Stamp in Red Ink: Controlled, Uncontrolled or Working Copy DOCUMENT COVER SHEET Document Number: UM 78-1 ExS Rev. No.: 1 Issue Date Document Title: ValveWatch II Hardware Installation and Setup Manual DESCRIPTION OF CHANGES: If this is a new document, steps 1 through 6 need not be completed. 1) This Revision/Addenda Supersedes Revision No.
CRANE VALVE SERVICES A CRANE Co.
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CRANE Nuclear ValveWatch II Hardware Installation and Setup Manual Page 4 of 34
Table of Contents Deleted: 7 1 INTENDED USE OF THE EQUIPMENT 8 2 PRODUCT SPECIFICATIONS 8 3 INSTALLING THE SYSTEM 12 4 ENTITY PARAMETERS FOR VALVEWATCH II SYSTEM 14 5 LOCAL DATA ACQUISITION UNIT INSTALLATION 17 6 HUB ASSEMBLY INSTALLATION 21 7 DYNAMIC PRESSURE TRANSDUCER INSTALLATION 23 8 STRAIN SENSOR INSTALLATION 25 9 STATIC PRESSURE SENSOR INSTALLATION 29 Deleted: 7 Deleted: 11 Deleted: 13 Deleted: 16 Deleted: 20 Deleted: 22 Deleted: 24 Deleted: 28 Deleted: 30 10 INSTALLATIO
THIS IS THE USER CAUTION SYMBOL. IT INDICATES A CONDITION WHERE DAMAGE TO THE EQUIPMENT OR INJURY TO THE OPERATOR COULD OCCUR IF OPERATIONAL PROCEDURES ARE NOT FOLLOWED. TO REDUCE THE RISK OF DAMAGE OR INJURY, FOLLOW ALL STEPS OR PROCEDURES AS INSTRUCTED. Note: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC. rules.
EC DECLARATION OF CONFORMITY Scan and insert into this page (Manager, Product Development) CRANE Nuclear (Manager, Quality Assurance) Kennesaw (Location) (Date) ValveWatch II Hardware Installation and Setup Manual Page 7 of 34
1 Intended Use of the Equipment The ValveWatch II system is intended for permanent installation and long term monitoring, trending and analysis of critical parameters for industrial equipment. Although ValveWatch was primarily developed for monitoring Emergency Shutdown Valves (ESD) for the petroleum industry, the design also allows other general purpose equipment parameter monitoring. The parameters measured are useful for determining equipment operation and integrity.
2.2 Hub Assembly (3-51006EX) Specifications FCC Notice: Changes or modifications to this device not expressly approved by the manufacturer could void the user’s authority to operate the equipment. FCC Radiation Exposure Statement This equipment complies with FCC radiation exposure limits for an uncontrolled environment. This equipment should be installed and operated with minimum distance 20 cm between the antenna and all persons. 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 Physical Size ~ 19.
2.4 Dynamic Pressure Kit (2-53306EX and 2-53005EX) Specifications 2.4.1 Physical Sensor: 3.0in(76 mm) high, 0.82in(22.5 mm) dia, 0.25 lbs(114 g) ¼ 18 NPT thread, 316 SS Base Mount: 1.8in(185mm) high, 1.5in(38mm) dia, 1.0 lbs(450 g) 1/2 14 NPT thread, 316 SS Protective Tube: 4.25in(115mm) high, 1.5in(38mm) dia, 0.
2.6 Static Pressure Kit (2-53300Ex-xxxxx) Specifications 2.6.1 Physical Sensor; 3.0in(76 mm) high, 1.0in(25 mm) dia, 0.25 lbs (114 g), hermetically sealed, SS housing Cable: 50 ft (18 m) long, 22 gauge twisted pair, shielded, royal blue, halogen free, Connector is hermetically sealed, stainless steel one end is open lead for wiring into field apparatus. Standard connection: ¼ in female NPT 2.6.2 2.6.3 2.6.
