Manual for: Hybrid 600 gas analysis system

Manual for: Hybrid 600 gas analysis system

Project name:

Lehigh Texas

FLO2R Project no:

2020-05-Lehigh Texas, USA

Customer Order no.:

2200148

Customer Equipment no. (Tag):

____________

File name: Hybrid 600 – Two probe system with serial analysis cells.

Manual rev. no: 1

Issue date: 2020 - April 17th

Lehigh Texas FLO2R – Hybrid 600 of 57

1. Content 1. Content .................................................................................................................................... 2

2. Typical applications ................................................................................................................. 4

3. Safety first – Read before installation ..................................................................................... 5

Warning - High Voltages ............................................................................................................. 5

Warning - Sample and calibration gasses .................................................................................. 5

Warning - Laser beam ................................................................................................................. 6

Warning – Hot surfaces............................................................................................................... 6

Warning – Acid condense ........................................................................................................... 7

General safety procedure ........................................................................................................... 7

4. System components - connections ......................................................................................... 8

5. Description – Probe 600 .......................................................................................................... 9

Specifications Probe ................................................................................................................... 9

Safety instructions Probe ............................................................................................................ 9

Installation Probe......................................................................................................................... 9

Function of the Probe ................................................................................................................ 10

Operation of the Probe .............................................................................................................. 10

Maintenance of the Probe ......................................................................................................... 10

Troubleshooting the Probe ........................................................................................................ 11

6. Description – Heated hose(s) ................................................................................................ 15

Specifications Heated Hose(s).................................................................................................. 15

Safety instructions Heated Hose(s) .......................................................................................... 15

Installation Heated Hose(s) ....................................................................................................... 15

Function of the Heated Hose(s) ................................................................................................ 15

Operation of the Heated Hose(s) .............................................................................................. 16

Maintenance of the Heated Hose(s) ......................................................................................... 16

Troubleshooting the Heated Hose(s) ........................................................................................ 16

7. Description – Analysis Cabinet ............................................................................................. 17

Specifications Analysis Cabinet ................................................................................................ 17

Safety instructions Analysis Cabinet ......................................................................................... 17

Installation Analysis Cabinet ..................................................................................................... 18

Function of the Analysis Cabinet .............................................................................................. 18

Operation of the Analysis Cabinet ............................................................................................ 19

Manual Analysis Cabinet valves and their default settings ...................................................... 20

Maintenance of the Analysis Cabinet ....................................................................................... 20


Troubleshooting the Analysis Cabinet ...................................................................................... 23

8. Description – Laser analyzers ............................................................................................... 32

Specifications Laser Analyzer(s) .............................................................................................. 32

Safety instructions Laser Analyzer(s) ....................................................................................... 32

Installation Laser Analyzer(s) .................................................................................................... 32

Function of the Laser Analyzer(s) ............................................................................................. 32

Operation of the Laser Analyzer(s) ........................................................................................... 32

Maintenance of the Laser Analyzer(s) ...................................................................................... 33

Troubleshooting the Laser Analyzer(s) ..................................................................................... 33

9. Description – Control Cabinet ............................................................................................... 34

Specifications Control Cabinet .................................................................................................. 34

Safety instructions Control Cabinet .......................................................................................... 34

Installation Control Cabinet ....................................................................................................... 34

Function of the Control Cabinet ................................................................................................ 35

Operation of the Control Cabinet .............................................................................................. 35

Maintenance of the Control Cabinet ......................................................................................... 35

Troubleshooting the Control Cabinet ........................................................................................ 35

10. System operation HMI ....................................................................................................... 38

Home Screen: ........................................................................................................................... 40

Alarm Screen: ............................................................................................................................ 41

Operation Screen: ..................................................................................................................... 43

Operation – Probe 1 & Probe 2:................................................................................................ 45

Flow: .......................................................................................................................................... 48

Purge: ........................................................................................................................................ 49

Temperatures: ........................................................................................................................... 50

Vacuum: .................................................................................................................................... 51

Trend: CO, NO, O2 analysis ..................................................................................................... 53

Trend: Flow and Probe Pressure .............................................................................................. 54

11. Appendix 1 – Electrical diagrams ...................................................................................... 55

12. Sub-suppliers manuals ...................................................................................................... 56

13. Declaration of Conformity .................................................................................................. 57


2. Typical applications Congratulation with your new Hybrid 600 gas analysis system from FLO2R. The Hybrid 600

system is a fast extractive hot/wet gas analysis with a patented air knife which protect the laser

analyzers from the potentially contaminated process gas.

The system is equipped with a fully heated Probe capable of separating the dust from the gas.

The Probe is equipped with an adjustable dust shield and high-pressure filter cleaning blow

back. The system has by default one Probe. Option for a double Probe configuration is

available.

The Probe is capable of operation in high dust concentrations.

The heated hose(s) brings the sample gas from the Probe into the Analysis Cabinet. This is

done at a relative high volume providing a fast response time. The system is fully heated all the

way from the tip of the Probe through the heated hose and through the Analysis Cabinet –

preventing condensation to occur.

The Probe accepting high dust concentrations and an analysis system having a fast response

time makes the Hybrid 600 system ideal for fast gas analysis in high dust process applications.

Typically seen in combustion process were a fast interlocking response is required to be in

compliance with explosion prevention standards.


