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RelaDyne THERMOJET G3000E Series, Installation And Operating Manual

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RelaDyne THERMOJET G3000E Series Installation And Operating Manual Download Page 21

 

THERMOJET

®

 G3000E SERIES 

OIL PURIFIER SYSTEM 

INSTALLATION AND OPERATING MANUAL 

Doc # 

77740122 

Rev 

14 

Date 

JUNE 2020 

Page 

21

 of 

104

 

 

 

 

Condensate Purifier Connection 

 
Condensate Purifier Assembly (CPA) connection is ½” FNPT.  Pipe CPA connection is to a dirty / oily water 
drain system.  

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Condensate Purifier Connection 

½ “NPT 
 

Condensate Purifier 
Connection 

Summary of Contents for THERMOJET G3000E Series

Page 1: ...ystem Installation and Operating Manual ______________________ 5615 W Fuqua Houston Texas 77085 1 713 464 6266 Fax 713 464 9871 Doc 77740122 Rev 14 READ AND UNDERSTAND THIS OPERATING MANUAL BEFORE ATT...

Page 2: ..._________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ____...

Page 3: ...urifier Connection 21 System Exhaust and Relief Valve Connections 22 Electrical Power Connection 24 Grounding 27 V SYSTEM START UP AND OPERATION 28 Start Up Procedures 29 Heater Operation 34 Adjusting...

Page 4: ...79 Quick Reference Troubleshooting Guide 82 Types of Product Misapplication and Misuse Not Covered By Warranty or Guarantees 83 IX PARTS LIST DRAWINGS SCHEMATICS 84 Maintenance Spare Parts List 85 Pro...

Page 5: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 5 of 104 I GENERAL INFORMATION...

Page 6: ...ion For additional information contact the manufacturing office nearest you or check our website For questions regarding this publication or if you have specific questions regarding the installation a...

Page 7: ...hazardous situation which if not avoided will result in death or serious injury WARNING This symbol is used to identify a WARNING level of hazard seriousness WARNING indicates a hazardous situation w...

Page 8: ...tion and observe all plant driving and safety regulations Do not transport equipment on public roadways using a fork truck This symbol can be used in conjunction with a SAFETY ALERT symbol with either...

Page 9: ...N severity level This symbol is used to indicate that the reader must read and understand referenced DATA AND INFORMATION This symbol may be used in conjunction with a NOTICE or with a SAFETY ALERT sy...

Page 10: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 10 of 104 II UNIT IDENTIFICATION AND LABELING...

Page 11: ...ing electrical power supplies The purchaser specifies supply voltage 460 VAC 60 Hz 3 Phase 380 VAC 60 Hz 3 Phase 575 VAC 60 Hz 3 Phase 380 VAC 50 Hz 3 Phase 400 VAC 50 Hz 3 Phase 415 VAC 50 Hz 3 Phase...

Page 12: ...in Hydrocarbon Processing Industry Unit for Class 1 Div 2 Grps BCD T3C 22 X 30 footprint Heater Type E Electric Heater Electrical Power Supply A 460 VAC 60 Hz 3 Phase B 380 VAC 60 Hz 3 Phase D 575 VAC...

Page 13: ...______ 460 VAC 380 VAC 575 VAC 380 VAC 400 VAC 415 VAC HZ Machinery is suitable for 50 or 60 hertz AC power as stipulated by the POWER option of the ThermoJet Oil Purifier Model Code Designation Key P...

Page 14: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 14 of 104 III DESCRIPTION OF THE PRODUCT...

Page 15: ...ed It is recommended replacement be made when the pressure differential across it as monitored by two easily read gages which are externally mounted on the panel above the access door reaches 2 BAR 30...

Page 16: ...ND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 16 of 104 IV INSTALLATION THIS INSTRUMENT MUST BE EARTHED WARNING If the equipment is not used in the manner described in this manual the pr...

Page 17: ...imensional Drawings in the PARTS LIST DRAWINGS SCHEMATICS section of this manual for anchor bolt and equipment clearance dimensions The base mounted ThermoJet Oil Purifier is constructed with lift rin...

Page 18: ...tion to the ThermoJet Oil Purifier is not practical ensure that the suction height from the reservoir drain to the inlet connection of the ThermoJet is no more than 8 feet 2 4 meters above the minimum...

Page 19: ...tice is to install a manual shut off valve if one does not already exist directly onto the reservoir connection routed to the ThermoJet inlet connection If the oil reservoir is located below the Therm...

Page 20: ...nitrogen supply pressure requirement is 30 PSIG 2 bar and must be capable of supplying minimum continuous flow rate of 200 liter minute 7 CFM During operation the pressure regulator is set at 15 30 PS...

