Dover PSG Ebsray R Series Installation, Operation & Maintenance Instructions Manual
For submersible lpg applications
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Summary of Contents for Dover PSG Ebsray R Series
- Page 1 Publication # 2403-15 EN EBSRAY PUMPS INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS R SERIES MODEL RX33 …. For Submersible LPG APPLICATIONS...
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Page 2: Table Of Contents
CONTENTS SECTION 1 – GENERAL .............................. 4 INTRODUCTION ........................... 4 TRANSPORTATION AND PACKING ....................4 RECEIVING INSPECTION ........................4 HANDLING ............................4 WARRANTY ............................4 SECTION 2 – SYSTEM DESCRIPTION ........................5 EBSRAY RX33 SUBMERSIBLE LPG PUMPING SYSTEM ..............5 “THREE-TIER”... - Page 3 IMPORTANT NOTES This Publication is TYPICAL ONLY and only relates to the specifications of the minimum equipment required to ensure the optimum performance, maximum life and trouble-free operation of the EBSRAY RX33 Submersible Pumpset and the Pumping System in general. Products with the mandatory European CE mark affixed indicate conformity to the essential health and safety requirements via their applicable EU Directives (e.g.
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Page 4: Section 1 - General
SECTION 1 – GENERAL 1.1 INTRODUCTION WARNING Never allow water or any This publication is intended to assist those involved corrosive product to enter the Pumpset, Motor or with the installation, operation and maintenance of electrical conduit. This may damage the Pumpset EBSRAY Model RX33... -
Page 5: Section 2 - System Description
5. To validate Warranty conditions, a completed copy Refer to EBSRAY or Appointed Representative for of the RX33 Pumpset Run Log, Appendix E clarification or further details on the RX33 New or MUST BE Service Exchange Pumpset Warranty conditions. completed in full and returned to EBSRAY for registration. -
Page 6: Section 3 - Installation
SECTION 3 – INSTALLATION Installation and removal of this equipment should be performed by suitably qualified CAUTION competent personnel in accordance with relevant Codes, Regulations, Standards, DANGER Directives and site restrictions - in conjunction with these instructions. Never loosen or remove fittings, flanges, etc. while under pressure (vapour pressure of DANGER LPG may be very high), always isolate components or pipework and depressurise prior to work. -
Page 7: Discharge Riser
Table 1 3.2.4 Discharge Riser To determine dimension ‘A’ (Refer to Figure 3): Top of Turret Cover to 1. Determine (measure) depth of pump housing inlet Pumpset Inlet Port (measured) port centreline from top of turret cover (X). Centreline 2. Add thickness of isolation gasket (Y). Gasket Thickness 3. -
Page 8: Recommended Order Of Assembly
NO WELDING is to be 11. Check overall length of riser/pumpset from cathodic WARNING performed on any part of insulation gasket to end of pumpset to ensure 5mm the system (discharge piping, vapour returns or (min) clearance to bottom (inside) of pump housing. conduits) with pumpset/wires installed. -
Page 9: Discharge Pipe Fittings
NOTE: 2. After this ball valve, a DN25 (min) branch is Before pumpset/discharge riser required for connection to the EBSRAY Inline assembly is completely inside the pump housing, RV18-NRV Bypass Valve. remove the adhesive tape holding the cathodic insulation gasket to the pump housing cover. 3. -
Page 10: Leak Check
5. Remove tape from conduit, refit compression tube 3.2.12 Leak Check fitting to conduit. Tighten nut on fitting as shown in 1. Tighten nut on 1" NPT bored through compression Figure 5 fitting as shown in Figure 5 2. Remove cover and gasket from Junction Box. 3. -
Page 11: Junction Box
Typical electrical connections are as shown in the 3.3.3 Connecting Cable accompanying diagrams Figure 9 and Appendix C. The connecting cable between the Zone 1 Compliant Items provided by EBSRAY are suitable for use in the Junction Box and the Pump Controller is a six (6) core specified intended areas. -
Page 12: Startup Procedure
3. Direction of rotation - This MUST be tested prior 2. Connect amp meter to Pump Controller lead(s) T1, to Pumpset operation by using a Phase T2 or T3 outside Hazardous Area Sequence Indicator at the Pump Controller. 3. Activate power to Pump Controller. With Pumpset wiring at the Junction Box in the order: BLACK (1), RED (2), ORANGE (3), the 4. -
Page 13: Section 5 - Pump Controller
16. The startup procedure is now complete for the NOTE: Dispensing/pumping may be interrupted RX33 Pumpset and Protection System. (Pumpset stopped) by DPS fault during tanker unloading operations. Resetting the RX33 must 17. Inspect Pumpset/pumping system frequently during only occur after unloading operation is completed the first few hours of operation, then periodically and the LPG in the storage tank has stabilised to thereafter. -
