System Description 30/23 Rev. Page Overview Probe Probe Cool
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Cement Analysis System Sampling Multi Component Analysis Monitoring Process Rotary Kilns Calciners
System Description
30/23 Rev.
Page Overview Probe Probe Cooling Probe Cleaning Probe Probe Retractor with Control Compressed-Air Cooling-Water Supply Requirements Sample Line Conditioning Analysis Output, Input Status Signals Analysis Cabinet
30/23-220 Rev.
Cement Analysis System System Description
Overview
Application (Advance Cement Kiln) cement analysis system used monitoring process cement plants. analysis system designed continuous, quantitative measurement concentrations during primary firing outlet rotary kiln during secondary firing outlet calciner.
Measuring Components Measuring Procedures
analysis system suitable measuring components CO2, CH4, infrared-active components measured using infrared analyzer AO2000-Uras14. process photometer AO2000-Limas11 (with quartz measuring cell) used measurement. electro-chemical oxygen sensor used measurement; alternatively, AO2000-Magnos17 oxygen analyzer used.
Modules
analysis system modules subdivided into three categories according their function: Functional Category sampling Modules Probe probe with probe cooling Probe retractor with control Sample line SCC-C sample cooler SCC-F sample feed unit SCC-K converter AO2000-Uras14 infrared analyzer AO2000-Limas11 process photometer AO2000-Magnos17 oxygen analyzer sensor Continued next page
conditioning
analysis
Cement Analysis System System Description
30/23-220 Rev.
Overview, continued
Principle Operation separate types probe available sampling sample gas: Probe used situations where properties process (see Fig. sampling conditions lead expect hard encrustations form probe. situations where hard encrustations expected, probe used. probe, along with pneumatic probe retractor, forms single unit. probe built into closed cooling-water circuit with heat exchanger. moved control box. sample filtered probe, passes through heated unheated sample line into sample cooler, where water vapor content sample reduced point. sample feed unit transports sample analyzer. converter optionally connected upstream analyzer. built-in unit controls monitors functions system.
Fig. Functional Diagram
Control probe retractor analyzer sensor
NO2/NO converter Pneumatic probe retractor Sample Probe Probe (Calibration) Heat exchanger Sample cooler Sample feed-in
Condensate drain
30/23-220 Rev.
Cement Analysis System System Description
Probe
Layout (see Fig. sample sucked through opening probe. plunger which welded onto cylindrical filter located this opening. filter attached pipe which connected cylinder compressed through gas-tight stainless steel bellows filtered sample flows through electrically-heated pipe outlet shock blower connected connection point mounting pipe shock blower included part standard system delivered. probe attached probe retractor with mounting flange 10). compressed-air connection cleaning filter cooling-water connections cooling probe. tube-sealing device adjusted position probe tube.
Fig. Structure Probe
Sample suction opening Plunger Filter Pipe Stainless steel bellows Compressed-air cylinder pipe
outlet Connection shock blower Fitting sleeve Mounting flange Compressed-air connection Cooling-water connections Tube-sealing device Continued next page
Cement Analysis System System Description
30/23-220 Rev.
Probe continued
Scope Delivery Technical Data Probe Stainless steel Mat. 1.4571 (AISI Sample temperature approx. probe tube) Internal metal sinter filter (electr. heated) Weight approx. (without cooling water) m-long probe Connecting components Water tube, with connections (incl. 100) Compressed-air tube, with connections Compressed-air tube, wire-braiding, Weight approx. Cleaning unit solenoid valves compressed-air tank, attached probe retractor Weight approx. Exhaust unit filter solenoid valves pump Terminal Components commissioning metal sinter filter stainless steel bellows compressed-air cylinder Weight approx. Heat exchanger Cooler block made from copper brass Dimensions 1005 Electric, speed-controlled motor Power supply with 3-phase connection (internal) Power consumption Weight approx. Tube-sealing device sealing between probe tube sampling opening, fitted probe tube Weight approx. Installation instructions With safety information installing probe kiln exit calciner exit
30/23-220 Rev.
Cement Analysis System System Description
Probe
Layout (see Fig. sample sucked through side openings probe. sample flows through pipe filter unit outlet filter unit compressed-air connections electrically heated ring heater Inside filter unit ceramic filter filter unit housed protective casing shock blower connected connection point fitting sleeve shock blower included part standard system delivered. probe attached probe retractor with mounting flange 10). cooling-water connections cooling probe. tubesealing device adjusted position probe tube.
Fig. Structure Probe
Sample suction openings pipe Filter unit outlet Compressed-air connections Ring heater Ceramic filter
Protective casing Connection injector Mounting pipe Mounting flange Cooling-water connections Tube-sealing device
Continued next page
Cement Analysis System System Description
30/23-220 Rev.