3. Safety first – Read before installation Read the instructions in this manual carefully before installing or operating the system. FLO2R

cannot accept any liability for damages due to non-observance of this manual.

On the Hybrid 600 system the following warnings signs will be used. Only qualified personnel

who are trained and capable of handling equipment subject to these warnings must operate and

service this equipment.

Warning - High Voltages

National and local regulation of electrical installation standards must be followed. Installation

must only be done by a certified electrician. All connections must be made in accordance with

this manual.

All electrical connections must be checked prior to applying voltages to the system. Special

attention must be related to a secure earth for the system. No altering of any earth connection

inside the system is allowed.

Warning - Sample and calibration gasses

Pay attention to any situation were leaking sample or calibration gasses could be present in or

around the equipment as these can be both toxic and potentially explosive.

It is recommended that the equipment is installed in a well-ventilated location. If the equipment

is installed in a closed enclosure it is recommended to install gas detectors to provide a

warning.

If a leakage occurs after the vacuum pump or in the calibration loop at over pressure conditions

sample/calibration gas can be present in the cabinet and its surroundings. Make sure to find and

close any leakage. In the event of a leakage make sure to ventilate the cabinet sufficiently

before any operation or service to the equipment is performed.


The gas outlet of the system can be connected to ambient at a well-ventilated location or

returned to the process.

In the event of sample or calibration gas is inhaled for a period dizziness or vomiting can occur.

Get to a well-ventilated location and call for help. Get fresh air and water and contact a

physician for evaluation and treatment if relevant.

In the event of sample gas or calibration is inhaled by accident for a long period at high

concentrations people may faint and, in the worst case, die.

Warning - Laser beam

The Hybrid 600 system utilize laser gas analysis to enable fast analysis. The light emitted from

a laser cannot be seen by the human eye. The light from a laser can damage the human eye

even if it’s a impact from a reflection.

All work on the laser taken off its installation flange or on an open measuring cell must therefore

only be done with the laser power turned off.

In the event of a laser eye burn use plenty of clean water and contact a physician for evaluation

and treatment if relevant.

Warning – Hot surfaces

The surface of Probe, heated hoses and heated cell are hot and can cause burns if touched

without protective wear.

Pay attention that it can take a long time to cool sufficient down to handle without protective

wear.

If any of the equipment is installed at locations were people can walk by make sure fencing

prevent accidental contact with any of the hot surfaces.


In the event of a burn use plenty of clean water and contact a physician for evaluation and

treatment if relevant

Warning – Acid condense

The outlet of the vacuum tank(s) and peristatic condense pumps carries an acid liquid that can

cause acid burns.

Always use protective gear for hands and eyes when working on the part of the system with

condensate to prevent contact.

In the event of an acid burn use plenty of clean water and contact a physician for evaluation and

treatment if relevant

General safety procedure

General minimum safety procedure working with any part of this gas analysis equipment:

The safety procedure before any service/work:

1. Get approval for work according to plant safety procedures

2. Set the system into test mode

3. Stop the system

4. Shut off the power supply

5. Shut off the air supply

The safety procedure after any service/work:

6. Any work that needs to be approved by an electrical or mechanical department must be

completed

7. Make sure all instruction in the manual is followed

8. Turn on the air supply

9. Turn on the power supply

10. Start the system

11. Turn off the test mode

12. Sign off the work as required


4. System components - connections

Figure 1: Connections/Supply


5. Description – Probe 600

Specifications Probe

Process temperature limitation: 600°C/1110°F

Ambient temperature limitation: -30°C …45°C/-22°F …113°F

Power consumption: 500W – supplied from Control Cabinet

Dust load limitations: 200 g/m3

Flange connection: 3” others on request (ISODN50 PN10, ANSI 2”)

Probe overall size: 1382mm long x 306mm wide x 453 high

Insertion length process: 993mm

Materials: Hot/wetted parts St. 316L, non-wetted parts St. 304

Safety instructions Probe

Only qualified personnel who are trained and capable of handling equipment subject to the

process and equipment warnings must operate and service this equipment. The general safety

procedure must always be followed.

Installation of the equipment must only take place during a process shutdown to avoid

hazardous situations caused by high temperature and over pressure in the process.

In the event the Probe needs to be installed/removed during operation the specific safety

requirements as demanded on the site must be followed. FLO2R cannot be responsibility for

any work or service done installing or removing the Probe during process operation.

Special attention to warning signs displayed on the Probe must be taken. Special attention to

hot surfaces.

Installation Probe

The installation point must be selected based on the primary objective for the measurement

observing the working conditions as specified above.

The measuring point should have a gas flow as homogeneous as possible avoiding installation

right after bends or reductions or other obstacles leaving ideally 3 - 5x the duct diameter of

distance between such installations.

The Probe should never be installed downstream in the same duct/channel section as a

water/liquid spray is present. In a downcomer with a water spray the Probe must be install prior

to the spray inlet flow wise.

The Probe is equipped with an adjustable dust deflector. The dust deflector must be orientated

in the direction of the flow in order to protect the filter surface.


A counter flange as specified on the drawing below is welded to the process duct/wall as

illustrated on the drawing in this section.

The Probe is installed by bolting the flange to the counter flange on the process duct/wall.

Please see the installation drawing in this section.

