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IG-Ver2.01.22.07
Online Magnetic Resonance Analyzer
Model D-MASH Ver. 2
Installation Guide
Atex Certification
1712
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IG-Ver2.01.22.07
Contents Cautions and Warnings............................................................................3 Reference Documents..............................................................................3 1.Introduction..........................................................................................4 1.1 Functional Specifications............................................................................4 2.Product specifications...........................................................................5 2.1 Operation, storage, and transportation conditions.......................................5 2.2 Physical specification.................................................................................6 2.3 Electrical & safety specifications.................................................................7 3. System block diagram..........................................................................8 4. Installation..........................................................................................9 4.1 Overview.................................................................................................9 4.2 Site preparation......................................................................................10 4.2.1 Shelter................................................................................................10 4.2.2 Mounting pad..................................................................................... 11 4.3 Instrument air supply..............................................................................11 4.4 Pneumatic control connections.................................................................12 4.5 Process connections................................................................................12 4.6 Purging system.......................................................................................12 5. Physical dimensions...........................................................................13 5.1 Front view..............................................................................................13 5.2 Left side view.........................................................................................14 5.3 Right side view.......................................................................................15 5.4 Top view................................................................................................16 5.5 Recommended dimension for installation..................................................17 6. Connections & PDP.............................................................................18 6.1 Power distribution panel..........................................................................19 6.2 Interlock Box & Terminal Box (JB-1).........................................................20 6.3 Main power/Communication connections....................................... ...........21 6.4 Remote computer terminal.......................................................................22 6.5 Distribute control system..........................................................................22 6.6 Alarms....................................................................................................22
7. Forwarding To operation - Safety Annex....................................................23
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Cautions and Warnings The symbol on the Process NMR Analyzer and in this manual means: “Read the
instructions carefully before proceeding.” The purpose of the symbol is to protect you from injury
and to protect the equipment from damage.
WARNING To prevent injury to personnel or damage to equipment, do not use the Process NMR Analyzer in
any manner not specified by Qualion Ltd.
CAUTION To avoid irreparable damage to the permanent magnet, do not permit the temperature of the
magnet to fall below 5°C (41°F) at any time, including storage and transportation of the system.
Reference Documents This document (IG-Ver1.0.7.06) contains descriptions and instructions for system
installation. For further information on the configuration, operation, and maintenance of
the system and related equipment, refer to the documents listed in Table 1.
Table 1. Reference Documents
Document Description UM-DMASH NMR D-MASH User Manual PL-DMASH NMR D-MASH Part List Gonnheimer F 850S
Instruction – Gonnheimer Electronic GmbH, Pressurized Enclosure System F
850S User Manual
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1. Introduction The D-MASH Process NMR Analyzer is designed to analyze the composition of process fluids
on an online, continuous basis. Using NMR spectroscopic techniques, it can detect the presence,
composition, and concentration of chemical constituents in a process stream and, with appropriate
software, provide closed loop supervisory control of a process unit. The range of applications is
extensive and is limited only by the availability of reliable prediction models of the processes.
Typical user benefits are increased throughput, better process control, timely detection of off-spec
product, and lower operating costs.
1.1 FUNCTIONAL SPECIFICATIONS
Nuclei Observed
H+
(primary), F
19, P
31(optional)
Operating Frequency
58±1.0 MHz for H+
Heavy Oil Probe (Type D-MASH)
Heavy Oil Type D-MASH Dewar Probe designed to
handle liquids at 5 to 120°C (41 to 248°F) and at
maximum pressure of 24.0 bar (350 psi).
