Installation Guide dedicated O-ring for demanding chemicals applications with 854 ATG

Transcription

1 Installation Guide dedicated O-ring for demanding chemicals applications with 854 ATG

2 Contact Information: Head Office Delft, the Netherlands Honeywell Enraf Delftechpark 39, 2628 XJ Delft PO Box 812, 2600 AV Delft The Netherlands Tel.: +31 (0) Fax: +31 (0) Honeywell International Inc.

3 Preface Preface The Honeywell Enraf 854 ATG (Advanced Technology Gauge) is a servo-based level gauge to be used in inventory measurement systems on bulk storage tanks. This installation guide is intended for technicians involved in the exchange of the standard FPM (Viton) O-ring by the special FFKM (Perlast ) O-ring for demanding chemical applications of the Honeywell Enraf Series 854 ATG and is part of the installation kit, part number U EC declaration of conformity Refer to the EC declaration of conformity, shipped with the instrument. Legal aspects The mechanical and electrical installation shall only be carried out by trained personnel with knowledge of the requirements for installation of explosion-proof equipment in hazardous areas. The information in this installation guide is the copyright property of Enraf B.V., the Netherlands. Enraf B.V. disclaims any responsibility for personal injury or damage to equipment caused by: Deviation from any of the prescribed procedures; Execution of activities that are not prescribed; Neglect of the general safety precautions for handling tools, use of electricity and microwave radiation. The contents, descriptions and specifications in this installation guide are subject to change without notice. Enraf B.V. accepts no responsibility for any errors that may appear in this installation guide. Additional information Do not hesitate to contact Honeywell Enraf or its representative if you require additional information. Page 3

4 Table of Contents Table of Contents Preface... 3 Safety... 5 Safety aspects of 854 ATG... 5 Personal safety... 6 Safety conventions... 6 Installation of the dedicated O-ring... 7 Contents of O-ring kit... 7 Required tools... 7 Removing the measuring drum... 7 Removing the magnet cover... 8 Replacing the O-ring... 9 Re-installing the magnet cover... 9 Re-installing the measuring drum... 9 Re-installing the displacer Closing the drum compartment cover Labelling the gauge Set level gauge operational Appendix Related documents Product compatibility Page 4

5 Safety Safety Safety aspects of 854 ATG Warning Do not use the instrument for anything else than its intended purpose. For medium pressure applications (till 6 bar), the 854 ATG drum compartment housing is of aluminium. For high pressure applications (max. 40 bar), the 854 ATG housing is of stainless steel. The housing of the 854 ATG is explosion-proof: II 1/2 G Ex d IIB T6 Ga/Gb or II 1/2G Ex de IIB T6 Ga/Gb or II 1/2 G Ex d [ia Ga] IIB T6 Ga/Gb or II 1/2G Ex de [ia Ga] IIB T6 Ga/Gb; certified by KEMA, the Netherlands Ex d [ia Ga] IIB T6 Ga/Gb or Ex de [ia Ga] IIB T6 Ga/Gb; acc. to IECEx, certified by KEMA, the Netherlands Class I, Division 1, Groups B, C & D acc. to ANSI/NFPA no. 70, certified by Factory Mutual Research USA Environmental conditions for the 854 ATG are: ambient temperature : -40 to + 65 C (-40 to +149 F) operating pressure : max. 6 bar for medium pressure and chemical version max. 40 bar for high pressure version relative humidity : % ingress protection : IP65 (NEMA 4), suitable for outdoor installation The drum compartment, which is in contact with the tank atmosphere, is separated from the electronic compartment. A magnetic coupling transfers the drum movement (hence, displacer movement) to the electronic compartment. The 854 ATG covers can optionally be provided with sealing facilities on the blocking devices, which traces unauthorized opening. Page 5

6 Safety Personal safety The technician must be trained and certified by Honeywell Enraf in how to exchange the O-ring in the 854 ATG. When the 854 ATG is installed in a hazardous area, the technician must work in accordance with the local, national and company regulations for electrical equipment in hazardous areas. Warning In hazardous areas it is compulsory to use personal protection and safety gear such as: hard helmet, fire-resistive overall, safety shoes, safety glasses and working gloves. Avoid possible generation of static electricity. Use non-sparking tools and explosion-proof testers when required or advised. Make sure no dangerous quantities of combustible gas mixtures are present in the working area. Never start working before the work permit has been signed by all parties. Pay attention to the kind of product in the tank. If any danger for health, wear a gas mask and take all necessary precautions. Safety conventions Warnings, Cautions and Notes are used throughout this installation guide to bring special matters to the immediate attention of the reader. A Warning concerns danger to the safety of the technician or user; A Caution draws the attention to an action which may damage the equipment; A Note points out a statement deserving more emphasis than the general text, but not requiring a Warning or a Caution. Page 6

