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PR-23-SD
User Manual
37 pgs2.87 Mb0

K-Patents PR-23-SD User Manual

Safe-Drive™ Process Refractometer PR-23-SD Generation 1
Best Practices for PR-23-SD with steam wash system
Contents
2.1 Installation Location Checklist ....................................................................................... 3
2.2 Component Checklist ..................................................................................................... 4
4.1 Spool piece assembly .................................................................................................... 8
4.2 Cutting Installation Opening for SDI Valve .................................................................... 9
4.3 Disassembling SDI Valve for Welding ......................................................................... 10
4.4 Welding SDI Valve in Place ..........................................................................................11
4.5 Reassembling SDI Valve ............................................................................................. 12
4.6 Installing Steam Prism Wash System .......................................................................... 14
4.7 Before Installing and Removing PR-23-SD Sensor .................................................... 17
4.8 Installing Sensor .......................................................................................................... 17
4.9 Box Flushing ................................................................................................................ 19
4.10 Removing Sensor ........................................................................................................ 21
4.11 Removing Wash Nozzle ............................................................................................... 23
4.12 Installing Wash Nozzle ................................................................................................ 25
4.13 Installing DTR Transmitter ........................................................................................... 26
Section 5 Commissioning SD Sensor System ................................................................................. 29
5.1 Prism Wash Test .......................................................................................................... 30
5.2 Calibration Check ........................................................................................................ 31
6.1 Preventive Maintenance Plan (PMP) ........................................................................... 32
6.2 Check Valve Maintenance ........................................................................................... 33
6.3 Resetting SD Sensor System ...................................................................................... 33
Section 7 Appendices .........................................................................................................................34
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Document/Revision No. BP-EN-SDGEN1 1.0 Effective: April 1, 2013
Safe-Drive™ Process Refractometer PR-23-SD Generation 1 Best Practices
1 About This Document
This document is intended for individuals installing, commissioning, operating, and/ or servicing the Safe-Drive™ Process Refractometer PR-23-SD generation 1 model that has been manufactured in years 2006–2013. The purpose of this document is to provide a quick guide for the abovementioned tasks in the form of K-Patents recommended best practices.
This document in intended for PR-23-SD applications that have a steam wash system (typical application for black liquor).
NOTE: These instructions are for quick reference only. For more thorough guidance, please refer to K-Patents user manual and documentation.
2 Before Installation
2.1 Installation Location Checklist
Before the SD sensor system is installed, it is important to inspect the installation location carefully for the following conditions:
●
Install the SD sensor system onto either vertical or horizontal pipeline. The
recommended ow rate is 0.4 m/s – 2 m/s (1.5 ft/s – 6 ft/s).
●
Mount the system at waist level. This is the natural and safe height for the system and enables you to use the tools more ergonomically.
●
Leave a 1 m (approximately 3 ft) space around the installation for operating around the SD sensor system. For the same reason, the steam connections should be installed on the sides or back of the sensor system.
●
Recommended maximum ambient temperature of installation location is 45°C (120°F).
●
Avoid locations that are blocked by other piping and/or equipment, or require additional tools, such as a ladder, to access the sensor. The installation location must be level, rm, and free of clutter to provide safe and easy access to the system.
© Copyright K-Patents 2013. All rights reserved.
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●
Use suitable type of steam for cleaning the prism. Dry saturated steam and 10-12 bar (150-180 psi) are recommended.
●
Access to steam. The distance between the steam supply and the SD sensor system should be considered for the length of steam piping.
●
Access to drain for steam trap condensate outlet.
●
Emergency shower and eye wash should be easily accessible. Water can also be used for cleaning SDI valve lip seals and sensor after sensor removal.
●
Shut-off valve needs pressurized instrumentation air (5-10 bars / 70-150 psi).
●
Ensure connection to the power supply (110-230V AC).
If these conditions do not apply, please reconsider the intended location for your installation or contact K-Patents.
2.2 Component Checklist
Before starting installation, make sure you have all the tools and components listed below.
NOTE: Components 4–6 are connected by union nipple or piping not included in the delivery.
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Document/Revision No. BP-EN-SDGEN1 1.0 Effective: April 1, 2013
Safe-Drive™ Process Refractometer PR-23-SD Best Practices, Generation 1
1 2 3
4 5 6
7 8 9
- 0 .
BACK
ENTER
System components included in K-Patents delivery
3
1
7
2
3c
3b
3a
8
5
Figure 1 System components included in K-Patents delivery
1
2
3
3a 3b 3c
4
5
6
7
8
4
PR-23-SD sensor
SDI valve
Retractor tool
Prism wash nozzle assembly Wash nozzle installation bolts M5x8 DIN912 A4-70
Compressed air operated solenoid shut-off valve with steam trap
Steam connection hose
Pressure regulator with lter and gauge
Sensor connection cable
DTR transmitter
6
NOTE: If any of tools or components are missing, contact your supplier before starting installation
© Copyright K-Patents 2013. All rights reserved.
5
Installation Equipment
1
4
3
2
9
8
7
6
5
PROCESS
REFRACTOMETER
PR-23
Figure 2 Installation equipment
Retractor inner casing Supplied by K- Patents
1
Retractor outer casing Supplied by K- Patents
2
Adjustable wrench
3
Combination wrench, 19 mm / 3/4 in
4
Flat head screwdriver
5
Allen key 8 mm / 5/16 in
6
Thread seak tape
7
Sensor insertion / removal instruction card Supplied by K- Patents
8
Product user manual Supplied by K- Patents
9
NOTE: The material of the SDI valve body that is welded onto a process pipe is Duplex steel SAF2205 (EN 1.4462, ASTM S32205/S31803). Choose the welding method and ller accordingly.
