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Bacharach HI FLOW Sampler Instruction

Natural gas leak rate measurement
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HI FLOW
Sampler
Natural Gas
Leak Rate Measurement
Instruction 0055-9017
Operation & Maintenance
Rev. 5 – June 2010
Product Leadership • Training • Service • Reliability

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  • Page 1 ® HI FLOW Sampler Natural Gas Leak Rate Measurement Instruction 0055-9017 Operation & Maintenance Rev. 5 – June 2010 Product Leadership • Training • Service • Reliability...
  • Page 2 Bacharach Inc.’s reasonable satisfaction to have been defective; provided that written notice of the defect shall have been given by Buyer to Bacharach Inc. within one (1) year after the date of delivery of this Product by Bacharach, Inc.

  • Page 3: Table Of Contents

    3.5.6 Claw Tool ....................12 3.5.7 3-Port Background Gas Sampler ............. 12 3.6 Turning ON the Hi Flow Sampler................12 3.7 Turning OFF the Hi Flow Sampler ................. 13 3.8 Selecting the Basic or Expanded Menu Mode............13 3.8.1 Basic Main Screen................... 15 3.8.2 Expanded Main Screen ................
  • Page 4 Contents Hi Flow Sampler 4.1 View Calibration Dates ..................43 4.2 Gas Calibration Equipment Setup .................43 4.3 Check Calibration Procedure .................44 4.4 Gas Calibration Procedure ..................45 4.5 Calibration Amplifier Gain Check ................47 4.6 Erase Calibration Procedure ..................47 5 Maintenance ..................49 5.1 Electrostatic Discharge Precautions...............49 5.2 Charging the Battery Pack ..................50...

  • Page 5: Introduction

    Introduction 1 Introduction General Description The Hi Flow Sampler is portable, intrinsically safe, battery-powered instrument designed to determine the rate of gas leakage around various pipefittings, valve packings, and compressor seals found in natural gas transmission, storage, and compressor facilities.

  • Page 6: Material Supplied

    Bag Nozzle w/ box of disposable bags Bellows Tool Claw Tool 3-Port Background Gas Sampler Why Use the Hi Flow Sampler?  Allows ranking of gas leaks in leak-rate order  Allows users to determine if the potential savings in lost gas by repairing a leak ...

  • Page 7: Control Unit Description

    Hi Flow Sampler Introduction Control Unit Description The control unit consists of an 8 line by 20 character LCD and the four pushbuttons. Figure 1-1. Control Unit Top Panel Connections & Controls The top panel contains the following items:  SCANNER – Bar code scanner input ...
  • Page 8 Introduction Hi Flow Sampler Notes: Instruction 0055-9017...

  • Page 9: Technical Data

    Hi Flow Sampler Technical Data 2 Technical Data Information Displayed ..- Date and Time - Battery voltage - Sampling flow rate in cfm - Background gas concentration in ppm or % by volume - Leak concentration in ppm or % by volume...
  • Page 10 Technical Data Hi Flow Sampler Natural Gas Sensor: Detection Method....Catalytic oxidation / Thermal conductivity Range: Catalytic oxidation..0 to 5% by volume methane Thermal conductivity ..5 to 100% by volume methane Accuracy......±5% of reading or 0.02 % methane, whichever is greater Battery: Type ........Intrinsically Safe NiMH rechargeable pack...

  • Page 11: Operation

    Hi Flow Sampler Operation 3 Operation Operating Precautions (Please Read) To ensure that the gas sensors are properly zeroed at startup, the Hi Flow Sampler must be turned ON in clean air (free of combustible gases or vapors). Calibrate the instrument about every 30 days to assure its accuracy. The frequency of calibration, however, may change depending on how often the instrument is used and the amount of gas that was sampled.

  • Page 12: Sampling Hose & Attachment Connections

    Operation Hi Flow Sampler Sampling Hose & Attachment Connections Connect the sampling hose to the instrument’s leak-gas inlet by clamping the hose to the inlet as shown in Figure 3-2. Also connect the background gas sampling hose to the unit’s BACKGROUND inlet.

  • Page 13: Grounding

    Hi Flow Sampler Operation Grounding WARNING: To prevent the possibility of a static discharge, the Hi Flow Sampler should be grounded while conducting a leak test. Attach the unit’s grounding clamp to the nearest earth ground. Tip: When not in use, the grounding clamp can be stored by attaching it to one of the shoulder straps.

