You are on page 1of 15

Model 7738 Model 7718

OPERATION & MAINTENANCE FIELD GUIDE v 2.47

MiniBLOCK Slave Injector

Chemtec
Chemtec Energy Services, Inc. 11745 Cude Road Willis, Texas USA 77318 Phone 936 856 1704 Facsimile 936 856 1669 www.ChemtecEnergy.com

Chemtec MiniBLOCK

INTRODUCTION
Page 2

DESCRIPTION MiniBLOCK is used to meter the injection of a wide range of liquid additives including fuel additives, petroleum dyes, and marker additives. MiniBLOCK is machined from a single 300 series stainless steel block, thereby greatly reducing the number of potential leak points. The product serves as a slave device to a customer supplied master controller. MiniBLOCK may be controlled by any device that is capable of controlling the solenoid valve and powering the 5-30 VDC sensor. Common master controller devices include Accuload III, Danload 6000, Toptech Multiload, and PLC based additive controllers. MiniBLOCK is simple in design, high quality, accurate, reliable, and compact Metering Positive displacement oval gears provide precise additive metering for low flow applications. The oval gear design is highly accurate, reliable and provides low pressure drop. 316 stainless steel oval gears (standard) offer enhanced chemical compatibility Flow Control Valve Additive flow control is provided by the normally closed ASCO solenoid valve. The solenoid valve is machined into the stainless steel block and is easily serviced utilizing a standard ASCO solenoid rebuild kit. Chemraz used on the solenoid plunger seat (standard) offers a soft seat to prevent internal valve leaking (unauthorized additive flow) and excellent chemical resistance 17.1 watt coil (standard) ensures CORE ASSEMBLY (plunger) operation across a wide range of operating conditions Sensor The standard meter sensor operates based on proven Hall-Effect technology and operates utilizing 5-30 VDC. The sensor is powered by the customer supplied master control device. A Reed Switch type sensor is available as an option. Both sensors are UL / CUL Listed and approved for Class 1, Div. 1 Group D locations. Important Notes Related To Wiring The Hall-Effect Sensor 1. POWER = RED, NEUTRAL = BLACK, and PULSE = BLUE, CLEAR, OR WHITE 2. Depending on the master controller used, a pull-up resistor may*** be required in order for the controller to count additive meter pulses properly. A pull-up resistor is normally NOT required. *** If a pull-up resistor is required, use a 5.6K ohm resistor for 12VDC powered systems and a 10K ohm resistor for 24VDC powered systems. Mount the resistor across the BLUE (pulse) and the RED (power) sensor wires. Use of a resistor that is not properly sized may damage the sensor. 3. In order to prevent damage to the DC powered sensor, terminate the Black Neutral wire first, then terminate the Pulse wire second, then terminate the RED Power wire LAST.

Other Components Needle Valves Calibration Fitting Strainer Check Valve

INLET / OUTLET, 300 series stainless steel, high pressure rated Swagelok, male 1/4, 300 series stainless steel, includes dust cap Internal, 316 stainless steel basket type strainer, 60 mesh (230 micron) External mounted, Swagelok, 316 stainless steel, 1 PSI cracking pressure

Chemtec MiniBLOCK

SPECIFICATIONS
Page 2 Page 3

Performance Model 7738 Model 7718 Electrical Solenoid Sensor

0.3 - 3.0 GPM (1.2 - 12 LPM) @ 1 cSt, 300 PSIG, 2,600 PPG nominal resolution 0.03 - 0.3 GPM (0.12 - 1.2 LPM) @ 1 cSt, 300 PSIG, 6,000 PPG nominal resolution

ASCO, explosion proof, 2-way, direct acting, normally closed, supply voltage 115 VAC/60 hZ. (standard), other voltages available as an option. Current 17.1 watt (standard). Hall-Effect type, non-intrusive, 3-wire, 5-30 VDC (std), rotates in 90 degree increments, 1/2 FNPT, Wiring Power = RED, Neutral = Black, and Pulse = Blue, White or Clear. A 2-wire Reed Switch sensor available as option. All sensors rated for Class 1, Div. 1 Group D hazardous areas.