Magnet System
Temperature stabilized, self-condensed field,
permanent (neodymium) magnet with integral field
gradient (shim) coils and automatic shim control
Field strength
1.35 tesla at 45°C
Fringe field
Less than 1 gauss on external enclosure of magnet
CAUTION ______________________________________________________________________ The NMR Analyzer is susceptible to signals at its operating frequency of 58 ±1 MHz
for H+ and at 22.5±0.3 MHz. The NMR Analyzer should not be installed in an area
with an active transmitter operating at those frequencies. However, the magnet
construction is such that the core frequency can be temperature shifted by ±100 kHz,
if required, to avoid interference with signals present at a particular installation site. In
the event that a site is subject to broadband or multiple frequency interference that
cannot be avoided by a frequency shift, additional mitigation measures are required.
This might include the use of isolation transformers, line filters, shielding, and other
means required to attenuate interference.
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2. Product specifications
2.1 OPERATING, STORAGE, AND TRANSPORTATION CONDITIONS
Environmental Parameter Normal Operating Conditions
Transportation and
Storage Limits
Ambient Temperature To be located inside temperature
controlled shelter.
Range:
Min 8°C – Max 38°C.
5 and 55°C (41 and 131°F)
NOTE: Failure to maintain magnet
temperature of 4°C (41°F) causes
permanent damage to the magnet.
Relative Humidity 5 to 95%, non condensing 0 to 100%
Vibration Not more than 0.3 mm/sec2 in all 3 axes 5G in each axes
Indirect Lightning Transients Can withstand a transient surge up to
2000 V common mode or 1000 V normal
mode without permanent damage.
N/A
RFI Effect Output error is less than 0.1% of
calibrated span for radio frequencies in
the range of 27 to 1000 MHz and field
intensity of 30 V/m when the analyzer is
properly installed with shielded conduit
and conductive door gaskets in place.
N/A
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2.2 PHYSICAL SPECIFICATIONS
Enclosure
NEMA 4, 12 gauge stainless steel, air purged
Dimensions
(See section 5 Physical Dimensions for more details)
175.3 cm H x 123.5 cm W x 74.5 cm D
(69 in H x 48.62 in W x 29.33 in D)
Add 15 cm (6 in) to height for shipping pallet.
Footprint
175.3 cm H x 98.2 cm W x 71.5 cm D
(69 in H x 38.66 in W x 28.2 in D)
Clearance
Left side 39 in (100cm) , Front 57 in (145 cm) , Right
side 39 in (100 mm) , Rear 4 in (10 cm) , Top 20 in
(50 cm) .
Weight
600 kg (1323 lb) net weight,
720 kg (1588 lb) gross shipping weight
Lifting Facilities
Forklift access front.
Anchor Bolts
Four 13 mm (0.51 in) holes for 11.9 mm (0.47 in)
anchor bolts.
Process Sample Probes
TYPE D-MASH HEAVY OIL PROBE –
HIGH TEMPERATURE, STANDARD PRESSURE
5 to 120°C, up to 24 bar (350 psi).
External diameter : 3/8 in (9.525 mm) .
Internal diameter: 0.3 in (7.745 mm).
Probe Length: 2.06 in (52.3 mm).
Utilities
POWER REQUIREMENTS
1. 3~380-415VAC, 7KVA,50-60HZ .
Recommended protection: 3 Poles 20A breaker
Slow Blow type.
-L1, L2, L3, N, Protective Earth.
2. 1~220-240VAC, 7KVA, 50-60Hz.
Recommended protection: 1 Pole 40A breaker
Slow-Blow type.
-USA: L1, L2, Protective Earth.
-Europe: L1, N, Protective Earth.
3. 2~110-240VAC, 7KVA, 50-60Hz.
Remote Computer Requirements
Pentium™ processor with 128 MB RAM and
Windows 2000/XP™ operating system with 10/100
LAN card.
Purging Gas Requirements
1.1 m3/h (40 cfm) 80 psi (5.5 bars) dry instrument air
during operation. 6.5 m3/h (230 cfm) 80 psi (5.5
bars) dry instrument air (dry, oil-free) required
during startup. A high purge time of approximately
17 minutes is required on startup (purged volume
during start-up = 1850 liters).
