Metso High Consistency Sampler Metso Nove H. Installation & Owner s Manual K10196 V1.1 EN

Transcription

1 Metso Nove H Installation & Owner s Manual K10196 V1.1 EN

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3 Table of contents Warnings & safety information 3. Actions during operation 19 Recycling and disposal 1. Introduction General description Installation Installation site and dimensions Mounting with clamp coupling Discharge tube Mounting with flanged coupling Mounting with a fiberglass-reinforced plastic coupling Mounting with AISI 316 flanged coupling Installing compressed air regulating valve Installing Metso Nove H Limit switch (option) Installing Muki H (option) Adjusting the direction of the closing piston flow inlet (sample inlet) Measuring piston stroke length Adjusting the sample discharge rate Flushing Sample taking Maintenance Removing the closing piston Removing the seal ring Installing the seal ring Replacing the bearing sleeve and O-ring Installing the closing piston...24 Technical specifications Spare parts 3

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5 Warnings & safety information Installing and disconnecting: Always make sure that the process pipe or chest is unpressurized and empty. Watch out for the cutting blade when testing a disconnected sampler. When adjusting the piston stroke with the cover removed, be careful to keep your fingers out of moving parts. Use a tool, not your fingers! While taking a sample: Do not stand at close proximity to the sample outlet pipe or discharge tube while sampling! Especially when taking a sample from a blow line, watch out for discharging steam and hot sample. 5

6 Recycling and disposal When sorted by material, nearly all parts of the device can be recycled. A materials list is delivered with the device. Upon request, the manufacturer will provide more detailed instructions for recycling and disposal. Used devices may also be returned to the manufacturer for recycling and disposal against a separate fee. 6

7 1. Introduction 1.1. General description (Metso Nove H) can be used for sampling high-consistency pulps and/or pulps that contain e.g. shives and knots. It is suited for all pulp types and for all application points in pulp and paper manufacture, including the digester blow line. Metso Nove H does not get blocked during operation or between operations. The internal parts of the sampler and the pulp discharge tube connected to it can be flushed clean after taking a pulp sample. The closing mechanism is provided with a cutting blade. When the sampler is closing, the blade cuts any knots or other pieces of wood so that they are not left between the sealing faces to prevent complete closing. The closing mechanism does not include any wearing rubber or plastic parts; all sealing faces are made of metal. The sampler has been designed to withstand all pressures and temperatures occurring at the various application points. Sample taking with the device is fully controlled and safe; no pulp will be splashed on the sample taker if the manufacturer's instructions and warnings are observed. Sample discharge rate can be regulated by adjusting the stroke of the closing piston. The position of the flow inlet can be selected in 90 degree steps in accordance with the direction of pulp flow. The amount of pulp flowing to sewer system in connection with sampling is very small. Fig. 1. Metso Nove H sampler. 7

8 Your notes here 8

9 Ø92 mm (3.62") Ø90 mm (3.54") 2. Installation 2.1. Installation site and dimensions Metso Nove H should be installed at a point where the pulp flows effectively. The process coupling is selected in accordance with Technical Specifications. Clamp coupling 1 (Fig. 1), for normal applications. Clamp coupling 2 (Fig. 2), for blow line applications. Fiberglass-reinforced plastic coupling (Fig. 3), for fiberglass-reinforced plastic pipelines. Standard AISI 316 coupling (Fig. 4), used when sampler is ordered without a coupling and customer supplies the installation parts. Sampler dimensions: see Figures 6, 8 and 10. weld A Lamination Fiberglass pipe Ø79 (3.11") B 20 mm (0.78") 45 mm (1.77") 140 (5.51") Fig. 3. Fiberglass-reinforced plastic coupling. Fig. 1. Clamp-mounted process coupling 1: A. Process coupling 1, B. Process pipe. 45 (1.77") A Flange DN80 PN40 DIN Ø92 (3.62") R75 Ø90 (3.54") B -weld Fig. 4. Standard AISI 316 coupling. Fig. 2. Clamp-mounted process coupling 2: A. Process coupling 2, B. Process pipe. 9

