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Technical Support Information No. 101 Revision 6.0 December 2006

A&D Sensors and Communication - Process Analytics - Karlsruhe Germany of 17

© SIEMENS AG Karlsruhe - A&D SC PA AS 2 - Niko Benas +49 721 595 7216 - [email protected]

Maxum II FID-Flammen-Überwachung / Automatische Zündung Zusammenfassung Erste Möglichkeit den Status der Flamme am Maxum II 302A FID zu überwachen erfolgt mittels eines künstlich erzeugten Peaks. Dieser wird generiert, indem kurzzeitig der Brenngas- bzw. Wasserstoff-Trägergas-Fluss zum FID geändert wird. Der so generierte „Flammen-Indikator“-Peak wird über EZChrom eingebunden und auf 100 % kalibriert. Die Flammenüberwachung erfolgt über einen festgelegten unteren Grenzwert von 10%. Die Zündungs-Sequenz wird ausgelöst sobald dieser Wert unterschritten wird. Der Status der Flamme ist in Ordnung wenn der Wert grösser bleibt. Ist die Flamme erloschen, so wird ein Alarm generiert und die automatische Zündung des FID ausgelöst. Eine zweite Möglichkeit besteht darin, das Abgleich-Signal des FID-Detektors zur Zündung heranzuziehen. Vorteilhaft, wenn LIVE-Schaltungen eingesetzt werden. FID Flame Detection / Auto-Ignition on Maxum II The first possibility to monitor the status of the flame in the Maxum II 302A flame Ionization detector (FID) is determined by monitoring an artificial peak, X_FID_Flame_Indicator (X = Detector Location; L = Left, C = Center, R = Right).

This peak is created by temporarily changing the hydrogen flame fuel or hydrogen carrier flow

to the FID. The Flame Indicator peak is integrated in the standard fashion using the EZChrom software package. The Flame Indicator peak has an associated low limit used to determine the status of the flame. The re-ignition sequence is triggered any time the value of the Flame Indicator peak falls below a minimum preset value. The flame status is normal when the Flame Indicator peak exceeds the minimum value. If the flame is extinguished a user alarm will be generated and the software will attempt to re-ignite the detector flame. The flame out alarm and the ignition sequence are triggered once a cycle when the Flame Indicator peak value falls below the minimum. Below is a typical Flame Indicator configuration for a FID in the right detector position.

The second alternative is to monitor the balance signal of the FID. Beneficial if LIVE-switching is used.

Als Betriebsgeheimnis anvertraut. Alle Rechte vorbehalten. Der Inhalt dieser TSI wurde auf Übereinstimmung mit der beschriebenen Hard- und Software geprüft, dennoch können Abweichungen nicht ausgeschlossen werden. Technische Änderungen vorbehalten. Proprietary data. All rights reserved. While we have verified the contents of this TSI in agreement with hardware and software described, variations remain possible. Thus we cannot guarantee full agreement. Technical data are subject to change.

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1. Monitoring the Flame Indicator Peak

The needed MaxBasic programs can be found at the SIEMENS Intranet Service Support site. Use the following steps when configuring the Flame Indicator peak: 1. Select the gas to alter. These are listed in order of most favorable to least favorable. • Hydrogen flame fuel. • Hydrogen carrier. 2. Temporarily increase the pressure 20-50% above the normal operating pressure for 1-5 seconds. Pressure

change and duration should be sufficient to meet the requirements of item 3. 3. The minimum peak height of the Flame Indicator peak should be approximately 0.005 volts. EZChrom Peak/Group Table:

Calibrated Range should be selected in the Group Type and the peak start / stop times should be entered in the Group Def field. The Quantitate field should be set to Height and enter 100 in Level 1 calibration field. The Units field should not have en entry. System Manager Result Table:

A Flame Indicator result must be created for each process and validation stream with the appropriate limitapp & limitref selection. Flame status is not monitored on the calibration streams. System Manager Limit Table:

Limit ID 923 shows typical setting for the Flame Indicator record. Any value below the lovalue triggers alarm handler 923. The low value is factory set at 10 (no units).


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System Manager Alarmhandler Table:

Alarm code 923 issues a flame out alarm and triggers digital output 230 (R_FID Man Ignite) to re-ignite the FID flame. Note: In case you have to use the temperature-dependent FID-ignition procedure simultaneously, modify the alarmhandler table like this:

Check Technical Support Information TSI No. 96 for more details regarding the implementation of temperature dependent FID-ignition! Because of the disabled FID_Man_Ignite-DO you have to run MaxBasic programs for enabling it:


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System Manager Application DO Table:

System Manager Sys_DO Table:

The pulse_duration is set to 45.000.000 µs (45 seconds) and the pulse_polarity_neg is set to zero. This last setting is very important, else the FID won’t ignite! You have to upgrade the database at least to version 4.0 since the pulse_duration is not implemented in version less than 4.0.


