Michell Instruments ES70 Operating Manual

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ES70

Sampling System

User’s Manual

97506 Issue 1

December 2017

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ES70

Sampling System

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www.michell.com

This document is the property of Michell Instruments Ltd. and may not be copied or

otherwise reproduced, communicated in any way to third parties, nor stored in any Data

Processing System without the express written authorization of Michell Instruments Ltd.

ES70 User’s Manual

Contents

Safety ................................................................................................................................vi

Electrical Safety ...........................................................................................................vi

Pressure Safety ............................................................................................................vi

Toxic Materials .............................................................................................................vi

Repair and Maintenance ...............................................................................................vi

Safety Conformity ........................................................................................................vi

Abbreviations .....................................................................................................................vii

Warnings ...........................................................................................................................vii

1 INTRODUCTION ............................................................................................VIII

1.1 Materials ......................................................................................................... viii

1.2 System Designs ................................................................................................ viii

1.3 Filtration and Fast Loop ....................................................................................... 1

1.4 Pressure / Flow Control and Measurement ........................................................... 1

1.5 Mounting Variants ............................................................................................. 1

1.6 Enclosure Environmental Control ........................................................................ 1

2 INSTALLATION ..................................................................................................2

2.1 Sampling System Installation ............................................................................... 2

2.1.1 Mounting Details ........................................................................................... 2

2.1.2 Gas Connections ........................................................................................... 2

2.1.3 Electrical Connections .................................................................................... 2

3 OPERATION ......................................................................................................3

3.1 Sampling Start-Up Procedure ............................................................................... 3

3.2 Sample Flow ‘Start-Up’ Procedure ........................................................................ 3

4 GOOD MEASUREMENT PRACTICE .......................................................................4

5 MAINTENANCE ..................................................................................................5

5.1 General Maintenance Guidelines .......................................................................... 5

5.2 Filter Element Maintenance ................................................................................. 5

5.2.1 Particulate Filter Maintenance ........................................................................ 5

5.2.2 Coalescing Filter Maintenance ........................................................................ 7

5.3 Transmitter Maintenance ..................................................................................... 9

Figures

Figure 1 Particulate Filter Maintenance 1 ...................................................................5

Figure 2 Particulate Filter Maintenance 2 ...................................................................6

Figure 3 Particulate Filter Maintenance 3 ...................................................................6

Figure 4 Particulate Filter Maintenance 4 ...................................................................6

Figure 5 Coalescing Filter Maintenance 1 ...................................................................7

Figure 6 Coalescing Filter Maintenance 2 ...................................................................7

Figure 7 Coalescing Filter Maintenance 3 ...................................................................8

Figure 8 Coalescing Filter Maintenance 4 ...................................................................8

Figure 9 Coalescing Filter Maintenance 5 ...................................................................8

Figure 11 Outdoor Enclosure Dimensions ..................................................................12

Figure 10 Indoor Panel Dimensions ..........................................................................12

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ES70 User’s Manual

Appendices

Appendix A Technical Speciﬁ cations .............................................................................. 11

Appendix B Quality, Recycling & Warranty Information ...................................................14

Appendix C Return Document & Decontamination Declaration ........................................ 16

Michell Instruments v

ES70 User’s Manual

Safety

The manufacturer has designed this equipment to be safe when operated using the procedures detailed in this manual. The user must not use this equipment for any other purpose than that stated. Do not apply values greater than the maximum value stated.

This manual contains operating and safety instructions, which must be followed to ensure the safe operation and to maintain the equipment in a safe condition. The safety instructions are either warnings or cautions issued to protect the user and the equipment from injury or damage. Use competent personnel using good engineering practice for all procedures in this manual.

Electrical Safety

The instrument is designed to be completely safe when used with options and accessories supplied by the manufacturer for use with the instrument.

Pressure Safety

DO NOT permit pressures greater than the safe working pressure to be applied to the instrument. Refer to Appendix A, Technical Speciﬁ cations.