10 2.2. Mounting with clamp coupling First make a 92 mm hole on the process pipe and prepare it for a V-weld. Then weld the process coupling carefully on the hole through the entire wall thickness of the process pipe, as shown in Figures 1 and 2. Attach the sampler to the process coupling (Fig. 5, part A) with a mounting collar (part B) Discharge tube Connect a discharge tube, min mm/2" (Fig. 5, part C) to the sample outlet of the sampler. The discharge tube should preferably be made of acid-resistant metal. Attach the tube to the clamp-mounted coupling sleeve (part D) by welding or through a threaded connection. Depending on tube length, support it at one or several points. Use as short discharge pipe as possible and preferably use Muki H for easy, safe and accurate sampling. See Fig. 15 and section 2.10 for more information. Fig. 5. Metso Nove H clamp mounting. 107 mm (4.21") R1/8 R1/8 54 mm (2.13") R3/4 Ø90 mm (3.54") Fig. 6. Metso Nove H clamp mounting, dimensions. 55 mm (2.16") 35 mm (1.38") R2 Ø56 (2.20") Ø50 (1.97") 307 mm (12.08") 95 mm (3.74") 10

11 2.4. Mounting with flanged coupling Fig. 7. Metso Nove H flange mounting. 80 (3.15") 537 (21.1") 69 (2.72") 138 (5.43") 140 (5.51") 90 (3.54") Fig. 8. Metso Nove H flange mounting, dimensions. 11

12 2.5. Mounting with a fiberglass-reinforced plastic coupling Fig. 9. Metso Nove H fiberclass-reinforced plastic mounting. 54 (2.13") R3/4 Ø160 (6.29") R1/8 58 (2.28") Ø18 (0.71") Ø200 (7.87") Ø79 (3.11") Ø69 (2.72") 407 (16.02") Ø56 (2.13") R2 140 (5.51") Fig. 10. Metso Nove H fiberclass-reinforced plastic mounting, dimensions. 12

13 2.6. Mounting with AISI 316 flanged coupling This instruction applies to model Nove H F20. The installation parts are not included in Metso delivery; customer provides and installs the process coupling according to the instruction drawing. Flange DN80 PN40 DIN 2635 Detail A Detail A Align pipe end with inside surface Fig. 11. Metso Nove H AISI 316 flanged coupling mounting. 13

14 2.7. Installing compressed air regulating valve Mount the manually operated compressed air regulating valve (Fig. 12) with screws on a steady base near the sampler. Dimensions and pneumatic connections, see Fig. 13 & 14. Attach the warning plate supplied for the regulating valve at close proximity to the valve, where it will be easy to see. NOTE: If sample temperature is over 100 C (212 F) or if the pulp contains hazardous chemicals, the control valve and warning sign must be mounted at least 3 m from the sampling point. The warning sign must be placed at a location where everyone moving in the area can see it! 32 mm (1.26") 68 mm (2.68") 48 mm (1.89") Ø7 mm (0.28") 45 mm (1.77") 91 mm (3.58") 1/8" Compressed air supply max. 8 bar Fig. 13. Compressed air regulating valve, dimensions and connections. Fig. 14. Manually operated air regulating valve, air connections. Fig. 12. Manually operated compressed air valve. 14

15 2.8. Installing Metso Nove H Connections: Water flushing connection: R3/4 (sampler should always be flushed after taking a sample). Actuator connections: R1/8 (2 connectors). Actuator control valve connections: R1/8 (5 connections). Sample discharge tube connection: clamp mounting + R2 thread. NOTE: Delivery contains NPT adapter set K Use adapters for connecting NPT1/8 air connectors. Silencers should be installed to valve open end connections. 2 Actuator 3 Cover 4 Nove H process coupling 1 * 5 Nove H process coupling 2 * 6 Mounting collar 7 Connection for sample discharge tube 8 Mounting collar for sample discharge tube 9 Cutting plunger 14 Water flushing connection 15 Manual regulating valve for compr. air 51 Water pipe ** 52 Sample discharge tube ** 54 Water supply ** 55 Process pipe ** 56 Compressed air supply ** 57 Muki H sample receptacle; option 58 Overflow funnel ** 59 Limit switch assembly; option * = optional process couplings ** = not included in delivery Muki H Nove H R1/8 R1/ Fig. 15. Installation of Metso Nove H

