Tank Indicator Installation Model: VSTI AE020, Stainless Reverse Read System

Transcription

1 Tank Indicator Installation Model: VSTI AE020, Stainless Reverse Read System Guide Cables No Guide Cables 1 August 4, 2011

2 ITEM NO. PART NUMBER DESCRIPTION UNIVERSAL MOUNTING BRACKET 2 FLOAT SUB ASSEMBLY A030, GUIDE CABLE CLIP CABLE TENSION ASSEMBLY COUPLING BRACKET TARGET TANK BRACKET STAFF GAUGE BOARD TOP MOUNTING BRACKET SHEAVE HOUSING WEIGHTED PLATE " UNION " X 3" THREADED PIPE NIPPLE " X 24" THREAD PIPE NIPPLE WIRE ROPE CLAMP 15 FLOAT CABLE 16 GUIDE CABLE 17 5/16" HEX HEAD BOLT 18 5/16" HEX NUT 19 5/16" FLAT WASHER 20 5/16" LOCK WASHER LONG T-SLOT NUT SHORT T-SLOT NUT 2 August 4, 2011

3 There are different ways to assemble & mount the Staff Gauge Boards to the tank. The method chosen largely depends on these factors: a. The height of the tank b. The equipment available c. Whether or not you are able to mount the Tank Brackets directly to the tank STEP A Assemble Staff Gauge Boards 1. Each Staff Gauge Board comes with a vinyl decal displaying height values. Lay the boards on a flat surface in the correct order/orientation. 2. Install the bottom bracket assembly using the following parts: (1) Tank Bracket, (1) Universal Mounting Bracket, (2) 5/16 Hex Head Bolts, (4) 5/16 Flat Washers, (2) 5/16 Lock Washers, (2) 5/16 Hex Nuts, (2) Short T Slot Nuts, and (2) 10 32x1/2 Phillips Pan Screws. Bottom Bracket Assembly Staff Gauge Board Universal Mounting Bracket /16 Hex Head Bolt 10 32x1/2 Phillips Pan Screw Short T Slot Nut Tank Bracket August 4, 2011

4 Connector Bracket Assembly Long T Slot Nut /16 Hex Head Bolt 10 32x1/2 Phillips Pan Screws 3. Configure and install the connector bracket assembly using the following parts: (1) Tank Bracket, (1) Universal Mounting Bracket, (2) 5/16 Hex Head Bolts, (4) 5/16 Flat Washers, (2) 5/16 Lock Washers, (2) 5/16 Hex Nuts, (2) Long T Slot Nuts, (8) ¼ 20x1/4 Set Screws, and (2) 10 32x1/2 Phillips Pan Screws. 4. Trim the bottom Staff Gauge Board as necessary to fit to the height of your tank. 5. Install the top bracket assembly 12 below the top of the top Staff Gauge Board using the following parts: (1) Tank Bracket, (1) Universal Mounting Bracket, (2) 5/16 Hex Head Bolts, (4) 5/16 Flat Washers, (2) 5/16 Lock Washers, (2) 5/16 Hex Nuts, (2) Short T Slot Nuts, and (2) 10 32x1/2 Phillips Pan Screws. Coupling Bracket Assembly Note: The pipe socket on the Coupling Bracket must point up to receive the Reeving Assembly. Coupling Bracket The reeving assembly screws into this pipe socket. Top Mounting Bracket x1/2 Phillips Pan Screws 1. Install the coupling bracket assembly at the top of the Staff Gauge Board using the following parts: (1) Top Mounting Bracket, (2) Short T Slot Nuts, (2) 10 32x1/2 Phillips Pan Screws, (1) Coupling Bracket, (2) 1/4 Hex Head Bolts, (2) 1/4 Flat Washers, (2) 1/4 Lock Washers, and (2) 1/4 Hex Nuts. 4 August 4, 2011

5 STEP B Mount the Staff Gauge Boards 2 Ways Mounting Option A: 1. Field conditions permitting, mount the Tank Brackets directly to the tank. Then mount each individual Staff Gauge Board to each bracket assembly One bracket, then one Staff Gauge Board, next bracket, etc. 2. Temporarily tape or tie the Target to the Staff Gauge Board so that it will not fall when the Staff Gauge Board is lifted vertically into position. Note: We recommend tanks over 12 tall to be done in sections to prevent bowing. Staff Gauge Board Attach the Wire Rope Clamp to the Target. 4. Slide the Target with attached Wire Rope Clamp onto the Staff Gauge Board. Mounting Option B: 1. If unable to mount brackets directly to the tank, the Staff Gauge Board can be mounted to a support channel first. This channel is supplied by the customer, and should be at least 5 wide and as tall as the tank in order to sufficiently support Staff Gauge Board assembly. Once all components of the Staff Gauge Board assembly have been mounted to the channel, the entire assembly can be raised and mounted onto the tank as a unit. Note: No cable installation is needed at this time. Target Wire Rope Clamp August 4, 2011

