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HomeMy WebLinkAboutKing Cove BFU P&M Manual 2004King Cove Bulk Fuel Upgrade PROCEDURES & MAINTENANCE MANUAL INDEX System Description & Operating Procedures ....................................................Tab I 1.0 Fuel System Facility Description...................................................................... I-1 1.1 Daily Start Up Procedures ........................................................................ I-3 1.2 End of Day Shut-Down Procedures..........................................................I-3 2.0 Fuel Transfer Procedures 2.1 Fuel Barge Offloading Procedures............................................................ I-4 2.2 Power Plant Day Tank Filling Procedures................................................. I-5 2.3 Power Plant Day Tank Filling Troubleshooting ......................................... I-5 2.4 Bulk Transfer (Truck Loading) Procedures ............................................... I-6 2.5 Bulk Transfer (Truck Loading) Troubleshooting........................................ I-7 2.6 Marine Fueling Procedures....................................................................... I-7 2.7 Marine Fueling Troubleshooting................................................................ I-8 3.0 Periodic Maintenance Procedures 3.1 Monthly Inspection .................................................................................... I-9 3.2 Monthly Inventory Reconciliation ............................................................ I-10 3.3 Stormwater Removal .............................................................................. I-11 3.4 Filter Replacement & Strainer Cleaning..................................................I-11 3.5 Annual Pipeline Integrity Testing............................................................. I-11 Tank Capacity Charts..........................................................................................Tab II Old Power Plant Day Tank ..........................................................(2,000 gallons) Bulk Tanks (#1-#5).....................................................................(29,500 gallons) Old Power Plant Day Tank .........................................................(12,000 gallons) Equipment Suppliers & Service Instructions ...................................................Tab III Index of Materials, Vendors, & Service Providers Record Drawings ................................................................................................Tab IV 2007 Bulk Fuel Upgrade Record Drawings 2004 City Fueling System Record Drawings 2002 City Fill Pipeline Record Drawings Tank Fabrication Drawings (Bulk and New Power Plant) Tab I. System Description & Operating Procedures KING COVE BULK FUEL UPGRADE PROCEDURES & MAINTENANCE INFORMATION 1.0 FUEL SYSTEM FACILITY DESCRIPTION The City fuel system consists of: (1) a lined earthen berm secondary containment dike, (2) five horizontal tanks with related piping and pumps, (3) marine header and fill pipeline, (4) marine diesel fueling station, (5) bulk transfer (truck loading) area for diesel, (6) a manual fill daytank at the old power plant, and (7) a truck fill daytank at the new power plant. Gross storage capacity of the tank farm totals 147,500 gallons of diesel fuel. The old power plant daytank has capacity of 2,000 gallons, and the new power plant truck fill daytank has capacity of 12,000 gallons. Fuel is delivered to the tank farm by barge that moors at the deepwater dock and connects its hose to the fill pipeline header. Fuel is distributed at the bulk transfer area and transferred by pipeline to the old power plant day tank and to the marine fueling station. Fuel is truck delivered to the new power plant tank. The marine receiving pipeline was installed in 2002. In 2005 the bulk transfer area and marine fueling station were installed, and piping, pump, and old power plant daytank improvements were initiated. In 2007 a major renovation of the tank farm facility was completed; including replacing all existing bulk tanks with five new horizontal skid mounted tanks, a new lined earthen-berm dike, and a new concrete truck fill area. The existing fill pipeline and marine header, old power plant daytank, marine fueling station and associated piping and pumps remain in service. A separate power plant project provided the new 12,000-gallon daytank at the new power plant. Bulk Storage tank data is as follows: TANK NO. DIMENSIONS TYPE GROSS CAPACITY 1 11.5’Ø X 38’L HORIZONTAL, SINGLE WALL, STORAGE 29,5000 GALS. 2 11.5’Ø X 38’L HORIZONTAL, SINGLE WALL, STORAGE 29,5000 GALS. 3 11.5’Ø X 38’L HORIZONTAL, SINGLE WALL, STORAGE 29,5000 GALS. 4 11.5’Ø X 38’L HORIZONTAL, SINGLE WALL, STORAGE 29,5000 GALS. 5 11.5’Ø X 38’L HORIZONTAL, SINGLE WALL, STORAGE 29,5000 GALS. TOTAL 147,500 GALS. Tanks (1 thru 5) are single wall, horizontal, welded steel, skid-mounted U.L. 142 tanks set on concrete footer foundations. Each tank is equipped with two top- mounted manholes, emergency vent, pressure/vacuum whistle vent, clock gauge, and gauge hatch and bottom-mounted fill/withdrawal steel gate valve. The tank farm manifold piping is four-inch diameter welded steel equipped with isolation and check valves, stainless steel flex connections, and pressure relief. Pressure test connections are installed to facilitate integrity tests of all new buried pipe. Above ground piping is secured to the tank skids. New welded distribution piping extends from the fill/withdrawal manifold, over the impound dike, to a pump station located at the truck loading area. The pump station consists of a security enclosure that houses two, manually activated, centrifugal transfer pumps: TP-1 transfers fuel to the marine fueling station, TP-2 transfers fuel to the bulk transfer area. Each pump is equipped with isolation and check valves, flex connections, and pressure relief. Normally closed motor actuated valves are installed in the distribution piping to the marine fueling station and old power plant day tank. Pump control switches are located in the control panel on the security enclosure, at the marine fueling station, and at the bulk transfer hose stand. The day tank transfer pump (TP-3) is located inside the old power plant. An emergency pump shutoff switch is also located at the marine fueling station. Pump run timer switches automatically shut down the pumps after pre-set durations. All bulk storage tanks are within the diked impound that has a synthetic liner covered with gravel fill. The earthen dike is 2.5-feet high. The impound is sized for 115% of I-1 KING COVE BULK FUEL UPGRADE PROCEDURES & MAINTENANCE INFORMATION the volume of the largest tank (29,500-gallons) plus 17-inches of freeboard for precipitation. Marine Fill Pipeline The marine fill pipeline delivers all fuel to the tank farm. It is a six-inch diameter welded steel pipe that extends about 2,600 feet from the deep-water dock to the tank farm. The pipe is buried except where it crosses a bridge to the deep-water dock. Buried pipe is HDPE coated and cathodically protected with dielectric flanges and sacrificial anodes. The receiving header on the dock is a capped camlock fitting with six-inch check and ball valves secured to steel pipe supports. A steel 84-gallon drip pan (spill box) is positioned beneath the header. Marine Fueling Station The marine fueling station is located at the small boat harbor bulkhead, approximately 600 feet east of the tank farm. A buried three-inch diameter welded steel pipe runs about 720 feet from the fueling station to the transfer pump (TP-1) at the tank farm. The pipe is HDPE coated and cathodically protected with dielectric flanges and sacrificial anodes. The fueling station consists of a wood frame security enclosure with aluminum siding that houses the pump control switch, emergency pump shutoff switch, a custody transfer meter, fire extinguisher, and hose reel with 100 feet of two-inch fuel rated hose with interchangeable one and two-inch bulk transfer nozzles. Transfer rate is approximately 80 gpm with the large nozzle. (Refer to 2004 design drawings.) Bulk Transfer Area The bulk transfer area is located between the tank farm and warehouse/power plant. The transfer area is a drive-through 24’ x 33’ concrete pad with adjacent hose stand and pump box. The concrete pad is surrounded by an integral concrete curb on three sides, and drains into the tank farm impoundment. The hose stand is located adjacent to the pump station. It consists of isolation and check valves, custody transfer meter, grounding reel, pressure relief, pump on/off switch, and 35 feet of 1¼-inch hose with safety break and automatic shutoff nozzle. Transfer rate is approximately 50 gpm. (Refer to 2007 record drawings.) Old Power Plant Pipeline, Day Tank The old power plant day tank is an existing 2,000 gallon, skid-mounted, double wall, U.L. 142, horizontal tank. It is equipped with top-mounted appurtenances including a fill connection with isolation, and check valves and float-type fill limiter (95%), remote-reading level sensor, emergency vents, manhole, gauge hatch, water draw, and secondary tank monitoring bung. The remote reading liquid level gauge is in the old power plant office. Supply and return piping extend from the top of the tank into the adjacent power plant. A normal pressure vacuum vent with high-level whistle alarm (90%) is to be installed on the tank to comply with EPA requirements for alternative secondary containment. The pipeline to the old power plant day tank is two-inch diameter welded steel buried pipe approximately 320 feet long. The pipe is HDPE coated and cathodically protected. The day tank is filled from the day tank control panel located in the plant office, which energizes the transfer pump TP-3 at the power plant and opens the actuator valve at the pump station at the tank farm. A high-level float switch in the day tank de-energizes the pump at 90% of capacity, and a critical high switch at 95% of capacity terminates power to the pump and activates visual and audible alarms. A pump run timer switch automatically shuts down the pump after a pre-set duration. Maximum tank fill rate is approximately 20 gpm. (Refer to 2004 design drawings for site plan/tank installation and 2007 record drawings for electric control panel drawings.) I-2 KING COVE BULK FUEL UPGRADE PROCEDURES & MAINTENANCE INFORMATION All pumps are labeled with color-coded tags indicating the pump designation, and function as indicated in the schedule on Sheet M1 of the 2007 record drawings. Electrical power for the tank farm is provided from an underground service to a meter base with main disconnect located on the north exterior wall of the warehouse/power plant. Above grade conduit runs from the meter base to the adjacent load center with circuit breakers. Underground conduit runs to the tank farm control panel mounted on the pump station box inside the tank farm fenced enclosure. Electrical plans and control panel schematics are shown on Sheets E1- E7 of the 2007 record drawings. Spare components for the control panel were provided and are located in the old power plant. Security The tank farm, bulk transfer area, and old power plant day tank are enclosed by chain link fence. All access gates are to be closed and locked when the area is unattended. All bottom-mounted tank valves are to be closed and locked when transfers are not in progress. Pump control panels are in security enclosures and in the plant office, which are to be locked when unattended. Pump switches at the bulk transfer area and marine fueling station are to be locked when unattended. The tank farm, bulk transfer area, and old power plant day tank are illuminated by lights on the warehouse/power plant building. Portable fire extinguishers are positioned near the entrance gates to the bulk transfer area, at the pump station, near the old power plant day tank, and at the marine fueling station. No smoking placards and warning signs are posted. Basic operating procedures are posted at the bulk transfer area. Spill response equipment and supplies are stored in the warehouse and in a 20' steel storage container adjacent to the marine fueling station. 1.1 Daily Start-Up Procedures: 1) Unlock gate to enter and inspect the tank farm. Visually inspect for leaks, spills, vandalism, or damage. Confirm main tank valves are closed and locked. Observe stormwater level in dike and remove as required. See Section 3.3 for procedure. 2) Check fuel level in bulk tank(s) to be used for fueling operations. 3) Verify fire extinguishers are in place and charged. Exit the tank farm and lock gate. 4) See Sections 2.2, 2.4 and 2.6 for operating procedures. 1.2 End of Day Shut-Down Procedures: 1) Unlock gate to enter and inspect the tank farm. Visually inspect for leaks, spills, vandalism, or damage. 2) On the control panel verify that the "MARINE FUELING CONTROL POWER" and “TRUCK LOADING CONTROL POWER” switches are turned to the “OFF” position. Confirm all main tank valves are closed and locked. 3) Exit the tank farm and lock gate. I-3 KING COVE BULK FUEL UPGRADE PROCEDURES & MAINTENANCE INFORMATION 2.0 FUEL TRANSFER PROCEDURES 2.1 Fuel Barge Offloading Procedures: 1) Prior to the first scheduled barge delivery of the season perform and document a static liquid pressure test of the marine fill pipeline. Coast Guard regulations (33 CFR, Part 156.170(4)) call for a static liquid pressure test at least 1½ times the pipeline working pressure maintained for 10 minutes, plus examination time for aboveground piping. 2) Review the U.S. Coast Guard Operations Manual, SPCC Plan, and the Facility Response Plan. The plans and all records (inspections, pressure tests, stormwater drainage logs, etc.) must be available for agency inspection. Ensure that all spill response supplies are in place. 3) Ensure that all required personnel are available and prepared. 4) Inspect the tanks, piping, and marine header. Remove water from the drip pan at the marine header. Remove stormwater from the dike, refer to Section 3.3. Verify that all fire extinguishers are in place and charged. Verify that all tank and fill pipeline valves are closed. 5) Dip all tanks and verify gauge readings. Use a water cut paste to determine water level in each tank. Use the Tank Capacity Charts following this section to determine the quantity of fuel in each tank and the maximum fill volume. Single wall (bulk storage) tanks may not be filled above the 95% level. Develop a receiving plan that lists the volume to be delivered to each tank in sequential order. 6) Conduct a pre-transfer meeting with barge personnel. Confirm receiving plan, topping off procedures, and emergency shutdown. Test radios and confirm communication procedures. Complete, sign, and obtain a copy of the Declaration of Inspection (DOI). 7) Remove quick connect coupling cap at marine header and allow barge personnel to connect their fuel hose. After barge personnel have pressure tested hose connections, open valve at marine header. 8) Open tank farm fill manifold ball valve labeled “NORMALLY CLOSED, MAIN FILL, OPEN ONLY FOR BARGE DELIVERY”. Confirm that all other valves connected to fill manifold are closed. 9) Upon command from barge personnel, open main valve on the first bulk tank to receive fuel and signal barge personnel to begin pumping. Continuously monitor fuel transfer and tank fuel level. Slow down pumping rate when fuel level reaches 90% of capacity and stop when level reaches 95% of capacity. Close and lock tank main valve. 10) Repeat previous step for each tank in order of receiving plan. 11) Visually inspect the hose connections, marine header, pipelines, and tank farm continuously for the first hour of delivery and every half hour thereafter. Verify radio communication with barge every half hour. 12) Upon completion of fuel transfer close and lock “NORMALLY CLOSED, MAIN FILL, OPEN ONLY FOR BARGE DELIVERY” valve at tank farm and valve at marine header. After barge personnel remove hoses, replace quick connect coupling cap. 13) Allow a minimum 30-minute relaxation period for static electricity to dissipate before gauging tanks or beginning transfer operations. Allow product to settle for a minimum of two days prior to dipping with water cut paste. Drain off residual water prior to freeze up. Removal of water must be performed by a qualified technician with proper equipment. I-4 KING COVE BULK FUEL UPGRADE PROCEDURES & MAINTENANCE INFORMATION 2.2 Old Power Plant Day Tank Filling Procedures (NOTE: This information applies to the old power plant daytank, only. Refer to the New Power Plant O&M Manual for operating, maintenance, and troubleshooting procedures for the 12,000-gallon truck fill daytank): 1) Check old power plant day tank level daily and fill when level is below 3'-0". 2) Go to tank farm and select bulk tank from which fuel is to be transferred. Check tank fuel level and use Tank Capacity Charts (Tab II) to verify quantity of fuel in tank. Do not attempt to transfer from tank if fuel level is less than 8". Open main valve on tank - all other bulk tank valves should be closed. 3) Go to the day tank and open the manual valve, labeled: “NORMALLY CLOSED, OPEN ONLY FOR FILLING DAY TANK” 4) Confirm Pneumercator E700-1 Level Monitor in Operator’s Room indicates same fuel level as clock gauge on tank. 5) At the day tank control panel, located in Operator’s Room adjacent to Pneumercator panel, turn the “FUEL TRANSFER SYSTEM” switch to the “ON” position and verify that the green power lamp is illuminated. Press the green “START & TIME-OUT RESET” button to begin filling the day tank. The actuator valve (square green valve in pump box) should stroke open and the pump should begin running. The green “DAY TANK PUMP ON” and amber "ACTUATOR VALVE OPEN” lamps on the day tank control panel should illuminate. 6) Monitor tank levels continuously. Make sure the bulk tank at the tank farm does not run empty during transfer. When the day tank level reaches 4'-6" (90%, 1,830+/- gallons) press the “STOP” button on the day tank control panel. Verify that the green “DAY TANK PUMP ON” and amber "ACTUATOR VALVE OPEN” lamps turn off. Turn the “FUEL TRANSFER SYSTEM” switch to the “OFF” position. 7) Go to the day tank and close the manual valve labeled: “NORMALLY CLOSED, OPEN ONLY FOR FILLING DAY TANK”. Return to the tank farm and close and lock main valve on bulk tank – if bulk tank is not in use for marine fueling or bulk transfer/truck loading operations. Note that all other daytank piping valves are to remain open for pressure relief. 8) The control system has a timer relay that automatically turns off the transfer pump after 120 minutes of operation. If the day tank is not full when the timer shuts off, another cycle can be started by repeating step 5. 9) If the transfer pump does not start or fuel does not flow into the day tank see Section 2.3 for troubleshooting instructions. 2.3 Old Power Plant Day Tank Filling Troubleshooting: 1) Check the control panel and verify the “FUEL TRANSFER SYSTEM” switch is in the “ON” position and the green lamp is illuminated. If the green lamp does not turn on check the disconnect switch and fuses located inside the control panel. 2) If the green lamp still does not come on, check the circuit breaker at the load center inside the fuel shed where pump TP-3 is located. If the breaker is on and there is no power to the day tank panel, the problem is most likely a fault in the wiring. Contact a qualified technician for service. 3) The control system is designed to automatically shut off the transfer pump TP-3 when the fuel level in the day tank reaches the full level. When this occurs, this is indicated by illumination of the amber lamp “TANK FULL” on the day tank control panel. Terminate transfer operations, press the “STOP” button on the day tank control panel, turn the “FUEL TRANSFER SYSTEM” switch to the “OFF” position, and close and lock valves. I-5 KING COVE BULK FUEL UPGRADE PROCEDURES & MAINTENANCE INFORMATION 4) The control system also has a lockout feature that shuts off the transfer pump in the event that the day tank is overfilled. This is indicated by illumination of the red lamp “OVERFILL ALARM” on the day tank control panel and activation of the exterior alarm horn/strobe. In the event of an overfill alarm condition immediately terminate transfer operations, press the “STOP” button on the day tank control panel, and close and lock the day tank fill valve. To silence the alarm, turn the “FUEL TRANSFER SYSTEM” switch to the “OFF” position. The fuel level must be lowered below the full level before a new fill cycle can be initiated. Prior to initiating a new fill cycle, troubleshoot and correct the overfill problem. 5) If the transfer pump runs but no fuel is flowing verify that the valves at the bulk tank, actuator valve, transfer pump, and day tank are open. Verify that the fuel level in the selected bulk tank is over 8". Verify that the actuator valve at the pump box opens. When the start button is pressed the actuator valve should begin to open. The shaft of the valve will rotate 90 degrees in approximately 10 seconds. There is a position indicator on the base of the actuator. If an actuator valve does not actuate, it can be manually operated (opened and closed) using a wrench for emergency operation. The actuator valve will need to be serviced by a qualified technician or replaced. 6) If fuel flow is slow, replace the filter elements in the pipeline filter (located behind the pump box). If fuel flow does not improve, verify that the strainer at the day tank is clean. See Section 3.4 for procedures. 7) If fuel flow is still slow check the fill limiter valve for proper operation. The fill limiter is located inside the day tank where the fill pipe enters through the top. Turn off transfer pump and close the valve at the day tank. Disconnect the piping at the flanged check valve being careful to catch all drips. Unscrew the 4" bushing to remove entire drop tube assembly. Verify that float and linkage are free to move up and down, and that the valve pilot hole is not plugged. Repair or replace as required, re-assemble, open valves and start pump. Verify there are no piping leaks and that the fill limiter shuts off flow at 4’-10” (95%). 8) Under normal operation when the transfer pump is started the green indicator lamp on the day tank control panel will illuminate. When the lamp illuminates the pump motor starter (contactor) inside the control panel should close making a solid "click" sound. If this occurs and the pump motor does not run the problem is most likely a failed pump or a fault in the wiring. Contact a qualified technician for service. 9) See the Sequence of Operations on Sheet E7 for additional troubleshooting information. See Section 3.4 for filter replacement and strainer cleaning procedures. 2.4 Bulk Transfer (Truck Loading) Procedures: 1) The bulk fuel transfer area is provided to allow portable tanks and tanker trucks to be filled with diesel fuel. Transfer pump TP-2 is used for bulk transfers. 2) Remove all storm water from the Bulk Transfer Area containment dike. See Section 3.3 for procedure. 3) Unlock and open gate. Park tanker truck or portable tank completely within the containment area. Turn off motor and chock wheels. Attach static grounding wire to the tank being filled. 4) Turn “TRUCK LOADING CONTROL POWER” switch on the control panel to the “ON” position and verify that the green power lamp is illuminated. 