3 Installing the System Caution: This document is considered a “Scheduled Drawing” document. No modifications are permitted without reference to the Notified Body. Caution: If the system is used in a manner not specified by the manufacturer, any protection provided by the manufacturer may be impaired. Installing the ValveWatch II System involves multiple steps. Perform the following installation tasks in their entirety, in the order that is appropriate for your installation. 3.
3.2 Site Survey Before a system is installed, an engineering survey is required. This survey should be accomplished by an authorized Crane Valve Services Field Engineer.
4 Entity Parameters for ValveWatch II System 4.1 Entity Parameters for Dynamic Pressure Sensor Crane Valve Services Part Number 1-53201EX (see CS-1-53210Ex for PCB certificates) Vi Ii Pi Ci Ii - 30 Volts - 200 milliamps - 1.0 Watts - 5.0 nF - 0.0 mH 4.2 Entity Parameters for Strain Sensor Kit Crane Valve Services Part Number 3-53100EX The strain sensor used for monitoring valve related forces transferring from the actuator to the valve is a simple device.
4.6 Entity Parameters for LDAU Communications Module Crane Valve Services Part Number 1-51001Ex 4.6.1 Power connection J2 Terminals 13, 14, 15 and 16 Vi Ii Pi Ci Ii - 23.3 Volts - 225 milliamps - 2 Watts - 0.0 uF - 0.0 mH 4.7 Entity Parameters for Strain/AC Module Crane Valve Services Part Number 1-52001Ex 4.7.1 Power connection J2 Terminals 13, 14, 15 and 16 Vi Ii Pi Ci Ii 4.7.2 - 30 Volts - 200 milliamps - 1.2 Watts - 0.0 uF - 0.
4.8 Entity Parameters for Dual AC Module Crane Valve Services Part Number 1-52002Ex 4.8.1 Power connection J2 Terminals 13, 14, 15 and 16 Vi Ii Pi Ci Ii 4.8.2 - 30 Volts - 200 milliamps - 1.2 Watts - 0.0 uF - 0.0 mH Sensor connection J1 Terminals 1, 2, 3 and 4 AC Input Voc, Uo Isc, Io Po Ca, Co Ia, Io CRANE Nuclear - 9.555 volts - 48.30 milliamps - 0.115 Watts - 3.60 uF - 15.
5 Local Data Acquisition Unit Installation The Local Data Acquisition Unit (LDAU) consists of DIN rail mounted electronics modules enclosed in a stainless steel IP66 enclosure. The number of modules and configurations may vary with customer options. There is one LDAU for each valve being monitored. Caution: The LDAU must be installed per Installation Drawing J-51008ExS. Mount the electrical enclosure according to specific site mounting specifications or codes.
5.1 Example Cable Length Calculations for Power Connection Cable lengths are critical for intrinsic safety. Before any installation is complete, an analysis of the cable length for verification of intrinsic safety is required. The Tables below are an example for verifying specific cable length requirements Assumptions for the Example Cable Length Calculation Tables 3, 4 and 5 For our example, use Ex ia IIC Table 1.
Table 3.
Table 5.
6 HUB Assembly Installation The HUB assembly consists of a 19in rack-mountable DIN rail assembly containing all necessary power and communications capabilities to monitor and acquire test data for up to eight LDAUs connected to eight valves. Caution: The HUB assembly is an associated apparatus. Follow both installation requirements and wiring diagram J-51008ExS to assure safe system operation. 6.
• • • • • • • • • • • • • • • The HUB assembly can be mounted in any vertical position in the 19 in cabinet. The assembly should be mounted so that the cables from the hazardous area enter the assembly on the hazardous entry side and are at least 2 inches from non-hazardous cables in the same cabinet. The HUB Assembly may be installed upside down to orient the hazardous cable entry openings with the hazardous cable location.
RF survey may be required to ensure correct RF operation in a heavily populated industrial application. NOTE: The ValveWatch II system is a 2.4GHz radio. It overlaps the frequency range used for WIFI networks and microwave ovens. Any additional 2.4 GHZ networks in the general vicinity of an RF configured ValveWatch system could cause performance reduction. 7 Dynamic Pressure Transducer Installation Caution: The pressure sensors shall be installed per this installation manual and wiring diagram J-51008ExS.
