Additive Injectors AccuPlus Issue/Rev. 0.1 (3/14) Installation and Operations Bulletin MN05002E The Most Trusted Name In Measurement
Caution The default or operating values used in this manual should not be construed as default or operating values for your system. Each system is unique and each parameter must be reviewed for that specific system application. Disclaimer FMC Technologies Measurement Solutions, Inc. and Smith Meter GmbH hereby disclaims any and all responsibility for damages, including but not limited to consequential damages, arising out of or related to incorrect values used in connection with the AccuPlus. Receipt of Equipment When the equipment is received the outside packing case should be checked immediately for any shipping damage. If the packing case has been damaged, the local carrier should be notified at once regarding his liability. Carefully remove the unit from its packing case and inspect for damaged or missing parts. If damage has occurred during shipment or parts are missing, a written report should be submitted to the Supplier. Prior to installation, the unit should be stored in its original packing case and protected from adverse weather conditions and abuse. Proprietary Notice This document contains information that is proprietary to FMC Technologies Measurement Solutions, Inc. and is available solely for customer information. The information herein shall not be duplicated, used, or disclosed without prior permission of FMC Technologies Measurement Solutions, Inc. FMC Technologies Measurement Solutions, Inc. will not be held responsible for loss of liquid or for damage of any kind from any cause to the person or property of others, or for loss of profit, or loss of use, or any other special, incidental, or consequential damages caused by the use or misapplication of the contents stated herein. Page ii MN05002E Issue/Rev. 0.1 (3/14)
Table of Contents Section I Introduction... 1 Product Description...1 How to Use This Manual...1 Section II Installation...2 General...2 Electrical Specifications...2 Coax Valve Wiring...3 Typical Application...3 Mounting Options...5 Dimensions (AccuPlus)...7 Section III Start-Up Procedure...9 Purging Air from the Meter...9 Section IV Operating Information...10 General Information...10 Injection Theory...10 Set-Up Calculation...11 Example...11 Setting the Maximum Flow Rate of the Unit...11 Section V Calibration...12 Section VI Related Publications...13 Issue/Rev. 0.1 (3/14) MN05002E Page iii
Section I Introduction Product Description The AccuPlus is an additive unit used for injection of small amounts of liquid mediums (additives) into a mainstream product (petroleum, diesel, heating oil, fuel oil, etc.). The AccuPlus is an oscillating piston type positive displacement meter designed with high resolution electronics to control additive injections for line products. The simple yet robust design provides a modular solution either as a single or multiple product injectors. Utilizing an advanced metering technology and electronic encoder, the AccuPlus provides dependable injection over a wide range of ppm rates. This allows the injector to react faster and provide better distributed injections. How to Use this Manual This manual is to be used as an Installation and Operations guide for the AccuPlus. This manual is divided into six sections: Introduction, Installation, Start-up Procedure, Operating Information, and Calibration and Related Publications. The Installation section describes the basic installation guide for the AccuPlus. The Start-up Procedure section describes the manner in which the AccuPlus should be operated upon each start-up. The Operating Information section describes the pertinent information regarding the operation of the AccuPlus. The Calibration section describes the process of calibrating the AccuPlus. The Related Publications section describes other documents relating to the AccuPlus. Inlet M18 x 1,5 Flowmeter Outlet M18 x 1,5 Dosing Unit Additive Valve Figure 1 Additive Unit AccuPlus Page 1 MN05002E Issue/Rev. 0.1 (3/14)
Section II Installation General Local codes and standards for electrical installations must be followed when installing the AccuPlus. CAUTION: When installing the AccuPlus to the desired bracket, ensure that the HRE cover is secured tightly and that the meter is not powered. Figure 2 HRE Board The HRE circuit board (Hall Rotary Effect) takes the rotation of the magnetically coupled meter and electronically senses the rotation to produce output pulses. The encoder is completely isolated from the product and meter internals. CAUTION: When handling the HRE board, ensure that proper grounding and static buildup is not present in order to prevent damage to the board. Improper handling and static discharge will cause failure to the