Petrotape / Chemtape Level Gauging System User`s
Contents
1. TANK TOP Y LIQUID SURFACE AS NEEDED TO PREVENT WHIPPING STILLPIPE 2 SCHED 40 PIPE V Figure 2 1 Stillpipe Mounting 2 3 1 Still pipe Location If the tank has an existing boss or pipe flange that is available it should be used to mount the required still pipe If no tank top penetration exists it will be necessary to cut a hole in the top suitable for the still pipe In general the still pipe should be located near the outside wall This allows the stillpipe to be braced to the inside wall long still pipes and it provides the greatest dimensional stability When mounted near the center of a tank the height above tank bottom may vary with tank temperature and pressure When selecting the still pipe location in a tank remember that adequate room must be available at the tank top where the still pipe is placed to allow for dispensing the sensor into the still pipe A minimum clearance of three feet is required 2 3 2 Still pipe Configuration The still pipe should be placed in a vertical straight position in the tank and braced to limit its movement Short still pipes under 10 feet normally do not need bracing Longer still pipes 12 Petrotape Chemtape Gauging System 3321 up to 20 feet may also not be braced if their is very little agitation or swirling of the tank contents 2 3 3 Pipe Material The still pipe material is not criti2. To other Tronsmitters and Meters Nate Pin numbers shown are for P amp F Borriers T 800L Transmitter Figure 2 11 Wiring to display meter with separate power supply 20 Petrotape Chemtape Gauging System 3321 Hazardous Location Hozordous Location Note Pin numbers shown are for P amp F Barriers 212 Wht 1 8 Exc Level Sensor Display Bik Bik 4 ps Wht 2 2 4l zb E 313 414 Em Y Sik Temperature 4 4 35 ago 9 Exc Display T 800L Transmitter 4 Figure 2 12 Wiring to level temperature displays with excitation 2 7 3 Entity Configuration The level only configurations of Petrotape and Chemtape have been entity approved by FM as shown on sheet 2 of drawing A1864900 Entity approval allows the user to add other entity approved intrinsically components such as loop powered displays to the same current loop The requirements for entity approved installations are as follows Every intrinsic safety barrier is provided with entity parameters Voc maximum output voltage Isc maximum output current Ca maximum capacitive load maximum inductive load Every entity approved apparatus including our transmitter has the following entity parameters assigned Vmax maximum allowable voltage Imax
3. Grn 333 4 4 2 Org Red 414 Sr 313 EXC Display Meter T 800L Transmitter Temperature Figure 2 7 Level temperature wiring to display with excitation 2 7 2 Intrinsically Safe Installations If the location is considered hazardous all of the following requirements must be met For the material being gauged determine its classification Class I Division 1 Group C or D The sensor and transmitter are not approved for Group A and B materials Acetylene and Hydrogen the transmitter both have a temperature rating of T3C For the material being gauged determine the autoignition temperature The sensor and The wiring must meet the requirements of the drawing A1864900 included in Appendix A This drawing defines all installation requirements that must be met to maintain an approved safe installation 18 Petrotape Chemtape Gauging System 3321 As specified on drawing A1864900 intrinsic safety barriers must be used JOWA USA US can supply these required intrinsic safety zener barrier in approved enclosures All wiring must meet the Wiring Practices in ISA ANSI RP12 6 Figures 2 8 through 2 12 show several suggested wiring configurations that meet the requirements of the drawing A1864900 You should determine the configuration that matches your requirements Hazardous Location Non Hazardous Location Loop Powered Meter Sensor 1 B Power Supp
4. To check the sensor a Using a multimeter check the resistance of the sensor by connecting the meter leads across the black and white wires coming from the sensor head b The resistance value should agree within 2 with the RS value stated on the sensor tag if the tank is empty If the tank is full or partially full the resistance should be approximately 305 ohms foot 1000 ohms meter for each foot meter that the liquid is below the sensor head c If the sensor is low in opening or does not reach its expected resistance value check for Loose filter connections Obstructions in the filter and its connections Obstructions or bends in the still pipe that could cause false contracting of the sensor Inadequate equalization of tank pressure that could prevent the sensor jacket and helix contacts from opening d If a sensor has been stored on its reel in hot conditions for several months the sensor jacket can be induced to its normally open position by using light internal pressure of less than 0 5 psi 31 Petrotape Chemtape Gauging System 3321 3 3 1 Checking the Resistance Temperature Detector RTD Ifthe RTD temperature detector is included on the sensor check the resistance The procedure is as follows a Attach the leads from the multimeter to the red and orange lead wires at the sensor head b Ifthesensor has a nickel iron RTD Models PGST 8 CGST the resistance should be approximately 675 ohms at
5. n Clean the mounting nipple of any remaining product or residue o Install the new sensor using the procedure in Section 3 and calibrate it according to the procedure in Section 4 p Either discard or prepare for return by Cleaning the sensor of any remaining residue Tying and padding the sensor head Coiling the sensor with the sensitive side out onto the reel from the new sensor installed in step o above put sensor head in first Carefully winding the rest of the sensor onto the reel Tying or taping the sensor to the reel to secure it 44 Petrotape Chemtape Gauging System 3321 6 3 Filter Replacement The following is the procedure for replacing the filter a Open the sensor housing by removing the four bolts at its corners b Disconnect the old filter from the breather tube on the sensor head by sliding it off the tube c Ifapplicable disconnect the tubing from the breather to the tank return fitting by sliding it off the fitting d Remove and discard the old filter e Use the procedure in Section 3 to install the new filter 6 4 Sensor or Pipe Washdown If the liquid or slurry being measured has a tendency to accumulate on the sensor or in the still pipe periodic flushing may be required This is accomplished using the baffled washdown fitting prescribed for such applications The application for which the PGS is used will determine the frequency of washdowns The procedure for a washdown is as follo
6. 4 Remove the cap from the tank return fitting 5 Remove the plug from the tubing coming from the tank return end of the filter 6 If this is a closed tank operating at positive or negative pressure connect the tubing from the filter to the tank return fitting by sliding it over the fitting Make sure that there are no kinks or bends in the tubing 30 Petrotape Chemtape Gauging System 3321 7 If this is an open tank at atmospheric pressure the tubing from the filter and the tank return fitting are normally connected together If conditions so require these may be left separated and vented to the atmosphere Ensure that the vent plug in the bottom of the housing is removed leave on bottom of sensor housing and that the filter tank return hose is not sitting on the housing bottom where it might rest in condensation or liquid 8 Once the filter is attached the sensor should ingest only clean and dry air 3 3 Checking the Level Sensor Several minutes after the filter has been attached to the sensor head breathing tube the sensor should inhale air and equalize with either the outside atmosphere or with tank pressure depending on how the tank return fitting has been connected During the time that the sensor jacket is being filled with air the resistance of the sensor should increase slowly until it reaches the RS value indicated on the sensor tag if the tank is empty or a fraction of the RS value if the tank is partly full
