Yokogawa Advanced Reflux Sampler User Manual

Operating & Maintenance

Advance Reux Sampler

Manual

YARS100-SAA

Yokogawa Corporation of America 2 Dart Road, Newnan, Georgia U.S.A. 30265 Tel: 1-800-258-2552 Fax: 1-770-254-0928

IM 11A00V01-01E-A

©Copyright January 2011

1st Edition

The following safety symbols are used on the product as well as in this manual.

DANGER

This symbol indicates that an operator must follow the instructions laid out in this manual in order to avoid the risks, for the human body, of injury, electric shock or fatalities. The manual describes what special care the operator must take to avoid such risks.

WARNING

This symbol indicates that an operator must refer to the instructions in this manual in order to prevent the instrument (hardware) or software from being damaged, or a system failure from occurring.

This symbol gives information essential for understanding the operations and functions.

CAUTION

NOTE

This symbol indicates information that complements the present topic.

Operating and Maintenance Manual

1. Introduction ........................................................................................................... 4

1.1 Features ................................................................................................. 4

2. General Specications .......................................................................................... 5

3. Theory of Operation ............................................................................................... 6

3.1 Brief History of Reux Samplers .......................................................... 6

3.2 Filter Section ......................................................................................... 6

3.3 Steam Supplement ............................................................................... 6

3.4 Inlet Temperature Section ..................................................................... 6

3.5 Heat Exchanger Section .................................................................... 6-7

3.6 Outlet Temperature Section ................................................................. 7

3.7 Self Acting Temperature Controller ...................................................... 7

3.8 Instrument Air for the Vortex Tube ....................................................... 7

3.9 Vortex Theory of Operation .................................................................. 7

4. Utility Requirements .............................................................................................. 8

4.1 Instrument Air ........................................................................................ 8

4.2 Low Pressure Steam ............................................................................ 8

5. Installation ............................................................................................................. 9

5.1 Mechanical Considerations .................................................................. 9

5.2 Fast Loop Line Size and Response Times .......................................... 9

5.3 Insulation ............................................................................................................. 9

6. Start-Up ............................................................................................................... 10

7. Operation ............................................................................................................. 10

7.1 Vortex Tubes ........................................................................................ 10

7.2 Steam Injection ................................................................................... 10

7.3 Controller ............................................................................................. 10

8. Maintenance ........................................................................................................ 11

8.1 Filter Section and/or Heat Exchanger Cleaning ................................ 11

8.1.1 Heat Exchanger Filter Mesh ............................................................ 11

9. Trouble Shooting .................................................................................................. 11

9.1 Vortex Tubes ........................................................................................ 11

10. Sub-Component Documentation ...................................................................... 12

10.1 Compressed air Line size ................................................................. 12

10.1.1 Compressed air Supply ........................................................ 12

10.1.2 Setting the Vortex Tube ......................................................... 12

10.1.3 Troubleshooting and Maintenance ....................................... 12

10.2 Installation and Maintenance for Control Valves ........................................... 13

10.2.1 General Safety Information ........................................................... 13

10.2.1.1 Warning-Laminated gaskets .......................................... 13

10.2.1.2 Isolation ........................................................................... 13

10.2.1.3 Pressure .......................................................................... 13

10.2.1.4 Temperature .................................................................... 13

10.2.1.5 Disposal ........................................................................... 13

10.2.2 Installation and Commissioning .................................................... 13

10.3 Supplement Safety Information ...................................................................... 14

10.3.1 Hazardous Liquids or Gases in the Pipeline ................................ 14

10.3.2 Hazardous Environment around the Product............................... 14

10.3.3 The System. ................................................................................... 14

10.3.4 Pressure Systems .......................................................................... 14

10.3.5 Temperature ................................................................................... 14

10.3.6 Tools and Consumables ................................................................ 15

10.3.7 Protective Clothing ........................................................................ 15

10.3.8 Permits to Work ............................................................................. 15

10.3.9 Handling ......................................................................................... 15

10.3.10 Residual Hazards ......................................................................... 15

10.3.11 Freezing ........................................................................................ 15

10.3.12 Disposal ....................................................................................... 15

10.3.13 Returning Products ..................................................................... 15

10.4 Installation and Maintenance Instructions for

Temperature Control Valve Systems ............................................................. 15

10.4.1 Safety Information ......................................................................... 15

10.4.2 Installation. ..................................................................................... 16

10.4.3 Display Adjustment ........................................................................ 17

10.4.4 Commissioning .............................................................................. 17

10.5 Supplement Safety Information, Installation and Maintenance Instructions for AS Temperature

Control Valve Systems .................................................................................. 18

