IOM002GVAE1614
Automation Solutions for oil & gas, defense and aviation applications
Copyright
2013, All rights reserved. Printed in the United States of America.
Except as permitted under the United States Copyright Act of 1976, no part of this publication
may be reproduced, stored in a retrieval system or transmitted in any form or by any means -
electronic, mechanical, photocopying, recording, or otherwise - without the prior written
permission of the Publisher:
Varec, Inc.
5834 Peachtree Corners East
Peachtree Corners (Atlanta), Georgia 30092
Phone: (770) 447-9202
Fax: (770) 662-8939
Trademarks Acknowledged
Varec, Inc. recognizes all other trademarks. Trademarks of other products mentioned in this
manual are held by the companies producing them.
All other product and service names mentioned are the trademarks of their respective
companies.
The 6700 Average Temperature/Water Bottom Sensor and Converter (ATC) has not been tested
by Varec under all possible operational conditions, and Varec may not have all the data relative
to your application. The information in this instruction manual is not all inclusive and does not
and cannot take into account all unique situations. Consequently, the user should review this
product literature in view of his or her application. If you have any further questions, please
contact Varec for assistance.
Use of parts that are not manufactured or supplied by Varec voids any warranty and relieves
Varec of any obligation to service the product under warranty. Varec recommends the use of
only Varec manufactured or supplied parts to maintain or service Varec 6700 Liquid Level
Indicator.
Terms of Use
The information provided in this document is provided "as is" without warranty of any kind.
Varec, Inc. disclaim all warranties, either express or implied, including the warranties of
merchantability and fitness for a particular purpose. In no event shall Varec, Inc. or its suppliers
be liable for any damages whatsoever including direct, indirect, incidental, consequential, loss
of business profits or special damages, even if Varec, Inc. or its suppliers have been advised of
the possibility of such damages.
This manual is solely intended to describe product installation and functions and should not be
used for any other purpose. It is subject to change without prior notice. This manual was
prepared with the highest degree of care. However, should you find any errors or have any
questions, contact one of our service offices or your local sales agent.
Warning! Direct injury to personnel or damage to equipment which can cause injury to
personnel may result if this precaution is not followed.
Safety Precautions
Read this manual carefully and make sure you understand its contents before using this product.
Follow all instructions and safety guidelines presented in this manual when using this product.
If the user does not follow these instructions properly, Varec cannot guarantee the safety of the
system.
Note Comply with all applicable regulations, codes, and standards. For safety precautions,
the user should refer to the appropriate industry or military standards.
Caution! Electrical Hazard! Read and understand static and lightning electrical protection
and grounding described in API 2003. Make certain that the tank installation, operation,
and maintenance conforms with the practice set forth therein.
Warning! Make certain that the tank is empty and not in service. Ensure that the tank has
been leak and pressure tested as appropriate for the liquid to be stored. Observe
appropriate safety precautions in flammable or hazardous liquid storage areas. Do not
enter a tank that has contained hydrocarbons, vapors, or toxic materials until a gas free
environment is certified. Carry breathing equipment when entering a tank where oxygen
may be displaced by carbon dioxide, nitrogen, or other gases. Wear safety glasses as
appropriate. Use a hard hat.
Warning! Under most circumstances, the mechanical connections between the guide
cables and the anchors provide a resistance to ground that is adequate for the safe electrical
drain of electrostatic charges that may accumulate in the tank and the product. Additional
grounding may be needed for products with low flash points. Worker activity and worker
clothing may accumulate electrostatic charges on the body of a worker. Care should be
used in flammable environments to avoid the hazard. Observe American Petroleum Institute
(API) Recommended Practice 2003 or other appropriate industry or military standard.
Varec, Inc. v
vi Installation and Operations Manual
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Oil Seal Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Installation of Oil Seal, 8.5-Inch Water Column Operating Pressure Model . . . . . . . . .9
Installation of Oil Seal, 27-Inch Water Column Operating Pressure . . . . . . . . . . . . . . .9
Cone Roof Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Initial Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Initial Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Cone Roof Tank (Bolted Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Initial Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Initial Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Cone Roof Tank Installation (Fiberglass Tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Initial Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Initial Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
In-service Tank Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
General Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Independent Pipe Support Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Installation of Model 228 Inspection Hatch to Existing Manhole Cover . . . . . . . . . . . . . . . . .26
Anchor Bar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Float Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Initial Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Installation of Model 226 for 20 and 24 Inch Manhole Covers with API Drilling . . . . . . . . . . .30
Typical Auxiliary Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Calibration and Volume Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Electrostatic Discharge Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Oil Recommendations for Oil Seal Accessory Units . . . . . . . . . . . . . . . . . . . . . . . . . .35
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Troubleshooting Common Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Varec,Inc. vii
5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Liquid Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Standard Installation Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Standard Float Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Bottom Anchor Bar Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Other Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Reference Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Indicator Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Float Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Sheave Elbow Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Bottom Anchor Bar Weight Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Oil Seal Accessory Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Order Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
6 Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
viii InstallationandOperationsManual
Chapter1
Introduction
Thismanualisdesignedtoassisttheuserwiththeinstallation,configuration,operation,
maintenance,andtroubleshootingoftheVarecModel6700LowPressureLiquidLevel
Indicator.
Getting Started
TheVarecModel6700LowPressureLiquidLevel
Indicatorsareforuseatatmosphericpressure.
Ifoilsealunitsareinstalled,pressureof1.0psigis
themaximumusedwiththe27inchW.C.seal.
Asystemconsistsofthegaugeboard,sliding
indicator,float,cables,elbows,andtheuser
furnishedgaugepipingwhichcarriestheindicator
cable.SeeFigure11onpage3.
Properoperationoftheindicatorrequiresthe
carefulattentionoftheusertoassurehighquality
controlduringinstallation.Longterm,satisfactory
performanceofthesightgaugecanthusbe
obtained.Iftheinstallationqualityiscompromised,
sightgaugeaccuracyandlifemaybedegraded.
Changesintheliquidlevelinthetankraiseorlower
thefloat,whichmovestheindicatorcable.Cable
movementdrivestheindicatorupanddownthegaugeboardonthesideofthetank.
Theliquidlevelinfeetandinches,ormeters,decimeters,andtwocentimeterincrementsis
indicatedbytheindicatorpositiononthegaugeboard.Theusermaythenconverttheliquid
leveltounitsofvolume.Thismaybeaccomplishedmanually,orVarec'scomputeraideddata
acquisitionsystemmayperformthetask.
Whentheindicatorisatthetopofthegaugeboard,thetankisemptywiththefloatatthe
bottomofthetank.
MostofChapter2,Installation,coversinstallationstobeperformedontanksthatareempty
andarenotinservice.Section2.11,InServiceTankInstallations,coverstheadditional
proceduresthatarerequiredformakinginstallationsontanksthatareinservice.
Varecservicecontractsprovidetheusersubstantialsavingsformaintainingandrefurbishing
thesystems.ContactFieldService,aVarecrepresentativeorProductMarketingforfurther
details.
Varec,Inc. 1
LiquidLevelIndicator
Accessories
VarecmanufacturesaccessoriesfortransmittingandtelemeteringtheinformationtoaVarec
DataAcquisitionSystem.LimitswitchesmaybeattachedtotheLiquidLevelIndicatorsystem
toprovidesignalingfunctions.Figures12through15illustratesomeoftheaccessories
available.
