4
4
This Page Intentionally Left Blank
G ~__P Gulf Professional Publishing An Imprint of Elsevier P
To my wife, Patricia M. Lee
Pocket Guide to
Instrumentation Copyright 9 1999 by Gulf Publishing Company, Houston, Texas. All rights reserved.This book, or parts thereof, may not be reproduced in any form without express written permission of the publisher. Permissions may be sought directly from Elsevier's Science & Technology Rights Department in Oxford, UK: phone: (+44) 1865 843830, fax: (+44) 1865 853333, e-mail:
[email protected]. You may also complete your request on-line via the Elsevier Science homepage (http://www.elsevier.com), by selecting 'Customer Support' and then 'Obtaining Permissions'. Gulf Publishing Company Book Division P.O. Box 2608 [] Houston, Texas 77252-2608 109 8 7 6 5 4 3 2
Library of Congress Cataloging-in-Publication Data Lee, R. R. (Robert R.), 1928m Pocket guide to instrumentation / R. R. Lee. p. cm. ISBN 0-88415-308-8 (alk. paper) 1. Automatic control Handbooks, manuals, etc. instruments Handbooks, manuals, etc. I. Title. TJ225.L43 1999 629.8--dc21
Printed in the United States of America. Printed on acid-free paper (oo).
2. Engineering
99-41792 CIP
Contents
Acknowledgments, viii Preface, ix 1
Control Devices .........................
1
Temperature and Pressure Transmitters. Instrument Indicating Devices. Pneumatically Operated Controls. Instrument Tubing. Armored Metal Tube Bundles. Stainless Steel Stick Tubing. Microprocessor Electronics. 2
I n s t r u m e n t Valves . . . . . . . . . . . . . . . . . . . . . . . 23 Uses for Valves. Gate Valves. Globe Valves. Check Valves. Ball Valves. Plug Valves. Butterfly Valves. Stem Variations. Bonnet Variations. Discs Used in Valves. End Connections for Valves. Valve Description. Project Tags. Important Rule When Receiving or Issuing Valves. Storing Valves. Operators for Valves. Valves for Instrument
Outlets. Substitute Valves. Relief Valves. Rupture Discs. Small Instrument Valves. Vacuum Valves. Regulating and Shut-off Valves. Instrument Check, Relief, and Plug Valves. Valves for High-Pressure Service. Materials Control for Valves. I n s t r u m e n t Fittings a n d M o n i t o r s . . . . . . . . . . 61 Outlet Fittings. Pipe Fittings. Tube Fittings. Part Displays and Manuals. High-Pressure Tube Fittings. In-line Filters. Steam Traps. Steam Tracing Control Valve. Sample Cylinders. Detectors and Monitors. Interface Detectors. Flow Switch Monitors/Level Interface Controllers. Spare Parts. Actual Sizes of Pipe/Tubing. Storage Batteries a n d Solar M o d u l e s . . . . . . .
96
AC and DC Systems for Offshore Applications. Photovoltaic Systems. Summary of Solar Module System. Glossary of Terms Used in Solar Applications. Batteries for Electronic Devices. Glossary of Terms Used for Batteries.
M i s c e l l a n e o u s Electrical a n d I n s t r u m e n t a t i o n Items . . . . . . . . . . . . . . . . . .
128 Cable and Wire Ties. Wire and Terminal Markers. Wire Connectors. Splicing Kits. Thermocouples and Accessories. Gauge Glasses. Vibration Control. Thermometers. Pressure Gauges. Expendable Items. B a r C o d i n g Systems . . . . . . . . . . . . . . . . . . . .
146
Suggested Bar Code Numbering System for Construction Trades. Appendix--Abbreviations for I n s t r u m e n t a t i o n Items . . . . . . . . . . . . . . . . . . . . .
156
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
159
A b o u t the A u t h o r . . . . . . . . . . . . . . . . . . . . . . . . . .
166
vii
Acknowledgments
I would like to express my appreciation to certain people, manufacturers and former co-workers, for support and contributions in the preparation of this book: L. L. Lee, G. Hale, Gulf Coast Oil & Gas Industries; J. M. Smith, J. E. Hardwick, C. L. Davis, MIS-U.A.E.; Roger Young, Das Nair, Mohd Razzaq, ARCO Dubai Inc.; Jill Maple, Duracell Inc.; Ed Shreeve, Dick van Gallen Last, Ras A1 Khaimah Gas Commission-U.A.E.; W. D. Wilson, Crawford Fitting Co.; H. H. Hittner, Yarway Corp.; K. D. Arndt, Jr., Keystone Valve Co.; Jeffrey A. Merchant, Jaqua-McKee; R. T. Burnstad Jr., The Walworth Company. I especially want to remember Frank Weirch for the ideas he contributed to this book.
Vlll
Prefi ce
This pocket guide is designed and intended to assist materials personnel in handling project instrumentation equipment and instrument fittings, valves, cable, and many other key components used in industrial plants. The many pictures, charts, tables, and other data serve as convenient references for identifying and describing the materials that are typical of such projects, and which are often the responsibility of various disciplines. It is practically impossible to cover all instrument items for the varied applications, but this guide provides an overview of most of the components. It describes in detail instrument specialty valves along with the major valves used in process systems, such as gate, globe, check, ball, plug, and butterfly valves, in addition to some of the minitypes. In addition, this guide covers various styles of steam traps, tracings, panels, and panel instruments. It illustrates instrument fittings in a cross-referenced chart that covers five major fittings vendors. Gauges, thermowelds, thermo-
couples, thermometers, and other unique product detectors are also included. This guide should be quite useful to drafters, purchasing agents, clerks, technicians, students, professors and project managers. The material in the book is believed to be technically correct; neither the author nor Gulf Publishing Company warrants its use. Always consult the applicable vendor's catalog or specifications issued by your project manager. R. R. Lee
Houston, Texas
1 Control Devices
A materials person receiving and issuing project instrumentation materials is deluged with an array of new and varied instrument items, but at the same time, he or she continues to receive items for older process sections of plants that may operate on air or gas. So, careful checking of all parts and instruments is still the prime requirement.
TEMPERATURE A N D PRESSURE TRANSMITTERS Today's inventory can include unusual instruments such as temperature recorders for low-temperature service inside buildings, refrigerators or ovens; and spring-wound clockdriven circular chart recorders that never require ink or any type of power, but simply are rewound when the chart is changed (Figure 1-1). And there are many variations of temperature transmitters and recorders, such as temperature recorders capable of programmable inputs, speeds, and alarms, and some have two alarm settings per pen, both
P o c k e t G u i d e to I n s t r u m e n t a t i o n
high and low with digital displays. These circular recorders are capable of recording up to 2,300~ (Figure 1-2). It is not the job of the materials person to know how these instruments operate, or which one to install. The materials person's job is to control and protect these units from damage during storage at the project warehouse until ordered installed by the engineers or the project manager.
Figurel- 1. Chart-Temp| recorder,key wound. ( 9 Omega Engineering, Inc. All rights reserved. Reproducedwith permission of Omega Engineering, Inc., Stamford, CT 06907.)
I - 2 . Circular 2-pen recorder.
Figure
(@Copyright Omega Engineering, Inc. All rights reserved. Reproducedwith permission of Omega Engineering, Inc., Stamford, CT 06 907.)
r - ~ ...... r
i
5 0 ...... ~
I
OCEAN O~S(GN
IJ ~
/---e.Ov
4"
s i......... - . ~ - t ............| !rt ill I ............
I
, iL .....
F i g u r e ! - 3 . Subsea pressure transmitter. (Courtesy BEI Edcliff
Instruments Division, Sensors & Systems Company, a subsidiary of BEI Technologies, Inc.)
II
1 i
~. ~'-, ~AT.~
.........
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Figure 1-3 shows an unusual pressure transmitter that operates in 10,000 ft of saltwater, withstands 35,000 psi internal failure pressure, and survives and operates on the seafloor for 20 years. Figure 1-4 is another pressure transmitter built for rugged service and transmits flow levels or pressures of 0-1,000 psid. New instrumentation products continue to appear at job sites. Colored tubing and hose, including conduit, are seen
Figure !-4. Heavy-duty process transmitter. ( 9 Omega
Engineering: Inc. All rights reserved. Reproduced with permission of Omega Engineering, Inc., Stamford, CT 06 907.)
Control Devices
5
often at job sites, as are static mixer assemblies for wastewater applications and chemical mixing inside a hose or pipe (Figure 1-5). Large display panel meters with 4-in.high digits are used. (Figure 1-6). Just as important, and still used in many plants are earlier modes of panel board and digital indicators (Figure 1-7). Intrinsically safe field temperature transmitters (Figure 1-8) are used in Class 1, Division 1, Groups A, B, C, D. Intrinsically safe is defined as "equipment and wiring that are incapable of releasing sufficient electrical energy to cause ignition of a specific hazardous mixture in its most easily ignited concentration." In plain terms, to have a fire or explosion, a source of ignition must be present. An intrinsically safe system assumes the source is present in the atmosphere, but the system is designed so that electrical or thermal energy of a particular instrument loop can never be great enough to cause ignition. See Figure 1-9 for the causes of combustion.
,
~\
~,~
~ ~
~
~
~ ........... ,,~,~:,~:~,
Figure 1-5. 304SS static mixer assemblies. ( 9 Omega Engineering, Inc. All rights reserved. Reproducedwith permisskm of Omega Engineering, Inc., Stamford, CT 06907.)
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Figure 1-6. Large display (2-4 in.) digital panel meters. ( 9 Omega Engineering, Inc. All rights reserved. Reproducedwith permission of Omega Engineering, Inc., Stamford, CT 06907.) INSTRUMENT INDICATING DEVICES Figure 1-7 illustrates control panel indicating devices by Foxboro. Figure 1-10 shows an electronic temperature indicating transmitter. The probe has a 3A-in. bushing that will screw directly into a thermowell outlet on a vessel or into a process pipe. There are many variations of temperature indicators and transmitters. This particular transmitter has a range of 450 to 1,000~ Figure 1-11A illustrates a liquid level controller/transmitter that is top mounted. A DC power supply is required on the Fisher electronic transmitter. It attaches to an opening in a vessel by a flange, gasket, and bolts. The typical level controller/transmitter shown in Figure 1-11B is an external displacement type with top and bottom pipe connections.
Control Devices
Figure 1-7. Control panel indicating devices. (Courtesyof Richardson Engineering Services, Inc.) Metering toxic fluids such as nitric and sulfuric acids, boiling caustics, wet chlorine at high temperatures and high pressures is performed by straight-through rotameters. The Wallace & Tiernan Varea-meters TM operate by a float magnet and a follower magnet on the pointer. At 50% on the scale (see Figure 1-12), unlike poles attract equally so that
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Figure 1-8. Intrinsically safe field transmitter. ( 9 Omega Engineering, Inc. All rights reserved. Reproducedwith permission of Omega Engineering, Inc., Stamford, CT 06907.)
Figure 1-9. Causes for combustion. ( 9 Omega Engineering, Inc. All rights reserved. Reproducedwith permission of Omega Engineering, Inc., Stamford, CT 06907.
the rotating magnet is parallel to the float magnet. Figure 1-13 shows a Varea-meter TM that is manufactured in carbon steel, stainless steel, and PVC. For service in hazardous locations, an explosion-dust-ignition-proof thick-walled
Control Devices
1 - 10. Temperature indicating transmitter.
Figure
(Courtesy of Richardson Engineering Services, Inc.)
aluminum enclosure with a heavy-duty glass is available, as shown in Figure 1-14. In specific hazardous atmospheres in oil refineries, chemical plants, paint manufacturing plants, metal finishing areas, coal processing locations, and grainaries, thermostats are used to control the line voltage equipment for heating, air-conditioning, and refrigeration. Figure 1-15 illustrates a thermostat with Mercoid control. For refrigeration and airconditioning, the switch contacts close on temperature rise, whereas for heating, they close on temperature fall. A removable knob is used to set the temperature setting. The ambient room temperature is indicated on the front.
10
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Process Piping "qP-
Instrument Piping
l
!
......
! .......
1-v-
II
(A)
i FLANGED
Figure 1 - 1 1. Level controller/transmitter. (Courtesyof Richardson
Engineering Services, Inc.) PNEUMATICALLY
OPERATED
CONTROLS
Many plants use and will continue to use pneumatic controis, therefore it is important to be familiar with pneumatic materials. Figure 1-16 shows a liquid level transmitter (A),
Control Devices
II
%
Figure 1 - ! 2. Magnetically operated rotameter. (Courtesy of Wallace & Tiernan Div., Pennwalt Corp.)
a pressure regulator (B), a backflow preventer (C), and a temperature regulator (D). Figure 1-17 shows a pneumatic temperature transmitter (A), a pneumatic indicating pressure transmitter (B), and pneumatic absolute pressure transmitter (C), and a pneumatic flow transmitter (D). Figure 1-18 illustrates a pneumatic flow indicator that totals actual flow on a six-digit counter from any flow transmitter (A), an air switch (B), and an indicator receiver gauge (C).
12
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Figure I- 13. Varea-meterTM for non-hazardous Wallace & Tiernan Div., PennwaltCorp.)
areas.
(Courtesyof
INSTRUMENT TUBING Air or some form of gas is used to activate pneumatic instruments, and instrument tubing transports it. The tubing is manufactured in copper, PVC, stainless steel, etc. Figure 1-19 shows three different types of single-line tubing used in pneumatic and low-pressure hydraulic installations where flexible connections are needed. They are:
Control Devices
13
,-4
~.
"
Figure 1- ! 4. Varea-meter TM for hazardous areas. (Courtesyof Wallace & Tiernan Div., PennwaltCorp.) 1. "P" tubing (polyethylene) tubing, which is used in low-pressure installations. 2. Dekoron | "N" tubing, which is used where maximum mechanical strength is required for high temperature and pressure. 3. Dekoron | FR (flame retardant) tubing, which is used where a plastic tubing with a flame retardant characteristic is desired.
14
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Figure 1 - 15. Thermostat for hazardous areas. (Courtesyof
Crouse-Hinds Co.)
(D)
c) Figure 1 - ! 6. Pneumatic controls. (Courtesy
Engineering Services, Inc.)
of Richardson
15
Control Devices
(B~
(A)
1 - 17. Pneumatic controls. (Courtesy of Richardson Engineering Services, Inc.)
Figure
16
P o c k e t G u i d e to I n s t r u m e n t a t i o n
(A)
(B)
(~
Figure I-18. Pneumatic panel-mounted controls. (Courtesyof Richardson EngineeringServices, Inc.) Packing of single-line tubing is shown in Figure 1-20. The numerals 1-30 are printed the full length of the tubing. These markings identify each end at a given point. By cutring the lead end at a given number, and marking the reel or carton by the same number, tubes can be easily identified for the proper connection or for materials control purposes in the project warehouse.
Control Devices
17
"P" Tubing
(pc~eU~~)
"N" Tubing
~ylon)
"FR" Tubing
(~
p.etarc~nt)
Figure 1- 19. Flexible instrument tubing. (Courtesyo[ Eaton Corp.,
Industrial Polymer Products Div.)
ARMORED METAL TUBE BUNDLES Copper or aluminum tubing is packaged, in some cases, in an armored tubing bundle, suitable for direct burial, designed for tight bends, resistant to chemical attacks, and flame retardant. The individual tubes are number coded, and a 22-gauge communication conductor is included to help coordinate bundle installation. There are many variations of multiple tube bundles. Figure 1-21 shows Dekoron | Type
18
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Shipping Weights and Lengths Dekoron "P", "HP", "FR" ESTIMATED TUBE COIL MASTER MASTER SIZE LENGTH PACK PACK (O.O.) (Feet) (Feet) SHIPPING WEIGHT (Ibl.) 5/32" 500 2000 12.5 1/4"
3/8"
I/2"
250
1000
500
10001
15,3
1000
2000
25,1
250
1000
32,2
,500
1000
30,2
250
500
22.6
.,~mlmL, ~
! : ~ ~
9
YO-YO PAK This Dekoron exclusive keeps 250' of 114" "P" or "FR" tubing, or 500' of 5/32" "FR" tubing clean, ~~ and dry.
16,8
OEKORON " N "
i
t
] ..... 4,..0
CONVENIENT FOOTAGE INDICATOR SCALE
CONVENIENT MARKING TEXT To identifyeither end of tubing when severalsingle tubes are used together, the numerals 1-30 are printed the full length of the tubing. By cutting ~tl the lead end at a given number, and marking the reel or carton by the same number, you can easily identify the tube at eilher end for proper connection.