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2. Monitoring the FID Balance Signal

There are two versions available. The first version is necessary, if an EPC is regulating combustion air. The second version is needed if a manual pressure regulator is used to adjust combustion air. The needed MaxBasic programs and the appropriate database textfiles can be found at the SIEMENS Intranet Service Support site. First version: electronic pressure regulator (EPC) is regulating combustion air System Manager Limit Table:

Limit ID 923 shows the setting for the balance monitoring record. Any value below the lovalue triggers Alarmhandler 923. Any value above the hivalue triggers Alarmhandler 924. The value is factory set at 6 %.

Limit ID 990 is monitoring the temperature dependent ignition of the FID. Any value below the lovalue triggers Alarmhandler/Program 991. Any value above the hivalue triggers Alarmhandler/Program 990. The value is factory set at 145 to149 °C. Check TSI #96 for more informations!


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Alarm code 923 issues a flame out alarm on R_FID and triggers digital output 800 (R_FID OUT) to re-ignite the R_FID flame by triggering the hivalue Limit ID 991. Alarm code 924 issues a ‘R_FID Flame On’-message and switches off digital output 800 (L_FID OUT).

Instead of implementing a MaxBasic program in the programid entry to ignite the FID’s like for the temperature dependent-ignition, we switch one DO. Advantage: it is possible to ignite the FID’s manually! Thus it can be avoided to try to ignite continously (in RUN or in HOLD it’s no odds) while monitoring the AI-balance-signal if there is no FID gas supply available/topped.


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It’s necessary to implement a DUMMY DO in the SYS_DO Table:

Program ID 990 is enabling and switching the R_FID Ignite-DO and afterwards disabling the DO and the program itself. Program ID 991 enables program 990. System Manager Program Table:

System Manager Parameter Table:

Parameter ID 992 indicates the AO ID of the EPC for the R_FID Air supply while parameter ID 993 identifies the EPC setpoint. Important Note: Always check if the ID’s and setpoint settings match with the recent application!


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The pulse_duration is set to 45.000.000 µs (45 seconds) and the pulse_polarity_neg is set to zero. This option is very important, else the FID won’t ignite! You have to upgrade the database at least to version 4.0 since the pulse_duration is not implemented in version less than 4.0. Additional Note: If the application is working in LOW sensitivity (FID Lo-Gain ON) you need to balance the FID twice via the EZChrom method: in the HIGH range and in the LOW range to get valid balance values. Example:


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© SIEMENS AG Karlsruhe - A&D SC PA AS 2 - Niko Benas +49 721 595 7216 - [email protected] Als Betriebsgeheimnis anvertraut. Alle Rechte vorbehalten. Der Inhalt dieser TSI wurde auf Übereinstimmung mit der beschriebenen Hard- und Software geprüft, dennoch können Abweichungen nicht ausgeschlossen werden. Technische Änderungen vorbehalten. Proprietary data. All rights reserved. While we have verified the contents of this TSI in agreement with hardware and software described, variations remain possible. Thus we cannot guarantee full agreement. Technical data are subject to change.

The appropriate Max-Basic programs: FID_Ignite_Control.bas Sub main() '============================================================================== 'Function: Disables the DO for any funktion 'input parameter 'Revision History Name Date Comments '1.0 USpi 11/20/03 Rewritten for 4.0 ' Modified W.Schr. 19.12.2003 (iArg1 added) ' Modified A.Fritz 25.07.2005 Erase Disable DO ' 'Arguments: iArg0 - id of appdo man ignite ' iArg1 - id of FID_Ignite program ' iArg2 - id of intFIDAirApp_AO ' rArg0 - dblIgnitionPressure '============================================================================== Dim tblDO As Table Dim sql As String Dim strSQL As String Dim n As Long Dim dblIgnitionPressure As Double Dim intFIDAirApp_AO_id As Integer '============================================================================== 'SET CONSTANTS intFIDAirApp_AO_id = iArg2 dblIgnitionPressure = rArg0 '=============================================================================== 'SET THE FID_AIR SET POINT TO THE IGNITION PRESSURE strSQL = strSQL & "; Update appao Set value = " & Str$(dblIgnitionPressure) strSQL = strSQL & " Where application_id = " & Appl strSQL = strSQL & " And id = " & intFIDAirApp_AO_id strSQL = strSQL & "; Send 'forcewrite' To appao" strSQL = strSQL & " Where application_id = " & Appl strSQL = strSQL & " And id = " & intFIDAirApp_AO_id n = db.ExecuteSQL(strSQL) '==============================================================================

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' set DO off/on for ignite FID sql = "Update appdo Set value = false" sql = sql + " Where application_id = " + Str$(Appl) sql = sql + " And id = " + Str$(iArg0) n = db.ExecuteSQL(sql) sql = "Update appdo Set value = true" sql = sql + " Where application_id = " + Str$(Appl) sql = sql + " And id = " + Str$(iArg0) n = db.ExecuteSQL(sql) Sql = "Update program Set enable = FALSE Where appcontext = " & Str$(Appl) Sql = Sql + " And id = " & Str$(iArg1) n = db.ExecuteSQL(Sql) End Sub FID_Control_Enable.bas Sub main() '============================================================================== 'Function: Enables PGM #990 'input parameter 'Revision History Name Date Comments '1.0 USpi 11/20/03 Rewritten for 4.0 ' Modified W.Schr. 19.12.2003 (iArg0 added) ' iArg0 = Program ID of FID Ignite PGM to Enable '============================================================================== Dim sql As String Dim n As Long Sql = " Update program Set enable = TRUE Where id = " & Str$(iarg0) n = db.ExecuteSQL(sql) End Sub