7 Installation O-ring Installation of the dedicated O-ring Contents of O-ring kit The O-ring kit contains of the following material: O-ring Ø x 3.53 mm; Perlast G75 LT (FFKM) Indication plate: Special O-ring installed Sealing wire (length: 100 mm) Seal Anti seize grease Protective gloves Required tools The following tools are required: 847 PET (Portable Enraf Terminal) or alternatively the service tool Engauge Tommy bar or strap wrench Ø14 mm (Ø 9 / 16 ) Test weight 25 grams (from set of test weights; Honeywell Enraf part number: A ) Rubber band Ø mm (Ø 1½ - 2½ ) Allen keys: 2.5 mm ( 3 / 32 ) and 5 mm ( 3 / 16 ) A pair of pliers Removing the measuring drum Removing the drum from the housing requires the use of the Portable Enraf Terminal (or the service tool Engauge). Keep the drum, the outer magnet and the outside of the magnet cap thoroughly clean. To remove the drum, proceed as follows (refer to figures 1 and 2): Issue the CA (calibrate) command to raise the displacer If applicable close the ball valve and release the pressure gently. Give the UN (unlock) command to lower the displacer from tank top position. Issue the FR (freeze) command when the displacer comes within reach. Switch-off the mains. If the drum compartment cover (6) is locked by a W&M seal, unseal it. Remove the drum compartment cover (6). Remove the displacer from the measuring wire. Attach a small weight on the wire to keep it positioned in the groove. Do not damage the measuring wire. Pull out the drum (4), remove the small weight and fix the wire to the drum with a rubber band. Do not kink the measuring wire and handle the drum carefully. If the displacer cannot be accessed through an opening, the gauge must be removed from its mounting position: Page 7

8 Installation O-ring Raise the displacer to the maximum height, at least above the ball valve, when present. Switch-off the mains. If applicable close the ball valve and release the pressure gently. Remove the drum compartment cover (6). Lift the 854 ATG, raising the displacer above the connecting flange. Remove the displacer from the measuring wire. Attach a small weight on the wire to keep it positioned in the groove. Do not damage the Figure 1 Measuring drum measuring wire. Pull out the drum (4), remove the small weight and fix the wire to the drum with a rubber band. Do not kink the measuring wire and handle the drum with care. No Description 1 Drum house 2 O-ring NBR 70 (145.00x3.00) 3 O-ring Sil/FEP (134.50x3.00) 4 Drum with measuring wire 5 Magnet cover 6 Drum compartment cover 7 Main shaft with inner magnet 8 O-ring NBR 70 (66.27x3.53) 9 Screw M6 x 16 with spring washer (6x) 10 W&M seal (optional) 11 O-ring FPM (98.02x3.53) (standard) to be replaced by: FFKM (98.02x3.53) (dedicated) Figure 2 Cross section drum compartment Removing the magnet cover Remove the 6 screws M6 x 16 (9) including spring washers (use Allen key 5 mm). Carefully remove the magnet cover (5) by pulling it towards you. If stuck, move the magnet cover a little left and right while pulling it towards you. Page 8

9 Installation O-ring Caution Move the magnet cap horizontally towards you and make sure not to damage the inner magnet. Replacing the O-ring Remove the standard Viton O-ring (FPM) (11). Clean the surface of the O-ring area in the back of the drum housing (1). Insert the dedicated Perlast O-ring (FFKM) (11) from this kit. Re-installing the magnet cover Clean the flange of the magnet cover (5) and apply a little anti seize grease. Use the protective gloves while applying the anti seize grease. Clean the inner magnet (7), making sure no metal parts are left behind on the inner magnet. Place the magnet cover (5); make sure not to touch the inner magnet (7) as to prevent damage. Fix the magnet cover (5) with the 6 screws M6 x 16 (9) including spring washers (use Allen key 5 mm ( 3 / 16 )). Re-installing the measuring drum Make sure the drum magnet (4) and outside of magnet cover (5) are clean (free from possible contamination such as rust particles). Remove the rubber band from the drum and attach a small weight to the measuring wire to keep the measuring wire under tension. Do not damage the measuring wire. Unwind some measuring wire; just enough to attach the displacer when the drum is in place. Feed the small weight and measuring wire through the neck of the gauge (refer to figure 3). Insert the measuring drum (4) into its bearings. Check the axial free-play of the drum as follows: - Push the drum towards the magnet cap in such a way that the drum shaft meets the magnet cap. Release the drum. - Bring the drum in a slight vibration. The drum and drum shaft should now move towards you with an axial movement of minimum 1 mm and maximum 2.5 mm. Figure 3 Re-installing drum Page 9