Figure 1-20. Flexible instrumenttubing. (Courtesy of Eaton Corp., Industrial Polymer Products Div.)
19
Control Devices
Insulated communication wire
Copper or aluminum tubes
PVC jacket
Galvanized inter-locked armor
Figure 1-21. Armoredtubingwith innerjacket. (Courtesy of Eaton Corp., Industrial Polymer Products Div.) 1002 armored metal tubing with inner jacketed multiple tube bundle, and Figure 1-22 shows Type 1003 armored metal tubing with outer jacketed multiple tube bundle.
STAINLESS STEEL STICK T U B I N G The most common example of poor materials handling practices is damage to the small sizes of stick tubing after it
20
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Insulated communication wire
Copper or aluminum tubes
Vinyl insulating tape
Galvanized
steel inter-locked armor
PVC jacket
Figure 1-22. Armored tubing with outer jacket. (Courtesyof Eaton Corp., Industrial Polymer Products Div.) has arrived at the project. The tubing is limber, and will require support during storage or while being handled. Always supervise the handling of stick tubing. Figure 1-23 shows several styles of stainless steel stick tubing and cut nipples that are available. The tubing is shipped in 20-ft
21
Control D e v i c e s
f-;~-:..l. I_L,__
-
. .
'
._
.
.
.
.
.
.
.
.
" . . . . . . . .
.
.
.
.
.
.
.
.
~
.
.
.
..... ~,,,..
.
: ::
.
.
. . . .
. .
.
.
.
......
.
................-~-,i ...... ,....... i iill '~" ..... ,~,,,~, ~i............~i-li ......... i...........~?~i ......ili l .......iiii,
~'~ . . . . . . . . . . . .
:L--~r~ I Iml r I
.
.
.
.
.
Figure 1-23. Stainless steel stick tubing. (Courtesy of Autoclave Engineers, Inc.)
lengths in cardboard tubes, or bundled along a board. It should be stored on a fiat surface, or on a rack with support braces every four feet. Tubing is identified by the outside diameter and by the wall thickness. An example would be for stainless steel tubing, 3~-in. OD by .035-in. wall thickness. If the shipping carton is suitable, leave the tubing in the carton while in the project warehouse to protect the stainless steel finish. Fittings for stainless steel and other instrument items are shown in Chapter 3.
22
P o c k e t G u i d e to I n s t r u m e n t a t i o n
MICROPROCESSOR ELECTRONICS Control rooms for large industrial plants are based on pneumatics or analog electronics, and have a maze of meters and levers spaced across three or four walls. The miles of wire or tubing in a plant are expensive to install and maintain. Behind the control panels are thousands of feet of tubing and wire that connect the gauges to each other and often to a computer. Microprocessor-based electronics is changing that. Computers, televisions, calculators and much of the controls industry now rely on the silicon chip. The tiny integrated circuit has eliminated the need for miles of wiring, making possible smaller and more powerful computers.
2 Instrument Valves
Uses for Valves Primitive man used a plug in a bamboo pipe as a valve to serve his needs. Modern-day valves are used to control the flow of liquids or gases by on-off service, throttling service, and backflow prevention. According to the Walworth Company,.about 50% of the industrial valves used fall in the on-off category, 40% in the throttling category, and 10% in the backflow prevention category. Basically, the six major valve types, which have almost innumerable variations, are as follows: U] Gate F1 Globe I--1Check
D Ball [D Plug [D Butterfly
23
24
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Gate Valves Figure 2-1 illustrates a flanged end gate valve and the flow characteristics. Gate valves are used for full on and off service.
FLOW CHARACTERISTICS.., GATE
CLOSED~StTK~N
O~
~O~TtON
Figure 2-1. Flanged end gate valve. (Courtesyof The Walworth Co.)
25
I n s t r u m e n t Valves
Globe Valves Figure 2-2 shows a globe valve with flanged ends and screwed ends. It is sometimes referred to as an "S" valve, and is fast closing. Globes are used mostly for throttling service.
No.52T5F, Globe r%OW~~CHARACTERI G~OB~E S~TICS.. GLOOt ~
pO~0N
~0~!
0~N
POS'T,0N
Figure 2-2. Flanged and screwed end globe valve.(Courtesyof The Walworlh Co.)
26
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Check Valves Figure 2-3 illustrates a swing check and a globe check with flanged ends. The three basic types of check valves are the swing, lift, and ball. Check valves are designed to prevent backflow.
S W I N G CHECK
FEATU~$ A LOWH ~SSU~E DaOP THAN OTI~EIt CHs VAtVE HOmZONTAt Oft VLq~K:AL t ~ $ .
LIFT CHECK A GrOtE V A t v l I~DY TMAT ~IOV~E$ A TIGHT SF,AL. U~I,D IN HORIZO~!~AI. LtN~S,
r, .....
t
,'
~
i
Figure 2-3. Flangedend checkvalves. (Courtesyof The Walworth Co.)
Instrument Valves
27
Ball Valves Figure 2-4 shows three basic styles of ball valves with flanged and screwed ends; full port, reduced port, and the venturi style. Ball valves do not require lubrication and are quick open and quick off.
Figure 2-4. Flanged and screwed end ball valves. (Courtesyof The Walworth Co.)
28
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Plug Valves This type of valve has evolved from a tapered plug in a bamboo line to modem versions such as the one shown in Figure 2-5. Lubrication not only ensures ease of operation, but acts to ensure tight sealing and resistance to corrosive solutions.
PLUG VALVE FLOW PATTERNS
Figure 2-5. Lubricated plug valve. (Courtesyof The Walworth Co.)
Instrument Valves
29
Butterfly Valves Figure 2-6 depicts two basic body styles of butterfly valves; the wafer style and the full-lug. Butterfly valves are mounted between flanges. It is the most popular throttling device. More detail on butterfly valves follows later in this chapter.
__. _ _ J
Figure 2-6. Butterfly valves. (Courtesy of The Walworth Co.) Stem Variations Figure 2-7 illustrates the various stem variations. The descriptions of the variations are important as they will appear in standard valve terminology. An example is OS&Y (outside screw and yoke).
30
Pocket Guide to I n s t r u m e n t a t i o n
STEM VARIATIONS
INSIDE SCREW, RISING STEM AND HAiNDWHEtEL
INSIDE SCREW NON-RISING STEM
OUTSIDE 5CREW AND YOKE NON-ROTATING RISING STEM
SLIDING STEM QUICK OPENING
Figure 2-7. Valve stemvariations. (Courtesyof The W alworth Co.)
Bonnet Variations
The bonnet seals the packing glands around the valve stem. Figure 2-8 shows several styles of bonnets for valves.
31
Instrument Valves
BONNET VARIATIONS
SCREWED BONNET
UNION BONNET
BOLTED BONNET
PRESSURE SEAL
Figure 2-8. Valve bonnetvariations.(Courtesyof The Walworth Co.)
32
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Discs Used in Valves The disc, when closed onto the valve seats, forms a seal against the flow. Figure 2-9 illustrates how various discs are used in gate valves.
DISCS
SOLID WEDGE
(GATE)
FLEXBLE WEDGE
DOUBLE DISC
gALL AND SOCKET ROTATING DISC( S.S. )
Figure 2-9. End connections for valves. (Courtesyof The Walworth Co.) End Connections for Valves A few of the more common end connections used on valves are shown in Figure 2-10. There are other variations used by different manufacturers in special applications.
VALVE DESCRIPTION Describing valves for entry into the materials accounting system is not difficult, but their description must remain consistent with the project commodity code descriptions
33
I n s t r u m e n t Valves ENDS
ND
SOLDER JOINT
W A t ~)IF,AL
Figure 2-10. End connections for valves. (Courtesyof The Waiworth Co.) from the computer bank used for the project. On each valve in one form or another, the manufacturer's nameplate has a valve figure number on it. With this number and the manufacturer's catalog, a good description is available. Basically, the following describe a valve for future use: 1. Size (nominal pipe size). 2. Body style--cast steel, bronze, stainless steel, etc. 3. Stem or ball--11-13.5% chrome, buna-n, viton, etc. 4. Seat materialsmreinforced teflon, stellite, 304 stainless steel, metal to metal, etc.
34
P o c k e t G u i d e to I n s t r u m e n t a t i o n
5. Pressure class--150, 300, 600, 900, 1500, 2500 ANSI, 10,000-1b psi, etc. 6. Type of operation--handwheel, lever, worm gear, power operated, chain wheel operator, etc.
Project Tags Project tags, usually called V-numbers, are unique for the one project only. An example would be V-2237 for a 4in. Walworth Figure number 5202F cast steel gate valve. The craftsman would simply request from you, a 4-in. V2237. On the next project, V-2237 may refer to a completely different item. Tags for V-numbers vary from round discs and wire to permanent weatherproof tags as shown in Figure 2-11. These permanent tags, also called dense metal weld identification tags, are made from copper plates 89x 2~ in. long. They are attached by using a fast-acting bonding agent (Loctite 326), which is included with the tags. The cryogenic and high-temperature dense metal weld identification tags referred to as Models 300 and 400 are made from copper or stainless steel, and furnished with banding and snap-clips. These tags are impervious to corrosion and weather, but most important, will withstand the stress of cleaning machines, such as a sand blasting unit.
Important Rule When Receiving or Issuing Valves Never remove project tags from valves, and if a tag is off, request your supervisor to verify a replacement tag as
35
Instrument Valves m
o D 34455,,
*l
Figure2-1 1. Dense metal weld identification tags. (Courtesyof
South Manufacturing Co.)
the correct number. Do not rely on the project tags. As the responsible materials person, verify the valve as correct by the figure number on the nameplate on each and every valve when either receiving or issuing the valves. Disaster can result from an incorrect valve being installed in a process line. Do not paint valves prior to issue. Surplus valves that have been painted cannot be returned for credit.
Storing Valves Figure 2-12 shows one method of storing valves on pallets and inside a warehouse under ideal conditions. Valves two inches and smaller, and any valves with threaded outlets, should be stored inside. Valves stored outside must be stored with the stem up, and in such a manner as not to trap
36
P o c k e t G u i d e to I n s t r u m e n t a t i o n
~
'~-,,,._Pallet Number Figure 2-12. Gatevalvesstoredon pallets.
water or sand. Corrosion will form on the ball or seat, and render a new valve worthless even before it is installed in the process line. Use end protectors for a reliable seal against the elements.
Operators for Valves Hand wheels, levers, and throttling levers are the most common types of devices to operate valves. A chain wheel operator is used to operate hand wheels that are out of reach of the plant personnel (see Figure 2-13). Butterfly valves are used as control valves. Three styles of operators are shown in Figure 2-14:
37
Instrument Valves
W h e n o r d e r | n 0 , give diameter of valve wheel to be fitted and No. of feet of chain required.
Diameter No.
0
1 11/z
Sproeket Wheel Inches
4
57A 7~
WillFit
Valve. Wheels, Diameter Inches
2
to 4
4 88to 57A 6 to 7 ~
2 21/z
9 12~
3
15 89
]28A to 15 89
4 41/2 S
19 22 26 30
15s/~ to 1 9 ~ to 221~ to 2 6 ~ to
31/z
7 ~ to 9 9 ~ to 12~ 19 22 26 30
Figure 2-! 3. Chain wheel operator. (Courtesyof The Walworth Co.)
38
P o c k e t G u i d e to I n s t r u m e n t a t i o n
(A)
(e)
(C)
Figure 2-14. KLOK| valve operators. (Courtesyof Keystone
International, Inc.)
Instrument Valves
39
A. K-Lok valve with electric actuator, with manual override. B. K-Lok valve with notch plate handle for manual operation/throttling. C. K-Lok valve with compact pneumatic rotary actuator. (See Figure 2-15 for a cutaway view of the Keystone Figure 790 actuator.) Figure 2-16 shows three additional types of instrument control valves: A. 3-way Fisher mixing valve with pneumatic diaphragm actuator. B. Fisher butterfly control valve, with piston operator, pneumatic positioner for throttling service. C. Fisher control valve, pneumatic diaphragm actuator.
Valves for Instrument Outlets All instrument outlets for pressure measurement, vents, drains, and sampling applications require a valve that will withstand the pressure and strain of the process line. Fi~gure 2-17 illustrates a Vogt Class 800 gate valve with an extended end, which has more strength than the traditional valve and nipple concept. (A nipple of incorrect rating installed in a process line could pove to be disastrous.) Applications of
40 Pocket Guide to Instrumentation
Figure 2-1 5. Cutaway view of pneumatic valve actuator. (Courtesy of Keystone Internationa/, Inc.)
41
Instrument Valves
(A) IB, 'i
4
(c)
Figure 2-16. Instrument control valves. (Courtesy of Richardson Engineering Services, Inc.)
these valves through insulation are shown in Figure 2-18. Insulation is typical and common in most processing plants.
Substitute Valves Line blinds are used in place of valves to close a line in the process system. There are many variations, and the line
42
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Integral Male Threaded Female Threaded
Integral Male Socket Weld Female Threaded
Integral Male Couplet Female Threaded
Integrally Reinforced Extended Length Male Couplet Female Threaded
Figure 2-1 7. VogtClass 800 gate valve with extended end. (Courtesyo#Henry VogtMachine Co.)
blinds are manufactured in most steel types, ANSI pressure classes, and buttweld or flanged ends. They provide a tight shut-off. A Stacey line blind is shown in Figure 2-19 with buttweld ends.
43
Instrument Valves
VogtSW-1211Couplet Vesselor PipeWall~
""lVogtST-2801 : :i Insulati~ l~~!i~;!~~i~ ~ ~~ Valve
Insulation~ ~ ; . ~ ] i
1~
Vesselor .~.....~h:.:~~-''*-r:i':t."~,~ ~
vo%o
Figure 2-18. Outlet valves through insulation. (Courtesy of Henry Vogt Machine Co. 9Marked ServiceCo., a//rights reserved.) Relief Valves These valves are often referred to as "PSV" valves, and are available in numerous sizes and designs. Figure 2-20 illustrates a typical relief valve in a cutaway view. The spring is designed to release the valve seat at a certain pressure. Earlier models used weights on a long extended handle. Most of the relief valves will be preset at the factory and have a car-seal attached showing the set pressure. Do not
44
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Figure 2-19. Stacey line blind. (Courtesyof Stacey
FetterolfCorp.)
remove this seal. In addition, each valve will be tagged on the nameplate for a specific location in the process system. Relief valves have an outlet that is usually larger than the inlet, and are piped to the vent system or vented to the atmosphere. A full-opening valve is installed below the relief valve, and between the valve and the relief valve, a test insert ring with a gate valve, such as those in Figure 2-17, will be installed. The test insert, which resembles a thick washer with a threaded hole for the outlet, requires a gasket on each side of the ring, and this in turn requires
45
Instrument Valves
Screw
Gasket
Ca
Adjusting Bolt Lock Nut
Spindle
Gasket Spring
Spring Lock Nut Plug Ball ---I--F == 3/4" NPTF Connection
Plug Guide
Seat
Valve Bod~
9/16" SlimLine
Seat Gland
STANDARD RELIEF VALVE F i g u r e 2 - 2 0 . Relief valve.
(Courtesy of Autoclave Engineers, Inc.)
46
P o c k e t G u i d e to I n s t r u m e n t a t i o n
longer than usual stud bolts. A barstock relief valve for high-pressure service is illustrated in Figure 2-21.
Rupture Discs These are available in a broad range of sizes and types, materials, and rupture pressure ratings. The size is measured
SERIES RVP Figure 2-2 I. Relief valve for highRELIEF VALVE pressure service. (Courtesyof Autoclave Engineers, Inc.)
47
Instrument Valves
by the diameter as shown in Figure 2-22. The discs serve as a form of a relief valve, and will be tagged for a specific location and rupture pressure. Always leave the discs in their original carton to prevent damage to the bulge and the edges.
Small Instrument Valves There are valves of every type and description used in instrument type service. Only a few of the valves manufactured by the leading valve companies are shown here. The same rules for identification and storage that apply to
~lr (4.7,ttram) 1/2" ,,o--(12. 7 mm)-.-,P DIAM.
,,HS,S mm)-t, DIAM.
FLAT SEAT RUPTURE DISC
3t~ ANGULAR SEAT RUPTURE DISC
1!4"
Figure 2-22. Rupture disc. (Courtesy of Autoclave Engineers, Inc.)
48
P o c k e t G u i d e to I n s t r u m e n t a t i o n
valves with screwed ends (previously mentioned) apply to these small valves.
