KAM LRW Manuale utente
KAM®LRW™
LOW RANGE WATERCUT
User Manual
LRWMANUAL 0321
PTB 08 ATEX 1026
II 2 G Ex db IIB T6 Gb
IECEx PTB 19.0048
Ex db IIB T6 Gb
TEL +1 713 784 0000
FAX +1 713 784 0001
Email [email protected]
KAM CONTROLS, INC.
3939 Ann Arbor Drive
Houston, Texas 77063 USA
www.KAM.com
An ISO 9001 certified company
LRWMANUAL 0321 KAM CONTROLS, INC.
1
TABLE OF CONTENTS
SECTION TITLE PAGE
1Introduction 2
•Available Models and Mounting Options 2
•Theory of Operation 3
2Specifications 4
•Specifications 4
3Installation 5
•Installation Flow Requirements 5
•Prior to Installation 6
•Flow through assembly 6
•Insertable/retractable installation 7
•Removal 10
•Wiring 11
4LRW Operation using Realterm 19
•Software configuration 19
•Output data 22
•Inline calibration and verification 26
•Calibration with lab results 28
•Process parameter values 29
•Density input reconfiguration 30
•Changing temperature units 32
•Setting alarm setpoints 33
•Setting alarm mode 34
•Enable/disable Modbus 35
•Change Modbus address 36
•Commmand list 37
5Maintenance 38
•Cleaning/Inspection 38
6Troubleshooting 39
•Checking the LCD Display 39
•Power connections 40
•Checking input power 40
•Checking 5 VDC supply 41
•Loop troubleshooting 41
•RS232 troubleshooting 42
•RS485 troubleshooting 42
APPENDIX A: Modbus Registers 43
KAM CONTROLS, INC. reserves the right to make changes to this document without notice.
LRWMANUAL 0321 KAM CONTROLS, INC.
2
1 INTRODUCTION
AVAILABLE MODELS and MOUNTING OPTIONS
Water 0.377 %
Temp 28.278 C
www.KAM.com
+1 713 784 0000
Made in the USA
LRW Low Range Watercut
2" Flow Through LRW with included
static mixer and manual draw-off valve
3" and 4" Flow Through LRW with included
static mixer and manual draw-off valve
Flanged Fixed Insertion LRW for pipelines 3" and up
with 2", 3" or 4" flanged process connection
1.25" NPT Fixed Insertion LRW for pipelines 3" – 8"
Insertable/retractable LRW for pipelines 3" and up
2", 3" or 4" flanged seal housing
or 2" MNPT process connection
Water 0.377 %
Temp 28.278 C
www.KAM.com
+1 713 784 0000
Made in the USA
LRW Low Range Watercut
Water 0.377 %
Temp 28.278 C
www.KAM.com
+1 713 784 0000
Made in the USA
LRW Low Range Watercut
Water 0.377 %
Temp 28.278 C
www.KAM.com
+1 713 784 0000
Made in the USA
LRW Low Range Watercut
Water 0.377 %
Temp 28.278 C
www.KAM.com
+1 713 784 0000
Made in the USA
LRW Low Range Watercut
FIG. 1-1 FLOW THROUGH MODELS
FIG. 1-2 FIXED INSERTION MODELS FIG. 1-3 INSERTABLE/RETRACTABLE MODEL
LRWMANUAL 0321 KAM CONTROLS, INC.
3
INTRODUCTION CONTINUED
The KAM LRW™ Low Range Watercut / BS&W meter uses a patented microwave resonance technology, responding
to the differing electrical properties of water and oil to determine water content for ranges 0-3%, 0-5% and 0-10%.
The technology is highly repeatable and offers industry-leading accuracy (±0.03% up to 3% water). Additionally,
proprietary AnyDensity™ technology allows the instrument to compensate for any change in density across the
entire API gravity range. Compensation is based on a density input from a mass flow meter or densitometer and
all compensation is automatic. This is paramount in situations where a single truck or rail unloading site could see
swings in API gravity from the 20s to the 70s.
The unit can be calibrated and verified in line.
The LRW's high-quality components are made and assembled entirely in the USA, providing reliable and consistent
performance for long-term use.
TABLE 1-1 MEASUREMENT CAPABILITIES: CALIBRATED RANGE AND ACCURACIES
THEORY OF OPERATION
Range (water in oil) 0-3% 3-5% 5-10%
Accuracy ±0.03% ±0.05% ±0.1%
LRWMANUAL 0321 KAM CONTROLS, INC.
