hsse installation guide - fafnir

HSSE

Installation guide

VISY-X System for Shell Petrol Stations

Art. No.: 350016 Release: 11/2015

Content


Page 1 / 59 Content

1 Introduction 1.1 General Description 1.2 Workflow 1.3 Safety Requirements

• Preconditions • Tools • Rules & Regulations • Site preparation

2 Tank Monitoring 2.1 Level Gauging (VISY-Stick)

• Flange reducer (optional) • Probe Unpacking • Screw-in unit sealing • Position Offset • Fixing

2.2 Sump Control (VISY-Stick Sump Manhole) 2.3 Probe Wiring (Junction Box) 3 Dispenser Monitoring 3.1 Sump Control (VISY-Stick Sump Dispenser) 4 Pipe Monitoring 4.1 Leak Detection of Tank Pipes (VIMS Tank) 4.2 Leak Detection of Dispenser Pipes (VIMS Dispenser) 5 Controller Units 5.1 Mounting 5.2 VISY-Command Connections 5.3 VISY-Input 8 Connections 5.4 VISY-Output 8 Connections 6 PC Connection 7 Annex 7.1 FAFNIR ATG Details 7.2 VISY-X System: Wired version 7.3 VISY-X System: RF version Imprint

1 Introduction


Page 2 / 59 1 Introduction 1.1 General Description

1.1 General Description The VISY-X System is designed for petrol station

monitoring. It consists of probes for level gauging and

environmental pollution control.

1.2 Workflow


Page 3 / 59 1 Introduction 1.2 Workflow

BOS Back Office System

Controller Units

Evaluation Unit External Display External Printer Alarm Devices

Pipe Monitoring

Leak Detection of Tank Pipes Leak Detection of Dispenser Pipes

Dispenser Monitoring

Unpacking Sump Control Probe Connection

Tank Monitoring

Unpacking Level Gauging Sump Control Probe Connection

Safety Requirements

Preconditions Tools Rules & Regulations

Site Preparation

1.3 Safety Requirements


Page 4 / 59 1 Introduction 1.3 Safety Requirements

Safety helmet

Safety vest

Safety shoes (S3) Anti-static, oil/petrol-resistant

Gloves Cut-resistant

Product training Regularly

Preconditions

Tools



Rules and Regulations

EX-approved tools

Check tools for malfunctions

Observe local safety and accident prevention regulations

Observe installation instructions

Entry in the Safety Book

Register with the operator

Fire, ignition sources, smoking prohibited

Site preparation



Check delivery

Protect installation site

Disconnect power supply and secure against reactivation

Establish potential equalization

Drain and degas manhole

Check wiring and cable connections

2 persons at manhole of depth > 1.25m

Security zones (red, green, emergency)

Preconditions



Product training Regularly

Personal Protective Equipment



Safety helmet

Safety vest/clothes

Safety shoes (S3) Anti-static, oil/petrol-resistant

Gloves Cut-resistant

Rules & Regulations



Register with the operator

Rules & Regulations



Observe local safety and accident prevention regulations

Entry in the Safety Book

Observe installation instructions

Site preparation



Security Zones

Site preparation



EX-approved tools

Site preparation



Controller

Probes Environmental sensors

Check delivery

Site preparation




Fire, ignition sources, smoking prohibited

Site preparation




Site preparation



Disconnect power supply and secure against reactivation

2 persons at manhole of depth > 1.25m

Site preparation




Site preparation



Establish potential equalization (PE)

Check wiring and cable connections

2 Tank Monitoring


Page 20 / 59 2 Tank Monitoring

1

2 3

Level gauging with “VISY-Stick”

Manhole monitoring with “VISY-Stick Sump Manhole”

Leak detection with “VIMS Tank”

1

2

3

Connections to VISY-Command

Tank

2.1 Level Gauging (VISY-Stick)


Page 21 / 59 2 Tank Monitoring 2.1 Level Gauging (VISY-Stick)

ca.1

23

47,2

Pro

be le

ngth

ca.1

23

47,2

Pro

be le

ngth

Centring rings

Screw-in unit

VISY-Stick VISY-Stick (Riser version) (Screw-in version)

Sample installation with VISY-Stick “screw-in” version !

Flange Reducer (optional)



Unscrew …

Unscrew …

and remove flange.

and remove blind plug.




Seal the reducer thread

Screw the reducer into the flange

Relocate the flange … and lock it.

