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THERMOJET

G-3700E SERIES

OIL PURIFIER SYSTEM

INSTALLATION AND OPERATING MANUAL

Doc #

77740151

Rev

Date

June 2020

Page

111

IV INSTALLATION

All ATEX approved constructions must be
installed in accordance with the requirements of
EN60079-14:2014 – Part 14 Electrical installations
in hazardous areas (other than mines).

WARNING

THIS INSTRUMENT MUST BE EARTHED

WARNING

If the equipment is not used in the manner
described in this manual the protection provided
by the equipment may be impaired

WARNING

Summary of Contents for THERMOJET G3700E Series

Page 1: ...W Fuqua St B 201 Houston Texas 77085 1 713 464 6266 Fax 713 464 9871 Doc 77740151 Rev 03 READ AND UNDERSTAND THIS OPERATING MANUAL BEFORE ATTEMPTING TO INSTALL COMMISSION OR USE THIS EQUIPMENT FAILURE...

Page 2: ..._______________________ ________________________________________________________________ ________________________________________________________________ ______________________________________________...

Page 3: ...22 System Exhaust and Relief Valve Connections 23 Electrical Power Connection 25 Grounding 28 V SYSTEM START UP AND OPERATION 29 Start Up Procedures 30 Heater Operation 35 Adjusting System Pressure 38...

Page 4: ...of Product Misapplication and Misuse Not Covered By Warranty or Guarantees 81 IX PARTS LIST DRAWINGS SCHEMATICS 82 Maintenance Spare Parts List 83 Process and Instrument Diagram 84 PID Symbol Legend...

Page 5: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date June 2020 Page 5 of 111 I GENERAL INFORMATION...

Page 6: ...ct the manufacturing office nearest you or check our website For questions regarding this publication or if you have specific questions regarding the installation and operation of ThermoJet Oil Purifi...

Page 7: ...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 which if not avoided could res...

Page 8: ...in its operation 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 symbo...

Page 9: ...understand referenced DATA AND INFORMATION This symbol may be used in conjunction with a NOTICE or with a SAFETY ALERT symbol with either a DANGER or WARNING or CAUTION severity level This symbol is...

Page 10: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date June 2020 Page 10 of 111 II UNIT IDENTIFICATION AND LABELING...

Page 11: ...with ATEX II 3G Ex db e nA IIB H2 T3 Gc Inlet Power The ThermoJet Model G3700 Oil Purifier is available for connection to either 380 400 415 or 460 VAC three phase power The purchaser specifies suppl...

Page 12: ...ical Area Classification G3700 Degassing Application in Hydrocarbon Processing Industry II 3G Ex db e nA IIB H2 T3 Gc 22 X 30 footprint Heater Type E Electric Heater Electrical Power Supply A 460 VAC...

Page 13: ...___________________ Option Code K 415 VAC power______________________ Option Code A 460 VAC power______________________ 380 VAC 400 VAC 415 VAC 460 VAC HZ Machinery is suitable for 50 or 60 hertz AC p...

Page 14: ...14 of 111 Operating Conditions ATEX Constructions Indoor outdoor Use Ambient temperature range 20 C to 50 C 4 F to 122 F Standard Construction Altitude to 2000m Relative humidity not exceeding 95 Powe...

Page 15: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date June 2020 Page 15 of 111 III DESCRIPTION OF THE PRODUCT...

Page 16: ...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 17: ...TEX approved constructions must be installed in accordance with the requirements of EN60079 14 2014 Part 14 Electrical installations in hazardous areas other than mines WARNING THIS INSTRUMENT MUST BE...

Page 18: ...PARTS LIST DRAWINGS SCHEMATICS section of this manual for anchor bolt and equipment clearance dimensions The ThermoJet Oil Purifier is constructed with lift rings Ensure that lifting equipment and rig...

Page 19: ...eter by at least one size All connections should be tight and free of air leaks If a flooded suction to the ThermoJet Oil Purifier is not practical ensure that the suction height from the reservoir dr...

Page 20: ...nections if the reservoir is constructed in accordance with API 614 When a flooded suction is provided to the ThermoJet Oil Purifier recommended practice is to install a manual shut off valves if one...

