Analytical Application Sets - Automation Technology

Analytical Application Sets

© Siemens AG 2015

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4/2 Introduction

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Continuous emission monitoring

Introduction

Set CEM CERT

Set CEM 1

4/17 HM-1400 TRX

Total mercury analyzer system

Dust and opacity measurement

4/19 - D-R 220 dust and opacity measuring instrument

4/21 - D-R 290 dust concentration measuring instrument

4/23 - D-R 320 dust measuring instrument

4/25 - D-R 800 dust measuring instrument

4/27 - D-RX 250 combination probe

Volume flow measurement

4/29 - D-FL 100 volume flow measuring system

4/31 - D-FL 220 volume flow measuring system

4/33 D-ISC 100 display and control unit for dust and volume flow measuring instruments

Environmental and process data management systems

4/35 - D-EMS 2000

4/37 - D-EMS 2000 CS

Analysis of biogas

4/38 Set BGA

Continuous monitoring of hydrogencooled generators

4/42 Set GGA

Determination of the quality of natural gas

4/47 Set CV

Communication and software

4/57 Analyzer System Manager ASM

Siemens AP 01 · 2015

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© Siemens AG 2015


Introduction

■

Overview

Standardization and the supply of complete packages are two trends that are currently on the up. This can be attributed to the fact that the same application is frequently required in different industrial sectors and overhead can be minimized in this case.

Furthermore, customers often want to purchase turnkey systems to minimize the risk of any technical problems.

With its Analytical Application Set initiative, Siemens is making use of its wealth of experience to offer standardized packages that are designed with a single application in mind. Its range of applications can cover a variety of industrial sectors.

It is now possible to simply configure and order complete applications straight from the catalog, thereby sharply reducing the amount of time taken between the request and order. All Analytical Application Sets are tested in advance and provide a high level of safety and reliability. The different versions cover a broad spectrum of potential applications and ensure that the sets can be configured for both minimum and maximum requirements.

The order structure makes it possible to choose from different versions and module components, as well as configure the system and order it directly.

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© Siemens AG 2015


Continuous emission monitoring

Introduction

■

Overview

The combustion of different fuels causes not only the development of carbon dioxide and water vapor but also other environmentally harmful exhaust gas substances (e.g. dust, nitrogen oxides and carbon monoxide, etc.) Emission limit values are determined for these substances according to the state of combustion engineering. The compliance with these limits does not only protect the environment from air pollutants but also ensures optimum combustion in the combustion plants. Emission measurements are a central element for complying with these limit values.

These measurements are required to document whether legal requirements relating to emission limits are complied with. Emission measurements still serve as warranty from plant constructors to operators that the plant runs in accordance with the specification and the law.

There are two reasons why the measuring and monitoring of flue gases for emission components is one of the key topics in continuous gas analysis. First, because of the necessity to comply with the legal regulations and directives. Second, because process plant operators draw conclusions regarding process efficiency from the gas analysis, for example, in boiler control.

So called Continuous Emission Monitoring Systems (CEMS) are used for the determination of the exhaust gas components. In

Europe, they are usually called Automated Measurements Systems (AMS). DIN EN 15267 determines corresponding minimum requirements and testing procedures for automated monitoring systems for the measurement of gases and particulate substances in the exhaust gas of stationary sources as well as for the measurement of the volume flow of the exhaust gas. It provides detailed procedures for the realization of the requirements for the first quality assurance level (QAL1) of DIN EN 14181 and, if required, the access data for the third quality assurance level

(QAL3).

Siemens expertise in the area of products and solutions for process analysis helps you meet all requirements for continuous emission monitoring quickly and smoothly in accordance with regional law. This solution package even ensures a secure investment in case of regulatory adjustments.

According to individual requirements, Siemens offers cold-extractive, hot-extractive, and in-situ automated monitoring systems.

The portfolio is completed by emission evaluation systems for data storage, visualization, remote transmission - permitted according to TA-Luft, 13., 17., 27., 30. and 31. BImSchV

Siemens does not only offer standard solutions but also complete emission analysis systems, e.g. in turnkey analysis containers.

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© Siemens AG 2015

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■

Set CEM CERT

Overview

■

Design

Tested component design

The complete system consists of the following tested individual components:

• Sampling probe: M&C, type: SP2000; Bühler/Siemens, type: GAS222/7MB1943-2F

• Heated sample gas line: Winkler/Siemens, type: 7MB1943-2A

• Temperature controller: Siemens, type: SIRIUS

• Two-stage compressor gas cooler: M&C, type: CSS;

Bühler, type: EGK 2-19

• Sample gas pump: Bühler/Siemens, type: P2.3/7MB1943-3C

• NO

X

converter: M&C, type: CG-2; Bühler/Siemens, type: BUENOX/7MB1943-2D

Performance-tested measuring ranges

Component Analyzer module

Set CEM CERT is a standardized and certified continuous emission monitoring system which is suitable for use in many plants requiring European legislation (13. BImSchV, 27. BImSchV, TA

Luft, 2001/80/EC and IED 2010/75/EC, Annex V) approval. The innovative CEMS meets the current quality standards of EU directives EN 14956, EN 15267 and EN 14181 (QAL1/2/3, AST).

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Benefits

• The tested measuring ranges can be selected for a variety of ranges to ensure use in different areas of application for the

CEMS (TÜV approved).

• The complete modular package allows the certified use of system components from different manufacturers (TÜV approved).

• Simple and fast to configure

• Very low costs of procurement and operation

Modular design

• Up to 2 analyzers with different measuring ranges can be configured

• Selection of versions for indoor or outdoor installation

• Selection of sample gas cooler and NO

X leading manufacturers

converter from

• Electric heaters and air conditioners can be configured to extend the ambient temperature range

• Selection of versions with appropriate sampling probes, heated sample gas lines

CO

NO

SO

2

U23-7MB2355

U23-7MB2357

U23-7MB2358

U23-7MB2355

U23-7MB2357

U23-7MB2358

(in test phase) UV600

U23-7MB2355

U23-7MB2357

U23-7MB2358


NO

2


O

2

, (paramag.) U23

O

2

, (electrochem.) U23

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Function

■

Application

• Emission monitoring of power plants fueled with solid, gaseous or liquid fuels

• Emission monitoring of so-called TA Luft plants (e.g. emission monitoring of glass melting furnaces or steel plants)

• Emission monitoring in crematorium facilities (27. BImSchV)

Smallest certified measuring range

Additional measuring ranges

0 ... 200 mg/m³ 0 ... 750/

3 000 mg/m³

0 ... 200 mg/m³ 0 ... 750/

3 000 mg/m³

0 ... 250 mg/m³ 0 ... 1 250 mg/m³

0 ... 150 mg/m³ 0 ... 750/

2 000 mg/m³

0 ... 150 mg/m³ 0 ... 750/

2 000 mg/m³

0 ... 400 mg/m³ 0 ... 2 000 mg/m³

0 ... 50 mg/m³ 0 ... 100/

1 000/2 000 mg/m³

0 ... 400 mg/m³ 0 ... 2 000 mg/m³

0 ... 400 mg/m³ 0 ... 2 000 mg/m³

0 ... 400 mg/m³ 0 ... 2 000/7 000 (in operation) mg/m³

0 ... 75 mg/m³ 0 ... 130/1 500/

2 000 mg/m³

0 ... 50 mg/m³ 0 ... 500 mg/m³

0 ... 25 vol %

0 ... 25 vol %

The complete tested modular measuring equipment is composed of the sampling probe, the heated sample gas line, a twostage sample gas cooler, a gas pump and the multi-component analyzers, ULTRAMAT 23 and SIPROCESS UV600.

An electrochemical or a paramagnetic oxygen measuring cell can be used for the measurement of oxygen.

The gas path splits in parallel after the sample gas cooler. This separately supplies each analyzer with sample gas. One advantage for maintenance is that each analyzer can be individually serviced without affecting the other. The sample gas coolers used have a moisture alarm in case of malfunction. For additional protection, each analyzer is protected by a condensation barrier, which stops the gas flow if moisture penetrates. This guarantees optimum protection for gas analyzers.

For semi-automatic calibration of the zero and calibration gases, a 3/2-way solenoid valve is installed between the first and second cooling stages. The valve can also be used for AUTOCAL calibration of the ULTRAMAT 23 (fully automatic timing) as well as by the integrated PLC (LOGO module).

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Set CEM CERT

■

Technical specifications

Climatic conditions

Ambient temperature

• With heater in sheet-steel cabinet

+5° ... +40 °C (standard)

Min. -5 °C

• With heating in GRP cabinet Min. -15 °C

• With air-conditioning Max. +52 °C

Relative humidity

Sample gas conditions

Max. sample gas pressure at inlet to sample preparation system

Max. moisture content in sample gas

Sample gas temperature

Sample gas flow

Sampling probe (standard)

75 % (annual average), non-condensing

500 hPa (mbar)

17 vol % (cooler type: CSS)

25 vol % (cooler type: EGK 2-19)

Max. 200 °C at cabinet entry

Approx. 60 l/h per analyzer module

Dust load: < 2 g/m

3

Mounting flange: DN 65, PN 6, form B

Including temperature controller with Pt100

With internal sampling tube, stainless steel, length: 1 m (can be shortened)

Sampling probe for higher temperatures and in other materials (optional)

With filter in probe, to 600 °C

On request

Sample gas line, electrically heated

Max. 35 m, longer lengths on request

Sample gas must not be flammable or explosive.

Power supply

Supply 1

Supply 2

Supply 3

Power

System design

Fusing of electronic consumers

Sample gas cooler

Output signals

115 V AC, 50 … 60 Hz (-15 %, +10 %)

230 V AC, 50 … 60 Hz (-15 %, +10 %)

400 V AC, 50 … 60 Hz (-15 %, +10 %)

4 000 VA max.

1-pole or 2-pole (selectable)

2-stage

4 … 20 mA (corresponding to the analyzer information)

Additional digital inputs and outputs via PLC

(LOGO)

Color

Weight

Sheet-steel cabinet/frame

GRP cabinet

RAL 7035

Approx. 160 kg

Indoor installation

Outdoor installation

Explosion protection classification

Installation outside the Ex zone

Degree of protection IP 54 (avoid direct sunlight for outdoor installation)

Calibration Semi-automatic; AUTOCAL freely adjustable on U23 up to max. 24-hour interval

Detailed information on the analyzers

You can find detailed information on the analyzers:

• in the "Continuous Gas Analyzers, extractive" chapter

- ULTRAMAT 23

- SIPROCESS UV600

Dimensions

Sheet-steel cabinet (with base) for indoor installation

2 000 x 800 x 800 mm (H x W x D)

GRP cabinet (with base) for indoor installation

2 060 x 900 x 800 mm (H x W x D)

500 mm spacing on the right or left must be provided for the cable inlet and connection of the heated sample gas line.

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Set CEM CERT

■

Selection and ordering data

Product description

Performance-tested emission measuring system (EN 15267) for the continuous emission measurement

Click on the Article No. for the online configuration in the PIA Life Cycle Portal.

Rack

Sheet-steel cabinet (2 100 x 800 x 800 mm), hose/cable inlet left

Sheet-steel cabinet (2 100 x 800 x 800 mm), hose/cable inlet right

Control cabinet for outdoor installation (2 060 x 900 x 600 mm), GRP, hose/cable inlet left

Control cabinet for outdoor installation (2 060 x 900 x 600 mm), GRP, hose/cable inlet right

Sampling probe

Sampling probe type: SP2000; Manufacturer: M&C

Sampling probe type: GAS 222; Manufacturer: Bühler

Ventilation/cooling

Cabinet fan with outlet filter

Cabinet air conditioner for sheet-steel cabinet

Cabinet air-conditioner for GRP protective cabinet

Heating

Without heating

Cabinet heating

Fuse protection

1-pole

2-pole

Sample gas cooler

Compressor gas cooler, type: CSS; Manufacturer: M&C

Compressor gas cooler, type: EGK 2-19, Manufacturer: Bühler

NO

2

/NO converter

Without NO

2

/NO converter

NO

2

/NO converter, type: CG series; Manufacturer: M&C

Power supply

115 V AC, -15 %, +10 %, 50 Hz

230 V AC, -15 %, +10 %, 50 Hz

400 V AC, -15 %, +10 %, 50 Hz (3-phase)

Additional versions

Add "-Z" to article number and then order code

Accessories

Condensate tank with level monitoring

Acidification module (for measuring low concentrations of SO

2

)

Extractive analyzers, the analyzers must be ordered separately

Preparation for the installation of an ULTRAMAT23

Preparation for the installation of two ULTRAMAT 23

Preparation for the installation of a SIPROCESS UV600

Preparation for the installation of two SIPROCESS UV600

Preparation for the installation of an ULTRAMAT 23 and a SIPROCESS UV600

Sample gas line, electrically heated (with temperature controller and circuit breaker)

Length: 5 m

Length: 10 m

Length: 15 m

Length: 20 m

Length: 25 m

Length: 30 m

Length: 35 m

Article number

7MB1957-

7 7 7 7 7

-

7 7 7

0

A03

A04

C01

C02

C03

C04

C05

D01

D02

D03

D04

D05

D06

D07

Order code

4

5

0

1

B

C

B

C

D

0

1

0

1

1

2

A

C

A

B

C

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© Siemens AG 2015


Electronic overcurrent protection for heated sample gas line

(only required when heated sample line is not selected from options D01 to D07)

Circuit breaker, 4 A, for lengths up to 5 meters






Documentation

German

English

French

■

Dimensional drawings

800

Option

Sample gas outlet

Air conditioner

(option)

395

Converter (option)

200

VF1

ULTRAMAT 23

VF2

SIPROCESS UV600

Air conditioner

(option)

Sample gas cooler

D21

D22

D23

D24

D25

D26

N01

N02

N03



Set CEM CERT

Order code

Cable glands electrical input/output

Zero gas

Calibration gas

U23

Calibration gas inlets 1 to 3

Sample gas inlet

4

Lateral view, right

Figure contains options, dimensions in mm

Frontal view hinged frame open

Heater mounted on the side

(option)

Condensate tank (option)

Hinged frame 40HE right stop

Filter VF1 and VF2 mounted on the back of the device

Condensate vent

Lateral view, left


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© Siemens AG 2015

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Set CEM 1

■

Overview

■

Application

The monitoring of emission components in flue gases is one of the most important topics for continuous gas analysis. This is a result of legislation for monitoring emissions, e.g. for large combustion plants, and also due to the requirements of companies operating process plants who can draw conclusions on the process efficiency from the gas analyses, e.g. with boiler control,

DENOX and DESOX plants.

The market requires a reliable complete system which is specially designed for the application. The Set CEM 1 (Continuous

Emission Monitoring) offered by Siemens is a system which reliably covers all requirements associated with sampling, sample preparation, and gas analysis.

It is possible to determine the concentrations of the gaseous components CO, CO

2 and H

2

O.

, NO, NOx, SO

2

, O

2

, C total

, HCl, HF, NH

3

The ULTRAMAT 23 and OXYMAT 6 are used for the extractive, continuous gas analysis.

■

The Set CEM 1 is a standardized system specially for monitoring the emission components in flue gases.

Benefits

Standardized complete system

• Highly exact and reliable monitoring of emission components in flue gases. System-specific certificate according to

DIN EN ISO 14956 and QAL 1, according to EN 14181.

• Modular complete package with gas sampling system, sample gas preparation system and gas analyzers from one source

The standardized Set CEM 1 provides great clarity and simple configuration facilities. Different versions mean that it is possible to appropriately adapt the system to the requirements. Standardization also means that not all imaginable versions can be included, and that it may not be possible to implement special requirements such as armored cables, varying gas compositions, customer-specific documentation or specific conductor labeling without an extra charge.

■

Design

Starting with a mounting frame with sample preparation system, it is possible to add additional units as options. These include:


• Tried and tested, harmonized and reliable set

• Low purchase price and economic operation

Proven, suitability-tested technologies

• Continuous determination of up to eight measured components

• In-situ measurements without sampling and preparation, using LDS 6 laser diode spectrometer

• Use of ULTRAMAT 23 with cleanable cells and automatic calibration with ambient air as well as optional electrochemical oxygen measurement

Optional:

• Paramagnetic oxygen measurement with OXYMAT 6

Simple operation

• Intuitive operation

• Configuration on large displays using plain text, in several languages

• Sampling probe with weather protection hood

• Heated sample gas line (for details see catalog PA11)

• Analyzers

• Air-conditioning unit

• NO

2

/NO converter

• Sample preparation extension for an additional ULTRAMAT 23 analyzer

• Single and dual (electrically isolated, not electrically isolated) analog signal processing

• Power supply modules (115 V, 230 V, 400 V)

• Outer panels with steel-plate door or with window

• Single-pole and double-pole fusing

• Condensation bottle

• Coalescence filter

Sampling probe

Simple maintenance

• Maintenance-friendly cabinet design with hinged frame and uniform design

• Digital display of maintenance requests on LOGO modules

The standard probe is fitted with a DIN flange DN 65, PN 6. The probe is provided with a regulated heater, and has a power consumption of 400 VA. It is supplied with a weather protection hood and 2 µm filter. The maximum dust concentration at the sampling point should not exceed 2 g/m³. The sampling pipe is 1 000 mm long, is made of stainless steel, and has dimensions of 20 x

1.5 mm. The sample gas temperature must not exceed 600 °C.