board. If handling, try to use the one hand rule where one hand is on the piping and the other used to handle the board. Terminal 1 +10 to +30 Vdc Terminal 2 A Signal (Leading) Terminal 3 B Signal Terminal 4 Logic Common (Ground) Terminal 5 Terminal 6 No electrical connection on Terminal 7 circuit board. Terminal 8 Table 1 CN1 Terminal Connections Electrical Specifications HRE Recommended wire for use: Power: 14-30 AWG depending on approvals Pulses: 18-24 AWG stranded copper (Belden Number 9418, 8404 or equivalent) Note: Resistance between the ground terminal and the power supply ground must not exceed 2 ohms. Electrical Inputs HRE - AccuPlus DC Power Range: 10 to 30 Vdc Input Current Quiescent Current (No Load): 20 ma @ 10 Vdc, 15 ma @ 24 Vdc, 15 ma @ 30 Vdc Output Signal 10 Vdc Input Power Supply: No Load: 9.7 ± 0.3 Vp-p square wave 270 Ω Load: 7.6 ± 0.3 Vp-p square wave (minimum) 24 Vdc Input Power Supply: No Load: 23.7 ± 0.3 Vp-p square wave 270 Ω Load: 16 ± 0.3 Vp-p square wave (minimum) 30 Vdc Input Power Supply: No Load: 29.7 ± 0.3 Vp-p square wave 270 Ω Load: 21 ± 0.3 Vp-p square wave Output Source Current (A & B @ 270 Ω Load): 70 ma @ 10 Vdc, 130 ma @ 24 Vdc, 160 ma @ 30 Vdc Output Current per Channel (A & B): Maximum Sink Current: 300 ma @ 30 Vdc Maximum Source Current: 80 ma @ 30 Vdc Approvals: FTZU 10 ATEX 0180 X II 2G Ex d IIB T6 Gb IECEx FTZU 13.0007X Ex d IIB T6 Gb GOST Certificate POCC DE.ГБ05.B04154 1 Ex d IIB T6 Gb Note: To maintain ATEX approval, the earth grounding screw on the flowmeter must be properly wired. Issue/Rev. 0.1 (3/14) MN05002E Page 2
Section II Installation (continued) COAX Solenoid Valve Nominal Voltage: 240 VAC, 60 Hz Current: 150 ma Power Consumption: 27.3 W 315 to 450 ma inline fuse recommended Approval: PTB 03 ATEX 2045 X II 2 G Ex mb II T4 II 2 D Este A21 IP68 T130 C IECEx TPS 14.0002X Ex mb llc T4 Gb Fx ld A21 IP68 T130 C Gc GOST Certificate POCC DE.ГБ05.B03801 2 Ex m II T4 X IP 68 (EN 60529) CE 0102 NEMA 4X Signal Cable Three-wire shielded for single-channel transmission. Sizes Distance # 20 AWG (0,75mm 2 ) Up to 2,000 ft. (610 m) # 18 AWG (1,00mm 2 ) Up to 3,000 ft. (915 m) # 16 AWG (1,50mm 2 ) Up to 5,000 ft. (1,525 m) Coax Valve Wiring Fuse 315-450mA BL + L1 BR - L2 Figure 3 Coax Valve Wiring Typical Application Figure 4 Application Flow Diagram (example for less than 1000ppm). Page 3 MN05002E Issue/Rev. 0.1 (3/14)
Section II Installation (continued) Typical Application Typical application for marker injection with less than 1,000 ppm: AccuPlus 8 Flow Direction Figure 5 Typical Application Less than 1,000 ppm Typical application for market injection with more than 1,000 ppm: AccuPlus 8 Flow Direction Figure 6 Typical Application above 1,000 ppm Local weights and measures recommended practices should be followed overall. Issue/Rev. 0.1 (3/14) MN05002E Page 4
Section II Installation (continued) Strainer Pump Back Pressure Valve Additive Tank Pump Fine Filter Gasoline or Diesel Tank Tank Field Area Pump Loading Bay Area Pump Isolation Valve Optional Filter AccuPlus Isolation Valve Filter Gas Extractor Check Valve Spray Valve Meter Flow Control Valve Figure 7 Simplified Additive System Application Mounting Options To ensure proper functionality of the AccuPlus it is highly recommended to follow the installation procedures in this manual. The AccuPlus should be mounted with two M8-1.25 bolts to a solid construction or bracket. An upstream and downstream isolation ball valve should be installed to allow a good start-up procedure and maintenance. If isolation valves are installed, a thermal pressure relief must be provided. If possible, the AccuPlus should be kept out of direct sunlight. To allow access to the AccuPlus for maintenance and cleaning, ensure there is 254mm (10") of clearance above the HRE cover and below the Dosing Unit. For additional configurations please consult the factory. Page 5 MN05002E Issue/Rev. 0.1 (3/14)
Section II Installation (continued) Installation Orientation Mounting Holes Figure 8 Mounting Bolt Attachment Holes (M8) Critical: The AccuPlus must be mounted with the monoblock in the horizontal plane with the HRE cover facing up. Figure 9 Proposed Installation Using Mounting Bolt Attachment Installation Issue/Rev. 0.1 (3/14) MN05002E Page 6
Section II Installation Dimensions (AccuPlus Shown with a single additive valve) mm (inches) Side View Dimensions 120 (4.7) Cable gland M20x1,5 for cable 7-12 mm Cable gland M16x1,5 2xM8x1,25 10 mm deep 109 (4.3) 173 (6.8) 72 (2.8) 31 (1.2) 37 (1.5) 42 (1.7) 60 (2.4) 64 (2.5) 5 (.2) Top View Dimensions M18x1,5 2xM8x1,25 15 mm thru 9 (.4) M18x1,5 113 (4.4) 129 (5.1) 7 (.3) 188 (7.4) 140 (5.5) 62 (2.5) 79 (3.1) Figure 10 AccuPlus Product Dimensions Note: Dimensions Millimetres to the nearest whole mm (inches to the nearest tenth), each independently dimensioned from respective engineering drawings. Page 7 MN05002E Issue/Rev. 0.1 (3/14)