Environmental
TEMPERATURE
See Environmental Parameter on page 4.
RELATIVE HUMIDITY
See Environmental Parameter on page 4.
Electrical Connections
POWER -One M25 Gland , accepts cables with outside
diameter from 13 to 18 mm .
COMMUNICATIONS
-Three M16 Gland , accepts cables with outside
diameter from 6 to 10 mm .
(Modem, Network , DCS –MODBUS RS485). - One RJ45 Ethernet Lan plug for service purpose.
-For alarms inputs contact local distributor
Process Connections
-9.5 mm (3/8 in) stainless steel lines from process to
sample entrance and exit.
- Over all inside cabinet pipes length (probe + pipes
= 100 in / 250 mm).
-Six 6.25 mm (1/4 in) air solenoids outputs
controlled by PLC (For activation of valves
actuators).
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2.3 Electrical & Safety Specifications ! DANGER ___________________________________________________________ To prevent possible explosions and injury to personnel, ensure that wiring meets
applicable safety codes.
__________________________________________________________________
WARNING ___________________________________________________________ To maintain IEC IP56 and NEMA Type 4 protections, any unused conduit opening
must be plugged in accordance with applicable electrical codes.
__________________________________________________________________
NOTE_______________________________________________________ This analyzer has been designed to meet the electrical safety description.For
detailed information or status of testing laboratory approvals and
certifications, contact Qualion Ltd.
___________________________________________________________________
Testing Laboratory , Types of Protection , and Area Classification
ATEX 1712
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3. System Block Diagram Block diagrams of typical NMR control system communication configurations are illustrated in
Figure 1. As shown in the diagrams, the system consists of:
♦ An optional sample switching unit
♦ The NMR analyzer with internal system PC
♦ A remote personal computer.
♦ A remote distributed control system (DCS) such as an I/A Series system
The NMR Analyzer accepts a flowing sample from the sample switching system, passes it
through a probe, and returns it to the sample switching system. Communication between the
NMR Analyzer and the remote computer is handled via Ethernet or a dedicated phone line and
between the NMR PC or the remote PC and a DCS by RS485/Modbus .
Figure 1. System Block Diagram
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4. Installation CAUTION ____________________________________________________________________ During the installation procedure all switches & circuit breakers must be set to OFF. After all installation requirements have been met, only an authorized person should startup the NMR analyzer. ____________________________________________________________________
NOTE__________________________________________________________
Use of corrosion-resistant hardware in the installation of this system is strongly
recommended.
__________________________________________________________
4.1 Overview
Installation of a Process NMR analyzer, Style D-MASH, consists of the major tasks listed below .
Detailed information about each item is included.
1. Verify that the site has been properly prepared.
♦ Shelter and temperature control environment
♦ Pad
♦ Clearance
♦ Access to all system equipment
♦ Location of anchor bolts
♦ Availability of process connections, including vents and drains
♦ Availability and quality of required utilities – drains, vents, instrument air
♦ Availability of suitable power and ground connections
♦ Availability of data communication connections
2. If a separate Sample Switching System is to be used , verify that it has been installed
and commissioned according to the manufacture’s specifications . If no such system is
specified, skip this step .
3. Verify that ambient conditions meet all the limiting requirements for temperature,
humidity, and weather exposure. Note that the magnet temperature must never be allowed
to fall below 5° C (41° F). Excessively low temperature can cause irreparable damage to
the magnet.
Also verify that the power line noise is below the acceptable limit.
4. Check crate for shipping damage. If crate is damaged, contact shipper.
5. If crate is OK, uncrate the unit.
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6. Place unit on pad and check access to interior of enclosure. Secure unit to anchor bolts.
7. Connect process piping, including drains and vents.
8. Connect system ground to system earth (plant earth grid, driven earth rot, or other
acceptable earth).
9. Install conduit (and appropriate seal fittings) in accordance with applicable safety
codes for power, ground, and data communication cables.