Reducer 2“ x 1½“ (optional)




Connect PE cable (green/yellow)

Probe Unpacking



Pull out the probe

Probe Unpacking



Remove the shipping protection

Probe Unpacking



Move the floats to the end …

… to protect against damages

Probe Unpacking



Attention: The probes must not be bended!

Screw-in unit sealing



Roughen

Sealing strip Sealing compound

Seal the thread of screw-in unit

Probe

Attention: The probes must not be bended!

Position Offset



… to the manhole. Transport …

Fill in the FAFNIR ATG Details (see annex)

Position Offset



Tank details

Installation Offset see next page!

Form attached to Annex

Probe details

FAFNIR ATG Details Terminal

No. (VP-

Board)

Tank No. / Dispenser

No.

Tank Volume

[l]

Tank Diamete

r [mm]

Type of Product Offset (see

Diagram)

VISY-Stick Ser. No.

VISY-Stick Sump

Manhole Ser. No.

VISY-Stick Sump

Dispenser Ser. No.

…

1 1 50000 2500 Diesel 10 28813 / /

2 2 25000 1600 V-Power Diesel 10 28814 / /

3 3 40000 2000 V-Power 10 28815 / /

4 4 50000 2500 Super 10 28812 / /

5 5 50000 2500 Diesel 10 28816 / /

6 6 50000 2500 Super 10 28811 / /

7 1/2 / / / / / / 28472

8 3/4 / / / / / / 28471

…

Position Offset



0

10

20

30

40

50

60

70

80

90

100

110

0 50 100 150 200 250 300 350 400

Prob

e di

stan

ce (b

) fro

m ta

nk b

otto

m [m

m]

Probe distance (a) from central vertical axis [mm]

Tank diameter

1600 mm 2000 mm 2500 mm 2900 mm

Offset = Vertical Distance (b) + Safety Distance The “Vertical Distance (b)” can be read out from the drawing below. The “Safety Distance” is the mounting distance to the tank bottom and should be 10 mm.

VISY-Stick

Tank

Fixing



Screw the screw-in unit into the flange

(resp. reducer)

Insert probe until bottom is reached

Screw-in unit

Gland bolt Locking screw

Probe

Mark this “Bottom Position”

Probe

Flange

Fixing



Mark the “Bottom Position” and pull out the probe

Tighten the gland bolt at this “Safety Distance”

“Bottom

position” “Safety

Distance” marking

Probe fixing

Flange

Mark the “Safety Distance” 10 mm below, press the probe down to this point

Fixing



Unscrew yellow cap

Fix the plug

handtight

1

and the PE cable

2

Fix the locking screw with hexagon socket key

Connect the probe cable

180°

Probe installation complete !

Fixing



2.2 Sump Control (Sump Manhole)


Page 37 / 59 2 Tank Monitoring 2.2 Sump Control (Sump Manhole)

VISY-Stick Sump Manhole

Sump Installation-Kit (optional)

blue

65

59

ca.

425

105

47,2

Installation



Remove shipping protection

Sump Installation-Kit

(optional) Mounting example

PE cable connector

Installation



Fix the plug

handtight

1 2

180°


Mounting example with washer welding

by installer Unscrew yellow cap

and connect the plug

Fix bracket

2.3 Probe Wiring (Junction Box)


Page 40 / 59 2 Tank Monitoring 2.3 Probe Wiring (Junction Box)

Close the Junction Box

VISY-Stick

Sump Manhole

To the Command

Up to three different types of VISY–X probes (e.g. VISY-

Stick, VISY-Stick Sump, VIMS) can be connected to VISY-

Command via one intrinsically safe cable.

Probe wiring complete !

VIMS

3 Dispenser Monitoring


Page 41 / 59 3 Dispenser Monitoring

Connection to VISY-Command 1

Sump monitoring under the dispenser with “VISY-Stick Sump Dispenser” 1

Dispenser

Sump

VISY-Stick Sump Dispenser

3.1 Sump Control (Sump Dispenser)


Page 42 / 59 3 Dispenser Monitoring 3.1 Sump Control (Sump Dispenser)

VISY-Stick Sump Dispenser


red

65

59

ca.

425

105

47,2

Installation



Remove shipping protection Pull out the probe

Unscrew yellow cap and connect the plug

Fix the plug

handtight

1

2

180°

Installation



Connect the wires using

Insert the probe into an existing open tube

Mounting example


FAFNIR Junction Tube

(optional)


Mounting example

4 Pipe Monitoring


Page 45 / 59 4 Pipe Monitoring

For installation instructions of the Leak Detection system “VIMS” please see the separate user guide.

