GE EVT-Pro 2.0 Operation And Technical Manual Download Page 2

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* DENOTES TRADEMARKS OF THE GENERAL ELECTRIC COMPANY

2016 GENERAL

OTHER COMPANY NAMES AND PRODUCT NAMES USED IN THIS DOCUMENT ARE THE

REGISTERED TRADEMARKS OR TRADEMARKS OF THEIR RESPECTIVE OWNERS

ALL INFORMATION ENCLOSED IS GE PROPRIETARY AND CONFIDENTIAL AND NOT FOR

COPY OR DISTRIBUTION

EVT* PRO 2.0

Summary of Contents for EVT-Pro 2.0

Page 2: ...CTRIC COMPANY ALL RIGHTS RESERVED OTHER COMPANY NAMES AND PRODUCT NAMES USED IN THIS DOCUMENT ARE THE REGISTERED TRADEMARKS OR TRADEMARKS OF THEIR RESPECTIVE OWNERS ALL INFORMATION ENCLOSED IS GE PROPRIETARY AND CONFIDENTIAL AND NOT FOR COPY OR DISTRIBUTION EVT PRO 2 0 ...

Page 3: ...tion 13 EVT PRO 2 0 Laptop User Interface GeTac V110 Page 16 Section 14 EVT PRO 2 0 Cable Assembly Page 17 Section 15 EVT PRO 2 0 Mounting the Bracket to a Valve Page 18 Section 16 EVT PRO 2 0 Load Cell Utilization Page 21 Section 17 Influence of Process Pressure Upon Accuracy Page 21 Section 18 EVT PRO 2 0 Load Cell Accuracy Page 21 Section 19 EVT PRO 2 0 Overall System Accuracy Page 22 Section 2...

Page 4: ... 43 Section 33 EVT PRO 2 0 Calculate Hardware Function Page 44 Section 34 EVT PRO 2 0 X CSA Certified Intrinsic Safe IS Units Page 46 Section 35 EVT PRO 2 0 Establishing the Communications Data Link Page 47 Section 36 EVT PRO 2 0 Software Updates Page 47 Section 37 EVT PRO 2 0 Calibration Requirements Page 47 Section 38 EVT PRO 2 0 Calibration Certificates Ventil Client Website Page 48 Section 39 ...

Page 5: ...environments and complete all site specific safety training and LOTOrequired by the customer prior to conducting in situ testing Ill Test Requirements 4 Technicians should ensure that all documentation JSA work permits and or safe work practices are completed and discussed prior to beginning in situ testing This includes verifying that the area where testing will occur is free of hazards and has p...

Page 6: ...essure see warning in Section 2 on page 3 11 Using slow and deliberate pumping strokes increase the load on the PRVspindle to the pre calculated value determined by the EVT PRO 2 0 computer until an audible or visual indication of set point is reached Once set point is reached stop pumping and release the hydraulic pressure If the determined set point is within the popping pressure tolerance estab...

Page 7: ...ble for use of the EVT PRO 2 0 also Only trained and certified valve technicians should use the EVT PRO 2 0 Always wear appropriate PPE when using the EVT PRO 2 0 Do NOT use the EVT PRO 2 0 during periods of inclement weather i e dense fog rain sleet slow etc Immediately abort the use of the EVT PRO 2 0 if lightning occurs EVT PRO 2 0 Operations and Technical Manual Rev 1 0 2016 NOT FOR COPY OR DI...

Page 8: ... inches It was designed with this requirement in mind USE CAUTION when testing PRVs installed in flammable or toxic environments Ensure appropriate protective measures are being implemented PREREQUISITE EVT PRO 2 0 operators must at a minimum be a VALVE TECHNICIAN 2 or be supervised by a certified LEVEL 3 VALVE TECHNICIAN DO NOT OPERATE THE EVT PRO 2 0 IF SAFETY OF THE DEVICE OR PERSONNEL IS EVER ...

Page 9: ... allowing test monitoring to occur from safe distances outside of hazardous zones Pump case battery life is vastly extended to over 8 hours of continuous use approx 300 tests 15 min per test Engineering configuration of the Test Bracket now has a time saving claw clamp The claw clamp grasps the lifting nut adapter for quick connection to valves and the bracket has turnbuckle style screws for fast ...

Page 10: ...EVT PRO 2 0 Operations and Technical Manual Rev 1 0 2016 NOT FOR COPY OR DISTRIBUTION Page 6 ...