Page 21: ...he nitrogen supply pressure requirement is 4 2 BAR 60 PSIG and must be capable of supplying minimum continuous flow rate of 200 liter minute 7 CFM During operation the pressure regulator is set at 3 4...

Page 22: ...densate Purifier Assembly CPA connection is FNPT Pipe CPA connection is to a dirty oily water sewer system NOTICE When cleaning oil spills consult with your lubricating oil supplier and the lubricatin...

Page 23: ...ection size will reduce the flow of nitrogen supply through the jet mixer This machine is designed to remove hydrocarbon and water contamination from the processed oil Discharge connection must be mad...

Page 24: ...g must be DN20 3 4 NPT or larger Exhaust to flare piping must extend vertically at least 4 5 m 15 feet above the ThermoJet Oil Purifier Piping for the pressure relief safety line must be routed back t...

Page 25: ...ements 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 circuit r...

Page 26: ...hould 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 within easy reach of the OP...

Page 27: ...uit breaker terminals L1 L2 and L3 located in a controller enclosure See the diagrams below for terminal location and user terminal connection identification The power connection is three phase Voltag...

Page 28: ...Date June 2020 Page 28 of 111 Grounding ThermoJet Oil Purifiers must be grounded to ensure safe operation External ground terminal is located on the left side of the terminal enclosure See diagrams be...

Page 29: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date June 2020 Page 29 of 111 V SYSTEM START UP AND OPERATION...

Page 30: ...ed Care should be taken to avoid spills and ground contamination with the drained waste NOTICE When cleaning oil spills consult with your lubricating oil supplier and the lubricating oil MSDS document...

Page 31: ...er at the energy source breaker Turn the Circuit Breaker handle to the ON position Use the ON OFF Selector switch to jog the electric motor and check proper motor rotation Verify the motor rotation ag...

Page 32: ...ndle 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 posit...

Page 33: ...tion 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 decont...

Page 34: ...et and outlet pressure to the oil filter will increase to near the normal operating pressure of 240 PSI NOTICE Wear appropriate personal protective gear When cleaning oil spills consult with your lubr...

Page 35: ...High Temperature 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 temper...

Page 36: ...signal to the temperature controller see above for heater ON OFF control A thermocouple is attached to one of the heater elements located in the oil stream inside of the heater vessel This thermocoup...

Page 37: ...ler setting the 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 te...

Page 38: ...pressure may be necessary If the pump 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...

Page 39: ...upply tank being serviced System pressure on the return oil circuit is maintained by a check valve set at 3 4 BAR 50 PSIG Return oil pressure can be monitored by observing the System Discharge pressur...

Page 40: ...rogen 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 th...

Page 41: ...ses above 0 34 BAR 5 PSIG 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 42: ...supplier and the lubricating oil MSDS documentation regarding safe guards and Personal Protective Equipment PPE requirements In case of oil spillage the user or other responsible body must ensure app...

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: ...wing how to read gauge values and alarm settings before attempting these procedures Dailey ThermoJet Oil Purifier System Operational Checks The following operating checks should be made daily a The no...

Page 45: ...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 from the ON to the OFF position If...

Page 46: ...a 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 Wher...

Page 47: ...fier and its subassemblies may be contaminated with the substances being removed from the processed oil Ensure that the methods used to manage and dispose of these materials are in compliance with all...

Page 48: ...Heater Controller X Check and Adjust Operating Pressures X Verify Low Oil Pressure Switch Operation X Verify Oil Heater High Temperature Cutout Operation X NOTICE Dispose of all contaminated cleaning...

Page 49: ...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 50: ...e bottom of the filter housing and allow 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 filt...

Page 51: ...om of the strainer 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...

Page 52: ...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 53: ...t 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 a...

Page 54: ...d to the oil filter drain valve and 6 oil pressure tube to the outlet oil pressure gauge Once all tubing has been removed remove the separation vessel cover plate from the vessel The cover plate is se...

Page 55: ...el control valve sticks or does not operate smoothly it should be replaced Use part number 51850100 VALVE LEVEL CONTROL Once all parts are inspected and determined to be in proper working order reasse...