10. Connect the power supply input and data communication cables to terminal strip X1
in JB-1 terminal box on the left side of the enclosure. Seal the cable entrance or conduit
required by the applicable safety code.
11. Plug and/or seal any unused openings as required by the applicable code.
12. Connect the instrument and purging gas to the
13. Close and secure all doors on the enclosure and prepare for commissioning.
14. Check clearance against specification.
15. Verify that installation meets all applicable safety code and practices.
16. If all requirements are met, contact your local distributor and request the field
engineer assigned to the project to perform system checkout and begin the initial
startup procedure.
4.2 Site Preparation
Site preparation for a Process NMR Analyzer consists primarily of providing an air
conditioned shelter, a mounting pad, suitable electric power and data communication
connections, instrument air purging source, and tubing runs to bring sample of the
process fluid to the analyzer. Each item is discussed in detail in the following section.
In many installations, the site must also be prepared in a similar manner for a process
sample conditioning/switching system, which accepts samples from a number of process
units and switches them sequentially into the analyzer.
4.21. Shelter
The analyzer unit should be mounted in a shelter with temperature controlled system
within the range of 8°C - 38°C (46°F - 100°F) that prevent direct sunlight from striking it
and that also shields it from direct rain and weather. The shelter should be tall enough to
accommodate the overall height of the cabinet of approximately 175.3cm (69 inch) plus
any necessary clearance required for connecting the process piping and air supplies. The
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length and width should be greater that the dimensions given for the mounting pad in
Figure 6.
4.2.2 Mounting Pad
The analyzer should be mounted on a concrete pad capable of supporting a weight of
700Kg with minimum dimensions as shown in Figure .Note that the recommended
clearance on 3 sides for access to equipment (internal and external) is approximately
100cm (39 inch). Rear side clearance is 10cm (4 inch).
Additional clearance may be needed at the front of the cabinet for equipment access
during magnet service and/or removal.
Allow 50 cm headroom above cabinet for lift equipment. Also, allow room for a sample
switching system, should be necessary.
4.3 Instrument Air Supply Instrument air is used as the purge gas for the protective gas supply system. Important safety
requirements that affect the design and installation of the protective gas supply system are
described below.
The analyzer relies on purging and pressurization with protective gas (air) to make it safe for use
in Zone 1 and 2, Gas Groups IIA, IIB, and IIC hazardous locations. Installation of this equipment
requires that the user-provided protective gas supply system.
The protective gas supply system must:
♦ Be capable of maintaining a pressure of at least 5.5 bars (80 psi) at a continuous flow
rate of 6.5 m3/hr (230 cfm).
♦ Be essentially free of contaminants or foreign matter and not contain more than trace
amounts of flammable vapor or gas. All protective gas supplies shall be carefully
designed to minimize the chances for contamination.
♦ Have an intake that is located in a no classified (no hazardous) location. If this
intake line passes through a classified (hazardous) location, it must be: (1) constructed
of noncombustible material; (2) designed to prevent the leakage of flammable gases,
vapors, or dusts into the protective gas; and (3) protected against mechanical damage
and corrosion.
♦ Receive power from a power source separate from that providing power to the
protected (NMR) equipment. The purpose of this requirement is to ensure that no
service disconnect switch that can interrupt power to the protected (NMR) equipment
can also interrupt power to the protective gas supply.
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4.4 Pneumatic Control Connections The Process NMR Analyzer has six 1/4-in pneumatic control line outputs used for control of
sample switching valves and a grab sample valve in the sample conditioning system. The lines
originate at the pneumatic manifold inside the analyzer cabinet and terminate in 1/4-in Swagelok
pneumatic compression fittings at the wall of the cabinet. The Port ID is also shown in the label
mounted below each fitting.
4.5 Process Connections The analyzer accommodates a 3/8-in tubing from the process.
Connections between the process tubing and the analyzer are made through 3/8 inch Swagelok
compression fittings on the 3-way bypass valves.
