KAM Simple Precision IAS User manual

KAM®IAS™
ISOKINETIC AUTOMATIC SAMPLER
TEL [phone]
FAX [phone]
Email [email protected]
KAM CONTROLS, INC.
3939 Ann Arbor Drive
Houston, Texas 77063 USA
www.KAM.com
User Manual
An ISO 9001:2015 certified company
IASMANUAL0821
PER API 8.2, ASTM D4177
AND ISO 3171

IASMANUAL 0821 KAM CONTROLS, INC.
1
TABLE OF CONTENTS
SECTION TITLE PAGE
1Introduction 2
•Available Models and Mounting Options 2
•Theory of Operation 3
•Sampler Sequence 3
2Specifications 4
•Specifications 4
3Installation 5
•Main Line 5
•PRV Cracking Pressure Setup 10
•Field Air Connections 11
•Removal 12
4Maintenance 13
•Seal Kit and Replacement Schedule 13
5Troubleshooting 15
CAUTION:
When installing the IAS™ sampler in a pipeline containing petroleum products, petro-chemicals,
waste waters with the presence of pressure & 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.

IASMANUAL 0821 KAM CONTROLS, INC.
2
INTRODUCTION
AVAILABLE MODELS and MOUNTING OPTIONS
FIG. 1-1 FIG. 1-2
SECTION BC-BC
SCALE 1 /7.5
BC
BC
1
1
2
2
A A
B B
Full-opening Ball Valve
Option 1: Insertable/Retractable IAS™ on a main pipe
with 2", 3", or 4" flanged seal housing
Full-opening Ball Valve
Option 2: Insertable/Retractable IAS™ on a main pipe
with 2" MNPT seal housing
FIG. 1-3
Option 3: IAS™ Flow Through Models
1
1
2
2
A A
B B
IAS™ 2" Flow Through IAS™ 1" Flow Through
1
1
2
2
A A
B B

IASMANUAL 0821 KAM CONTROLS, INC.
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INTRODUCTION CONTINUED
SAMPLER SEQUENCE
FIG. 1-4
THEORY OF OPERATION
Operating similarly to a downhole pump, the KAM®IAS™ Isokinetic Automatic Sampler extracts a known volume of
pipeline fluids for collection in a KAM®SR™ Sample Receiver. Sampling is pneumatically or hydraulically driven, and
the time interval can be flow-based or time-based. All KAM sampling components comply with API MPMS Chapter
8.2, ASTM D4177, and ISO 3171 standards requirements.

IASMANUAL 0821 KAM CONTROLS, INC.
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SPECIFICATIONS
Media: Crude oil, refined products, chemicals, water and wastewater
Wetted parts: 316 stainless steel shaft and probe cage
304 stainless steel sample tube
PEEK bottom seal, Teflon available
Other materials available
Fluid temperature: -40º to 350ºF (-40º to 177ºC)
Power: Pneumatic, hydraulic
Sample size: 0.5 ml – 5 ml (per customer requirements)
Repeatability: Exceeds API 8.2 requirement
Mounting: Insertable/Retractable – 2" MNPT Seal Housing
Insertable/Retractable – 2", 3", or 4" Flanged Seal Housing
Flow Through – 1" or 2" Flow Through Spool
Pressure ratings: ANSI 150, 300, 600, 900*
Probe dimensions: Ø1.25" x 3.1" (32 mm x 79 mm)
Shaft length: 30" (762mm) for insertable/retractable models.
Pipe size: 1" to 42" (50 mm to 1067 mm)
Weight: From 30 lbs. (13.6 kg)
*Flow-through models only
REQUIREMENTS
Air: 70 to 125 psi
Consumption: 20 cubic inches per stroke
Maximum sample rate: 20 samples/minute

