K-Patents SAFE-DRIVE PR-23-SD User manual

Safe-Drive®Process
Refractometer PR-23-SD
Generation 2
Best Practices for PR-23-SD
with steam wash system
IM-EN-SDGEN2-BP v. 1.02

Document/Revision No. IM-EN-SDGEN2-BP 1.02 Effective: December 2, 2014
2
Contents
Section 1 About This Document .......................................................................................................... 3
Section 2 Before Installation ................................................................................................................ 3
2.1 Installation Location Checklist ....................................................................................... 3
2.2 Component Checklist..................................................................................................... 4
Section 3 Safety Requirements............................................................................................................ 6
Section 4 Installation Process ............................................................................................................. 7
4.1 Spool piece assembly.................................................................................................... 7
4.2 Cutting Installation Opening for SDI2 Valve .................................................................. 8
4.3 Disassembling SDI2 Valve for Welding ......................................................................... 9
4.4 Welding SDI2 Valve in Place ....................................................................................... 10
4.5 Reassembling SDI2 Valve ............................................................................................11
4.6 Installing Steam Prism Wash System.......................................................................... 13
4.7 Before Inserting and Removing PR-23-SD Sensor..................................................... 15
4.8 Inserting Sensor........................................................................................................... 16
4.9 Box Flushing ................................................................................................................ 18
4.10 Removing Sensor ........................................................................................................ 20
4.11 Removing Wash Nozzle............................................................................................... 22
4.12 Inserting Wash Nozzle................................................................................................. 24
4.13 Installing DTR Transmitter ........................................................................................... 25
Section 5 Commissioning SD Sensor System ................................................................................. 28
5.1 Prism Wash Test .......................................................................................................... 30
5.2 Calibration Check ........................................................................................................ 30
Section 6 Operating and Monitoring SD Sensor System................................................................ 31
6.1 Preventive Maintenance Plan (PMP) ........................................................................... 31
6.2 Check Valve Maintenance ........................................................................................... 32
6.3 Resetting SD Sensor System ...................................................................................... 32
Section 7 Appendices ......................................................................................................................... 34

© Copyright K-Patents 2014. All rights reserved. 3
Safe-Drive®Process Refractometer
PR-23-SD Generation 2
Best Practices
1 About This Document
This document is intended for individuals
installing, commissioning, operating, and/
or servicing the Safe-Drive®Process
Refractometer PR-23-SD, generation 2
model. The purpose of this document
is to provide a quick guide for the
abovementioned tasks in the form of
K-Patents recommended best practices.
This document in intended for PR-23-SD
applications that have a steam wash system (typical application for black liquor).
NOTE: These instructions are for quick reference only. For more thorough guidance, please
refer to K-Patents user manual and documentation.
2 Before Installation
2.1 Installation Location Checklist
Before the SD sensor system is installed, it is important to inspect the installation location
carefully for the following conditions:
●Install the SD sensor system onto either vertical or horizontal pipeline. The
recommended ow rate is 0.4 m/s – 2 m/s (1.5 ft/s – 6 ft/s).
●Mount the system at waist level. This is the natural and safe height for the system and
enables you to use the tools more ergonomically.
●Leave a 1 m (approximately 3 ft) space around the installation for operating around the
SD sensor system. For the same reason, the steam connections should be installed
on the sides or back of the sensor system.
●Recommended maximum ambient temperature of installation location is 45°C (120°F).
●Avoid locations that are blocked by other piping and/or equipment, or require additional
tools, such as a ladder, to access the sensor. The installation location must be level,
rm, and free of clutter to provide safe and easy access to the system.

Document/Revision No. IM-EN-SDGEN2-BP 1.02 Effective: December 2, 2014
4
●Use suitable type of steam for cleaning the prism. Dry saturated steam and 10-12 bar
(150-180 psi) are recommended.
●Access to steam. The distance between the steam supply and the SD sensor system
should be considered for the length of steam piping.
●Access to drain for steam trap condensate outlet.
●Emergency shower and eye wash should be easily accessible. Water can also be used
for cleaning SDI2 valve lip seals and sensor after sensor removal.
●Shut-off valve needs pressurized instrumentation air (5-10 bars / 70-150 psi).
●Ensure connection to the power supply (110-230V AC).
If these conditions do not apply, please reconsider the intended location for your installation
or contact K-Patents.
2.2 Component Checklist
Before starting installation, make sure you have all the tools and components listed below.
NOTE: Components 4 and 5 are connected by union nipple or piping not included in
the delivery.
System components included in K-Patents delivery:

Safe-Drive®Process Refractometer PR-23-SD Best Practices, Generation 2
© Copyright K-Patents 2014. All rights reserved. 5
Figure 1 System components included in K-Patents delivery
1 PR-23-SD sensor
2 SDI2 valve
3 Retractor tool
3a
3b
Prism wash nozzle assembly
Wash nozzle installation bolts and locking plate
4 Compressed air operated solenoid shut-off valve with steam trap
5 Steam connection hose
6 Sensor connection cable
7 DTR transmitter
NOTE: If any of tools or components are missing, contact your supplier before
starting installation

Document/Revision No. IM-EN-SDGEN2-BP 1.02 Effective: December 2, 2014
6
Installation Equipment
Figure 2 Installation equipment
1 Retractor inner casing Supplied by K-Patents
2 Retractor outer casing Supplied by K-Patents
3 Adjustable wrench
4 Combination wrench, 19 mm / 3/4 in
5 Flat head screwdriver
6 Allen key 3 mm
Allen key 4 mm
7 Allen key 8 mm / 5/16 mm
8 Thread seal tape
9 Sensor insertion / removal card Supplied by K-Patents
10 Product user manual Supplied by K-Patents
11 Pocket guide Supplied by K-Patents
NOTE: The material of the SDI2 valve body that is welded onto a process pipe is Duplex
steel SAF2205 (EN 1.4462, ASTM S32205/S31803). Choose the welding method and
ller accordingly.
K-Patents recommends complying with the applicable EN / ASTM standards.
3 Safety Requirements
These safety requirements must be followed at all times when installing, operating, or
servicing PR-23-SD sensor. These are the minimum safety requirements – your company
may require additional PPE (personal protective equipment).
PROCESS
REFRACTOMETER
PR-23
POCKET
GUIDE
1
2
3
4
5
6
7
9
8
10 11

Safe-Drive®Process Refractometer PR-23-SD Best Practices, Generation 2
© Copyright K-Patents 2014. All rights reserved. 7
For more information on safety issues, please see K-Patents Safety Instructions.
Figure 3 Safety symbols
WARNING: Watch out for hot steam and process pipes. Wear protective clothing as
instructed below to work safely.
●Only authorized personnel can perform the tasks instructed in this document.
●Long-sleeved safety clothing.
●Protective gloves.
●Safety glasses and/or goggles.
●Hard hat or helmet.
●Locate the nearest emergency shower and eye wash before starting the work.
●Never operate the Safe-Drive®Retractor alone.
●Hard-cap safety boots.
4 Installation Process
For more thorough instructions, please refer to K-Patents user documentation or visit the
K-Patents website to see the instructional video (www.kpatents.com, PR-23-SD Safe-Drive®
Operation Guide Video).
Installation of the SD sensor system consists of
●Cutting pipe opening for SDI2 isolation valve.
●Welding and assembling the SDI2 valve onto the processing piping.
●Installing the steam prism wash system.
●Installing the PR-23-SD sensor.
●Installing the DTR transmitter.
4.1 Spool piece assembly
If the SDI2 valve was supplied pre-welded and assembled onto a pipe spool piece for
integration in existing piping on site, please skip ahead to installing prism wash.

Document/Revision No. IM-EN-SDGEN2-BP 1.02 Effective: December 2, 2014
8
Figure 4 Vertical and horizontal spool piece assemblies
4.2 Cutting Installation Opening for SDI2 Valve
Use the installation guide sticker provided by K-Patents to determine the installation opening
shape and size suitable for your process pipe. If you do not have the guide sticker at hand,
please follow the instructions in the images below:
Figure 5 Installation guide sticker
NOTE: For larger pipes, use the same dimensions as for 24” (610 mm) pipes.
To cut the installation opening
1. Cut the installation guide sticker to match the pipe size.
2. Clean the surface of the pipe around the installation area and attach the sticker onto
the pipe.