7. You must determine whether the tank contents vapors or the area through which the field wire cable must pass is considered a hazardous classified location The National Fire Protection Association document NFPA 497M Classification of Gases Vapors and Dusts for Electrical Equipment in Hazardous Classified Locations is one source for this in formation If the area is considered non hazardous proceed to section 2 7 1 and ignore sections 2 7 2 and 2 7 3 if it is considered hazardous proceed to section 2 7 2 ignore 2 7 1 Note that in all of the suggested wiring configurations there is a power supply required In many cases the power supply is integral to the display device or to the PLC system This power supply output required for the transmitter is available on a terminal pin designated Excitation Transducer Power Transducer Excitation 24VDC etc If an external power supply is required it may be used to power multiple transmitter channels as shown in Figure 2 3 Power Supply sensor Wht 24VDC Transmitter 1 Bik _ Display 1 ye Wht Eu 0 3 Sensor 2 Blk Transmitter 2 Display 2 425 zm Grn ILL lit Red Display 3 To other Transmitters and Displays Figure 2 3 Powering multiple transmitter channels Ensure that the steady state power supply excitation
8. indicated level can be calibrated temperature coefficient RTD location 2 0 feet 0 6 meter from sensor bottom 22 Ib 10 kg plus 0 4 Ib ft 0 6 kg m Table 7 1 Sensor Specifications 47 Petrotape Chemtape Gauging System 3321 7 2 Sensor Filter Specifications Table 7 2 lists the sensor filter specifications Specification Filter materials High density polyethylene polypropylene and viton Filter life Desiccant life of 12 to 48 months depending on liquid level cycle activity Pressure vacuum equalization Direct equalization over 2 psi range Table 7 2 Sensor Filter Specifications 7 3 Sensor Housing Specifications Table 7 3 list the sensor housing specifications 8 x 8 x 7 203 mm x 203 mm x 178 mm 3 125 150 Ib ANSI Table 7 3 Sensor Housing Specifications 7 4 Transmitter Specifications Table 7 4 lists the transmitter specifications Specification Minimum operating voltage full 7 5 VDC specifications Maximum continuous operating voltage 28 0 VDC full specifi ications Maximum continuous voltage 71 Reverse polarity protection 34VDC 1 1 Transient protection type MetalOxide Varister Transient energy level____________ JO5joules__________l ____ Table 7 4 Transmitter Specifications 48 Petrotape Chemtape Gauging System 3321 Table 7 4 Transmitter Specifications continued Specification Maximum continuous current n
9. 77 F 25 C This increases at the positive rate of 1 6 ohms F 3 1 ohms C If the sensor has a 1000 ohm platinum RTD Models PGSTP 8 CGSTP the resistance should be approximately 1096 ohms at 77 F 25 C This increases at the positive rate of 2 1 ohms F 3 85 ohms C 3 2 3 Cable Connection to Field Wiring Installation The field wiring is brought into the housing using the field wiring cable a Feed the field wiring cable through the housing conduit hole using cable gland or cable clamp Leave the connector inside the housing b Connect the field wiring to the pigtail leads of the field wiring cable 3 4 Transmitter Initial Installation For Wireless System see Manual M332 It is generally recommended that initial calibration be performed on the bench as described in section 4 1 If initial calibration is going to be performed the bench do not install the transmitter in the sensor housing at this time and proceed to paragraph 4 1 The current transmitter has two connectors that must be attached One connector mates with the sensor connector while the other connector mates to the field wiring connector To connect the transmitter a Attach the connector at the sensor head to the connector on the transmitter The connectors are keyed b Attach the field wiring cable connector to the other connector on the transmitter c Place the current transmitter in the upper region of the sensor housing No fixed mounti
10. appears only to effect the level channel refer to Table 6 3 for guidance Probable Cause Level channel Sensor to a Plug in connectors current is very low transmitter b Check pins of connectors to ensure no pins lt 2mA connector is open have been pushed in Pull out pins c Sensor has failed open circuit Replace sensor Level output Sensor Filter not Connect sensor filter appears high connected and when connected equalized to sensor Table 6 2 Level Channel Troubleshooting 41 Petrotape Chemtape Gauging System M3321 Probable Cause Large Current Liquid level above a Lower liquid level 20 30 mA Over 20mA point b Recalibrate for wider range range display Short or low resistance in field Disconnect transmitter connector from field wires wiring connector If short still exists problem is in field wiring if not problem is in transmitter or sensor or their wiring Check connections in sensor housing redo if bad Check cable replace if bad Check connections at instrumentation redo if bad Current or display Waves or ripples Filter data in display jumps slightly on liquid surface around or near expected value Put Sensor Simulator or fixed resistor on transmitter input If current or display is now steady problem is with sensor or noise pickup with sensor Low current Liquid level is a Raise liquid level Under range connectors are making proper connection Lev
11. authorization number as described in Section 3 1 2 The following is the procedure for removing the sensor from the tank a Remove the sensor housing cover Save all the housing hardware for reuse b Disconnect the filter from the sensor head breather tube by sliding the tubing off c Ifthe tubing from the filter is attached to the tank return fitting remove it d Lift the filter clear of its mounting and discard e Disconnect the sensor leadwires by pulling apart the two black connectors f Route the leadwires out of the way to prevent damage tie back if necessary 43 Petrotape Chemtape Gauging System 3321 g Using the old and new sensor data tags compare the data to ensure that the two are interchangeable The critical dimension is the over all sensor length LS The two sensors should have the same listed LS to within 5mm h Select an unobstructed surface area where the removed sensor may be laid down without damaging it i Unscrew the slip nut at the top of the sensor until it is clear of the mounting nipple j Grasp the sensor handle nut and pull straight up to ensure the sensor is free to be lifted out of its still pipe Note The next two steps require two people k Person 1 Lift the sensor out of the sensor housing Person 2 Receive sensor head from Person 1 and walk away sensor housing keeping sensor face up If necessary coil sensor face out in large 5 foot 1 5 meter diameter circle
12. maximum allowable current Ci capacitance contributed to the loop Li inductance contributed to the loop 21 Petrotape Chemtape Gauging System 3321 The entity parameters of the T 800L transmitter are shown in Table 2 1 32 0 VDC 120 mA 0 24 VDC Table 2 1 T 800L Entity Parameters To properly apply entity parameters the following conditions must all be met Mmax gt Voc gt Isc Ci Interconnection cable capacitance lt Ca Li Interconnection cable inductance lt La Note that the Ci above is the sum of the Ci s for all entity devices in the loop and the Li above is the sum of the Li s for all of the entity devices in the loop If the cable capacitance and inductance are unknown it is acceptable to use 60 pF foot 200 pF meter and 0 2 mH foot 0 66 mH meter When intrinsic safety barriers are purchased from JOWA USA Metribarrier they are supplied from one of two manufacturers The necessary data for each of these manufacturers is shown in table 2 2 Return diode 1 0V 1 0V voltage max Table 2 2 JOWA USA Metribarrier Data 22 Petrotape Chemtape Gauging System 3321 2 7 5 Transmitter Loop Voltage The transmitter requires a minimum voltage of 7 5 VDC This voltage must be available accounting for all voltage drops at maximum current 20 mA are subtracted including the following Intrinsic safety barrier resistance if applicable Intrinsic
