943-TGS

Automatic Process UV Spectrophotometer for Tail Gas Analysis – Split Oven

OPERATION MANUAL P/N: MA7474 Revision 1

June 27, 2017

Galvanic Applied Sciences, Inc. 7000 Fisher Road S.E.

Calgary, Alberta, T2H 0W3 Canada

Phone: (403) 252-8470 Fax: (403) 255-6287

E-mail: info@galvanic.com World Wide Web: http://www.galvanic.com

mailto:info@galvanic.comhttp://www.galvanic.com/

NOTICES This system is covered by a limited warranty. A copy of the warranty is included with this manual. The operator is required to perform routine maintenance as described herein on a periodic basis to keep the warranty in effect. For routine maintenance procedures, refer to Section 8. All information in this manual is subject to change without notice and does not represent a commitment on the part of Galvanic Applied Sciences, Inc. No part of this manual may be reproduced or transmitted in any form or by any means without the written permission of Galvanic Applied Sciences, Inc. Note: Changes or modifications not expressly approved by Galvanic Applied Sciences, Inc. could void the user's authority to operate the equipment. © Copyright 2011, 2012 Galvanic Applied Sciences, Inc. All rights reserved. Printed in Canada

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Table of Contents

SECTION 1 MODEL 943-TGS TAIL GAS ANALYZER SPECTROPHOTOMETER OVERVIEW ...................... 12

1.1 OVERVIEW ........................................................................................................................... 12 1.2 ANALYTICAL METHOD ........................................................................................................... 12 1.3 ANALYZER DESIGN ............................................................................................................... 13 1.4 SAMPLING SYSTEM .............................................................................................................. 13 1.5 SYSTEM OPERATING CONTROL............................................................................................. 14 1.6 CONTENTS OF THIS MANUAL ................................................................................................. 14

SECTION 2 INSTALLATION................................................................................................................ 16

2.1 RECEIVING THE SYSTEM ....................................................................................................... 16 2.2 ENVIRONMENTAL REQUIREMENT ........................................................................................... 16

2.2.1 Electrical Requirements ........................................................................................ 16 2.2.2 Temperature ......................................................................................................... 16 2.2.3 Space Requirements ............................................................................................ 16 2.2.4 Instrument Air ....................................................................................................... 17 2.2.5 Steam ................................................................................................................... 17 2.2.6 Area Classification ................................................................................................ 17

2.3 UNPACKING ......................................................................................................................... 17 2.4 INSTALLATION STEPS ........................................................................................................... 18

2.4.1 Mounting of the Oven Cabinet .............................................................................. 18 2.4.2 Mounting of the Control Cabinet ........................................................................... 18 2.4.3 Mating of the Process and Analyzer System Flanges .......................................... 20 2.4.4 Connection of the Interconnecting Cables ........................................................... 22 2.4.5 Installing the Fiber Optics Cables ......................................................................... 22 2.4.6 Connection of the AC Power Service ................................................................... 26 2.4.7 Connection of the Analog Signal Cables .............................................................. 26 2.4.8 Connection of the Digital Signal Cables ............................................................... 27 2.4.9 Connection of Instrument Air Services ................................................................. 27 2.4.7 Connection (s) of Steam ....................................................................................... 27 2.4.8 Connection of the ‘Loss of Purge Signal’ ............................................................. 27

SECTION 3 OPERATION ................................................................................................................... 28

3.1 OVERVIEW ........................................................................................................................... 28 3.2 FLOW CONTROL SETTINGS ................................................................................................... 28

3.2.1 Cabinet Purge Air Flow Adjust Valve ................................................................... 28 3.2.2 Condenser Cooling Air Flow Adjust Valve ............................................................ 29 3.2.3 Zero Air Flow Adjust Valve ................................................................................... 29 3.2.4 Aspirator Drive Air Flow Adjust Valve ................................................................... 30 3.2.5 System Regulator ................................................................................................. 30

3.3 ANALYZER OUTPUTS ............................................................................................................ 30 3.3.1 Analog Outputs ..................................................................................................... 30 3.3.2 Digital Outputs ...................................................................................................... 31

SECTION 4 SYSTEM CONTROL ........................................................................................................ 33

4.1 THE USER INTERACTION PROGRAM - OVERVIEW ................................................................... 33 4.2 USING THE ONBOARD DISPLAY AND HAND HELD KEYPAD ...................................................... 33

4.2.1 The Onboard Display ............................................................................................ 33

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4.2.2 The Hand Held Keypad ........................................................................................ 34 4.3 THE ANALYSIS 1 TAB ........................................................................................................... 35

4.3.1 Online/Offline Button ............................................................................................ 35 4.3.2 Air Demand, H2 S, SO2, COS, CS2 and Svap Fields .............................................. 36 4.3.3 Relay Indicator Fields ........................................................................................... 36 4.3.4 Manual Zero ......................................................................................................... 37 4.3.5 Back Purge ........................................................................................................... 37 4.3.6 Graphic Display .................................................................................................... 38

4.4 ANALYSIS 2 PANEL ............................................................................................................... 38 4.5 INDICATORS PANEL .............................................................................................................. 39 4.6 SPECTRUM PANEL ............................................................................................................... 40 4.7 ABSORBANCE PANEL ........................................................................................................... 42 4.8 CONFIG PANEL .................................................................................................................... 43

4.8.1 Outputs Sub-Panel ............................................................................................... 43 4.8.2 Calculation Sub-Panel .......................................................................................... 44 4.8.3 Display .................................................................................................................. 46 4.8.4 Timers/Alarms ...................................................................................................... 47 4.8.5 Network Sub Panel ............................................................................................... 49

SECTION 5 WEB BASED OPERATION................................................................................................ 51

5.1 OVERVIEW ........................................................................................................................... 51 5.2 ANALYSIS SECTION .............................................................................................................. 52

5.2.1 Analysis Page ....................................................................................................... 52 5.2.1.1 Value Display ............................................................................................ 52 5.2.1.2 Status and Control .................................................................................... 53 5.2.1.3 Relay Indicator Fields ................................................................................ 54 5.2.1.4 Graphic Display ......................................................................................... 55

5.2.2 Calibration Matrix Page ........................................................................................ 56 5.2.3 Indicators Page ..................................................................................................... 57 5.2.4 Spectrum Curve Page .......................................................................................... 58 5.2.5 Absorbance Page ................................................................................................. 59

5.3 PARAMETERS SECTION ........................................................................................................ 61 5.3.1 Parameters ........................................................................................................... 61 5.3.2 Modbus ................................................................................................................. 62

5.3.2.1 Overview ................................................................................................... 62 5.3.2.2 The Enron Modbus Protocol ..................................................................... 64 5.3.2.3 The Modicon 16 Protocol .......................................................................... 64 5.3.2.4 Modicon with Floating Point Protocol ........................................................ 64

5.4 FACTORY SECTION .............................................................................................................. 65 5.4.1 Changing the Passwords...................................................................................... 66

5.5 HELP SECTION ..................................................................................................................... 67 5.5.1 Drawings ............................................................................................................... 67 5.5.2 User Manual ......................................................................................................... 67 5.5.3 Revision History .................................................................................................... 67

SECTION 6 MAINTENANCE ............................................................................................................... 68

6.1 OVERVIEW ........................................................................................................................... 68 6.2 ROUTINE PREVENTATIVE MAINTENANCE ............................................................................... 68

6.2.1 Visual Inspection of Key Operating Parameters................................................... 68 6.2.2 Maintenance Check Out Procedure ..................................................................... 70

6.3 CHANGING THE ANTI-SOLARANT SOLUTION ........................................................................... 72

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6.4 OPTIMIZING THE SPECTROMETER ENERGY LEVEL .................................................................. 74 6.4.1 Automated Optimization ....................................................................................... 74 6.4.2 Manual Optimization ............................................................................................. 74

SECTION 7 SERVICE ....................................................................................................................... 76

7.1 OVERVIEW ........................................................................................................................... 76 7.2 ANALYZER FAULT TABLE ...................................................................................................... 76 7.3 CHANGING THE UV SOURCE LAMP ....................................................................................... 79 7.4 CHANGING THE FIBRE OPTIC CABLE (S) ................................................................................ 82 7.5 MEASUREMENT CELL REMOVAL ............................................................................................ 84 7.6 CELL WINDOWS REPLACEMENT ............................................................................................ 86 7.8 MEASUREMENT CELL INSTALLATION...................................................................................... 87 7.9 STEAM PURGING THE SAMPLE PROBE ASSEMBLY .................................................................. 89 7.10 SPECTROMETER REPLACEMENT ........................................................................................... 90