IASMANUAL 0821 KAM CONTROLS, INC.
5
• Before installing the IAS™ Sampler, unpack and carefully inspect to ensure that it was not damaged during
transit.
• The IAS™ Sampler is normally shipped with a PRV spring per the pressure range of the application. Ensure the
PRV is set to 50 to 100 psi above the maximum operating pressure as per instructions on page 11. Refer to
Table 3-1 to ensure provided spring matches line pressure.
• The IAS™ Sampler should be installed per KAM recommendations, including the mixing requirement calculated
per customer provided flow conditions.
• At the time of installation, the pipeline pressure needs to be reduced to under 100 psi or use a KAM®IT™
Insertion Tool where line pressure exceeds 100 psi in order to be able to install the IAS™ Sampler.
• The IAS™ Sampler Probe should be inserted so that the middle of the sampling window is approximately in the
center half area of the pipe per API MPMS Chapter 8.2 guidelines. FIG. 3-1.
• For insertable/retractable models, before mounting the IAS™ Sampler on the Full-Opening Ball Valve, determine
the insertion length required per procedure on page 7. The Full-Opening Ball Valve is used to isolate the IAS™
Sampler from the pipeline during installation or removal. The Seal Housing of the IAS™ Sampler allows the
Sampler Probe to be inserted in and out of the pipe under pressure and flow conditions up to 100 psi. It is the
user's responsibility to ensure that the IAS™ Sampler is placed in the most representative point in the flow
profile.
PRIOR TO INSTALLATION
Locking Collar
Seal Housing
Full-opening
Ball Valve
Socket Cap Screw
FIG. 3-1 End View of a KAM®IAS™ Installed on a Main Pipe
Sampler Probe
TABLE 3-1
INSTALLATION
PRV Spring Cracking Pressure Range (psig) Spring Color
50 to 350 Blue
350 to 750 Yellow
750 to 1500 Purple
1500 to 2250 Orange

IASMANUAL 0821 KAM CONTROLS, INC.
6
• Insertable models of the IAS™ Sampler should be installed according to FIG. 3-2. The Full-Opening Ball Valve is
used to isolate the IAS™ Sampler from the pipeline during installation or removal.
• In horizontal lines, the IAS™ Sampler should be installed with the probe horizontally oriented at 3 or 9 o'clock.
At the time of installation, the pipeline pressure needs to be reduced to under 100 psi in order to safely install the
IAS™ Sampler or installed using a KAM®IT™ Insertion Tool.
• The IAS™ Sampler Probe should be inserted so that the middle of the sampling window is approximately in the
center half area of the pipe. It is the user’s responsibility to ensure that the IAS™ Sampler is placed in the most
representative point in the flow profile as per API MPMS Ch. 8.2 guidelines.
CONSIDERATIONS FOR INSERTABLE/RETRACTABLE MODELS INSTALLATION
INSTALLATION CONTINUED
Locking Collar
Flow indicators
Full-opening
Ball Valve
Socket Cap Screw
FIG. 3-2
Sampler Probe

IASMANUAL 0821 KAM CONTROLS, INC.
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INSTALLATION CONTINUED
WARNING: Do not actuate the IAS until you have set the appropriate cracking pressure (page 11).
1. With the probe on the ground or a table, use a 3/8" Allen wrench to loosen the Socket Cap Screws on the Locking
Collar. FIG. 3-2. This will allow the IAS™ Sampler Shaft to slide through the Seal Housing.
2. If not already done, push the IAS™ back through the Seal Housing until the sampler probe is fully retracted inside
the Seal Housing. FIG. 3-3 and FIG. 3-4.
NOTE: On flanged models with 5 cc bite size, the sampler probe may rest flush with or slightly extend from the
end of the seal housing.
FIG. 3-4 Flanged Seal Housing
FIG. 3-3 2" MNPT Seal Housing
INSERTABLE/RETRACTABLE MODELS INSTALLATION
3. Re-tighten the Socket Cap Screws on the Locking Collar. This will prevent the IAS™ shaft from sliding and the
probe from getting damaged during mounting.
Seal Housing Seal Housing

IASMANUAL 0821 KAM CONTROLS, INC.
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INSTALLATION CONTINUED
4. Measure the distance (D1) from the top of the main pipe to the end of the connection where the IAS™ Sampler
is going to be installed. FIG. 3-5 and FIG. 3-6.
5. Calculate the insertion distance:
For Flanged Seal Housing
MID – Minimum Insertion Distance
D1 – Distance from the top of the valve to the pipe
Lg – Gasket Width (Typical 0.134")
WT – Pipe Wall Thickness
Ls – Pipe ID x 0.25
MID=D1 + Lg + WT + Ls + IAS Factor (per Table 3-2)
Example: D1=14"
Lg=0.134"
WT=0.322"
ID=7.98"
IAS Factor 2" 150#=2.5"
MID=14 + 0.134 + 0.322 + (7.98 x 0.25) + 2.5
MID=14 + 0.134 + 0.322 + 1.995 + 2.5=18.951"
D1
WT
Ls
Pipe OD
Pipe ID
Lt
D1
WT
Pipe OD
Pipe ID
Ls
FIG. 3-5
Measurements for
Flanged Models
FIG. 3-6
Measurements for
MNPT Models
Class Rating 2" Size 3" Size
150# 2.50" 2.69"
300# 2.62" 2.87"
600# 3.00" 3.25"
900# 3.50" 3.50"
TABLE 3-2 IAS Factor- Flanged SH
* Dashed line represents center 50% of pipe internal diameter (specified sample location per API MPMS Chapter 8.2)