Probe 60S, continued
Scope Delivery Technical Data Probe tube Stainless steel Mat. 1.4541 (AISI 321) Sample temperature approx. pipe) Weight approx. (without cooling water) m-long probe Filter unit with ceramic filter, filter housing flange made from stainless steel Mat. 1.4571, connection cleaning with compressed air, weight approx. Ring heating element: unregulated, weight approx. Protective casing probe 60S: Galvanized, insulated, weight approx. Connecting components Water tube, with connections (incl. 100) Compressed-air tube, with connections Compressed-air tube, wire-braiding, Weight approx. Cleaning unit solenoid valves compressed-air tank, attached probe retractor Weight approx. Components commissioning ceramic filter O-ring flange gasket Weight approx. Heat exchanger Cooler block made from copper brass Dimensions 1005 Electric, speed-controlled motor Power supply with 3-phase connection (internal) Power consumption Weight approx. Tube-sealing device sealing between probe tube sampling opening, fitted probe tube Weight approx. Installation instructions With safety information installing probe kiln exit calciner exit
30/23-220 Rev.
Cement Analysis System System Description
Cooling Probe
does probe need cooled? extremely high temperatures outlet from rotary kiln (approx. 1300 calciner (approx. 1000 °C), gas-sampling probe needs protected cooling system.
Cooling Probe (see Fig.
probe cooled water circulating totally closed system. circulating pump transports least m3/h through probe tube Fitted water outlet probe tube resistance thermometer 100) which functions primary detector controlling water temperature. water flows through heat exchanger pressure compensation vessel Additional instruments installed water pipe measuring pressure flow temperature pressure gauge equipped with min. contact max. contact. When water pressure bar) min. contact automatically triggers probe move out; when water pressure high bar) max. contact triggers alarm. flow monitor equipped with min. contact, which again automatically causes probe move when flow rate l/min). Fitted outside analysis cabinet mechanical safety valve which opens when water pressure rises above bar. When system first filled with water (approx. water flows through filter measured signal from resistance thermometer converted transmitter passed frequency converter which controls speed electric motor heat exchanger. frequency converter point fixed controlling water temperature. temperature cooling water shown analyzer's display. Continued next page
Cement Analysis System System Description
30/23-220 Rev.
Cooling Probe, continued
Fig. Piping Diagram Probe Cooling
Analysis cabinet
Signalling Tubes Pipes
Circulating pump Probe tube Resistance thermometer Heat exchanger Pressure compensation vessel Pressure gauge Flow monitor
Resistance thermometer Filter Safety valve Transmitter Frequency converter Motor
30/23-220 Rev.
Cement Analysis System System Description
Cleaning Probe
imperative observe compressed-air supply requirements (see page 16)!
Cleaning Probe (see Fig.
process cleaning probe incorporates following procedures: Cleaning fitting sleeve Cleaning outside probe retracting inserting probe Cleaning suction opening probe moving plunger (only probe Cleaning probe filter
Cleaning Fitting Sleeve
beginning cleaning process sets control signal cleaning mounting pipe. shock from shock blower breaks material build-ups that have blocked area between probe mounting pipe.
Cleaning Outside Probe
Material build-ups encrustations probe tube removed regular movement probe. retraction insertion probe controlled compressed from control
Cleaning Suction Opening Probe (only probe
probe sample suction opening located probe tube. periodic pneumatically-driven movement plunger effect breaking crusty deposits suction opening. sampling carries uninterrupted this process.
Cleaning Probe Filter
filter, which probe located probe tube probe located filter device (connected gasket), cleaned periodically with compressed air.
Cleaning Unit
cleaning unit contains control valves cleaning with compressed moving plunger compressed-air cylinder cleaning unit fitted probe retractor Continued next page
Cement Analysis System System Description
30/23-220 Rev.
Cleaning Probe, continued
Fig. Pneumatic Diagram Probe Cleaning
shock blower Probe tube Control Probe retractor Cleaning unit Control valve cleaning with compressed
Control valve moving plunger (only with probe Compressed-air cylinder Pneumatic motor Control valve filter Compressed-air tank (250
30/23-220 Rev.
Cement Analysis System System Description
Probe Retractor with Control
Probe Retractor function probe retractor move probe regularly prevent from being seized bended. movements probe retractor controlled PLC.
Retracting Probe
probe automatically retracted kiln following problems occur: Temperature cooling water high, Flow rate cooling water low, Cooling-water pressure low, Circulating pump operation, Power supply break down.