SECTION 8 THE PRODUCT QUALITY ASSURANCE PROGRAM ............................................................. 91

8.1 OVERVIEW ........................................................................................................................... 91 8.2 OVERALL SYSTEM IDENTIFICATION ........................................................................................ 91 8.3 QA DOCUMENT PACKAGE CHECK LIST AND REQUIREMENTS .................................................. 92

SECTION 9 DRAWINGS .................................................................................................................... 93

SECTION 10 SPECIFICATIONS .......................................................................................................... 102

SECTION 11 RECOMMENDED SPARE PARTS .................................................................................... 103

SECTION 12 THE PERIPHERAL BOARD ............................................................................................. 105

12.1 ACCESSING THE BOARD ..................................................................................................... 105 12.2 THE STATUS TAB ............................................................................................................... 106

12.2.1 Information on the Status Tab ............................................................................ 106 12.3 MANUAL OVERRIDE TAB ..................................................................................................... 107

12.3.1 Analog Output Fields .......................................................................................... 108 12.3.1.1 Calibrating and Testing the Analog Outputs ........................................... 108

12.3.2 Testing the Digital Inputs .................................................................................... 109 12.3.3 Testing Digital Outputs ....................................................................................... 109

INDEX 110

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Tables TABLE 6-1: NORMAL VALUES OF KEY OPERATING PARAMETERS ......................................................... 69 TABLE 7-1: ANALYZER FAULT TABLE .................................................................................................. 78 TABLE 8-1: DOCUMENT PACKAGE CHECK LIST ................................................................................... 92 TABLE 11-1: ONE YEAR KIT ............................................................................................................. 104 TABLE 11-2: TWO YEAR KIT ............................................................................................................ 104

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Safety Symbols used in Manual

The Danger symbol indicates a hazardous situation that, if not avoided will result in death or serious injury.

The Warning symbol indicates a hazardous situation that, if not avoided could result in death or serious injury.

The Caution symbol with the safety alert symbol indicates a hazardous situation that, if not avoided could result in minor or moderate injury.

The Notice symbol is used to highlight information that will optimize the use and reliability of the system. Applies to the 943-TGS-CE only.

943-TGS-CE

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Important Safety Guidelines for the 943-TGS Field Programmable Tail Gas Analyzer System

Please read the following warnings and cautions carefully before using the 943-TGS Tail Gas Analyzer System:

This equipment must be used as specified by the manufacturer or overall safety will be impaired.

Access to this equipment should be limited to authorized, trained personnel ONLY.

Due to the thermal mass of the hardware, cooling of the items takes substantial time.

Observe all warning labels on the analyzer enclosures. The analog outputs and alarm relay contacts may be powered by a source separate from the one (s) used to power the analyzer system. Disconnecting the AC Mains Source (s) may not remove power from the analog output signals. Any safety recommendations or comments contained herein are suggested guidelines only. Galvanic Applied Sciences Inc. bears no responsibility and assumes no liability for the use and/or implementation of these suggested procedures. This system, when operating in its normal mode, and/or when it is being serviced, maintained, installed and commissioned contains items which may be hazardous to humans if handled or operated incorrectly or negligently. These items include, but are not limited to: • High Voltage Electrical Energy • Toxic and Explosive Gases • Intense Ultraviolet Radiation • High Temperature Surfaces Installation of the system requires the opening of the process sample point to allow for the insertion of the system sample probe assembly. To achieve this, removing the process access point blind flange is necessary. When the flange is removed, toxic, hot (approximately 150ºC/300ºF) gases and molten sulfur may be expelled to the atmosphere until the system sample probe and its associated flange are in place and securely fastened. It is recommended that the personnel installing the probe wear plant approved breathing air apparatus, and approved personal protective equipment (i.e. gloves, coveralls and protective eye

943-TGS-CE Refer to the 943-TGS-CE User Manual Important Safety Guidelines for the 943-TGS-CE Tail Gas Analyzer System.

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wear) suitable for high temperature work. This applies even if the Tail Gas Line (Process Stream) is believed to be at negative pressure. During normal operation, toxic gases, (H2S, SO2, COS and CS2) are present in the tubing, measurement cell, aspirator and all other system components through which the tail gas sample flows. They should not be opened before the complete system is purged with zero gas (an inert gas or instrument air), and the system is blocked using the two valves in the sample oven identified as the Sample Flow and Vent Flow on/off valves. Purging of the system should be performed with both valves in the open position and maintained for approximately five (5) minutes. Once purging is complete, and with the purge gas still flowing, the two valves should be switched to the Off position. The purge gas can now be shut off and the tubing or associated apparatus opened. The sampling system will be under positive pressure. Loosen a fitting and allow the pressure to be released before completely disconnecting the tubing. The entire system is enclosed in an oven cabinet that is heated and maintained at approximately 150ºC/300ºF to prevent the condensation of sulfur. Maintenance performed before the cooling of the oven and hardware should be done while wearing suitable protective clothing, eye wear, and gloves to prevent burns to the hands and arms. The system includes an Ultraviolet spectrometer which employs a source that generates intense UV radiation that is transmitted to the measurement cell and spectrometer through fibre optic cables. This radiation is extremely harmful to the naked eye and skin, even in short duration exposures. Always extinguish the UV radiation source (lamp) before removing a fibre optic cable or the lamp power supply cover by turning the AC power to the lamp power supply ‘Off’. Should the lamp be turned on for any reason while the cover is off, ensure that certified eye protection is worn and that the exposure is limited to the bare minimum. Although the UV radiation is transmitted through a narrow diameter fibre, it should never be viewed directly. The beam is extremely intense and will cause permanent eye damage. Should visual inspection of the beam be required, point the end of the fibre at an inanimate object and view the illumination reflection. Never expose human skin to the radiation from the optical fibres.

943-TGS-CE Device Group: II 2 G. Ex protection: II 2 G Ex d e ia mb px IIC T3 Gb. Ambient Temperature: -20°C to +60°C. The control cabinet purge gas is to be air only.

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Manufacturer’s Warranty Statement Galvanic Applied Sciences Inc. (“Seller”) warrants that its products will be free from defects in materials and workmanship under normal use and service in general process conditions for 12 months from the date of Product start-up or 18 months from the date of shipping from Seller’s production facility, whichever comes first (the “Warranty Period”). Products purchased by Seller from a third party for resale to Buyer ("Resale Products") shall carry only the warranty extended by the original manufacturer. Buyer agrees that Seller has no liability for Resale Products beyond making a reasonable commercial effort to arrange for procurement and shipping of the Resale Products. Buyer must give Seller notice of any warranty claim prior to the end of the Warranty Period. Seller shall not be responsible for any defects (including latent defects) which are reported to Seller after the end of the Warranty Period. THIS WARRANTY AND ITS REMEDIES ARE IN LIEU OF ALL OTHER WARRANTIES OR CONDITIONS EXPRESSED OR IMPLIED, ORAL OR WRITTEN, EITHER IN FACT OR BY OPERATION OF LAW, STATUTORY OR OTHERWISE, INCLUDING BUT NOT LIMITED TO, WARRANTIES OR CONDITIONS OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WHICH SELLER SPECIFICALLY DISCLAIMS. Seller’s obligation under this warranty shall not arise until Buyer notifies Seller of the defect. Seller’s sole responsibility and Buyer’s sole and exclusive remedy under this warranty is, at Seller’s option, to replace or repair any defective component part of the product upon receipt of the Product at Seller’s production facility, transportation charges prepaid or accept the return of the defective Product and refund the purchase price paid by Buyer for that Product. If requested by Buyer, Seller will use its best efforts to perform warranty services at Buyer’s facility, as soon as reasonably practicable after notification by the Buyer of a possible defect provided that Buyer agrees to pay for travel time, mileage from the Seller’s facility or travel costs to the airport / train station closest to Buyer’s facility plus all other travel fees, hotel expenses and subsistence. Except in the case of an authorized distributor or seller, authorized in writing by Seller to extend this warranty to the distributor’s customers, the warranty herein applies only to the original purchaser from Seller (“Buyer”) and may not be assigned, sold, or otherwise transferred to a third party. No warranty is made with respect to used, reconstructed, refurbished, or previously owned Products, which will be so marked on the sales order and will be sold “As Is”. Limitations These warranties do not cover:

• Consumable items such as lamps.

