miniblock maintenance field guide v2.47

ChemtecChemtec Energy Services, Inc.

11745 Cude RoadWillis, Texas USA 77318

Phone 936 856 1704Facsimile 936 856 1669

www.ChemtecEnergy.com

MiniBLOCK “Slave Injector”

OPERATION & MAINTENANCEFIELD GUIDE

v 2.47

Model 7738Model 7718

DESCRIPTION

MiniBLOCK is used to meter the injection of a wide range of liquid additives including fuel additives, petroleumdyes, and marker additives. MiniBLOCK is machined from a single 300 series stainless steel block, therebygreatly reducing the number of potential leak points. The product serves as a “slave device” to a customersupplied “master controller”. MiniBLOCK may be controlled by any device that is capable of controlling thesolenoid 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

MeteringPositive displacement oval gears provide precise additive metering for low flow applications. The oval geardesign is highly accurate, reliable and provides low pressure drop.

316 stainless steel oval gears (standard) offer enhanced chemical compatibility

Flow Control ValveAdditive flow control is provided by the normally closed ASCO solenoid valve. The solenoid valve is machinedinto 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 preventinternal valve leaking (unauthorized additive flow) and excellent chemical resistance

17.1 watt coil (standard) ensures CORE ASSEMBLY (plunger) operation across a widerange of operating conditions

SensorThe 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 isavailable 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 WHITE2. 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 ComponentsNeedle Valves INLET / OUTLET, 300 series stainless steel, high pressure ratedCalibration Fitting Swagelok, male 1/4”, 300 series stainless steel, includes dust capStrainer Internal, 316 stainless steel basket type strainer, 60 mesh (230 micron)Check Valve External mounted, Swagelok, 316 stainless steel, 1 PSI cracking pressure

Chemtec MiniBLOCK INTRODUCTION

Chemtec MiniBLOCK SPECIFICATIONS

PerformanceModel 7738 0.3 - 3.0 GPM (1.2 - 12 LPM) @ 1 cSt, 300 PSIG, 2,600 PPG nominal resolutionModel 7718 0.03 - 0.3 GPM (0.12 - 1.2 LPM) @ 1 cSt, 300 PSIG, 6,000 PPG nominal resolution

ElectricalSolenoid 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).Sensor 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 Switchsensor available as option. All sensors rated for Class 1, Div. 1 Group D hazardous areas.

MechanicalElastomers Chemraz dynamic seals & Teflon static seals (standard), other elastomers available as optionField Mounting (2) mounting holes provide for the mounting of the device to backplane or unistrut utilizing

5/16-inch hex socket cap screwConfiguration Multi-PAC configurations include 1-PAC through 6-PAC, each PAC pre-wired and mountedMeter Access Meter access via four (4) recessed socket head bolts located under sensorMeter Gears Oval gear design, 300 series stainless steel (standard)Needle Valves 316 stainless steel with Teflon packing, high pressure ratedCalibration Swagelok quick-connect fitting with dust cap, 316 stainless steel, mates with PN 77-CTK-50Strainer Stainless steel filter screen, basket type, 230 micron (60 mesh)Check Valve Swagelok, 1 PSIG cracking pressure, stainless steel, 3/8” male inlet x 3/8” female outletDimensions 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 AccessoriesCalibration Kit PN 77-CTK-50 (standard), or PN 77-CTK-50HR (recommended for all dye additives)Thermal Relief Kit PN 77-TRK-10 (device recommended for all dye applications)

Note In addition to the use of the external mounted MiniBLOCK check valve on the injector, theuser should always install a check valve at the injection point on the main product line. Thecheck valve provides redundant support in preventing main product from flowing throughthe injector in the reverse direction.

For DYE injection systems, a solenoid valve or other blocking valve should be installed atthe injection point. The installed valve prevents unauthorized DYE leakage due to thermalexpansion. Whenever a valve is installed at the injection point, a Thermal Relief Kit must beinstalled on the MiniBLOCK injector.