Page 21: ...ING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 21 of 104 Condensate Purifier Connection Condensate Purifier Assembly CPA connection is FNPT Pipe CPA connection is to a dirty oily water drain syste...

Page 22: ...ated at 1 2 PSIG 0 04 BAR Do not reduce the connection size Smaller connection size will reduce the flow of nitrogen supply through the jet mixer NOTICE When cleaning oil spills consult with your lubr...

Page 23: ...ety line must be routed back to the vented oil reservoir from the pressure relief safety valve The pressure relief valve is set to relieve at 0 35 BAR 5 PSI The safety relief valve set 0 35 BAR 5 PSI...

Page 24: ...quirements as long as the unit meets the operating conditions ThermoJet Oil Purifier is wired for the power supply stated on the nameplate It must not be re wired for any other voltage The power circu...

Page 25: ...electrical connections should only be made by a qualified electrician A switch or circuit breaker shall be included in the building installation it shall be in close proximity to the equipment and wi...

Page 26: ...terminals L1 L2 and L3 located in a terminal enclosure See the diagrams below for terminal location and user terminal connection identification The power connection is three phase Voltage is as specif...

Page 27: ...of 104 Grounding ThermoJet Oil Purifiers must be grounded to ensure safe operation An external ground terminal is located on the left side of the terminal enclosure See diagrams below for circuit gro...

Page 28: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 28 of 104 V SYSTEM START UP AND OPERATION...

Page 29: ...ervoir to drain any free water which may have accumulated Care should be taken to avoid spills and ground contamination with the drained waste Avoid inputting free water from the serviced reservoir fr...

Page 30: ...r rotation against the directional arrow located on drive end of the motor If incorrect place the Circuit breaker in the OFF position and disconnect supply power at the source NOTICE Recycle all drain...

Page 31: ...dle to the ON position and again use the ON OFF Selector Switch to jog the electric motor and verify proper motor rotation Once the motor rotation is correct leave the Selector Switch in the ON positi...

Page 32: ...ion line can escape As soon as oil flow is established close this valve to prevent any oil spills In case of oil spillage the user or other responsible body must ensure appropriate cleanup and deconta...

Page 33: ...no oil is flowing trace the inlet piping for blockages such as a closed valve If the oil path is free from obstructions manually prime the pump and the inlet piping Ensure that the suction line dista...

Page 34: ...ature Alarm reset button to reset the high temperature alarm and turn the Heater High Temperature alarm pilot light OFF The yellow Heater On pilot light will remain ON until the oil temperature approa...

Page 35: ...is in the oil stream located at the heater vessel discharge This thermocouple provides the oil temperature signal to the temperature controller see above for heater ON OFF control A thermocouple is cl...

Page 36: ...he heater controller will sense the decreasing oil temperature and attempt to energize the heater However the high limit controller will prohibit the oil heater from energizing and oil temperature wil...

Page 37: ...discharge pressure is too low adjust PCV1 by turning adjustment screw clock wise to increase the oil pressure and c clockwise to decrease the oil pressure setting Once adjusted the filter discharge p...

Page 38: ...pply tank being serviced System pressure on the return oil circuit is maintained by a check valve set at 50 PSIG 3 4 BAR Return oil pressure can be monitored by observing the System Discharge pressure...

Page 39: ...needle valve While the ThermoJet is running and with the nitrogen supply needle valve in the closed position the compound pressure gauge will be reading a negative pressure vacuum Slowly open the need...

Page 40: ...ses above 5 PSIG 0 34 BAR pressure relief safety valve will vent the exhaust to the vented oil reservoir The pressure relief safety valve precludes the potential for over pressurizing the separation t...

Page 41: ...INATION in the ROUTINE MAINTENANCE section of this manual NOTICE Dispose of all contaminated cleaning materials in accordance with all environmental laws ordinances and directives Consult your company...

Page 42: ...tinuous operation with initial results being achieved in 8 12 passes after starting The number of initial passes necessary to clean the oil in a reservoir is contingent upon the contamination level pr...

Page 43: ...oride Pentene Cyclobutane Isoprene Propadiene Cyclohexane Methane Propane Cyclopropane Methanol Propylene Cyclopentane Methyl Bromide Propyne Dimethylbutane Methyl Chloride Materials removed by the Th...

Page 44: ...fset the failure symptoms and lead to more serious problems before detection and corrections can be made Keeping system adjustments to a minimum is intended to make the systems more reliable and to in...

Page 45: ...ing temperature depending upon size configuration of the oil return line d The temperature controller output setting gauge reading is relatively steady within 10o F of the temperature controller set p...

Page 46: ...ressure will falls to zero To shut down the system 1 turn the selector switch form the ON to the OFF position 2 allow the system to operate until the motor turns off 3 turn the main disconnect switch...