It is also possible to purchase the Set CEM 1 without sample probe.

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© Siemens AG 2015

Heated sample gas line

The temperature of the heated line is regulated at 200 °C by a temperature controller. The power consumption is 100 VA per meter. The internal core is made of PTFE 4/6. The heated line can be up to 35 m in length. Lengths greater than 35 m can be provided upon special request. If desired, the system can also be supplied without a heated sample gas line.

Mounting frame

The basis of each CEM 1 set is the mounting frame with hinged frame (40 HU) for installation of up to five 19" rack units. The mounting frame includes a standardized sample preparation system designed for an ULTRAMAT 23.

The sample preparation system includes a 3/2-way solenoid valve, 3-way switchover ball valve, regulating valve, corrosionresistant sample gas pump (power consumption 60 VA), condensation trap, room air suction filter with filter element, LOGO for digital display of individual signals in the cabinet, 24 V DC power supply unit (power consumption 70 VA). Also included are a sample gas cooler (power consumption 200 VA) with integral heat exchanger, hose pump, moisture sensor with flow cell and Teflon filter. Teflon tubes connect the components.

The external dimensions without plinth are 2 000 x 800 x 800 mm

(H x W x D). A cabinet depth of 600 mm is also optionally available (not suitable for LDS 6). Hoses and cables can be connected from the left or right. A distance of 500 mm must be provided on the left or right at the installation site for introduction of the hoses and cables.

In addition to the sheet-steel mounting frames for indoor installation, an FRP version is also available for outdoor use. The FRP cabinet is always provided complete with side panels and plinth.

The external dimensions are 2 080 x 800 x 600 mm (H x W x D).

The GRP cabinet cannot be combined with the LDS 6.

Preparation of sample preparation system for second

ULTRAMAT 23

The standard system with sample preparation system and electronics is prepared for one ULTRAMAT 23. If a second

ULTRAMAT 23 is to be fitted, this option must be selected so that the sample preparation system and electronics are extended accordingly.

Additional filter

In addition to the fine filter and moisture filter which are always present, a coalescence filter can be optionally fitted in the sample preparation system.

Side panels with doors

Optional outer panels can be selected for the sheet-steel mounting frames. This possibility allows use of the CEM 1 set in analysis cabinets as a rack design on one hand, or on the other as a cabinet design in halls requiring degree of protection IP54. Either a sheet-steel door without window or a glass door can be selected.

Base

Plinths with a height of 100 and 200 mm are additionally available.

Cabinet cooling and ventilation

Optionally available are a fan with outlet filter, an air-conditioning unit for indoor installation, and an air-conditioning unit for outdoor installation. The system can be ordered without a fan or airconditioning unit if the side panels and the door with window are omitted.

The fan with outlet filter has a power consumption of 60 VA, and is fitted in the cabinet wall. The delivery also includes a thermostat with a power consumption of 25 VA.

The air-conditioning unit has a cooling power of 820 VA.



Set CEM 1

Frost protection heater

The power consumption of the optional cabinet heater is 500 VA.

The delivery includes a thermostat with a power consumption of

25 VA for controlling the frost protection heater.

Fusing of the analog signals

In addition to single-pole fusing of the electronic consumers, it is possible to provide double-pole fusing.

The double-pole fuse is mainly required in Benelux countries.

Removal of condensation

A 19 liter condensation bottle can be provided as an option. It is also possible to order the system without a condensation bottle if the condensation can be removed on-site.

NO

2

/NO converter

The mounting frame and cabinets can be optionally extended by a 19" rack unit with NO

2

/NO converter with carbon cartridge. The power consumption is 520 VA. The flow rate is 90 l/h. An NO

2

NO converter is required if the share of NO greater than 5 % and/or if total NO

2

in the total NO x

/

is x

is to be always determined.

Power supply

The system can be designed either for 115 V AC, 230 V AC or

400 V AC (-15 %, +10 %) with 50 or 60 Hz.

Three phases, neutral and ground must be provided by the customer at 400 V AC.

Analog signal processing

As standard, the analog signals are simply connected to isolating terminals. As an option, the analog signals can be processed twice without electrical isolation by a diode module, or twice with electrical isolation.

Analyzers

The standardized set is prepared for an ULTRAMAT 23. The system can be supplemented by a second ULTRAMAT 23,

OXYMAT 6 and/or LDS 6. Various measured components and measuring ranges can be selected. Other combinations of measured components and measuring ranges are available on request, but you must check that the desired certificates and approvals are available. The analyzers, measured components and measuring ranges used are described briefly below.

Details on the analyzers, alternative components and ranges can be found under the topics "Continuous gas analyzers, extractive" and "Continuous gas analyzers, in-situ".

ULTRAMAT 23: CO, NO

For measuring two infrared components.

Component Smallest tested measuring range

CO

NO

0 ... 150 mg/Nm³

0 ... 100 mg/Nm³

Switchable to

0 ... 750 mg/Nm³

0 ... 500 mg/Nm³

One or two measuring ranges can be freely set within the limits.

The ULTRAMAT 23 carries out automatic self-calibration with ambient air. The power consumption is 60 VA.


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Set CEM 1

ULTRAMAT 23: CO, NO, SO

2

For measuring three infrared components.


CO

NO

0 ... 250 mg/Nm³

0 ... 400 mg/Nm³

SO

2

0 ... 400 mg/Nm³

Switchable to

0 ... 1 250 mg/Nm³

0 ... 2 000 mg/Nm³

0 ... 2 000 mg/Nm³



ULTRAMAT 23: CO, NO, CO

2

For measuring three infrared components.


CO

NO

CO

2

0 ... 250 mg/Nm³

0 ... 400 mg/Nm³

0 ... 5 %

Switchable to

0 ... 1 250 mg/Nm³

0 ... 2 000 mg/Nm³

0 ... 25 %



The component CO

2

has not been type approved by the TÜV.

ULTRAMAT 23: CO

2

For measuring one infrared component.

Component Smallest measuring range

CO

2

0 ... 5 %

Largest measuring range

0 ... 25 %

One or two limits can be freely set within the limits. The ULTRA-

MAT 23 carries out automatic self-calibration with ambient air.

The power consumption is 60 VA.

The component CO

2

has not been type approved by the TÜV.

The ULTRAMAT 23 analyzers can be optionally equipped with an electrochemical oxygen sensor.

O

2

: Tested measuring ranges 0 to 10/25 %

OXYMAT 6: O

2

For paramagnetic measurement of oxygen. Instead of

ULTRAMAT 23 with electrochemical cell.

O

2

: Tested measuring ranges 0 to 10/0 to 25 %

Sample chamber without flow-type compensation branch, made of stainless steel 1.4571.

LDS 6: HCl

Component

HCl

Smallest tested measuring range

0 ... 15 mg/Nm³

Application for channel 1: Emission monitoring

The power consumption is 50 VA. Suitable for connection of non-

Ex sensors, including non-Ex-protected sensor electronics.

The delivery includes a pair of sensors for instrument air or N

2

on the process side. The pair of sensors is designed for a moderate flow rate of 0 to 120 l/min. The 400 mm long purging tubes are made of stainless steel. The process connection is DN 65, PN 6.


Limitation:

Applies to measurement paths > 2 000 mm, applies to gases with a methane content < 15 mg/m³. Necessary gas temperature between 120 and 210 °C.

LDS 6: HCl / H

2

O

Component

HCl

H

2

O


0 ... 15 mg/Nm³

0 ... 30 %





2



Limitation:

Applies to measurement paths > 2 000 mm, applies to gases with a methane content < 15 mg/m³. Necessary gas temperature between 120 and 210 °C.

LDS 6: HF

HF: Smallest possible measuring range depends on the gas composition.





2


The power consumption is 2 VA. The HF measurement has not been type approved by the TÜV.

Limitation:

Component has not been type approved by TÜV. Necessary gas temperature between 0 and 150 °C.

LDS 6: HF/H

2

O

HF: Smallest possible measuring range depends on the gas composition.

H

2

O: Smallest tested measuring range 0 to 30 %





2


The power consumption is 2 VA. The HF measurement has not been type approved by the TÜV.

Limitation:

Component has not been type approved by TÜV. Necessary gas temperature between 0 and 150 °C.

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LDS 6: NH

3

Component

NH

3


0 ... 20 mg/Nm³





2



Limitation:

Applies to measurement paths > 1 250 mm. Necessary gas temperature between 0 and 150 °C.

LDS 6: NH

3

/ H

2

O

Component

NH

3

H

2

O


0 ... 20 mg/Nm³

0 ... 15 %





2



Limitation:

Applies to measurement paths > 1 250 mm. Necessary gas temperature between 0 and 150 °C.

Hybrid cable

A hybrid cable is required to connect a central unit to one pair of sensors. Versions for 5, 10, 25, 40 and 50 m are available. Cable lengths cannot be combined. Lengths greater than 50 m can be ordered on request.

Sensor cable

A sensor cable is required to connect one pair of sensors. Versions for 5, 10 and 25 m are available. Cable lengths cannot be combined. Lengths greater than 25 m can be ordered on request.

Electrical preparation for dust measurement

Electrical preparation for connection of an external dust measurement to the system (contains a switch amplifier).

Electrical preparation for flow measurement

Electrical preparation for connection of an external flow measurement to the system (contains a switch amplifier).

Electrical preparation for pressure measurement

Electrical preparation for connection of an external pressure measurement to the system (contains a switch amplifier).

Electrical preparation for temperature measurement

Electrical preparation for connection of an external temperature measurement to the system (contains a switch amplifier).

Electrical preparation for emission data memory on rail module

On request.

Electrical preparation for emission data memory in 19" rack unit

On request.



Set CEM 1

Additional LOGO for four or more 19" rack units

Sets with more than three 19" rack units integrated require a

LOGO extension module. The delivery also includes connection and programming.

Core end labeling

It is optionally possible to order core end labeling according to the Siemens standard (VDE 0100 Part 200).

Documentation

The Siemens standard documentation is available in German or

English.

The documentation includes gas path diagram, circuit diagram, terminal diagram, installation diagram, consumable materials list, signal list, cable list, and parts list. Also included are technical data sheets and Operating Instructions for the components and devices used. The documentation language for parts provided by other suppliers may deviate. Plant description, LOGO program and test certificates are also included in the documentation.

The documentation contains no customer-specific/project-specific drawings, and consists of two folders and one CD per set.


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Set CEM 1

Measuring equipment

© Siemens AG 2015

LOGO TD

Option

L = max. 35 m

Option

Sample gas inlet

LDS 6

HCL,

H

2

O

Option

CLF

NO

Option

Converter

Option

Water trap

CO/NO

U23

SO

2

U23

2nd ULTRAMAT 23 (option)

O

2

O6E

OXYMAT 6E (option)

Sample gas outlet

19 liters

Calibration gas inlet

Option

LDS 6

LDS 6 (option)

Cabinet heating

(option)

Cabinet ventilation (option)

Optional

Fan/outlet filter or air-conditioning unit

Set CEM 1, gas flow chart, figure contains options

4/12


© Siemens AG 2015

■

Function

A sample is extracted via the heated sample gas probe. The dust concentration may be up to 2 g/m³, the sample gas temperature up to 600 °C. The gas is transported to the analysis cabinet via a heated sample gas line. The heating prevents condensate.

The gas cooler cools and dries the sample in the analysis cabinet. Condensate is drained. The level in the condensate trap is monitored. For safety purposes, a coalescence filter can be provided in addition to the fine filter and moisture filter which are always present. The sample gas is analyzed by analyzers such as the ULTRAMAT 23, OXYMAT 6 and LDS 6. The ULTRAMAT 23 operates on the basis of molecular-specific absorption of infrared radiation or with an electrochemical oxygen measuring cell.

The OXYMAT 6 is an analyzer for paramagnetic oxygen measurements. The in-situ LDS 6 laser diode spectrometer operates according to the molecular-specific absorption of near-IR radiation. The delivery may also include an NO

2

/NO converter which permits measurement of total nitrogen oxides. In order to qualify the set for low or high temperature ranges (-5, +45 °C), it is possible to use a cabinet heater or air-conditioning unit. Power supply versions are available for 115, 230 or 400 V AC. Electronic consumers can be provided with single-pole or double-pole fusing. The components of the sample preparation system and the analyzers are connected to LOGO modules via a binary signal, and transmit maintenance requirements. The analog signals can be processed either singly or twice. Electrical isolation is additionally possible for the double processing.

■



Ambient temperature

• With heater in sheet-steel cabinet

• With heating in GRP cabinet

• With air-conditioning

Relative humidity

Corrosive atmosphere

0 ... 35 °C

Min. -5 °C

Min. -15 °C

Max. 52 °C

70 %, non-condensing

No

Gas inlet conditions

Max. sample gas pressure at inlet to sample preparation system

500 hPa (mbar)

Max. moisture content in sample gas 17 vol-%

1)

Max. water dew point

Min. sample gas pressure at inlet to sample preparation system

60 ?

180 °C

Dust content at inlet to sample preparation system

Dust-free

Sampling probe

Max. sample gas pressure at sampling probe

Sampling tube 20 x 1.5,

1 000 mm long, stainless steel, flange: DN 65, PN 6

500 hPa (mbar)

Max. sample gas temperature at sampling probe

600 °C

Max. dust content at sampling probe 2 g/Nm³

Sample gas must not be flammable or explosive.

Power supply

Supply 1

Supply 2

Supply 3

115 V AC (-15 %, +10 %)

230 V AC (-15 %, +10 %)

400 V AC (-15 %, +10 %)



Set CEM 1

Connections

Hose material

Cables

Electrical design

Cable ID

Fusing of electronic consumers

Duplication of analog signals

Teflon

Not armored, not halogen-free

According to IEC

Individual core labeling as option

1-pole; 2-pole as option

• Not electrically isolated as option

• Electrically isolated as option

Installation

Site

• In sheet-steel cabinet/frame

• In GRP cabinet

Ex zone

Indoor installation

Outdoor installation

Non-Ex area

System design

Type

Cabinet degree of protection

Automatic calibration

Mounting frame or cabinet

IP54

Yes, with ULTRAMAT 23

Detailed information on the analyzers

You can find detailed information on the analyzers:

• In the "Continuous Gas Analyzers, extractive" chapter

- ULTRAMAT 23

- OXYMAT 6

• In the "Continuous Gas Analyzers, in-situ" Chapter

- LDS 6

Dimensions (without plinth)

Depth of sheet-steel frame

• 800 mm (without plinth)

• 600 mm (without plinth)

2 000 x 800 x 800 mm (H x W x D)

2 000 x 800 x 600 mm (H x W x D)

GRP cabinet (with plinth) 2 080 x 900 x 600 mm (H x W x D)

It is necessary to provide a 500 mm gap to the right or left for the tube or cable inlet.

Use of the LDS 6 requires a cabinet with a depth of 800 mm.

1)

Higher performance sample gas coolers can be offered upon request (not

TÜV suitability-tested). A higher performance cooler is generally required for high sulfide content in fuels (e.g. heavy oil).

4


4/13

4

© Siemens AG 2015



Set CEM 1


Set CEM 1 – Continuous Emission Monitoring


Rack

Rack 1: 2 000 x 800 x 800 mm (H x W x D), with sample preparation device, with hinged frame 40 HU, hose/cable inlet on left side, with lighting, prepared for 1 x ULTRAMAT 23, max. five 19" rack units possible

Rack 2: 2 000 x 800 x 800 mm (H x W x D), with sample preparation device, with hinged frame 40 HU, hose/cable inlet on right side, with lighting, prepared for 1 x ULTRAMAT 23, max. five 19" rack units possible

Rack 3: 2 000 x 800 x 600 mm (H x W x D), with sample preparation device, with hinged frame 40 HU, hose/cable inlet on left side, with lighting, prepared for 1 x ULTRAMAT 23, max. five 19" rack units possible, not suitable for LDS 6

Rack 4: 2 000 x 800 x 600 mm (H x W x D), with sample preparation device, with hinged frame 40 HU, hose/cable inlet on right side, with lighting, prepared for 1 x ULTRAMAT 23, max. five 19" rack units possible, not suitable for LDS 6

Rack 5: 2 060 x 900 x 600 mm (H x W x D), GRP, base 80 mm, with sample preparation device, with hinged frame 40 HU, hose/cable inlet on left side, with lighting, prepared for 1 x ULTRAMAT 23, with side panels, incl. door with window, max. five 19" rack units possible, not suitable for LDS 6

Rack 6: 2 060 x 900 x 600 mm (H x W x D), GRP, base 80 mm, with sample preparation device, with hinged frame 40 HU, hose/cable inlet on right side, with lighting, prepared for 1 x ULTRAMAT 23, with side panels, incl. door with window, max. five

19" rack units possible, not suitable for LDS 6

Sampling probe

Without

Standard sampling probe

Ventilation/cooling

Without

Fan with outlet filter

Cabinet air-conditioning unit

Cabinet air-conditioning unit for GRP rack

Heating

Without

Cabinet heating

Fuse protection

1-pole

2-pole

Removal of condensation

Without

19 l container with level monitoring

NO

2

/NO converter

Without

NO

2

/NO converter

Power supply

115 V AC, -15 %, +10 %, 50 or 60 Hz

230 V AC, -15 %, +10 %, 50 or 60 Hz

400 V AC, -15 %, +10 %, 50 or 60 Hz (3 phases, neutral, ground provided by customer)

Connection set for heated line

Without controller

Standard controller (max. 35 m heated line can be connected)

Note:

The heated sample gas line must be ordered separately using Catalog PA 11.

