light liquid sampler - tri-pacific 2lm.pdflight liquid sampler s y s t e m s u p p o r t m a n u a l...
TRANSCRIPT
Light Liquid SamplerS Y S T E M S U P P O R T M A N U A L
PNR-2LM-0(1)
Version 05202004
PNR-2LM-0(1)Light Liquid Sampler
System Support Manual
4
Table Of Contents
Section 1System Introduction 4
Section 2Sample Pump and Balance Valve 8
Section 3System Installation and Start-up 16
Section 4DuraSite Vessel Instructions 22
PNR-2lLM-0(1) Version 05202004 ATEX Rev.
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
5
About This Manual...
IntroductionThe purpose of this manual is to provided a step-by-step guide to the operation, installation andmaintenance of your YZ Light Liquid HydrocarbonSampling System. It should be read by both first-time and experienced measurement technicianswho want to learn about the components andoperation of the system. The manual has beenorganized into sections, which are summarized asfollows:
• Section 1 - System IntroductionIncludes an overview of the system components, a description of how the systemoperates, a schematic system diagram, anda system layout.
• Section 2 - Sample Pump and Balance Valve
• Section 3 - System Installation and Start upIncludes detailed instruction on the properway to install your YZ sampler. Likewise, astep-by-step start-up procedure is to guidethe commissioning of the unit.
• Section 4 - DuraSite Vessel InstructionsThese sections include details of theDuraSite portable constant pressuresample vessel., operation andmaintenance .
6
Section 1 System Introduction
The PNR-2LM-0(1) is a sampling system designedto sample light liquid hydrocarbons.
Operation of the system centers around the PNR-2Sample Pump, and control functions that are totallycustomer supplied. The pump is mounted on astainless steel panel, with a support tray for aportable sample. The pump and panel are shown inthe diagram on the following page.
The purpose of the YZ light liquid hydrocarbonsampling system is to capture a representativeliquid sample of the pipeline product. In order forthe system to function properly, a pipeline productmust be single phase, liquid product. By properlyadjusting both the sample size and the samplefrequency, the sample vessel will fill to 80% capacityat the end of the sample period.
The system operates on a simple concept. Eachtime the sample pump is actuated a preset volumeof sample is gathered at pipeline pressure andcollected into a portable sample vessel for transferto a lab for analysis.
PNR-2lLM-0(1) Version 05202004 ATEX Rev.
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
7
Section 1 System Introduction
PIPELINE
SOLENOID VALVE
PRESSURE REGULATOR
NORMALLY OPEN VALVE
NORMALLY CLOSED VALVE
RUPTURE DISC
ELECTRICAL
S
PRODUCT
PNEUMATIC
102
4
Pulse Input Module
Inpu t Adj.
PIM-100
1
3282 4
16
256
512
64
128
-SIG 2
1+SIG
3276
8
819
216
384
409
62
048
262
144
PO
WE
R
6553
61
3107
2
Red -1
Wh ite-3
Black-5
PI
F actory
SystemA ppr oved
Mutual
Z-65 CONTROLLER
AIR RELAY VALVE
PRESSURE GAUGE
PIM-100
SAMPLING
VALVEISOLATION
L E G E N D
CNR-2
PUMP
RELIEF VALVE
(BY CUSTOMER)
MAGNETIC PICKUP SIGNAL
(BY CUSTOMER)
(BY CUSTOMER)TO Z-65 CONTROLLER
DPS SIGNAL INDRY CONTACT OR
PULSED VOLTAGE OR
100 PSIINSTRUMENT AIR IN
ENCLOSURE
S
327
68
Factory
SystemApproved
Mutual
Input Adj.
