JP3 Measurement Verax 75 and Verax VPA Installation Manual

Verax 75 and Verax VPA Installation Manual JP3 Measurement 4109 Todd Lane Austin TX 78744 512-537-8450 www.jp3measurement.com 03/31/2016 Verax 75 Installation Manual, Rev 10 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 Probe Assembly page 9 5. Probe Assembly to Control Panel Connections page 11 6. Z-purge installation (optional) Page 16 7. Heater Blanket for Probes (optional) Page 18 8. Power Up and Commissioning Page 19 03/31/2016 Verax 75 Installation Manual, Rev 10 2 2 1) Facilities Requirements: Intended Use: The Verax 75 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. The Verax 75-Z model incorporates a Z-purge system for mounting in a Class I / Division 2 location. Location Rating: • • • • • Verax 75 Analyzer is in a Type 4 NEMA Enclosure, and all provided fittings are Type 4 rated. For General Purpose Location, Conforms to ANSI/UL Std 610101 For Class I / Division 2 A,B,C,D, T Code- T4 a Type Zpressurization must be used. With Z-purge, Conforms to NFPA Std 496 Certified to CAN/CSA Std C22.2 No. 61010-1 Operational temperature range: -29C to 50C (-20⁰ 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 3) For surge protection a 20A breaker is recommended as the customer-provide disconnection device Other Facilities Requirements (for Z-purge only): • Instrument Air or Nitrogen • Supply pressure: 80-120 psig • Safe Pressure Set Point: 0.25’ water column • Safe pressure flow rate: 0.13-3.5 SCFH • Exchange Flow Rate: 4 SCFH 03/31/2016 Verax 75 Installation Manual, Rev 10 3 Explanation of Warning Labels: The following warning applicable only when using the Z-purge option: WARNING – PRESSURIZED INCLOSURE This enclosure must not be opened unless the area atmosphere is known to be below the ignitable concentration of combustible materials or unless all the devices within have been de-energized AVERTISSEMENT : BOÎTIER SOUS PRESSION: Ce boîtier ne doit pas être ouvert à moins que l'atmosphère de la zone ne soit inférieure à la concentration inflammable de matières combustibles ou à moins que tous les dispositifs qui s’y trouvent n’aient été mis hors tension. The following warning applicable only when using the Z-purge option: WARNING: Power must not be restored after enclosure has been opened and until enclosure has been purged for 3.5 minutes for Verax 75-Z model or 6 minutes for Verax 75M-Z AVERTISSEMENT: L'alimentation ne doit pas être rétablie après l’ouverture du boîtier et jusqu'à ce que le boîtier ait été purgé pendant 3,5 minutes pour le modèle Verax 75-Z ou 6 minutes pour le modèle Verax 75M-Z. The following warning applicable to all models: 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 Figure 1: Warning Label Located on the left side of the analyzer below the antenna port. (see Figure 3) 03/31/2016 Verax 75 Installation Manual, Rev 10 4 2) Unpacking and Handling: Shipped Materials: • Verax Analyzer Control Panel (qty 1) • Probe Assembly (qty 1) • Antenna (qty 1) • Z-purge w/ fittings (optional, 1 set) Handling Instructions: • • • • Weight: 51lbs Dimensions: 24’’ x 30’’ x 9.35’’ Mounting Holes: 18” x 31.25” Uncrate and mount the analyzer to unistrut or other mounting surface capable of handling the weight of the unit. Do not drop. 24” 18” 9.35” 30” 31.25” Front View Side View Figure 2 – Verax 75 Analyzer Control Panel - Dimensions 03/31/2016 Verax 75 Installation Manual, Rev 10 5 Antenna Fitting Serial # & Warning Label Wiring Terminal Blocks Incoming Power Connection Radio / Modem PLC PC Ethernet Switch (Comm) RTD and Transducer Terminal Block Spectrometer Figure 3 – Verax 75 Analyzer Control Panel – Front View 03/31/2016 Verax 75 Installation Manual, Rev 10 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. The Probe Assembly must be mounted next to the analyzer – separation is limited by 10 linear feet of fiber. Shade is required if mounting outdoors where ambient temps can exceed 90⁰ F. Do not mount the analyzer in such a way to make it difficult to operate the customer-provided electrical disconnect device (witch, breaker or other) Antenna Connection: 1. 2. 1. 2. 3. 4. 5. 6. 7. 