Hoses are connected to the Probe as illustrated on the drawing below. All hoses must be

installed in a practical and protective way allowing for access for future service. All hoses must

be protected against high temperature surfaces. Bend radius for any hose should not be less

than 40cm/16”.

Function of the Probe

The Probe is a heated extractive Probe with air blow back of the filter.

The objective of the Probe is to separate a sample gas of the process from the dust. A sintered

stainless-steel filter collects the dust on the surface allowing only the gas to enter inside. The

size of the filter allows a large amount of sample gas to be collected in order to make a fast

replacement/analysis response time.

A blow back function/solenoid valve will remove the dust from the surface of the filter.

A pressure sensor measures the performance of the filter.

A heating element runs in the entire length of the Probe. The heater will make sure that the

Probe temperature is kept above the dew point of water and acid.

A calibration valve will allow a zero or calibration gas to be connected to the Probe to make a

“full train” validation test of the system. The calibration valve will lead the test gas to the Probe

filter. The calibration gas must be supplied with enough force to blow out any process gas. This

is done by turning the calibration gas up until the measurement becomes steady.

Operation of the Probe

The Probe is operated from the control panel. As soon as the Probe has been bolted to the

flange and all hoses and wires are secured according to the safety instruction the operation of

the Probe can begin.

For instructions on operating the Probe please see the section covering HMI operation.

Maintenance of the Probe

Under normal operation the Probe will not require daily maintenance. As long as the sample

flow, and Probe temperature are within target no action is required.

During a process shutdown the heater of the Probe must be left turned on – or the Probe must

be removed from the process during the process shutdown. This to protect the filter from the

possible combination of dust and humidity/water.


During a process heat-up with new lining materials in the process line it can be an advantage to

the Probe to wait to be installed until after the process temperature in the kiln has released the

mechanical bounded water +400°C/750°F of new lining of brick work. This is only possible if the

safety instruction for the plant allows it. Alternatively, the Probe can operate with the heater

turned on to prevent water to settle in the filter.

Daily maintenance:

Observe that no alarms occur for sample flow and Probe temperature.

Half yearly – or at a given process stop:

Remove Probe and check filter and remove any dust buildups.

Yearly – or at a given plant outing.

Remove Probe and check filter and remove any dust buildups.

Check hoses for leakages

Troubleshooting the Probe

Problem Origin Cause Solution

Low sample flow Dust Blockage - dust Increase blow back sequence, check dust deflector position

Low sample flow Water Instrument air supply Fix water removal for instrument air

Low sample flow Water/Acid Low temperature Check Probe heater and temperature sensor

High Probe sample pressure

Dust Blockage - dust Increase blow back sequence

Low Probe temperature

Heater Heating element Check that the heating element and temperature sensor is functioning correctly


Figure 2: Probe layout


Figure 3: Probe layout - expl. view


Figure 4: Probe electrical cabinet


6. Description – Heated hose(s)

Specifications Heated Hose(s)


Tube diameter: 10/8mm

Length: Custom made 4m & 12m

Power consumption: 500W – 1.500W Depending on hose length. Power supplied

from Analysis Cabinet.

Materials: Core - PTFE, Outside - Steel braid galvanized

Safety instructions Heated Hose(s)




Special attention to warning signs displayed on the heated hose must be taken. Special

attention to hot surfaces.

Installation Heated Hose(s)

The heated hoses are mechanically and electrically installed on the Analysis Cabinet. The

heated hose is connected to the Probes as illustrated on the drawing in the Probe section of the

manual. The heated hoses must be installed in a practical and protective way allowing for

access for future service. All hoses must be protected against high temperature surfaces. Bend

radius for any hose should never be less than 40cm/16”.

Make sure that enough free hanging hose available approx. 1,5m/5’ to remove the Probe from

the installation flange without having to dismantle the hose from the Probe.

Function of the Heated Hose(s)

The heated hose is maintaining the temperature of the sample gas as it is transported from the

Probe to the Analysis Cabinet.

The Heated hose is equipped with a pt100 temperature sensor. The heated hose is maintained

at a temperature of 180°C/395°F.


Operation of the Heated Hose(s)

The Heated Hoses are operated from the Control Panel. As soon as the Heated Hoses have

been connected to the Probes and all wires are secured according to the safety instruction the

operation of the Probe can begin.

For instructions on operating the Probe please see the section covering HMI operation.

Maintenance of the Heated Hose(s)

Under normal operation the Heated Hoses will not require daily maintenance. As long as the

sample flow and Heated Hose temperature are within target no action is required.

During a process shutdown the heaters of the Heated Hoses must be left turned on – or the

Probe must be removed from the process during the process shutdown. This to protect the

sample hose from condensing water.

The Heated hoses takes approx. 30min to heat up.

The heated hoses must be handled with care in hot conditions as the hoses are more

vulnerable when they are hot. Wait until the hose is “hand warm” before any handle.

Daily maintenance:

Observe that no alarms occur for sample flow and Heated Hose temperature.