5) Select bulk tank from which fuel is to be transferred. Check tank fuel level and use Tank Capacity Charts (Tab II) to verify quantity of fuel in tank. Do I-6 KING COVE BULK FUEL UPGRADE PROCEDURES & MAINTENANCE INFORMATION not attempt to transfer from tank if fuel level is less than 8". Open main valve on tank. All other bulk tank valves should be closed. 6) Stretch out hose and place nozzle into tank being filled. Unlock and open the valve on the hose stand (located on back of the hose stand box). Reset meter to zero. Unlock on/off switch located on the pump box and turn switch to the on position. 7) Squeeze the handle on the bulk fuel nozzle to begin transfer. Monitor transfer continuously. Keep nozzle in contact with tank fill opening while fueling. Stop filling portable tank at a level sufficiently below the top to allow for movement during transport. 8) The control panel has a timer relay that automatically turns off the transfer pump after 30 minutes of operation. If the portable tank is not full when the timer shuts off, another cycle can be started by turning the on/off switch located on the pump box off and then back on. 9) After fuel transfer is complete turn off and lock switch, close and lock valve at hose stand, recoil hose and hang nozzle on hose stand, and remove static grounding wire. Close and lock main valve on tank if bulk tank is not in use for power plant day tank or bulk transfer/truck loading operations. Turn “TRUCK LOADING CONTROL POWER” switch on the control panel to the “OFF” position and verify that the green power lamp turns off. After pulling tank out, lock all fence gates. 10) If the transfer pump does not start or fuel does not flow from the nozzle see Section 2.5 for troubleshooting instructions. 2.5 Bulk Transfer (Truck Loading) Troubleshooting: 1) Check the control panel and verify the “TRUCK LOADING CONTROL POWER” switch is in the “ON” position and the green lamp is illuminated. If the green lamp does not turn on check the disconnect switch located inside the control panel, the main disconnect circuit breaker at the electric meter on the north end of the power plant/warehouse, and the circuit breakers at the load center adjacent to the electric meter. 2) If the transfer pump runs but no fuel is flowing verify that the valves at the hose stand, bulk tank, and transfer pump are open. Verify that the fuel level in the selected bulk tank is over 8". 3) If fuel flow is slow, verify that the fuel filter located at the back of the pump box is clean. See Section 3.4 for procedure. 4) If flow is slow during winter operations check the nozzle for frost. If the nozzle is frozen turn off the on/off switch, close and lock valve at hose stand, remove the nozzle - being careful to catch all drips, place nozzle in warm space to thaw and dry thoroughly, reinstall nozzle, open valve, and resume Bulk Transfer Procedures. 5) Under normal operation when the on/off switch is turned to the on position the green “PUMP TP-2 ON” lamp should illuminate at the control panel. When the lamp illuminates the pump motor starter (contactor) inside the control panel should close making a solid "click" sound. If this occurs and the pump motor does not run the problem is most likely a failed pump or a fault in the wiring. Contact a qualified technician for service. 6) See the Sequence of Operations on Sheet E5 for additional troubleshooting information. 2.7) Marine Fueling Procedures: 1) The marine fueling system is designed for fueling fishing vessels with diesel fuel. Transfer pump TP-1 is used for marine fueling. I-7 KING COVE BULK FUEL UPGRADE PROCEDURES & MAINTENANCE INFORMATION 2) Conduct annual static liquid pressure test of the pipeline to the marine fueling station. See Fuel Barge Offloading Procedures above. 3) Complete a Declaration of Inspection form (DOI) for all vessels that have fuel storage capacity of 250 barrels or more and maintain a copy with the fuel sales receipt. Blank DOI forms are to be retained at the Marine Fueling Station. 4) Go to tank farm and select bulk tank from which fuel is to be transferred. Check tank fuel level and use Tank Capacity Charts (Tab II) to verify quantity of fuel in tank. Do not attempt to transfer from tank if fuel level is less than 8". Open main valve on tank. All other bulk tank valves should be closed. 5) Turn “MARINE FUELING CONTROL POWER” switch on the control panel at the tank farm to the “ON” position and verify that the green power lamp is illuminated. A remote indicator panel is also located inside the marine fueling station. Verify the green “MARINE FUELING CONTROL POWER” lamp on the indicator panel is also illuminated. 6) The hose reel at the marine fueling station is equipped with both 1” and 2” nozzles and dry-connect fitting. Use the 1” nozzle for “low” fuel transfer rate and the 2” nozzle for “high” fuel transfer rate. Select and install proper nozzle for vessel being fueled. 7) Stretch out hose and place nozzle into vessel fuel tank. Unlock and open the valve at the hose reel labeled: “NORMALLY CLOSED, OPEN ONLY FOR MARINE FUELING”. Reset meter to zero. Unlock on/off switch located on the back wall and turn switch to the “on” position. The actuator valve (square green valve in pump box) should stroke open and the pump TP-1 should begin running. The green “PUMP TP-1 ON” and amber "ACTUATOR VALVE OPEN” lamps at both the tank farm control panel and remote indicator panel at the marine fueling station should illuminate. 8) Squeeze the handle on the bulk fuel nozzle to begin transfer. Monitor transfer continuously. Do not top off vessel tank. In the event of an emergency, actuate the Emergency Pump Shutoff Switch located on the exterior wall of the marine fueling station to the left of the door. 9) The control panel has a timer relay that automatically turns off the pump TP-1 after 30 minutes of operation. When the timer times-out, the red “TP-1 TIME- OUT” lamp on the remote indicator panel will illuminate. If vessel fueling is not complete when the timer shuts off, another cycle can be started by turning the on/off switch on the back wall of the marine fueling station “off” and then back on. 10) After vessel fueling is complete turn off and lock switch, close and lock valve at hose reel, recoil hose and hang nozzle. Verify the green “PUMP TP-1 ON” and amber "ACTUATOR VALVE OPEN” lamps at the remote indicator panel turn off. 11) When marine fueling has been completed for the day, secure and lock the marine fueling station and return to the tank farm and close and lock main valve on tank. Turn “MARINE FUELING CONTROL POWER” switch on the control panel to the “OFF” position and verify that the green power lamp turns off. 12) If the transfer pump does not start or fuel does not flow from the nozzle confirm the “Emergency Pump Shutoff” button located adjacent to the marine fueling station door has not been actuated. If fuel still does not flow see Section 2.7 for troubleshooting instructions. 2.7 Marine Fueling Troubleshooting: 1) Check the control panel and verify the “MARINE FUELING CONTROL POWER” switch is in the “ON” position and the green lamp is illuminated. If I-8 KING COVE BULK FUEL UPGRADE PROCEDURES & MAINTENANCE INFORMATION the green lamp does not turn on check the disconnect switch located inside the control panel, the main disconnect circuit breaker at the electric meter on the north end of the power plant/warehouse, and the circuit breakers at the load center adjacent to the electric meter. After confirming the control power is on at the control panel, verify the green “MARINE FUELING CONTROL POWER” lamp on the remote indicator panel is also illuminated. If there is no control power at the control panel or remote indicator panel the problem is most likely a fault in the wiring. Contact a qualified technician/journeyman electrician for service. 2) If there is control power and the transfer pump TP-1 does not run, confirm the Emergency Pump Shutoff Switch has not been actuated (pull it out). If TP-1 runs but no fuel is flowing verify that the valves at the hose reel, bulk tank, and transfer pump are open. Verify that the actuated ball valve is open, and the fuel level in the selected bulk tank is over 8". Verify that the actuator valve at the pump box opens. The shaft of the valve will rotate 90 degrees in approximately 10 seconds. There is a position indicator on the base of the actuator. If an actuator valve does not actuate, it can be manually operated (opened and closed) using a wrench for emergency operation. The actuator valve will need to be serviced by a qualified technician or replaced. 3) If fuel flow is slow, replace the filter elements in the pipeline filter (located behind the pump box). If fuel flow does not improve, verify that the strainer at the custody transfer meter is clean. See Section 3.4 for procedures. 4) If flow is slow during winter operations check the nozzle for frost. If the nozzle is frozen turn off the on/off switch, close and lock valve at hose stand, remove the nozzle - being careful to catch all drips, place nozzle in warm space to thaw and dry thoroughly, reinstall nozzle, open valve, and resume Marine Fueling Procedures. 5) Under normal operation when the on/off switch is turned to the on position the green “PUMP TP-1 ON” lamp should illuminate at the control panel. When the lamp illuminates the pump motor starter (contactor) inside the control panel should close making a solid "click" sound. If this occurs and the pump motor does not run the problem is most likely a failed pump or a fault in the wiring. Contact a qualified technician/journeyman electrician for service. 6) See the Sequence of Operations on Sheet E5 for additional troubleshooting information. 3.0 PERIODIC MAINTENANCE PROCEDURES 3.1 Monthly Inspection: 1) Visually inspect all security fencing and barbed wire at the tank farm and old power plant day tank. Verify that chain-link fabric and barbed wire are tight. Verify that all gates are operational and are locked closed. 2) Verify that area lights at the tank farm, truck loading area, marine fueling station, and day tank are operational. Verify that all fire extinguishers are in place and fully charged. 3) Visually inspect dike and liner. Look for exposed sections of membrane liner and cover with gravel as required. Clean dike of trash and foreign debris. Check stormwater level in dike and remove as required. See Section 3.3 for procedure. 4) Visually inspect tanks for leaks or damage. Repair of tanks must be performed by a qualified technician with proper equipment, in accordance with STI SP001. Visually inspect all tank foundations and verify they are sound. Repair any failed foundations. I-9 KING COVE BULK FUEL UPGRADE PROCEDURES & MAINTENANCE INFORMATION 5) Visually inspect all gauges, vents, and tank appurtenances for proper operation. Repair or replace any damaged or leaking component. 6) Visually inspect all tanks and above grade piping for corrosion. Remove surface rust and loose paint with a wire brush and apply touch-up paint in accordance with manufacturer instructions. Painting must be performed in warm and dry weather (above freezing, no rain). 7) Verify valves open and close completely and are in good condition. Replace any worn or non-operational valves. Verify all normally closed valves are locked in the closed position. Valves that should be normally closed include bulk tank main fill valves, water draw valves, and those ball valves that are tagged normally closed. See valve tag schedule on Sheet M1. Verify that plugs are in place and tight on all water draw valves and strainers. 8) Visually inspect valves, pumps, meters, strainers, filters, and pipe joints for evidence of leaks. Repair or replace any leaking part or piping connection. Install new gaskets on any flanged joints that are taken apart using spiral wound metallic or dielectric flange gaskets to match original. Clean threads and use oil compatible pipe joint compound (Hercules Grip) on all threaded joints that are taken apart. 9) Visually inspect all flex connectors for damage or leaks. Replace any damaged or leaking flex connectors. When ordering replacement flex connectors require vendor to pressure test flex prior to shipping. 10) Visually inspect pipe and conduit supports. Piping should be supported securely. Tighten or replace any loose, missing, or damaged pipe straps, pipe clamps, or timber sleepers. 11) Visually inspect all conduit joints, fittings, and junction boxes and verify that all fitting covers are tight. Check all flexible conduit for cracks and damage. Check control panels for damage. Verify that control panel doors are closed tight. Verify operation of all switches, buttons, and lamps. Control panel spare parts are stored in the bottom of the control panel. Repair of electrical components must be performed by a qualified technician (journeyman electrician). 12) Visually inspect the truck loading and marine fueling station hoses, nozzles and accessories. Look for leaks or damage and replace any worn or non- operational accessory. Replace any burnt out lights in the pump control panel and the marine fueling station indicator panel. 13) Verify marine header quick connects are capped and valves are locked closed. 14) Visually inspect the day tank and accessories. Look for leaks, damage, or alarm lights. Replace any burnt out lights on the day tank control panel. 15) Inventory spill response supplies and spare parts and replace used or missing items. 16) Verify that Facility Response Plan, Operations Manual, and SPCC Plan are in place and up to date. Complete “VISUAL INSPECTION MONTHLY CHECKLIST” form in the Appendix of the SPCC Plan. 3.2 Monthly Inventory Reconciliation: 1) Reconcile fuel inventory every month or more frequently if desired. 2) Read fuel level indicated on tank gauge and record for each tank. Take all readings at one time. Use the Tank Capacity Charts following this section to determine the current quantity of fuel in each tank and total the quantity of product on hand. I-10 KING COVE BULK FUEL UPGRADE PROCEDURES & MAINTENANCE INFORMATION 3) Check prior month's records for fuel on hand. Add any fuel deliveries received and subtract all fuel sold or consumed from the prior month total. Compare this to the current total. Any significant discrepancy may indicate the possibility of a spill or theft. Report discrepancies to the facility manager immediately. 3.3 Stormwater Removal: 1) Storm water that accumulates in the tank farm dike and the bulk transfer (truck loading) area must be removed frequently. At a minimum, remove water after every heavy rainfall and any time the depth of accumulated water exceeds 2". 2) Only trained facility operators are to perform stormwater removal. All stormwater removal activities are to be monitored continuously. Remove water only during hours of daylight. 3) Prior to removing storm water from diked areas, read Section III, Paragraph “B”, “Facility Drainage”, of the Spill Prevention Control and Countermeasure (SPCC) Plan. 4) Conduct a thorough visual inspection of accumulated water to ensure the release will not cause a harmful discharge as defined by 40 CFR Part 110 (any visible sheen) and to ensure compliance with applicable water quality standards. Remove any visible oil sheen with sorbents prior to draining. Properly dispose of all used sorbents. 5) Stormwater may be removed by using a portable dike pump placed outside of the dike with suction and discharge hoses. Alternatively, water may be removed with a siphon by filling a hose. Discharge stormwater over the dike to facility property adjacent to the tank farm. Verify that hose discharge does not cause erosion of the facility dike or pad. Use splash blocks as required. 6) Upon completion of removal complete the “TANK FARM IMPOUND AREA – STORMWATER DRAIN LOG” found in the Appendix of the SPCC Plan. Record the date, the time draining was started and completed, and confirmation by the operator that no oil sheen was discharged. 3.4 Filter Replacement and Strainer Cleaning: 1) The pipeline filter is located behind the pump box and filters all fuel to the day tank, truck loading area and marine fueling station. The filter contains water blocking elements that provide freeze protection for the underground pipelines. The elements should be changed at a minimum every fall after freeze up. More frequent replacement may be required if pumping rate slows down significantly. Cease all transfer operations. Close valves on suction side of transfer pumps TP-1 and TP-2. Close valves labeled "NORMALLY OPEN, CLOSE ONLY FOR SERVICING PUMP/FILTER/ACTUATOR VALVE" near filter. Drain fuel from filter housing through drain valve being careful to catch all drips. Unscrew filter top bolts and remove element being careful to remove gasket. Make sure replacement units are 30 micron water absorbing elements equal to the original units. Install new element, fill canister with clean fuel, install new Buna-N cover gasket, and bolt on canister top. Open valve labeled "NORMALLY OPEN, CLOSE ONLY FOR SERVICING PUMP/FILTER/ACTUATOR VALVE" near filter and valves on suction side of transfer pumps. Perform trial transfer operation using Bulk Transfer area with portable tank (55-gallon drum) in order to bleed air from system and check for leaks. Resume normal transfer operations. 2) The piping system has strainers located at the top fill connection on the day tank, and at the custody transfer meters. If fuel flow is slow the strainer screen(s) may be clogged. Cease transfer operations. Close valve on upstream side of strainer. Remove the plug and open the drain valve on the bottom of the strainer being careful to catch all drips in a bucket. Unbolt the I-11 KING COVE BULK FUEL UPGRADE PROCEDURES & MAINTENANCE INFORMATION I-12 3.5 Annual Pipeline Integrity Testing: 1) Pressure testing must be performed by a qualified technician with proper equipment. See Tab III for a list of Contractors. Obtain a written pressure test record from the Contractor and file copies in the U.S. Coast Guard Marine Transfer Operations Manual (Ops Manual) and the E.P.A. Spill Prevention Control and Countermeasures Plan (SPCC Plan) or in another secure location (permanent file). 2) U.S. Coast Guard regulations require any marine delivery (fill and marine fueling piping) outside of the secondary containment dike to be pressure tested annually. At a minimum the fill pipeline needs to be tested from the marine header to the first valve within the secondary containment dike, and the marine fueling pipeline needs to be tested from the marine fueling station to the pump station box. 3) In order to comply with the requirements of the EPA SPCC plan, day tank piping outside of the secondary containment dike is also required to be pressure tested annually. The daytank pipeline needs to be tested from the daytank main fill valve to the pump station box. 4) All piping requiring testing should be tested each spring prior to receiving new fuel deliveries. Additional testing may be required when leaks are observed, piping is damaged, or significant repairs or alterations are made. 5) When pressure testing piping take steps to protect pumps, meters, filters, and hoses from the high pressure involved. Close isolation valves and/or blind flange piping as required. Remove the pressure relief valve (PRV) from each section being tested and blind flange for test. Upon completion of testing relieve pressure, remove blind flanges, re-install pressure relief valves, and open valves. Install new gaskets on any flanged joints that are taken apart using spiral wound metallic or dielectric flange gaskets to match original. Clean threads and use oil compatible pipe joint compound (Hercules Grip) on all threaded joints that are taken apart. Tab II. Tank Capacity Charts 4 in. 2 in. Gross Volume = Volume Volume Volume 0 ft. 0 in. 0 gal. 4 ft. 0 in. 1,636 gal. 1 in. 7 gal. 1 in. 1,671 gal. 2 in. 19 gal. 2 in. 1,704 gal. 3 in. 35 gal. 85% 3 in. 1,737 gal. 4 in. 53 gal. 4 in. 1,769 gal. 5 in. 74 gal. 5 in. 1,801 gal. 6 in. 96 gal. 90% 6 in. 1,830 gal. 7 in. 121 gal. 7 in. 1,859 gal. 8 in. 147 gal. 8 in. 1,887 gal. 9 in. 174 gal. 9 in. 1,913 gal. 10 in. 203 gal. 95% 10 in. 1,937 gal. 11 in. 233 gal. 11 in. 1,960 gal. 1 ft. 0 in. 264 gal. 5 ft. 0 in. 1,980 gal. 15% 1 in. 296 gal. 1 in. 1,999 gal. 2 in. 329 gal. 2 in. 2,014 gal. 3 in. 363 gal. 3 in. 2,027 gal. 4 in. 398 gal. 4 in. 2,033 gal. 5 in. 433 gal. 6 in. 469 gal. 7 in. 506 gal. 8 in. 543 gal. 9 in. 581 gal. 10 in. 619 gal. 11 in. 657 gal. 2 ft. 0 in. 696 gal. 1 in. 736 gal. 2 in. 775 gal. 3 in. 815 gal. 4 in. 855 gal. 5 in. 896 gal. 6 in. 936 gal. 7 in. 976 gal. 8 in. 1,017 gal. 9 in. 1,057 gal. 10 in. 1,098 gal. 11 in. 1,138 gal. 3 ft. 0 in. 1,178 gal. 1 in. 1,218 gal. 2 in. 1,258 gal. 3 in. 1,298 gal. 4 in. 1,337 gal. 5 in. 1,376 gal. 6 in. 1,415 gal. 7 in. 1,453 gal. 8 in. 1,490 gal. 9 in. 1,528 gal. 10 in. 1,564 gal. 11 in. 1,600 gal. Depth Depth Depth KING COVE 2,000 GALLON - OLD POWER PLANT DAY TANK Diameter = 5 ft.2,033 gal.Length = 12 ft. 6 in. 0 in. Gross Volume = Volume Volume Volume 0 ft. 0 in. 0 gal. 4 ft. 0 in. 9,132 gal. 8 ft. 0 in. 21,927 gal. 1 in. 31 gal. 1 in. 9,392 gal. 1 in. 22,177 gal. 2 in. 87 gal. 2 in. 9,654 gal. 2 in. 22,425 gal. 3 in. 160 gal. 3 in. 9,916 gal. 3 in. 22,671 gal. 4 in. 245 gal. 4 in. 10,180 gal. 4 in. 22,916 gal. 5 in. 342 gal. 5 in. 10,444 gal. 5 in. 23,158 gal. 6 in. 448 gal. 6 in. 10,710 gal. 6 in. 23,399 gal. 7 in. 564 gal. 7 in. 10,976 gal. 7 in. 23,637 gal. 8 in. 687 gal. 8 in. 11,243 gal. 8 in. 23,873 gal. 9 in. 818 gal. 9 in. 11,511 gal. 9 in. 24,106 gal. 10 in. 956 gal. 10 in. 11,780 gal. 10 in. 24,337 gal. 11 in. 1,101 gal. 11 in. 12,049 gal. 11 in. 24,566 gal. 1 ft. 0 in. 1,251 gal. 5 ft. 0 in. 12,319 gal. 9 ft. 0 in. 24,792 gal. 1 in. 1,408 gal. 1 in. 12,589 gal. 1 in. 25,016 gal. 2 in. 1,570 gal. 2 in. 12,860 gal. 85% 2 in. 25,236 gal. 3 in. 1,737 gal. 3 in. 13,131 gal. 3 in. 25,454 gal. 4 in. 1,909 gal. 4 in. 13,403 gal. 4 in. 25,668 gal. 5 in. 2,085 gal. 5 in. 13,675 gal. 5 in. 25,880 gal. 6 in. 2,267 gal. 6 in. 13,947 gal. 6 in. 26,088 gal. 7 in. 2,452 gal. 7 in. 14,219 gal. 7 in. 26,293 gal. 8 in. 2,642 gal. 8 in. 14,491 gal. 8 in. 26,494 gal. 9 in. 2,836 gal. 9 in. 14,764 gal. 90% 9 in. 26,692 gal. 10 in. 3,034 gal. 10 in. 15,036 gal. 10 in. 26,885 gal. 11 in. 3,235 gal. 11 in. 15,309 gal. 11 in. 27,075 gal. 2 ft. 0 in. 3,440 gal. 6 ft. 0 in. 15,581 gal. 10 ft. 0 in. 27,261 gal. 1 in. 3,648 gal. 1 in. 15,853 gal. 1 in. 27,442 gal. 2 in. 3,859 gal. 2 in. 16,125 gal. 2 in. 27,619 gal. 3 in. 4,074 gal. 3 in. 16,396 gal. 3 in. 27,791 gal. 4 in. 4,292 gal. 4 in. 16,668 gal. 4 in. 27,958 gal. 15% 5 in. 4,512 gal. 5 in. 16,938 gal. 95% 5 in. 28,120 gal. 6 in. 4,735 gal. 6 in. 17,209 gal. 6 in. 28,276 gal. 7 in. 4,962 gal. 7 in. 17,479 gal. 7 in. 28,427 gal. 8 in. 5,190 gal. 8 in. 17,748 gal. 8 in. 28,571 gal. 9 in. 5,421 gal. 9 in. 18,016 gal. 9 in. 28,709 gal. 10 in. 5,655 gal. 10 in. 18,284 gal. 10 in. 28,840 gal. 11 in. 5,891 gal. 11 in. 18,552 gal. 11 in. 28,964 gal. 3 ft. 0 in. 6,129 gal. 7 ft. 0 in. 18,818 gal. 11 ft. 0 in. 29,079 gal. 1 in. 6,369 gal. 1 in. 19,083 gal. 1 in. 29,186 gal. 2 in. 6,612 gal. 2 in. 19,348 gal. 2 in. 29,282 gal. 3 in. 6,856 gal. 3 in. 19,611 gal. 3 in. 29,368 gal. 4 in. 7,102 gal. 4 in. 19,874 gal. 4 in. 29,441 gal. 5 in. 7,351 gal. 5 in. 20,135 gal. 5 in. 29,497 gal. 6 in. 7,600 gal. 6 in. 20,395 gal. 6 in. 29,528 gal. 7 in. 7,852 gal. 7 in. 20,654 gal. 8 in. 8,105 gal. 8 in. 20,912 gal. 9 in. 8,360 gal. 9 in. 21,168 gal. 10 in. 8,616 gal. 10 in. 21,423 gal. 11 in. 8,873 gal. 11 