Article No.

7MB1953-

7 7 7 7 7

-

7 7 7 7

0

1

2

3

4

5

A

B

C

D

A

B

0

1

0

1

0

1

A

B

A

B

C

0

1

Cannot be combined

A03, A04, B02, B04

A03, A04, B02, B04

A01, A02, B01, B03,

E01 ... E06,

F01 ... F06,

G01 ... G04

A01, A02, B01, B03,

E01 ... E06,

F01 ... F06,

G01 ... G04

A01 ... A04,

B01 ... B04,

E01 ... E06,

F01 ... F06,

G01 ... G04

A01 ... A04,

B01 ... B04,

E01 ... E06,

F01 ... F06,

G01 ... G04

4/14



Add "-Z" to Article No. and specify Order code

Bases

Base for rack 1, 2, height 100 mm




Rack accessories

Outer panel painted, for rack 1 and 2, viewing door

Outer panel painted, for rack 3 and 4, viewing door

Outer panel painted, for rack 1 and 2, sheet steel door

Outer panel painted, for rack 3 and 4, sheet steel door

ULTRAMAT 23, OXYMAT 6 extractive analyzers

ULTRAMAT 23: CO, NO

ULTRAMAT 23: CO, NO, SO

2

ULTRAMAT 23: CO, NO, CO

2

ULTRAMAT 23: CO

2

ULTRAMAT 23: Electrochemical O

2

sensor for ULTRAMAT 23 expansion

OXYMAT 6: OXYMAT paramagnetic O

2

analyzer

Preperation for free choice ULTRAMAT 23 analyzer

Additional sample preparation components

Coalescence filter

LDS 6 in-situ analyzers

HCl including sensor pair

HCl/H

2

O including sensor pair

HF including sensor pair, not suitability-tested

HF/H

2

O including sensor pair, not suitability-tested

NH

3

including sensor pair

NH

3

/H

2

O including sensor pair

LDS 6 hybrid cable per LDS 6

5 m

10 m

25 m

40 m

50 m

Customer-specific > 50 m

LDS 6 connecting cable per LDS 6

5 m

10 m

25 m

Customer-specific > 25 m

Electrical preparation

Preparation for dust measurement

Preparation for flow measurement

Preparation for pressure measurement

Preparation for temperature measurement

Preparation for emission data memory – DIN rail module (on request)

Preparation for emission data memory – 19" rack unit (on request)

Additional LOGO

LOGO for a third and fourth 19" rack unit

© Siemens AG 2015

J01

J02

J03

J04

J05

J06

K01

F01

F02

F03

F04

F05

F06

E01

E02

E03

E04

E05

E06

G01

G02

G03

G04

C01

C02

C03

C04

C05

C06

C07

D02

A01

A02

A03

A04

B01

B02

B03

B04

Order code



Set CEM 1

4


4/15

© Siemens AG 2015



Set CEM 1


Core end labeling

Single-core labeling Siemens standard

Analog signal processing

Double, galvanically connected, 1 x per analog signal

Double, galvanically isolated, 1 x per analog signal

Documentation

German

English

French (on request)

■


Order code

L01

M01

M02

N01

N02

N03

4

Option:

Control cabinet ventilation (when using side walls) **

Either fan and outlet filter or air-conditioning unit

Mounting on left or right

800

Outlet filter

Standard: voltage 230 V/50 Hz, 1-pole fusing

Option: voltage 115 V/50 Hz / 400 V/50 Hz, 2-pole fusing

Spare location for converter

(option)

Option:

Analog signal duplication with electrical isolation

Option:

+ -

Coalescence filter

Option:

Electronic and pneumatic inputs and outputs either on left or right

0.00

0.00

s LOGO! TD

Spare location

LOGO

Optionally extendable

Depends on number of analyzers.

2. ULTRAMAT 23 (option)

0.00

0.00

Electrical input/output

OXYMAT 6E (option)

Siemens

LDS 6E (option)

-RV3

LDS 6E

Sample gas outlet

Spare

Calibration gas inlet

Sample gas inlet

Fan

Side view from right

Condensation outlet

Front view

Hinged frame open

Standard: without plinth

Option: with plinth 100 or 200 mm high

Hinged frame 40 HU

Option: condensation bottle with level monitoring

19 liters

Sample gas cooler

Option:

Cabinet heater

Side view from left

Available cabinet sizes:

Metal: W x H x D: 800 x 2 000 x 600

Metal: W x H x D: 800 x 2 000 x 800

FRP: W x H x D: 900 x 2 140 x 600

** FRP cabinet is always with side walls and 80 mm plinth

Design of the Set CEM 1, figure contains options, dimensions in mm

4/16


© Siemens AG 2015



HM-1400 TRX Total mercury analyzer system

■

■

Overview

The HM-1400 TRX is a total mercury monitor for fully automatic and continuous measurement of emissions of mercury in flue gas ducts.

Benefits

• Extractive measuring procedure

• Low maintenance dry reactor

• High operational reliability

• Easy maintenance, easy replacement of components

• Low cross sensitivities

• Easy to read LC display

■

Application

The HM-1400 TRX monitors not only the performance of the mercury separators by measuring the total mercury concentration, but also reports and registers (also online) any violation of the high limits. As a result it is often possible to intervene directly in the process of the plant to be monitored and thus ensure reliable compliance with the specified limit values.

Areas of application

• Waste incineration plants (municipal waste, industrial waste, hospital waste)

• Sewage sludge and hazardous waste incineration

• Steel plants with scrap metal preparation

• Contaminated soil burning plants (thermal cleanup of soil)

• Crematoriums

• Mercury mines and refineries

• Fluorescent light bulb recycling

Approvals

• Suitability-tested by the TÜV North, test report 109 GMT007/

8000632287 dated 30 June 2011

• Certified according to DIN EN 15267-3

• Itemized in the list of suitable measuring devices for continuous emission measuring

• MCERTS

■

Design

Heated sample probe

Pump

Thermocatalytic reactor

Zero gas filter

Calibration reactor

Option

Gas/liquid separator

Liquid watchdog

Hg-photometer

Stack

4

Reference standard

Condensate

System components HM-1400 TRX

Sampling system

The sampling system consists of a sampling probe and a sampling line. Both components are heated to 180 °C. With flue gas temperatures < 200 °C, the sampling tube must also be in heated tube design to prevent faulty measurements (lower findings for the mercury concentration measurement due to the absorption properties of HgCl

2

).

Gas patch switchover

The sample gas is extracted condensate-free from the exhaust stack with approx. 100 Nl/h and fed via a three-way ball valve to the thermocatalytic reactor. The path switchover is also heated and is operated as component of the measuring device by means of the device control. You can select between sample gas connection, reference connection or zero gas connection.


4/17

© Siemens AG 2015

4



HM-1400 TRX Total mercury analyzer system

Thermocatalytic reactor

The total mercury analysis measures not only the elementary metallic mercury that is stored freely in the sample gas or deposited in the materials, but also measures the chemically bonded mercury that is found in the flue gas. The ionic mercury must also be converted into elementary, atomic mercury so that the detector can acquire and evaluate the total mercury. The thermocatalytic reactor carries out this function at a pre-set operating temperature.

■


Measured variable

Measuring ranges

Measuring principle


Sample gas pressure

Duct diameter

Gas drying

Ambient temperature

Before the mercury content is determined, the now created sample gas containing Hg

0

is dried while flowing through a Peltier cooler. At the same time the system pressure and the measured gas temperature are continuously recorded.

Degree of protection

Measured value outputs

Relative expanded uncertainty

Digital outputs

Prefilter

Before the prepared and dried sample gas flows through the photometer, it passes through an additional filter with hygroscopic effect to eliminate even lower residual humidity components. This is important first for recording the gas volume flow in dry form and, second, pollution and deposits are avoided in the photometer and the maintenance-free service life increased.

Digital inputs

Detection limit

Reference point drift

Zero point drift

Total mercury

0 ... 45, 0 ... 75 to 0 ... 500

μg/Nm 3

UV absorption

0 ... 250 °C

-50 ... +50 hPa

> 0.5 m

5 °C ... 40 °C

IP40 (IP54)

2 x 0/4 ... 20 mA, 500

Ω

5.5 % CR

4 relay outputs, permissible load 250 V, 100 VA

1 isolated input

< 0.1

μg/Nm 3

< 2 % ZRE

< 0.5 % ZRE automatic zero offset

2-beam UV photometer

The sample gas enters the measuring cuvette and is then routed over a selective filter in which the mercury is absorbed. The sample gas thus freed from the mercury then flows through the reference cuvette. The advantage of this cuvette switching is that the entire gas matrix flows through both the measuring cuvette and the reference cuvette and most of the mercury is selectively filtered out before it reaches the reference cuvette. This principle of differential measurement means that the measurement is less sensitive to spectrometric interference components than the single-beam photometer that has only one cuvette. With the cuvette switching of the two-beam device this cross sensitivity for SO

2

, for example, only becomes effective after 1000 mg/m³. The measured signal from the photometer is taken over by the internal

PLC.

Supply voltage

• Measuring instrument

• Sampling probe

• Sampling line

• Heated sample pipe 0.6 m, 1.0 m,

1.5 m

Dimensions (H x W x D) control cabinet

Weight

Purge air supply, compressed air

■

More information

230/400 V AC, 50 Hz, 3 x L, N, PE

1200 VA

650 VA

100 VA/m

600 VA/800 VA/1200 VA

1700 x 800 x 500 mm

220 kg

6 ... 8 bar (for reference gas generator only)

A HM-1400 TRX total mercury analyzer consists of, for example:

Gas volume flow generation

• 1 sampling pipe, heated and temperature-controlled, with connecting cable

When the sample gas volume flow leaves the 2-beam UV photometer, it passes through the vacuum pump which generates the gas flow. The volume flow of approx. 100 Nl/h is set manually with the fine regulating valve. The system pressure and sample gas temperature parameters are measured after the gas drying at the photometer, where the mercury is also measured, and are used ultimately to convert the gas volume flow to standard conditions. The mercury concentration as result of a measurement is output as 4 to 20 mA current signal to match the set measuring range of 0 to X µg/Nm

3

(dry).

• 1 sampling probe, heated and temperature-controlled, with connecting cable

• 1 sampling line, heated and temperature-controlled

• 1 measuring device

• Operating instructions, service manual, maintenance manual

Please consult your Siemens sales partner for information on how to correctly configure and order a HM-1400 TRX total mercury analyzer for a Siemens CEMS project.

Optional:

• Larger measuring range with dilution device

• Side-mounted cooling device

• Integrated system to generate reference gas

• Heated sample pipe 0.6 m, 1.0 m, 1.5 m

■

Function

In the HM 1400 TRX total mercury analyzer the sample gas is converted into mercury vapor by a combination of thermal and chemical treatment. It is then continuously measured in a photometer. The sample gas flow is measured after a sample game cooler at 2 °C. The concentration is calculated and displayed as

"dry flue gas".

4/18


© Siemens AG 2015



■

The D-R 220 is a scattered light dust and opacity measurement device for monitoring dust emissions in smaller plants and process applications.

■

Benefits

• In-situ measurement directly in the flue gas flow

• Digital operation with microprocessor

• Adjustable limit value

• 2 contact switch outputs

• Measuring value integral 4/15/60 seconds

• Internal event memory with real-time clock

• Modbus RTU interface

• Measurement results shown as opacity or extinction

• No weather protection covers needed

■

Application

The D-R 220 monitors not only the efficiency of the filter plants by registering the residual dust content, but also reports instantaneously when permissible levels of dust or flue gas emissions are exceeded. As a result it is often possible to intervene directly in the process of the plant to be monitored and thus ensure reliable compliance with the specified limit values.


• Compact device for smaller plants

• Heating plants, power plants

• Boiler plants in industry, barracks, hospitals, schools

• Dust extraction and filter plants

• Process monitoring

■

Overview

Design

Optical measuring unit

Supply box

Reflector

D-R 220 dust and opacity measuring instrument

Measuring head

The transmitter and receiver optics are integrated together with the electronics in a sturdy but compact polyamide housing. The measuring head is mounted on the weld-in flange.

Reflector

The reflector is installed in a sturdy polyamide housing. The reflector is mounted on the weld-in flange directly opposite the measuring head.

Supply box with purge air unit

A hose connects the measuring head and the reflector with the supply box. The filtered air is used to keep clean the scattered light interfaces of the measuring head and the reflector. A cable connects the measuring head to the supply box.

Optional:

Quick-closing shutters

The quick-closing shutters are mounted on the measuring head and the reflector side between the weld-in flanges and the connected devices (measuring head, reflector). In the event of a fault (failure of the power supply or purge air) they automatically close the path between the exhaust gas duct and the measuring equipment.

Electronics for quick-closing shutter

A control electronics is required for each quick-closing shutter.

Universal control unit D-ISC 100

The connected equipment can be operated and configured conveniently using the D-ISC 100. The display provides an immediate overview of the current measured values and the status of the measuring instruments.

Measured-value acquisition

In the simplest case a recorder is used to record the measured values and the reference values. The measured values and status signals that are output can also be fed into systems that will process these further.

Weather protection covers

Weather protection covers are available to protect the measuring head and the reflector when the measuring system is installed outdoors.

Additional options:

• Neutral density filters for linearity check

• Sighting scope for easy alignment

■

Function

The device operates using the double-pass method according to the auto-collimation principle. The light beam traverses the measuring distance twice. The attenuation of the light beam by the dust content in the measuring section is measured and evaluated.

The universal control unit D-ISC 100 can be connected for the measured value display, which allows up to eight dust and flowrate measurement instruments.


4

System components D-R 220


4/19

© Siemens AG 2015

4



D-R 220 dust and opacity measuring instrument

■


Measuring instrument D-R 220

Measurements • Opacity

• Extinction

Measuring ranges

• Opacity

• Extinction

• Dust

1)

Measuring principle


Sample gas pressure

Duct diameter

Ambient temperature


Measured value output

Digital outputs

Digital inputs

Accuracy

Detection limit

Supply voltage

Dimensions (H x W x D) measuring head

0 ... 25/50/100 %

0 ... 0.2/0.4 ... 1.6

• 0 ... 160 mg/m

3

• 0 ... 4000 mg/m

3

Transmission

Above dew point up to 200 °C, optional up to 500 °C

-50 ... +10 hPa, optional higher

0.4 ... 10 m

-20 ... +50 °C

IP65

0/4 ... 20 mA, 400

Ω

2 relay outputs, 30 VA, max. 48 V/0.5 A

None

< 2 % of the measuring range


24 V DC, 0.4 A from the supply unit

160 x 150 x 314 mm

Weight

• Measuring head

• Reflector

Supply box

Purge air supply

Supply voltage

Dimensions (H x W x D)

Weight

2.7 kg

1.6 kg

From the supply box

85 ... 264 V AC, 46 ... 63 Hz, 50 VA

210 x 300 x 380 mm

13 kg

Degree of protection IP65

1) with reference to one meter of path length after gravimetric calibration

■


In general, a dust concentration measuring instrument D-R 220 consists of:

• 1 measuring head D-R 220 M

• 1 zero point reflector

• 1 reflector

• 2 welded tubes with adjustment flange

• 2 purge air adapters with clips

• 1 operating unit (for up to 8 sensors)

• Parameterization software with stick and USB cable

• 1 supply box (incl. purge air blower) 115/230 V, 50/60 Hz

• Operating instructions

• Weather protection covers for measuring head, reflector, blower, control unit, etc.

Please consult your Siemens sales partner for information on how to correctly configure and order a D-R 220 measuring instrument for a Siemens CEMS project.

4/20


■

Overview

© Siemens AG 2015



■

Design

D-R 290 dust concentration measuring instrument

Optical measuring unit

Reflector

The D-R 290 is an optical opacity/dust monitor for plants with small to medium dust concentrations.

■

Benefits

• In-situ measuring procedure, continuous measurement

• Semiconductor source with long service life

• Super-wide band diodes (SWBD), which provides more stable measuring results in comparison to devices with conventional

LEDs

• Powerful microprocessor technology

• Measured value display on LC display in opacity, extinction or in mg/m

3

• Automatic function tests with correction of measured values in relation to soiling

• Optics and electronics in a hermetically sealed unit - no smoke gas can enter device

• Easy adjustment without additional equipment

• Low-maintenance thanks to optimal purge air conduction

• Heated end plate

■

Application



• Furnace plants with semi-anthracite coal, brown coal, fuel oil and combined heating

• Converter plants, asphalt mixing plants

• Cement manufacturing plants

Approvals

• Suitability-tested by the TÜV Cologne, test report 936/801017



• MCERTS

Purge air unit

Control and display unit


Measuring head

The transmitter and receiver optics are integrated together with the electronics in a rugged and robust aluminum housing. The measuring head is mounted on the weld-in flange.