IASMANUAL 0821 KAM CONTROLS, INC.
9
1
1
2
2
A A
B B
Fig 3-6 & Fig 3-7
INSTALLATION CONTINUED
For 2" MNPT Seal Housing
MID – Minimum Insertion Distance
D1 – Distance from the top of the valve to the pipe
WT – Pipe Wall Thickness
Ls – Pipe ID x 0.25 (Sampling Area Length)
Lt – Thread Engagement (0.75")
IAS Factor – 3.25"
MID=D1 + WT + Ls + IAS Factor - Lt
Example: D1=14"
WT=0.322"
ID=7.98"
IAS Factor=3.25
Lt=0.75"
MID=14 + 0.322 + (7.98 x 0.25) + 3.25 - 0.75
MID=14 + 0.322 + 1.995 + 3.25 - 0.75=18.817"
FIG. 3-7 MID for 2" MNPT Seal Housing
6. Measure the calculated MID from the top of the Locking Collar and place a mark with a permanent marker or
tape on the Shaft (Do not use anything sharp to mark the shaft as this will create grooves that will damage the
O-rings in the seal housing.) FIG. 3-7 and FIG. 3-8.
7. You are now ready to attach either model to the valve on the pipeline.
Mark here
8. Slowly open Full-opening Valve and check for leaks.
9. Loosen Socket Cap Screws on the Locking Collar using a 3/8" Allen wrench.
MID
1
1
2
2
AA
B B
Fig 3-1 , Fig 3-8 Fig 3-9, Fig
3-11
1
1
2
2
A A
B B
Fig 3-6 & Fig 3-7
Mark here
MID
FIG. 3-8 MID for Flanged Seal Housing

IASMANUAL 0821 KAM CONTROLS, INC.
10
10. Align window of the IAS™ Sampler to face the flowing stream. This can be done by aligning the Flow Indicators in
parallel with the main pipe. The Flow Indicators are located at the bottom of the Actuator Housing. FIG. 3-9.
11. Push the IAS™ Sampler in until the MID Mark is at the top edge of the Locking Collar. FIG. 3-9.
INSTALLATION CONTINUED
FIG. 3-9
MID Mark
Flow Indicators
12. Re-tighten the Socket Cap Screws so that the gaps
between each half of the Locking Collar are even, as
tight as possible done by hand. Failure to properly
tighten could result in ejection of the unit under
process conditions. FIG. 3-10.
13. Use a 3/4" wrench to tighten the Hex Nuts holding
the Locking Collar from ¼ to ½ of a turn. The Hex
Nuts holding down the Locking Collar should never be
over-tightened. Their major function is to apply light
pressure on the Chevron Packing to ensure a seal
between the Seal Housing body and the Insertion
Shaft. FIG. 3-11.
Socket Cap Screw
Locking Collar
Hex Nut
FIG. 3-11
SECTION A-A
SCALE 1 / 2
1
1
2
2
A A
B B
MATERIAL
FINISH
DRN
THIS DRAWING IN DESIGN AND
DETAIL IS THE PROPERTY OF
KAM CONTROLS INCORPORATED.
IT SHALL NOT BE REPRODICED
AND SHALL BE RETURNED TO US
ON DEMAND
ALL RIGHTS RESERVED
APPVD SCALE DATE
DWG NO. REV
TITLE
UNLESS OTHERWISE
SPECIFIED
ALL DIM IN INCHES
ANGULAR TOL ±1/2
FRACTIONAL TOL ±1/64
3 PLACE DEC ±0.005
2 PLACE DEC ±0.010
REMOVE ALL BURRS
BREAK SHARP EDGES
DO NOT SCALE DWG
SHEET
SS316
Gerry Alejos
1:2 03-13-2013
A
2"-150 Seal Housing
Assembly
211-001-000
Kam
Controls
Incorporated

3939 Ann Arbor Dr.
Houston TX 77063
USA
WWW.KAM.COM
1 OF 1
A
1/4
5/32
FIG. 3-10 Top View Locking Collar
Socket Cap Screw
Locking Collar
Gap
Hex Nut

