Flue Gas Analysis System Model 9700 Flue Gas Analysis System Instr uction Manual Instruction P/N M48985 10/27/94 TELEDYNE BROWN ENGINEERING Analytical Instruments i
Model 9700 Copyright © 1994 Teledyne Brown Engineering Analytical Instruments All Rights Reserved. No part of this manual may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any other language or computer language in whole or in part, in any form or by any means, whether it be electronic, mechanical, magnetic, optical, manual, or otherwise, without the prior written consent of Teledyne Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 917491580.
Flue Gas Analysis System Table of Contents 1 Introduction 1.1 General .............................................................................. 1 1.2 Sample Conditioning .......................................................... 2 1.3 Oxygen Analyzer Section .................................................. 4 1.3.1 Standard Features .............................................. 1-4 1.3.2 Optional Features ................................................... 7 1.4 Combustible Gas Analyzer Section...
Model 9700 4. 3 System Startup .................................................................. 7 4.3.1 Analyzer Startup ..................................................... 7 4.3.2 Sample System Startup .......................................... 7 5 Maintenance & Troubleshooting 5.1 Maintenance ...................................................................... 1 5.1.1 Routine Maintenance .............................................. 1 5.1.2 Oxygen Cell Replacement ...............................
Flue Gas Analysis System General Information Introduction 1 Overview The Model 9700 analyzer system (see Figure 1) is an integrally housed combination of analyzers designed to continuously monitor the two primary components of flue gas which are the best indicators of combustion efficiency and safe operation. Through use of volumetric percentage measurements of oxygen and combustibles, it is possible to optimize the air-fuel ratio and approach the idealized condition of stoichiometric combustion.
General Information 2 Model 9700 Sample Conditioning When the flue gas is drawn into the analyzer system, it enters at a relatively high temperature and carries a significant content of moisture, dirt and corrosives. The sample stream is preconditioned to cool the gases and remove contaminants. This processing of the sample assures clean and continuous operation of the instrument.
Flue Gas Analysis System General Information Next, the gas and water mixture enter the pump. The pump contains no valves or packing and will handle the dirtiest of samples without any detrimental effect Exiting the pump under positive pressure, the sample mixture is forced through a mixer which contains a series of baffles which function to thoroughly scrub the sample gas. At the next stage of conditioning, the sample solution enters a separator where water is gravitated to drainage.
General Information 3 Model 9700 Oxygen Analyzer Section The analysis system (see Figure 3) employs a Model 326B Analyzer which features a TBE/AI unique, patented Micro-Fuel Cell oxygen sensor. This electrochemical transducer provides an electrical signal that is directly proportional (and specific) to the oxygen concentration in the gas phase immediately adjacent to its sensing surface. The analyzer is capable of oxygen measurements as small as 0.05% and is unaffected by flow rate changes.
Flue Gas Analysis System General Information Figure 3: Oxygen Analyzer Section • Integral Meter Readout The analyzer is equipped with a 5" panel meter for direct readout of the analysis. A linear scale (mirror equipped to eliminate parallax) promotes reliable, accurate readout of the analysis at any point on the scale. Resolution and accuracy of the meter eliminates the necessity of an accessory readout device, unless permanent recording or remote indication is required.
General Information Model 9700 To protect the Micro-Fuel Cell against damage from low ambient temperatures and reduce the range required of the compensation circuit, the analyzer is equipped with a thermostatically controlled heating system that will not permit the interior of the instrument to drop below 85 deg F.
Flue Gas Analysis System General Information 3.2 Optional Features The following optional features are available with the system. • Integral Alarm Circuitry One (Model 326B-1) or two (Model 326B-2) adjustable, fullscale alarm and/or control circuits are available. Control over an external circuit is achieved by a relay whose solenoid coil is operated by an electronic “comparator” circuit.
General Information • Model 9700 E-to-I Converter A voltage (E) to current (I) conversion of the output signal generated by the analyzer is available. This conversion allows I (current) to P (pneumatic) devices, as well as low-impedance current-operated indicating and/or recording and controlling instruments to be directly driven without the need of accessory equipment. One of the following three ranges of current output is available: • 1 to 5 mA dc, • 4 to 20 mA dc • 10 to 50 mA dc.
Flue Gas Analysis System General Information 4 Combustible Gas Analyzer Section The combustibles analyzer (see Figure 4) is a compact detector for reliably sensing all combustible gases. The analyzer consists of two parts: (1) The control unit housing the calibration controls, analyzer circuitry, meter readout, alarm relays and power supply. 2) The sensor unit including the sensor, flowmeters, valves and heater circuit.
