I-Site Manual - version 2

I-Site Manual - version 2
Gauge Pneumatic Bubbler Readout
Model 1103/1103hp
User Manual
Man 136
2.0.1
06/08/2014
C. Spalton
Andy Small
Chris Rasmussen
Manual No.
Revision
Date
Originator
Checked
Authorised for
Issue
User Manual
1
Contents
Section 1 :
FOREWORD ................................................................................................... 3
Section 2 :
INTRODUCTION............................................................................................. 4
Section 3 :
EQUIPMENT SUPPLIED .................................................................................. 5
3.01
3.02
Equipment....................................................................................................... 5
Accessories...................................................................................................... 5
Section 4 :
GENERAL DESCRIPTION ................................................................................ 6
Section 5 :
PERFORMANCE .............................................................................................. 7
5.01
5.02
Model 1103 ..................................................................................................... 7
Model 1103-HP ................................................................................................ 7
Section 6 :
PREPARING THE READOUT FOR USE .............................................................. 8
Section 7 :
CHARGING THE NITROGEN CYLINDERS ......................................................... 9
Section 8 :
TAKING READINGS ...................................................................................... 10
8.01
8.02
8.03
Section 9 :
9.01
“NO FLOW MODE METHOD” ............................................................................. 10
"FLOW MODE METHOD" .................................................................................. 11
GENERAL NOTE ON TAKING READINGS ............................................................. 11
TROUBLE SHOOTING ................................................................................... 12
Leaking in the Pneumatic Circuit ...................................................................... 12
Section 10 : CARE AND MAINTENANCE............................................................................ 13
Section 11 : HEALTH AND SAFETY REQUIREMENTS ......................................................... 14
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Section 1 : Foreword
It is essential that the equipment covered by this manual is both installed and operated by
competent and suitably qualified personnel. They must READ AND UNDERSTAND the
procedures outlined in this manual before attempting installation or operation of the equipment on
site. Failure to do this may result in degraded performance and reduced reliability.
All systems are designed to operate consistently under normal field conditions. The Gauge
Pneumatic Bubbler Readout is a precise and sensitive instrument which must be handled with the
same care as sensitive surveying instruments. Although the components are relatively robust for
such sensitivity they will not survive mishandling or neglect. Treat all items with respect and
HANDLE WITH CARE.
Obviously these techniques can only serve as a general guide and will require modification to suit
particular circumstances on site. If difficulties are encountered time will usually be saved by
contacting Soil Instruments Ltd at the earliest opportunity.
SAFETY NOTE. This readout contains pressure reservoir cylinders which have been tested
and certified in accordance with "Home Office" requirements. The cylinder must be retested and certified every five years in accordance with BS 5430 Part 3 or overseas in line
with the local regulations. It is also a UK requirement that when a charged readout unit is
transported on public roads that both the unit and the vehicle carry a non-flammable
compressed gas hazard label.
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Section 2 : Introduction
The Bourdon Gauge Pneumatic Bubbler Readout is a portable readout unit for use with all Soil
Instruments pneumatic transducers (and other manufacturers instruments) which operate on the
"NO FLOW" or "FLOW” principle.
A schematic drawing of the basic principle of operation of the pneumatic transducer system is
given in Drg. A3/1103 -008. In this measuring technique the pressure to be monitored is caused to
act on one side a sealed flexible rubber diaphragm in the transducer unit which is thus held
against the back plate by the applied pressure.
Two ports are drilled through the back plate surface and connected to nylon tubes which extend to
the reading point. Referring to Drg. A3/1103-008, when a reading is required, gas pressure is
applied to the black (send) tube and the magnitude is increased via the pressure regulator until it
becomes greater than that of the hydraulic pressure acting on the other side of the diaphragm. The
diaphragm moves away from the pneumatic ports and gas passes into the return tube. As bypass
continues in the return tube, gas is detected visually by the air bubbles escaping at a water pot or
through a flowmeter. A flow control valve is adjusted to reduce the return line gas flow to a
minimum.
This stable balance pressure is read directly from the Bourdon Tube Test Gauge on the front
panel.
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Section 3 : Equipment Supplied
Pneumatic Readout Model 1103 consists of the following items.
The Pneumatic Bubbler Readout is housed in a strong high impact polypropylene moulded case
with a hinged sealed lid and carrying handle. The readout is connected to pneumatic instruments
through two quick release couplings and fly tubes provided as accessories.
