PipeCon as

Technical Documentation
MAN Diesel SE – 45D/4500380107
Karadeniz, Barge

Code no.: 11.60001-0179

Cooling Water Expansion Tank 500/500L

Cooling Water
Expansion Tank

PipeCon as - Project 15072

Ribovej 4, PipeCon as Tlf.: +45 96 92 20 00
6950 Ringkøbing Reg. No. 24 31 06 Fax: +45 96 92 20 02
Denmark CVR No. DK 20 66 10 97
1) Drawing No.: 36002-01-1001 Cooling Water Expansion
Tank
15072-13-01 Sign plate
2) 36001-07-50 Technical Specification

3) Qualitrol - Liquid Level Control Gages Technical

Information

4) Länger & Reich – Pressure/vacuum Valve

5) Delivery, transport and installation

6)

7)

8)

9)

10)

11)

12)
 Technical Specification
36001-07-50-0

Customer: MAN Diesel SE

Project: Karadeniz Barge Ref.: 45/4500380107
PipeCon ref.: 15072

Non pressurised Tanks:

Materials: Plates: DS/EN 10025, cert. EN10204, 3.1B
Flanges: DIN, 2633, cert. EN10204, 2.2
Pipes: DIN 1626 st.37.0, cert. EN10204, 3.1B
Bolts and nuts: DIN933-5.6 / DIN 934-5.2 - Qual. 8,8, Hot dip galv.
Washers: DIN 125A, Hot dip galv.
Gaskets: DIN 2690

Welding: ISO 13920 class B and EN25817 quality level C

WPS acc. to EN288-3 or EN288-5
Welder to be certified acc. to EN287-1

Surface treatment.

Cooling water expansion tank: 36002-01-1001.

Inside: Cleaned and sandblasted SA 2,5 according to ISO 8501-1 –

Rucotest No. 3
3* 100 μm Hempadur 8567 Colour RAL 9003, Signal white.

Outside: Cleaned and sandblasted to SA 2,5 according to ISO 8501-1 –

Rucotest No. 3
150 μm Hempadur 4515
50 μm Hempadur 5521 Colour: RAL 7035 grey.
Equipment:
According to “List of components”
Surface treatments and colour acc. to makers standards

Final test of non pressurised tanks:

According to Quality management plan .

Leak test: All welding and connections to be leak tested with air pressure, 0,1 bar and brushing
with soapy water.

Check of all main dimensions and placement of all connections on tank.

PipeCon as
Edit. 0 Page 1/2
 Technical Specification
36001-07-50-0
QC – documentation: Workshop test sheet.

Final documentation:
Final documentation will consist of

Specific to each tank: As build drawings, incl detail of sign plate.

Workshop test sheet, incl this sheet.
Material certificates
Welding procedures
Welder certificate

Equipment: Acc. to makers standards

PipeCon as
Edit. 0 Page 2/2
 6 “Liquid Level Control Gages

Prevent
problems
long life, 6” Liquid Level
Control Gages

high reliability,
low price
Qualitrol Liquid Level Control Gages
are designed to provide level control
for machinery, day tanks, storage vessels
and most any equipment requiring
liquid level control. Models are
available for top- or side-mounting in
vessels with pressure up to 25 psig.
A gage can provide the following
functions:
Low level alarm or control
High level alarm or control
Indicate level at all times
actuate two switches, if included, at
the pre-selected levels.
The Qualitrol magnetic gage design
permits the complete sealing of the
liquid inside the vessel from the dial
switching assembly, outside. This
eliminates fire hazards, loss of product,
incorrect level reading or equipment
downtime due to broken glass or
leaking seals, bellows, or diaphragms.

Au tomation made easy

These control gages are simple to
operate, which prevents problems.
They rely on a magnetic operating
principle with a minimum of moving The 6” Liquid Level
Control Gages offer:
parts for trouble-free service.
Significant cost savings
The float, on a float rod inside the Switching versatility
tank, senses the liquid level and as it
moves up and down, turns the drive Ease of use
magnet. The drive magnet inside the Options available
support tube turns the follower magnet
attached to the pointer in the dial
assembly via a “magnetic coupling”
through a solid metal flange. The
movement of the pointer assembly will
Significant cost savings Both initial and operating cost savings are obtainable from the low
price, long life and high reliability of these control gages.

Qualitrol Liquid Level Control Gages cost less than separate instruments
performing similar functions. Installation costs are also reduced by
mounting only one rather than several controls.