General Information Model 9700 The sample is sent through one side (SAMP) of twin indicating flowmeters. Since it is necessary that there is sufficient oxygen in the sample being analyzed to insure full combustion of any combustible gases present, the sample is blended, or diluted, with an equal amount of “clean” compressed air. The compressed air is introduced through the second (AIR) of the two flowmeters. Two flowmeters are used so that an equal volume of both sample and air flow can be visually set.
Flue Gas Analysis System General Information TABLE 1: Detector Response To GASES COMPOUND LEL* Methane Hydrogen Carbon Monoxide Ethane Ethylene Acetylene Propane Propylene Butane Hexane Cyclohexane Heptane Benzene Pentane Toluene Ethylene oxide Methyl Ethyl Ketone Methyl Acrylate RESPONSE FACTOR 5.0 4.0 12.5 3.0 2.7 0.5 2.2 2.0 1.9 1.1 1.3 1.05 1.3 1.5 1.2 3.6 1.8 1.00 0.86 0.32 1.20 1.26 1.39 1.42 1.33 1.54 1.50 1.44 1.59 1.50 1.45 1.48 0.76 0.96 2.8 0.
General Information 4.1 Note: Operating Controls and Indicators • The POWER toggle switch is used to turn the combustible gas analyzer ON and OFF. • The meter displays the gas concentration at the detection point as a percentage of the combustible gas and is graduated from 0–5% combustibles. • The green SAFE light is illuminated during normal operation and indicates that the combustible gas sensing element is operating.
Flue Gas Analysis System 4.2 General Information Recessed Secondary Controls NOTE: The recessed potentiometric controls are provided for calibration purposes. They should not be changed once calibration is established. • The SPAN control adjusts for manufacturing variations in sensitivity between elements and for various gases. • The ZERO control adjusts for zero meter reading with zero gas (air) flowing through the sample cell.
General Information Model 9700 CURRENT OUTPUT (mA) 4–20 MAX LOAD IMPEDANCE (Ohms) 1K NOTE: The remote meter or recorder should have an input impedance less than the indicated values.
Flue Gas Analysis System Theory of Operation 2 Theory of Operation 2.1 Oxygen Analyzer The cathode of the oxygen cell sensor is connected to electrical ground, while the anode is connected to input amplifier A1., a current-tovoltage transducer. The output voltage from A1 is equal to the input current multiplied by the resistance of the feedback resistor (R1, R2, or R3). The feedback resistance can be varied by RANGE switch SW1.
2 Theory of Operation Model 9700 electrolysis. Only after the oxygen is reduced to a low enough concentration can the cell be used to measure the flue gas sample.
Flue Gas Analysis System 2.2 Theory of Operation 2 Combustible Analyzer The detector assembly and resistors R7 and R8 form a Wheatstone Bridge. The signal for the bridge is taken from the junction of R7 and R8 for the reference signal which is applied to A1—A3, and from the junction of the measuring (or active) and reference beads of the detector for the measuring signal which is applied to A1—2 (See drawing C-11751.
2 Theory of Operation Model 9700 An optional CAUTION alarm circuit utilizes potentiometer P4 to establish the setpoint. When the setting of P4 is exceeded. transistor Q2 is turned on and relay K1 is energized, resulting in an alarm. The optional FAILURE alarm circuit is set up so that if the detector opens up, an alarm comparator will trip and turn off a relay, which is normally energized, i.e.
Flue Gas Analysis System Theory of Operation 2 The temperature of the active bead will be influenced by other factors such as initial gas temperature, gas thermal conductivity, flow rates and the temperature of its housing. The reference bead, having similar electrical and thermal properties and being heated by the same current, but lacking the catalytic material will be similarly affected by these extraneous factors but not significantly affected by oxidation of the combustible gas.
2 Theory of Operation 2-6 TELEDYNE BROWN ENGINEERING Analytical Instruments Model 9700
Flue Gas Analysis System Installation 3 Installation 3.1 Electrical Connections All wiring is to be connected to the barrier type terminal strips on the back plate assembly within the analyzer. Refer to Figure 6, Interconnection Diagram, and be certain that the wiring installation complies with the directions contained in the illustration and in the following discussion. 3.1.1 Power Refer to the drawings in the supplement at the back of this manual.