10.5.1 Intended Use .................................................................................. 18

10.5.2 Access ............................................................................................ 18

10.5.3 Lighting ........................................................................................... 18

10.5.4 Hazardous Liquids or Gases in the Pipeline ................................ 18

10.5.5 Hazardous Environment around the Product............................... 18

10.5.6 The System .................................................................................... 18

10.5.7 Pressure Systems .......................................................................... 19

10.5.8 Temperature ................................................................................... 19

10.5.9 Tools and Consumables ................................................................ 19

10.5.10 Protective Clothing ...................................................................... 19

10.5.11 Permits to Work ........................................................................... 19

10.5.12 Handling ....................................................................................... 19

10.5.13 Residual Hazards ......................................................................... 19

10.5.14 Freezing ........................................................................................ 19

10.5.15 Disposal. ...................................................................................... 19

10.5.16 Returning Products ..................................................................... 19

11. Dimensional Drawings .................................................................................20-22

1. INTRODUCTION

Overview

The Advanced Reux Sampler (YARS100) has been developed specically to meet the needs of modern petrochemical analyzer sampling, especially ethylene cracked gas euents.

1.1 Features

Based on a proven simpler concept, the YARS includes several technologically advanced features outlined below:

• Self-acting temperature controller requiring no electrical power supply – Adjustable across the selected control range.

• Dual 360o cooling coils section ensures optimal sample cooling

• Outlet lter mesh/screen for mist trap to deter liquid carry over

• Sample outlet over temperature shut-o valve – Factory set for a pre-determined shut-o temperature and

typically with a 10oF span between fully open and fully closed.

• Enhanced, high stability temperature control system design

• High sample ow rate 3-5 liters per minute for reduced lag time

• A multitude of options congured specically for your application

SAFETY should be considered rst and foremost importance when working on the equipment described in this manual. All persons using this manual in conjunction with the equipment must evaluate all aspects of the task for potential risks, hazards and dangerous situations that may exist or potentially exist. Please take appropriate action to prevent ALL POTENTIAL ACCIDENTS.

CAUTION

2. GENERIC SPECIFICATIONS

Product development is a continuous policy of Yokogawa and therefore specications may be subject to change without

notice

The following generic specications apply however; please check exact features and model number with serial numbers

on the units provided.

A) Process Connection:

Process ange ratings are ASME B16.6-1996

B) Sample Outlet Connection:

Standard 3/8” o.d. Sawgelock® stainless steel

Flow Rate: Typically 3 Lts./min conditioned at 15°C or 4 Lts./min conditioned at 20°C, pending application

Pressure: ΔP across ARS, < 1psi

NOTE

The sample transport line should be heat traced and insulated to prevent subsequent sample condensation.

C) Mounting:

Vertical on top of customer supplied process isolation valve for horizontal process line.

NOTE

If mounting on vertical process line, install appropriate elbow or Y-piece prior to process isolation valve to ensure ARS mounted in vertical position – Refer to Installation details.

D) Instrument Air Connection:

Standard 1/2” o.d. Sawgelock®, stainless steel

Supply Pressure: 60-110 psig (~ 54-7.5 Bar)

Flow Rate: Dual 10 SCFM Vortex Tubes: Standard

Dual 15 SCFM Vortex Tubes: Optional

Grade: Clean, Dry, Oil Free and <5μ particles with

–40oC dew point and ISA grade HC free

E) Steam Supplement Connection: Filter Section

Standard ¼” o.d. Sawgelock®, stainless steel

Pressure: 50-150 psig

Temperature: maximum 238oC

F) Materials of Construction:

Lower lter section: 316 stainless steel

Lower lter mesh: 316 stainless steel knitted, 0.011”

diameter wire

Inlet temperature section: 316 stainless steel

Heat Exchanger: 316 stainless steel

G) Electrical Power supply:

Not Required

H) Self Acting Controller:

Adjustable set-point indicating dial

316 Stainless steel sample wetted parts

Brass body air control valve, high CV

Highly reliable with practically no moving parts

I) Shipping Details

Size: Approximately 56 in (1422 mm) H x 24 in (609 mm) W x 12 in (304 mm)D

Weight: Approximately 110 lbs (49.8 kg) without optional equipment

3. THEORY OF OPERATION

This section of the manual describes the basic theory of operation, designed to give the user a better understanding and help in operation and maintenance.

3.1 Brief History of Reux Samplers

The concept of the Reux Sampler was introduced in mid 1970’s and until the inception of the Advanced Reux Sampler (YARS), it had changed very little. Process analysis needs during the mid 1970’s were not as critical as they are now and consequently, the Reux Samplers designed previously no longer meet today’s demands that are more stringent. The reux sampler was originally designed to overcome the problem of constantly plugging sample probes installed on the Transfer Line Exchangers (TLE) of ethylene cracking furnace euents. This high temperature cracked gas euent is high

in particulate and condensables (moisture and heavy hydrocarbons) content and therefore prone to plugging. The idea

that the condensables could be used to backwash a particulate lter was conceived and a Reux Sampler was then developed. A simple lter mesh was used to trap the particulate matter.