  • Page 14: Attachments

    Flange leaks can be captured by wrapping this attachment around the edge of the flange, and securing in place using the two Velcro strips. Attach the Hi Flow Sampler’s main sampling hose to the flange strap by simply pushing the end of the hose into the attachment’s hose coupling.

  • Page 15: Capture Bag

    Attach the Hi Flow Sampler’s main sampling hose to the bag by simply pushing the end of the hose into the bag’s hose coupling. A click should be heard when the hose has been successfully connected.

  • Page 16: Claw Tool

    3.5.7 3-Port Background Gas Sampler Attaches to the end of the background gas sample hose to give better average background gas readings. Turning ON the Hi Flow Sampler Instruction 0055-9017...

  • Page 17: Turning Off The Hi Flow Sampler

    Hi Flow Sampler Operation With the Hi Flow Sampler located in an area containing clean air (no combustible gases or vapors), turn ON the instrument by first pulling up the ON/OFF switch and then moving it to its ON position.
  • Page 18 Operation Hi Flow Sampler Select the Basic or Expanded Menu Mode as follows: 1. From either the Basic or Expanded Main Screen, select Menu > Menu Mode. 2. Highlight the desired menu mode, and then press the I/O key to select that mode.

  • Page 19: Basic Main Screen

    Hi Flow Sampler Operation 3.8.1 Basic Main Screen Date and Time: Date displayed as : GPS (Global Positioning System) icon mm/dd/yy, while time is displayed in a 12- appears when instrument detects that a GPS hour format. The date and time are set per receiver is connected to the unit’s GPS port...

  • Page 20: Expanded Main Screen

    Operation Hi Flow Sampler 3.8.2 Expanded Main Screen Date and Time: Date displayed as Save: Select to save all current measurement mm/dd/yy, while time is displayed in a 12- parameters in memory** hour format. The date and time are set per Start / Stop: Select to Start and Stop a test** Section 5.8.

  • Page 21: Menu System

    Hi Flow Sampler Operation Menu System Selecting Menu from either the Basic or Expanded Main Screen provides the user access to a system of submenus as shown in Figures 3-4 and 3- The items that are listed in the submenus depend on whether the instrument is in its Basic or Expanded menu mode.

  • Page 22: Battery Status

    Operation Hi Flow Sampler 3.10 Battery Status Battery status is displayed as a single battery icon shown in the lower- left hand portion of the LCD. Since the voltage curve of the battery pack drops off rapidly towards the end of its charge, the Battery status icon is useful only in showing when the battery pack is nearing depletion.

  • Page 23: Menu Mode - Basic Or Expanded

    Hi Flow Sampler Operation 3.13 Menu Mode – Basic or Expanded Selecting Menu Mode from the Menu System allows the user to select whether only the most basic amount of information is displayed on the Main Screen (Basic Menu mode), or if all available information is displayed (Expanded Menu mode).

  • Page 24: Manual Measurement Mode

    Operation Hi Flow Sampler 3.14.2 Manual Measurement Mode 3.14.2.1 Manual 2-Stage Mode In the Manual 2-Stage mode the user starts a measurement at a high flow rate, waits for a stable leak rate reading, and then manually saves the readings using the Save function. The unit then automatically lowers the flow rate, at which time the user makes a second leak rate measurement.

  • Page 25: Manual 1-Stage Mode

    Hi Flow Sampler Operation 3.14.2.2 Manual 1-Stage Mode In the Manual 1-Stage mode the user starts a measurement at a high flow rate and then waits for a stable leak rate reading to occur. During this time the flow rate can be changed using the Speed function on the Main Screen.

  • Page 26: Access Records

    2. On the computer, start HyperTerminal by doing one of the following: - If HyperTerminal has already been set up to communicate with the Hi Flow Sampler, then select Start > Programs > Accessories > Communications > HyperTerminal, and double-click the filename or icon that has been associated with the instrument.
  • Page 27 Hi Flow Sampler Operation d. Set Port Settings to: - Bits per second: 115200 - Data bits: 8 - Parity: None - Stop bits: 1 - Flow control: None Then click OK to display HyperTerminal’s main window. e. Click File > Save. This creates a file with an .ht extension using the name that was entered in Step b.

  • Page 28: View Records

    Operation Hi Flow Sampler 3.15.2 View Records View the records stored in memory on the unit’s LCD screen as follows: 1. Access the Review Record Screen from the Expanded Main Screen by selecting Menu > Access Records > View Records. This screen allows the user to view a short summary of each record stored in memory.