Section II Installation (continued) Dimensions (AccuPlus Shown with 8 additives and a proportioning valve) mm (inches) 79 (2.9) 35 (1.4) 9 (.4) 140 (5.5) 180 (7) 79 (2.9) 79 (2.9) 365 (14.4) 444 (17.5) 120 (4.7) 175 (6.9) 108 (4.3) M18x1,5 79 (3.1) 7 (.3) M18x1,5 306 (12.1) 95 (3.7) 79 (3.1) 217 (8.5) 87 (3.4) 50 (2) 87 (3.4) Figure 10 AccuPlus Product Dimensions Issue/Rev. 0.1 (3/14) MN05002E Page 8
Section III Start-Up Procedure After installation and connection of the plumbing, the unit flow rate can be adjusted, as required. Once the desired flow through the inlet needle valve is set, the holes will be sealed with a sealing label. Critical: The outlet needle valve is normally 100% open to avoid delayed meter pulses after the inlet solenoid valve has closed. Delayed pulses may cause injector alarms to occur. Inlet Needle Valve Outlet Needle Valve Sealing Label Sealing Label Strainer Figure 12 Flow rate adjustment and strainer location Purging Air From The Meter When the meter is first installed in the line, air is present inside the meter. The air may take some time to work out. If the meter is subjected to hydraulic shock during this vulnerable time, the meter can be damaged. Following the procedure listed below will greatly reduce the likelihood of meter damage: 1. If possible, a gravity head (not pump pressure) should be used to initially fill the meter as air is vented from a high-point vent. 2. Close the upstream inlet needle and ensure that the meter can flow freely with no restrictions downstream of the meter, this includes opening the outlet needle valve to 100%. 3. Energize the pump. 4. Energize the Additive Control Solenoid. If required, use a service mode from an AccuLoad III or microload.net preset. 5. Slowly open the inlet needle valve. It is important that the inlet needle valve is gradually opened to ensure that the meter will be operated at a very low flow. 6. Vent air from a junction downstream of the meter until there is no sign of air. Once all air has been released, continue venting for an additional 30 seconds. Ensure no air pockets are present in the upstream piping. 7. Adjust the flow rate with the inlet needle valve only. Note: This procedure should be used whenever air has entered the system. Page 9 MN05002E Issue/Rev. 0.1 (3/14)
Section IV Operating Information General Information To obtain maximum service, it is strongly recommended that detail records be maintained throughout the life of the AccuPlus. Data such as model, serial number, operating rate, type of product, totalizer readings, meter factor and other pertinent information should be recorded. Such information is an excellent guide in scheduling a preventive maintenance program. Injection Theory It is typically desired to have additives injected as stable as possible. There are two operation modes available: 1. Continuous Injector Flow Rate Continuous Injector Flow Rate is proportional to the main stream flow rate. This mode requires the injector flow meter to flow at various flow rates. This potentially introduces an error from a meter factor, related to flow rate and hydraulic conditions. 2. Pulsed Injection Mode A fixed flow rate is initialized proportional to the main stream. This mode requires the injector flow meter to flow at one flow rate only. The acceleration and stop influence can be compensated via calibration at operating conditions. Note: The AccuPlus is designed to operate in Pulsed Injection Mode. Issue/Rev. 0.1 (3/14) MN05002E Page 10
Section IV Operating Information (continued) Set-Up Procedure Recommended Set-up Parameters: Operate the AccuPlus between the minimum and maximum flow rate to ensure optimum accuracy A minimum injector on time of 1.0 sec A maximum frequency of 30 cycles/min A maximum duty cycle of 50% Example: Main product flow rate is 2,500 LPM 100 PPM of additive to be injected 10 injections/minute 50% duty cycle maximum 1. Amount per injection 2,500 l/min x (100/1,000,000) 10 injections/min Note: Value used for AccuLoad set-up in Recipe parameter 17, 20, 86 Injector Volume 2. Calculate injector flow rate to maintain maximum 3 second injector on time Time cycle 60 sec = 6 sec/cycle 10 cycles 50% Duty Cycle 6 sec/cycle x 0.5 = 3 sec/injection (injector on time) 3. Injector minimum flow rate (to maintain 50% duty cycle) 0.025 l/injection 3 sec/injection = 0.025 l/injection 4. Injector maximum flow rate (to ensure minimum 1 sec on-time): 0.025 l/injection 1 sec/injection x 60 (sec/min) = 0.50 l/min x 60 (sec/min) = 1.5 l/min Note: Flow rate minimums or maximums (Calculations 3 and 4, or AccuPlus specification limits) must not be exceeded. Adjust injection rate (number of injections per minute), if