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Second version: manual pressure regulator is regulating combustion air System Manager Limit Table:

Limit ID 929 shows the setting for the balance monitoring record. Any value below the lovalue triggers Alarmhandler 929. Any value above the hivalue triggers Alarmhandler 930. The value is factory set at 6 %.

Limit ID 790 is monitoring the temperature dependent ignition of the FID. Any value below the lovalue triggers Alarmhandler/Program 791. Any value above the hivalue triggers Alarmhandler/Program 790. The value is factory set at 145 to149 °C. Check TSI #96 for more informations!


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Alarm code 929 issues a flame out alarm on C_FID and triggers digital output 802 (C_FID OUT) to re-ignite the C_FID flame by triggering the hivalue Limit ID 791. Alarm code 930 issues a ‘C_FID Flame On’-message and switches off digital output 802 (C_FID OUT).

Instead of implementing a MaxBasic program in the programid entry to ignite the FID’s like for the temperature dependent-ignition, we switch one DO. Advantage: it is possible to ignite the FID’s manually! Thus it can be avoided to try to ignite continously (in RUN or in HOLD it’s no odds) while monitoring the AI-balance-signal if there is no FID gas supply available/topped. It’s necessary to implement a DUMMY DO in the SYS_DO Table:


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Program ID 790 is enabling and switching the C_FID Ignite-DO and afterwards disabling the DO and the program itself. Program ID 791 enables program 790. System Manager Program Table:

System Manager Parameter Table:

Parameter ID 790 indicates the DO ID of the C_FID ignition. Important Note: Always check if the ID’s and setpoint settings match with the recent application!


The pulse_duration is set to 15.000.000 µs (15 seconds) and the pulse_polarity_neg is set to zero. This option is very important, else the FID won’t ignite! You have to upgrade the database at least to version 4.0 since the pulse_duration is not implemented in version less than 4.0.


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Additional Note: If the application is working in LOW sensitivity (FID Lo-Gain ON) you need to balance the FID twice via the EZChrom method: in the HIGH range and in the LOW range to get valid balance values. Example:


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The appropriate Max-Basic programs: FID_Ignite_Control.bas Sub main() '============================================================================== 'Function: Disables the DO for any funktion 'input parameter 'Revision History Name Date Comments '1.0 USpi 11/20/03 Rewritten for 4.0 ' Modified W.Schr. 19.12.2003 (iArg1 added) ' 'Arguments: iArg0 - id of appdo Man_Ignite ' iArg1 - id of program to disable '============================================================================== Dim tblDO As Table Dim sql As String Dim n As Long ' set DO off/on for ignite FID sql = "Update appdo Set value = false" sql = sql + " Where application_id = " + Str$(Appl) sql = sql + " And id = " + Str$(iArg0) n = db.ExecuteSQL(sql) sql = "Update appdo Set value = true" sql = sql + " Where application_id = " + Str$(Appl) sql = sql + " And id = " + Str$(iArg0) n = db.ExecuteSQL(sql) Sql = "Update program Set enable = FALSE Where appcontext = " & Str$(Appl) Sql = Sql + " And id = " & Str$(iArg1) n = db.ExecuteSQL(Sql) End Sub

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FID_Control_Enable.bas Sub main() '============================================================================== 'Function: Enables PGM #990 'input parameter 'Revision History Name Date Comments '1.0 USpi 11/20/03 Rewritten for 4.0 ' Modified W.Schr. 19.12.2003 (iArg0 added) ' iArg0 = Program ID to Enable -FID_Ignite '============================================================================== Dim sql As String Dim n As Long Sql = " Update program Set enable = TRUE Where id = " & Str$(iarg0) n = db.ExecuteSQL(sql) End Sub

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Required Records for Various Detector Locations: The table below is a matrix of various FID locations and the typical identification of the required records.

Left FID Center FID Right FID FID Manual Ignite Application DO: 110 170 230 Alarm Handler Record: 919 921 923 Limit Record: 919 921 923 Result: 1100 1700 2300 Result (simulated distillation): 50 - -

Simulated distillation analyzers should use the total area result to monitor the flame status. The result ID is configurable, but the factory default is 50. Gas Flow Rates: The hydrogen and combustion air flow to the FID effect the flame ignition process. The combustion air flow should be based on the total hydrogen flow to a respective detector. The total hydrogen flow is a sum of the column flow and an additional hydrogen flow such as make-up gas. Reference the table below to select proper combustion air flow:

Hydrogen (cc/min) Combustion Air (cc/min) 20-24 300 25-29 350 30-39 400 40-50 500

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