6700

IOM002GVAE0704

6700 Liquid Level Indicator

Accurate gaugeboard indicator for level measurement

Installation and Operations Manual

Service Manual

www.varec.com
Varec, Inc. 5834 Peachtree Corners East, Norcross (Atlanta), GA 30092 USA Tel: +1 (770) 447-9202 Fax: +1 (770) 662-8939

Liquid Level Indicator

Installation and Operations Manual

6700

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) GA 30096 USA

Trademarks acknowledged
Varec, Inc. recognizes all other trademarks. Trademarks of other products mentioned in this document are held by the companies producing them. Microsoft is a registered trademark of Microsoft Corporation. Acrobat is a registered trademark of Adobe Systems Incorporated. MODBUS is a registered trademark of Modicon, Inc. TIWAY is a registered trademark of Texas Instruments Corporation HART interface is a registered trademark of HART Communications Foundation Delrin is a registered trademark of E. I. du Pont de Nemours Co. (Inc.), Wilmington, DL Dow Corning RTV 737 is a registered trademark of Dow Corning Inc., Midland MI Loctite is a registered trademark of Loctite Corp., Newington, CT Teflon is a registered trademark of E. I. du Pont de Nemours Co. (Inc.), Wilmington, DL Viton is a registered trademark of E. I. Du Pont de Nemours Co. (Inc.), Wilmington, DL FuelsManager is a registered trademark of Varec, Inc. Copyright 2004 RTU8130 is a registered trademark of Varec, Inc. Copyright 2003 TankGate is a trademark of Varec, Inc. 2003 TankView is a registered trademark of Varec, Inc. Copyright 2003 Varec is a registered trademark of Varec, Inc. Copyright 2003

IOM002GVAE0704

Liquid Level Indicator

Disclaimer of Warranties
The contract between the Seller and the Buyer states the entire obligation of the Seller. The contents of this document 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 document. The only warranties that apply are those in the existing contract between the Seller and Buyer. Varec, Inc. products have not been tested by Varec, Inc. under all possible operational conditions, and Varec, Inc. may not have all the data relative to your application. The information in this document 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/her application. If you have any further questions, please contact Varec, Inc. for assistance.

Limitations of Seller's Liability

In the event that a court holds that this document created some new warranties, Seller's liability 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.

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. Use of parts that are not manufactured or supplied by Varec, Inc. voids any Varec, Inc. warranty and relieves Varec, Inc. of any obligation to service the product under warranty. Varec, Inc. recommends the use of only Varec, Inc. manufactured or supplied parts to maintain or service Varec, Inc. products.

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6700

Safety Precaution Definitions

Caution! Warning! Damage to equipment may result if this precaution is disregarded. 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 AND UNDERSTAND THIS INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR PERFORMING MAINTENANCE ON VAREC 6700 SERIES LOW PRESSURE LIQUID LEVEL INDICATOR. FOLLOW ALL PRECAUTIONS AND WARNINGS NOTED HEREIN WHEN INSTALLING, OPERATING OR PERFORMING MAINTENANCE ON THIS EQUIPMENT. 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 displaced by carbon dioxide, nitrogen, or other gases. Wear safety glasses as appropriate. Use a hard hat. Under most circumstances, the mechanical connections between the guide cables and the anchors 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. Additional grounding may be needed for products with low flash points. 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. Observe American Petroleum Institute (API) Recommended Practice 2003 or other appropriate industry or military standard.

Warning!

IOM002GVAE0704

Liquid Level Indicator

Preface
This manual is intended for users of the Varec 6700 Liquid Level Indicator. Chapter 1 - Introduction This chapter provides a general overview of the 6700 Liquid Level Indicator. Chapter 2 - Installation This chapter describes various installations and accessories for the 6700 Liquid Level Indicator. Chapter 3 - Operation This chapter describes the normal operations and calibration of the 6700 Liquid Level Indicator. Chapter 4 - Maintenance This chapter explains the care and routine maintenance needed for the continued operation of the 6700 Liquid Level Indicator. Chapter 5 - Specifications This chapter describes the materials and available installation kits for the 6700 Liquid Level Indicator.

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Contents

1
1.1 1.2 1.3

Introduction
Getting acquainted with the Liquid Level Indicator Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Feature/Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2
2.1

Installation
Oil Seal Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.1.1 Installation of Oil Seal, 8.5-Inch Water Column Operating Pressure Model . . . . . . . . . . . . . 18 2.1.2 Installation of Oil Seal, 27-Inch Water Column Operating Pressure . . . . . . . . . . . . . . . . . . . 19 Cone Roof Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 Initial Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 Initial Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 26 26 26

2.2

2.3 2.4 2.5 2.6 2.7 2.8 2.9

Cone Roof Tank (Bolted Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Initial Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Initial Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Cone Roof Tank Installation (Fiberglass Tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Initial Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Initial Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.10 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 2.11 In-service Tank Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 2.11.1 General Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 2.12 Independent Pipe Support Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 2.13 Installation of Model 228 Inspection Hatch to Existing Manhole Cover . . . . . . . . . . . . . . . . . . . . . . . 35 2.14 Anchor Bar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 2.15 Float Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2.15.1 Initial Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 2.15.2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 2.16 Installation of Model 226 for 20 and 24 Inch Manhole Covers with API Drilling . . . . . . . . . . . . . . . . . 39 2.17 Typical Auxiliary Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3
3.1 3.2 3.3

Operation
Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Calibration and Volume Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4
4.1 4.2 4.3 4.4 4.5 4.6

Maintenance
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Electrostatic Discharge Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Oil Recommendations for Oil Seal Accessory Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Troubleshooting Common Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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Liquid Level Indicator

5
5.1 5.2 5.3 5.4 5.5 5.6

Specifications
Liquid Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Standard Installation Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Standard Float Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Bottom Anchor Bar Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Other Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Reference Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.1 Indicator Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.2 Float Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.3 Sheave Elbow Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.4 Bottom Anchor Bar Weight Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.5 Oil Seal Accessory Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 50 50 50 50 50

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Introduction

This manual is designed to assist the user with the installation, configuration, operation, maintenance, and troubleshooting of the Varec Model 6700 Low Pressure Liquid Level Indicator.

1.1

Getting acquainted with the Liquid Level Indicator Systems

The Varec Model 6700 Low Pressure Liquid Level Indicators are for use at atmospheric pressure. If oil-seal units are installed, pressure of 1.0 psig is the maximum used with the 27-inch W.C. seal. A system consists of the gaugeboard, sliding indicator, float, cables, elbows, and the user furnished gauge piping which carries the indicator cable. See Figure 1-1 on page 11. Proper operation of the indicator requires the careful attention of the user to assure high quality control during installation. Long term, satisfactory performance of the sight gauge can thus be obtained. If the installation quality is compromised, sight gauge accuracy and life may be degraded. Changes in the liquid level in the tank raise or lower the float, which moves the indicator cable. Cable movement drives the indicator up and down the gaugeboard on the side of the tank. The liquid level in feet and inches, or meters, decimeters, and two-centimeter increments is indicated by the indicator position on the gaugeboard. The user may then convert the liquid level to units of volume. This may be accomplished manually, or Varec's computer aided data acquisition system may perform the task. When the indicator is at the top of the gaugeboard, the tank is empty with the float at the bottom of the tank. Most of Chapter 2, Installation, covers installations to be performed on tanks that are empty and are not in service. Section 2.11, In Service Tank Installations, covers the additional procedures that are required for making installations on tanks that are in service. Varec service contracts provide the user substantial savings for maintaining and refurbishing the systems. Contact Field Service, a Varec representative or Product Marketing for further details.