2 InstallationandOperationsManual
Introduction
ITEM DESCRIPTION
1 HOUSING
2 COVER
3 SHEAVE
4 SHAFT
5 BEARING
6 SPACER
7 RETAINING RING
8 RETAINING RING
9 FLANGE
10 FLANGE GASKET
11 COVER GASKET
12 HEX HEAD CAP SCREW
13 FLANGE CAP
14 CAP GASKET
15 HEX HEAD CAP SCREW
16 WASHER
17 HEX NUT
1-1/2 Inch NPT (Typical)
Section: A - A
6.12
[155]
A
6.12
[155]
Figure1: Model6700AccessoryDriveElbow
Table 1-1:
Type PartNumber
English BM4129
Metric BM8564
Varec,Inc. 3
LiquidLevelIndicator
ITEM DESCRIPTION
1 PIPE, 1-1/2 X 15.50 [394] NPT ENDS
2 PIPE, 1-1/2 X 7.25 [184] NPT ENDS
3 135 SHEAVE ELBOW
4 135 SHEAVE ELBOW WITH DRAIN
19.69
[500]
90 elbow furnished
with level indicator kit
Section: A-A
1-1/2 inch NPT
3
A
13.62
[346]
20.56 2
[522]
4.50
[114]
1 4 4.06
[103]
Figure2: OilSeal,8.5inchWaterColumnOperatingPressureModel
4 InstallationandOperationsManual
Introduction
ITEM DESCRIPTION
1 180 ELBOW
2 PIPE, 1-1/2 X 38 [965], NPT ENDS (LONG)
3 PIPE, 1-1/2 X 32 [813], NPT ENDS (SHORT)
4 180 ELBOW WITH DRAIN
1-1/2 inch NPT
90 elbow furnished
with level indicator kit
4.00
[102]
Approximate
Figure3: OilSeal,27inchWaterColumnOperatingPressureModel
Varec,Inc. 5
LiquidLevelIndicator
(5.75)
[146]
3.75
[95.2]
Gaugeboard section
Reinforcing bracket
(02-10721-003)
Figure4: Options
6 InstallationandOperationsManual
Chapter2
Installation
RefertoChapter1,Introductiontodeterminethefeatureandoptioncodesoftheunittobe
installed.UsetheTableofContentstodeterminetheappropriateinstallationfigureinthis
InstructionManual.Thesearetypicalinstallations.Allsituationsmaynotbecovered.Contact
Varecifadditionalinformationisneeded.Itisparamountthattheusermonitorthequalityof
theinstallationtoassurelongterm,accurateperformance.Ifthequalityiscompromised,
inferioroperationmayresult.
Particularlyimportantare:
Accuratehandgaugingreferencedtothetankbenchmark
Cleaninteriorofthegaugepiping
Nokinksinthetape/cable
Nonoticeablebindingfrictioninthemechanism
Installationcleanliness
Trueverticalgaugepiping
Locationoffloatawayfrominletpipesofmixers
Warning Makecertainthatthetankisemptyandnotinservice.Ensurethatthetankhas
beenleakandpressuretestedasappropriatefortheliquidtobestored.Observe
appropriatesafetyprecautionsinflammableorhazardousliquidstorageareas.Donot
enteratankthathascontainedhydrocarbons,vapours,ortoxicmaterialsuntilagasfree
environmentiscertified.Carrybreathingequipmentwhenenteringatankwhereoxygen
maybedisplacedbycarbondioxide,nitrogen,orothergases.Wearsafetyglassesas
appropriate.Useahardhat.
Warning Undermostcircumstances,themechanicalconnectionsbetweentheguide
cablesandtheanchorsprovidearesistancetogroundthatisadequateforthesafe
electricaldrainofelectrostaticchargesthatmayaccumulateinthetankandtheproduct.
Additionalgroundingmaybeneededforproductswithlowflashpoints.Workeractivity
andworkerclothingmayaccumulateelectrostaticchargesonthebodyofaworker.Care
shouldbeusedinflammableenvironmentstoavoidthehazard.ObserveAmerican
PetroleumInstitute(API)RecommendedPractice2003orotherappropriateindustryor
militarystandard.
Theuserprovidesthe1.5inchpipethatcarriesthetape/cableandthenecessarymounting
andsupportwelding.Theusermustdrillholesinthetankasneeded.Assemblethenecessary
toolsandequipmentattheworksite.Table21onpage10liststypicaltoolsandequipment
thatmaybeneeded.Useadropclothtomaintaintool,equipment,andinstallationkit
cleanliness.
Planthepiperouting.Locatetheroofconnectionintothetankinteriorwithinarmsreachofa
manholeoraninspectionhatch.
Table2:TypicalTools,Equipment,andMaterialsList
Tool/Equipment
Breathingequipment Pick
Varec,Inc. 7
LiquidLevelIndicator
Table2:TypicalTools,Equipment,andMaterialsList
Tool/Equipment
Cablecutter Pipecutter
Chalk Pipetaps/dies
Chalkline Pliers
Cleandropcloth Plumbbob
Compass Protractor
Drillbits Screwdrivers
Electricdrill Sheetmetalshears
Holecutters Shovel
Level String
Lightoil Tankhandgauge
Loctite262 Vice
Loctite567 Weldingequipment
Longmeasuringtape Wrenches
Note InstallaVarecmanholeorinspectionhatch,ifthereisnonelocatedwithinarms
reachofthetapepipelocation.RefertoInserviceTankInstallationslaterinthissection
forhatchandmanholeinstallations.
Locatethefloatatapositioninsideofthetankwhereagitationonitwillbeataminimum.
Installadeflectoriftheproductstreamisclosetothefloat.ContactVarecifagitatorswillcause
excessfloatdisturbances.Verticalpiperunsmustbeplumbedandperpendiculartoprevent
thetapefrombindinginsidethepipe.
Theusermustattachthegaugeboardtothetankbyweldingorboltingthesupplied
gaugeboardsupportbrackets.Iftheenvironmentissuchthatweldingcannotbeperformed,
theusercanconstructasupportstructurewith3inch[76mm]pipeorconduitclosetothe
outsideofthetank.Thebracketscanbeweldedtothesupportstructureatanotherlocation,
ifnecessary,andthepipestructureassembledatthetanksite.RefertoInServiceTank
Installationslaterinthissectionforadditionaldetails.
Warning Theusershouldcomplywithallapplicableregulations,codes,andstandards.
Forsafetyprecautions,theusershouldrefertotheappropriateindustryormilitary
standards.
Note Varecrecommendsanoilsealiftheprocesstemperatureexceeds200F(93C).
8 InstallationandOperationsManual
Installation
1. Applyappropriatepipethreadcompoundandinstalllongpipe(1)into135degreeelbow
withbottomdrain(4).
2. Applypipethreadcompoundandinstallshortpipe(2)into135degreeelbowwithbottom
drain(4).
3. Applypipethreadcompoundandinstall135degreeelbow(3)ontolongpipe(1).
4. Applypipethreadcompoundandinstall90degreeelbowsuppliedwithgaugekitonto
shortpipe(2).
5. Adjusttheassemblytoprovidethetape/cablepathillustratedinFigure28onpage29.
6. Provide1.5inchpipeinstallation,asrequired.
7. ProceedwiththeremainderofthetankinstallationtotheparagraphInitialLubrication,
thenfilltheoilsealasfollows:
a. SeeChapter4,Maintenance,foroilselection.
b. Removethecoverfrom90degreeelbow.
c. Filltohalfwayintheshortpipe.
Note Todraintheoil,opentheplugin135degreeelbow(4).
1. Applythreadpipecompoundandinstallshortpipe(3)into180degreeelbow(1).
2. Applypipethreadcompoundandinstall180degreeelbow(4)ontoshortpipe(3).
3. Applypipethreadcompoundandinstalllongpipe(2)intoelbow(4).
4. Applypipethreadcompoundandinstall90degreeelbowsuppliedwithgaugekitonto
longpipe(2).