Design simplicity and ruggedness coupled with long life snap switches
provide long term reliability—to minimize costly maintenance and
equipment downtime.

Switching versatility Switching can be supplied for various liquid levels. Large differential
levels, up to 140° of float travel, can also be controlled. Switches can
be preset to within 2° of dial reading.

Snap switches are rated at 10 AMPS, 125-150 VAC; 1/8 AMP, 250
VCD; 1/4 AMP, 125 VDC, Inductive.

Ease of use High visibility dials can be custom lettered or selected from standard
designs. Standard dials are calibrated a full 280° for gear-driven gages
and 140° for lever-driven models. To provide monitoring at maximum
distances, large characters are placed on a contrasting background.
Standard scratch resistant glass lens gives clear visibility without
distortion, even when viewed at an angle.

Standard dial layouts are for use on a square-sided vessel with the gage
mounted at the center of the liquid to be measured.

Options available Gages with switches are supplied with 12” long, “flying” leads. Optional
quick connect, sealed, weatherproof, electrical connectors, with
neoprene-jacketed flexible control cable, are available.

The standard units are supplied with black and white dials, as shown,
but for unusual applications special printing is possible.
 Model Selection and Installation

switches
Cutaway view of typical 6”
gear drive gage with switches

solid metal flange

float
float rod

Wide model selection

2”, 3”, 3 1/2”, 6” models support tube
Top- or side-mounting
Corrosion-resistant components
Floats for each application drive magnet
Gear or lever drive
Snap switches pointer
Bolt or welded mounting follower magnet

Easy to install and test

Qualitrol modular construction
simplifies installation. The flange drive
assembly can be mounted by bolts or
welding. On models designed for
welding, the float assembly detaches Standard Model Selection Chart
and is easily fastened to the flange after (see appropriate data sheet for additional information)
welding. The dial switching assembly
Total
can be attached to the flange after Gage part # Drive Dial, character & Nitrophyl liquid
pressure testing, painting, or even after & size mech. pointer colors float size level* Switching
shipment and field installation of the
vessel or equipment. Finally, if your 020-006-01 Lever White dial with .81”d x 1.75”l 19.88” not avail.
gage has a switch or switches, the 16 2” black characters
AWG “flying” leads can be terminated & pointer
in a junction box of your choice or you 028-009-01 Gear 16.62”
can select the optional quick-connect, 3”
weatherproof connector to be plugged 030-018-01 Lever
into the dial switching assembly. This 3”
connector can be located at any specified 041-005-01 Gear 1.38”d x 2.0”l 20.00” 1-SPDT
angle on the dial-switching assembly. 3.5” **
The connector is normally assembled 035-022-01 Lever 19.88”
to Type SO, neoprene-jacketed cable. 3.5”
012-003-01 Gear 20.00” not avail.
Serviceable while installed 6” 6” Liquid Level Control Gages
The Qualitrol design permits removal 026-006-01 Lever 19.88”
of the dial-switching assembly in the 6”
field for repair or replacement without 042-012-01 Gear 20.00” 1-SPDT
destroying the tank seal or lowering the 6” **
liquid level below the gage location. 032-014-01 Lever 19.88”
6”

* Dimension shown is maximum liquid level that the specific gage will monitor.
Consult the factory for any variation you may require.
**Gage supplied with 3. #16 AWG, 12” long “flying” leads.
 Dimensions

Lever drive
Gear drive Lever drive
4 1/2” 2 3/16”
full 7 1/8” 4 1/4”

1000 1500 high

B 500 2000
5 7/8” filling
level 1 3/8”d
3/8”d
gallons
0 2500 low 2 1/2”
1/4 1/2 3/4
0 F
gage

140° max.
travel
20°
stop
empty
Note: all dimensions are for reference and
1/2” clearance are subject to change
bottom of tank
H
full
1/2 Gear drive high alarm
1/4 3/4

0 F

C
full J D
E
tank
20° stop 140° max. A
travel
low alarm
empty
empty F empty
1/2” clearance G
bottom of tank
B
Note: maximum of 2 SPDT switches are available

To order or for quotation specify:

6” Liquid Level 1) Tank dimensions ‘A’ thru ‘H’ when 9) Quantity
applicable 10) For special dials—marking and
Control Gages 2) Liquid in vessel volume versus level data
3) Liquid temperature range 11) Length of connector cable
Ordering Information 4) Maximum pressure 12) If switches are required, specify related
5) Flange material levels to be controlled.
6) Bolted or welded flange
7) Float material See appropriate data sheets for
8) Application standard models listed in the model

1385 Fairport Road Phone: 585-586-1515 E-mail: info@qualitrolcorp.com

Fairport, New York 14450 Fax Orders: 585-377-0220 www.qualitrolcorp.com
USA Fax Quotes: 585-377-9613

© Qualitrol 2003 Qualitrol is an ISO 9001 system certified company.