Safe-Drive®Process Refractometer PR-23-SD Best Practices, Generation 2
© Copyright K-Patents 2014. All rights reserved. 9
NOTE: Make sure that the FLOW marker is parallel to the pipe and points to the correct
ow direction. On a horizontal pipe the nozzle points downwards and on a vertical pipe
it points to right. The SD sensor system must always be installed in horizontal position
and on the side of the pipe.
3. Drill two holes – 50 mm (2”) and 25 mm (1”) – as guided by the sticker.
4. Remove the bridge between the holes so that the opening is exactly the shape of
the sticker.
Weld
Cutout
Safe Drive
mounting flange
Process pipe
Weld
Cutout
Safe Drive
mounting flange
Process pipe
Figure 6 Installation on vertical and horizontal pipes
4.3 Disassembling SDI2 Valve for Welding
To avoid thermal damage to the isolation valve sealing, you must separate the valve body
from the valve assembly before it is welded onto the pipe.

Document/Revision No. IM-EN-SDGEN2-BP 1.02 Effective: December 2, 2014
10
NOTE: Be very careful not to drop or lose any parts that come loose when separating the
body from the assembly.
To disassemble the SDI2 valve, open the four (4) M10 allen key bolts with an 8 mm (5/16”)
allen key (1).
Figure 7 Disassembling valve
4.4 Welding SDI2 Valve in Place
After you have disassembled the SDI2 valve, the valve body is welded onto the
process pipe.
●The material of the SDI2 valve body is Duplex steel SAF2205 (EN 1.4462, ASTM
S32205/S31803). Choose the welding method and ller accordingly.
●See the attached drawings 2149 (MTG) and MTG472 for more detailed
welding instructions.
●Follow all local requirements for welding.
●K-Patents recommends complying with the applicable EN / ASTM standards.
●Consider the materials and shapes of the welded objects when performing welding
pre-processing (tools, cleaning, preheating).
●Consider the materials and shapes of the welded objects when performing welding
post-processing (postheating, fluxing).
1

Safe-Drive®Process Refractometer PR-23-SD Best Practices, Generation 2
© Copyright K-Patents 2014. All rights reserved. 11
Figure 8 Welding on vertical and horizontal pipes
4.5 Reassembling SDI2 Valve
After the SDI2 valve body has been welded in place, reassemble the valve in reverse order.
NOTE: Make sure that the seals for the ball valve are propely aligned.
Valve handle always
positioned at top
Widest bayonet lug
always positioned at top
90°
Weld
Process
pipe
90°
Weld
Process
pipe
NOTE!
The material
of the welded
parts is
Duplex steel
SAF2205

Document/Revision No. IM-EN-SDGEN2-BP 1.02 Effective: December 2, 2014
12
Valve handle always
positioned at top
Widest bayonet lug
always positioned at top
Figure 9 Reassembling valve on vertical and horizontal pipes
●Make sure that the SDI2 valve handle and the largest bayonet connection are on top.
Otherwise, you will not be able to insert the sensor in its place.
●Tighten the bolts to a torque of 36 N-m (26 lb-ft) with an 8 mm (5/16”) allen key.
WARNING: Always shut the main steam valve before performing any work on the
wash nozzle.
To re-install the wash nozzle assembly
1. Insert the wash nozzle assembly to its place (1).
2. Place the nozzle guide plate in the correct position and tighten the two (2) M5 bolts (2).
3. Secure the wash nozzle with a locking plate (3, 4).

Safe-Drive®Process Refractometer PR-23-SD Best Practices, Generation 2
© Copyright K-Patents 2014. All rights reserved. 13
1
2
3 4
4.6 Installing Steam Prism Wash System
In black liquor service material deposit, scaling or coating may occur on the prism surface.
To avoid this, you need to install an integral prism wash with steam that uses the retractable
nozzle included in the SDI2 valve.
Important Steam Prism Wash Considerations
●The distance from the steam nozzle on the SDI2 valve to the steam shut-off valve
should be kept as short as possible to avoid condensate. The recommended length of
the distance is 0.6 m (2 ft) or less.
●Separate or isolate the power to the solenoid from the power to the transmitter by
installing a safety switch. This enables the steam wash to be serviced without having
to power down the whole SD sensor system.
●Pipe the steam trap properly to drain so that the trap is not blowing hot steam.
●Steam piping upstream of shut-off valve is ½” or larger.
●In addition to the SDI2 valve steam ttings, the following components must be included
in the steam wash installation:
●steam shut-off valve
●air-operated solenoid valve
●steam trap
●switch or terminal for power isolation
For K-Patents recommendations, please see K-Patents Steam Instructions.
●OPTIONAL, in case of contaminants: To remove any contaminants within the
steam source, installing a steam strainer is recommended. See K-Patents list of
recommended accessories.