13. on the sensor head to the mounting nipple 3 2 3 Filter Installation The procedure connects the tube from the filter to the sensor head breathing tube In most cases the tube from the filter is attached to the housing tank return 1 Verify that the filter desiccant is functional Table 3 1 lists the desiccant colors along with the functional condition of the filter Filter Condition Fully Functional Slightly depleted Table 3 1 Sensor Filter Color Indicator 2 With the filter desiccant cartridge on top place the filter so that it surrounds the nipple and sensor head 3 Remove the protective plug from the inside of the tubing coming from the filter bottle and quickly connect the tubing to the breathing tube on the sensor head by sliding the tubing 29 Petrotape Chemtape Gauging System 3321 over the breathing tube Make sure that there are no sharp bends or kinks in the tubing Refer to Figure 3 3 REMOVE PROTECTIVE REMOVE PROTECTIVE CAPS PLUGS FROM CAPS PLUGS FROM A AND a NSTANTLY 8 AND b NSTANTLY JON TUBE END A JON TUBE END B TO a AND CLAMP TO b AND CLAMP a TANK RETURN b FITTING SENSOR MOUNTING NIPPLE Figure 3 3 Connecting the filter to the sensor
14. safety barrier return diode voltage drop if applicable User load resistance Lead wire resistance Minimum power supply voltage Voltage drop of other loop powered entity approved devices Typically a 24 VDC power supply will provide more than enough voltage after normal voltage drops are subtracted To ensure proper operation the following calculation must be made VxurR Vs 0 02 x Rzg Ruw Ri Vp where Vxmtr Voltage at the transmitter Vs Minimum excitation voltage from power supply Rz Intrinsic safety zener barrier series end to end resistance in ohms will be O if there is no barrier Riw Lead wire resistance in ohms R User load resistance in ohms frequently 250 ohms Vz intrinsic safety zener barrier voltage drop of return diode will be 0 if there is no barrier Vo of voltage drops from any other displays or devices in series with loop This voltage drop must be subtracted if these devices are on either side of the intrinsic safety barrier EXAMPLE As an example if the transmitter is used with 24 VDC power supply minimum voltage is 24 0 x 95 22 8 a Metribarrier and a user load resistance of 250 ohms the minimum transmitter voltage is Vs 0 02 x Ruw Ri Vp 22 8 0 02 x 320 0 250 1 0 0 0 10 4 23 Petrotape Chemtape Gauging System 3321 2 7 5 Shielding All cables between the sensor housing an
15. there is no possibility of material build up If the still pipe is longer than 10 feet it can be clamped to the tank with standard pipe hangers 2 5 Preparation for Mounting the Sensor Housing A typical sensor housing mounting is shown in Figure 2 2 14 Petrotape Chemtape Gauging System 3321 SENSOR AND SE PART OF HOUSING G NOT SOR FILTER ASSEMBLY NOT SHOWN SENSOR MTG NIPPLE HOUSING ASKET SUPPLIED 3 125 150 LB EDUCING FLANGE PART OF STILLPIPE ASSEMBLY MTG HARDWARE BY CUSTOMER P NOT SUPPLIED emisse 2 SCHEDULE 40 PIPE TANK TOP BY CUSTOMER Figure 2 2 Sensor Housing Mounting The customer supplied components needed to install the sensor housing are Gasket A 3 125 150 Ib gasket is located between the stillpipe flange and the bottom of the sensor housing Bolts Nuts and Washers Four sets of bolts nuts flat washers and lock washers are required to mount the housing to the stillpipe mounting flange Standard flange and housing holes accommodate 5 8 diameter bolts Cable entry gland The sensor housing has a 0 875 diameter hole on one side intended for mounting a standard 3 4 cable gland thread For more information refer to the engineering drawings in Section 9 15 Petrotape Chemtape Gauging System 3321 2 7 Initial Electronics Power and Field Wiring For wireless installation skip to section 3 0
16. voltage does not exceed 28 VDC 24VDC nominal recommendea 2 7 1 Non intrinsically Safe Installations Figures 2 4 through 2 7 show several suggested wiring configurations that are not intended for hazardous locations You should determine the configuration that matches your requirements In addition review the manuals of the instrumentation used with your Petrotape Chemtape system 16 Petrotape Chemtape Gauging System 3321 Display Meter Sensor Wht IRN 43212 24 VDC Wht Bik Power 212 N 111 T 800L Transmitter Figure 2 4 Level Wiring to Process Current Display Sensor Bik Wht Exc 111 4212 Display Wht Bik 35134 414 NE T 800L Transmitter Figure 2 5 Level Wiring to PLC 17 Petrotape Chemtape Gauging System 3321 Sensor Bik Wht Display Wht Bik T 800L Transmitter Display Display To other Transmitters and Meters Figure 2 6 Wiring to display with separate power supply Level Sensor Blk Wht Exc Displa 1 1 212 play bod Meter Wht Blk us 2 2 Nr 1271
17. 0 mms ee 55 C to 85 E Size 4 5 x 2 5 x 1 6 e aci Connector type ITT Sure Seal ITT Sure Intrinsic Safety Approval Factory Mutual per 3610 Intrinsic Safety Rating Class I Division 1 GmuscaD C amp D Entity Parameters S2 VD VDC A 04 4 00 2 Temperature Rating T3C 50 Petrotape Chemtape Gauging System 3321 Section 8 Terms and Abbreviations This section contains common abbreviations and acronyms used in the text Note All sensor lengths and distances are measured from the sensor zero reference location at the top rim of the sensor head 8 1 Abbreviations and Acronyms Used for Sensor Distances Terms used in measuring sensor parameters are defined in Table 8 1 Distance Distance to top of helix 4 NEN Nominal value is 0 15 ft 44 mm Actuation depth the distance between the liquid surface and the first closed helix Defined for specific gravity of 1 000 nominal 0 41 ft 125 mm Distance from sensor zero to resistance temperature detector Total sensor resistance unshorted Resistance gradient rate of change of sensor resistance per unit length Resistance of sensor at measured level Resistance of temperature detector 8 2 Abbreviations used in Application Parameters Abbreviations used in measuring application parameters are defined in Table 8 2 Abbreviation Distance from stillpipe flange to tank bott
18. 802 MOUNTING BOX LOCATION FLANGE TOP TO BE FLAT 02 5 CLEARANCE JZ FOR BOLTS TANK TOP ge N 7 2 0 51 OTE COUPLINGS AND PIPE 772777777774 22227777727 AS REQUIRED SEE NOTE 1 FLOW HOLES 1 0 25 DIA THRU TYP NOTES 5 amp 6 NOTES MIN PIPE 1 0 1 8 46 MAX 4 0 101 DEBURR ALL HOLES AND CUTS INSIDE AND OUT 2 0 51 NOTE 3 LLL BOTTOM CLEARANCE RECOMMENDED BRACE PIPE AS NEEDED TO PREVENT WHIPPING FLOW HOLES REQUIRED TO ALLOW LIQUID ENTRANCE VISCOUS LIQUIDS REQUIRE ADDITIONAL HOLES LENGTH DETAIL IF TANK CONTAINS IMMISCIBLE LIQUIDS FLOW HOLES MUST EXTEND ABOVE HIGHEST EXPECTED LIQUID LIQUID INTERFACE SENSOR OVERALL LENGTH OAL STILLPIPE MUST HAVE A TOP VENT HOLE STILLPIPE BOTTOM TO MTG FLANGE FACE RETURNING TO TANK JUST BELOW TANK TOP ss J TANK BOTTOM A Ne TO SENSOR ZERO PIPE MAY BE ATTACHED DIRECTLY TO TANK AND OR 2 0 REF MTG FLANGE FACE TO TANK BOTTOM INSTALLED THROUGH A NOZZLE AND SUPPORTED BY A 51 NOTE 3 REDUCING FLANGE SEE SHEET 2 MAKE MULTIPLE STILLPIPES THE SAME LENGTH CONSTRUCTION DETAIL FOR CONVENIENT SPARING OF SENSORS RECOMMENDED LS LP TYPICAL LANDBASED STILLPIPE FOR HI CUSTOMER FABRICATION A 1677800 BY CONSILIUM 0 SENSOR AND SENSOR FILTER ASSEMBLY NOT SHOWN BY CONSILIUM ea m S STILLPIPE 2 SCHEDULE 40 PIPE SENSOR MTG NIPPLE PART OF HOUSING BY CONSILIUM GASKETS BY CU
19. M LEVEL TEMP SENSOR MODELS LAabcd LSabcd AGSe S PGSe fS CGSe fS b CR AF R HN SN SP b b TN TP TC c b EP d b SP e T TP f b HN HP SN SP WIRING SHALL BE IN ACCORDANCE WITH ANSI ISA RP12 6 APPROVED INTRINSIC SAFETY BARRIERS BI B2 MANUFACTURER MANUFACTURER S JOWA CONSILIUM NUMBER NUMBER 8901 31 280 165 80 9122523 8901 31 280 100 70 9122524 R STAHL INC 9001 01 280 165 10 9122526 R STAHL INC 9001 01 280 100 10 9122527 MTL INC 728 9122528 PEPPERL FUCHS 2728 9122542 R STAHL INC R STAHL INC SEE SHEET 11 FOR BARRIER TERMINAL CONNECTIONS BARRIERS B1 AND B2 SHALL BE THE SAME WITHIN A SINGLE INSTALLATION THE MAXIMUM CABLE CAPACITANCE INDUCTANCE ALLOWED IS 77uF 1 7mH FOR GROUP C AND 1 99uF 3 2mH FOR GROUP D BASED ON 60pF FT AND O 2uH FT THE MAXIMUM CABLE LENGTH IS 8500 FT 2600 M FOR GROUP C AND 16000 FT 4880 M FOR GROUP D SYSTEM CONFIGURATION JOWA Consilium JA 1650003 Ikone NONE