  • Page 29: Importing Saved Data Into A Spreadsheet

    Hi Flow Sampler Operation 3.16 Importing Saved Data into a Spreadsheet Test records that were downloaded to a personal computer per Section 3.15.1 can be imported into spreadsheet programs that are capable of importing comma-delimited files. Note that each data record consists of 24 fields, some of which may be blank because of options not being installed.
  • Page 30 Operation Hi Flow Sampler TABLE 3-2. TYPICAL SPREADSHEET* Record# Instr.Serial# Date#1(MM/DD/YY) Time#1(HH:MM:SS) Btry#1(V) Flow#1(cfm) 123456 01/20/03 10:15:05 123457 01/20/03 01:25:30 Back#1(%) Leak#1(%) Leak#1(cfm) Date#2(MM/DD/YY) Time#2(HH:MM:SS) Btry#2(V) 0.0350 15.1500 1.49 01/20/03 10:16:05 0.0155 21.3250 2.09 01/20/03 01:27:45 Flow#2(cfm) Back#2(%) Leak#2(%) Leak#2(cfm)

  • Page 31: Access Test Ids

    Hi Flow Sampler Operation 3.17 Access Test IDs Note: Access Test IDs can only be selected if operating in the Expanded Menu Mode. Refer to Section 3.8. Saved test records can be identified (e.g., location of test, type of test, name of operator, etc.) by manually entering up to two lines of text, with...

  • Page 32: Edit Test Ids

    Operation Hi Flow Sampler 3. Select the displayed Test ID by pressing the I/Okey, and then return to the Main Screen by pressing ESC twice. Observe that [0005] is now displayed at the bottom of the screen. 3.17.2 Edit Test IDs Edit a previously entered Test ID or to create a new one as follows: 1.

  • Page 33: Send Test Ids

    2. On the computer, start HyperTerminal by doing one of the following: - If HyperTerminal has already been set up to communicate with the Hi Flow Sampler, then select Start > Programs > Accessories > Communications > HyperTerminal, and double-click the filename or icon that has been associated with the instrument.

  • Page 34: Erase Test Ids

    Operation Hi Flow Sampler 4. From the High Flow Sampler’s Expanded Main Screen, start the download process by selecting Menu > Access Test IDs > Send Test IDs. Observe that the Hi Flow’s LCD displays the message “Sending record x of y @ 115.2kbps,” where “x” is the current record being sent and “y”...
  • Page 35 Hi Flow Sampler Operation 2. Select Yes to erase all Test ID information, or select No to return to the previous screen. 3. Press ESC twice to return to the Main Screen. Instruction 0055-9017...

  • Page 36: Making A Leak Rate Measurement

    Operation Hi Flow Sampler 3.18 Making a Leak Rate Measurement Before making a leak rate measurement, the user must decide whether to use . . .  the Basic or Expanded Menu Mode (Section 3.8)  lpm or cfm for the flow rate (Section 3.12) ...

  • Page 37: Leak Rate Measurement - Automatic 2-Stage Mode

    Hi Flow Sampler Operation 6. In the example below, the current flow rate is 216.5 lpm, the background gas concentration is 0.8%, the leak concentration is 15% gas, and the calculated leak rate is 42.5 lpm. 7. The measurement process continues until Stop is selected.
  • Page 38 Operation Hi Flow Sampler 5. The user is now asked to choose a new or different Test ID. Selecting Yes causes the Access Records menu to appear (refer to Section 3.15). After selecting or creating a new Test ID, start the measurement by pressing ESC until the Main Screen appears.
  • Page 39 Hi Flow Sampler Operation 7. After both measurements are complete, the values in the Main Screen are put on hold (as indicated by “H--” appearing at the bottom of the screen), allowing the user to make note of these values before turning off the instrument or proceeding to the next measurement.

  • Page 40: Leak Rate Measurement - Manual 2-Stage Mode

    Operation Hi Flow Sampler 3.18.3 Leak Rate Measurement – Manual 2-Stage Mode Note: The Manual 2-Stage Mode can only be selected if operating in the Expanded Menu Mode. Refer to Section 3.8. 1. If not already done, place the instrument into its Manual 2-Stage mode.
  • Page 41 Hi Flow Sampler Operation 7. Once a stable leak measurement is obtained, highlight Save and press the I/Okey. Observe that the measurement is saved in memory, and that the flow rate is automatically lowered. In the example below, the measured leak concentration for measurement #1 was 15% gas, and the calculated leak rate was 42.5...