Toxic Materials

The use of hazardous materials in the construction of this instrument has been minimized. During normal operation it is not possible for the user to come into contact with any hazardous substance which might be employed in the construction of the instrument. Care should, however, be exercised during maintenance and the disposal of certain parts.

Repair and Maintenance

The instrument must be maintained either by the manufacturer or an accredited service agent. Refer to www.michell.com for details of Michell Instruments’ worldwide ofﬁ ces contact information.

Safety Conformity

This product meets the essential protection requirements of the relevant EU directives.

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ES70 User’s Manual

Abbreviations

The following abbreviations are used in this manual:

AC alternating current

barg pressure unit (=100 kP or 0.987 atm)

ºC degrees Celsius

ºF degrees Fahrenheit

DC direct current

dp dew point

Hz Hertz

kg kilogram(s)

lb pound

Nl/min normal liters per minute

mA milliampere

max maximum

min minute(s)

% percentage

psig pounds per square inch

scfh standard cubic feet per hour

temp temperature

V Volts

W Watts

Ω Ohms

Warnings

The following general warning listed below is applicable to this instrument. It is repeated in the text in the appropriate locations.

Where this hazard warning symbol appears in the following

sections it is used to indicate areas where potentially hazardous

operations need to be carried out.

Michell Instruments vii

INTRODUCTION

1 INTRODUCTION

Michell Instruments designs and manufactures a broad range of sampling systems for a wide spectrum of industries and processes from the economical compressed air market to the oil and gas process market.

Sample extraction, handling and conditioning techniques are of critical importance to assure optimal performance and reliability of all analysers which accurately quantify speciﬁ c components within a process gas or liquid composition. With a wide variety of options required for pressure and ﬂ ow control, ﬁ ltration, isolation and sample temperature control it can be difﬁ cult to see what is really required to get maximum performance from your analysers in any given application.

The ES70 series is designed to simplify sample system conﬁ guration by providing a set of choices for all requirements, such as panel or enclosure mount, ﬁ ltering, upstream and downstream pressure and ﬂ ow control etc. This provides a quick and simple method to choose all the required components suitable for the application requirements.

1.1 Materials

ES70 User’s Manual

To ensure continuous and reliable dew-point or moisture measurement it is important that the dew-point transmitter is exposed to stable conditions of the gas to be monitored.

The ES70 systems utilizes high quality materials which ensure that the sample gas travels smoothly through the system.

Gas wetted parts:

• Stainless steel tube, ﬁ lter housing and ﬁ ttings (316 stainless steel)

• Filter element (oleo-phobic membrane or stainless steel mesh)

• Single- or dual-stage pressure reduction

• Transmitter sample block (316 stainless steel)

• Flowmeter (borosilicate glass) with Viton® seals or high-pressure rated armored type

1.2 System Designs

Our sampling system designs ensure that dew-point and moisture measurements can be performed in the most suitable conditions. The ES70 sampling systems can be supplied in various conﬁ gurations and are designed to be used in conjunction with other Michell products, as follows:

• Easidew PRO XP Transmitter

• Easidew PRO I.S. Transmitter (with or without display)

• Promet I.S. (with or without pressure transmitter)

• Liquidew I.S.

Process connections are available with either 6mm or 1/4” tube ﬁ ttings.

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ES70 User’s Manual

1.3 Filtration and Fast Loop

If the sample contains impurities it is crucial to remove the contaminants before they reach the sensing device. A fast-loop bypass ﬂ ow arrangement can also be included to reduce sample ﬂ ow response time lag and to enable the ﬁ lter to be drained automatically of any potential hydrocarbon liquids and hydrates formed. The ES70 system can be supplied with various ﬁ ltration and fast loop options;

• Particulate Filter: 5 micron Stainless Steel Mesh

• Coalescing Filter with manual drain

• Combined coalescing/oleophobic membrane with continuous drain ﬂ ow (fast loop) - with Single Stage Regulation & Glass tube (20 barg rated) or Armoured ﬂ ow meter (138 barg rated) with integral ﬂ ow metering valve.

