Related Manuals for K-Patents SAFE-DRIVE PR-23-SD
Summary of Contents for K-Patents SAFE-DRIVE PR-23-SD
- Page 1 Installation Instructions for K-Patents SAFE-DRIVE ™ Process Refractometer PR-23-SD Upgrade Kits Upgrading to Generation 2.1 IM-EN-SDI21UPG May 1, 2017...
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Page 2: Table Of Contents
Contents Section 1 Background information ..................... 3 Section 2 Identifying your SAFE-DRIVE system version ..............4 2.1 Generation 1 ........................4 2.2 Generation 2 ........................5 Section 3 Upgrading from Generation 1 to Generation 2.1 .............. 6 3.1 Upgrade options......................6 3.1.1 SDR2-KIT for Isolation valve and Retractor ............6 3.1.2 ... -
Page 3: Background Information
Installation Instructions for K-Patents SAFE-DRIVE ™ Process Refractometer PR-23-SD Upgrade Kits Background information We have upgraded the SAFE-DRIVE safety documentation. The new Generation 2.1 improvements in the safety instructions allow for better understanding of the most significant safety parameters, and emphasize different safety layers, check-points and parts that must be in place when operating the SAFE-DRIVE equipment. The safety pin and safety clip are attached to the retractor handle with a cable wire. Furthermore, contrasting colors and marks are used to highlight the safety check points (see Figure 1). For instance, the safety bracket between the isolation valve and the retractor is painted in red to draw the user’s attention. For safe insertion and retraction of the sensor, the user must lock the bracket with the safety pin or a padlock. Locking is possible only when the bayonets of the outer casing and isolation valve are aligned, and it secures that the casing is properly mounted. Figure 1 Examples of the upgraded safety documentation. K-Patents strongly recommends all SAFE DRIVE Generation 1 and 2 users to update to the latest Generation 2.1 as a preventative measure to enhance the product safety. The upgrade from Generation 1 to Generation 2.1 should be scheduled during the next upcoming shut-down. The upgrade from Generation 2 to Generation 2.1 does not require a shut-down of the process line and can be implemented immediately. © Copyright K-Patents 2017. All rights reserved. -
Page 4: Identifying Your Safe-Drive System Version
Identifying your SAFE-DRIVE system version Generation 1 Generation 1 System components are shown in Figure 2. In this system version the SDI isolation valve (No. 2) and the Retractor (No. 3) do not have locking brackets. Also the wash nozzle assembly (3a, b, c) is of original design. Figure 2 Generation 1 System components. Effective: May 1, 2017... -
Page 5: Generation 2
Installation Instructions for K-Patents SAFE-DRIVE Process Refractometer PR-23-SD Upgrade Kits Generation 2 Generation 2 re-engineered components are shown in Figure 3. In this system version the other components remain intact, but the Isolation valve and Retractor (No. 1) have locking brackets (No. 2) and a safety pin (No. 3), but no locking pin. Generation 2 Retractors have a product label G2 on the handle indicating that the Retractor is of Generation 2. Also the wash nozzle assembly (4, 4a, b) has been re-designed and it has a safety pin (No. 3). Figure 3 Generation 2 re-engineered system components. Figure 4 Generation 2 locking brackets (highlighted with red color) mounted on the Isolation valve and Retractor © Copyright K-Patents 2017. All rights reserved. -
Page 6: Upgrading From Generation 1 To Generation 2.1
Upgrading from Generation 1 to Generation 2.1 Upgrade options 3.1.1 SDR2-KIT for Isolation valve and Retractor The SDR2-KIT consists of parts for upgrading the existing Isolation valve and replacing the Retractor and all SAFE-DRIVE safety documentation with new ones. The kit contains a new Retractor tool (complete kit consisting of the inner and outer casing), a PR-11026 locking bracket and new SAFE-DRIVE safety guides and instructions. 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 PR- 11026 for each upgraded isolation valve. It is recommended to dispose of the old Retractor Tool(s) and earlier versions of safety documentation to avoid their accidental use. -
Page 7: Wp2-Kit For Prism Wash Nozzle For High Pressure Water
Installation Instructions for K-Patents SAFE-DRIVE Process Refractometer PR-23-SD Upgrade Kits 3.1.3 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 Part No. WP2-KIT = High pressure water upgrade kit to WP2 WP2-KIT Consisting of the following: PR-11024 = SDI2 High pressure water wash nozzle WP2 PR-11024 PR-11025 = Nozzle isolation valve assembly for SDI2 PR-11025 Complete with safety pin and cable wire, Best Practice manual, Pocket guide, laminated insertion/retraction guide, upgrade installation instructions (this document) © Copyright K-Patents 2017. All rights reserved. -
Page 8: Before Installation
Before installation 3.2.1 Components checklist Before starting installation, make sure you have all the tools and components listed in Figure 5 and 6. 23SD-008 Figure 5 System components included in K-Patents delivery Retractor SDR2-23, Generation 2.1 containing Safety pin, clip and cable wire connected on retractor handle Locking bracket PR-11026 3 - 5 Orders with Wash nozzle assembly contain the following components: Wash nozzle assembly SN2-KIT or WP2-KIT containing nozzle locking plate 4b 2 pcs of M5 bolt 3, 5 Safety pin and cable wire for prism nozzle isolation valve connected on wash nozzle assembly SAFE-DRIVE pocket guide IM-EN-SDI21-PG SAFE-DRIVE pocket guide for installation IM-EN-SDI21INST-PG SAFE-DRIVE Process refractometer PR-23-SD Generation 2.1 Best Practices IM-EN-SDGEN21-BP Laminated instructions for removal and insertion of SAFE-DRIVE Process refractometer... - Page 9 Installation Instructions for K-Patents SAFE-DRIVE Process Refractometer PR-23-SD Upgrade Kits 23SD-009 Figure 6 Installation equipment Retractor inner casing Supplied by K-Patents Retractor outer casing Supplied by K-Patents Combination wrenches, 32 mm (1 pc), 14 mm (1 pc), 8 mm (1 pc) Allen keys 8 mm (1 pc), 5 mm (1 pc) Torque wrench open end fitting 19 mm 5b hex bit socket 8 mm Screw driver Phillips head 6b Flathead Pliers Thread seal tape Pocket guide for insertion and retraction of sensor and wash Supplied by K-Patents nozzle Laminated instructions for insertion and removal of SAFE-DRIVE Supplied by K-Patents sensor SAFE-DRIVE Process refractometer PR-23-SD Generation 2.1 Supplied by K-Patents Best Practices IM-EN-SDGEN21-BP © Copyright K-Patents 2017. All rights reserved.
