Weir HYDRAU-FLO HF1007Z0001 Installation, Operation And Maintenance Manual Download | Manualshive

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Weir Minerals Multiflo

®

Safety Solutions for Liquid Filling

HYDRAU-FLO

®

FUEL FILLING SYSTEM

Installation, Operation and Maintenance Manual

Document Number:

Revision: 0

Issue Date: 23 February 2015

CONTROLLED DOCUMENT

Copyright © 2015, Weir Minerals Australia Ltd. All rights reserved.

Installation, Operation and Maintenance Manual

Copyright © 2015, Weir Minerals Australia Ltd trading as Weir Minerals Multiflo

®

. All rights reserved.

MULTIFLO, VACTRONIC and HYDRAU-FLO are registered trademarks of Weir Minerals Australia Ltd. This
document contains information which is confidential to Weir Minerals Australia Ltd. It should not be disclosed
in whole or in part to parties other than the recipient without the express written permission of Weir Minerals
Australia Ltd authorized personnel.

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Summary of Contents for HYDRAU-FLO HF1007Z0001

Page 1: ...n Operation and Maintenance Manual Copyright 2015 Weir Minerals Australia Ltd trading as Weir Minerals Multiflo All rights reserved MULTIFLO VACTRONIC and HYDRAU FLO are registered trademarks of Weir...

Page 2: ...FLO FUEL FILLING SYSTEM Installation Operation and Maintenance Manual Document Number Revision 0 Issue Date 23 February 2015 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights r...

Page 3: ...O FUEL FILLING SYSTEM Installation Operation and Maintenance Manual Document Number Revision 0 Issue Date 23 February 2015 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights res...

Page 4: ...Equipment Placement Sales and Services 170 Kewdale Road Kewdale WA 6105 Ph 08 9479 4988 Fax 08 9479 4588 Email sales equipmentplacement com au PT Weir Minerals Multiflo Jl Mulawarman No 29A RT 003 Bat...

Page 5: ...ended Use of the Product 2 6 2 10 Unintended Use of the Product 2 6 2 11 Warranty 2 7 3 Description 3 9 3 1 Hydrau Flo Fuel Filling Valve 3 9 3 2 Working Principle 3 9 3 3 Hydrau Flo Configurations 3...

Page 6: ...oat Valve 4 31 4 6 4 Check Valve Arrangement 4 32 4 6 5 Lever Float Height Adjustment 4 32 5 Commissioning 5 33 6 Operation 6 34 6 1 Fuel Filling 6 34 6 2 Flow Specification 6 34 6 3 Fuel Filling of D...

Page 7: ...8 13 Vertical Float Shutoff Point Drawing 8 50 8 14 Vertical Float Shutoff Point Drawing 8 51 8 15 Check Valve Selection Drawing 8 52 8 16 Black Valve Drawing 8 53 8 17 Red Valve Drawing 8 54 8 18 Bl...

Page 8: ...Over Protection 3 14 Figure 3 4 Hydrau Flo Pilot Line Arrangement for Vertical and Lever Float Control Valves 3 20 Figure 3 5 Converting External Pilot Line to an Internal Line 3 21 Figure 3 6 Hydrau...

Page 9: ...lves 3 13 Table 3 3 Anti Surge Breathers 3 14 Table 3 4 Lever Float Control Valve 3 15 Table 3 5 Black Valve Adaptors 3 16 Table 3 6 Black Gold and Red Valve Adaptors 3 17 Table 3 7 Pilot Line Hose Fi...

Page 10: ...her the author nor the publisher can be held liable for any consequential damages resulting from possible errors in this publication The English language was used to write the original manual Any vers...

Page 11: ...ulatory organisation having jurisdiction Use trained competent people to assess all site risks involved with the installation of this equipment in accordance with the Installation and Operations Manua...

Page 12: ...1 Safety Colours Signal Warning Level Description Danger Indicates a hazard with high level of risk which if not avoided could result in death or catastrophic equipment damage DANGER Warning Indicate...

Page 13: ...ling injuries Fatal or crippling injuries likely to result from any exposure Possibility of a harmful situation Minor or slight injuries possible Mandatory Instructions Failure to follow may lead to f...

Page 14: ...ultiflo disclaims all liability 2 3 Qualified Workers All personnel involved in the installation operation and inspection of the Hydrau Flo Components must be qualified to carry out the work involved...

Page 15: ...ge of materials and operate with a range of chemicals For specific material safety datasheets relating to the Hydrau Flo Components please contact Weir Minerals Multiflo 2 9 Intended Use of the Produc...

Page 16: ...damage resulting from the incorporation of or failure of non Weir manufactured or supplied parts in the Goods or g Repairs to rubber lining Weir does not warrant any equipment or other goods of other...