Mechanical Elastomers Field Mounting Configuration Meter Access Meter Gears Needle Valves Calibration Strainer Check Valve Dimensions

Chemraz dynamic seals & Teflon static seals (standard), other elastomers available as option (2) mounting holes provide for the mounting of the device to backplane or unistrut utilizing 5/16-inch hex socket cap screw Multi-PAC configurations include 1-PAC through 6-PAC, each PAC pre-wired and mounted Meter access via four (4) recessed socket head bolts located under sensor Oval gear design, 300 series stainless steel (standard) 316 stainless steel with Teflon packing, high pressure rated Swagelok quick-connect fitting with dust cap, 316 stainless steel, mates with PN 77-CTK-50 Stainless steel filter screen, basket type, 230 micron (60 mesh) Swagelok, 1 PSIG cracking pressure, stainless steel, 3/8 male inlet x 3/8 female outlet 8.88 L x 4 H x 1.5 D (225.6 mm x 101.6 mm x 38.1 mm), unmounted, length includes installed external mounted check valve

Optional Accessories Calibration Kit Thermal Relief Kit

PN 77-CTK-50 (standard), or PN 77-CTK-50HR (recommended for all dye additives) PN 77-TRK-10 (device recommended for all dye applications)

Field Installation Considerations

Note

In addition to the use of the external mounted MiniBLOCK check valve on the injector, the user should always install a check valve at the injection point on the main product line. The check valve provides redundant support in preventing main product from flowing through the injector in the reverse direction. For DYE injection systems, a solenoid valve or other blocking valve should be installed at the injection point. The installed valve prevents unauthorized DYE leakage due to thermal expansion. Whenever a valve is installed at the injection point, a Thermal Relief Kit must be installed on the MiniBLOCK injector.

Chemtec MiniBLOCK

PERFORMANCE CURVES
Page 4

Note Performance data provided below was generated using low differential pressure. The use of a higher differential pressure (145 PSI maximum) will result in flow rates approximating 3.0 GPM (Model 7738) and 0.7 GPM (Model 7718). All flow rates measured using 15 injection cycles per minute.

SSU cSt

SSU cSt

Chemtec MiniBLOCK

DIMENSIONAL DRAWING
Page 5

Chemtec MiniBLOCK

GENERAL ASSEMBLY
Page 6

Chemtec MiniBLOCK

CALIBRATION KIT
Page 6 Page 7

The Chemtec Calibration Kit provides service personnel with the means to Calibrate the MiniBLOCK injector. The Swagelok manufactured stainless steel female Quick Connect fitting (Item 1 below) mates with the male Swagelok calibration fitting mounted on the MiniBLOCK injector. User MUST utilize the Calibration Kit in order to calibrate the injector. PRODUCT ORDERING PN# 77-CTK-50 (standard) PN# 77-CTK-50HR (High Resistant Option**) Includes Chemraz O-rings installed on Check Valve & Quick Connect Fitting. Note Recommended for all petroleum DYE applications

5 8

Item 1 2 3 4 5 6 7 8

Qty. 1 1 1 1 1 1 1 1

Description Quick Connect, SS, Viton O-ring (std.)** T, SS, 1/4" x 1/4" x 1/4" FNPT Check Valve, SS, 50PSIG, 1/4" MNPT x 1/4" MNPT, Viton** Tube Fitting, SS, 1/4" Tube x 1/4" FNPT Tubing, SS, 1/4", .035 Pressure Gauge, SS, Liquid Filled, 0-160 PSIG Graduated Cylinder, Plastic, 1000 ML (IVD, diesel additives) Graduated Cylinder, Plastic, 500 ML (Dye, Marker, additives)

Part No. SS-QCH-B-4PM SS-4-T SS-4CPI-50V SS-400-7-4 SS-T4-S-035-20 PGI-63C-PG160-LA01 3BW-47315-1000 3BW-47314-500

** Chemraz O-ring available as an Option for Dye Additives and other fuel additives requiring higher chemical resistance

Chemtec MiniBLOCK

THERMAL RELIEF KIT


Page 8

PRODUCT ORDERING PN# 77-TRK-10HR Includes Chemraz O-ring in Check Valve

Model 7718 With Installed Thermal Relief Kit

Item 1 2 3 4 5 6 7 8 Note

Qty. 1 1 2 1 2 1 1 1

Description Strainer Assembly Reducing Bushing, 3/8 MNPT x 1/4 FNPT, Swagelok Street T, SS, 3/8" MNPT x 3/8" FNPT x 3/8"F, Swagelok Fitting, SS, 3/8 MNPT x 1/4 Tube, Swagelok 1/4 Tube Fitting, SS, Swagelok, with 1/4 tubing, .035 Elbow, SS, 1/4" Tube x 1/4" FNPT Check Valve, SS, 1/4", 10 PSIG cracking pressure Outlet Check Valve, SS, 3/8NPT x 3/8NPT, Swagelok

Part No. SS-8F-K4-230 SS--6-RB-4 SS-6-ST SS-0400-1-6 SS-T4-S-035-20 SS-400-8-4 SS-4CP2-10 SS-CHM6-1

Thermal Relief Kit includes Items 2-7 only. Items 1 & 8 included with MiniBLOCK injector.