Design Probe Retractor (see Fig.
probe retractor comprises parallel bearing rails which carriage with flange-mounted probe runs. When retracted, probe turned left right. pneumatic motor chain drive that makes particularly well-suited dusty environment. motor attached probe retractor. designed pressure approx. (approx. positive pressure). speed using control valve motor's compressed-air outlet. compressed-air outlet equipped with filter
Control (see Fig.
control installed close probe retractor on-site supply compressed connected control box. compressed must dried pressure approx. (approx. positive pressure). compressed piped compressed-air tank 12and probe retractor added compressed destined pneumatic motor.
Functions Control
"Automatic" operating mode, monitoring control functions handled PLC. following functions activated "Manual" operating mode: Retract probe, Insert probe, Clean probe, Activate shock blower. Emergency Stop button used stop probe retractor time. Continued next page
Cement Analysis System System Description
30/23-220 Rev.
Probe Retractor with Control Box, continued
Technical Data Probe retractor Double beam design with carriage, probe tube connection, proximity switches Pneumatic flap, max. Pneumatic motor with gear, tractive power 5000 positive pressure), chain drive mounting flange, similar 2573, outside diameter bolt circle, holes diameter Removable dust cover Dimensions: probe length 1500 Weight (without probe) approx. probe length Control Sheet-steel wall mounting, color 7032 Dimensions 1000 Compressed-air filter pressure regulator; lubricator pneumatic valves Transformer heating tube (only probe Push buttons probe control emergency stop Key-operated switch maintenance Warning light Weight approx.
30/23-220 Rev.
Cement Analysis System System Description
Compressed-Air Cooling-Water Supply Requirements
Compressed-Air Supply Requirements Compressed needed cleaning probe moving probe retractor. compressed must free from contamination well from water droplets. must dried have pressure approx. (approx. positive pressure). Consumption approx. 3m3/h. There must compressed-air tank with capacity least installed close probe retractor. This ensures that probe retracted kiln even when on-site supply compressed available. When ambient temperature below essential ensure that compressed-air supply cannot freeze.
Compressed-Air Supply from Analytical
Analytical offer following options supply compressed air: Compressed-air tank, volume 3/4-inch inlet outlet nozzles weight: approx. Complete compressed-air conditioning unit, comprising: Screw compressor, Drier, dried down Compressed-air tank, Power supply 380/400 Noise level dB(A) distance Weight approx.
Cooling-Water Supply Probe probe cooled with water. Requirements closed cooling-water circuit must filled with approx. drinking water anti-corrosion agents). When ambient temperature below approx. glycol must added.
Cement Analysis System System Description
30/23-220 Rev.
Sample Line
Unheated Sample Line unheated sample line only used situations where ambient temperature higher than Insulation material supplied along with sample line; this should used insulate sample line together with cooling-water hose (probe outlet) order minimize amount condensate formation sample line. Since impossible completely prevent condensation, must prepared spend extra time maintenance. Material: PTFE
Heated Sample Line
heated sample line must used situations where ambient temperature when measuring SO2. Technical data: Sample line made PTFE, electrically selfregulating, flexible able shortened length, temperature approx. insulated with silicon foam, Pt-100 sensor, outside diameter approx.
30/23-220 Rev.
Cement Analysis System System Description
Conditioning
Layout gas-conditioning modules installed analysis cabinet (see Figs.
Cleaning Probe
When probe cleaned, solenoid valve closes allows flow into analyzer system. cleaning process ventilation valve opens seconds order release positive pressure which sample line.
Switching Sample
AO2000-Magnos17 oxygen analyzer being used measuring then zero (N2) passed through solenoid valve
Aerosol Filter
aerosol filter installed upstream sample cooler. function filtrate aerosols very fine particles.
Vacuum Monitoring
vacuum gauge monitors pressure loss through probe, filter sample line. When probe gets blocked, vacuum gauge's minimum contact (-0.3 bar) activated cleaning process triggered automatically.
Sample Cooler
SCC-C sample cooler reduces water vapor content sample gas. condensate that been separated pumped built-in condensate pump. maximum level condensate-collecting bottle monitored.
Feed-In
SCC-F sample feed unit contains fine dust filter with condensate monitor, flow monitor, needle valve, diaphragm pump dosing pump. sample feed unit monitors flow formation condensate sample gas. sample flow l/h, minimum switching point approx. l/h.
Reagent Dosing
metering system used H2O2 sample gas. thereby selectively eliminated from sample gas, thus preventing harmful formation sulfuric acid. This dosing should always carried when coal used kiln firing, pure firing. minimum level reagent supply bottle monitored.
Converter
SCC-K converter optionally installed upstream analyzer. converter converts content sample (normally NOx) into only NO-part interest that which been formed thermally through heat kiln, converter does generally need installed. Continued next page
Cement Analysis System System Description
30/23-220 Rev.