in. 21,676 gal. Depth Depth Depth KING COVE 29,500 GALLON TANK (TANKS 1 THRU 5) Diameter = 11 ft.29,528 gal.Length = 38 ft. 0 in. 0 in. Gross Volume = Volume Volume Volume 0 ft. 0 in. 0 gal. 4 ft. 0 in. 4,609 gal. 8 ft. 0 in. 10,582 gal. 1 in. 16 gal. 1 in. 4,737 gal. 1 in. 10,686 gal. 2 in. 45 gal. 2 in. 4,866 gal. 2 in. 10,788 gal. 3 in. 82 gal. 3 in. 4,996 gal. 3 in. 10,888 gal. 4 in. 126 gal. 4 in. 5,125 gal. 4 in. 10,987 gal. 5 in. 176 gal. 5 in. 5,255 gal. 90% 5 in. 11,084 gal. 6 in. 231 gal. 6 in. 5,385 gal. 6 in. 11,178 gal. 7 in. 290 gal. 7 in. 5,516 gal. 7 in. 11,271 gal. 8 in. 353 gal. 8 in. 5,646 gal. 8 in. 11,361 gal. 9 in. 420 gal. 9 in. 5,777 gal. 9 in. 11,448 gal. 10 in. 491 gal. 10 in. 5,908 gal. 10 in. 11,534 gal. 11 in. 565 gal. 11 in. 6,038 gal. 11 in. 11,617 gal. 1 ft. 0 in. 642 gal. 5 ft. 0 in. 6,169 gal. 9 ft. 0 in. 11,697 gal. 1 in. 722 gal. 1 in. 6,300 gal. 95% 1 in. 11,774 gal. 2 in. 805 gal. 2 in. 6,431 gal. 2 in. 11,848 gal. 3 in. 890 gal. 3 in. 6,562 gal. 3 in. 11,918 gal. 4 in. 978 gal. 4 in. 6,693 gal. 4 in. 11,985 gal. 5 in. 1,068 gal. 5 in. 6,823 gal. 5 in. 12,049 gal. 6 in. 1,161 gal. 6 in. 6,954 gal. 6 in. 12,108 gal. 7 in. 1,255 gal. 7 in. 7,084 gal. 7 in. 12,163 gal. 8 in. 1,352 gal. 8 in. 7,214 gal. 8 in. 12,212 gal. 9 in. 1,450 gal. 9 in. 7,343 gal. 9 in. 12,256 gal. 10 in. 1,551 gal. 10 in. 7,472 gal. 10 in. 12,294 gal. 11 in. 1,653 gal. 11 in. 7,601 gal. 11 in. 12,323 gal. 2 ft. 0 in. 1,757 gal. 6 ft. 0 in. 7,730 gal. 10 ft. 0 in. 12,339 gal. 15% 1 in. 1,862 gal. 1 in. 7,858 gal. 2 in. 1,969 gal. 2 in. 7,985 gal. 3 in. 2,078 gal. 3 in. 8,112 gal. 4 in. 2,188 gal. 4 in. 8,239 gal. 5 in. 2,299 gal. 5 in. 8,365 gal. 6 in. 2,412 gal. 6 in. 8,490 gal. 7 in. 2,526 gal. 7 in. 8,615 gal. 8 in. 2,641 gal. 8 in. 8,738 gal. 9 in. 2,758 gal. 9 in. 8,861 gal. 10 in. 2,875 gal. 10 in. 8,984 gal. 11 in. 2,994 gal. 11 in. 9,105 gal. 3 ft. 0 in. 3,113 gal. 7 ft. 0 in. 9,225 gal. 1 in. 3,234 gal. 1 in. 9,345 gal. 2 in. 3,355 gal. 2 in. 9,463 gal. 3 in. 3,477 gal. 3 in. 9,581 gal. 4 in. 3,600 gal. 4 in. 9,697 gal. 5 in. 3,724 gal. 5 in. 9,812 gal. 6 in. 3,849 gal. 6 in. 9,926 gal. 7 in. 3,974 gal. 7 in. 10,039 gal. 8 in. 4,100 gal. 8 in. 10,151 gal. 9 in. 4,226 gal. 9 in. 10,261 gal. 10 in. 4,353 gal. 10 in. 10,369 gal. 11 in. 4,481 gal. 85% 11 in. 10,476 gal. Depth Depth Depth KING COVE 12,000 GALLON POWER PLANT DAY TANK Diameter = 10 ft.12,339 gal.Length = 21 ft. Tab III. Equipment Suppliers & Service Instructions KING COVE BULK FUEL UPGRADE PROCEDURES & MAINTENANCE MANUAL CONTRACTORS FOR SERVICE AND REPAIR (907) 522-4684 (907) 451-1905 Pinnacle Construction (Anchorage)(907) 522-0040 (907) 562-3344 ACTUATOR VALVE 2" Ball Valve Nutron T3-R20R01LZ-05 DG Valve Systems (780) 413-1760 NEMA 4 Electric Actuator (std) RCS SXR-0994 BULK TRANSFER METER, HOSE, NOZZLE, & ACCESSORIES 1-1/2" - 250# Safety Break OPW 66SP Ace Supply (907) 277-4113 1-1/2" Breakaway Hose Goodyear Ortac with Brass Scoville Fittings 2" AND 1-1/4" Arctic Grade Hose Goodyear Ortac with Brass Scoville Fittings 1-1/2" Straight Swivel OPW 25 3/4" Nozzle OP 11B w/ 15/16" spout 1-1/2" Nozzle OPW 1290 w/ 1-3/8" spout 2" Nozzle OPW 190 w/ 2-3/8" spout Static Grounding Reel Hannay GR75 Hose Reel Hannay E8234-33-34 1-1/2" Custody Transfer Meter (60 GPM) Liquid Controls Model M5C1-P (with strainer & air eliminator) 2" Custody Transfer Meter (100 GPM) Liquid Controls Model M7C1-P (with strainer & air eliminator) DIKE PUMP (See Note) 2"x25' Suction Hose HPS250SQD 2"x50' Discharge Hose HPS250DQD Female Camlock HOM2D Male Camlock HOM2A Pump Homelite 320 FILTERS Pipeline Filter Body - Cim Tek General II 40166 Cover Gasket - Cim Tek 90137 Cartridge - Cim Tek 30037 Hydrosorb II (30 micron water blocking element) Ace Supply (907) 277-4113 FIRE EXTINGUISHER (See Note) Fire Extinguisher Type 3A-40BC, 10# Alaska Industrial Hardware (907) 561-1781 FLEX CONNECTOR (See Note) Flex Connector Double braid stainless steel. Require all flexes to be pressure tested. Alaska Rubber & Supply (907) 562-2200 Alaska Plus (Anchorage) Statewide Petroleum Services (Anchorage) Inland Petro Service (Fairbanks) Alaska Industrial Hardware (907) 561-1781 III-1 KING COVE BULK FUEL UPGRADE PROCEDURES & MAINTENANCE MANUAL GAUGES Clock Type Liquid Level Gauge Morrison Figure 818 Ace Supply (907) 277-4113 LEVEL SWITCHES Two Point Level Switch (OLD POWER PLANT) ISE-MAGTECH: MLS-4EX-B-6-4"NPT-0.68-T-P-14"-8"-12" Alaska Instrument Co. (907) 561-7511 LINER Dike Membrane Seaman Corp. XR-5 8130 Polar Supply (907) 563-5000 LOCKS (See Note) Locks MAS 140KA (large) MAS 130KA (small) Able Locksmith (907) 276-4147 PAINT Tank Paint Primer - Devoe Catha-Coat 302 Inorganic Zinc, No Substitutes Top Coat - Devoe Bar-Rust 236 Epoxy, No Substitutes, Color White Pipe, Stairs, & Miscellaneous Structures Paint Prime Coat - Red Oxide Primer, Devoe Rustguard 4160 or equal. Top Coat - Alkyd Enamel, Devoe Speedenamel 4318 Or Equal Color Haze Gray Except Off White for Storage Vans and Contingency Tanks Cleaner/Degreaser Devprep 88 PIPING SPECIALTIES Flange Gaskets Lamons Spiraseal Style WR Spiral Wound Metallic Gasket Puget Sound Pipe (907) 277-7473 Dielectric Flange Isolation Calpico EQDW Kit Complete with Gasket, Bolt Sleeves, & Washers Quick Connect Couplings PT Coupling Dry-Connect Adapter PT Maxi-Dry Adapter Dry-Connect Coupling PT Maxi-Dry Coupling Strainer Mueller #781 - 150# Flanged Ends, With Optional 100 Mesh SS Screen PUMPS 1-1/2" Centrifugal Pumps TP-2 Gorman-Rupp 81-1/2D3X1, 1 HP, 230V with Buna-N Seal Ace Supply (907) 277-4113 2" Centrifugal Pumps TP-1 Gorman-Rupp O2K3-X2, 2 HP, 230V with Buna-N Seal Polar Supply (907) 563-5000 III-2 KING COVE BULK FUEL UPGRADE PROCEDURES & MAINTENANCE MANUAL SMART ASH INCINERATOR Smart Ash Smart Ash 100A 55 Gallon Drum For Smart Ash D80014 Lid Clamps Assembly E108026 Spark Screen E108017 Two-Pack Blower Motor Filter E108084 SPILL RESPONSE SUPPLIES (See Note) 95 Gallon Overpack Drums U00507 Poly Coated Tyvek Suits 90021A Nitrile Gloves 90008 4"x40' Absorbent Boom 51011 19"x100' Absorbent Sweep WSWL-100 16"x20" Absorbent Pad 54602 40"x150' Absorbent Roll 56634 TANKS Bulk Storage Tanks U.L. 142 Listed Single Wall Horizontal Skid Mounted Tanks REFER TO DWGS IN TAB IV Intermediate Tanks U.L. 142 Listed Tight-Wrap Double Wall Horizontal Skid Mounted Tanks Greer Steel, Inc. (253) 581-4100 TANK APPURTENANCES Flanged Emergency Vent Morrison Figure 244-F 16 oz/sq.in Ace Supply (907) 277-4113 Threaded Emergency Vent Morrison Figure 244-M 16 oz/sq.in Pressure/Vacuum Whistle Vent Morrison Figure 922 Gauge Hatch Morrison Figure 307 VALVES - STANDARD (See Note) Flanged Ball Valve PBV C-5410-31-2236-GLNL Puget Sound Pipe (907) 277-7473 Flanged Gate Valve Crane Class 150, No. 47 Flanged Swing Check Valve 2" and Larger Crane Class 150, No. 147 Flanged Swing Check Valve Smaller Than 2" Bonney Forge L1-61 Flanged Piston Check Valve Bonney Forge L1-41 1" Flanged Pres. Relief Valve Hydroseal 1FLARV00 1" Threaded Pres. Relief Valve Hydroseal 4FRV00 Threaded Ball Valve PBV C-5312-38-2236-TL-NC Threaded Check Valve Milwaukee 510-S Note: Spill Shield International (907) 561-6033 On the following pages manufacturer's literature has been included for specialty items that may require service or replacement. For common items such as fire extinguishers, spill response supplies, valves, etc. the manufacturer and model has been listed above along with vendor contact. Spill Shield International (907) 561-6033 III-3 Actuator Valve NUTRON TC1836 08/04 NP-3M2 T3 STANDARD FEATURES MODEL T3 STEM SEAL O-ring installed on stem shaft on all valves 1 1/2 in. (40 mm) full port through 3 in. (80 mm) reduced port. BODY SEALS Body seal O-rings are placed ahead of the body cap threads to protect the threads from the flow media. PACKING Self adjusting by means of a Belleville washer. Allows for long service life before manual packing adjustment is necessary. HANDLE Rugged cast handle. Handle position indicates flow position. When the handle is positioned in line with the pipe, the valve is open. When the handle is positioned perpendicular to the pipe, the valve is closed. Locking handle is standard for all 2 in. (50 mm) reduced port and smaller valves with either socket weld or FNPT end connections. FLOATING BALL VALVES BODY CONSTRUCTION Forged steel three piece threaded construction. A machined pad area is drilled and tapped for actuation as a standard. Threaded construction allows for combinations of end connections. STEM Blowout proof stem is back-seated through the valve body. BALL The floating ball design allows for positive shut off in either flow direction. Includes pressure equalization hole to prevent trapping of pressure in the body cavity. THRUST WASHER Acts as a bearing between the body and stem. SEATS Materials available are Teflon, Delrin, PEEK and Devlon. CAP SCREWS Dual purpose; allows for easy stem packing adjustment without handle removal while providing a stop for the handle. 3 NUTRON TC1836 08/04 NP-3M T3-F07S20SZ =Model T3, Full Port, 3/4 in. (20 mm), Female NPT, 2000 WOG, Sour Valve, Fire Safe. T3-R10TS30B =Model T3, Reduced Port, 1 in. (25 mm), Female NPT x Socket Weld, 3000 WOG, Standard Valve. T3 - F 07 S 20 S Z 10 - 1000 WOG 20 - 2000 WOG 30 - 3000 WOG 40 - 4000 WOG 60 - 6000 WOG How to develop figure numbers: Examples: *Consult Cooper Cameron Valves - NUTRON Sales Department for detailed valve style descriptions, full range of options, materials, actuation packages or for a particular special valve service application. Cooper Cameron Valves reserves the right to substitute materials listed on the following pages with alternate materials for the designated service. ORDERING INFORMATION MODEL T3 SIZES AVAILABLE A - RF SMOOTH FACE B - BW SCH 40 C - BW SCH 80 D - BW SCH 160 E - BW SCH XXH F - FNPT X MNPT G - FNPT X RF H - FNPT X RTJ J - RTJ M - MALE NPT R - RAISED FACE S - FEMALE NPT TS - FNPT X SOCKET WELD WS - SOCKET WELD 01 -150 ASME 03 -300 ASME 06 -600 ASME 09 -900 ASME 15 -1500 ASME 25 -2500 ASME J -HIGH TEMP/ STAINLESS STEEL L -SOUR LOW TEMP -50°F (-46°C) N -MONEL STEEL Q -DUPLEX STEEL S -SOUR -20°F (-29°C) A -STAINLESS STEEL -50°F (-46°C) B -STANDARD D -FULL STAINLESS STEEL -150°F (-100°C) E -STEAM HIGH TEMP/ STAINLESS STEEL F -HIGH TEMP/SOUR LOW TEMP G -STEAM HIGH TEMP/SOUR H -HIGH TEMP/SOUR ASME CLASS 150 300 600 900 1500 2500 (PN)(20)(50)(100)(150)(250)(420) Full Port in.1/2 thru 3 1/2 thru 3 1/2 thru 2 1/2 thru 2 1/2 thru 2 1/2 thru 2 (mm)(15 thru 80)(15 thru 80)(15 thru 50)(15 thru 50)(15 thru 50)(15 thru 50) Reduced Port 3/4 thru 4 3/4 thru 4 3/4 thru 3 3/4 thru 3 3/4 thru 3 3/4 thru 3 (20 thru 100)(20 thru 100)(20 thru 100)(20 thru 80)(20 thru 80)(20 thru 80) WOG (psi)1000 2000 3000 4000 6000 Full Port, Threaded in.3 1/4 thru 3 1/4 thru 2 1/4 thru 2 1/4 thru 2 (mm)(80)(8 thru 80)(8 thru 50)(8 thru 50)(8 thru 50) Reduced Port, Threaded 4 3/4 thru 3 3/4 thru 3 3/4 thru 3 3/4 thru 3 (100)(20 thru 80)(20 thru 80)(20 thru 80)(20 thru 80) Full Port, Socket Weld 1/2 thru 2 1/2 thru 2 1/2 thru 2 1/2 thru 2 (15 thru 50)(15 thru 50)(15 thru 50)(15 thru 50) Reduced Port, Socket Weld 3/4 thru 3 3/4 thru 3 3/4 thru 3 3/4 thru 3 (20 thru 80)(20 thru 80)(20 thru 80)(20 thru 80) MODEL BORE STYLE* END CONNECTION PRESSURE OPTIONS T3 - 3 PIECE THREADED F - FULL PORT R -REDUCED PORT SIZE in. (mm) 02 -1/4 (8) 03 -3/8 (10) 05 -1/2 (15) 07 -3/4 (20) 10 -1 (25) 12 -1 1/4 (32) 15 -1 1/2 (40) 20 -2 (50) 25 -2 1/2 (65) 30 -3 (80) 40 -4 (100) ANTI-STATIC SPRING BLEEDER HOLE BLEEDER VALVE CARR. SEAL CLOSE CARR. SEAL OPEN DELRIN SEATS DEVLON SEATS ELECTROLESS NICKEL PLATING (ENP) EXTENDED STEM GRAPHITE PACKING HSN O-RINGS IMPREGLON COATING LOCKING HANDLE NITRILE O-RINGS PEEK SEATS SEAL WELDED SEAL INJECTION SPRING RETURN HANDLE TAC WELD CAP TEFLON O-RINGS VITON O-RINGS FIRE SAFE NUTRON TC1836 08/04 NP-3M4 T3 FLOATING BALL VALVES THREADED END CONNECTIONS 11 10 9 15 14 13 13 12 6 5 4 1 3a 3 5 6 2 2 8 5 NUTRON TC1836 11/05 MATERIALS LIST - THREADED END CONNECTIONS T3 ITEM PART WORKING PRESSURE STANDARD -20°F (-29°C)SOUR -20°F (-29°C) 1 Body All ASTM A105 ASTM A105 2 End Caps All ASTM A105 ASTM A105 +3 Stem 2000 & 3000 ASTM A108, Plated ASTM A564 17-4PH 4000 & 6000 ASTM A564 17-4PH ASTM A564 17-4PH +! 3a*Stem O-Ring All Buna Viton 4 Ball 2000, 3000 & 4000 Carbon Steel, Chrome Plated ASTM A351 Gr. CF8M 6000 ASTM A564 17-4PH ASTM A564 17-4PH 5 Seats 2000 Teflon Teflon 3000 & 4000 Delrin Delrin 6000 PEEK PEEK 6 Body O-Rings All Buna Viton 8 Thrust Washer 2000 Teflon Teflon 3000 & 4000 Delrin Delrin 6000 PEEK PEEK 9 Packing All Teflon (Graphite 6000 psi)Teflon (Graphite 6000 psi) 10 Packing Follower All Carbon Steel, Plated Stainless Steel 11 Belleville Washer All Carbon Steel Stainless Steel 12 Gland Flange **All Carbon Steel, Plated Carbon Steel, Plated 13 Cap Screws All Carbon Steel Stainless Steel 14 Handle All Carbon Steel Carbon Steel 15 Handle Nut All Carbon Steel, Plated Carbon Steel, Plated + +! +! +! +! ITEM PART WORKING PRESSURE SOUR & LOW TEMP -50°F (-46°C)STAINLESS STEEL -50°F (-46°C) 1 Body All ASTM A350 LF2 ASTM A479 TYPE 316 2 End Caps All ASTM A350 LF2 ASTM A479 TYPE 316 +3 Stem All ASTM A564 17-4PH ASTM A564 17-4PH with Nitriding +! 3a*Stem O-Ring All HSN HSN +4 Ball 2000 ASTM A351 Gr. CF8M ASTM A351 Gr. CF8M 3000 & 4000 ASTM A351 Gr. CF8M ASTM A564 17-4PH 6000 ASTM A564 17-4PH ASTM A564 17-4PH +!5 Seats 2000 Teflon Teflon 3000 & 4000 Delrin PEEK 6000 PEEK PEEK +!6 Body O-Rings All HSN Teflon +!8 Thrust Washer 2000 Teflon Teflon 3000 & 4000 Delrin PEEK 6000 PEEK PEEK +!9 Packing All Teflon (Graphite 6000 psi)Teflon (Graphite 6000 psi) 10 Packing Follower All Stainless Steel Stainless Steel 11 Belleville Washer All Stainless Steel Stainless Steel 12 Gland Flange **All Carbon Steel, Plated Carbon Steel, Plated 13 Cap Screws All Stainless Steel Stainless Steel 14 Handle All Carbon Steel Carbon Steel 15 Handle Nut All Carbon Steel, Plated Carbon Steel, Plated + *Item 3a is only available on sizes 1 1/2 in. full port through 3 in. reduced port (40 mm through 80 mm) valves. **Locking device is standard on 1/4 in. full port through 2 in. reduced port (8 mm through 50 mm) valves. Note:Fire safe trim offered as standard whenever possible. Consult Cooper Cameron Valves - NUTRON Sales Department for fire safe trim. Major repair kit. !Minor repair kit. NUTRON TC1836 08/04 NP-3M8 11 10 9 15 14 13 13 12 6 5 4 1 3a 3 5 6 2 2 8 THREADED END CONNECTIONS T3 FLOATING BALL VALVES 11 NUTRON TC1836 08/04 NP-3M REDUCED PORT - THREADED NOTE: “ A ” dimension to be within ± 0.062 in. (1.5 mm). DIMENSIONS B A E C F D G C T3 FLOATING BALL VALVES 3/4 (20)2000 4.38 (111)0.50 (13)0.75 (19)0.82 (21)3.29 (83)4.82 (122)1.73 (44)14 2.5 (1.1) SIZE WOG A B C D E F G C WEIGHTVin. (mm)lb. (kg) 3000 4.38 (111)0.50 (13)0.75 (19)0.82 (21)3.29 (83)4.82 (122)1.73 (44)14 2.5 (1.1) 4000 4.38 (111)0.50 (13)0.75 (19)0.82 (21)3.29 (83)4.82 (122)1.73 (44)14 2.5 (1.1) 6000 4.38 (111)0.50 (13)0.75 (19)0.82 (21)3.29 (83)4.82 (122)1.73 (44)14 2.5 (1.1) 1 (25)2000 4.25 (108)0.88 (22)1.00 (25)1.12 (28)4.40 (112)6.75 (172)2.16 (55)35 4.5 (2.0) 3000 4.25 (108)0.88 (22)1.00 (25)1.12 (28)4.40 (112)6.75 (172)2.16 (55)35 4.5 (2.0) 4000 4.25 (108)0.88 (22)1.00 (25)1.12 (28)4.40 (112)6.75 (172)2.16 (55)35 4.5 (2.0) 6000 5.25 (133)0.88 (22)1.00 (25)1.50 (38)4.40 (112)6.75 (172)2.16 (55)35 7.5 (3.4) 1 1/4 (32)2000 6.00 (152)0.88 (22)1.25 (32)1.30 (33)4.40 (112)6.75 (172)2.16 (55)35 8.0 (3.6) 3000 6.00 (152)0.88 (22)1.25 (32)1.30 (33)4.40 (112)6.75 (172)2.16 (55)35 8.0 (3.6) 2 (50)2000 6.25 (159)1.50 (38)2.00 (51)1.98 (50)5.62 (143)11.00 (279)3.52 (89)100 17.5 (7.9) 3000 6.25 (159)1.50 (38)2.00 (51)1.98 (50)5.62 (143)11.00 (279)3.52 (89)100 17.5 (7.9) 4000 6.25 (159)1.50 (38)2.00 (51)1.98 (50)5.62 (143)11.00 (279)3.52 (89)100 17.5 (7.9) 6000 7.25 (184)1.50 (38)2.00 (51)1.98 (50)5.62 (143)11.00 (279)3.52 (89)100 21.0 (9.5) 3 (80)2000 10.0 (254)2.00 (51)3.00 (76)2.53 (64)6.96 (177)11.88 (302)4.83 (123)420 39.0 (17.6) 3000 10.0 (254)2.00 (51)3.00 (76)2.53 (64)6.96 (177)11.88 (302)4.83 (123)420 39.0 (17.6) 4000 10.0 (254)2.00 (51)3.00 (76)2.53 (64)6.96 (177)11.88 (302)4.83 (123)420 39.0 (17.6) 6000 10.0 (254)2.00 (51)3.00 (76)2.53 (64)6.96 (177)11.88 (302)4.83 (123)420 48.0 (21.8) 4 (100)1000 9.5 (241)3.00 (76)4.00 (102)3.50 (89)8.26 (210)23.88 (607)5.37 (137)770 80.0 (36.3) MAR10, 50, 90 – A.C. Supply DCR10, 50, 90 – D.C. Supply Models For on/off and modulating control of: • Part turn ball, butterfly or plug valves • Rotary dampers • Rotating equipment • Multi-turn valve types Typical Application Standard: -40°F to +150°F -40°C to +65°C Optional: -60°F to +120°F -50°C to +48°C (Note: With Heaters Installed) Optional: Compliance to NFPA 130, capable of operation after exposure to ambient temperature of 482°F (250°C) for a minimum of 1 hour 115 VAC, 1 Phase, 50/60 Hz. 230 VAC, 1 Phase, 50/60 Hz. 24 VAC, 1 Phase, 50/60 Hz. 12 VDC / 24 VDC .5 to 60 seconds for 90° revolution 7.5 and 30 RPM for multi-turns 120 to 1,000 inch pounds (13.5 to 112 newton meters) Temperature Range Voltage Torque Range Speed Range MAR Models Only Canadian Standards Association CSA NRTL/C—Class I, Divisions 1 & 2, Groups C & D CSA NRTL/C—Class II, Divisions 1 & 2, Groups E, F & G CSA NRTL/C—Approved to UL standard No. 429, Electrically Operated Valves CSA NRTL/C—Approved to UL Standard No. 1203, Electrical Equipment for use in Explosion - proof And Dust - Ignition - proof Hazardous(Classified) Locations Approvals MAR Models Only Canadian Standards Association CSA NRTL/C—Enclosure 4 Approvals Open/Close Modulating Multi-Turn NEMA 4 Enclosure NEMA 7 Enclosure Optional 7" Handwheel Available AC Voltages 2 – SPDT Switches, PTC Heater DC Voltages 2 – SPDT (High Current) Switches Standard Features The percentage of time the electric motor is energized vs. the time it is at rest, in reversing duty and with the actuator running at it’s rated load - maximum published torque. Duty Cycle • 12 motor starts (corrections) per minute. • At the rated duty cycle for that model. • With the speed of operation a minimum of 15 seconds for 90° or slower. • With positioning accuracy of (+/-) 1% of total span. Standard Modulating Duty Rating 115 & 230 VAC, 1 Phase, 50/60 Hz.MARCurrent Ratings Current Ratings 115 VAC 230 VAC N.L.A.* L.R.A.* N.L.A.* L.R.A.* * (N.L.A.) — No Load Ampere (L.R.A.) — Locked Rotor Ampere (1) — Open/Close Service (2) — Open/Close or Modulating Service Note — Multi-turn models are available with the following number of turns: 1.4, 5, 8, 13, 18, 26 or 50. Must be specified when the order is placed. To operate multiple actuators in parallel from a single signal requires isolating relays in the field wiring. Consult factory. Isolation Relays Model Output Torque Type Speed of Operation Duty Cycle Rating Duty Cycle Rating Inch Pounds (N.m) 60 Hz. (50 Hz.) 115 Vac, 1Ph., 50/60 Hz. 230 Vac, 1Ph., 50/60 Hz. MAR10-.5MT 30 (3.4) Multi-Turn 30 RPM 25% 25% N/A (2) (2) MAR10-2 120 (13.5) Part Turn 2 second/90° 50% 50% (2.5 seconds/90°) (1) (1) MAR10-2MT 120 (13.5) Multi-Turn 7.5 RPM 50% 50% (6.2 RPM) (2) (2) MAR10-10 350 (40) Part Turn 10 seconds/90° 50% 50% (12 seconds/90°) (1) (1) MAR10-30 425 (48) Part Turn 30 seconds/90° 50% 50% (35 seconds/90°) (2) (2) MAR10-60 400 (45) Part Turn 60 seconds/90° 50% 50% (70 seconds/90°) (2) (2) MAR50-2 600 (67) Part Turn 2 seconds/90° 40% 50% (2.5 seconds/90°) (1) (1) MAR50-2MT 600 (67) Multi-Turn 7.5 RPM 40% 50% (6.2 RPM) (2) (2) MAR50-.5MT 200 (22.5) Multi-Turn 30 RPM 25% – N/A (2) – MAR50-10 600 (67) Part Turn 10 seconds/90° 50% 50% (12 seconds/90°) (1) (1) MAR50-30 700 (79) Part Turn 30 seconds/90° 50% 50% (35 seconds/90°) (2) (2) MAR50-60 600 (67) Part Turn 60 seconds/90° 50% 50% (70 seconds/90°) (2) (2) MAR90-5 1,000 (112) Part Turn 5 seconds/90° 50% 50% (6 seconds/90°) (1) (1) MAR90-5MT 1,000 (112) Multi-Turn 3 RPM 50% 50% (2.5 RPM) (2) (2) MAR90-15 1,000 (112) Part Turn 15 seconds/90° 75% 50% (17.5 seconds/90°) (2) (2) 0.5 0.82 0.25 0.40 0.40 0.60 0.30 0.40 0.40 0.60 0.20 0.25 0.40 0.60 0.20 0.25 0.30 0.50 0.20 0.25 0.35 0.55 0.20 0.25 1.60 2.20 0.50 0.95 1.60 2.20 0.50 0.95 1.9 3.10 – – 0.50 0.80 0.30 0.50 0.35 0.55 0.20 0.25 0.30 1.50 0.20 0.25 0.55 1.55 0.25 0.85 0.55 0.55 0.25 0.85 0.50 0.60 0.20 0.35 Bulk Transfer Meter, Hoses, Nozzles & Accessories "•'~.....~•'..•I.•',',.•f''.f OPW MANUAL NOZZLE ACCESSORIES 29-0016 29-0004 [he OPW 29 is designed for e be ween the hose and nozzle an helps pre ent draining of the hose w n the po r is shut-off. • E temal type inlet check v lve. •Sta dard pipe threads. •Pop et opens at 2Y2 psi fo lY2 p i for lY2"size. Material Body:bron e Spring:bra e Stem:bronz Disc:buna-N Product N.Inlet in.mm. Ordering pecifications Materials Body:Alumin m Seals:buna- 60 40 60 80 100 120 140 FLOW·RATE-I./MIN.(WASQUNE) OL-"!~_-J.L-_I----L.-+--l-____J o OL.-~=t---L_L---L-....-'-----L--\ o Material Body:alum urn Adaptor:zin aluminum Seals:buna-a-ring,viton a-ring Bearings:nylo I OPW 36S Hose Swivel Designed for use with fuel oil nozzles (at inlet only),the OPW 3 S provi es 360 0 swivel action.The ull circle wivel reduces the physica strain of alig ing the nozzle with the fi pipe. The S is UL listed. 36S-5080 36S-5090 ~15 l----l---l---I-l---\}---+----1 0:.-o 0::: ~10 l----l----I-+--b£---+\--+----1 0::: :::l V'l~51---+-~-6-L-++--f---I c.. 36SW-5090 For Potable Water ,0.8 r----r----rl---r--r---.