JP3 Measurement Verax CTX and Verax VPA Installation Instructions

Verax CTX and Verax VPA Installation Instructions JP3 Measurement 4109 Todd Lane Austin TX 78744 512-537-8450 www.jp3measurement.com 8/23/2016 Verax CTX Install Instructions, Rev07 1 Table Of Contents: 1. Facilities Requirements Page 3 2. Unpacking and Handling Page 5 3. Mounting the Control Panel Page 7 4. Mounting the Flow Cell Page 8 5. Running Fiber Page 9 6. Flow Cell to Panel Connections Page 10 7. Other Panel Connections Page 13 8. Power Up Sequence Page 15 9. Heater Block Kit for Flow Cell (Optional) Page 16 8/23/2016 Verax CTX Install Instructions, Rev07 2 2 1) Facilities Requirements: Intended Use: The Verax CTX is an optical NIR analyzer for determining the constituents and physical properties of a hydrocarbon fluid stream by using NIR spectroscopy to model the parameter of interest. Contact a JP3 sales representative to discuss the range of analysis available. Location Rating: • • • • • • • • Verax CTX Analyzer is in a Type 4 NEMA Enclosure Class 1 / Division 2 A,B,C,D, T4 Class 1 / Zone 2 IIC Certified to UL 61010-1 Certified to CAN/CSA Std C22.2 No. 61010-1 Conforms to ISA 12.12.01 Conforms to CSA/CSA C22.2 No 213 Operational temperature range: -20C to 50C (-4⁰ F to 122⁰F). Electrical Input Requirements: • • • Per customer specification one of the two options below: • 100-240V AC, 50-60 Hz, 1.6-0.7 Amp or • 24V DC, 3.5 Amp The input electrical configuration is indicated on the warning tag below the antenna on the left side of the box (see Figure 1). For surge protection a 20A breaker is recommended as the customer-provide disconnection device. 8/23/2016 Verax CTX Install Instructions, Rev07 3 Explanation of Warning Labels: The model and electrical configuration on the warning label are specified with punched holes next to the applicable value. Le modèle et la configuration électrique sur l'étiquette d'avertissement sont spécifiés avec des trous percés à côté de la valeur applicable WARNING: EXPOSURE TO SOME CHEMICALS MAY DEGRADE THE SEALING PROPERTIES OF MATERIALS USED IN THE FOLLOWING DEVICES; [Relay Module - PLC-RSC-24DC/21 C1D2- 5603154; Miniature Plug-in Relay: 8501RSD34V53] AVERTISSEMENT: L'exposition à certains produits chimiques peuvent dégrader les propriétés d'étanchéité des matériaux utilisés dans les appareils suivants; [Module de Relais - PLC-RSC-24DC / 21 C1D2- 5,603,154; Miniature Plug-in relais: 8501RSD34V53] WARNING: EXPLOSION HAZARD. DO NOT REMOVE OR REPLACE FUSES OR PLUG-IN MODULES UNLESS POWER HAS BEEN DISCONNECTED OR THE AREA IS KNOWN TO BE FREE OF IGNITIBLE CONCENTRATIONS OF FLAMMABLE GASES OR VAPORS. AVERTISSEMENT: RISQUE D'EXPLOSION. NE PAS RETIRER OU remplacer les fusibles ou des modules de plug-in à moins que le courant electrique est déconnectée ou que l'environnement est exempt de concentrations de gaz inflammables ou des vapeurs inflammables. WARNING: EXPLOSION HAZARD. DO NOT DISCONNECT WHILE THE CIRCUIT IS LIVE OR UNLESS THE AREA IS KNOWN TO BE FREE OF IGNITIBLE CONCENTRATIONS. ATTENTION: RISQUE D'EXPLOSION. Ne débranchez pas alors que le circuit est sous tension à moins que la zone est connue pour être dépourvue de concentrations inflammables. WARNING: SUBSTITUTION OF THE FOLLOWING COMPONENTS MAY IMPAIR SUITABILITY FOR DIVISION 2: AVERTISSEMENT: remplacement d'éléments suivants peuvent nuire à la conformité DIVISION 2: Reference Designation Description Type of protection SPC Reboot Relay PLC-RSC-24DC/21 C1D2– Part Number: 5603154 Sealed Relais SPC Reboot Scellée PLC-RSC-24DC/21 C1D2– Numéro de pièce:5603154 TB1 Reboot Relay Miniature Plug-in Relay: Part Number: 8501RSD34V53 Relais TB1 Reboot Hermetically sealed Scellée hermétiquement Numéro de pièce: 8501RSD34V53 SPC (Spectrometer) Part Number: XL 410 SPC (Spectromètre) Numéro de pièce: XL 410 Non arcing [Limited Product evaluation to Class 1 Div 2 requirements] Non arc [évaluation de produit limitée à la classe 1 Div 2. exigences] OBC (On Board Computer) Part Number: MIO-5271Z2-4GS9A1E Non arcing [Limited Product evaluation to Class 1 Div 2 requirements] Numéro de pièce: MIO-5271Z2-4GS9A1E Non arc [évaluation de produit limitée à la classe 1 Div 2. exigences] Ordinateur embarqué 8/23/2016 Verax CTX Install Instructions, Rev07 4 2) Unpacking and Handling: Shipped Materials: • Verax CTX Control Panel (qty 1) • Flow Cells (qty 1-4 depending on the order) • Optical Fiber Pair (qty 1-4, one for each flow cell). Handling