3.2 Filter Section

The lower section of the YARS is for particulate ltration and provides some primary sample cooling. Typically ange mounted directly to a customer supplied process isolation valve and ange mounted to the heat exchanger section of the YARS. The lter media is nominally stainless steel wire mesh that traps any particulate matter such as coke from the ethylene furnaces and/or catalyst nes. During normal operation, the temperature at the lter section outlet should be

in the order of 120oF (50oC), indicating a balanced reuxing condition is established. This lter section is cooled by the

condensate that has dropped out from the heat exchanger mounted directly above the lter. The condensate also acts as a trap for ner particulate matter. In certain environmental conditions where sub-zero temperatures are anticipated, it may be desirable to insulate the lter section. This will prevent premature condensing and allow for a balanced reuxing action.

3.3 Steam Supplement

For the YARS to function reliably there must be sucient quantity of condensable media in the sample. For applications that have high particle loading and limited condensables present, steam should be added at the inlet. The YARS lter section has a steam inlet facility located at the inlet. A suitably rated needle valve is provided for regulating a nominal ow of steam in to the lter section via an inverted tube such that the steam is directed up in to the lters. Note that the steam is added directly to the sample and therefore the composition will be aected the H2O addition. As each application has many dierent operating parameters, there are no specic settings for the quantity of steam addition and each application

is set-up individually.

3.4 Inlet Temperature Section

Mounted between the lter and heat exchanger section is the inlet temperature thermowell. As standard, a suitable

temperature gauge is installed in the thermowell. The purpose of temperature measurement at this point in the YARS is

to help establish the correct temperature gradient required for reuxing. The two undesirable conditions within the ler

section are as below:

• Temperature reading too high – will cause the heat exchanger to work excessively and indicates a problem elsewhere in the system

• Temperature reading too low – will cause the condensable media to dropout early in the lter section and not provide proper lter cleansing by reux.

When troubleshooting the YARS, consider the correct temperature at this point.

3.5 Heat Exchanger Section

This is truly unique to the YARS in many respects. This section provides the cooling of the sample and is most critical to

the overall operation. As the sample gas rises from the lter section, through the inlet temperature section, it is channeled

in to the heat exchanger chamber. The sample gas rises through a chamber in which the cooling coils are concentrically mounted. The design of the heat exchanger is such that maximum surface area contact between the cooling coils and

the sample gas is achieved. There are two cooling coils located in the same heat exchanger chamber, which helps

provide more accurate and ecient cooling. In the head-space of the heat exchanger, a stainless steel ne lter mesh is installed to act as a mist trap and nal liquid sample droplet trap prior to existing the sampler. Flow of the cooling media

through each coil is automatically controlled to ensure a constant outlet temperature is maintained. The sample is normally saturated at the outlet temperature and pressure. The cooling media is supplied by vortex air cooler(s) via the self-acting controller.

3.6 Outlet Temperature Section

Located on the outlet of the heat exchanger is the outlet temperature indicator. For self-acting controller units, a temperature sensor is installed. The self-acting temperature controller is located (screwed) directly in to the top of the heat exchanger in to the headspace area. This provides the most accurate temperature reading and control of the actual

sample outlet temperature. The purpose of temperature measurement at this point in the YARS is to control the nal outlet

temperature (or maximum dewpoint). Depending upon the application, this outlet temperature may be typically between 41-80oF (5-27oC).

3.7 Self Acting Temperature Controller

The operation and maintenance of the adjustable self-acting temperature controller is described herein.

3.8 Instrument Air for the Vortex Tube

The standard media used by the Vortex air tube(s) is ISA grade Instrument air. It is possible to change the cool air outlet temperature by adjusting the recessed screw (needle valve) located in the hot air exhaust. A counter-clockwise adjustment of the valve will produce colder temperatures while a clockwise adjustment will produce warmer temperatures.

This ability to adjust the temperature may be considered when ne-tuning the temperature control system to ensure

optimum temperature stability. The performance of the Vortex tubes is also based on the incoming instrument air

temperature. For more ecient operation, avoid direct sun light (and other heat emitting sources) when running the air line.

3.9 Vortex Theory of Operation:

Vortex tubes are simple devices that contain no moving parts and therefore may be used as a reliable device for generating a cold air supply. Compressed air (clean, dry, ISA Grade) will enter the cylindrical chamber (to the left of the diagram) and is caused to rotate internally. This rotating air moves down the inner walls of the hot air exhaust chamber at extremely high velocity. When exiting the hot exhaust (to the top of the diagram), a portion of the air is directed back through the center at lower speed than the exiting air. Heat transfer from the inner, slow moving air to the exiting, fast moving air causes cold air to be generated. This cold air exits via the cold air exhaust (shown at the bottom of the diagram).