Page 47: ...is clear of all hazardous or explosive gases or materials and that a HOT WORK PERMIT or other authorization to work has been issued and posted according to all facility standards and procedures Where...

Page 48: ...Wear appropriate personal protective gear When cleaning oil spills consult with your lubricating oil supplier and the lubricating oil MSDS documentation regarding safe guards and Personal Protective...

Page 49: ...il Heater Maintenance X p n 40500060 Flange Gasket 6 Inch Auto Tune Oil Heater Controller X Check and Adjust Operating Pressures X Verify Low Oil Pressure Switch Operation X Verify Oil Heater High Tem...

Page 50: ...ecessary this list should be expanded to include additional check points applicable to your particular installation that are important in assuring proper and continuous and safe operation Check and re...

Page 51: ...llow the oil to drain into a suitable container Turn the locking ring on the filter housing counter clockwise using the supplied wrench that is attached to the filter housing until the housing is loos...

Page 52: ...Collect and properly dispose of all collected contents To remove and clean the strainer screen remove the large plug The suction screen along with the dirty oil and particulate can be removed from the...

Page 53: ...oil absorption media sock if saturated This absorption media sock should remain effective for two to four weeks Periodic visual inspection is the only way to determine if sock is saturated To replace...

Page 54: ...oil inlet and outlet connection First drain all oil from the separation vessel and the inlet oil filter A drain plug is located in the outlet pump suction line between the separation vessel outlet an...

Page 55: ...vessel cover plate from the vessel The cover plate is secured in place with twelve socket head screws Remove the screws and set aside for reuse Lift the cover plate from the separation vessel Note th...

Page 56: ...spected and determined to be in proper working order reassemble the clean out cover onto the separation vessel using a new gasket and the screws from disassembly Use replacement part number 40511031 G...

Page 57: ...sel The heater vessel drain is located on the interior of the ThermoJet G3000E cabinet Remove the closure cap from the drain valve and set aside Using a pail to gather the oil open the drain valve loc...

Page 58: ...way of the conduit union Loosen the conduit union and separate the two halves of the fitting so that the heater bundle can be removed WARNING Use suitable transport equipment for removing the heater b...

Page 59: ...elements Clean the heater bundle to remove any residue or contamination that may have entered the heater vessel Inspect the interior of the heater vessel and wipe clean with a lint free cloth NOTICE W...

Page 60: ...60 of 104 Remove the drain tubing between the heater tube and the inlet of the jet mixer Remove the elbow at the heater vessel end and inspect the drain orifice Insure that the drain orifice is clear...

Page 61: ...all terminal cover Install the cap on the drain valve in the bottom of the heater vessel and insure that the drain valve is in the close position Take care to guard against pinching and crushing hazar...

Page 62: ...repaired in the field If the flame path is damaged the enclosure is to be removed from service and replaced with a new properly working enclosure Before performing this maintenance task ensure that th...

Page 63: ...g process begins Once the auto tune process is completed the process display will cease to flash and the unit will revert to normal operation Insure that the oil temperature operates at the prescribed...

Page 64: ...turn oil pressure is for the purpose of insuring that the systems operating pressures are correctly adjusted For information on adjusting the inlet oil pressure refer to the section titled Adjusting S...

Page 65: ...circuit so that the oil heater is inoperable if the oil pressure drops below 135 PSI 9 3 BAR For additional information refer to the wiring diagram included in the section of this manual titled IX PAR...

Page 66: ...pressure switch operation has been confirmed adjust the pressure control valve by turning the adjusting screw C Clockwise to set the system operating pressure to it normal operating set point of 240...

Page 67: ...temperature alarm heater cutout setting power to the oil heater element is interrupted When this happens the oil temperature as indicated on the heater controller display will begin to decrease As th...

Page 68: ...the thermocouple simulator to the same screws Take care to observe proper polarity for and terminations Restart the ThermoJet by turning the main disconnect to the ON position and then switching the...

Page 69: ...erature and attempt to energize the heater However the high limit controller will prohibit the oil heater from energizing and oil temperature will continue to fall The Heater ON pilot light will be il...

Page 70: ...and re connect the high limit thermocouple Take care to observe proper connections for and terminations Securely re install the enclosure covers NOTICE When a Heater High Temperature alarm occurs the...

Page 71: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 71 of 104 VII CLEANING AND DECONTAMINATION...

Page 72: ...hermoJet Oil Purifier cabinet and reservoir may be wiped down with cloth rags or recyclable paper wipes or towels that are able to absorb oil and remove any accumulation of dust In case of oil spillag...

Page 73: ...ith your lubricating oil supplier and the lubricating oil MSDS documentation regarding safe guards and Personal Protective Equipment PPE requirements NOTICE Dispose of all contaminated cleaning materi...