1.2

Accessories

Varec manufactures accessories for transmitting and telemetering the information to a Varec Data Acquisition System. Limit switches may be attached to the Liquid Level Indicator system to provide signaling functions. Figures 1-2 through 1-5 illustrate some of the accessories available.

Liquid Level Indicator

1.3

Feature/Options

There are a number of tank installation kit options available. See Table 1-1 and contact Varec Product Marketing for complete details.
6700 Liquid Level Indicator Tank Type BL ST SV SS Bolted Standard Severe Stainless Steel Code 06F 13F 20F 27F 34F 41F 48F 55F 63F Code 02M 04M 06M 08M 10M 12M 14M 16M 19M Code 13H 27H 41H 55H 69H 83H 97H 6700 BL 06F Board Type and Length - English Tank to 6 feet Tank to 13 feet Tank to 20 feet Tank to 27 feet Tank to 34 feet Tank to 41 feet Tank to 48 feet Tank to 55 feet Tank to 63 feet Board Type and Length - Metric Tank to 2M (1.8 meters) Tank to 4M (4.0 meters) Tank to 6M (6.1 meters) Tank to 8M (8.2 meters) Tank to 10M (10.4 meters) Tank to 12M (12.5 meters) Tank to 14M (14.6 meters) Tank to 16M (16.5 meters) Tank to 19M (18.9 meters) Half Travel - Vertical Tank Tank to 13 feet - half travel Tank to 27 feet - half travel Tank to 41 feet - half travel Tank to 55 feet - half travel Tank to 69 feet - half travel Tank to 83 feet - half travel Tank to 97 feet - half travel Example of Typical Model Number

Table 1-1:

Feature/Options

10

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6700

Figure 1-1:

Typical Model 6700 Installation with optional drive elbow and Model 2557 Limit Switch Unit

11

Liquid Level Indicator

ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

DESCRIPTION HOUSING COVER SHEAVE SHAFT BEARING SPACER RETAINING RING RETAINING RING FLANGE FLANGE GASKET COVER GASKET HEX HEAD CAP SCREW FLANGE CAP CAP GASKET HEX HEAD CAP SCREW WASHER HEX NUT

6.12 [155]

1-1/2 Inch NPT (Typical) Section: A - A A

6.12 [155]

Figure 1-2:

Model 6700 Accessory Drive Elbow

Type English Metric Part Number BM4129 BM8564

12

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ITEM 1 2 3 4

DESCRIPTION PIPE, 1-1/2 X 15.50 [394] NPT ENDS PIPE, 1-1/2 X 7.25 [184] NPT ENDS 135 SHEAVE ELBOW 135 SHEAVE ELBOW WITH DRAIN

19.69 [500] 90 elbow furnished with level indicator kit 1-1/2 inch NPT Section: A-A

3
A

20.56 [522]

13.62 [346] 4.50 [114]

1-1/2 inch NPT

4.06 [103]

Figure 1-3:

Oil Seal, 8.5-inch Water Column Operating Pressure Model

13

Liquid Level Indicator

ITEM 1 2 3 4

DESCRIPTION 180 ELBOW PIPE, 1-1/2 X 38 [965], NPT ENDS (LONG) PIPE, 1-1/2 X 32 [813], NPT ENDS (SHORT) 180 ELBOW WITH DRAIN

1-1/2 inch NPT

90 elbow furnished with level indicator kit

1-1/2 inch pipe X 43 inches [1092] long NPT both ends by customer

1/2 inch NPT drain plug 4.00 [102] Approximate

1-1/2 inch NPT coupling by customer

Figure 1-4:

Oil Seal, 27-inch Water Column Operating Pressure Model

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6700

GAUGEBOARD EXTENSION, 2 INCH [50.8 MM] (13-10720-003) ITEM 1 2 3 4 DESCRIPTION EXTENSION BRACKET HEX NUT HEX NUT HEX HEAD CAP SCREW FLAT WASHER 3 4 1 Bolt or weld to tank Standard support bracket (B14177-003) furnished with gaugeboard 4 2

(5.75) [146]

CENTER GAUGEBOARD REINFORCING BRACKET (02-10721-003)

3.75 [95.2] Gaugeboard section

Reinforcing bracket (02-10721-003)

Figure 1-5:

Options

15

Liquid Level Indicator

16

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6700

Installation

Read Chapter 1, Introduction. Determine the feature and option codes of the unit to be installed. Use the List of Figures in the Table of Contents to determine the appropriate installation figure in this Instruction Manual. These are typical installations. All situations may not be covered. Contact Varec if additional information is needed. It is paramount that the user monitor the quality of the installation to assure long term, accurate performance. If the quality is compromised, inferior operation may result. Particularly important are: Accurate hand gauging referenced to the tank bench mark Clean interior of the gauge piping No kinks in the tape/cable No noticeable binding friction in the mechanism Installation cleanliness True vertical gauge piping Location of float away from inlet pipes of mixers 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, vapours, 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. Wear safety glasses as appropriate. Use a hard hat. Under most circumstances, the mechanical connections between the guide cables and the anchors 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. Additional grounding may be needed for products with low flash points. 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. Observe American Petroleum Institute (API) Recommended Practice 2003 or other appropriate industry or military standard.

Warning!

Warning!

The user provides the 1.5-inch pipe that carries the tape/cable and the necessary mounting and support welding. The user must drill holes in the tank as needed. Assemble the necessary tools and equipment at the work site. Table 2-1 on page 18 lists typical tools and equipment that may be needed. Use a drop cloth to maintain tool, equipment and installation kit cleanliness. Plan the pipe routing. Locate the roof connection into the tank interior within arms reach of a manhole or an inspection hatch.

17

Liquid Level Indicator

Tool/Equipment Breathing equipment Cable cutter Chalk Chalk line Clean drop cloth Compass Drill bits Electric drill Hole cutters Level Light oil Loctite 262 Loctite 567 Long measuring tape Pick Pipe cutter Pipe taps/dies Pliers Plumb bob Protractor Screwdrivers Sheet metal shears Shovel String Tank hand gauge Vice Welding equipment Wrenches

Table 2-1:

Typical Required Tools, Equipment and Materials

Note!

Install a Varec manhole or inspection hatch, if there is none located within arms reach of the tape pipe location. Refer to In-service Tank Installations later in this section for hatch and manhole installations.