Document/Revision No. IM-EN-SDGEN2-BP 1.02 Effective: December 2, 2014
14
●OPTIONAL, in case of excessive pressure: If the steam pressure exceeds to
maximum pressure differential, a pressure reducing valve (PRV) needs to be
installed to reduce the steam pressure to optimal design. See K-Patents list of
recommended accessories.
Figure 10 Mounting steam wash system
For more detailed information on steam-realted issues, please see K-Patents
Steam Instructions.
To install the wash system
1. Dene the wash setting values for the wash system:
●steam source minimum and maximum pressures
●wash time – the time one wash will last (seconds)
●recovery time – the time after the wash has nished, before the measurement is
live data again (seconds)
●interval – the time between washes (minutes)
Recommended steam prism wash settings
CONC %
value
Minimum above
process pressure
Maximum above
process pressure Wash time Recovery Interval
10-30 % 2 bar (30 psi) 4 bar (60 psi) 2-3 s 20 s 120-360 min
30-60 % 3 bar (45 psi) 6 bar (90 psi) 3 s 20 s 20-60 min
60-90 % 4 bar (60 psi) 8 bar (120 psi) 3-5 s 20 s 15-25 min

Safe-Drive®Process Refractometer PR-23-SD Best Practices, Generation 2
© Copyright K-Patents 2014. All rights reserved. 15
NOTE: Damage caused to prism by excessive pressure or washing is not covered by the
product warranty.
Choose the correct steam source pressure by comparing it to the process pressure.
The steam source pressure must be higher than process pressure to provide adequate
washing, but excessive pressure may also cause premature damage or etching of the
prism. Also, if the washing phase is programmed to last too long, the prism may wear
out prematurely.
2. Install the steam pipes in the SDI2 valve, as instructed below.
NOTE: All the necessary wash ttings are included in the valve.
3. Connect the steam wash system power supply.
For more information, please see K-Patents Steam Instructions.
Figure 11 Wiring steam wash system
For more information on controlling the prism wash cycle, please refer to chapter
Conguring relays in K-Patents user documentation.
4.7 Before Inserting and Removing PR-23-SD Sensor
WARNING: Always use the Safe-Drive®Retractor tool for inserting and removing the sensor.
Removing the sensor without the Retractor tool may cause a life-threatening situation, if
there is any pressure in the process pipe. Inserting or removing sensor without Retractor tool
may also cause damage to the lip seal. Always store the Retractor tool indoors in a clean
and dry location.

Document/Revision No. IM-EN-SDGEN2-BP 1.02 Effective: December 2, 2014
16
Successful sensor insertion and removal can only be guaranteed when the Retractor tool is
used and the instructions for insertion or removal are carefully followed.
NOTE: Check the Retractor tool visually before starting insertion / removal process. Make
sure the handwheel rotates freely.
WARNING: If you detect leaking at any point of sensor insertion or removal process, revert
immediately to the previous step in the process. Do not continue insertion / removal until the
reason for leakage has been cleared and fixed.
Insert and remove the sensor as instructed in the following chapters. For more thorough
instructions, please refer to K-Patents user documentation or visit the K-Patents website to
see the instructional video on inserting and removing the sensor (www.kpatents.com,
PR-23-SD Safe-Drive®Operation Guide Video).
4.8 Inserting Sensor
Before you start
●check that the gaskets and gasket surfaces are clean
and undamaged
●remove the sensor cable gland and unlock Inner casing
1. Insert the sensor to Inner casing so that Inner casing latch
is slightly to the left of top and sensor cable passage is
straight down.
2. When sensor ange is ush with the bottom of Inner
casing, turn Inner casing 60 degrees (1/6 turn) right to lock
it to the flange.
3. Push down the locking latch.
Put the Safe-Drive®Retractor with sensor onto a table or
similar surface so that the hand wheel has space to turn.
1. Fit Outer casing over Inner casing so that the groove on
Inner casing matches the groove on Outer casing.
2. Turn the hand-wheel clockwise until it stops to draw the
sensor into the Retractor.
Lift the Retractor (with sensor) handle up over the isolation
valve ange.
1
23
1
1
2
2
LIFT POINTS
3

