KAM CHA™ COLORIMETER/HAZE ANALYZER -...
14
TEL +1 713 784 0000 FAX +1 713 784 0001 Email [email protected] KAM CONTROLS, INC. 3939 Ann Arbor Drive Houston, Texas 77063 USA www.KAM.com User Manual KAM ® CHA™ COLORIMETER/HAZE ANALYZER PTB 04 ATEX 1027 CHAMANUAL-0413
Transcript of KAM CHA™ COLORIMETER/HAZE ANALYZER -...
API COMPLIANT
TEL +1 713 784 0000 FAX +1 713 784 0001 Email [email protected]
KAM CONTROLS, INC.
3939 Ann Arbor Drive Houston, Texas 77063 USA
www.KAM.com
User Manual
KAM® CHA™ COLORIMETER/HAZE ANALYZER
PTB 04 ATEX 1027
CHAMANUAL-0413
1CHAMANUAL 0413 KAM CONTROLS, INC.
T A B L E O F C O N T E N T S
SECTION TITLE PAGE 1 Introduction 2 •AvailableModelsandMountingOptions 2 •TheoryofOperation 2 •Features 3 •Applications 3
2 Specifications 4 •Specifications 4 •DimensionalDrawings 5
3 Installation 7 •MainLine 7 •Removal 9 •Wiring 10 •4-20mAOutputs 11 4 Maintenance 12 5 CommunicationsInterface 13
6 AdditionalDrawings 14
CAUTION:
WheninstallingtheCHA™sensorinapipelinecontainingpetroleumproducts,petro-chemicals,wastewaterswiththepresenceofpressure&temperature,andhigh-pressuresteamrefertothePipelineOperators’“Health,SafetyandEnvironmentalPolicyProcedures”toensuresafeinstallation.
KAMCONTROLS,INC.reservestherighttomakechangestothisdocumentwithoutnotice.
2CHAMANUAL 0413 KAM CONTROLS, INC.
I N T R O D U C T I O N
AVAILABLE MODELS and MOUNTING OPTIONS
THEORY OF OPERATION
Colorvariationsinrefinedproductsindicateimpuritiesand/orthepresenceofwater.Refinedproductsareoftenpronetohazeordiffusedwatercontaminationduetocoolingtowerswhichusewaterandinturncansaturatetheproduct.Thiscanbeasignificantliabilityascolordifferentiationcanbeeasilydetectedbytheenduser.TheKAM®CHA™Colorimeter/HazeAnalyzeristheidealquantitativesolutionformonitoringboththecolorofrefinedproducts,includingdyedproduct,andthepresenceofhaze(trace/dissolvedwater)inpipelinesfollowingtherefiningprocess.TheKAM®CHA™detectsinterfacecolorvariationswithin1%,andunlikemostcolorimeterscandetecttheentirerangeofvisiblecolorasdefinedbyCIE1931(InternationalCommissiononIllumination).ThesimplicityofdesignandqualityofengineeringemployedintheColorimeter/HazeAnalyzermeantherearenomovingparts.Usinglong-lastingLEDlightsourcesensureslong-term,stableperformancewithlimitedmaintenanceandpowerrequirements.Inaddition,locatingtheelectronicswithinanexplosion-proofenclosuredirectlyontheatmosphericendoftheopticalprobecreatesacompleteandcompactunitwithmaximuminstallationflexibility.TheKAM®CHA™easilyinstallswhereothercolorimeters,weigheddownbylargeelectronics/computerunits,cannot.
ThefiveLEDsources(Red,Blue,Green,Yellow,andIR)sendlightviafiberopticstothesensorendinsertedintothepipelineoranalyzerloop.Thesebeamsoflightpassthrougha25mmwindowofpipelinefluidsandthenarereflectedbackthroughfiberopticstotheelectronicsenclosureforatotalpathof50mm.
FIG. 1-1 FIG. 1-2 FIG. 1-3
RectractableCHA™onamainpipe,with2",3",or4"flanged
sealhousing
RectractableCHA™onamainpipe,with
2"MNPTsealhousing
CHA™FTFlowThroughwith1"ANSI150flanges
Full-openingballvalve
Full-openingballvalve
3CHAMANUAL 0413 KAM CONTROLS, INC.