3.01 Equipment
Gauge Type Pneumatic Bubbler Readout (Model 1103) housed in yellow moulded box.
Dimensions
:
360 x 280 x 160mm.
Weight
:
7 Kg.
3.02 Accessories

Pair of 2m long nylon flyleads with quick release couplings to connect Readout with
pneumatic instruments through a terminal panel.

Single High Pressure nylon tube with end fittings to connect readout to external
industrial Nitrogen cylinder regulator for recharging internal gas cylinder.

Pair of safety goggles for use when recharging internal gas cylinder.
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Section 4 : General Description
The front panel is shown in Drawing No. A3/1103-006. All main parts involved in operation and
function of the readout are located on the front panel except for the gas bottles and pneumatic
tubes. Identification with brief function description is as follows;
A.
Pressure Control Valve. It has three positions as marked on the front panel. It connects
the send line to regulated gas pressure or exhaust as shown in Drawing No. A3/1103 -009.
B.
Flow Control Valve. It is a needle valve which controls the gas flow rate into the send
line Ref. Drawing 1103-009.
C.
Pressure Regulator. It is located between high pressure gas cylinders and the operational
part of pneumatic circuit. Turning it clockwise increases the regulated i.e. operating,
pressure and anticlockwise to reduce or completely shut the gas pressure.
D.
Regulated Pressure Gauge 0-200 psi. Indicates the operating pressure to which the send
line and pneumatic sensor will be subjected on switching Valve "A" to apply pressure
position. This should always be slightly higher than the expected reading.
E.
Flow Meter. Floating ball type with flow rate of 20 to 30 ml per minute.
F.
Cylinder Pressure Gauge. 0 to 1000 psi. This indicates the gas pressure in the internal
cylinders. Maximum gas charging pressure of 950 psi may not be exceeded while
charging the nitrogen.
G.
Bourdon Tube 6" Test Gauge. Depending on the range of pneumatic instruments the
gauges can range from zero to 20, 40, 60, 100m Hd or zero to 200 or 350m Hd
(1103 HP).
H.
Flowmeter connection to front panel. Quick release fitting for return line. Quick release
fitting for send line. "Nitrogen" Nitrogen Gas charging point.
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Section 5 : Performance
The general description and operational procedures described in this manual are common to Model
1103low and high pressure Pneumatic Bubbler Readouts. Higher pressure readouts i.e. 0 to 200m
Hd and 0 to 350m Hd will consume greater volumes of gas for same number of readings. The user
is hence advised to prepare for more frequent nitrogen gas charging for higher ranged Readouts.
The performance specifications are limited by the operating pressures and the range of test gauge
in the readout which is as follows:-
5.01 Model 1103
Fitted with 6" Test Gauge Ranges of 0 to 100m Hd.
Gauge Ranges available: 0 to 20, 40, 60 and 100m Hd.
Gauge Reading Accuracy: ± 0.5% F.S.D.
5.02 Model 1103-HP
Fitted with 6" Test Gauges Range of 0 to 350m Hd.
Gauge Ranges available: 0 to 200 and 0 to 350 m Hd.
Gauge Reading Accuracy: ± 0.5% F.S.D.
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Section 6 : Preparing the Readout for Use
Before embarking on a visit to site to take a series of readings it is important to ensure that the
readout is properly prepared as follows;
1. Ensure that all items are available i.e. Readout, pneumatic flyleads, cleaning materials for
cleaning couplings and notepad/pencil for recording readings.
2. The internal Nitrogen cylinders must be sufficiently charged to ensure enough gas is
available for the readings to be taken (refer to Section 7 for charging details). In case of
high pressure readings greater quantity of gas per reading will be consumed. A careful
planning of recharging the gas cylinders is advised to save trips back to base especially
over long distances.
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Section 7 : Charging the Nitrogen Cylinders
Refer to Drg. No. A3/1103-007
WARNING
The regulator fitted to external nitrogen cylinder controls the charging
pressure eliminating any chance of accidentally over pressurising the
nitrogen reservoir in the readout. However the operator MUST ALWAYS
watch the gauges and never exceed an indicated CYLINDER PRESSURE of
65 bar (950 psi) while adjusting the regulator setting during charging
operation.