IASMANUAL 0821 KAM CONTROLS, INC.
11
PRV CRACKING PRESSURE SETUP
1. Turn the PRV Locking Nut clockwise until it
reaches the start of the PRV threads. FIG. 3-12.
2. Turn the PRV Cap clockwise until it reaches the
Locking Nut to reach reference/starting point for
cracking pressure procedure. FIG. 3-12.
4. Hold the PRV Cap in place using a 3/4" wrench
while turning the Locking Nut counterclockwise
until it reaches the PRV Cap and tighten to the
point that the cap cannot move. Lock the PRV
Cap with the Locking Nut and the provided wire
and lead lock. FIG. 3-13.
5. Thread provided wire through holes in Locking
Nut and PRV Cap and twist to tighten.
NOTE: See included PRV manual for further
instructions.
INSTALLATION CONTINUED
FIG. 3-12
Locking Nut
PRV Cap
#
Turns
Blue
(50-350 psi)
Yellow
(350-750 psi)
Purple
(750-1,500 psi)
2 340 N/A N/A
2.5 320 795 1,520
2.75 310 744 1,466
3 285 664 1,379
3.5 248 607 1,242
4 225 494 1,095
4.5 184 431 945
5150 316 810
5.5 105 N/A N/A
6 75 N/A N/A
6.5 50 N/A N/A
3. Turn the PRV Cap counterclockwise to set the PRV
cracking pressure to 50 psi above your maximum
operating pressure per Table 3-3.
Example:
Maximum operating pressure=175 psi
Desired cracking pressure=175 psi + 50 psi=225 psi
Turning the PRV Cap counterclockwise 4 full turns will
set the cracking pressure to around 225 psi.
NOTE: Pressure vs. number of turns are estimates
only. Always make sure there are no leaks at the
set cracking pressure with the maximum operating
pressure. Not setting the PRV correctly will lead to an
incorrect amount of sample being drawn.
TABLE 3-3 Spring Cracking Pressure (psi)
FIG. 3-13
Locking Nut
PRV Cap
NOTE: If your line pressure is within the range of the cracking pressure of the PRV, follow steps on the next section
"PRV Cracking Pressure Setup" to set the correct cracking pressure.

IASMANUAL 0821 KAM CONTROLS, INC.
12
FIELD AIR CONNECTIONS
Sample Outlet
to Sample
Container
Solenoid connection to
Sampler Controller/PLC
Regulated
Air Supply
INSTALLATION CONTINUED
1. Using Stainless Steel Tubing or Stainless Steel Braided Hose, connect the normally open port (usually marked
with a letter "A" or "NO") of the Solenoid Valve to the bottom of the Actuator Housing. Connect the normally
closed port (usually marked "B" or "NC") to the top of the Actuator Housing. FIG. 3-14.
NOTE: If solenoid valve is not provided by KAM, please consult with manufacturer for further instructions.
2. Connect the Solenoid Valve to the KAM®SC™ Sampler Controller or PLC according to the manual for the Solenoid
Valve. The Controller/PLC should be programmed in a way that it energizes the coil for at least 1.5 seconds. Every
time the coil is energized and de-energized the IAS™ Sampler will take a sample.
3. Using ¼" Stainless Steel Tubing and/or Stainless Steel Braided Hose, connect the IAS™ Sampler PRV outlet to
the inlet of a Sample Container. Sample Outlet line should slope consistently downward from sampler to sample
container.
FIG. 3-14
NOTE: All wiring and maintenance on the KAM®IAS™ must be done in accordance with regional and classification
requirements. It is the user's responsibility to understand these requirements.

IASMANUAL 0821 KAM CONTROLS, INC.
13
1. Turn off the air supply going to the Solenoid Valve.
2. Disconnect the ¼" air connections going to the IAS™ Sampler Actuator Housing. FIG. 3-15.
3. Disconnect the ¼" connection going to the IAS™ Sampler PRV sample outlet. FIG. 3-15.
NOTE: If line pressure exceeds 100 psi, use a KAM® IT Insertion Tool when installing/removing the IAS™ Sampler.
Failure to do so could result in bodily injury or damage to the sampler.
4. Use a 3/4" wrench to loosen the Hex Nuts holding the Locking Collar ¼ to ½ turn. FIG. 3-15.
5. Slowly loosen the Locking Collar by turning the Socket Cap Screws counter-clockwise using a 3/8" Allen wrench.
If there is pressure on the line, it will push the IAS™ Sampler out when the Locking Collar is loose. If there is
not enough pressure on the line, manually pull the IAS™ Sampler until the end of the probe stops inside the Seal
Housing.
6. Tighten the Locking Collar by turning the Socket Cap Screws clockwise to prevent the IAS™ Sampler from sliding
back in the pipeline or in the way of the Full-Opening Ball Valve.
7. Close the Full-Opening Ball Valve.
8. Remove the IAS™ Sampler from the Full-Opening Ball Valve.
INSTALLATION CONTINUED
REMOVING THE IAS™ SAMPLER
Socket Cap Screw
Full-Opening Ball Valve
Seal Housing Locking Collar Actuator Housing
FIG. 3-15
PRV
Sample
Outlet
Hex Nut