5. Completetheassemblytotheuserfurnished1.5inchpipe.
6. Adjusttheassemblytoprovidethetape/cablepathasillustrated.
7. ProceedwiththeremainderofthetankinstallationtotheparagraphInitialLubrication,
thenfilltheoilsealasfollows:
a. SeeChapter4,Maintenance,foroilselection.
b. Removethecoverfrom90degreeelbow.
c. Filltohalfwayintheshortpipe.
Note Todraintheoil,opentheplugin180degreeelbow(4).
Varec,Inc. 9
LiquidLevelIndicator
RefertoTable11onpage2.SeeFigure21onpage14forfulltravelorFigure22onpage15
halftravelLiquidLevelIndicators.
1. Determinethepositiononthetankroof,beneathwhichthecenterofthefloatwillriseand
fall.Noticethatthispositionislocatedaminimumof16inches[406mm]andamaximum
of36.00inches[914mm]fromthewallofthetank.
2. Providetheroofholesshowninthefigure,centeredonthisposition.Thefloatdiameteris
14.50inches[368mm].Theguidecableholesarecentered8.50inches[216mm],each
sideofthecenterofthefloat.Theindicatorcablepipeiscenteredona17.00inch[432
mm]diameter.
3. Checktheangleoftheroof.
4. Connectapipecouplingtothe1.5inchverticalpipethatistobeattachedtotheroofand
holditplumbwhileweldingthecouplingintotheholeintheroof.Failuretoplacethecou
plingandpipeinatrueverticalpositionmayaffecttheaccuracyoftheLiquidLevelIndica
tor.Makesurethattheinteriorofallpipesarecleanandcorrosionfree.
5. Afterthecouplingandpipearecheckedtomakecertainthattheyareplumb,unscrewthe
pipefromthecoupling.
6. Sealthethreadswithpipethreadcompoundandreconnectthepipetothecoupling.
7. Centerthebaseofatopcableanchorinitshole.Holditplumbwhileweldingittotheroof.
Dothesamefortheothertopcableanchor.
8. Removethehousingnippleandcapfromthetopcableanchorsandhangplumblinesfrom
thematthecentertomarkthepositionwherethebottomcableanchorwillbewelded.
9. Marktheplumbbobstringattheheightofthetankbenchmark.Thiswillassurethatthe
plumbbobjusttouchesthebottom,whenthereferenceismadefromthebenchmarkdis
tancetothebottom.
10. Hangaplumblinethroughthecenterofthetoptape/cablepipetothebottomtomark
thefloatcenter.Thisshouldbe8.50inches[216mm]atthebottomfromeachofthebot
tomcableanchorpositions.
11. Whenthepositioninghasbeenchecked,weldthebottomcableanchorintoplace.
12. Threadthefloatguidecablesintothetankthroughthetopanchorfittings.Fastenthemto
thebottomcableanchorwiththefurnishedhardware.Threadtheupperendofeachguide
cablethroughthetopanchorassembly.Handtighten.Usethelocknuttolockthecablein
place,thentightentheadjustmentnut,untiltheguidecableistensionedbythespring.
Trimoffexcessivecable.
13. Replacethetopanchornippleandcap.
14. Applyappropriatepipethreadcompoundandinstallthesheaveelbowontheverticalpipe
tothetankinterior.Installapipeunioninthehorizontalpiperun,inorderthattheelbows
canbeeasilyremoved,ifnecessary.Theninstallthehorizontalpipeassemblyintothetank
dropelbow.Adjustthelengthasneededtoproperlypositiontheoutboardelbow.
15. Installtheoutboardelbowonthehorizontalpipe.
10 InstallationandOperationsManual
Installation
16. Applypipethreadcompoundandscrewthegaugeboardconnectorpipeintotheoutboard
elbow.
17. Removethebolts,cover,andgasketfromtheoutboardelbowanddropaplumbline
throughthecenter.
18. Dropachalklinefromthetopofthetankparallelwiththeplumblineandmarkthechalk
lineonthetankwall.SeeFigure21onpage14.
19. Usethewidthofthegaugeboard(7.44inches[189mm])atthebottomofthetankwall
andchalkregistermarksforthewidthasfollows:
FullTravelGaugeboard:
Boardcenteredwithchalkedplumbline(seeFigure21onpage14).
HalfTravelGaugeboard:
Boardoffset(1.03inches[26.2mm])totherightofthechalkedplumbline(seeFigure2
2onpage15).
20. Dothesameatthetopofthetank.
21. Makechalklinemarksbetweenthetopandbottomregistermarktoaidinkeepingthe
gaugeboardsectionscenteredandparallelduringinstallation.
22. Weldthegaugeboardsupportbracketsintoposition.SeeFigure21andnoticetherelative
positionofthetopbracket.Allotherweldsaresevenfeetbelowthepreviousweld,except
forthelastoneatthebottomofthetank,whichissixinches[152mm]abovethegrade
line.
23. UsetheUboltandnuts(seeFigure21)toattachthegaugeboardconnectortothepipe.
Thepipeshouldextendoneinch[25.4mm]belowtheUbolt.
24. Attachthetopsectionofthegaugeboardtotheconnectorplate.Makecertainthatitis
centeredonthechalkline.
25. Attachtheremainderofthesectionstothebottomofthetank.Makecertainthateach
sectioniscenteredonthechalkline(seeFigure21).
Note Tofitthegaugeboardtothetank,cutthehighestnumberedgaugeboardsection
atthemarkerthatis4.50inchesgreaterthanthetankheighttoadjustthefittothetotal
heighttothetank.
Varec,Inc. 11
LiquidLevelIndicator
12.50
[318]
Figure5: ConeRoofTankInstallation
12 InstallationandOperationsManual
Installation
16.50
[419]
Figure6: HalfTravelConeRoofTankInstallation
Varec,Inc. 13
LiquidLevelIndicator
Tank Wall
Chalk Lines Tank Wall
Chalk Lines
Full Travel Face of gaugeboard
Half Travel
Tank Wall
Chalk Line
Tank Wall
Chalk Line
Support Bracket
Detail
Face of gaugeboard
Gaugeboard Splice
at Support Bracket
Figure7: GaugeboardInstallation
14 InstallationandOperationsManual
Installation
Figure8: Tape/CableClamps
26. Tiltthefloatonedgeandsliptheguidecablesthroughtheloopsontheinsideofthetank.
Setitonthetankbottomwiththetape/cableconnectionup.
27. Attheelbowonthetankentrypipe,unrolloneortwoturnsofthetape/cableandstartto
feeditintothehorizontalpipe.Continuetounrollthetape/cableseveralturnsatatime
untilitreachesthegroundatthebottomofthegaugeboardinstallationposition.Make
surethatthetape/cableonthegrounddoesnotbecomekinkedordirty.
Note Throughouttheseinstructionsthetermtape/cableisusedtodesignateeither
theindicatorcabledriveorthecombinationtapeandcabledrivethatisusedtoalsodrive
theaccessorydriveelbow.Ifthetape/cablecombinationisused,thecableendgoeson
thegaugeboardside.
28. Lowerthetapecabletothetankbottomandletseveralinchesfallonthetankbottom.
29. Temporarilyattachthetape/cabletothefloatwiththefurnishedfastener(seeFigure22
onpage15).Feedtheotherendoftheindicatorcableoverthesheaveintheelbowand
makesurethatitisseatedonthepulley.Finalattachmenttobemadeatinitialcalibration.