Vacuum Valves Any analytical instrument or industrial process that requires the use of vacuum, such as gas analysis, electronic component manufacturing, cosmetics, freeze dried foods and drugs, requires vacuum valves. Shown in Figure 2-23 is a Nupro | 304-24VFBG Bellows sealed butterfly vacuum
m ~
H r~q
I k~ NUPRO G 304-24VFBG i H BUTTERFLY VALVE
Figure 2-23. Bellows sealed butterfly vacuum valve. (Courtesyof Nupro| Co.)
Instrument Valves
valve. This valve is used in systems with up to 1 89 ing, and can be air operated.
49
tub-
Plug Valves The compact and quick-acting plug valves are used in applications for chemical and petrochemical plants for bleed and drain valves, test equipment, air lines, sampling, and general instrumentation. The valves are color coded for systems to prevent mixing of materials in the process system. They are available in pipe end and tubing connections. Figure 2-24 illustrates plug valves.
Figure 2-24. Instrument plug valves. (Courtesyof Nupro| Co. 9Markad Service Co., all rights reserved.)
50
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Regulating and Shut-off Valves Figure 2-25 illustrates a straight-through plug valve used for regulating, and for gauge installation, sampling, and test instruments. The cylinder valve with a rupture disc provides a positive method of over-pressure protection for any system or cylinder. The rupture disc provides instantaneous and unrestricted opening to atmosphere at a predetermined pressure. Figure 2-26 shows a variety of valve patterns and end connections of the regulating and shut-off valves.
Ball Valves for Instrument Service Small ball valves are used where quick on-off service is required in acid lines, treated water lines, inert gas lines,
VALVE INLET
Figure 2-25. Regulating and shut-off valves. (Courtesyof Whitey Co. @1972-1978 Markad Service Co., all rights reserved.)
Instrument Valves
51
! ~i ANGpATTLEEFI ~ N A-1VM6-S6-A
•
PATTEFIN
SS-1VS4-X
STRAIGH~RAIGHT
M-0VM2 S-18VMS-F8
Figure2-26. Regulating and shut-offvalves. (Courtesyof Whitey Co. 9Markad Service Co., all rights reserved.)
natural gas lines, and gas manifolds. It is used in all types of hydraulic and air lines. Figure 2-27 illustrates a threeway ball valve for switching systems, fluid mixing, sampiing and bypass systems (A), a swing-out ball valve that features easy valve maintenance, and offers leak-tight seal(text
continued on page 54)
52
P o c k e t G u i d e to I n s t r u m e n t a t i o n
(A)
(B)
Figure 2-27. Multiport ball valves. (Courtesy of Whitey Co. 9Markad Service Co., all rights reserved.)
53
Instrument Valves
(C)
(D)
Figure 2-27. Continued.
54
P o c k e t G u i d e to I n s t r u m e n t a t i o n
ing at high- and low-pressures (B), a 5-way ball valve used to direct a number of flows or pressures through a single valve (C), and a ball valve for on and off service (D). These ball valves have a directional handle feature. Figure 2-28 shows a group of fine metering valves of angle and straight
SS-21RS4 STRAIGHT PATTERN SWAGELOK CONNECTIONS TFE PACKING
SS-22RS4-A
SS-22RF2
Figure 2-28. Fine metering valves. (Courtesyof Whitey Co. and Nupro| Co. @1973-1978 Markad Service Co., all rights reserved.)
I n s t r u m e n t Valves
55
patterns that are used to control gas or liquid flow precisely in critical processes.
Instrument Check, Relief, and Purge Valves Instrument check valves allow unrestricted flow in one direction, and no flow in the opposite direction. Relief valves are set to open at a preset pressure to protect the gauges, instruments, and systems from over-pressurization. Purge valves are used to manually bleed, vent, or drain instruments and systems. Figure 2-29 shows a variety of these valves with cutaway views: in-line check valve, purge valve, and in-line relief valve.
Valves for High-Pressure Service Severe service conditions of high pressures up to 150,000 psi, hazardous or corrosive fluids, and very high temperatures to 1,200~ are controlled with valves manufactured by many of the leading valve makers. Figure 2-30 illustrates a valve for service at 45,000 psi at 450~ These valves, and other makes and patterns, have replaceable port fittings as shown on each side of the illustration. The various fittings can be used to adapt the valves to any tube or piping system. Valves for extreme pressures are required for various applications such as an offshore oilwell head. A few of such valves are shown in Figure 2-31.
56
P o c k e t G u i d e to I n s t r u m e n t a t i o n
(1) B4C-1
(3)
$S,,4CA,,3
Figure 2-29. Instrument in-line check valve (1); purge valve (2); and in-line relief valve. (Courtesy of Nupro | Co. 91973-1978 Markad Service Co., all rights reserved.)
57
Instrument Valves
SS-44M-A-400 SWAGELOK
SS.44M-7-4
High PressureMale Thread to
High PressureMate Thread I0 Fema|e Pipe Adapter
SS-44M-A-4TSW
High PressureMale Thread to Tube Sockel Weld
I..
SS-44M-1-4 High PressureMale Thread to Mate Pipe Adapler
I
I
SS.44M-A.441 A~pte~
High PressureMale Thre~ to Coned Tube Stub
$5-440-1-44M
Figure 2-30. High-pressurevalveandport adapters.(Courtesy of Sno-Tril~ Co. 9Markad Service Co., all rights reserved.)
Materials Control for Valves Valves of all types represent a major part of the cost of a project. Regardless of size or ratings, each valve received at your project warehouse has been assigned to serve in a specific line of the process system. It is your responsibility to verify that each valve received or issued complies to the
58
P o c k e t G u i d e to I n s t r u m e n t a t i o n
~ 60,000 psi
150,000 psi
_<50,000 psi
_<150,000 psi (air operated) rr'""
'"""
Figure 2-31. High-pressurevalves. (Courtesyof Autoclave Engineers, Inc.)
Instrument Valves
59
purchase order figure numbers stamped on each valve as the manufacturer's model number, and the same number on your project purchase order. If they do not match and the problem cannot be resolved, notify the project manager as soon as possible. Project schedules are usually very tight, and some valves are long-delivery items.
Needle Valves for Accurate Flow Needle valves are machined from bar stock for reliable performance. These valves are used in oil and gas production, processing plants, or anywhere a flow of fluid must be carefully regulated. Figure 2-32 shows three patterns of needle valves each with two-prong color-coded handles.
Figure 2-32. Needle valves for accurate flow regulation.
(@Copyright Omega Engineering, Inc. All rights reserved. Reproduced with permission of Omega Engineering, Inc., Stamford, CT 06907.)
60
P o c k e t G u i d e to I n s t r u m e n t a t i o n Two-prong coded ha
bon serv or ~ : Precision mach~ SS stem for concentric~bt, eas Heat.treated to pl stress cra~
integ~a~ bac$ stem prevents removal of sl elzmmatespo,~ stem bfo~,. . . . .
iearance washers id nongaIling ~phile packing ~ stem for
tife
6 SS annealed body ~nd bonnet prevent fide stress c~acking m ur tiuid enwronments Bonnet tock~ng pin prevents accidental loosening of bonne! Metal.tometal seat
Figure 2-33. Hard seat needle valve for NACE. (@CopyrightOmega
Engineering, Inc. All rights reserved. Reproducedwith permission of Omega Engineering, Inc., Stamford, CT 06907.)
Figure 2-33 is a cutaway of a 316 stainless steel needle valve with NACE trim that prevents sulfide cracking per Standard MR-01-75 in offshore and other petroleum environments where sour conditions may be present.
3 I n s t r u m e n t Fittings and Monitors
OUTLET FITTINGS Outlets on process lines are required near equipment or utility stations for providing plant air or plant gas. There are many types of fittings that can be used for these outlets such as tees, O-lets, and reducing tees. Shown in Figure 3-1 are two outlet fittings called weld couplets. These fittings are acceptable as nozzles on vessels, or can be used on large or small diameter pipe. The threaded couplet is suitable for installing gauges, thermometers, thermocouples, etc.
PIPING FITTINGS Many standard piping fittings are used in the instrument lines en route to the servic~ area. Figure 3-2 illustrates the basic type fittings whose &,scriptions remain constant and repetitive. The pressure ratings vary, however, as well as the ends, i.e., screwed, socketweld, combinations, etc. 61
62
P o c k e t G u i d e to I n s t r u m e n t a t i o n
MINIMUM INVENTORY REQUIRED Fits small diameter p i p e . . , large diameter vessels
Figure 3-!. Weld couplets. (Courtesyof Henry VogtMachineCo.) TUBE FII"rlNGS Table 3-1 is a cross-reference chart for tube fittings. Part numbers may change without notice. Therefore, it is important to verify the part numbers from the various cata-
63
Instrument Fittings and Monitors
90"
COUPLINGS
ELLS
45"
HALF COUPLINGS
TEES
WELD COUPLETS
ELLS
CROSSES
LATERALS
~i~
BUSHINGS
INSERTS
STREET ELLS UNIONS CAPS
Figure 3-2. Basictypesof pipe fittings. (Courtesyof Henry Vogt
MachineCo.)
P o c k e t G u i d e to I n s t r u m e n t a t i o n
logs for project use. The fittings displayed in Table 3-1 are Swagelok | The part numbers under the other brand names refer to an equal fitting. Regardless of the brand name, tube fittings are made and tested to very high standards to provide service without leaks and other problems. Scratches or other surface defects can lead to gas leaks. Tube fittings should be handled and stored with care to prevent damage. Protect the surface of the fittings by storing them in bin boxes inside their original cartons. (The same rule applies to t u b i n g n n e v e r drag it out of a rack or across a cement floor.) (text continued on p a g e 68)
Table 3-1 Tube Fittings Cross Reference
Swagelok
Gyrolok Imperial Parker Tylok
'~6 CAp
100-C
CP
708-F
FNZ
CAP
P
721-F
PNZ
FPLUG
731-SS
ZHBW
m
~6 PLUG
$WAGELOK TO TUBE SOCKET
WtLO~tON
SWAGELOK TO T~BE SOCKET
~u~D
100-P
~/~
400-6-4TWS
600-9-6TSW
ZEBW
MC
1~6 X 88 100-1-1
CM
768-F
FBZ
BHMP
65
Instrument Fittings and Monitors
Swagelok !
~
WW-
.
.
.
.
.
.
~x~
.
BULKHEAD MALE CONNECTOR
TO PIPE
-
.ALE
RUN TEE
CONNECTOR
BCM
788-F
FH2BZ
88215 100-2-2
LM
769-F
CBZ
ATPM
AM
722-F
T2HF
~ x ~-in.
200-3TMT
TMT
771-F
RBZ
TMT
rE~ 200-3TTM
TTM
772-F
SBZ
TTM
CF
766-F
GBZ
FC
200-71-2
BCF
786-F
GH2BZ
BHFP
~ x ~-in. 200-8-2
LF
770-F
DBZ
FE
AF
723-F
T2HG
ATPF
FEMALECONNECTOR
BULKHEAD FEMALE
200-11-2
lxl 16-TA-I6
MALE AOAPTE. T U ~
'qmll- ~
Gyrolok Imperial Parker Tylok
~x~ 200-7-2
~x~
~ll~' ~ a~b,, ;.<.; F ~ , ~ , , , , , ,--. , ~ - EteC~ ~
FEMALE ADAPTER
TUBETOP . ' E
~x~
2-TA-7-2RT
(table continued on next page)
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Table 3-1 (continued) Swagelok
F ~
Gyrolok Imperial Parker Tylok
~x
RUNTEE ~ ; . J
200-3TFT
FEMALE BRANCH TEE
200-3TI'F
TFT
767-F
MBZ
TFr
TTF
777-F
OBZ
TTF
200-6
U
762-F
HBZ
IU
200-61
BU
782-F
WBZ
BHU
500-6-4
RU 756-F - -
~x '~
~4-in. 9 mmmmd
aUL~H~AOu.lo.
REDUCING
~,,~nn
eL"~IJ ~.JTEE
SWACdELOKTO AN UN|ON
m,mm~
poreeoNNer
a
~-9
RU
LU
765-F
EBZ
ELU
300-3
'Iq'T
764-F
JBZ
TTI'
400-4
C
752-F
KBZ
CR
~x 88 800-6-4AN
UAN
792-F
XHBZ
1,4 811-PC-4/6
2PC
m
Instrument Fittings and Monitors
Swagelok SWAGELOKTO MALE PIPEWELD CONNECTOR SWA
MALEpiPE I! 9 W1ELO ELBOWL J
~MALE CONNECTOR PIPETHREAD
~
Gyrolok Imperial Parker Tylok
88 x 88 400-1-4MPW
CW
LBW
--
ZHBF5
COS
--
T2HOA5
761-F
BZ
88
SWm~ELOK TO ANBULKHEAD .~m~
KN
BZB
88 404-1
~ L FRONT FERRULE
N
88 402-1K
C iBACK FERRULE
ZEBW2
COM
402-1
KNURLED NUT
2HBW
88 400-1-40R
CONNECTOR3 0 0 - 1 - O R
~
729-FSS
~ x
810-2-8MPW
O' SEAL STRAI GHT 3~6 X THREAD NUT
67
FR
760-F
--
--
403-1
FF
760-F
TZ
FCRC
200-6 I - 2 A N
BUAN
733-F
--
--
BA
785-F
T2H2BZ BHA
1~
88 nULKHEAOeEOUCEe
4 0 0 - A 1-4
(table continued on next page)
68
Pocket Guide to Instrumentation
Table 3-1 (continued) Swagelok
Gyrolok Imperial Parker Tylok
~x~6 .Eour~.
200-R-3
s**,;,:,.oK ~o,. 9o,Pr~:.
R
783-F
TRBZ
RATT
AAN
734-F
X6HBZ6 --
~x~ 200-A-2ANF
(text continued from page 64)
PARTS DISPLAYS A N D MANUALS The various manufacturers of the tube and tube fittings will be happy to supply your project with poster-type illustrations of their fitting with each component part shown in the illustration. There are manuals for tube fitting and installation that cover topics such as terminology, trouble shooting, types of fittings by number, and other data useful to the craftsmen on the job. Figure 3-3 is an example of the topics that appear in the manuals and catalogs. Request these manuals through your project manager.
HIGH-PRESSURE TUBE Frl'rlNGS Fittings for extreme pressures are shown in Figure 3-4. A typical use for high-pressure tube fittings and valves is illustrated in Figure 3-5, an oilwell tubing head. The Bourdon gauge (see inset in Figure 3-5) operates from force effect, and uncurls in response to internal pressure in a pro-
Instrument Fittings and Monitors
1 Simply insert the tubing into the SWAGELOK tube fitting. Make sure that the tubing rests firmly on the shoulder of the fitting and that the nut is finger-tight,
1
t
2 Before tightening the SWAGELOKnut, scribe the nut at the 6 o'clock position.
3 Now while holding the fitting body steady with a backup wrench, tighten the nut 1.1/4turns.~ Watch the scribe mark, make one complete revolution and continue to the 9 o'clock position.
Figure 3-3.
Installation instructions for tube fittings. (Courtesy of
Crawford Fitting Co.)
70
P o c k e t G u i d e to I n s t r u m e n t a t i o n
(e)
(B)
:
-~~
Figure 3-4. High-pressuretube fittings: tubing tee (A); tubing elbow (B); and tubing cross (C). (Courtesy of Autoclave Engineers, Inc.)
portional manner. The more sophisticated well heads have shut-down devices, automated flow controls, and are triple completed (or more), within the many strings of pipe. The wells can be controlled at several stagesmthe test separator, the disposal pit or caisson, on-off flow cycles, etc. If a line breaks, the pressure-drop activates a shut-down valve that closes the line immediately, and then sounds an alarm in the control panel.
IN-LINE FILTERS Small in-line filters remove contamination as small as two microns. The filter bodies are not removed from the
Instrument Fittings and Monitors
71
Bourdon gauge. (Courtesy of Transmation, inc.)
Figure 3-5. Typical oilwell head with valve and pressuregauge. (Courtesy of Autoclave Engineers, inc.)
line to change the elements. For sampling, a bypass feature is provided on some of the filters. There are several sizes of elements used depending on the size of the particles to be removed. Figure 3-6A shows the "TF" series of in-line fil-
72
P o c k e t G u i d e to I n s t r u m e n t a t i o n
(A)
(B)
(c)
Figure 3-6. In-line tube filters: TF series (A) and F series (B & C). (Courtesy of Nupro ~ Co.)
Instrument Fittings and Monitors
73
ters that offers a bypass version and easy in-line removal of the element; Figure 3-6B shows an "F" series, a compact model where space is limited (the element is also replaceable). Figure 3-6C is also an "F" series. Figure 3-7 illustrates two types of elements, a sintered and strainer. As fluid enters the filter, the stainless steel sintered element or strainer will stop the contamination, and permit the clean fluid to pass.