Page 17: ...owner of the products at all times is responsible for the correct installation and operation of the components as prescribed in this manual To establish that the products have been serviced and mainta...

Page 18: ...to provide a reliable hydraulically operated arrangement which depends on fluid level rather than pressure The system is designed to be used in conjunction with existing fast fill systems or traditio...

Page 19: ...s equalised on both sides of the piston Spring pressure will force the piston back to close the fuel ports preventing any extra fuel from entering the fuel tank NOTICE The fuel nozzle cannot be overri...

Page 20: ...e highest flow rate capacity in the range Red FFV HF1105Z0002 800 Lpm 211 USgpm 2 NPT Male Valve Mount The retro fit Hydrau Flo fuel filling red valve is designed to fit into tanks using the Wiggins Z...

Page 21: ...ld valve has been designed to fit into compact installations which make it suitable for the bonded fuel tank market where space limitations apply Gold FFV HF1105Z0007 800 Lpm 211 USgpm 2 NPT Male Valv...

Page 22: ...r vent to prevent spillage that can occur as a result of vehicle motion when using conventional valves Standard FCV HF1008Z0009 1000 Lpm 264 USgpm 1 NPT Male Valve Mounting The standard Hydrau Flo flo...

Page 23: ...er Option HF1008Z0010 1000 Lpm 264 USgpm 2 NPT Male Valve Mounting The anti surge breather with filter option has the same functions as the float control valves including the rollover protection It al...

Page 24: ...Lever Float Control Valve Lever Float Control Valve LFCV Description Reference Image Standard LFCV HF1007Z0001 110mm Stem HF1007Z0002 250mm Stem 1 5 bar Working Pressure 7 8 UNF Mounting Stem Availabl...

Page 25: ...LED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 3 16 Issue Date 23 February 2015 3 4 Hydrau Flo Hardware 3 4 1 Hydrau Flo Black Fuel Filling Valve Adaptors Table 3 5 B...

Page 26: ...ED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 3 17 Issue Date 23 February 2015 3 4 2 Hydrau Flo Blue Gold and Red Fuel Filling Valve Adaptors Table 3 6 Black Gold and...

Page 27: ...OCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 3 18 Issue Date 23 February 2015 3 4 3 Pilot Line Hose Fittings and Accessories Table 3 7 Pilot Line Hose Fittings and Acces...

Page 28: ...a Ltd All rights reserved Page 3 19 Issue Date 23 February 2015 3 4 4 Breather Line Connectors Table 3 8 Breather Line Connectors Fitting Size 3 4 Breather Line 3 4 5 Exhaust Line Float Control Valves...

Page 29: ...e either internally or externally of the tank NOTE EXTERNALLY ONLY FOR LEVER FLOATS Figure 3 4 Hydrau Flo Pilot Line Arrangement for Vertical and Lever Float Control Valves The standard pilot hose pro...

Page 30: ...ng External Pilot Line to an Internal Line CAUTION While using internal pilot lines single wire braided hose is used for abrasion resistance The hose lines have swivel fittings at their ends to facili...

Page 31: ...ls thereby providing an option to set the maximum level of fuel in a tank at any point of time The barrel extensions are available for the Float control valves and are available in set length extensio...

Page 32: ...ats are used as the actuator in stationary tanks using the fast filling process These lever floats are also suitable for providing over fill protection on remote trickle feed systems NOTICE For furthe...

Page 33: ...e fuel is consumed from the smaller tanks and the fuel level in the tank drops the Hydrau Flo fuel filling system will top up until the tank is full and ensures that the tank is always full The Hydrau...

Page 34: ...mponents are to be installed must be checked prior to installation The release of fuel in the tanks or residual fuel present could result in contact with persons and could also be a source of ignition...

Page 35: ...ap wrench or other suitable device is recommended Reconnect the fuel supply line to the hose adaptor ensuring a fuel tight connection Ensure all connection points are clean and smooth Use a thread sea...

Page 36: ...commended Reconnect the fuel supply line to the hose adaptor ensuring a fuel tight connection Ensure all connection points are clean and smooth Use a thread sealer such as Loctite 242 on the bolts Rem...

Page 37: ...ress the spring in the receiver and refit the Circlip Failure to change the springs may result in poor performance of the system Place the O ring on the black valve fit the valve to the adaptor and ti...

Page 38: ...y 2015 4 6 Additional Information on Installation 4 6 1 General Arrangement The general arrangement for the Hydrau Flo Fuel Filling System with a single Vertical Float Valve and Single Lever Float Val...