32
Pulse Input Module
1 82 4
PIM-100
16
1024
256
51264
128
8192
163
84
2048
4096
+SIG
-SIG
1
2
262
144
PO
WE
R
655
361
3107
2
R ed-1
White-3
Black-5
CONTROLSYSTEM
PRODUCT LINE(BY CUSTOMER)
SAMPLE VESSELISOLATION VALVE
CNR-2 PROBE
ROB VALVE
PI
DURASITE
DURASITE
PRECHARGE IN(BY CUSTOMER)
PI
DURASITE
PI
Pneumatic Control Signal(By Customer)
(Sold Separate)
8
19 7/8"
PSI
PIM-100
MODELZ-65 TIMER
15 3/8"
SystemApproved
FactoryMutual
CABLE ENTRY)(7/16" Max.
LIQUID TIGHTFITTING
FILTERREGULATOR
262
144
PO
WE
R
6553
632
768
8192
1638
4
131
072
2048
1024
409664 128168
32
1 2 4
256
512
Black-5
White-3
Red-1
Pulse Input ModulePIM-100
Input Adj.
2-SIG
1IG
(1/4" FNPT)
RELIEF VALVE
ROB VALVE
500
1000
1500
psi2000
AIR RELAYVALVE
SOLENOID VALVE
(BY CUSTOMER)
PRODUCT SAMPLEOUT TO DURASITE(1/8" TUBING)
VESSEL RACK
Section 1 System Introduction
ACTUATION GAS IN(BY CUSTOMER)(1/4" FNPT)
4 1/4"
DPS SIGNAL IN
(BY CUSTOMER)TO Z-65 CONTROLLER
PULSED VOLTAGE ORDRY CONTACT OR
2" NOM. PIPEU-BOLT ASSY. (2)
PRODUCT IN FROM PUMP(PORT B 1/4" FNPT)
ACTUATION GAS TO PUMP(PORT A 1/4" FNPT)
ISOLATION VALVE
FLOW
SUPPLY PROBE
(FROM SKID)PNEUMATIC SUPPLY
(TO SKID)PRODUCT OUT
Product InFrom Pump
5-Way Cross
PNR-2lLM-0(1) Version 05202004 ATEX Rev.
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
9
10
Section 2 PNR Sample Pump
The PNR-2P Sample Pump is a positive displacementplunger pump designed to be mounted directly on thepipeline. It has an adjustable displacement of 0.25 to1.8cc and achieves proportional-to-flow samplingthrough adjustment of the customer supplied, andcustomer controlled pneumatic signal.
As the plunger returns upward after completing astroke, the pump chamber fills with product throughthe inlet check valve. The inlet check valve is a darttype valve designed to seat on an o-ring. The inletcheck valve is spring loaded to ensure a positiveseating action after every stroke. When the pumpis actuated, the plunger moves downward, displacingproduct through the discharge check valve knownas the balance valve.
The balance valve automatically senses pipelinepressure and adjusts to ensure that product is notallowed to free-flow to the product vessel. Whenthe pipeline pressure is greater than the pre-chargepressure on the accumulator vessel, the balancevalve dart is pushed up against the seat and the tophead of the balance valve. As the pump strokes,the pressure created in the pump chamber forcesthe balance valve dart off the seat, allowing productto be pumped to the accumulator vessel. Once thepump completes its stroke, the pressure across thebalance valve equalizes and the dart is returned to asealing position by its spring.
In the event that the accumulator vessel pre-chargepressure is greater than the pipeline pressure, thebalance valve dart and seat are pushed apart by theproduct pressure in the accumulator vessel. In thissituation the check valve wafer located between thebalance valve and the sample pump acts as a backcheck to prevent the escape of product previouslycaptured in the accumulator vessel. As the pumpstrokes, the pressure created in the pump chamberforces the check valve wafer off the seat, allowingproduct to be pumped to the accumulator vessel.Once the pump completes its stroke, the pressureacross the check valve equalizes and the wafer isreturned to a sealing position by its spring.
PNR-2lLM-0(1) Version 05202004 ATEX Rev.