Blow back hoses with compressed air



Blow back hoses with compressed air


Troubleshooting the Heated Hose(s)


Low sample flow Dust Blockage - dust Check filter in probe for cracks

Low sample flow Hose bended Blockage – restricted flow

Straighten out hose

Low temperature Power loss Power failure Check Control Cabinet and turn on

Low temperature Weather Water Remove and protect hose from water


7. Description – Analysis Cabinet

Specifications Analysis Cabinet


Power consumption: 3.500W supplied form the Control Cabinet

Instrument air supply*: Min. 6 bar according to ISO 8573-1 class 2 - 3

Ambient protection: IP64

Cell measuring path: 500mm

Cabinet overall size: 1377mm high x 967mm wide x 620mm deep

Materials: Hot/wetted parts St. 316L, non-wetted parts St. 304

Laser connection: ANSI 2” others on request (ISO DN50 PN10)

*The air quality should conform to standard set by ISO 8573.1, Class 2- 3. This means particles

down to 1 micron should be removed, including coalesced liquid water and oil, and a maximum

allowed remaining oil aerosol content of 0.5 mg/m3 at 21C. (instrument air).

Figure 5: Analysis Cabinet shown with open cabinet and heat box and two probes and NEOM lasers

Safety instructions Analysis Cabinet




Special attention to warning signs displayed on the Analysis Cabinet must be taken. Special

attention to hot surfaces.

All external connections are made in the electrical connection box to the right of the cabinet.

Cables between the Analysis Cabinet and the Control Cabinet are included and prewired at the

Control Cabinet.


Installation Analysis Cabinet

The Analysis Cabinet must be hanging on a wall or on a custom-made rack – see dim. drawing

of Analysis Cabinet for information. The cabinet must be hanging in an area where

service/maintenance can be done safely and comfortably. The Analysis Cabinet must be

installed protected from heat radiation from hot surfaces and from direct sun light. The cabinet is

made for outdoor installation in a production environment but can of cause be installed indoor in

a shelter if beneficial.

Make sure that enough free space is available to open door to the Analysis Cabinet.

Make sure that space and support for heated hoses are available going in through the side of

the Analysis Cabinet.

The heated hose(s) going to the Probe(s) must be mechanically connected int the Swagelok

fitting and in the soft install flange on the side of the Analysis Cabinet – one on each side for

each of the probes. The power connection terminal is parred so it matches the correct

hose/side. Due to difference in length of the hoses/power consumption the hoses must only be

installed in the side with corresponding power terminals.

Function of the Analysis Cabinet

The Analysis Cabinet is containing the pipe arrangement used to present the sample gas for the

laser in a fast, well define and clean manner. The laser(s) are installed on the side of the cabinet

and analyzes the gas by sending a laser beam at a given wavelength through an analysis cell.

The gas inside the analysis cell is replaced very fast by mean of an ejector pump driven by

instrument air.

The pipe arrangement is heated by mean of a heat soft box in order to keep the sample gas

above the dew point temperature (150-180°C/395°F) of water and acid components and thereby

preventing contamination of the pipe system.

The two probes are connected to heated solenoid valves in order to make it possible to shift

measuring point from Probe 1 to Probe 2.

The sample speed/flow is controlled by the pressure of the instrument air going to the ejector

pump. As soon as the sample air has been diluted by instrument air the sample gas no longer

poses a risk of contaminating the system.

A patented optical arrangement with a perpendicular air flow on the process side is called an Air

Knife. The purpose of the Air Knife is to prevent contact between the optical arrangement and

the process gas. This because that even if the whole pipe system is heated some contamination

must be expected over time. By introducing the Air Knife contamination of the optical surface

can be eliminated.

To make sure the Air Knife instrument air is not mixed with the sample gas which would damage

the analysis a directional orifice and a suction outlet underneath the Air Knife removes all air

from the Air Knife. The Air Knife is designed so it only is 2-3mm thick.


Figure 6: Analysis cell - with patented Air Knife

In order to ensure a stable flow/vacuum in the sample system, vacuum tanks are integrated. As

some condense can occur in these tanks, they are service by condensate pumps.

The entire cabinet is force ventilated in order to remove excessive heat from the heat box.

The layout of the cabinet is having the following arrangement:

Top: Heated hose inlet and Air Knife and laser purge control

Mid: Analysis section inside heat box

Bottom: Vacuum section and electrical connections

Operation of the Analysis Cabinet

The Air Knife and Laser Analyzer(s) purge valves are operated from the Analysis Cabinet.

Vacuum control is controlled from the HMI. However, two valves V3.3 & V4.3 can be used to

level any wanted/compensation in difference deployment of the vacuum between the two

analysis cells.


Manual Analysis Cabinet valves and their default settings

V3: Calibration gas on/off (Default: off)

V3.1: Air Knife purge air CO analysis cell left (Default: 2 l/min)

V3.2: Air Knife purge air CO analysis cell right (Default: 2 l/min)

V3.3: Air Knife CO vacuum compensation (Default: off)

V4.1: Air Knife purge air NO analysis cell left (Default: 2 l/min)

V4.2: Air Knife purge air NO analysis cell right (Default: 2 l/min)

V4.3: Air Knife NO vacuum compensation (Default: off)

R1: Instrument air purge supply pressure control (Default: 2 bar P5)

R2: Instrument air pump drive supply pressure control (Default: 5 bar P6)

Fan temperature: Removal of excessive heat (Default 30°C/85°F)

See flow sheet for analysis system for reference (Figure 7:Flow sheet Hybrid 600).

For instructions on operating the Analysis Cabinet please see the section covering HMI

operation.