Page 11: ...EVT PRO 2 0 Operations and Technical Manual Rev 1 0 2016 NOT FOR COPY OR DISTRIBUTION Page 7 ...

Page 12: ...3 Pump case The EVT PRO 2 0 Valve testing system consists of 4 distinct hardware items They are as follows Load cell assembly case Figure 5 1 Bracket assembly case Figure 5 2 Pump case with laptop Figure 5 3 and 5 4 Cable assembly Figure 5 5 EVT PRO 2 0 Operations and Technical Manual Rev 1 0 2016 NOT FOR COPY OR DISTRIBUTION Page 8 ...

Page 13: ... THE EVT PRO 2 0 SYSTEM Figure 5 4 Getac V110 Laptop Figure 5 5 Cable Assembly shown connected to bracket Orange cable insulation sheathing not shown EVT PRO 2 0 Operations and Technical Manual Rev 1 0 2016 NOT FOR COPY OR DISTRIBUTION Page 9 ...

Page 14: ...Various other items are housed in this case Please refer to Figure 6 1 below for part identification Figure 6 1 EVT PRO 2 0 Load Cell Case Assembly Extra storage space for Acoustic and Lift Sensor Cables Acoustic Sensor Spindle Adapter Kit 1kN Hydraulic Lift Cylinder 1 20 kN Load Cell Acoustic Sensor Clamp Lift Sensor 50 kN Load Cell 1 kN Load Cell 10 kN Load Cell 20 kN Hydraulic Lift Cylinder 3 E...

Page 15: ...lls and 4 hydraulic lifting cylinders If a greater lifting and measuring capability is needed a fifth 100 kN load cell and hydraulic lifting cylinder can be requested It uses a separate bracket assembly and is issued upon special request The 4 load cells and the associated hydraulic lifting cylinders of the EVT PRO 2 0 system are Hydraulic lifting cylinder 1 kN 1 kN Load cell Approx 220 lbF Hydrau...

Page 16: ...Claw 2 SECTION 9 EVT PRO 2 0 BRACKET ASSEMBLY The EVT PRO 2 0 Bracket assembly is vastly improved over previous versions It utilizes turn screw micro height adjustment which allows for a minimum height of just 13 inches This is well below the 19 inch PRV overhead clearance requirement as stipulated by NBIC Section 3 API RP 520 and ASME Sec 1 VII and VIII The mounting adapter to the PRV spindle has...

Page 17: ...pump assembly electronics motherboard battery supply and the Getac V110 laptop computer Refer to figure 10 1 The EVT PRO 2 0 Hand Pump Case with electronics is a state of the art assembly It is assembled from lightweight aircraft aluminum and consists of a hydraulic pump a directional control lever and an electronics interface that sends test data to the computer via a wireless Wi Fi connection Th...

Page 18: ...nking Yellow 1 Charging Battery 1 is almost full Blinking Yellow 2 Charging Battery 2 Faster Blinking Yellow 2 Charging Battery 2 is almost full Both Green 2 and Red LED s on Battery 1 and 2 fully charged NOTE 1 If you only see one 1 Green LED that means the battery pack is bad Two is a GO One is a NO NOTE 2 If the battery pack is fully loaded and you place the battery on the charger again Only th...

Page 19: ...ing bent connection pins in both the interface panel and the cables Each receptacle is also keyed so only the proper cable will fit into it s corresponding receptacle Refer for figure 12 1 below for Interface Panel component identification Figure 12 1 Interface Panel Male Hydraulic Connection Restriction device Use Full open or full closed ONLY Female Hydraulic Connection Main Power Switch and Wi ...

Page 20: ...roper electronic operation The Getac V110 has an average run time of 8 hours under battery power per battery which can be hot swapped during operation without interruption Wi Fi wireless communications link Eliminates the USB cable and limitations of the previous unit The Wi Fi data link is low power and CSA approved Large 11 6 LumiBond 2 0 sunlight readable display 6th generation Intel CoreTM pro...

Page 21: ...can only be connected to the correct sensing device or correct receptacle on the interface panel Refer to figure 14 1 and 14 2 The cable is coated in heat RESISTANT Neoprene It can withstand TEMPORARY less than 5 seconds contact with surfaces up to 400 F A protective Orange sheath is provided with the Cable Assembly on all US units This sheath can withstand temperatures up to 1832 F 1000 C for up ...

Page 22: ...ass thumb screws to open the bracket base and fit it onto the valve Tighten the thumbscrews for a secure fit Step 4 Select the correct load cell as indicated by the software Step 5 Select the correct Load Cell Claw device which matches the load cell Screw the Claw device onto the load cell as shown NOTE When placing the Bracket Assembly onto the valve make sure to verify that the columns and the b...