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
11
Section 2 PNR Sample PumpPump Diagram
EXHAUST FILTER, 1/8" SS
LPR/PNR INLET CHECK DART
SEAL W/SS SPRING TFE/GLASS/MOLY 3/8" ID
1/8" ALLEN HEAD PLUG SS
PNR-2 UP/MID/CV BODY ASSY
PNR-2 UP/MID/CV BODY ASSY
PNR-2 PLUNGER BUSHING 3/8
PNR-2 UP/MID/CV BODY ASSY
B2-1106
A2-0177
6 FLAT WASHER SS
OR -210, NITRILE
OR -010, NITRILE
6-32 x 3/16 PAN HD SS
INLET CV SPRING PNR-2
A5-2210
C0-0157
C0-0080
C3-0027
A5-2010
B2-1017
A7-0011
A6-0040
B2-1106
C4-0028
B2-1106
PRODUCT IN
STROKE SCALE, 3/8" PD PUMP
PNR-2 ACTUATOR CYLINDER
PNR-2 STROKE SCREW ASSY
PNR-2 STROKE SCALE IND
B2-1003
ACTUATION SUPPLY
3/8-24 JAM NUT, SS
PNR-2 PNEU ACT PISTON
C0-0118
B2-1009
5/16 FLAT WASHER, SS
MCONN, 1/4T 1/8P, SS
5/16-18 x 5/8" HHCS SS
A1-0003
C0-0017
C0-0098
B2-1002
D5-0020
PRODUCT OUT
BV-200 ASSY (STD)
VALVE, PURGE, SS 1/8" NUPRO
MCONN, 1/8T 1/8P, SS
1/8" 316 SEAMLESS .035W
MCONN, 1/8T 1/8P, SS
PNR-2 CHECK VALVE FOR USE W/ BV-200
A1-0099
C7-0044
1/8" SS PLUG
A3-0161
B2-1520
B2-1529
A1-0099
1/4-28UNF x 1/2" BHCS SS
3/8 STAR WASHER (EXT) SS
PD PUMP PACKING
5/16-24 JAM NUT SS
PNR-2 PACKING GLAND NUT
PNR-2P PLUNGER RTN SPRING CAD PLATED
U-CUP WIPER SEAL (PNR-2 ACT PISTON)
PNR-2 3/8 CERAMIC PLUNGER
PNR-2 ACORN NUT
B2-1102
C3-0016
C0-0117
A6-0036
A6-0035
B2-1006
C0-0108
B2-1001
A2-0177
B2-1041
13377 (3)
12
Section 2 PNR Sample PumpBalance Valve Diagram
P/N B2-1529
PNR-2lLM-0(1) Version 05202004 ATEX Rev.
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
13
14
Section 3 Installation/Start-up/Operation
Panel InstallationThe sampling system should be located as closeas possible to the pipeline. 2" U-bolt assembliesare provided to mount the panel to a 2" vertical pole.
Pneumatic SupplyA 1/4" connection on the Pump is provided for apulsed pneumatic supply (40 - 60 psi). The neces-sary regulators, solenoid valve, control functions,etc. are customer provided. The pneumatic pulse tooperate the sampler typically will require 2-3 seconddwell time to assure proper pump operation.
Pump InstallationThe PNR-2 sample pump is designed to bemounted directly to a threaded connection on thepipeline. The probe tubing should be cut such thatthe tip of the probe will be located in the center 1/3of the pipeline after installation. After the pipelinehas been depressurized, the threads on the probebody should be taped and doped and the pumpinstalled into the pipeline connection. Next youmust install 1/4" stainless steel tubing between theconnection top of the pump, to the source of thepulsed pneumatic actuation, upplied by the cus-tomer. Finally connect 1/4" stainless steel tubingfrom the discharge connection of the pump balancevalve to the connection for product in from pump onthe 5-way cross.