Vortex tubes produce less air ow at colder temperatures and have less

BTUH capacity. Tubes are available in a variety of sizes depending upon

the application. Maximum eciency will be achieved when operating

at 100 psig instrument air pressure and while they can operate at lower

pressure, the eciency will be less (typically 60% ecient at 55 psig)

4. UTILITY REQUIREMENTS

Section 2 – General Specication listed above denes the required utilities needed for YARS operation. Also, refer to the General Installation drawing provided specically for the YARS by serial number for the hook-up details.

4.1 Instrument Air

The media used by the Vortex air tube(s) is ISA grade Instrument air. Plant Nitrogen may be used in place of the air,

provided it meets the required pressure and ow demands of the YARS. The air shall be clean, dry (-40oC dew point), oil free and contain particles <5µ. The instrument air pressure at the YARS shall be 60-100 psig (~ 4-7 Barg). Failure to use a lter will cause potential freezing and clogging of the compressed air path inside the Vortex Tube. Filter elements

must be changed on a regular basis. Frequency of change is determined by the conditions of the compressed air supply.

At pressure less than this, the Vortex tube performance declines signicantly and may be unable to provide the required quantity of cooling air. Any instrument air-line run to the YARS in the eld should be 1/2” o.d. to ensure adequate ow at

the desired pressure.

Electronically controlled samplers use two vortex tubes, each typically with a 4 SCFM ow capacity (Check Data Sheets

for your installed model) however, the actual air demand during normal operation will vary depending on the changing process and climatic conditions at each site.

CAUTION

• COMPRESSED AIR COULD CAUSE DEATH, BLINDNESS OR INJURY

• DO NOT OPERATE A VORTEX TUBE AT AIR PRESSURES ABOVE150PSIG (10.3 BARG)

• DO NOT OPERATE A VORTEX TUBE AT LINE TEMPERATURES ABOVE 110OF (43OC)

• AVOID DIRECT CONTACT WITH COMPRESSED AIR

• DO NOT DIRECT COMPRESSED AIR AT ANY PERSON

• WHEN USING COMPRESSED AIR, WEAR SAFETY GLASSES AND SIDE SHIELDS

The performance of the Vortex tubes is also based on the incoming instrument air temperature and therefore, for more

ecient operation, avoid direct sun light (and other heat emitting sources) when running the air-line.

4.2 Low Pressure Steam

The sampler is equipped with low-pressure steam injection valve located in the lower lter section. Steam may be used either as an addition at the inlet (for assisted reux action), or for cleansing through either the inlet or outlet.

NOTE

Do not use steam temperatures in excess of 232oC (450oF).

Ensure the needle valves are closed prior to connecting the steam supply and ensure the steam supply line is adequately insulated. Connect the steam supply directly to the needle valve supplied with the sampler.

NOTE

WHEN OPERATING WITH STEAM, NOTE THAT SURFACES MAY BE EXTREMELY HOT AND CAN CAUSE SEVERE BURNS AND OTHER PERSONAL INJURIES – ADHERE ALL SAFETY PROCEDURES APPLICABLE AT SITE FOR STEAM SERVICES

- FAILURE TO DO SO COULD RESULT IN INJURY OR DEATH.

5. INSTALLATION

5.1 Mechanical Considerations

Typically, the YARS will be subject to large vibration conditions and therefore a sound mechanical installation is required.

While ange mounting to the customer supplied process isolation valve provides an installation, it is also recommended that the upper section of the YARS be secured mechanically. The heat exchanger and controller give the YARS ‘top-heavy’

properties that should be considered during installation.

It is also desirable to have ready access to the unit such that routine maintenance checks can be made on the operation of the unit in a safe manner.

Ensure that an appropriate gasket is used between the ange mounting faces and when tightening the ange mounting

bolts to the process isolation valve, please ensure that the correct torque is applied (typically 100 foot pounds for a 2”

300# ange). As with any anged bolt tightening, ensure that the correct sequence of tightening is followed (typically as

shown below):

5.2 Fast Loop Line Size and Response Times

The following table may be used when estimating sample line sizes, response times and resultant pressure drop through

the line. These calculations are based on a typical ethylene cracked gas euent sample and should be used for estimating

purposes only:

Sample Line Size

Stainless Tube

¼” 200’ 1.5 39

¼ 200’ 3 19

¼ 200’ 4.5 13

/8” 200’ 1.5 108

/8” 200’ 3 54

/8” 200’ 4.5 34

Sample Line

Length

Sample Flow Rate Lts/min

Response Time

Seconds

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