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THERMOJET

H-2500E SERIES

OIL PURIFIER SYSTEM

INSTALLATION AND OPERATING MANUAL

Doc #

77740119

Rev

Date

June 2020

Page

100

Model Code Designation Key

ThermoJet ® Model H2500E

Oil Purifier

Option Description

Option Code

Description

Application Type

Electrical Area

Classification

H2500

Dewatering Application in

Hydrocarbon Processing Industry

Unit for Class 1 Grps CD T3C

22" X 30" footprint

Heater Type

Electric Heater

Electrical Power Supply

460 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

440 VAC, 50 Hz, 3 Phase

Mounting

Base Mounted with feet and lifting eyes

Portable base with casters and towing

handle

Trailer mounted, single axle

Fork-lift able

Export Crating

(excluding North America,

South America & Canada)

Export Crating

Summary of Contents for THERMOJET H-2500E Series

Page 1: ...m Installation and Operating Manual ______________________ 5615 W Fuqua St B 201 Houston Texas 77085 1 713 464 6266 Fax 713 464 9871 Doc 77740119 Rev 15 READ AND UNDERSTAND THIS OPERATING MANUAL BEFOR...

Page 2: ...____________________________________________________________ ______________________________________________________________________ ____________________________________________________________________...

Page 3: ...Oil Piping Connections 18 Condensate Purifier Connection 20 System Exhaust Connections 21 Electrical Power Connection 22 Grounding 25 V SYSTEM START UP AND OPERATION 26 Start Up Procedures 27 Heater O...

Page 4: ...SHOOTING 75 Trouble Shooting Guide 76 Quick Reference Troubleshooting Guide 79 Types of Product Misapplication and Misuse Not Covered By Warranty or Guarantees 80 IX PARTS LIST DRAWINGS SCHEMATICS 81...

Page 5: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 5 of 100 I GENERAL INFORMATION...

Page 6: ...tion 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...

Page 7: ...a 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...

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 H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 10 of 100 II UNIT IDENTIFICATION AND LABELING...

Page 11: ...ing electrical power supplies The purchaser specifies supply voltage 460 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 440 VAC 50 Hz 3 Phase...

Page 12: ...ion in Hydrocarbon Processing Industry Unit for Class 1 Grps CD T3C 22 X 30 footprint Heater Type E Electric Heater Electrical Power Supply A 460 VAC 60 Hz 3 Phase D 575 VAC 60 Hz 3 Phase E 380 VAC 50...

Page 13: ...suitable for 50 or 60 hertz AC power as stipulated by the POWER option of the ThermoJet Oil Purifier Model Code Designation Key Power Option Code A 460 VAC 60 Hz ______________ Power Option Code D 575...

Page 14: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 14 of 100 III DESCRIPTION OF THE PRODUCT...

Page 15: ...t as monitored by two easily read gages which are externally mounted on the panel above the access door reaches 30 PSI 2 BAR From the filter the oil passes through the heater that elevates the oil to...

Page 16: ...ND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 16 of 100 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: ...Dimensional 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 ri...

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: ...densate Purifier Assembly CPA connection is FNPT Pipe CPA connection is to a dirty oily water drain system Condensate Purifier Connection NPT NOTICE When cleaning oil spills consult with your lubricat...

Page 21: ...t be piped away to a location that is not occupied The ends of the vent header pipe should be such that rain animals and blowing dust and dirt cannot enter Exhaust piping must be 3 4 NPT DN20 or large...

Page 22: ...equirements 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 circ...

Page 23: ...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 24: ...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 speci...

Page 25: ...of 100 35 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 g...

Page 26: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 26 of 100 V SYSTEM START UP AND OPERATION...

Page 27: ...servoir 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 f...

Page 28: ...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 29: ...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 30: ...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 31: ...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 32: ...rature 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 appro...

Page 33: ...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 c...

Page 34: ...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 temperature wi...

Page 35: ...p 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...

Page 36: ...upply 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 pressur...

Page 37: ...e to the condensate purifier assembly The excess oil is removed from the condensate and the water is properly routed to the sewer system The discharge from the Condensate Purifier Assembly may be cont...