16 2.9. Limit switch (option) Nove H is available with a limit switch that provides a binary signal to the system from the sampling moment. Install the limit switch as instructed below, test its operation by opening and closing the sampler and adjust the switch position if necessary. Installing (Fig. 16): 1. Make sure that the fixing plate (a) is in the lower position. 2. Install the limit switch as instructed. 3. Use a 1.5 mm Allen key to turn the screw so that the fixing plate catches below the opening of the slot and locks the switch in place. 4. Do not use too much force to fasten the switch, it may damage the screw socket! (Fig. 16, step 4). 5. To release the switch, first turn the screw two rounds back. Specifications: Inductive measuring principle Ambient temperature C ( F) Max. output current 100 ma Operating voltage range DC V Polarity protected for all electrical connections Electrical connection: 2-core cable, see Fig. 17. Fig. 16. Installation of limit switch. Fig. 17. Connection of limit switch. 16

17 2.10. Installing Muki H (option) In hazardous conditions if you install the sampler on a digester bow line or if the pulp contains any hazardous chemicals use Muki H sample receptacle (see Fig. 18). Order code M With Muki H, the sample discharge tube should be as short as possible. Directly on Nove H sampler If Metso Nove H is installed at an easily accessible height, you can install Muki H directly on the sampler. 1. Before attaching Muki H to Metso Nove H, make sure that the gasket is in its groove on the mounting flange of Muki H. 2. Attach Muki H with mounting clamps in a position where it will be easy to disconnect and reconnect. At the end of discharge tube from Nove H 1. The tube from Metso Nove H to Muki H must be as short as possible. Weld the coupling supplied with Metso Nove H at the end of the outlet pipe. 2. Place the gasket in the groove on the Muki H coupling and attach Muki H with mounting clamps to the end of the outlet pipe. Sample taking procedure 1. Before taking a sample, make sure that the receptacle is properly mounted in its holder. 2. Run some flushing water through the sampler. This will ensure that the sampler and outlet pipe are empty of pulp. (See step 5.) 3. Run pulp sample from Metso Nove H to receptacle until pulp runs over through the Muki H overflow pipe for 1 2 seconds. 4. Remove the sample receptacle from its holder and empty the sample with a spatula to an approx. 1 liter sample container equipped with a cap. 5. Reconnect the sample receptacle to the body of Muki H. Run flushing water through Nove H until all pulp is removed from the sampler, outlet pipe and overflow basin. If the basin has its own flushing water supply, also allow it to run. 6. Deliver the sample containers in a basket to laboratory. NOTE: Take as many samples from each sampling point as the mill-specific instructions specify. Pulp overflow basin 1. Make a flat-bottomed basin below Muki H to catch overflowing pulp, and install a pipe from the bottom of the basin to sewer. The basin should be large enough to contain also the pulp and flushing water from the outlet pipe. It is also recommendable to provide a separate flushing water supply for the overflow basin. Discharge velocity of pulp sample from Nove H When using Muki H the sample discharge rate from Nove H sampler should be adjusted as high as possible. Maximum velocity is recommended, provided that no disturbing splashing will occur. Fig. 18. Muki H sample receptacle. NOTE: The sample overflow pipe from Muki H must not be extended, because this would cause an increased pressure inside the sample receptacle. 17

18 Your notes here 18

19 3. Actions during operation 3.1. Adjusting the direction of the closing piston flow inlet (sample inlet) 1. Remove the cover (Fig. 1, M10 screw, 4 pcs). Use Allen key 8 mm. 2. The longest flat surface (Fig. 2, 0) on the piston shaft shows the direction of the flow inlet. Loosen the retaining M6 socket head screw (Fig. 3, use Allen key 5 mm). Rotate the shaft clockwise by the stroke limiter screw (Fig. 4) in one of the four optional directions 4 x 90. Use wrench key 17 mm. 3. Tighten the screw (Fig. 3) carefully. 4. Reinstall the cover. Recommendation: Set the flow inlet at 90 angle against the direction of flow of the pulp. If the pulp contains stones, pieces of metal wire or other hard objects, you can protect the cutting blade by turning the flow inlet in the direction of pulp flow in downstream direction (Fig. 5). Fig. 3. Adjusting the direction of the flow inlet, step 2. Fig. 4. Adjusting the direction of the flow inlet, step 3. Fig. 1. Adjusting the direction of the closing piston flow inlet, step A A 8 Fig Flat surface indicating direction of flow inlet. 8. Socket head screw, 19. cover. Fig. 5. Closing piston. A. Cutting blade. The arrow indicates the direction of pulp flow. 19

