Fuel Probe Calibration

Work Instruction HT-OP-08-10-SOP.01-EN

Operations Revision: 01

Revision History

Revision Date of Issue / Revision Revised Section Revision Details

1 22/02/2022 ALL New Document

Document Authorisation

Prepared Reviewed Approved

Name
Rob Salbego Steve Jephcott Will Richardson-White

Designation
Group Product Manager Group Applications Engineering Manager Group Head of HSE and Quality

Date
14/01/22 22/02/02 22/02/02

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 CONTENTS
Page Number Title

3 Overview and Related Documents

4 Safety and Introduction

5 Preparation

8 Preparing for Calibration

11 Checking Calibration

14 Calibrating Fuel Probe

21 Re-Calibration

23 Final Checks

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 OVERVIEW
This document contains instructions for verifying and calibrating of fuel probes connected to a Deepsea 7320 or 7420 Controller.

The tasks in this document are to be performed by Field Maintenance Engineers and Field Maintenance Supervisors prior to installing an RMS, during a Preventative
Maintenance Audit, when completing a SWO instructing to do so or at any time when a fuel probe is suspected to be providing incorrect readings.

RELATED DOCUMENTS
2006 Helios Towers Safety Standards R3
2001 HT Standard 1 (PPE) R1
2006 HT Standards 2 (Vehicle Safety) R0
2006 HT Standards 3 (Working at Height)

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 SAFETY
First Aid kit Ensure you follow all applicable COSHH and Risk assessments.
Portable Fire Extinguisher Ensure you wear the correct PPE at all times.
Gloves Latex Use correct lifting technique, if manual lifting is required.
Hard Hat
Safety Boots
Safety Vest
Spill kit

INTRODUCTION
It is important that the fuel level reading on the Deepsea controller is providing the correct information of how much fuel is in the fuel tank and to verify how much
fuel is being delivered and how much fuel is being consumed. This can only be achieved if the fuel probe is functioning correctly and if it is correctly calibrated.

The purpose of this document is to firstly determine if the fuel probe is functioning and that the Deepsea has been correctly configured. Secondly it provides
instruction on how to calibrate the fuel probe if found to be un-calibrated.

This process is to be done during a Fuel Delivery work order and requires up to 400 litres of fuel be dispensed into the site fuel tank.

This process is estimated to take 90 minutes to complete.

Prior to visiting the site, take spare Deepsea 7320 or 7420 controller and a spare fuel pressure probe so that these may be installed if the controller or the fuel probe is
found to be faulty.

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 Preparation

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VISUAL EQUIPMENT
▪ Mobile Phone
1 2 3 ▪ Fuel
▪ USB printer cable
▪ Laptop with DSE software
▪ Fuel probe calibration curves (saved on laptop)

TOOLS
▪ Electrical Tool kit

5
4

INSTRUCTION
1. This procedure must be done when a fuel delivery is taking place.
2. Prior to attending a site, assemble all equipment and tools required to carry out
your task.
3. Check each item with the lists displayed. NOTES
▪ Ensure all equipment and tools are in a good working condition.

▪ Ensure that a minimum of 400 litres of fuel is available to pour into the site
fuel tank.

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VISUAL CONSUMABLES
▪ None

SAFETY & PPE

▪ Hard Hat
▪ Safety Boots
▪ Safety Vest
▪ Gloves
▪ Spill Kit

INSTRUCTION
1. Prior to attending a site, assemble all consumables, PPE and safety equipment
required to carry out your task.
2. Check each item with the list displayed.
NOTES
▪ Ensure your consumables, PPE and safety equipment is complete, in
order to carry out the activities.