Page 74: ...recycling the following steps should be performed All oil must be drained from the separation tank the oil heater tube the oil filer housing and interconnecting piping and tubing Disconnect all exter...

Page 75: ...g Use appropriate lifting and transport equipment to remove this machinery Ensure that all previously connected sources of electrical power are disconnected before opening the AC power enclosures and...

Page 76: ...fting lugs For safe lifting and placement of equipment use approved lifting cables and accessories WARNING Use suitable transport equipment for lifting and setting the equipment into place Ensure that...

Page 77: ...housing and allow the oil to drain into a suitable container 4 To drain the heater vessel open the drain valve and drain the oil into a suitable container 5 Remove the oil filter element and install...

Page 78: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 78 of 104 VIII TROUBLE SHOOTING...

Page 79: ...inlet line sizes are as specified in Section III of this manual G Verify that suction lift does not exceed 8 feet 2 4 meters H Verify that oil viscosity does not exceed 3 000 SSU I If the pump is nois...

Page 80: ...of accomplishing this might be to remove the thermocouple that is in the ThermoJet and attempt to read ambient condition or a known temperature Then verify that the temperature reading being displayed...

Page 81: ...30 PSIG 2 bar differential If filter discharge pressure range is too low with a clean filter reset pressure relief safety valve PRV1 by turning off machine for 15 seconds and allow the pop off valve...

Page 82: ...t used Contact manufacturer for technical assistance if frequent filter loading occurs Clean Y strainer screen Attempt to remove contaminants not designed for air stripping such as heavy hydrocarbons...

Page 83: ...ng to purify motor oils 6 Presence of contaminants which attack Viton seals 7 High differential pressure on oil filter 8 Operating without oil filter element or inlet Y strainer element 9 Operating wi...

Page 84: ...g should only be made by a qualified electrician Before removing the cover to the controller contact appropriate operating personnel and obtain all required hot work permits Ensure that the area has b...

Page 85: ...ION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 85 of 104 Maintenance Spare Parts List Part Number Description Quantity 19103006 Oil Filter Element 6 Microns 1 40520235 Filter Housing...

Page 86: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 86 of 104 Process and Instrument Diagram...

Page 87: ...E JET MIXER SYMBOL LEGEND OIL TUBING OIL PIPING COUPLING PUMP OIL LEVEL CONTROL VALVE SIGHT FLOW INDICATOR Y STRAINER CUSTOMER CONNECTIONS CHART CONN QTY DESCRIPTION TYPE RATING A 1 OIL SUPPLY INLET 1...

Page 88: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 88 of 104 Electrical Wiring Diagram...

Page 89: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 89 of 104 Transformer Wiring 575VAC...

Page 90: ...haracteristics Item Part Number Quan Description 1 30571032 1 TRIP BLOCK 8 32 AMPS 2 77750215 R13 3 Time Delay Fuse Class CC 600V 6 Amp 3 30180010 2 Time Delay Fuse Class CC 600V 1 Amp 4 30180021 1 Ti...

Page 91: ...ay For Three Phase Motor 2 4 4 Amp Direct Mount note 1 2 3 4 5 10 30180010 2 Time Delay Fuse Class CC 600V 1 Amp 11 77750215 R13 3 Time Delay Fuse Class CC 600V 6 Amp 12 30180021 1 Time Delay Fuse 13i...

Page 92: ...mp to NEMA 143TC Flanged Motor 37 35500409 35500403 35500401 35500404 1 MOTOR ELECTRIC 1 1 2HP NEMA 145TC TEFC 1 1 2 HP 380VAC 3 PHASE 60HZ 1750 RPM note 2 MOTOR ELECTRIC 1 1 2HP NEMA 145TC TEFC 1 1 2...

Page 93: ...let Supply 0 017 51 03501011 1 O ring Viton Nitrogen Supply 0 032 Note 1 Used in Model G3000 EE 380Volt 50 Hz Electrical Power Supply 2 Used in Model G3000 EB 380Volt 60 Hz Electrical Power Supply 3 U...

Page 94: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 94 of 104 General Arrangement Drawings...

Page 95: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 95 of 104 Front View w Door Opened Left Side View Top View...

Page 96: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 96 of 104 Rear View Controller...

Page 97: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 97 of 104 Dimensional Outline Drawings...

Page 98: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 98 of 104 Front View...

Page 99: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 99 of 104 Left Side View...

Page 100: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 100 of 104 Rear View...

Page 101: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 101 of 104 Right Side View...

Page 102: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 102 of 104 Top View...

Page 103: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 103 of 104 Bottom View Anchor bolt spacing...

Page 104: ...THERMOJET G3000E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740122 Rev 14 Date JUNE 2020 Page 104 of 104...

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