Page 23: ...e hole for the Lifting Sensor Step 7 Use the height adjustment turn screws to lower the claw device so that the claws reach under the spindle adapter Then using the height adjustment screws raise the claw assembly to that it is snug but not applying any loading of the spindle EVT PRO 2 0 MOUNTING THE BRACKET TO A VALVE EVT PRO 2 0 Operations and Technical Manual Rev 1 0 2016 NOT FOR COPY OR DISTRI...

Page 24: ... trials have shown that this is the best location to place the Acoustic Sensor Ensure a good metal to metal contact Step 10 Insure NO part of the cable is in contact with hot surfaces Use the Velcro straps not shown to secure the cable if needed so that the cable and sensor leads are supported and out of the way for testing SECTION 15 Continued EVT PRO 2 0 MOUNTING THE BRACKET TO A VALVE EVT PRO 2...

Page 25: ...et pressure is minimal However technicians and plant personnel must realize that the possibility of putting a PRV into full lift also increases when process pressure is close to PRV set pressure Do not conduct in situ testing when the process pressure is less than 50 or greater than 90 of the PRV set pressure See Warnings in Section 2 page 3 The transducers provided with the EVT PRO 2 0 are calibr...

Page 26: ...Of the three effective seat area is the most critical element in determining an accurate set pressure Typically the accuracy of the EVT PRO 2 0 is within 1 of expected set pressure The ability to accurately determine PRV set pressure during in situ testing relies on three known factors Refer to figure 20 1 Hydraulic force generated by test equipment Inlet pressure resulting from process pressure E...

Page 27: ...luation of the hydraulic force lift and sound enables the technician to accurately determine the PRV set pressure Fig 21 1 Figure 21 1 Example of Valve Test Graph Results Hydraulic Force Line During testing the hydraulic force gradually increases When the PRV is closed inlet pressure applies a static force on the disc contained between the area of the nozzle and disc seat Upon opening media flow a...

Page 28: ...t SECTION 22 EVT PRO 2 0 FUNCTIONAL EFFECTIVE SEAT AREA Accuracy of the functional seat area is critical to the overall accuracy of in situ testing The EVT PRO 2 0 software contains various methods for determining functional seat area There are four 4 databases available for selecting the functional seat area along with three 3 additional methods for calculating the functional seat area The databa...

Page 29: ...al input of the inner then outer seat diameter Finger Print Test Linear Regression requires testing the PRV at a minimum of three different inlet pressures Upon successful completion the software will calculate the functional seat area of the PRV and normal testing can continue Be aware that the use of this method will require coordination with the plant in order to achieve the 3 different inlet p...

Page 30: ...ined in the software A search function enables the technician to enter PRV data to locate the appropriate PRV The EVT PRO 2 0 software stores PRV data under the specific client customer name and location Upon selecting a specific client and location the software will display all PRV data for that client and location The software stores all relevant test information for a particular PRV with a corr...

Page 31: ...navigate the program using the instructions provided below Step by step pictures of each screen is repetitive and adds unnecessary bulk to this manual Use the following steps to enter desired PRV data Examples of the final data screens are provided for clarity Adding a new Customer to the database Refer to figure 25 1 Main Menu Edit Database Customers Activate the New action F1 button Enter all ap...

Page 32: ... 2 Main Menu Edit Database Locations Select the applicable Client Activate the New action button Enter all applicable information Activate the Save action button to store the data EVT PRO 2 0 PRV DATA ENTRY EVT PRO 2 0 Operations and Technical Manual Rev 1 0 2016 NOT FOR COPY OR DISTRIBUTION Page 28 ...

Page 33: ... PRV data Activate the Save action button to store the data Modifying Existing Valve Details and or Test Parameters Refer to figure 25 3 Main Menu Edit Database Safety Valves Select the applicable Client Select the applicable Plant Highlight the applicable PRV and activate the Modify F3 action button Enter revise all applicable information Activate the Save action button EVT PRO 2 0 PRV DATA ENTRY...

Page 34: ...Ensure the laptop is powered on with the EVT PRO 2 0 software running Verify that the Hand Pump Case Electronics automatically established communications with the laptop by verifying for Green data link light on the electronics interface panel If not linked follow manual communications datalink procedure as found in Section 35 to establish the datalink 6 Securely attach the Bracket to the PRV Inst...