20. Petrotape Chemtape Level Gauging System User s Manual 3321 September 23 2009 JOWA USA JOWA USA Inc 59 Porter Road Littleton MA 01460 USA Telephone 978 486 9800 Fax 978 486 0170 Preface This manual sets forth the principles properties and methods of using the Petrotape and Chemtape Gauging Systems We believe that you will find your system to be a good solution to your petroleum or chemical gauging requirements If you need further information or application assistance please contact the JOWA USA factory or your local JOWA USA representative This manual is written primarily for systems that utilize the T 800 series current transmitter If you have chosen to use the Wireless option WRT 8 WBR please refer to those separate manuals when this manual mentions the T 800 Conventions and Safety Concerns This manual uses the following symbols to indicate special considerations in the text WARNING WARNING statements indicate either a personnel or severe equipment hazard This calls attention to an operating procedure or practice which if not done correctly or adhered to could result in possible harm or injury to personnel or damage to the product Do not proceed beyond a WARNING statement until the conditions are fully understood and met Caution CAUTION statements indicate an equipment hazard This calls attention to an operating procedure or practice which if not done correctly or adhered to could result
21. S WITHOUT FACTORY MUTUAL APPROVAL DIMENSIONS ARE INCHES ARE DERIVED FROM INCHES JOWA Consilium EE i RESISTANCE TAPE LEVEL TEMPERATURE GAUGING SYSTEM DAS A 1650000 usen fare EDO HAZARDOUS LOCATION JOWA CONSILIUM LEVEL SENSOR LEVEL SENSOR NON HAZARDOUS LOCATION NOTES 1 HAZARDOUS LOCATION CLASS I DIVISION 1 ENTITY GROUPS C amp D APPROVED ENTITY PARAMETERS BARRIER VMax 32 V IMax 200mA Ci 0 01 uF Li 0 2 mH ENTITY APPLICATION REQUIREMENTS VMax gt VOC gt ISC SEE Ci Interconnection cable Ca Li Interconncetion cable lt La 4 JOWA CONSILIUM LEVEL SENSOR MODELS LAacd LSacd AGS S PGS fS 5 15 a b CR AF HT R HN HP SN SP c b EP d b SP f b HN HP SN SP THE MAXIMUM VOLTAGE OF THE NON HAZARDOUS LOCATION SHALL NOT EXCEED 250 VRMS WIRING SHALL BE IN ACCORDANCE WITH ANSI ISA RP12 6 LEVEL ALARM AND CONTROL EQUIPMNET ENTITY CONFIGURATION JOWA Consilium ROUN A 1650000 GROUND HAZARDOUS LOCATION JOWA CONSILIUM LEVEL TEMP SENSOR LEVEL SENSOR RTD OPTIONAL NON HAZARDOUS LOGATION c j EARTH GROUND LEVEL ALARM AND CONTROL EQUIPMNET NOTES 1 HAZARDOUS LOCATION CLASS I DIVISION 1 GROUPS C amp D 2 THE MAXIMUM VOLTAGE OF THE NON INTRINSICALLY SAFE APPARATUS SHALL BE 250VRMS 3 JOWA CONSILIU
22. STOMER 3 REDUCING FLANGE PART STILLPIPE ASSEMBLY BY CUSTOMER BY CUSTOMER STILLPIPE VENT DEBURR INSIDE APPROX 1 00 25 DIA 2 HOLES ESSENTIAL FOR PROPER OPERATION OF METRITAPE SENSOR SEE NO DETAIL STILLPIPE TANK TOP NOTES 1 DEBURR AND REMOVE ALL SHARP EDGES FROM INSIDE OF STILLPIPE 2 INSIDE OF STILLPIPE TO HAVE NO WELD PENETRATIONS OR PROTRUSIONS 3 PUT DEBURRED HOLES IN STILLPIPE TO ENSURE LIQUID EQUALIZATION 4 BOTH SIDES OF REDUCING FLANGE MUST BE FACED OFF TE 3 HOUSIN BY CONSILIUM 3 REDUCING FLANGE PART OF STILLPIPE ASSY BY CUSTOMER SEE NOTE 4 MOUNTING HARDWARE BY CUSTOMER STILLPIPE VENT DEBURR APPROX 1 00 25 DIA HOLES ESSENTIAL FOR PROPER OPERATION OF METRITAPE SENSOR SEE NOTE 3 SENSOR AND SENSOR FILTER ASSEMBLY NOT SHOWN BY CONSILIUM DETAIL NOZZLE TANK TOP SENSOR MTG NIPPLE PART OF HOUSING BY CONSILIUM NOM 3 BY CUSTOMER NOZZLE STANDOFF 3 SCHEDULE 80 PIPE BY CUSTOMER TANK TOP STILLPIPE SCHEDULE 40 PIPE BY CUSTOMER e 1677800 REVISIONS DATE ORIGINAL RELEASE 10 92 EDC CHANGED PER ECO 871 10 92 EDC CHANGED PER 884 11 92 EDC CHANGED PER ECO 2326 11 98 DAS CHANGED PER ECO 2364 CHANGED PER ECO 2545 CHANGED PER ECO 2612 CHANGED PER ECO 3155 12 04 EDC Q O U 2lI m I m T fri li STATUS 11110 9 8 7161514131211 OF SHEETS NO REVISION
23. cal for proper operation of the sensor as long as it does not allow rust or scale build up It must be compatible with the liquid or slurry being gauged Although mild steel is typically used stainless steel glass reinforced plastic and PVC have been used 2 3 4 Pipe Diameter Either 2 or 3 pipe is typically used In either case a 3 125 150 Ib ANSI flange must be mounted to the top of the stillpipe 2 3 5 Pipe Couplings On long still pipes couplings will be required to connect sections together Any type of coupling is acceptable to JOWA USA as long as there are no sharp edges or burrs If sections are welded together it is essential that no weld slag penetrate to the inside of the pipe There should be no gaps in coupling that would resist sensor insertion If there is a gap greater than 0 4 1 cm the lower section of the pipe should be chamfered to facilitate installation 2 3 6 Still pipe length The stillpipe length LP is the distance from the still pipe housing mounting flange to the bottom of the pipe LP should be equal to the height of the tank at the stillpipe location plus approximately 1 foot 0 3 meters This number should be adjusted higher or lower to come to the nearest integral foot or integral meter length The still pipe must extend above the tank top at least 6 inches to allow access to housing mounting bolts The still pipe should be equal or longer than the sensor to provide full protection 2 3 7 V
24. cture to be free from defects in material and workmanship under normal use and service for a period of twelve months from date of factory shipment or if installation is delayed and JOWA USA equipment is stored carefully in its protective packaging for a period of twelve 12 months from date of factory supervised installation but not later than eighteen 18 months from date of shipment Equipment not of JOWA USA manufacture is subject to the warranty given to JOWA USA by such manufacturer Freight insurance or customs costs are excluded and will be billed Installation labor costs and or services of a factory engineer are not included in warranty coverage or adjustment Improper service performed on JOWA USA products claimed to be defective will void warranty JOWA USA does not warranty suitability of its product for specific applications and cannot predict performance or operating life under particular conditions of service JOWA USA recommends the conduct of field tests or extended usage under representative conditions as the only valid means for determining suitability or for defining operating life and performance in service 2 Petrotape Chemtape Gauging System M332l Section Introduction The Petrotape Gauging System and the Chemtape Gauging System is used to measure the liquid level in a tank This product is used in land based industrial applications and measures the following types of liquids Petrotape Crude oil Petr
25. d the user instrumentation or intrinsic safety barriers should have an overall shield The shield is best left open at the sensor end and tied either to chassis earth ground or signal ground in the instrumentation The best connection may have to be determined experimentally In intrinsically safe installations the shields should be tied to either the IS ground rail or if available to the IS GND connection on the IS barrier 2 7 6 General Note the polarity of the loop current the transmitter is protected but will not operate if the leads are reversed All of the field wiring from the instrumentation up to the sensor housing should be completed before the sensor housing is installed 24 Petrotape Chemtape Gauging System 3321 Section 3 Installation 3 1 Unpacking and Inspection Installation of the Petrotape and Chemtape systems consists of the following Unpacking and inspection Pre installation measurements Installation of housing sensor filter and transmitter When the Petrotape Chemtape equipment arrives 1 Perform an initial inspection by verifying that the boxes are intact and undamaged If there is external damage to the containers ask the carrier s agent to be present when the equipment is unpacked 2 Check the equipment for external damage such as broken components dents and scratches If damage is found refer to Claims for Damage in this section 3 Check the cushioning material for signs of any s
