Operating & Maintenance Manual Yokogawa Corporation of America 2 Dart Road, Newnan, Georgia U.S.A.
The following safety symbols are used on the product as well as in this manual. DANGER This symbol indicates that an operator must follow the instructions laid out in this manual in order to avoid the risks, for the human body, of injury, electric shock or fatalities. The manual describes what special care the operator must take to avoid such risks.
10.2.1.3 Pressure........................................................................... 13 10.2.1.4 Temperature..................................................................... 13 10.2.1.5 Disposal............................................................................ 13 10.2.2 Installation and Commissioning..................................................... 13 10.3 Supplement Safety Information....................................................................... 14 10.3.
1. INTRODUCTION Overview The Advanced Reflux Sampler (YARS100) has been developed specifically to meet the needs of modern petrochemical analyzer sampling, especially ethylene cracked gas effluents. 1.1 Features Based on a proven simpler concept, the YARS includes several technologically advanced features outlined below: • Self-acting temperature controller requiring no electrical power supply – Adjustable across the selected control range.
2. GENERIC SPECIFICATIONS Product development is a continuous policy of Yokogawa and therefore specifications may be subject to change without notice The following generic specifications apply however; please check exact features and model number with serial numbers on the units provided. A) Process Connection: Process flange ratings are ASME B16.6-1996 B) Sample Outlet Connection: Standard 3/8” o.d. Sawgelock® stainless steel Flow Rate: Typically 3 Lts./min conditioned at 15°C or 4 Lts.
3. THEORY OF OPERATION This section of the manual describes the basic theory of operation, designed to give the user a better understanding and help in operation and maintenance. 3.1 Brief History of Reflux Samplers The concept of the Reflux Sampler was introduced in mid 1970’s and until the inception of the Advanced Reflux Sampler (YARS), it had changed very little.
the sample gas is achieved. There are two cooling coils located in the same heat exchanger chamber, which helps provide more accurate and efficient cooling. In the head-space of the heat exchanger, a stainless steel fine filter mesh is installed to act as a mist trap and final liquid sample droplet trap prior to existing the sampler. Flow of the cooling media through each coil is automatically controlled to ensure a constant outlet temperature is maintained.
4. UTILITY REQUIREMENTS Section 2 – General Specification listed above defines the required utilities needed for YARS operation. Also, refer to the General Installation drawing provided specifically for the YARS by serial number for the hook-up details. 4.1 Instrument Air The media used by the Vortex air tube(s) is ISA grade Instrument air. Plant Nitrogen may be used in place of the air, provided it meets the required pressure and flow demands of the YARS.
5. INSTALLATION 5.1 Mechanical Considerations Typically, the YARS will be subject to large vibration conditions and therefore a sound mechanical installation is required. While flange mounting to the customer supplied process isolation valve provides an installation, it is also recommended that the upper section of the YARS be secured mechanically. The heat exchanger and controller give the YARS ‘top-heavy’ properties that should be considered during installation.
5.3 Insulation The heat exchanger and top flange section of the YARS MUST always be insulated by at least two inches (obtained from a local supplier). This will reduce the influences of ambient air temperature fluctuations and cause the heat exchanger to operate more efficiently. Insulation should be installed at site after installation and leak testing and should be configured for possible future maintenance and access.
6. START-UP 1. Ensure the installation has been carried out in accordance with the unit requirements and any appropriate regulations/ standards applicable for the site. 2. Turn on instrument air supply and adjust pressure as required. Check for any leaks in the system. 3. Check for any leaks in the process and sample line connection. Rectify Accordingly. 4. Insulate the heat exchanger section, including the top flange assembly and over-temp shut off valve on top of the heat exchanger. 5.
8. MAINTENANCE When set-up and operated correctly, the YARS will require no routine maintenance other than filter cleansing, normally during a routine de-coke cycle and/or shut-down. 8.1 Filter Section and/or Heat Exchanger Cleaning To avoid filter section plugging, it is recommended that a routine steam clean be carried out on the filter section. Actual site operating conditions will determine the optimal cleansing period and duration and this may typically be required every 3-4 months.