ACTUATION GAS IN(BY CUSTOMER)(1/4" FNPT)
4 1/4"
DPS SIGNAL IN
(BY CUSTOMER)TO Z-65 CONTROLLER
PULSED VOLTAGE ORDRY CONTACT OR
2" NOM. PIPEU-BOLT ASSY. (2)
PRODUCT IN FROM PUMP(PORT B 1/4" FNPT)
ACTUATION GAS TO PUMP(PORT A 1/4" FNPT)
ISOLATION VALVE
FLOW
SUPPLY PROBE
(FROM SKID)PNEUMATIC SUPPLY
(TO SKID)PRODUCT OUT
ACTUATION GAS TO PUMP
PRODUCT FROM PUMP
5-Way Cross
Pneumatic Supply(By Customer)
PNR-2lLM-0(1) Version 05202004 ATEX Rev.
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
15
Section 3 Installation/Start-up/Operation
Pump Sample SizeThe sample size is adjustable from 0.25 to 1.8 cc/stroke. The sample size is adjusted by loosening thelock/seal nut on top of the pump and turning the volumeadjustment screw in to decrease the sample volume orout to increase the sample volume. Once the newsample size has been set, the lock/seal nut should beretightened.
Sample Pump PrimingBefore the pump begins normal operation after initialinstallation or maintenance, the sample pump must bepurged of all air in the sample chamber. The purgevalve on the sample pump is used to evacuate the airfrom the chamber and to make sure the pump is liquid-packed. If the pump is not purged before being placedinto operation, it will not function properly.
To purge the pump, open the purge valve located onthe left side of the sample pump balance valve. Theproduct supply valve can then be opened to allowpipeline product to purge the air within the pump. Onceproduct begins exiting the purge valve, close the purgevalve. The sample pump is now ready to begin opera-tion.
16
Section 3 Installation/Start-up/Operation
= # of Pump Strokes Required/Sample Cycle
= Time in Minutes Between Strokes
= 1600 Pump Strokes Required/Sample Cycle
10,080 (Minutes in Week)1600 Pump Strokes Required/SampleCycle
= 6.3 Minutes Between Strokes (Round up to the next whole minute.)
Calculating Time-
Sample Volume DesiredPump Displacement
Number of Minutes/Sample Cycle#of Pump Strokes Required/Sample Cycle
Example400 cc(500cc DuraSite filled to 80% Volume).25cc Pump Displacement/Stroke
Z-65 Controller Set UpProportional To Time Mode
PNR-2lLM-0(1) Version 05202004 ATEX Rev.
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
17
Sample Vessel Size x 80% = Grabs Required/Sample Cycle. Sample Grab Size
Pulse/Metered Volume x Monthly Average Flow = Pulses/Sample Cycle
Pulses/Sample Cycle = Pulses/Grab Grabs Required
Z-65 Controller Set UpProportional To Flow Mode
Section 3 Installation/Start-up/Operation
ie: 15,000 Pulses/Sample Cycle = 33.78 Pulses/Grab 444 Grabs Required
ie: 500cc Vessel x 80% = 400cc = 444 Grabs Required .9 cc/Grabie
ie: 1 Pulse/BBL x 15,000 BBL/Month = 15,000 Pulses/Sample Cycle
18
Purpose: The DuraSite Portable Sample Vessel permits theuser to remove a liquid or gas hydrocarbon sample from apipeline or a sampling device. This is accomplished withoutchanging the pressure of the product or exposing it to a con-taminant fluid. If properly used and maintained the DuraSitewill provide many years of safe, accurate and clean sampling.
Use: The DuraSite is a very safe device to use. As with anyequipment dealing with flammable products, it is mandatorythat a good, thorough operator training procedure be establishedprior to use.
Typical use of the cylinder would be as follows:
Step 1: (In The Lab) Connect a regulated inert gas supply tothe pre-charge valve. The product valve should be open. Bycarefully controlling the pre-charge valve and the regulator, thecylinder can be slowly charged with pre-charge gas (NOTE:This should be done slowly to prevent slamming the pistondown to the opposite end). The pressure on the pre-chargepressure gauge should be brought to a reading of 10-50 psiabove the expected pressure of the product in the field . Closethe pre-charge valve and disconnect the gas supply. Checkthe pre-charge valve, relief device, and the pre-charge pressuregauge for leaks. Any leaks should be stopped before continuing.The vessel should be placed in a padded carrying case andmade ready for field use.Proceed to EITHER Step 2, or Step 3 as required for yourapplication.