Instructions: • • • • Weight: 60lbs Dimensions: 24’’ x 36’’ x 11.2’’ Mounting Holes: 18” x 37.3” Uncrate and mount the analyzer to unistrut or other mounting surface capable of handling the weight of the unit. Do not drop. 24” 18” 11.2” Front View Side View 37.3” 36” Figure 1 – Verax CTX Control Panel - Dimensions 8/23/2016 Verax CTX Install Instructions, Rev07 5 Firewall Ethernet Switch (Comm) Power Distribution Antenna Fitting Serial # & Warning Label Incoming Power Connection PLC Modem On Board Computer Spectrometer Send Fiber Connections RTD and Transducer Terminal Block Return Fiber Connections Figure 2 – Verax CTX Control Panel – Front View 8/23/2016 Verax CTX Install Instructions, Rev07 6 3) Mounting the Control Panel: Mounting Requirements: • • • • Select a location that is easily accessible at grade level. Mounting holes are provided for easy installation. Shade is required if mounting outdoors where ambient temps can exceed 100⁰ F. Do not mount the analyzer in such a way to make it difficult to operate the customer-provided electrical disconnect device (switch, breaker or other) Antenna Connection: • • 16dB Antenna is provided along with a 90 degree fitting. The Antenna is attached to the bulkhead fitting on the upper left of the Analyzer Panel using the 90 degree fitting (see Figure 2). Pass-through for Electrical Wires: • The Verax CTX Control Panel is shipped without holes or wire ways for incoming electrical service or optical fibers. • Control Panel penetrations are made by the customer in order to provide the maximum flexibility for routing incoming fiber and electrical and communications. • All connections or fittings chosen by the customer should by rated for Type 4 enclosure. • All ports and penetrations must be plugged with duct putty or some other standard industry practice to assure the sealed integrity of the enclosure. • The customer should plan for the following when choosing the size and placement of ports on the Verax CTX Control Panel: • One Incoming Electrical Cable • One Incoming Communications Cable (usually CAT5) • One RTD Cable from each Flow Cell • One Transducer Cable from each Flow Cell • Two Fiber Optic Cables from each Flow Cell • The customer is responsible to protect the inside of the control panel when cutting or punching holes. DO NOT ALLOW METAL SHAVINGS TO FALL ON THE TERMINAL BLOCKS OR OTHER COMPONENTS INSIDE THE CONTROL PANEL. 8/23/2016 Verax CTX Install Instructions, Rev07 7 4) Mounting the Flow Cell: Placement: • • The Flow Cells can be mounted to a unistrut frame, or other solid structure. Probes should be accessible at grade level. Pressure and Temp Rating: • • • Operational Max Pressure: 1500 psi Operational Ambient Temperature Range: -30C to 50C (-22⁰ F to 122⁰F) Operational Fluid Temperature Range: -23C to 107C (-10⁰ F to 225⁰F) JP3 Provided Flow Cell Bypass Configuration: • • Customer provided bypass • • Minimum 1psi delta between inlet and return Inlet • • Return Stinger in order to sample from center of the pipe Figure 3 – Example of a Bypass Configuration 8/23/2016 • Flow Cell should be mounted horizontally, as shown in Figure 3. For a bypass Flow Cell, the customer taps into the process stream and plumbs the fluid to the inlet on Flow Cell, then from the Flow Cell outlet back to the process stream. The customer provides all materials for the bypass plumbing. It is recommended that the customer use a stinger at the inlet and return points in order to pull fluid from the center of the pipe. ½” Swagelok fittings are supplied on the inlet and return ports on the Flow Cell. The customer must assure flow of liquid or gas over the probe windows by providing a pressure drop of at least 1 psi from inlet to outlet. To get a good delta P, choose your inlet and return points such that flanges, valves, meters or similar instruments are located between these two points, as these often provide the necessary bypass pressure differential. When using a heater blanket with the Flow Cell, 120VAC, 2 Amp service is required. A 5’ pigtail is provided on the blanket. Verax CTX Install Instructions, Rev07 8 Scoop Configuration: • • • • With this configuration a scoop is used to direct flow from the pipe to the probe using the kinetic energy of the process stream itself. With a scoop, a pressure differential is not required, and often a bi-direction scoop can be used such that only one tap is necessary. However, certain process flow and