I N T R O D U C T I O N C O N T I N U E D
FEATURES
•Userfriendly•Lowpower•Explosionproof•Lowmaintenance•Compactformatincludesrequisiteelectronics•Long-lastingLEDlightsources
APPLICATIONS
•Batching•Interface•Production•Transmix/regradereduction•Qualitycontrolinrefinedproductsincludingdyedandundyedmotorandaviationgasoline,jetpropulsionfuels,naphthasandkerosine•Qualitycontrolinpharmaceuticalwhiteoilsandpetroleumwaxes•BrinedetectioninLPGtransferfromstoragecaverns
KAMusesfourLED'sforcolordeterminationtoincreasetheaccuracyoverthree-color(RGB)models.Thefifth(IR)LEDprovideshazedetection.Thedisparityinlightoutputversuslightreflectedbackisthenconvertedintoanelectronicoropticalsignaturewhichisamplifiedandsenttothecomputer.Thecomputerinturnutilizesamathematicalformulatodeterminetheexactcolorandhaze(turbidity)ofthefluidinthepipeline.FinalcolormeasurementfromtheKAM®CHA™canbeexpressedashazeplusthreecolor(X,Y,Z,CIE1931)orinseveralotherindustry-standardcolorscalesincluding,Saybolt,PlatinumandCobalt,andASTM1500(seeSpecifications,Section2).
ThecomputerautomaticallyadjustsforelectronicnoiseandanyLEDfluctuations.Becausetheabsorptionratesofthedifferentcoloredfluidsvaryresultingindifferentsignalstrengths,thecomputeralsoautomaticallyadjuststheamplificationorgainaccordingly.
Measurementisfullyautomaticwithouttheneedforoperatorinterventionorsupervision.TheoutputsignalcanbesenttotheSCADA,PLC’s,ortoaCentralControlRoomforloggingordisplayonchartrecordersor monitors.
TheKAM®CHA™probecanbeinstalledinananalyzerlooporinthemainline,andbecauseit’seasilymountedthroughafull-openingballvalve,youcaninsertorretracttheprobewithouthavingtoeverdrainthepipe.
4CHAMANUAL 0413 KAM CONTROLS, INC.
S P E C I F I C A T I O N S
Media: Refinedproducts
Material: Wettedparts–316stainlesssteel,sapphire
Power: 12–24VDC20Wattsmax
CommunicationInterface: RS-485reflectsvaluesforHazeplusdesignatedcolorscale(seeColorRange)
Fluidtemperature: -40ºto200ºF(-40ºto93ºC)
Electronicstemp.: -22ºto185ºF(-30ºto85ºC)
Pressureratings: ANSI150,300,600
Accuracy: Haze±5%,Color±1%
Repeatability: Haze±1%,Color±1%
Reproducibility: Haze±1%,Color±1%
HazeRange: 0-100%
ColorRange: Completerangeof:ASTMD1500;ASTMD156(Saybolt);ASTMD1209 (APHAPlatinum-Cobalt)
Mounting: ¾",1",1½",and2"FNPTFlowThrough(Metricsizesavailable) 2"MNPTSealHousing 2",3",or4"FlangedSealHousing
SensorDimensions: 3.5"x1.25"Ø (90mmx32mm),Flowthrough5.8"x2.75"Ø(148mmx70mm)
EXenclosure: 3"x6"x3"(76mmx152mmx76mm)
Shaftlength: 12"to60"–Off-the-shelflengthsare12",24",36",48",and60" (305mmto1524mm) (Off-the-shelf609.6mm,762mm,914.4mm,1219mm,1524mm)
Pipesize: ¾"to48"(20mmto1200mm)
Weight: from20lbs.(9kg)
5CHAMANUAL 0413 KAM CONTROLS, INC.
S P E C I F I C A T I O N S C O N T I N U E D
DIMENSIONAL DRAWINGS
"
2
3
4
INCHES
8.40
8.60
8.60
INCHES
8.50
8.75
8.90
INCHES
8.90
9.15
9.40
INCHES
9.40
9.40
9.65
MM
213
218
218
MM
216
222
226
MM
226
232
240
MM
240
240
245
150 300 600 900TABLE 2-2 FLANGE SIZE AND CLASS (SL)
A
B
C
D
E
F
INCHES
1.25
3.5
7.25
4.7
.47
1
MM
32
90
184
119
12
25
TABLE 2-3 DIMENSIONSShaftLengthsareavailablein.5"(12.7mm)increments.
Standardsizesare24",30",36",48",and60".(609.6mm,762mm,914.4mm,1219mm,1524mm)
FIG. 2-1CHA™ SENSOR
SensorProfile
A SealHousing
¾"FNPT
B
ShaftLength±.5"
C
D
E F
SL
6CHAMANUAL 0413 KAM CONTROLS, INC.
S P E C I F I C A T I O N S C O N T I N U E D
FIG. 2-4 FLOW THROUGH CHA™
A
B
C
D
INCHES
11.8
11
7.25
4.7
MM
299
279
184
119
TABLE 2-5 DIMENSIONS
C
D
A
B
ANSIFLANGES
7CHAMANUAL 0413 KAM CONTROLS, INC.
Removealltheprotectivepackagingmaterials,andensurethattheCHA™sensorwasnotdamagedduringtransit.