IASMANUAL 0821 KAM CONTROLS, INC.
14
During normal operation of the KAM®IAS™ Sampler, some seals will wear. In order to ensure continuous accurate
sampling, KAM CONTROLS recommends replacing the seals on your IAS™ Sampler every six (6) months. High levels
of sediment may reduce required time for seal replacement.
A complete kit with all the IAS™ Sampler O-rings, seals, etc. can be ordered by contacting KAM CONTROLS at
[email protected], by calling [phone] or faxing your request to [phone].
For instructions on changing seals, see the IAS™ Seal Replacement manual.
MAINTENANCE
TABLE 4-1 Seal Kit 360440 Insertion Models
19
4
3
5 6
7 8
12
13
14
1617
21 22
18
15
1 2
23 11
109
98
FIG. 4-1 Seal Kit for Insertion Models
2
4
5 6
20
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
DESCRIPTION
2-014 O-ring
2-014 Backup ring
Check Spring
2-011 O-ring
2-020 O-ring
2-020 Backup ring
2-114 O-ring
2-114 Backup ring
2-022 O-ring
2-022 Backup ring
4300 Series Polypak Seal
4300 US Symmetrical U-Cup Seal
PSP338 Piston Seal
2-234 O-ring
Wiper Seal SH959
2-018 O-ring
2-024 O-ring
Suction Spring
Bottom Seal
2-004 O-ring
2-214 O-ring
2-214 Backup ring
V-Groove Packing
PART #
150014
151014
360425
150011
150020
151020
150114
15 1114
150022
151022
153000
153005
153040
150234-N70
153010
150018-N70
150024
360390
360410
150004
150214
151214
153020
QTY
1
2
1
1
1
1
4
4
1
1
1
3
1
1
3
1
2
1
1
1
1
2
1
15 15

IASMANUAL 0821 KAM CONTROLS, INC.
15
MAINTENANCE CONTINUED
19
3
7 8
12
13
14
1617
18
15
1 2
109
98
FIG. 4-2 Seal Kit for Flow Through Models
21
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
DESCRIPTION
2-014 O-ring
2-014 Backup ring
Check Spring
2-011 O-ring
2-020 O-ring
2-020 Backup ring
2-114 O-ring
2-114 Backup ring
2-022 O-ring
2-022 Backup ring
4300 Series Polypak Seal
4300 US Symmetrical U-Cup Seal
PSP338 Piston Seal
2-234 O-ring
Wiper Seal SH959
2-018 O-ring
2-024 O-ring
Suction Spring
Bottom Seal
2-004 O-ring
2-028 O-ring
PART #
150014
151014
360425
150011
150020
151020
150114
15 1114
150022
151022
153000
153005
153040
150234-N70
153010
150018-N70
150024
360390
360410
150004
150028
QTY
1
2
1
1
1
1
4
4
1
1
1
3
1
1
3
1
2
1
1
1
2
TABLE 4-2 Seal Kit 360441 Flow Through Models
4
5 6
20
11
21

IASMANUAL 0821 KAM CONTROLS, INC.
16
TROUBLESHOOTING
PROBLEM SOLUTION
Poor sample draw or no sample. Check the Spring inside Sample Piston and the O-ring on
the Bottom Stop. Replace if broken or worn.
Oil in air lines. Usually, this means that the Seals inside the Seal
Bushings are worn out. Perform standard maintenance
(seal replacement). If problem persists, the Piston Tube
may be scratched and will need to be replaced.
Piston's not moving. Check air supply and Solenoid Valve.
Oil leaking through Seal Housing. Perform standard maintenance (seal replacement).
Sampler is actuating but there is no sample output. Replace the Bottom Seal. This is especially necessary
if the sampler has more than 6 months of operation
(complete seal replacement is strongly recommended).
The sampler is overfilling the Sample Receivers or the
sampler doesn't stop outputting samples.
The line pressure is higher than the cracking pressure of
the PRV. Please follow instructions on page 11 of this
manual to adjust the PRV cracking pressure correctly.