The use of a second sensor in the upstream or downstream position will provide optimum leak detection when the valve is in the open position. Review the orientation of the tap and verify that there are no obstacles preventing the sensor from being installed into the location. Review the Unit Under Test and determine an appropriate sensor cable routing path to the LDAU enclosure. • • 7.
8 Strain Sensor Installation Caution: Follow all installation procedure steps and wiring diagram J-51008ExS when connecting the strain gage to its associated apparatus. One of the key parameters of ValveWatch is to monitor the actuator to valve forces. This parameter can serve as a trigger for the data acquisition circuits and more importantly to trend relative torque or thrust values during valve strokes.
8.2 Pre Installation Strain Sensor Test Caution: The strain sensor’s Kapton mounting face is very sensitive to strain and exceptionally durable when installed but can be damaged if handled roughly prior to installation. The Kapton face mounting material also provides electrical insulation from earth ground. Do not remove the protective cap except for inspection or in preparation for installation. Do not apply unnecessary pressure or press on the sensor face during inspection or installation.
8.4 Preparing the Valve Yoke Surface Caution: It is strongly recommended that safety glasses and gloves be worn during this procedure. Caution: Follow site specific work permit requirements for work in an explosive environment. • There are three things to remember for successfully mounting a strain sensor every time. CLEAN, CLEAN, CLEAN.
8.5 Mounting the Strain Sensor Caution: It is strongly recommended that safety glasses and gloves be worn during this procedure. Within 15 minutes after the mounting location has been fully prepared, sensor installation can proceed. • The Epoxy comes in a two part packet for easy mixture. Remove the separating clip and mix the epoxy achieving a paste of uniform color and consistency. There is a 90 minute pot life for the epoxy.
8.6 Strain Sensor Wiring Route the sensor cable in site approved cable tray or tubing to the ValveWatch Local Data Acquisition Unit enclosure. Route the cable through an appropriate cable gland and secure. Connect the four strain sensor conductors and cable shield conductor as required on J-51008ExS. Yellow Green Brown White Shield - SIG + - SIG – - EXC + - EXC - Ground terminal 8.
9.1 Initial Equipment Check List Before going out to install any sensor, an inventory of the items needed to perform the job is always a good way to start. Below is a list of the minimum items needed to perform the task of sensor installation. Static Pressure Sensor with cable assembly of 50 feet. Thread sealant Wrench set Eye protection Gloves Cable labels 9.
9.5 Static Pressure Sensor Wiring The static pressure sensor kit is provided with a cable for connecting the pressure sensor to the LDAU enclosure. Route the sensor cable in site approved cable tray or tubing to the enclosure. Route the cable through an appropriate cable gland and secure. Connect the four strain sensor conductors and cable shield conductor as required on J-51008ExS. Connect the cable connector into the sensor connector.
11 Equipment Cleaning Instructions Caution: Follow applicable site procedures to access and ensure that the cleaning process does not impact the plant safety or operation requirements. 11.1 LDAU Assembly Cleaning Instructions The LDAU assembly is installed in a NEMA 4 enclosure in the plant environment. Before starting any cleaning process, the DC power to the unit must be disconnected. For lose particles, vacuum and or air pressure can be used effectively to remove most typical plant type dirt.
11.4 Strain Sensor Cleaning Instructions The strain sensor is an encapsulated module permanently attached to the valve assembly. Cleaning may be required for purposes of component identification or part of a routine plant cleaning process. Do not use high pressure or high temperature liquids as part of the cleaning process. Such use could inadvertently damage the wire connecting the sensor to the LDAU. Use of water soluble detergents should be used with a cloth or sponge and rubbing effort. 11.
12 Technical Assistance ValveWatch II is developed and supported by Crane Valve Services a CRANE Co. Company. CRANE Nuclear, Inc.