Installation Instructions for
K-Patents SAFE-DRIVE®
Process Refractometer PR-23-SD
Upgrade Kits
Contents
Section 1 Background Information ...................................................................................................... 3
®
Section 2 SAFE-DRIVE
2.1 SDR2-KIT for Isolation Valve and Retractor Tool .......................................................... 3
2.2 SN2-KIT for Prism Wash Nozzle for Steam................................................................... 4
2.3 WP2-KIT for Prism Wash Nozzle for High Pressure Water........................................... 4
Section 3 Before Installation ................................................................................................................ 5
3.1 Components Checklist ................................................................................................... 5
Section 4 Installation .............................................................................................................................6
4.1 Safety Requirements ..................................................................................................... 6
4.2 Locking Bracket Installation in the Generation 1 Isolation Valve .................................. 7
4.3 Removal of Generation 1 Nozzle Assembly .................................................................. 7
4.4 Installation of Generation 2 Nozzle Assembly ............................................................... 9
Upgrade Options ......................................................................................... 3
2
Effective: May 1, 2014
Installation Instructions for
K-Patents SAFE-DRIVE
Process Refractometer PR-23-SD
Upgrade Kits
1 Background Information
K-Patents SAFE-DRIVE® Process Refractometer operators’ safety risk assessment in
2013 revealed that the biggest safety risk was neglecting the operating instructions. The
assessment results have been used for further improvement of the SAFE-DRIVE
safety in the following ways:
®
®
operators’
1. The SAFE-DRIVE
improve safety of their Refractometer and wash nozzle insertion and removal operations.
• The new safety features can be upgraded into the existing SAFE-DRIVE
Refractometers with an upgrade kit
2. Introducing two new easy-to-use guides: SAFE-DRIVE
Best Practice Guide
3. It is a recommended practice to never operate the SAFE-DRIVE
4. Offering training and certication to support the K-Patents SAFE-DRIVE
needs. The purpose is to ensure that the SAFE-DRIVE
by following the manufacturer’s installation instructions and specications, and to provide
safety instructions and hands-on training on the use of the SAFE-DRIVE
®
Refractometer design has been re-engineered to help operators
®
®
Pocket Guide and SAFE-DRIVE®
®
Retractor alone.
®
users’ training
®
Refractometer is installed correctly
®
Refractometer.
2 SAFE-DRIVE® Upgrade Options
2.1 SDR2-KIT for Isolation Valve and Retractor Tool
The SDR2-KIT consists of parts for upgrading the existing isolation valve to generation 2
SAFE-DRIVE
consisting of the inner and outer case), a PR-11026 locking bracket and operational and
safety guides.
®
using a locking bracket. The kit contains a new Retractor tool (complete kit
When multiple isolation valves are to be operated with the same Retractor tool, it is
recommended to specify and order one SDR2-KIT and additional Locking brackets PR11026 for each upgraded isolation valve.
It is recommended to dispose of the old Retractor Tool(s) to avoid its accidental use.
© Copyright K-Patents 2014. All rights reserved.
3
Model and Description
SDR2- KIT = Retractor upgrade kit to SDR2
Consisting of the following:
SDR2-23 = SAFE-DRIVE
PR-11026 = Locking bracket for SDI isolation valve
Complete with safety pin, Best Practice manual, Pocket
guide, laminated insertion/retraction guide, upgrade
installation instructions
Additional locking brackets
PR-11026 = Locking bracket for SDI isolation valve
®
Generation 2 RETRACTOR
Part No.
SDR2-KIT
SDR2-23
PR -1102 6
PR -1102 6
2.2 SN2-KIT for Prism Wash Nozzle for Steam
The SN2-KIT contains parts for upgrading steam wash nozzle with added safety features
during the insertion and removal operation. The kit contains operational and safety guides.
Model and Description
SN2-KIT = Steam wash upgrade to SN2
Consisting of the following:
PR-11023 = SDI2 Steam wash nozzle SN2
PR-11025 = Nozzle isolation valve assembly for SDI2
Complete with safety pin, Best Practice manual, Pocket
guide, laminated insertion/retraction guide, upgrade
installation instructions
Part No.
SN2-KIT
PR-11023
PR -1102 5
2.3 WP2-KIT for Prism Wash Nozzle for High Pressure
Water
The WP2-KIT contains parts for upgrading high pressure wash nozzle with added safety
features during the insertion and removal operation. The kit contains operational and
safety guides.