4
2 SPECIFICATIONS
Media: Crude oil, water and refined products
Wetted parts: 316 SS, Hastelloy, & PEEK (Other materials available)
Fluid temperature: 32ºF to 176ºF (0ºC to +80ºC)
Ambient temperature: -4º F to 131º F (-20º C to +55º C)
Power requirements: 24 VDC
Power consumption: 12 watts
Available ranges: 0-3%, 0-5%, 0-10% water in oil
Accuracy: +/- 0.03% up to 3% water; +/- 0.05% from 3-5% water; +/- 0.1% from 5-10% water
Repeatability: +/- 0.01%
Resolution: +/- 0.01%
Minimum water detection: 100 ppm
Outputs: 4–20 mA
Alarm relay
RS232/RS485
Input: 4-20 mA for density
Density Correction: AnyDensity™compensates for changes in fluid density across entire API gravity range
(requires density input)
Ingress protection: NEMA IV; IP66
Pressure ratings: ANSI 150, 300, 600, 900
Flow conditions: Well mixed in accordance with KAM recommendations
Hazardous area: PTB 08 ATEX 1026
II 2 G Ex db IIB T6 Gb
IECEx PTB 19.0048
Ex db IIB T6 Gb
LRWMANUAL 0321 KAM CONTROLS, INC.
5
3 INSTALLATION
KAM HIGHLY RECOMMENDS VERTICAL INSTALLATIONS WHEREVER POSSIBLE FOR OPTIMAL MIXING. For LACT
units, truck unloading risers, etc., KAM recommends installation of the LRW in the vertical flow up, immediately after
the pump (OPTION 1) or in the vertical flow down after a static mixer (OPTION 2). For other options, please consult
with the KAM factory.
INSTALLATION FLOW AND LOCATION REQUIREMENTS
PLEASE NOTE: The LRW should always be installed per KAM recommendations, including the mixing requirement
calculated per customer provided flow conditions. Vertical installations are ALWAYS preferred.
QQ
Static Mixer
CAUTION: When installing the LRW®sensor in a pipeline containing petroleum products, petrochemicals,
waste waters with the presence of pressure & temperature, and high-pressure steam refer to the Pipeline Operators'
"Health, Safety and Environmental Policy Procedures" to ensure safe installation.
LRWMANUAL 0321 KAM CONTROLS, INC.
6
Remove all the protective packaging materials, and ensure that the LRW®sensor was not damaged during transit.
The following items are provided with the KAM®LRW®sensor:
One (1) RS232 communication cable, for connecting your PC to the LRW
One (1) USB-to-serial converter, in case your computer does not have an RS232 serial port
Please ensure you have received these items and store them properly, they will be used for initial startup and
operation of the LRW sensor.
REMINDER: Please refer to the Installation Flow Requirements on page 5 of this manual to ensure proper sensor
placement where at all possible.
In installations below -4°C where the LRW is exposed to an open environment, KAM CONTROLS recommends
operators insulate the LRW, and if the pipeline is heated, that the heating trace be extended to include the LRW.
If pipeline flow is going to be stopped for an extended amount of time and the pipeline is not heated, then the LRW
should be removed from the line to avoid damage to the sensor from freezing water.
Flow through (spool) units will be shipped
partially assembled. LRW unit can be wired prior
to insertion into the spool for convenience, but
this is not required.
For 2" units (FIG. 3-1):
1. Grease around the O-ring below the small
flange.
2. Insert LRW body into the spool and ensure
unit is fully seated.
NOTE: LCD screen face should be aligned
with direction of pipe flow.
3. Using a 5/8" Allen wrench, install (8) hex
screws around the circumference of the
flange until tight. Screw manual sample
probe into valve until tight.
PRIORTO INSTALLATION
LRW FLOWTHROUGH ASSEMBLY
For 3" and 4" flow through units (FIG. 3-2):
1. Screw LRW body into spool using 1 3/4"
wrench flat. KAM Controls recommends
using liquid pipe sealant rather than Teflon
tape.
2. Screw manual sample probe into valve
until tight.
Water 0.377 %
Temp 28.278 C
www.KAM.com
+1713 784 0000
Madein the USA
LRWLow Range Watercut
Water 0.377 %
Temp 28.278 C
www.KAM.com
+1713 784 0000
Madein the USA
LRWLow Range Watercut
Manual
sample probe
Manual
sample probe
Hex nutsO-ring
FIG. 3-1 LRW FLOW THROUGH 2" MODELS
FIG. 3-2 LRW FLOW THROUGH 3" and 4" MODELS
INSTALLATION CONTINUED
Water 0.377 %
Temp 28.278 C
www.KAM.com
+1 713 784 0000
Made in the USA
LRW Low Range Watercut
1 3/4" wrench flat
LRWMANUAL 0321 KAM CONTROLS, INC.
7
Prior to mounting the LRW™ sensor on the Full-opening Ball Valve, you must determine the insertion length required.