• Combined coalescing/oleophobic membrane with continuous drain ﬂ ow (fast loop) - with Two Stage Regulation & Armoured ﬂ ow meter (138 barg rated) with integral ﬂ ow metering valve

INTRODUCTION

1.4 Pressure / Flow Control and Measurement

Various options are available for management of pressure and ﬂ ow within the sampling system;

• Upstream and Downstream, single stage or two stage pressure regulation, with a choice of gauges.

• Downstream ﬂ ow metering with a choice of glass tube or armoured ﬂ ow meters.

1.5 Mounting Variants

Depending on the application the sampling system can be supplied in 3 variations:

• Mounted on an open panel for indoor systems

• Mounted in an Outdoor Enclosure, IP66/NEMA4X rated, with window, 304 grade stainless steel

• Mounted in an Outdoor Enclosure, IP66/NEMA4X rated, with window, 316 grade stainless steel

1.6 Enclosure Environmental Control

Sampling systems ﬁ tted within enclosures may need heating to maintain a constant temperature environment of at least 10oC above the highest envisaged dew point temperature independent of surrounding temperature variations. Similarly, the enclosure may require cooling when ambient temperatures rise in summer months.

• Electrical heating with a choice of 20°C or 40°C set-point thermostats.

• Vortex Cooling with thermostat control (instrument air required) recommended for climates exceeding 45°C.

• Trace heated sample tubing is available as a factory supplied option.

Michell Instruments 1

INSTALLATION

2 INSTALLATION

2.1 Sampling System Installation

It is essential that the connection of electrical and gas supplies

to this instrument be undertaken by competent personnel.

Relevant sections of this manual must be read in full before

commencing measurement (see below).

ES70 User’s Manual

2.1.1 Mounting Details

The ES70 base plate or enclosure is designed to be wall-mounted. It should be rigidly mounted vertically in a position free from high vibration levels and shaded from direct sunlight.

Dimensional drawings are shown in Appendix A

2.1.2 Gas Connections

Gas connections to the ES70 are via 6mm or ¼” Swagelok® tube ﬁ ttings located at the base of the mounting plate or enclosure.

Connections are marked as follows:

GAS IN Sample gas entry point with a maximum supply pressure of 138 barg (2,000spig)

GAS OUT Sample gas exit point for connection to atmospheric vent or ﬂ are (up to maximum 3 barg)

Care must be taken to ensure that the outlet isolation valve is

not fully closed.

2.1.3 Electrical Connections

All cables to or from the sampling system should go through the M20 plastic cable gland provided at the base of the enclosure.

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ES70 User’s Manual

3 OPERATION

3.1 Sampling Start-Up Procedure

The ES70 sampling system is designed for continuous operation.

Immediately after the power is applied, the dew-point transmitter will begin operation and all output signals will be live.

It is essential that the connection of electrical and gas supplies

to this instrument be undertaken by competent personnel.

Relevant sections of this manual must be read in full before

commencing measurement (see below).

OPERATION

3.2 Sample Flow ‘Start-Up’ Procedure

Refer to 'As Built' drawings for actual pressure and ﬂ ow values.

Proceed as follows:

1. Ensure the outlet isolation valve is fully CLOSED.

2. Open the inlet isolation valve slowly, making sure that the pressure indicated on the pressure gauge does not exceed the maximum operational

pressure. If achievable, ensure that the inlet isolation valve is fully OPEN.

3. Adjust the outlet isolation valve, setting the sample gas ﬂ ow rate to the value shown on the system ﬂ ow diagram.

4. Allow the sample gas to purge the system for the period of time indicated in the Good Measurement Practice Section (Stabilization Times).

Michell Instruments 3

GOOD MEASUREMENT PRACTICE

4 GOOD MEASUREMENT PRACTICE

The ES70 is designed to operate in a ﬂ owing gas stream and is suitable for the measurement of the moisture content of a wide variety of gases. In general, if the gas (in conjunction with water vapor) is not corrosive to ceramics or base metals then it will be suitable for measurement by the ES70.