Varec,Inc. 15
LiquidLevelIndicator
30. Checktheindicatortape/cablepathbetweenthefloatandthegaugeboardtobesurethat
thetape/cableisnotkinkedortwisted.Alsocheckthefloatguidecablesforkinks.
31. Makecertainthatthefloatguidecablesareparallel.
Note Ifauxiliaryequipmentistobeinstalled,doitpriortocrimpingthecableconnector.
Theaccessorydriveelbowshouldnotbeusedforhalftravellevelindication.Theuseof
auxiliaryunitsnotmanufacturedorsuppliedbyVarecwillvoidanyVarecwarrantyandwill
relieveVarecofanyobligationtoservicetheproductunderwarranty.
32. Installindicator.
FullTravelGaugeboard:
Sliptheindicatoroverthegaugeboard.Putthecablecrimpontheendofthecable,then
threadthecablethroughtheholeintheindicator.Loopthecableontheoutsideback
throughthecablecrimpandtemporarilytapeittothecrimp(seeFigure21onpage14).
HalfTravelGaugeboard:
Removeonesidechannelfromtheindicator.Positionindicatoronthegaugeheadand
reassemblethesidechannel.Threadthecablethroughthepulleyontheindicator.Put
thecablecrimpontheendofthecable.Threadthecablethroughtheholeinthe
gaugeboardconnectorplate.Loopthecableonbackthroughthecablecrimpand
temporarilytapeittothecrimp(seeFigure22onpage15).
33. Tapethegaugeboardindicatortothegaugeboardat2.00inches[50.8mm]toholditin
place.Adjustthecabletensionuntilthefloatbarelyliftsoffthetankfloor,thencrimpthe
cableconnectorandremovethetape.
Note Asthefloatisfourinches[101.6mm]highanditswaterlineisatitsequator,itcan
notregisterthelasttwoinches[50.8mm]ofliquidinthetank.
34. Tiealinelongerthantheheightofthetanktotheindicator.
Caution Donotallowthefloattofallbacktothefloorofthetank.Damagemayresult.
35. Slowlypulldownontheindicatorandliftthefloattothetopofthetank.Travelshouldnot
producenoticeablebinding.Slowlylowerthefloattothefloorofthetank.
36. Removethepullline.
Initial Calibration
Theseinstructionsapplytosystemsthatuseahollowshell,weldedfloatthatis14.5inches
[368mm]indiameterby4.0inches[102mm]deep.Calibrationisbaseduponthestandard
specificgravityofwater(1.0).
Note Forproductsofotherspecificgravitiestobegauged,adjusttheindicatoraccord
ingly.Refertotheindustryrelatedchartsfortheparticularproduct.
Withthefloatjusttouchingthebottomofthetank,waterwillbeatthefloatequator(water
line).Usethefloatconnectingclamps(seeFigure22)tomakethefinaladjustment,thentrim
excesstapeorcableatthefloatend,leavingsomeadditionaltapeorcableforfuture
adjustmentneeds.
16 InstallationandOperationsManual
Installation
Initial Lubrication
Applyalightoiltotheelbowandindicatorsheaves.
Reassembly
1. Reinstallthecovers,gaskets,andboltsontheelbows.
2. Closethetankmanholesandinspectioncovers.
RefertoTable11onpage2.SeeFigure25onpage22.
1. Determinethepositiononthetankroof,beneathwhichthecenterofthefloatwillriseand
fall.Noticethatthispositionislocatedaminimumof16inches[406mm]andamaximum
of36.00inches[914mm]fromthewallofthetank.
2. Providetheroofholesshowninthefigure,centeredonthisposition.Thefloatdiameteris
14.50inches[368mm].Theguidecableholesarecentered8.50inches[216mm],each
sideofthecenterofthefloat.Thetapepipeiscenteredona17.00inch[432mm]diame
ter.
3. Checktheangleoftheroof.Theroofpitchforthefurnishedgaugeboardis1inch[25.4
mm]in12inches[305mm].
4. Connectapipedeckflangetothe1.5inchverticalpipethatistobeattachedtotheroof.
5. Bolttheflangetotheroof.Checkthatitisplumb.
Note Failuretoplacetheflangecouplingandpipeinatrueverticalpositionmayaffect
theaccuracyoftheindicator.Makesurethattheinteriorofallpipesarecleanandfreeof
corrosion.
6. Afterthedeckflangeandpipearecheckedtomakecertainthattheyareplumb,unscrew
thepipefromthecoupling.Applypipethreadcompoundandreconnectthepipetothe
coupling.
7. Centerthebaseofatopcableanchorinitshole.Holditplumandboltittotheroof.Do
thesamefortheothertopcableanchor.
8. Removethehousingnippleandcapfromthetopcableanchorsandhangplumblinesfrom
thematthecentertomarkthepositionwherethebottomcableanchorwillbeattached.
AhangingweightanchormaybeorderedfromVarecifitisnotpracticaltoboltorweld
thebottomguidecableanchortothefloorofthetank.Fortanksthatareinservice,the
hanginganchormustbeused.
9. Marktheplumbbobstringattheheightofthetankbenchmark.Thiswillassurethatthe
plumbbobjusttouchesthebottomwhenthereferenceismadefromthebenchmarkdis
tancetothebottom.
Varec,Inc. 17
LiquidLevelIndicator
10. Hangaplumblinethroughthecenterofthetoptape/cablepipetothebottomtomark
thefloatcenter.Thisshouldbe8.50inches[216mm]atthebottomfromeachofthebot
tomcableanchorpositions.Whenthepositioninghasbeenchecked,attachthebottom
cableanchorintoplace.
11. Threadthefloatcablesintothetankthroughthetopanchorfittings.Fastenthemtothe
bottomcableanchorswiththefurnishedhardware.
12. Threadtheupperendofeachguidecablethroughthetopanchorassembly.Handtighten.
Usethelocknuttolockthecableinplace,thentightentheadjustmentnut,untiltheguide
cableistensionedbythespring.
13. Replacethehousingnippleandcap.
14. Applyappropriatepipethreadcompoundandinstallthesheaveelbowontheverticalpipe
tothetankinterior.Installapipeunioninthehorizontalpiperun,inorderthattheelbows
canbeeasilyremoved,ifnecessary.Theninstallthehorizontalpipeassemblyintothetank
dropelbow.Adjustthelengthasneededtoproperlypositiontheoutboardelbow.
15. Installtheoutboardelbowonthehorizontalpipe.
16. Applypipethreadcompoundandscrewthegaugeboardconnectorpipeintotheoutboard
elbow.
17. Removethebolts,cover,andgasketfromtheoutboardelbowanddropaplumbline
throughthecenter.
18. Dropachalklinefromthetopofthetankparallelwiththeplumblineandmarkthechalk
lineonthetankwall.SeeFigure23onpage16.
19. Usethewidthofthegaugeboardatthebottomofthetankwallandchalkregistermarks
forthewidthcenteredonthechalkline.
20. Dothesameatthetopofthetank.
21. Makechalklinemarksbetweenthetopandbottomregistermarktoaidinkeepingthe
gaugeboardsectionscenteredandparallelduringinstallation.
22. Boltthegaugeboardsupportbracketsintoposition(seeFigure25).Thefirstgaugehead
supportbracketmountsnearthetopofthetank.Theothersarespacedatsevenfoot
[2.13.m]intervalsexceptfortheoneatthebottomofthetank.
23. UsetheUboltandnuts(seeFigure23)toattachthegaugeboardconnectortothepipe.
Thepipeshouldextendoneinch[25.4mm]belowtheUbolt.