Locate the float at a position inside of the tank where agitation on it will be at a minimum. Install a deflector if the product stream is close to the float. Contact Varec if agitators will cause excess float disturbances. Vertical pipe runs must be plumbed and perpendicular to prevent the tape from binding inside the pipe. The user must attach the gaugeboard to the tank by welding or bolting the supplied gaugeboard support brackets. If the environment is such that welding cannot be performed, the user can construct a support structure with 3-inch [76 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 In Service Tank Installations later in this section for additional details. Warning! The user should comply with all applicable regulations, codes, and standards. For safety precautions, the user should refer to the appropriate industry or military standards.

2.1

Oil Seal Installations

Tank configuration instructions that follow do not include the use of the oil seal accessories (see Figure 1-3and Figure 1-4). If these are to be installed, refer to these illustrations as appropriate and perform the following additional installation procedures.

2.1.1

Installation of Oil Seal, 8.5-Inch Water Column Operating Pressure Model

Refer to Figure 1-3 on page 13. 1. 2. 3. Apply appropriate pipe thread compound and install long pipe (1) into 135-degree elbow with bottom drain (4). Apply pipe thread compound and install short pipe (2) into 135-degree elbow with bottom drain (4). Apply pipe thread compound and install 135-degree elbow (3) onto long pipe (1).

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Installation and Operations Manual

6700 4. 5. 6. 7. Apply pipe thread compound and install 90-degree elbow supplied with gauge kit onto short pipe (2). Adjust the assembly to provide the tape/cable path illustrated in Figure 2-8 on page 37. Provide 1.5-inch pipe installation, as required. Proceed with the remainder of the tank installation to the paragraph Initial Lubrication, then fill the oil seal as follows: a. See Chapter 4, Maintenance, for oil selection. b. Remove the cover from 90-degree elbow. c. Fill to halfway in the short pipe. Note! To drain the oil, open the plug in 135 degree elbow (4).

2.1.2

Installation of Oil Seal, 27-Inch Water Column Operating Pressure

Refer to Figure 1-4 on page 14. 1. 2. 3. 4. 5. 6. 7. Apply thread pipe compound and install short pipe (3) into 180-degree elbow (1). Apply pipe thread compound and install 180-degree elbow (4) onto short pipe (3). Apply pipe thread compound and install long pipe (2) into elbow (4). Apply pipe thread compound and install 90-degree elbow supplied with gauge kit onto long pipe (2). Complete the assembly to the user furnished 1.5-inch pipe. Adjust the assembly to provide the tape/cable path as illustrated. Proceed with the remainder of the tank installation to the paragraph Initial Lubrication, then fill the oil seal as follows: a. See Chapter 4, Maintenance, for oil selection. b. Remove the cover from 90-degree elbow. c. Fill to halfway in the short pipe. Note! To drain the oil, open the plug in 180-degree elbow (4).

19

Liquid Level Indicator

2.2
Note!

Cone Roof Tank Installation

Be sure to read General Preparation at the beginning of this section before proceeding with this installation.

Refer to Table 1-1 on page 10. See Figure 2-1 on page 22 for full travel or Figure 2-2 on page 23 half travel Liquid Level Indicators. 1. Determine the position on the tank roof, beneath which the center of the float will rise and fall. Notice that this position is located a minimum of 16 inches [406 mm] and a maximum of 36.00 inches [914 mm] from the wall of the tank. Provide the roof holes shown in the figure, centered on this position. The float diameter is 14.50 inches [368 mm]. The guide cable holes are centered 8.50 inches [216 mm], each side of the center of the float. The indicator cable pipe is centered on a 17.00 inch [432 mm] diameter. Check the angle of the roof. Connect a pipe coupling to the 1.5-inch vertical pipe that is to be attached to the roof and hold it plumb while welding the coupling into the hole in the roof. Failure to place the coupling and pipe in a true vertical position may affect the accuracy of the Liquid Level Indicator. Make sure that the interior of all pipes are clean and corrosion free. After the coupling and pipe are checked to make certain that they are plumb, unscrew the pipe from the coupling. Seal the threads with pipe thread compound and reconnect the pipe to the coupling. 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 cable anchors and hang plumb lines from them at the center to mark the position where the bottom cable anchor 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.

2.

3. 4.

5. 6. 7. 8. 9.

10. Hang a plumb line through the center of the top tape/cable 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. 11. When the positioning has been checked, weld the bottom cable anchor into place. 12. Thread the float guide cables into the tank through the top anchor fittings. Fasten them to the bottom cable anchor 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. Trim off excessive cable. 13. Replace the top anchor nipple and cap. 14. Apply appropriate pipe thread compound and install the sheave elbow on the vertical pipe to the tank interior. Install a pipe union in the horizontal pipe run, in order that the elbows can be easily removed, if necessary. Then install the horizontal pipe assembly into the tank drop elbow. Adjust the length as needed to properly position the outboard elbow. 15. Install the outboard elbow on the horizontal pipe. 16. Apply pipe thread compound and screw the gaugeboard connector pipe into the outboard elbow. 17. Remove the bolts, cover, and gasket from the outboard elbow and drop a plumb line through the center. 18. Drop a chalk line from the top of the tank parallel with the plumb line and mark the chalk line on the tank wall. See Figure 2-1 on page 22.

20

Installation and Operations Manual

6700 19. Use the width of the gaugeboard (7.44 inches [189 mm]) at the bottom of the tank wall and chalk register marks for the width as follows: Full Travel Gaugeboard: Board centered with chalked plumb line (see Figure 2-1 on page 22). Half Travel Gaugeboard: Board offset (1.03 inches [26.2 mm]) to the right of the chalked plumb line (see Figure 2-2 on page 23). 20. Do the same at the top of the tank. 21. Make chalk line marks between the top and bottom register mark to aid in keeping the gaugeboard sections centered and parallel during installation. 22. Weld the gaugeboard support brackets into position. See Figure 2-1 and notice the relative position of the top bracket. All other welds are seven feet below the previous weld, except for the last one at the bottom of the tank, which is six inches [152 mm] above the grade line. 23. Use the U bolt and nuts (see Figure 2-1) to attach the gaugeboard connector to the pipe. The pipe should extend one inch [25.4 mm] below the U bolt. 24. Attach the top section of the gaugeboard to the connector plate. Make certain that it is centered on the chalk line. 25. Attach the remainder of the sections to the bottom of the tank. Make certain that each section is centered on the chalk line (see Figure 2-1). Note! To fit the gaugeboard to the tank, cut the highest-numbered gaugeboard section at the marker that is 4.50 inches greater than the tank height to adjust the fit to the total height to the tank.