10. SUB-COMPONENT DOCUMENTATION This section contains sub-component manufacturers information and supporting documentation that may be of use to operators. 10.1 Compressed Air Line Sizes Compressed air lines should be sized to hold pressure drops to a minimum. So not used restrictive fittings such as quick connects. They can “starve” the Vortex Tube by causing line pressure drop. The following chart gives suggested line sizes for pipe and hose.
inlet of the Vortex Tube while it is operating. Restrictions in the compressed air supply line can cause excessive pressure drops and deteriorate performance. 3.) Inlet Temperature- A Vortex Tube provides a temperature drop from supply air temperature. In some cases, the supply air is warmer than ambient air due to compressed air lines running across ceilings, near furnaces, direct sun, etc.
10.2.2 Installation and Commissioning NOTE Before starting any installation observe the “Safety information” Section 10.2.1. The valve should always be fitted in a horizontal pipeline with the flow in the direction indicated by the arrow marked on the body with the sensor in a vertical plane below the pipeline as shown in Fig. 1 .(SA control system). Valves should be mounted in the pipeline in accordance with the actuator installation and Maintenance Instructions.
10.3.4 Pressure Systems Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double isolation (double block and bleed) and the locking or labeling of closed valves. Do not assume that the system has depressurized even when the pressure gauge indicates zero. 10.3. 5 Temperature Allow time for temperature to normalize after isolation to avoid danger of burns. 10.3.
10.4 Installation and Maintenance Instructions for Temperature Control Valve Systems 10.4.1 Safety Information This product is designed and constructed to withstand the force encountered in normal use. Use of the product for any purpose other than as a temperature controller could cause Injury or fatality to personnel. NOTE This product contains Kerosene which is highly inflammable. 10.4.2 Installation Check that the control system supplied is of the temperature range required.
10.4.3 Display Adjustment The adjustment head provided (Figure 1), enables the set temperature to be raisd or lowered, one the drive screw ‘C’ has been engaged. B To make any adjustment the blue knob is turned clockwise to lower the temperature, and counterclockwise to increase it.
10.5 Supplementary Safety Information, Installation and Maintenance Instructions for SA Temperature Control Systems: Safe operation of these products can only be guaranteed if they are properly installed, commissioned, used and maintained by qualified personnel 10.6 in compliance with the operating Instructions. General installation and safety instructions for pipeline and plant construction, as well as the proper use of tools and safety equipment must also be complied with. 10.5.
10.5.7 Pressure Systems Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double isolation (double block and bleed) and the locking or labeling of closed valves. Do not assume that the system has depressurized even when the pressure gauge indicates zero. 10.5.8 Temperature Allow time for temperature to normalize after isolation to avoid danger of burns. 10.5.
11 DIMENSION DRAWINGS writing including Health and Safety data sheets relating to any substances identified as hazardous or potentially hazardous. All Rights Reserved. Copyright © 2011, Yokogawa Electric Corporation. Subject to change without notice.
11 Dimension Drawings (continued) All Rights Reserved. Copyright © 2011, Yokogawa Electric Corporation. Subject to change without notice.
11 Dimension Drawings (continued) All Rights Reserved. Copyright © 2011, Yokogawa Electric Corporation. Subject to change without notice.
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Yokogawa Corporation of America North America 2 Dart Road, Newnan, GA 30265-1094, USA Phone: 800-258-2552 Fax: 770-254-0928 12530 West Airport Blvd., Sugar Land, TX 77478 Phone: 281-340-3800 Fax: 281-340-3838 Yokogawa has an extensive sales and distribution network. Please refer to the website (www. yokogawa.com/us) to contact your nearest representative. Mexico Melchor Ocampo 193, Torre C, Oficina 3”B” Veronica Anzures D.F., C.P. 11300 Phone: (55) 5260-0019, (55) 5260-0042 Yokogawa Canada, Inc.