3 Installation Model 9700 1& & 12 1& & 12 ` ` ` 6 ( 73 7 6 ( 73 7 ` ` $ / $ 5 0 &,5 &8 ,7 2 ; <* ( 1 $ 1 $ / <=( 5 0 $ 6 ,* 1 $ / 2 8 7 2 ; <* ( 1 ` $ 1 $ / <=( 5 ( 0 ) 6 ,* 1 $ / 2 8 7 * 1' 1( 87 / ,1 ( ` +] 6 <6 7( 0 3 2 : ( 5 ,1 1& & 12 6 ,* 1 $ / 2 8 7 &2 0 %8 6 7,%/ ( $ 1 $ / <=( 5 ` $/ $5 0 &,5 &8 ,7 &2 0 %8 6 7,%/ ( $ 1 $ / <=( 5 76 76 Figure 6: Interconnection Diagram Note: Ground the shield of the signal cable at the analyzer only as shown in the diagram.
Flue Gas Analysis System Installation 3 3.1.3 Alarm and/or Control Circuitry Models having a -1 or -2 as part of their model number are equipped with single (-1) or double (-2) alarm and/or control circuits. The SPDT form "C" (NC/C/NO) contacts of the relay (or relays) are available on the terminal strip within the oxygen analyzer. To properly use the switch that the relay contacts represent, the customer must determine when the relay (or relays) is energized (above or below the setpoint).
3 Installation 3-4 Model 9700 TELEDYNE BROWN ENGINEERING Analytical Instruments
Flue Gas Analysis System Operation 4 Operation 4.1 Startup of Oxygen Analyzer 4.1.1 Preliminary Before applying power to the instrument, TBE/AI suggests that the electrical wiring installation be checked against the interconnection diagram (see Figure 6), especially if the installation has been made by personnel other than those responsible for startup and operation. In many instances, proper attention to this preliminary check will prevent severe damage due to accidental wiring transpositions. 4.1.
4 Operation Model 9700 The Micro-Fuel Cell is supplied separately in a controlled atmosphere package and must be installed prior to startup. To install the cell, use the following procedure: Note: Do not open the sealed package until the system is to be started and a flue gas sample is available . (1) Make sure that the RANGE switch is in the OFF position (power “off”).
Flue Gas Analysis System Operation 4 If, on the other hand, reliable analysis, free of instrument distortion, is required from the very onset of operation, TBE/AI recommends a 24 hour run-in period before operational calibration and service . In either case, emlploy the following procedure: (1) Set the analyzer RANGE switch to the 0–25% position. Power has now been applied to the instrument circuitry and to the sample pump.
4 Operation 4.1.5 Model 9700 Operational Calibration After the equilibration period following the installation of any new cell, or whenever it is desirable to recheck the calibration of the instrument, use the following calibration procedure: (1) Place the RANGE selector switch on the 0+25% Position. (2) Rotate the selector valve so that calibration (or span) air is flowing.Allow air to flow for 3 to 5 minutes.
Flue Gas Analysis System Operation 4 4.1.6 Routine Operational Calibration Span calibration should be checked every two to four weeks on a routine basis. Whenever there is the slightest suspicion of abnormal performance, an inspection of the possible trouble should be made, followed by span calibration. Use trouble shooting procedures as required. 4.2 Startup of Combustibles Analyzer 4.2.1 Procedure The combustibles monitor comes ready to operate.
4 Operation Model 9700 (6) After air has been flowing for a couple of minutes, adjust the ZERO control on the control unit (use the small screwdriver supplied) until the meter pointer lines up with the zero mark on the dial (be sure that the mechanical zero of the meter is first adjusted with the power off.) (7) Turn on supply of span gas and open the SPAN toggle valve. Then adjust the SPAN flow control valve until a flow rate of 2–3 SCFH is indicated on the right hand flowmeter.
Flue Gas Analysis System 4.2.2 Operation 4 Span Gas It is recommended that the span gas have a concentration of 4.0–4.8% methane or other desired combustible gas with the balance being nitrogen. Note: It is important that the dilution air flow is never turned off during operation or calibration. Combustibles without at least a 2 : 1 ratio of oxygen should never be allowed to flow past the sensor.
4 Operation 4-8 Model 9700 TELEDYNE BROWN ENGINEERING Analytical Instruments
Flue Gas Analysis System Maintenance & Troubleshooting 5 Maintenance & Troubleshooting 5.1 Maintenance 5.1.1 Routine Maintenance No moving parts other than the meter movement and the relay contacts are contained in the analyzers. Periodic service, therefore, other than oxygen cell replacement, is not required. The periodic calibration contained in Sections 4.1 and 4.2 should be adequate to keep the analyzers functioning.