Page 14: Description Of Pump Controller
To View Settings & Set ‘Run-On’ Time 5.1 DESCRIPTION OF PUMP CONTROLLER 5.2.4 (Valid Options 0 or 2mins) The L861002 Series of Pump Controllers are designed to manage the RX Series Submersible Pumpsets and pumping system as described in Appendix A. There are three primary functions of the Pump Controller: –... -
Page 15: Run-On' Time
This time displayed is the actual time it has taken for The faults are divided into the following groups: the Pumpset to build the minimum required differential 5.4.1 Critical Faults pressure after each re-start. If the Pump Controller detects a Critical Fault, the ‘Run-On’... -
Page 16: Preventative Faults
5.4.1.3 HBT Faults The Pump Controller monitors 5.5 PUMPSET/PUMPING SYSTEM DIAGNOSTICS the Pumpset’s Bearing Cooling and Lubrication The Pump Controller stores various information in the (BCL ) liquid temperature via the High Bearing which useful system diagnostics, Temperature (HBT) switch, embedded in the Motor. maintenance, troubleshooting, etc. -
Page 17: Section 6 - Maintenance
SECTION 6 – MAINTENANCE Prior system 6.3 SERVICE EXCHANGE CAUTION disassembly or service, DANGER EBSRAY maintains RX33 Service Exchange Pumpsets verify that all requirements of relevant Codes, to facilitate rapid and economical changeover should Regulations, Standards or Directives are met and the need arise. -
Page 18: Section 7 - Troubleshooting
SECTION 7 – TROUBLESHOOTING Error Possible Possible Cause Remedy Condition Problem Insufficient LPG in Storage Tank Fill Storage Tank Differential Pressure too low *** DPS FAULT *** Incorrect Bypass Valve setting. Adjust (Increase) Bypass Valve setting to achieve required AFTER DPS BYPASS differential pressure. - Page 19 Error Possible Possible Cause Remedy Condition Problem Insufficient LPG in Storage Tank Fill Storage Tank Pumpset has not reached minimum Excessive inlet restriction Check/open Inlet Valve *** DPS FAULT *** differential - Inlet Isolation Valve not opened Check, repair or replace Inlet BEFORE DPS BYPASS pressure.
- Page 20 Error Possible Possible Cause Remedy Condition Problem MOL Relay set too Incorrect setting on MOL Relay Reset MOL setting to FLA of Motor as per Specification (See *** MOL FAULT *** Section 4.3) AFTER STARTUP AND SWITCH NOT RESET Differential Incorrect Bypass Valve Setting.
- Page 21 Error Possible Possible Cause Remedy Condition Problem Pumpset operating but Vehicle Tank already full No problem exists fails to deliver LPG No Vehicle Insufficient LPG in Storage Tank Fill Storage Tank Fill Excessive pressure in Vehicle Tank Allow Vehicle Tank to cool until pressure compared to Storage Tank decreases or increase vapour pressure in Storage Tank, or increase bypass...
- Page 22 Error Possible Possible Cause Remedy Condition Problem Insufficient LPG in Storage Tank - Fill Storage Tank Pumpset cavitating Pumpset Inlet (suction) Port not fully "Pulsing" (restriction at inlet to covered with liquid Flow Pumpset) Excessive Inlet (suction) restriction Check / Open Inlet Valve, repair or - Inlet Valve not opened fully replace Excess Flow Valve as required - Faulty Inlet Excess Flow Valve...
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Page 23: Appendix A - Typical Installation P&Id
APPENDIX A – TYPICAL INSTALLATION P&ID... -
Page 24: Appendix B - Submersible Pumpset - Outline Dimensions And Specifications
APPENDIX B – SUBMERSIBLE PUMPSET – OUTLINE DIMENSIONS AND SPECIFICATIONS... -
Page 25: Appendix C - Typical Wiring Schematic And Connection Diagram
APPENDIX C – TYPICAL WIRING SCHEMATIC AND CONNECTION DIAGRAM... -
Page 26: Appendix D - System Pre-Startup Commissioning Checklist
APPENDIX D – SYSTEM PRE-STARTUP COMMISSIONING CHECKLIST Date:________________ Location:__________________________ Pumpset Serial No. _______________________ Installation Company:______________________________ Installer's Name: _________________________________ Indicate Inspection Satisfactorily Completed with a in the appropriate box 1. Check that all electrical wiring is insulated from the ground, conduits, tank etc............... -
Page 27: Appendix E - Ebsray Pumpset Run Log
APPENDIX E – EBSRAY PUMPSET RUN LOG INSTALLATION RECORD PUMPSET PUMP CONTROLLER DATE NUMBER OF HOSES SITE INSTALLED BY COMPANY/PERSONNEL SERIAL No. SERIAL No. COMMISSIONED SERVED COMMISSIONING RECORD TANK PUMPSET INSPECT MOTOR CURRENT VAPOUR DISCHARGE NOTES SYSTEM TEMP HOURS (AMPS) PRESSURE PRESSURE (NAME) -
Page 28: Appendix F - Certifications & Declarations Of Conformity
APPENDIX F – CERTIFICATIONS & DECLARATIONS OF CONFORMITY...
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