• Analyzer components which may be damaged by exposure to contamination or fouling from the process fluid due to a process upset, improper sample extraction techniques or improper sample preparation, fluid pressures in excess of the analyzer’s maximum rated pressure or fluid temperatures in excess of the analyzer’s maximum rated temperature. These include but are not limited to sample filters, pressure regulators, transfer tubing, sample cells, optical components, pumps, measuring electrodes, switching solenoids, pressure sensors or any other sample wetted components.

• Loss, damage, or defects resulting from transportation to Buyer’s facility, improper or inadequate maintenance by Buyer, software or interfaces supplied by Buyer, operation

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outside the environmental specifications for the instrument, use by unauthorized or untrained personnel or improper site maintenance or preparation.

• Products that have been altered or repaired by individuals other than Seller personnel or its duly authorized representatives, unless the alteration or repair has been performed by an authorized factory trained service technician in accordance with written procedures supplied by Seller.

• Products that have been subject to misuse, neglect, accident, or improper installation.

• The sole and exclusive warranty applicable to software and firmware products provided by Seller for use with a processor internal or external to the Product will be as follows: Seller warrants that such software and firmware will conform to Seller’s program manuals or other publicly available documentation made available by Seller current at the time of shipment to Buyer when properly installed on that processor, provided however that Seller does not warrant the operation of the processor or software or firmware will be uninterrupted or error-free.

The warranty herein applies only to Products within the agreed country of original end destination. Products transferred outside the country of original end destination, either by the Seller at the direction of the Buyer or by Buyer’s actions subsequent to delivery, may be subject to additional charges prior to warranty repair or replacement of such Products based on the actual location of such Products and Seller’s warranty and/or service surcharges for such location(s). Repaired Products Repaired products are warranted for 90 days with the above exceptions. Limitation of Remedy and Liability IN NO EVENT SHALL SELLER BE LIABLE TO BUYER FOR ANY INDIRECT, CONSEQUENTIAL, INCIDENTAL, SPECIAL OR PUNITIVE DAMAGES, OR FOR ANY LOSS OF USE OR PRODUCTION, OR ANY LOSS OF DATA, PROFITS OR REVENUES, OR ANY CLAIMS RAISED BY CUSTOMERS OF BUYER OR ANY ENVIRONMENTAL DAMAGE OR ANY FINES IMPOSED ON BUYER BY ANY GOVERNMENTAL OR REGULATORY AUTHORITIES, WHETHER SUCH DAMAGES ARE DIRECT OR INDIRECT, AND REGARDLESS OF THE FORM OF ACTION (WHETHER FOR BREACH OF CONTRACT OR WARRANTY OR IN TORT OR STRICT LIABILITY) AND WHETHER ADVISED OF THE POSSIBILITY OF SUCH DAMAGES OR NOT.

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Section 1 Model 943-TGS Tail Gas Analyzer Spectrophotometer Overview

1.1 Overview The use of a Tail Gas Analyzer to assist in the control of combustion air to acid gas ratios in Claus Sulfur Recovery Plants is a standard procedure in industry. The plant tail gas is analyzed using ultraviolet spectroscopy and an output signal that corresponds to the air requirement is determined. This observed signal is proportional to the percentage change required in the combustion air to provide stoichiometric concentrations of the principal reactants; H2S and SO2. When the process is optimized and the correct stoichiometric concentrations of H2S and SO2 are achieved, the feedback signal (normally referred to as Air Demand) is zero (which means that no change is required). The simplified Air Demand equation is: Air Demand = F × ([H2S] - Rop [SO2]) where: F = plant specific gain factor [H2S] = concentration of H2S [SO2] = concentration of SO2 Rop = operating ratio (typically 2) When the stoichiometric concentrations of H2S and SO2 ([H2S] / [SO2]) are equal to 2, the Air Demand output becomes zero regardless of the plant specific gain factor (F) when the operating ratio (Rop) is two (2). When the plant specific gain factor (F) is established for a particular process, the units of Air Demand become ‘percent change required in process air’. (i.e., a computed Air Demand of +1.5% means that the process is 1.5% excess in air.) To achieve optimum performance of the Claus Sulfur Recovery Plant, the Air Demand should be kept near zero. The sample gas obtained from the sulfur plant waste or tail gas stream may also contain other sulfur species such as COS, CS2, and Svapour. These species, if present in significant concentrations, must be analyzed for and a correction be made to avoid interference with the H2S and SO2 analysis.

1.2 Analytical Method The analyzer uses a spectrometer with a diffraction grating that is optimized in the spectral region where the species of interest absorb (the compounds of interest absorb between 200 and 400 nm) coupled to a detection system that maximizes sensitivity and resolution while minimizing dark current and stray light noise (a 2048 element CCD detector is employed). The UV radiation is supplied by a highly stable deuterium broadband source and is transmitted to/from the measurement cell via UV fibre optic cables. This approach provides for analytical accuracy and allows for more precise multi-species analysis than that of a

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conventional photometer which uses narrow band optical filters. The conventional photometer measures only a few discrete wavelengths and spectrometers having lower resolution and fewer elements in the detector are also less precise. If, as is frequently the case, more than one of the sulfur containing compounds indicated above are present, their spectra will overlap. The system uses a deconvolution protocol to separate the signals for each component via a multi component algorithm.

1.3 Analyzer Design The Model 943-TGS analyzer consists of two separate assemblies: a) An oven cabinet which contains the sample handling system and associated hardware

(i.e., solenoids, oven, heaters, etc.). All electrical equipment residing in the oven cabinet is installed using appropriate explosion proof and/or intrinsically safe wiring methods.

b) A control cabinet which contains the electrical hardware necessary for the operation of

the analyzer. Under normal operating circumstances, the interior of the control cabinet maintains a general purpose area classification through a purge system. Both visual and electrical (contact closure) indications are provided for monitoring the status of the control cabinet purge.

Typically the oven cabinet is mounted directly to the process piping to allow for close coupling of the sample extraction probe. The control cabinet may be mounted at a distance from the oven to allow for easy operator access. A set of fiber optics cables, power cables and RTD signal cables run between the two cabinets. The two cabinets can be mounted a distance apart such that the length of the fiber optics cables does not exceed 6 meters.

1.4 Sampling System The Analyzer system utilizes a close coupled mounting arrangement of the measurement cell to the tail gas process sampling point to minimize the sample system length. The short length allows for analyzer response times to be optimized while sample transport problems are mitigated. A small volume of tail gas sample is educted through the measurement cell where the concentrations of the various species are determined photometrically. The measurement sample is drawn from a central point of the process duct using a specifically sized sample probe. After measurement, the process sample (mixed with the educting media) is vented to the wall of the process duct. The concentric chamber design of the sample probe provides both the eduction and venting of the tail gas sample through a single sampling point on the process duct. The sample probe incorporates a mechanism for reducing the dew point of sulfur vapour in the sampled gas stream. Instrument air can be introduced to provide an exposed cool surface to the incoming sample gas. Excess condensed sulfur is hydrostatically returned to the process duct. The sulphur vapour concentration is measured and displayed on the analyzer display. The sulphur vapour concentration is useful for system troubleshooting. Incoming sample gas is filtered to 60 micron and drawn through the measurement cell by the aspirator. The measurement cell exposes a known length of sample to UV radiation for

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spectroscopic analysis. The aspirator is integral to the measurement cell and uses instrument air (or other inert gas) as the educting media. The analyzer turns on the aspirator drive media only when a ‘no fault’ state exists. Analyzer zeroing is accomplished by introducing higher pressure instrument air (or other inert gas) upstream of the measurement cell. The zero gas flushes the entire sample system (probe to vent) and allows readings to be taken through the measurement cell when no absorbing species are present. To the sample system, zeroing and back purging are the same thing. The default state (power ‘off’) of the analyzer is to have the sample system in the back purge (zeroing) mode. Valving is provided for isolating the sample system components from the process stream. A provision is included in the oven plumbing for the steam purging of the sample probe after a plant shut-down or turn-around, should it be required. A temperature-controlled oven maintains all components exposed to the tail gas sample at higher than dew point values. The oven and sample probe are mounted to an interface plate, which in turn is directly mounted to the steam heated process duct sample nozzle (typically a 2 inch, 150 pound pipe flange configuration). Electrical heat is applied to the measurement cell to achieve precise temperature control.