24. Attachthetopsectionofthegaugeboardtotheconnectorplate.Makecertainthatitis
centeredonthechalkline.
25. Attachtheremainderofthesectionstothebottomofthetank.Makecertainthateach
sectioniscenteredonthechalkline(seeFigure23).
Note Tofitthegaugeboardtothetank,cutthelowestgaugeboardsectionatthemarker
thatis4.50inchesgreaterthanthetankheighttoadjustthefittothetotalheighttothe
tank
26. Tiltthefloatonedgeandsliptheguidecablesthroughtheloopsontheinsideofthetank.
Setitonthetankbottomwiththetape/cableconnectionup.
27. Attheelbowonthetankentrypipe,unrolloneortwoturnsofthetape/cableandstartto
feeditintothehorizontalpipe.Continuetounrollthetape/cableseveralturnsatatime
untilitreachesthegroundatthebottomofthegaugeboardinstallationposition.Make
surethatthetape/cableonthegrounddoesnotbecomekinkedordirty.
18 InstallationandOperationsManual
Installation
Note Throughouttheseinstructionsthetermtape/cableisusedtodesignateeither
theindicatorcabledriveorthecombinationtapeandcabledrivethatisusedtoalsodrive
theaccessorydriveelbow.Ifthetape/cablecombinationisused,thecableendgoeson
thegaugeboardside.
28. Lowerthetapecabletothetankbottomandletseveralinchesfallonthetankbottom.
29. Temporarilyattachthetape/cabletothefloatwiththefurnishedfastener(seeFigure24
onpage17).Feedtheotherendoftheindicatorcableoverthesheaveintheelbowand
makesurethatitisseatedonthepulley.Finalattachmenttobemadeatinitialcalibration.
30. Checktheindicatortape/cablepathbetweenthefloatandthegaugeboardtobesurethat
thetape/cableisnotkinkedortwisted.Alsocheckthefloatguidecablesforkinks.
31. Makecertainthatthefloatguidecablesareparallel.
32. Sliptheindicatoroverthegaugeboard.
33. Putthecablecrimp(seeFigure25)ontheendofthecable,thenthreadthecablethrough
theholeinthetank.Loopthecableontheoutsidebackthroughthecablecrimpandtem
porarilytapeittothecrimp.
Note Ifauxiliaryequipmentistobeinstalled,doitpriortocrimpingthecableconnector.
TheuseofauxiliaryunitsnotmanufacturedorsuppliedbyVarecwillvoidanyVarecwar
rantyandwillrelieveVarecofanyobligationtoservicetheproductunderwarranty.
34. Tapethegaugeboardindicatortothegaugeboardat2.00inches[50.8mm]toholditin
place.Adjustthecabletensionuntilthefloatbarelyliftsoffthetankfloor,thencrimpthe
cableconnectorandremovethetape.
Note Asthefloatisfourinches[101.6mm]highanditswaterlineisatitsequator,itcan
notregisterthelasttwoinches[50.8mm]ofliquidinthetank.
35. Tiealinelongerthantheheightofthetanktotheindicator.
Caution Donotallowthefloattofallbacktothefloorofthetank.Damagemayresult.
36. Slowlypulldownontheindicatorandliftthefloattothetopofthetank.Travelshouldnot
producenoticeablebinding.Slowlylowerthefloattothefloorofthetank.
37. Removethepullline.
Initial Calibration
Theseinstructionsapplytosystemsthatuseahollowshell,weldedfloatthatis14.5inches
[368mm]indiameterby4.0inches[102mm]deep.Calibrationisbaseduponthestandard
specificgravityofwater(1.0).
Note Forproductsofotherspecificgravitiestobegauged,adjusttheindicatoraccord
ingly.Refertotheindustryrelatedchartsfortheparticularproduct.
Withthefloatjusttouchingthebottomofthetank,waterwillbeatthefloatequator(water
line).Setthegaugeboardindicatorto2.00inches[50.8mm].Usethefloatconnectingclamps
(seeFigure24onpage17)tomakethefinaladjustment,thentrimexcesstapeorcableatthe
floatend,leavingsomeadditionaltapeorcableforfutureadjustmentneeds.
Varec,Inc. 19
LiquidLevelIndicator
Initial Lubrication
Applyalightoiltotheelbowandindicatorsheaves.
Reassembly
1. Reinstallthecovers,gaskets,andboltsontheelbows.
2. Closethetankmanholesandinspectioncovers.
20 InstallationandOperationsManual
Installation
16.50
[419]
Figure9: BoltedTankInstallation
Varec,Inc. 21
LiquidLevelIndicator
RefertoTable11onpage2.SeeFigure26onpage25.
1. Determinethepositiononthetankroof,beneathwhichthecenterofthefloatwillriseand
fall.Noticethatthispositionislocatedaminimumof16inches[406mm]andamaximum
of36.00inches[914mm]fromthewallofthetank.
2. Checktheangleoftheroof.
3. LayoutthecouplingpositionsasshowninFigure26.Thefloatdiameteris14.50inches
[368mm].Theguidecablecouplingsarecenteredat8.50inches[216mm]eachsideof
thefloatcenter.Theindicatorcablecouplingiscenteredona17.00inch[432mm]diam
eter.
4. Installthecouplingsintothetopofthetankinaverticalposition.Lengthsofpipescrewed
intothecouplingsandheldplumbwillaidinproperorientationofthesefittings.Failureto
placethecouplingsinatrueverticalpositionmayaffecttheaccuracyoftheLiquidLevel
Indicator.
5. Makesurethattheinteriorofallpipesarecleanandcorrosionfree.
6. Useappropriatepipethreadcompoundonallpipethreadsandinstallthe11/2inchindi
catorpipecableandthetopcableanchorsintotheirrespectivecouplings.
7. Removethehousingnippleandcapfromthetopcableanchorsandhangplumblinesfrom
thematthecentertomarkthepositionwherethebottomcableanchorwillbeinstalled.
8. Marktheplumbbobstringattheheightofthetankbenchmark.Thiswillassurethatthe
plumbbobjusttouchesthebottomwhenthereferenceismadefromthebenchmarkdis
tancetothebottom.
9. Hangaplumblinethroughthecenterofthetopindicatorcablepipetothebottomtomark
thefloatcenter.Thisshouldbe8.50inches[216mm]atthebottomfromeachofthebot
tomcableanchorpositions
10. SeeFigure26forsuggestedbottomanchorconfiguration.Whenthepositionhasbeen
checked,installthebottomanchorintoplace.
11. Threadoneendofthefloatguidecableintothetankthroughoneofthetopanchorfit
tings,throughthebottomanchorchannelandbackupthroughtheothertopanchorfit
ting.Threadeachendoftheguidecablethroughthetopanchorassembly,pullingthe
cablehandtight.Usethelockingnuttolockthecableinplace.Tightentheadjustingnuts
oneachanchorassemblyevenlyuntiltheguidecableistensionedbythespring.Trimoff
excessivecable.
12. Performsteps1321underConeRoofTankInstallation.
13. Installthegaugeboardsupportbracketsintoposition.SeeFigure26andnoticetherela
tivepositionofthetopbracket.Allothersupportbracketsaresevenfeet[2.436meters]
belowthepreviousbracket,exceptforthelastonewhichisaminimumofsixinches[152
mm]abovethegradeline.
14. Performsteps2325underConeRoofTankInstallation.
15. Loosenthenutoneachsideofthefloatthatsecurestheguidecableretainer.Rotatethese
retainerstoopenthekeyholeinthefloatcableguide.Positionfloatwithguidecables
22 InstallationandOperationsManual
Installation
routedthroughthefloatguideholesandrotatetheguidecableretainerstolocktheguide
cableinplace.Tightenthenutsandsetthefloatonthetankbottomorbottomanchor.