Field Installation Considerations

PERFORMANCE CURVESChemtec MiniBLOCK

NotePerformance data provided below was generated using low differential pressure. The use of a higher differentialpressure (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

DIMENSIONAL DRAWINGChemtec MiniBLOCK

Chemtec MiniBLOCK GENERAL ASSEMBLY

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

Item Qty. Description Part No.1 1 Quick Connect, SS, Viton O-ring (std.)** SS-QCH-B-4PM2 1 T, SS, 1/4" x 1/4" x 1/4" FNPT SS-4-T3 1 Check Valve, SS, 50PSIG, 1/4" MNPT x 1/4" MNPT, Viton** SS-4CPI-50V4 1 Tube Fitting, SS, 1/4" Tube x 1/4" FNPT SS-400-7-45 1 Tubing, SS, 1/4", .035 SS-T4-S-035-206 1 Pressure Gauge, SS, Liquid Filled, 0-160 PSIG PGI-63C-PG160-LA017 1 Graduated Cylinder, Plastic, 1000 ML (IVD, diesel additives) 3BW-47315-10008 1 Graduated Cylinder, Plastic, 500 ML (Dye, Marker, additives) 3BW-47314-500

CALIBRATION KITChemtec MiniBLOCK

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 maleSwagelok 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

8

7

5 4 3 2

6

1

Item Qty. Description Part No.1 1 Strainer Assembly SS-8F-K4-2302 1 Reducing Bushing, 3/8” MNPT x 1/4” FNPT, Swagelok SS--6-RB-43 2 Street T, SS, 3/8" MNPT x 3/8" FNPT x 3/8"F, Swagelok SS-6-ST4 1 Fitting, SS, 3/8” MNPT x 1/4” Tube, Swagelok SS-0400-1-65 2 1/4” Tube Fitting, SS, Swagelok, with 1/4” tubing, .035 SS-T4-S-035-206 1 Elbow, SS, 1/4" Tube x 1/4" FNPT SS-400-8-47 1 Check Valve, SS, 1/4", 10 PSIG cracking pressure SS-4CP2-108 1 Outlet Check Valve, SS, 3/8”NPT x 3/8”NPT, Swagelok SS-CHM6-1

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

PRODUCT ORDERING

PN# 77-TRK-10HRIncludes Chemraz O-ring in Check Valve

Model 7718With Installed Thermal Relief Kit

THERMAL RELIEF KITChemtec MiniBLOCK

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

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

6-PAC EXP. Configuration6-PAC

Load Rack Mounted

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-PACWith NEMA 12 Enclosure

PAC CONFIGURATIONSChemtec MiniBLOCK

ADDITIVE SYSTEM P&IDChemtec MiniBLOCK

DYE SYSTEM P&IDChemtec MiniBLOCK

BackgroundThe accuracy of an injector calibration may be affected by several variables including additive viscosity, pumppressure, meter to meter variation, and the volume of additive injected for each injection cycle. Additiveviscosity for most fuel additives changes with temperature, thus necessitating the need for seasonal calibra-tions. In order to minimize the adverse effect of these variables, a final calibration MUST be performed in thefield utilizing the specific additive to be metered.

NoteWhen new injectors are installed, trapped air in additive lines is a common occurrence. Air in theadditive lines may adversely affect meter calibration and meter accuracy, as well as prevent thesolenoid valve from opening. Ensure all air is eliminated prior to performing a Field Calibration.

MiniBLOCK ControlMiniBLOCK injectors are typically controlled by a customer supplied “master” control device, such as anAccuload III preset, Danload 6000 preset, Multiload, PLC, or other electronic control device capable of count-ing high speed meter pulses and controlling the solenoid control valve. MiniBLOCK serves as a “slave”device to the “master” controller.

NoteAn 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 accuratefield calibration using the additive to be metered.For initial testing, a K-Factor of 2,600 PPG may beused for the Model 7738 and 6,000 PPG for Model 7718. Some “master” control devices may in-corporate an automated calibration feature. Always refer to the product manual for the “master”control device utilized.