20 3.2. Measuring piston stroke length Measure the piston stroke length between the flow rate regulator nut and the piston rotation guard. Sample flow rate is dependent on piston stroke length, as the stroke regulates how much the flow opening opens. The piston stroke length default setting is 20 mm. The flow opening = piston stroke length - 8 mm Adjusting the sample discharge rate Sample flow rate from the sampler is dependent on process pressure and on the size of the flow opening. With Muki H adjust the stroke to maximum. 1. Remove the cover (Fig. 6, part 19). Use Allen key 8 mm. 2. Loosen the retaining nut (part 16, use wrench key 17 mm) and adjust the stroke of the closing piston by means of the limiter (part 14). - clockwise - weaker flow, - counter clockwise - stronger flow. The longer the piston stroke the more the flow inlet will open. When testing the sampler, take care to keep your fingers off the moving parts. Secure the retaining nut and close the cover carefully after making the adjustment Flushing For Metso Nove H flushing is compulsory. Flushing can be arranged by connecting a water pipe equipped with manually operated valves to the sampler. See chapter 2, Fig Sample taking When taking a sample from a digester blow line or if the pulp contains a hazardous amount of dangerous chemicals, use Muki H sample receptacle. In other conditions you may take the sample directly to a 1-5 liter container which you can hold in your hands, but Muki H is good to use also in these applications mm Fig. 6. Adjusting the sample discharge rate: 14. limiter, 16. retaining nut, 19. cover. 20

21 4. Maintenance 4.1. Removing the closing piston If the closing piston shows any wear or damage, it must be replaced. 1. Remove the M10 socket head screws and remove the back cover (Fig. 1). Use Allen key 8 mm. 2. Remove the M10 socket head screws of actuator connection (Fig. 2, 4 pcs). Use Allen key 8 mm. 3. Remove the actuator-piston rod joint: hold the piston rod in place and unscrew the actuator by its shaft (Fig. 3). Use wrench key 17 mm. 4. Push out the piston. Fig. 1. Removing the cover. Fig. 3. Removing the actuator. Fig. 2. Removing the actuator screws. 21

22 4.2. Removing the seal ring If the seal ring shows any wear or damage, it must be replaced. Replacing requires a special tool, available from Metso: part Mount the sampler e.g. on a vise. 2. Insert the counter pin (Fig. 4, 70) into the sampler body. 3. Use the extractor tool (Fig. 4, 71) to remove the seal ring Installing the seal ring The seal ring is secured with a press-on fit. 1. Place the seal ring in a freezer, preferably keeping it attached to the mounting tool (Fig. 4, 71), and allow it to cool to min. -10 C. 2. Heat the sampler tip section to approx. 100 C, for instance in boiling water. 3. Attach the sampler e.g. to a vise. 4. Take the seal ring and mounting tool from the freezer. Insert the seal ring together with the mounting tool into the sampler body with the a help of a hammer (Fig. 5). Fig. 4. Removing the seal. Fig. 5. Installing the seal ring. 22

23 4.4. Replacing the bearing sleeve and O-ring If the bearing sleeve shows considerable slack, it should be replaced. 1. Remove the four M6 socket head screws and remove the mounting plate (Fig. 6). Use Allen key 5 mm. 2. Remove the rotation lock ring with a screwdriver (Fig. 7) 3. Attach the sampler to a vise with the actuator end upwards. 4. Remove the PTFE bearing sleeve with the extracting tool, or pry it out with a screwdriver (Fig. 8). The end of the tool has a screw pin. Screw the tool by its turning arms into the bearing sleeve and pull the sleeve. 5. Remove the old O-ring (Fig. 9 ) 6. Press in the new O-ring. 7. Use the tool kit push bar (Fig. 10) to insert in the new bearing sleeve into the body. The sleeve is deep enough when the groove of the locking ring is visible. Fig. 8. Removing the sleeve. NOTE: Be careful not to push the bearing bush with too much force and so deep that it exerts pressure on the O-ring! Fig. 9. Removing the O-ring. Fig. 6. Removing the mounting plate. Fig. 10. Inserting the sleeve. Fig. 7. Removing the lock ring. 23

