manual Doc no 15 CFC09026 FuelCom 5040 in NON Ex environment Install the FuelCom controller indoor in a dry place office or technical rom according to the user manual Doc no 15 CFC09023 4 3 Calculate tilt angles Before installing the probes the tank angles should be calculated In order to get an accurate strap table calculating the tank angle is essential This is done by measuring the liquid height at two different points normally at the tank end and on the mid point of the tank Remember to
9. om However these may be verified using service menu password 10 or XML DUMP through a terminal window In both cases a communication cable should be connected to COM1 on FuelCom with a terminal program e g Hyper Terminal in Windows at 9600 baud 8 data bits no parity 1 stop bit no flow control Verify with password 10 Turn the wheel until the SERVICE menu appears Press the wheel The complete pump hose tank list is reported in the terminal window Verify with XML DUMP Write XML DUMP in the terminal window The complete setup of FuelCom is reported as XML code Stop the dump by writing EXIT EXIT in the terminal window View the pump hose tank links inside the setup information Document no 15 CFC08044 Rev B Page 8 of 10 7 5 Vert y calibration Create initial period report in FuelWin This initial report will not be present in FuelWin since it has no valid start time Wait for a few pump transactions to happen e g for 5 10 minutes while you start to write your report or tidy up Generate a new period report and verify the measured sales against the pump sales 7 5 1 Large discrepancies Check strap tables o Select Strap tables from the Options menu o Select Tank number o Select Read o Check Strap table Check tank parameters o Check span against probe type 160mBar 1600 200mBar 2000 FuelBar 410 probe o Check Density setting FuelBar 410 probe o Check Offset
10. seceseeeeecesseseaeeeeeessessessneaeeeeseesees 6 P SealinStallation iris cccAssswcesessctervdasdevevsageecstasteersPesseceguduvcecsedagedcslayudevelessedesedesdeveedageecSasdueestesseteasessdes 7 A e He E H 7 1 Configure volume parameters 7 7 2 Generate gauge Lables 8 7 3 Define manifolded tanks cccesscccssssseceeseneececceaeeceseeaecesseaaeceseeaaeceeseaaeeeeseauecesseaaeeeeseaeeeeseaas 8 7 4 Define pump tank LINKS ccecsscceessecsseeecsececsceceseeecsseeecssececseeceaeeccaaececsseceeseecsaeecesaeeseaeeceeeees 8 7 5 Verify calibration sesine n aeeai aa a E E E E E a 9 7 5 1 targe discrepancies EE 7 5 2 Small discr panti S srein a i a SEA SEELEN 8 Tidy up Briefing and acceptance ceescesssecsessecssscecsecesaecsensecseesecsaesessuecseseeceeeesesaeesssuesseseesegs 10 8 1 Set alarm limits according to customers need 10 8 2 FuelWin main window and reportsl 10 8 3 FuelCom console cicca a a R A 10 8 4 Fae Nison S 10 8 5 Certificates and declarations EN 10 8 6 Customer ACCEPTS CO ssicsvicsisessevsvcathes aiee ie iek E iaae eE A ORE ae Eiaa Eiaa 10 9 Write e bsevecc secdeeskicc ct eieacten si ducacdeateddenebbve dds saxsdbecdh becuddeseeccevebaveeds saundtevebdvcudteatecdevebsvedd saxddevants 10 Document no 15 CFC08044 Rev B Page 2 of 10 1 Installation overview This installation guide takes you through the main activities of a complete installation of FuelCom 5080 FuelCom 5040 as illustrate
11. the kit shall be installed according to the FuelCom user manual Mount the cable screen to the grounding kit on the FuelCom controller side only 5 Calibrate height and temperature 5 1 Synchronise FuelWin with the controller If a FuelWin installation is ordered this is the time to install FuelWin on the on site computer Otherwise you have to make sure you have a working version of FuelWin on your own installation lap top Please refer to the FuelWin user manual for details on installation and synchronisation of parameters with FuelWin Initial actions Synchronise all parameters between FuelWin and FuelCom Set correct date and time 5 2 Define tanks height parameters These parameters determine the height calibration of the gauges Set up the following parameters for each tank Product type Product density Label volume Probe span Probe offset Tank type 5 3 Get correct height and temperature Carefully gauge each tank manually and adjust the density and offset values in order to get the correctly calibrated height measurement Verify against the Real time logger see FuelWin user manual while adjusting the values Adjustment rules Higher density gives lower height measurement Lower density gives higher height measurement Higher offset gives higher height measurement Lower offset gives lower height measurement Verify that the temperature reading seams to be correct as well A temperature of
12. the reinforcement plate at the tank bottom if any Mount length This is the distance from the lowest tank end to where the probe is mounted Diameter This is the tank inner diameter Angle This is the angle of the tank Tot Lenght Cyl Length Mount Lenght With these parameters entered a gauge table can be generated and programmed into the FuelCom 5080 5040 memory NOTE If one or more of the above tank parameters are changed a new gauge table must be calculated Document no 15 CFC08044 Rev B Page 7 of 10 7 2 Generate gauge tables Press the Generate gauge table in the gauge table window for each tank ES a ee Element 8 Volume Height TankNr 1 35 UNL T0 J 000 0cm Calculate 351 010 0cm Mount length mm 2750 990 Tonnen Reinforcement mm 0 Generate gauge table I OH e EE oo o oO CL 6171 070 0 cm FuelCom 7423 080 0 cm e 8704 090 0 cm 12579 120 0 cm r Fuelwin database ew E 13831 130 0 cm 15038 140 0 cm 3 SS Le Se ECH 20017 200 0 cm Label volume 20010 Litre Set Labelvolume Element 20 EI 2 OK Cancel Figure 2 The gauge table window in FuelWin 7 3 Define manifolded tanks Make sure all tank groups are defined 7 4 Define pump tank links Enter the pump hose tank links according to the prepared POS report see section 2 1 3 FuelWin is unable to read the pump hose tank links from FuelC
13. ulling pipes Check the availability of the pulling pipes and whether they are sealed with gas proof sealant or not 2 2 Local authorities and legislations Installation of equipment for explosive areas may require permission from the local authorities in advance of the installation Make sure you are familiar with the local legislations in advance of the installation Energy calculations and specific grounding are often required for installation of intrinsically safe equipment in explosive areas Please refer to the FuelCom user manual for further details 2 3 Verify equipment 2 3 1 To be installed Make sure you have the required equipment for the installation In particular Correct number of probes Correct probe spans and probe lengths The FuelCom control unit with power supply Power outlet Correct cable lengths Glue joints Flanges 2 3 2 Spare parts Please make sure you always have some spare parts with you Gasket glue joints Schotch Locks probes AD424 modules cable etc Document no 15 CFC08044 Rev B Page 4 of 10 2 3 3 Tools Make sure you have the necessary tools for the installation including an installation laptop with FuelWin installed and a communication cable We also recommend having an EX approved loop calibrator for being able to analyse the probe signals 4 20mA with the probe being mounted inside the tank It is not necessary to use an Ex approved instrument when install
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