1. Remove dust cover from bulkhead fitting marked NITROGEN on the front panel.
2. Examine charging flylead and ensure it is undamaged and end fittings are in good clean
condition.
3. Wear Safety Goggles for the following procedures.
4. Ensure Pressure Regulator Valve on the deliver cylinder is closed by turning adjustment knob
fully anticlockwise.
5. Connect flylead from readout to regulator on delivery cylinder. Do not over tighten the
brass coupling nuts (it is only necessary to use two fingers on the spanner when
tightening the nuts).
6. Using special cylinder key open delivery cylinder valve.
7. Slowly open pressure regulator on delivery cylinder by turning the adjustment knob
clockwise until flow is heard, accompanied by a rising pressure indicated on the readout
CYLINDER PRESSURE GAUGE "F".
8. Continue to turn the delivery cylinder regulator knob clockwise in stages. Wait until the
readout cylinder pressure gauge stabilises before continuing.
9. When the readout cylinder pressure gauge registers 65 Bar (950 psi) close off delivery
cylinder with the key.
10. Close Pressure Regulator Valve by turning adjustment knob on delivery cylinder
regulator fully anticlockwise.
11. Carefully remove flylead by slightly loosening brass nut at readout connection
marked "NITROGEN". Allow residue of pressure in flylead to exhaust completely
before disconnecting flylead.
INFORMATION
Always make sure that the flylead is never left connected to
the cylinder regulator when not in use. This will prevent
"whip-lash" of the flylead in the event of the delivery cylinder
valve being accidentally opened.
12. Replace dust cap on "NITROGEN" fitting.
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Section 8 : Taking Readings
All pneumatic instruments of 3P5.2, 3W5.20, 7P5.1 and 8P2.12 type can be read with this
readout using "No Flow" or "Flow Mode" of reading. It is advised that one of the two modes is
always used to avoid variance in readings. The two methods are described below.
8.01 “No Flow Mode Method”
Refer to Drg.No. A3/1103-006.
Connect the Pneumatic Readout to the instrument desired to be read either directly or through the
terminal panel. Make sure that quick release couplings are clean and dry. Set Valve "A" to
"EXHAUST" position and open Flow Control Valve "B" (turn knob anticlockwise 1 to 2 turns). This
exhausts the system to atmosphere making the gauge read zero pressure.
1. Close Valve "B" (screw in gently).
2. Set Valve "A" to "OFF" position.
3. Adjust Pressure Regulator "C" to indicate an output pressure on gauge "D" just in excess of
expected reading.
4. Set Valve "A" to APPLIED PRESSURE position.
5. Slowly open FLOW CONTROL Valve "B" (approximately 1/4 turn only) and observe the
gauge "G". The reading should slowly rise. Adjust control Valve "B" as necessary to
maintain steady increase on gauge "G". After delay (dependent on installed tube lengths)
the Flowmeter "E" will indicate gas returning by the float rising in the flowmeter. Adjust
flow control Valve "B" to maintain the correct flow, the ball should float between the two
indicator lines.
6. Allow flow to continue for approximately 20/30 seconds. 8.1.7 Set
Valve "A" to "OFF" position.
7. Reading on the Test Gauge "G" will settle at the balanced pressure and is recorded.
8. Reading may be repeated as a check by resetting Valve "A" to "APPLY PRESSURE"
position repeating from Step 2.
9. On completion of readings set Valve "A" to EXHAUST position. Decrease Pressure
Regulator "C" to zero pressure (shown on Gauge "D") and open Flow Control Valve "B".
Set Valve "A" once again to APPLIED PRESSURE to exhaust the control circuit of residue
gas.
10. Finally reset Valve "A" to "OFF" position.
11. Disconnect flyleads and protect fittings with dust caps.
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8.02 "Flow Mode Method"
This method of reading is less convenient due to time necessary to accurately maintain a constant
low gas flow rate throughout the reading cycle. To obtain the most accurate reading a minimum
gas flow must be achieved to "just open" the diaphragm valve in the installed pneumatic
transducer. To achieve this requirement the flow rate must be adjusted to maintain the flowmeter
ball floating on the lower indicator line in the flow tube.
1.
This reading method is identical to the "NO FLOW MODE" method up to step 8.1.6. Further
steps are as follows.
2.
Refine flow rate adjustment to float the ball on lower indicator line.
3.
Take the reading on Gauge "G" and record it. This completes the sequence of one reading.