24 4.5. Installing the closing piston NOTE: Secure all threads and screws with locking medium (Loctite or equivalent). NOTE: Watch out for the cutting blade! Procedure: 1. Connect the mounting plate to the body. 2. Align the direction of the closing piston and insert it into the sampler body. 3. Mount the rotation stopper and fasten its screw (Fig. 11). Use Allen key 5 mm. 4. Connect the actuator-piston rod joint: hold the piston rod in place and screw in the actuator by its shaft (Fig. 12). Use wrench key 17 mm. 5. Install the four M10 actuator connection screws (Fig. 13). Use Allen key 8 mm. 6. Assemble and adjust the stroke limiter (Fig. 14). See chapter Install the back cover and secure it with the four M10 screws. Use Allen key 8 mm. Fig. 13. Mounting the actuator screws. Fig. 11. Installing the piston. Fig. 14. Adjusting the stroke limiter. Fig. 12. Installing the actuator. 24

25 1 (3) Metso High Consistency Sampler (Metso Nove H) Technical specification - Metso Nove H is a pneumatically controlled sampler designed for sampling high consistency wood pulps and/or pulps containing knots and shives. - Metso Nove H can be used for all pulp types, in all applications of the pulp and paper manufacturing process also in the digester blow line. Applicability Consistency range % Cs Materials Wetted parts... AISI 316 L / Hastelloy C276 / Titanium / SMO 254; see type specification chart Other parts (actuator, stroke limiter)... AISI 316L, aluminum alloy and structural steel with protective paint Actuator operating pressure - When air supply is cut off, a spring keeps the valve closed Range bar ( psi) Recommended... 6 bar (87 psi), corresponds to plunger opening/closing force 3000 N Process conditions Temperature... max. 200 C (392 F) Pressure minimum... 0 bar, depending on sample consistency Pressure maximum bar (363 psi) For fiberglass-reinforced plastic coupling: - Temperature... same as for process piping - Pressure max bar (145 psi) Connections - Adapters for NPT 1/8 connectors included Flushing water... R3/4 (flushing recommended after each sample) Actuators... 2 pcs, R1/8 Actuator control valve... 5 pcs, R1/8 Sample discharge tube... R2 thread + clamp mounting Patents - FI FI Weight Nove H S kg (17 lbs) Process couplings - Process coupling, seal and mountings are supplied with the sampler. - Exception: Coupling for model Nove H F20 is not included in delivery; customer supplies standard parts according to installation instruction. Coupling 1... Clamp-mounted, for normal use Coupling 2... Clamp-mounted, for especially abrasive applications (e.g. digester blow line) Flange-mounted... Fiber-glass reinforced plastic coupling, for fiberglassreinforced plastic pipelines Minimum required process pressure: Pressure, Bar Consistency, % Metso Automation Manufacturer reserves the right to changes without prior notice.

26 Metso Nove H Technical specification 2 (3) Type specification chart Metso Nove H Connection type S Clamp F Flange Sampler material 2 AISI316 L 3 Hastelloy C276 4 SMO254 6 Titanium ASTM B348 gr. 2 Process coupling material 2 AISI316 L 3 Hastelloy C276 4 SMO254 6 Titanium ASTM B348 gr. 2 8 Fiberglass-reinforced plastic 0 Process coupling not supplied Application point 1 Standard, process coupling 1 2 Blow line, process coupling 2 Open/close detector (option) 0 No detection 1 Limit switch Recommended models Code Nove H type K09854 Nove H S22 10 K09903 Nove H S22 20 DN150 K09904 Nove H S22 20 DN K09905 Nove H S22 20 DN K09906 Nove H S22 20 DN K09907 Nove H F60 Ti K09908 Nove H F68 10 K09909 Nove H S44 10 SMO K09910 Nove H S33 10 K09911 Nove H S66 10 K09859 Nove H F20 Code Options K05914 Limit switch for open/close detection M MUKI H AISI 316L - If other materials/combinations are required, please consult your Metso specialist! Example: Metso Nove H S2210 Metso Automation Manufacturer reserves the right to changes without prior notice.