1.5 System Operating Control The analyzer system operation is controlled by a dedicated data acquisition system which provides supervisory control, performs all calculations and provides the user interface. The system includes an onboard computer system which provides a graphic display of key system control parameters and their status, a digital display of the instantaneous value of the Air Demand, H2S, SO2, and COS, and historical graphic displays of the Air Demand, H2S and SO2. The display monitor is mounted on the door of the control cabinet. Cabinet access is not required for viewing or operation. The analyzer is equipped with 4 loop powered analog outputs. Each output can be configured to output Air Demand, H2S, SO2, COS, Sigma S (the sum of the H2S and SO2 concentrations), H2S/SO2 ratio or CS2. An RS485 serial port is also provided which can be used for available for Modbus communication. A hand held key pad is provided for user interface with the analyzer. Operation of the system with the keypad is described in Section 4.2. As an alternative, a web based graphical user interface (GUI) can be used to view and enter information on a remote basis (Section 4.3).

1.6 Contents of this Manual This manual contains the following information: • Section 1: Model 943-TGS Tail Gas Analyzer Spectrophotometer Overview presents

introductory information about spectrophotometry and the system. • Section 2: Installation describes unpacking the analyzer, installing it in the facility and

interfacing with other devices. • Section 3: Operation of the System explains how the operator interacts with the analyzer. • Section 4: Control of the System describes how the user enters data and views system

parameters.

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• Section 5: Operating the Spectrophotometer via the Controller Module describes the role of the keypad controller.

• Section 6: The Graphical User Interface presents a detailed discussion of the various aspects of the application program on the personal computer.

• Section 7: Operating the System discusses routine operation of the analyzer. • Section 8: Maintenance and Troubleshooting includes a discussion of required

maintenance activities and presents information that is useful in diagnosing problems with the analyzer.

• Section 9: Wiring Book includes information about interfacing auxiliary components such as relays, solenoids, etc. to the controller module.

• Section 10: Spare Parts lists a number of items which may be required to maintain operation of the analyzer.

• Section 11: Specifications presents the specifications for the analyzer.

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Section 2 Installation

The initial installation of the analyzer system is usually completed by the purchaser. The start-up and commissioning is usually performed by Galvanic Applied Sciences Inc. personnel.

2.1 Receiving the System When the system arrives, inspect the packaging for external signs of damage. If there is any obvious physical damage, contact the shipping agent and Galvanic Applied Sciences to report the damage and request that the carrier's agent be present when the unit is unpacked. It is recommended that you retain the shipping container so that it may be used for future shipment of the unit, if necessary.

2.2 Environmental Requirement

2.2.1 Electrical Requirements The power input is 100 – 240 V, 1 phase, 50/60 Hz, 800 W. The operating voltage is specified on the serial number name plate

2.2.2 Temperature The system is designed to be operated at ambient temperatures from -20 oC to +60 oC. Galvanic offers complete analyzer shelters from sun shades to complete building, please contact Galvanic Applied Sciences, Inc. (or your local representative) for additional information.

2.2.3 Space Requirements The overall outer dimensions of the oven enclosure are 27.5”H (700 mm) x 30.5” W (775 mm) x 25.5” D (648 mm). The installation should allow for access to the oven and the ability to remove the cover. The overall outer dimensions of the control cabinet are 46” H (1168 mm) x 33” W (838 mm) x 15” D (381 mm). See Figures 2-1 and 2-2 for more details.

943-TGS-CE Refer to the 943-TGS-CE User Manual Sections 2.1, 2.2, 2.3, 2.4, 2.5, and 2.6.

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2.2.4 Instrument Air The system requires 22 SCFM at 50-100 psi.

2.2.5 Steam Two supplies are required: • Nozzle: Pressure = 40-80 psi, maximum temperature = 160oC • Oven Heater: Pressure = 140-175 psi, maximum temperature = 200oC

2.2.6 Area Classification

2.3 Unpacking The 943-TGS analyzer system is packed for shipment in a wooden crate. To unpack the system: a) Remove the lid by undoing the marked lag bolts.

b) Once the lid is off, remove the excess packing material, boxes and sample probe from

the shipping crate. The sample probe will be wrapped in packing material. Probes with a guide length of 5.5 feet or longer are packed in a separate crate.

c) Visually inspect the small packages and the sample probe to ensure that no major

damage has occurred. If damage has occurred, contact the shipping company and Galvanic Applied Sciences. Place the small packages and the sample probe aside in a safe, secure storage area as they are not needed at this stage of the system installation.

The control cabinet weighs approximately 62 kg and the oven cabinet weighs approximately 60 kg. Use suitable precautions when removing it from the crate and placing it in the facility.

d) Locate and remove the four (4) bolts that secure the control cabinet framework to the 2' x

4' boards at the bottom of the shipping crate.

e) Once the bolts are removed the control cabinet can be lifted from the crate.

943-TGS-CE Device Group: II 2 G. Ex protection: II 2 G Ex d e ia mb px IIC T3 Gb. Ambient Temperature: -20°C to +60°C.

943-TGS-CE Steam is supplied to the nozzle only. There is no requirement for oven heater steam on the 943-TGS-CE. There is no steam heater in 943-TGS-CE oven.

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f) Remove the oven enclosure from the crate.

g) Remove the plastic wrap from the control, cabinet and oven cabinet.

h) Open the control cabinet doors and carefully remove the packing material from inside the cabinet.

i) Remove the oven cabinet lid and carefully remove the packing material from inside the

cabinet.

Care should be taken while removing the cabinet packing material so that no hardware or wiring is damaged.

j) Inspect the internal equipment to ensure that no damage has occurred and that no

components have become loose during transport. If any damage is visible contact Galvanic Applied Sciences Inc. immediately and do not proceed with the system installation. Do not attempt to facilitate repairs yourself as this will negate and/or invalidate any possible insurance claim or equipment warranty.

k) If no damage is apparent, the analyzer system is ready for transport to the installation

(sample point) site.

2.4 Installation Steps

The user should read each step and make certain that it is fully understood before proceeding to installing the analyzer.

2.4.1 Mounting of the Oven Cabinet The oven cabinet is supported by a cradle that mounts to the process pipe structure. The oven must be situated such that the probe opening in the bottom of the cabinet aligns with the process connection. See Figure 2-1 for mounting details. The steam jacketed ball valve must be installed on the process sample point before mounting the analyzer system.

2.4.2 Mounting of the Control Cabinet The framework of the control cabinet must be securely attached to a support structure at the mounting site. The control cabinet must be mounted a distance away from the oven cabinet such that the path for the fiber optics cables does not exceed 6 meters. See Figure 2-2 for mounting details.

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The Steam jacketed ball valve must remain closed until the sample probe is installed and connected in the sample handling oven.

Figure 2-1: Oven Cabinet Dimensions

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Figure 2-2: Control Cabinet Dimensions

2.4.3 Mating of the Process and Analyzer System Flanges

The analyzer is shipped with a 316 SS blind flange plate and gasket mounted inside the oven compartment to prevent the process gas from flowing into the compartment before installation of the sample probe assembly. Check to ensure that this blind flange is in place and secure.

943-TGS-CE Refer to the 943-TGS-CE User Manual Section 2.7.2.

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Explosive, toxic and hot gases and molten sulfur may be released once the stream jacketed ball valve is opened. All company and/or regulatory agency safety procedures and rules should be adhered to. Breathing apparatus and personal protective equipment (ie. gloves, coveralls and protective eye wear) should be worn and a safety person(s) should be observing. Do not take unnecessary risks even if you believe the tailgas line to be at negative pressure.

Before mounting the oven cabinet at the process (sample) connection, check to ensure that: a) The bolt holes in the steam jacketed nozzle flange are large enough to accommodate the

four (4) bolts on the analyzer system flange

b) The two (2) flanges are correctly aligned

c) A new gasket of proper size and material is available

d) The appropriate nuts are available to put onto the system flange bolts.

The actual sample probe is sized so that it provides a minimum of 25% penetration into the process pipe. The diameter of the pipe is provided by the customer.

If all of the above conditions are satisfied:

a) Put the new gasket in place and move the analyzer system into position placing the four

(4) bolts through the steam jacketed nozzle flange holes.

b) Place the four (4) nuts onto the bolts and tighten.

c) Inspect the flange connection using company and/or regulatory agency procedures to ensure that the connection is leak-tight (no gases are escaping).

d) Check that process gas is not leaking into the analyzer oven.