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Preparing for Calibration

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VISUAL EQUIPMENT
▪ Mobile Phone
1 2

TOOLS
▪ None

Check if the Check if the

Controller is a controller is a CONSUMABLES & PPE
DSE7320 DSE7420
▪ Safety Vest
▪ Safety Boots
INSTRUCTION ▪ Hard Hat
Before commencing with the refuelling of the site fuel tank:

1. Check if there is a functional Deepsea DSE7320MKI or MKII or a DSE7420MKII

controller installed on site.
NOTES
▪ If there is no functional DSE7320 or DSE7420 installed on site then this procedure
cannot be followed and refueling of site is to continue as normal.
▪ Open a SWO to replace the controller with a DSE7420MKII.
▪ If you have spare Deepsea controller and the training to install it, this can be
done and the process can continue.

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VISUAL EQUIPMENT
▪ Mobile Phone
1 2

TOOLS
▪ None

Check if fuel probe is displaying a On the Engine Fuel Level

value on the Engine Fuel Level screen there should be a
screen value % and a value Litre
CONSUMABLES & PPE
▪ Safety Vest
▪ Safety Boots
INSTRUCTION ▪ Hard Hat
If confirmed that there is a functional DSE7320/7420 installed:

1. Navigate to the Engine Fuel Level screen of the DSE controller.

2. If the display is indicating XXXX% or ++++% and not showing a % value and a Litre NOTES
value then check wiring of fuel probe.
▪ If after checking the wiring, the fuel level is still not being displayed on the
3. Check that the wiring to the controller and to the fuel probe is connected and screen then the fuel probe is faulty and needs to be replaced. Continue
that the cable is not cut or damaged. refueling process as normal. Open SWO to replace fuel probe.
▪ If you have a spare fuel probe and the training to install it, this can be done and
4. Do a continuity Check on each wire between Deepsea and fuel probe. the process can continue.

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Checking Calibration

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VISUAL EQUIPMENT
▪ Mobile Phone
1 2 3 ▪ Fuel

TOOLS
▪ None

Add 40 litres of fuel at a time and Do this until exactly 200 litres has
record the fuel level being
displayed after every 40 litres.
been poured into the tank.
CONSUMABLES & PPE
▪ Safety Vest
Safety Boots
INSTRUCTION ▪
▪ Hard Hat
Having confirmed that there is functional DSE7320/7420 on site which is displaying % ▪ Spill Kit
and Litres values on the screen:

1. Record the fuel level being displayed on the screen (% and Litres).
NOTES
2. Adding 40 litres of fuel at a time to the fuel tank, record the fuel level on the
display after every 40 litres. ▪ Take a photo of the % and Litres being displayed on the screen to record
the values after every 40 litres. Add these photos to the SWO.
▪ Use 20 litre drums filled to the 20 litre mark or refuel using a calibrated fuel
flow meter on the refueling vehicle.

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VISUAL EQUIPMENT
▪ Mobile Phone
1 2 ▪ Fuel

TOOLS
▪ None

Subtract the initial litre value from Example:

the final litre value after 200 litres 490 litres – 290 litres = 200 litres
poured into tank
CONSUMABLES & PPE
▪ Safety Vest
Safety Boots
INSTRUCTION ▪
▪ Hard Hat
Stop refuelling once 200 litres of fuel has been poured into the fuel tank. ▪ Spill Kit

1. Record the fuel level after exactly 200 litres of fuel has been poured into the site
fuel tank.
NOTES
2. Deduct the initial Litre value recorded on arrival from the Litre value after the 200
litres was added. If the value is between 190 and 210 litres then the value is ▪ If the fuel level increased by between 190 and 210 litres after the 200
acceptable (within 5%). litres was added (within 5%), then the fuel probe is considered to be
calibrated and no further action is required. Refueling to continue as
3. In the photo example above, 490 litres – 290 litres = 200 litres so the probe is usual.
calibrated. ▪ If variance is greater than 5% then proceed to Calibrating Fuel Probe.
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Calibrating Fuel Probe

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VISUAL EQUIPMENT
▪ Mobile
2 ▪ Laptop with DSE software
▪ USB printer cable