5 Maintenance & Troubleshooting Note: Model 9700 Do not over-order or stockpile Micro-Fuel Cells. Only one cell per instrument should be kept in reserve. When installing the oxygen cell in the probe housing, make certain that the shorting clip is re- moved and that the cell membrane is facing up (or outward). Do not install the oxygen cell upside down. Caution: When replacing the oxygen cell, use care not to scratch the membrane covering the gold-plated electrode.
Flue Gas Analysis System 5.1.4 Maintenance & Troubleshooting 5 Spray Nozzle It will be necessary to clean the mineral deposits from the spray nozzle periodically (see Figure 1). If water flow through the system diminishes significantly, it is an indication that the nozzle is plugged. The nozzle can easily be
5 Maintenance & Troubleshooting Model 9700 5.1.8 Pump The pump (shown in Figure 1) uses a flexible Nordel liner which is actuated by a roller on an eccentric. This liner requires oiling weekly. The pump is equipped with an oiler which holds a large supply of oil. Use the following procedure to oil the liner: • Fill the oiler. (This needs to be done only occasionally.) • Once the oiler is filled, it is only necessary to open the toggle valve on the top of the oiler.
Flue Gas Analysis System Maintenance & Troubleshooting 5 When subjecting the analyzer circuits to checkout, it is appropriate to first check the power supplies for correct output. If voltages are incorrect, then take corrective action with power supply components . 5.2.2 Oxygen Analyzer Section 5.2.2.
5 Maintenance & Troubleshooting Model 9700 The best way to check Q1 is to remove it, then check it, or substitute a replacement . The meter drive circuitry, as shown on Dwg. B-l0913, is straightforward and relatively simple to follow. If any troubles occur in this circuitry, consult the schematic diagram. The heater (H1) control is controlled by SW3, R15 and the Triac (SCR1). During various periods of the heater cycle, both R15 and SW3 are required to carry a heavy load.
Flue Gas Analysis System Maintenance & Troubleshooting 5 original detector is probably defective and requires replacement. If problems still occur in the detector circuit, then the dummy sensor will give a signal that can be tracked through the system. • Measure the voltage at the tiepoint of R7, R8 and R10 with respect to terminal 14 which is the center of the sensor bridge. With the zero potentiometer adjusted up and down, the voltage should change by about 1/4 volt.
5 Maintenance & Troubleshooting Model 9700 5.2.3.3 Lamp Failure For failure in any circuit involving a lamp, always check the lamp for failure before embarking upon more involved diagnostic checkout. The lamps are the most failure-prone components of the system .
Flue Gas Analysis System Appendix Appendix Specifications SYSTEM Operating Power: 115 VAC, 50/60 Hz, single phase (other voltages available as option) Power Consumption: 6 A Operating Temperature: 32 deg F to 125 deg F (0–52 deg C) (Optional auxiliary heating available for operation in below freezing ambient environment.) Output Signal: 0–1 VDC or less (Optional mA output available) Enclosure: Sheet steel equipment case Dimensions: width: 24" (60.96 cm) length: 36" (91.44 cm) depth: 111/2 " (29.
Appendix Model 9700 OXYGEN ANALYSIS SECTION Ranges: 0–5%, 0–10%, 0–25% O2 Sensitivity: 0.5% of full scale Accuracy: +/- 2% of full scale at const. temp. +/- 5% of full scale across temp. range Response Time: 90% of O2 in 45–60 seconds Calibration: Air Cooling Water: 10–100 psi, 1/4 –11/2 gpm Sensor: Class A-3 Micro-Fuel Cell (warranted for 6 months in normal flue gas applications) Alarms (optional): 1 or 2 (3 Amp resistive) COMBUSTIBLE GAS SECTION Ranges: 0–5%, combustibles (CH4 equiv.
Flue Gas Analysis System Appendix Recommended Spare Parts List Model 9700 System (Standard Unit Only) PART NO. F-77 S-81 T-199 T-267 H-2 H-28 N-49 C-11577 F-6 . R-179 T-231 P-122 R-564 A-38 A-9348 A-19 T-261 S-89 P-l00 B-12115 P-146 C-6689 F-96 G-26 L-32 A-6544 A-7023 DESCRIPTION QTY Fuse, Tvpe 3AG, 6-1/4A, Slo-Blo Triac, G. E.
Appendix Model 9700 Orders should be sent to: Teledyne Brown Engineering Analytical Instruments 16830 Chestnut Street P.O. Box 1580 City of Industry, CA 91749-1580 U.S.A.