Chemtec MiniBLOCK

PAC CONFIGURATIONS
Page 9

OPTION 1: Explosion Proof (EXP) Enclosures Mounted, pre-wired and pre-plumbed to enhance field installation and wiring Available 1-PAC through 6-PAC configuration Provides separate AC & DC explosion proof enclosures for enhanced electrical safety Product design facilitates future expansion

OPTION 2: NEMA 12 Enclosure Includes NEMA 12 wire trough enclosure mounted and pre-plumbed Design facilitates direct field wiring from master controller to each MiniBLOCK Eliminates need for intermediate wire splices Includes WAGO connectors in each T box Available in 1-PAC through 6-PAC configuration Product design facilitates future expansion

3-PAC EXP. Configuration (designed for future expansion)

3-PAC With NEMA 12 Enclosure

6-PAC EXP. Configuration

6-PAC Load Rack Mounted

Chemtec MiniBLOCK

ADDITIVE SYSTEM P&ID


Page 10

Chemtec MiniBLOCK

DYE SYSTEM P&ID


Page 11

Chemtec MiniBLOCK

FIELD CALIBRATION
Page 12

Background The accuracy of an injector calibration may be affected by several variables including additive viscosity, pump pressure, meter to meter variation, and the volume of additive injected for each injection cycle. Additive viscosity for most fuel additives changes with temperature, thus necessitating the need for seasonal calibrations. In order to minimize the adverse effect of these variables, a final calibration MUST be performed in the field utilizing the specific additive to be metered. Note When new injectors are installed, trapped air in additive lines is a common occurrence. Air in the additive lines may adversely affect meter calibration and meter accuracy, as well as prevent the solenoid valve from opening. Ensure all air is eliminated prior to performing a Field Calibration.

MiniBLOCK Control MiniBLOCK injectors are typically controlled by a customer supplied master control device, such as an Accuload III preset, Danload 6000 preset, Multiload, PLC, or other electronic control device capable of counting high speed meter pulses and controlling the solenoid control valve. MiniBLOCK serves as a slave device to the master controller. Note An accurate Additive K-Factor for each MiniBLOCK meter must be entered into the program of the master control device. The final Additive K-Factor is always derived from performing an accurate field calibration using the additive to be metered.For initial testing, a K-Factor of 2,600 PPG may be used for the Model 7738 and 6,000 PPG for Model 7718. Some master control devices may incorporate an automated calibration feature. Always refer to the product manual for the master control device utilized.

MiniBLOCK Meter & Sensor MiniBLOCK utilizes a positive displacement flow meter for metering additive. Additive flow through the flow meter generates electrical pulses via a Hall-Effect sensor, whereby each meter pulse represents a specific quantity of additive dispensed through the injector. The specific quantity dispensed for each meter pulse can only be determined by performing an accurate calibration check in the field. K-Factor is defined as pulses per unit of measure. (Example: 2,600 pulses = 1 US gallon). The Additive KFactor affects the volume of additive ACTUALLY DELIVERED verses the volume DISPLAYED by the master control device. Note The displayed volume of additive in the master control device is accurate ONLY when an accurate Additive K-Factor has been entered into the program following completion of the injector calibration.

Equipment Requirements: Safety goggles or glasses and protective gloves and clothing Graduated cylinder (1,000 ML for standard fuel additives and 500 ML for dye & marker additives) Chemtec Calibration Kit PN# 77-CTK-50 Note The Chemtec Calibration Kit MUST be utilized in order to calibrate the injector

Chemtec MiniBLOCK

FIELD CALIBRATION
Page 10 Page 13

Manual Calibration Procedure Step 1 1A Comply with all safety procedures 1B Prior to initiating a calibration test, ensure that no trucks are loading at a position whereby product pulses may be sent to the injector being calibrated 1C Assemble Calibration Kit equipment and prepare Calibration Form (Reference last page) Step 2 2A Record the current Additive K-Factor if a factor is already entered in the master control device. For new installations, enter the standard Additive K-Factor for the MiniBLOCK being calibrated. 2B Record the Additive Set value (CCs per injection request), as programmed in master control device 2C When ready to calibrate, ensure the selector switch for the additive pump & motor is positioned ON Step 3 3A Initiate several injections into the additive line or bucket prior to starting the calibration test. This action ensures pump pressure is adequate and that the injector is working properly. Note If air is trapped in the additive line, clear all air prior to performing calibration test. Air in the additive line may prevent the solenoid from opening.