Maintenance of the Analysis Cabinet

Under normal operation the Analysis Cabinet will not require daily maintenance. As long as the

sample flows, purge air and temperatures are within target no action is required.

During a process shutdown the sample gas collection can be turned off. The heat to the system

should be kept on protecting the system against moisture. If the sample gas collection is turn off

the purge gas flow can be stopped.

To heat of all components inside the heated box allow approx. 1 hour before analysis start. heat

up.

Daily maintenance:

Observe that no alarms occur for sample and air flows and temperature.

Check transmission % > 50%

Monthly – or at a given process stop:



Check condensate pumps Y5 &Y6 is running sufficiently


Half yearly – or at a given plant outing.



Check condensate pumps Y5 &Y6 is running correctly

Check analysis cell for contamination on optics

Check analysis optics for contamination – Clean only on process side* of optics (Water)

*The optic has a process facing side and a laser facing side. The optic is made from sapphire

and is very tough and resistant to scratches and rough handling. The optic is coated on the

laser facing side (The side facing the laser is the side of the optic on the outside of the analysis

cell). The laser facing side will not become dirty as only instrument air must be used for purging

of the cell. Should the laser facing side of the optic become dirty rinse it in warm water

(40°C/105°C) no soap and then air dry. The process facing side can over time become dirty.

Use warm water to clean no soap. If dirt is difficult to get off a wet soft cloth can be used to

clean it – no soap.


Figure 8:Flow sheet Hybrid 600


Troubleshooting the Analysis Cabinet


Low sample flow Probe Blockage - dust Check filter in probe for cracks

Low sample flow Ejector pump Low instrument pressure

Re-establish pressure

Low sample flow Ejector pump Dirt in pump Dismantle and clean

Low sample flow Piping leakage Loss of vacuum Leak check

Low sample flow Piping blockage Contamination of pipes

Find blockage and cause (Dust, contamination, condensation)

Low instrument pressure for purge or pump

Instrument air Re-establish

Low temperature Heat box Electrical Check heat box

Low temperature Heat box Open cabinet/box Close door/cover

Low transmission Laser Bad alignment Re-align laser

Low transmission Laser Low transmission Clean optics for dirt


Figure 9: Analysis Cabinet


Figure 10: Analysis Cabinet components


Figure 11: Analysis Cabinet analysis cells


Figure 12: Analysis Cabinet optical cell


Figure 13: Analysis Cabinet vacuum system


Figure 14: Analysis Cabinet purge system


Figure 15: Analysis Cabinet inlet and flow sensor arrangement


Figure 16: Analysis Cabinet mounting and pipe connections


8. Description – Laser analyzers

Specifications Laser Analyzer(s)

Please refer to the laser product data sheet found in sub. Supplier information section.

Safety instructions Laser Analyzer(s)




Special attention to warning signs displayed on the laser must be taken. Special attention to

potential damage by high energy laser beam. Never handle the laser while turned on. Laser

bean can damage an eye even as the laser bean is being reflected on a remote surface.


Installation Laser Analyzer(s)


The laser is installed on the two ANSI 2” flanges of the Analysis Cabinet.

After install, the Analysis Cabinet must be heated up before the laser is aligned to get good

transmission.

All external laser wires go directly to Control Cabinet.

All internal wires go between laser unit’s sender/receiver.

The supply power of the laser can be turned on/off in the Control Cabinet.

Function of the Laser Analyzer(s)

The laser emits a laser beam with a wavelength corresponding to the absorption spectra of the

gas to be analyzes. By measuring the amount of absorption as it goes through the analysis cell

the concentration of a given gas can be determined.


Operation of the Laser Analyzer(s)


The laser is setup to auto start when power is put on. The laser will run through self-check after

power is put on. After a cold start the laser might need some time before a stable result is

available (Approx. 15 min).


Maintenance of the Laser Analyzer(s)

Under normal operation the Lasers will not require any daily maintenance. As long as the

transmission in above 10%.

If transmission get below 10% check the operation and status of the Analysis Cabinet.

Daily maintenance:

None.


Check optics in the Air Knife


Check optics in the Air Knife

Check zero and span with analysis calibration gas

Troubleshooting the Laser Analyzer(s)


Alarm code Laser Ref. manual Ref. manual

Low transmission Laser Bad alignment Re-align laser

Low transmission Laser Low transmission Clean optics for dirt


9. Description – Control Cabinet

Specifications Control Cabinet


Power distribution entire system: max. 7,5kW

Power connection: 3x115VAC + Neutral + PE, 60Hz, 40A

Group protection: 40A at 115VAC

Ambient protection: IP64

Cabinet overall size: 700mm high x 700mm wide x 300mm deep

Materials: St. 304

Approvals: CE + All electrical components and wire materials are UL

approved

Safety instructions Control Cabinet

System emergency turn-off control place at the right lower side of the Control Cabinet. This will

turn off all power supply to the entire system.




Special attention to warning signs displayed on the Control Cabinet must be taken. Special

attention to high current voltage.

All external connections are made through the electrical connections in the bottom of the

cabinet. Cables between the Analysis Cabinet and the Control Cabinet, Probes are included.