STEAM TRAPS Lost energy increases the cost of usable energy. Air escaping from under your door during the air conditioning
REPLACEMENT
-- SINTERED & STRAINER
SINTERED CONSTRUCTION Sintered 316 stainless steel filter elements in nominal micron sizes of 2 to 90, trap particulate contamination in the tortuous matrix. (Magnified 13X.)
WIRE MESH CONSTRUCTION 316 stainless steel mesh strainer elements available in 140, 230 and 440 micron sizes effectively remove large particle contamination. (Magnified 2X.)
Figure 3-7. Filter elements. (Courtesyof Nupro~ Co. 9Markad Service Co., all rights reserved.)
74
P o c k e t G u i d e to I n s t r u m e n t a t i o n
season will ensure a larger electric bill for you. The same applies to plants that lose money through steam leaks in steam tracing traps, line drip traps, and process traps. The primary purposes of steam traps on steam line and branch lines are to drain condensate, purge air and non-condensibles to assure dry steam supply to process equipment, and protect the steam piping system from erosion, corrosion, and water hammer. Steam tracing is used to provide a uniform temperature on process lines and equipment in hostile areas where freezing temperatures prevail. One of the most important services provided by traps is to prevent the accumulation of condensate from forming water slugs in lines. These slugs of water cause water hammer, which, when carried through a line at 100 mph, can cause serious damage to control valves, heating coils, and other components. Condensate forming in a line and an example of water hammer are shown in Figure 3-8.
Types of Steam Traps There are three major types of steam traps: s t e a m t r a p s , shown in Figure 3-9, are also known as "bucket traps." They work by the weight of the bucket, together with changing buoyant forces and the pressure differential across the seat, providing onoff discharge of condensate near steam temperature. Another style, which is furnished with a strainer, is the UniBody TM trap shown in Figure 3-9, bottom.
9M e c h a n i c a l
I n s t r u m e n t Fittings a n d M o n i t o r s
75
Condenllale Forming In Smarn Main
71177//III/i/i/!III
,//2//////,i~ll',i//.-/d///...
Figure 3-8. Condensate forming in main steam (top) to create water hammer; condensate trap (bottom). (Courtesyof YarwayCorp.) are activated by the temperature of the fluid reaching the trap. The thermostatic diaphragm type trap illustrated in Figure 3-10 is actually a complete condensate drainage station including a full-size Y-type strainer and blow-off valve. 9 T h e r m o d y n a m i c traps, as shown in Figure 3-11, are used with flash steam, which is caused by a system discharging hot condensate into a lower pressure system, developed during discharge of hot condensate to control the opening and closing of the trap. 9 T h e r m o s t a t i c traps
76
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Figure 3-9. Mechanical steam traps. (Courtesyof Yarway Corp.)
Four other traps are shown in Figure 3-12 to increase your ability to recognize the various styles of traps: A. A dual range trap that has two valvesmthe pilot valve, which functions thermostatically, and the main valve, which stays closed and opens when the pilot valve's load becomes excessive. B. A bimetallic steam trap for instrumentation and winterization tracings. The operating principle is based on two opposing forces.
I n s t r u m e n t Fittings a n d M o n i t o r s
77
Figure 3-10. Thermostatic diaphragm type steam trap.
(Courtesyo~ Yarway Corp.)
Figure 3-! 1. Thermodynamic steam trap.
(Courtesyof Yarway Corp.)
78
P o c k e t G u i d e to I n s t r u m e n t a t i o n
(A)
(s)
Figure 3- ! 2. Types of steam traps. (Courtesy of YarwayCorp.) C. Another bimetallic trap, which has a bimetallic pilot that controls a large diameter discharge valve, and operates on the principle based on two opposing forces. Used in large reboilers and heat exchangers. D. Also a bimetallic steam trap that operates similar to B and C.
I n s t r u m e n t Fittings a n d M o n i t o r s
(D)
Figure 3-12. Continued.
7'9
80
P o c k e t G u i d e to I n s t r u m e n t a t i o n
STEAM TRACING CONTROL VALVE It is obvious that operation costs would soar if steam lines used for tracing instruments and process lines had to be left open until some plant operator could shut them down, when the temperature is above freeze conditions. Figure 3-13 shows a temperature responsive ambient con-
Figure 3-13. TRACTM valve. (Courtesy
of Yarway Corp.)
81
Instrument Fittings and Monitors
trol valve. The valve automatically opens and closes at preset actuation points. Warm air causes the thermostat to expand, cold air causes it to close. Figure 3-14 shows the manufacturer's recommended installation plan, and is a good example of how the traps, drains, and tracing operate.
SAMPLE CYLINDERS These are used to safely and reliably contain pressurized fluid samples. They permit the safe handling of fluids during sampling and transporting to the laboratory. The cylin-
PIPE SIZE--SAME AS T RA C " VALVE A
C
E
B
s
A
A--Full ported stop valves End connechon not less than T R A.C. valve end connection. E)--Unions--mstalled on downstream side, only if needed. C--Yarway 901 (cast iron) or 921 (cast slee]) strainer, D--Test tee tor inspection.of T R A C. valve E - - T R,A.C valve F --I/2" Series 720 or 7 t 0 drip trap, with weather cap, to protect the system against condensate accumulation.
Figure 3-14. Piping plan for steam control. (Courtesy of YarwayCorp.)
82
P o c k e t G u i d e to I n s t r u m e n t a t i o n
ders are safe for corrosive, toxic, hazardous, or very expensive fluids. They meet applicable D.O.T. Specifications. Four styles of sample cylinders are illustrated in Figure 3-15. Smaller cylinders are also available and used to divide samples into several smaller samples that may be subjected to a series of analyses.
DETECTORS A N D M O N I T O R S Gas leaks out of the process areas can be detected by several means. One method is to use portable units, as
(B) ~ ' (c)
t
Figure 3-15. Samplecylinders.(Courtesy of Whitney Co. 9Markad Service Co., all rights reserved.) .
I n s t r u m e n t Fittings a n d Monitors
83
shown in Figure 3-16. One unit is equipped with a metal probe, rubber hose, and soft rubber aspirator, which draws a sample from manholes, bar holes, and passes it through the measurement cells. The two-position valve is first set in
Figure 3- lb. Combustible gas detectors. (Courtesyof Southern Cross Corp.)
84
P o c k e t G u i d e to I n s t r u m e n t a t i o n
the high range after purging with air. If the reading is very low in this range the valve is switched to the low range. No additional adjustment is required when switching from one range to another. The second portable unit is shown in the case on top of the metered unit. The flame pack, as it is called, is a sensitive, single-purpose gas leak detector. It uses the flame ionization principle and patented circuitry. A high-capacity, fully automated air sampling unit is also available, which mounts on the front of a vehicle, and will analyze the entire intake sample. Bar holes made in asphalt, if not plugged, may later enlarge to pot holes, and erode the plant paving area. Figure 3-17 shows how to patch bar holes made during leak detection periods. Figure 3-18 shows a pipe and cable detector (left) and a valve box and manhole locator (right). The Pipe Horn TM (left) can be used to trace wiring in buildings, telephone lines, ground wires, etc., as well as pipe and cables. The detector on the fight is used in conjunction with the Pipe Horn TM and can detect whether or not the object is directly over the buffed pipe or cable. It can also be used to locate cast iron drain lines, conduits, and piping in reinforced concrete slabs or walls.
INTERFACE DETECTORS A device that detects changes in the sound velocity rather than changes in density can detect different liquids in
Instrument Fittings and Monitors
i'~
"FILm.
'
"'~ , 9
9 .T_..~" ~ ' . ~ ~1"
'P
o
.
!
o
.
.
.
.
Figure 3-17. Bar hole plugs and sampling device. (Courtesyof Southern Cross Corp.)
85
86
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Figure 3-18. Pipe and cable detectors. (Courtesyof Southern Cross Corp.)
Instrument Fittings and Monitors
87
a pipeline, even liquids with the same specific gravity such as leaded or unleaded gasoline. Figure 3-19 illustrates the Nusonics | pipeline interface detector that applies microprocessor-based electronics to produce the sound velocity readings for petroleum products. There are no moving parts in the probe assembly.
FLOW SWITCH MONITORS/LEVEL INTERFACE CONTROLLERS Flow, level, and interface monitors are designed to sense variations in the heat transfer properties of any liquid or
Figure 3-19. Interface products detector. (Courtesyof Mapco Controls Co.)
88
P o c k e t G u i d e to I n s t r u m e n t a t i o n
gas. In this manner, reduction or stoppage of flow, loss of product, change in phase from wet to dry and dry to wet, or the interface between dissimilar products can be accurately detected. Figure 3-20 shows three flow switch monitors: (A) detects reduction or loss of flow in any liquid or gas; (B) responds to a change in flow rate or liquid level; (C) is extremely sensitive to low-flow rates. Similar devices include relief valve leakage monitors, sample rate verifiers, injection rate monitors, bearing lube oil monitors, bearing seal leak detectors, and low- and high-level pump start and stop alarms.
SPARE PARTS Most of the items described in this chapter, except the pipe fittings, may have spare parts sent to the project for future use. The spare parts are usually' on a separate purchase order and tagged as such. These items should be checked and received, left in their original cartons, labeled with project or client commodity code numbers, and then entered into the materials accounting system.
ACTUAL SIZES OF PIPE/TUBING Learning to instantly recognize pipe and tubing sizes may require considerable practice and skill, and at times
89
I n s t r u m e n t Fittings a n d M o n i t o r s
(8)
i
9
)-
(c)
Figure 3-20. Flow switch monitors. (Courtesyof Fluid Components, Inc.)
P o c k e t G u i d e to I n s t r u m e n t a t i o n
90
Actual Sizes Pipe/Tubing
1116" MPT I/8"RAPt 1/4" MPT
o !/16"
0 1/8" O 3/16"
O 1/4" O
5/16"
0
3/8"
Figure 3-21. Actual sizes of pipe/tubing. (Courtesyof Crawford Fitting Co.)
91
Instrument Fittings and Monitors
3/8"MeT~
0
1/2" s/8"
/2" MPT
3/4"
3/4M"PT
C ~ 7/8"
Figure 3-21. Continued.
may cause an incorrect size to be entered on the receiving report. Always measure the size of pipe or tubing, or use a template. Figure 3-21 shows the actual sizes for male nomi(text continued on page 95)
92
P o c k e t G u i d e to I n s t r u m e n t a t i o n
1" MPT
1"
1.1/4"
Figure 3-21. Continued.
93
I n s t r u m e n t Fittings a n d M o n i t o r s
I-I/2"
L
Figure 3-21. Continued.
94
P o c k e t G u i d e to I n s t r u m e n t a t i o n
11
| ~i i i
'
........ i iiiiiiiiiiiiii!iiii_ i
Figure 3-21. Continued.
95
Instrument Fittings and Monitors
o o 0
3mm 6mm
8mm
O0 lOmm
12mm
18mm
Figure 3-22. Actual sizesof pipe/tubing--metric. (Courtesyof
Crawford Fitting Co.)
(text continued from page 91)
nal pipe threads and tubing sizes. Figure 3-22 shows the actual sizes of metric tubing through 18mm.
4 Storage Batteries and Solar Modules
AC AND DC SYSTEMS FOR OFFSHORE APPLICATIONS When normal electrical power fails on an offshore drilling platform or on a production platform, nickel-cadmium block batteries supply the power for engine and turbine starting systems (Figure 4-1) and for emergency lighting and communications (Figure 4-2). This type of battery is also mounted on various configurations of racks, and each rack may contain several batteries.
Receiving the Shipment Unpack the batteries completely. Do not throw out small packages that may be in the packing materials. The batteries are shipped either filled and charged or empty and discharged. A plastic film is used as a transport seal on the
96
Storage Batteries and Solar Modules
97
Figure 4-1. Nickel cadmium battery for engine and turbine starting systems. (Courtesy of Sab Nife, Inc.) batteries. Never charge or discharge the batteries until the plastic seal is removed.
Safety Precautions The nickel-cadmium block batteries are an alkaline system with potassium hydroxide as electrolyte. The alkaline
98
P o c k e t G u i d e to I n s t r u m e n t a t i o n
" IIIIIIIIIIIIIIIIIIiiiiiiiiii
_
",
........
:
Figure 4-2. Nickel cadmium battery for emergency lighting and communications. (Courtesyof Sab Nile, Inc.)
electrolyte is a strong caustic agent, so wear rubber gloves, eye protection and long-sleeved clothing when handling the batteries. Remove tings, watches, and articles of clothing that may come in contact with the battery terminals. The
99
Storage Batteries and Solar Modules
Material: Hard PVC plastic Vents Material. Potyprol3ytene and stainless steel.
Plate Grot~ Bus connects the plate tabs w4h the terminal pOSt Plate tai3s and terminal post are projection wek:Jedto the plate group bus
dCetl Containqr , Material: Translucent po~prowlene
the plates and insulate the plate haines from each other The grids allow tree circulation of electrolyle belween Ihe Dlales
:
Prevents electrolyte Splash and possible shortcircuit by oblects i ~ r t e d in the cell.
h"~l:qate Groul~. Plate T ~ s~t-welded both Io the plale sk::lefr~u'nesand ~. to the uf]per edge of the ' pockel plate.
pockets and serves as a currenl collector i:1
%
~,,-,,-Rate with horizonlal pockets of ~ r f o r a l e d steel strq:)s Examiole of block designation: M 304-2 C.elllype M304 M-M-sertescell 3- PlateSiZe 04 NurrlDeloi rnoCluleI~alesin iftecell -2 Numberol cellsin Ilhelok~k
Figure 4-3. Cutawayview of nickelcadmiumbattery. (Courtesy of Sab Nife, Inc.) terminals are illustrated in a partial view of nickel-cadmium battery in Figure 4-3.
Storing Batteries Figure 4-4 illustrates several models of the nickel-cadmium block battery that you may store until project startup. Regardless of what kind of battery you may receive, never
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Fieure 4-4. Styles of nickel cadmium batteries. (Courtesy of Sab Nile, Inc.)
store a battery on a metal deck or on a concrete floor. Always store them on a decking of plywood or boards. The battery storage room should be dry, clean, and preferably cool. Fully discharged and empty batteries can be stored for an unlimited time, provided the cells are hermetically sealed. A battery filled with electrolyte that is to be stored for a maximum of one year should be charged before storing. No charging is needed during the storage period. However, before being put into service, the battery
Storage Batteries and Solar Modules
101
should be given a normal charge. The battery storage room should be vented. Battery gas is explosive.
PHOTOVOLTAIC SYSTEMS Figure 4-5 illustrates how the production of electricity starts as soon as sunlight strikes the photovoltaic module. Solar cells within the module will respond to the light by creating an electrical current that moves through the series of cells and is then stored in a battery, such as the one shown in Figure 4-6. Many photovoltaic systems are used offshore to produce current for warning lights and other components of the power system. A more simple example of how it works is
SOLAR CELL (A SILICON SEMICONDUCTOR DIODE)
Figure 4-5. Solar cell (silicon semiconductor diode). ( 9 Inc., a subsidiary of Atlantic Richfield Co.)
Solar,
102
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Figure 4-6. Batteryfor photovoltaic use. ( 9 Solar, Inc., a subsidiary of Atlantic Richfield Co.)
TYPICAL 12-VOLT )TOVOLTAIC SYSTEM.
SOLAR
Figure 4-7. Typical photovoltaic system. ( 9 subsidiary of Atlantic Richfield Co.)
Solar, Inc., a
103
Storage Batteries and Solar Modules
I
12.VOLT~
12-VOLT APPLIANCE
iNVERTER
APPLIANCE
Figure 4-8. Typical photovoltaic system. ( 9 subsidiary of Atlantic Richfield Co.)
Solar, Inc., a
shown in Figures 4-7 and 4-8, which illustrate a typical 12volt photovoltaic system. The production of electricity from direct sunlight allows power to be brought to remote areas for purposes ranging from emergency lighting to pumping water from a well in the desert. The applications of solar power are endless, and will continue to be used to
104
P o c k e t G u i d e to I n s t r u m e n t a t i o n
provide power where other systems would be prohibitively expensive.
Photovoltaic Module Figure 4-9 shows an ARCO SolarTM M81 Photovoltaic Module, which employs 33 electrically matched, single-cell crystal solar cells that directly convert sunlight into electricity. The module is suitable for a wide variety of lowpower applications, such as powering navigation aids, telemetry relay stations, valve control, auxiliary equipment, recreational vehicles, and maintaining the charge on storage batteries.