The system is designed for operation with sample gas ﬂ ow rates of 1-5 Nl/min (sample block). Ideally, the ﬂ ow rate should be set-up between 4 and 6 Nl/min. Flow regulation is provided within the ES70. Always use high quality valve gear, coupling connections and pipework.

The system will operate successfully at ﬂ ow rates within its operational range and it is important to ensure that the ﬂ ow rate through the sample block is high enough to avoid long time lags in response to humidity changes at the sample source.

Avoid pressure gradients in the system by placing excessive ﬂ ow restriction on the output side of the sample block. In applications where the test gas has a very high ﬂ ow rate, an instrument by-pass arrangement is preferable to ﬂ ow restriction after the transmitter.

ES70 User’s Manual

Flow Rates

Theoretically ﬂ ow rate has no direct effect on the measured moisture content, but in practice it can have unanticipated effects on response speed and accuracy. The optimal ﬂ ow rate varies depending on the measurement technology, and can always be found in the instrument or sensor manual.

An inadequate ﬂ ow rate can:

• Accentuate adsorption and desorption effects on the gas passing through the sampling system.

• Allow pockets of wet gas to remain undisturbed in a complex sampling system, which will then gradually be released into the sample ﬂ ow.

• Increase the chance of contamination from back diffusion: ambient air that is wetter than the sample can ﬂ ow from the exhaust back into the system. A longer exhaust (sometimes called a pigtail) can also help alleviate this problem.

• Slow the response of the sensor to changes in moisture content.

An excessively high ﬂ ow rate can:

• Introduce back pressure, causing slower response times potential changes in expected dew point.

Stabilization Times

Ensure that the system has sufﬁ cient time to stabilize before taking any readings. Typically the system should be allowed at least 24hrs to stabilize, but for measurements below -60°C dew point, up to 5 days should be allowed for the system to reach total equilibrium with the sample, given the very low moisture contents involved.

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ES70 User’s Manual

5 MAINTENANCE

5.1 General Maintenance Guidelines

Routine maintenance of the sampling system is conﬁ ned to ﬁ lter element replacement and regular recalibration of the dew-point transmitter.

5.2 Filter Element Maintenance

The composition of the gas determines the frequency of the ﬁ lter element replacement, i.e. liquid and particulate contaminates, corrosive elements etc.

A disposable ﬁ lter element continues to ﬁ lter at its original efﬁ ciency as long as it is kept in service. The life of the element is determined by the increase in ﬂ ow resistance caused by trapped solids in the element. The element should be changed when the ﬂ ow falls below an acceptable level, or the pressure drop becomes too high. In any case the element should be replaced before the pressure drop across it reaches 0.7 barg (10.2 psig). The disposable ﬁ lter elements cannot be cleaned as the solids are trapped within the depth of the element not on the surface.

MAINTENANCE

5.2.1 Particulate Filter Maintenance

To replace the particulate ﬁ lter element proceed as follows:

1. Isolate any gas supplies to the sampling system.

NOTE: Wear protective gloves when handling the ﬁ lter housing.

2. Remove the bowl (1,2), element retainer (3) and ﬁ lter element (4).

Figure 1

Particulate Filter Maintenance 1

NOTE: In order to untighten the bowl a spanner/wrench may be needed.

Michell Instruments 5

MAINTENANCE

ES70 User’s Manual

Figure 2

Disposable and sintered PTFE ﬁ lter elements are sealed by compression against a ﬂ at surface (5). Gaskets are not required between the ﬁ lter element and components of the housing. The element is located by guides which ﬁ t the inside diameter of the tube at each end.

Figure 3

The ﬁ lter tube is securely sealed by tightening the element retainer a 1/4 to 1 turn after it ﬁ rst contacts the ﬁ lter element, the amount will depend on the housing type and element size. A mark on the end of the retainer is used as a guide.

3. Before replacing the housing bowl ensure that the mating threads and sealing faces are clean and damage free. It is recommended that the threads and sealing faces are lubricated with a small amount of silicone grease before assembly.