16. Performsteps2732underConeRoofTankInstallation.
17. Tapethegaugeboardindicatortothegaugeboardatalevelindicationof2.00inches[50.8
mm]plustheheightofthebottomanchor.Adjustthecabletensionuntilthefloatbarely
liftsfromitsrestingplace.Crimpthecableconnectorandremovethetape.
Note Asthefloatisfourinches[101.6mm]highanditswaterlineisatitsequator,itcan
notregisterthelasttwoinches[50.8mm]plusanybottomanchorheightofliquidinthe
tank.
18. Completetheinstallationbyperformingsteps3436underConeRoofTankInstallation.
Initial Calibration
Theseinstructionsapplytosystemsthatuseahollowshell,fiberglassfloatthatis14.5inches
[368mm]indiameterby4.0inches[102mm]deep.Calibrationisbaseduponthestandard
specificgravityofwater(1.0).
Note Forproductsofotherspecificgravitiestobegauged,adjusttheindicatoraccord
ingly.Refertotheindustryrelatedchartsfortheparticularproduct.
Withthefloatjusttouchingthebottomofthetank,waterwillbeatthefloatequator(water
line).Usethefloatconnectingclamps(seeFigure24onpage17)tomakethefinal
adjustment,thentrimexcesstapeorcableatthefloatend,leavingsomeadditionaltapeor
cableforfutureadjustmentneeds.Installtheheatshrinkablesealcapoverthecutendofthe
cable.
Initial Lubrication
Applyalightoiltotheelbowandindicatorsheaves.
Reassembly
1. Reinstallthecovers,gaskets,andboltsontheelbows.
2. Closethetankmanholesandinspectioncovers.
Varec,Inc. 23
LiquidLevelIndicator
12.50
[318]
Figure10: FiberglassConeRoofTankInstallation
24 InstallationandOperationsManual
Installation
General Preparation
UsetheTableofContentstodeterminetheappropriateinstallationfigureinthisInstruction
Manual.Thesearetypicalinstallations.Allsituationsmaynotbecovered.ContactVarecif
additionalinformationisneeded.
Warning Makecertainthatthetankisemptyandnotinservice.Ensurethatthetankhas
beenleakandpressuretestedasappropriatefortheliquidtobestored.Observe
appropriatesafetyprecautionsinflammableorhazardousliquidstorageareas.Donot
enteratankthathascontainedhydrocarbons,vapours,ortoxicmaterialsuntilagasfree
environmentiscertified.Carrybreathingequipmentwhenenteringatankwhereoxygen
maybedisplacedbycarbondioxide,nitrogen,orothergases.Wearsafetyglassesas
appropriate.Useahardhat.
Warning Undermostcircumstances,themechanicalconnectionsbetweentheguide
cablesandtheanchorsprovidearesistancetogroundthatisadequateforthesafe
electricaldrainofelectrostaticchargesthatmayaccumulateinthetankandtheproduct.
Additionalgroundingmaybeneededforproductswithlowflashpoints.Workeractivity
andworkerclothingmayaccumulateelectrostaticchargesonthebodyofaworker.Care
shouldbeusedinflammableenvironmentstoavoidthehazard.ObserveAmerican
PetroleumInstitute(API)RecommendedPractice2003orotherappropriateindustryor
militarystandard.
Theuserprovidesthe1.5inchpipethatcarriesthetape/cableandthenecessarymounting
andsupportwelding.Theusermustdrillholesasneeded.
Assemblethenecessarytoolsandequipmentattheworksite.RefertoTable21onpage10
forsuggestedtoolsandequipment.Planthepiperouting.Positiontheroofconnection
installationintothetankinteriorwithinarmsreachofamanholeoraninspectionhatch.
UsetheseprocedurestoinstallaVarecmanholeorinspectionhatch,ifthereisnonelocated
withinarmsreachofthetapepipelocation.
Locatethefloatatapositioninsideofthetankwheresurfaceagitationonitwillbeata
minimum.Installadeflector,iftheproductstreamisclosetothefloat.ContactVarecif
agitatorswillcauseexcessfloatdisturbances.Verticalpiperunsmustbeplumbedand
perpendiculartopreventthetape/cablefrombindinginsidethepipe.
Theusermustattachthegaugeboardtothetankbyweldingorboltingthesupplied
gaugeboardbrackets.Iftheenvironmentissuchthatweldingcannotbeperformed,theuser
canconstructasupportstructureclosetotheoutsideofthetank.
Varec,Inc. 25
LiquidLevelIndicator
Warning Theusershouldcomplywithallapplicableregulations,codes,andstandards.
Forsafetyprecautions,theusershouldrefertotheappropriateindustryormilitary
standards.
1. Removethecovertoasafeweldinglocation.
2. Cutarectangularhole6.00inches[152mm]x15.75inches[400mm]inthecover.
3. Cuta2.50inch[63.5mm]diameterholeinthecovertocarrythetapedroppipe.
4. Cuttwo1.75inch[44.5mm]diameterholesinthecovertocarrythetopguidecable
anchors.
5. Disassembletheinspectioncoverandgasketfromtheframe.
6. Weldtheinspectioncoverframetothemanholecover.
7. Weldtheguidecableanchornipplesandthetape/cabledroppipecouplinginplace.make
certainthattheyareverticalandcorrectlycentered.
8. Carrythemodifiedcoverassemblybacktothetanksite.Orientthemodifiedmanhole
coverasshownandreinstall.
9. Refertotheappropriatetankconfigurationfigureandinstallthetape/cablepipingand
gaugeboard.
26 InstallationandOperationsManual
Installation
.25
36.00 [914] maximum [6]
16.00 [406] minimum
Guided float
15.00
[381] (6.00 [152])
3 Places
.25 [6]
3.31
[84]
67.00
[1702] .18
1.75 [4.8]
2X Thru
[44.5] Guide cable
anchor nipple
14 Places
10.00 [254]
Float guide
cable
.12 Typical
[3] Hex head
cap screw
Cable clamps
Detail: C
Anchor bar
Detail: A
Figure11: TypicalInServiceTankInstallation
Varec,Inc. 27
LiquidLevelIndicator
12.50
[318]
Figure12: SevereServiceConeRoofTankInstallation
28 InstallationandOperationsManual
Installation
Float Installation
1. Refertoappropriatetankconfigurationandinstalltopanchorslesslongnippleandcap.
2. Threadthefloatguidecablesintothetankthroughthetopanchorfittingsandpullthe
endsbackthroughtheinspectionhatch.
3. Fastenthebottomanchortotheguidecables(seeFigure27onpage28)andlowerthe
anchorslowlythroughtheinspectionhatchintothetank.
4. Whenanchorbarisrestingontankbottom,removecableslackbyhand.Tightencable
lockingnuttosecurecableinplace.
5. Tightentheadjustmentnutuntiltheguidecableistensionedbythespring.Trimexcess
cable.
6. Usepipethreadcompoundandinstalltopanchornipplesandcap.
Note Throughouttheseinstructionsthetermtape/cableisusedtodesignateeither
theindicatorcabledriveorthecombinationtapeandcabledrivethatisusedtoalsodrive
theaccessorydriveelbow.Ifthetape/cablecombinationisused,thecableendgoeson
thegaugeboardside.
Caution Ifthetape/cablebindsinthepipeduringthreading,checkthepipeforcorrosion
andotherobstructions.Checkthetape/cabletomakecertainthatitdidnotkink.Friction
inthepipewillaffectaccuracyandmaybreakthetape/cable.