21

Liquid Level Indicator

Figure 2-1:

Cone Roof Tank Installation

22

Installation and Operations Manual

6700

Figure 2-2:

Half travel cone roof tank installation

23

Liquid Level Indicator

Tank Wall Chalk Lines

Tank Wall Chalk Lines Face of gaugeboard

Full Travel

Half Travel
Tank Wall Chalk Line Tank Wall Chalk Line

Face of gaugeboard Gaugeboard Splice at Support Bracket

Support Bracket Detail

Figure 2-3:

Gaugeboard Installation

24

Installation and Operations Manual

6700

ITEM

DESCRIPTION CLIP JAM NUT HEX HEAD CAP SCREW CABLE PERFORATED TAPE CONNECTING CLAMP ROUND HEAD SCREW FLOAT CONNECTOR CABLE CLAMP (CRIMP TYPE) BLOCK NUT ASSEMBLY SEAL CAP

PART NUMBER BM3612

BM5478-600 B6065-006 P004-02-002

6 inch [155] Piece of tape formed into "U" for reinforment. Avoid bending at hole.

Figure 2-4:

Tape/Cable Clamps

26. Tilt the float 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/cable connection up. 27. At the elbow on the tank entry pipe, unroll one or two turns of the tape/cable and start to feed it into the horizontal pipe. Continue to unroll the tape/cable several turns at a time until it reaches the ground at the bottom of the gaugeboard installation position. Make sure that the tape/cable on the ground does not become kinked or dirty. Note! Throughout these instructions the term tape/cable is used to designate either the indicator cable drive or the combination tape and cable drive that is used to also drive the accessory drive elbow. If the tape/cable combination is used, the cable end goes on the gaugeboard side.

28. Lower the tape cable to the tank bottom and let several inches fall on the tank bottom. 29. Temporarily attach the tape/cable to the float with the furnished fastener (see Figure 2-2 on page 23). Feed the other end of the indicator cable over the sheave in the elbow and make sure that it is seated on the pulley. Final attachment to be made at initial calibration. 30. Check the indicator tape/cable path between the float and the gaugeboard to be sure that the tape/cable is not kinked or twisted. Also check the float guide cables for kinks.

25

Liquid Level Indicator 31. Make certain that the float guide cables are parallel. Note! If auxiliary equipment is to be installed, do it prior to crimping the cable connector. The accessory drive elbow should not be used for half-travel level indication. 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.

32. Install indicator. Full Travel Gaugeboard: Slip the indicator over the gaugeboard. Put the cable crimp on the end of the cable, then thread the cable through the hole in the indicator. Loop the cable on the outside back through the cable crimp and temporarily tape it to the crimp (see Figure 2-1 on page 22). Half Travel Gaugeboard: Remove one side channel from the indicator. Position indicator on the gaugehead and reassemble the side channel. Thread the cable through the pulley on the indicator. Put the cable crimp on the end of the cable. Thread the cable through the hole in the gaugeboard connector plate. Loop the cable on back through the cable crimp and temporarily tape it to the crimp (see Figure 2-2 on page 23). 33. Tape the gaugeboard indicator to the gaugeboard at 2.00 inches [50.8 mm] to hold it in place. Adjust the cable tension until the float barely lifts off the tank floor, then crimp the cable connector and remove the tape. Note! As the float is four inches [101.6 mm] high and its waterline is at its equator, it cannot register the last two inches [50.8 mm] of liquid in the tank.

34. Tie a line longer than the height of the tank to the indicator. Caution! Do not allow the float to fall back to the floor of the tank. Damage may result. 35. Slowly pull down on the indicator and lift the float to the top of the tank. Travel should not produce noticeable binding. Slowly lower the float to the floor of the tank. 36. Remove the pull line.

2.2.1

Initial Calibration

These instructions apply to systems that use a hollow-shell, welded float that is 14.5 inches [368 mm] in diameter by 4.0 inches [102 mm] deep. Calibration is based upon the standard specific gravity of water (1.0). Note! For products of other specific gravities to be gauged, adjust the indicator accordingly. Refer to the industry related charts for the particular product.

With the float just touching the bottom of the tank, water will be at the float equator (water line). Use the float connecting clamps (see Figure 2-2) to make the final adjustment, then trim excess tape or cable at the float end, leaving some additional tape or cable for future adjustment needs.

2.2.2

Initial Lubrication

Apply a light oil to the elbow and indicator sheaves.

2.2.3
1. 2. 26

Reassembly

Reinstall the covers, gaskets, and bolts on the elbows. Close the tank manholes and inspection covers. Installation and Operations Manual

6700

2.3
Note!

Cone Roof Tank (Bolted Installation)

Be sure to read General Preparation at the beginning of this section before proceeding with this installation.

Refer to Table 1-1 on page 10. See Figure 2-5 on page 30. 1. Determine the position on the tank roof, beneath which the center of the float will rise and fall. Notice that this position is located a minimum of 16 inches [406 mm] and a maximum of 36.00 inches [914 mm] from the wall of the tank. Provide the roof holes shown in the figure, centered on this position. The float diameter is 14.50 inches [368 mm]. The guide cable holes are centered 8.50 inches [216 mm], each side of the center of the float. The tape pipe is centered on a 17.00 inch [432 mm] diameter. Check the angle of the roof. The roof pitch for the furnished gaugeboard is 1 inch [25.4 mm] in 12 inches [305 mm]. Connect a pipe deck flange to the 1.5-inch vertical pipe that is to be attached to the roof. Bolt the flange to the roof. Check that it is plumb. Note! Failure to place the flange coupling and pipe in a true vertical position may affect the accuracy of the indicator. Make sure that the interior of all pipes are clean and free of corrosion.

2.

3. 4. 5.

6. 7. 8.

After the deck flange and pipe are checked to make certain that they are plumb, unscrew the pipe from the coupling. Apply pipe thread compound and reconnect the pipe to the coupling. Center the base of a top cable anchor in its hole. Hold it plum and bolt it to the roof. Do the same for the other top cable anchor. 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 anchor will be attached. A hanging weight anchor may be ordered from Varec if it is not practical to bolt or weld the bottom guide cable anchor to the floor of the tank. For tanks that are in service, the hanging anchor must be used. 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.

9.

10. Hang a plumb line through the center of the top tape/cable 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, attach the bottom cable anchor into place. 11. Thread the float cables into the tank through the top anchor fittings. Fasten them to the bottom cable anchors with the furnished hardware. 12. 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. 13. Replace the housing nipple and cap. 14. Apply appropriate pipe thread compound and install the sheave elbow on the vertical pipe to the tank interior. Install a pipe union in the horizontal pipe run, in order that the elbows can be easily removed, if necessary. Then install the horizontal pipe assembly into the tank drop elbow. Adjust the length as needed to properly position the outboard elbow. 15. Install the outboard elbow on the horizontal pipe. 16. Apply pipe thread compound and screw the gaugeboard connector pipe into the outboard elbow. 17. Remove the bolts, cover, and gasket from the outboard elbow and drop a plumb line through the center. 18. Drop a chalk line from the top of the tank parallel with the plumb line and mark the chalk line on the tank wall. See Figure 2-3 on page 24.