When the oven cabinet is securely fastened to the process sample point flange, make sure that the oven cabinet cradle is secured to the support structure. This is to ensure that the framework and support structure, not the flange connection, are bearing the weight of the analyzer system.

Install the sample probe:

a) Remove the oven cabinet lid and insert the probe into the packing gland at the bottom of

the oven until it reaches the steam jacketed ball valve.

943-TGS-CE Refer to the 943-TGS-CE User Manual Section 2.7.3.

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Explosive, toxic and hot gases and molten sulfur may be released once the stream jacketed ball valve is opened. All company and/or regulatory agency safety procedures and rules should be adhered to. Breathing apparatus and personal protective equipment (ie. gloves, coveralls and protective eye wear) should be worn and a safety person(s) should be observing. Do not take unnecessary risks even if you believe the tailgas line to be at negative pressure.

b) Open the steam jacketed ball valve and continue inserting the probe until the probe

flange contacts the packing gland.

c) Tighten the packing gland and connect the tubing to the probe.

If the connections are leak-tight and company safety personnel have deemed the atmosphere to be safe, breathing apparatus may now be removed.

2.4.4 Connection of the Interconnecting Cables

All interconnecting electrical cables must comply with local standards. Heater Power: Refer to drawing 9-5 in Section 9 of this manual for heater power connection detail. Solenoid Control: Refer to drawing 9-5 in Section 9 of this manual for the solnoid valve control connection detail. Intrinsically Safe Wiring (RTD’s and Pressure Transducer): Refer to drawing 9-5 in Section 9 of this manual for the RTD’s and pressure transducer connection detail.

2.4.5 Installing the Fiber Optics Cables There are 2 fiber optics cables supplies with the analyzer: one is labelled “Source Fiber” and the other is labelled “Spectrometer Fiber”. Each fiber optic cable has a potted fixture near one end as shown in figure 2-3. The potted fixture passes through a cable gland in the control cabinet as shown in Figure 2-4.

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Figure 2-3: Potted Fixture

Figure 2-4: Control Cabinet Fiber Optics Entries

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Connect the “Source Fiber” to the UV Lamp block and the “Spectrometer Fiber” to the Spectrometer as shown in Figure 2-5.

Figure 2-5: Fiber Optics Cables Connections Inside Control Cabinet Route the fiber optics cables from the control cabinet to the oven cabinet. Pass the fiber optics cables into the oven enclosure entries located at the rear of the oven enclosure as shown in Figure 2-6.

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Figure 2-6: Fiber Optics Cables Entries for the Oven Enclosure

Connect the “Source Fiber” to the top of the measurement cell inside the oven and the “Spectrometer Fiber” into the bottom of the measurement cell as shown in Figure 2-7.

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Figure 2-7: Fiber Optics Cables Connection Inside Oven Enclosure

2.4.6 Connection of the AC Power Service

2.4.7 Connection of the Analog Signal Cables

943-TGS-CE Refer to the User Manual Section 2.7.4.

943-TGS-CE Refer to the User Manual Section 2.7.5.

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2.4.8 Connection of the Digital Signal Cables

2.4.9 Connection of Instrument Air Services

2.4.7 Connection (s) of Steam

2.4.8 Connection of the ‘Loss of Purge Signal’

943-TGS-CE The “loss of purge” is an integral function of the purge controller.

943-TGS-CE Refer to the User Manual Section 2.7.6.

943-TGS-CE Refer to the User Manual Section 2.7.8.

943-TGS-CE Refer to the User Manual Section 2.7.7.

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Section 3 Operation

3.1 Overview The 943-TGS analyzer system is designed to operate automatically with a minimum need for human intervention. Once installation, commissioning and initial start-up have been completed, the only human intervention required is when the system indicates a problem or when routine preventative maintenance is scheduled. The user interaction program is described in Chapter 4. The analyzer system computer automatically performs all of the normal operational procedures including sample flow initiation, analysis, on-line calibration, range sensitivity selection, fault detection, temperature zone control and fail-safe back purge (should a fault occur). Operators are alerted to an abnormal state or fault occurrence through indicators on the display on the front panel and the output alarm contact closures. The only manual adjustments to system controls (not through the computer) are the flow control of various instrument air streams. Flow adjustment valves for the zero/purge gas flow rate, the aspirator drive air flow rate and the sulfur condenser air flow rate are provided and located according to Oven Cabinet Component Locations drawing. All valves are clearly labeled according to their title and function. The Flow Diagram drawing provides a schematic of the flow streams in the analyzer system. Isolation on/off block valves are provided in the oven compartment to do the sample probe steam-out procedure, if required.

3.2 Flow Control Settings The flow control settings govern system operation. Once the system has been commissioned and the flow rates have been set, only occasional adjustments should be required. Flow settings will be checked and verified when doing the recommended routine preventative maintenance procedure. The flow control valves can be located using the diagrams in Section 9.

3.2.1 Cabinet Purge Air Flow Adjust Valve

943-TGS-CE The pressure control (needle) valve on the purge controller is set for an enclosure pressure of 1.07mbar as read on the purge controller display.

943-TGS-CE The rapid purge minimum duration is 5 minutes at a minimum flow rate of 0.14m3/min.

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3.2.2 Condenser Cooling Air Flow Adjust Valve The system provides on/off control of the probe cooling air via a solenoid operated valve. The Condenser Cooling Air Flow Adjust Valve is a coarse flow rate adjustment of air used to cool the condenser section of the sample probe. The sample probe contains an internal surface, exposed to the process sample gas path, which can be cooled by the introduction of instrument air. Sulfur condensing on this surface is hydrostatically returned to the process stream. The concentration of sulphur vapour in the process sample gas exiting the probe is measured and displayed on the computer Front Panel as Sulphur Vapour. The Condenser Cooling Air Flow Adjust Valve is opened to reduce the Sulphur Vapour. There is normally a long time constant associated with this adjustment. Several factors can impact the temperature of the gas exiting the probe. These factors include: • changes in process gas temperature • changes in cooling air temperature • changes in the process gas sample aspiration rate and elapsed time since and the duration

of a probe back purge. During a calibration sequence or back purge operation, instrument air is forced into the sample probe from the oven. The indicated sulphur vapour concentration during and immediately after a back purging operation is NOT the sulphur vapour concentration in the process sample gas.

The desired situation is that the concentration of the sulphur vapour in the process sample gas exiting the sample probe is lower than with the probe cooling air off without causing plugging of the sample probe.

3.2.3 Zero Air Flow Adjust Valve The Zero Air Flow Adjust Valve (controls the flow rate of air used in the zeroing and back purging operations (the analyzer ‘zero’ is adjusted under back purge conditions). Under normal operating circumstances, the Zero Air Flow Adjust Valve is adjusted to provide sufficient air flow to obtain a 2-5 second stabilized zero response time from a ‘sampling’ state. The stabilized zero response is ascertained by monitoring the time required for the analyzer gas concentration outputs to stabilize at a near zero level once the analyzer has been switched from a sample to zero (back purge) mode. Excessive zero air flow rates will overly cool oven components. A deficient zero air flow rate may not provide adequate flushing of the measurement cell before a zero adjustment is made. In extraordinary circumstances, during sample system clogging (liquid accumulation), the Zero Air Flow Adjust Valve may be opened wide to provide a solid back purge pressure. Alternately, the Zero Air Flow Adjust Valve may be turned down to a trickle for an extended period (20-30 minutes) allowing the heat of the oven to re-liquefy any solid accumulation (plugging) before increasing the back purging pressure to clean out the plumbing.

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3.2.4 Aspirator Drive Air Flow Adjust Valve The Aspirator Drive Air Flow Adjust Valve controls (indirectly) the rate of process sample gas extraction from the tail gas duct. The aspirator drive air is plumbed to a venturi type eductor integral to the measurement cell block. The design of the analyzer sample system is such that process sample gas is extracted from near the centre of the process duct, and vented at the wall of the process duct through the same access port. Ideally, enough aspirator drive air is provided to present a measurement cell pressure of 2-3" H2O below the process duct pressure. In practice, the aspirator drive air flow adjustment is made to obtain a nominal 5-10 second stabilized sample response time from a ‘zeroing’ state. (The length of time is impacted by the actual probe length.) This adjustment is made by monitoring the time required for the analyzer display outputs of gas concentration to return to a stable process level, after the ‘zero’ state has been released.

3.2.5 System Regulator The system regulator is normally set to 30 psig. The absolute value of this setting is not critical for system operation however, sufficient pressure to provide adequate sample aspiration and system zeroing is necessary. In situations where additional supply pressure is required, the system regulator may be adjusted to its maximum output of 50 psig without harming the analyzer.