26. e have been ordered they may come in a box that holds up to five reels Current Transmitter Packed inside the sensor housing If wired system ordered Sensor Filter Packed inside the sensor housing Sensor Housing Packed with the current transmitter and filter inside The cover of the sensor housing has the securing hardware already attached Transmitter to field wiring cable Manual Packed with the sensor housing 3 1 4 Storing the Sensor The operational sensor is designed to withstand harsh operating environments Outside the still pipe however the sensor may be subjected to a number of hazards and therefore should be stored away from sharp objects that may damage it The sensor reels should be stored in a dry indoor area until needed 3 1 5 Pre Installation Measurements Before installing the sensor measure the tank depth DTB from the sensor housing mounting flange to the tank bottom This is required for instrument calibration 26 Petrotape Chemtape Gauging System 3321 3 2 Housing Sensor Filters and Transmitter Installation Caution The sensor should not be installed until All hot work and painting in the tank is complete Leadwires are in place for wired systems Sensor housing is properly mounted Tank pressure testing is complete If trouble is experienced with the installation contact JOWA USA Service to arrange for a consultation with a service engineer 3 2 1 Sensor Housing Installa
27. ed Improper calibration Bottom water in stillpipe Check wiring Ensure that transmitter current wires are not reversed Rework as required Verify that connector pins on transmitter to field wiring connector are not pushed in Verify that DC power supply is supplying sufficient voltage at transmitter Calibrate per Section 4 Check sensor filter connections Replace sensor Replace transmitter Check connector pins to ensure they aren t pushed in Replace sensor Connect filter Stillpipe must have vent holes just below tank top to prevent air lock Add holes Check SPAN calibration Add more vent holes in bottom of stillpipe Table 6 1 Initial System Troubleshooting Petrotape Chemtape Gauging System 3321 6 3 General Troubleshooting If the level or level temperature gauging system has been operating properly and has subsequently failed refer to Table 6 2 for general troubleshooting procedure The following applies to both level and temperature channels These tests assume that the system was initially working i e there are now no wiring errors Probable Cause No current output Power supply not Check voltage turned on or not connected Open field wire Check wiring Very large current Failed com Replace Transmitter gt 100mA ponents due to over range nearby lightning Table 6 2 General troubleshooting 6 4 Level Channel Troubleshooting If the problem with the system
28. el transmitter a Open connector between sensor and transmitter leads are open Place short between level input pins and verify that current get large If current does not increase problem is with transmitter otherwise problem is with sensor Table 6 3 Level Channel Troubleshooting continued 42 Petrotape Chemtape Gauging System M332l 6 5 Temperature Channel Troubleshooting If the problem with the system appears only to effect the temperature channel refer to Table 6 4 for guidance Probable Cause Temperature Sensor to a Plug in connectors channel transmitter b Check pins of connectors to ensure no pins have been current is high connector is pushed in gt 20mA open Temperature a Lower temperature above 20mA b Recalibrate for wider range point a Verify that pins on both sensor and transmitter connectors are making proper connections RTD open a Open connector between sensor and transmitter Short RTD pins at transmitter input connector If no response replace transmitter otherwise problem is with sensor Temperature Short in sensor a Open connector between sensor and transmitter If channel transmitter high current goes low problem is with sensor check current is low cables sensor lt 4mA b Replace transmitter Table 6 4 Temperature Channel Troubleshooting 6 6 Sensor Replacement If the sensor is being returned it should be coiled onto its reel for shipment Obtain a return
29. ent Holes A pair of opposing 3 4 19 mm vent holes must be provided at the top of the stillpipe directly under the tank top This will prevent an air lock that would not allow the level in the still pipe to equalize to the level in the remainder of the tank 2 3 8 Flow Holes Flow holes at the bottom of the stillpipe are recommended especially if the liquid has any viscosity or if there is a possibility of build up on the bottom of the tank They are also required if there may be bottom water or some other immiscible liquid on the tank bottom 13 Petrotape Chemtape Gauging System 3321 2 3 9 Identify Whether a Baffled Washdown is Necessary A baffled washdown fitting should be considered if the material being measured is apt to leave a residue in the still pipe and on the sensor The washdown fitting is used to flush out the still pipe and any residue on the sensor Contact the factory for support Caution All inside edges of the still pipe including holes and couplings must be deburred to remove any sharp or cutting edges which could damage the sensor jacket 2 4 Still pipe Installation The still pipe should extend down to approximately 2 50 mm off tank bottom This will generally allow free flow of liquid in the presence of sand wax scale or other such material build up Figure 2 1 illustrates the positioning of the still pipe With sensors under 10 feet in length the bottom clearance may be lowered to 1 25mm if
30. g the damage to the sensor may have been done already Equipment m EIC Yearly Inspection Filter Verify that the desiccant chemical is blue If the chemical is pink or white replace the filter Every 3 years If the filter has not been replaced in the last three Replacement years replace it Every 3 years Stillpipe Check for silting or other plugging Be certain that the stillpipe is securely anchored and not damaged in any way Check for evidence of flooding It should be clean and dry If necessary tighten sensor slip nut or filter tank return fitting Check for corrosion of conductors and degradation of insulation Depends on Sensor The sensor can be raised from time to time to application and inspect its physical condition If it is producing stability of values smooth and accurate readings it is likely to be in good condition Table 5 1 Scheduled Maintenance 37 Petrotape Chemtape Gauging System 3321 5 2 Replacement Parts The specific application of the Petrotape Chemtape installation determines whether or not spare parts should be kept on site Since the sensor filter contains desiccant which has a short shelf life it should not be stored as a spare part it can however be delivered on short notice Other parts may take several weeks to be delivered specify length of integral feet or integral meters Petrotape level temperature sensor NiFe RTD specify length of integral feet or integral mete