6 STEP C Reeving Assembly Reeving Assembly 1 x 24 Threaded Pipe Nipple x 3 Threaded Pipe Nipple Sheave Housing Union Note: Positioning of the Reeving Assembly is important because it is used to determine the exact point of penetration for the 1 NPT Coupling, where the Reeving Assembly meets the roof of the tank. The Staff Gauge Board is mounted to the outside of the tank wall, and the Reeving Assembly directs the Float Cable from the Staff Gauge Board over and through the roof of the tank. 1. Using the two Sheave Housings, assemble the 1 x 24 Threaded Pipe Nipple, 1 Unions, and 1 x 3 Threaded Pipe Nipples as shown above. 2. One end of the Reeving Assembly is attached to the Coupling Bracket. The other end connects to the customer provided 1 NPT Coupling, located on the roof of the tank. 3. Placement of the Reeving Assembly should mark exactly where the cable meets the tank. It can be adjusted when necessary by adding or removing length to the 1 NPT nipples. 4. Disassemble the Reeving Assembly to seal all its pipe joints. 5. Reassemble the Reeving Assembly onto the tank. 6. The two Cable Tension Assemblies can now be installed at the roof of the tank. The Float Guide Cable will be installed in a later step. Note: The customer is encouraged to use all safety precautions, devices, and procedures when working in elevated locations. 6 August 4, 2011

7 Typical Arrangement on Roof 34 1/4 Distance dependent upon field conditions Pipe may need to be cut & threaded to adjust for field conditions (3) 1 NPT Couplings (Customer Provided) Partial tank shown (2) Cable Tension Assemblies /16 Float Cable Float Guide Cable STEP D Feeding the Float cable 1. Remove the covers of the Sheave Housing to aid in feeding the Float Cable through. 2. Attach the Float Cable to the Weighted Float. 3. Feed the Float Cable: The taped end of the Float Cable comes up from the Weighted Float, than feeds up and through the Reeving Assembly, down to the Target, outside the tank. 4. Make sure the Float Cable is running on the pulleys in the Sheave Housing before placing the covers back on. 5. Temporarily attach the Float Cable to the Wire Rope Clamp on the Target using two set screws. Note: You will later need to calibrate the length of the Float Cable by positioning the Target outside of the tank, to the same height as the float riding on top of the liquid inside the tank. 7 August 4, 2011

8 STEP E Weighted Plate at the bottom of the tank Float Guide Cable Wire Rope Clamp Weighted Plate The Weighted Plate should be secured to the tank floor while the tank is empty. This can be done by welding, or using the two mounting holes provided. The eyes in the plate should line up with the Cable Tension Assembly on top of the tank. These eyes are 12 apart and are positioned in line with the Weighted Float. A plumb bob may be used for accurate locating. Note: If the tank currently has liquid inside, the Weighted Plate and Float Guide Cable assemblies can be lowered into the tank. 8 August 4, 2011

9 2. Feed the Float Guide Cables through the Weighted Float; One Float Guide Cable should feed through the hole on each side of the Weighted Float. 3/16 Float Cable Set Screws Wire Rope Clamp Target STEP F Calibrate Target 1. Finally, adjust the Target to the height of the Weighted Float. This is done by loosening the two set screws, and pulling the Float Cable through until the Target represents the correct height of the Weighted Float inside the tank. 2. Tighten the screws and check for smooth operation by pulling down on the Target. 9 August 4, 2011

10 3. Cut off the excess Float Cable. Float Guide Cables Wire Rope Clamp Weighted Plate STEP G.a Tension Guide Cables on an Empty Tank 1. Pull up on the Float Guide Cable to provide tension. The Weighted Plate should be affixed to the tank floor, so you will not be able to lift if off the tank floor. 2. Compress the conical spring and locking collar 3/8 to ½ ; Mark the cable at the top of the locking collar. Tighten the locking collar using the two set screws. (Be careful not to overtighten as this will damage the Float Guide Cable). 3. Install the 3 Threaded Pipe Nipple back onto the base of the Cable Tension Assembly. 4. Cut the excess Float Guide Cables at the top of the 3 Threaded Pipe Nipple. 5. Replace the pipe caps using a sealant that is strong enough to retain the cap, but allowing you to remove it later to adjust tension as required. STEP G.b Tension Guide Cables on a Live Tank 1. Pull up on the Float Guide Cable until you feel the Weighted Plate being lifted off the tank floor. 2. Using a marker; mark the cable at the top of the locking collar. 3. Tighten the locking collar to the cable 3/8 to 1/2 down from the mark using the two set screws. (Be careful not to over tighten as this will damage the Float Guide Cable). 4. Lower the conical spring, locking collar and Float Guide Cable down into the base. This should tension the Float Guide Cables without lifting the Weighted Plate off the bottom of the tank. 5. Install the 3 Threaded Pipe Nipple back onto the base of the Cable Tension Assembly. 6. Cut the excess Float Guide Cables at the top of the 3 Threaded Pipe Nipple. 10 August 4, 2011

11 7. Replace the pipe caps using a sealant that is strong enough to retain the cap, but allowing you to remove it later to adjust tension as required. PIPE CAP 1 x 3 Threaded Pipe Nipple Cable Tension Assembly Locking Collar Set Screws Conical Spring Guide Cable Shoulder Bushing Float Guide Cable STEP H Tension the Float Guide Cables 1. Tension the Float Guide Cable at the top of the tank using the Cable Tension Assembly. 2. Remove the cap from the Cable Tension Assembly and the 3 Threaded Pipe Nipple. 3. Slide the Float Guide Cable through the customer provided 1 NPT Coupling. 4. Feed each Float Guide Cable through the base of each Cable Tension Assembly. 5. Loosen the 2 set screws on the locking collar to feed the Float Guide Cable through the conical spring & locking collar. CONGRATULATIONS, YOU ARE NOW DONE INSTALLING A TROUBLE FREE TANK LEVEL INDICATOR FROM VERSA STEEL INC.! 11 August 4, 2011

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