3.3 Analyzer Outputs The 943-TGS analyzer generates both analog and digital output signals for connection to the users’ plant control system. The analog signals include the calculated Air Demand, and the measured concentrations of H2S, SO2, and optionally a user selectable signal for analog output 4. The provided digital signals (relay contacts) represent indications of the current analyzer and enclosure purge state.

3.3.1 Analog Outputs The analog outputs are ranged in software, based on information provided specifically for a particular plant. Four loop powered 4 – 20 mA outputs are available. Each output can be configured to represent Air Demand, H2S, SO2, Sigma S (the sum of H2S and SO2 concentrations), CS2 or H2S/SO2 ratio. Each output can be programmed to be either Track or Hold. If the output is programmed to be ‘Track’, the output will track the calculated values displayed on the Front Panel of the computer. (Tracking outputs will follow the zero calibration sequence as it occurs.) If the output is programmed to be ‘Hold’, the output will track the calculated value displayed on the Front Panel until an abnormal condition, zero calibration or fault condition exists. The output will then be held until normal operation is re-established. The Air Demand analog output is Hold only. When the analyzer is in normal operation, the Air Demand analog output tracks the displayed value. When an abnormal condition, zero

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calibration or fault condition exists, the analyzer automatically holds the last valid Air Demand output value until normal operation is re-established. The analog outputs are updated at a rate of once per second, driven by the calculation cycle frequency.

3.3.2 Digital Outputs There are four (4) digital outputs available from the analyzer. The digital outputs are present in the form of zero potential form C relay contacts. The digital outputs are isolated to 250 Vrms. The digital outputs are provided to indicate analyzer operational status. The operational status outputs are: • Status (Fault / Normal) • Service (Warning / Normal) • Mode (Calibrate / Run) • Control (Manual / Auto). In addition to the 4 digital outputs associated with the analyzer operation, there is an independent Purge Fail Alarm attached to the purge system.

a) Status (Fault / Normal) Indicator

The Status (Fault / Normal) output provides analyzer system readiness information. Before ‘Normal’ status indication is given, the analyzer temperature zones and spectrometer signal must be within the specific set point ranges. This indicator will be in the ‘Normal’ state only when ALL of the following are true: • the analyzer is receiving mains power. • the cell temperature is between the cell ‘Low Alarm’ temperature and ‘High Alarm’

temperature set points. • the probe temperature is between the probe ‘Low Alarm’ and cell ‘High Alarm’

temperature setpoints or the sulphur vapour signal is less than the High Svap alarm. • the last spectrometer ‘Measure’ scan was within range. • the last spectrometer ‘Reference’ scan was within range. • the last spectrometer ‘Dark’ scan was within range. The purpose of this indicator is to signify an analyzer problem. When this indicator is in the ‘Fault’ state, the analyzer reverts to a ‘Back purge’ state. Should the fault causing criterion clear, the analyzer will automatically return to ‘Normal’ status and start sampling.

b) Service (Warning / Normal) Indicator

The Service (Warning / Normal) output indicates when service is requested. This indicator will be in the ‘Normal’ state unless one or more of the following is true: • the control cabinet temperature is below 15ºC or over 40ºC. • the spectrometer integration period is greater than 500 ms. • the peak value of the absorbance vector is greater than 2.0. • the sulfur vapour concentration is greater than 0.2%. • the peak value of the raw scan during last zero is less than 2500 A/D (analog to digital)

counts.

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The purpose of this indicator is to signify the analyzer is approaching the extremes of optimum levels. When this indicator is in the ‘Warning’ state, the analyzer will NOT be placed in the back purge mode. The analyzer will continue to function normally, producing useable outputs. The analyzer will self-clear the ‘Warning’ condition and automatically return to ‘Normal’ status once the offending parameter is found to be within range.

c) Mode (Calibrate / Run) Indicator The Mode (Calibrate / Run) output indicates when a zero calibration or a manually requested forced zero back purge is in progress. This indicator will be in the ‘Run’ state unless one of the following is true: • a clock triggered (auto) zero calibration sequence is in progress. • a manually requested zero calibration sequence is in progress. • the analyzer has been placed in the ‘Force Zero’ mode (manually). • the analyzer is not receiving mains power. When this indicator is in the ‘Calibrate’ state, the analyzer is not measuring the process tail gas. When, during a calibration sequence, the zero calibration adjustment is complete, this indicator is held in the ‘Calibrate’ state for a period of time specified by the Zero Hold Interval configuration parameter. This buffer period allows the analyzer to draw process gas and commence measurement before clearing the ‘Calibrate’ indicator. At the expiration of the Zero Hold Interval, this indicator returns to the ‘Run’ state.

d) Control (Manual / Auto) Indicator The Control (Manual / Auto) output indicates the validity of the analog output signals. When this indication is in the ‘Auto’ state, the analyzer believes that output data are real and current measurements of the tail gas process stream. Under conditions where the validity of the output data is suspect, the analyzer places the Control flag in the ‘Manual’ state. This indicator will be in the ‘Auto’ state only when ALL of the following are true: • the Status indicator is in the ‘Normal’ state (i.e. no instrument fault). • the Mode indicator is in the ‘Run’ state (i.e. not in calibration). • the computer’s On Line / Off Line switch in is the ‘On Line’ position (i.e. not being

serviced). • the analyzer is receiving mains power. The purpose of this indicator is to signify when the analyzer outputs are suitable for use as closed loop control inputs. When this indicator is in the ‘Manual’ state, no control action should be taken on the basis of the analyzer output signals. This indicator is generated on the basis of the other analyzer indicators, as well as the condition of the manual ‘On Line / Off Line’ button on the display. The Control flag state is automatically returned to ‘Auto’ once the offending condition (s) has cleared. When in ‘Manual’, Track and Hold outputs are held.

e) Purge Fail Indicator The Purge Fail indicator indicates the status of the analyzer’s safety purge. If the proper purge pressure is maintained in the control cabinet, the Purge Fail Indicator will show normal. If the purge pressure drops to an unsafe level, then the Purge Fail Indicator will indicate a fault.

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Section 4 System Control

4.1 The User Interaction Program - Overview The system includes an onboard computer, display panel and a hand held keypad that is local to the analyzer. As an alternative, a web based graphical user interface (GUI) can be used to view and enter information on a remote basis.

4.2 Using the Onboard Display and Hand Held Keypad

4.2.1 The Onboard Display The main screen of the onboard display is presented in Figure 4-1. There are six panels which are accessed via pressing the Panel Prev or Panel Next buttons on the keypad (Figure 4-2). The various panels are described in Section 4.3-4.8. The main panel presents the present air demand, historical air demand, the present level of various gases, status of the relays and access to the Manual Zero and Back Purge function.

Figure 4-1: Main Screen of the Onboard Display (Analysis 1 Panel)

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The green dot in the upper right corner indicates that the system is monitoring a sample. If the Back Purge function is selected (see Section 4.3.5), the system is performing a Manual Zero operation (Section 4.3.4) or if the system is offline, the dot will be red. This dot is common to all panels.

4.2.2 The Hand Held Keypad The hand held keypad (Figure 4-2) is used to navigate between the various panels and enter information. This keypad is used on the North American version of the analyzer

Figure 4-2: Hand Held Keypad (North American Version)

The buttons on the keypad provide the following: • Panel Prev - Changes the active panel to the previous panel. • Panel Next - Changes the active panel to the next panel. • Field Prev - Moves the cursor to the previous entry on the active panel for editing. • Field Next - Moves the cursor to the next entry on the active panel for editing. • Home - Returns to the Analysis 1 panel. • Purge - Toggles from Back Purge to Sample. • Del - Deletes the last numerical value. • Exit - Erases the current input • Enter - Used to enter numerical information on various tabs. The ATEX / IECEx version of the analyzer uses the keypad shown in Figure 4-3.

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Figure 4-3: Keypad (ATEX / IECEx Version)

The buttons on the keypad provide the following: • F1 - Panel Prev - Changes the active panel to the previous panel. • F2 - Panel Next - Changes the active panel to the next panel. • F3 - Field Prev - Moves the cursor to the previous entry on the active panel for editing. • F4 - Field Next - Moves the cursor to the next entry on the active panel for editing. • F5 - Home - Returns to the Analysis 1 panel. • F6 - Purge - Toggles from Back Purge to Sample. • Del - Deletes the last numerical value. • Exit - Erases the current input • Enter - Used to enter numerical information on various tabs.