4.6 Purging System The purging unit is a rapid exchange system designed to remove and/or prevent accumulation of
flammable vapors within the NMR enclosure. It supplies purging gas at a maximum rate of
6.5 m3/hr (230 cfm). Before it permits power to be applied, the system makes ten gas exchanges
and verifies that a safe gas pressure is present in the enclosure.
When power is first switched on, the unit performs a self-test and then starts up. When it detects
a safe pressure in the enclosure, it energizes the alarm relay. It then waits for the exchange
pressure to reach a safe level and initiates an exchange cycle time delay, which must complete
successfully, before it energizes the enclosure power relay or contactor. Loss of safe pressure
causes the power relay to de-energize and shut down the system.
To apply power and start the system, you must turn a key switch to ON. Refer to Figure 1.2 for
location. When the pressure switch and timer indicate safe conditions, power is connected to the
system. The air supply connects to the purging system through a 3/8 Swagelok compression
fitting. Refer to Figure 3 for location.
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5. Physical Dimensions
5.1 Front View
Figure 2 – Front view
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5.2 Left side view
Figure 3 – Left side view
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5.3 Right side view
Figure 4 – Right side view
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5.4 Top View
Figure 5 – Top View
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5.5 Recommended dimension for installation
Figure 6 – Recommended dimension for installation
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6. Connections & PDP (Power Distribution Panel)
CAUTION ______________________________________________________________________ Before doing any connections to the system it should be verified that all switches & circuits breaker within the NMR Analyzer are switched off (See section 6.1 Power Distribution Panel & section 6.2 Interlock Box & Terminal Box for more details). Any electrical power will be turned ON only during startup procedure by an authorized service engineer. ______________________________________________________________________
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6.1 Power Distribution Panel The Power Distribution Panel is located behind the magnet of the NMR enclosure. This
panel distributes power to NMR system except the purging system and interlock transformer.
Figure 7 - Power Distribution Panel
Identification Description Function F3 Motor Starter switch Fan 1 F4 Motor Starter switch Fan 2 F5 Motor Starter switch Fan 3 F6 Circuit Breaker – 2 Pole , 16A Air Conditioner 1 F7 Circuit Breaker – 2 Pole , 16A Air Conditioner 2 F8 Circuit Breaker – 2 Pole , 16A Air Conditioner 3 F9 Circuit Breaker – 2 Pole , 6A NMR Power Supply F10 Circuit Breaker – 2 Pole , 6A Temperature controller F11 Circuit Breaker – 2 Pole , 6A NMR Computer F12 Circuit Breaker – 2 Pole , 6A Internal Light
Z1 RFI Filter N/A
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6.2 Interlock Box & Terminal Box (JB-1) The Interlock Box is mounted on the outside of the enclosure on the left side. Attached to the
interlock box is the terminal box (JB-1 - see Figure 6). The interlock box contains the circuit
breakers for the purge system and interlock transformer, the main power contactor and interlocks.
The terminal box contains all of terminations for power and communications.
Figure 8 – Interlock Box & Terminal Box
Identification Description Function F0 Main Contactor N/A F1 Circuit Breaker – 2 Pole , 6A Purge System F2 Circuit Breaker – 2 Pole , 6A Power to Interlock
Transformer PS 24 DC Power Supply AC-DC Converter for interlock
R1-R7 Interlocks Disconnect Relays X1 Terminal Strip Main Power & Communication
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6.3 Main Power / Communication Connections All of the power and communication connections are made in the terminal box JB-1. Details are
shown in Figure 9.
Figure 9 –User connections Terminal strip X1 –JB1
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6.4 Remote Computer Terminal The remote computer, which is connected to the Process NMR Analyzer by an Ethernet or
modem link, should be located in a no hazardous area. This computer is the one used most by
the process operator. Under normal conditions, the operator should never need to go physically to the NMR unit except to operate the key switch on the purge unit for a normal restart after
maintenance* to reset the grab sample valve or to service* the unit. All other operator tasks, such
as a hot or cold restart following a normal shutdown or power outage, can be performed from the
remote computer.