1
TOOLS
▪ None

Open Deep Sea Electronics

Connect laptop to DSE7320/7420

Configuration Suite and
click on Read from module.
CONSUMABLES & PPE
▪ Safety Vest
▪ Safety Boots
INSTRUCTION ▪ Hard Hat
If the difference between fuel added and fuel recorded is more than 5% (less than 190
litres or more than 210 litres) then the probe is not calibrated:

1. Connect your laptop to the back of the DSE7320/7420 controller using a USB A/B
printer cable. NOTES
2. Open the Deep Sea Electronics Configuration Suite software, connect to the ▪ None
controller and click on the Read from module button in the top left corner.

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VISUAL EQUIPMENT
▪ Mobile
1 2 ▪ Laptop with DSE software
▪ USB printer cable

TOOLS
▪ None

DSE7320MKI: Click DSE7320MKII and DSE7420MKII:

on Inputs then
Fuel Level
Click on Engine then Fuel
Options then Fuel Control and CONSUMABLES & PPE
Monitoring
▪ Safety Vest
▪ Safety Boots
INSTRUCTION ▪ Hard Hat
Navigate to the Fuel Level page as follows:

1. DSE7320MKI: Click on Inputs then Fuel Level

2. DSE7320MKII and DSE7420MKII: Click on Engine then Fuel Options then Fuel Control NOTES
and Monitoring
▪ None

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VISUAL EQUIPMENT
▪ Mobile
1 2 ▪ Laptop with DSE software
▪ USB printer cable

TOOLS
▪ None

Check that
correct fuel probe
has been
selected
CONSUMABLES & PPE
DSE7320MKI DSE7320/7420MKII
▪ Safety Vest
▪ Safety Boots
INSTRUCTION ▪ Hard Hat
In the Fuel Level/Fuel Control and Monitoring screen, we need to check that the
correct fuel probe has been selected:
1. Input Type: The correct fuel probe must be selected using the drop-down menu:
1. Elcos generator original probe: a bracetto NOTES
2. Gen Logic generator original probe: VDO Ohm range (10-180)
3. Pressure Probe: DSGE-25 ▪ The various fuel probe types and their calibration graphs are available from
your Technical Manager as computer files. If unsure of fuel probe type to select,
4. Any Other fuel probe or generator: Contact your Engineering / Technical
check with you Field Supervisor or Technical/Engineering Manager.
Manager ▪ If the correct fuel probe type is not know then the calibration process cannot be
completed.

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VISUAL EQUIPMENT
▪ Mobile
▪ Laptop with DSE software
1 2 ▪ USB printer cable

3 TOOLS
▪ None

Elcos Fuel Probe – Gen Logic Fuel Pressure Probe – Red,

Yellow, White and Probe – Black and Green and Black wires
Black wires Green/Yellow wires connected to #20 (F) of
Deepsea
CONSUMABLES & PPE
▪ Safety Vest
▪ Safety Boots
INSTRUCTION ▪ Hard Hat
Identifying and selecting the correct fuel probe types:
1. Elcos: see image 1 (select: a bracetto)
2. Generator Logic: see image 2 (select: VDO Ohm range (10-180))
3. Pressure Probe: see image 3 (select: DSGE-25)
NOTES
4. Input Type: Select the correct fuel probe type as above. ▪ Note that some fuel probes may be covered with epoxy resin and may
not be visible. Check the wire colours connected to the Deepsea
controller.
▪ If the correct fuel probe type is not know then the calibration process
cannot be completed.
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VISUAL EQUIPMENT
▪ Mobile
1 2 ▪ Laptop with DSE software
▪ USB printer cable