3B Following the completion of Step 3A, install a Calibration Kit to the MiniBLOCK via the quick-connect fitting Step 4 4A Prior to performing the calibration test, ensure there is NO residual additive in the graduated cylinder 4B Position the graduated cylinder under Calibration Test Kit tubing and prepare for the test 4C Partially close the Inlet needle valve in order to prevent high pressure splashing of additive into the cylinder Step 5 5A With an Additive Set of < 100 CCs and with the proper Additive K-Factor entered, initiate ten (10) injections into the 1,000 ML graduated cylinder. For Dye Additives using an Additive Set of < 50 CCs, utilize the 500 ML graduated cylinder dedicated for dye additive. CAUTION! DO NOT overfill the beaker. Do not splash additive. Step 6 6A Following the completion of the ten (10) calibration injections into the graduated cylinder, record the volume of additive as displayed by the master controller (Cummulative CCs, as displayed by controller) 6B Following completion of all injection cycles and after all air has escaped from the additive in the graduated cylinder, record the Additive Volume in the graduated cylinder 6C Calculate the revised Additive K-Factor utilizing the folowing formula: New Additive K-Factor = (Current K-Factor X *Additive CCs Displayed) Actual Additive CCs In Graduated Cylinder * Note Use the Calibration Form located at the end of this document

6D Enter the New Additive K-Factor in the master control device program, then EXIT program

Chemtec MiniBLOCK

FIELD CALIBRATION
Page 14

Step 7 7A Repeat Steps 5 through 7 until the actual volume of additive in the graduated cylinder equals the displayed volume of additive, as indicated on the master control device Step 8 8A On completion of calibration, remember to OPEN the Inlet needle valve and remove the Calibration Kit 8B Re-position the additive pump & motor selector switch to Automatic Position. The MiniBLOCK is now ready to resume normal operation.

Calculating A New Additive K-Factor: Example (Current K-Factor X Additive CCs Displayed) = New Additive K-Factor Actual Additive CCs in Graduated Cylinder Example Assumptions: Current Additive K-Factor = 2710 Additive CCs Displayed (cummulative total following end of test injections) = 453.6 Actual Additive CCs in Graduated Cylinder = 475.0 Calculation: 2710 X 453.6 = 2587.91 (New Additive K-Factor) 475.0 User Action: User Enter program for master control device and modify the programmed value to reflect the New Additive K-Factor of 2587.91 Calculating Additive Set Value: Example Treat Rate per 1000 gal. X 3785.44 = Additive Set (CCs per 40 gallons of product) 25 Injection Cycles Example Assumptions: Injection Rate = 0.750 gal. additive per 1000 gal. of product CCs per gallon = 3785.44 Product Pulse = 40:1 (40 gal. of product per pulse) Injection Cycles per 1000 gal. = 25 (1000/40 = 25) Calculation: 0.750 X 3785.44 = 113.56 CCs (Additive Set) 25 Note US gallon = 3785.44 CC US gallon = 3.785 Liters

Calibration Form
Customer Location Injector ID Calibration Performed By Date

Beginning Additive K-Factor

Additive Set (CCs per injection)


TEST RESULTS (CCs)

Test Injections
Record CCs after each injection cycle (1 thru 10)

Test 1

Test 2

Test 3

Test 4

Test 5

1 2 3 4 5 6 7 8 9

10 Additive CCs DISPLAYED Additive CCs ACTUAL New Additive Factor


Notes: 1. CAUTION! DO NOT OVERFILL graduated cylinder 2. Always wear eye protection and protective clothing while performing testing 3. For each Test Injection, record the raw data (ccs injected), as indicated by master controller 4. Following testing, return all valves & switches to normal operating position 5. One (1) US Gallon = 3785.44 CCs 6. ATTENTION! You MUST enter any new Additive K-Factor into the master controller program.

Calculation:
New Additive Factor = (Current K-Factor X Additive CCs Displayed) Actual Additive CCs in Graduated Cylinder

Comments/Recommendations:

Signature

Date