QT2-220, 10/03. Information subject to change without notice.
 Product Information
6 Inch Gear Drive Liquid Level Gauge
General

MAX

9
G DA L-0 26 -6 2
LIQUID
+25°C LEVEL

MIN
QU
AL I
T RO L COR P . FA I
RP
O RT
NY
U
.S
.A

© Qualitrol n Qualitrol and Qualitrol AKM are Control #______________________

PI-LLG042 REV. 24018 Issue Date _______
8-21-03
ISO 9001 system certified companies. Information
subject to change without notice. Replaces ________________________
REV. 23617 Sheet ___
1 Of ___
5
 Product Information
6 Inch Gear Drive Liquid Level Gauge
Option Sheet Part 1 of 2

Specify Switch Rating

o Case Assembly only o STD 10 Amp @ 125/250 VAC w/ 2K Hi-Pot
o Flange Assembly only o GOLD 0.10 Amp @ 125 VAC w/ 2K Hi-Pot
o LLG complete
Switch Settings
Specify settings at either
Switch Sequence
Environment Conditions Number of Dimension 'A', 'B', 'C', or 'D' First switch operates min.
o Outdoor, Vented (std.) Switches (see note 3, refer to option sheet part 2)
5 dial degree prior to grad
o Switch #1 before Switch #2
o Outdoor, Sealed
o None Switch #1 (min. 5 dial degrees separation)
o Tropical, High Humidity
o1 Switch #2
If switch #1 setting = o Switch #2 before Switch #1
o2 switch #2 setting, then (min. 5 dial degrees separation)
o None
(max. 5 dial degrees separation)
Dial Style Connection Styles
(refer to sheet 4) (refer to device wiring & connector styles)
o MAXMIN25 (Max, Min, and 25°C) o Qualitrol (detachable)
o MAXMIN20 (Max, Min, and 20°C) o ANSI (detachable)
Side
o HILO25 (High, Lo, and 25°C) o Perm. Attached
Reading
o ALBA25 (Alto, Bajo, and 25°C) o Terminal Box (requires Outdoor, Vented and
o CUSTOM (consult factory) 6 o'clock connector orientation)
o MAXMIN25/T (Max, Min, and 25°C) o Military
*Top o ALBA25/T (Alto, Bajo, and 25°C)
o None
Reading
o CUSTOM/T (consult factory)
*for pointer travel > 180°
Device Wiring
(refer to device wiring
Dial Color & connector styles)
o White Characters / Black Background
o Yellow Characters / Black Background

Connector
Nut Style
(refer to device wiring
Bezel Type Lens Material
& connector styles)
o Permanent (std.)
o Tempered Glass
o Removable
o Polycarbonate
(requires Outdoor, Vented) External Wiring
o Snap-On w/ Test Feature (refer to device wiring & connector styles)
(requires Outdoor, Vented) o Polycarbonate
o Cable o 16 Ga. SOW-A/SO (Std.)
o Other (consult factory)
o Flying o 16 Ga. TEW (Std.)
Leads o 16 Ga. TEF
o 14 Ga. TEW
o None
o Connector
Note: Not all option combinations are available, Parts Only
please consult factory.
Length of Cable or Flying Leads
o Inches o Meters
Specify 6" increments Can be specified to 0.1 m
Length

Connector Orientation
o At 3 o'clock (requires Outdoor, Sealed)
o At 6 o'clock (std.)

Note: Case mounting holes remain at 3 o'clock and

9 o'clock regardless of connector orientation.