Figure 4-9. ARCO SolarTM photovolt'aic module. ( 9 Inc., a subsidiary of Atlantic Richfield Co.)
Solar,
Storage Batteries a n d Solar M o d u l e s
(~
105
TILTANGLE
TILT ANGLE HORIZON
Figure4-10. Tilt angle for solar module. ( subsidiary of Atlantic Richfield Co.)
9
Solar, Inc., a
Tilt Angles Figure 4-10 illustrates the tilt angle desired to ensure that maximum sunlight strikes the module(s). Consequently, the module must be tilted to be as perpendicular to the sun as possible at all times. Table 4-1 provides a suggested single position tilt angle for different locations throughout the world. (If your area is not listed, choose the closest city indicated on the chart.) Table 4-1 is presented here as an example only, and does not imply to be 100% accurate. It is
106
P o c k e t G u i d e to I n s t r u m e n t a t i o n
based on a nominal yearly average of plus or minus 10% ampere-hours per day. The performance in any given day may be quite different. (text continued on p a g e 113)
Table 4-1 Performance Guide
* 13.4V represents the charge voltage of a typical lead calcium battery operating @ 90% state-of-charge, 28~ temperature and a 2 amp charge rate.
Amp Hrs Generated By One M-61 Module Per Day Tilt Angle
Lat.
Location
27N 30N 34N 25N 23N 30N
Algeria, Aoulef Algeria, Beni-Abbes Algeria, Chottech Cherqui Algeria, Quallen Algeria, Tamanrasset Arab Rep. Of Egypt, Giza
41S 35S 28S 31S 35S 35S 38S 32S *9
9.93 10.39 9.24 10.40 10.77 9.43
35S 40S 55S 25S 25S 50S
Argentina, Bariloche Argentina, Buenos Aires Argentina, Corrientes Argentina, Rafaela Australia, Adelaide Australia, Canberra
6.44 7.83 8.13 4.92 8.29 8.63
65N 60N 50N 55N 60N 60N
Australia, Melbourne Australia, Perth
7.02 8.67
60N 55N
Solar, Inc., a subsidiary of Atlantic Richfield Co.
Storage Batteries a n d Solar M o d u l e s
107
33S 19S 48N 17S
Australia, Sydney Australia, Townsville Austria, Vienna Bolivia, La Paz
8.93 9.67 4.34 10.36
45N 25N 70S 25N
20S 59N 45N 54N 62N 46N
Botswana, Maun Canada, Churchill Canada, Dartmouth Canada, Edmonton Canada, Fort Simpson Canada, Montreal
9.65 6.81 5.71 7.46 5.25 5.73
20N 80S 70S 70S 85S 70S
44N 49N 12N 23N 34S 44N
Canada, Toronto Canada, Vancouver Chad, Ford Lamy Chile, Atacama Chile, Santiago China, Changchun
5.95 4.66 9.84 12.77 8.16 7.40
65S 70S 20S 30N 55N 60S
38N 31N 5N 4S 14N 63N
China, Chefoo China, Shanghai Colombia, Bogota Congo Republic, Brazzaville E1 Salvador, San Salvador Finland, Luonet Jarvi
7.65 6.76 7.38 6.92 9.83 3.98
55S 55S 15N 25N 20S 85S
49N 52N 48N 6N 38N
France, Paris Germany, Bochum Germany, Munich Ghana, Accra Greece, Athens
4.87 2.68 5.54 7.50 7.11
70S 75S 70S 15N 60S
12N 22N
Guinea-Bissau Hong Kong
9.35 7.42
20S 15S
(table continued on next page)
108
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Table 4-1
(Continued)
Amp Hrs Generated By One M-61 Module Per Day Tilt Angle
Lat.
Location
19N 23N 13N 6S
India, Bombay (Mumbai) India, Calcutta India, Madras Indonesia, Jakarta
4S 32N 32N 41N 46N 35N
Indonesia, West Irian Iraq, A1-Kut Israel, Jerusalem Italy, Napoli Italy, Palianza Japan, Nagoya
43N 36N 1S 35N 38N 34N
Japan, Sapporo Japan, Tokyo Kenya, Nairobi Korea, Puzan Korea, Seoul Lebanon, Ksara
15N 17N 20N 28N 23N 20N 18N 17N 28N
9.54 8.59 9.66 6.82
15S 15S 20S 15S
9.34 9.29 10.20 5.87 6.28 7.73
20N 50S 50S 65S 70S 25S
5.39 5.17 8.30 9.20 7.64 9.05
65S 40S 25N 25S 50S 55S
Manana Is., Saipan Mauritania, Nema Mexico, Mexico City Mexico, Nonoava Mexico, Cabo San Lucas Mexico, Tomatlan
9.18 8.70 9.23 10.81 9.04 9.10
25S 20S 15S 30S 35S 25S
Mexico, Tuxtla Guiterrex Mexico, Acapulco Morocco, Cabo Juby
7.20 9.09 8.81
15S 20S 35S
Storage Batteries and Solar Modules
109
23S 30N 9S
Namibia (SWA), Windhoek Nepal, Saga New Guinea, Merauke
11.34 8.56 7.31
20N 15S 30N
4S 18S 29S 41S 17N 7N
New Guinea, Rabul New Zealand, Nandi New Zealand, Raoul Is. New Zealand, Wellington Niger, Agadez Nigeria, Benin City
8.11 9.69 8.24 6.48 10.29 5.94
20N 30N 50N 65N 20S 15N
9N 60N 25N 30N 9N 12S
Nigeria, Yola Norway, Bergen Pakistan, Karachi Pakistan, Queta Panama, Panama Peru, Huancayo
8.14 2.72 8.69 10.52 7.16 11.68
15N 85S 15S 45S 15N 20N
15N 38N 19N 26N 24N
Philippines, Quezon City Portugal, Lisbon Puerto Rico, San Juan Saudi Arabia, Dhahran Saudi Arabia, Riyadh
7.03 8.77 10.41 9.74 9.55
25S 60S 20S 35S 35S
9N IN 41N 14N 20N 63N
Sierra Leone, Longo Singapore Spain Madrid Sudan, E1-Fasher Sudan, Port Sudan Sweden, Froson
7.09 6.56 7.33 9.20 9.37 4.41
15N 15N 65S 20S 25S 85S
56N 25N
Sweden, Svalov Taiwan, Taipei
3.86 5.35
80S 50S
(table continued on next page)
110
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Table 4-1
(Continued)
Amp Hrs Generated By One M-61 Module Per Day Tilt Angle
Lat.
Location
23N 24N 14N 3N 29S
Taiwan, Tainan Taiwan, Kwarenko Thailand, Bangkok Uganda, Moroto Republic, So. Africa, Alexander Bay Republic, So. Africa, Durban Republic, So. Africa, Capetown Republic, So. Africa, Pietersburg Republic, So. Africa, Pretoria Republic, So. Africa, Upington United Kingdom, Cambridge
8.53 7.08 8.17 10.31
15S 45S 20S 15N
11.26 8.41 9.41
45N 35N 55N
10.52 10.13 10.42 3.87
25N 25N 25N 75S
United States of America 32N AL, Montgomery 6IN AK, Bethel 65N AK, Fairbanks 62N AK, Matanuska 33N AZ, Phoenix 35N AR, Little Rock
7.55 6.41 5.19 5.60 10.50 7.29
55S 60S 90S 75S 45S 60S
39N 37N 34N 34N 40N 40N
8.27 8.42 9.57 10.28 8.40 10.27
60S 60S 50S 45S 50S 40S
30S 34S 24S 26S 29S 52N
CA, CA, CA, CA, CO, CO,
Davis Fresno Los Angeles Riverside Boulder Granby
Storage Batteries and Solar Modules
39N 30N 26N 34N 21N 44N
D.C., Washington FL, Gainsville FL, Miami GA, Atlanta HI, Honolulu ID, Boise
42N 40N 42N 38N 39N 38N
111
6.74 8.72 9.25 7.80 9.74 8.17
60S 45S 30S 55S 35S 65S
IL, Chicago IN, Indianapolis IA, Ames KN, Dodge City KN, Manhattan KY, Lexington
4.57 6.46 7.10 10.27 7.35 8.09
65S 65S 65S 45S 60S 60S
30N 32N 44N 42N 43N 46N
LA, New Orleans LA, Shreveport ME, Portland MA, Boston MI, E. Lansing MN, St. Cloud
6.35 7.32 7.49 5.92 6.29 7.50
55S 55S 65S 65S 65S 70S
39N 47N 41N 36N 40N 35N
MO, St. Louis MT, Great Falls NM, N. Omaha NV, Las Vegas NJ, Sea Brook NM, Albuquerque
7.11 7.85 8.09 10.89 6.55 11.64
60S 70S 60S 45S 65S 40S
41N 39N 36N 47N
NY, New York City NC, Ely NC, Greensboro ND, Bismark
6.26 10.81 7.43 8.51
65S 50S 60S 65S
(table continued on next page)
112
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Table 4-1
(Continued)
Amp Hrs Generated By One M-61 Module Per Day Tilt Angle
Lat.
Location
41N 35N
OH, Cleveland OK, Oklahoma City
6.08 9.21
65S 50S
42N 40N 41N 33N 44N 36N
OR, Medford PA, Pittsburgh RI, Newport SC, Charleston SD, Rapid City TN, Nashville
7.20 4.76 6.68 7.95 9.39 6.85
65S 65S 65S 55S 55S 60S
32N 33N 41N 38N 47N 48N
TX, Big Spring TX, Fort Worth UT, Salt Lake City VA, Richmond WA, Seattle WA, Spokane
9.20 8.95 8.24 6.61 5.43 7.37
45S 50S 65S 60S 70S 70S
38N 43N 43N
WV, Charleston WI, Madison WY, Lander
6.61 6.88 11.03
60S 65S 45S
46N 43N 60N 35S I0N llN
USSR, Odessa USSR, Vladivostok USSR, Leningrad Uruguay, Montevideo Venezuela, Barcelona Venezuela, Maracaibo
5.68 7.86 3.58 8.49 8.75 8.67
70S 35S 85S 60N 20S 20S
13N 45N
Yeman, Aden Yugoslavia, Beograd
9.31 5.64
20S 70S
Storage Batteries and Solar Modules
12S 1N 20S
Zaire, Lubumbash Zaire, Kisangani Zimbabwe, Bulawayo
8.20 7.29 10.16
113
15S 15N 15N
(text continued from page 106)
SUMMARY OF SOLAR MODULE SYSTEM A complete photovoltaic system contains one or more solar modules, a structure to mount the modules, a battery storage system, and a charge control device to prevent the batteries from overcharging. In comparing solar modules, the most important consideration is the ability to charge batteries, not the number of cells. Increasing the number of cells might increase the voltage to the theoretical maximum power point, but past a certain point that voltage is not usable.
GLOSSARY OF TERMS USED IN SOLAR APPLICATIONS A C (alternating current)--An electrical current that reverses from a positive to a negative voltage, changing at regular intervals and constantly changing in magnitude. Expressed in cycles per second or hertz, it is the current commonly used in household electricity. Ampere or AMP--The standard unit for measuring the rate of flow of an electrical current. One ampere will flow when one volt is applied across a resistance of one ohm.
114
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Array--More than one solar module joined together forming a group of modules. CapacitymThe amount of stored electricity in a battery, measured in amp hours. CurrentmThe net transfer of electric charge per unit of time propelled by voltage. Expressed in amperes. Cycle life~A measure of how many times (cycles) a battery may be charged or discharged to a given state of charge until the capacity is reduced to 89% of original. DC (direct current)--The direct or constant flow of electrical current in one direction, from the negative to the positive potential. Produced by batteries and by solar modules. Load~The appliance consuming electricity generated by the solar system. Module~The lowest denominator of encapsulated solar cells, another name for a single solar panel containing numerous cells. Photovoltaic~Capable of generating a voltage as a result of exposure to light. State of chargemA measure in percentage of how much of total capacity is contained in battery storage. Solar cell~The basic unit of measuring electrical pressure that causes electricity to flow. Watts~The unit of measuring electrical power, equal to the power developed in a circuit by current of one ampere flowing through a potential difference of one volt. (Simply, volts • amps = watts.)
S t o r a g e Ba t teries a n d S o l a r M o d u l e s
115
BATTERIES FOR ELECTRONIC DEVICES The performance of an electronic device is only as good as the battery inside it. The service life of high-performance batteries has been improved significantly in recent years, and it continues to improve. Today's batteries produce a high-energy output, are reliable, have a long shelf life, and are excellent in low-temperature applications. Detailed technical information on all types of batteries is readily available from the various battery manufacturers.
Types of Batteries Alkaline-manganese dioxide, mercury oxide, silver oxide, zinc air, and lithium/manganese dioxide batteries are compared in Table 4-2, and shown in Figure 4-11. (Refer to the Glossary of Terms Used in Battery Applications.)
Storing Batteries Extra batteries should be stored in a dry place at normal room temperature. Refrigerating batteries is not necessary. Extreme heat or cold reduces battery performance. If batteries must be stored in either hot or cold conditions, alkaline batteries will generally perform better in these conditions than regular carbon batteries. (text continued on page 118)
Table 4-2 Battery Characteristic Comparison Principal Chemical Systems
General Characteristics (under optimum operating conditions)
AlkalineManganese Dioxide (Zn/Mn02) Mercuric Oxide (Zn/HgO)
Popular, multi-use premium battery; good low temperature and high rate performance; good shelf life; sloping discharge characteristic. High volumetric capacity; good shelf life; flat discharge characteristic.
Silver Oxide (Zn/Ag,O) Zinc Air (Zn/Od
High gravimetric capacity; good shelf life; flat discharge characteristic. Highest energy density on continuous discharge; excellent shelf life (unactivated); moderate rate capability limited shelf life when activated; flat discharge characteristic. High energy density; excellent rate capability and low temperature performance; excellent shelf life; relatively flat discharge characteristic.
Lithium/ Manganese Dioxide (Li/Mn02)
*Courtesy of Duracell, Inc.
Confi urations
Nominal
anc?Rated Capacity*
Voltage
Cell
Cylindrical cells to 20 Ah; also available in small button cells.
1 .s
Button and cylindrical cells from 40 mAh to 13 Ah; also available in special larger sizes. Button cells to 180 mAh for specialized applications. Button cells to 6.6 Ah.
I .35
Coin cells to 550 mAh; spiral-wound cylindrical cells to 1.3 Ah; cylindrical (bobbin-type) cells to 1.9 Ah
3.0
I .5 1.4
Principal Chemical Systems
Energy Density Weight Volume Wh/lb. Wh/kg Wh/in.3 Wh/l
AlkalineButton: Manganete Cylindrical: (Zn/MnO,)
25 60
55 I30
2.4 5.8
Mercuric Oxide (Zn/HgO)
50 55
110 I20
7.3 7.4
60
I30
8.2
310
19.0
Button: Cylindrical:
Silver Oxide Button: (Zn/Ag,O) Zinc Air (Zn/OL)
Button:
I40
Lithium/ Manganese Dioxide (Li/Mn02)
Coin: Cylindrical: Spiral-Wound Bobbin:
80
I75
8.3
I05 135
230 300
8.3 10.1
Courtesy of Duracell, Inc
Typical Applications
Shelf Life (% loss/year
Typical Operating @ 70°F) Temperature
145 General purpose, e.g., lighting, 3% 350 photographic equipment, toys, radio and T.V.. tape recorders, watches and instruments. Popular for high drain application\. 445 Hearing aidr, medical and photo4% 450 devices, pagers, detection and emergency equipment, and other applications requiring steady output voltage. 500 Hearing aids, watches, photo6% graphic equipment, and special electronics requiring small, high capacity batteries. 1,150 Hearing aids, medical monitoring 2% instruments, pagers, hand-held (unactivated) portable two-way radios, telephones, emergency lighting, and other frequent use applications. 505 General purpose in photographic 0.5-I% and electronic applications requiring 505 small, high power batteries, e.g., 615 calculators, lighting, clocWcalendar, memory-backup, photoflash, motordriven cameras, medical equipment and instruments.
-4°F to 130°F (-20°C to 54°C)
15°F to 130°F (-9°C to 54°C)
-4°F to 130°F (-20°C to 54°C) 32°F to 122°F (0°C to 50°C)
-40°F to 140°F (-40°C to 60°C)
118
Pocket Guide to Instrumentation
,,,~p,+......
! J
Alkaline
Figure 4-1
Lithium
1. Primary battery systems.
Mercury
(Courtesyof Duracell, Inc.)
(text continued from page 115)
Safety Tips 9Keep battery contact surfaces clean by wiping them off with a pencil eraser or rough cloth. 9Never dispose of batteries in a fire, as the batteries may explode.