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Page 10: Installation
Installation 3.3.1 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 the safety instructions included in the delivery. 3.3.2 Locking bracket installation in 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 7 Locking bracket installed 3.3.3 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. Effective: May 1, 2017... - Page 11 Installation Instructions for K-Patents SAFE-DRIVE Process Refractometer PR-23-SD Upgrade Kits Figure 8 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 9 Removal of Gen 1 nozzle asembly 8. Remove nozzle assembly. © Copyright K-Patents 2017. All rights reserved.
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Page 12: Installation Of Generation 2.1 Nozzle Assembly
3.3.4 Installation of Generation 2.1 Nozzle assembly Pass pin and ring through end loop of retaining wire and pull tight Figure 10 Installation of the Gen 2.1 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). 4. Pass pin and ring through end loop of retaining wire and pull tight to connect the cable wire on nozzle isolation valve. 5. Lock the safety pin on the nozzle plate. Effective: May 1, 2017... -
Page 13: Upgrading From Generation 2 To Generation 2.1
Installation Instructions for K-Patents SAFE-DRIVE Process Refractometer PR-23-SD Upgrade Kits Upgrading from Generation 2 to Generation 2.1 SDR2-KIT-2.1 for documentation and parts The SDR2-KIT-2.1 consists of parts for upgrading the existing Generation 2 Retractor and replacing all SAFE-DRIVE safety documentation with new ones. When multiple Generation 2 wash nozzles are upgraded, it is recommended to specify and order additional Safety pins and cable wires for prism nozzle isolation valve PR-11040 for each upgraded nozzle assembly. It is recommended to dispose of the earlier versions of the safety documentation to avoid their accidental use. -
Page 14: Installation
Figure 11 Upgrade documents and parts included in K-Patents delivery Installation instructions for K-Patents Safe-Drive Process refractometer PR-23-SD Upgrade kits IM-EN-SDI21-UPG (this document) Safety pin, clip and cable wire for Retractor handle PR-11040 Safety pin, clip and cable wire for prism nozzle isolation valve PR-11041 Yellow locking bracket safety label for Retractor Product version information label for Retractor handle Removal/insertion instruction label for Retractor SAFE-DRIVE pocket guide IM-EN-SDI21-PG SAFE-DRIVE pocket guide for installation IM-EN-SDI21INST-PG SAFE-DRIVE Process refractometer PR-23-SD Generation 2.1 Best Practices IM-EN- SDGEN21-BP Laminated instructions for removal and insertion of SAFE-DRIVE Process refractometer Upgrade Report Form URF to be completed and returned to K-Patents Installation 4.3.1 Labels First place the new labels on Retractor: - Yellow locking bracket safety label is placed next to the locking bracket so that the red part is aligned with the bracket. - Removal-insertion instructions label is placed next to the handle, the top part nearest to the handle. - Product label indicating the SAFE-DRIVE Retractor code and Generation 2.1 is placed on the retractor handle. It replaces the former G2 label. Effective: May 1, 2017... -
Page 15: Safety Pins And Cable Wires
Installation Instructions for K-Patents SAFE-DRIVE Process Refractometer PR-23-SD Upgrade Kits ® SAFE-DRIVE G2.1 Safe-Drive casing locking bracket 23SD-015 Figure 12 Placing the labels 4.3.2 Safety pins and cable wires The locking pin assembly is looped over the Retractor handle. Pull the safety clip and safety pin through the loop on the end of the wire to secure the assemply to the Retractor. © Copyright K-Patents 2017. All rights reserved. -
Page 16: Upgrade Report Form
23SD-005 Figure 13 Attaching the cable wire with safety pin and clip For installing the wash nozzle safety wire, see Figure 10. Upgrade report form You can find an Upgrade Report Form URF in the upgrade kit SDR2-KIT-2.1 delivery. Once the equipment has been upgraded, please complete and return the Upgrade Report Form back to K-Patents via mail or e-mail to: K-PATENTS OY TECHNICAL SUPPORT P.O.BOX 77 FI-01511 VANTAA FINLAND SERVICE-SUPPORT@KPATENTS.COM The form is requested for keeping the installation data records up to date on SAFE-DRIVE generations in the field. Accurate data records are vital part of K-Patents technical and product support. Effective: May 1, 2017... - Page 17 Installation Instructions for K-Patents SAFE-DRIVE Process Refractometer PR-23-SD Upgrade Kits © Copyright K-Patents 2017. All rights reserved.
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- Page 19 © Copyright K-Patents 2017. All rights reserved.
- Page 20 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...