16dB Antenna is provided along with a 90 degree fitting. Attach Antenna to the fitting on the upper left of the Analyzer Panel using the 90 degree fitting (see Figure 3 for location of the fitting). Fiber Optic Connection: The Fiber is passed through the flex conduit/liquid tight fittings on the bottom of the analyzer control panel. Customer provides flex conduit. Send Fibers will be labeled with 2” Red Shrink Tube reading “SEND”. Receive Fibers will be labeled with 2” Yellow Shrink Tube reading “RECEIVE”. Pull the fibers through the flex conduit, and let the excess hang coiled up under the analyzer until ready to connect to the probe assembly. Leave the caps on the end of the fiber. Do not let the fiber drag on the ground. See Section 5 for instructions to connect the fiber to the probe assembly 03/31/2016 Verax 75 Installation Manual, Rev 10 Figure 4 – Fiber Optic Cables installed with the Liquid Tight Fitting and Flex Conduit 7 Pass-through for Electrical Wires: • The Verax Control Panel is shipped without holes or wire ways for most of the incoming electrical service or fiber connections. The only pre-positioned holes are: • The Antenna fitting (top left), and • Two fittings for the fiber (bottom left) • Additional wire pass-throughs will need to be installed by the customer. The placement of these holes is left up to the customer’s installation teams in order to provide maximum flexibility to bring the cables and fiber from below or above, and attach them to the Verax Control Panels with a sufficient size conduit or fitting. • All connections or fittings chosen by the customer should by rated for Type 4 enclosure. • After the wires and fibers are run, all ports and pass-throughs must be plugged with duct putty or some other standard industry practice to assure the sealed integrity of the enclosure. • The customer must plan for the following cables when choosing the size and placement of ports on the Verax Control Panel: • One Incoming Electrical Cable • One Incoming communications Cable • One RTD cable from the probe assembly • One Transducer cable from the probe assembly • Read instructions in Section 6 regarding where these fibers/cables attach inside the control panel before you start cutting holes. • The customer is responsible to protect the inside of the control panel when cutting or punching holes for the wire way. DO NOT ALLOW METAL SHAVINGS TO FALL ON THE ELECTRICAL CONNECTIONS OR COMPONENTS INSIDE THE CONTROL PANEL. • Contact your local JP3 sales representative to discuss options 03/31/2016 Verax 75 Installation Manual, Rev 10 8 4) Mounting the Probe Assembly: Placement: • • The Probe Assembly are typically mounted to a unistrut frame, or other solid structure Probes should be accessible at grade level. Pressure and Temp Rating: • • All probe windows and probe assemblies are tested to 1500 psi Operational temperature range: -29C to 50C (-20⁰ F to 122⁰F). Bypass Probe Configuration: • • • • • • For a bypass probe assembly, the customer taps into the process stream they want to monitor, plumbs the fluid to the inlet on probe assembly, and back to the process stream. (see Figure 4 on the next page) It is highly recommended that the customer supply a stinger at the inlet and return of the pipe you are monitoring in order to pull fluid from the center of the pipe. Either ½” or ¼” Swagelok fittings are supplied on the inlet and return ports of the probe assembly. Customer supplies ¼” or ½” stainless steel tubing as dictated by the fittings supplied on the probe assembly. • ½” is typical for liquids • ¼” is typical for gas The customer must assure sufficient flow of liquid or gas over the probe windows by providing a pressure drop of at least 1 psi from inlet to outlet. Choosing the correct inlet and return points on the process pipe is critical to assure flow. Often choosing inlet and return points such that flanges, valves, meters or similar instruments are located between these two points is sufficient to provide the necessary bypass pressure differential. Actual Installation details vary by location and application; consult with JP3 Sales representative to discuss options. When using a heater blanket with the probe assembly, 120VAC, 2 Amp service is required. The junction box must be within 4 feet of the probe assembly. 03/31/2016 Verax 75 Installation Manual, Rev 10 9 Minimum ∆P from Inlet to Return is 1 psi Return Inlet Stinger at the Inlet to sample from center of the pipe Figure 5 – Example Probe Bypass Arrangement 36” 31.7” 21” Return Port Receive Fiber Fitting Transducer RTD Service Port DO NOT REOME CAP Send Fiber Fitting 13.2” Service Port DO NOT REMOVE CAP Conduit Housing Inlet Port 4.4” Top-Down View Figure 6 – Bypass Probe Assembly 03/31/2016 Verax 75 Installation Manual, Rev 10 10 5) Probe Assembly to Control Panel Connections Connect Fiber Optics to Probe Assembly: Warning – Read Carefully • • • • Fiber optic cable is extremely sensitive to sharp bend angles and contamination. Handle very carefully to avoid kinks and keep the ends capped until ready to attach to the probes. Maintain a minimum 7” bend radius when running/routing the fiber from control box to probe assembly It is recommended that the fiber optic cable be run in it’s own dedicated conduit, or elevated cable trays. Do not place fiber in ground level open cable trays where it can be stepped on. Keep the fiber ends capped until you a are ready to connect the ends. Attach Fiber to Probe Assembly: 1. 