Safe-Drive®Process Refractometer PR-23-SD Best Practices, Generation 2
© Copyright K-Patents 2014. All rights reserved. 17
1. Turn the Retractor 60 degrees (1/6 turn) to the right to lock
the bayonet.
2. Push down the latch on Outer casing.
Attach the safety pin for additional locking.
1. Close the blow-out ball valve underneath the
isolation valve.
2. Lift up the isolation valve handle locking plate.
3. Open the isolation valve by turning the valve handle
90 degrees (a quarter turn) to the right.
Turn the hand-wheel counterclockwise until it stops.
WARNING: If you detect leaking, revert immediately to the
previous step. Do not continue installation until the reason for
leakage has been cleared and xed.
Fit the four M12 nuts to the bolts holding the sensor to the
isolation valve and screw them on with a 19 mm or 3/4”
wrench.
NOTE: Set the torque at 50 Nm.
1. Turn the wheel 90 degrees (a quarter turn) to the right.
2. Remove the safety pin.
3. Unlock the latch of Outer casing.
4. Turn the casing 60 degrees (1/6 turn) to the left i.e. until the
handle is up on top.
1. Turn the hand-wheel to the left to drop the thread.
2. Lift off Outer casing.
1
2
4
3
1
2
3
5
140 mm
(5.5”)
6
1(4xM12)
50Nm (37ft/lbs)
7
2
1
8
3
4
1
2
9

Document/Revision No. IM-EN-SDGEN2-BP 1.02 Effective: December 2, 2014
18
1. Lift up and pull the latch of Inner casing to unlock.
2. Turn the casing 60 degrees (1/6 turn) to the left to release
it from the flange.
Lift Inner casing away from the sensor head.
1. Take off sensor nameplate and the gasket underneath.
2. Put interconnecting cable through the cable gland.
3. Connect the interconnecting cable to the sensor.
4. Screw the cable gland to the sensor.
5. Fit the gasket and nameplate onto the sensor and screw
the nameplate back on.
Turn on transmitter power to power up the SD sensor system.
4.9 Box Flushing
Carry out box ushing before sensor removal when the sensor has been in process for
several months. Box ushing removes dried process medium from isolation valve and
makes sensor removal easier.
WARNING: Do not activate box steam ush, if the sensor and the Retractor tool are not
installed to the isolation valve!
1
2
10
11
2
4
3
1&5
12

Safe-Drive®Process Refractometer PR-23-SD Best Practices, Generation 2
© Copyright K-Patents 2014. All rights reserved. 19
1. Close the 1/4” valve to
the nozzle (1).
2. Open the 1/4” valve to
the box (2).
3. In the DTR transmitter,
go to MENU › SENSOR
STATUS and activate
wash by pressing
WASH button.
Repeat the wash 3–5 times.
4. Close the 1/4” valve to
the box (4).
5. Open the 1/4” valve to
the nozzle (5).
1
2
OPEN
CLOSE
5
4
CLOSE
OPEN

Document/Revision No. IM-EN-SDGEN2-BP 1.02 Effective: December 2, 2014
20
4.10 Removing Sensor
Switch off the DTR to cut off power from the sensor.
1. Remove the sensor nameplate and the gasket underneath.
2. Screw off the cable gland.
3. Disconnect the interconnecting cable
4. Remove the cable from sensor
5. Place gasket and nameplate on the sensor head and screw
the sensor nameplate back on.
NOTE: If another inline sensor is connected to the same DTR,
disconnect the loose cable from the DTR and turn power on
again.
1. Unlock the latch on Inner casing.
2. Lift Inner casing over the sensor head. Connect the casing
to the sensor ange bayonet.
1. Turn the casing 60 degrees (1/6 turn) to the right to lock it
onto the flange.
2. Lock Inner casing latch. Ensure that Inner casing is
fully locked.
1. Grab Outer casing with one hand on the handle and the
other hand on the wheel. Fit Outer casing over Inner casing
and all the way to the isolation valve bayonet keeping the
handle upwards.
2. Rotate the hand wheel clockwise to get thread of Inner
casing running through the wheel.
1. Turn Outer casing 60 degrees (1/6 turn) to the right to lock
it onto the isolation valve.
2. Push down Outer casing latch.
3. Insert safety pin to Outer casing.
21&5
3
1
4
1
2
1
2
3
60°
1
2
4
11
60°
2
5
3