Storage Batteries and Solar Modules
119
9Don't carry loose batteries in your pocket or purse, as the batteries can be shorted by contact with metal objects, and may leak or rupture. 9Never attempt to recharge a battery unless it is specifically marked "rechargeable." 9Replace batteries in your equipment with the manufacturer's suggested type and size. 9Always make sure that the positive and negative terminals on the battery are aligned properly when inserting them into your equipment. 9Remove batteries from equipment that will not be used for several months or longer.
GLOSSARY OF TERMS USED FOR BATTERIES*
Ambient Humidity The average humidity of the surroundings.
Ambient Temperature The average temperature of the surroundings.
Ampere-Hour Capacity The quantity of electricity measured in ampere-hours (Ah) which may be delivered by a cell or battery under specified conditions.
Anode The electrode in an electrochemical cell where oxidation takes place. During discharge, the negative electrode of the cell is the anode. *Courtesy of Duracell, Inc.
! 20
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Battery Two or more electrochemical cells electrically interconnected in an appropriate series/parallel arrangement to provide the required operating voltage and current levels. Under common usage, the term "battery" is often also applied to a single cell.
Bobbin A cylindrical cell design utilizing an internal cylindrical electrode, and an external electrode arranged as a sleeve inside the cell container. C Rate (also see Hourly Rate) Discharge or charge current, in amperes, expressed in multiples of the rated capacity. For example, C/20 discharge current for a battery rated at 5-h discharge rate is: C 5 (AH) -- current (A) 20
As a cell's capacity is not the same at all discharge rates and usually increases with decreasing rate, a discharge at the C5/20 rate will run longer than 20 hours. Capacity The total number of ampere-hours or watt-hours that can be withdrawn from a fully charged battery under specified conditions of discharge.
Storage Batteries and Solar Modules
12 l
Capacity Retention The fraction of the full capacity available from a battery under specified conditions of discharge after it has been stored for a period of time.
Cathode The electrode in an electrochemical cell where reduction takes place. During discharge, the positive electrode of the cell is the cathode. Cell The basic electrochemical unit used to generate or store electrical energy.
Closed-Circuit Voltage (CCV) The potential or voltage of a battery when it is discharging.
Continuous Test A test in which a battery is discharged to a prescribed end-point voltage without interruption. Coulomb The amount of electricity transported by a current of one ampere flowing for one second.
Current Collector An inert member of high electrical conductivity used to conduct current from or to an electrode during discharge or charge.
! 22
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Current Density The current per unit active area of the surface of an electrode. Cutoff Voltage The battery voltage at which the discharge is terminated. The cutoff voltage is specified by the battery manufacturer and is generally a function of discharge rate.
Depth of Discharge The ratio of the quantity of electricity (usually in ampere-hours) removed from a battery to its rated capacity.
Discharge The conversion of the chemical energy of a battery into electrical energy, and the withdraw of the electrical energy, usually in order to operate and electronic device.
Discharge Rate The rate, usually expressed in amperes, at which electrical current is taken from the battery.
Drain The current withdrawn from a battery during discharge. Dry Cell A cell with immobilized electrolyte. The term "dry cell" is often used to describe the Leclanche cell. Duty Cycle The operating regime of a battery including factors such as charge and discharge rates, depth of discharge, cycle length, and length of time in the standby mode.
S t o r a g e Ba tt eri es a n d S o l a r M o d u l e s
123
Electrochemical Equivalent Weight of a substance that is deposited at an electrode when the quantity of electricity which is passed is one coulomb.
Electrode The site, area, or location at which electrochemical processes take place.
Electrolyte The medium which provides the ion transport mechanism between the positive and negative electrodes of a cell.
End Voltage The prescribed voltage at which the discharge (or charge, if end-of-charge voltage) of a battery may be considered complete (also cutoff voltage).
Energy The output capability of a cell, usually expressed in watthours, which is the ampere-hour capacity multiplied by the average discharge voltage.
Energy Density The ratio of the energy available from a battery to its volume (Wh~) or weight (Wh/kg).
Forced Discharge Discharging a battery, with external battery or power source, below zero volts into voltage reversal.
] 24
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Gassing The evolution of gas from one or more of the electrodes in a cell. Gassing commonly results from local action (selfdischarge) or from the electrolysis of water in the electrolyte during charging.
Hertz The standard unit of frequency. A frequency of one complete cycle per second is a frequency of one hertz. Hourly Rate (also see C RATE) A discharge rate, in amperes, of a battery which will deliver the specified hours of service to a given end voltage.
Intermittent Test A test during which a battery is subjected to alternate periods of discharge and rest according to a specified discharge regime.
Internal Impedance The opposition exhibited by a circuit element (cell or battery) to the flow of an alternating current (a.c.) of a particular frequency as a result of resistance, induction and capacitance.
Internal Resistance The opposition exhibited by a circuit element to the flow of direct current (d.c.). In a cell, the internal resistance is the sum of the ionic and electronic resistances of the cell components.
Storage Batteries a n d Solar M o d u l e s
! 25
Limiting Current The maximum current drain under which the particular battery will perform adequately under a continuous drain. The rate is based on whatever drain rate reduces the running voltage to 1.1 volts.
Midpoint Voltage The voltage of a battery midway in the discharge between the fully charged state and the end voltage.
Nominal Voltage The characteristic operating voltage or rated voltage of a battery (as distinct from Working Voltage, Midpoint Voltage, etc.)
Open-Circuit Voltage (OCV) The difference in potential between the terminals of a cell or voltage when the circuit is open (no-load condition).
Parallel Term used to describe the interconnection of cells or batteries in which all the like terminals are connected together.
Positive Temperature Coefficient (PTC) Device A thermally reactive device which becomes highly resistive at a specific temperature.
Polarization The lowering of the potential of a cell or electrode from its equilibrium value caused by the passage of an electric current.
126
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Primary Battery A battery which is not intended to be recharged and is discarded when the battery has delivered all its electrical energy. Pulse Current A periodic current drain of higher than normal drain rates.
Rated Capacity The number of ampere-hours a battery can deliver under specific conditions (rate of discharge, end voltage, temperature); usually the manufacturer's rating.
Reversal The changing of the normal polarity of a battery due to overdischarge.
Safety Vent A venting mechanism designed into a cell which activates under specific conditions of abuse to relieve internal pressure.
Self-Discharge The loss of useful capacity of a battery in storage due to internal chemical action (local action).
Separator An ionic permeable electronically nonconductive spacer which prevents electronic contact between electrodes of opposite polarity in the same cell.
Storage Batteries and Solar M o d u l e s
127
Series The interconnection of cells in such a manner that the positive terminal of the first is connected to the negative terminal of the second, and so on. Service Life The period of useful life of a primary battery before a predetermined end-point voltage is reached. Shelf Life The duration of storage under specified conditions at the end of which a battery still retains the ability to give a specified performance. Short-Circuit Current (SCC) The initial value of the current obtained from a battery in a circuit of negligible resistance. Spiral-Wound An electrode structure of high surface area created by winding the electrodes and separator into a spiral-wound, jelly-roll configuration.
Voltage Delay Time delay for a battery to deliver the required operating voltage after it is placed under load. Working Voltage The typical voltage or range of voltage of a battery during discharge (also called operating voltage or running voltage).
5 Miscellaneous Electrical and Instrumentation Items
CABLE A N D WIRE TIES Wires and cables go through a maze of paths in a project--up and down, around and inside of tight comers, and then the same over again. Figure 5-1 shows a few of the types of cable ties used to anchor the wires and cables to each other and to objects in the path.
WIRE A N D TERMINAL MARKERS Thousands of self-adhesive strips printed with numbers, letters, symbols, etc. are mounted on dispenser cards. There are many similar type markers for voltage ratings, tape for color coding, safety stripes, and aiste marking. Figure 5-2 depicts some of the types of markers and their use. Wider
128
M i s c e l l a n e o u s Electrical a n d Instrumentation Items
129
(A)
(B) ,| I
~_ z-~_~F ~,.~--~ I
:~--_:~;-,~A~--
!
I
(E)
~I
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5-I. Cable ties:Panduit Pan-T~ nylon ties(A), black weather-resistant cable ties (B); PCL clamps (C); lashing ties (D); and push mount ties (E). (Courtesyof Jaqua-McKee, Inc.)
strips and different methods are available for marking wires, cable, conduit, telephone line, systems, etc.
WIRE CONNECTORS Figure 5-3 illustrates only a few of the many styles of wire connectors. Crimp type connectors are used for small (text continued on page 132)
130
P o c k e t G u i d e to I n s t r u m e n t a t i o n
SIZES TO FIT ALL WIRES
1~" Long Standard Markers for wires up to ,~" O . D .
~
3 ~
31
~lli
: iii i ~ - - -
~4" Long Standard Markers for wires up to %" O.D.
~*'~ --
1~,, Long Miniature Markers for wires up to '/~" O . D .
~"~III~W|I~IIKUM~II|K.-PlIiI~IIIIII~AUI~IIII|IlI|IL|KSIIIIKI t...~777"7"77'7777'7'7"7'7'7"77'7'777'7777"7'77 -17777777777777777777777777777~ '77777777777777777777~,7717777 ~,~7"777777777'7777777777777777777 ? ? ~ t 77777777777777777777777"777773 7777.7
[
Figure 5-2. Wire and terminal markers. (Courtesy of Jaqua-McKee,
Inc.)
Miscellaneous Electrical and Instrumentation Items
13 |
(I)
(6)
(7)
(2) (3) (4)
(5)
Figure 5-3. Wire connectors: crimp type (1); Scotchlok| ring tongue terminal (2); spade tongue (3); female quick-slide connector (4); butt connector (5); Scotchlok aluminum one-hole lug (6); two-hole lug (7); Ideal wire-nut connectors (8). (Courtesy of Jaqua-McKee, Inc.)
132
Pocket Guide to Instrumentation
(text continued from page 129)
wire gauges. Several styles of the connectors are shown in (1) and enlarged in the other views. The connectors are color coded for size range, and have internal barrel serrations to grasp the wire strands firmly. A crimping tool is used to apply the connectors. In Figure 5-3, (2) is a Scotchlok ring tongue terminal; (3) is a spade tongue; (4) is a female quick-slide connector; (5) is a butt connector; (6) is a Scotchlok | aluminum one-hole lug; (7) is a two-hole lug; and (8) shows Ideal wire-nut connectors that are simply twisted on the ends of two wires to be joined, and provide a tight wire grip. The nuts are identified for size by color coding.
SPLICING KITS Larger cables require more elaborate splicing methods. Figure 5-4A is the 3M 5400 series quick-splice incline splicing kit. The kit contains everything needed to make a splice that consists of a slip-on insulation body, and two end caps. The splice insulates and seals for a water proof connection for direct burial. Figure 5-4B is the Scotchcast 82-A1, 2, 3 splicing kit used for splicing nonshielded cables rated up to 5KV. (Multi-conductor cables rated up to 600 volts.) The kits have a two-piece, transparent snaptogether mold body. The ends are sealed, and then a resin is poured into the mold until it rises in the funnel. After 30 minutes, the splice is ready. Figure 5-4C shows Scotch brand 5701, 1, 3 K Tape termination kits. These kits con-
Miscellaneous Electrical and Instrumentation Items
| 33
(A)
(C)
(D)
Figure 5-4. Wire splicing kits. (Courtesyof Jaqua-McKee, Inc.)
134
P o c k e t G u i d e to I n s t r u m e n t a t i o n
tain enough tape to make three terminations, and are designed to terminate cables from 5 to 15 KV. Figure 5-4D is the 3M porcelain termination kit. The kits are designed to terminate single-conductor cables rated from 5 to 25 KV. They contain a wet process porcelain insulator and materials for the termination.
THERMOCOUPLES A N D ACCESSORIES The measurement of temperature is one of the most vital functions in the control of manufacturing and processing operations. At the heart of all temperature measurements is the thermocouple. The concept of all thermocouples is the same. Two wires of dissimilar metal are joined together at one end. An increase in temperature creates an electronic force (emf) or voltage, which is transmitted through these wires to a monitoring device that reads this signal and displays it on a previously calibrated meter or digital device. Figure 5-5 shows the thermocouple and some of the accessories used in a system: A. The thermocouple element with a t.c. head, and thermocouple wire (extension cable). B. A thermowell. (The thermocouple element screws directly into the thermowell either in a process line or process vessel.)
135
Miscellaneous Electrical and Instrumentation Items
iI~~THERMOCOUPLE HEAD
EXTENSION CABLE
(B)
MONITOR
(D)
..
Figure 5-5. Thermocoupleand thermowells. (Courtesyof Alpha
Wire Corp.)
136
P o c k e t G u i d e to I n s t r u m e n t a t i o n
C. Thermocouple head on pipe nipple. (The element is inside the pipe nipple. Base metal thermocouple.) D. Ceramic protection tubes for use in very high temperature areas. Figure 5-6 shows insulators for thermocouple wire used in high temperature areas.
Ip
Figure 5-6. Thermocouple insulators for elevated temperatures.
(Courtesy of Alpha Wire Corp.)
Miscellaneous Electrical and Instrumentation Items
| 37
E. An alternative to ceramic thermocouple connectors are molded-on Zenite TM 6130 thermocouple connectors from DuPont. These are color coded to match the thermocouple in the circuit. They sell for $7 to $9 less than ceramic thermocouple connectors. Figure 5-7 shows thermocouples made from liquid crystal polymer resin. Figure 5-8 shows more thermocouple items plus connectors and connector blocks. Make sure all small items for thermocouples are tagged with their part number (leave in manufacturer's carton if possible), and your commodity code number. Thermocouple assemblies are made from
Figure 5-7. Low-cost, high-temperature ZeniteTM LCPthermocouples.
(@Copyright Omega Engineering, Inc. All rights reserved. Reproduced with permission of Omega Engineering, Inc., Stamford, CT 06907.)
138
P o c k e t G u i d e to I n s t r u m e n t a t i o n
\
Figure 5-8. Thermocouple sensors and accessories. (Courtesyof
Alpha Wire Corp.)
Miscellaneous Electrical and Instrumentation Items
| 39
brass, carbon steel, stainless steel, and monel. Thermocoupies will be engineered and tagged for a specified project location.
GAUGE GLASSES Level gauges mount on the outside of vessels usually on a bridle with other instrument items attached as well by pipe nipples and valves. The three liquid level gauges with transparent windows are types TL, TCL, and TM (Figure 5-9). These gauges will be tagged for a specific unit or application.
TL
TM
TLC
Figure 5-9. Gaugeglasses.(Courtesy of Richardson Engineering Services, Inc.)
140
P o c k e t Guide to Instrumentation
VIBRATION CONTROL Fittings such as those shown in Figure 5-10 are used to control vibration on pumps, motors, and other applications in the process system. Illustrated are: 1. Stainless steel hose and braiding. Carbon steel nipples and braid ferrules are standard in this type of flexible hose connector. 2. A stainless steel braided connector with plate carbon steel flanges. 3. The expansion joint has heavy pipe attached to a stainless steel bellows. 4. The same expansion joint described in (3) but this one has carbon steel plate flanges.
THERMOMETERS Only a few thermometers are shown in Figure 5-11. The types shown are most common and typical for use on vessels. Thermometers are described by their range (i.e., 30 to 240~ size of dial (i.e., 4-in.), and style of connection (i.e., back connection, adjustable angle, bottom connection, and flexible extension). Note in Figure 5-11 the element is screwed into the thermowell on the thermometer on the fight. (text continued on page 143)
M i s c e l l a n e o u s E l e c t r i c a l a n d I n s t r u m e n t a t i o n 1terns
(1)
(3)
Figure 5-10. Flexible pump connectors and expansion joints. (Courtesy of Richardson Engineering Services, Inc.)
| 41
142
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Back Connection
Adjustable Angle
Bottom Connection
Figure 5-1 1. Thermometers. (Courtesy of Richardson Engineering Services, Inc.)
Miscellaneous Electrical and Instrumentation Items
| 43
PRESSURE GAUGES Figure 5-12 shows only five of the hundreds of styles and types of pressure gauges. Gauges are described by their pressure range (i.e., 0 to 15,000 psi), the size of the dial (i.e., 4 89in.), the type of case (i.e., brass or black steel), and the bourdon tube, which is the heart of a gauge, being a
Figure 5-12. Pressuregauges. (Courtesyof Autoclave Engineers, Inc.)