--~__+r___, l,p.6 l---I---II--+-l---I----i'-l---+~ ti::l;;,,; o~'0.4 1__-+-~~....._f-7L~~~_\___1 ~. ~O.2 l---+---J'--l--~~J-----:.,-'1---I--+_+_I L.U Q:;.' .Q..' Product No.Used On 25-(523 1W(NPT)~t~a:{l For Potable Water Materials Body:hard coated aluminum Bearings:molded plastic Seals:buna-N a-ring,felt dust seal,viton a-ring Ordering Specifications 25-0120 1Y7"(NPT) 25(-0130 1X"(NPT) 25L-011 L 1XU (BSPP) 25L-012L 1W(BSPP)if; Product No.in.mm. 295SRK-0001 25 and 295 Series 1",114" 295SRK-0002 25 and 295 Series 1WI Materials Body:hard coated aluminum Bearings:molded plastic Seals:buna-N a-ring,felt dust seals,viton a-ring Ordering Specifications OPW295SRK Seal Repair Kit Designed for use un 25 series swivels and 295 nozzles,the OPW 295SRK consists of a dust seal,o-ring,3 button head screws and hex key. ---7 OPW 25 Hose Swivel Designed for use with fuel oil nozzles (at inlet only),the OPW 25 provides 360 0 swivel action.The full circle swivel reduces the physical strain of aligning the nozzle with the fillpipe. Note:The OPW 25C is a lW'swivel with a check valve,opens at 2Y2 psi. c>pvy ADOVER ~~:~::CCE:M;~~I::{f:~?Telephone:(513)870-3219 +(800)422-2525 +Fox:(513)870-9186 +(800)421-3297 ~ ©1998 OPW Fueling Components +P.O.Box 405003 •Cincinnati,Ohio 45240-5003 +Printed In USA +TDACCES +1/98 ~ IMPORTANT: OPW products should be used in compliance with applicable federal, state, provincial, and local laws and regulations. Product selection should be based on physical specifications and limitations and compatibility with the environment and materials to be handled. OPW MAKES NO WARRANTY OF FITNESS FOR A PARTICULAR USE. All illustrations and specifications in this literature are based on the latest product information available at the time of publication. OPW reserves the right to make changes at any time in prices, materials, specifications and models and to discontinue models without notice or obligation. OPW 11B Pressure-Sensitive Automatic Nozzles (11B, 11BP) OPW 11B® Series The OPW 11B® Series high-quality automatic shut-off nozzle is designed specifically for self-service prepay or card-lock systems to help prevent gasoline spills. The OPW 11B® cannot be opened until the pumping system is pressurized, and closes automatically when the pressure is removed. This means the OPW 11B® is closed when placed back in the dispenser storage position. Table of Contents: Features & Benefits • Two-Piece spout - The OPW spout offers the highest flow rates in the industry. Replacement Kits available from OPW. • “Accu-Stop®” flow control - allows your customers to top off their tanks to the exact amount they want…easy to stop gasoline flow precisely. • Low-profile aluminum body - light-weight, easier to handle, provides an attractive, image- enhancing appearance. • Unique Hands Insulators - OPW offers both a full hand insulator and a unique two-piece option. Protects both nozzle and vehicle, and insulates user's hand. • Hold-open rack is available for full-service applications - the one-hand control means easy setting to flow rate for customer convenience. • Duratuff® lever and lever guard - for additional durability to protect against rough handling. • Blocker on lever guard - to help prevent the nozzle from being jammed into open position with a foreign object. • Listed by Underwriters Laboratories, Inc. - for gasoline, diesel, 15% ethanol/methanol gasoline blends. UL and ULC Listed. See web site at: www.opw-fc.com for specific listings. • Low reliable shut-off - specially designed to ensure proper shut-off as low as 3 gallons per minute. • Exclusive two-stage lever assembly - provides a positive shut-off, even if held in wide-open position by user. • FlowLock™ -designed to shut-off automatically when the spout is tipped up, limiting spillage. • Design Working Pressure- OPW products are designed to work at 50 PSI (3.45 bar) maximum pressure. Materials Body: aluminum Lever & Lever Guard: Duratuff® Packing: Graphite with Teflon® Disc: Viton® Spout: aluminum Inlet Size: 3/4" NPT Weight: 2.73 lbs. each, 43.1 lbs./case of 15 1.25 kg. each, 19.9 kg./case of 15 UL Listed ULC Listed Available Colors Black, Blue, Bright Red, Gold, Green, Red, Silver, Yellow GPM LPM Ordering Specifications Full Hand Insulator Color For Unleaded Service 13/16" O.D. Spout For Leaded Service 15/16" O.D. Spout Price With hold- open rack & trigger Without hold-open rack With hold- open rack & trigger Without hold-open rack Green 11BP-0100 11B-0100 See PNET 2006 Silver 11BP-0200 11B-0200 See PNET 2006 Red 11BP-0300 11B-0300 See PNET 2006 Black 11BP-0400 11B-0400 See PNET 2006 Blue 11BP-0500 11B-0500 See PNET 2006 Yellow 11BP-0900 11B-0900 See PNET 2006 Bright Red 11BP-0301 11B-0301 See PNET 2006 Gold 11BP-0750 11B-0750 See PNET 2006 Bare 11BP-0009 11BKP-0009 11B-0009 11BK-0009 See PNET 2006 Ordering Specifications Two-Piece Hand Insulator For Unleaded Service 13/16" O.D. Spout For Leaded Service 15/16" O.D. Spout Price Color With hold-open rack & trigger With hold-open rack & trigger Green 11BP-0102 11B-0102 See PNET 2006 Red 11BP-0302 11B-0302 See PNET 2006 Black 11BP-0402 11B-0402 See PNET 2006 Blue 11BP-0502 11B-0502 See PNET 2006 Yellow 11BP-0902 11B-0902 See PNET 2006 For complete ordering description, use both the product number and the 4-digit code number shown above: Example: OPW 11BP-0400 (black hand insulator, unleaded spout, with hold-open rack and trigger) Notes: 1. Unless specified, nozzles will be provided with black hand insulators. 2. OPW may add or delete colors without notice. 3. Actual color may vary slightly from production run to production run. 4. For custom colors, price quote, and lead time, contact OPW. 5. For ordering specifications not listed in this catalog, contact OPW Customer Service at 1-800- 422-2525. Replacement Parts Product Product # O.D. Length Weight Used On in. mm. in. mm. lbs. kg. Two-Piece Spout Kit 5BBI-2135 15/16" 24 7" 178 0.47 0.22 11B- Leaded Two-Piece Spout Kit 5BBPI-2137 13/16" 21 7" 178 0.47 0.22 11BP- Unleaded Hold-Open Kit 18KVA-1000 (36 qty.) 2 position w/rivets 11B/11BP Hold-Open Kit 18KR-3000 (1 qty.) 2 position w/screws 11B/11BP Bushing 28S-0350 3/4"M x 1"F (NPT) Step-Up 11B/11BP Hand Insulator See Nozzle Accessories Replacement Hand Insulator 11B/11BP OPW 5BBI Leaded, Diesel, Kerosene OPW 5BBPI Please see OPW’s website: www.opw-fc.com for further information ONE COMPANY. ONE WORLD. ONE SOURCE.™ AUTOMATIC SHUT-OFF NOZZLE USE OObbsseerrvvee aallll wwaarrnniinnggss ppoosstteedd oonn ddiissppeennsseerr.. H15893PAE DATE 4/05 info@opw-fc.com Figure 1 Figure 4 Figure 3 Figure 2 Figure 5 STEP 1 ••Insert nozzle right side up in the fuel pipe.(See Figure 1) Never dispense fuel when the nozzle is upside down. This may cause spills and a hazardous condition. (See Figure 2) ••Ensure nozzle is properly engaged in fuel pipe before engaging dispenser.Some fuel pipe designs prohibit proper retention of the nozzle.In those cases,the nozzle must be hand-held to prevent it from falling out of the fuel pipe.Failure may result in a hazardous spill.(See Figure 3) STEP 2 ••Lift lever on nozzle to start flow. Do not leave nozzle unattended while dispensing fuel. (See Figure 4) ••Nozzle must be pointed in the downward position in the fuel pipe or approved portable container. ••Do not use foreign objects to hold the nozzle lever open (See Figure 5). Only use the nozzle hold-open device.If nozzle is not equipped with hold-open device,nozzle must be hand-held.(See Figure 4) STEP 3 ••Once a nozzle has an automatic shut-off,DO NOT TOP OFF. Allow the nozzle to remain in the car fuel pipe for 10 seconds before removing and returning to dispenser.(See Figure 6) North America Toll Free – TELEPHONE: (800) 422-2525 ◆ Fax: (800) 421-3297 ◆ Email: domestic sales@opw-fc.com International – TELEPHONE: (513) 870-3315 or (513) 870-3261 ◆ Fax: (513) 870-3157 ◆ Email: intlsales@opw-fc.com www.opw-fc.com 9393 Princeton-Glendale Road P.O. Box 405003 Cincinnati, Ohio 45240-5003 Figure 6 If a problem is reported or failure occurs with the nozzle,other dispensing equipment or the dispenser,lock down or place the dispenser out of service until repairs can be made by a qualified technician. The OPW 11B Series and 7HB,12VW Series and 11VA Series nozzles contain a no-pressure/no-flow mechanism.The hose must be pressurized for nozzle to operate. Therefore,should the customer attempt to open the lever before the pump is zeroed and switched on,the customer will not receive fuel. The 14VI Series,the 14VB Series and the 11VF Series contain an anti-spill mechanism. The collection device bellows must be compressed for the nozzle to operate.Therefore,should the customer attempt to open the lever before the nozzle is inserted into the fill pipe compressing the bellows and before the pump is zeroed and switched on,the customer will not receive fuel. OPW recommends Do’s & Don’ts At The Gas Pump video. Video can be found at: www.opw-fc.com or by calling 1-800-422-2525 TROUBLESHOOTING FOR CONVENTIONAL NOZZLES 1Please see OPW’s website: www.opw-fc.com for further information ONE COMPANY. ONE WORLD. ONE SOURCE“. H15891PAE DATE 4/05 info@opw-fc.com TROUBLESHOOTING GUIDE Every OPW nozzle is tested on a pump at the factory and is guaranteed to be in proper working condition when shipped. Its continued proper operation is dependent upon reasonable care in handling. Automatic nozzles should not be dragged or thrown on the ground or paved surfaces. The automatic shut-off elements are subject to damage by such handling which can result in failure to shut off properly. EXPERIENCING LEAKS AT THE INLET What to check? √Check if there is sufficient sealant on the pipe threads. (See Figure 1) • SSoolluuttiioonn: Disconnect and apply proper sealant to the threads. √Check the nozzle for proper attachment to the hose. • SSoolluuttiioonn: Disconnect the hose from the nozzle,reconnect the hose and tighten.(See Figure 2) √Verify that teflon tape was NOT used. • Note:Use of teflon tape can allow for over tightening which leads to cracked inlet threads. CONTINUOUSLY LEAKS OUT OF THE SPOUT What to check? √Leaks out spout and doesn’t stop. Debris or foreign objects in the main poppet.(See Figure 3) • SSoolluuttiioonn: Replace nozzle. √Leaks out spout and slowly stops. There may be debris or foreign object in bleeder poppet. • SSoolluuttiioonn: Remove spout and clean debris. Always use new spout kit and/or new o-rings approved by the manufacturer for replacement.(See Figure 5) THE NOZZLE DOES NOT SHUT OFF OR SPLASH-BACK OCCURS What to check? √Check the minimum flow rate of nozzle.11A & 11B Series minimum flow rate is 3 GPM. 7H Series minimum flow rate is 5 GPM. • SSoolluuttiioonn: Improve flow rate. May need to change dispenser filter. √Check to see if the nozzle is properly in the fill pipe. Liquid must cover the venturi port on the spout tip for shut off.(See Figure 4) • SSoolluuttiioonn: Reposition nozzle in the fill pipe. √Check the spout o-rings to make sure they are not cut or missing.(See Figure 5) • SSoolluuttiioonn: Remove the spout to replace o-rings. Figure 1 Figure 2 Figure 3 Figure 4 O Ring Figure 5 2Please see OPW’s website: www.opw-fc.com for further information ONE COMPANY. ONE WORLD. ONE SOURCE“. LEAKS DURING A FILL What to check? √If the leak is occurring at the lever guard or stem,there may be seal wear.(See Figure 6) •SSoolluuttiioonn: Replace the nozzle. THE NOZZLE SHUTS OFF EARLY (PREMATURE SHUT OFF) What to check? √Check the flow. The flow may be faster than the fill pipe allows.(See Figure 7) •SSoolluuttiioonn: Reduce the flow rate by using a lower clip position. √Make sure the nozzle is properly inserted in the fill pipe.(See Figure 8) •SSoolluuttiioonn: Adjust the nozzle as needed to improve flow. Note:To verify if it is a vehicle fill pipe situation,check nozzle in an approved test container. If nozzle functions properly in the approved test container,fill pipe may be cause of premature shut off. √Check for debris or foreign material in the venturi port. •SSoolluuttiioonn: Remove Debris. √Make sure spout is not bent or damaged.(See Figure 9) •SSoolluuttiioonn: Replace spout. √Check the angle of the spout in the fill pipe. Outlet end of the spout must be below horizontal or the nozzle will shut off. •SSoolluuttiioonn: Reposition nozzle in the fill pipe.(See Figure 10) NOZZLE HARD TO OPEN √Check the hose point static pressure. Maximum static pressure is 50 psi •SSoolluuttiioonn: Verify system is relieving pressure. FILTERS Dirt and debris in the filter can restrict flow. Check dispenser filters. Replace as required. (See Figure 11) HOSES Inspect your hoses regularly. Restrictions in the line will restrict flow rate.(See Figure 12) Figure 6 Figure 7 Figure 8 Figure 11 Figure 12 Figure 10 Figure 9 North America Toll Free – TELEPHONE: (800) 422-2525 ◆ Fax: (800) 421-3297 ◆ Email: domestic sales@opw-fc.com International – TELEPHONE: (513) 870-3315 or (513) 870-3261 ◆ Fax: (513) 870-3157 ◆ Email: intlsales@opw-fc.com w w w.opw-fc.com 9393 Princeton-Glendale Road P.O. Box 405003 Cincinnati, Ohio 45240-5003 TROUBLESHOOTING FOR CONVENTIONAL NOZZLES H15891PAE DATE 4/05 info@opw-fc.com NOTES & WARNINGS NFPA 30-A Automotive and Marine Service Station Code (9-1.2.1) At any installation where the normal flow of product may be stopped other than by the hose nozzle valve, such as at prepay stations, the system shall include listed equipment with the feature that causes or requires the closing of the hose nozzle valve before product flow can be resumed, or before the hose nozzle valve can be replaced in its normal position in the dispenser; or the nozzle valve shall not be equipped with a latch-open device. WARNING Do not use OPW 11A nozzles with a hold-open device at installations (such as pre-pay) where the normal flow of product may be stopped or started by means other than with the nozzle valve. Use the OPW 11B or the OPW 11A without a hold-open device. Failure to comply is a violation of NFPA Code 30-A, and may create a hazardous condition. Use of foreign objects to hold open automatic nozzles could result in shut-off failure and personal injury. NOTE See OPW's Website at: www.opw-fc.com for product instruction sheets, trouble-shooting guides, how-to-use guide and to view Do's and Don'ts at the Gas Pump video. o PW 1 290 AUTOMATIC SHUT-OFF NOZZLES 2 length Weight in.mm.Ibs.kg. 8W'215 1.5 O(iQ Description Upper Poppet Sub-Assy. lower Disc Sub-Assy. lever Sub-Assy. Packing Spout 2 H-01841 4 H-05331 1 H-l0432 5 50-0125 ''3 C04495M Key Part No. Ibs.kg.Description 6.8 3.1 New 6.8 3:1 Rebuilt 6.8 3.1 New 50-0125 1%"i35 Replacement Parts Product No.0.0. in.mm. Replacement Spout IMPORTANT:OPW products should be used in compliance with applicable federal,state and local laws and regulations.Product selection should be based on physical specifications and limitations and compatibility with the environment and materials to be handled. OPW MAKES NO WARRANTY OF FITNESS FOR A PARTICULAR USE.All illustrations and specifications in this literature are based on the latest product information available at the time of publication. OPW reserves the right to make changes at any time in prices,materials,specifications and models and to discontinue models without notice or obligation. / V V / / /-V / V V /' V ~v- Product No.in.mm. 1290-0050 1W'38 1290-0055 1WI 38 12906-0050 1W'38 6ovt.Natl.Stock No.4930-01-290-0756 oo 10 20 30 40 50 60 70 FLOW RATE-GPM (GASOLINE) o o 40 80 120 160 200 240 280 rrrrm FlOWiRATE-LPIv1(GASOUNE}~ 40 30 10 4.0 Ordering SpecificationsForHeavyDuty,High Flow Truck,Bus,and Home Fuel Oil Delivery Service •Venturi type shut-off mechanism - for automatic shut-off. •Aluminum body -lighter in weight and easier to maneuver than other nozzles on the market. •fuo position hold-open device. •One hand control of hold-open mechanism -means easy setting of flow rate. •Easily replaced spout -simply remove the spout retainer nut. •Right angle design -provides larger lever area for better grips and easier control,permitting the nozzle to fit into awkward spaces close to walls and into corners. •Built-in outlet check valve -meets all known requirements of the Division of Measurement Standards. •Dual poppets -make nozzle easy to open against high inlet pressure. .(Maximum static operating pressure 50psi.) Materials Body:aluminum Main stem:stainless steel Packing:Graphite with Teflon® Main Disc:Viton® Inlet size:1WI NPT (Also 1WI BSPP threads - order 1290L) IMPORTANT: OPW products should be used in compliance with applicable federal, state, provincial, and local laws and regulations. Product selection should be based on physical specifications and limitations and compatibility with the environment and materials to be handled. OPW MAKES NO WARRANTY OF FITNESS FOR A PARTICULAR USE. All illustrations and specifications in this literature are based on the latest product information available at the time of publication. OPW reserves the right to make changes at any time in prices, materials, specifications and models and to discontinue models without notice or obligation. OPW 190 High-Flow Nozzles (190-0112 190-0113 190-0114 190-0115 190G-B104 190GW-5115) 190 Right angle design, dual poppets, replaceable hold-open rack. Available in 1”, 1 1/4”, 1 1/2” & 2” threaded inlets. Table of Contents: 1. Features & Benefits 2. Flow Charts 3. Ordering Specifications 4. Replacement Parts Features & Benefits: • Aluminum body - lighter weight, easier to maneuver. • Dual poppets - allow for low flow metering (This nozzle is not intended for high pressure pump applications). • Replaceable Hold-Open Rack - for use when fueling large capacity tanks. Nozzle must be attended at all times during usage. • Right angle design - provides larger lever area for better grip and easier control; permits nozzle to fit into awkward spaces close to walls and into corners. • Drag lugs - protect the nozzle when dragged across rough surfaces; enhances long life durability. • Easily replaced spout - the spout is easily threaded into the body. Replacement spouts are readily available from OPW. • NPT female threads at inlet end - standard pipe threads accept all standard 1", 1 1/4", 1 1/2" and 2" male connections. • Design working pressure - OPW nozzles are designed to work at 50 PSI maximum pressure. Materials Body: cast aluminum Main Stem: stainless steel Stem Seal: Graphite with Teflon® Disc: Viton® Spout: OPW 296 brass or 297 aluminum (optional) GPM LPM Ordering Specifications Product # Inlet Thread Spout dia. lbs. kg. in. mm. in. mm. 190-0112 1" 25 1 1/4" 32 2.3 1.0 190-0113 1 1/4" 32 1 1/4" 32 2.3 1.0 190-0114 1 1/2" 38 1 1/2" 38 3.0 1.4 190-0115 2" 51 2" 51 5.8 2.6 190G-B104 w/Spout and Ground Wire 1 1/2" 38 1 1/2" 38 5.1 2.3 Govt. Natl. Stock #: 4930-01-360-5540 190GW-5115 for Potable Water w/Spout 1 1/2" 38 1 1/2" 38 4.2 1.9 Govt. Natl. Stock #: 4610-01-188-8198 (G threads – call OPW for availability & pricing) OPW 190 (Spout Optional) Replacement Parts Key Part # Description 190- 0112 190- 0113 190- 0114 190- 0115 190- B104 1 H-00195-RB Stuffing Box X X X X 1 H-00250-RB Stuffing Box X 2 H-00538-RE Stem X X X 2 H-06742-RE Stem X 3 H-09600-AH Cap X X X 3 H-09601-AH Cap X 3 H-11592-AH Cap X 4 H-00136-M Spring X X X X 4 H-03666-M Spring X 5 190K-0001 Upper Poppet S/A X X X X 5 H-01814 Upper Poppet S/A X 6 H-01817 Lower Poppet S/A X X X X 6 H-01818 Lower Poppet S/A X 7 H-11925-M Lever X X X X 7 H-06733-M Lever X 8 C-04495-M Packing X X X X X 9 H-07012-M Packing Gland X X X X 9 H-00520-RB Packing Gland X 10 H-00113-RA Packing Nut X X X 10 H-00252-RA Packing Nut X 10 H-00113- RAG Packing Nut X 11 H-08163-M Push Nut X X X X X 12 H-08164-RE Pin X X X X 12 H-08165-RE Pin X 13 297-9020 Spout (optional) X X 13 297-9030 Spout (optional) X 13 297-9040 Spout (optional) X 13 296-0040 Spout, Brass (optional) X 13 296-0060 Spout, Brass (optional) X 13 296-0080 Spout, Brass (optional) X 14 C-04698-M Rack X X X X X 14 H-14105-M Screw X X X X X Not Shown 296CA- 4000 Dust Cap X 153-0910 Strainer X Key Static Grounding Reels FOR REFUELING OR HAZARDOUS AREAS •Aircraft Refueling •Chemical Plants •Grain Elevators •Rescue and HazMat Operations H0606-SG • These reels bond and/or ground aircraft, fuel trucks and other equipment. • Provide smooth operation and require minimum cable pull. • Declutching arbor and adjustable guide arm with cable guide. • Optional stainless steel construction of spool, frame & ratchet system available on HGR series. • Standard finish is oven-cured enamel. • Also available, manual rewind version. All shown with optional cable and/or “Y” branch. Model HGR100Model SS HGR 50 Optional unpolished stainless steel HGR 50 Model HGR 50 (shown with optional “Y” branch) Model GR 75 Model MGR 75Model MHGR 50 Optional Browne Clamp Part No. 9951.0031 Optional Grounding Jack per MIL-C-8341D/4 Part No. 9951.0033 WARNING These Reels are for Static Grounding ONLY NOT intended for lightning protection! . HGR/GR STATIC GROUNDING REELS H0606-SG2M • HP • 08-06 . • Available with 1/8", 7x19 galvanized carbon steel cable • 100 amp Alligator Clamp. • Stainless steel or plastic-covered cable and "Y" branches are available at an additional charge. • Cable guide arm of cast aluminum and 2A+12 Alum Zinc Alloy. Series GR75 • Sealed spring is a good economical choice compact and lightweight. Series HGR • A non-sparking ratchet assembly. • Reels are repairable and parts are readily available. Y D E H G B C X A F C F E G H D Y B X A Model GR75/MGR75 GR75 Shown Models HGR50/HGR100/MHGR50 HGR Shown 553 State Route 143 Westerlo, NY 12193-0159 Telephone 518-797-3791 Toll Free 1-877-GO REELS (467-3357) FAX 1-800-REELING (733-5464) USA FAX 1-518-797-3259 (International) Website: www.hannay.com E-mail: reels@hannay.com To Order (Specify all items listed): • Gauge, length, O.D., and coating if required • Specify “Y” branch if required • Finish if other than standard • Complete model number Reels can be shipped as a parcel package (via FedEx or UPS ground). Model Cable Capacity of Reel Approx. Weight Reel Dimensions Number feet lb. inches m. kg mm Without With A B C D E F G H X Y cable cable GR 75 75 11 14 2 2 7 9 9.25 3.5 9.88 5.06 1 7.88 23 5 6 51 51 178 229 235 89 251 129 25 200 MGR 75 100 11 13 2 2 7 9 9.25 5.25 9.88 5.06 1 7.88 30 5 6 51 51 178 229 235 133 251 129 25 200 HGR 50 75 28 30 4 1.25 10.75 11.5 14.25 5.5 16.75 8.88 2.38 7.5 23 13 14 102 32 273 292 362 159 425 226 60 191 MHGR 50 200 18 20 4 1.25 10.75 11.5 14.25 6.25 16.75 8.88 2.38 7.5 61 8 9 102 32 273 292 362 159 425 226 60 191 HGR 100 100 37 40 4 1.25 13.25 11.5 16.75 5.5 17.75 8.88 2.38 7.5 30 17 18 102 32 337 292 425 140 451 226 60 191 Parts Drawing: HGR Series – ISO 10 Hannay Reels, Inc.Phone 518-797-3791 Toll Free 1-877-GO REELS (467-3357) FAX 1-800-REELING (733-5464) USA or FAX 518-797-3259 (International) www.hannay.com reels@hannay.com Notes: 1. Specifications subject to change. 2. Upon request, reels can be supplied with drum lengths other than shown and with disc sizes in other diameters. 3. Weights shown in chart are for crank rewind models. ADD these amounts for power rewind models: Net (lbs.) Ship (lbs.)Net (kg.) Ship (kg.) Electric 40 40 18.1 18.1 Hydraulic 20 20 9.1 9.1 Air 20 20 9.1 9.1 4. When ordering power rewind models, prefix model number with: A = Air Rewind EP = Electric Rewind (1/2 HP) HD = Hydraulic Rewind (Air rewind reels are supplied with control valve and hose; 12v and 24v DC rewind reels are supplied with switch and solenoid; 115v AC rewind reels are not supplied with switch but can be ordered separately; hydraulic rewind reels are not supplied with control valve.) 5. Finish:refer to Page 4. 6. Be sure to check dimensions and weights prior to ordering. NOTICE:A Flexible Connector must be used between the inlet pipe and the inlet swivel joint. *** x,y indicate mounting holes. See page 2 27 Model Hose Capacity of Reel Approx. Weight Reel Dimensions*** Number feet Crank Rewind 3 inches m.lb.mm. kg. I.D. (in) 1-1/2" 2" I.D. (mm) 38 51 O.D. (in) 2-1/16" 2-9/16" NET SHIP A B D E F F G H X Y O.D. (mm) 52 65 CRANK POWER 8234-26-27 80 60 120 170 26.25 20 27 25.75 33.75 34.75 26.62 13.75 18.75 23.25 24 18 54 77 667 508 686 654 857 883 676 349 476 591 8238-26-27 100 75 145 195 30.25 24 27 25.75 37.75 38.75 26.62 13.75 22.75 23.25 30 23 66 88 768 610 686 654 959 984 676 349 578 591 8246-26-27 145 100 196 245 38.25 32 27 25.75 45.75 46.75 26.62 13.75 30.75 23.25 44 30 89 112 972 813 686 654 1162 1188 676 349 781 591 8226-33-34 85 60 80 150 17.75 11.5 31.5 31.75 25.25 26.25 33.38 17.75 10.25 27.75 26 18 36 68 451 292 800 806 641 667 848 445 260 705 8234-33-34 150 115 133 230 26.25 20 31.5 31.75 33.75 34.75 33.38 17.75 18.75 27.75 46 35 60 105 667 508 800 806 857 883 848 445 476 705 8238-39-40 340 225 218 420 30.25 24 40 39 37.75 38.75 39.88 20.38 22.75 37 104 69 99 191 768 610 1016 991 959 984 1013 518 578 940 C 15.5 393 B X A F Y D H G E SERIES For Power Rewind See Note 4 Parts Drawing – ISO 35 Installation & Parts Manual M/MA Meters Installation: M100-10 2 Table of Contents and Safety Procedures Description Page Number Safety Procedures .............................................. 3 Owner’s Information Packet ................................ 4 How LC Meters Work.......................................... 6 Meter Maintenance ............................................. 7 Relieving Internal Pressure .................................. 7 Installation Requirements ................................... 8 Operation Requirements ..................................... 9 Meter Start Up and Operation ............................. 10 Reversing the Meter Registration ........................ 11 Setting the Standard Adjuster ............................. 12 Servicing the Drive Components .......................... 13 Removing the Dust Cover .................................... 