This computer should be supplied with Windows NT 4.0 (or later) operating system plus the
PcAnywhere networking software.
The PcAnywhere software permits an operator to perform remote control and supervision of
the NMR analyzer. For restarts under abnormal conditions, contact Qualion Ltd. for assistance.
*
DANGER SERVICE AND MAINTENANCE SHELL BE PERFORMED ONLY BY QUALIFIED
PERSONAL
6.5 Distributed Control System (DCS) A remote DCS system, may be used with the NMR Analyzer as shown in the block diagrams of
Figure 4. Note that the remote computer is required b
y the system as a troubleshooting and startup tool.
6.6 Alarms Emergency operation (or shutdown) of the NMR Analyzer in response to alarm conditions is
controlled through hard-wired interlocks. Information alerts about alarm conditions is
transmitted to the DCS via Modbus.
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7.Forwarding To operation - Safety Annex General
• This Document guides the final procedures and final steps that should be taken after first installation or after maintenance\site visit and before leaving the site, forwarding to Work Mode.
• The purpose of this procedure is to make sure the enclosure is sealed protected and safety and set according to the following procedure to operation mode.
Step I
(Purge System is switched to bypass Mode, ‘ON’ position) Check Description Note\Measurement
A\C Functioning
□ Fuse Check – Verify All Fuses F3-F12 are switched
On
□ Air Flow Outside the cabin – Verify that Air is
flowing From all sides of the upper cover of the
enclosure.
□ Air Flow Inside the cabin – Verify that Air is
flowing under each Cooling device
Total 3
□ Cooling device Functionality – Verify that the
cooling devices are working, by touching its sides
and feel it cold.
Total 3
□ Temperature measurement – Use the CalComm
application and read the temperature, verify that
displayed on the cabin controller and Calcomm
Temp’ are equal
Cabin
Temp______________
Calcomm
Temp___________
System Functioning
□ Application Running - Run all application and
verify functionality • Process NMR
• Calcomm SW
□ Communication – Verify connectivity to DCS, By at
least on of the following 1. RS485 2. Telephone line
3. Ethernet (LAN)
Connection
type___________
□ Actuator – Verify (by operating) both Actuators (1
& 2) are functioning
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Step II
Check Description Note\Measurement
Sealing
□ Turn Internal Light off– Turn off internal
light from the lamp panel
□ Door Close– Verify All 3 Doors are closed and
that all 13 locks are locked as well.
Total: 3 Doors
13 Locks
□ Interlock Box – Verify Visually that the box is
closed and sealed
□ JB-1 Box – Verify Visually that the box is
closed and sealed
□ Network Service Plug Box – Verify Visually
that the box is closed and sealed
□ Glands\Cables\Tap – Verify all Glands, cables
Connectors etc’ aren’t damaged and the upper
and lower service tap are closed
□ General check – Visually Check all bolts and
nuts are closed and the covers are sealed
Remarks:_________________
________________________
Step III
• After completing steps 1 & II Switch the Purge System key to Work
Mode, turn the key to ‘OFF’ position
• Verify that after switching the key to ‘OFF’ position a ‘Click’ of the main contactor should be sounded (After ~20 min).
Signatures
Serial # of the tested System:
Comments:______________________________________________________
________________________________________________________________
______________________________________________________________
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# Site
name
Full
name
Company
Name
Time
of Visit
Date
Of Visit
Signatu
re
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2.
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3.
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4.
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* Please save a copy in known and pre-defined place! *
Telephone: +972-4-8551161 Fax: +972-4-8551162 Web: www.qualion-nmr.com
Matam Bldg. 22 P.O.Box 15017 Haifa ,Israel,39105