10 Installation O-ring Re-installing the displacer Remove the test weight, insert the displacer via a mounting hatch and attach it to the wire. Note: If there is no mounting hatch available, the displacer can be installed by temporarily removing the gauge from the nozzle. To provide electrical contact between the measuring wire and displacer, thus permitting the discharge of static electricity and preventing loss of the displacer, the displacer must be secured to the measuring wire. Recommended method with grounding block on displacer: Take an extra piece of wire with a length of cm (6 8 inch) and fasten one end Figure 4 Re-installing displacer to the measuring wire as follows (refer to (recommended method) figure 4, red coloured part). Loop the wire 2 to 3 times around the eyelet. Twist the wire around the measuring wire directly above the eyelet (about 5 7 times), so the wires are interlocked. Take the other end of the measuring wire and loop it thru the hole in the end of the displacer hook. Twist the wire 2 or 3 times around the hook and thru the hole in the end of the displacer hook. Bend the wire double and feed it into the small hole of the grounding block, next to the ground symbol. Secure the end of the wire by fixing the screw. Use Allen key 2.5 mm ( 3 / 32 ). Cut off the remaining part of the measuring wire. Note: If your displacer does not have the grounding block, it is strongly recommended to replace the displacer by a newer model with grounding block. Page 10

11 Installation O-ring Previous method for displacers without grounding block: Take an extra piece of wire with a length of cm (6 8 inch) and fasten one end to the measuring wire as follows (refer to figure 5, red coloured part). Loop the wire 2 to 3 times around the eyelet Twist the wire around the measuring wire directly above the eyelet (about 5 7 times), so the wires are interlocked. Take the other end of the measuring wire and loop it thru the hole in the end of the displacer hook. Twist the wire 2 or 3 times around the hook and thru the hole in the end of the displacer hook. Loosen the nut on the hook just above the displacer. Take the end of the measuring wire and twist the wire several times around the hook just above the displacer. Tighten the nut using a pair of pliers. Twist the end of the measuring wire a few times (3 4 times) around the wire running to the nut. Cut off the remaining part of the measuring wire. Figure 5 Re-installing displacer (previous method) Closing the drum compartment cover In order to ensure that the cover opens easily, the screw thread must be greased. Caution Keep screw threads free from dirt. Grease them lightly with anti seize grease before closing the instrument. Use the protective gloves while applying the anti seize grease. When closing, turn the cover counter clock wise until the thread clicks into place, and then turn clockwise. Page 11

12 Installation O-ring Labelling the gauge Engrave, or stamp the installation date of the special O-ring (month year will do) on the black part of the special O-ring indication plate (refer to figure 6). Secure the label by means of the sealing wire and seal to the hoisting eye (refer to figure 7). Firmly press the seal preferable by sealing pliers, or otherwise by suitable pliers. Figure 6 Label for special O-ring Figure 7 Labelling the gauge Set level gauge operational If applicable, open the ball valve. Switch on the mains. Give the UN (unlock) command to lower the displacer from its current position and let the displacer decent to the product surface. Perform the Balance test (refer to chapter 5.1 of the Instruction manual Series 854 ATG level gauge). The outcome should be within the limits ( 3 grams). Perform the level calibration test (refer to chapter 3.4 of the Instruction manual Series 854 ATG level gauge) and, if applicable, seal the gauge according to W&M procedures. If the gauge is used in a SIL loop, the 854 SIL Checklist should be completed by a qualified technician to validate the gauge. Page 12

13 Appendix Appendix Related documents Installation guide 854 Advanced Technology Gauge Instruction manual Series 854 ATG level gauge Safety Manual Series 854 ATG/XTG level gauges 854 SIL checklist Instruction manual 847 PET Page 13

14 Appendix Product compatibility Refer to the following links for product compatibility of the original (FPM) O-ring and special (FFKM) O-ring: prsense TM Chemical Resistance Chart A technical guide to Elastomer Compounds and Chemical Compatibility C. Otto Gehrckens GmbH & Co. KG Chemical resistance list Page 14

15 Notes Page 15

16 Honeywell Enraf Delftechpark XJ Delft The Netherlands Tel.: +31 (0) Revision 03 February 2015 Honeywell International Inc.