13 Removing the Adjuster and Adjuster Drive Assembly ..................................... 13 Buna/Viton/Teflon Packing Gland........................ 16 The Retaining Plate ............................................. 16 Disassembling the Meter .................................... 17 Removing the Non-Corroded Rotor Gears ........................................................ 19 Removing Corroded Rotor Gears ......................... 20 Reassembling the Meter ..................................... 21 Timing the Rotor Gears ....................................... 22 Torque Chart ....................................................... 23 Wrench and Socket Size Chart .......................... 24 Troubleshooting .................................................. 25 How to Order Replacement Parts ....................... 27 Illustrated Parts Breakdown ................................28-31 Please have the following information available when you make inquires, order replacement parts, or schedule service. If a specific meter accessory is involved, please provide the model and serial number of the accessory in question (see page 4). Your Meter’s Serial Number: ________________________ Your Full-Service Distributor: _______________________ Your Full-Service Distributor’s Telephone Number: _______________________________ NOTICE This manual provides warnings and procedures that are intended to inform the owner and/or operator of the hazards present when using the Liquid Controls Meter on LP-Gas and other products. The reading of these warnings and the avoidance of such hazards is strictly in the hands of the owner-operators of the equipment. Neglect of that responsibility is not within the control of the manufacturer of the meter. Publication Updates and Translations The most current English versions of all Liquid Controls publications are available on our website, www.lcmeter.com. It is the responsibility of the Local Distributor to provide the most current version of LC Manuals, Instructions, and Specification Sheets in the required language of the country, or the language of the end user to which the products are shipping . If there are questions about the language of any LC Manuals, Instructions, or Specification Sheets, please contact your Local Distributor. !!!!! WARNING WARNING WARNING WARNING WARNING • Before using this product, read and understand the instructions. • Save these instructions for future reference. • All work must be performed by qualified personnel trained in the proper application, installation, and maintenance of equipment and/or systems in accordance with all applicable codes and ordinances. • Failure to follow the instructions set forth in this publication could result in property damage, personal injury, or death from fire and/or explosion, or other hazards that may be associated with this type of equipment. 3 Safety Procedures Be Prepared Make sure that all necessary safety precautions have been taken. Provide for proper ventilation, temperature control, fire prevention, evacuation and fire management. Provide easy access to the appropriate fire extinguishers for your product. Consult with your local fire department and state and local codes to make sure that you are adequately prepared. Read this manual as well as all the literature provided in your owner’s packet. In the Event of a Gas Leak In the event of a large gas leak: Evacuate the area and notify the fire department. In the event of a small, contained gas leak: 1. Stop the leak and prevent accidental ignition. 2. Prevent the entrance of gas into other portions of the buildings. Some gases, such as LPG, seek lower levels, while other gases seek higher levels. 3. Evacuate all people from the danger zone. 4. See that the gas is dispersed before resuming business and operating motors. If in doubt, notify your local fire department. Safety Procedures !!!!!WARNINGWARNINGWARNINGWARNINGWARNING Before disassembly of any meter or accessory component, ALL INTERNAL PRESSURES MUST BE RELIEVED AND ALL LIQUID DRAINED FROM THE SYSTEM IN ACCORDANCE WITH ALL APPLICABLE PROCEDURES. Pressure must be 0 (zero) psi. Close all liquid and vapor lines between the meter and liquid source. For Safety Rules Regarding LPG, refer to NFPA Pamphlet 58 and local authorities. Failure to follow this warning could result in property damage, personal injury, or death from fire and/or explosion, or other hazards that may be associated with this type of equipment. In the Event of a Gas Fire In the event of large fires or fires that are spreading: Evacuate the building and notify your local fire department. Stop the leakage only if you can safely reach the equipment. In the event of small, contained fires that you can safely control: Stop the leakage if you can safely reach the equipment. Then use the appropriate extinguisher: Class B fire extinguisher, water, fog, etc., depending on the materials. If in doubt, call your local fire department. 4 Owner’s Information Packet 1. Is all your documentation included with your meter? LC meters come in many variations. The information sent to you depends on the accessories you have ordered with your meter. Make an inventory of your owner’s information packet. First, find your LC packing slip with the computer printout. Locate the serial number and the meter model number on this printout. Cross reference the packing slip number with the actual meter numbers. The illustration on this page will help you locate the Specification and Serial Number Plates on the meter and its accessories. 2. Record your meter serial number in the space provided on the inside cover of this manual. The inside cover also provides a space for your full-service distributor’s name and telephone number. Fill in this information and keep it handy. You will always need your meter serial number and model number when calling for service or parts! See ‘How to Order Replacement Parts’ in this manual. 5 3. Identify your meter’s model-accessory letter. Use the charts shown above to familiarize yourself with meter accessories. Find the meter and letter on the chart which represents your meter, then check with the chart below to see that your red owner’s information packet is complete. Not all accessory levels are available for every model of LC meter. 4. Check your owner’s information packet with the chart shown above to make sure that all the documentation needed for your meter and accessories is in your red information packet. If documentation is missing, call your full-service distributor or Liquid Controls for replacement materials. Owner’s Information Packet 6 How LC Meters Work Liquid Controls meters are positive displacement meters. They are designed for liquid measurement in both custody transfer and process control applications. They can be installed in pump or gravity flow systems. Because of their simple design, they are easy to maintain, and easy to adapt to a variety of systems. The meter housing (1) is designed with three cylindrical bores (2). Three rotors, the blocking rotor (3) and two displacement rotors (4, 5), turn in synchronized relationship within the bores. The three rotors are supported by bearing plates (6, 7). The ends of the rotors protrude through the bearing plates. Blocking rotor gear (8) is placed on the end of the blocking rotor. Displacement rotor gears (9, 10) are placed on the ends of the displacement rotors. These gears create the synchronized timed relationship between the three rotors. As fluid moves through the meter housing, the rotor assembly turns. The liquid is broken into uniform sections by the turning rotors. Fluid displacement happens simultaneously. As fluid enters, another portion of the fluid is being partitioned and measured. At the same time, the fluid ahead of it is being displaced out of the meter and into the discharge line. Since the volume of the bores is known, and the same amount of fluid passes through the meter during each revolution of the blocking rotor, the exact volume of liquid that has passed through the meter can be accurately determined. This true rotary motion is transmitted through the packing gland, the face gear, the adjuster drive shaft, and the adjuster to the register stack and counter. True rotary motion output means consistent accuracy since the register indication is in precise agreement with the actual volume throughput at any given instant. At any position in the cycle, the meter body, the blocking rotor, and at least one of the displacement rotors form a continuous capillary seal between the un-metered upstream product and the metered downstream product. Capillary seals mean no metal-to-metal contact within the metering element. This means no wear. No wear means no increase in slippage, and no increase in slippage means no deterioration in accuracy. Throughout the metering element, the mating surfaces are either flat surfaces or cylindrical faces and sections that are accurately machined. These relatively simple machining operations, plus the fact that there is no oscillating or reciprocating motion within the device, permits extremely close and consistent tolerances within the LC meter. The product flowing through the meter exerts a dynamic force that is at right angles to the faces of the displacement rotors. The meter is designed so that the rotor shafts are always in a horizontal plane. These two facts result in no axial thrust. Therefore, with no need for thrust washers or thrust bearings, the rotors automatically seek the center of the stream between the two bearing plates eliminating wear between the ends of the rotors and the bearing plates. Once again, no wear results in no metal fatigue and no friction. The Liquid Controls meters are made of a variety of materials to suit a variety of products. Because of our no-wear design, capillary seals, and unique rotary metering, LC meters provide unequalled accuracy, long operating life, and unusual dependability. Meter Element Exploded Line Drawing 7 Meter Maintenance Prevent pipe strain or stress from occurring when making meter or accessory repairs. Pipe strain and stress occurs when the pipes are not supported or are not aligned correctly to the meter. The weight of the pipes must always be supported independent of the meter. This means that the meter and accessories can be easily removed without affecting the pipes or the pipe alignment. Never leave any of the pipes hanging. Seasonal meter storage If the meter is used for seasonal work, at the end of each season the meter should be removed from the system and thoroughly flushed with a compatible liquid. This includes removing the drain on the front and rear covers. Then flush the product from the front and rear covers. If flushing with water is preferred, extra care should be taken to drain the meter completely and dry all internal parts. Immediate refilling with a compatible liquid (or oil misting) is essential to prevent corrosion as well as ice damage to parts from moisture that was overlooked after flushing and drying. Do not mar or scratch any of the precision machined surfaces by prying or sanding parts. Torque all fasteners such as screws and bolts in accordance with specifications listed in the ‘Torque Chart’ in this manual (page 22). Stone the machined surfaces when reassembling the meter to assure that the machined surfaces are free of burrs and mars. Repair pulled threads with threaded insert fasteners. These can be used in many instances. Contact your full- service distributor for advice if this occurs. Coat threads with anti-seize when removing and replacing bolts and castings in a meter. Removing flange gaskets When removing the flange assembly, always carefully scrape off the flange gaskets. Make sure that the flange surface has been scraped clean. Discard the old flange gasket and install a new flange gasket. Never reuse old flange gaskets. Examine all fasteners to make sure they are not bent, rusted, or have pulled threads. The threads should all appear evenly placed. If the bolts are bent, check the housing and cover for flatness. Use a straight edge to determine flatness. Look for gaps when disassembling a meter. Use a feeler gauge to check for gaps between the bearing plate and housing. If you do find gaps, check the bearing plates for flatness with a straight edge. Gaps can be caused by shock problems that must be resolved. Contact your full- service distributor for assistance if this occurs. Check the O-rings for damage. Cracked, rough, or worn O-rings should be replaced. However, a more serious problem of shock may be indicated if the O-rings look nibbled. Shock problems must be verified and resolved. Contact your full-service distributor for assistance if this occurs. Check the bearing plates for flatness. Use a straight edge. Warped bearing plates can be caused by shock problems that must be resolved. Contact your full-service distributor for assistance if this occurs. Check with regulatory agency that governs Weights & Measures in your area. Removing the dust cover seal wire or other maintenance procedures may require Weights & Measures recalibration. Relieving Internal Pressure All internal pressure must be relieved to zero pressure before disassembly or inspection of the strainer, air eliminator any valves in the system, the packing gland, and the front or rear covers. Serious injury or death from fire or explosion could result from maintenance of an improperly depressurized and evacuated system. Meter Maintenance and repeatability. 4. Slowly open the valve/nozzle at the end of the supply line. 5. After product has bled off, close the valve/nozzle at the end of the supply line. 6. Slowly crack the fitting on top of the differential valve to relieve product pressure in the system. Product will drain from the meter system. 7. As product is bleeding from the differential valve, slowly reopen and close the valve/nozzle on the discharge line. Repeat this step until the product stops draining from the differential valve and discharge line valve/ nozzle. 8. Leave the discharge line valve/nozzle open while working on the system. Procedure for Non-LPG Meters 1. Turn off pump pressure to the system. 2. Close valves before and after the meter. 3. Remove pressure by removing the drain plugs and draining the meter. Procedure for LPG Meters 1. Close the belly valve of the supply tank. 2. Close the valve on the vapor return line. 3. Close the manual valve in the supply line on the inlet side of the meter. If no manual valve exists on the inlet side, consult the truck manufacturer for procedures to depressurize the system. !!!!! WARNING WARNING WARNING WARNING WARNING 8 Installation Requirements Make sure that all necessary safety precautions have been taken. Provide for proper ventilation, temperature control, fire prevention, evacuation and fire management. Provide easy access to the appropriate fire extinguishers for your product. Consult with your local fire department and state and local codes to make sure that you are adequately prepared. Read this manual as well as all the literature provided in your owner’s manual. If you have any questions, consult with your full-service distributor or call the Service Department at Liquid Controls. Install the meter and accessories in conformance with applicable state and federal construction, electrical and safety codes. NOTE: Class 10 LPG meters must be installed in accordance with the requirements of ANSI-NFPA 58 in addition to all other state and local codes. WARNING: Under normal operation, do not expose any portion of the LP-Gas system to pressures in excess of rated working pressures without an automatic safety valve to vent the over pressure discharge to a place of safety away from the operator and other people. Failure to provide such a safety relief may result in leakage or rupture of one or more of the components in the system. This can result in injury of death from the gas, a fire, or pieces of flying debris from the rupture. Before shipment, protective thread caps were placed in all meter and accessory openings. They should remain in place until you are ready to attach piping. Prior to meter installation, the entire piping system should be thoroughly flushed of all debris, with a liquid that is compatible with the construction of the meter. Keep external surfaces of the meter clean. The meter must always be securely bolted to a platform or supporting member, regardless of the mounting position of the meter. Never ‘hang’ a meter on the connecting piping. Install meter only on the discharge side (downstream) of the system pump. Apply pipe compound to male threads only. Position the meter with service in mind. Provide ample work space. Removing covers can be difficult when work space is not available. Always supply a platform or support for the meter mounting. A meter is metallurgically designed to be physically compatible with a given type of liquid, as originally specified by the customer, and as indicated on the Serial Number Plate. A meter should not be used with a liquid different from the liquid originally specified, unless the physical characteristics and pH rating are similar and the application has been checked with LC Sales and Engineering through your full-service distributor. Install a strainer on the meter inlet to avoid damage from foreign matter, such as weld slag, from entering the system. The strainer must always be located on the inlet side. All meters are tagged identifying their direction of flow. Meters are set with a flow direction of left to right as standard. However, when a meter is ordered, the customer can specify that the flow be set from either direction. If the meter register counts in reverse, the meter is reading the direction of flow in reverse. If this occurs, the meter registration must be reset. See ‘Reversing the Meter Registration’ in this manual for mechanical output meters. Refer to your accessory manual for electrical output meters (such as meters equipped with a pulser). NOTE Always request up-to-date, engineering approved, dimensional drawings before starting any construction. Do not rely on catalog pictures or drawings which are for reference only. After receiving prints, check to see that all equipment ordered is shown and that any extra pressure taps, plugs, etc. are noted and their size specified. 9 Operation Requirements The meter must remain full of product at all times. An easy way to accomplish this is to put the meter assembly in the line below the piping center-line (a sump position). This requires adding elbows and flanges prior to installing the meter. The meter should be installed in a bypass loop, below the pipe center-line, with block valves upstream and downstream. A block valve should be located in the mainstream, labeled as the bypass valve. Caution: Any portion of pipe system that might isolate or block flow should be provided with a pressure relief to prevent damage from thermal expansion. There are excellent benefits to this type of installation. First, the meter is kept full. Second, this type of installation allows the meter to be isolated for servicing and calibration while continuing flow through the bypass valve. Upstream lines must be maintained full to prevent air from entering the meter. If upstream or inlet lines are constructed in a manner which allows reverse flow, foot valves or back checks must be installed. Underground tanks that are furnished with a submersible pump will eliminate many problems that occur with positive displacement pumps (suction pumps) when suction piping is incorrectly sized or when the lift is too great. Every meter should be calibrated under actual service and installation conditions per the API Manual of Petroleum Measurement Standards: Chapter 4 - Proving Systems Chapter 5 - Metering Chapter 6 - Metering Assemblies Chapter 11 Section 2.3 - Water Calibration of Volumetric Provers Chapter 12 Section 2 - Calculation of Petroleum Quantities These chapters of the API Manual of Petroleum Measurement Standards supersedes the API standard 1101. Provide a means of conveniently diverting liquid for calibration purposes. Give careful attention to your system’s pumping equipment and piping because of their influence on liquid being measured as it enters the metering assembly. Systems should be made free of conditions that cause or introduce entrained air or vapor. Follow the manufacturer’s recommendation fully when installing pumps. Give particular attention to factors like: use of foot valves, pipe size to the inlet and conformance to net positive suction head (NPSH) conditions when suction pumping is required. Following the manufacturer’s recommendations will minimize air and vapor elimination problems. For liquids such as light hydrocarbons that tend to flash or vaporize easily at higher ambient temperatures, it is desirable to use flooded suctions and piping sized larger than the nominal pump size. On systems such as vehicle tank installations, piping layout is important in preventing problems with split compartment test conformance. Piping should slope away from a P.D. pump to prevent resurgent re-priming of the pump due to drain back. Hydraulic shock is harmful to all components of an operating system including valves, meter and the pump. In particular, meters must be afforded protection from shock because of their need to measure with high precision. Generally the best protection is prevention, which can be readily accomplished by adjusting valve closing rates in such a manner that shock does not occur. Thermal expansion like hydraulic shock is a phenomenon that can easily damage meters and systems in general. Care should be taken in designing the system to include pressure relief valves in any portion or branch of the system that might be closed off by closure of operating valves or block valves. 10 Meter Start Up and Operation Prior to meter start up, use extreme caution. Make sure that: 1. The meter is properly secured 2. All connections are tight 3. All valves are in the closed position Placing your meter in operation: When placing your meter in operation, the meter and system must be filled slowly with liquid and be free of air prior to start-up. Extreme care must be taken to avoid damaging the meter during this time. The system may be filled by gravity (preferred) or by use of the pump (if required) when filling the system with liquid for the first time. Gravity filling - systems with positive head pressure from product storage above the inlet port of the meter. 1. Make sure all valves (up stream and down stream of the meter) in the system are closed. 2. Crack open the valve located at the storage tank. The meter’s register/counter will start to move and then stop, provided there is not a valve between the tank and the meter inlet. If there is another valve between the tank and meter, repeat this process with each valve until the meter is exposed to the liquid. 3. Once you are assured that the meter has registered some volume and stopped, continue to fully open the tank valve. 