2. 3. 4. 5 Open the conduit housing on the probe assembly Install the fiber using LT50 fittings and flex conduit at either end of the probe assembly (see Figure 6). The flex conduit approach offers the best protection for the fiber. Connect the fiber to the back of the probe inside the conduit housing by screwing the fiber end onto the threaded probe connection. (see Figure 7) DO NOT THROW AWAY THE KNURLED CAPS. These should be left in the conduit housing to be used to protect fiber and probe connections when disconnected during servicing. Replace conduit housing cover Liquid Tight Fitting Figure 7 – Fiber Installation on Probe Assembly 03/31/2016 Fiber/Probe Connection Point Verax 75 Installation Manual, Rev 10 11 JP3 Measurement Fiber Optic Cable Specification JP3 uses a custom optical fiber assembly, design and characterized to maximize the characteristics of the optical loop from laser to probe and back to the detector. 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) • Male SMA connections on both ends. • Each end will be labeled as below: Figure 8 – Fiber Assembly dimensions and labeling 03/31/2016 Verax 75 Installation Manual, Rev 10 12 Wire the Probe Assembly to the Control Panel: 1. 2. 3. 4. The Analysis Points on the RTD and Transducer terminals are numbered 1-2 from top to bottom Run the RTD and transducer cables through customer-provide wire pass through port and route to the terminal blocks on the left side of the panel. Connect the RTD cable to number 1 on the RTD terminal block, as shown in Figure 9: • one red wire to the top terminal tier • the other red wire to the middle terminal tier • the white wire to the bottom terminal tier Connect the transducer cable to number 1 on the transducer terminal block as shown in Figure 9: • Red wire on the top terminal tier • Black on the second terminal tier • Brown on the third terminal tier • Gray on the bottom terminal tier Figure 9 – RTD and Transducer Wiring Instructions 03/31/2016 Verax 75 Installation Manual, Rev 10 13 Connect the Ethernet Communications Cable: 1. 2. Run the Ethernet communications cable through customer-provide wire pass through and route to the Ethernet switch on the right side of the analyzer control panel. ( See Figure 3) Connect to any available Ethernet port Connect Main Power: • For 24V DC Power Configuration 1. Run the power cable through customer-provide wire pass through port and route to the terminal blocks on the upper right side of the analyzer control panel. ( See Figure 3) 2. Connect hot wire to 24V fuse 3. Connect neutral wire to 0V terminal Figure 10 – Main 24VDC Power Wiring Instructions 03/31/2016 Verax 75 Installation Manual, Rev 10 Components shown inside dotted line only included with100-240V AC option 14 Connect Main Power: For 100-24VAC Power Configuration 1. Run the power cable through customer-provide wire pass through port and route to the terminal blocks on the upper right side of the analyzer control panel. ( See Figure 3) 2. Connect hot wire to 100-240V fuse 3. Connect neutral wire to 0V terminal 4. Connect ground wire to the green/yellow ground terminal Figure 11 – Main 100-240VAC Power Wiring Instructions 03/31/2016 Verax 75 Installation Manual, Rev 10 Components shown inside dotted line only included with100-240V AC option 15 6) Z-Purge Installation (optional): Warning – Read Carefully • You must install the Z-purge if the Verax 75 will be in a Class I / Division 2 Hazardous location. Installation: • Mounting Configuration and Pipe Routing are shown below in Figures 11 and 12. All fittings are ¼” Figure 12 – Pipe Fitting Schematic, (Viewed from back of Verax Panel) 03/31/2016 Verax 75 Installation Manual, Rev 10 16 Figure 13 – Z-Purge Hardware Configuration. 03/31/2016 Verax 75 Installation Manual, Rev 10 17 7) Probe Heater Blanket (optional): Installation: • Heater blankets are designed to wrap around the sample cell cross to keep the probes warm and free of paraffins. Electrical: • • • Heater blankets use Thermon self-regulating 12W/ft heating tape 2Amp, 120V AC electrical service A 5’ pigtail is provided using ½” flex conduit. Figure 14 – Heater Blanket 03/31/2016 Verax 75 Installation Manual, Rev 10 18 8) 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. 24V fuse (Power to PLC, Switch) 3. 12V fuse (Powers PC and Radio) 4. 12V fuse (Powers Spectrometer) Figure 15 – Power up sequence 4th 3rd 2nd 1st • At this point the Verax 75 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 03/31/2016 Verax 75 Installation Manual, Rev 10 19