STEP 2: FOR COLLECTION OF SAMPLE VIA SPOT SAMPLEOR FROM COMPOSITEACCUMULATOR VESSEL.
2a: Connect the product end of the pre-charged sample vessel tothe product supply. (Sampler product removal valve, or Pipelinesample probe)NOTE: the pre-charge pressure gauge reading should begreater than the product supply pressure reading. If not,repeat Step 1 above.
2b: Once the vessel is connected to the product supply, it isnecessary to vent a small amount of product prior to filling thevessel. This assures fresh product and removes any air orgas when dealing with liquids. This can be done by looseningthe product purge valve a very small amount until the product ispurged. After thorough purging, the product purge valve shouldbe tightened.
2c: The product pressure gauge reading should be 10-50 psibelow the pre-charge pressure gauge reading. By carefully openingthe pre-charge valve, the pressure becomes equalized, thenbegins to drop below the product pressure. The pre-chargevalve should be carefully controlled so as to not vent the pre-charge gas too fast.
2d: When the cylinder becomes a maximum of 80% full (seevolume indicator), all valves should be closed. The productconnection is slowly broken in order to vent any trapped product.After vessel removal, all connections should be checked forleaks and the pre-charge and product valve ports capped toprevent leakage.
2e: Pack the DuraSite in appropriate carrying case to meetD.O.T. guideline, with D.O.T.paperwork and transport to lab for analysis.
STEP 3: FOR DIRECT CONNECTION TO SAMPLER.
3a: Connect the sampler discharge port to the product inletport to the DuraSite using 1/8" stainless steel tubing.
3b: (Gas sampling) Connect the pre-charge port to theDuraSite to the pipeline for pre-charge pressure (Proceed tostep 3d), or configured like the liquid sample applicationbelow. (Step 3c)
3c: (Light sampling) Pre-charge the DuraSite as indicated inStep 1, then install a pressure relief valve to the pre-chargeport and open the pre-charge valve on the DuraSite. (The pressurerelief valve should have a relief pressure setting of approximately100 psi above line pressure.)
3d: Open the product inlet valve of the DuraSite and the purgevalve on the sampler. Next open the purge valve on the productend of the DuraSite and allow product to purge all lines andconnections out.
3e: Close purge valves and begin sample cycle.
3f: At the end of sample cycle, close product inlet valve on theDuraSite and remove the DuraSite. Pack the DuraSite in appropriatecarrying case to meet D.O.T. guideline, with D.O.T. paperwork andtransport to lab for analysis.
Step 4: (In The Lab) Prior to analysis, the product should bemixed. This is accomplished simply and efficiently by invertingthe cylinder end-over-end, causing the mixing ball to fallthrough the product. Approximately 10-12 trips of the mixingball through the product assures a homogenous solution.
Step 5: The regulated pre-charge gas should be reconnectedto the pre-charge side of the cylinder. The pre-charge gassupply should remain open during analysis.
Step 6: Purging a small amount of product from the vesselremoves unmixed product from the tee, relief device, gauge,etc. The unit can now be connected to a chromatograph andthe product analyzed.
Step 7: After analyzing, the remainder of the product shouldbe dumped and the vessel properly cleaned. Normal cleaningcan be accomplished by rinsing the product end with a petroleumsolvent and flushing with acetone. If a more thorough cleaningis required, the vessel should be disassembled.
WARNING: A portable sample vessel should never be filledto more than 80%. This allows a 20% pre-charge cushion toabsorb thermal expansion of the product.Shipping: Extreme care should be taken when preparing avessel for shipment. Both valves should be capped to preventpossible leakage. The vessel should be placed in asnug-fitting, well-padded and durable case. All applicableDOT regulations should be adhered to.
Section 4 DuraSite Portable Sample Vessel Instructions
PNR-2lLM-0(1) Version 05202004 ATEX Rev.