the minimum or maximum flow rates cannot be maintained. Setting the Flow Rate of the Unit 1. Close the upstream isolation valve 2. Close the outlet needle valve located in the dosing unit 3. Remove the dosing unit calibration port plug 4. Properly install the calibration male quick connect fitting 5. Connect the calibration set 6. Place the graduated cylinder below the calibration set nozzle 7. Energize the pump 8. Energize the additive solenoid valve 9. Open the upstream isolation valve to allow flow, until the graduated cylinder is full 10. Close the upstream isolation valve 11. Operate the unit and determine the volume collected in graduated cylinder for a suitable time period 12. If the flow rate is too high, reduce the inlet needle valve opening Page 11 MN05002E Issue/Rev. 0.1 (3/14)
Section V Calibration Calibration To gain maximum accuracy from using the AccuPlus, a field calibration is required. The calibration should be performed after start-up and at typical operating conditions. Below are some general guidelines: During calibration it is important that sufficient quantity can be measured by a suitable graduation cylinder Furthermore, the graduation cylinder should provide sufficient resolution and accuracy. The calibration chamber must be located downstream of the AccuPlus. The calibration chamber should be done equally to the operating conditions. If required, a temporary back pressure valve should be used for filling the calibration chamber. With back pressure valves installed, too long and/or soft hoses can cause calibration repeatability problems. Calibration can be done either in continuous mode or for maximum accuracy in normal operations pulsed injection ON/OFF mode. It is recommended repeating each test 3 times and verifying the repeatability of the results. It is recommended calculating and averaging a result of 3 successful repeats. The determined meter factor should be programmed by the meter pulse receiving device. Proper Personal Protection Equipment (safety glasses, rubber gloves, etc.) should be worn at all times while calibrating the AccuPlus. Calibration of the additive unit is done using the Calibration Kit. AccuPlus Calibration Quick Connect Pressure Gauge Ball Valve Hose The Calibration is Performed as Follows: Close the upstream isolation valve Close the outlet needle valve Remove the plug by the outlet of calibration Mount the quick connect part of the calibration set Connect the rest of the calibration set Place the hose and the graduated cylinder so that the fluid exits the nozzle into the graduated cylinder. Open the upstream isolation valve Perform the calibration by filling the calibration chamber with a predefined injection volume (ex. 0.0225ml x 40 injections = 900ml). This will allow an accurate comparison of input volume to output volume. After the calibration, remove the hose and fitting of the calibration set from the additive unit Re-install the plug and open outlet needle valve Nozzle Graduated Cylinder Figure 13 Calibration Set Issue/Rev. 0.1 (3/14) MN05002E Page 12
Section VI Related Publications The following literature can be obtained from FMC Technologies Measurement Solutions Literature Fulfillment at measurement.fulfillment@fmcti.com or online at www.fmctechnologies.com/measurementsolutions. When requesting literature from Literature Fulfillment, please reference the appropriate bulletin number and title. AccuPlus Installation/Operation... Bulletin MN05002E Maintenance... Bulletin MN05003E Parts List... Bulletin PO05001E Specifications...Bulletin SS05001E Revisions included in MN05002E issue/rev. 0.1 (3/14): Page 2: Electrical specifications - AccuPlus approvals - electrical safety/approvals. Headquarters: 500 North Sam Houston Parkway West, Suite 100, Houston, TX 77067 USA Phone: +1 (281) 260 2190 Fax: +1 (281) 260 2191 Operations: Measurement Products and Equipment: Ellerbek, Germany +49 (4101) 3040 Erie, PA USA +1 (814) 898 5000 Integrated Measurement Systems: Corpus Christi, TX USA +1 (361) 289 3400 Kongsberg, Norway +47 (32) 286700 The specifications contained herein are subject to change without notice and any user of said specifications should verify from the manufacturer that the specifications are currently in effect. Otherwise, the manufacturer assumes no responsibility for the use of specifications which may have been changed and are no longer in effect. Contact information is subject to change. For the most current contact information, visit our website at www.fmctechnologies.com/measurementsolutions and click on the Contact Us link in the left-hand column. www.fmctechnologies.com/measurementsolutions Page Printed 13 in U.S.A. MN05002E 3/14 FMC Technologies Measurement Solutions, Inc. All rights reserved. MN05002E Issue/Rev. 0.1 (3/14) Issue/Rev. 0.1 (3/14)