Conditioning, continued
Fig. Pneumatic Diagram Conditioning
Fig. Pneumatic Diagram Conditioning with Optional Measurement
Sample inlet Ventilation valve Solenoid valve connecting (when cleaning probe) Solenoid valve connecting zero (only AO2000-Magnos17) Aerosol filter Vacuum gauge SCC-C sample cooler Condensate-collecting bottle
Reagent supply bottle SCC-F sample feed unit Condensate trap SCC-K converter (optional) AO2000-Uras14 infrared analyzer AO2000-Magnos17 oxygen analyzer (optional) AO2000-Limas11 process photometer (optional)
30/23-220 Rev.
Cement Analysis System System Description
Analysis
Operation infrared analyzer AO2000-Uras14 measures concentration components concentration generally measured using electro-chemical sensor. AO2000-Uras14 analyzer housed along with sensor casing central unit. waste products containing chlorides combusted kiln, then paramagnetic oxygen analyzer AO2000-Magnos17 should used measuring this analyzer housed separate casing. Normally, process photometer AO2000-Limas11 with quartz cell used measurement. case firing content ppm, also infrared analyzer AO2000-Uras14 used measurement.
Calibration
analyzers always calibrated automatically. Cylinders test generally required weekly calibration. AO2000-Magnos17 oxygen analyzer requires zero gas. activation calibration time-controlled cyclical, calibration also started manually. AO2000-Uras14 infrared analyzer Measuring ranges (examples): 0.0.5 vol. vol. 0.3000 0.5000 Automatic calibration using calibration cells AO2000-Limas11 process photometer Measuring ranges (examples): 0.5000 0.20000 Automatic calibration using calibration cell Electro-chemical sensor Measuring ranges 0.10 vol. 0.25 vol. Automatic calibration using ambient AO2000-Magnos oxygen analyzer Measuring ranges 0.10 vol. 0.25 vol. Zero-point calibration with nitrogen ambient air; this, solenoid valve needs installed upstream sample cooler. test cylinder outside analysis cabinet. further technical information Data Sheet "AO2000 Series" (Publication 10/24-1.10
Technical Data
Cement Analysis System System Description
30/23-220 Rev.
Output, Input Status Signals
Indication status signals displayed clear text.
Analog Outputs (Current Signals)
current output 4.20 measuring component (max. measuring components), load max.
Binary Outputs
common status (error, maintenance mode, maintenance request)
Single Status Signals (Option)
Output floating relay contacts, max. load rating VAC, Status signals: Manual Automatic Measure Clean Error Probe inserted Probe retracted Maintenance Failure Maintenance mode Maintenance request Probe tube heating Plunger seized (only probe Min. temperature sample line Min. pressure compressed Min. pressure sample Cleaning failed Probe seized Min. pressure cooling water Max. pressure cooling water Min. temperature cooling water Max. temperature cooling water Min. flow cooling water Cooling water pump motor protection Frequency converter malfunction
Interfaces
Profibus slave RS232 RS485 (option) Ethernet (gas analyzer only) remote operation remote diagnosis with TCP/IP protocol Further interfaces possible request
30/23-220 Rev.
Cement Analysis System System Description
Analysis Cabinet
Layout analysis cabinet produced versions: sheet steel plastic (GRP). analyzers mounted swing frame. electrical connections located left side wall.
Fig. Analysis Cabinet
unit Sample pressure gauge SCC-F sample feed unit SCC-C sample cooler Water filter Flow monitor Cooling water pressure gauge
Circulating pump Reagent supply bottle Condensate-collecting bottle Pressure compensation vessel Frequency converter analyzers
Continued next page
Cement Analysis System System Description
30/23-220 Rev.
Analysis Cabinet, continued
Installation Notes sheet-steel analysis cabinet should always installed air-conditioned room order protect from dust from ambient temperatures that high low. Ambient temperature range: with filter fans +5.+35 with filter fans electric heating -10.+35 with cooler electric heating -10.+50 plastic cabinet with filter fans, electrical heating cooler available outdoor installation. this case filters must cleaned daily basis. Ambient temperature range: -20.+50
30/23-220 Rev.
Cement Analysis System System Description
IndustrialIT word mark mentioned product names form XXXXXIT registered pending trademarks ABB. Sales Customer Support expertise over countries worldwide. www.abb.com
Company's policy continuous product improvement right reserved modify information contained herein without notice. Printed Fed. Rep. Germany (05.05) 2005
Automation GmbH Analytical Division Stierstaedter Strasse 60488 Frankfurt Main Germany Phone: 7930 Fax: 7930 4566 Mail: analytical mkt.deapr@de.abb.com
30/23 Rev.
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