Particulate Filter Maintenance 2

Particulate Filter Maintenance 3

4. Re-connect the tube with its ﬁ tting to its original conﬁ guration.

Figure 4

5. Resume normal system operation by opening up the gas supplies to the sampling system as described in the relevant section of the Start-up Procedures (Section 3).

Particulate Filter Maintenance 4

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ES70 User’s Manual

5.2.2 Coalescing Filter Maintenance

To replace the coalescing ﬁ lter element proceed as follows:

1. Isolate any gas supplies to the sampling system.

NOTE: Wear protective gloves when handling the ﬁ lter housing.

2. Unscrew the couplings (1 and 2) on the picture below

MAINTENANCE

2 3

Figure 5

3. Disconnect the tube with its ﬁ tting (3).

4. Remove the bowl (1,2), element retainer (3) and ﬁ lter element (4).

Figure 6

Coalescing Filter Maintenance 1

Coalescing Filter Maintenance 2

NOTE: In order to untighten the bowl a spanner/wrench may be needed.

Michell Instruments 7

MAINTENANCE

ES70 User’s Manual

Figure 7

Figure 8

5. Before replacing the housing bowl ensure that the mating threads and sealing faces are clean and damage free. It is recommended that the threads and sealing faces are lubricated with a small amount of silicone grease before assembly.

Coalescing Filter Maintenance 3

Coalescing Filter Maintenance 4

6. Re-connect the tube with its ﬁ tting to its original conﬁ guration.

Figure 9

7. Resume normal system operation by opening up the gas supplies to the sampling system as described in the relevant section of the Start-up Procedures (Section 3).

Coalescing Filter Maintenance 5

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ES70 User’s Manual

5.3 Transmitter Maintenance

Calibration

Routine maintenance of the Easidew transmitter is conﬁ ned to regular re-calibration by exposure of the Easidew to sample gases of known moisture content to ensure that the stated accuracy of the Easidew is maintained. Calibration services traceable to the UK National Physical Laboratory (NPL) and the US National Institute of Standards and Technology (NIST) are provided by Michell Instruments.

Michell Instruments offers a variety of re-calibration and exchange sensor schemes to suit speciﬁ c needs. A Michell representative can provide detailed, custom advice (for Michell Instruments’ contact information go to www.michell.com).

Transmitter replacement

The composition of the gas determines the frequency of the transmitter replacement, i.e. liquid and particulate contaminates, corrosive elements, etc.

It is recommended that the transmitter is changed on an annual basis to maintain the accuracy of the system.

MAINTENANCE

Michell Instruments can provide an exchange transmitter. Prior to recalibration being necessary, an exchange transmitter can be ordered from Michell Instruments or any authorized dealer. Once the transmitter and calibration certiﬁ cate have been received it can be ﬁ tted and the original transmitter returned to Michell Instruments.

To replace the transmitter, proceed as follows:

1. Isolate the sampling system from the sample gas supply and switch off all electrical supplies.

2. Disconnect the wiring from the transmitter and the sample tubes from the sample block. Remove the transmitter and sample block from the sampling system.

3. Remove the sample block from the transmitter.

4. Fit a new/recalibrated transmitter ensuring the bonded seal is positioned between the transmitter and the sample block.

5. Reﬁ t the transmitter and sample block to the sampling system and reconnect the sample tubes and transmitter cable (see Sample Block Section of the Easidew PRO XP Manual 97442).

6. Resume normal system operation by opening up the gas supplies to the sampling system in accordance with the relevant section of the Start-up Procedures (Section 3).

Michell Instruments 9

APPENDIX A

ES70 User’s Manual

Appendix A

Technical Speciﬁ cations

10 97506 Issue 1, December 2017

ES70 User’s Manual

APPENDIX A

Appendix A Technical Speciﬁ cations

Operating Speciﬁ cations

Operating Temperature -15 to +60°C (+5 to +140°F)

Operating Inlet Pressure Up to 138 barg dependent on conﬁ guration

Flow Rate 1 to 5 Nl/min (2.1 to 10.6 scfh)