Repeat readings or other transducers can be read using same sequence again.
4.
After completion of a set of readings, exhaust the pneumatic lines by turning Valve "A" to
"Exhaust" and "B" to open position (2 turns anticlockwise). Disconnect the readout
pneumatic flyleads and cover fittings with dust caps.
8.03 General Note on Taking Readings
When carrying out a reading sequence avoid applying excessive flow rate setting by careful
adjustment of "FLOW CONTROL Valve B". Never intentionally allow the flowmeter ball to float to
the top of the flow tube; this may give rise to inaccurate readings. Should application of excessive
gas flow occur it is important to re-set Valve "A" to "OFF" position and allow the flowmeter ball to
return to the bottom of the flow tube.
A period of several minutes delay should be allowed (depending on tube lengths) before carrying
out a new reading sequence. This ensures that any over pressure in the installed instrument tubes
dissipates before attempting to carry out further readings.
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Section 9 : Troubleshooting
Faults due to failure of mechanical components may be divided into two categories. Those due to
leakage in the pneumatic circuit lines and those due to the failure of moving components such as
valves and mechanical linkages.
9.01 Leaking in the Pneumatic Circuit
The most critical part of the pneumatic circuit is that relating to the send line. Here the smallest of
leaks will produce a continuing fall off of indicated pressure at the reading phase rendering the unit
unusable. Should leaking be suspected, proceed as follows;
1. Ensure the nitrogen cylinders are charged.
2. Remove the front panel of the readout and fix so that both faces are accessible.
3. Set the readout in the operating mode by setting valve "A" to "APPLY PRESSURE" position,
open Control Valve "B" half turn and adjust PRESSURE REGULATOR "C" to indicate a typical
output pressure on gauge "F". Ensure symptom is apparent.
4. Listen for sound of leaking gas. Locate leak by ear and touch.
5. If nothing is heard take a length of flexible tubing and use as a stethoscope, moving one end
over the area of the circuit where a leak is suspected.
6. If the above measures fail to positively locate the leak, paint all joints with a soapy water
solution and inspect for bubbles.
7. Leaks at tube connections/fittings may be sealed in most cases by carefully tightening the
offending fitting.
8. Reset valves "A" to "OFF" and "B" to Close (fully clockwise) and adjust regulator "C" to off
position (full anticlockwise).
9. Should the leak remain undetected it is likely that a valve is leaking internally. The offending
valve must be stripped, examined and cleaned. Apply a thin film of light oil over the seals
before re-assembly. Should the leak persist after the above action has been taken a
replacement valve should be sought.
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Section 10 :
Care and Maintenance
The Unit is basically a simple pneumatic system and requires little maintenance other than
general cleaning of the box and panel after use on site, particularly the quick-connect couplings.
The unit should be protected from heavy rain or excessive moisture (it must never be immersed
in water) and if such conditions are prevalent on the site arrangements must be made to dry out
the readout after use.
Always take great care to avoid ingress of water into the pneumatic circuits as this is the primary
cause of problems with this type of Readout.
Care should be taken to avoid damage by dropping the readout since this may affect the
calibration of the Test Gauge. More severe abuse will cause serious damage and can be
dangerous as the unit contains compressed gas cylinders.
For long term accuracy of readings it is advisable to arrange for periodic calibration check of
the Test Gauge. The intervals between checks would depend on usage but is advised that
the unit should be checked annually at least.
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Section 11 :
Health and Safety Requirements
The readout unit contains steel high pressure gas cylinders which have been tested and certified
in accordance with "Home Office" requirements.
The gas cylinders must be retested and certified every 5 years in accordance with BS 5430. The
date of last certification is shown on a test label attached to the neck of the cylinders.
Soil Instruments will carry out the test on return of the readout. Alternatively the cylinder may be
re-certified by any recognised authority. Most Insurance Companies can arrange for this service.
When transported on the public road it is a requirement that the unit and the vehicle in which it is
being carried carry the non-flammable compressed gas hazard label.
Bell Lane, Uckfield, East Sussex
t: +44 (0) 1825 765044
e: [email protected]
TN22 1QL United Kingdom
f: +44 (0) 1825 744398
w: www.itmsoil.com
Soil Instruments Ltd. Registered in England. Number: 07960087. Registered Office: 5th Floor, 24 Old Bond Street, London, W1S 4AW
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