Model and Description
WP2-KIT = High pressure water upgrade kit to WP2
Consisting of the following:
PR-11024 = SDI2 High pressure water wash nozzle WP2
PR-11025 = Nozzle isolation valve assembly for SDI2
Complete with safety pin, Best Practice manual, Pocket
guide, laminated insertion/retraction guide, upgrade
installation instructions
Part No.
WP2-KIT
PR -11024
PR -1102 5
4
Effective: May 1, 2014
Installation Instructions for K-Patents SAFE-DRIVE® Process Refractometer PR-23-SD Upgrade Kits
3 Before Installation
3.1 Components Checklist
Before starting installation, make sure you have all the tools and components listed below.
1
4b
4a
4
2
3
3
Figure 1 System components included in K-Patents delivery
Retractor SDR2-23
1
Locking bracket PR-11026
2
2 pcs of Safety pin PR-11029
3
Wash nozzle assembly SN2-KIT or WP2-KIT
4
containing nozzle locking plate
4a
2 pcs of M5 bolt
4b
NOTE: If any of components are missing, contact your supplier before starting installation.
© Copyright K-Patents 2014. All rights reserved.
5
Figure 2 Installation equipment
Retractor inner casing Supplied by K- Patents
1
Retractor outer casing Supplied by K-Patents
2
Combination wrenches, 32 mm (1 pc), 14 mm (1 pc), 8 mm (1 pc)
3
Allen keys 8 mm (1 pc), 5 mm (1 pc), 4 mm (1 pc)
4
Torque wrench
5
open end tting 19 mm
5a
hex bit socket 8 mm
5b
Pliers
6
Thread seal tape
7
Pocket guide for insertion and retraction of sensor and wash
8
nozzle
Sensor insertion / removal instruction card Supplied by K- Patents
9
Product user manual Supplied by K- Patents
10
Supplied by K- Patents
6
Effective: May 1, 2014
Installation Instructions for K-Patents SAFE-DRIVE® Process Refractometer PR-23-SD Upgrade Kits
4 Installation
4.1 Safety Requirements
WARNING: The SAFE-DRIVE® Isolation valve SDI can only be upgraded during a shutdown
of the process line.
WARNING: Always shut down the main steam valve before performing any work on the
wash nozzle. Ensure process pipe is empty and not pressurized.
For more safety requirements, please see K-Patents Safety Instructions.
4.2 Locking Bracket Installation in the Generation 1
Isolation Valve
1. Remove top left bolt
2. Insert safety locking bracket according to Figure 3
3. Tighten all four bolts to 36Nm (26lb ft).
Figure 3 Locking bracket installed
4.3 Removal of Generation 1 Nozzle Assembly
WARNING: Always shut the main steam valve before performing any work on the wash
nozzle. Ensure process pipe is empty and not pressurized.
© Copyright K-Patents 2014. All rights reserved.
7
Figure 4 Removal of Gen 1 nozzle assembly
1. Close the steam connections
2. Detach the steam line
3. Open safety cover M5 Allen screw (1)
4. Detach the safety cover over the nozzle nut (2)
5. Remove three M5x8 screws (3, 4)
6. Remove nozzle guide plate (5)
7. Open the large nozzle nut (6)
Figure 5 Removal of Gen 1 nozzle asembly
8. Remove nozzle assembly.
8
Effective: May 1, 2014
Installation Instructions for K-Patents SAFE-DRIVE® Process Refractometer PR-23-SD Upgrade Kits
4.4 Installation of Generation 2 Nozzle Assembly
Figure 6 Installation of the wash nozzle
To re-install the wash nozzle assembly
1. Insert the wash nozzle assembly to its place (1). Tighten up 32 mm nozzle nut with a
combination wrench
2. Place the nozzle guide plate in the correct position and tighten the two (2) M5 bolts (2)
3. Secure the wash nozzle bolts with a locking plate (3, 4).
© Copyright K-Patents 2014. All rights reserved.
9
www.kpatents.com
K-Patents Oy
P.O. Box 77
FI-01511 Vantaa, Finland
Tel: +358 207 291 570
Fax: +358 207 291 577
Email: info@kpatents.com
K-Patents, Inc.
1804 Centre Point Circle, Suite 106
Naperville, IL 60563, USA
Tel: (630) 955 1545
Fax: (630) 955 1585
Email: info@kpatents-usa.com
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