Installation Control Cabinet

The Control Cabinet must be hanging on a wall or on a custom-made rack – see dim. drawing of

Control Cabinet for information. The cabinet must be hanging in an area where

service/maintenance can be done safely and comfortably. The Analysis Cabinet must be

installed protected from heat radiation from hot surfaces and from direct sun light. The cabinet is

made for outdoor installation in a production environment but can of cause be installed indoor in

a shelter if beneficial.

Make sure that enough free space is available to open door to the Control Cabinet.


Function of the Control Cabinet

The task of the Control Cabinet is to collect data from all sensors and operate all components.

The Control system is equipped with an HMI for operation of the equipment, displaying trends

and alarms.

All setpoints for temperatures and vacuum pumps are configured in the Control Cabinet.

All power breakers for groups and system heaters are operated from the Control Cabinet

The layout of the cabinet is having the following arrangement:

Top: Power distribution

Mid: PLC control section

Bottom: Electrical terminals for internal and external connections

Operation of the Control Cabinet

For instructions on operating the Control Cabinet please see the section covering HMI

operation.

Maintenance of the Control Cabinet

Under normal operation the Analysis Cabinet will not require daily maintenance.

Daily maintenance:

Non

Monthly – or at a given process stop:

Non

Half yearly – or at a given plant outing.

Vacuum cleaning of cabinet

Troubleshooting the Control Cabinet


Power breakers Power failure Supply or failure on component

See power breaker connections


Figure 17: Control Cabinet component layout


Figure 18: Control Cabinet functions


10. System operation HMI

This chapter describes how to operate the system through the HMI.

The HMI has a user interface build up with the following structure:

Home – Navigation and information about the system

Alarms – oversee alarm status and the individual alarms/Maintenance request

Operation – Probe activation and test activation

Probe 1 – Probe 1 operation parameters

Probe 2 – Probe 2 operation parameters

Flow – Flow entering the system and going between analysis cells active probe

Purge – Info page on default values for purge Valves

Temperature – Oversee temperatures in the analysis cell

Vacuum – Input page for vacuum/flow control

Trend Analysis

CO, NO, O2 analysis

Flow and Probe Pressure – Display flow and probe sample pressure

The system will after powering automatically start at the Home screen. The system will

remember the variable entered in the input boxes.

Input poxes have blue numbers.

The HMI is a touch display made for outdoor usages.

A number of screens is included in the system in order to operate and monitor the system.

On pages with Input boxes these can be found as boxes with blue numbers. A numeric input

pad will be available as soon as a input box as touched.

In the lower part of all pages two navigation boxes is available. The House icon will call the

Home screen. The Arrow left will call the previous screen.


In the upper part of all pages in the center a Drop-Down Menu Bar will allow to navigate directly

from a page to any of the pages in the system.


Home Screen:

Figure 19: Home Screen

Values of the analysis can bee seen together with alarm and test status of the system. From this

page there is access to the following sub menus by touch of:

The analytical values of the gas analysis of O2, CO and NO is displayed.

Status for System Alarm and Maintenance Request is shown with green if no alarm is present.

Red if an Alarm or Maintenance Request is present. By pushing the Alarm sub menu button

seen above the status page with the individual alarms causing the status can be seen (See next

section for further information)

A Test Allowed is shown with green if test is allowed. The allowance is given by an input pulse

signal from the Central Control Room (CCR). The allowance will last for 10 min. for each

allowance if the test button on the Operation Sub Menu is pushed. During this period, no alarms

will be set on the output to the CCR. This allows for maintenance and service to work on the

system without causing a lot of alarms going to the CCR. 10 min. after the allowance is given it

will be reset.


Alarm Screen:

On the alarm screen the overall status of the system can be seen. Also, the individual alarm

causing an alarm is listed with individual markings.

In the event of an alarm/maintenance request the individual cause will shift from green to red.

The indication will stay until the alarm is gone and the Ach (Acknowledge) is pushed to green

and back to grey (Two push). If the alarm is still active the alarm will stay regardless of the Ach

button is pushed as a memory function.

Alarms: The analysis is not valid

Maintenance request: The analysis is valid, but maintenance is required

Figure 20: Alarm screen

Alarm causes:

F1: Sample flow into the measuring cell is below alarm limit. The alarm limit is set in the Flow

Sub menu as an input value.

F2: Flow through between the two measuring cells is below alarm limit. The alarm limit is set in

the Flow Sub menu as an input value

X1 status: The CO laser status is in alarm

X2 status: The NO laser status is in alarm


P5 Purge: The supply pressure for instrument air to the purge system too low. The limit is set on

the P5 pressure switch directly and has a default value of 2 bar.

P6 Vacuum: The supply pressure for instrument air to the vacuum system too low. The limit is

set on the P6 pressure switch directly and has a default value of 5 bar.

Probe select: No probe is selected on the Operation Sub Menu.

Maintenance Request causes:

T1.1 Probe 1: Alarm limit for probe 1 heater. The limit is 120°C

T2.1 Probe 2: Alarm limit for probe 1 heater. The limit is 120°C

T1.2 Hose 1: Alarm limit for heated hose for probe 1. The limit is 120°C

T2.2 Hose 1: Alarm limit for heated hose for probe 2. The limit is 120°C

T3 Gas in: Alarm limit for temperature for gas entering the analysis cells. The limit is 120°C

T4 Gas out: Alarm limit for temperature for gas exiting the analysis cell. The limit is 120°C


Operation Screen:

Figure 21: Operation Screen

On the Operation screen there is access to Sub Menus for:

Test:

If the CCR has issued a Test Allowed input pulse to the system, the Test Allowed is indicated

with a green.

