Elevated temperature sensor head installation
Contents
1. Process Monitoring System Installation amp Startup Manuals The information contained in this supplement pertains only to the Elevated Temperature Sensor Head Assembly The Installation Manual should be read and understood prior to use of this manual The Elevated Temperature Sensor Head is rated for use in General Purpose non hazardous locations All installation guidelines and safety related items listed in the VF 100 or GVF 100 Manual pertain to installation of the Elevated Temperature Sensor Head For additional information contact your local sales agent or Customer Support by telephone at 1 877 243 7277 1 877 CIDRA77 or by E Mail at customersupport Wcidra com Page 1 1 2 SENSOR HEAD INSTALLATION 2 1 Caution High Temperatures Be careful when installing or removing the high temperature system Incidental contact with the process pipe may cause serious burns The sensor cover and fasteners may become extremely hot Always use appropriate gloves and clothing WARNING Potential burn hazard Always wear appropriate gloves when installing or removing system from hot pipes 2 2 Tools Required For Installation Refer to the VF 100 Installation Manual for a list of tools required for installation Additional tools and supplies are listed below Sensor Materials Sensor Tools Supplies a 9 32 socket or slotted screwdriver ROO Snes adapter for use with torque wrench Sensor alignment sheet Torque wrench with 22 in2. preamplifier housing is oriented up 12 o clock position for horizontal pipe installations Remove the tape If used from the Kapton sheet Note For vertical installations install the cover inner support ring Y2 inch from the upper edge of the Kapton sheet Page 2 3 Note Wires 9 and 10 on the alignment sheet are used for grounding and temperature Alignment sheet Alignment sheet retaining springs e Spong Kapton sheet Xs Xa Se 1 inch Cover inner support ring ires 49 amp 10 partial vertical installations view installed Y2 inch from Kapton Important X refers to sensor installation locations Figure 2 Alignment Sheet Attachment to Pipe 21020 01 Rev 01 Page 2 4 2 3 3 21020 01 Rev 01 Sensor Installation Slightly bend the alignment tabs on the sensor band alignment sheet upward These will serve to align the sensors during installation Wrap the sensor bands around the alignment sheet Align the edge of the sensor band with the alignment tabs on the alignment sheet IMPORTANT The alignment tabs on the alignment sheet are not symmetrical Install the sensors on the side of the tab shown in Figure 2 above Install the sensors so the cable exiting from under the sensor clamp does not touch the alignment tabs this may cause the sensor element to be cut and cause a short Install the sensor such that their connectors are opposite the direction of wires 9 amp 10 on the alignment
3. sheet Orient the sensor band attachment bolts with the top of the pipe horizontal installation so they will be directly under the cover assembly Tighten the screw on each of the sensor bands to 20 22 in Ib using a torque wrench with a 9 32 socket or slotted screwdriver adapter Wait 10 minutes Re torque the band screws to 20 22 in lb If the sensors have not been previously numbered label each of the leads from the sensors with wire numbers Apply the tag near the connector end of the wire Label the first sensor with respect to flow direction with 1 tag label the second sensor with tag 2 etc Figure 3 Installed Sensor Band Page 2 5 Remove the springs from the alignment sheet Bundle the individual sensor wires and wires 9 and 10 together and attach them to the alignment sheet using the tabs provided using a blue Tefzel wire tie Tefzel can withstand high temperature Refer to the following figure Sensor and wires 9 amp 10 bundled at 2 places Figure 4 Sensor Assembly Wires Bundled 21020 01 Rev 01 Page 2 6 2 4 2 4 1 Sensor Cover Installation Cover Seal Installation Note The seals to be installed on each cover half must seal on each other when the cover halves are assembled Also the crossing seals start and stop ends must be on opposite sides of the cover when installed Remove a short length of the adhesive backing covering on the joint seal strip to expose the adhesiv
4. 2 inches before the center bolt hole on the top of the cover Push the seal into the space between the cover and the pipe using an Allen wrench or similar tool so the adhesive on the seal will stick to the seal material that was pre installed on the cover reference Figure 6 Continue to push the seal in until it is fully seated The end of the seal should overlap the start point of the seal by about 1 inch or extend beyond the center bolt hole by about inch Center bolt hole on cover end LT Seal end point about 2 inches from hole Figure 13 End Seal Installation 21020 01 Rev 01 Page 2 12 21020 01 Rev 01 Repeat this installation procedure on the opposite end of the cover Install the cover end seal compression rings so that they overlap the cover flange seam The double pair of bolt holes in the end seal compression rings will align with the corresponding double threaded holes in the cover halves NOTE lf the end seal compression rings do not have a double pair o bolt holes as shown align the end seam of the compression rings between the two closely spaced tapped holes on the end of the cover Cover flange seam Note overlap of compression ring with respect to cover flange Figure 14 Cover End Seal Compression Ring Install 5 16 18 bolts fitted with a washer and lock washer in each cover end seal compression ring bolt hole Tighten the bolts gradually so that the rings pull in gradually and evenly w
5. Ib capacity Alignment sheet attachment springs 2 ea 4 x 20 roll of 100 expanded g pring Value Seal Joint Sealant 8 sensors Cover Materials Tefzel cable tie Cover Assembly Wire number tags Preamplifier Assembly Sensor alignment sheet springs Cover Fastener Kit Table 1 Materials amp Tools For Elevated Temperature Sensor Head Installation 21020 01 Rev 01 Page 2 2 2 3 2 3 1 2 3 2 21020 01 Rev 01 Sensor Installation Sensor Insulator Installation Properly clean the process pipe as described in the VF 100 or GVF 100 Manual along a 36 inch length of process pipe Wrap the polyimide Kapton sheet around the pipe such that it is in the middle of the cleaned section The goal is to electrically insulate the alignment sheet from the pipe Temporarily secure the sheet with tape if needed outboard of where the sensors will be located 36 inches cleaned Process pipe Polyamide sheet Tape outboard of sensor location Figure 1 Sensor Polyimide Sheet Installation Sensor Alignment Sheet Installation WARNING Use care when handling alignment sheet sharp edges may cause cuts CAUTION Use care when handling alignment sheet do not damage wires attached to alignment sheet Attach alignment sheet to pipe using 4 springs The seam of alignment sheet should be aligned such that it will be as close as possible to the preamplifier housing on the cover when the cover is installed It is preferred that the
6. SONARtrac gt gt SUPPLEMENT TO INSTALLATION amp STARTUP MANUAL PROCEDURE FOR ELEVATED TEMPERATURE SENSOR HEAD INSTALLATION CiDRA Corporate Services 50 Barnes Park North Wallingford CT 06492 265 294 www cidra com Table of Contents i INTRODUCTION 22 ee ee ee 1 1 2 SENSOR HEAD INSTALLATION ss ee ee 2 2 2 1 Gaution High Temperatura 2 2 2 2 1 0018 Required FOr Installation sip o il 2 2 2 3 Sensor INS Alla one ee eos 2 3 2 3 1 Sensor Insulator Installation ehe ini 2 3 2 3 2 Sensor Alignment Sheet InstallatiON ooccccooccconccconnonncconnonnnnonnnncnnnnnonoss 2 3 2 3 3 Sensor MStar 2 5 24 Sensor Gover Installal n su use ee SE ENESES 2 7 2 4 1 Cover Seallastala Ma ee En 2 7 2 4 2 Installing Gover on RIDE ac T MEE 2 9 2 4 3 Cover End Seal NA ace Neden ut Gud weenie 2 12 2 5 Sensor Pre Amplifier Connections ccooccccocccconcncoonnconnnnononnnonnnconnnnonnnnonnrnnonrncnnannnnoos 2 14 2 5 1 Sensor Band to Pre Amplifier CONNECtION ccooonncccccoonnonccnoccnncnnnncnncnnnncnnnnnanoos 2 14 2 5 2 Sensor to Transmitter Cable Connection ccccoocncnccccocccncccnncnncnnononncononnnnconanens 2 16 List of Figures Figure 1 Sensor Polyimide Sheet InstallatiOD ooocccncccoccnncoconnnnnonoonnnnnonaconnnnnanonnnnnos 2 3 Figure2 Alignment Sheet Attachment to Pip6 cccccccoccnnccccccnnccnoncnnnononcnonononcnnnononenncononennnos 2 4 Figure 3 Installed Sensor Band eia ai
7. aa i a E N ETa 2 5 Figure 4 Sensor Assembly Wires Bundled cccccoocccnccconcnccononcncnononcnnnononcnnnnnononnnonenennnos 2 6 Figure 5 Gover seal lnstallation nes 2 7 Figure o Gover seal EinalbInstallallOEss iiec bete eU ettet e ese Me tte i eu 2 8 Figure 7 Pre amplifier Mounting SCrews ueassussesnsnnennnnnnonennnennnnnennnnnnn nenne nnne nnn nnns 2 9 Figure8 Remove Fiberglass Insulation 1 sees 2 9 Figure9 Sensor Cable Feed Through Assembly eene 2 9 Figure 10 Cover Lower Support Ring ccccssssecccesseeecceesseeeceeaseeeesageeeeseaseeessanseeessaaseess 2 10 Figure 11 Cover Bolt Tightening SequenCe occcccccoccnnccconccnncnonconnononnonnonnnnonnononnnnnnnnanennnonaness 2 11 Figure 12 Measure amp Gut End sedsl asmia tavi ee 2 12 Figure 13 End Seal Install dio ld 2 12 Figure 14 Cover End Seal Compression RiNQ occcccccccccnnccccccnncconccnnnnnnncnnonnnncnnnnnancnnnnnanens 2 13 Figure 15 Pre amplifier Housing Feed through cccccccccccnccocncconcnccocncnnnnoconcoconnnnonnncnnnnnnos 2 14 Figure 16 Pre amplifier Top and Bottom VieW oonoccconncccconccccnccnnonnncnononcncnnncnnonanonennncononos 2 14 Figure 17 Wired and Mounted Pre amplifier coooocccoooccncccncnncconnnononcncnnnnnnonanonononcnnnnos 2 15 21020 01Rev 01 Page i 21020 01 Rev 01 INTRODUCTION This manual is intended to be a supplement to the SONARtrac
8. e Apply the joint seal strip starting at a middle of either the top or bottom cover half such that it curves partially around the inside of a bolt hole on the flange Continue to install the seal material on the flange so that it runs just inside the inner edge of the flange bolt holes At the last hole on the flange side see picture install the seal in a straight line toward the face seal Wrap around the end of the flange face and install the seal along the outer edge of the face seal Continue installing seal around cover flanges and end seals Cross the starting end of the seal with the end point as shown in the figure below Start adhering seal by wrapping around middle hole in the flange Turn at tangency point of bolt hole i Seal installed on outer edge of face seal End of seal dix Start of seal Figure 5 Cover Seal Installation 21020 01 Rev 01 Page 2 7 21020 01 Rev 01 Repeat the seal installation on the opposite cover half Note Ensure the seals are installed to mirror each other as they must seal on each other during cover installation Also the crossing seals must be on opposite sides of the covers when they are installed Seals must be one continuous length on each cover half Crossing seals must be on opposite sides when cover halves are installed Cover Top Cover Bottom Figure 6 Cover Seal Final Installation Page 2 8 2 4 2 Installing Cover on Pipe Remove the pre am
9. fier module Repeat for the remaining 9 wires Note lt may be easier to connect the sensors by first removing the connector block and then re installing the block after all connections have been made Turn the pre amplifier over Re install the four pre amplifier mounting screws Connect the wire interconnect wire connector to the pre amplifier Interconnect wire connector u i LJ a mi a a 47m z soe E E ol 7 vdd T Qd F Figure 17 Wired and Mounted Pre amplifier Ensure the grounding wire is attached to the pre amplifier cover Install the preamplifier cover and install the four cover screws 21020 01 Rev 01 Page 2 15 2 5 2 21020 01 Rev 01 Sensor to Transmitter Cable Connection Install the sensor cover to transmitter cable connector Terminate the individual sensor to transmitter cable conductors in the transmitter per the Installation Manual This completes installation of the high temperature sensor head Refer to the SONARtrac VF 100 user manual for transmitter installation and start up instructions Page 2 16 SONARtrac CIDRA Corporate Services 50 Barnes Park North Wallingford CT 06492 In U S 877 cidra77 Tel 203 265 0035 Fax 203 294 4211 Visit CIDRA Online at www cidra com CiDRA Corporate Services 50 Barnes Park North Wallingford CT 06492 Tel 203 265 0035 Fax 203 294 4211 www cidra com
10. he cover support ring Temporarily install the cover lower support ring on the bottom of the cover assembly E i Figure 10 Cover Lower Support Ring Install the lower cover half and temporarily clamp the upper and lower cover halves in place using spring clamps or equivalent Important Do not allow the cover end seals to touch any part of the sensor array including the polyamide insulation The seals and seal rings to be installed in the following steps should only be in contact with the process pipe Page 2 10 21020 01 Rev 01 Install 5 16 18 cover bolts fitted with a washer and lock washer in each cover bolt hole numbered 1 16 in the following figure Tighten the bolts gradually per the tightening sequence given in the following figure so that the flanges remain essentially parallel Bring halves together evenly until most or the entire gap is removed Maximum allowable gap is 0 10 Install 14 20 bolts with nuts washers and lock washers in holes numbered 17 20 15 11 7 3 1 5 9 13 19 20 Figure 11 Cover Bolt Tightening Sequence Page 2 11 2 4 3 Cover End Seal Installation Un spool a length of adhesive backed seal and wrap it around the pipe Overlap the length of seal by about 1 5 inches and then cut it Repeat for the opposite end of the cover Figure 12 Measure amp Cut End Seal Peel the backing on the seal strip to expose the adhesive strip Start installing the sealant about 1
11. ith respect to the cover The final gap between the compression ring and the cover should be less than 1 8 inch around the circumference Note It might be necessary to start the seal ring bolts without the washers due to the length of the bolts Once the seal has compressed remove the bolts and install the flat and lock washer Page 2 13 2 5 Sensor Pre Amplifier Connections 2 5 1 Sensor Band to Pre Amplifier Connection Carefully feed the eight sensor wires and wires 9 and 10 from the sensor band through the slot in the sensor band feed through Reinstall the feed through in the pre amplifier housing Figure 15 Pre amplifier Housing Feed through Reinstall the fiberglass insulation in the pre amplifier housing and route the sensor band wires on top of the insulation Lay the pre amplifier in the pre amplifier housing with the bottom side facing up Sensor shorting plug may be mounted in alternate position Fre Pac di OCS TS lc FO SE TODO SONATA GT my Dama ng Pre amplifier top side Figure 16 Pre amplifier Top and Bottom View 21020 01 Rev 01 Page 2 14 WARNING Discharge each sensor per user manual instructions just prior to connecting sensors to preamp Failure to do so may result in damage to preamp Starting with sensor 1 discharge that sensor by attaching it to the sensor shorting plug Insert the sensor connector into the mating connector connector 41 mounted on the bottom of the preampli
12. plifier housing cover from the upper cover assembly Disconnect external connector cable assembly from pre amplifier assembly Remove the four screws holding the pre amplifier assembly in place Remove the pre amplifier and place it in a secure location so it will not be damaged Pre amplifier mounting screw s lower screw removed a Figure 7 Pre amplifier Mounting Screws Carefully remove the fiberglass insulation from the pre amplifier housing by grasping it along the edge and pull it upward Place it in a secure location to keep it from being damaged W Figure 8 Remove Fiberglass Insulation Hemove the sensor cable feed through from the pre amplifier housing E i Figure 9 Sensor Cable Feed Through Assembly 21020 01 Rev 01 Page 2 9 21020 01 Rev 01 For horizontal pipe installations install the cover half with the preamplifier box over the sensor band such that it is centered on the band and over the sensor band cables allows for maximum sensor cable length Ensure the cables are accessible Install the lower cover half and temporarily clamp the upper and lower cover halves in place using spring clamps or equivalent Important Do not allow the cover end seals to touch any part of the sensor array including the polyamide insulation The seals and seal rings to be installed in the following steps should only be in contact with the process pipe For vertical pipe installations hang the cover halves from t
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