© Qualitrol n Qualitrol and Qualitrol AKM are Control #______________________

PI-LLG042 REV. 24018 Issue Date _______
8-21-03
ISO 9001 system certified companies. Information
subject to change without notice. Replaces ________________________
REV. 23617 Sheet ___
2 Of ___
5
 Product Information
6 Inch Gear Drive Liquid Level Gauge
Option Sheet Part 2 of 2

min/max length
Application/Float Rod Style in inches [mm]
o Roller (for Bladder bags, U.S. Style) 27.0 [686] / 105.0 [2667]
o Straight (for Straight Float Rods) 6.0 [152] / 42.0 [1067]
o G-Roller (for Bladder Bags, Euro Style) 11.8 [300] / 98.4 [2500]
minimum A,B,C,D
Gear Ratio angular separation
o 2:1 Recommended for float travel > 45 degrees 6°
o 3:1 Non-Standard 4°
o 4:1 Recommended for float travel 45 degrees 3°

Data Type *use minus sign (-) for angles or oil levels below horizontal c/l
Radius Data Input and plus sign (+) for angles or oil levels above horizontal c/l
o Angles
Given from o Inches Can be o Millimeters Specify Max Angle/Level *A = 20°C/25°C Angle/Level
(required) (required except when ordering *C =
Horizontal Center Line specified to .10" increments in 1 mm increments flange assembly only)
o Oil Levels Min Angle/Level Optional Grad Angle/Level
Length = (required) *B = D must be between C & B *D =
Given from (optional 4th graduation mark)
Horizontal Center Line Note : If radius is specified in mm, then ROLLER/ Notes: (A-B) x (Gear Ratio) must be between 45° and 270° inclusive.
(Same Units as Radius)
G-ROLLER float rod hardware will be metric. Maintain minimum A,B,C,D angular separation per Gear Ratio table.

Gear Drive Flange Mounting Styles (in inches unless otherwise noted) Flange Construction
o 45E31 45° 3.125 Ø.28 2.75 O.D. x 2.13 I.D. x .13 x .06 DP. #10-32 o STD o HEAVY DUTY Support Tube Flange
o 45E32 45° 3.125 Ø.34 2.75 O.D. x 2.13 I.D. x .06 DP. #10-32 o STD Length (inches/mm) Construction
o 45E33 45° 3.125 Ø.34 2.75 O.D. x 2.13 I.D. x .13 x .06 DP. #10-32 o STD o HEAVY DUTY o 2.17 / 55MM
o 45E34 45° 3.125 Ø.34 2.63 O.D. x 1.75 I.D. x .08 DP. #10-32 o STD o 2.50 / 63MM STD Only
o 45E41 45° 4.000 Ø.44 3.38 O.D. x 2.63 I.D. x .06 DP. #10-32 o STD o 2.76 / 70MM
o 45E42 45° 4.000 Ø.44 N/A #10-32 o STD o 3.15 / 80MM
o 45E43 45° 4.000 Ø.44 3.38 O.D. x 2.63 I.D. x .13 x .09 DP. #10-32 o STD o HEAVY DUTY o 3.58 / 91MM
o 45E44 45° 4.000 Ø.44 3.38 O.D. x 2.63 I.D. x .09 DP. #10-32 o STD o 3.94 / 100MM
o 45E45 45° 4.750 Ø.56 4.00 O.D. x 3.12 I.D. x .12 DP. #10-32 o STD STD or
o 4.25 / 108MM
o 45E51 45° 5.000 Ø.34 3.81 O.D. x 3.31 I.D. x .13 DP. #10-32 o STD o HEAVY DUTY HEAVY DUTY
o 4.92 / 125MM
o 90E31 90° 3.125 Ø.34 2.75 O.D. x 2.13 I.D. x .06 DP. #10-32 o STD o 5.25 / 133MM
o 90E32 90° 3.125 Ø.28 2.75 O.D. x 2.13 I.D. x .06 DP. #10-32 o STD o HEAVY DUTY o 5.91 / 150MM
o 90E33 90° 3.125 Ø.28 N/A #10-32 o STD o 6.38 / 162MM
o 90E34 90° 3.125 Ø.34 2.75 O.D. x 2.13 I.D. x .13 x .06 DP. #10-32 o STD HEAVY DUTY
o 7.87 / 200MM
o 90E35 90° 3.125 Ø.34 2.63 O.D. x 1.75 I.D. x .08 DP. #10-32 o STD Only
o 10.4 / 265MM
o 45M41 45° 4.000 Ø13MM N/A M5 o STD o HEAVY DUTY o 11.5 / 292MM
o 45M42 45° 4.000 Ø7MM 87MM O.D. x 72.4MM I.D. x 4.3MM DP. M5 o STD o HEAVY DUTY

FLANGE
OPTION
B.C. HOLE GASKET GROOVE CASE MOUNTING Mounting Angle
o 0 (Horizontal)
o -15 degrees
o -30 degrees
o -45 degrees
HOLE o Other
ORIENTATION