K-Patents recommends complying with the applicable EN / ASTM standards.
3 Safety Requirements
These safety requirements must be followed at all times when installing, operating, or servicing PR-23-SD sensor. These are the minimum safety requirements – your company may require additional PPE (personal protective equipment).
For more information on safety issues, please see K-Patents Safety Instructions.
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Document/Revision No. BP-EN-SDGEN1 1.0 Effective: April 1, 2013
Safe-Drive™ Process Refractometer PR-23-SD Best Practices, Generation 1
Figure 3 Safety symbols
WARNING: Watch out for hot steam and process pipes. Wear protective clothing as
instructed below to work safely.
●
Only authorized personnel can perform the tasks instructed in this document.
●
Long-sleeved safety clothing.
●
Safety glasses and/or goggles.
●
Hard hat or helmet.
●
Protective gloves.
●
Locate the nearest emergency shower and eye wash before starting the work.
●
Never operate the Safe-Drive™ Retractor alone.
●
Hard-cap safety boots.
4 Installation Process
For more thorough instructions, please refer to K-Patents user documentation or visit the K-Patents website to see the instructional video (www.kpatents.com, PR-23-SD Safe­Drive™ Operation Guide Video).
Installation of the SD sensor system consists of
●
Cutting pipe opening for SDI isolation valve.
●
Welding and assembling the SDI valve onto the processing piping.
●
Installing the steam prism wash system.
●
Installing the PR-23-SD sensor.
●
Installing the DTR transmitter.
4.1 Spool piece assembly
If the SDI valve was supplied pre-welded and assembled onto a pipe spool piece for integration in existing piping on site, please skip ahead to installing prism wash.
© Copyright K-Patents 2013. All rights reserved.
7
Figure 4 Vertical and horizontal spool piece assemblies
4.2 Cutting Installation Opening for SDI Valve
Use the installation guide sticker provided by K-Patents to determine the installation opening shape and size suitable for your process pipe. If you do not have the guide sticker at hand, please follow the instructions in the images below:
Figure 5 Installation guide sticker
NOTE: For larger pipes, use the same dimensions as for 24” (610 mm) pipes.
To cut the installation opening
1. Cut the installation guide sticker to match the pipe size.
2. Clean the surface of the pipe around the installation area and attach the sticker onto the pipe.
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Document/Revision No. BP-EN-SDGEN1 1.0 Effective: April 1, 2013
Safe-Drive™ Process Refractometer PR-23-SD Best Practices, Generation 1
NOTE: Make sure that the FLOW marker is parallel to the pipe and points to the correct
ow direction. On a horizontal pipe the nozzle points downwards and on a vertical pipe
it points to right. The SD sensor system must always be installed in horizontal position and on the side of the pipe.
3. Drill two holes – 50 mm (2”) and 25 mm (1”) – as guided by the sticker.
4. Remove the bridge between the holes so that the opening is exactly the shape of the sticker.
Process pipe
Cutout
Cutout
Safe Drive
mounting flange
Process pipe
Weld
Weld
Safe Drive
mounting flange
Figure 6 Installation on vertical and horizontal pipes
4.3 Disassembling SDI Valve for Welding
To avoid thermal damage to the isolation valve sealing, you must separate the valve body from the valve assembly before it is welded onto the pipe.
© Copyright K-Patents 2013. All rights reserved.
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NOTE: Be very careful not to drop or lose any parts that come loose when separating the
body from the assembly.
To disassemble the SDI valve, open the four (4) M10 allen key bolts with an 8 mm (5/16”) allen key (1).
1
Figure 7 Disassembling valve
4.4 Welding SDI Valve in Place
After you have disassembled the SDI valve, the valve body is welded onto the process pipe.
●
The material of the SDI valve body is Duplex steel SAF2205 (EN 1.4462, ASTM S32205/S31803). Choose the welding method and ller accordingly.
●
See the attached drawings 2149 (MTG) and MTG472 for more detailed welding instructions.
●
Follow all local requirements for welding.
●
K-Patents recommends complying with the applicable EN / ASTM standards.
●
Consider the materials and shapes of the welded objects when performing welding pre-processing (tools, cleaning, preheating).
●
Consider the materials and shapes of the welded objects when performing welding post-processing (postheating, fluxing).
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Document/Revision No. BP-EN-SDGEN1 1.0 Effective: April 1, 2013
Safe-Drive™ Process Refractometer PR-23-SD Best Practices, Generation 1
90°
NOTE!
Weld
The material of the welded parts is Duplex steel SAF2205
Process
pipe
Figure 8 Welding on vertical and horizontal pipes
4.5 Reassembling SDI Valve
After the SDI valve body has been welded in place, reassemble the valve in reverse order.
Weld
90°
Process
pipe
NOTE: Make sure that the seals of the ball valve are propely aligned.
Widest bayonet lug always positioned at top
Valve handle always positioned at top
© Copyright K-Patents 2013. All rights reserved.
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Widest bayonet lug always positioned at top
Figure 9 Reassembling valve on vertical and horizontal pipes
●
Make sure that the SDI valve handle and the largest bayonet connection are on top.
Valve handle always positioned at top
Otherwise, you will not be able to insert the sensor in its place.
●
Tighten the bolts to a torque of 36 N-m (26 lb-ft) with an 8 mm (5/16”) allen key.
WARNING: Always shut the main steam valve before performing any work on the wash nozzle.
To reinstall the wash nozzle assembly
1. Insert the wash nozzle assembly to its place (1)..
1
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Document/Revision No. BP-EN-SDGEN1 1.0 Effective: April 1, 2013
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