The Test button can then start a test period of 10 min. if chosen. When chosen and the Test

Allowed signal is given from the control room the Test Active becomes green and active for 10

min. In this period no alarms will be transmitted to the CCR allowing free maintenance work

within the time frame without causing a lot of false alarms to the control room.

The test will be reset automatically after 10 min.


Probe selector:

For each of the two probes a probe selector is available. To select a probe for operation the

probe selector is chosen from 0 to 1 (Touch). If no probe is selected an alarm will occur. The

system can operate with one probe or two probes in sequence. The operation setting for each

probe is settled on the sub menu for the individual probes. Above the probe selector a time

indicator will show how long time the probe has left for analysis before probe cleaning/probe

shift will occur.


Operation – Probe 1 & Probe 2:

The operation of the two probes are identical. Only sub menu for probe 1 is shown.

Figure 22: Operation - Probe 1 Sub Menu

Temperatures:

The probe heater and heated hose is for probe 1 is controlled on this page.

The setpoint for the two heaters can be entered in the field with blue numbers. A num-pad will

come up as soon as the setpoint field is touched.

The default setpoint value for the two heaters is the same: 180°C

The actual temperature of the probe and heated hose can be seen in the field below the

setpoint field. It takes approx. 30 min for the heaters to reach the setpoint from an ambient

temperature.

Next to the temperature input field a 0/1 button is placed. This will turn the specific heater on or

off. The individual heaters have a power circuit relay in the control cabinet which must be

engaged when the heater is in operation.


Blow Back:

It is possible at any time to make a forced air Blow Back (BB) of the probe. This is done by

pushing BB Forced for as long as and as many times a blow back is wanted.

The sample period of a probe is entered in the BB/Shift set point. The value is entered in the

input field with blue numbers. The period is entered in minutes. Default 15 min.

The time till the Next BB is shown in sec. just below the BB/Shift set point.

The number of BB in each sampling period can be entered in BB number pulses. Default 3

The length of each BB can be entered in the BB pulse time in seconds. Default 1 sec.

Calibration gas:

CALIBRATION SAFETY WARNING

To make sure the test is safe check that the exit gas of the Analysis Cabinet is securely vented

or returned to the process. If vented in an area not well-ventilated toxic level can be reached.

Make sure that the test concentration of the gas will not cause a risk for explosion when

exposed to higher temperatures in the probe and process. Calibration gas should never contain

a higher concentration than 1/10 of a given calibration gas Lower Explosion Level (LEL).

CO LEL: 12.5 Vol% max calibration gas concentration 1,25 Vol%

CH4 LEL: 5 Vol% max calibration gas concentration 0,5 Vol%

Cal. Gas.

The probe is equipped with a solenoid valve which can direct zero or calibration gas directly into

the inside of the filter of the probe. This is a very effective way of performing a “full train”

validation/calibration test.

The calibration test can be performed only if a Test Allowed from CCR has been given and the

Test has been active (See the Menu for Operation).

The calibration test can be performed with the probe is installed and in operation.

The calibration test can be a zero-calibration test or a span calibration test.

Zero calibration of CO, CH4 and NO laser analyzers normal instrument air can be used for zero

calibration.


Span calibration of CO, CH4, NO laser analyzers will require calibration gas.

Zero and span calibration will require that the filter be floated with the calibration gas in order to

flush out the process gas inside the filter. The required amount of calibration gas can be found

by monitoring the measurement of the laser. When steady the flow amount is correct and then

increase it a little to be sure. Monitor that the sample flow of F1 only is changed a little (less than

20%)

Alternative manual calibration V3:

The Analysis Cabinet is equipped with a manual valve V3 for direct injection of calibration gas

into the Analysis Cell. This manual calibration method will be more calibration gas friendly in

terms of a lower usage of gas in order to perform a calibration.

In order to perfume the manual calibration, the two probes must be closed by de-selecting the

sample operation in the Operation Menu during the test. All purge gas must be turned off:

V3: Calibration gas on/off (On - Open)

V3.1: Air Knife purge air CO analysis cell left (Default: 0 l/min)

V3.2: Air Knife purge air CO analysis cell right (Default: 0 l/min)

V3.3: Air Knife CO vacuum compensation (Default: off)

V4.1: Air Knife purge air NO analysis cell left (Default: 0 l/min)

V4.2: Air Knife purge air NO analysis cell right (Default: 0 l/min)

V4.3: Air Knife NO vacuum compensation (Default: off)

With above setting the calibration flow only needs to be very low like 1 l/min which can

monitored on F1. Wait until analysis values of the laser are steady in order to do calibration or

validation of the lasers.

Pressure Probe:

The probe is equipped with a vacuum/pressure indicator. This pressure measurement is plotted

as a graph against the flow through the probe. This trend is useful in order to see if the filter is

being blocked indicated with an increase in probe vacuum during sample.


Flow:

This sub menu will provide information regarding the sample flow coming from the probe. On

the menu it can be seen from which probe the sample is taken from – indicated by a green

marker.

Figure 23: Operation - sub menu Flow

The alarm setpoint for low flow of F1 – sample flow and F2 – Flow through can be entered.