MiniBLOCK Meter & SensorMiniBLOCK utilizes a positive displacement flow meter for metering additive. Additive flow through the flowmeter generates electrical pulses via a Hall-Effect sensor, whereby each meter pulse represents a specificquantity of additive dispensed through the injector. The specific quantity dispensed for each meter pulse canonly 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 K-Factor affects the volume of additive ACTUALLY DELIVERED verses the volume DISPLAYED by the “master”control device.

NoteThe displayed volume of additive in the “master” control device is accurate ONLY when an accurateAdditive 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

FIELD CALIBRATIONChemtec MiniBLOCK

Manual Calibration Procedure

Step 11A Comply with all safety procedures1B 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 calibrated1C Assemble Calibration Kit equipment and prepare Calibration Form (Reference last page)

Step 22A 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 (CC’s per injection request), as programmed in “master” control device2C When ready to calibrate, ensure the selector switch for the additive pump & motor is positioned ON

Step 33A Initiate several injections into the additive line or bucket prior to starting the calibration test. This actionensures 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 additiveline 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 44A Prior to performing the calibration test, ensure there is NO residual additive in the graduated cylinder4B Position the graduated cylinder under Calibration Test Kit tubing and prepare for the test4C Partially close the Inlet needle valve in order to prevent high pressure splashing of additive into the cylinder

Step 55A With an Additive Set of < 100 CC’s 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 CC’s, utilize the 500 ML graduated cylinder dedicated for dye additive.

CAUTION! DO NOT overfill the beaker. Do not splash additive.

Step 66A 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 CC’s”, 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 cylinder6C Calculate the “revised” Additive K-Factor utilizing the folowing formula:

New Additive K-Factor = (Current K-Factor X *Additive CC’s Displayed) Actual Additive CC’s 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


Step 77A 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 88A On completion of calibration, remember to OPEN the Inlet needle valve and remove the Calibration Kit8B Re-position the additive pump & motor selector switch to “Automatic Position”. The MiniBLOCK is now readyto resume normal operation.

Calculating A New Additive K-Factor: Example

(Current K-Factor X Additive CC’s Displayed) = New Additive K-Factor Actual Additive CC’s in Graduated Cylinder

Example Assumptions:Current Additive K-Factor = 2710Additive CC’s Displayed (cummulative total following end of test injections) = 453.6Actual Additive CC’s 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 toreflect the New Additive K-Factor of 2587.91

Calculating Additive Set Value: Example

Treat Rate per 1000 gal. X 3785.44 = Additive Set (CC’s per 40 gallons of product) 25 Injection Cycles

Example Assumptions:Injection Rate = 0.750 gal. additive per 1000 gal. of productCC’s per gallon = 3785.44Product 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 CC’s (Additive Set)

25

Note US gallon = 3785.44 CCUS gallon = 3.785 Liters


Test Injections

1

2

3

4

5

6

7

8

9

10

Additive CC’sDISPLAYED

Additive CC’sACTUAL

New AdditiveFactor

Notes:1. CAUTION! DO NOT OVERFILL graduated cylinder2. Always wear eye protection and protective clothing while performing testing3. For each Test Injection, record the raw data (cc’s injected), as indicated by master controller4. Following testing, return all valves & switches to “normal” operating position5. One (1) US Gallon = 3785.44 CC’s6. ATTENTION! You MUST enter any new Additive K-Factor into the “master” controller program.

Calculation:

New Additive Factor =

Comments/Recommendations:

Customer Location Injector ID Calibration Performed By Date

Beginning Additive K-Factor

Test 1 Test 2 Test 3 Test 4 Test 5

TEST RESULTS (CC’s)

Record CC’s after each injection

cycle(1 thru 10)

Signature Date

Additive Set (CC’s per injection)

Calibration Form

(Current K-Factor X Additive CC’s Displayed) Actual Additive CC’s in Graduated Cylinder

miniblock maintenance field guide v2.47

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