27

Liquid Level Indicator 19. Use the width of the gaugeboard at the bottom of the tank wall and chalk register marks for the width centered on the chalk line. 20. Do the same at the top of the tank. 21. Make chalk line marks between the top and bottom register mark to aid in keeping the gaugeboard sections centered and parallel during installation. 22. Bolt the gaugeboard support brackets into position (see Figure 2-5). The first gaugehead support bracket mounts near the top of the tank. The others are spaced at seven foot [2.13.m] intervals except for the one at the bottom of the tank. 23. Use the U bolt and nuts (see Figure 2-3) to attach the gaugeboard connector to the pipe. The pipe should extend one inch [25.4 mm] below the U bolt. 24. Attach the top section of the gaugeboard to the connector plate. Make certain that it is centered on the chalk line. 25. Attach the remainder of the sections to the bottom of the tank. Make certain that each section is centered on the chalk line (see Figure 2-3). Note! To fit the gaugeboard to the tank, cut the lowest gaugeboard section at the marker that is 4.50 inches greater than the tank height to adjust the fit to the total height to the tank

26. Tilt the float 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/cable connection up. 27. At the elbow on the tank entry pipe, unroll one or two turns of the tape/cable and start to feed it into the horizontal pipe. Continue to unroll the tape/cable several turns at a time until it reaches the ground at the bottom of the gaugeboard installation position. Make sure that the tape/cable on the ground does not become kinked or dirty. Note! Throughout these instructions the term tape/cable is used to designate either the indicator cable drive or the combination tape and cable drive that is used to also drive the accessory drive elbow. If the tape/cable combination is used, the cable end goes on the gaugeboard side.

28. Lower the tape cable to the tank bottom and let several inches fall on the tank bottom. 29. Temporarily attach the tape/cable to the float with the furnished fastener (see Figure 2-4 on page 25). Feed the other end of the indicator cable over the sheave in the elbow and make sure that it is seated on the pulley. Final attachment to be made at initial calibration. 30. Check the indicator tape/cable path between the float and the gaugeboard to be sure that the tape/cable is not kinked or twisted. Also check the float guide cables for kinks. 31. Make certain that the float guide cables are parallel. 32. Slip the indicator over the gaugeboard. 33. Put the cable crimp (see Figure 2-5) on the end of the cable, then thread the cable through the hole in the tank. Loop the cable on the outside back through the cable crimp and temporarily tape it to the crimp. Note! If auxiliary equipment is to be installed, do it prior to crimping the cable connector. 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.

34. Tape the gaugeboard indicator to the gaugeboard at 2.00 inches [50.8 mm] to hold it in place. Adjust the cable tension until the float barely lifts off the tank floor, then crimp the cable connector and remove the tape. Note! As the float is four inches [101.6 mm] high and its waterline is at its equator, it cannot register the last two inches [50.8 mm] of liquid in the tank.

35. Tie a line longer than the height of the tank to the indicator. 28 Installation and Operations Manual

6700 Caution! Do not allow the float to fall back to the floor of the tank. Damage may result.

36. Slowly pull down on the indicator and lift the float to the top of the tank. Travel should not produce noticeable binding. Slowly lower the float to the floor of the tank. 37. Remove the pull line.

2.4

Initial Calibration

These instructions apply to systems that use a hollow-shell, welded float that is 14.5 inches [368 mm] in diameter by 4.0 inches [102 mm] deep. Calibration is based upon the standard specific gravity of water (1.0). Note! For products of other specific gravities to be gauged, adjust the indicator accordingly. Refer to the industry related charts for the particular product.

With the float just touching the bottom of the tank, water will be at the float equator (water line). Set the gaugeboard indicator to 2.00 inches [50.8 mm]. Use the float connecting clamps (see Figure 2-4 on page 25) to make the final adjustment, then trim excess tape or cable at the float end, leaving some additional tape or cable for future adjustment needs.

2.5

Initial Lubrication

Apply a light oil to the elbow and indicator sheaves.

2.6
1. 2.

Reassembly
Reinstall the covers, gaskets, and bolts on the elbows. Close the tank manholes and inspection covers.

29

Liquid Level Indicator

Figure 2-5:

Bolted Tank Installation

30

Installation and Operations Manual

6700

2.7
Note!

Cone Roof Tank Installation (Fiberglass Tank)

Be sure to read General Preparation at the beginning of this section before proceeding with this installation.

Refer to Table 1-1 on page 10. See Figure 2-6 on page 33. 1. Determine the position on the tank roof, beneath which the center of the float will rise and fall. Notice that this position is located a minimum of 16 inches [406 mm] and a maximum of 36.00 inches [914 mm] from the wall of the tank. Check the angle of the roof. Lay out the coupling positions as shown in Figure 2-6. The float diameter is 14.50 inches [368 mm]. The guide cable couplings are centered at 8.50 inches [216 mm] each side of the float center. The indicator cable coupling is centered on a 17.00 inch [432 mm] diameter. Install the couplings into the top of the tank in a vertical position. Lengths of pipe screwed into the couplings and held plumb will aid in proper orientation of these fittings. Failure to place the couplings in a true vertical position may affect the accuracy of the Liquid Level Indicator. Make sure that the interior of all pipes are clean and corrosion free. Use appropriate pipe thread compound on all pipe threads and install the 1-1/2 inch indicator pipe cable and the top cable anchors into their respective couplings. 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 anchor will be installed. 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. Hang a plumb line through the center of the top indicator cable 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

2. 3.

4.

5. 6. 7. 8. 9.

10. See Figure 2-6 for suggested bottom anchor configuration. When the position has been checked, install the bottom anchor into place. 11. Thread one end of the float guide cable into the tank through one of the top anchor fittings, through the bottom anchor channel and back up through the other top anchor fitting. Thread each end of the guide cable through the top anchor assembly, pulling the cable hand tight. Use the locking nut to lock the cable in place. Tighten the adjusting nuts on each anchor assembly evenly until the guide cable is tensioned by the spring. Trim off excessive cable. 12. Perform steps 13 - 21 under Cone Roof Tank Installation. 13. Install the gaugeboard support brackets into position. See Figure 2-6 and notice the relative position of the top bracket. All other support brackets are seven feet [2.436 meters] below the previous bracket, except for the last one which is a minimum of six inches [152 mm] above the grade line. 14. Perform steps 23 - 25 under Cone Roof Tank Installation. 15. Loosen the nut on each side of the float that secures the guide cable retainer. Rotate these retainers to open the key hole in the float cable guide. Position float with guide cables routed through the float guide holes and rotate the guide cable retainers to lock the guide cable in place. Tighten the nuts and set the float on the tank bottom or bottom anchor. 16. Perform steps 27 - 32 under Cone Roof Tank Installation. 17. Tape the gaugeboard indicator to the gaugeboard at a level indication of 2.00 inches [50.8 mm] plus the height of the bottom anchor. Adjust the cable tension until the float barely lifts from its resting place. Crimp the cable connector and remove the tape. Note! As the float is four inches [101.6 mm] high and its waterline is at its equator, it cannot register the last two inches [50.8 mm] plus any bottom anchor height of liquid in the tank.