7. Threadthetape/cablethroughthehorizontalpipeandintothegaugeboardconnector
pipe.
8. Putacleandropclothonthegroundandpushthetapethroughafewturnsatatimefrom
thedroppipeelbow,untilthetape/cableisunrolled.Makesurethatthetape/cablefalling
tothegrounddoesnotbecomekinkedordirty.
9. Usethetankbenchmarkasaguideandpullbackenoughtape/cabletodropfromthe
benchmarktothetankbottom.Markthatpositiononthetapeforreference.
10. Threadthetapethroughthedroppipeintothetankandpulltheendbackthroughthe
inspectionhatch.
11. Installthetape/cabletothefloatconnectorwiththeclampsandscrewsprovided(seeFig
ure24onpage17).
12. Attachthetape/cableconnectortothefloat,passitthroughthehatchandattachtheeyes
totheguidecables.
Caution Donotallowthefloattofalltothesurfaceoftheproduct.Damagemayresult.
13. Lowerthefloatuntilitishangingfromthetape/cable.Inspectthetape/cableandcables
fortwistsandkinks.Makesurethatthecablesareparallel,thenlowerthefloattothesur
faceoftheproduct.
14. Makeahandgaugemeasurementofthetankproductlevel.Usethebenchmarkreference
tocalibratethehandgauge.Useextracaretomakecertainthatthismeasurementisaccu
ratebecausetheaccuracyofthesightgaugeindicatordependsuponit.
15. Ifanaccessoryistobeinstalled,performtheinstallation.Refertothemaintextauxiliary
equipmentinstallationparagraphsandthencontinuetheinstallation.Theholesize,bolt
pattern,andcouplingofVarecaccessoriesmateswiththesheavedriveelbow.Eachmating
auxiliaryunithasaslottedcouplingthatengagesthedrivepinonthesprocketsheave.
Varec,Inc. 29
LiquidLevelIndicator
Matetheaccessorywiththesprocketsheavedrive.Usethehexheadcapscrewsand
washerstoattachtheaccessoryunittothedriveelbow.
Refertothemanualfortheaccessoryunit,ifinstalled,andcheckouttheoperationofthe
accessoryasappropriate.
Note TheuseofauxiliaryunitsnotmanufacturedorsuppliedbyVarecwillvoidany
VarecwarrantyandwillrelieveVarecofanyobligationtoservicetheproductunderwar
ranty.
16. Installthegaugeboardandindicator.Refertotheappropriatetankconfiguration.
17. Setindicatoratmeasuredproductlevel.
18. Adjustthetape/cabletensionuntilthefloatbarelyliftsfromitsnaturalfloatingposition,
thencrimpthecableconnector.
19. Tiealinetotheindicator.
20. Slowlypulldownontheindicatorandliftthefloattothetopofthetank.Travelshouldnot
producenoticeablebinding.Slowlylowerthefloattotheproductlevel.Checkthatany
installedaccessoryperformedproperlyduringthistest.
Caution Donotallowthefloattofalltothesurfaceoftheproduct.Damagemayresult.
21. Refertoappropriatetankconfigurationtosettheindicatoratthefulltankposition,then
usethehandgaugemeasurementtorecheckthecurrentproductlevel.
Initial Lubrication
Applyalightoiltotheelbowandindicatorsheaves.
Reassembly
1. Reinstallthecovers,gaskets,andboltsontheelbows.
2. Closethetankmanholesandinspectioncovers.
1. Removetheexistingmanholecover.
2. SeparatetheModel226coverbyremovingtheflangeconnectingbolts.
3. Installthecoverhalfwiththepipecouplingtothetopofthetank.
4. Refertotheappropriatetankconfigurationfiguretocheckthetankconfigurationand
installthetape/cablepipingandgaugeboard.
30 InstallationandOperationsManual
Installation
CompletetheAnchorBarInstallation,FloatInstallation,InitialLubrication,andReassembly
sectionsofthepreviousprocedure,InstallationofModel228InspectionHatchtoExisting
ManholeCover.Seealsothefollowingsection,TypicalAuxiliaryEquipmentInstallation.
Note TheuseofauxiliaryunitsnotmanufacturedorsuppliedbyVarecwillvoidany
VarecwarrantyandwillrelieveVarecofanyobligationtoservicetheproductunderwar
ranty.
Theperforatedtapeportionofthetape/cablecombinationmustbeseatedonthesprocket
sheavethroughoutthetraveloftheindicator.Thecableportioncannotdriveanauxiliary
device.Thecableportionattachedtothepulleyofthehalftravelindicatormayreachthe
gaugeboardconnectorsheavebeforeaverticaltankisemptyifthegaugeboardismounted
highonthetank.
1. Removethebolts,cover,andgasketfromtheelbow.
2. Removethedriveadapterflangebolts,washers,flangecap,andgasket.
3. Installtheelbowontheindicatorconnectorpipe.
4. Refertotheappropriatetankconfigurationinstallationproceduresaboveandthreadthe
tape/cablethroughtheelbow.Thecablesegmentattachestothegaugeboardindicator.
Thetapesegmentattachestothefloat.Positionthetape/cablesplicebelowtheauxiliary
driveelbowwiththefloatatthebottomofthetank.
5. Seattheperforatedtapeportionofthetape/cablecombinationonthesheavesprocket
andthreaditthroughtheindicatorconnectorpipe.
6. Attachtheauxiliaryunittotheadapterflange.
7. Attachtheauxiliaryunitwithadapterflangetothedriveelbowensuringthatthesprocket
drivepinengagestheslottedcouplingoftheauxiliaryunit.
8. Refertotheauxiliaryunitmanualforoperationandcheckoutprocedures.
9. Refertotheappropriatetankconfigurationtocompletetheinstallation.
Varec,Inc. 31
LiquidLevelIndicator
ITEM DESCRIPTION
1 COVER PLATE ASSY.
2 HEX NUT
Whesoe Varec Figure 226 3 HEX BOLT
Manhole Cover
(Standard for 20 inch API-650.
Other sizes available on
special order.)
Figure13: API20/24InchManholecoverInstallation
32 InstallationandOperationsManual
Chapter3
Operation
Initial Operation
Caution Initialfillingofthetankmustbeareducedrateofflow,untilthefloattraveland
sightindicatoroperationareverified.Thischecksthattheinstallationwascorrectlymade
andpreventspossibledamagetothegaugesystem.Onfloatingrooftanksthisisparticu
larlyimportantbecausethetape/cabletravelhasnotbeencheckedduringtheinstallation.
1. Stationanobserveratthegaugeboard.
2. Beginfillingthetanktoraisethefloatseveralfeet(aboutthreefeetoronemeter)from
thebottom.
3. Continuefillingthetanktothedesiredlevel.
4. Handgaugetheproductandcomparethemeasurementwiththegaugeboardindication.
Iftheydonotcoincide,adjustthecableattheindicatororconnectorplate.Usethespare
cablecrimp,ifnecessary.
Normal Operation
Whenthetankisfull,theindicatorwillbeatthebottomofthegaugeboard.Astheliquidis
removedfromthetank,thefloatwillfallandtheindicatorwillrise.
Densityandspecificgravityofproductasdeterminedfromrepresentativesamples
Sedimentinthetank
Watercontentintheproduct
Grossvolume
Temperatureoftheproduct
Tankbottomdeformation
Itistheuser'sresponsibilitytoappropriatelyconsidertheseandotherfactorsinhis
application.Forexample,oiltankcapacitytablesarecalculatedforproductat60oF.Ahigher
temperaturewillcausethetanktoexpandandtheactualvolumewillbegreaterthanthe
volumeatthestandardtemperature.