pipe conditions must be met in order to use the scoop. Consult your local JP3 representative to discuss options. ½” Swagelok fittings are supplied on the inlet and return ports of the Flow Cell. When using a heater blanket with the Flow Cell, 120VAC, 2 Amp service is required. The junction box must be within 4 feet of the Flow Cell. Figure 4 – Example of a Scoop Configuration A bidirectional scoop is shown in this image – the stinger has a double chamber, and both inlet and return is achieved with the same tap. Flow Cell Inlet 5) Running Optical Fiber Return Warning – Read Carefully • • • • • JP3’s Verax Technology uses unique large core multi-mode fiber to attenuate the optical signal between the control panel to Flow Cell. The large core NIR cable is sensitive to sharp bend angles and contamination. Handle very carefully to avoid kinks and keep the ends capped until ready to commission. Maintain a minimum 7” bend radius when running/routing the fiber from control box to Flow Cell. When pulling the fiber, do not attach pull ropes to the boots at the ends of the fiber – you can damage the boot. Keep the fiber ends capped until you a are ready to connect the ends. 8/23/2016 Verax CTX Install Instructions, Rev07 9 JP3 Measurement Fiber Optic Cable Specification The following are specifications important for handling and installation of the fiber: • 600um-core multimode fiber with a Kevlar jacket. • 5.5mm black PVC weather proof furcation jacket, UV resistant • Outdoor rated construction, and all components nonconductive  (most similar to OFNR indoor construction) • Weight = 22 lbs/1000 feet (3.3kg/100m) • Max Installation Tension, 180 lbs (800N) • Max Operating Tension, 90 lbs (400N) • Installation Temp Range, 15⁰ F to 176⁰ F (-9C to 80C) • Operational temp range, -40⁰ F to 122⁰ F (-40C to 50C) • Minimum Bend Radius = 7” (18cm) • Send Fibers us keyed APC connectors • Receive Fibers use SMA connectors Figure 5 – • Fibers will be labeled as below: Fiber Assembly Dimensions and Labeling 6) Flow Cell to Control Panel Connections Fiber: • • • • Run Fiber Optic Pair between the Flow Cell and CTX Control Panel according to the specification in Section 5 of this Instructions. JP3 will provide the Optical Fiber Pairs (Send and Receive) for each probe set, cut to length. A pull apparatus is provided on one end of the fiber if the customer is pulling through conduit. Do not remove and pull the fiber by applying force to the termination boot. This can cause damage to the fiber At Commissioning, JP3 Field Operations professionals will clean and terminate the optical fibers in order to assure the best possible optical signal between the CTX Panel and Flow Cell. Therefore: o Do not terminate the fibers at Flow Cell, or Control Panel. o Do not remove protective caps at the fiber ends. 8/23/2016 Verax CTX Install Instructions, Rev07 10 Electrical: • • • • The customers will provide all electrical cables between Flow Cell and CTX Control Panel. For the Temperature RTD run a 3-conductor cable between each Flow Cell and the Control Panel. For Pressure Transducer run a 4-conductor cable between each Flow Cell and the Control Panel. For both RTD and Transducer a 4-5’ pigtail is provided at the Flow Cell. These should be connected to the customer-provided cable in such a way as to comply with the site’s electrical and safety standards. Wire the Flow Cell to the Control Panel: • • • • Inside the Control Panel the RTD and Transducer terminals blocks are numbered 1-4 which corresponds to each flow cell, 1-4 (see Figure 6). All Fiber Optics, RTD, and Transducer terminations from the flow cell should use the same number designation inside the panel. Connect the RTD cable from each Flow Cell to its corresponding RTD terminal block: • one red wire to the third terminal from the left, • the second red wire to the second terminal from the left, • the white wire to the far left terminal. Connect the Transducer cable from each Flow Cell to its corresponding Transducer terminal block: • Brown wire on the fourth terminal from the left, • Red on the third terminal from the left, • Black on the second terminal from the left, • Gray on the far left terminal. Figure 6 – RTD and Transducer Wiring Instructions 8/23/2016 Verax CTX Install Instructions, Rev07 11 Attach Fiber Optics to Spectrometer: 1. 2. 3. 4. 5. 