4. With the valve(s) open between the tank and the meter, now go to the valve located down stream of the meter. Open the down stream valve slowly until the meter’s register/counter starts to move. Do not run the meter any faster than 25% of its rated flow during start-up. Once the product is flowing out the end of your system, the outlet valve can be opened all the way provided that the system is designed not to exceed the flow rate marked on the meter. NOTE Make sure that your pump can operate against a dead head pressure. If NOT, consult the factory for assistance. NOTE: If the valves are not manual, consult the valve manufacturer for slow flow start-up. Filling the system with a pump - Consult the pump manufacturer for proper pump priming. Once the pump is primed with product, proceed as follows: • Follow steps one through four above for proper meter start-up. Never operate the meter or system when partially filled with liquid, or with pockets of compressed air or vapor present. If these conditions cannot be avoided, air and vapor elimination systems may be required. If you cannot fill the meter slowly by gravity or by using a valve to throttle back the flow, consult the factory. Do not operate the meter at a pressure exceeding that marked on the Serial Number Plate. Under any and all pressure producing circumstances, for instance, thermal expansion and hydraulic shock, the working pressure must not exceed the indicated maximum. If the meter is operated at a rate greater than the maximum recommended GPM, excessive wear and premature failure may occur. The meter can be calibrated for flows below minimum ratings if the flow remains constant and varies within narrow limits or if the product is viscous. A meter should never be run beyond the maximum flow rate determined for that class meter and/or liquid measured. !!!!!WARNINGWARNINGWARNINGWARNINGWARNING Before disassembly of any meter or accessory component, ALL INTERNAL PRESSURES MUST BE RELIEVED AND ALL LIQUID DRAINED FROM THE SYSTEM IN ACCORDANCE WITH ALL APPLICABLE PROCEDURES. Pressure must be 0 (zero) psi. Close all liquid and vapor lines between the meter and liquid source. For Safety Rules Regarding LPG, refer to NFPA Pamphlet 58 and local authorities. Failure to follow this warning could result in property damage, personal injury, or death from fire and/or explosion, or other hazards that may be associated with this type of equipment. 11 Reversing the Meter Registration The direction of flow is specified by the customer when the meter is ordered. The standard direction of flow is from left to right when facing the front of the meter. A red pressure sensitive label indicating inlet is affixed to the meter at time of shipment. If the meter is equipped with a strainer and/or valve, the strainer (and/or valve) MUST be moved when reversing the direction of flow through the meter. The strainer should always be located on the inlet side of the meter. When the meter is equipped with a valve, it is moved to the outlet side of the meter. Some repositioning of the valve components may be required. See the Valve Manual in the Owner’s Information Packet. When the meter is first installed, check the register. If the register counts DOWN, meaning that the register numbers decrease rather than increase, you must reverse the direction of registration by reversing the position of the adjuster drive gear. Reversing the drive to the register is accomplished by reversing the position of the adjuster drive gear relative to the pinion gear of the packing gland, as shown to the left. See below for step-by-step instructions. 1. Refer to “Servicing the Drive Components”, Step 1 to remove the dust cover (page 12). 2. Remove the retaining ring (4) with a screwdriver or pliers. 3. Remove the two retaining spring screws (1) with a standard screwdriver. Note: For M-15, M-25, M-30, and M-40 models loosen the single set screw. 4. Remove the retaining spring (2). 5. Remove the drive shaft (3) mounted with the adjuster drive gear assembly including (4) Retaining Ring and (5) Adjuster Drive Gear. 6. Remove the adjuster drive gear (5) and turn it 180° so that it is upside down from the original installation position. The bushing (7) supports the adjuster drive gear in the lower position. The retaining ring (4) supports the adjuster drive gear in the upper position. Adjuster drive gear engaged from the top.Adjuster drive gear engaged from the bottom. 7. Reassemble the parts in reverse order. Make sure that the adjuster drive gear meshes with the packing gland’s pinion gear (6) without being too tight. Make sure there is a little play in the gear teeth. The retaining ring (4) should be placed in the groove provided on the drive shaft (3), regardless of the adjuster drive gear position. The packing gland pinion gear to adjuster drive gear ratio is either 1:1 or 2:1. In the 2:1 ratio, the pinion of the packing gland is smaller in diameter. Packing Gland 12 Setting the Standard Adjuster NOTE: These instructions apply to meters equipped with mechanical output accessories only. If your meter is equipped with an electrical output (i.e., electronic pulser) refer to your accessory manual, such as the Pulser Manual supplied in your owner’s information packet. 1. Refer to “Servicing the Drive Components”, Step 1 to remove the dust cover (page 12). 2. Check meter registration by delivering product to a reliable, accurate prover. Perform multiple delivery tests to verify the meter repeatability. 3. Record the setting indicated on the adjuster: 4. Note the difference between the volume of the prover and the volume indicated on the meter counter. Calculate the % correction required, as follows: 5. Loosen the adjuster clamp screw. 6. When the prover volume is less than the meter counter volume, add the percentage to the original adjuster setting by turning the thimble towards the arrow marked larger (volume). Correct the original setting by approaching the number desired from the next larger number. For example, if the desired adjuster setting is 2.4, turn the adjuster thimble to the left to number 5, then to the right to obtain the 2.4 setting. Adjuster is currently set at 2.3 in the illustration to the right. 7. When the prover volume is more than the meter counter volume, subtract the percentage from the original adjuster setting by turning the thimble in the direction of the arrow marked smaller volume percent. 8. Retighten the adjuster clamp screw. Run product through the meter to allow the adjuster to take a set. Then make several prover runs to check for accuracy Volume in prover - volume on meter counter % correction = X 100 volume in prover 13 Servicing the Drive Components Removing the Dust Cover Removing the Adjuster and Adjuster Drive Assembly 1. Record the adjuster micrometer setting. 2. Carefully note the adjuster drive gear position. The gear engages the packing gland pinion from below or above. This gear must be reinstalled in its original position or the meter counter will run backwards. 1. Cut the dust cover seal wire with a side cutters. Remove the dust cover screws with a 5/16’ wrench or slotted screwdriver and then remove the dust cover. See “Relieving Internal Pressure” and “Regulatory Agency” in the ‘Meter Maintenance’ section (page 7) of this manual. !!!!!WARNINGWARNINGWARNINGWARNINGWARNING Before disassembly of any meter or accessory component, ALL INTERNAL PRESSURES MUST BE RELIEVED AND ALL LIQUID DRAINED FROM THE SYSTEM IN ACCORDANCE WITH ALL APPLICABLE PROCEDURES. Pressure must be 0 (zero) psi. Close all liquid and vapor lines between the meter and liquid source. For Safety Rules Regarding LPG, refer to NFPA Pamphlet 58 and local authorities. Failure to follow this warning could result in property damage, personal injury, or death from fire and/or explosion, or other hazards that may be associated with this type of equipment. 14 Servicing the Drive Components 3. Use a standard screwdriver to loosen (or remove) the two retaining spring screws. 4. Swing the retaining spring off the adjuster drive bushing. 5. Loosen the adjuster mounting clamp screw with a phillips head screwdriver. Removing the adjuster from the top of the meter when top access is easiest. Front access instructions are on the next page. 6. Remove screws that secure adjuster mounting plate to counter adapter. 7. Lift adjuster mounting bracket with adjuster out of the counter adapter. 8. Remove the adjuster drive assembly from the housing. 15 Servicing the Drive Components Removing the adjuster from the front of the meter when front access is easiest. Top access instructions are on the previous page. 9. Remove the adjuster drive assembly from the housing. 10. Remove the slotted head screw that secures the adjuster to the mounting plate. 11. Bring the adjuster out through the front of the meter by rotating it from left to right to clear the adjuster mounting plate and then pull down to remove from the meter. Servicing the Packing Gland The packing gland is affected by the liquid being metered, the operating temperature, and other system conditions. After prolonged use, the gland may show leakage from the metering chamber. This is a sign of wear. The gland should be replaced or repaired if this occurs. It can be serviced in the field. 1. Remove the two packing gland retaining plate screws with a 5/16” socket and ratchet drive extension or 5/16” nut driver. 2. Pull out the packing gland. 3. Take apart the packing gland by gently prying off the retaining ring with a standard screwdriver. 4. Pull the driver out from the assembly. !!!!! WARNING All internal pressures must be relieved before disassembly or inspection of the strainer, air eliminator, any valves in the system, the packing gland, and the front or rear covers. See “Relieving Internal Pressure” (page 7). 16 Buna/Viton/Teflon Packing Gland 1. Driver 2. Shaft 3. Stainless steel thrust washer 4. Rulon thrust washer 5. Buna/Viton/Teflon “U” Cup 6. Aluminum/stainless housing 7. Washer - Nylon 8. Output gear 2:1 9. Retaining ring 10. Bushing 11. Retaining plate 12. Buna/Viton/Teflon O-ring 13. Two retaining plate screws 14. Output gear 1:1 15. Carbon Guide Bearing 16. Washer - Stainless Steel Packing Gland Retaining Plate The retaining plate has four holes: two that are drilled 1-1/ 2” on center and two that are drilled 1-5/8” on center. If your meter has a counter adapter dust cover (Item #0366) shaped like the illustration shown below, use the holes drilled 1- 5/8” on center to mount the packing gland retaining plate. If your meter does not have the counter adapter dust cover shaped like the illustration shown on the right, use the two holes drilled 1-1/2” on center to mount the packing gland retaining plate. Packing Gland Components Adapter Dust Cover for holes drilled 1-5/8” on center Standard Packing Gland LPG Packing Gland Item 11 (above) 17 Disassembling the Meter Mechanical Output Meters* * For electrical output meters refer to the Pulser Manual supplied in your owner’s information packet. 1. Remove the counter bracket screws with a box wrench or socket driver. The counter bracket can be removed with or without removing the adjuster assembly. NOTE: For Aluminum M-30 and M-40 models the counter bracket and front cover are one piece. Go to step 2. 2. Turn the meter on either the inlet or outlet side. Let it stand to allow the product to drain from the meter chamber. 3. Locate the drain plugs on the front and rear covers. Remove the drain plugs using an allen wrench. Let the meter stand to allow product to drain from the front and rear covers. !!!!! WARNING All internal pressures must be relieved before disassembly or inspection of the strainer, air eliminator, any valves in the system, the packing gland, and the front or rear covers. See “Relieving Internal Pressure” (page 7). !!!!!WARNINGWARNINGWARNINGWARNINGWARNING Before disassembly of any meter or accessory component, ALL INTERNAL PRESSURES MUST BE RELIEVED AND ALL LIQUID DRAINED FROM THE SYSTEM IN ACCORDANCE WITH ALL APPLICABLE PROCEDURES. Pressure must be 0 (zero) psi. Close all liquid and vapor lines between the meter and liquid source. For Safety Rules Regarding LPG, refer to NFPA Pamphlet 58 and local authorities. Failure to follow this warning could result in property damage, personal injury, or death from fire and/or explosion, or other hazards that may be associated with this type of equipment. 18 4. Use a socket wrench or box end wrench to remove the screws securing the front cover. Remove the screws that hold the rear cover. The number of screws will vary depending on meter size. 5. Remove the front and rear covers. MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models have a driven reduction gear attached with a shoulder bolt to the center of the front bearing plate. 6. Carefully remove the O-rings / flat gaskets from front and rear of the housing. Undamaged Buna or Viton O- rings may be reused. Flat gaskets and Teflon O-rings should always be replaced and never reused. 7. Hold a spare displacement rotor gear between the right displacement rotor gear and the blocking rotor gear to keep them from turning (if unavailable, use a shop rag between gear teeth). Use the rotor gear wrench or socket to remove the right displacement rotor gear screw and washer. MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models: Rotor gears are on the meter back. All other models: Rotor gears are on the front. 8. Hold the spare gear between the left displacement rotor gear and blocking rotor gear. Use the rotor gear wrench or socket to remove the screw and the packing gland driver held by the screw. 9. Hold the spare gear between the right displacement rotor gear and the blocking rotor gear. Use the rotor gear wrench or socket to remove the left displacement rotor gear screw and washer. Disassembling the Meter 19 Disassembling the Meter 1. Insert two standard screwdrivers behind the blocking rotor gear: Gently pry the gear off its rotor tapered end. If the gears show signs of corrosion, or do not pry off easily, use the alternative method described in steps 5-8. 2. Use the same method to remove the left rotor gear and the right rotor gear. Remember, if the gear does not pry off easily, or feels stuck, use the alternative method described in steps 5-8. 3. As each gear comes off the rotor remove the key (1) from the rotor keyway (2). Save the key to use when reassembling the meter. 4. Use the bearing plate wrench to remove the screws that hold the front bearing plate to the meter housing. On the back of the meter housing, remove the screws that hold the rear bearing plate to the housing. Go to step 1, Removing the Bearing Plates. Removing Corroded Rotor Gears 5. Replace all three rotor gear screws, without washers, halfway onto each of the rotor ends. 6. On the back of the meter housing, remove the screws that hold the rear bearing plate to the housing using the bearing plate wrench or socket. The number of screws varies with the size of meter. Removing Non-Corroded Rotor Gears 20 Disassembling the Meter 7. With a plastic or non-metallic mallet, tap on the heads of the screws lightly and equally. As you tap on the screw heads, the gears are driven off the rotors. As the rotors are driven in, the rear bearing plate and the rotor assembly are pushed away from the housing. NOTE: For carbon insert bearing plates, remove the rear plate first and then each rotor as it is hand supported. 8. Use the bearing plate wrench or socket to remove the screws that hold the front bearing plate to the meter housing. The number of screws varies between different meter sizes. Removing the Bearing Plates and Rotors 1. Insert a screwdriver into each of the two notches near the dowel pins. Be careful not to mar any of the surfaces. Gently pry the front bearing plate off the dowel pins. 2. Remove the front bearing plate and rotor assembly by pulling a rotor straight out from the housing. Be careful not to mar any of the surfaces. MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models: Pull the rotor from the rear bearing plate. This will also remove the drive reduction gear which is attached to the blocking rotor. 3. Remove the remaining bearing plate from the other side by inserting a screwdriver into each of the two notches near the dowel pins. Be careful not to mar any surfaces. Gently pry the front bearing plate off the dowel pins. NOTE: MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models have a driven reduction gear in attached with a shoulder bolt to the center of the front bearing plate. 4. Inspect and clean all critical surfaces like gear teeth, rotors and internal housing faces. Remove any crystalline formations using fine emery cloth or a fine wire brush. Be careful not to mar or alter the shape of any of the parts. Changing the shape of the parts may interfere with their operation. Remove nicks and burrs on metal parts with a stone. Remove all grit and other foreign particles. These may also damage parts and interfere with proper operation. Replace all parts that appear worn or damaged. 21 Reassembling the Meter 1.MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models: Rotor gears are on the rear bearing plate. All other models: Rotor gears are on the front bearing plate. Install the non-rotor gear bearing plate using the bearing plate screws and wrench. 2. Insert the non-tapered ends on the three rotors into the housing. Place each rotor into its respective bore in the installed bearing plate. MA-4, M-5, and MA-5 old style models, M-60 and M-80 current models: Make sure that the teeth of the driving reduction gear mesh with the teeth of the driven reduction gear. 3. Place the remaining bearing plate over the three tapered rotor ends and fasten it with the bearing plate screws. Use the bearing plate wrench. The number of screws varies with meter size. 4. The rotors should have a small amount of end-play and be easy to turn. Test each rotor, one at a time. Turn the rotors to make sure that they revolve freely. Jog the rotors from end to end to check for end-play. If they do not move easily in both tests, remove the rotors and check for burrs and corrosion deposits. Clean them thoroughly. Repeat Steps 2, 3 and 4. 5. The rotor key is a small wedge of metal. Each rotor has a notch, or “keyway”, to hold a key. Position a key into each one of the three rotors. Press the keys into the rotor keyways with your thumb and forefinger. 6. Slide the blocking rotor gear on its tapered rotor end. Slide the right displacement rotor gear on its tapered rotor end so that the timing marks line up between the two gears. See ‘Timing the Rotor Gears’ on the next page. Hint: Before you place the right displacement rotor gear on its tapered end, hold the right rotor gear in position. Turn the blocking rotor gear. Try to line up the timing marks before you place the right displacement rotor gear on its tapered rotor end. 7. Position the left displacement rotor gear on its tapered rotor end so that its timing mark lines up with the blocking rotor gear. See ‘Timing the Rotor Gears’. 22 Reassembling the Meter Timing the Rotor Gears Rotor gears are timed by lining up the timing marks. The blocking rotor gear has a tooth directly in front of its timing mark. On the displacement rotor gears, the timing mark falls in front of the space between two gear teeth. Make sure that the tooth in front of the timing mark on the blocking rotor gear connects with the space in front of the timing mark on the displacement rotor gear. You may need to remove the gears and reposition them several times on their rotor ends in order to get the timing marks to line up correctly. For more information, See ‘Troubleshooting’. 1. Position the spare displacement rotor gear between the left displacement rotor gear and the blocking rotor gear to prevent the gears from moving. Attach the right displacement gear washer and screw using the rotor gear wrench. Tighten the screw to the torque specification listed in the Torque Chart (page 22). 2. Keep the spare displacement rotor gear positioned by the left displacement rotor gear. Attach the left displacement gear washer and screw using the rotor gear wrench. Tighten the screw to the torque specification listed in the Torque Chart. 3. Position the spare displacement rotor gear between the right displacement rotor gear and the blocking rotor gear. Attach the blocking rotor gear with the packing gland driver and screw using the rotor gear wrench. Tighten the screw to the torque specification listed in the Torque Chart. 4. Rotate the gears to make sure that the rotors turn freely. Burrs, foreign material, or marred surfaces can restrict the rotor movements. It may be necessary to remove the gears and rotors and deburr and clean the surfaces again. 5. Install an O-ring (1) into the groove (2) on the front of the meter housing. The M-60 and M-80 models use a flat gasket. 6. Fasten the front cover (3) with the cover screws (4) using the cover socket or open end/box end wrench. NOTE: 6A. LC recommends tightening the front cover screws in a criss-cross or “star” pattern with a minimum of two passes. First pass should be at half-torque, with final pass(es) at full torque. This will ensure uniform seal compression on cover O-ring or gasket. See M-7 pattern on page 22 for reference. Meter Assembly Exploded View 7. Install the front drain plug (6) in the front drain plug hole (7) using the drain plug allen wrench. 8. Install an O-ring (8) into the groove (9) on the rear of the meter housing. The M-60 and M-80 models use a flat gasket. 9. Fasten the rear cover (10) with the cover screws (11) using the cover socket or open end/box end wrench. NOTE: 9A. LC recommends tightening the rear cover screws in a criss-cross or “star” pattern with a minimum of two passes. First pass should be at half torque, with final pass(es) at full torque. This will ensure uniform seal compression on cover O-ring or gasket. See M-7 pattern on page 22 reference. 10. Install the rear drain plug (12) in the rear drain plug hole (13) using the drain plug allen wrench. 11. If your meter is equipped with an electrical output accessory, such as a digital pulser, reinstall it according to the instructions outlined under ‘Reinstalling...’ in your accessory manual, such as the Pulser Installation, Operation and Maintenance Manual supplied in your owner’s information packet. Install the front drain plug (6) in the front drain plug hole (7) using the drain plug allen wrench. 23 Torque Chart Torque Chart TORQUE PATTERN M-7 COVERS Bolt Size Foot-Pounds Newton-Meter NOMINAL* NOMINAL* #8 (.164) - 32 UNC-2A 42 4.8 #10 (.190) - 24 UNC-2A 63 7.1 1/4" (.250) - 20 UNC-2A 7.3 9.9 5/16" (.3125) - 18 UNC-2A 15.3 20.7 3/8" (.375) - 16 UNC-2A 27 37 7/16" (.4375) - 14 UNC-2A 43 58 1/2" (.500) - 13 UNC-2A 66 90 5/8" (.625) - 11 UNC-2A 132 179 3/4" (.750) - 10 UNC-2A 233 316 Grade 5 Fasteners *Torque Tolerance is ± 10% 24 Wrench and Socket Size Chart Meter Element MA-4 M-5 MA-5 M-7 MA-7 M-10 M-15 M-25 MA-15 M-30 M-40 M-60 M-80 Dust Cover Screws 5/16 hex wrench 5/16 hex wrench slotted screwdriver slotted screwdriver slotted screwdriver slotted screwdriver Drain Plug 1/4" Allen wrench 1/4" Allen wrench 3/8" Allen wrench 3/8" Allen wrench 3/8" Allen wrench 3/8" Allen wrench Meter Cover Screws 1/2" hex wrench/socket 1/2" hex wrench/socket 1/4" Allen or 1/2" hex wrench/socket 1/4" Allen or 1/2" hex wrench/socket 9/16" hex wrench/socket 3/4" hex wrench/socket Counter Bracket Screws 3/8" hex wrench/socket 3/8" hex wrench/socket N/A 3/8" hex wrench/socket N/A 3/8" hex wrench/socket Bearing Plate Screws 5/16" hex wrench/socket 5/16" hex wrench/socket 5/16" hex wrench/socket 5/16" hex wrench/socket 7/16" hex wrench/socket 1/2" hex wrench/socket Rotor Gear Screws 5/16" hex wrench/socket 3/8" hex wrench/socket 3/16" Allen wrench 3/16" Allen wrench 3/16" Allen wrench 3/16" Allen wrench NOTE: FOR ROTOR GEAR SCREWS Please apply these techniques when repairing meters in the field. 1. Prior to installation, apply a small amount of Locquic Primer N764 to each screw. 