31

Liquid Level Indicator

18. Complete the installation by performing steps 34 - 36 under Cone Roof Tank Installation.

2.8

Initial Calibration

These instructions apply to systems that use a hollow-shell, fiberglass float that is 14.5 inches [368 mm] in diameter by 4.0 inches [102 mm] deep. Calibration is based upon the standard specific gravity of water (1.0). Note! For products of other specific gravities to be gauged, adjust the indicator accordingly. Refer to the industry related charts for the particular product.

With the float just touching the bottom of the tank, water will be at the float equator (water line). Use the float connecting clamps (see Figure 2-4 on page 25) to make the final adjustment, then trim excess tape or cable at the float end, leaving some additional tape or cable for future adjustment needs. Install the heat shrinkable seal cap over the cut end of the cable.

2.9

Initial Lubrication

Apply a light oil to the elbow and indicator sheaves.

2.10
1. 2.

Reassembly

Reinstall the covers, gaskets, and bolts on the elbows. Close the tank manholes and inspection covers.

32

Installation and Operations Manual

6700

Figure 2-6:

Fiberglass cone roof tank installation

33

Liquid Level Indicator

2.11

In-service Tank Installations

This section covers the additional procedures that are required for making installations on tanks that are in service. Varec service contracts provide the user substantial savings for maintaining and refurbishing the systems. Contact Varec Product Marketing for further information.

2.11.1

General Preparation

Use the Table of Contents to determine the appropriate installation figure in this Instruction Manual. These are typical installations. All situations may not be covered. Contact Varec if additional information is needed. 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, vapours, 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. Wear safety glasses as appropriate. Use a hard hat. Under most circumstances, the mechanical connections between the guide cables and the anchors 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. Additional grounding may be needed for products with low flash points. 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. Observe American Petroleum Institute (API) Recommended Practice 2003 or other appropriate industry or military standard.

Warning!

The user provides the 1.5-inch pipe that carries the tape/cable and the necessary mounting and support welding. The user must drill holes as needed. Assemble the necessary tools and equipment at the work site. Refer to Table 2-1 on page 18 for suggested tools and equipment. Plan the pipe routing. Position the roof connection installation into the tank interior within arms reach of a manhole or an inspection hatch. Use these procedures to install a Varec manhole or inspection hatch, if there is none located within arms reach of the tape pipe location. Locate the float at a position inside of the tank where surface agitation on it will be at a minimum. Install a deflector, if the product stream is close to the float. Contact Varec if agitators will cause excess float disturbances. Vertical pipe runs must be plumbed and perpendicular to prevent the tape/cable from binding inside the pipe. The user must attach the gaugeboard to the tank by welding or bolting the supplied gaugeboard brackets. If the environment is such that welding cannot be performed, the user can construct a support structure close to the outside of the tank. Warning! The user should comply with all applicable regulations, codes, and standards. For safety precautions, the user should refer to the appropriate industry or military standards.

2.12

Independent Pipe Support Structure

Where the environment is such that welding cannot be performed, construct an appropriate support structure of 3-inch [76 mm] pipe in segments away from the tank and weld the brackets there. Use good commercial practices. Make certain that vertical segments will be plumb and the horizontal segments level. Use a concrete footing to support the tankside vertical segment (see Figure 2-7 on page 36).

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Installation and Operations Manual

6700

2.13

Installation of Model 228 Inspection Hatch to Existing Manhole Cover

See Figure 2-7 on page 36 to modify an existing manhole cover with a model 228 (Part Number BM6746) type inspection hatch. 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove the cover to a safe welding location. Cut a rectangular hole 6.00 inches [152 mm] x 15.75 inches [400 mm] in the cover. Cut a 2.50-inch [63.5 mm] diameter hole in the cover to carry the tape drop pipe. Cut two 1.75-inch [44.5 mm] diameter holes in the cover to carry the top guide cable anchors. Disassemble the inspection cover and gasket from the frame. Weld the inspection cover frame to the manhole cover. Weld the guide cable anchor nipples and the tape/cable drop pipe coupling in place. make certain that they are vertical and correctly centered. Carry the modified cover assembly back to the tank site. Orient the modified manhole cover as shown and reinstall. Refer to the appropriate tank configuration figure and install the tape/cable piping and gaugeboard.

2.14

Anchor Bar Installation

Varec supplies an anchor bar for in-service installations (Part Number BA4481) that must be ordered separately. It is for normal service only. The guide cables fasten to the anchor bar with cable clamps (see Figure 2-7 on page 36). For severe or extreme service installations, contact Varec. A severe service installation is shown in Figure 2-8 on page 37.

35

Liquid Level Indicator

Piping and fittings furnished by customer

Figure 228 Inspection Cover (for existing 20 inch and larger manhole covers) See Details B & C

ITEM 1 2 3 4 5

DESCRIPTION FRAME ASSEMBLY COVER GASKET HEX HEAD CAP SCREW HEX NUT

Existing standard roof manhole with gasket and mounting hardware

36.00 [914] maximum 16.00 [406] minimum .25 [6]

Guided float 15.00 [381] 3 Places .25 [6] (6.00 [152]) 3.31 [84] .18 [4.8] Guide cable anchor nipple

67.00 [1702]

1.75 2X Thru [44.5]

Sized for 1-1/2 inch NPT pipe coupling by customer 8.50 [216] 84.00 [2133.6] (Typical) Float guide cables 17.00 [432] 8.50 [216]

Detail: B Existing Manhole Cover Modifications

"In Service" anchor bar ordered separately

14 Places 10.00 [254] 2.75 [70] (Assembled)

Pipe support brackets for welding to customer support structure

19.75 [502]

Float guide cable .12 [3] Typical Hex head cap screw 14 Places 6.00 [152] Cover cutout

Customer constructed support structure set in concrete Cable clamps

15.75 [400] Cover cutout

Anchor bar

Detail: C

Detail: A

Figure 2-7:

Typical Installations for In-service Tanks

36

Installation and Operations Manual

6700

Figure 2-8:

Severe service cone roof tank installation

37

Liquid Level Indicator

2.15
1. 2. 3. 4. 5. 6.

Float Installation

Refer to appropriate tank configuration and install top anchors less long nipple and cap. Thread the float guide cables into the tank through the top anchor fittings and pull the ends back through the inspection hatch. Fasten the bottom anchor to the guide cables (see Figure 2-7 on page 36) and lower the anchor slowly through the inspection hatch into the tank. When anchor bar is resting on tank bottom, remove cable slack by hand. Tighten cable locking nut to secure cable in place. Tighten the adjustment nut until the guide cable is tensioned by the spring. Trim excess cable. Use pipe thread compound and install top anchor nipples and cap. Note! Throughout these instructions the term tape/cable is used to designate either the indicator cable drive or the combination tape and cable drive that is used to also drive the accessory drive elbow. If the tape/cable combination is used, the cable end goes on the gaugeboard side.

Caution! If the tape/cable binds in the pipe during threading, check the pipe for corrosion and other obstructions. Check the tape/cable to make certain that it did not kink. Friction in the pipe will affect accuracy and may break the tape/cable.