4.1 Leak Detection of Tank Pipes (VIMS Tank) 4.2 Leak Detection of Dispenser Pipes (VIMS Dispenser)

5 Controller Units 5.1 Mounting


Page 46 / 59 5 Controller Installation 5.1 Mounting

Input-Box

Electrical Switchboard

(example)

Wall mounted (example)

Output-Box Command

Command

Input-Box

Output-Box

Output-Box

Output-Box

5.2 VISY-Command Connections


Page 47 / 59 5 Controller Installation 5.2 VISY-Command Connections

VISY-Command with opened cabinet door

Wiring Overview

Probes

Power supply

VISY-View Touch Host

Input and

Output

Interface VI-4

2 3 LNPE

Host

Display :

5:

+5V

1 2

S1

1 - 8 9 - 16

-RxD Host

3: RxD

probesRxD Service

TxD Service

4 5

S2

7 8 PE

Tank

21

O N

VISY -IC I

Expansion

1

RS-485 Bias

-TxD Expan sion

-TxD HostService

Status of

Service

Reset

6

2: TxD

43O N

VISY-Command Connections



Terminal assignment

Connect Host (PoS) and Expansion (e.g. VISY-View Touch) with the terminal

VP Board

VISY-Command ICI Interface VI

1 2 3 4 5 6 7 8 9

RxD TxD A+ B- A+ B- PE

RS-232 RS-485 RS-485

Host Expansion

+ A B-

Probe

Probe

2

Probe

3

Probe

4

Probe

5

Probe

6

-

7

Probe

8

PEN L

Power SupplyN L

to Interface VI-4

(230V 50Hz)

+ A B- + A B- + A B + A B- + A B- + A B- + A B-

+ A B- + A B- + A B- + A B-

+ A B- + A B - + A B- + A B-

Probe

VP Board

1




Connect the probes to the VP Board according to the FAFNIR ATG form

Tank 1

Tank 1

Tank 1

VISY-Command

ICI

Connect power supply

Interface VI

VP Board




GND A B

VISY-Input 8 / Output 8

GND A B

VISY-Input 8 / Output 8

ICI Interface VI

VISY-Command

VP Board

Connection diagram

Connect VISY-Input 8 and VISY-Output 8 with the VISY-ICI screw terminal

GND A B

VISY-ICI screw terminal

5.3 VISY-Input Connections


Page 51 / 59 5 Controller Installation 5.3 VISY-Input Connections

VISY-Input 8

from alarm detectors

to ICI Power supply

GND A

B

PE N

L

GND In +12V GND In +12V GND In +12V GND In +12V Input 2 Input 4 Input 6 Input 8 Input 1 Input 3 Input 5 Input 7

5.4 VISY-Output Connections


Page 52 / 59 5 Controller Installation 5.4 VISY-Output Connections

VISY-Output 8

to ICI

to alarm indicators or safety equipment

Power supply

GND A

B

NO C NC NO C NC NO C NC NO C NC

Relay 2 Relay 4 Relay 6 Relay 8

Relay 1 Relay 3 Relay 5 Relay 7

PE N

L

6 PC Connection


Page 53 / 59 6 PC Connection

… with serial RS-232 cable

The software VISY-Setup is required for the configuration of VISY-Command. It can be downloaded from the site www.fafnir.com

Connect VISY-Command to PC

…

END


Page 54 / 59 Completion

Annex: FAFNIR ATG Details


Page 55 / 59 7 Annex 7.1 FAFNIR ATG Details

Station Name

System Type wired wireless

Tank Components VISY-Stick Standard (also for Biodiesel / E10 / Ethanol)

VISY-Stick Advanced (also for Biodiesel / Ethanol)

VISY-Stick N for urea solution (AdBlue®)

VISY-Stick Flex (also for Biodiesel / E10)

VISY-Stick LPG

VISY-Density

VISY-Stick Interstitial Dry / Wet

VISY-Reed Interstitial Dry / Wet

VISY-Stick Sump Manhole

VISY-Reed Sump Manhole

Dispenser Components VISY-Stick Sump Dispenser

VISY-Reed Sump Dispenser

Date of Installation

Date of Commissioning

Warranty Start

Warranty End

Date Signature (Installer)

Date Signature (Station Manager / Project Manager)


Page 56 / 59 7 Annex 7.1 FAFNIR ATG Details

FAFN

IR A

TG D

etai

ls

VISY

-Ree

d

Sum

p D

ispen

ser

Ser.