31. he construction cycle and do not need to be subjected to potentially damaging tank preparation procedures 2 1 Identify the Liquid to be Measured If the liquid to be gauged is thick viscous or has suspended solids consider punching more holes in the still pipe Also consider placing the still pipe in an area where there is enough liquid turbulence to keep the still pipe flushed out and clear 2 2 Safety Considerations When installing a wired system if the liquid being gauged or its vapors are flammable or potentially explosive or if the sensor leadwires pass through an area classified as hazardous an approved zener barrier MUST be used to achieve intrinsic safety When wiring for intrinsic safety follow the requirements of the Factory Mutual FM approved installation drawing A1865900 contained in Appendix A 2 3 Design of the Still pipe The sensor must be installed in a still pipe when tank contents are agitated For non agitated tanks an optional weighted sensor installation may be possible Consult the factory for additional details and separate instruction provided with the sensor weight when this option is 11 Petrotape Chemtape Gauging System 3321 selected When using a stillpipe several design criteria should be reviewed and followed and are presented in the following sections Figure 2 1 shows a typical stillpipe installation MOUNTING NIPPLE 6 MIN SELECT STILL PIPE 8 OF INTEGRAL LENGTH
32. in damage to the product Do not proceed beyond a CAUTION statement until the conditions are fully understood and met Note Notes are used to call attention to additional information to further clarify or emphasize information 1 Petrotape Chemtape Gauging System 3321 Energy Barrier in Hazardous Area It is your responsibility to judge the requirements for safety protection If specifically requested JOWA USA Inc will assist you in designing a system that meets all pertinent requirements for electrical safety in the presence of explosion hazards Approved JOWA USA assemblies are available for Petrotape and Chemtape systems which use zener barrier isolators to limit the energy that can pass from the non hazardous area into leadwires sensors indicating meters and current transmitters located in the hazardous area These units are comprised of discrete barriers for each active signal lead Notice JOWA USA Inc shall not be held liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material The information contained in this document is subject to change without notice This document is protected by copyright and all rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of JOWA USA Inc Warranty JOWA USA Inc warrants equipment of its own manufa
33. ly Bik Wht Bi Wht k l 22H r1 HH l rh Note Pin numbers shown are for P amp F Barriers T 800L Transmitter Figure 2 8 Hazardous location wiring to loop powered entity application 2 EN re shown are for P amp F Barriers T 800L Transmitter Entity Approved Hazardous Location Non Hazardous Loop Location Powered Sensor Meter Te UNNE Power Supply Wht BIk 4 5 212 r1 313 Yr 414 ute Pin numbers Figure 2 9 Hazardous location wiring to entity approved loop powered meter 19 Petrotape Chemtape Gauging System 3321 Hazardous Location Non Hazordous Locotion Sensor Display 1 8 Exc Bik Wht Bl Wht k 411 Age d 3 3 44 4 m l Note Pin numbers shown are for P amp F Barriers T 800L Transmitter Figure 2 10 Wiring to display meter with excitation Hazardous Location Nun Hazordous Locotion Power 1 Supply Sensor 1 8 Bik Wht Bi Wht k 2 24 111 I Display 14414 mE
34. ng is required Note At this point in the installation the housing cover is still removed pending the calibration which is detailed in Section 4 32 Petrotape Chemtape Gauging System 3321 3 4 Transmitter Final Installation a Install transmitter cover using screws removed in step 4 5 c above b Install housing cover using bolts removed in step 4 5 a above Caution Ensure that the filter tubing is not pinched or kinked and that wiring does not extend under cover 33 Petrotape Chemtape Gauging System 3321 34 Petrotape Chemtape Gauging System 3321 Section 4 Calibration REFER TO T 800 SERIES CURRENT TRANSMITTER INSTRUCTION MANUAL M323 or WRT Manual for Wireless Systems M332 WHEN CALIBRATION IS COMPLETE PERFORM FINAL INSTALLATION PER SECTION 3 4 39 Petrotape Chemtape Gauging System 3321 36 Petrotape Chemtape Gauging System 3321 Section 5 Maintenance 5 1 Scheduled Maintenance A properly installed Petrotape or Chemtape should experience neither drift nor wear It is extremely important however to change the filter as required A typical maintenance schedule is shown in Table 5 1 Adjust the schedule to accommodate equipment usage Caution It is extremely important that the filter be changed at least every three years If the filter is not operating properly the sensor will be damaged and require replacement By the time the filter appears to need changin
35. oleum products Petroleum water mixtures Chemtape Industrial chemicals Pharmaceuticals Petrochemicals As an option the Petrotape or Chemtape sensor may include a single nickel iron resistance temperature detector or a single 1000 ohm platinum resistance temperature detector The temperature is measured at a single point that is two feet from the bottom end of the sensor The Petrotape Chemtape may be used in a tank located in an oilfield at a chemical plant near a stream or at a hazardous wastewater holding site Several Petrotapes Chemtapes may be used in applications that have multiple tanks such as a processing plant This type of system is usually connected to a centralized monitoring system supplied either by JOWA USA or by others 1 1 Physical Overview The Major elements of the Petrotape Chemtape Gauging System are Sensor Sensor filter Sensor housing Current transmitter In addition a customer supplied still pipe maybe required for the sensor Figure 1 1 shows on overview of an installed Petrotape Chemtape Gauging System 3 Petrotape Chemtape Gauging System 3321 TRANSMITTER HOUSING I TE SENSOR ILTER STILLPIPE LIQUID SURFAC BOTTOM Figure 1 1 Petrotape Chemtape Gauging S
36. om RAMA Distance from stillpipe flange to customer 4 mA level 51 Petrotape Chemtape Gauging System 3321 52 Petrotape Chemtape Gauging System 3321 53 Section 9 Engineering Drawings This section contains the following engineering drawings Note Only the applicable pages of the drawings have been included Drawing 1650000 Intrinsic Wiring for the Sensor Sheets 1 3 Drawing 1677800 Suggested Mounting amp Flange Gasket Requirements Drawing 1825001 Sensor Housing Petrotape Chemtape Gauging System 3321 SEE WELD SCREW STAINLESS STEEL 8 32 X 38 LG OHIO NUT amp BOLT CO P N GWZ 1406 OR EQUIVALENT CUSTOMER ELECTRICAL GROUND 437 11 10 2 656 16 76 THRU VENT DRAIN HOLE SUITABLE FOR 5 8 HARDWARE SEE TABLE FOR DESCRIPTION OF METRITAPE STANDARD HOLE PATTERNS FOR 125 150 POUND FLANGES 3 FLANGE SHOWN TANK RETURN FITTING ANGLE SEE TABLE SHOWN WITH COVER REMOVED NOTES Rev revsons oa farro A ORIGNAL RELEASE 7 83 EDC CHANGED PER 41186 2 94 enc 1 COVER WITH GASKET AND SCREWS 304 SST SUPPLIED MOUNTING FLANGE BOLTS AND GASKET BY OTHERS 1 1 2 PIPE NIPPLE 2 3 8 STIFFENER MAT L HOT ROLLED STEEL ZINC PLATED NOTE 2 3 WEIGHT APPROXIMATELY 15 LBS 6 4 KG 3 4 CONDUIT WIRING ACCESS 9 1 06 27 SQUARE JOWA USA ef OUTLINE amp MOUNTING CGS amp PGS ome CBS 7 0 03 Les mx 1408
37. on 30 mA fault Level Type Image 1 y Zero Adjustment minimum 800 ohms 2 6 feet 0 8 meters Zero Adjustment maximum 31000 ohms 102 8 feet 31 meters Zero Coarse Adjustment 3 position DIP switch Zero Coarse Resolution 3250 ohms 10 6 ft 3 2 m fs Zero Fine Adjustment 20 turn potentiometer Zero Fine Adjustment 800 NMS Range Span Coarse Adjustment 3 position DIP switch Span Fine Adjustment 20 turn potentiometer _ J gm Linearity 0 00196 of full scale or 0 05 Temperature stability 0 001 mA C 005 Power supply rejection t0002mA VDC DampingC6dB RTD Types allowed 7 604 1000 RTD Selection Ni Fe position 35 F to 77 F 37 C to 25 C O 7 1 1000 ohm Pt position 24 F to 55 F 31 C to 13 C Zero Fine Adjustment 20 turn potentiometer A Span Coarse Adjustment 2 position DIP switch EA AA 4 steps Span Coarse Resolution 69 ohm 69ohms Span Coarse Adjustment 137 ohms to 414 ohms Ni Fe position 87 F to 238 F me 46 C to 127 C Span Coarse Adjustment 194 ohms to 588 ohms 1000 ohm Pt position 90 F to 276 F 50 C to 154 C 49 Petrotape Chemtape Gauging System 3321 Table 7 4 Transmitter Specifications continued Specification Span Fine Adjustment 20 turn potentiometer 40 C to 6