Reflector

The reflector is installed in a rugged and robust aluminum housing. The reflector is mounted on the weld-in flange directly opposite the measuring head.

Evaluation unit

The D-R 290 measuring system is connected to and operating on the evaluation unit. The evaluation unit is connected to the measuring head by means of an approx. 2 m long cable.

Purge air unit

A hose connects the measuring head and the reflector with the purge air unit. The filtered air is used to keep clean the scattered light interfaces of the measuring head and the reflector.

Optional:

Quick-closing shutters

The quick-closing shutters are mounted on the measuring head and the reflector side between the weld-in flanges and the connected devices (measuring head, reflector). In the event of a fault (failure of the power supply or purge air) they automatically close the path between the exhaust gas duct and the measuring equipment.

Electronics for quick-closing shutter

A control electronics is required for each quick-closing shutter.


In the simplest case a recorder is used to record the measured values and the reference values. The measured values and status signals that are output can also be fed into an emission calculator system for further processing.


Weather protection covers are available to protect the measuring head, the reflector, the purge air unit and the terminal boxes when the measuring system is installed outdoors.


4/21

4

© Siemens AG 2015

4



D-R 290 dust concentration measuring instrument


• Bus interface, for example, Modbus or similar

• Explosion proof design for EEx p, Zone 1 or Zone 2

• With an additional display unit at the measuring location, the control and display unit can be installed at a distance of up to

1000 m away

• Temperature compensation through additional analog input

• Special model for measuring distances up to 18 m with

2 purge air units

• Filter set for sensitivity and linearity control

■



■

Function

The device operates using the double-pass method according to the auto-collimation principle. The light beam traverses the measuring distance twice. The attenuation of the light beam by the dust content in the measuring section is measured and evaluated.

■



Measurements • Opacity

• Extinction

Measuring ranges

• Opacity

• Extinction

• Dust

1)

Measuring principle


Sample gas pressure

Duct diameter

Ambient temperature



Digital outputs

Digital inputs

Accuracy

Detection limit


Zero point drift

Auxiliary power

Dimensions (H x W x D) measuring head

Weight

Purge air supply

Purge air quantity

Auxiliary power

0 ... 20 to 0 ... 100 %

0 ... 0.1 to 0 ... 1.6

0 ... 80 mg/m

3 to 0 ... 4 000 mg/m

3

Transmission

Above dew point up to 250 °C, optional up to 1 000 °C, depending on application


1 ... 12 m, optional up to 18 m

-20 ... 50 °C, optional higher

IP65, Ex optional

2 x 0/4 ... 20 mA, 500

Ω

Manual or automatic measurement range switching optional Modbus RTU, PROFIBUS DP

6 programmable relay outputs, permissible load 48 V/0.5 A

6 programmable isolated inputs

< 1 % of measuring range

0.75 % at extinction 0 ... 0.1

< 0.4 % of measuring range / month


95 ... 264 V AC, 47 ... 63 Hz, 30 VA

363 x 185 x 398 mm

17 kg

Approx. 80 m

3

/h

115/230 V AC, 50/60 Hz,

0.37/0.43 kW


Weight


350 x 550 x 500 mm

12 kg

IP55

1) with reference to one meter of path length after gravimetric calibration

4/22


■

Overview

© Siemens AG 2015

■

Design

Measuring head

Mounting flange



D-R 320 dust measuring instrument

Universal control unit D-ISC 100

Supply unit with integrated purge air supply

The D-R 320 is an optical dust monitor for the smallest to medium dust concentrations in dry emissions and process gas.

■

Benefits

• Continuous measurement of dust concentration

• Easy installation on standard flanges

• Easy setup without manual adjustment

• Automatic background light compensation, no light trap

• Convenient operation, remote access option

• Automatic control functions

• Integrated purge air regulation and purge air control

• Long maintenance intervals

• Certified to EN 15267-3

• Data transmission via Modbus, in compliance with VDI 4201-3

■

Application



Continuous emission monitoring, for example, on:

• Incineration plants in general

• Plants according to IED 2010/75/EU/17. BImschV

• Plants according to 2001/80/EG LCPD/13. BImschV/German

TA-Luft

• Waste, hazardous waste and sewage sludge incineration plants

• Cement manufacturing plants

• Power plants with gas, oil, coal or co-firing

• Plants for the incineration of biomass

Monitoring of:

• Ventilation units

• Filter units

Approvals

• Suitability-tested by the TÜV Cologne, test report

936/21217455/A



Transmitter / receiver unit D-R 320 M

The transmitter and receiver optics are integrated together with the electronics in a compact unit in a rugged housing. The transmission-reception unit consists of the measuring head, the swivel adapter, the process connection and the field facing panel. This measuring unit is installed directly above the waste gas duct, on a DIN 100 PN 6 or ANSI 4" 150 lbs flange. No adjustment is required.

Supply unit D-TB 200

The supply unit of the dust concentration measuring instrument

D-R 320 is used to supply electricity and purge air and provides the connection for the transfer of the measured data. The regulated purge air is used to keep clean the optical interfaces of the transmission and reception optics of the D-R 320. The device automatically reports any failure of the purging air.

Optional:




In the simplest case the measured values and reference values are transferred to the plant's control system. The measured values and status signals that are sent can also be fed to an emission calculator system for further processing, either via discrete signals (4 to 20 mA and configurable relay contacts) or via

Modbus according to VDI 4201-3.

Quick-closing shutter

The swivel adapter can be optionally replaced with an adapter with a fully integrated quick-closing shutter. By using this quickclosing shutter the path between the measuring device and the waste gas is closed mechanically, but not airtight in the event of a fault (failure of power supply or purge air); the measuring device is temporarily protected against overheating in such cases.

The measuring head takes over the control of the quick-closing shutter.


A weather protection cover is available to protect the measuring system when it is installed outdoors.


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Explosion proof design

An explosion proof design with pressurized enclosure according to EEx p, Zone 1 or Zone 2 is available for use in hazardous areas.

■

Function

The device operates according to the backscattering principle.

The light of a laser diode illuminates the dust particles in the measuring volume of the flue gas duct. The light reflected by the particles is measured and evaluated.

The D-R 320 does not require a light trap. The background light in the stack is detected by means of a special optical system with an integrated dual detector and automatically compensated without manual adjustment.

The universal control unit D-ISC 100 can be connected for the measured value display, which allows up to eight dust and flowrate measurement instruments.


Control functions

The D-R 320 automatically performs zero and span check as well as contamination check at regular intervals and on demand.

The device features an automatic contamination correction.

Need for maintenance is immediately indicated by the electronics.

■


Measuring head

Measured variable

Measuring ranges

Measuring principle


Sample gas pressure

Duct diameter

Ambient temperature



Digital outputs

Digital inputs

Auxiliary power


Weight

Supply box

Purge air supply

Supply voltage

Dust concentration

0 ... 5 mg/m

3 to 0 ... 200 mg/m

3

Backscattering

0 ... 600 °C


0.7 ... 20 m

-40 ... +60 °C

IP65

0/4 ... 20 mA, 400

Ω

Modbus RTU bi-directional

2 relay outputs, permissible load

60 V DC, 30 V AC/0.5 A

None

24 V DC/0.5 A

200 x 190 x 260/410 mm

15 kg


Weight


Integrated blower

115/230 V AC, 50/60 Hz,

0.37/0.43 kW

480 x 450 x 320 mm

12 kg

IP65

■



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© Siemens AG 2015




■

Overview

■

Design

Supply unit with integrated purge air supply

Measuring lance

Evaluation unit

D-R 800 is an innovative laser measuring instrument for monitoring small to medium dust emissions according to the new European regulations.

■

Benefits

• Built-in display: Measured value, limit, parameter in the probe

• In-situ measuring procedure with continuous measurement

• High sensitivity

• Easy installation on one side of the flue

• Use also on thick-walled stone/insulated channels

• No difficult device calibration

• Long service life, since there are no moving parts, not even within the flue

• Hermetically sealed electronics housing opposite the exhaust

• Parameter assignment and operation via keyboard and easily readable display directly on the device or via bus interface

• Automatic function test with contamination correction

• Two analog outputs with adjustable measuring ranges

• Automatic measuring range switching according to

17th BImSchV

■

Application

The D-R 800 not only monitors the efficiency of the filter systems by registering the residual dust content, but also reports instantaneously when permissible levels of dust or flue gas emissions are exceeded. As a result, it is often possible to intervene directly in the process of the plant to be monitored and thus ensure reliable compliance with the specified limits.


• Power plants

• Cement works, metallurgy and timber industry, chemical industry etc.

• Waste incinerators

• Monitoring of dust filter systems

Certifications

• Qualification tested by the TÜV Cologne, test report

936/21205307/A



• MCERTS

RS 485 and analogue current output


Measuring probe

The measuring probe of nano-treated stainless steel 1.4571 can be delivered in two lengths of approx. 400 and 800 mm (from mounting flange). A difference is made here between installation on a horizontal or vertical flue and between the German and

English language. The measuring probe is firmly connected to the operating unit including display.

Terminal unit with integrated purge air supply

The connection unit supplies the probe with the required signals and the supply voltage over a connecting cable 3 or 10 m in length as well as with purge air through an additional air hose.

Mounting flange 130/240/500 mm

The connection flange made of carbon steel or stainless steel

1.4571 should protrude approximately 30 mm into the channel.

Optional:

Temperature compensation through additional analog input

Using an additional analog input, the temperature of the exhaust gas can be passed to the operating unit, thus enabling calculation of the dust concentration corrected by the gas temperature.

Special material alloy 59 2.4605

As an alternative to the nano-treated stainless steel 1.4571, the probe can be manufactured from alloy 59 2.4605 (comparable to Hastelloy 2.4819).


Weather protection covers are available to protect the measuring system and the purge air unit for outdoor installation.

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■

Function

The D-R 800 device operates according to the forward-scattering principle. The concentrated and modulated light from a laser diode penetrates the measuring volume. The light scattered by the dust particles in the forward direction is measured and evaluated.

■

Technical Specifications


Measured variable

Measuring ranges

Measuring principle


Sample gas pressure

Channel diameter

Probe length

Ambient temperature



Digital outputs

Digital inputs

Accuracy

Detection limit


Zero point drift

Auxiliary power


• Measuring probe

• Supply box

Weight

• Measuring probe

• Supply box

Purge air supply

1)

After gravimetric calibration

Dust concentration

0 ... 10 mg/m

3 to 0 ... 200 mg/m

3 1)

Forward scattering

Above dew point up to 220 °C

-50 ... +10 hPa

0,4 ... 8 m

400/800 mm

-20 ... +50 °C

IP65

2 x 0/4 ... 20 mA, 500

Ω

Modbus RTU (RS 485)

4 programmable relay outputs, permissible load 24 V/25 VA

2 isolated inputs, programmable


< 0,5 % of the measuring range

< 0,7 % of measuring range/month

< 0,15 % of measuring range/month

85 ... 264 V AC, 47 ... 63 Hz, 50 VA

160 x 160 x 600/1 000 mm

380 x 300 x 210 mm

7 kg

13 kg

Integrated in terminal box

■



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D-RX 250 combination probe

■

Overview

The combined probe sensor D-RX 250 is a single rod measurement probe for simultaneous measurement of dust concentration, volume flow, temperature and absolute pressure.

■

Application

By combining four selected measuring functions in a single device it is possible to automatically calculate the pollutant mass flow for the preparation of the emission declaration in addition to monitoring the pollutant dust.


• For measurements in accordance with TIA Air (Technical

Instructions for Maintaining Air Purity) 13., 17. and 27.

BlmSchV

• Not suitable for use behind electrostatic precipitators

■

Benefits

• Only one probe/installation opening in the exhaust gas channel

• Compact design, no moving parts, no consumable parts

• Continuous conversion to normalized dust concentration in mg/Nm

3

and to normalized volume flow in Nm

3

/h

• LCD display in mg/Nm

3

, Nm

3

/h, °C and hPa, one analog output for each measurement value

• Parameterization at the control unit without the need of a PC or other tools

• Remote connection of control and evaluation unit via two-wire bus interface up to 1000 m

Approvals

• Suitability-tested by the TÜV Cologne, test report 936/800006/A


• MCERTS

■

Design

4

Probe Transmitter Differential pressure unit

Control and evaluation unit

Max. 1 000 m

System components D-RX 250

Probe

The probe consists of the probe measuring rod and the measured value processing by the electronics in the measuring head. The probe measuring rod is a probe section that protrudes into the dust duct and is fastened with a flange in the duct. The probe measuring rod is insulated in design because of the triboelectric measurement and has two chambers for differential pressure measurement. The two chambers for pressure measurement are connected to a differential pressure transmitter.

One of the two chambers is also connected to the absolute pressure transducer in the transmitter. The gas temperature is measured via a measurement resistance in a third chamber in the center of the probe section. The electronic measured value processing is performed in the probe housing. The temperature of the measurement resistance and the triboelectric raw value are determined here. The two raw values of temperature and tribo signal are transferred digitally to the transmitter.

Differential pressure transducer

The differential pressure transducer converts the differential pressure, created by the gas flowing in the probe measuring rod, into a gas velocity variable.

Transmitter

The transmitter provides the supply voltages for the probe and the measuring transducer for absolute pressure and differential pressure, reads in the raw measured values of these modules and transfer the measured values via the RS 485 interface to the evaluation unit. Through the RS 485 interface the transmitter reads the probe values of the triboelectric measured signal and the temperature.

The differential pressure transducer is connected to the transmitter by means of a two-wire cable. The absolute pressure transducer is located inside the transmitter housing. It receives the pressure from the chamber via a special rod.


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D-RX 250 combination probe

■

Control and evaluation unit

The control and evaluation unit reads out the raw measured values from the transmitter. The measured values for normalized dust concentration and normalized volume flow are calculated in the unit.

■


D-RX 250 combined probe sensor

Measurements

It is possible to output all analog values via Modbus or 4/20 mA signals and all status signals via isolated contacts.


In the simplest case a recorder is used to record the measured values and the reference values. The measured values and status signals that are output can also be fed into an emission calculator system for further processing.

Optional:

• Weather protection cover

• Change-over cock for back purging/zero point control

• Automatic cyclical probe back purging for high dust concentrations

• Hastelloy probes for corrosive gases

• Purge air connection at flange

Function

Dust concentration

The dust concentration is calculated according to the triboelectric measuring principle. The tribo probe measures the electrical charge of the incident particles.

Volume flow

The measurement of the volume flow is based on the mechanical action principle. The probe has two separate chambers, between which a differential pressure builds up under flow.

Absolute pressure

The absolute pressure in the flue gas is measured by a pressure transmitter in one chamber of the probe.

Temperature

The temperature is measured directly in the center of the flue gas in a separate chamber within the probe with a temperature sensor.

Measuring ranges

• Dust concentration

• Volume flow

• Pressure

• Temperature

• 0 ... 10 to 0 ... 500 mg/Nm

3

• 0 ... 9 999 999 Nm

3

/h

1)

• 800 ... 1300 hPa

• 0 ... 200 °C, optional 0 ... 350 °C

Measuring principle

• Dust

• Volume


Sample gas humidity

Sample gas pressure

Duct diameter

Ambient temperature



Tribo electric

Differential pressure


< 80 %

-200 ... +200 hPa

0.3 ... 5 m

-20 ... +50 °C

IP65

4 x 0/4 ... 20 mA, 500

Ω

Modbus RTU (RS 485)

Digital outputs

Digital inputs

Accuracy

Detection limit

7 relay outputs, permissible load

48 V/0.5 A

6 isolated inputs



Zero point drift

Auxiliary power

Dimensions

• Probes

• Probe length


< 1 % of measuring range / month

< 1 % of measuring range / month

115/230 V AC, 50/60 Hz, 50 VA

180 x 180 x (340 + probe length) mm

250/400/700/1000 mm

Weight

• Probe

• Electronics

Options

9.5 kg

22 kg

Probe back purging, purge air supply 3 bar

Isolator purging, continuous purge air supply

Approx. 2 m

3

/h

1)

Flue gas velocity > 5 m/s concentration after gravimetric calibration

■


Please consult your Siemens sales partner for information on how to correctly configure and order a D-RX 250 combined probe sensor for a Siemens CEMS project.

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© Siemens AG 2015



D-FL 100 volume flow measuring system

■

Overview

The D-FL 100 volume flow measuring system measures the flow rate in dry emissions with a probe using the differential pressure principle.

■

Application

As in-situ measuring system, the measuring equipment determines the measured values without sampling directly in the duct through which gas is flowing.