Varec,Inc. 33
LiquidLevelIndicator
Table3:APIStandards
APIStandard Description
2550 MethodForMeasurementAndCalibrationOfUpright
CylindricalTanks(ANSI/ASTMD1220)
2545 MethodofGaugingPetroleumandPetroleum
Products(ANSI/ASTMD1085)
2540 Chapter11.1(ANSI/ASTMD1250)forVolume
CorrectionFactors.ReferalsotoAPI2545.
ManualofPetroleumMeasurementStandards,Chapter3TankGauging,
Section1B,StandardPracticeforLevelMeasurementofLiquid
HydrocarbonsinStationaryTanksbyAutomaticTankGauging.
Accuracyofhandgaugingisextremelyimportant,asitisusedtosettheVarecLiquidLevel
Indicator.Carefulreferencetothebenchmarkofthetankwillhelpassureaccuracyofthelevels
astheyarereadfromtheindicatorduringoperation.
34 InstallationandOperationsManual
Chapter4
Maintenance
Periodic Maintenance
VarecModel6700LowPressureLiquidLevelIndicatorsaredesignedforlongservicelife.Like
anyothermeasuringdevice,LiquidLevelIndicatorsrequireregular,periodicserviceto
maintaintheoriginalperformance.Table41onpage38providessomesuggestedperiodic
service.Minimummaintenancewilllengthentheservicelifeandassuremoreaccuratereading
oftheindicator.
Varecprovidesmaintenanceservicecontractsthatprovideregularperiodicinspectionand
maintenanceatsubstantialsavings.Somerepairtasksmayrequirespecialtools.
Warning Observeappropriatesafetyprecautionsinflammableorhazardousliquid
storageareas.Donotenteratankthathascontainedhydrocarbons,vapors,ortoxic
materials,untilagasfreeenvironmentiscertified.Carrybreathingequipmentwhen
enteringatankwhereoxygenmaybedepletedwithcarbondioxide,nitrogenorother
gases.
Lubrication
Lubricatemovingpartsoftheelbowandindicatorsheavesatregularintervals.Usealight
weightoil.
Lowpourpoint,foodgrade,waterwhite,mineraloil.
Varec,Inc. 35
LiquidLevelIndicator
BrandNames:
ARCOPrimeGrade70
LyondellDuoPrime70(ProductCode16402)
SERVICEBELOW250F(40C)
Automotiveantifreezeandwater(50/50mix)
(PropyleneGlycolbasedantifreezesuchasSierrashouldbeconsideredfor
environmentallysensitiveareas.)
Caution Theseoilsmaynotbecompatiblewithedibleoilsandedibleliquids.Useprod
uctcompatiblesubstitutesfortanksholdingproductsforhumanoranimalconsumption
orproductsthatmayreactchemicallywiththeoil.
Table4:SuggestedPeriodicMaintenanceSchedule
Routine 90Days 6Months 1Year 5Years
Operationcheck X X X
Guidecables X X
Float X X
Lubricate X
Leakcheck X X X
Changeoil X
Calibration X X
Corrosioncheck X
Sedimentcheck X X X
Deformationcheck X X X
Refurbish X
Inspection
Itisrecommendedthatthefirstinspectionaftertheunithasbeenplacedinservicebemade
attheendofthefirstthirtydayperiod.Oilsealedunitsshouldbeinspectedimmediatelyafter
beingplacedinserviceandthendailyforthefirstweek.Subsequentinspectionsshouldbe
madeevery90days(Table41).Theusermayadjustthescheduleforhisownconvenienceand
safety,dependingupontheproduct.Varecmaintenanceservicecontractsareavailablefor90
day,6month,1yearand5yearperiodsatsubstantialsavings.
36 InstallationandOperationsManual
Maintenance
Table5:INDICATORATGROUNDLEVEL(TANKNOTFULL)
PossibleCause Action
1 Cablebroken? Yes
Replacecable.
No
Goto2.
2 Floatdetached? Yes
Reattach.
Table6:GAUGEBOARDINDICATORSTOPPED
PossibleCause Action
1 Cablestuck? Yes:
Checkcablepath.
Checkforfrozensheaveshafts(repair/replace).
Checkforfrozenaccessoryshafts(repair/replace).
No:
Goto2.
2 Pipesdirty? Yes:
Cleanwithautomotivetypespraydegreaser.
No:
Goto3.
3 Indicatoror Yes
gaugeboardslidesdirty Clean.Repair/replace.
ordamages?
Table7:CALIBRATIONREPEATABILITYUNSTABLE
PossibleCause Action
1 Indicatoror Yes:
gaugeboardslides Cleanwithautomotivetypespray
dirtyordamaged? degreaser.Repair/replace.
No:
Goto2.
Varec,Inc. 37
LiquidLevelIndicator
Table7:CALIBRATIONREPEATABILITYUNSTABLE
PossibleCause Action
2 Tape/cableoff Removeelbowcovers.
elbowpulley? Yes:
Reseatandlubricatepulleyshafts.
No:
Goto3.
3 Pulleyshaft/ Yes:
bushingworn/ Repairorreplace.
corroded?
No:
Goto4.
4 Cablepipe/ Yes:
conduitdirty? Removeandclean.
No:
Goto5.
5 Guidecables Yes:
loose,kinkedor Tighten,repairorreplace.
broken?
38 InstallationandOperationsManual
Chapter5
Specifications
Varec,Inc. 39
LiquidLevelIndicator
Weight: 52lbs.(22.2kg)
Material: CastIron
Other Specifications
OperatingRange: FullTravel
48ft.[14M]Maximum
HalfTravel
97ft.Maximum(EnglishOnly)
ServiceRating: Atmospheric
PipeConnections: 11/2inchNPT
40 InstallationandOperationsManual
Specifications
Allpipesaresteel.
Varec,Inc. 41
LiquidLevelIndicator
42 InstallationandOperationsManual
Chapter6
Order Codes
BoardTypeandLength
F06 EnglishTankto6ft
F13 EnglishTankto13ft
F20 EnglishTankto20ft
F27 EnglishTankto27ft
F34 EnglishTankto34ft
F41 EnglishTankto41ft
F48 EnglishTankto48ft
F55 EnglishTankto55ft
F62 EnglishTankto62ft
H13 EnglishTankto13fthalftravel
H27 EnglishTankto27fthalftravel
H41 EnglishTankto41fthalftravel
H55 EnglishTankto55fthalftravel
H69 EnglishTankto69fthalftravel
H83 EnglishTankto83fthalftravel
H97 EnglishTankto97fthalftravel
M02 MetricTankto2m
M04 MetricTankto4m
M06 MetricTankto6m
M08 MetricTankto8m
M10 MetricTankto10m
M12 MetricTankto12m
M14 MetricTankto14m
M16 MetricTankto16m
M19 MetricTankto19m
Varec,Inc. 43
LiquidLevelIndicator
BoardTypeandLength
M21 MetricTankto21m
N23 MetricTankto23m
Y SpecialVersion
N6700 CompleteProductDesignation
44 InstallationandOperationsManual
Document Code
IOM002GVAE1614
Varec, Inc. 5834 Peachtree Corners East, Peachtree Corners (Atlanta), GA 30092 USA
Tel: +1 (770) 447-9202 Fax: +1 (770) 662-8939
www.varec.com
2013 Varec, Inc. All Rights Reserved. This document is for information purposes only. Varec, Inc. makes no warranties, express or implied, in this summary. The names
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