KAM® CHA™ COLORIMETER/HAZE ANALYZER
Contents
1. Controls Incorporated simple precision TEL 1 713 784 0000 FAX 1 713 784 0001 Email Sales Kam com User Manual CHAMANUAL 0413 KAM CONTROLS INC 3939 Ann Arbor Drive Houston Texas 77063 USA www KAM com SECTION TITLE J dem m 1 Introduction Available Models and Mounting Options e Theory of Operation Features Applications WWNN NY 2 Specifications Specifications e Dimensional Drawings an KR 3 Installation Main Line e Removal Wiring 4 20 mA Outputs 0 4 Maintenance 12 5 Communications Interface 13 6 Additional Drawings 14 CAUTION When installing the CHA sensor in a pipeline containing petroleum products petro chemicals waste waters with the presence of pressure amp temperature and high pressure steam refer to the Pipeline Operators Health Safety and Environmental Policy Procedures to ensure safe installation KAM CONTROLS INC reserves the right to make changes to this document without notice CHAMANUAL 0413 1 KAM CONTROLS INC AVAILABLE MODELS and MOUNTING OPTIONS FIG 1 2 Full opening ball valve Full opening ball Rectractable CHA on a main pipe with 2 3 or 4 flanged seal housing Rectractable CHA on a main pipe with 2 MNPT seal housing CHA FT Flow Through with 1 ANSI 150 flanges THEORY OF OPERATION Color variations in refined products indicate impurit2. CONNECTIONS CONNECTIONS POWER COMMUNICATION INTERFACE 12 or 24 VDC 5 watts max RS 485 CAUTION When electronics enclosure is open be extremely careful to avoid any contact with interior fiber optic connections Failure to do so could result in the CHA malfunctioning CHAMANUAL 0413 10 KAM CONTROLS INC INSTALLATION CONTINUED OUTPUTS LOOP1 and LOOP2 can output signals for any 2 of 4 different scales ASTM Saybolt Platinum Cobalt and Haze To select which signal or scale is associated with which 4 20 mA output insert a jumper across the pins next to the label for the desired scale See Fig 3 9 Place ONE jumper in J5 and one in J7 to select two scales total Inserting more than one jumper for either LOOP or inserting the jumper across two inputs or two outputs will result in the malfunctioning of the instrument COLOR SCALE RANGES SCALE ASTM Saybolt Platinum Cobalt Haze CHAMANUAL 0413 WISV gt lt JUMPER INPUT JUMPER OUTPUT PROPER JUMPER PLACEMENT ACROSS INPUT AND OUTPUT RANGE 5 to 8 30 to 16 01 500 01 100 11 KAM CONTROLS INC CLEANING AND INSPECTION Under normal operation the KAM CHA should not require cleaning unless pipeline usage is limited to a small number of products Gasoline products or jet fuel in the pipeline will clean the CHA without removal To remove any oil residues for visual inspection use a clean cloth with oil solvent or part washer Pr
3. a 25mm window of pipeline fluids and then are reflected back through fiber optics to the electronics enclosure for a total path of 50mm CHAMANUAL 0413 2 KAM CONTROLS INC INTRODUCTION CONTINUED KAM uses four LED s for color determination to increase the accuracy over three color RGB models The fifth IR LED provides haze detection The disparity in light output versus light reflected back is then converted into an electronic or optical signature which is amplified and sent to the computer The computer in turn utilizes a mathematical formula to determine the exact color and haze turbidity of the fluid in the pipeline Final color measurement from the KAM CHA can be expressed as haze plus three color X Y Z CIE 1931 or in several other industry standard color scales including Saybolt Platinum and Cobalt and ASTM 1500 see Specifications Section 2 The computer automatically adjusts for electronic noise and any LED fluctuations Because the absorption rates of the different colored fluids vary resulting in different signal strengths the computer also automatically adjusts the amplification or gain accordingly Measurement is fully automatic without the need for operator intervention or supervision The output signal can be sent to the SCADA PLC s or to a Central Control Room for logging or display on chart recorders or monitors The KAM CHA probe can be installed in an analyzer loop or in the main line and beca
4. 3 Measure the distance D1 from the outside diameter of main pipe to the end of the connection where the CHA sensor is going to be installed FIG 3 4 4 Calculate the minimum insertion distance for the CHA Minimum insertion distance MID D1 Wall Thickness 2 Example for D1 16 pipe WT 71 4 Seal Thickness 1 8 MID 16 1 4 1 8 2 MID 18 3 8 5 Measure the calculated MID from the top of the seal clamp and place a mark with a permanent marker or tape on the Shaft FIG 3 5 6 Bolt or screw the CHA sensor to the valve or designated installation location KAM CONTROLS recommends using thread sealant and not Teflon tape for the threaded CHA 7 Open full opening valve 8 Loosen Socket Cap Screws on the locking collar REMINDER Line pressure must be below 100 psi for CHA installation and removal CHAMANUAL 0413 8 KAM CONTROLS INC INSTALLATION CONTINUED 9 Push CHA sensor in until the mark is at the top edge of the locking collar Ensure that CHA flow indicator is aligned with pipeline flow direction FIG 3 6 OQ Nuts 10 Re tighten the Socket Cap Screws with a torque of 750 800 Ib in or 62 5 to 66 6 lb ft 11 Tighten the Hex Nuts on the top of the Locking Collar one half turn These nuts should never be over tightened Their major function is to app
5. able 2 MNPT Seal Housing 2 3 or 4 Flanged Seal Housing 3 5 x 1 25 90mm x 32mm Flow through 5 8 x 2 75 148mm x 70mm 3 x 6 x 3 76mm x 152mm x 76mm 12 to 60 Off the shelf lengths are 12 24 36 48 and 60 305mm to 1524mm Off the shelf 609 6mm 762mm 914 4mm 1219mm 1524mm 3 4 to 48 20mm to 1200mm from 20 lbs 9kg 4 KAM CONTROLS INC SPECIFICATIONS CONTINUED DIMENSIONAL DRAWINGS Seal Housing Q am FNPT 4 Shaft Length 5 Sensor Profile inches ces INCHES INCHES 3 DIMEN AB ON a INCHES Shaft Lengths are available in 5 B 35 90 Standard sizes 24 30 36 48 and 60 609 6mm 762mm 184 914 4mm 1219mm 1524mm az 19 az 2 111 25 CHAMANUAL 0413 5 CONTROLS INC SPECIFICATIONS CONTINUED ANSI FLANGES oan Qe CHAMANUAL 0413 6 KAM CONTROLS INC PRIOR TO INSTALLATION Remove all the protective packaging materials and ensure that the CHA sensor was not damaged during transit MAIN LINE INSTALLATION The KAM CHA sensor should be installed according to FIG 3 1 ideally at the 3 or 9 o clock position within the pipeline Installing the instrument horizontally prevents the long term buildup of any sedimen
6. eferred solvents include any petroleum solvent such as mineral spirits xylene toluene gasoline or diesel Do not use WDAO or other chemicals If you have a question regarding cleaning solvents please contact KAM CONTROLS directly at 1 713 784 0000 or email AskAnEngineer Kam com CHAMANUAL 0413 12 KAM CONTROLS INC HYPERTERMINAL PROMPTS FOR 5483 CONNECTION 1 Once Hyperterminal software is launched a dialogue window will prompt you to Enter a name and choose an icon for the connection Name the connection whatever you want for example CHA 1 Ignore the choose icon option Hit OK 2 The Connect To dialogue box will now appear On the last line where it says Connect using choose the name of the communication port connected to the CHA via RS 485 from the drop down menu Hit OK 3 The Port Settings dialogue box will now appear Enter the following values from the drop down menv Bits per second 1200 Data bits 7 Parity Even Stop bits 2 Flow control None Hit OK 4 A blank screen with prompt will now open To display CHA readings type one of three prompts E1 E2 1 Displays values for 2 Y 2 and T haze E2 Displays values for ASTM Saybolt PtCo Platinum Cobalt and T haze E3 Displays all values CHAMANUAL 0413 13 KAM CONTROLS INC
7. ies and or the presence of water Refined products are often prone to haze or diffused water contamination due to cooling towers which use water and in turn can saturate the product This can be a significant liability as color differentiation can be easily detected by the end user The KAM CHA Colorimeter Haze Analyzer is the ideal quantitative solution for monitoring both the color of refined products including dyed product and the presence of haze trace dissolved water in pipelines following the refining process The KAM CHA detects interface color variations within 1 and unlike most colorimeters can detect the entire range of visible color as defined by CIE 1931 International Commission on Illumination The simplicity of design and quality of engineering employed in the Colorimeter Haze Analyzer mean there are no moving parts Using long lasting LED light sources ensures long term stable performance with limited maintenance and power requirements In addition locating the electronics within an explosion proof enclosure directly on the atmospheric end of the optical probe creates a complete and compact unit with maximum installation flexibility The KAM CHA easily installs where other colorimeters weighed down by large electronics computer units cannot The five LED sources Red Blue Green Yellow and IR send light via fiber optics to the sensor end inserted into the pipeline or analyzer loop These beams of light pass through
8. ly light pressure on the chevron packing to ensure a seal between the seal housing body and the insertion shaft REMOVING THE CHA SENSOR 1 To remove the CHA sensor first disconnect all electrical connections to the CHA enclosure 2 Make sure that the line pressure is below 100 psi Then slowly and with caution loosen the Socket Cap Screws on the Lock Down Collar NOTE Once the Socket Cap Screws have been loosened the CHA shaft may push out from the line If pres sure in the line is above 100 psi it may do so with enough force to cause bodily injury or damage to the instru ment 3 Slide the CHA sensor upward until it stops and the probe rests inside the seal housing Fig 3 7 The mechani cal stop prevents further movement or ejection of the shaft and or sensor 4 Next close the Full opening Ball Valve tightly The CHA sensor may now be unbolted from the system Mechanical Stop d Socket Cap Screws CHAMANUAL 0413 9 KAM CONTROLS INC INSTALLATION CONTINUED WIRING 3ZVH Il1OSAVS WISV JUMPERS TO SELECT SIGNAL SCALE FOR 4 20 mA OUTPUTS v 4 Controls Incorporated KAM CHA 3939 Ann Arbor Drive Houston Texas 77063 USA 1 713 784 0000 www KAM com ODOODDOD OOD S S z go COMMUNICATION INTERFACE Rev 2 01 12 2012 Made in USA POWER 4 20 mA
9. t on the sapphire windows A full opening ball valve is used to isolate the CHA sensor from the pipeline during installation or removal The seal housing of the CHA 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 CHA sensor be placed at the most representative point within the flow profile The CHA sensor should be inserted so that the window of the probe is fully located within the pipeline NOTE Line pressure must be below 100 psi for CHA installation and removal Pressure above 100 psi could cause the probe to forcibly move outward from the pipeline risking bodily injury and or dam age to the probe l Prior to mounting verify that the tip of the sensor is all the way inside the seal housing FIG 3 2 3 3 2 If sensor is not fully enclosed inside the seal housing pull the shaft back until the probe is all the way in the seal housing and tighten the socket cap screws on the locking collar This will prevent the CHA shaft from sliding and the probe from getting damaged during mounting CHAMANUAL 0413 Locking Collar Seal Housing Full opening Ball Valve UN Socket Cap Screw KAM CONTROLS INC INSTALLATION CONTINUED
10. use it s easily mounted through a full opening ball valve you can insert or retract the probe without having to ever drain the pipe FEATURES User friendly Low power Explosion proof Low maintenance Compact format includes requisite electronics Long lasting LED light sources APPLICATIONS Batching Interface Production Transmix regrade reduction Quality control in refined products including dyed and undyed motor and aviation gasoline jet propulsion fuels naphthas and kerosine Quality control in pharmaceutical white oils and petroleum waxes Brine detection in LPG transfer from storage caverns CHAMANUAL 0413 3 KAM CONTROLS INC Media Material Power Communication Interface Fluid temperature Electronics temp Pressure ratings Accuracy Repeatability Reproducibility Haze Range Color Range Mounting Sensor Dimensions EX enclosure Shaft length Pipe size Weight CHAMANUAL 0413 Refined products Wetted parts 316 stainless steel sapphire 12 24 VDC 20 Watts max RS 485 reflects values for Haze plus designated color scale see Color Range 40 to 200 40 to 93 C 22 to 185 30 to 85 C ANSI 150 300 600 Haze 5 Color 1 Haze 1 Color 1 Haze 1 Color 1 0 100 Complete range of ASTM D 1500 ASTM D 156 Saybolt ASTM D 1209 APHA Platinum Cobalt 34 1 112 and 2 FNPT Flow Through Metric sizes avail
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