144
P o c k e t G u i d e to I n s t r u m e n t a t i o n
curved tube with a flattened cross section and closed on one end. The crystal may be made of acrylic, glass, laminated safety glass, or other types of clear product. The connection size and the mounting options can be bottom mount, back mount, etc. Some gauges are equipped with a blow out back for pressure relief in case of bourdon tube failure. Some have a pointer zero adjustment located on the front of the gauge behind the dial cover. Gauges can be equipped with adjustable low and high electrical contacts to provide pressure control for automatic or remote operation, or for fail-safe points. Store the gauges in their manufacturer's cartons. Never apply oil or other chemicals to the threads or any other parts of the gauge. The gauges will be engineered for a specific location in the project, and will be tagged as such. Only the extra gauges for spares will not be tagged to specific locations. Check the dial face for damage when gauges are received. Never issue a gauge for use in pressures that may exceed the ratings.
EXPENDABLE ITEMS One of the very first material shipments to arrive at a project when process unit construction has commenced are the expendable electrical items. The materials, after the receiving formalities have been accomplished, should then be submitted to the craft foreman for his signature and reissued to the electricians. (On large projects, this system
Miscellaneous Electrical and Instrumentation Items
145
may not be feasible. Request advice from the project manager through your supervisor.) Expendables may consist of various quantities of the following materials: Hex head cap screws, lockwashers, flatwashers, hex nuts Wire terminals, tongue and blade Electrical tape Glyptol and thinner Wire markers Thread cutting oil Insulating tape Scotchlok| types Y and R Chico A3 and Chico Fibre Duxseal Wire pulling compound Ty-rap Cans thread lubricant Bills of materials may vary from project to project for expendable materials. They are a very important part of any project.
6
Bar Coding Systems
Bar coding systems are widely used throughout the world for accuracy, cost reduction, speed, accounting, time keeping, material control, identification, and tracking, and are very flexible for adding your own applications. For materials control in field warehouses, the bar codes may be prepared along with purchase orders from data stored in a text file and retrieved to print whenever required. Numbering systems or commodity code numbers already existing in the users' archives may already be used in your facility, but if not, you may consider the uniform-universal system for the construction industry worldwide that is suggested later in this chapter. The flexibility in preparing your bar code labeling allows you to have full control of the size, design, and layout of the labels or plates. In addition to the bar code itself, labels can include text, graphics, radio frequencies, and fields merged from data files. You'll find more details about bar coding on the Internet. There are other information sources such as books, trade magazines, trade shows, and even your favorite computer store. 146
147
Bar Coding Systems
"Bumpy bar codes" have been created by Norcom Electronics Corporation. These codes are ideal for harsh environments, and are virtually indestructible during sandblasting and painting. They stand up to high temperatures, moisture, solvents, and chemical baths, and can last the life of the object as permanent identification. The 3-D bumpy bar codes are scanned by a bar code reader that "reads" the height differences between the bars and spaces rather than traditional character contrast. Norcom's Endure 1800 Series machine can emboss 15,000 characters per hour onto metal plates of various sizes. Examples of these plates are shown in Figure 6-1.
~
", miuterg ) I.D.Tags
metal
I
Imprinter StationPtetes
StandardI~nl~'RetidlCords
flddressPlates StaredC~deT~]lS
I
"- o I I 1 ~ Tags
f .,~m.
-]
L O OutomotigePlates 0 I s ~ J o.d n,uq r ~ .
[o
n u t m u ~ rot,,
o]
PlMesare shown at lessthan edual size.
Figure 6-1. Variety of plate sizes. (Courtesy Norcom Electronics Corp.)
148
P o c k e t G u i d e to I n s t r u m e n t a t i o n
To run a bar codes system on your PC, the latest Windows software will probably suffice. However, it will be wise to consult your dealer about selecting a bar code system for your applications. Software is available to print label bar codes on any laser jet printer for normal use. Bar codes may be printed on any suitable printer for testing and practice. A simple system for entry level tracing, inventory, shipping/receiving, and document control is used as an introduction to bar coding. TimeWand II | offers suitable memory, programmability, and hardware features for demanding applications. This unit is is available in 128K and 320K. The unit is the size of a credit card and weighs 2 ounces (see Figure 6-2). A fully portable bar code reader, the Videx | TimeWand | can be used as a remote system, as shown in Figure 6-3.
Figure 6-2. TimeWand| portable bar code reader. (Courtesy of Videx~, Inc.)
Bar Coding Systems
149
Remote (via Modem) System Singleor Multiple
Cable to Modem (25 pin)
V-TWC-003 ~ T . . . . . Z . . . _
Downloader/Recharger
to Host Computer
TimeWand /
~
~
J
v..1-91.016 16k memory
Modem
Figure 6-3. Remote bar code systemvia modem. (Courtesyof TimeKeepingSystems,Inc.) These small bar code readers will fit in a shirt pocket. Each contain an internal clock, and time-stamp each code as it is read. Because the communication is keyless, the scanned information is error free (see Figure 6-4). On a project, different craftsmen could use these types of code readers while performing their varied duties. As bar codes are read with the TimeWand | a beeper indicates a good or bad read, and whether the TimeWand | is nearly full or full of data. It can operate up to three days without recharging, and can be recharged overnight in the Downloader/Recharger units, as shown in Figure 6-5. Code data stored in the TimeWand | is transferred to a PC by means of the Downleader/Recharger unit. For use by various employees in a large fabricating facility, a multiple
150
~.~"~,~;. X
P o c k e t G u i d e to I n s t r u m e n t a t i o n
~i
-
Figure 6-4. Portable TimeWand II| bar code reader. (Courtesy of
ViJex ~, Inc.)
Additional Single Downloader/Rechargers can be daisy chained using an interconnect cable, V-TWC-O06
Cab~ lo PC/XT (2~ pro) V-TWC-001 -or-
9.......
TimeWz~i V-TW-OI 6 10k memory
/
S i n ~ Downloid~r/Recluurg~r v-'rWR..O00
Cable to PC/AT 19 pin) V-TWC-00$
Caddieto Maclnto~ (25 pin) V-TWC-005
Figure 6-5. Single TimeWand| System. (Courtesyof TimeKeeping
Systems, Inc.)
Bar Coding Systems
151
Downloader/Recharge unit, consisting of a controller and up to 25 add-ons, can be downloaded via one serial port (see Figure 6-6). After downloading, the TimeWand | can be stored overnight for recharging, and the various reports printed from the PC as required. Bar coding is exciting and has the potential for many different applications in the future, such as for picking and placing parts, keeping medical records, tracking waste dis-
TimeWand
V-TW4)I6 16k memory Multiple Downloader/Recharger Controller
V-TW4)02 Cable to PC/XT(25 pin) V-TWC-001
i I
-Of-
Cable to PC/AT (9 pin)
V-TWC-O08 -or-
Cable to Macintosh (25 pin)
V-TWC4)05 %
Multiple Downloader/Rechaxger Add-On "~'~,~
V-TWR-003
Figure 6-6. Multiple TimeWand| System. (Courtesyof TimeKeeping Systems, Inc.)
152
P o c k e t G u i d e to I n s t r u m e n t a t i o n
posal, evaluating currency exchange, recording debit cards, and on and on, even to invisible asset marking for moving and tracking property within your complex, or for tracing stolen assets. Numbering systems can vary to include a numeric and verbal description on the bar code, to include either description alone, or to include a combination of the two. An industry-wide universal numbering system would contribute to uniformity in the industry. The numbering system could use steel specifications, tag numbers of engineered items, and other miscellaneous numbers.
SUGGESTED BAR CODE NUMBERING SYSTEM FOR CONSTRUCTION TRADES To create uniformity, one suggested bar code numbering system would be to use the first digit or letter of the bar code to identify some type of steel, an item, or a combination of both. The next one or two digits would identify what the item is, such as a valve or a flange. Additional digits or letters would then show the schedule or thickness, bore size, or pressure rating, as required, and the last digits would indicate the size of the item, such as "12" for something that was 12 in. in diameter. The various systems can also be programmed to show metric equivalents. Bar codes may be made with as many numbers and letters as the user requires, but ten or less is suggested.
Bar Coding Systems
153
As an example, a typical bar code for a 6-inch gate valve, 150-1b RF, having an assigned V-number for a certain project, would be as follows: From Table 6-1, the first digit for carbon steel is "0." The second digit is the code for a valve, again "0." The next three numbers and letters show the valve's V-number, in this case V58. The last two digits indicate the size of the valve, which in this example is 12 in. Our number, therefore, would be 00V5812 and, if desired, a verbal description could also be embedded in the bar code. Table 6-1 Number Codes for Bar Codes
Symbol
Material
0 1 2 3 3L 4 5 6 6L 7 8 PL SH
Carbon Steels Special Carbon Steels Alloy Steels (Exotics) 304 Stainless Steels 304L Stainless Steels Unassigned Unassigned 316 Stainless Steels 316L Stainless Steels Unassigned Miscellaneous Structural Plates Structural Shapes (table continued on next page)
154
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Table 6-1
(Continued)
Secondary Identification Symbols Symbol Material SP ST SX 0 1 2 3 4 5 6 7 8
Structural Pipe Miscellaneous Structural Expanded Metals Valves Pipes Flanges Fittings Bolts Socketweld Fittings Screwed Fittings Gaskets Miscellaneous
Additional Identification Symbols Symbol Type 80 125 150 160 1500RTJ .500 FP PI239 RF WF
Schedule 80 125 psig 150 lb. Schedule 160 1,500-lb. Ring-type Joint .500-inch wall thickness Full Port Pressure Indicator #239 Raised Face Wide Flange
Bar Coding Systems
Symbol 21 31 41 51 61 O1 14 15 02 25 03
SuggestedSize Codes Size l•Pr
]" ] 88
and continuing
155
Appendix Abbreviations for I n s t r u m e n t a t i o n Items AC AO AT AY AE BVD CC ESD FC FCV FI FIC FR FRC
FT FE FAH
Air to close Air to open Analyzer transmitter Analyzer computer Analyzer element Blowdown valve Corrosion coupon Emergency shutdown Flow controller Flow control valve Flow indicator Flow indicating controller Flow recorder Flow recording controller Flow transmitter Flow element Flow alarm, high
FSH FG FIT
Flow safety, high Sight glass Flow indicating transmitter FAL Flow alarm low FQY Totalized flow computer FS Flow switch FY Flow relay FV Flow valve FM Flow meter FQI Flow totalizing indicator I-IS Head switch I-IV Hand valve HCV Hand control valve LAL Level alarm, low LAI-I Level alarm, high LC Level controller LCV Level control valve
156
Appendix: Abbreviations f o r Instrumentation Items
LG LI LIC LS LT PDM PAL PAH PC PCV PDI PDR PI PR PS PSE
PSH PSL PSV PT PY
QX RO ROV
Level gauge Level indicator Level indicating controller Level switch Level transmitter Positive displacement meter Pressure alarm, low Pressure alarm, high Pressure controller Pressure control valve Differential pressure indicator Differential pressure recorder Pressure indicator Pressure recorder Pressure switch Pressure safety element (rupture disc) Pressure safety, high Pressure safety, low Pressure safety valve Pressure transmitter Pressure relay Event indicator Restriction orifice Remote-operated valve
SAH SC SD SDV Sl SP SV SDY TAH TAL TC TE TI TIC TR TT TW VSH WR XI XT ZI ZS
157
High-speed alarm Speed controller Shutdown Shutdown valve Speed indicator Specialty item Solenoid valve Shutdown relay Temperature alarm, high Temperature alarm, low Temperature controller Temperature element Temperature indicator Temperature indicating controller Temperature recorder Temperature transmitter Thermowell Vibration safety, high (low) Wind recorder Wind direction indicator Wind direction transmitter Position indicator Position switch
Index
Abbreviations for instrument items, 156-157 AC appliance, 103 systems offshore, 96, 103 Acid lines, 50 Actual flow, 12 sizes pipe/tubing, 88-95 Actuation points, 76, 78, 80 Adjustable angle, 140, 142 bolt, 45 Air, 16 conditioning, 12 lines, 49, 51 operated, 49 sampling unit, 82-84 switch, 12, 15 Aisle marking, 128 Alarms, 68, 70 indicating devices, 6-12 Alkaline system, 97-98 Alternating current, 113 Aluminum enclosures, 16 one-hole lug, 131-132
tubes, 18-19 tubing, 12, 17 Ambient control valve, 80-81 Ambient temperature, 12 Analog electronics, 22 Analytical instrument process, 48 Angle pattern valve, 51 Angular seat rupture disc, 47 ANSI, 33, 34, 41, 43 ARCO SolarTM Inc., 101-103 ARCO SolarTM Module, 104 Armored metal tube bundles, 12, 18-19 tubing, 18-19 Array, 113 Aspirator, 82-84 Atlantic Richfield Company, 101-103 Atmosphere, 43, 44, 46 Autoclave Engineers, Inc., 46 Automated flow controls, 68, 70 Auxiliary equipment, 104
158
Back connection, 140, 142 ferrule, 67 flow preventer, 12, 13, 23, 26 mount, 144 Ball, 36, 39, 45 bearing, 28 check, 26 socket disc, 33 valves/instrument service, 23, 27, 36, 39, 51-54 Ballast, 33 Bamboo pipe, 23, 28 Banding clips, 33, 34 Bar holes, 82-85 plugs, 82-85 Bar codes, 146-157 computer equipment needed, 147 numbering system for construction trades, 152-157 portable reading systems, 148-149 remote systems, 148-151
Index
Videx| TimeWandTM, 148-151 Barstock relief valves, 43, 44, 46 Base metal thermocouple, 134 Basic pipe fittings, 63 Battery block, 96 cells, 101-103 for electronic devices, 115-127 characteristics, 116-117 gas explosive, 101 glossary of terms, 118-127 safety tips, 118-119 storing, 115 types, 115 photovoltaic use, 102 rack, 97-98 storage room, 99-103 storage system, 113 terminals, 97-98 Bearing lube oil monitor, 87-88 seal leak detector, 87-88 BEI Technologies, 3 Bellows-sealed, 48 Bin boxes, 62, 64 Bimetallic pilot, 76, 78, 80 steam trap, 76, 78, 80 Black steel, 143 Bleed and drain valves, 49-55 Blow-off valve, 75, 77 Blow-out back, 144 Boiling caustics, 7 Bonnet bolted, 31 seals, 30-31 valves, 30-31 variations, 30-31