38. ower DC power supplies shared meters etc 2 If only the values for a particular tank are defective or erratic determine whether the fault lies in the sensor or in the current transmitter This is done by disconnecting the sensor leads going to the current transmitter and substitution a sensor simulator or decade box If the problem is corrected with the sensor simulator attached the problem lies in the sensor If the problem still exists the transmitter wiring or other connected equipment is suspect Note The sensor is a non repairable assembly and must be replaced if defective The transmitter may be repaired but only at the JOWA USA factory 39 Petrotape Chemtape Gauging System 3321 6 2 Initial System Troubleshooting If the system has been installed but has never been operating properly Table 6 1 provides troubleshooting guidance Probable Cause No Current Output from Transmitter Incorrect current output with Sensor Simulator Tank level always reads high current is high Tank level always reads low current is low Tank level OK near bottom faulty near top 40 Wiring Error Connector pins pushed in No DC Voltage Improper calibration Sensor Filter not connected or plugged Short in sensor Short in transmitter sensor side Open circuit in sensor transmitter cable Open circuit in sensor Sensor filter not connected or plugged Tank vent holes not install
39. person can be removing the polyethylene packing sleeve and guiding the sensor through the mounting nipple into the tank Caution When the sensor is being installed do not subject it to sharp bends If it must be bent the bend must be circular and not less than 3 feet in diameter Do not cut the ties holding the sensor on the reel To install the sensor a Untie the strings holding the sensor on the reel Caution Do not use a knife or other sharp instrument to cut strings Avoid twisting or scraping the sensor against sharp edges or rough surfaces b While carefully removing the sensor clear plastic packing sleeve once started it will tear easily from the sensor curve the sensor gently and dispense it from the reel into the still pipe Refer to Figure 3 2 28 Petrotape Chemtape Gauging System 3321 Minimum Radius Feet Sensor Reel S 2 Housin Figure 3 2 Removing the sensor from the reel c Ifthe sensor does not slide easily into the still pipe or if it bends or meets an obstruction do not force it any further Carefully remove the sensor correct the problem in the still pipe and then try inserting the sensor again d After the full length of the sensor has been inserted into the still pipe the sensor head will rest on the mounting nipple Make sure the sensor head is properly seated on the mounting nipple and then tighten the mounting ring nut
40. re The current transmitter is powered over the leadwire pair with nominal 24 VDC excitation Note If you have a wireless system please refer to the WRT manual M357 8 Petrotape Chemtape Gauging System M3321 1 2 3 Actuation Depth AD A certain amount of pressure from the liquid is required for helix to base strip contacting to occur This contacting occurs below the liquid surface and is known as the actuation depth AD The AD is uniform for any given sensor and is nominally 125 mm for liquids with a specific gravity of 1 000 water This is equivalent to a pressure of approximately 0 2 psi The AD varies slightly from sensor to sensor The precise AD of the sensor can be determined and offset by the user 1 2 4 Sensor Filter Operation The relaxed and uncompressed sensor jacket has an internal gas volume of approximately 0 1 cubic inch per foot of sensor length As liquid is introduced into the tank the sensor jacket collapses and the contained gas volume is exhaled out the tube at the top of the sensor head Liquid leaving the tank causes the reverse situation To prevent condensation of vapors and to ensure that only clean dry air is inhaled into the sensor jacket a filter is connected to the sensor head In addition if the tank has any vapor pressure other than atmospheric the sensor filter must be returned to the tank to equalize that pressure From paragraph 1 2 3 above it takes only 0 2 psi to close every contact on the
41. red This is illustrated in Figure 1 6 7 Petrotape Chemtape Gauging System M3321 TO SENSOR FILTER BASE STRIP SEALED AS NI JACKE LIQUI OO ELIX SHORTED BELOW SURFACE Figure 1 6 Petrotape Chemtape Sensor Operation As the level of liquid in the tank falls the jacket helix contacts open as they are relieved of pressure and the unshorted resistance increases The resistance gradient RG which is the change in resistance per change in liquid level is specified on the sensor identification tag This has a nominal value of 304 8 ohms per foot 1 000 ohms per meter The resistance of the helix is measurable across the two leadwires brought out at the sensor head This resistance is used to determine the level of the liquid 1 2 2 Current Transmitter The two wires from the sensor head are connected to the current transmitter The resistance value from the sensor is converted to the 4 20 mA process current by the current transmitter This current output is customer wired to monitoring equipment The Petrotape and Chemtape sensors with temperature operate in the same fashion except that there are four wires coming from the sensor head two for level and two for temperatu
42. rs specify length of integral feet or integral meters specify length of integral feet or integral meters Chemtape Hastelloy level temperature sensor NiFe RTD specify length of integral feet or integral meters Chemtape Hastelloy level temperature sensor platinum RTD specify length of integral feet or integral meters specify length of integral feet or integral meters Chemtape Teflon level temperature sensor NiFe RTD specify length of integral feet or integral meters CGSTP S Chemtape Teflon level temperature sensor platinum RTD specify length of integral feet or integral meters SS 904D Sensor simulator service and calibration tool Table 5 2 Replacement Parts 38 Petrotape Chemtape Gauging System M332l Section 6 Troubleshooting 6 1 Isolating Faults The Petrotape Chemtape is designed to be modular with all the key elements easily separable and in most instances plug in The sensor is totally accessible from outside the tank The sensor leadwires are attached through sealed and keyed connectors making it virtually impossible to improperly attach them If the system appears to be malfunctioning use these steps to determine the source of the problem and to correct it 1 Determine whether the problem affects all the tanks the whole system or only certain tanks by defining which tank or tanks have erratic values If it is the whole system check the common circuit elements such as fuses primary p
43. s the sensor filter Figure 1 3 Sensor Filter 5 Petrotape Chemtape Gauging System 3321 Sensor housing Used to mount the sensor head and to house the filter current transmitter and wire connections The sensor housing is a model PGS CGS SH887 and is made of 304 stainless steel with dimensions of 8 x 8 x 7 There are four holes which have been bottom punched to mate with a standard 3 150 psi flange customer supplied The mounting nipple is used to mount and retain the sensor head to the sensor housing There is a hole located at the bottom of the sensor housing for drainage and another hole on the side of the sensor housing which is used as a conduit for wiring The sensor housing is shown in Figure 1 4 VENT DRAIN HOLE WITH REMOVABLE PLUG INSTALLED FARSIDE E GROUND STUD 9 25 SQUARE Y SENSOR MOUNTING NIPPLE LOCATION TANK RETURN TUBE 316 STAINLESS STEEL Figure 1 4 Sensor Housing Top view with cover removed Current Transmitter Provides a 4 20 mA current output which corresponds to the liquid level in the tank The measurement at 4 mA corresponds to a level at the bottom of the tank while 20 mA corresponds to a level near the top of the tank The current transmitter is either a model T 800L level or a T 800LT level and temperature Externall