  • Page 42: Leak Rate Measurement - Manual 1-Stage Mode

    Operation Hi Flow Sampler 3.18.4 Leak Rate Measurement – Manual 1-Stage Mode Note: The Manual 1-Stage Mode can only be selected if operating in the Expanded Menu Mode. Refer to Section 3.8. 1. If not already done, place the instrument into its Manual 1-Stage mode.
  • Page 43 Hi Flow Sampler Operation Speed Bar 7. Once a stable leak measurement is obtained, all current readings can be saved in memory by highlighting Save and pressing the I/Okey. In the example below, the current measured leak concentration is 15% gas, and the calculated leak rate is 42.5 lpm.

  • Page 44: Message Line

    Operation Hi Flow Sampler 3.19 Message Line Various messages will appear at the bottom of the LCD that describe what functions are currently being performed or errors that have been detected. The following list describes the meaning of these messages.

  • Page 45: Gps Data

    Hi Flow Sampler Operation Check Zeroing Bypassed Error – The ESC key was pressed during start up, thus bypassing the normal sensor-zeroing process. Refer to Section 6.2. Check Leak Rate Difference Error–The calculated leak rate difference between measurements #1 and #2 during an automatic or manual leak test was greater than 100%.

  • Page 46: Barcode Scanner Data

    Operation Hi Flow Sampler The GPS data is saved along with all other measured and calculated values at the conclusion of an automatic test, or when Save is selected during a manual test. 3.21 Barcode Scanner Data Note: Barcode scanning can only be performed if operating in the Expanded Menu Mode.

  • Page 47: Calibration

    Zero Air, P/N 0051-7131 (optional) Connect the components of the calibration kit, calibration gas cylinder, and Hi Flow Sampler together as shown in Figure 4-1. DO NOT, however, attach the calibration equipment to the instrument until instructed to do so in the calibration procedure.

  • Page 48: Check Calibration Procedure

    Calibration Hi Flow Sampler Figure 4-1. Calibration Equipment Setup Check Calibration Procedure This procedure checks the calibration of both the leak-gas sensor and the background-gas sensor using 2.5% CH . After setting up the calibration equipment as described in Section 4.2, proceed to check the instrument’s sensor calibration as follows:...

  • Page 49: Gas Calibration Procedure

    Hi Flow Sampler Calibration 5. Disconnect the hose from the BACKGROUND inlet port and connect it to the GAS inlet port. 6. Again wait several minutes for the gas reading to stabilize. At this time the gas concentration shown on the display should match the concentration stamped on the calibration gas cylinder.
  • Page 50 Calibration Hi Flow Sampler 5. Apply the appropriate level of calibration gas from the calibration equipment to the instrument’s GAS or BACKGROUND inlet port. (In the example above, apply 2.5% CH to the BACKGROUND port.) Then press the I/Okey to start the calibration process. Observe that the gas-sampling-pump motors start and the calibration screen appears.

  • Page 51: Calibration Amplifier Gain Check

    Hi Flow Sampler Calibration Calibration Amplifier Gain Check Use this procedure to display the gain values of the calibration amplifier circuits in hexadecimal. This procedure is useful to service technicians for troubleshooting purposes. 1. From the Main Screen select Menu > Calibration > Calibration Gains to display the Calibration Gains Screen.
  • Page 52 Calibration Hi Flow Sampler Notes: Instruction 0055-9017...

  • Page 53: Maintenance

    Hi Flow Sampler Maintenance 5 Maintenance Routine maintenance of the Hi Flow Sampler consists of the following:  Charging the battery pack  Replacing the internal filters  Replacing the gas sensors  Verifying flow rate  Setting the time and date ...

  • Page 54: Charging The Battery Pack

    Maintenance Hi Flow Sampler Charging the Battery Pack WARNING: Explosion hazard! DO NOT charge the battery pack in an unsafe atmosphere. 1. Unplug battery pack from the instrument’s power cord; then remove battery pack from backpack. 2. Interconnect the supplied power supply, power cord, and charger as shown in Figure 5-1.

  • Page 55: Removing The Cover

    Hi Flow Sampler Maintenance Removing the Cover When instructed to do maintenance inside the instrument, remove its protective cover as follows: 1. Do the following before removing the instrument from the backpack: - Disconnect battery pack - Unscrew metal-cage diffuser from the instrument’s gas exhaust...

  • Page 56: Replacing The Internal Filters

    Maintenance Hi Flow Sampler Replacing the Internal Filters Three internal filters protect the instrument from being contaminated by dust and dirt. Replace these filters when they look contaminated. A good indication that a filter needs replaced is when the instrument’s gas- response time increases.