Mechanical Speciﬁ cations

Process Connection and Material Inlet/outlet connections via 6mm or ¼” stainless

steel ﬁ ttings, 316 stainless steel Stainless steel tube, ﬁ lter housing and ﬁ ttings (316

Gas Wetted Parts

Ingress Protection

Indoor

Outdoor

Dimensions

Indoor base plate

Outdoor SS enclosure

Pressure and Flow Control Via isolation valves, pressure gauge and ﬂ owmeter

Gas Filtration

stainless steel), Filter element, Transmitter sample block (316 stainless steel), Flowmeter (borosilicate glass) with Viton® seals

No protection (base plate only) IP66, NEMA 4X

750 x 750 x 2mm (29.5 x 29.5 x 0.07") (h x w x d) 800 x 800 x 300mm (31.4 x 31.4 x 11.8") (h x w x d)

Particulate Filter: 5 micron stainless steel mesh or Combined coalescing/oleophobic ﬁ lter

Michell Instruments 11

APPENDIX A

Dimensions

Indoor

750 29.5"

770 30.3"

ES70 User’s Manual

750 29.5"

700 27.6"

Outdoor

838 33"

800 31.5"

Figure 10

800 31.5"

758 29.8"

Indoor Panel Dimensions

300 11.8"

Figure 11

Outdoor Enclosure Dimensions

12 97506 Issue 1, December 2017

ES70 User’s Manual

APPENDIX B

Appendix B

Quality, Recycling

& Warranty

Information

Michell Instruments 13

APPENDIX B

ES70 User’s Manual

Appendix B Quality, Recycling & Warranty Information

Michell Instruments is dedicated to complying to all relevant legislation and directives. Full information can be found on our website at:

www.michell.com/compliance

This page contains information on the following directives:

• ATEX Directive

• Calibration Facilities

• Conﬂ ict Minerals

• FCC Statement

• Manufacturing Quality

• Modern Slavery Statement

• Pressure Equipment Directive

• REACH

• RoHS2

• WEEE2

• Recycling Policy

• Warranty and Returns

This information is also available in PDF format.

14 97506 Issue 1, December 2017

ES70 User’s Manual

APPENDIX C

Appendix C

Return Document

Decontamination Declaration

Michell Instruments 15

APPENDIX C

ES70 User’s Manual

Appendix C Return Document & Decontamination Declaration

'HFRQWDPLQDWLRQ&HUWL¿FDWH

IMPORTANT NOTE: Please complete this form prior to this instrument, or any components, leaving your site and being returned to us, or, where applicable, prior to any work being carried out by a Michell engineer at your site.

Instrument Serial Number Warranty Repair? YES NO Original PO # Company Name Contact Name

Address

Telephone # E-mail address Reason for Return /Description of Fault:

Has this equipment been exposed (internally or externally) to any of the following? Please circle (YES/NO) as applicable and provide details below

Biohazards YES NO Biological agents YES NO Hazardous chemicals YES NO Radioactive substances YES NO Other hazards YES NO Please provide details of any hazardous materials used with this equipment as indicated above (use continuation sheet

if necessary)

Your method of cleaning/decontamination

Has the equipment been cleaned and decontaminated? YES NOT NECESSARY Michell Instruments will not accept instruments that have been exposed to toxins, radio-activity or bio-hazardous

PDWHULDOV)RUPRVWDSSOLFDWLRQVLQYROYLQJVROYHQWVDFLGLF EDVLFÀDPPDEOHRUWR[LFJDVHVDVLPSOHSXUJHZLWK GU\ JDVGHZSRLQW&RYHUKRXUVVKRXOGEHVXI¿FLHQWWRGHFRQWDPLQDWHWKHXQLWSULRUWRUHWXUQ

Work will not be carried out on any unit that does not have a completed decontamination declaration.

Decontamination Declaration

I declare that the information above is true and complete to the best of my knowledge, and it is safe for Michell personnel to service or repair the returned instrument.

Name (Print) Position

Signature Date

F0121, Issue 2, December 2011

16 97506 Issue 1, December 2017

NOTES:

http://www.michell.com

Michell Instruments ES70 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual