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Additive Injector
MANUAL
MN05002E Issue/Rev. 0.2 (9/17)
Installation / Operation ManualAccuPlus™
Page ii • MN05002E Issue/Rev. 0.2 (9/17)
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 ship-ment 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.
Issue/Rev. 0.2 (9/17) MN05002E • Page iii
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
Page 1 • MN05002E Issue/Rev. 0.2 (9/17)
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
Additive ValveDosing Unit
Flowmeter
Outlet M18 x 1,5
Figure 1 – Additive Unit AccuPlus
Issue/Rev. 0.2 (9/17) MN05002E • Page 2
Section II – Installation
Figure 2 – HRE Board
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 supplyground 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 Signal10 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
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.
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.
Terminal 1 +10 to +30 VdcTerminal 2 “A” Signal (Leading)Terminal 3 “B” SignalTerminal 4 Logic Common (Ground)Terminal 5
No electrical connection on circuit board.
Terminal 6Terminal 7Terminal 8
Note: To maintain ATEX approval, the earth grounding screw on the flowmeter must be properly wired.
Table 1 – CN1 Terminal Connections
Page 3 • MN05002E Issue/Rev. 0.2 (9/17)
Section II – Installation (continued)
Figure 4 – Application Flow Diagram (example for less than 1000ppm).
Coax Valve Wiring
Fuse
BL
BRL2
L1
315 - 450mA
+
-
Figure 3 – Coax Valve Wiring Typical Application
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 CableThree-wire shielded for single-channel transmission.
Sizes Distance # 20 AWG (0,75mm2) Up to 2,000 ft. (610 m) # 18 AWG (1,00mm2) Up to 3,000 ft. (915 m) # 16 AWG (1,50mm2) Up to 5,000 ft. (1,525 m)
Issue/Rev. 0.2 (9/17) MN05002E • Page 4
Section II – Installation (continued)
Figure 6 – Typical Application above 1,000 ppm
8
Flow Direction
AccuPlus
Typical application for market injection with more than 1,000 ppm:
Local weights and measures recommended practices should be followed overall.
Figure 5 – Typical Application Less than 1,000 ppm
8
Flow Direction
AccuPlus
Typical Application
Typical application for marker injection with less than 1,000 ppm:
Page 5 • MN05002E Issue/Rev. 0.2 (9/17)
MeterFilter Gas
Extractor
Flow
Control Valve
Gasoline or Diesel
Tank Pump
Pump
Additive Tank
Pump
Pump
Fine Filter
Strainer
BackPressureValve
AccuPlus
IsolationValve
IsolationValve
SprayValve
Filter
LoadingBay AreaTank Field Area
CheckValve
Section II – Installation (continued)
Mounting Options
To ensure proper functionality of the AccuPlus it is highly recommended to follow the installation proce-dures 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 200mm (8") of clearance above the HRE cover, below the Dosing Unit, in front of filter and calibration connection.
• For additional configurations please consult the factory.
• The Medium entering the unit must be clean (max. 25 µm). Therefore, it is recommended to install a filter to the inlet side of each solenoid.
Figure 7 – Simplified Additive System Application
Issue/Rev. 0.2 (9/17) MN05002E • Page 6
Mounting Holes
Section II – Installation (continued)
Figure 8 – Mounting Bolt Attachment Holes (M8)
Figure 9 – Proposed Installation Using Mounting Bolt Attachment Installation
Critical: The AccuPlus must be mounted with the monoblock in the horizontal plane with the HRE cover facing up.
Installation Orientation
Page 7 • MN05002E Issue/Rev. 0.2 (9/17)
Section II – Installation
Dimensions (AccuPlus – Shown with a single additive valve)
113(4.4)
173(6.8)
31(1.2)
129(5.1)
7(.3)
62(2.5)
140(5.5)
64(2.5)
37(1.5)
42(1.7)
72(2.8)
M18x1,5
79(3.1)
188 (7.4)
M18x1,5
109 (4.3)
9(.4)
5(.2)
2xM8x1,2515 mm thru
Side View Dimensions
Top View Dimensions
Cable glandM20x1,5 for cable 7-12 mm
Cable glandM16x1,5
2xM8x1,2510 mm deep
60(2.4)
Figure 10 – AccuPlus Product Dimensions
mm (inches)
Note: Dimensions – Millimetres to the nearest whole mm (inches to the nearest tenth), each independently dimensioned from respective engineering drawings.
Issue/Rev. 0.2 (9/17) MN05002E • Page 8
Section II – Installation (continued)
Dimensions (AccuPlus – Shown with 8 additives and a proportioning valve)
444(17.5)
180(7)
140(5.5)
35(1.4)
9(.4)
120 (4.7)
175(6.9)
365(14.4)
108(4.3)
7(.3)
M18x1,5
M18x1,5
79(2.9)
79(2.9)
79(2.9)
79(3.1)
306(12.1)
50(2)
87(3.4)
217(8.5)
87(3.4)
95(3.7)
79(3.1)
mm (inches)
Figure 10 – AccuPlus Product Dimensions
Page 9 • MN05002E Issue/Rev. 0.2 (9/17)
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.
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. Ensure that the upstream additive supply piping of all solenoids is clean. For the initial start up flush all sup-ply lines.
2. 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.
3. 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%.
4. Energize the pump.5. Energize the Additive Control Solenoid. If required, use a service mode from an AccuLoad® III or
microLoad.net™ preset. 6. 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.7. 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.8. Adjust the flow rate with the inlet needle valve only.
Note: This procedure should be used whenever air has entered the system.
Section III – Start-Up Procedure
Figure 12 – Flow rate adjustment and strainer location
Strainer
Outlet Needle Valve
Sealing Label
Inlet Needle Valve
Sealing Label
Issue/Rev. 0.2 (9/17) MN05002E • Page 10
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.
Page 11 • MN05002E Issue/Rev. 0.2 (9/17)
Section IV – Operating Information (continued)
Setting the Flow Rate of the Unit1. Close the upstream isolation valve2. Close the outlet needle valve located in the dosing unit 3. Remove the dosing unit calibration port plug4. Properly install the calibration male quick connect fitting 5. Connect the calibration set6. Place the graduated cylinder below the calibration set nozzle7. Energize the pump8. Energize the additive solenoid valve9. Open the upstream isolation valve to allow flow, until the graduated cylinder is full10. 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
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
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
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)
4. Injector maximum flow rate (to ensure minimum 1 sec on-time):
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.
2,500 l/min x (100/1,000,000) = 0.025 l/injection
10 injections/min
= 6 sec/cycle 60 sec 10 cycles
0.025 l/injection 3 sec/injection
x 60 (sec/min) = 0.50 l/min
0.025 l/injection 1 sec/injection
x 60 (sec/min) = 1.5 l/min
Issue/Rev. 0.2 (9/17) MN05002E • Page 12
AccuPlus
Pressure Gauge
CalibrationQuick Connect
Ball Valve
Hose
Nozzle
GraduatedCylinder
Figure 13 – Calibration Set
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.
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
• 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.
Page 13 • MN05002E Issue/Rev. 0.2 (9/17)
Section VI – Related Publications
The following literature can be obtained from FMC Technologies Measurement Solutions Literature Fulfillment at [email protected] or online at www.fmctechnologies.com/measurementsolutions.
When requesting literature from Literature Fulfillment, please reference the appropriate bulletin number and title.
AccuPlusInstallation/Operation.................................................................................................................... Bulletin MN05002EMaintenance ................................................................................................................................. Bulletin MN05003EParts List........................................................................................................................................Bulletin PO05001ESpecifications ................................................................................................................................Bulletin SS05001E
TechnipFMC.com
© TechnipFMC 2017 All rights reserved. MN05002E Issue/Rev. 0.2 (9/17)
TechnipFMCFMC Technologies Measurement Solutions, Inc.500 North Sam Houston Parkway West,Suite 100Houston, Texas 77067 USAP:+1 281.260.2190
USA Operation 1602 Wagner AvenueErie, Pennsylvania 16510 USAP:+1 814.898.5000
Germany Operation Smith Meter GmbHRegentstrasse 125474 Ellerbek, GermanyP:+49 4101 304.0
Revisions included in MN05002E Issue/Rev. 0.2 (9/17):Page 5: Information pertaining to filtration at the inlet of the AccuPlus has been added.Page 9: Asterisk added under Purging Air From The Meter.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 ef-fect. 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 TechnipFMC.com and click on the “Contact Us” link.