TOOLS
▪ None

Check that
correct fuel tank
capacity in litres
has been
CONSUMABLES & PPE
DSE7320MKI DSE7320/7420MKII
selected ▪ Safety Vest
▪ Safety Boots
INSTRUCTION ▪ Hard Hat
In the Fuel Level/Fuel Control and Monitoring screen, we need to check that the
correct fuel tank capacity has been selected:
1. Fuel Monitoring: Check that the correct Fuel Tank Size has been selected (in litres)
2. If necessary, adjust the fuel tank size up or down to the correct amount in litres NOTES
based on the fuel tank that is installed on site.
▪ If you are unsure of the fuel tank size, confirm with your Field Supervisor
3. Note that Elcos, Gen Logic and Pramac generators should be set to 1000 litres. or Technical/Engineering Manager.
▪ If no changes were made and everything was correct, then there must
be a problem with the fuel probe. Open SWO to replace fuel probe and
continue refueling as usual.
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VISUAL EQUIPMENT
▪ Mobile
▪ Laptop with DSE software
▪ USB printer cable
1
2
TOOLS
▪ None

Go to Engine Fuel
Click on Write
to module
Level screen
CONSUMABLES & PPE
button
▪ Safety Vest
▪ Safety Boots
INSTRUCTION ▪ Hard Hat
If fuel correct fuel probe has been selected and the correct fuel tank size has been
selected:

1. Click on the Write to module button in the top left hand corner of the screen.
NOTES
2. Disconnect the cable from the laptop and go to the Engine Fuel Level screen of
the Deepsea. ▪ If no changes were made and everything was correct, then there must
be a problem with the fuel probe. Open SWO to replace fuel probe and
continue refuelling as usual.
▪ If you have a spare pressure probe, open a SWO and replace the fuel
probe.
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Re-Calibration

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VISUAL EQUIPMENT
▪ Mobile Phone
1 2 3

TOOLS
▪ None

Add 40 litres of fuel at a time and Do this until exactly 200 litres has
record the fuel level being
displayed after every 40 litres.
been poured into the tank.
CONSUMABLES & PPE
▪ Safety Vest
Safety Boots
INSTRUCTION ▪
▪ Hard Hat
Having made the changes and confirmed that the correct fuel probe has been ▪ Spill Kit
selected and the correct fuel tank size in litres has been selected:

1. Redo the process of adding 40 litres of fuel at a time to the fuel tank and record
the fuel level on the display after every 40 litres. NOTES
▪ Take a photo of the % and Litres being displayed on the screen to record
the values.
▪ Use 20 litre drums filled to the 20 litre mark or refuel using a calibrated fuel
flow meter on the refueling vehicle.

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VISUAL EQUIPMENT
▪ Mobile Phone
1 2

TOOLS
▪ None

Subtract the initial litre value from Example:

the final litre value after exactly 690 litres – 490 litres = 200 litres
200 litres poured into tank
CONSUMABLES & PPE
▪ Safety Vest
Safety Boots
INSTRUCTION ▪
▪ Hard Hat
Stop refuelling once 200 litres of fuel have been poured into the fuel tank. ▪ Spill Kit

1. Record the fuel level after exactly 200 litres of fuel has been poured into the site
fuel tank.
NOTES
2. Deduct the initial Litre value recorded on arrival from the Litre value after the 200
litres was added. If the value is between 190 and 210 litres then the value is ▪ If the fuel level increased by between 190 and 210 litres after the 200 litres was
acceptable (within 5%). added, then the fuel probe is considered to be calibrated and no further
action is required. Refueling to continue as usual.
▪ If the variance is still more than 5% then there must be a problem with the fuel
probe. Open SWO to replace fuel probe and continue refuelling as normal.

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 Final Checks

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VISUAL EQUIPMENT
▪ Mobile Phone
1 2

TOOLS
▪ None

Access the Mobile

Reach App
Access your SWO
CONSUMABLES & PPE
▪ None
INSTRUCTION
1. Once all activities have been completed:
▪ Access the Mobile Reach app.
▪ Access your SWO.
▪
▪
Update the work order for the activities carried out.
Place the generator controller in Auto Mode.
NOTES
▪ Remember to report any issues to the NOC, so that an SWO can be
created, if required.

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End of Document

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