• Volume flow measurement at high temperatures

• Plants with small or large flue cross-sections

• Volume flow measurement at high pressure

Approvals

• Suitability-tested by the TÜV Cologne, test report 936/800006/A


• MCERTS

■

Benefits

• Measuring of emission speed

• Adjustable parameters

• Versions with or without counter-support and for point measurement

• Calculation of volume flow at standard conditions with evaluation unit D-FL 100-20

• Maintenance interval 6 months

• Automatic backpurging device (optional)

■

Design

Differential pressure transducer

Flow 4 ... 20 mA

4 ... 20 mA

Evaluation unit

4 ... 20 mA

Cross over cock

Absolute pressure transducer

(optional)

Temperature transducer

(optional)

Flow probe

4

Flow direction

System components D-FL 100

Dynamic pressure probe

Each dynamic pressure probe of type D-FL 100 is a customized product for the respective measuring location. Three different sizes are available depending on the length of the planned measurement path:

• System 1: 22 x 24 mm

2

for 0.4 to 2 m length, with one-sided

(max. 1 m) or two-sided mounting

• System 2: 50 x 53 mm

2

for 0.4 to 4 m length, with one-sided

(max. 1.5 m) or two-sided mounting

• System 3: 90 x 100 mm

2

for 0.4 to 8 m length, two-sided mounting


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Adapter Additional options:

The cross-over cock is either connected by an adapter to the differential pressure transducer directly on the probe (not for system 3) or via a hose or tube connection.

• Absolute pressure transducer

• Temperature transducer

Cross-over cock

• Special designs in other materials for applications with particularly aggressive exhaust gases or higher gas temperatures:

Standard material for probe stainless steel 1.4571, depending on measurement task also Hastelloy, Inconel or other materials

Cross-over device for the backpurging of the dynamic pressure probe

• dP transducer in Ex-version

Differential pressure transducer

The transducer is delivered with factory set defaults for the order-specific configuration. The zero point should be calibrated after the installation.

Counter-support

A counter-support is required for a probe mounted on two sides.

The counter-support supports the probe not only mechanically, but also enables the compensation of the temperature-dependent longitudinal expansion of the probe.

Mounting tubes with flange

■

Function

The D-FL 100 measuring system operates according to the mechanical action principle. The probe has two separate chambers, between which the flow builds up a differential pressure.

Taking account of the other flow parameters such as absolute pressure and temperature, for example, the volume flow can be converted from operating to standard conditions with the help of the D-FL 100-20 evaluation unit.

■


Mounting tubes made of stainless steel 1.4571, adapted to the plant conditions, are available in various lengths. A single flange is required for a one-sided probe; otherwise two flanges are always required.

Optional:

Measuring system D-FL 100

Measurements

Measuring ranges

Measuring principle

• Flue gas velocity

• Volume flow

1)

• 2 ... 50 m/s

• 0 ... 3 000 000 m

3

/h

Differential pressure

Evaluation unit

The evaluation unit D-FL 100-20 evaluates the measured signal from the differential pressure transducer. A 4 to 20 mA current signal is available as measured value output. A Modbus interface according to VDI 4201 for the connection of an emission evaluation calculator with digital interface is available in addition to the 4 to 40 mA current signal output. The front panel contains five LEDs and one USB port. The LEDs signal the system's current status/operating state.

The various parameters, such as standard density, substitute values for pressure and temperature in the exhaust gas duct, k-factor and measuring ranges are input via the USB port with the help of a PC or the associated software D-ESI 100.


Sample gas pressure

Duct diameter

Ambient temperature



Digital outputs

Digital inputs

Accuracy

Detection limit



0.4 ... 8 m

-20 ... +50 °C

IP65

0/4 ... 20 mA, 500

Ω

2 relay outputs, permissible load 48 V/0.5 A

None


< 3 m/s

Software D-ESI 100

Software for assigning parameters, visualizing the measured data, and carrying out AST, QAL2 and QAL3 for D-FL 100-20.


Zero point drift



The D-ESI 100 can be parameterized, maintained and (when faults occur) analyzed via the USB port with the help of a PC and the associated software.

Auxiliary power 18 ... 32 V DC/1 A, 90 ... 264 V AC,

48 ... 62 Hz, 100 VA

Universal control unit D-ISC 100 with evaluation unit

D-FL 100-20

Dimensions

• Probes

• Probe length

380 x 160 x (300 + probe length) mm

0.4 ... 2/0.4 ... 4/0.4 ... 8 m


Automatic back purging unit

Weight

Purge-air supply (optional)

1)

32 kg + 6.8 kg/m probe length

6 ... 8 bar for back purging

Optional pressure and temperature correction

■


An automatic back purging device to keep the measuring openings clean is available for applications with high dust loads.

Please consult your Siemens sales partner for information on how to correctly configure and order a D-FL 100 measuring system for a Siemens CEMS project.


A weather protection cover is available to protect the probe head and the back purging control when the measuring system is installed outdoors.

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■

Overview

The D-FL 220 is a volume flow measuring system for ultra-sonic measuring of flow and volume flow, especially for wet and aggressive smoke emissions.

■

Benefits

• In-situ measuring method

• Measurement possible below dew point and for high dust concentrations

• Continuous measurement of normal volume flow and gas velocity

• Automatic zero point and reference point control

• Digital signal processing

• Remote access possible, digital interface according to

VDI 4201-3

• Operation with or without control unit

• Very low maintenance

■

Application

As in-situ measuring system, the measuring equipment determines the measured values without sampling directly in the duct through which gas is flowing.


• Volume flow measuring at low speeds

• Plants with damp and/or aggressive exhaust gas, for example, in waste incineration plants

• Volume flow measurement at high dust content

Approvals

• Suitability-tested by the TÜV Cologne, test report

936/21218490/A


■

Design

Duct

Measuring head




Measuring heads

Two identically designed measuring heads, set for type A and type B, are used. Depending on the application data, different depth-of-penetration lengths are required, for example, from 100 to 1100 mm.

Stainless steel 1.4571 is used as probe material. The housing is made of impact-proof polyamide.

A 4 mA to 20 mA current signal is available as measured value output which measures the velocity and/or the volume flow and can be connected, for example, to a emission evaluation calculator or a recorder. Two relay contacts are available for signaling.

Also available is a Modbus interface according to VDI 4201-3 for the connection of an emission evaluation calculator with digital interface. The various parameters are entered during the installation on site. The USB port is on the rear.

Purge flanges

The purge air which cools the ultra-sonic transducer and keeps it clean is supplied via purge flange (one for each measuring head). A toggle-type fastener connects the purge flange to the measuring head.

Mounting tubes with flange

Mounting tubes made of stainless steel 1.4571 or of glass-fiber reinforced plastic, adapted to the plant conditions, are available.

Purge air unit

A hose connects the two measuring heads to the purge air unit.

The filtered air is used to cool the measuring heads and to keep the transducers clean.

Terminal box

Terminal box to output the data with connecting cable for the two sensors and customer terminal strip.

Software D-ESI 100

Software to assign parameters, to visualize the measured data, and to carry out AST, QAL2 and QAL3.

The D-ESI 100 can be parameterized, maintained and (when faults occur) analyzed via the USB port with the help of a PC and the associated software.

Optional:




Weather protection covers are available to protect the measuring heads when the measuring system is installed outdoors.


• Absolute pressure transducer

• Temperature transducer

Purge air

4

Purge air

System components D-FL 220


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■

Function

The D-FL 220 measuring system operates according to the acoustic transit time differential method.

Two identical sensors transmit and receive ultra-sonic pulses reciprocally. The system calculates precisely the gas velocity and the gas temperature from the transit time difference dependent on the direction. The volume flow is calculated taking into consideration the cross-section, the sample gas temperature and the absolute pressure. The D-FL 220 performs internal self-monitoring routines and is very low maintenance.

■


Measuring system D-FL 220

Measurements

Measuring ranges

Measuring principle


Sample gas pressure

Duct diameter

Ambient temperature



Digital outputs

• Flue gas velocity

• Volume flow

1)

• Temperature

• 0 ... 40 m/s

• 0 ... 3 000 000 m

3

/h

• 0 ... 400 °C

Ultrasonic transit-time differential

0 ... 300 °C, optional higher


0.5 ... 13 m, temperature-dependent

-20 ... +50 °C, measuring head: -40 ... +70 °C

IP65

0/4 ... 20 mA, 400

Ω

Modbus RTU bi-directional

2 relay outputs, permissible load 48 V/0.5 A

None Digital inputs

Accuracy

Detection limit


Zero point drift

< 2 %

< 0.3 % of measuring range



Auxiliary power 24 V DC/0.5 A

Dimensions standard measuring head Ø 190 x 570 mm

Weight

Purge air supply

17 kg

Purge air quantity Approx. 80 m

3

/h

Auxiliary power


Weight


115/230 V, 50/60 Hz, 0.37/0.43 kW

350 x 550 x 500 mm

12 kg

IP55

1)

Optional pressure and temperature correction

■


Please consult your Siemens sales partner for information on how to correctly configure and order a D-FL 220 measuring system for a Siemens CEMS project.

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D-ISC 100 display and control unit for dust and volume flow measuring instruments

■

Overview

■

Application

The control unit can supply a single sensor or a system consisting of two sensors with power. Several sensors that are connected via a network can also be connected to the D-ISC 100. In this case each of the sensors must be supplied with power by means of a separate terminal box, supply unit or evaluation unit.

Modbus links the sensors to each other and to the D-ISC 100.

The display provides an immediate overview of the status of the connected devices. The current measured values can be displayed without the necessity of direct access to the sensors. It is also possible to visualize the measured values with bar chart display.

The connected sensors can be queried, controlled and parameterized with the control unit. Operation takes place directly via the membrane keyboard of the control unit. Alternatively, you can connect a PC via the integrated USB port. In conjunction with the Web server technology software D-ESI 100, remote support is possible via the Internet.

The D-ISC 100 universal control unit permits the connection of up to 8 sensors combining dust and volume flow measurements on one display.

The control unit features four slots for extension modules, for example, Modbus RTU or analog / digital input and output modules.

■

Benefits

• Connection of up to 8 sensors

• Large liquid crystal display (LCD) for display of the measured values

• Automatic detection of connected sensors

• Easy parameter assignment of connected sensors

• Operation locally via membrane keyboard or USB port, or remote control via the RS 485 interface

• Modular design, four slots available for extension modules

• Slot for external converter

• No maintenance costs

• Easy to update via SD card

You also have the option of including an external converter (e.g.

PROFIBUS DP) inside the unit. This eliminates the need for an additional housing in equivalent degree of protection.

Approvals

Type-tested according to European directive EN 15267 for continuous emission measurements in connection with the test reports no. 936/21217455, 936/21218492 and 936/21218490 of the Technical Inspectorate of the Rhineland region (TÜV Rheinland)

■

Design

The following functions can be added to the D-ISC 100 control unit by means of plug-in modules:

• Modbus RTU module

• Analog input module with four analog inputs: 0 to 20 mA with

2/4 mA live zero, burden 50

Ω

• Analog output module with four analog outputs: 0 to 20 mA with 4 mA live zero, max. burden 400

Ω

• Digital input module with eight digital inputs

• Digital output module with eight digital outputs

4


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D-ISC 100 display and control unit for dust and volume flow measuring instruments

■


Basic unit

Output signal

Maximum burden

Relay outputs

0 ... 20 mA, zero point 4 mA

400

Ω

3 x status, isolated (limit value, fault, control cycle, etc.)

48 V/0.5 A

1 x function, isolated

-20 ... +50 °C, optional -40 ... +60 °C

Maximum switching power

Inputs

Ambient temperature

Electrical data

Line voltage

Power

Auxiliary power for sensors

Mechanical specifications

Material

Color


Weight


90 ... 264 V, 48 ... 62 Hz

Approx. 100 W

24 V DC/2 A

Stainless steel 1.4301

RAL 5017

IP65

5 kg

130 x 330 x 220 mm

Expansion options

Modbus RTU module

Interface

Baud rate

Analog input module

Output signal

RS 485, serial

9600 ... 57 600 Bd

0 ... 20 mA, zero point 0/2/4 mA adjustable

50

Ω

Load

Analog output module

Output signal

Maximum burden

Digital input module

Inputs

Digital output module

Relay outputs

0 ... 20 mA, zero point 4 mA

400

Ω

8 x function, isolated

8 x status, isolated (limit value, fault, control cycle, etc.)

Converter module

Type PROFIBUS DP

■


Please consult your Siemens sales partner for information on how to correctly configure and order a D-ISC 100 control unit for a Siemens CEMS project.

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© Siemens AG 2015



D-EMS 2000 Environmental and process data management system

■

Overview

4-20 mA,

Modbus,

PROFIBUS,

OPC, ELAN

Ring memory

6 years int, day

+ protocols

30 days 1 min + 1 s

4-20 mA,

Modbus,

PROFIBUS,

OPC, ELAN

Ring memory

> 32 days

D-EMS

2000 CS

Authority

4-20 mA,

Modbus,

PROFIBUS,

OPC, ELAN

TCP/IP

Internet

Ring memory

> 32 days

D-MS

500 KE

D-EMS 2000

Client

D-EMS 2000

Client

TCP/IP

Ring memory

> 5 years

Individual values

Protocols

System

Raid 1

D-EMS 2000

Client

Backup on

HD/SSD

DCF77

GPS

System Workstation D-EMS 2000

The D-EMS 2000 environmental and process data management system is a modular system for the continuous acquisition, long-term storage, calculation and visualization of environmental and process data.

■

Benefits

■

Application

• Instrument for monitoring legally prescribed limit values and recording their observance

• Emission monitoring and remote data transmission to the authorities

• Corresponds to EU directives 2000/76/EU, 2001/80/EU and

2010/75/EU

• Adjustable to any plant size through to complete assessment of complex industrial sites

• Continuous monitoring of 1 to 320 components per system workstation

• Interconnection of any number of components via data networks

• Visualization available in 19 languages

The D-EMS 2000 standard system is designed for small to medium sized industrial sites whose emission data, immission data or process data must be recorded in line with government regulations for measured data logging.

Approvals

• Suitability-tested by TÜV in accordance with German TA-Luft,

1., 2., 13., 17., 27., 30. and 31. BImSchV

• Itemized in the list of suitable systems for evaluation of continuous emission measuring


• MCERTS certified

■

Design

Measured data acquisition:

• Analog/digital inputs as

- 19" rack with ring memory

- Local DIN rail modules

• Data communication via bus systems, Modbus RTU/ TCP,

PROFIBUS, Elan, OPC UA

4


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D-EMS 2000 Environmental and process data management system

■

Function

Data sources

• Emission data

• Immission data

• Meteorological data

• Water data

• Process data

Data export

• Data interface to MS-Excel with option of further measured data evaluation, e.g. for fulfillment of environmental protection officer’s reporting duties

• Measured data can be transferred to authorities via standard remote communication or via Internet

• Merging of measured data e.g. for greenhouse emission trading

• Remote service interface for fast and cost effective service

Data security

• Industrial type evaluation PC with vibration-proof hard disks in

RAID 1 array and special air cooling with filter system

• Paperless data storage to replace recorders and printers is possible through integrated data security, which is guaranteed on several levels in the system

• Intermediate storage of the raw input values at minute intervals in data communication unit D-MS 500 KE

• Storage of raw input values in one-second intervals

• Data backup on external redundant drive

Internet/intranet connection

• Data transmission to an Internet server with HTML standard masks via standard software (MS Internet Explorer)

• Password protected control of daily emission values including the classification records

Visualization

• Measured data logging according to official regulations

• Classification tables, daily, monthly and annual records

• Representation of current, prognostic and historic measured data in bar/linear form

• Pollutant compensation, characteristics curve and correlation

• Automatic alarm and information system

Annual emission declaration

• Automatic preparation of annual emission declaration, from the individual values stored in the system, according to

11. BlmSchV

• Compatible with official software, import/export module

• Automatic filling in of forms

• Reading in of historical emission declarations

■


Please consult your Siemens sales partner for information on how to correctly configure and order a D-EMS 2000 environmental and process data management system for a Siemens CEMS project.

4/36


© Siemens AG 2015



D-EMS 2000 CS Environmental and process data management system

■

Overview

Authority

4-20 mA, Modbus, PROFIBUS, OPC, ELAN

D-EMS 2000

Client

Internet

D-EMS 2000

Client

TCP/IP

Ring memory

6 years int, day

+ protocols 30 days

1 min + 1 s

D-EMS 2000

Client

Backup on

HD/SSD

DCF77

GPS

The D-EMS 2000 CS environmental and process data management system is an affordable compact system for small to medium plants.

■

Benefits

• Independently operating module for the acquisition, long-term storage, calculation and visualization of environmental and process data

• Instrument for monitoring legally prescribed limit values with automatic recording

• Continuous monitoring of 1 to 12 components, connected via bus communication or hard-wired

• Compact system, no additional evaluation PC required

• Windows-based and certified D-EMS 2000 software

• All modules of the D-EMS 2000 system can be used

• Visualization available in 19 languages

■


Device versions

PC

Inputs / outputs

• Compact system in 19", 3HU rack

• Desktop version with monitor/ keyboard/mouse

• 19" slide-in assembly

Intel based dual-core PC with

Windows 7 Pro & 8, 2 GB RAM and

120 GB SDD

Max. 3 cards:

• Combination card

4 AI, 8 DI, 2 AO, 4 DO

• Input card 8 AI, 15 DI

• Output card 8 AO

• Output card 16 DO

■

Application

Connection of bus systems • Modbus RTU/ TCP, PROFIBUS,

Elan, OPC UA

• Analog/digital inputs: 12/24

• Analog/digital outputs: 12/24

The D-EMS 2000 CS compact system is designed for small to medium sized industrial plants whose emission data, immission data or process data must be recorded in line with public authority regulations for measured data logging.