Page 35: ...1 Enter the Process Pressure 12 Ensure there is no load on the load cell and activate the Zero Force action button on the test screen Testing can begin by either pressing the space bar on the keyboard or by slowly pumping the hand pump EVT PRO 2 0 PERFORMING A TEST EVT PRO 2 0 Operations and Technical Manual Rev 1 0 2016 NOT FOR COPY OR DISTRIBUTION Page 31 ...

Page 36: ...restriction device located on the interface panel Refer to figure 12 1 During normal operation this check valve should remain open FOR THE FOLLOWING REFER TO FIGURE 26 1 16 Once the measuring process has been stopped the test graph is ready for evaluation 17 If a change in inlet pressure occurred before the valve was tested or if the wrong inlet pressure value was entered activate the Correct Line...

Page 37: ...SECTION 26 Continued Figure 26 1 Example of Test Results Screen EVT PRO 2 0 PERFORMING A TEST EVT PRO 2 0 Operations and Technical Manual Rev 1 0 2016 NOT FOR COPY OR DISTRIBUTION Page 33 ...

Page 38: ...d flow diagram of the steps used to add a new valve to the database or modify an existing valve EVT PRO 2 0 SOFTWARE QUICK REFERENCE GUIDE EVT PRO 2 0 Operations and Technical Manual Rev 1 0 2016 NOT FOR COPY OR DISTRIBUTION Page 34 ...

Page 39: ...Continued Below is a simplified flow diagram of the steps used test a valve EVT PRO 2 0 SOFTWARE QUICK REFERENCE GUIDE EVT PRO 2 0 Operations and Technical Manual Rev 1 0 2016 NOT FOR COPY OR DISTRIBUTION Page 35 ...

Page 40: ... Certificate is available after a valve is tested It is not necessary to complete all three 3 valve tests to generate a certificate with test results however GE Consolidated requires three tests of a valve in order to certify set point Refer to figures 28 1 and 28 2 for examples of the Test Certificate Figure 28 1 Test Certificate Page 1 EVT PRO 2 0 Operations and Technical Manual Rev 1 0 2016 NOT...

Page 41: ... by making changes to the global template which is found under the Options section of the software It is not recommended that you change the Global Template Refer to Section 30 if you wish to customize the Global Test Certificate Figure 28 2 Test Certificate Page 2 EVT PRO 2 0 Operations and Technical Manual Rev 1 0 2016 NOT FOR COPY OR DISTRIBUTION Page 37 ...

Page 42: ...the Password is entered the user will be taken to the Options Settings main menu screen Hardware settings are only available to the Manufacturer This is where sensor specific data is stored which affects unit performance Clicking on the Software Settings action button will take you to the Graph Settings screen Clicking on each graph option listed enables the user to change widths and pen colors of...

Page 43: ... on an indicated interval The interval can be changed here Only change the back up location if necessary To recover a backed up database activate the Recover action button and select the appropriate back up from the list Figure 29 4 Category Settings Screen GE Consolidated highly recommends that backups to the EVT PRO 2 0 database be stored on other external drives or storage devices in case of ha...

Page 44: ... Contact Consolidated if required language is not available in pull down menu Date Format Select required date format Show Accuracy Displays results based on calculations of set pressure using inner outer seat diameters Normally this box is not checked Show Reseat Pressure Enables the software to display a secondary vertical line to indicate reseat pressure Show Certificate Reminder Enables a prom...

Page 45: ...e right mouse button In editing mode both font type and color can be changed using the toolbox provided Switch off editing mode by activating the Enter key Test reports can be generated with a maximum of 4 images or pictures The size of the box can be adjusted by activating the box using the left mouse button and adjusting the dimensions using the toolbox provided Confirm the changed value by acti...

Page 46: ...p may be required as a result of frequent use of the EVT PRO 2 0 due to air accumulation Bleed the hydraulic hoses in the following manner 1 Connect both hydraulic hoses to the pump 2 Interconnect the hydraulic hoses on the cylinder end 3 Stroke the hand pump allowing the excess air to vent into the pump tank 4 Pump the hand pump until the air bubble clears 5 Close the vent cap 6 If testing reconn...

Page 47: ...cate Management Option Step 2 On the left side of the screen select the client location date or serial number for the test you wish to display Then on the right side of the screen select the desired test you wish to playback Step 3 Next select the desired playback speed Three 3 speeds are provided EVT PRO 2 0 Operations and Technical Manual Rev 1 0 2016 NOT FOR COPY OR DISTRIBUTION Page 43 Step 4 ...