Page 56: ...ssel The heater vessel drain is located on the interior of the ThermoJet G2700E cabinet Remove the closure cap from the drain valve and set aside Using a pail to gather the oil open the drain valve lo...

Page 57: ...e cables through the cable gland so as to remove them from the two electrical terminal enclosures WARNING Use suitable transport equipment for removing the heater bundle from the heater vessel lifting...

Page 58: ...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 59: ...0 Page 59 of 111 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...

Page 60: ...re Take care to observe proper connections for and terminations Reinstall 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...

Page 61: ...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 62: ...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 63: ...eturn 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...

Page 64: ...circuit so that the oil heater is inoperable if the oil pressure drops below 9 3 BAR 135 PSI For additional information refer to the wiring diagram included in the section of this manual titled IX PA...

Page 65: ...w 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 16...

Page 66: ...heater vessel surface Should the heater element or vessel surface thermocouple output reach the high temperature alarm heater cutout setting power to the oil heater element is interrupted When this h...

Page 67: ...CE A round tool is required to depress the high temperature reset button Use a the blunt end of a pencil pen or a blunt end round dowel rod 8 11 mm 0 312 0 375 diameter NOTICE Thermocouple simulators...

Page 68: ...ion The unit will start and oil temperature will increase to the normal operating temperature Allow the machine to reach normal operating temperature Adjust the thermocouple simulator output so that t...

Page 69: ...temperature indication on the heater temperature controller The oil heater will resume operation and the oil temperature will increase to the normal set point Shut down the ThermoJet as described abov...

Page 70: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date June 2020 Page 70 of 111 VII CLEANING AND DECONTAMINATION...

Page 71: ...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 72: ...with 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 mater...

Page 73: ...cycling 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 external...

Page 74: ...d with lifting lugs for lifting and moving Use appropriate lifting and transport equipment to remove this machinery Ensure that all previously connected sources of electrical power are disconnected be...

Page 75: ...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 a new one 6 Remove the screen from...

Page 76: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date June 2020 Page 76 of 111 VIII TROUBLE SHOOTING...

Page 77: ...cified 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 noisy check for damage wear for...

Page 78: ...hing 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 by the temp...

Page 79: ...nt Replace filter element at maximum 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...

Page 80: ...ter package is not used Contact customer service for technical assistance if frequent filter loading occurs Clean Y strainer screen Attempt to remove contaminants not designed for air stripping such a...

Page 81: ...taminants which attack Viton seals 7 High differential pressure on oil filter 8 Operating without oil filter element or inlet Y strainer element 9 Operating with inlet Y strainer plugged 10 Incoming o...

Page 82: ...77740151 Rev 03 Date Dec 2019 Page 82 of 111 IX PARTS LIST DRAWINGS SCHEMATICS NOTICE All electrical checks and circuit testing should only be made by a qualified electrician EXPLOSION HAZARD Substitu...

Page 83: ...ter Element 6 Microns 1 4052 0235 Filter Housing O Ring Viton 1 77750108 Oil Absorption Media Sock box of 12 1 77750101 Filter Element Demisting 1 Microns 1 Before removing the cover to the controller...

Page 84: ...VALVE CLOSED ON RISING LEVEL PUMP DISCHARGE PRESSURE GAUGE 0 300 PSIG 0 20 7 BARG PRESSURE RELIEF SAFETY VALVE SET 270 PSIG 18 6 BARG PRESSURE CHECK VALVE SET 25 PSIG 1 72 BARG SAMPLE VENT VALVE 1 4 T...

Page 85: ...RATING A 1 OIL SUPPLY INLET 1 FNPT B 1 OIL RETURN OUTLET 1 FNPT C 1 NITROGEN SUPPLY INLET 3 8 FNPT D 1 SAFETY RELIEF OUTLET 1 FNPT E 1 VENT TOFLARE OUTLET 3 4 FNPT F 1 PAN DRAIN 3 4 FNPT G 1 CONDENSA...