Bottom connection, 142 mount, 143-144 Bourdon gauge, 68, 70 Bourdon tube, 143-144 Boxes, bin, 62, 64 Braid ferrules, 140-141 Branch lines, 70, 7 l, 73, 74 Brass, 139, 143 Bridle, 139 Bucket steam trap, 74, 75 Bulkhead female connector, 66 male connector, 65 reducer, 68 unions, 67 Bundled, 22 Butterfly valve vacuum valves, 48 valve, 23, 29, 36, 39 Buttweld ends, 44 Bypass feature, 70, 71, 73, 74 systems, 54 Cable wire ties, 128-129 Caisson, 68, 70 Calculators, 22 Calibrated meter, 134 Cans thread lubricant, 145 Capacity, 113 Caps, 45, 62-64 Car seal, 43 Carbon steel, 6, 139 flanges, 140-141 pipe nipples, 140-141 Cardboard tubes, 22 Care of gauges, 144 Ceramic protection tube, 134 Chain wheel operator, 33, 34, 36, 37, 39 Charge controllers, 102, 113 Charging batteries, 96
159 Check valves, 23, 26 Chemical attacks, 14 plants, 49 Chico| A, sealing compound, 145 Circular recorders, 1-3 Cleaning machines, 33, 34 Coal pIx~ssing locations, 144 Color code, 49, 128, 129 Combination ends, 58 Commodity item numbers, 32 Communication conductor, 12, 17-19 Compact filters, 70-74 Computer, 22 bank, 32 bar code creation on, 147-152 Condensate, 74, 75 drainage station, 75, 77 trap, 74-75 water slugs, 73-75 Conductor communication, 70, 71, 73, 74 Connector blocks, 137 crimp type, 129, 131 Contamination, 70 Control devices, 68 industry, 22 panel indicating devices, 67 panels, 22, 68 rooms, 22 valves, 36, 39 Copper, 33, 34 tubes, 18-19 tubing, 12, 16-17 Corrosion, 36, 39, 73, 74
160
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Corrosive fluids, 50 solutions, 28 Cost of usable energy, 73 Couplets, 195-197 Couplings, 195 Crawford Fitting Company, 69 Cross-reference charts, 62--68 Cross-pattern valve, 51 Crosses, 63 Crystal, 144 Current, 114 Cut nipples, 20 Cycle life, 114 Cylinder valve, 50 Damage control, 73, 74 Date code markings, 33 DC, 6 systems offshore, 96, 103 Dense metal tags, 33-35 Density, 84, 87 Detectors and monitors, 82-88 Diaphragm actuator, 36, 39 Direct burial, 12, 17, 132 current, 128 sunlight, 102 Directional handle feature, 54 Disaster, 35 Disc double, 33 for valves, 32, 33, 46 Discharge valve, 78, 80 Dispenser cards, 128 Disposal pit, 68 Dissimilar metal, 134 Drain, 42 condensate, 74, 75 Drugs, 48
Dry steam supply, 73, 74 Dual range trap, 76 Dust-proof enclosure, 8-9 DuxSeal| 145 Eaton Corporation, 17-20 Elbows, ells, 63 Electric actuator, 36, 39 Electrical bill of materials, 144-145 Electrolyte, 97-98 Electronic component manufacturing, 48 temperature transmitter, 6--9 transmitter, 9, 10 Elements, 140, 142 Ells, 45 ~, 63 Emergency communications, 96, 98 lighting, 95, 98, 102 End caps, 132, 133 connections for valves, 32-33 protectors, 36, 39 Energy, cost of usable, 73 Engine starting systems, 96 Equipment stations, 61 Erosion, 73, 74 Expansion joints, 139-140 Expendable items, 144-145 Extended end valve, 41--43 Extension cable, 134, 135 Extreme pressure, 55 pressure fittings, 68, 70 Eye protection, 97-98
Figure number, 32, 34, 35, 57 Filter bodies, 70, 71, 73, 74 Fine metering valves, 55 Fisher, 6 butterfly control valve, 39 mixing valves, 36, 39 Fittings, 22, 68 Five-way ball valve, 54 Flame ionization principal, 82-84 pack, 82-84 retardant, 20 retardant tubing, 17 Flanges, end, 24-27, 33, 44 Flash steam, 75 Flat seal ruptured SC, 47 washers, 145 Flexible extension, 140, 142 hose connector, 140 instrument tubing, 16 pump connectors, 142 wedge, 33 Flow characteristics, 24-25 rates, 87-88 switch monitors, 87-89 transmitter, 11 Fluorescent lamps, 31-33 Freeze-dried foods, 48 Front ferrule, 67 Full lug, 29 port, 27 Fuse box, 103
Fail-safe points, 298 Female adaptors and connectors, 41--43, 66, 131,132
Galvanized steel armor, 18-19 Gas, 16 analysis, 48
161
Index
flow, 55 leak detector, 82-83 leaks, 62, 64, 82-84, 198, 220 manifolds, 51 Gaskets, 43-45 Gasoline, 87-88 Gate valve, 23-24, 32-35, 43-46 Gauge, 22, 55, 61 Bourdon, 68, 70, 71 glasses, 139 installation, 50 General instrumentation, 49 Globe check valve, 26 valve, 23, 25 Glyptol and thinner, 145 Gyrolok| 62-68 Handwheel, 30, 35, 36 Hazardous areas, 9-11 atmospheres, 9 fluids, 55, 81-82 locations, 9 Heat exchangers, 76, 78, 80 transfer properties, 87-88 Henry Vogt Machine Company, 62 Hex head capscrews, 145 High -level alarms, 87-88 -pressure service, 43, 44, 46 -pressure tubing fittings, 68, 70 -pressure valves, 55 57-58, 68, 71 pressures, 12, 17 range, 82-84
temperature, 12, 17, 33, 34, 55, 134 Hot condensate, 75, 77 Hydraulic installations, 12 lines, 51 Ideal| wire-nut connectors, 131-132 Identification of materials, 47 Ignition-proof meters, 8 Imperial| , 62-68 Indicators, 1-11 receiver gauge, 15 Inert gas line, 51 Injection rate monitors, 87-89 In-line check valve, 55-56 filters, 70-74 purge valve, 55-56 relief valve, 55-56 Inner jacket, 18 Inserts, 63 Inside screw, 30 Installation plan, 76, 78, 80, 81 Installing gauges, 61 tube fittings, 69 Instrument bridle, 139 check valve, 55-56 control valves, 36-39 fittings and monitors, 61 lines, 61 piping, 12 plug valves, 49 tubing, 12-22 valve outlets, 42 valves, 23, 55
Insulated communication wire, 18-19 Insulation, 41, 43 body, 132 tape, 145 Integrated circuit, 22 Interface detectors, 84, 87 Interlocked armor, 18-19 Inverter, 103 Issuing valves, 33-34 Jacketed multiple tube bundle, 18-19 Jaqua-McKee, Inc., 129 Keystone actuators, 36, 38--40 valve operators, 36, 38-40 K-Lok| valve, 34, 35 Knurled nut, 67 Laboratory, 79 Laminated safety glass, 144 Large-diameter vessels, 62 Laterals, 45 ~, 63 Leak detection periods, 82-84 monitor, 87-88 tight sealing, 54 Level gauges, 139 interface controller, 87-88 Levers, 22, 33, 34, 36, 39 Lift check valve, 26 LimitronTM fuses, 273 Line blinds, 41, 43 drip traps, 70, 71, 73, 74 Liquid flow, 55 level controller/transmitter, 6-12 level gauges, 139
162
P o c k e t G u i d e to I n s t r u m e n t a t i o n
Load, 114 Locating pipe/conduit, 84-87 Locite delivery items, 57 sleeved clothing, 97-98 Lock nut, 45 pressure, 12, 17 washers, 145 Low
-level alarms, 87-88 -power applications, 104 pressures, 12, 17, 54 range, 82-84 Lubricated grooves, 28 Lubricated plug valves, 28, Lug style, 29 Magnetically operated rotameters, 7 Main steam, 74, 75 valve, 76, 78, 80 Male adaptors and connectors, 41-43, 65, 88, 90 Manhole, 82-84 locater, 86 Manual operation/throttling, 36, 39 Manufacturers catalogs, 32 Mapco Controls Company, 84, 87 Materials accounting system, 32, 57, 61, 89, 91,144 control, 12, 17, 57, 144 description, 61, 88, 90 handling, 19-21, 32, 34-39, 57, 62-64,
87-89, 96, 99-100 person, 34, 35 receiving, 33-36, 39, 57 Maximum power point, 113 sunlight, 105 Measurement cells, 82-84 of temperature, 134 Mechanical steam traps, 74-76 Metal tags, 33-35 Metering, 6-12 valves, 54 Meters, 22 Metric tubing sizes, 88, 90, 95 Microprocessor electronics, 22, 87-88 Minimum inventory required, 196 Miscellaneous instrument items, 128-133 Mixer assembly, static, 5 Modem plug valves, 28 Modules, 105, 114 Mold, 132, 133 Monel, 139 Monitors, 61, 82-84, 87-89, 134-135 MPT, 88, 90 Multiconductor cable, 132 Multipair cable, 132 Multiport ball valves, 52-54 Multitube bundles, 12, 17 Nameplate, 34, 35, 3, 44, 46 Natural gas lines, 51 Navigation aids, 104 Needle valves, 59-60 Nickel cadmium batteries, 95-103 NIFE| 97-98
Nitric acid, 7 Nominal micron sizes, 73, 74 pipe sizes, 88-95 tubing sizes, 88-95 Non-rising stem, 30 Non-shielded cable, 132 Notch plate handle, 36, 39 Nozzles, 61 NPTF connection, 45 Numbering system for bar codes, 152-157 NUPRO| valves, 48, 49, 54, 56 Nusonics| pipeline detector, 84, 87-88 Nut, 67 Nylon tees, 129 tubing, 13, 17 Offshore areas, 35 drilling platform, 96 oilwell head, 55, 68, 70, 71 O-lets, 61 Omega Engineering, 2-5 On-off category, 23 discharge, 74, 75 flow cycles, 68, 70 services, 23, 24, 51, 54 Operators, styles, 36, 39 Original vendor carton, 62, 64, 87-88 OS&Y, 29, 30 O-Seal| male connector pipe, 67 Outer jacket, 19 Outlet fittings, 61
163
lndex
valves through insulation, 41-43 Outside diameter, 22 screw and yoke, 30 Overcharging, 113 Over-pressurization, 55 Packaging, 12, 13, 16, 17 Packing gland, 30 Paint valves, 35 Pallet number, 35 Panduit Pan-Ty| 129 Parker, 62-68 Part displays/manuals, 68 numbers, 62, 64 PCL clamps, 129 Performance guide, 106-112 Permanent tags, 33, 34 Photovoltaic, 114 system, 101-104 Pilot valve, 76 Pipe and cable detector, 82-86 Pipe fittings, 61, 63, 87-88 nipple, 134, 139 wall, 41, 43 Pipe Horn| , The, 84 Pipeline, 87-88 Pipe/tubing, actual sizes, 88-95 Piping plan/steam control, 81 Piston operator, 39 Plastic tubing, 12, 17 Plate flanges, 140 Plug, 45, 62--64 guide, 45 valve flow patterns, 28 valves, 23, 29, 49
Pneumatic controls, 6-15, 22, 36, 39 Pneumatic diaphragm activator, 36, 39 Pneumatic flow indicator, 6-12 Polyethylene tubing, 12, 13, 17 Porcelain insulator, 132-133 Port adapters, illustrated, 57 connector, 67 fittings, 55, 57 Potassium hydroxide, 97-98 Power system, 102 Preset actuation points, 76, 78, 80 Pressure class, 33, 34 drop, 26, 68, 70 gauges, 3, 143, 144 measurements, 42 range, 143 ratings, 61 seal bonnet, 31 strain, 42 Pressurized fluid samples, 81 Probe assembly, 98 Process piping, 61 Process steam traps, 70, 71, 73, 74 Project manager, 68, 144 number, 57 purchase order, 57 schedule, 57 tags, 33-35 valve tag, 35, 57 PSV valves, 25
Purchase order, figure numbers, 57 Purge air, 70, 71, 73, 74 valves, 55-56 Push mount ties, 129 PVC, 12 jacket, 18-19 tubing, 16 Quick off, 27 Quick open, 27, 30 Range temperature, 140 Reboilers, 76, 78, 80 Receiving materials, 144 procedures, 88, 90, 94, 134-135 report, 88, 90 shipment, 96, 144 Recorders, 1-4 Reduced port valve, 27 Reducer, 68 Reducing tees, 61 union, 67 Regulating valves, 50-51 Relief valves, 43-46, 55-56, 87-88 Replaceable port fittings, 55 Returns for credit, 35 Richardson Engineering Services, Inc., 139 Rising stem valve, 30 Rotameters, 7 Rotating disc, 33 magnet, 8 Rupture disc, 43, 44, 46, 47, 50
164
P o c k e t G u i d e to I n s t r u m e n t a t i o n
pressure ratings, 43, 44, 46 unit body, 50 Safety precautions for batteries, 97-98, 118-119 stripes, 128 Sampling, 49, 81 applications, 42, 54 cylinders, 81-82 device, 71, 85 instruments, 50 rate verifiers, 87-88 systems, 54 Scotchcast| splicing kit, 132-133 Scotchlok| ring-tongue terminal, 131-132 Screwed bonnet, 31 ends, 25, 27, 33 Seat, 36, 39, 45, 60 gland, 45 materials, 33, 34, 60 Self-adhesive strips, 128,130 Series RVP relief valve, 181 Service area, 195 Set pressure, 179 Shipping lengths/weights, 13, 16, 17 Shutdown devices, 68, 70 off valves, 50-51 Single cell crystal, 104 Single line tubing, 16-17 Single valves, 54 Sintered construction, 73, 74 filter element, 71-74 Sliding stem, 30 Slimline| connection, 45
Slip-on insulation body, 132-133 Small diameter pipe, 61 diameter valve, 61 instrument valves, 47-58 wire gauges, 129 Snap clips, 33, 34, 168 Sno-Trik| Company, 57 Socket weld ends, 33, 61 Solar application terms, 113-114 cell, 101-105, 114 modules, 96, 102, 113 Solder joint ends, 33 Solid wedge, 33 Sound alarm, 68, 70 velocity, 84, 87, 88 Southern Cross Corporation, 83 Spade tongue terminaI, 131-132 Spare parts, 88 Spindle, 45 Splice kits, 132-133 non-shielded cable, 132, 133 Spring cylinders, 45 Stacey line blind, 44 Stainless steel, 33, 34, 140 bellows, 140-144 braided connector, 140-141 finish, 22 fittings, 22 hose, 140-144 stick tubing, 19-22 tubing, 16, 19-22 Standard relief valve, 45 Start/stop alarms, 87-88
State of charge, 114 Static mixer assembly, 4-5 Steam control, 81 leaks, 70, 71, 73, 74 main, 74, 75 piping systems, 73, 74 temperature, 75, 77 tracing, 73, 74 tracing control valve, 76, 78, 80, 81 tracing traps, 70-81 traps, 70-81 Stem variations, 29-30 Stick tubing, 19-22 Storage battery, 96-100, 102, 115 procedures, 47 valves, 35-36, 39 Straight patterns, 55 through-plug valves, 50 through rotameters, 7 Strainer filter element, 70-74 Street ells, 62 Strings of pipe, 68 Stripping, 28 Subsea pressure transmitter, 3 Substitute valves, 41, 43 Sumary-module solar system, 113 Sun tilt angle, 105 S-valves, 25 Swing check valve, 26 -out ball valves, 54 Switch systems, 54 Systems, 55 Tapered plug, 28
165
Index
Tee, 61 Telemetry relay stations, 104 Television, 22 Temperature, 22 controls, 22 regulator, 6-12 transmitter, 1-12 Templates, 88, 90 Terminal markers, 128, 132 Termination cables, 132-133 Test equipment, 49 insert ring, 43, 44, 46 instruments, 50 separator, 68 Thermocouples, 134-139 Thermodynamic traps, 75, 77 Thermometers, 140, 142 Thermostatic traps, 75, 77 Thermowell, 134-135, 140 Thread cutting oil, 145 Threaded couplet, 61 Three-way ball valve, 54 mixing valve, 36, 39 Throttling category, 23 levers, 34, 35 service, 23, 25, 39 Tight bends, 12, 17 seal, 26-27 shut-off, 44 wire grip, 132 Tilt angle, 105-112 TimeWandTM, 146-150 TL, TLC, TM gauge glass, 139 Tortuous matrix, 73, 74 Toxic fluids, 81-82 Trace pipe/cable, 82-84, 86 Transmitters, 3, 4 Treated water lines, 51
Triple completed oilwell, 68, 70 Trouble shooting, 68 Tube cross-reference chart, 62--68 fittings, 62--68 reducer, 68 socket weld elbow, 65 socket weld union, 62, 64 union, 66 Tubing, 16, 19-21 nut, 67 Turbine starting systems, 96 Twelve-volt appliance, 103 battery, 102, 103 photovoltaic system, 102, 103 Two-hole lug, 131-132 Two-position valve, 82-84 Tylok| 62-68 Ty-rap| 145 U-bolt bonnet, 31 Unions, 63, 66--67 Usable energy, 73 Vacuum valves, 48 Valve(s), 139 body, 45 bonnet variations, 31 box locator, 82-84 central, 104 figure number 32 maintenance, 54 outlet, 50 patterns, 50 seats, 32 stem variations, 30 terminology, 29, 32-34 types, 23 uses for, 23 Vent system, 43, 44, 46
Venturi style, 27 Vessel nozzle, 61 Vibration control, 140-141 Videx| TimeWantTM, 146-152 Vinyl insulating tape, 19 V-numbers, 33, 34 Vogt gate valves, 42--44, 46 Voltage, 134 not usable, 113 ratings, 128 Wafer style valve, 29 Wallace & Tierman, 7-8 Walseal| Ends, 33 Walworth Company, 23 Warning lights, 102 Water hammer, 73-75 Watts, 114 Weather-resistant cable ties, 129 Weatherproof connection, 132 Weatherproof taps, 33, 34 Weld couplets, 61--63 identification tags, 33-35 Wet process insulator, 132 Winterization tracings, 76, 78, 80 Wire, 19 connectors, 129-132 markers, 145 mesh construction, 73, 74 pulling compound, 145 terminal markers, 128, 130 terminals, tongue/blade, 145 ties, 128-129 "Xmas tree," 69 Yarway Corporation, 74, 75 Y-type strainer, 75, 77
A b o u t the A u t h o r
R. R. Lee is the vice-president/owner of Lee's Material Services, Inc. in Houston, Texas, which received the prestigious Presidential "E" Award for excellence in export. Mr. Lee's 35 years' experience includes serving as material takeoff section leader with McDermott Engineering, purchasing agent, material/inventory control supervisor, and specialist/manager with Brown & Root International, Texaco, and Oasis Oil Company of Libya.