2. Apply a light coat of Loctite 242 in three even strokes to each screw. The Loctite and Locquic primer are not to be applied to the female connection in the rotor. 25 Troubleshooting PROBLEM: Leakage past packing gland drive shaft housing from internal metering chamber. PROBABLE CAUSE AND SOLUTION: Internal seal of packing gland assembly is worn. Replace packing gland and O-ring seal. OPERATING NOTE: Two common causes of packing gland leakage are thermal expansion and hydraulic shock. If two valves in a piping system (on either side of the meter) are closed at one time, and if the temperature rises as little as 1°F in the system, it could result in a rise in pressure within the system that would exceed the working pressure rating of the meter. To avoid this hazard caused by thermal expansion, a pressure-relief valve of some kind must be installed in the system. Hydraulic shock occurs when a large volume (mass) of liquid is moving through a pipe line at some flow rate and a valve is suddenly closed. When the flow is stopped, the entire mass of the liquid in the piping system acts as a battering ram causing a shock effect within the meter. The greater the mass length of line and/or velocity, the greater the hydraulic shock. Since the valve is usually located at the meter outlet, the meter housing, packing gland and the meter internal members receive the full impact of such hydraulic shock. To prevent this hazard a slow closing two-stage valve should be used with the meter. On those systems where mass length of line, etc. are of such magnitude as to preclude the elimination of hydraulic shock with the use of a two-stage slow closing valve, an impact-absorbing air cushioning device should be used. PROBLEM: Leakage from the cover gasket. PROBABLE CAUSE AND SOLUTION: Gasket has been damaged due to shock pressure or cover bolts have not been tightened sufficiently. PROBLEM: Product flows through meter but the register does not operate. PROBABLE CAUSE AND SOLUTION: A.Check packing gland, and gear train. B.If all meter parts are moving then problem is in register. Faulty register should be checked and repaired by trained mechanic. C.Remove register from meter. If all meter parts are moving but output shaft of adjuster assembly is not, adjuster is worn and must be replaced. D.If totalizer numerals (small numbers) on register are recording, but the big numerals are not moving, register needs repair. E.Packing gland gear not turning. For M-60 and M-80 meters, the drive blade may be sheared. Replace the packing gland. This may be caused by starting the flow too rapidly. !!!!!WARNINGWARNINGWARNINGWARNINGWARNING Before disassembly of any meter or accessory component, ALL INTERNAL PRESSURES MUST BE RELIEVED AND ALL LIQUID DRAINED FROM THE SYSTEM IN ACCORDANCE WITH ALL APPLICABLE PROCEDURES. Pressure must be 0 (zero) psi. Close all liquid and vapor lines between the meter and liquid source. For Safety Rules Regarding LPG, refer to NFPA Pamphlet 58 and local authorities. Failure to follow this warning could result in property damage, personal injury, or death from fire and/or explosion, or other hazards that may be associated with this type of equipment. 26 Troubleshooting PROBLEM: Breaking teeth on timing gears. PROBABLE CAUSE AND SOLUTION: A.Starting or stopping flow in meter too rapidly. B.Pump bypass not adjusted properly. PROBLEM: Product flows through meter but register does not record correctly. PROBABLE CAUSE AND SOLUTION: A.Adjuster not properly calibrated. B.Incorrect gear plate or gear ratio has been installed. C. Air is in the system. PROBLEM: No flow through meter. PROBABLE CAUSE AND SOLUTION: A.Faulty non-functioning pump. B.Valve not open or not functioning. C.Meter “frozen” due to build-up of chemical “salts” or foreign material inside metering chamber. To correct, clean the meter and inspect for damage. PROBLEM: Meter runs too slowly. PROBABLE CAUSE AND SOLUTION: A.Valve internal mechanism faulty. Valve does not open fully. B.Meter gears or rotors partially “salted” enough to slow up rotation of parts. To correct, clean the meter. C. Downstream restriction. D. Clogged strainer basket. PROBLEM: The meter counts down in reverse (the meter numbers decrease). PROBABLE CAUSE AND SOLUTION: It is necessary to reverse the direction of flow by reversing the adjuster drive gear. See ‘M-7/MA-7 Meter Start Up and Operation: Reversing the Meter Registration’ in this manual. 27 How to Order Replacement Parts 1. Refer to the exploded view drawings on Pages 27-31. Find the four digit item number for the part you want to order. The item numbers are listed on the exploded drawings. 2. Find the computer printout titled Parts List that has been inserted in the Owner’s Information Packet which was shipped with your order. Look up the item number on the Parts List. The Parts List shows each item number with a corresponding part number. Find the corresponding five digit part number for the item you want to order. The part number represents an individual piece, a kit, or a complete assembly. 3. Inform your distributor of the part number that you need. The part number is the only number that allows the distributor to find the correct component for your meter. The Bills of Material for most meter classes are on the LC public website. Always check the website for the most current BOM. 28 Illustrated Parts Breakdown M5 through M25 Meters (including MA Meters) NOTE: Numbers shown are ITEM numbers, not Part Numbers. Refer to the Bill of Materials supplied in the red Owner’s Information Packet to locate the PART NUMBER associated with these ITEM NUMBERS. NOTE: Meter components may appear different between models. 29 Illustrated Parts Breakdown M30, M40 Meters NOTE: Numbers shown are ITEM numbers, not Part Numbers. Refer to the Bill of Materials supplied in the red Owner’s Information Packet to locate the PART NUMBER associated with these ITEM NUMBERS. NOTE: Meter components may appear different between models. 30 Illustrated Parts Breakdown M60, M80 Meter Cover NOTE: Numbers shown are ITEM numbers, not Part Numbers. Refer to the Bill of Materials supplied in the red Owner’s Information Packet to locate the PART NUMBER associated with these ITEM NUMBERS. NOTE: Meter components may appear different between models. 31 Illustrated Parts Breakdown M60, M80 Meter Element NOTE: Numbers shown are ITEM numbers, not Part Numbers. Refer to the Bill of Materials supplied in the red Owner’s Information Packet to locate the PART NUMBER associated with these ITEM NUMBERS. NOTE: Meter components may appear different between models. © 2005 Liquid Controls Pub. No. 48683 (01/03/05) A Unit of IDEX Corporation 105 Albrecht Drive Lake Bluff, IL 60044-2242 1.800.458.5262 • 847.295.1050 Fax: 847.295.1057 www.lcmeter.com Filters Gauges The Morrison Fig. 818 Clock Gauge is used for mea- suring liquid level in aboveground storage tanks. Readout format is on a standard 12 hour clock face. Small hand represents feet and the large hand inches. Gauge can be read up to 20-30 ft. away to within 1/8”. Maximum measurement capability is 12 feet. The gauge can be rotated 360° after mounting. The stan- dard float will pass through a 2” opening. SPECIFICATION / DETAIL OPTIONS A—Overfill Alarm: Yes/No B—Body Connection: Male (M), Female (F) C—Float Device: Standard 2” Drop Tube Float (2”) or No Float (NO) D—Face Plate: Standard (S), Metric (M), Floating Suction (I) E—Height: (Inches) F—Width: (Inches) G—Clock Diameter: (Inches) H—Shipping Weight: (lbs) I—Body: Aluminum with 2” NPT or BSP (Metric) Connection Float: Stainless Steel; Cable: Stainless Steel Fig. 818 Patent # 5144836 I.D. NUMBER A B C D E F G H I 818F--0100 AG N F 2" S 9.62 3.48 6.06 4.5 NPT 818MEF0100 AG N F 2" M 9.62 3.48 6.06 4.5 NPT 818---0100 AG N M 2" S 8.42 3.48 6.06 4.5 NPT 818MET0100 AG N M 2" M 8.42 3.48 6.06 4.5 NPT 818I--0000 AG N M NO I 8.42 3.48 6.06 4 NPT 818SS-0100 AG N M 2" S 8.42 3.48 6.06 4.5 NPT 818MEB0100 AG N M 2" M 8.42 3.48 6.06 4.5 BSP Not to Scale P.O. Box 238 • Dubuque, Iowa 52004-0238 563.583.5701 (tel) • 800.553.4840 • 563.583.5028 (fax) www.morbros.com E F Floating Suction Face PlateStandard Face Plate Face Plate Options: Metric Face Plate Fig. 818 Clock GaugeMorrison Bros. Co.www.morbros.com Specification Sheet Level Switches Liner 1000 VENTURE BLVD. WOOSTER, OHIO 44691 USA, U.S. Toll-Free: Phone 800-927-8578, Fax 800-649-2737 Phone 330-262-1111, Fax 330-263-6950 www.xr-5.com ©2009 Seaman Corporation G E O M E M B R A N E S P E C I F I C AT I O N S Test Method MetricStandardXR-5®8130 Reinforced High Performance XR-5 ®8130 Reinforced Geomembrane 30.0 2 oz/yd 2 1017 70 g/m 2 30.0 mils min 0.76 mm min 175/245 N min 2448/2448 N min Pass @ -34° C 0.5% max each direction 17.5 daN/5 cm min 5 cm seam, 4 hrs, 2.5 cm strip 1068 N/2.54cm @21° C 534 N/2.54cm @ 70° C 3330 N min 40/55 lb min 550/550 lb min Pass @ -30° F 0.5% max each direction 40 lb/2 in min 2 in seam, 4 hrs, 1 in strip 240 lb @ 70° F 120 lb @ 160° F 750 lb min Weight Thickness ASTM D751 ASTM D751 ASTM D4533 Trapezoid Tear ASTM D751 Grab Tensile ASTM D2136 4 hr - 1/8” mandrel ASTM D1204 100°C - 1 hr ASTM D751 Dielectric Weld ASTM D751 4-hour test ASTM D751 Ball Tip Tear Strength Breaking Yield Strength Low Temperature Resistance Dimensional Stability Adhesion Heat Sealed Seam Dead Load Seam Strength Bursting Strength +-+- Polyester 6.5 oz/yd 2 Polyester 220 g/m 2 Base Fabric Type Base Fabric Weight (nominal) ASTM D751 Seaming:Thermal welding methods are recommended. No glues or solvents are suggested. Test Method MetricStandardXR-5®8130 Reinforced #2 Rating max 800 psi min 5.51 MPa min 13 daN/5 cm min or Film Tearing Bond 2450 N min 0.3 cm max 1200 N min 1.4 x 10 -5 cm/cm/°C max 15 lb/in min or Film Tearing Bond 550 lb min 2000 cycles (min) before fabric exposure 50 mg/100 cycles maximum weight loss 8000 hrs (min)-No appreciable changes or stiffening or cracking of coating 0.025 kg/m 2 max @ 70° F/21° C 0.14 kg/m 2 max @ 212° F/100° C 1/8 in max 275 lb min 8 x 10 -6 in/in/°F max Blocking Resistance Hydrostatic Resistance ASTM D751 Procedure A ASTM D751 180° F ASTM D413 Type A ASTM D751 Grab Test Method Procedure A ASTM D3389 H-18 Wheel 1kg Load ASTM G153 (Carbon-Arc) ASTM D471 Section 12 7 Days ASTM D751 ASTM D4833 ASTM D696 Adhesion - Ply Bonded Seam Strength Abrasion Resistance Weathering Resistance Water Absorption Wicking Puncture Resistance Coefficient Of Thermal Expansion/Contraction We believe this information is the best currently available on the subject. We offer it as a suggestion in any appropriate experimentation you may care to undertake. It is subject to revision as additional knowledge and experience are gained. We make no guarantee of the results and assume no obligation or liability whatsoever in connection with this information. In case of conflict between standard and metric specifications, standard shall apply. Revised April 2009 High Performance XR-5 ®8130 Reinforced Geomembrane 350 lb (approximate) FED-STD 101C Method 2031 Puncture Resistance See Chemical Resistance Table Environmental/Chemical Resistant Properties 1550 N (approximate) Paint Piping Specialties Maxi-Dry Dry Disconnect Couplings PT CouplingI PT Coupling Company •P.O.Box 3909 •Enid,OK 73702 •Tol l-Fr e e :(8 0 0 )6 5 4 -03 2 0 •To ll -F ree F a x :(8 00 )8 2 8 -26 4 9 •F a x :(58 0 )2 37 -3 4 35 •in f o @ptco u p li n g .c o m •ww w.ptc o u p li n g .c o m 70 M a x i - D r y — D r y D i s c o n n e c t C o u p l i n g s I Size Alum/Buna Alum/Viton Item #Part #Item #Part # 3"x 4"40000342 MD30X40D 40000342V MD30X40D Size Alum/Buna Alum/Viton Alum/Teflon Alum/EPDM Item #Part #Item #Part #Item #Part #Item #Part # 1 1/2"40001500 MD15D 40001500V MD15D 40001500T MD15D 40001500E MD15D 2"40000200 MD20D 40000200V MD20D 40000200T MD20D 40000200E MD20D 3"40000300 MD30D 40000300V MD30D 40000300T MD30D 40000300E MD30D Size SS/Buna SS/Viton SS/Teflon SS EPDM Item #Part #Item #Part #Item #Part #Item #Part # 1 1/2"44001500 MD15D 44001500V MD15D 44001500T MD15D 44001500E MD15D 2"44000200 MD20D 44000200V MD20D 44000200T MD20D 44000200E MD20D 3"44000300 MD30D 44000300V MD30D 44000300T MD30D 44000300E MD30D PA R T M D **2 0 P FA M A X I -D RY FLANGED ADAPTER Made in U.S.A. PA R T M D **D M A X I -D RY C O U P L E R COUPLER X FEMALE NPT THREAD Made in U.S.A. PA R T M D **A M A X I -D RY A D A P T E R ADAPTER X FEMALE NPT THREAD Made in U.S.A. Size Alum/Buna Alum/Viton Alum/Teflon Alum/EPDM Item #Part #Item #Part #Item #Part #Item #Part # 1 1/2"40001530 MD15A 40001530V MD15A 40001530T MD15A 40001530E MD15A 2"40000230 MD20A 40000230V MD20A 40000230T MD20A 40000230E MD20A 3"40000330 MD30A 40000330V MD30A 40000330T MD30A 40000330E MD30A Size SS/Buna SS/Viton SS/Teflon SS EPDM Item #Part #Item #Part #Item #Part #Item #Part # 2"47000230 MD20PFA 47000230V MD20PFA 47000230T MD20PFA MD20PFA Size SS/Buna SS/Viton SS/Teflon SS EPDM Item #Part #Item #Part #Item #Part #Item #Part # 1 1/2"44001530 MD15A 44001530V MD15A 44001530T MD15A 44001530E MD15A 2"44000230 MD20A 44000230V MD20A 44000230T MD20A 44000230E MD20A 3"44000330 MD30A 44000330V MD30A 44000330T MD30A 44000330E MD30A Size Alum/Buna Alum/Viton Item #Part #Item #Part # 3"x 4"40000340 MD30X40A 40000340V MD30X40A *Dimensions are in inches Adapter MD15A MD20A MD30A MD30X40A A 4.3 5.2 6.8 6.8 B 3.2 3.7 5.6 5.6 C 1 1/2"NPT 2"NPT 3"NPT 4”NPT D22.5 44 A B C D PT Coupling Company •P.O.Box 3909 •Enid,OK 73702 •To l l-F r e e:(8 0 0)6 5 4-0 3 2 0 •To ll -F r e e F ax :(8 00 )8 2 8-26 4 9 •F a x :(5 8 0 )2 3 7 -34 3 5 •i n f o @p tc o u p li n g .c o m •w w w.p t c o u p l i n g .c o m 71 PT Coupling M a x i - D r y — D r y D i s c o n n e c t C o u p l i n g sI M A X I -D R Y Made in U.S.A. Size Coupler Pressure Rating ABCDEFG H I 1 1/2"MD15D 200 PSI 6.9 1.5 3.9 6.1 4.1 2.5 5.0 1 1/2"NPT 2.0 2"MD20D 150 PSI 7.5 2.0 4.4 6.1 4.3 2.5 5.1 2"NPT 2.5 3"MD30D 125 PSI 9.5 2.5 6.5 9.0 5.5 4.0 6.0 3"NPT 4.0 3”x 4”MD30X40 125 PSI 9.5 2.5 6.5 9.0 5.5 4.0 6.2 4”NPT 4.0 PT Coupling Company •P.O.Box 3909 •Enid,OK 73702 •Tol l-Fr e e :(8 0 0 )6 5 4 -03 2 0 •To ll -F ree F a x :(8 00 )8 2 8 -26 4 9 •F a x :(58 0 )2 37 -3 4 35 •in f o @ptco u p li n g .c o m •ww w.ptc o u p li n g .c o m 72 M a x i - D r y — D r y D i s c o n n e c t C o u p l i n g s I Ref #Description Material 1-1/2"Item #2"Item #3"Item # 1 Stem 17-4PH SS 44001502 44000202 44000355 3 Bushing 303 SS 44001503L 44000203L 44000303L 4 Link 304 SS 44001504 44000204 44000304 5 Poppet CF8M 44001505 44000205 44000305 6 Poppet Pin Kit 304 SS 44000150 44000261 44000318 8 O-Ring Retainer 303 SS 44001508 44000208 N/A 9 Coupler Seal Kit Buna-N 40001515 40000217 44000315 Viton 44001523 44000223 44000316 EPDM 44001550 44000229 44000360 Teflon Encap.Viton 44001524 44000224 44000317 10 Handle Kit Stainless A351 CF8M 44001512 44000212 44000312 11 Stop Plate 303 SS 44001525 44000225 44000325 12 Cam Arm ASBY Sintered SS 5001520A 5001520A 5001530A 12a STA-LOK II Cam Asby Sintered SS 44001564 44001564 44000321 14 Adapter Poppet Kit 303 SS 44001565 44000262 44000319 17 Adapter Seal Kit Buna-N 40001540 40000240 44000340 Viton 44001544 44000244 44000344 EPDM 44001560 44000235 44000365 Teflon Encap.Viton 44001545 44000245 44000345 18 Spring SS 44001538 44000238 44000338 19 Swivel Seal Kit Buna-N N/A 40010290 40010390 Viton N/A 40010280 40010380 M A X I -D RY C O U P L E R A N D A D A P T E R R E P L A C E M E N T PA R T S Made in U.S.A. PT Coupling Company •P.O.Box 3909 •Enid,OK 73702 •To l l-F r e e:(8 0 0)6 5 4-0 3 2 0 •To ll -F r e e F ax :(8 00 )8 2 8-26 4 9 •F a x :(5 8 0 )2 3 7 -34 3 5 •i n f o @p tc o u p li n g .c o m •w w w.p t c o u p l i n g .c o m 73 PT Coupling M a x i - D r y — D r y D i s c o n n e c t C o u p l i n g sI PA R T M D ** D S S W -M A X I -D R Y STRAIGHT SWIVEL COUPLER X FEMALE NPT THREAD SWIVEL Made in U.S.A. Alum/Buna Alum/Viton Alum/Teflon Alum/EPDM Item #Part #Item #Part #Item #Part #Item #Part # 40000260 MD20DSSW 40000260V MD20DSSW NA MD20DSSW NA MD20DSSW MD30DSSW MD30DSSW MD30DSSW MD30DSSW Size 2" Coupler MD20D Swivel Press.Rating 150 PSI A9 B 3.5 C 4.4 D 6.1 E 4.3 F 2.5 G 5.1 H 2"NPT I 2.5 Alum/EPDM Stainless/Buna Stainless/EPDM Item #Part #Item #Part #Item #Part # 40000200SE MD20DSW 44000200S MD20DSW MD20DSW MD30DSW 44000300S MD30DSW 44000300SE MD30DSW PA R T M D **D 9 0 - MAXI-DRY COUPLER 90°SWIVEL COUPLER X FEMALE NPT THREAD 90°ELBOW SWIVEL Made in U.S.A. Size 2"3" Coupler MD20D 90 degree Swivel MD30D 90 Degree Press.Rating 150 PSI 125 PSI A 10.9 14.05 B45 C 4.4 6.85 D 6.1 9 E 4.3 5.5 F 2.5 4 G 5.1 6.2 H 1"NPT 3"NPT I 2.5 4 J 2.8 4.4 *Dimensions are in inches. Alum/Buna Alum/Viton Alum/Teflon Item #Part #Item #Part #Item #Part # 40000200S MD20DSW 40000200SV MD20DSW 40000200ST MD20DSW 40000300S MD30DSW 40000300SV MD30DSW MD30DSW ES-MS-781SS_781SSWE Models: 781-SS*, 781-SS-WE* Cast Stainless Steel Flanged & Butt Weld End Y Strainers Sizes: 1⁄2" – 24" (15 – 600mm) Typical Service • Used extensively to strain foreign matter from pipelines and provide economical protection for costly pumps, meters, valves, and other similar mechanical equipment. • Especially important where weld debris is likely present in the pipeline. • Well suited for long service in high pressure and temperature applications. Features • Machined seats in both body and cap align and lock the screen in place to stop sediment bypass. • Machined seats facilitate alignment and accurate reseating after servicing. Construction • Designed for Class 150 specifications. • Heavy gauge reinforced screens are used. IMPORTANT NOTE:Model 781-SS-WE ends are machined to match Schedule 40 pipe. Other connections are available, consult factory. Self-Cleaning • Self-cleaning is accomplished by opening the plug or valve connected to the blowoff outlet. Blowoff Outlets • Blowoff outlets are NPT tapped at location C. See next page for NPT sizes. • Blind covers are available, consult factory. Capacity • Generously proportioned bodies. • Open Area Ratio much greater than pipe size, ensuring low pressure drop. • Minimum of 4 to 1 Open Area Ratio. Screens Materials ALSO AVAILABLE: Body/Cap: Alloy 20 (ASTM A351 Gr.CN7M) Hastelloy C Monel (Ni-Cu) STANDARD (WATER) STEAM RECOMMENDATION MODEL SIZES MATERIAL OPENING MATERIAL OPENING All 1⁄2" - 4" 304SS .062 perf 304SS .033 perf All 5" and Up 304SS .125 perf 304SS .062 perf *781/781-WE supersedes model 761/761-WE. 761/761-WE still available upon request 781-SS Class 150 781-SS-WE Class 150 781-SS, 781-SS-WE Body Stainless Steel, ASTM A351 Grade CF8M Cover Stainless Steel, ASTM A351 Grade CF8M Gasket 316 Graphite Pressure/Temperature–Non-Shock Model Material Rating 781-SS, Stainless 290psi@-20°F to100°F 781-SS-WE Steel 19.99 bar @ 37.78°C 150psi @ 565°F 10.34 bar @ 296.11°C Model 781-SS Model 781-SS-WE Dimensions and Weights A Division of Watts Water Technologies, Inc.USA: 1491 NC Hwy 20 West St. Pauls, NC 28384; www.muellersteam.com Tel: 910-865-8241 Fax: 910-865-6220 Toll Free Phone 1-800-334-6259 Toll Free Fax: 1-800-421-6772 ES-MS-781SS_781SSWE 0715 © Mueller Steam Specialty, 2007 Mueller Steam Specialty product specifications in U.S. customary units and metric are approximate and are provided for reference only. For precise measure- ments, please contact Mueller Steam Specialty Technical Service. Mueller Steam Specialty reserves the right to change or modify product design, construction, specifications, or materials without prior notice and without incurring any obligation to make such changes and modifications on Mueller Steam Specialty products previously or subsequently sold. SIZE DIMENSIONS WEIGHT AB CD (NPT) Screen Removal in. mm in. mm in. mm in. mm in. mm lbs. kgs. 781-SS 1⁄2 15 5 7⁄8 149 3 1⁄2 89 3⁄8 10 5 130 5.5 2.5 3⁄4 20 7 3⁄8 187 3 3⁄4 95 1⁄2 15 5 130 10.25 4.6 12573⁄8 187 3 3⁄4 95 1⁄2 15 5 130 10.25 4.6 11⁄4 32 7 178 4 3⁄4 121 1⁄2 15 7 178 9.75 4.4 11⁄2 40 7 1⁄8 181 4 3⁄4 121 1⁄2 15 7 178 12.5 5.6 25077⁄8 200 5 1⁄4 133 1⁄2 15 7 178 18 8.1 21⁄2 65 9 3⁄4 248 6 1⁄2 165 1 25 9 3⁄4 248 28 12.7 380101⁄16 256 7 178 1 25 10 254 34 15 4 100 12 1⁄8 308 8 1⁄4 210 1 1⁄2 40 12 305 55 25 5 125 15 5⁄8 397 11 1⁄4 286 2 50 20 508 90 40 6 150 18 1⁄2 470 13 1⁄2 343 2 50 20 508 153 69 8 200 21 3⁄8 543 15 1⁄2 394 2 50 22 3⁄4 578 220 100 10 250 26 660 18 1⁄2 470 2 50 28 711 320 145 12 300 29 7⁄8 759 22 1⁄4 565 2 50 30 762 550 250 14 350 36 914 25 635 2 50 36 1⁄2 927 975 442 16 400 41 9⁄6 1056 26 1⁄2 673 2 50 42 1067 1635 741 18 450 46 1168 34 7⁄8 886 2 50 50 7⁄8 1292 2376 1078 20 500 49 1⁄2 1257 39 991 2 50 55 3⁄8 1407 2675 1213 24 600 58 3⁄8 1483 44 1⁄6 1122 2 50 67 1⁄4 1708 4880 2213 781-SS-WE 1⁄2 15 6 5⁄8 168 3 1⁄2 89 3⁄8 10 5 130 3 1.3 3⁄4 20 8 5⁄16 211 3 3⁄4 95 1⁄2 15 5 130 9 4 12585⁄16 211 3 3⁄4 95 1⁄2 15 5 130 9 4 11⁄4 32 10 1⁄8 257 5 1⁄4 133 1⁄2 15 7 178 12 5.4 11⁄2 40 10 1⁄4 260 5 1⁄4 133 1⁄2 15 7 178 13 5.9 250101⁄4 260 5 1⁄4 133 1⁄2 15 7 178 13 5.9 21⁄2 65 10 5⁄8 269 6 1⁄2 165 1 25 9 3⁄4 248 14 6.3 3 80 12 305 7 178 1 25 10 254 20 9 4 100 14 1⁄2 368 8 1⁄4 210 1 1⁄2 40 12 305 40 18 5 125 19 5⁄16 491 13 1⁄2 343 2 50 20 508 90 40 6 150 19 5⁄16 491 13 1⁄2 343 2 50 20 508 90 40 8 200 23 3⁄8 594 15 3⁄4 400 2 50 22 3⁄4 578 168 76 10 250 27 3⁄8 695 19 483 2 50 28 711 250 113 12 300 32 813 22 1⁄4 565 2 50 30 762 440 200 14 350 36 914 25 635 2 50 36 1⁄2 927 815 370 16 400 41 1⁄16 1056 26 1⁄2 673 2 50 42 1067 1433 650 18 450 46 1168 34 7⁄8 886 2 50 50 7⁄8 1292 2152 976 20 500 49 1⁄2 1257 39 991 2 50 55 3⁄8 1407 2393 1085 24 600 58 3⁄8 1483 44 1⁄6 1122 2 50 67 1⁄4 1708 4486 2034 Pressure Drop See Pressure Drop Charts in Technical Data Section of the Mueller Steam Specialty Engineering binder. Model 781-SS Model 781-SS-WE A B D C A B D C Before installing the “Y” strainer, be sure its pressure rating is correct for the system. If the end connections are threaded or designed for sol- dering or brazing, be sure the piping is straight and not at an angle or offset. If the strainer has flanged ends, be sure the flanges of the con- necting piping are square with the pipe so that no undue stresses are put on the strainer or piping when tightening flange bolts. Tighten in sequence, crossing to opposites. For maximum efficiency, a differential pressure gauge installed across the inlet and outlet will indicate pressure loss due to clogging and may be used as a guide to determine when cleaning is required. Normally, when differential pressure reaches 5–10psi, screen must be cleaned. If the strainer is equipped with a blow-down valve, open and flush out until any sediment is removed. If the strainer is not fitted for blow-down cleaning, (strainer must be off line), remove the cover or cap and clean the screen. Reinstall the screen in the strainer in the same position as before and tighten cover or cap. Replace the gasket if necessary. Keeping a spare, clean screen will minimize shut down time. Warning Individuals performing removal and disassembly should be provided with suitable protection from possibly hazardous liquids. Note: Large size “Y” strainers are supplied with Breech-Lok screens. To remove screen, rotate screen 45°, Breech-lok will disengage. Spare Parts To order replacement screens or gaskets, which are the only items nor- mally required, you should specify the following: A. Size and model number of strainer or casting number as it appears on the body of the strainer B. Specify the type of service. For example: water, steam, gas, oil, air. The working pressure and temperature of the system and the parti- cle size to be strained out should also be specified. IOM-MS-YStrainers “Y” Strainers Installation, Operation and Maintenance Limited Warranty:Mueller Steam Specialty warrants each product to be free