4.3 The Analysis 1 Tab The Analysis 1 tab (Figure 4-1) presents a summary of the present status of the system

4.3.1 Online/Offline Button Clicking the Online / Off Line button changes the status from On Line (green) to Off Line (red) and vice-versa. When the analyzer is changed to Off Line, the relay indication for Control is forced to the Manual state (amber). The state of the On Line / Off Line button does not affect the operation of the analyzer. The ability to remotely signal plant operations using the relay output of the Control (in conjunction

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with the On Line / Off Line button) has been incorporated as a convenience to the user. The On Line / Off Line function essentially provides a method of signaling that the analyzer data is invalid (undergoing maintenance or servicing). When returning the analyzer to On Line status, the relay indication for Control will return to the Auto state only if no fault or calibration conditions exist. The plot displays the air demand as a function of time. The range for the x and y axes can be edited as described in Section 4.8.

4.3.2 Air Demand, H2 S, SO2, COS, CS2 and Svap Fields

The Air Demand, H2 S, SO2, COS, CS2 and Svap fields indicate the present values of these parameters and cannot be edited. The analyzer physical scaling is optimized for the measurement of the typical on-ratio concentrations of H2S and SO2. Sulfur vapor (Svap) is monitored to indicate when there may be a problem with the cooling finger in the probe. CS2 may optionally be included in the analysis.

4.3.3 Relay Indicator Fields The relay indicators show the state of the analyzer outputs: a) Status

Normal (Green) status indicates that the system is working properly Fault (Red) status indicates that the computer has detected an error in one of the critical analyzer functions. The Status indicator and alarm relay are placed in a fault state. The analyzer will go into the backpurge mode and instrument air will flow through the cell. An occurrence of a fault status automatically forces the ‘Control’ to Manual.

b) Service Normal (Green) status indicates that service is not required Warning (yellow) indicates that the computer has detected that one of the parameters for a warning condition is out of range. This indicates that service is requested but not required immediately. The analyzer continues to function normally, producing usable outputs.

c) Mode Run (Green) status indicates that the system is in Run mode Calibrate (Amber) indicates that a zero calibrate sequence is in progress. At the end of the calibration sequence the Mode indicator returns to Run. A manually initiated Force Zero condition also causes a Calibrate mode. The mode alarm relay contacts are changed in conjunction with the indicator. An occurrence of the Calibrate mode automatically forces the Control to Manual.

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d) Control

Auto (Green) indicates that the analyzer output signals are deemed to be a valid measurement of the process gas stream and may be used for control purposes if desired. Manual (amber) indicates that the analyzer output signals should be assumed to be invalid (with respect to process stream measurement) and should not be used for control purposes. The analyzer automatically forces the Control indicator to Manual in case of any analyzer fault, a calibration sequence in progress (either manual or auto), or a user initiated Off Line request

4.3.4 Manual Zero The Manual Zero button starts the zero calibration sequence of the analyzer which incorporates the checking and adjusting of the instrument zero (baseline). No span correction is required under normal circumstances on an installed analyzer. The calibration sequence is identical whether triggered manually or automatically. When triggered, the calibration sequence proceeds in the following order: a) The Mode relay output changes to Calibrate and the Control relay output changes to

Manual.

b) Zero gas is introduced into the measurement cell and is allowed to purge the measurement cell for the number of seconds specified by the Zero Purge Interval configuration parameter (Section 4.8).

c) At the conclusion of the Zero Purge Interval, the computer averages the last ten (10)

spectrometer scans and determines a new reference scan vector (captures the new zero value).

d) The analyzer waits for the number of seconds specified by the Zero Hold Interval

parameter of the configuration data (Section 4.8.4)

e) During this period, process sample gas is drawn into the measurement cell and the displayed concentration values will rise from zero to the measured values. The Zero Hold Interval allows the analyzer concentration outputs to stabilize at on-line values before the controller updates the outputs.

f) The Mode relay output changes to Run and Control relay outputs changes to Auto at the

expiration of the Zero Hold Interval (barring a pre-existing fault condition).

4.3.5 Back Purge

The default condition of the analyzer is to have instrument air flowing through the sample cell. When Back Purge is selected, the analyzer sampling system is continuously back purged with zero gas. This is useful as a precursor to maintenance activities or when long term purging is required.

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4.3.6 Graphic Display The Graphic display of the air demand is updated once per second. The time and intensity scales can be set on the Config panel (Section 4.8).

4.4 Analysis 2 Panel The Analysis 2 panel (Figure 4-3) presents the present H2S and SO2 concentrations in a single graphic window. The default full scale values and the time scale can be set on the Config panel (Section 4.8) a range between 0% and the configured full scale analog output concentration. The default full scale values are determined at software restart to a range between ± the configured full scale analog output value for the Air Demand signal.

Figure 4-4: Analysis 2 Panel

The default full scale values and the time scale can be set on the Config panel (Section 4.8) using a range between 0% and the configured full scale analog output concentration. The default full scale values are determined at software restart to a range between ± the configured full scale analog output value for the signals. The Cell Pressure and Temperature fields indicate the instantaneous readings for these parameters, updated every second.

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4.5 Indicators Panel The Indicators panel (Figure 4-4) is used to present details of the last 25 fault and warning events. The current status of each of the items is indicated on the right side and the last 25 events are indicated on the grid. Green - System is functioning within the accepted range Yellow - System requires service Red - System is not functioning properly To clear the present display, use the Field Next or Field Prev buttons to activate the Clear Fault/Warning History button and press Esc.

Figure 4-5: Indicators Panel

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4.6 Spectrum Panel The Spectrum Panel (Figure 4-5) displays the present spectrum and allows the operator to change the integration time. The Peak Height, First Vector Pixel and Dark Level refer to the instantaneous readings for those parameters.

Figure 4-6: Spectrum Tab

The Integration time refers to the period of time for which the data is collected to provide a data point. See Section 6.4 for information about how to optimize the spectrometer signal. The optimum integration time for the present set of conditions can be obtained by pressing the Optimize Integ. Time button. If desired, the operator can select the integration time by selecting the Set Integ. Time button which will present the Integration Period dialog box (Figure 4-6). To change the time, enter the desired value and pressing Okay.

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Figure 4-7: Integration Period Dialog Box

The Factory Reference spectrum refers to a spectrum of zero gas that was saved at the time of analyzer calibration at the factory. If the Show Factory Reference check box is selected, the spectrum will be superimposed on the same set of axes as the active spectrum (Figure 4-7).

Figure 4-8: Factory Reference Spectrum Superimposed on Spectrum

New Reference - saves the scan to be used as a reference for calculation without running a Zero Calibration. The analyzer must be backpurging zero gas before this feature can be used.

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Peak Height - Height of the highest point in the spectrum First Vector Pixel - corresponds to starting wavelength for the analysis and is spectrometer dependent. Dark Level - the signal from dark current

4.7 Absorbance Panel The Absorbance panel (Figure 4-8) presents the Absorbance spectrum and reports the concentration of H2 S, SO2, COS and Svap. The range can be edited on the Config panel (Section 4.8).

Figure 4-9: Absorbance Tab

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4.8 Config Panel The Config panel is used to set a broad range of operating parameters and includes 8 sub-panels. The Configuration Panel should be accessed only by qualified personnel.

4.8.1 Outputs Sub-Panel The Outputs sub-panel (Figure 4-9) is used to define analog outputs and SVAP control.

Figure 4-10: Outputs Sub-Panel

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Output Parameter Radio Buttons – Use the “Next Field” and “Previous Field” buttons on the keypad to select the parameter to be assigned to the analog output. Track or Hold – Use the “Next Field” and “Previous Field” buttons on the keypad to navigate to the “Track” or “Hold” field and press enter to place an “X” beside the desired output behavior. Select “Track” if the output is to be updated when the analyzer is in back purge or performing a zero calibration. Select “Hold” if the output is to hold the last valid reading while the analyzer is in back purge or performing a zero calibration. Full Scale – Enter the value of the desired full scale for the output.

4.8.2 Calculation Sub-Panel The Calculation sub-panel (Figure 4-10) is used to set a broad range of calibration parameters.

Figure 4-11: Calculation Sub-Panel

To edit a parameter, use the Field Prev or Field Next button to access the field and press Enter. A dialog box similar to Figure 4-6 will be presented. Enter the desired value, select the Okay button and press Enter. When all desired changes have been made, select Save. Selecting Revert will keep the parameter values that were used before the start of the editing process.