7. 8.

Thread the tape/cable through the horizontal pipe and into the gaugeboard connector pipe. Put a clean drop cloth on the ground and push the tape through a few turns at a time from the drop pipe elbow, until the tape/cable is unrolled. Make sure that the tape/cable falling to the ground does not become kinked or dirty. Use the tank bench mark as a guide and pull back enough tape/cable to drop from the bench mark to the tank bottom. Mark that position on the tape for reference.

9.

10. Thread the tape through the drop pipe into the tank and pull the end back through the inspection hatch. 11. Install the tape/cable to the float connector with the clamps and screws provided (see Figure 2-4 on page 25). 12. Attach the tape/cable connector to the float, pass it through the hatch and attach the eyes to the guide cables. Caution! Do not allow the float to fall to the surface of the product. Damage may result. 13. Lower the float until it is hanging from the tape/cable. Inspect the tape/cable and cables for twists and kinks. Make sure that the cables are parallel, then lower the float to the surface of the product. 14. Make a hand gauge measurement of the tank product level. Use the bench mark reference to calibrate the hand gauge. Use extra care to make certain that this measurement is accurate because the accuracy of the sight gauge indicator depends upon it. 15. If an accessory is to be installed, perform the installation. Refer to the main text auxiliary equipment installation paragraphs and then continue the installation. The hole size, bolt pattern, and coupling of Varec accessories mates with the sheave drive elbow. Each mating auxiliary unit has a slotted coupling that engages the drive pin on the sprocket sheave. Mate the accessory with the sprocket sheave drive. Use the hex head cap screws and washers to attach the accessory unit to the drive elbow. Refer to the manual for the accessory unit, if installed, and check out the operation of the accessory as appropriate. 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.

16. Install the gaugeboard and indicator. Refer to the appropriate tank configuration. 38 Installation and Operations Manual

6700 17. Set indicator at measured product level. 18. Adjust the tape/cable tension until the float barely lifts from its natural floating position, then crimp the cable connector. 19. Tie a line to the indicator. 20. Slowly pull down on the indicator and lift the float to the top of the tank. Travel should not produce noticeable binding. Slowly lower the float to the product level. Check that any installed accessory performed properly during this test. Caution! Do not allow the float to fall to the surface of the product. Damage may result. 21. Refer to appropriate tank configuration to set the indicator at the full tank position, then use the hand gauge measurement to recheck the current product level.

2.15.1

Initial Lubrication

Apply a light oil to the elbow and indicator sheaves.

2.15.2
1. 2.

Reassembly

Reinstall the covers, gaskets, and bolts on the elbows. Close the tank manholes and inspection covers.

2.16

Installation of Model 226 for 20 and 24 Inch Manhole Covers with API Drilling

See Figure 2-9 on page 41 to install Model 226 20 inch (Part Number BM3443) and 24 inch (Part Number BM3607) manhole covers with API drilling. 1. 2. 3. 4. Remove the existing manhole cover. Separate the Model 226 cover by removing the flange connecting bolts. Install the cover half with the pipe coupling to the top of the tank. Refer to the appropriate tank configuration figure to check the tank configuration and install the tape/cable piping and gaugeboard.

Complete the Anchor Bar Installation, Float Installation, Initial Lubrication, and Reassembly sections of the previous procedure, Installation of Model 228 Inspection Hatch to Existing Manhole Cover. See also the following section, Typical Auxiliary Equipment Installation.

2.17

Typical Auxiliary Equipment Installation

To install auxiliary equipment, an auxiliary elbow drive adapter kit (P/N 13-08821) is required. The kit contains the English drive elbow (P/N BM4129) and the tape/cable combination (P/N B7678-106). This has a sprocket sheave that is driven by the English tape/cable combination. Usually this is installed on the outboard connection pipe elbow. 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.

39

Liquid Level Indicator The perforated tape portion of the tape/cable combination must be seated on the sprocket sheave throughout the travel of the indicator. The cable portion cannot drive an auxiliary device. The cable portion attached to the pulley of the half-travel indicator may reach the gaugeboard connector sheave before a vertical tank is empty if the gaugeboard is mounted high on the tank. 1. 2. 3. 4. Remove the bolts, cover, and gasket from the elbow. Remove the drive adapter flange bolts, washers, flange cap, and gasket. Install the elbow on the indicator connector pipe. Refer to the appropriate tank configuration installation procedures above and thread the tape/cable through the elbow. The cable segment attaches to the gaugeboard indicator. The tape segment attaches to the float. Position the tape/cable splice below the auxiliary drive elbow with the float at the bottom of the tank. Seat the perforated tape portion of the tape/cable combination on the sheave sprocket and thread it through the indicator connector pipe. Attach the auxiliary unit to the adapter flange. Attach the auxiliary unit with adapter flange to the drive elbow ensuring that the sprocket drive pin engages the slotted coupling of the auxiliary unit. Refer to the auxiliary unit manual for operation and checkout procedures. Refer to the appropriate tank configuration to complete the installation.

5. 6. 7. 8. 9.

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ITEM 1 2 3

DESCRIPTION COVER PLATE ASSY. HEX NUT HEX BOLT

Whesoe Varec Figure 226 Manhole Cover (Standard for 20 inch API-650. Other sizes available on special order.)

Manhole cover gasket and mounting hardware furnished by customer.

Figure 2-9:

API 20/24-inch Manhole Cover Installation

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3
3.1
Caution!

Operation
Initial Operation
Initial filling of the tank must be a reduced rate of flow, until the float travel and sight indicator operation are verified. This checks that the installation was correctly made and prevents possible damage to the gauge system. On floating roof tanks this is particularly important because the tape/cable travel has not been checked during the installation.

1. 2. 3. 4.

Station an observer at the gaugeboard. Begin filling the tank to raise the float several feet (about three feet or one meter) from the bottom. Continue filling the tank to the desired level. Hand gauge the product and compare the measurement with the gaugeboard indication. If they do not coincide, adjust the cable at the indicator or connector plate. Use the spare cable crimp, if necessary.

3.2

Normal Operation

When the tank is full, the indicator will be at the bottom of the gaugeboard. As the liquid is removed from the tank, the float will fall and the indicator will rise.

3.3

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: Density and specific gravity of product as determined from representative samples Sediment in the tank Water content in the product Gross volume Temperature of the product Tank-bottom deformation

It is the user's responsibility to appropriately consider these and other factors in his application. For example, oil tank capacity tables are calculated for product at 60 oF. A higher temperature will cause the tank to expand and the actual volume will be greater than the volume at the standard temperature.
API Standard 2550 2545 2540 Description Method For Measurement And Calibration Of Upright Cylindrical Tanks (ANSI/ASTM D1220) Method of Gauging Petroleum and Petroleum Products (ANSI/ASTM D1085) Chapter 11.1 (ANSI/ASTM D1250) for Volume Correction Factors. Refer also to API 2545.

