KAM Simple Precision IAS User Manual

An ISO 9001 certied company

KAM® IAS™ ISOKINETIC AUTOMATIC SAMPLER

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PER API 8.2, ASTM D4177
AND ISO 3171

User Manual

IASMANUAL-0513

KAM CONTROLS, INC.

3939 Ann Arbor Drive

Houston, Texas 77063 USA

www.KAM.com

TABLE OF CONTENTS

SECTION TITLE PAGE

1 Introduction 2

•Available Models and Mounting Options 2

•Theory of Operation 3

•Features 4

•Applications 4

•Sampler Sequence 4

2 Specications 5

•Specications 5

3 Installation 6

•Main Line 6

•Field Air Connections 11

•Removal 12

4 Maintenance 13

Seal Kit and Replacement Schedule 13
Sampler Disassembly 14
Replacing Seals and O-rings 18
Reassembly 22
Testing 26

5 Troubleshooting 27

CAUTION:

When installing the IAS™ sampler in a pipeline containing petroleum products,
petro-chemicals, waste waters with the presence of pressure & temperature, and high-pressure
steam refer to the Pipeline Operators’ “Health, Safety and Environmental Policy Procedures” to
ensure safe installation.

KAM CONTROLS, INC. reserves the right to make changes to this document without notice.

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INTRODUCTION

AVAILABLE MODELS and MOUNTING OPTIONS

FIG. 1-1

Option 1: Retractable IAS™
on a main pipe, with 2”, 3”, or 4” anged seal housing

Full-opening Ball Valve

Recommended

KAM® SMS™

Static Mixing Spool

FIG. 1-2

Option 2: Retractable IAS™
on a main pipe, with 1 1/4" or 2" MNPT seal housing

Q

Full-opening Ball Valve

Recommended

KAM® SMS™

Static Mixing Spool

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Q

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INTRODUCTION CONTINUED

FIG. 1-3

Option 3: IAS™ FT
Flow Through with
2" 150# anges

THEORY OF OPERATION

Employing the simplest design in the industry, the KAM® IAS™ Isokinetic Automatic Sampler is the ideal instrument
for pipeline sampling during custody transfer. The IAS™ sampler is designed to extract a representative sample
of the pipeline into a KAM® SR™ Sample Receiver. With a KAM® CSM™ Circulating Sample Mixer, you may then
mix and analyze the sample for custody transfer, API gravity measurements, shrinkage, chemical composition, etc.

FIG. 1-2

Sampling Chamber

Locking Collar

Seal Housing

Actuator Housing

Pressure Relief Valve

Air Inlets

Sample Outlet

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INTRODUCTION CONTINUED

FEATURES

• User friendly

• Positive displacement design

• Pneumatic, hydraulic

• Insertable and extractable through
full-opening ball valve

• Fast loop and main line models

• Variable insertion

• Simple design

• Isokinetic

• Pressure relief valve

SAMPLER SEQUENCE

FIG. 1-3

APPLICATIONS

• Custody transfer

• Marine loading, unloading, lightering

• Pipeline

• Truck loading, unloading

• Production

• Renery

• Power plant fuel oil

• Research

• Quality control in

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SPECIFICATIONS

Media: Crude oil, rened products, chemicals, water and wastewater

Wetted parts: 316 stainless steel shaft and probe cage
304 stainless steel sample piston
Teon sample chamber seal

Fluid temperature: -40º to 350ºF (-40º to 177ºC)

Power: Air pneumatic, hydraulic

Sample size: 0.5 ml - 3 ml (Please specify)

Repeatability: Exceeds API 8.2

Mounting: Main line - 1¼" MNPT, 2" MNPT seal housing,
or 2", 3", or 4" anged seal housing
Fast loop - ¼" FNPT

Pressure ratings: ANSI 150, 300, 600, 900

Probe dimensions: Ø1.25" x 3.1" (32mmh x 79mm)

Shaft length: 30" (762mm) Other sizes available

REQUIREMENTS

Air: 70 to 125 psi

Consumption: 20 cubic inches per stroke

Minimum Sample Time: 1.5 seconds

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INSTALLATION

PRIOR TO INSTALLATION

Before installing the IAS™ Sampler, make sure that it was not damaged during transit.

KAM CONTROLS recommends that the IAS™ Sampler be installed 2 to 4 pipe diameters downstream of a

KAM® static mixer or ow conditioner. At the time of installation the pipeline pressure needs to be reduced to

under 100 psi in order to be able to install the IAS™ Sampler.