Page 48: ...or to arriving on the job site It also lessons the equipment which needs to be carried to the actual valve site This is a great advantage when carrying the unit up several levels at a plant location Main Menu Calculate Hardware Requirements EVT PRO 2 0 Operations and Technical Manual Rev 1 0 2016 NOT FOR COPY OR DISTRIBUTION Page 44 SECTION 33 EVT PRO 2 0 CALCULATE HARDWARE FUNCTION The first step...

Page 49: ...drop down bar Then enter the expected process pressure and likewise select the appropriate units from the dropdown bar options Finally enter a force overload value GE Consolidated always recommends using a 10 force overload value Once all required data is entered press the calculate action button The EVT PRO 2 0 software will then calculate the required load cell and lifting cylinder needed to tes...

Page 50: ...Appendix for more details on interpreting CSA ATEX codes listed above Consult local requirements agencies to see which approval is appropriate for use in your region In either case the components used on the EVT PRO 2 0 X unit or Intrinsic Safe unit have been engineered and tested to meet specific electrical standards The units have special electronics barriers sensors grounding devices built into...

Page 51: ...ablished repeat this procedure If at that point no connection has been established please contact the Ventil Service Desk at http oms ventil nl ClientLogIn aspx Upon start up if the EVT PRO 2 0 detects an internet connection it will automatically check for the latest version of software If updates need to be made then it will give the user the option to install the downloaded new software version ...

Page 52: ...EVT PRO 2 0 There are four of them and all four will need to be returned When the calibration is completed both a paper Certificate of Calibration and an electronic one will be available for the owner On the Ventil Client Website EVT PRO 2 0 CALIBRATION CERTIFICATES VENTIL CLIENT WEBSITE SECTION 38 First enter the serial number of the EVT PRO 2 0 unit then enter the displayed security code as show...

Page 53: ...urned When the calibration is completed both a paper copy and an electronic one will be provided for the owner EVT PRO 2 0 SERVICE REQUESTS AND KEY CONTACTS SECTION 40 EVT PRO 2 0 Operations and Technical Manual Rev 1 0 2016 NOT FOR COPY OR DISTRIBUTION Page 49 With the release of software 5 2 10 version Ventil has added key Service contacts on line to your EVT PRO 2 0 device This will allow you t...

Page 54: ...then service charges will apply on a time and material basis per the rate schedule below Service rate charge is 65 USD per hour Premiums may apply for certain after hour requests GTC is responsible for all shipping and other related charges EVT PRO 2 0 SERVICE REQUESTS AND KEY CONTACTS How to Make a Request for Service 1 Use one of the key contacts above either e mail or telephone 2 Be prepared wi...

Page 55: ...r basic training and software usage questions should be directed to your local GE Training team which is listed below Figure 40 2 Service Response Process Flowchart EVT PRO 2 0 Operations and Technical Manual Rev 1 0 2016 NOT FOR COPY OR DISTRIBUTION Page 51 Figure 40 3 Regional Support Key Contacts ...

Page 56: ...CTRIC COMPANY ALL RIGHTS RESERVED OTHER COMPANY NAMES AND PRODUCT NAMES USED IN THIS DOCUMENT ARE THE REGISTERED TRADEMARKS OR TRADEMARKS OF THEIR RESPECTIVE OWNERS ALL INFORMATION ENCLOSED IS GE PROPRIETARY AND CONFIDENTIAL AND NOT FOR COPY OR DISTRIBUTION EVT PRO 2 0 ...

Page 57: ...APPENDIX INFORMATION EVT Pro 2 0 Operations and Technical Manual Rev 1 0 2016 ...

Page 58: ...e Secure all proper permits and approvals before testing obtain hot works permits Best engineering practices should be adhered to in hazardous environments such as the use of PPE non sparking tools no flames and other Consult local plant personnel Seek out additional specialized training when testing in hazardous environments This overview is not intended to serve as training on Hazardous environm...

Page 59: ...ue to it being present continuously intermittently or periodically or from the equipment itself under normal operating conditions Division 2 indicates that the hazardous material has a low probability of producing an explosive or ignitable mixture and is present only during abnormal conditions for a short period of time Group The Group defines the type of hazardous material in the surrounding atmo...

Page 60: ...G ia T4 environments How to read the code below Appropriate engineering practices shall be applied when in hazardous environments to include best practices for grounding tools ignition sources static electricity Always consult local authorities and plant engineering to ensure compliance ...

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