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a) Plant Factor - This parameter specifies the Plant Factor term used in the analyzer’s

calculation of Air Demand. The Plant Factor is a gain term applied to the air demand output used to adapt the process variable (Air Demand) to the plant’s front end air adjustment capability. Plant Factor is defined as follows: pf = -Qtg (100) / ([H2S]ag) (Qag) where: Qtg = flow rate of the tail gas stream in moles/unit time (typical) Qag = flow rate of the acid gas feed stream in moles/unit time (typical) [H2S]ag = molar concentration of H2S in the acid gas feed stream (typical) PF = plant factor The value for Plant Factor is typically in the order of -3.0.

b) Operating Ratio - Under stoichiometric concentrations of H2S and SO2 ([H2S] / [SO2] = 2/1) the Air Demand output becomes zero regardless of the plant specific gain factor (F) when the operating ratio (Rop) is two (2). When the plant specific gain factor (F) is established for a particular process, the units of Air Demand become ‘percent change required in process air’. (i.e., a computed Air Demand of +1.5% means that the process is 1.5% excess in air.) To achieve optimum performance of the Claus Sulfur Recovery Plant, the Air Demand should be kept near zero.

c) H2S Span - This parameter specifies the span factor utilized for the H2S concentration

display and output. This value should always be close to 1.0.

Any deviation of the H2S span parameter will impact the output calibration of the analyzer.

d) SO2 Span - This parameter specifies the span factor utilized for the SO2 concentration

display and output. This value should always be close to 1.0.

Any deviation of the SO2 span parameter will impact the output calibration of the analyzer.

e) COS Span - This parameter specifies the span factor utilized for the COS concentration

display and output. This parameter (when used) should always be close to 1.0.

f) SVAP Span - This parameter specifies the span factor utilized for the SVap concentration. This parameter (when used) should always be close to 1.0.

g) CS2 Span - This parameter specifies the span factor utilized for the CS2 concentration.

This parameter (when used) should always be close to 1.0.

h) Cell Length - Indicates the cell length of the measuring cell. This value is used in the calculation of the gas concentrations.

i) Fixed Temperature - To select Fixed Temperature, click on the Fixed Temperature on/off

field using the Field Next button on the keypad. Use the Enter key to toggle the x on and off in this field. If the x is present, the analyzer will use the temperature indicated here

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when calculating the concentration of the various gases If the x is not present, the analyzer will use the live value for cell temperature when calculating the concentration of the various gases.

j) Fixed Pressure - To select Fixed Pressure navigate to the Fixed Pressure on/off field

using the Field Next button on the keypad. Use the Enter key to toggle the x on and off in this field. If the x is present, the analyzer will use the pressure indicated here when calculating the concentration of the various gases. If the x is not present, the analyzer will use the live value for cell pressure when calculating the concentration of the various gases.

4.8.3 Display The Display sub-panel (Figure 4-11) is used to set the X and Y range for the display on the Analysis 1 and Analysis 2 panels.

Figure 4-12: Display Sub-Panel

To edit a parameter, use the Field Prev or Field Next button to access the field, enter the desired value for the parameter via the keypad and press Enter. The X range is from 1-15 min and the Y range is from 0.1 to 1000.

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The LCD Backlight field is used to adjust the backlighting of the display to allow the user to adjust for ambient lighting. The slide bar or the buttons can be used to set the desired amount of backlighting. When all desired changes have been made, select Save. Selecting Revert will keep the parameter values that were used before the start of the editing process.

4.8.4 Timers/Alarms The Timers/Alarm panel is presented in Figure 4-12.

Figure 4-13: Timers/Alarms Sub-pane

To edit a parameter, use the Field Prev or Field Next button to access the field. A dialog box similar Figure 4-6 will be presented. Enter the desired value for the parameter via the keypad and press Enter. When all desired changes have been made, select Save. Selecting Revert will keep the parameter values that were used before the start of the editing process.

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a) Timers Auto Cal Interval - The time period between automatic calibrations. The range is 0 – 16,666 minutes. This parameter defines the integer time interval, in minutes, between autocalibration cycles. A value of zero (0) disables the auto-calibration function. An auto-calibration is simply an automated Manual Zero sequence. Typical values are between 60 (once every hour) and 1440 (once every day). The auto-calibration will not run if the analyzer is in a fault condition. Zero Purge Interval - The length of time (integer number of seconds) that zero gas is allowed to flush the measurement cell during the purging part of the calibration sequence, before a new Reference value is computed. The interval must be at least ten (10) seconds longer than the time typically required to flush the measurement cell of the sample. During the last ten (10) seconds of this interval, data is accumulated for the computation of the new ‘Reference’ value. The interval is typically greater than fifteen (15) seconds.

The Auto Cal Interval is timed from the completion of the last zero sequence, whether manually or automatically initiated.

Zero Hold Interval - The length of time (integer number of seconds) that the relay outputs and indicators are held in a calibration state after a new zero has been established. During this time interval, process sample gas is aspirated into the measurement cell and the concentration outputs climb to actual readings. At the expiration of this interval, relay outputs and indicators are returned to a valid data state. This value is typically fifteen (15) seconds.

b) Temperature Control Cell Setpoint -This parameter specifies the temperature control setpoint of the measurement cell in degrees C (ºC). This set point is typically 150oC. Cell Prop Band -This parameter specifies the proportional term (in percent) used in the PID temperature control algorithm for the measurement cell heater. This value is typically 1.0%. Cabinet Set Point (ºC) - This parameter specifies the set point temperature, in degrees C (ºC), of the control cabinet. This value is typically 35ºC. If the cabinet set point temperature is exceeded, the cabinet cooling air solenoid is energized to deliver air to the cabinet Vortec cooler. Cabinet Deadband (ºC) - This parameter specifies the control cabinet set point deadband in degrees C (ºC). This parameter is typically set to 5 or more to reduce the number of solenoid cycles. Probe Set Point (ºC) - This parameter specifies the set point temperature, in degrees C (ºC), at which the gas sample at the probe outlet is to be maintained by the probe cooler. This value is typically 110-120ºC. This parameter is used only when a probe RTD is installed and the Control with RTD function is selected. Probe Deadband (ºC) - This parameter specifies the probe set point deadband, in degrees C (ºC). This parameter is typically set to 5 or more to reduce the number of

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solenoid cycles. This parameter is used only when a probe RTD is installed and the Control with RTD function is selected.

c) Alarms Low Cell (ºC) - This parameter specifies the set point temperature, in degrees C (ºC), which will cause a Low Cell Temperature fault. When the measured cell temperature falls below this value, the analyzer is placed in a Fault Delay condition. The relay outputs and Status indicator are forced to ‘Fault’, and the Control indicator is forced to ‘Manual’. There is a three (3) degree deadband imposed on this alarm. The alarm will clear when the measured cell temperature rises to more than 3ºC above the set point. If at the time of clearing, no other fault conditions exist, the analyzer will return to a normal operating condition. The relay outputs and Status indicator will return to Normal and the Control indicator will return to Auto. This value is typically 135ºC. Low Probe (ºC) - This parameter specifies the set point temperature, in degrees C (ºC), measured at the probe outlet which will cause a Low Probe Temperature fault. When the measured probe temperature falls below this value, the analyzer is placed in a Fault Delay condition. The relay outputs and Status indicator are forced to ‘Fault’, and the Control indicator is forced to ‘Manual’. There is a three (3) degree deadband imposed on this alarm. The alarm will clear when the measured probe temperature rises to more than 3ºC above the set point. If at the time of clearing, no other fault conditions exist, the analyzer will return to a normal operating condition. The relay outputs and Status indicator will return to ‘Normal’ and the Control indicator will return to ‘Auto’. This value is typically 100ºC. This parameter is used only when a probe RTD is installed and the Control with RTD function is selected. High S8 Warning - Level of Sulfur vapour concentration that will reduce the sensitivity of measurement of the other species. High S8 Fault - Level of sulfur vapour concentration that will cause plugging of the sample system.

4.8.5 Network Sub Panel The Network sub-panel is presented in Figure 4-13. The parameters on this sub-panel are set during manufacturing and are not editable by the user. The information under the Network column shows the connection data for the web GUI. The information under the Direct Connect column shows the connection data for the laptop Ethernet port.

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Figure 4-14: Network Sub-Panel

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Section 5 Web Based Operati