6. Two Optical Fibers from each probe assembly are connected to the spectrometer at the bottom of the box. Pass the Fibers into the Control Panel through customer-provided pass-through. Send Fibers are connected with APC connections labeled 1-4 at the left side of the spectrometer. JP3 will terminate the fiber. Receive Fibers are connected with SMA connections at connectors on the right side of the spectrometer. JP3 will terminate the fiber. DO NOT THROW AWAY KNURLED CAPS FROM THE FIBER. These are needed to protect the connections during servicing. A box for storage of the caps is provided in the bottom of the CTX Control Panel. All Fiber Optics, RTD, and Transducer terminations from the flow cell should use the same number designation inside the panel. Receive Fibers terminate on the right side of the spectrometer, labeled 1-4 Send Fibers terminate on the left side of the spectrometer, labeled 1-4 Figure 7 – Send and Receive Fiber Termination Points 8/23/2016 Verax CTX Install Instructions, Rev07 12 7) Other Control Panel Connections Connect the Ethernet Communications Cable: 1. 2. 3. For Modbus communications run the Ethernet communications cable through customer-provided wire pass through and route to the Ethernet switch on the left side of the analyzer control panel. (See Figure 3) Connect to any available Ethernet port. For analog or other communications protocols contact our offices to arrange a meeting with one of our engineering team members to discuss options. Connect Main Power: • For 24V DC Power Configuration 1. Run the power cable through customer-provided wire pass through port and route to the terminal blocks on the upper right side of the analyzer control panel. (See Figure 8) 2. Connect hot wire to 24V fuse. 3. Connect neutral wire to 0V terminal. Figure 8 – Main 24VDC Power Wiring Instructions 8/23/2016 Verax CTX Install Instructions, Rev07 Components shown inside dotted line only included with 100-240V AC option 13 Connect Main Power: • For 100-240V AC Power Configuration • Run the power cable through customer-provided wire pass through port and route to the terminal blocks on the upper right side of the analyzer control panel. (See Figure 3) • Connect hot wire to 100-240V fuse. • Connect neutral wire to 0V terminal. • Connect ground wire to the green/yellow ground terminal. Figure 9 – Main 100-240VAC Power Wiring Instructions 8/23/2016 Verax CTX Install Instructions, Rev07 14 9) Power-up and Commissioning: Power Up Sequence: • To Engage Power engage the fuses in the following order 1. 100-240V fuse (if applicable – for the AC configuration only) 2. 12V fuse 3. 12V fuse Figure 10 – Power Up Sequence 3rd 2nd 1st • At this point the Verax CTX Analyzer is ready to be commissioned. Contact JP3 Field Service team to complete installation and commissioning. • Contact JP3 Field Service team for all maintenance and servicing needs. • service@jp3measurement.com • 512-537-8450 8/23/2016 Verax CTX Install Instructions, Rev07 15 10) Heater Block Kit for Flow Cell (Optional): Heater Block Kit: • • • • • The heater block kit is designed for a JP3 Flow Cell, and consists of a C1/D2 80W heater, a 140° F thermostat, and a surrounding thermal blanket. The heater block and thermostat are wired in series such that the heater turns on only if the thermostat senses less than 140° F. Attach the heater block and thermostat to the flow cell with the provided hardware. BOTH components should use the same two screws. Attach front and back portions of the blanket using the attached velcro straps. WARNING: when heater block kit is energized, the block, and flow cell are too hot to touch. De-energize and allow to cool before servicing. Back-side blanket Flow Cell Assembly WARNING: Hot Surface Heater Block and Thermostat. Attach to flow cell using provided hardware. Figure 11 – Heater block and blanket assembly 3’ pigtail to electrical conduit Front-side blanket (with velcro straps) 8/23/2016 Verax CTX Install Instructions, Rev07 16 Electrical Requirements and Wiring: • • • • 110-277 VAC, 0.7 – 0.3 A, 80 W Incoming power from customer should be attached in the provided conduit housing per the diagram below (live, neutral, and ground). The Thermostat and Heater Block are pre-wired in series so that the thermostat controls the flow of current to the block. Connect power to the wires in the provided electrical conduit housing per Figure 12. Flow Cell (with heater block kit attached) Conduit Housing Electrical Connections Figure 12 – Wiring 8/23/2016 Verax CTX Install Instructions, Rev07 17