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K-Patents Safe-Drive PR-23-SD Manual

Process refractometer generation 2
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Safe-Drive
Process
®
Refractometer PR-23-SD
Generation 2
Best Practices for PR-23-SD
with steam wash system
IM-EN-SDGEN2-BP v. 1.02

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Summary of Contents for K-Patents Safe-Drive PR-23-SD

  • Page 1 Safe-Drive Process ® Refractometer PR-23-SD Generation 2 Best Practices for PR-23-SD with steam wash system IM-EN-SDGEN2-BP v. 1.02...

  • Page 2: Table Of Contents

    Contents Section 1 About This Document ......................3 Section 2 Before Installation ........................ 3 Installation Location Checklist ..................3 Component Checklist ..................... 4 Section 3 Safety Requirements ......................6 Section 4 Installation Process ......................7 Spool piece assembly ....................7 Cutting Installation Opening for SDI2 Valve ..............

  • Page 3: About This Document

    This document in intended for PR-23-SD applications that have a steam wash system (typical application for black liquor). NOTE: These instructions are for quick reference only. For more thorough guidance, please refer to K-Patents user manual and documentation. Before Installation Installation Location Checklist...

  • Page 4: Component Checklist

    Before starting installation, make sure you have all the tools and components listed below. NOTE: Components 4 and 5 are connected by union nipple or piping not included in the delivery. System components included in K-Patents delivery: Document/Revision No. IM-EN-SDGEN2-BP 1.02 Effective: December 2, 2014...
  • Page 5 Wash nozzle installation bolts and locking plate Compressed air operated solenoid shut-off valve with steam trap Steam connection hose Sensor connection cable DTR transmitter NOTE: If any of tools or components are missing, contact your supplier before starting installation © Copyright K-Patents 2014. All rights reserved.

  • Page 6: Safety Requirements

    NOTE: The material of the SDI2 valve body that is welded onto a process pipe is Duplex steel SAF2205 (EN 1.4462, ASTM S32205/S31803). Choose the welding method and filler accordingly. K-Patents recommends complying with the applicable EN / ASTM standards. Safety Requirements These safety requirements must be followed at all times when installing, operating, or servicing PR-23-SD sensor.

  • Page 7: Installation Process

    Retractor alone. ® ● Hard-cap safety boots. Installation Process For more thorough instructions, please refer to K-Patents user documentation or visit the K-Patents website to see the instructional video (www.kpatents.com, PR-23-SD Safe-Drive ® Operation Guide Video). Installation of the SD sensor system consists of ●...

  • Page 8: Cutting Installation Opening For Sdi2 Valve

    Vertical and horizontal spool piece assemblies Cutting Installation Opening for SDI2 Valve Use the installation guide sticker provided by K-Patents to determine the installation opening shape and size suitable for your process pipe. If you do not have the guide sticker at hand,...

  • Page 9: Disassembling Sdi2 Valve For Welding

    Installation on vertical and horizontal pipes Disassembling SDI2 Valve for Welding To avoid thermal damage to the isolation valve sealing, you must separate the valve body from the valve assembly before it is welded onto the pipe. © Copyright K-Patents 2014. All rights reserved.

  • Page 10: Welding Sdi2 Valve In Place

    ● See the attached drawings 2149 (MTG) and MTG472 for more detailed welding instructions. ● Follow all local requirements for welding. ● K-Patents recommends complying with the applicable EN / ASTM standards. ● Consider the materials and shapes of the welded objects when performing welding pre-processing (tools, cleaning, preheating).

  • Page 11: Reassembling Sdi2 Valve

    After the SDI2 valve body has been welded in place, reassemble the valve in reverse order. NOTE: Make sure that the seals for the ball valve are propely aligned. Widest bayonet lug Valve handle always always positioned at top positioned at top © Copyright K-Patents 2014. All rights reserved.
  • Page 12 Widest bayonet lug Valve handle always always positioned at top positioned at top Figure 9 Reassembling valve on vertical and horizontal pipes ● Make sure that the SDI2 valve handle and the largest bayonet connection are on top. Otherwise, you will not be able to insert the sensor in its place. ●...

  • Page 13: Installing Steam Prism Wash System

    For K-Patents recommendations, please see K-Patents Steam Instructions. ● OPTIONAL, in case of contaminants: To remove any contaminants within the steam source, installing a steam strainer is recommended. See K-Patents list of recommended accessories. © Copyright K-Patents 2014. All rights reserved.
  • Page 14 ● OPTIONAL, in case of excessive pressure: If the steam pressure exceeds to maximum pressure differential, a pressure reducing valve (PRV) needs to be installed to reduce the steam pressure to optimal design. See K-Patents list of recommended accessories. Figure 10...

  • Page 15: Before Inserting And Removing Pr-23-Sd Sensor

    2. Install the steam pipes in the SDI2 valve, as instructed below. NOTE: All the necessary wash fittings are included in the valve. 3. Connect the steam wash system power supply. For more information, please see K-Patents Steam Instructions. Figure 11 Wiring steam wash system For more information on controlling the prism wash cycle, please refer to chapter Configuring relays in K-Patents user documentation.

  • Page 16: Inserting Sensor

    Insert and remove the sensor as instructed in the following chapters. For more thorough instructions, please refer to K-Patents user documentation or visit the K-Patents website to see the instructional video on inserting and removing the sensor (www.kpatents.com, PR-23-SD Safe-Drive Operation Guide Video).
  • Page 17 4. Turn the casing 60 degrees (1/6 turn) to the left i.e. until the handle is up on top. 1. Turn the hand-wheel to the left to drop the thread. 2. Lift off Outer casing. © Copyright K-Patents 2014. All rights reserved.