No.

VISY

-Ree

d Su

mp

Man

hole

Se

r. N

o.

VISY

-Ree

d In

ters

titia

l

Ser.

No.

VISY

-Stic

k In

ters

titia

l

Ser.

No.

VISY

-Stic

k D

ensit

y

Ser.

No.

VISY

-Stic

k Su

mp

Disp

ense

r Se

r. N

o.

VISY

-Stic

k Su

mp

Man

hole

Se

r. N

o.

VISY

-Stic

k

Ser.

No.

Offs

et

(see

D

iagr

am)

Type

of

Prod

uct

Tank

D

iam

eter

[m

m]

Tank

Vo

lum

e [l]

Tank

No.

/

Disp

ense

r N

o.

Term

inal

N

o.

(VP-

Boar

d)

1 2 3 4 5 6 7 8 9 10

11

12

13

14

15

16


Page 57 / 59 7 Annex 7.2 VISY-X System, Wired Version

2010

-01-

1414

:06:

30Sy

stem

-Sta

tus:

OK

1: R

egul

ar

Ulla

ge: 1

878

LVo

lum

e: 7

622

LUl

lage

: 137

37 L

Volu

me:

526

3 L

Ulla

ge: 1

2378

LVo

lum

e: 6

622

LUl

lage

: 404

7 L

Volu

me:

545

3 L

2: P

rem

ium

3: D

iese

l4:

Bio

-Die

sel

PO

WE

RE

RR

OR

FE

ET

ON

LIN

E

VIS

Y-X

Prin

ter

VIS

Y-Vi

ew T

ouch

with

op

tiona

l prin

ter

with

indi

catio

n of

en

viro

nmen

tal a

larm

2010

-01-

1414

:06:

30Sy

stem

-Sta

tus:

OK

1: R

egul

ar

Ulla

ge: 1

878

LVo

lum

e: 7

622

LUl

lage

: 137

37 L

Volu

me:

526

3 L

Ulla

ge: 1

2378

LVo

lum

e: 6

622

LUl

lage

: 404

7 L

Volu

me:

545

3 L

2: P

rem

ium

3: D

iese

l4:

Bio

-Die

sel

Elec

trica

l-sw

itch

boar

d ST

P-C

ontro

ller

BOS

Bac

k O

ffice

Sys

tem

VIS

Y-M

onito

rSo

ftwar

e

VIS

Y-O

utpu

tC

onfig

urab

le

mul

tipur

pose

re

lay

outp

uts

for

alar

m in

dica

tion

and/

or d

evic

e sh

utdo

wn

Ext

erna

l thi

rd p

arty

de

vice

sen

ding

ala

rms

to V

ISY-

Inpu

t

RS2

32/4

85 h

ost i

nter

face

fo

r Poi

nt o

f Sal

e, s

ite c

ontro

ller

or IF

SF (w

ith o

ptio

nal

IFS

F-LO

N c

onve

rter)

con

nect

ion.

FA

FNIR

VIS

Y-Q

uick

pro

toco

l with

AT

G a

nd e

nviro

nmen

tal a

larm

da

ta, I

FSF

and

third

par

t pr

otoc

ols

with

ATG

dat

a on

ly

VIS

Y-In

put

To c

onne

ct n

on

VIS

Y-X

com

pone

nts

VIS

Y-S

tick

Sum

pD

iscr

imin

atin

gdi

spen

ser s

ump

sens

or

Up

to tw

o di

ffere

nt

VIS

Y-X

bas

ed s

enso

rs a

ndtw

o di

ffere

nt V

IMS

sen

sors

via

on

e in

trins

ical

ly s

afe

cabl

e

Junc

tion

Box

VIM

S P

ipe

Sen

sor

Mon

itorin

g of

doub

le-w

alle

d pi

pes

STP

Sub

mer

sibl

e Tu

rbin

e P

ump

VIS

Y-St

ick

Auto

mat

ic T

ank

Gau

ging

leve

l sen

sor

VIM

S Ta

nk S

enso

rVa

cuum

Inte

rstic

e M

onito

ring

of d

oubl

e-w

alle

d ta

nks

VIS

Y-S

tick

Sum

p D

iscr

imin

atin

g m

anho

le s

ump

sens

or

Dis

pens

er

VIS

Y-C

omm

and

2/4/

8/16

GU

I

Opt

iona

l Prin

ter

FAFN

IR V

ISY-

X sy

stem

arc

hite

ctur

e in

clud

ing

envi

ronm

enta

l sen

sors


Page 58 / 59 7 Annex 7.3 VISY-X System, RF Version

PO

WE

RE

RR

OR

FE

ET

ON

LIN

E

2010

-01-

1414

:06:

30Sy

stem

-Sta

tus:

OK

1: R

egul

ar

Ulla

ge: 1

878

LVo

lum

e: 7

622

LUl

lage

: 137

37 L

Volu

me:

526

3 L

Ulla

ge: 1

2378

LVo

lum

e: 6

622

LUl

lage

: 404

7 L

Volu

me:

545

3 L

2: P

rem

ium

3: D

iese

l4:

Bio

-Die

sel

2010

-01-

1414

:06:

30Sy

stem

-Sta

tus:

OK

1: R

egul

ar

Ulla

ge: 1

878

LVo

lum

e: 7

622

LUl

lage

: 137

37 L

Volu

me:

526

3 L

Ulla

ge: 1

2378

LVo

lum

e: 6

622

LUl

lage

: 404

7 L

Volu

me:

545

3 L

2: P

rem

ium

3: D

iese

l4:

Bio

-Die

sel

Elec

trica

l-sw

itch

boar

d ST

P-C

ontro

ller

VIS

Y-C

omm

and

GU

I RF

BOS

Bac

k O

ffice

Sys

tem

VIS

Y-M

onito

rSo

ftwar

e

VIS

Y-O

utpu

tC

onfig

urab

le

mul

tipur

pose

re

lay

outp

uts

for

alar

m in

dica

tion

and/

or d

evic

e sh

utdo

wn

Ext

erna

l thi

rd p

arty

de

vice

sen

ding

ala

rms

to V

ISY-

Inpu

t

RS

232/

485

host

inte

rface

fo

r Poi

nt o

f Sal

e, s

ite c

ontro

ller

or IF

SF (w

ith o

ptio

nal

IFS

F-LO

N c

onve

rter)

conn

ectio

n.

FAFN

IR V

ISY-

Qui

ck p

roto

col w

ith

ATG

and

env

ironm

enta

l ala

rm

data

, IFS

F an

d th

ird p

art

prot

ocol

s w

ith A

TG d

ata

only

VIS

Y-In

put

To c

onne

ct n

on

VIS

Y-X

com

pone

nts

VIS

Y-S

tick

Sum

pD

iscr

imin

atin

gdi

spen

ser s

ump

sens

or

VIS

Y-X

Prin

ter

Dis

pens

er

VIS

Y-Vi

ew T

ouch

with

op

tiona

l prin

ter

with

indi

catio

n of

en

viro

nmen

tal a

larm

Ext

erna

l Ant

enna

Ext

erna

l Ant

enna

VIS

Y-St

ick

Inte

rstit

ial (

Liqu

id)

VIS

Y-S

tick

Sum

p D

iscr

imin

atin

g m

anho

le s

ump

sens

or

VIS

Y-S

tick

Aut

omat

ic T

ank

Gau

ging

leve

l sen

sor

STP

Subm

ersi

ble

Turb

ine

Pum

p

VIS

Y-R

FTTr

ansm

itter

VIS

Y-R

FTTr

ansm

itter

VIS

Y-R

FTTr

ansm

itter

Opt

iona

l Prin

ter

FAFN

IR V

ISY-

X sy

stem

arc

hite

ctur

e in

clud

ing

envi

ronm

enta

l sen

sors

Imprint


Page 59 / 59 Imprint

FAFNIR GmbH Bahrenfelder Straße 19 22765 Hamburg Germany Phone: +49/40/39 82 07–0 Fax: +49/40/39 06 33 9 E-mail: [email protected] Internet: www.fafnir.com Managing directors: René Albrecht, Claudia Ploog, Patrick Forsythe Registered Office and Commercial Register Hamburg HRB 11010, VAT-ID No.: DE 811 235 507 Article no.: 350016 © Copyright Reproduction and translation only with the written consent of the FAFNIR GmbH. The FAFNIR GmbH reserves the right to carry out product alterations without prior notice.

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