27 Metso Nove H Technical specification 3 (3) Dimensions S (clamp model) 107 Pipe thread IS0 7/1-R3/4" ( 68) Coupling L, 2" F (flange model) Air supply R1/4" /open 200 Pipe thread ISO 7/1-R3/4" ( 68) Coupling L, 2" Metso Automation Manufacturer reserves the right to changes without prior notice.

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29 1 (2) Metso Nove H Spare parts Metso Nove H, clamp model No. Code Part pcs / assembly 1 T00786 Pneumatic actuator AEVU K09778 Limiter 1 3 K09776 Adjusting ring O-ring 18x3 Viton 75 S 1 5 T Bearing sleeve Screw M6x14 DIN912 A Screw M10x70 DIN933 A Hexagon nut M10 DIN934 A4 1 9 K09899 Cover assembly 1 11 K09803 Piston assembly, Nitronic (for AISI 316L models) 1 K09836 Piston assembly, Titanium 1 K09804 Piston assembly, Hastelloy C K09805 Piston assembly, 254 SMO 1 12 K09770 Flushing unit 1 13 K09772 Seat insert, Nitronic (for AISI 316L models) 1 K09825 Seat insert, Titanium 1 K09774 Seat insert, Hastelloy C K09775 Seat insert, 254 SMO 1 Installation parts (not shown in the drawing; see Nove H manual ch. 2) K09783 Process coupling 1 1 K09837 Process coupling 2 (DN150) 1 K09838 Process coupling 2 (DN ) 1 K09839 Process coupling 2 (DN ) 1 K09841 Process coupling 2 (DN ) 1 K09896 Mounting clamp assembly NS Gasket D86/81 x 2.5 (for process coupling) 1 K11587 Closing flange set SS DN65 1 K11588 Closing flange set TI DN65 1 K11589 Closing flange set HC DN65 1 K09897 Mounting clamp assembly NS50 (for discharge coupling) 1 K09888 Gasket D64/58 x 2 (for discharge coupling) 1 K09991 Valve assembly (manually operated compressed air valve) 1 Metso Automation Manufacturer reserves the right to changes without prior notice.

30 Metso Nove H Metso Nove H, flange model Spare parts 2 (2) No. Code Part pcs / assembly 1 T00786 Pneumatic actuator AEVU K09778 Limiter 1 3 K09776 Adjusting ring O-ring 18x3 Viton 75 S 1 5 T Bearing sleeve Screw M6x14 DIN912 A Screw M10x70 DIN933 A Hexagon nut M10 DIN934 A4 1 9 K09899 Cover assembly Snap ring 26x2.0 DIN7993B 1 11 K09816 Piston assembly, Nitronic (for AISI 316L models) 1 K09817 Piston assembly, Titanium 1 12 K09770 Flushing unit 1 13 K09772 Seat insert, Nitronic (for AISI 316L models) 1 K09825 Seat insert, Titanium 1 Installation parts (not shown in the drawing; see Nove H manual ch. 2) K09933 Process coupling DN80 (fiberglass) Screw M16 x 70 DIN933 A Nut M16 DIN934 A Gasket D86/81 x 2.5 (for process coupling) 1 K09897 Mounting clamp assembly NS50 (for discharge coupling) 1 K09888 Gasket D64/58 x 2 (for discharge coupling) 1 K09991 Valve assembly (manually operated compressed air valve) 1 Metso Automation Manufacturer reserves the right to changes without prior notice.

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32 This document discloses subject matter in which the manufacturer has proprietary rights. Neither receipt nor possession thereof confers or transfers any right to reproduce or disclose the document, any part thereof, any physical article or device, except by written permission from the manufacturer. Manufacturer reserves the right to alter the contents of this document without prior notice. Copyright July 2012 Metso Automation Inc. Documentation: JT-Tieto Oy & Metso Automation Metso Automation Inc., Kehräämöntie 3, P.O.Box 177, FI Kajaani, Finland Tel , fax ,