Interfaces • 1 x VGA

• 2 x USB

• 1 x RJ 45

• 3 x serial (RS 232 or RS 485)

• BNC for DCF77 - radio clock

■

Approvals

• Suitability-tested by TÜV in accordance with German TA-Luft,

1., 2., 13., 17., 27., 30. and 31. BImSchV

• Itemized in the list of suitable systems for evaluation of continuous emission measuring


• MCERTS certified

Ambient temperature


Operating voltage

■


Design

5 ... 40 °C

IP20

115/230 V AC, 50/60 Hz, 100 VA

Please consult your Siemens sales partner for information on how to correctly configure and order a D-EMS 2000 CS compact system for a Siemens CEMS project.

Three available device types:

• Compact system in 19", 3HU rack

• Desktop version with monitor / keyboard / mouse

• 19", 1HU slide-in unit with extendable keyboard and hinged monitor

4


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© Siemens AG 2015

4


Analysis of biogas

Set BGA

■

■

Overview

The Set BGA (

b

io

g

as

a

nalyzer) is a standardized system for stationary, continuous operation for the analysis of landfill gas, sewage gas or biogas.

Benefits


The standardized complete system has a modular configuration and can thus be used at various measuring locations for different measuring tasks.


• Field-tested and matched Set in rugged industrial design

• Extremely high long-term stability

• The Set BGA is based on the proven ULTRAMAT 23

■

Application

The efficiency of biogenic production processes and optimum operation of the plant largely depends on continuous monitoring of the biogas composition. The basic version of the Set BGA analyzes CH

4

and CO

2

using the proven ULTRAMAT 23 IR analyzer. The concentrations of O

2

and H

2

S are optionally measured using electrochemical sensors and also converted into output signals of 4 to 20 mA. In this manner, the Set BGA contributes to operational safety and explosion protection in addition to process optimization.

The modular design of the system takes into account the physical conditions of the gas with regard to temperature and moisture in that various gas preparation components for heating or drying the sample gas can be configured as required.

The gas mixture can be explosive at critical concentration ratios between methane and oxygen. Even if such critical gas compositions occur extremely rarely, the danger of ignition must nevertheless be avoided. For this reason, the Set BGA is designed with a high safety standard and even the basic version is equipped with flow monitoring and detonation protection in accordance with EN 12874 in the sample gas path. To increase safety even further, a gas sensor for monitoring the ambient air can be connected as an option.

It is also possible to monitoring up to four measuring points using an optional sample switching cabinet. In this case the sample flows are sucked in continuously using a powerful pump in order to achieve fast measuring times.

Field-proven, reliable technologies

• Autocalibration function with ambient air reduces the maintenance requirements

• Detonation protection in accordance with EN 12874

• Modular system design based on long-term tested components

• LEL sensor for cabinet monitoring (optional)


• Intuitive menu guidance

• Configuration on large displays with plain text

• Two freely-configurable limits per measured component

4/38


© Siemens AG 2015


Analysis of biogas

Set BGA

■

Design

The Set BGA consists of the following components:

• ULTRAMAT 23 analyzer with four measured components max.

• Analyzer cabinet with modularly configurable gas preparation components

• Cabinet for measuring point switchover (option)

• Heated line (option)

The ULTRAMAT 23 is selectable with two IR components (CO

2 and CH

4 an electrochemical oxygen sensor and/or an electrochemical

). Furthermore, the configuration can be equipped with hydrogen sulfide sensor. The corresponding measuring ranges are listed in the table below.

Measured component Smallest measuring range

CO

2

CH

4

O

2

H

2

S (high)

H

2

S (low)

0 … 20 %

0 … 20 %

0 … 5 %

0 … 5 ppm

Largest measuring range

0 … 100 %

0 … 100 %

0 … 25 %

0 … 5 000 ppm

0 … 50 ppm

The ULTRAMAT 23 calibrates the IR components and the electromechanical oxygen sensor automatically with ambient air.

Calibration with calibration gas is recommended once a year or after oxygen sensor replacement. In order to comply with the technical specification data, the hydrogen sulfide sensor must be calibrated every three months. An appropriate calibration gas is therefore required. It is supplied to the analyzer through a manually switchable ball valve.

■


Technical data of Set BGA

Installation

Ambient temperature

Site


Sample gas pressure

5 … 38 °C, with cabinet heating ± 0 °C

Indoor/outdoor installation (configurable)

Pump performance


Power supply

Supply 1

Supply 2

Power consumption

• With pump, depressurized suction mode, selectable with internal or external pump

• Provision must be made for a pressure reduction for pressures greater than

1 200 mbar absolute

Adjustable to 60 … 80 Nl/h

Max. 45 °C, with moisture saturation

200 … 240 V AC, 47 … 63 Hz

100 … 120 V AC, 47 … 63 Hz

Approx. 180 VA (without cooler and sample preparation)

Connection systems

Teflon hose

Connection systems

Dimensions

Set BGA measuring system

(W x H x D)

Sample preparation

(W x H x D)

Weight

With PVDF screwed glands

Metric (6 mm) or imperial (1/4") selectable

600 x 781 x 600 mm

600 x 600 x 220 mm

Set BGA measuring system Approx. 50 kg

Sample preparation Approx. 22 kg

System design

Set BGA measuring system

System housing


Cabinet conditioning

Cooling system

Sample preparation

Analog outputs

3-part sheet-steel housing with window

IP54

Fan

Peltier cyclone cooler (optional)

Max. six sample streams can be controlled using Logo module with fast loop pump in separate housing

Per component 0/2/4 … 20 mA; NAMUR, floating, max. load 750

Ω

Measured components / measuring ranges

CH

O

2

4

CO

2

0 … 100 vol% to 0 … 20 vol% (NDIR)

0 … 100 vol% to 0 … 20 vol% (NDIR)

0 … 25 vol% to 0 … 5 vol% (electrochemical or paramagnetic optionally selectable)

H

2

S 0 … 5 000 ppm (electrochemical); optional

0 … 5 ppm to 0 … 50 ppm (electrochemical); optional

Safety assemblies

Assembly 1

Assembly 2

Assembly 3

Comment

Detonation protection F501

Flow measurement with limit monitoring at the output

LEL monitoring (optional)

• The system concept of the Set BGA is based on the preconfigured ULTRAMAT 23 solutions (7MB2335-…, 7MB2337-…)

• The technical performance data concerning the measuring response correspond to the catalog data of the ULTRAMAT 23. The preconfigured version does not contain any

ULTRAMAT 23 add-ons or retrofitting sets.

2-stream sample preparation


4/39

4

© Siemens AG 2015

4


Analysis of biogas

Set BGA

■


Set BGA basic configuration, including flame arrestor

Click on the Article No. for the online configuration in the

PIA Life Cycle Portal.

Gas connections, external

6 mm

¼ inch

Sample conditioning

Without gas cooling

Passive cooling (supplied separately)

Peltier cooler, integrated in Set BGA enclosure

Enclosure design

Not heated

Electrically heated

Pump design

Without pump

Internal pump in analyzer

External pump, fitted in Set BGA enclosure

Power supply

AC 120 V, 60 Hz

AC 230 V, 50 Hz

AC 110 V, 50 Hz

AC 220 V, 60 Hz

Infrared measured components

Version with one measured component

Highly selective ULTRAMAT 23 single-beam infrared gas analyzer for measuring methane; mounted in 19-inch rack unit for installation in wall cabinet

Specification:

• ·Measured component CH

4

- Smallest measuring range: 0 ... 20 %

- Largest measuring range: 0 … 100 %

Version for two measured components

Highly selective ULTRAMAT 23 single-beam infrared gas analyzer for measuring carbon dioxide and methane; mounted in

19-inch rack unit for installation in wall cabinet

Specification:

• 1. Measured component CO

2



• 2. Measured component CH

4



Version with one measured component

Highly selective ULTRAMAT 23 single-beam infrared gas analyzer for measuring carbon dioxide; mounted in 19-inch rack unit for installation in wall cabinet.

Specification:

• Measured component CO

2

- Smallest measuring range: 0 ... 0.5 %

- Largest measuring range: 0 … 2.5 %

Oxygen measurement

Gas analyzer without oxygen sensor

Electrochemical oxygen sensor; sensitive to CO

2

Specification:

• Smallest measuring range: 0 ... 5 %

• Largest measuring range: 0 ... 25 %

• Repeatability: approx. 0.05 % O

2

Paramagnetic oxygen measuring cell; no sensor wear

Specification:

• Smallest measuring range: 0 ... 2 %

• Largest measuring range: 0 ... 100 %

• Repeatability: < 1 % of smallest measuring range

Article No.

7MB1955-

7 7 7 7 7 7 7 7 7 Cannot be combined

0

1

A

B

C

A

B

0

1

2

0

1

2

3

0

1

2

A

B

C

C

4/40


Set BGA basic configuration, including flame arrestor

H

2

S measurement

Without H

2

S sensor

With H

2

S sensor, 0 … 5 000 ppm

With H

2

S sensor, 0 … 5 ppm to 0 … 50 ppm

Documentation

German, 1 set (paper and CD)

English, 1 set (paper and CD)

French, 1 set (paper and CD)

Further versions (add-ons)


Heated sample gas line, self-regulating, Ex-proof

Length: 5 m, supplied separately







Communication

PROFIBUS PA interface

PROFIBUS DP interface

Fast loop design and sample switching

2-stream sample switching with Logo and external pump





Gas sensor for leak monitoring of the Set BGA system

Alarm monitoring: 20 % LEL methane

A12

A13

B02

B03

B04

B05

B06

C01

A01

A02

A03

A04

A05

A06

A07

© Siemens AG 2015


Analysis of biogas

Set BGA

7MB1955-

7 7 7 7 7 7 7 7 7 Cannot be combined

A

B

D

0

1

2

B

D

4


4/41

© Siemens AG 2015

4


Continuous monitoring of hydrogen-cooled generators

■

Set GGA

Overview

In addition, contamination of the hydrogen cooling gas reduces the efficiency of the turbo generator, as it leads to considerably higher friction loss. For a 970 MW generator, a difference of 4 % is equivalent to a 0.8 MW difference in power. There are also good reasons related to cost-effectiveness why the cooling gas should be continuously monitored for contamination.

The Set GGA is a complete solution for monitoring hydrogencooled turbo generators, with the dual benefit of being simple to handle and having low initial investment costs.

■

The standardized Set GGA (Generator Gas Analyzer) has been specially designed for monitoring hydrogen-cooled turbo generators.

Benefits



• Field-proven, harmonized and reliable set

• Low purchase price and economic operation

• Suitable for optimizing the efficiency of H

2 generators

-cooled turbo

Field-proven, reliable technologies

• High-precision and reliable purity monitoring of hydrogen

• Microchip-based thermal conductivity measurement

• Redundant measuring system

• SIL 1 certificate for the analysis hardware


• Intuitive menu prompting

• Configuration on large displays with plaintext

• Use of CO

2

and AR as inert gas possible

■

Application

This set is used in power generation applications.

Turbo generators in power plants are cooled with gas in order to increase their efficiency. In spite of the strict safety requirements hydrogen is used as a cooling gas. This offers huge advantages over air. These include considerably better cooling properties, lower friction loss on rotating parts, and a higher electrical breakdown strength. These features enable hydrogen to satisfy the requirements for the turbo generator to reach an optimum level of efficiency.

However, mixtures of hydrogen and air with a hydrogen content of anything from 4 to 77 % are explosive. For safety reasons, it is imperative that this is prevented during operation filling and emptying of the turbo generators. International standards

(EN 60034-3 and IEC 842) state that redundant safety monitoring with two independent operating systems must be used for this.

■

Design

The Set GGA is available in the following versions:

• Generator Gas Analyzer (GGA)

• GGA with test gas skid

• GGA with test gas skid and installation frame

Analyzers

The GGA contains two CALOMAT 6E analyzers (19" rack unit versions). From the gas sampling system right through to the gas outlet, these are completely separate from one another, thereby ensuring full redundancy.

The CALOMAT 6E is a continuous gas analyzer for determining

H

2

and He in binary or quasi-binary gas mixtures.

To measure the hydrogen and inert gases continuously, the exact thermal conductivity of the sample gas mixture is measured and the concentration calculated from this. Only binary gas mixtures can be directly measured.

The CALOMAT 6E is used to measure 0 to 100 % CO

2

0 to 100 % H

2

in CO

2

/Ar or 80 to 100 % H

2

/Ar in air,

in air, in the context of monitoring hydrogen-cooled turbo generators, on account of its high measuring range dynamics.

The units are approved for use in ATEX Zone 2. Gas mixtures may also be fed in according to the definition of Zone 1. In terms of tightness and compressive strength, the measuring cell and entire physical structure of the gas path, from inlet to outlet, are certified up to 55 000 hPa . This is much higher than the pressure that arises when oxyhydrogen gas is ignited.

A flame arrestor at the sample gas inlet provides additional safety.

The integrated LCD display shows the measured values, status bar and measuring ranges simultaneously.

The T90 time is less than 5 s. This means that the delay between the measurement and displaying the result is very short.

Tests carried out under harsh field conditions have indicated that the 3-week drift of the measurement results is less than 0.1 %.

Combined with a repeatability value of 0.1 %, this ensures that the measurement results gathered will be both accurate and precise.

4/42


© Siemens AG 2015



Set GGA

Analyzer cabinet

Another feature of the GGA is a protective cabinet for the analyzers. This provides a compact location where the system can be easily installed, and offers protection against dust and water.

The system is approved in accordance with IP54 degree of protection.

The cabinet measures 616 x 615 x 600 mm (H x D x W) and is made from painted sheet steel.

■

Function

There are three distinct processes in monitoring hydrogencooled turbo generators: normal operation, filling and emptying.

The measuring task entails preventing a gas mixture of hydrogen and air outside the specified limits, or detecting the risk of this happening in good time, as well as monitoring the hydrogen purity.

A key advantage of this type of construction is that it eliminates the need for a restricted breathing enclosure, allowing maintenance to be carried out without any difficulty. If a restricted breathing enclosure is required, it must be ensured that the system is operated in an airtight room. Restoring the restricted breathing enclosure once maintenance procedures have been performed is a costly and time-consuming process.

To keep operating and maintenance costs low, the GGA set supports natural cabinet ventilation and a filter element provides protection against particles of dirt. Purging with instrument air is not necessary.

During normal operation, the purity of the generator cooling gas is monitored. If the purity falls below a specific limit (e.g. < 95 %

H

H

2

), a message is output. The monitored range is 80 to 100 %

2

in air.

Filling the generator is a two-stage procedure: first, the air in the generator is replaced by inert gas (argon or CO

2

), and then this is replaced by hydrogen. During this, the concentration trends of the gases are measured and the replacement processes monitored. To prevent explosive mixtures from being formed, it is necessary to monitor the measuring range of 0 to 100 % inert gas in air in the first step and 0 to 100 % H

2

in inert gas in the second step.

Test gas skid

The analyzers and analyzer cabinet are supplied as part of the basic configuration of the set. As an option, however, it is also possible to obtain a suitable test gas skid on a mounting plate.

The procedure is performed in reverse when emptying the generator: The hydrogen is first replaced with inert gas and the generator is then filled with air. The measuring tasks remain unchanged in this case. Here it is necessary to monitor the measuring ranges of 0 to 100 % H to 100 % inert gas in air.

2

in inert gas first, and then 0

The test gas skid is responsible for preparing the extracted sample ready for analysis. This ensures that the sample, calibration and inert gases are fed into the analyzers at the right pressure and flow rate, and without having been mixed with other gases.

The skid is fully equipped with a flame arrestor, stopcock ball valve, stainless steel overflow regulator, single-stage pressure reducer, stainless steel 5-way transfer ball valve, all-metal flow meter for air, 1-channel isolating switch amplifier and installation material. The flowmeters are designed to transmit a limit monitoring signal. The connection is made on-site.

The test gas skid guarantees that all the requirements in terms of safety, quality and simplicity are satisfied when connecting sample, calibration and inert gases.

Installation frame

The installation frame is a supplementary feature of the set. It enables free-standing installation of the analyzer cabinet and test gas skid.

The installation frame is supplied in a fully assembled state (including feet). Its overall height is 2 000 mm.