Manual of Petroleum Measurement Standards, Chapter 3 - Tank Gauging, Section 1B, Standard Practice for Level Measurement of Liquid Hydrocarbons in Stationary Tanks by Automatic Tank Gauging.

Accuracy of hand gauging is extremely important, as it is used to set the Varec Liquid Level Indicator. Careful reference to the benchmark of the tank will help assure accuracy of the levels as they are read from the indicator during operation.

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4
4.1

Maintenance
Periodic Maintenance

Varec Model 6700 Low Pressure Liquid Level Indicators are designed for long service life. Like any other measuring device, Liquid Level Indicators require regular, periodic service to maintain the original performance. Table 4-1 on page 46 provides some suggested periodic service. Minimum maintenance will lengthen the service life and assure more accurate reading of the indicator. Varec provides maintenance service contracts that provide regular periodic inspection and maintenance at substantial savings. Some repair tasks may require special tools.

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 depleted with carbon dioxide, nitrogen or other gases.

4.2
Warning!

Electrostatic Discharge Hazard

Under most circumstances, the mechanical connections between the guide cables and anchors 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. Additional grounding may be needed for products with low flash points. 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. Observe American Petroleum Institute (API) Recommended Practice 2003 or other appropriate industry or military standard.

4.3

Lubrication

Lubricate moving parts of the elbow and indicator sheaves at regular intervals. Use a light-weight oil.

4.4

Oil Recommendations for Oil Seal Accessory Units

GENERAL SERVICE Low pour point, food grade, water white, mineral oil. Brand Names: SERVICE BELOW 25 0F (-4 0C) Automotive antifreeze and water (50/50 mix) (Propylene Glycol-based antifreeze such as Sierra should be considered for environmentally sensitive areas.) ARCO Prime Grade 70 Lyondell DuoPrime 70 (Product Code 16402)

Caution!

These oils may not be compatible with edible oils and edible liquids. Use product compatible substitutes for tanks holding products for human or animal consumption or products that may react chemically with the oil.

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Routine Operation check Guide cables Float Lubricate Leak check Change oil Calibration Corrosion check Sediment check Deformation check Refurbish

90 Days X

6 Months X X X

1 Year X X X X X X X X X X

5 Years

X X

X X

X X

Table 4-1:

Suggested Periodic Maintenance Schedule

4.5

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. Oil sealed units should be inspected immediately after being placed in service and then daily for the first week. Subsequent inspections should be made every 90 days (Table 4-1). 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, 6-month, 1-year and 5-year periods at substantial savings.

4.6

Troubleshooting Common Problems

Friction is a common problem that affects indicator accuracy. Some liquids produce corrosion in the mechanism. Periodic inspection and maintenance provided by a Varec service contract can prevent problems from occurring. Periodic cleaning, lubrication and replacement of worn parts stops trouble before it starts. INDICATOR AT GROUND LEVEL (TANK NOT FULL)
Possible Cause 1 Cable broken? Action

Yes No

Replace cable. Go to 2.

Float detached?

Yes

Re-attach.

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6700 GAUGEBOARD INDICATOR STOPPED

Possible Cause 1 Cable stuck? Action

Yes

Check cable path. Check for frozen sheave shafts (repair/replace). Check for frozen accessory shafts (repair/replace).

No
2 Pipes dirty?

Go to 2.

Yes No

Clean with automotive type spray degreaser. Go to 3.

Indicator or gaugeboard slides dirty or damages?

Yes

Clean.Repair/replace.

CALIBRATION REPEATABILITY UNSTABLE

Possible Cause 1 Indicator or gaugeboard slides dirty or damaged? Action

Yes No

Clean with automotive type spray degreaser.Repair/replace. Go to 2.

Tape/cable off elbow pulley?

Remove elbow covers.

Yes No

Reseat and lubricate pulley shafts. Go to 3. 3 Pulley shaft/bushing worn/corroded?

Yes No

Repair or replace Go to 4.

Cable pipe/conduit dirty?

Yes No

Remove and clean. Go to 5.

Guide cables loose, kinked or broken?

Yes

Tighten, repair or replace.

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5
5.1

Specifications
Liquid Level Indicator
3003-H14 Aluminum Type 304 Stainless Steel and UHMW Polyethylene UHMW Polyethylene Type 316 Stainless Steel Type 316 Stainless Steel Type 316 Stainless Steel Type 316 Stainless Steel

Indicator Gaugeboards: Indicator Sight Target: Half Travel Sheave: Float Cable: Float Cable Clamp: Float Tape/Cable (Elbow Drive Kit): Gauge Float:

5.2

Standard Installation Kits

Steel 360 Aluminum Delrin Steel Zinc Plated Steel Steel 3/32" Diameter Type 316 Stainless Steel

Mounting Brackets: Elbow Sheave Housing & Cover: Elbow Sheave Wheel: Top Anchor: Top Anchor Spring: Bottom Anchor: Guide Cable:

5.3

Standard Float Specifications

Type 316 S. S. 14.5 inches (36.8 mm) 17 inches (43.2 mm) 8.8 lbs. (3.99 kg)

Material: Diameter: Eyelet Centers: Net Weight:

5.4
Weight: Material:

Bottom Anchor Bar Weight

52 lbs. (22.2 kg) Cast Iron

5.5

Other Specifications
Full Travel48 ft. [14 M] Maximum Half Travel 97 ft. Maximum (English Only) Atmospheric 1 1/2 inch NPT

Operating Range: Service Rating: Pipe Connections:

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5.6
5.6.1

Reference Part Numbers

Indicator Part Numbers
Type Full Travel Half Travel Service All All

Part Number 06-09830 06-09831

5.6.2

Float Part Numbers

Type Service Normal/Severe Extreme Extreme Extreme

Part Number BM9074-000 BM12338-000 BM12339-000 P29-43

316 S.S.
Monel Carpenter 20 Fiberglass

5.6.3

Sheave Elbow Part Numbers

Description Aluminum 90
o o o

Part Number 06-08564 BM3480 BM3481 BM4675 BM4129 BM8514

Service Normal Normal Normal Severe/Extreme Normal, English Normal, Metric

Aluminum 135 Aluminum 180 Cast Iron 90

o

Elbow Drive, Aluminum Elbow Drive, Aluminum

5.6.4

Bottom Anchor Bar Weight Part Number

Description Cast Iron Bottom Guide Wire Anchor Assembly (2 Wire) Service Normal

Part Number BA4481

5.6.5

Oil Seal Accessory Part Numbers

Type Aluminum, Working Pressure 8.5 in. W.C. Iron Working Pressure 8.5 in. W.C. Aluminum Working Pressure 27 in. W.C. Service Normal Severe Normal

Assembly Part Number 10-01994-AAA 10-01994-BAA 10-02861-AAA

Note! All pipes are steel.

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NOTES

IOM002GVAE0704

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Your offical representative

www.varec.com
Varec, Inc. 5834 Peachtree Corners East, Norcross (Atlanta), GA 30092 USA Tel: +1 (770) 447-9202 Fax: +1 (770) 662-8939