PRIOR TO INSTALLATION
MAIN LINE INSTALLATION
TheKAM®CHA™sensorshouldbeinstalledaccordingtoFIG.3-1,ideallyatthe3or9o'clockpositionwithinthepipeline.Installingtheinstrumenthorizontallypreventsthelong-termbuildupofanysedimentonthesapphirewindows.Afull-openingballvalveisusedtoisolatetheCHA™sensorfromthepipelineduringinstallationorremoval.ThesealhousingoftheCHA™sensorallowstheprobetobeinsertedandremovedfromthepipeunderpressureandflowconditions.Itistheuser’sresponsibilitytoensurethattheCHA™sensorbeplacedatthemostrepresentativepointwithintheflowprofile.TheCHA™sensorshouldbeinsertedsothatthewindowoftheprobeisfullylocatedwithinthepipeline.
NOTE:Linepressuremustbebelow100psiforCHAinstallationandremoval.Pressureabove100psicouldcausetheprobetoforciblymoveoutwardfromthepipelineriskingbodilyinjuryand/ordam-agetotheprobe.
Priortomountingverifythatthetipofthesensorisallthewayinsidethesealhousing.(FIG.3-2,3-3) Ifsensorisnotfullyenclosedinsidethesealhousing,pulltheshaftbackuntiltheprobeisallthewayinthesealhousingandtightenthesocketcapscrewsonthelockingcollar.ThiswillpreventtheCHA™shaftfromslidingandtheprobefromgettingdamagedduringmounting.
1.
2.
FIG. 3-1 KAM® CHA™ INSTALLED ON A MAIN PIPE
FIG. 3-2
FIG. 3-3
I N S T A L L A T I O N
LockingCollar
SealHousing
Full-openingBallValve
SocketCapScrew
8CHAMANUAL 0413 KAM CONTROLS, INC.
I N S T A L L A T I O N C O N T I N U E D
Measurethedistance(D1)fromtheoutsidediameterofmainpipetotheendoftheconnectionwheretheCHA™sensorisgoingtobeinstalled.FIG.3-4.
3.
CalculatetheminimuminsertiondistancefortheCHA.
Minimuminsertiondistance(MID)=D1+WallThickness+2"
ExampleforD1=16",pipeWT=1/4",SealThickness=1/8":
MID=16+1/4+1/8+ 2 MID=183/8"
4.
MeasurethecalculatedMIDfromthetopofthesealclampandplaceamarkwithapermanentmarkerortapeontheShaft.FIG.3-5.
5.
MID
6. BoltorscrewtheCHA™sensortothevalveordesignatedinstallationlocation.(KAMCONTROLSrecommendsusingthreadsealantandnotTeflontapeforthethreadedCHA™).
Openfullopeningvalve.7.
LoosenSocketCapScrewsonthelockingcollar.
REMINDER:Linepressuremustbebelow100psiforCHAinstallationandremoval.
8.
FIG. 3-5
D1D1
FIG. 3-4
9CHAMANUAL 0413 KAM CONTROLS, INC.
I N S T A L L A T I O N C O N T I N U E D
PushCHA™sensorinuntilthemarkisatthetopedgeofthelockingcollar.EnsurethatCHA™flowindicatorisalignedwithpipelineflowdirection.FIG.3-6.
9.
Mark
Re-tightentheSocketCapScrewswithatorqueof750-800lb-inor62.5to66.6lb-ft.
TightentheHexNutsonthetopoftheLockingCollaronehalfturn.Thesenutsshouldneverbeover-tightened.Theirmajorfunctionistoapplylightpressureonthechevronpackingtoensureasealbetweenthesealhousingbodyandtheinsertionshaft.
10.
11.
REMOVING THE CHA™ SENSOR
ToremovetheCHA™sensor,firstdisconnectallelectricalconnectionstotheCHA™enclosure.
Makesurethatthelinepressureisbelow100psi.Then,slowlyandwithcautionloosentheSocketCapScrewsontheLockDownCollar.
NOTE:OncetheSocketCapScrewshavebeenloosened,theCHAshaftmaypushoutfromtheline.Ifpres-sureinthelineisabove100psi,itmaydosowithenoughforcetocausebodilyinjuryordamagetotheinstru-ment.
SlidetheCHA™sensorupwarduntilitstopsandtheproberestsinsidethesealhousing.Fig.3-7.Themechani-calstoppreventsfurthermovementorejectionoftheshaftand/orsensor. Next,closetheFull-openingBallValvetightly.TheCHA™sensormaynowbeunboltedfromthesystem.
FIG. 3-6
Hex Nuts
1.
2.
3.
4.
FIG. 3-7
MechanicalStop
SocketCapScrews
10CHAMANUAL 0413 KAM CONTROLS, INC.