from defects in material and workmanship under normal usage for a period of one year from the date of original shipment. In the event of such defects within the warranty period, the Company will, at its option, replace or recondition the product without charge. This shall constitute the sole and exclusive remedy for breach of warranty, and the Company shall not be responsible for any incidental, special or consequential damages, including without limitation, lost profits or the cost of repairing or replacing other property which is damaged if this product does not work properly, other costs resulting from labor charges, delays, vandalism, negligence, fouling caused by foreign material, damage from adverse water conditions, chemi- cal, or any other circumstances over which the Company has no control.This warranty shall be invalidated by any abuse, misuse, misapplication or improper installation of the product.THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.Any implied warranties that are imposed by law are limited in duration to one year. Some States do not allow limitations on how long an implied warranty lasts, and some States do not allow the exclusion or limitation of incidental or consequential damages. Therefore the above limitations may not apply to you. This Limited Warranty gives you specific legal rights, and you may have other rights that vary from State to State. You should consult applicable state laws to determine your rights. USA: 1491 NC Hwy 20 West St.; Pauls, NC 28384; www.muellersteam.com A Division of Watts Water Technologies, Inc. Te l: 910-865-8241 Fax: 910-865-6220 To ll Free Phone 1-800-334-6259 Toll Free Fax: 1-800-421-6772 IOM-MS-YStrainers 0641 EDP# 1915978 © Mueller Steam Specialty, 2006 Body Screen Gasket Cover Bolts Typical flanged end "Y" strainer Typical threaded "Y" strainer Mounting Positions The cover of the "Y" side should face down Cover NPT tapping for drain plug (Optional on some models) Body Screen Gasket Ve r tical Horizontal Cap (Tapping for NPT drain plug optional on some sizes) Pumps The Gorman-Rupp Company80Series® 80 Series®pumps are designed for non-stop workloads.The straight-in-suction design of these high-efficiency pumps guarantees quick,positive self-priming and allows them to operate at high suction levels than most other self-priming centrifugal pumps.Liquid enters directly into the impeller eye.A suction check valve presents in-line return flow when the pump is shut off.And,because 80 Series pumps have few moving parts,maintenance is minimal.80 Series pumps are available with self-lubricated mechanical shaft seals. Specifications Size: 1-1/4"(31.25 mm),1-1/2"(37.5 mm),2"(50 mm),3"(75 mm), 4"(100 mm),6"(150 mm),8"(200 mm),10"(250 mm) Max Capacity:2,800 GPM (177 lps) Max Head:205'(62 m) Max Solids:2.5"(64 mm) Max Temperature:160 F (71 C) Materials of Construction:Cast Iron,Stainless Steel Features Straight-In Suction Design Exclusive 80 Series pump design provides higher suction lift,increased efficiency and allows pumps to operate at higher suction lifts than most other self-priming centrifugal pumps. Multiple Seal Options 80 Series pumps are available with Gorman-Rupp grease seal,mechanical shaft seal,depending on pump application. High Efficiency Impeller Multi-vane open impeller is designed for high efficient.Impeller will handle up to 2-3/8"(60 mm)solids, depending on pump model. Replaceable Wearplate Replaceable wearplate provides maximum operating efficiency at all times.No expensive castings to Copyright by the GormanRupp Company 2000 Single Phase. Totally Enclosed; Fan Cooled. Explosion Proof. Thermal Overload Protection. Sealed Bearings.Capacity Start/Induction Run. Model 81 1/2D3X1 1P/3P Specification Data THE GORMANRUPP COMPANY MANSFIELD, OHIO GORMANRUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Specifications Subject to Change Without Notice Printed in U.S.A. Sec. 50 PAGE 515 APRIL 2000 Self Priming Centrifugal Pump Electric Motor Driven Size 1 1/2" x 1 1/2" A B C D E PUMP SPECIFICATIONS Size: 1 1/2" x 1 1/2" NPT (38,1 mm x 38,1 mm) F emale. Casing: Gray Iron No. 30. Maximum Operating Pressure 34 psi (2,4 kg/cm2).* Open Type, Five Vane Impeller: Copper Alloy No. C93700. Handles 1/2" Diameter Spherical Solids. Impeller Shaft: Stainless Steel No. 416. Replaceable Vane Plate: Gray Iron No. 30. Intermediate Bracket: Gray Iron No. 30. Bearing Lubrication: Sealed. Gasket: Cork. ORing: BunaN. Internal Wetted Hardware: Brass and Standard Plated Steel. External Hardware: Standard Plated Steel. Optional Equipment: Consult Factory. MOTORVOLUTE HOUSING SUCTION INTERMEDIATE BRACKET IMPELLER SEAL ASSEMBLYDISCHARGE SEAL DETAIL Type 21, Mechanical, SelfLubricated. Carbon Rotating Face. NiResist Stationary Face. Fluorocarbon Elastomers (DuPont Viton or Equivalent). Stainless Steel No. 188 Cage and Spring. Maximum Temperature of Liquid Pumped, 160 F. (71 C.)* *Consult Factory for Applications Exceeding Maximum Pressure and/or Temperature Indicated. VANE PLATE MOTOR SPECIFICATIONS Description Frame Size Hertz Service Factor RPM Voltage 56 60 1.0 115/230 Type x Horsepower Three Phase. Induction Start/ Run. Explosion Proof. Totally Enclosed; Fan Cooled. Thermal Overload Protection. Sealed Bearings. 208/230/460 34501.0 x Copyright by the GormanRupp Company 2000 Specification Data APPROXIMATE DIMENSIONS and WEIGHTS SECTION 50, PAGE 515 NET WEIGHT: 79 LBS. (35,8 KG.) SHIPPING WEIGHT: 89 LBS. (40,4 KG.) EXPORT CRATE: 3.5 CU. FT. (0,1 CU. M.) THE GORMANRUPP COMPANY MANSFIELD, OHIO GORMANRUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Specifications Subject to Change Without Notice Printed in U.S.A. The Gorman-Rupp CompanyOSeries® O Series®pumps have a straight-in suction design (there is no check valve) which eliminates entrance restrictions and provides better suction performance when handling solvents and similar liquids.O Series pumps can be used as transfer pumps,clean water supply pumps,on spray applications and many other industrial uses.They provide reliable performance with few moving parts and offer savings in maintenance and efficiency.O Series pumps are available pedestal mounted for flex coupling or v-belt coupling to a power source (not availabe for petroleum applications)or close coupled to electric motors.Power- take-off models are also available with helical gear increasers for heads up to 400 feet (121 meters). Specifications Size:2"(50 mm),3"(75 mm),4"(100 mm),6"(150 mm) Max Capacity:1,350 GPM (85 lps) Max Head:400'(122 m) Max Solids:0.688"(17 mm) Max Temperature:160 F (71 C) Materials of Construction: Aluminum,Bronze,Cast Iron, Ductile Iron Features High-Efficiency Impeller High efficiency,closed impeller.Brass or aluminum construction standard.Other metals available for special applications. Long Life Seals O Series pumps are available with self-lubricated mechanical shaft seals for dependability and long life. Viton®/Fluoroelastomers are standard.Teflon®and double seals available on some model.Consult factory for special applications. Adaptability O Series Pumps are available pedestal mounted for flexible coupling to a power source.Sturdy pedestal has heavy- duty shaft and ball bearings.Some models available close coupled to electric motors.Power take-off models incorporate pump gear increaser with helical gears. Straight-In Suction Design Smart Ash Incinerator Over 3,000 in use around the world This Multipurpose Incinerator is used for: • Remote Locations • Mining Camps • Job Sites • Oil Drilling Operations • Truck Stops • Construction Sites • Islands • Barges • Campsites • Military Installations EPA Approved for Small Batch Incineration www.smallincinerators.com Ask for our instructional video, CD or DVD on the operation of the Smart Ash Multipurpose Incinerator. The air powered Smart Ash uses no external fuel. Simply load a 55 gallon (208L), open head steel drum, light the load and clamp on the lid. A whirlwind of fire and intense heat is created inside the drum, burning your refuse with no smoke and no smell. Thousands of satisfied customers are currently using Smart Ash around the world to eliminate a wide variety of burnable waste materials. Combustion is complete, leaving ash equal to 3% by volume of the original load. Air pollution tests: Smart Ash has been tested following EPA testing formats. Federal EPA publication (Federal Register 40 CFR part 60) exempts Cyclonic Barrel Burner from State Emission Plans. Emission test data available upon request. Smart Ash Burns: • Oil Soaked Absorbent Materials • Used Filters • Waste Oil • Paper Waste • Wood By-Products • Oily Rags, Gloves, Clothes • Grease • Domestic Waste ATTACH AIR HOSE – REST LID ON DRUM2 IGNITE LOAD - TURN ON MINIMUM AIR3 CLOSE & CLAMP LID4 WASTE IS REDUCED TO 3% ASHES BY VOLUME6INCREASE AIR SUPPLY SLOWLY FIRE WILL BURN CLEAN5 LOAD DRUM1 SPECIFICATIONS Construction Stainless Steel Lid, Painted tubular Steel Frame, 2-Blowers, Axial Vane 120V standard or 220V optional Requirements 55 Gallon (208L) Steel Open Head Drum Weight 96 lbs. (44 kg) Without Drum, 139 lbs. (63 kg) With Drum Height 46" tall, (116 cm) Floor Space (With Drum) 36" x 26" (91 x 66 cm) Average Burn Rate 50 lbs./HR (22 kg./HR) Requirements Electrical 120volt or 220volt Location Exterior Smart Heat is used in conjunction with Smart Ash or Smart Ash with the Oil Away Attachment installed. Smart Heat is easy to operate. Load the Smart Ash, light load and when positioned under Smart Heat’s heat exchanger, switch on Smart Heat’s 1000 cfm blower. Heat from the Smart Ash warms the air flowing through the heat exchanger and returns air to the facility. Smart Heat burns on site materials and generates free heat for buildings, a smart solution for the disposal of oily absorbents, rags and filters. An accessory for waste oil disposal and general incineration The Oil Away Attachment is an accessory for the Smart Ash Incinerator. The Oil Away System injects waste oil into a burning Smart Ash and can be used for “wet” loads typically not burnable in the Smart Ash because the waste stream has high moisture content. Designed for loads with moisture contents above 15%, a Smart Ash with the Oil Away Attachment significantly increases the types of refuse and waste materials that can be burned. Waste oil is eliminated at rates up to 6 gallons (23 L) per hour. 10" DUCT1000 CFM BLOWER HEAT EXCHANGER SMARTASH MODEL 100COLD AIR FLOWHOT AIR FLOWENERGY RECOVERY FURNACE SPECIFICATIONS Construction Heat exchanger, heavy duty steel with heat resistant coatings Weight 420 lbs. (191 kg) Dimensions 67" tall, 60" long, 37" wide (170 cm x 152 cm X 94 cm) Fuel source Oily waste Fuel Container Smart Ash Model 100 (55 gallon (208L) steel drum not included) REQUIREMENTS Electrical Two, 120volt outlets or 220volt optional Location Exterior Located outside the facility, Smart Heat pulls cool air from inside the building and circulates heated air back into the building. Smart Ash with the Oil Away Attachment can burn: • Waste Oil for Disposal • Restaurant Waste • Organic Materials • Oily Rags, Gloves, Clothes • Paper Waste • Absorbent Materials • Filters • Wood By-Products • General Non-Hazardous Waste Oil Away Attachment includes: • Metered pump (3-6 gallons per hour) (11 - 23 Liters/Hr) • Hose to Riser • Riser inside drum • Nozzle • Fittings and attachments www.smallincinerators.com Oil Away Attachment BIN-001 06/10/051309 West Main, Carmi IL 62821 USA Our Smart Ash portable incinerators have had fantastic success around the world. Customers have written telling us how great a job the Smart Ash does for them. We are from the USCG Aids to Navigation Team and we would like to say that your Smart Ash is an excellent product. I suggested that we should have one due to our excess of waste products from the lighthouses. We now have two Smart Ash burners and we use them for all the trash that is included in the regulations. EM3 Richard Hoyt Our company purchased an Elastec Incinerator and we are very pleased with the performance of the unit. Management is quite satisfied with the results because it saves us disposal costs and leaves very little ash. It is a very good unit. Rodrigo Bustamante – Maintenance Engineer Puerto Ventanas S.A. We work at a remote Hydraulic Generating Station in Northern Manitoba. As part of an Environmental Management System initiative plan to minimize the effects of our waste stream, we bought a Smart Ash burner. It has proven itself beyond a doubt. It reduces piles of greasy oily rags to mere cups of ash with no smoke and the residue is harmless. I would recommend this product to anyone. Don – Manitoba Hydro The Smart Ash is a great product. It is very efficient and fast. Nothing is left but the metal part of the oil filters and a small amount of ash. We are very pleased with it. Mickey – Mississippi River Transporters www.smallincinerators.com Smart Ash success stories Tel: (618) 382-2525 Fax: (618) 382-3610 E-mail: elastec@elastec.com Over 3,000 in use around the world. Tank Appurtenances UL Listed Emergency vent (pressure relief only) used on aboveground storage tanks, as a code requirement, to help prevent the tank from becoming over-pressurized and possibly rupturing if ever exposed to fire. Vent must be used in conjunction with a “normal vent.” Correct application of this vent requires proper vent size and selection for the tank system in order to meet the specific venting capacity. CHART KEY: A—Size: 8” or 10” B—Venting Capacity/CFH (in 1000’s) C—Mounting Connection: Female N.P.T. (BLANK); Male N.P.T.(M); Flanged (F) D—Pressure Settings: 2.5, 8, 16 oz/ in2. Pressure Required to Open Vent. E—Cover: Cast Iron Painted (I); Aluminum (AL); Optional Iron Powder Coated (Consult Factory for Details); Bolt: Steel-Zinc Plated F—Seat Material: Brass (BR) or Viton O-Ring (O) G—Body Material: Aluminum (AL) or Iron (I) Diameter—Dimension Across Vent Height—Dimension From Base to Top When Closed Weight—Shipping Weight Conformance Including: NFPA 30, 30a, UL 142, UL 2244, API 2000 and PEI RP200. Additional References: NFPA 30, UL 142, Morrison Venting Guide SPECIFICATION OPTIONS: Fig. 244 8” & 10” Emergency VentMorrison Bros. Co. Specification Sheet www.morbros.com P.O. Box 238 • Dubuque, Iowa 52004-0238 563.583.5701 (tel) • 800.553.4840 • 563.583.5028 (fax) www.morbros.com WARNING: DO NOT FILL OR UNLOAD FUEL FROM A STORAGE TANK UNLESS IT IS CERTAIN THAT THE TANK VENTS WILL OPERATE PROPERLY. Morrison tank vents are designed only for use on shop fabricated atmospheric tanks which have been built and tested in accordance with UL 142, NFPA 30 & 30A, and API 650 and in accordance with all applicable local, state, and federal laws. In normal operation, dust and debris can accumulate in vent openings and block air passages. Certain atmospheric conditions such as a sudden drop in temperature, below freezing tempera- tures, and freezing rain can cause moisture to enter the vent and freeze which can restrict internal movement of vent mechanisms and block air passages. All storage tank vent air passages must be completely free of restriction and all vent mechanisms must have free movement in order to insure proper operation. Any restriction of airflow can cause excessive pressure or vacuum to build up in the storage tank, which can result in structural damage to the tank, fuel spillage, property damage, fire, injury, and death. Monthly inspection, and immediate inspection during freezing conditions, by someone familiar with the proper operation of storage tank vents, is required to insure venting devices are functioning properly before filling or unloading a tank. I.D. Number A B C D E F G Diameter Height Weight 244M--0600 AV 8 453.30 M 8 I BR AL 10.1 5.9 34 244MI-0600 AV 8 453.30 M 8 I BR I 10.1 5.9 34.6 244OM-0600 AV 8 453.30 M 8 I O AL 10.1 5.7 34 244OMI0600 AV 8 453.30 M 8 I O I 10.1 5.7 34.6 244M--0700 AV 8 453.30 M 16 I BR AL 10.1 7.5 68 244MI-0700 AV 8 453.30 M 16 I BR I 10.1 7.5 75.4 244OM-0700 AV 8 453.30 M 16 I O AL 10.1 7.4 68 244OMI0700 AV 8 453.30 M 16 I O I 10.1 7.4 75.4 244F--0100 AV 8 509.55 F 8 I BR AL 10.1 4.6 42 244OF-0100 AV 8 509.55 F 8 I O AL 10.1 4.5 42 244F--0200 AV 8 509.55 F 16 I BR AL 10.1 6.1 75 244OF-0200 AV 8 509.55 F 16 I O AL 10.1 6.1 75 244---0600 AV 8 462.00 8 I BR AL 10.1 5.5 34.7 244I--0600 AV 8 462.00 8 I BR I 10.1 5.5 44.3 244O--0600 AV 8 462.00 8 I O AL 10.1 5.3 34.7 244OI-0600 AV 8 462.00 8 I O I 10.1 5.3 44.3 244---0700 AV 8 462.00 16 I BR AL 10.1 7.1 68 244I--0700 AV 8 462.00 16 I BR I 10.1 7.1 77.6 244O--0700 AV 8 462.00 16 I O AL 10.1 6.9 68 244OI-0700 AV 8 462.00 16 I O I 10.1 6.9 77.6 244F--0300 AV 10 808.35 F 2.5 AL BR AL 16 6.1 32 244OF-0300 AV 10 808.35 F 2.5 AL O AL 16 5.1 32 244F--0400 AV 10 808.35 F 8 I BR AL 16 6.9 71 244OF-0400 AV 10 808.35 F 8 I O AL 16 5.5 71 244F--0500 AV 10 808.35 F 16 I BR AL 16 8.1 125 244OF-0500 AV 10 808.35 F 16 I O AL 16 6.8 125 244FI-0400 AV 10 808.35 F 8 I BR I 16 6.8 104.6 244FI-0500 AV 10 808.35 F 16 I BR I 16 8.1 151.5 244OFI0400 AV 10 808.35 F 8 I O I 16 5.6 99.4 244OFI0500 AV 10 808.35 F 16 I O I 16 6.8 146.3 244MT-0600 AV 8 453.30 M 8 I BR AL 10.1 8.2 38.5 244MT-0700 AV 8 453.30 M 16 I BR AL 10.1 9.8 72.5 244OMT0600 AV 8 453.30 M 8 I BR AL 10.1 8.1 38.5 244OMIT0700 AV 8 453.30 M 16 I BR AL 10.1 9.7 72.5 EMERGENCY VENTEMERGENCY VENTEMERGENCY VENTEMERGENCY VENTEMERGENCY VENT FIG. 244 SERIESFig. 922 Combination Vent/Overfill AlarmMorrison Bros. Co. Specification Sheet www.morbros.com P.O. Box 238 • Dubuque, Iowa 52004-0238 563.583.5701 (tel) • 800.553.4840 • 563.583.5028 (fax) www.morbros.com CHART KEY: A—Size B—Pressure Poppet Setting C—CFH D—dB Rating (this is measured at a distance of 1’ with a fill rate of 90 GPM) Height—Dimension From Bottom to Top of Vent Weight—Shipping Weight The Fig. 922 Combination Vent/Overfill Alarm is a fully mechanical, high intensity audible alarm that alerts you when your tank is near full while also allowing your tank to breathe during filling and dispensing operations. The unit is equipped with a whistle which incorporates a 2” or 3” full port pressure/vacuum vent. The pressure poppet setting is 6 oz./in2 or 8 oz./in2 with a vacuum relief setting of 1 oz./in2. The unit can be set to activate at 90% fill height by adjusting the cable length to the float device. The adjustment tool is provided. The unit attaches to a 2” or 3” N.P.T. pipe mounted on the tank. Minimum fill rate for alarm to operate is 20 GPM. CONSTRUCTION: • Anodized Aluminum Body • Viton Seals • Stainless Steel Screens • Stainless Steel Handle • Aluminum Rainguard • Stainless Steel Float • Stainless Steel Cable Compatible with gasoline, diesel, ethanol and methanol. WARNING: All emergency vents, fill connections, tank openings and piping connections must be airtight. Alarm/vent airway must be free of any obstruction such as dirt or ice when filling or unloading tank. Emergency vent should be set at least 2 oz. higher than the combination vent. WARNING: DO NOT FILL OR UNLOAD FUEL FROM A STORAGE TANK UNLESS IT IS CERTAIN THAT THE TANK VENTS WILLOPERATE PROPERLY. Morrison tank vents are designed only for use on shop fabricated atmospheric tanks which have been built and tested in accordance with UL 142, NFPA 30 & 30A, and API 650 and in accordance with all applicable local, state, and federal laws. In normal operation, dust and debris can accumulate in vent openings and block air passages. Certain atmospheric conditions such as a sudden drop in temperature, below freezing temperatures, and freezing rain can cause moisture to enter the vent and freeze which can restrict internal movement of vent mechanisms and block air passages. All storage tank vent air passages must be completely free of restriction and all vent mechanisms must have free movement in order to insure proper operation. Any restriction of airflow can cause excessive pressure or vacuum to build up in the storage tank, which can result in structural damage to the tank, fuel spillage, property damage, fire, injury, and death. Monthly inspection, and immediate inspection during freezing conditions, by someone familiar with the proper operation of storage tank vents, is required to insure venting devices are functioning properly before filling or unloading a tank. WARNING: Normal vents such as pressure vacuum and updraft vents for aboveground storage tanks should be sized according to NFPA 30 (2008) 21.4.3 I.D. NUMBER A B C D WIDTH HT WT. 922---0200 AA 2" 8 oz. 30,300 120 6.8" 9.0" 7.50 lbs. 922---0400 AA 2" 6 oz. 30,120 120 6.8" 9.0" 7.50 lbs. 922---0300 AA 3" 8 oz. 43,020 110 6.8" 9.0" 5.25 lbs. 922---0500 AA 3" 6 oz. 44,160 105 6.8" 9.0" 5.25 lbs. SPECIFICATION OPTIONS: Page 6 Morrison Bros. Co. 800•553•4840○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○ 178 Series Threaded Style Fill Cap Tight-seal style threaded cap. For fill port of small storage tanks. Lockable with a padlock. Body is available in iron (IB) or brass (BB). Cap is available in iron (IC) or brass (BC). Buna- N gasket. Fig. 178DT…made for a drop tube with 2" straight pipe threads and Buna-N gasket. Fig. 178GSP…2" brass body, aluminum cap labeled, “Gauge Stick Port.” Fig. 178 Fig. 307 Fig. 179 Fig. 179M Fig. 155S 307 and 307P Fill Cap, Adaptor and Probe Cap Brass fill cap and adaptor with chain. Available as a complete unit, brass adaptor separate, or brass cap and chain separate. Buna-N gasket. Fig. 307P…2" cap only—drilled and tapped with 3/8" or ½" NPT hole for probe. Fig. 178DT Fill Cap Options Size BB-BC BB-IC Weight Weight 2" NPSF 2.25 lbs 2.0 lbs 155 and 155SSize Complete Adaptor Cap, Chain with Cap and Gasket 2" 1.75 lbs 0.5 lbs 0.75 lbs 3" 3.75 lbs 1.25 lbs 1.25 lbs NOTE...Tank fill caps must not be used as a substitute for proper normal and emergency venting on tanks. It is essential that proper venting be provided in compliance with all appli- cable codes for every tank system. 379 Combination Fill Cap and Vent Fill cap and open style vent used on small storage tanks. Aluminum with brass screen. Fig. 379 155 and 155S Double Outlet Vent Aluminum T-style vent used primarily on small fuel oil storage tanks. Outlet ports on either side of the inlet with 20 mesh stainless steel screen keeps debris out of the airway. Fig. 178 Fill Cap Options Size IB-IC IB-BC BB-IC BB-BC Weight Weight Weight Weight 2" NPT 2.0 lbs 2.0 lbs 2.0 lbs 2.25 lbs 3" NPT 4.5 lbs 4.25 lbs 4.25 lbs 4.25 lbs 4" NPT 6.75 lbs 7.0 lbs 7.0 lbs 7.0 lbs Fig. 179 Fill Cap Options Fig.Material Size/Mounting Weight 179 aluminum 2" NPT female 0.75 lbs 179 aluminum 2½" NPT female 1.0 lbs 179 aluminum 3" NPT female 1.0 lbs 179 aluminum 4" NPT female 2.0 lbs 179M aluminum 2" NPT male 0.75 lbs 179M aluminum 2½" NPT male 1.25 lbs 179CI cast iron 2" NPT female 2.5 lbs 179MCI cast iron 2" NPT male 2.75 lbs 179 Series Hinged Style Fill Cap Loose-seal style cap with hinged cover. For fill port of small storage tanks. Lockable with a padlock. Aluminum or cast iron. Also available with male or female threads. Cast iron caps available painted or powder coated black. Custom labeled caps available upon request. Fig. 155…threaded (NPT) Fig. 155BSP…2" with British Pipe Threads Fig. 155FA…2" with Flash Arrestor Fig. 155S…slip-on with set screw Tank Fill Caps and Vents Size Weight 2" NPT 1.25 lbs Size Weight ¾" .25 lbs 1" 0.5 lbs 1¼" 0.5 lbs 1½" .75 lbs 2" 1.0 lbs 3" 2.5 lbs ○○○○○○○○○○○○○○○○○○○○○○○○○○○○○ ○○○○○○○○○○○○○○○○○○○○○○○○○○○○○ ○○○○○○○○○○○○○○○○○○○○○○○○○○○○○ Tab IV. Record Drawings 2004 City Diesel Fueling System Upgrade drawing sheets: M1, M4, M5, E1, E2, E3 Provided for reference to the old power plant day tank and marine fueling system.