Page 38: ...spillage the user or other responsible body must ensure appropriate cleanup and decontamination is carried out Reference CLEANING AND DECONTAMINATION in the ROUTINE MAINTENANCE section of this manual...

Page 39: ...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 40: ...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 41: ...ing is between 50 to 100 PSIG 3 5 and 6 9 BAR at operating temperature depending upon size configuration of the oil return line d The temperature controller output setting gauge reading is relatively...

Page 42: ...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 43: ...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 44: ...l in the ThermoJet Oil Purifier 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...

Page 45: ...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 46: ...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 47: ...ousing 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 filter housing until the hou...

Page 48: ...he 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 be remo...

Page 49: ...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 50: ...tube from the bottom of the filter housing Next firmly grasp the filter housing with both hands and lift upward and turn to the left Clock wise The filter housing can then be lowered away from the fi...

Page 51: ...s open the cabinet door and locate the jet mixer The inlet air screens are located on top of the jet mixer To access the air filter screens remove the wing nuts from the top of the air breathers and l...

Page 52: ...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 53: ...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 secu...

Page 54: ...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 55: ...ssel The heater vessel drain is located on the interior of the ThermoJet H2500E 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 56: ...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 57: ...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 58: ...e 58 of 100 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 clea...

Page 59: ...tall 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 haza...

Page 60: ...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 61: ...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 62: ...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 63: ...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 PA...

Page 64: ...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 240...

Page 65: ...emperature 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 the...

Page 66: ...e 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 67: ...perature 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 i...

Page 68: ...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 69: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 69 of 100 VII CLEANING AND DECONTAMINATION...

Page 70: ...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 71: ...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 72: ...ling facility or disassembly for 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...

Page 73: ...ry Ensure that all previously connected sources of electrical power are disconnected before opening the AC power enclosures and attempting to disconnect electrical wiring Do not tip or stand equipment...

Page 74: ...r 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 75: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 75 of 100 VIII TROUBLE SHOOTING...

Page 76: ...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 noi...

Page 77: ...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 78: ...m 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 79: ...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 as heavy hydrocarbon...

Page 80: ...ing 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 w...

Page 81: ...testing 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 are...

Page 82: ...Doc 77740119 Rev 15 Date June 2020 Page 82 of 100 Maintenance Spare Parts List Part Number Description Quantity 1910 3006 Oil Filter Element 6 Microns 1 4052 0235 Filter Housing O Ring Viton 1 1920 1...

Page 83: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 83 of 100 Process and Instrument Diagram...

Page 84: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 84 of 100 PID Symbol Legend and Customer Connection Chart...

Page 85: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 85 of 100 Electrical Wiring Diagram...

Page 86: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 86 of 100 Transformer Wiring 575VAC 460VAC 440VAC 115VAC 110VAC...

Page 87: ...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 88: ...se Class CC 600V 1 Amp 11 77750215 R13 3 Time Delay Fuse Class CC 600V 6 Amp 12 30180021 1 Time Delay Fuse 13i32 X 1 1i2 _ 250V 2 Amp 13 30201014 1 Ground Lug 14 30571000 1 Basic Switching Device 15 3...

Page 89: ...45TC EXP Proof 1 1 2 HP 1 1 2 HP 230 460VAC 60HZ 1750RPM 190 220 380 440VAC 3 PHASE 50HZ 1400 RPM note 1 2 3 4 5 MOTOR ELECTRIC 1 1 2HP NEMA 7 145TC 1 1 2 HP 575VAC 3 PHASE 60HZ 1750RPM note 6 38 7778...

Page 90: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 90 of 100 General Arrangement Drawings Front View w Door Opened...

Page 91: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 91 of 100 Left Side View...

Page 92: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 92 of 100 Top View Rear View...

Page 93: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 93 of 100 Controller...

Page 94: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 94 of 100 Dimensional Outline Drawings Front View...

Page 95: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 95 of 100 Left Side View...

Page 96: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 96 of 100 Rear View...

Page 97: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 97 of 100 Right Side View...

Page 98: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 98 of 100 Top View...

Page 99: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 99 of 100 Bottom View Anchor bolt spacing...

Page 100: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 100 of 100...

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