I N S T A L L A T I O N C O N T I N U E D
WIRING
KAM CHA
3939 Ann Arbor DriveHouston, Texas77063, USA+1 713 784 0000www.KAM.com
J5
J7
485 +
485 -
GN
D
Loop1 RTN
Loop1 IN
Loop2 IN
Loop2 RTN
Vin ( – )
Vin ( + )
LOOP1
LOOP2A
STMSAYBO
LTPt/CoH
AZE
R e v 2 . 0 1 1 2 / 2 0 1 2 M a d e i n U S A
1234
FIG. 3-8
POWER COMMUNICATION INTERFACE
12or24VDC(5wattsmax) RS–485
COMMUNICATION INTERFACE
JUMPERSTOSELECTSIGNAL/SCALEFOR4-20mAOUTPUTS
CAUTION:Whenelectronicsenclosureisopen,beextremelycarefultoavoidanycontactwithinteriorfiberopticconnections.FailuretodosocouldresultintheCHAmalfunctioning.
POWERCONNECTIONS
4-20mACONNECTIONS
11CHAMANUAL 0413 KAM CONTROLS, INC.
LOOP1andLOOP2canoutputsignalsforany2of4differentscales:ASTM,Saybolt,Platinum/Cobalt,andHaze.
Toselectwhichsignalorscaleisassociatedwithwhich4-20mAoutput,insertajumperacrossthepinsnexttothelabelforthedesiredscale.SeeFig.3-9.PlaceONEjumperinJ5andoneinJ7toselecttwoscalestotal.InsertingmorethanonejumperforeitherLOOPorinsertingthejumperacrosstwoinputsortwooutputswillresultinthemalfunctioningoftheinstrument.
I N S T A L L A T I O N C O N T I N U E D
OUTPUTS
COLOR SCALE RANGES
SCALE RANGE
ASTM .5to8Saybolt -30to16Platinum/Cobalt 0to500Haze 0to100
KAM CHA
3939 Ann Arbor DriveHouston, Texas77063, USA+1 713 784 0000www.KAM.com
J5
J7
485 +
485 -
GN
D
Loop1 RTN
Loop1 IN
Loop2 IN
Loop2 RTN
Vin ( – )
Vin ( + )
LOOP1
LOOP2
ASTM
SAYBOLT
Pt/CoH
AZE
R e v 2 . 0 1 1 2 / 2 0 1 2 M a d e i n U S A
1234
JUMPER INPUT
SCALE
JUMPER OUTPUT
PROPER JUMPER PLACEMENT ACROSS INPUT AND OUTPUT
FIG. 3-9
12CHAMANUAL 0413 KAM CONTROLS, INC.
M A I N T E N A N C E
Undernormaloperation,theKAMCHAshouldnotrequirecleaning,unlesspipelineusageislimitedtoasmallnumberofproducts.GasolineproductsorjetfuelinthepipelinewillcleantheCHAwithoutremoval.
Toremoveanyoilresiduesforvisualinspectionuseacleanclothwithoilsolventorpartwasher.Preferredsolventsinclude,anypetroleumsolventsuchasmineralspirits,xylene,toluene,gasoline,ordiesel.DonotuseWD40orotherchemicals.
Ifyouhaveaquestionregardingcleaningsolvents,pleasecontactKAMCONTROLSdirectlyat+1713784-0000,oremail:[email protected]
CLEANING AND INSPECTION
13CHAMANUAL 0413 KAM CONTROLS, INC.
OnceHyperterminalsoftwareislaunched,adialoguewindowwillpromptyouto"Enteranameandchooseaniconfortheconnection."Nametheconnectionwhateveryouwant,forexample"CHA1."Ignorethechooseiconoption.HitOK.
The"ConnectTo"dialogueboxwillnowappear.Onthelastlinewhereitsays"Connectusing"choosethenameofthecommunicationportconnectedtotheCHAviaRS-485fromthedrop-downmenu.HitOK.
The"PortSettings"dialogueboxwillnowappear.Enterthefollowingvaluesfromthedrop-downmenu:
Bitspersecond:1200
Data bits: 7
Parity:Even
Stopbits:2
Flowcontrol:None
Hit OK.
Ablankscreenwithpromptwillnowopen.TodisplayCHAreadingstypeoneofthreeprompts,E1,E2,orE3.
C O M M U N I C A T I O N S I N T E R F A C E
HYPERTERMINAL PROMPTS FOR RS-485 CONNECTION
E1:DisplaysvaluesforZ,Y,Z,andT(haze)E2:DisplaysvaluesforASTM,Saybolt,PtCo(PlatinumCobalt),andT(haze)E3:Displaysallvalues
1.
2.
3.
4.