Page 86: ...N 14 AWG SW3 HEATERS SHELL CUTOUT TE2 A2 A1 T1 NO 6 A2 A1 A2 SCR TC 10 11 9 2 3 4 5 1 L N HLC1 HLC2 TB5 TB5 TB4 TB4 TB4 TB3 TB3 TB2 TB2 TB1 TB1 TB1 L1 10 NO 6 L2 9 3 TC 5 1 RESET C 7 NC 8 2 RESET 4 TC...

Page 87: ...ION AND OPERATING MANUAL Doc 77740151 Rev 0 Date Dec 2014 Page 87 of 111 Transformer Wiring H1 H2 H4 X4 X2 X3 X1 CPT 115VAC H3 415VAC H1 H2 H4 X2 X1 CPT 115VAC H3 460VAC H1 H2 H4 X4 X2 X3 X1 CPT 115VA...

Page 88: ...t Breaker_3 Pole 25 Amp note 1 Molded Case Circuit Breaker_3 Pole 30 Amp note2 2 30180020 3 Time Delay Fuse Class CC 600V 6 Amp 3 30180010 2 Time Delay Fuse Class CC 600V 1 Amp 4 30180021 1 Time Delay...

Page 89: ...RIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 89 of 111 Tagging and Labeling P N 01401031 by Killark by Killark by Killark P N 77760644 by Killark b...

Page 90: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 90 of 111 P N 77750209 P N 77750175 P N 77750175 P N 77750171...

Page 91: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 91 of 111 P N 77750188 P N 77750169 P N 77781570 P N 77750208...

Page 92: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 92 of 111 P N 77780536 P N 77750210...

Page 93: ...i2 _ 250V 2 Amp 13 30201014 1 Ground Lug 14 30561025 30561030 1 Molded Case Circuit Breaker_3 Pole 25 Amp note 4 Molded Case Circuit Breaker_3 Pole 30 Amp note 1 2 3 15 30600123 1 Temperature Controll...

Page 94: ...king 1 4 kW 50 C 460 3 60 4 pole 1785 rpm Ex nA II T3 note 4 Motor Non Sparking 1 4 kW 50 C 400 3 50 4 pole 1435 rpm Ex nA II T3 note 5 38 77780680 3 Fuse Holder Class CC Type Fuse DIN Rail Mount Sing...

Page 95: ...IES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 95 of 111 General Arrangement Drawings Front View w Door Opened 46 4 6 3 25 28 1 31 35 36 37 29 22 30 1...

Page 96: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 96 of 111 5 26 47 34 44...

Page 97: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 97 of 111 Top View 23 33 27 35 19...

Page 98: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 98 of 111 Rear View 15 18 21 39...

Page 99: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 99 of 111 Controller 7 10 12 20 16 8 9 11 38 14 40...

Page 100: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 100 of 111 Dimensional Outline Drawings...

Page 101: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 101 of 111 Front View...

Page 102: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 102 of 111 Left Side View...

Page 103: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 103 of 111 Rear View...

Page 104: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 104 of 111 Right Side View...

Page 105: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 105 of 111 Top View...

Page 106: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 106 of 111 Bottom View Anchor bolt spacing...

Page 107: ...3PH 12 Kw 300 ANSI FLANGE Ex de IIC T3 w T C FOR HIGH TEMP CUTOUT CHROMALOX Type CFP4 FPF01215 12 415V 12kW ITS 02 ATEX 1022X 5 Manufacturers C of C Intertek Testing Services Chromalox EEX de IIC T3...

Page 108: ...RESSURE SWITCH_ADJ 40 200 PSI Viton O Ring 135 DEC Ashcroft APA N7 1H 012C V 02 200 135D XNO Sira 13ATEX1123X SIRA Ex d IIC Gb X X 15 450 CABLE GLAND EEX d 9 5 15 9 MM DIA CABLE M20 THRD Ni BRASS CMP...

Page 109: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 109 of 111 1 2 18 14 17 15 21 21 15 20...

Page 110: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 110 of 111 8 16 19 9 or 10 or 11 or 12 or 13 3 or 4 or 5 or 6...

Page 111: ...THERMOJET G 3700E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740151 Rev 03 Date Dec 2019 Page 111 of 111 2 16 7...

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