Flue Gas Analysis System Appendix Response of Combustible Sensor to Various Gases Response factors have been determined to relate the sensor output of a specific compound to the output obtained using methane. A list of some typical compounds is given in Table 1 along with their LEL (Lower Exposure Limits) values. To determine the output of the sensor for any of the gases listed, compared to the same concentration of methane, multiply the reading obtained by the factor listed.
Appendix Model 9700 To determine the concentration of a compound present at the sensor from a meter reading, when calibrated with methane, divide the reading (in percent methane) by the factor. For example, if ethylene is flowing by the sensor, and a meter reading of 2.
Flue Gas Analysis System Appendix Supporting Equipment for Flue Gas Analysis Systems Two basic types of sample probes for flue gas applications are shown in Figures A-1 and A-2. The straight, dry type of probe (Figure A-1) consists of a length of 1" 316 stainless-steel pipe with a mounting flange or coupling welded to the outboard end for connection to the duct or stack (length of probe, as required). The second type is similar to the first except for the addition of a water spray nozzle .
Appendix Model 9700 0 RXQW LQJ&RXSO LQJRU IO DQJH ' XFW : DO O &O HDQ2 XW 3O XJ 6 DP SO H/ LQH 6 KRXO GEHVO RSHGW R SURP RW HFRQGHQVDW H GUDLQDJH 7\ SH 66 3 LSH )O XH * DV 6 \ VW HP Figure A-1: Typical Dry Probe 6 SUD\ : DW HU,Q 6 KXW 2 II9 DO YH 6W UDLQHU 6 SUD\ 1 R] ] O H ' XFW : DO O &O HDQ2 XW 3O XJ 6 DP SO H/ LQH 0 XVW EHVO RSHGIRUFRQW LQXRXV JUDYLW \ GUDLQDJHRIZ DW HUDQGSDUW LFXO DW HV 7\ SH 66 3 LSH0 RXQW LQJ &RXSO LQJRU) O DQJH ' UDLQ ' URS 2 XW 3 RW )O XH * DV 6 \ VW HP Figure A-2: Typic
Flue Gas Analysis System Appendix General Maintenance for CC-2B Series Pumps Maintenance The pump is equipped with a Gits-type oiler which permits the occasional lubrication of the Flex-I-Liner interior with Vanton Pump oil or pure Silicone oil of 2000 centistokes viscosity. If the pump is used in continuous service, add a small amount of this oil each week (about 7 drops); less often for less severe service.
Appendix Model 9700 (7) Install new Flex-I-Liner: clean all chemicals from exposed parts of pump. (8) Apply a liberal amount of Vanton Pump oil to the inside of the Flex-I-Liner. Spread this oil over the inside interior to the very edge. (9) Push the body block back onto the bracket. Shaft should be rotated at the same time that pressure is being applied to the block to push it “home”. This will allow the Flex-I-Liner to seat over the Pilot of the bracket.
Flue Gas Analysis System Appendix (15) Remove flexible coupling by tapping out the groove pin (8) and then withdrawing coupling from pump shaft. The shaft (26) can then be pressed out of the bracket (7) by tapping or pushing on the coupling end. An arbor press can facilitate this operation. (16) When the shaft is pressed out it will still be assembled to the rotor (19), the rotor bearing (20) the bearing guard (23), bearing guard spacer (22), and retaining ring (3).
Appendix Model 9700 NO.QTY DESCRIPTION 30 1 Support Bracket 29 1 Handle (opt) 28 4 5/16 x 5/8 Dowel Pin 27 1 1/4hp 1725rpm Motor 26 1 Shaft 25 1 Alemite Hydr.
Flue Gas Analysis System Appendix Supplementary Instructions for Servicing the CC-60B Flex-I-Liner Pump Except for a greater overall length, this pump is essentially the same as the following models CC-2B, CC-6B, CC-12B, CC-18B and CC-30B. (Refer to Figure A-3). Important differences include: (1) The first outboard bearing (13) on the abovementioned drawing is of extra heavy-duty double roll construction.
Appendix Model 9700 Replacing the Liner in the Flex-I-Liner Pump On occasion, it will be necessary to replace a worn liner. It is imperative that this member be correctly installed to insure maximum longevity of the liner and satisfactory future performance and operation of the pump. In Figure A-4, the bracket shown in the top photo is that for close-coupled models. The bracket in the other photos is for pedestal mount models. Other components remain basically the same for all Vanton Flex-I-Liner pumps.
Flue Gas Analysis System TELEDYNE BROWN ENGINEERING Analytical Instruments Appendix A-15