4


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© Siemens AG 2015

4



Set GGA

■



Ambient temperature

Relative humidity

Corrosive atmosphere


• Calomat 6E

- Sample gas pressure

- Sample gas flow

• Test gas skid

- Sample gas pressure

- Sample gas flow

Power supply

• Supply 1

• Supply 2

• Supply 3

Type of connections

Pipe material

Connections/components

5 ... 50 °C

70 %, non-condensing

No

800 ... 1 100 hPa (absolute)

30 ... 90 l/h (0.5 … 1.5 l/min)

55 000 hPa (absolute)

30 … 90 l/h (0.5 … 1.5 l/min)

200 ... 240 V AC, 47 ... 63 Hz

100 ... 120 V AC, 47 ... 63 Hz

24 V DC for switch amplifiers

Stainless steel

• Metric (6 mm)

• Imperial (¼")

Cabling

Electrical design

Type of cables

Cable ID

Installation

Site

Ex-zone analyzer

System design

Version


Automatic calibration

Signal outputs

With sample gas return flow

According to IEC

Non-armored cables

No single core labeling

Interior

ATEX II, 3G

Cabinet

IP54

No

4 ... 20 mA/isolated contact

Max. 24 V AC/DC 1 A

On request

Measuring response

(relating to sample gas pressure 1 013 hPa absolute,

0.5 l/min sample gas flow and 25 °C ambient temperature)

Output signal fluctuation < ± 0.75 % of the smallest possible measuring range according to rating plate, with electronic damping constant of 1 s (

σ = 0.25 %)

Zero point drift < 1 %/week of the smallest possible span according to rating plate

Measured-value drift

Repeatability

Detection limit

< 0.5 %/of the smallest possible span according to rating plate

< 1 % of the current measuring range

1 % of the current measuring range

Linearity error

< ± 1 % of the current measuring range

Influencing variable

(relating to sample gas pressure 1 013 hPa absolute,

0.5 l/min sample gas flow and 25 °C ambient temperature)

Ambient temperature < 1 %/10 K referred to smallest possible span according to label

Accompanying gases

Sample gas flow

Sample gas pressure

Deviation from zero point

< 0.1 % of the smallest possible span according to rating plate with a change in flow of 0.1 l/h within the permissible flow range

< 1 % of the current measuring range with a pressure change of 100 hPa

Power supply < 0.1 % of the current measuring range with rated voltage ± 10 %

Generator gas analyzer

Analysis

Component

Ar/CO

2

in air

H

2

in Ar/CO

2

H

2

in air

Sample temperature

Dust content

0

0

80

Measuring point designation

Concentration

Min. Typical

H

2

O dew point

Aggregate state, sample

1)

Gaseous

1)

Standard state at 20 °C, 101.3 kPa

50

0

-50

Max.

100

100

100

Generator gas analyzer

Unit Measured component

vol. % vol. % vol. %

°C mg/m

3

°C

Yes

Yes

Yes

Measuring range

Small Large

0

0

80

100

100

100

4/44


© Siemens AG 2015



Set GGA


Set GGA


Gas connections

6 mm pipe

1/4" pipe

Version

H

2

monitoring (turbo generators)

Add-on electronics

Without

Auxiliary power

100 ... 120 V AC, 47 ... 63 Hz

200 ... 240 V AC, 47 ... 63 Hz

Variants

Set GGA, cable glands M20x1.5 power supply with cable diameter of 6 ... 12 mm

(e.g. in accordance with EMT674-057, EMT674-059)

Set GGA, with test gas skid, cable glands M20x1.5 power supply with cable diameter of 6 ... 12 mm (sampling unit on stainless steel plate), delivery batch in 2 parts

Set GGA, cable glands M25x1.5 power supply with cable diameter of 14 ... 18 mm

(e.g. in accordance with EMT674-070, EMT674-071)

Set GGA, with test gas skid factory-assembled on mounting frame, cable glands

M20x1.5 power supply with test gas skid (PA on stainless steel plate), ready mounted on frame, delivery batch 1 part

Explosion protection

Certificate: ATEX II 3G, flammable and non-flammable gases

Documentation

German

English

French

Spanish

Article No.

7MB1950-

7 7 7

0

7

-

7 7 7 7

0

1

G A

0

0

1

A

B

C

E

B

2

3

0

1

Cannot be combined

4


4/45

© Siemens AG 2015



Set GGA

■


4

Line pressure regulator

5-way ball valve

Stopcock ball valve

Test gas skid

685 615

CALOMAT

Siemens

MKG31 CQ001

Siemens

MKG32 CQ001

-FA1 -FA2

-RB4

-QR1

-PF1

-RB5

-QR2

-PF2

-FA3

Protective casing

Flame arrestor

Mounting rack

(screwed)

Flow meter

-SV1 -SV2

-RB1 -RB2 -RB3

Low-pressure overflow regulator

40

910

110

Test gas skid

Test gas skid, fully piped with VA pipe 6 x 1

Weight: 115 kg

Set GGA, dimensions in mm, figure corresponds to 7MB1950-0GA00-1EB0

4/46


© Siemens AG 2015

■

Overview


Determination of the quality of natural gas

Set CV

■

Design

Standardization of systems means good clarity and simple facilities for configuration. Different versions mean that it is possible to appropriately adapt the system to the requirements. The modules can be combined as desired. Standardization also means that not all imaginable versions are included, and that special requirements such as armored cables, customer-specific documentation, specific conductor labeling, or certificates such as

CE or 31B cannot be implemented at all, or not without an extra charge.

The design is divided into the following standard modules: sampling, pressure reduction, sample preparation system,

SITRANS CV, gas supply, calibration gases.

Gas supply station

The Set CV (Calorific Value) is a standardized system for determining the quality of natural gas with SITRANS CV and

MicroSAM.

■

Benefits


• Easily and quickly configured, from sampling to the gas supply

• Field-proven, harmonized and reliable set

• Suitable for determining the natural gas quality with high accuracy

Field-proven, reliable technology

• GC MEMS technology with low consumption levels, high linearity/accuracy over the entire measuring range, and short cycle times

Easy installation

• Installation in EEx Zone 1 possible

• Compact and rugged design for erecting indoors and outdoors

• Minimum space requirements

■

Application

For the chromatography industry, the natural gas market is one of the fastest growing in the world. There are a variety of reasons for this. While global energy requirements are increasing, there is a parallel trend of fossil fuel reserves being depleted. Natural gas is one type of fossil fuel that can still be found in vast, untapped reserves. In addition to this, the market is becoming increasingly liberalized, and the number of participants has risen considerably as a result - from the production stage, across the entire distribution network, right through to the end customer. In turn, this has generated more transfer points at which the quality and quantity of natural gas need to be determined for accounting purposes.

The market requires a reliable complete system which is specially designed for natural gas. With the Set CV, Siemens offers a system that covers all the requirements of such applications, from sampling to pressure reduction, sample preparation and determination of quality, supplying carrier and calibration gases, right through to expansion of the communication interfaces.

The set offers various modules to cover market requirements.

Using the different versions, the set can be adapted, and the modules can be freely-combined.

Such a system can be used wherever the quality of natural gas has to be determined. For example, during the conditioning of natural gas and feeding into the pipeline network, during transportation and distribution in the network, and when extracting it for supply purposes.

Sampling probe

Sample preparation

SITRANS CV

CV Control SW

Flow computer

General information

The set can be dimensioned for a 230 V AC or 115 V AC power supply. It is not possible to switch between supplies.

The gas connections can be supplied with either metric or imperial dimensions.

On the metric line, the gas connections are in the form of metric clamping ring glands with a diameter of 3 mm. The imperial line contains gas connections in the form of imperial clamping ring glands with a diameter of 1/8 inch. The pipes between the sampling probe, pressure reduction, sample preparation device, and SITRANS CV are optionally available. The system is generally designed for temperatures between -20 and +55 °C in areas with a risk of explosions. When provided with heating, the system can also be used down to -30 °C. The natural gas to be measured should be in a stable gaseous form, dry and clean.

Sampling probe

The basic components of a sampling probe are a lance, process connection, process isolation and, if necessary, pressure reduction. The high-pressure version is not supplied pre-assembled.

Lance

A representative sample should be taken from the central third of the pipeline. With a lance length of 1 m it is therefore possible to extract a sample from a pipeline with a diameter of up to

1 600 mm. In addition, two versions with different types of lance diameter are available. On the one hand, a pipe whose outer diameter is 6 mm and inner diameter is 2 mm. And on the other, a pipe whose outer diameter is 12 mm and inner diameter is 8 mm.

The lance can be supplied in a permanently installed or removable state (not for 12 mm).

Process connection

There are four versions for the flange connection to the pipeline.

Flange DN 65 PN 16 Form C for pressures up to 1 600 kPa, flange ANSI 2" for pressures up to 300 lbs RF as well as flange

DN 65 PN 160 Form E for pressures up to 16 000 kPa and flange

ANSI 2" for pressures up to 2 500 lbs RF.


4/47

4

4

© Siemens AG 2015



Set CV

Process isolation

It may be necessary to isolate the natural gas line from the system for maintenance and repair work. To do this, you can select either a simple stopcock or a double block and bleed structure.

While the stopcock is a cost-effective solution for minimum requirements, the double block and bleed structure stands for enhanced safety, as it has two valves that prevent any gas from being transferred further.

High-pressure reduction on the primary side

Pressure can be reduced in three ways: directly at the probe

(primary side), in an external casing with a pressure reduction unit (primary side), or in the sample preparation system (secondary side).

If the sample preparation system and the natural gas chromatograph are installed directly next to the sampling point, the highpressure reduction can be implemented in the sample preparation system. The pressure should always be reduced as close to the sampling point as possible in order to keep the dead volume as small as possible. The permissible sample and calibration gas pressure is 10 to 60 kPa above atmospheric pressure. Notice: Sample must not contain ethine!

The incoming carrier gas pressure must range from 500 to

700 kPa (g). 600 kPa (g) is recommended. Important: A continuous carrier gas supply is required for error-free operation (frequent carrier gas failure has a negative effect on the durability of the detectors and the device-internal pressure settings). In addition, an external two-step pressure regulator for the carrier gas pressure is strongly recommended.

Heated and unheated pressure reduction units are available in the external casing for high-pressure reduction on the primary side. Pressure reduction in the external casing is suitable for combination with the permanently installed and retractable standard probe. The heated pressure regulators have a power consumption of 150 W, and reliably maintain the sample in a gaseous state.

Special probe with high-pressure reduction

A third option offers an alternative to the two standard probes: a permanently installed probe with integrated separation of aerosols (so-called BTU diaphragm) in the pipeline and a pressure reduction unit. The lance is integrated in this at a depth of

228 mm. The protection pipe has an outer diameter of 22.8 mm.

The lance and pressure reduction do not need to be separately defined.

Heated pipeline

To ensure that the sample is maintained in a gaseous state, it is recommendable to use a heated sample gas line – for example, between the sampling point and the sample preparation system.

The pipeline is encased in a PE corrugated hose with an outer diameter of 43 mm. The self-regulating maintenance temperature remains at approximately 80 °C. The electrical connection is in the terminal box.

The power consumption is approx. 38 W/m.

Pipe base for enclosure attachment

A hot-dip galvanized 2" pipe base, 1 700 mm high, with mounting brackets and joining sheet enables free-standing mounting of the protective casing.

Sample preparation

The permissible sample and calibration gas pressure is 10 to

60 kPa above atmospheric pressure. Notice: Sample must not contain ethine!

The incoming carrier gas pressure must range from 500 to

700 kPa (g). 600 kPa (g) is recommended. Important: A continuous carrier gas supply is required for error-free operation (frequent carrier gas failure has a negative effect on the durability of the detectors and the device-internal pressure settings). In addition, an external two-step pressure regulator for the carrier gas pressure is strongly recommended.

The basic configuration of the sample preparation system for a stream includes a stopcock, 0.5 µm filter, flowmeter for the fast loop, pressure-relief valve, 3/2-way solenoid valve with sealed cable for automatic switching between calibration gas and sample gas, and a terminal box for connecting the solenoid valve.

This solenoid valve must either be protected by the customer at

0.5 A, or a ready-assembled terminal box with power supply and fuses can be ordered from the list of supplementary items.

There are also a number of other options for modifying the basic configuration.

Secondary pressure adjustment

The pressure adjustment unit with unheated pressure regulators can be ordered for one, two and three sample flows. This type of structure meets the minimum secondary pressure adjustment requirements. Please note that a reduction in pressure cools the sample down considerably, which can cause moisture to condense if the dew point is fallen below.

Another alternative, however, is pressure adjustment with a heated pressure regulator (150 W) for one, two or three sample streams. Heating the sample ensures that it remains in a gaseous state. The Joule-Thomson effect is thus compensated. The regulators can reduce pressures from 16 to 100/170 kPa.

If the pressure is to be reduced directly at the sampling probe or in an external casing outside the sample preparation system, no further pressure reduction is required during sample preparation.

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Protective top cover

Another option is a protective top cover made from fiber glassreinforced plastic and supplied with mounting brackets, for protection against solar radiation and storms. It must be mounted to a pipe base.

Heated sample gas line

To prevent condensation of the sample, it may be necessary to use a heated prepared pipeline – for example, between the sample preparation device and SITRANS CV/MicroSAM. The pipeline is encased in a PE corrugated hose with an outer diameter of 43 mm. The self-regulating maintenance temperature is around 80 °C.

Set CV

Sample injection

Where sample injection is concerned, straightforward and safety versions are available for between one and three streams.

Considered simply, sample injection is carried out for one, two or three streams using one solenoid valve per sample stream (cascade connection). Its job is to block any gas flows that are not required without preventing the desired gas from flowing. A

0.5 A fuse is required per solenoid valve and flowmeter. These are available in the ready-assembled terminal box.

The safety version of the sample injection system for one, two or three streams with double block and bleed technology enables the sample to be switched over, which in turn allows clean separation between gas streams by partially closing and venting the line. Since two valves are used to prevent the flow of gas that is not to be measured, rather than just one, the functional safety of the system remains at an optimum level for a long time. In addition, 0.5 A fuses are required for the sample valves and calibration valve. These are included in the electrical connection (supplementary item).

Monitoring the sample gas monitoring chromatograph (GC)

The sample flow to the GC can also be monitored electronically as an option. An alarm signal is output when necessary. A switch disconnector for the power supply is also required; this can be ordered along with the ready-assembled terminal box.

Protective casing/mounting plate for sample preparation system

The sample preparation system is available mounted either on a plate, in the protective casing, or in the heated protective casing.

The stainless steel mounting plate, measuring 682 x 482 x 3 mm

(H x W x D), is suitable for wall mounting. The system components selected are mounted on the plate and supplied with all pipes and wires installed.

The unheated protective transmitter box, made from fiber glassreinforced plastic and suitable for wall mounting measures

800 x 600 x 480 mm (H x W x D) and is fitted with stainless steel hinges, quick-release locks, safety glass windows and a stainless steel mounting plate.

The system components selected are mounted and supplied with all pipes and wires installed in the protective casing.

It is also possible to provide a heater in the protective transmitter box which can be controlled between 10 and 40 °C in steps of

5 degrees. The system components selected are mounted and supplied with all pipes and wires installed in the protective casing. The heating has a power of 400 W.

Aerosol filter/glycol filter

These filters have the task of removing any impurities that may have been introduced into the natural gases by aerosols or glycols, thus providing an additional level of safety for the

SITRANS CV and, therefore, the system functionality. The aerosol filter is supplied with 5 replacement diaphragms and the glycol filter with 10 replacement cartridges.

Manual laboratory sampling

An additional control valve permits manual laboratory sampling as an option. When not in use, it is fitted with a blanking plug on the output end.

Pipe base for enclosure attachment

A hot-dip galvanized 2" pipe base, 1 700 mm high, with mounting brackets and joining sheet enables free-standing mounting of the protective casing or the mounting plate as an alternative to wall mounting.

Example of single-stream sample preparation system: may deviate from the supplied system

SITRANS CV/MicroSAM

The core component of the Set CV is the GC SITRANS CV/

MicroSAM (for more detailed information see catalog AP 01, section 3).

SITRANS CV/MicroSAM system components

Protective casing/plate for SITRANS CV/MicroSAM

The SITRANS CV/MicroSAM is available mounted either on a plate, in the protective casing, or in the heated protective casing.

The stainless steel mounting plate, measuring 682 x 482 x 3 mm

(H x W x D), is suitable for wall mounting.

The unheated protective transmitter box, made from fiber glassreinforced plastic and suitable for wall mounting measures

800 x 600 x 480 mm (H x W x D) and is fitted with stainless steel hinges, quick-release locks, safety glass windows and a stainless steel mounting plate.

The protective casing can also be supplied with heating as an option. The heating can be adjusted between 10 and 40 °C, in increments of 5. The system components selected are mounted and supplied with all pipes and wires installed in the protective casing. The heating has a power of 400 W.

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Set CV

Terminal box

There are five connection options in total to choose from:

The simplest option is the interface in accordance with

SITRANS CV/MicroSAM (open cable end).

The terminal box with the dimension of 340 x 170 x 91 mm

(H x W x D) is made from polyester resin. The scope of delivery includes terminals, isolating terminals, cable glands and a PE rail. If ordered with the pipe base add-on part, the terminal box is supplied attached to the base, and the scope of supply includes 2.5 mm² terminals for connection by the customer and

M16/M20 cable glands. The power supply is 24 V DC. The terminal box is not suitable for connecting a heater, flow meter with limit value transmitter, and Double Block and Bleed (DB&B).