Page 39: ...ing Valves with Single Lever Float Valve If multiple filling valves are installed and a single Lever Float Control valve is used the combined flow rate of the filling valves must not exceed the rated...

Page 40: ...s with Single Vertical Float Valve If multiple filling valves are installed and a single Vertical Float Control valve is used the combined flow rate of the filling valves must not exceed the rated flo...

Page 41: ...heck Valve Arrangement When installing the check valves care must be taken to ensure that the direction of the check valve is correct Refer to the figure below for further information Figure 4 3 Check...

Page 42: ...ropriately Check if there are leaks in the Filling Valve Float Valve and other connections etc Check the integrity of pilot line check for correct pilot line size and correct length Pilot line size ha...

Page 43: ...system due to incorrect operation Before any filling operations the operator must ensure that the pump stations rated flow specifications comply with the rated flow capacities of the installed Hydrau...

Page 44: ...al sources of contamination in the system 6 7 Fuel Reticulation The operator must have an understanding of the potential for reticulation over filling scenario considered for appropriate operations Th...

Page 45: ...ges and any remaining warranty will be voided If there are any issues with the operation of the Hydrau Flo system please contact Weir Minerals Multiflo directly Despite this the following points must...

Page 46: ...ill height Restriction in pilot line Check line for damage crushes or kinks Replace if necessary Fuel nozzle not shutting off Float valve not stopping bleeding from pilot line Check the operation of t...

Page 47: ...oning safely shut down the fuel supply and refer to the troubleshooting guide 3 Follow up any defects with approved service personnel CHECK LIST O K DEFECT ACTION TAKEN 1 All components are fitted and...

Page 48: ...here is a defect identified upon commissioning safely shut down the fuel supply and refer to the troubleshooting guide 3 Follow up any defects with approved service personnel CHECK LIST O K DEFECT ACT...

Page 49: ...O Valves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 40 Issue Date 23 February 2015 8 3 Black Valve with Hydrau Flo...

Page 50: ...lves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 41 Issue Date 23 February 2015 8 4 Red Valve in Adapter with Hydrau...

Page 51: ...LO Valves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 42 Issue Date 23 February 2015 8 5 Blue Valve with Hydrau Flo...

Page 52: ...ces Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 43 Issue Date 23 February 2015 8 6 Single Receiver and Single Vertical Float Mo...

Page 53: ...ces Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 44 Issue Date 23 February 2015 8 7 Single Receiver and Single Lever Float Stati...

Page 54: ...U FLO Valves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 45 Issue Date 23 February 2015 8 8 Lever Float Dimension Dr...

Page 55: ...RAU FLO Valves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 46 Issue Date 23 February 2015 8 9 Fuel Lever Float Setti...

Page 56: ...DRAU FLO Valves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 47 Issue Date 23 February 2015 8 10 Vertical Float Drawi...

Page 57: ...ves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 48 Issue Date 23 February 2015 8 11 Float Control Valve Drawing Catc...

Page 58: ...ves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 49 Issue Date 23 February 2015 8 12 Catch Tank Option with Breather...

Page 59: ...O Valves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 50 Issue Date 23 February 2015 8 13 Vertical Float Shutoff Poin...

Page 60: ...O Valves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 51 Issue Date 23 February 2015 8 14 Vertical Float Shutoff Poin...

Page 61: ...FLO Valves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 52 Issue Date 23 February 2015 8 15 Check Valve Selection Dr...

Page 62: ...YDRAU FLO Valves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 53 Issue Date 23 February 2015 8 16 Black Valve Drawing...

Page 63: ...HYDRAU FLO Valves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 54 Issue Date 23 February 2015 8 17 Red Valve Drawing...

Page 64: ...AU FLO Valves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 55 Issue Date 23 February 2015 8 18 Blue Filter Valve Draw...

Page 65: ...HYDRAU FLO Valves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 56 Issue Date 23 February 2015 8 19 Gold Valve Drawing...

Page 66: ...LO Valves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 57 Issue Date 23 February 2015 8 20 Environmental Exposure Cer...

Page 67: ...O Valves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 58 Issue Date 23 February 2015 8 21 Explosive Atmospheres Certi...

Page 68: ...DRAU FLO Valves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 59 Issue Date 23 February 2015 8 22 Hydrau Flo Parts Lis...

Page 69: ...AU FLO Valves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 60 Issue Date 23 February 2015 Hydrau Flo Parts List Conti...

Page 70: ...RAU FLO Valves Appendices Document Number Revision 0 CONTROLLED DOCUMENT Copyright 2015 Weir Minerals Australia Ltd All rights reserved Page 8 61 Issue Date 23 February 2015 8 23 Hydrau Flo Deliverabl...

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