44. sensor 1 2 5 Temperature Detector The Petrotape and Chemtape can be provided with an optional resistance temperature detector RTD The sensor may have either a 604 ohm nickel iron or a 1000 ohm platinum RTD For the nickel iron RTD the average resistance temperature gradient is 1 7 ohm F 3 1 ohm C This gradient can be determined more precisely over a narrow defined temperature range Table 4 9 shows the resistance versus temperature values for both RTD types 9 Petrotape Chemtape Gauging System 3321 Petrotape Chemtape Gauging System 3321 Section 2 Site Preparation Prior to the installation of the Petrotape or Chemtape the following should be done Identify the liquid to be measured Identify the safety concerns Determine placement of the still pipe unless using weighted sensor option Determine whether a baffled washdown is necessary Prepare and install the still pipe if required Prepare for mounting the sensor housing Review the precautions necessary for installing the sensor Prepare the field wiring These topics covered in more detail in this section Caution Petrotape and Chemtape sensors should not be installed until all structural welding sand blasting painting and pressure testing operations have been completed Sensor installation does not require entry into the tank and usually takes a few minutes Sensors can therefore be installed late in t
45. tion The gauging equipment must be accessible and serviceable from out side the tank The flange gasket and bolts are customer supplied Figure 3 1 details the mounting of the sensor housing SENSOR AND SENSOR FILTER ASSEMBLY NOT SHOWN SENSOR MTG NIPPLE PART OF HOUSING HOUSING GASKET NOT SUPPLIED 3 125 150 LB EDUCING FLANGE PART OF STILLPIPE ASSEMBLY MTG HARDWARE BY CUSTOMER NOT SUPPLIED S 2 SCHEDULE 40 PIPE BY CUSTOMER TANK TOP Figure 3 1 Sensor housing mounting 27 Petrotape Chemtape Gauging System 3321 Caution The sensor housing drainage hole must be kept clear of paint rust and other materials If the sensor housing is not properly installed the sensor housing may be flooded if the tanks are overfilled Water tight gas tight connections between the housing and the tank are critical To install the housing a Place a gasket customer supplied on the still pipe flange b Remove the housing cover set aside the four bolts and remove the filter and current transmitter located inside the housing c Orient the housing so that the field wire entry hole is easily accessed d Mount the sensor housing on top of the gasket e Bolt customer supplied the sensor housing in place 3 2 2 Sensor Installation Installing the sensor is accomplished more easily with two people While one person is handling the sensor shipping reel the other
46. tress or evidence of rough handling in transit 4 Keep the packaging material in case the equipment must be re turned 3 1 1 Claims for Damage If there is physical damage to the shipping carton or the equipment contact the carrier and JOWA USA Inc JOWA USA will arrange for repair or replacement of damaged equipment without waiting for settlement of the claim against the carrier 3 1 2 Returning Equipment A return authorization number is required from the factory before equipment is returned to JOWA USA Inc When returning equipment attach a tag to the equipment that has the following information Authorization number Original purchase order number Equipment model number Serial number if applicable Owner s name and address Required repair 25 Petrotape Chemtape Gauging System 3321 Pack any piece of equipment being returned in its original shipping container with packing material to protect its surfaces and then seal the container If the original shipping container is not available contact a freight forwarder for an appropriate container and packing material 3 1 3 Components The Petrotape and Chemtape Gauging Systems are usually shipped in two containers One box contains the sensor and the other box contains the remaining items Details are as follows Sensor Usually shipped on a reel very short sensor may be shipped straight Sensors are either packed one to a box or if three or mor
47. ws 1 Remove the cover from the washdown fitting 2 Make sure the baffle is in place 3 Connect the liquid supply hose 4 Using water or a mild detergent which is compatible with the sensor jacket system wash down for a minimum of three minutes using the parameters shown in Table 6 2 5 Remove the liquid supply hose and cap the washdown fitting Pressure 5 to 25 psi 35 to 175 kilopascals DO NOT exceed 15 psi 105 kilopascals if the wash down fitting does not have a baffle or diffuser 0 to 160 F 18 to 71 C 1 to 5 gallons minute 0 06 to 0 32 liters sec Table 6 2 Washdown Parameters 45 Petrotape Chemtape Gauging System 3321 46 Petrotape Chemtape Gauging System 3321 Section 7 Specifications Specifications for the Petrotape and Chemtape Gauging Systems are listed in the following tables 7 1 Sensor Specifications Table 7 1 lists the sensor specifications Operating temperature Petrotape 5 F to 225 F 15 to 107 C Chemtape with Hastelloy jacket 5 F to 225 F 15 to 107 C Chemtape with Teflon jacket 5 F to 180 F 15 to 82 C Wetted materials Hastelloy for Petrotape and Hastelloy jacketed Chemtape FEP Teflon for Teflon jacketed Chemtape Polypropylene head assembly Protective channel for Chemtape is polypropylene for Petrotape it is Nylon 11 12 Active helix Starts 6 3 inches 160 mm from sensor zero extends to approximately 1 6 inches 40 mm from sensor bottom end
48. y both types are the same Internally the T 800L contains only a level board while the T 800LT contains a level board and a temperature board The transmitter itself is sealed to protect the internal electronics from moisture or corrosive vapors The current transmitter is located inside the sensor housing A current transmitter is shown in Figure 1 5 Note If you have a wireless system please refer to the WRT manual M357 6 Petrotape Chemtape Gauging System 3321 Figure 1 5 Current Transmitter Still pipe customer supplied Protects the elongated portion of the sensor yet allows free movement of liquid to and from the sensor A typical stillpipe is shown in Section 2 Figure 2 1 1 2 Operational Overview The following sections describe the operation of the Petrotape and Chemtape Gauging Systems 1 2 1 Sensor The sensor is suspended vertically from the top to the bottom of a storage tank As liquid is introduced into the tank and covers the sensor the pressure of the liquid causes the sensor s sealed outer jacket to collapse This squeezes the helix against the gold strip causing a short The helix is shorted from the bottom end to a location just underneath the surface of the liquid but the wound helix above the liquid surface remains unshorted The sensor s gold plated base steel serves as the return path from the point of uppermost helix contact The unshorted resistance is the parameter by which the liquid level is measu
49. ystem The sensor and transmitter variations are summarized in Table 1 1 below Petrotape with level only PGS S T 800L detector temperature detector Chemtape with level only CGS S T 800L detector temperature detector Table 1 1 Petrotape Chemtape System Configurations 4 Petrotape Chemtape Gauging System M3321 Sensor Used to measure the liquid level The sensor hangs down into the tank and acts like an electronic dipstick Figure 1 2 illustrates a cut away view of the sensor The sensor structure consists of a stainless steel strip with a gold contact stripe down the center Film insulation is wrapped around the edges and the back A nichrome resistance helix wire is wound around this core The helix is gold plated allowing gold on gold contacting to occur The sensor is enclosed by a laser welded Hastelloy C276 or a heat sealed and compliant jacket of Teflon A channel has been added to surround and protect the edges but the total structure remains sufficiently flexible to be coiled on a one meter diameter reel for storage and shipping CORROSION RESTAN INSULATION HASTELLOY OR TEFLON WOUND RESISTIV H ROSION Sensor Filter Used to prevent moisture and other contaminates from entering the sensor and to equalize the vapor pressure within the sensor jacket The filter is a model PGS CGS SF7 and is located inside the sensor housing Figure 1 3 show
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