The IAS™ Sampler should be installed horizontally at 3 or 9 o’clock. Fig. 3-1.

The IAS™ Sampler Probe should be inserted so that the middle of the sampling window is in the 20% center
area of the pipe. Fig. 3-1.

MAIN LINE INSTALLATION

Before mounting the IAS™ Sampler on the Full-Opening Ball Valve, determine the insertion length required.

The IAS™ Sampler should be installed according to Fig. 3-1. The Full-Opening Ball Valve is used to isolate the IAS™
Sampler from the pipeline during installation or removal. The Seal Housing of the IAS™ Sampler allows the Sam­pler Probe to be inserted in and out of the pipe under pressure and ow conditions up to 100 psi. It is the user’s
responsibility to ensure that the IAS™ Sampler is placed in the most representative point in the ow prole. Prior
to installation, make sure you have the correct Pressure Relief Valve. The IAS™ Sampler is normally shipped with
a PRV designed for pressures up to 750 psi. If the line pressure is greater than 750 psi, please replace the spring
inside the PRV with the appropriate Spring. See Table 3-2.

FIG. 3-1 END VIEW OF A KAM® IAS™ INSTALLED ON A MAIN PIPE

Sampler Probe

Seal Housing

Full-opening

Ball Valve

TABLE 3-2

PRV Spring Cracking Pressure Range (psig) Spring Color

50 to 350

350 to 750

750 to 1500

1500 to 2250

Blue

Yellow (included with IAS™ Sampler)

Purple

Orange

Locking Collar

Hex Socket Cap

Screw

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INSTALLATION CONTINUED

1.

Lay the IAS™ Sampler on the ground or a table.

Loosen Hex Socket Cap Screws on the Locking Collar. Fig. 3-1. This will allow the IAS™ Sampler Shaft to slide

2.

through the Seal Housing.

3.

Push the IAS™ Sampler Shaft though the Seal Housing until the middle of the sampler window chamber is
aligned with the end of the Seal Housing. Fig. 3-3 or Fig. 3-4.

4.

Use a Sharpie or other permanent marker to mark the shaft at the edge of the Locking Collar. (Do not use any­thing sharp to mark the shaft. This will create grooves that will damage the O-rings in the Seal Housing.)

FIG. 3-3 MNPT SEAL HOUSING

Mark HereAlign Here

Pull Shaft back until the Probe is all the way in the Seal Housing and tighten the Hex Socket Cap Screws on the

5.

FIG. 3-4 FLANGED SEAL HOUSING

Align

Here

Mark Here

Locking Collar. This will prevent the IAS™ Sampler Shaft from sliding and the Probe will be protected inside
the Seal Housing.

6.

Measure the distance (D1) from the top of the main pipe to the end of the connection where the IAS™ Sampler
is going to be installed. Fig. 3-5.

FIG. 3-5

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INSTALLATION CONTINUED

Calculate the insertion distance using the following formula:

7.

TID – Total Insertion Distance
D1 – Distance from the top of the valve to the pipe
WT – Pipe Wall Thickness
TD – Threaded Depth
ID – Inside Diameter

For Flanged Seal Housing

Total Insertion Distance (TID)= D1 + WT + (Pipe ID x 7/16) + Seal Thickness

Example: D1= 14"
WT= .25"
ID = 8.125"
Seal Thickness=1/8"

TID=14 + .25 + (8.125 x 7/16) + 1/8
TID=14 + .25 + 3.55 + .125= 17.93

For 2" MNPT Seal Housing

TID cannot be calculated until the Seal Housing is screwed into place. Bolt or Screw the IAS™ Sampler to the
Valve or designated installation location. (KAM CONTROLS recommends liquid thread sealant and not teon
tape for the threaded IAS™ Sampler.)

You must then measure the Threaded Depth (TD) into the Valve or connection in order to calculate TID. You can
do this by measuring the distance from the edge of the Valve or female connection to the top of the Seal Hous­ing body and subtracting that distance from 5.25". Fig 3-6.

Total Insertion Distance (TID)= D1 + WT + 7/16 Pipe ID -Threaded Depth (TD)

FIG. 3-6

Threaded Depth
Measuring Points

For example: If the measured distance from the top of the Valve and the top of the Seal Housing body is 4.65"
you should calculate the threaded depth (TD) by subtracting 4.65" from 5.25". (5.25-4.65=0.6)

In this case the threaded depth (TD) would be .6"

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