  • Page 57: Leak-Gas Sensor Filter

    Hi Flow Sampler Maintenance 5.4.2 Leak-Gas Sensor Filter The leak-gas sensor filter is located inside the flow block of the leak-gas sensor assembly. See Figure 5-4. Equipment Required:  Medium Phillips Head Screwdriver  Replacement Filter (P/N 0055-0045) Procedure: 1. Remove cover per Section 5.3.

  • Page 58: Gas Sensor Replacement

    Maintenance Hi Flow Sampler Gas Sensor Replacement Replace a gas sensor when it fails to calibrate per Section 4 Calibration. The gas sensors are located inside their associated flow blocks of the leak-gas and background-gas sensor assemblies. See Figure 5-5.

  • Page 59: Pump Replacement

    Hi Flow Sampler Maintenance Pump Replacement The pump located in either the leak-gas or background-gas sensor assembly (see Figure 5-5) may become inoperative due to water or solid particles getting into the valves. This will require replacement of the pump to correct.

  • Page 60: Flow Rate Verification

    Important: To assure accurate flow readings, conduct the following procedure in clean air, free of any combustible gases. 1. Install the flow meter onto the Hi Flow Sampler’s gas intake as shown in Figure 5-7. 2. Place the Hi Flow Sampler into its Manual 1-Stage Mode per Section 3.14.2.2.
  • Page 61  Ensure that no obstruction is present inside the flow- measurement tube.  If none of the above solves the problem, return the unit to your nearest Bacharach Service Center for evaluation. Instruction 0055-9017...
  • Page 62 Maintenance Hi Flow Sampler Figure 5-9. Gas Flow System Instruction 0055-9017...

  • Page 63: Setting Date And Time

    Figure 5-10. Plumbing Diagram Setting Date and Time The following describes how to set the date and time as displayed on the Hi Flow Sampler’s LCD using a personal computer that is running Windows HyperTerminal as the communications program. If a different ®...

  • Page 64: Resetting The Microprocessor

    OK). The Connect To dialog box should appear. c. Click the Connect using drop-down menu and choose the COM port to which the Hi Flow Sampler is connected. Then click OK to display the COM Properties dialog box for that COM port.

  • Page 65: Troubleshooting

    Hi Flow Sampler Troubleshooting 6 Troubleshooting Instrument Repair It is recommended that field repair of the Hi Flow Sampler be limited to:  Cleaning gas-inlet screen  Replacing internal filters  Replacing sensors  Replacing sensor assembly pump  Simple checks of printed circuit board connectors All other repairs should be performed by an authorized Bacharach Service Center.
  • Page 66 Troubleshooting Hi Flow Sampler TABLE 6-1. TROUBLESHOOTING GUIDE (Cont.) Instrument won’t respond when a control Microprocessor needs reset. Disconnect unit key is pressed. battery pack for several seconds. Low flow rate reading with fully charged Flow path obstructed. Check flow path and battery.

  • Page 67: Error Codes In Saved Test Records

    Hi Flow Sampler Troubleshooting TABLE 6-1. TROUBLESHOOTING GUIDE (Cont.) “Check Background Offset” message The background-gas sensor did not zero appears at bottom of display. properly during start-up. Switch OFF instrument and restart in an area with clean air. Replace sensor if necessary.
  • Page 68 Troubleshooting Hi Flow Sampler Notes: Instruction 0055-9017...

  • Page 69: Parts & Service

    Hi Flow Sampler Parts & Service 7 Parts & Service Replacement Parts Complete Hi Flow Sampler Assembly ........0055-8020 Standard Attachments: 3-Port Background Gas Sampler ........0055-0271 Bellows Tool ..............0055-0259 Beveled Nozzle Tool: 6.5" ................0055-0213 24" ................0055-0247 Capture Bag: Disposable, clear plastic, 38"...

  • Page 70: Service Centers

    Parts & Service Hi Flow Sampler Service Centers United States Bacharach Sales/Service Center 621 Hunt Valley Circle New Kensington, PA 15068 Phone: 724-334-5051 Fax: 724-334-5723 Email: help@mybacharach.com Canada Bacharach of Canada, Inc. 20 Amber St. Unit #7 Markham, Ontario L3R SP4...
  • Page 72 Headquarters: 621 Hunt Valley Circle, New Kensington, PA 15068 Ph: 724-334-5000 • Fax: 724-334-5001 • Toll Free: 1-800-736-4666 Website: www.mybacharach.com • E-mail: help@mybacharach.com Printed in U.S.A.

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