Note: Not all option combinations are available,

please consult factory.
© Qualitrol n Qualitrol and Qualitrol AKM are Control #______________________
PI-LLG042 REV. 24018 8-21-03
Issue Date _______
ISO 9001 system certified companies. Information
subject to change without notice. Replaces ________________________
REV. 23617 Sheet ___
3 Of ___
5
 Product Information
6 Inch Gear Drive Liquid Level Gauge
Dial Styles, Device Wiring & Connector Styles

MAX MAX HI ALTO

5

2 0

5
2

2
I N

I N

B A
L
- M A X M

- M A X M

L
I
+25°C +20°C +25°C +25°C

A
-

-
6 W

6 W
D 6 W

D 6 W

D
MIN NY
U
.S
.A
MIN NY
U
. S
.A
LO NY
U
.S
.A
BAJO NY
U
.S
.A

T RT RT T
QU OR QU O QU O QU OR
AL I RP AL I RP AL I RP AL I RP
TRO L FA I T ROL FA I T ROL FA I T ROL FA I
CO R P . C OR P . C OR P . COR P .

+25°C +25°C

MIN MAX BAJO ALTO

T

T
Q

Q
/

/
A A
U

U
5

5
L 2 L 2
I N I
T I T A
R R B
O M O
L X L L
C A C A
OR - M OR -
P W P W
. . 6
FA D 6 FA D
I RP I RP
O RT O RT
NY U .S .A NY U . S .A

© Qualitrol n Qualitrol and Qualitrol AKM are Control #______________________

PI-LLG042 REV. 24018 Issue Date _______
8-21-03
ISO 9001 system certified companies. Information
subject to change without notice. Replaces ________________________
REV. 23617 Sheet ___
4 Of ___
5
 Product Information
6 Inch Gear Drive Liquid Level Gauge
Device Wiring & Connector Styles

STANDARD NUT

CONDUIT ADAPTOR

SPIN NUT (FLEX CONDUIT ADAPTOR)

SPIN NUT (CONDUIT ADAPTOR)

TERMINAL BOX: 1 & 2 SWITCH W/ GROUND
(2 SWITCH VERSION SHOWN)

© Qualitrol n Qualitrol and Qualitrol AKM are Control #______________________

PI-LLG042 REV. 24018 Issue Date _______
8-21-03
ISO 9001 system certified companies. Information
subject to change without notice. Replaces ________________________
REV. 23617 Sheet ___
5 Of ___
5
 ~----

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 PipeCon as
Delivery, transport and installation of vertical and
horizontal cylindrical tanks.
1) Before unpacking:
Tanks delivered by Pipecon are packed according to customer specifications
either in boxes or containers. The tanks have been carefully packed and
fastened before shipping to prevent damage during transportation. When
receiving the tanks check for damage to the boxes and containers. Damage
during transport has to be reported to the transportation company for
insurance.

To avoid damage during storage the tanks must be kept in the boxes and
containers until erection starts. Before removing the tank from the box or
container please check if the tank is still in place with no defects.

Warning!
Improper and careless handling of the tanks can lead to danger to persons
and property. Handling of tanks has to be performed by skilled personnel,
trained for handling heavy equipment.

2) Unpacking:
Tanks from boxes:
Remove the top and sides of the box by suitable tools. Lift the tank by
attaching a suitable lifting hook in the lifting lug/lugs or with slings around the
tank .See figure 1 and 2. Never use chains or steel ropes around the tank, but
only slings.

Tanks from containers:

Remove fastening gear from the tank. Carefully lift out tanks by forklift as
shown in figure 4.

Figure 1. Figure 2.
 PipeCon as
Figure 3. The tanks must
never be lifted directly
underneath with forklifts or
palletizers, The tank can roll
and cause danger for
persons and the surface of
the tank may be damaged.

Figure 4. When lifting with

forklift - use beams as
shown.
 PipeCon as
2.1) Raising of vertical tanks.
Figure 5. Attach slings in the
lifting lugs. Loose the tank
from the pallet or supporting
wood beams.

Figure 6. Lift the tank slowly from

the pallet – keep two legs
supporting the tank.

Figure 7. Raise the tank into vertical position.

2.2) Installation of the tank.

After unpacking and raising the tank, bring it to
its final position at the installation site and align
it on a suitable concrete foundation. Remove
the slings and other aids. Then anchor the tank
to the ground.

The tank has been set up.