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
19
DuraSite (illustrated)
P/N C6-1002 (Ser. #4088+)
Set ScrewP/N C0-0099
P/N A3-0155Knob
P/N C6-1003 (Ser. #4608+)
Magnet Assembly
Piston
P/N C6-1004Piston Washer
YZ UniValve
P/N A5-4222B
P/N A5-2222
Back-Up Washer
O-Ring
Product Head
Stainless Steel
P/N C6-1000
P/N C0-0048Hex Nuts
Valve SeatP/N A3-0063
Purge Valve NutP/N A3-0080
P/N A8-0013
Magnetic Volume IndicatorP/N C6-1203 (DS-150)P/N C6-1303 (DS-300)P/N C6-1403 (DS-500)P/N C6-1503 (DS-800)P/N C6-1603 (DS-1000)
Gauge
P/N A3-0083
Rupture DiscP/N A3-0084
YZ UniValve
P/N C6-1001Pre-Charge Head
P/N A3-0095Valve Stem AssemblyP/N A3-0062Seat Retaining WasherP/N A3-0063Valve Seat
P/N C6-1200 (DS-150)P/N C6-1300 (DS-300)P/N C6-1400 (DS-500)
P/N C6-1600 (DS-1000)
P/N C6-1301 (DS-300)P/N C6-1401 (DS-500)P/N C6-1501 (DS-800)P/N C6-1601 (DS-1000)
P/N C6-1201 (DS-150)
P/N C6-1500 (DS-800)
Cylinder
Rupture Disc Nut
Tie Rod
Mixing Ball
Snap RingP/N C3-0018
Piston Seal
P/N A5-2021
P/N A6-0023
O-Ring
P/N C6-1005
P/N 12-1008 (Ser. #0614 - #4087)P/N 12-1007 (Ser. #0322 - #0613)
P/N 12-1019 (Ser. #0614 - #4607)
P/N 12-1006 (Ser. #0321 and Prior)
P/N 12-1018 (Ser. #0613 and Prior)
Section 4 DuraSite Portable Sample Vessel Instructions
20
Notes
PNR-2lLM-0(1) Version 05202004 ATEX Rev.
YZ Systems, Inc. • 3101 Pollok Drive • Conroe, Texas • USA • 77303 • P: 936.788.5593 • F: 936.788.5720
21
Notes
3101 Pollok Drive
Conroe, Texas 77303
P: 936.788.5593
F: 936.788.5720
Web: www.yzsystems.com
YZ Systems, Inc. represents and warrants that for a period of 3 years from receipt of the product: (1) the product will be free from defects in materials andworkmanship; and (2) the product will perform substantially in accordance with product manuals, literature, or documentation. Any written or oral information or advicegiven by YZ representatives, agents, or employees will in no way increase the scope of this warranty. If the product fails to comply with the warranty set forthherein, YZ's entire liability and the customer's exclusive remedy will be replacement of the product(s) or, at YZ's option, YZ's reasonable effort to make the productmeet the warranty set forth herein. YZ disclaims all other warranties, either expressed or implied, including but not limited to, implied warranties ormerchantability and fitness for a particular purpose, with respect to the product. This limited warranty gives you specific legal rights. You may have others,which vary from state to state. These remedies are not available outside of the United States and Canada. In no event shall YZ or its suppliers be liable forany damages whatsoever (including, without limitation, damages for loss of profits, business interruption, loss of information, or other pecuniary loss) arising outof the use of or inability to use the product, even if YZ has been advised of the possibility of such damages. Information contained in this document is subjectto change without notice and does not represent a commitment on the part of YZ Systems, Inc. All prices quoted are in U.S. dollars, F.O.B. Snyder, Texas. NJEXis a trademark of YZ Systems, Inc. All other product names and/or registered trademarks are the property of their respective holders. YZ support services aresubject to YZ's then-current prices, terms, and conditions, which are subject to change without notice. All prices and specifications, if published, are subject tochange without notice.