1. Lay the LRW™ sensor on the ground or a table.
2. Loosen the Socket Cap Screws, using a
3/8" Allen wrench on the locking collar. This will
allow the LRW™ shaft to slide through the seal
housing.
FIG. 3-4
FIG. 3-5
INSTALLATION CONTINUED
MAIN LINE INSTALLATION INSERTABLE MODELS
The KAM®LRW sensor should be installed
according to FIG. 3-3. A full-opening ball valve is
used to isolate the LRW®sensor from the pipeline
during installation or removal. The seal housing of
the LRW®sensor allows the probe to be inserted
and removed from the pipe under pressure and
flow conditions. It is the user’s responsibility to
ensure that the LRW®sensor be placed at the most
representative point within the flow profile (see flow
recommendations on page 5 of this manual). The
LRW®sensor should be inserted so that the window
of the probe is located in the center half of the
diameter of the pipeline.
NOTE: If line pressure exceeds 100 psi, use a KAM®
IT Insertion Tool when installing/removing the KAM®
LRW®sensor.
Locking Collar
Seal Housing
Full-opening
Ball Valve
FIG. 3-3 KAM®LRW INSTALLED ON A MAIN PIPE
Socket cap screw
CALCULATINGTHE REQUIRED INSERTION LENGTH
3. Pull the LRW™ back through the seal housing
until the LRW probe is retracted inside the seal
housing. FIG. 3-4 and FIG.3-5.
NOTE: The antennas on the LRW sensor probe
won't necessarily end up all the way inside the
seal housing.
4. Retighten the Socket Cap Screws on the locking
collar. This will prevent the LRW™ shaft from
sliding and the probe from getting damaged
during mounting.
LRWMANUAL 0321 KAM CONTROLS, INC.
8
INSTALLATION CONTINUED
5. Measure the distance (D1) from the outside diameter of main pipe to the end of the connection where the LRW®
sensor is going to be installed. FIG. 3-6a and FIG. 3-6b.
D1
WT
Ls
Pipe OD
Pipe ID
Lt
D1
WT
Pipe OD
Pipe ID
Ls
FIG. 3-6a FIG. 3-6b
6. Calculate the insertion distance:
For flanged Seal Housing models
MID – Minimum Insertion Distance
D1 – Distance from the top of the valve to the pipe
Lg – Gasket Width (Typical 0.134")
WT – Pipe Wall Thickness
Ls – Pipe ID x 0.25 (Measurement Area Length)
Ds – Pipe ID x 0.5 (Measurement Diameter Area)
Minimum Insertion Distance (MID)=D1 + Lg + WT + Ls + LRW Factor
Example: D1=14"
Lg=0.134"
WT=0.25"
ID=8.125"
LRW Factor 2" 150#=1"
MID=14 + 0.134 + 0.25 + (8.125 x 0.25) + 1
MID=17.41"
Take note of the calculated MID and proceed to step 7.
Class Rating 2" Size 3" Size
150# 1.00" 1.20"
300# 1.12" 1.37"
600# 1.50" 1.75"
900# 2.00" 2.00"
TABLE 3-1 LRW FACTOR - Flanged SH
LRWMANUAL 0321 KAM CONTROLS, INC.
9
INSTALLATION CONTINUED
For 2" MNPT Seal Housing models
D1 – Distance from the top of the valve to the pipe
WT – Pipe Wall Thickness
Ls – Pipe ID x 0.25 (Measurement Area Length)
LRW Factor – 1.65"
Lt – Thread Engagement (0.75")
Minimum Insertion Distance (MID)= D1 + WT + Ls + LRW Factor - Lt
Example: D1=14"
WT=0.25"
ID=8.125"
LRW Factor=1.65
Lt=0.75"
MID=14 + 0.25 + (8.125 x 0.25) + 1.65 - 0.75
MID=17.18"
7. Measure the calculated MID from the top of the
Locking Collar and place a mark with a permanent
marker or tape on the Shaft (Do not use anything
sharp to mark the shaft as this will create grooves
that will damage the O-rings in the seal housing.)
FIG. 3-7.
8. You can now attach the LRW to the valve on the
pipeline. For threaded models, KAM CONTROLS
recommends liquid thread sealant and not Teflon
tape for the threaded LRW™ sensor.)
FIG. 3-7
MID
Mark Here
9. Open Full-opening Valve.
10. Loosen Socket Cap Screws on the Locking Collar.
11. Push LRW®sensor in until the mark is at the top edge of the Locking Collar. Ensure that LRW®flow indicator is
aligned with pipeline flow direction. FIG. 3-8.
Mark
FIG. 3-8
Hex Nuts
Flow indicator
Indice
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