The default value for F1 – sample flow alarm is: 6 l/min

The default value for F2 – Flow through alarm is: 3 l/min


Purge:

This is purely an informational page.

V3.1 and V3.2 are the needle valves controlling the flow to the Air Knife of the CO laser.

V4.1 and V4.2 are the needle valves controlling the flow to the Air Knife of the NO laser.

V5 is the needle valve controlling the purge of the CO and NO laser sender and receiver

flanges.

Figure 24: Operation - sub menu for Purge

The flow will run through cobber piping inside the soft cell heating box in order to preheat the

purge air before it enters the analysis cell. This is done in order to prevent cold spots inside the

analysis cell attracting moisture to condensate on.

The default value for all valves: 2 l/min


Temperatures:

This menu gives information about the analysis cell temperatures.

Figure 25: Operation - Temperatures

T3: Sample gas temperature as it enters the soft cell heating box. The alarm value is min

120°C.

T5 & T6 are the two heating circuits in the soft cell heating box. The soft cell heating box set

point can be adjusted here. Setpoint T5/T6: Default value 180°C.

T4: Sample gas temperature as it leaves the analysis cells. The alarm value is min 120°C.

In the lower right corner of the menu a 0/1 button is placed. This will turn the specific heater on

or off. The heaters have a power circuit relay in the control cabinet which must be engaged

when the heater is in operation.


Vacuum:

This is the last but not least of the operational sub menus. This because this is the page

operating the sample gas pump and the Air Knife purge pump.

Figure 26; Operations - Vacuum

The pumps are ejector type pumps operated by instrument air. The pumps vacuum and sample

flow are controlled by the feed pressure for each of the pumps. The pressure is electronically

controlled by pressure regulators.

Pump drive

Turns the electronical pressure controller to zero. No sample gas is collected.

Turns the electronical pressure controller to one and the ejector pumps are feed with the

setpoint values.

Cell Pump feed: Setpoint for sample flow – Default value 2 bar. This value is process pressure

depended. This value is process pressure depended and will need to be adjusted on site.

Air Knife Pump feed: Setpoint for Air Knife sample flow through purge outlet – Default value 1

bar. This value is process pressure depended and will need to be adjusted on site.


After start-up and when the process is in normal operation the default values of the feed

pressure is entered. Then the Flow in is monitored – and the Cell Pump feed is adjusted until

the Flow in is approx. 12-15 l/min.

Then the Flow through is monitored – and the Air Knife Pump feed is adjusted until the Flow

through is approx. 5-8 l/min.

The adjustment of Cell Pump feed and Air Knife Pump feed often needs to be done a couple of

times. The Cell Pump feed > Air Knife Pump feed. In some situation the above flow amounts

cannot be achieved without adding a pressure drop for one of the analysis cells. This can be

done on V3.3 and V4.3.

There will be a green field indicating that the supply pressure for the feed air to the pump is

good. It will change to red if it becomes too low. The alarm limit is set on P6. The default value

of P6 is 5 bar.

There will be a green field indicating that the supply pressure for the purge air to the analysis

cell is good. It will change to red if it becomes too low. The alarm limit is set on P5. The default

value of P5 is 2 bar.

IMPORTANT:

It is very important that the air supply for the pump feeds is clean instrument air. If the air supply

is not clean it can cause the electronical pressure controllers Y4.1 and Y4.2 to fail or even to

become damaged.

It is very important that the air supply for the purge air is clean instrument air. If the air supply is

not clean it can cause the optics to become polluted and the lasers will loss transmission.

Furthermore, if the instrument air is not clean for water and oil the measurements will be

influenced by there present in the analysis cell.


Trend: CO, NO, O2 analysis

This trend will show 30 min of analysis results.

The data are analytical representations of the process measured as hot/wet.

Figure 27: Trend - CO, NO, O2


Trend: Flow and Probe Pressure

This trend will show 30 min of data.

The data are representations of the correspondence values between sample flow and probe

pressure. This can be helpful information to determine if an issue with the filter is present. If the

sample vacuum pressure increases over time its an indication of a filter not being cleaned

sufficiently enough or the sample flow being too high – or both.

Figure 28: Trend - Probe pressure and flow


11. Appendix 1 – Electrical diagrams

(See separate attachment)


12. Sub-suppliers manuals

(See separate attachment)


13. Declaration of Conformity

For:

Hybrid 600

Gas Analysis system for cement process

Project ref.: 2020-05-Lehigh Texas, USA

Produced by:

FLO2R

Ved Stranden 90

9560 Hadsund

Denmark

Ph.: +45 42495970

[email protected]

hereby declares that the product complies with the requirements of the following European directives and

normative documents:

Machinery Directive 2006/42/EF IIA from 17 May 2006

Low voltage Directive 2006/95/EF EN 60-204-1

Electrical equipment on machinery (3. edition)

EMC Directive 2004/108/EF

EN 50081-2 EMC emissions

EN 50082-2 (A) Immunity

and is in accordance with the supplement approach directives on legislation on machinery of the member

states.

All electrical components and electrical wires are UL approved. No pressure vessels are included in

this vacuum operated analysis system.

FLO2R ApS 01.07.2020

Karsten Brink Floor/Managing Director

Manual for: Hybrid 600 gas analysis system

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