  • Page 18: Box Flushing

    1. Lift up and pull the latch of Inner casing to unlock. 2. Turn the casing 60 degrees (1/6 turn) to the left to release it from the flange. Lift Inner casing away from the sensor head. 1. Take off sensor nameplate and the gasket underneath. 2.
  • Page 19 STATUS and activate wash by pressing WASH button. Repeat the wash 3–5 times. 4. Close the 1/4” valve to the box (4). 5. Open the 1/4” valve to the nozzle (5). OPEN CLOSE © Copyright K-Patents 2014. All rights reserved.

  • Page 20: Removing Sensor

    4.10 Removing Sensor Switch off the DTR to cut off power from the sensor. 1. Remove the sensor nameplate and the gasket underneath. 2. Screw off the cable gland. 3. Disconnect the interconnecting cable 4. Remove the cable from sensor 1&5 5.
  • Page 21 1. Remove the safety pin. 60° 2. Lift Outer casing locking latch. 3. Turn Outer casing 60 degrees (1/6 turn) to the left so that the handle comes up on top. © Copyright K-Patents 2014. All rights reserved.

  • Page 22: Removing Wash Nozzle

    4.11 Removing Wash Nozzle Remove the wash nozzle as instructed in the following illustrations: For more thorough instructions, please refer to K-Patents user documentation or visit the K-Patents website to see the instructional video on inserting and removing the sensor (www.kpatents.com, PR-23-SD Safe-Drive Operation Guide Video).
  • Page 23 (3) out. WARNING: The nozzle tip is hot and may be covered with liquor. It is recommended to rinse the nozzle tip and the isolation valve with hot water. © Copyright K-Patents 2014. All rights reserved.

  • Page 24: Inserting Wash Nozzle

    4.12 Inserting Wash Nozzle Insert the wash nozzle as instructed in the following illustrations: For more thorough instructions, please refer to K-Patents user documentation or visit the K-Patents website to see the instructional video on inserting and removing the sensor (www.kpatents.com, PR-23-SD Safe-Drive Operation Guide Video).

  • Page 25: Installing Dtr Transmitter

    200 meters (660 feet). You can use your own cable as long as it meets IEC 61158-2 type A standard requirements. For more information, please refer to chapter Interconnecting cable specifications in K-Patents user documentation. © Copyright K-Patents 2014. All rights reserved.
  • Page 26 WARNING: The transmitter does not have a built-in power switch so it is always powered when connected to a power source. K-Patents recommends mounting an external power switch to control the power supply.
  • Page 27 33/PE (protective earth), which is directly connected to the exposed metal parts if the transmitter. 5. Connect the wiring wash relay to solenoid valve from the RELAYS terminals. 6. Connect the 4-20mA output. Figure 15 Transmitter H1 and motherboard connections © Copyright K-Patents 2014. All rights reserved.

  • Page 28: Commissioning Sd Sensor System

    After installing the SDI2 valve, PR-23-SD sensor, and DTR transmitter, go through the following check list to make sure the SD sensor system is functioning correctly. For more thorough instructions, please refer to K-Patents user documentation or visit the K-Patents website to see the instructional video (www.kpatents.com, PR-23-SD Safe- Drive Operation Guide Video).
  • Page 29 For more information, corresponds to the lab results › CHEMICAL see chapter 5.2 & FIELD Calibration Check in PARAMETERS these instructions and › FIELD chapter Calibrating PARAMETERS the concentration measurement in K-Patents PR-23 Instruction Manual. © Copyright K-Patents 2014. All rights reserved.

  • Page 30: Prism Wash Test

    (see Prism wash test in the commissioning checklist). When comparing lab results if there is a consistent offset, perform a BIAS adjustment from CALIBRATION menu. For more information, see chapter Calibrating the concentration measurement in K-Patents PR-23 Instruction Manual. Document/Revision No. IM-EN-SDGEN2-BP 1.02 Effective: December 2, 2014...

  • Page 31: Operating And Monitoring Sd Sensor System

    The main task of the operator is to make sure that the washes and steam connections are functioning as they should. To rehearse the use of DTR transmitter, please visit demo.kpatents.net. K-Patents recommends that all new users participate in K-Patents training before using the product. Preventive Maintenance Plan (PMP) Preventive Maintenance Plan (PMP) should be adopted in order to prevent bigger maintenance procedures.

  • Page 32: Check Valve Maintenance

    HD HUM (internal humidity% If HUM HD rises above 50%, the system of sensor) issues an alarm to replace the desiccant. For more information, see K-Patents PR-23 Instruction Manual. Check the functionality of See Prism wash test in Commissioning wash system.
  • Page 33 1. Open the DTR transmitter front panel. 2. Press the reset button on the inside of the front panel using a thin stick or a similar tool. The display will black out for a few seconds. The SD sensor system will be back up in operation within 30 seconds.

  • Page 34: Appendices

    Appendices Preventive Maintenance Inspection Weekly Checklist Data Sheets for Accessories Welding diagrams Installation diagrams (MTG DIM) Wiring Diagrams (WRG) Document/Revision No. IM-EN-SDGEN2-BP 1.02 Effective: December 2, 2014...
  • Page 35 Preventive Maintenance Inspection Weekly Checklist Date CONC CALC TEMP Steam Wash Checked...
  • Page 36 1804 Centre Point Circle, Suite 106 Naperville, IL 60563, USA Tel: (630) 955 1545 Fax: (630) 955 1585 Email: info@kpatents-usa.com K-Patents (Shanghai) Co., Ltd 17-05H, 17F, Times Square No. 500 Zhyang Yang Road Pudong District, Shanghai, China Tel: +86 21 5178 2775 Fax: +86 21 5178 2799 www.kpatents.com...

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