The terminal box with the dimension of 360 x 360 x 190 mm

(H x W x D) is made from painted sheet steel. The scope of delivery includes switch amplifiers, terminals, and cable glands. If ordered with the pipe base add-on part, the terminal box is supplied attached to the base, and the scope of supply includes

2.5 mm² terminals for connection by the customer and M16/M20 cable glands. The power supply is 24 V DC. The terminal box is not suitable for connecting a heater and DB&B.

The terminal box, including switch amplifier and a power supply

(115 V AC or 230 V AC, not switchable), with the dimension of

360 x 360 x 190 mm (H x W x D), is made from painted sheet steel. The scope of delivery includes terminals, 0.5 A fuses, terminals, cable glands and a PE rail. If ordered with the pipe base add-on part, the terminal box is supplied attached to the base, and the scope of supply includes 2.5 mm² terminals for connection by the customer and M16/M20 cable glands. The terminal box is not suitable for using DB&B.

The terminal box, including switch amplifiers and a power supply (115 V AC or 230 V AC, not switchable), with the dimension of 360 x 360 x 190 mm (H x W x D), is made from painted sheet steel. The scope of delivery includes isolating terminals, 0.5 A fuses, terminals, cable glands, relays and a PE rail. If ordered with the pipe base add-on part, the terminal box is supplied attached to the base, and the scope of supply includes 2.5 mm² terminals for connection by the customer and M16/M20 cable glands.

Gas supply

A gas chromatograph requires calibration and carrier gases.

Therefore the set offers various options with regard to gas connection, gas cylinder design, and calibration gases. Either individual components or complete systems can be ordered.

Cylinder pressure reducer, separate

The cylinder pressure reducer for calibration gases is supplied separately. It is made from stainless steel and has a cylinder connection conforming to DIN 477 No. 14 (calibration gas). The cylinder pressure reducer is also fitted with a gauge for primary and back pressure.

Contact gauge for supply gases

Two gauges with a 50 mm diameter and mounted on the battery pressure reduction station can also be ordered. The intrinsicallysafe slot initiators in accordance with NAMUR must be operated via a switch amplifier. This is not included in the delivery. The line is in the terminal box on the station panel.

Heated line

A heated prepared line is available for heating the calibration gas line from the cylinder cabinet to the sample preparation device. The power consumption is 38 W/m with an outer diameter of 43 mm on the corrugated hose. The integrated heating system is self-regulating with a maintenance temperature of approximately 80 °C.

Automatic cylinder changeover switch with separate coils

The stainless steel automatic cylinder changeover switch, supplied on a mounting plate, is designed for back pressures of between 50 and 1 000 kPa and contains two coiled pipes for helium that conform to DIN 477. The maximum permissible cylinder pressure is 20 000 kPa. This version also includes a gauge for measuring primary and back pressure. A contact gauge cannot be fitted when supplied separately.

Simple supply unit

This simple supply unit consists of a hot-dip galvanized 2-inch pipe base, 2 200 mm high, with a fiber glass-reinforced plastic protective top cover as well as two cylinder holders and a cylinder changeover switch. The gas cylinders are not included in the basic scope of supply.

Painted sheet steel gas cylinder cabinet

This version is supplied with the automatic cylinder changeover switch and coils, as well as the stainless steel calibration gas cylinder pressure reducer in a sheet metal cabinet.

The gas cylinder cabinet has room for two 50 l cylinders and one

10 l calibration gas cylinder. The dimensions are 2 050 x 1 250 x

400 mm (H x W x D). It contains the cylinder station, a stopcock for carrier gas, cylinder holder and pipe coils for the gas cylinders. The cabinet pipes are fully installed and the cabinet is equipped with bulkhead fittings for carrier gas, calibration gas and exhaust gas from the pressure relief valves.

As an option, this gas cylinder cabinet can also be supplied with heating from a heating sleeve for a 10 l calibration gas cylinder at 20 °C retaining temperature. The cylinder head is heated separately, in a fiber glass-reinforced plastic enclosure. The cylinder pressure reducer is also located here. The heating sleeve prevents condensation from building up in the gas cylinder. To ensure seamless gas heating, a heated line for accepting the calibration gas is recommended.

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Set CV

Calibration gases

Six different calibration gases are available as standard.

Component groups

Special feature n-butane 0.20

Neopentane

0.05

Isopentane

0.05

n-pentane 0.05

n-hexane 0.05

n-heptane n-octane n-nonane

C6+ with

O

2

C6+ without O

2

C6+ without O

2

C7+ without O

2

C6, C7,

C8, C9 without

O

2

Certified in acc. with PTB-

A 7.63

1.00

0.20

0.20

0.05

0.05

0.05

0.05

1.00

0.20

0.20

0.05

0.05

0.05

0.05

1.00

0.20

0.20

0.1

0.05

0.05

0.05

0.05

1.00

0.20

0.20

0.1

0.05

0.05

0.01

0.01

0.01

0.01

Biomethane with H

1.00

0.50

0.50

2

(mol %) (mol %) (mol %) (mol %) (mol %) (mol %)

Hydrogen

Nitrogen 4.00

4.00

4.00

4.00

4.00

0.20

4.00

Carbon monoxide

Carbon dioxide

1.50

Oxygen 0.50

Methane 88.40

1.50

88.90

1.50

88.90

1.50

88.80

1.50

88.86

2.50

0.40

88.40

Ethane

Ethene

4.00

Propane 1.00

Isobutane 0.20

4.00

4.00

4.00

4.00

2.50

■

Function

It is the job of the sampling probes to take a representative sample from the pipeline. It is important to ensure that this sample is extracted from the central third of the pipeline. One advantage of the retractable probes is that there is no risk of damage being caused to them when pigging is taking place in the pipeline.

There is also the option of reducing pressure directly at the sampling probe. This is especially advisable if sample preparation and gas analysis are not carried out directly next to the sampling point.

As a general rule, implementing a reduction in pressure reduces the sample pressure to between 10 kPa and 500 kPa. Heated pressure regulators must be used if the dew point could be fallen below in the process.

In the sample preparation system, pressure reducers and flowmeters can be used to set the sample flow and pressure that will ultimately be required. Electronic monitoring of the sample flow transmits an alarm signal to the SITRANS CV/MicroSAM if necessary. The filters ensure that the sample is appropriately clean.

An optional double block and bleed (DB&B) arrangement of the solenoid valves can ensure extremely safe isolation between the sample streams and the calibration gas. All versions of the sample preparation system are available for one, two or three flows plus the calibration flow.

The prepared sample is then analyzed in the natural gas analyzer and the calorific value, standard density and Wobbe index are calculated. Connecting the SITRANS CV/MicroSAM to a flow computer enables an energy value to be calculated from the measured quality and quantity with consideration of the pressure, temperature and flow measurement. SITRANS CV is preferably used in connection with flow computers. For the use of

MicroSAM, please consult the parent company.

In order to regularly carry out calibration and supply carrier gas to the SITRANS CV/MicroSAM, gases that are typically found in shelving or cabinet structures must be made available. Heating the gas cylinders prevents condensation from building up in them. The gas cylinder transfer station enables the cylinders to be exchanged during operation. Individual cylinders can be connected and disconnected by means of valves.

The communication functionalities of the SITRANS CV can be extended using a SIMATIC Extension Unit. It is then possible to connect a further Modbus master and/or up to 16 AO. For the generation of analog outputs in combination with MicroSAM, we recommend the I/O Extender solution (see catalog AP 01, section 3)

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4



Set CV

■


General information

Ambient temperature

Explosion protection

Supply voltage

-30 ... 55 °C (with heating)

ATEX Category II 2G, T3

230 V AC, 115 V AC or 24 V DC

Max. permissible pressure at input of high-pressure reduction

16 000 kPa

Max. permissible pressure at input of sample preparation system with pressure regulator

16 000 kPa

Max. permissible pressure at output of sample preparation system

10 ... 60 kPa above atmospheric pressure

Notice: Sample must not contain ethine!

Sampling

Lance

Special probe with BTU diaphragm and pressure reduction, non-retractable

Process connection

Outer diameter 6 mm and inner diameter

2 mm or outer diameter 12 mm and inner diameter

8 mm

Length 1 000 mm

Immersion depth approx. 380 mm

Protection pipe outer diameter 25.4 mm

High-pressure reduction in casing with pressure regulators, optional heating

At flange DN 65 PN 16 Form C, max. 1 600 kPa gas pressure

At flange DN 65 PN 160 Form E, max. 16 000 kPa gas pressure

At flange ANSI, 2-inch, 300 lbs RF

At flange ANSI, 2-inch, 2 500 lbs RF

Casing with dimensions 385 x 485 x 380 mm

Primary pressure 16 000 kPa, output pressure 100/170 kPa (power consumption 150 W)

Pipe base

Heated line

2-inch pipe base for free-standing transmitter box, 1 700 mm high

Heating power is 38 W per meter

Self-regulating heating up to approx. 80 °C

Outer material is PE corrugated hose with

43 mm outer diameter

Sample preparation for 1 to 3 sample gas flow, plus calibration gas flow

Basic configuration 0.5 µm filter, 3/2-way solenoid valve, flowmeter, overflow valve and stopcock

Pressure regulator, optional heating

Simple sample injection

Primary pressure 16 000 kPa, output pressure 100/170 kPa (power consumption 150 W)

One 3/2-way solenoid valve per sample gas stream

DB&B sample injection

On mounting plate

In protective casing

Protective casing heating

Pipe base

Additional filters

Two 3/2-way solenoid valves per sample gas flow

652 x 422 x 3 mm

750 x 520 x 430 mm

Power consumption 300 W

Adjustable between 10 and 40 °C, in increments of 5

2-inch pipe base, 1 700 mm high

Aerosol, glycol

System components

On mounting plate

In protective casing

Protective casing heating

Terminal box

Pipe base

Heated line

682 x 482 x 3 mm

800 x 600 x 480 mm

Power consumption 400 W

Adjustable between 10 and 40 °C, in increments of 5.

340 x 170 x 91 mm

2-inch pipe base, 1700 mm high


Self-regulating heating up to approximately

80 °C

Outer material is PE corrugated hose with 43 mm outer diameter

Gas supply

Transfer station

Pipe base

Gas cylinder cabinet

Cylinder heating

Cylinder pressure reducer

Heated line

Max. cylinder pressure 20 000 kPa

Output pressure 50 ... 1 000 kPa

2-inch pipe base, mounted

Height 2 200 mm

Gas cylinder cabinet for two 50 l carrier gas cylinders and one 10 l calibration gas cylinder. Dimensions are 1 250 x 400 x 2 050 mm

The cylinder heating system is dimensioned for 10 l calibration gas cylinders and ensures that no condensation occurs within the gas cylinder.

Cylinder pressure reducer for reducing primary pressure of max. 30 000 kPa to back pressure 0 … 400 kPa


Self-regulating heating up to approximately

80 °C

Outer material is PE corrugated hose with 43 mm outer diameter

Calibration gas

Gas mixture 1 ... 6 The gas mixture is stable for 36 months.

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© Siemens AG 2015



Set CV


CV set, probe (supplied separately) and high-pressure reduction


Explosion-proof version, in accordance with ATEX

Supply voltage

Without

230 V AC

115 V AC

Pneumatic connections

Metric

Imperial

Lance (length always 1 m)

Without

OD/ID 6 mm/2 mm

OD/ID 12 mm/8 mm

Process connection

Without

Flange DN 65 PN 16 Form C

Flange DN 65 PN 160 Form E

Flange ANSI, 2", 300 lbs RF

Flange ANSI, 2", 2 500 lbs RF

Analysis isolation

Without

Stopcock

DB&B

Probe installation

Without

Standard (without pressure reduction)

Removable (without pressure reduction)

Special installation (with pressure reduction)

High pressure reduction

Without

Separate high-pressure reduction box with mech. pressure regulators

Separate high-pressure reduction box with evaporation pressure regulator



Base for high-pressure reduction device

Protective top cover GRP

Preparation of heated line

Heated line from the high-pressure reduction box to the sample preparation device

(C03 + C03 = 2 m)

Separate stainless steel pipe 3 x 0.5 mm in 5 m intervals for connection to the sample preparation device (example: C04 + C04 = 10 m)

Article No.

7KQ2150-

7 7 7 7 7

-

7 7 7

Order code

B01

B02

B03

C03

C04

0

A

B

C

A

B

0

1

2

0

1

2

3

4

0

1

2

C

D

A

B

A

B

C

Cannot be combined

A A A

2

C

B03,

C03

4


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4

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Set CV


Sample preparation device, basic configuration



Supply voltage

Without

230 V AC

115 V AC


Metric

Imperial

Pressure adjustment

Without

Pressure regulator unheated for 1 sample flow

Pressure regulator unheated for 2 sample flows

Pressure regulator unheated for 3 sample flows

Pressure regulator heated for 1 sample flow

Pressure regulator heated for 2 sample flows

Pressure regulator heated for 3 sample flows

Sample gas pump (Ex) für 1 sample flow

Sample injection

Without

Standard for 1 sample flow (automatic)

Standard for 2 sample flows (automatic)

Standard for 3 sample flows (automatic)

For 1 sample flow in DB&B technology (automatic)

For 2 sample flows in DB&B technology (automatic)

For 3 sample flows in DB&B technology (automatic)

Monitoring the sample gas flow to the gas chromatograph

Visual, mechanical monitoring

With electrical monitoring

Plate/enclosure

Without

Mounting plate for wall mounting

GRP protective casing (unheated) for wall mounting

GRP protective casing (heated) for wall mounting

GRP protective casing (unheated) mounted on base

GRP protective casing (heated) mounted on base

Mounting plate mounted on base



Aerosol filter per sample flow with 5 replacement diaphragms

Glycol filter per sample flow with 10 replacement cartridges

Manual lab sampling per sample flow

Connection of second calibration gas through solenoid valve


Replacement filter element for sample flow filter (5 units)

A01

A02

A03

A04

B01

E01

Article No.

7KQ2151-

7 7 7 7 7

-

7 7

0

A

B

C

A

B

6

7

4

5

2

3

0

1

4

5

6

2

3

0

1

0

1

E

F

G

C

D

A

B

Order code

Cannot be combined

A A A

4

5

6

4

5

6

D

F

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© Siemens AG 2015



Set CV


System components



Supply voltage

230 V AC

115 V AC

24 V DC


Metric

Imperial

Plate/enclosure SITRANS CV

Without

On plate, with stopcock and connection pieces

In the GRP protective casing, unheated

In the GRP protective casing, heated

Electrical connection

Interface in accordance with technical data of SITRANS CV (free cable end)

Ex terminal box with standard terminals; 24 V DC connection

Ex terminal box with electrical sample gas monitoring; 24 V DC connection

Ex terminal box with electrical sample gas monitoring and standard sample injection;

115/230 V AC connection

Ex terminal box with electrical sample gas monitoring and DB&B sample injection;

115/230 V AC connection



Pipe bases for securing the enclosure without mounting plate/box



Heated line for sample preparation device/SITRANS CV (C01 + C01 = 2 m)

Installation kit (pipe/glands/cable) for connecting to the sample preparation device

Separate stainless steel pipe 3.0 x 0.5 mm or 3.18 x 0.56 mm (continuous) at 5 m intervals (example: C03 + C03 + C03 = 15 m)

Article No.

7KQ2152-

7 7 7 7 7

0

Order code

B01

B02

B03

C01

C02

C03

A

B

C

A

B

4

2

3

0

1

2

3

0

1

Cannot be combined

C C C

3

3

4

B03, C01

4


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4

© Siemens AG 2015



Set CV


Gas supply



Supply voltage

Without

230 V AC

115 V AC


Metric

Imperial

Automatic transfer station (stainless steel) with coils

Without

Installed on the mounting panel

Installed on the base

Installed in the metal cabinet

Installed in the metal cabinet with calibration gas cylinder heating

Cylinder pressure reducer for calibration gas

Without

Separate

Installed (base/metal cabinet)



2 contact pressure gauges for transfer station, only floating contact


Heated line for calibration gas from the cylinder cabinet to the sample preparation device (only with 115 V/230 V); length per meter (C01+C01 = 2 m)

Separate stainless steel pipe 3.0 x 0.5 mm or 3.18 x 0.56 mm (continuous) at 5 m intervals (example: C02+C02+C02=15 m)

A01

B03

C01

C02

Article No.

7KQ2153-

7 7 7 7 7

0

A

B

C

A

B

2

3

0

1

4

0

1

2

Order code


Calibration gas for SITRANS CV


Calibration gas in 10 liter cylinder

Mixture 1

Mixture 2

Mixture 3

Mixture 4

Mixture 5

Mixture 6

Article No.

7KQ2158- 0 A

7

0 0

D

E

B

C

F

G

Cannot be combined

A C01

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© Siemens AG 2015


Communication and software

Analyzer System Manager ASM

■

Overview

■

Application

ASM is a PC-based HMI system for monitoring, testing and management of analyzers in subsystems or in the complete plant. The relevant information of different analyzers is collected via various communications protocols and saved in a central database. Using the PC's user-friendly operator interface, it is possible to access measured value trends, device states and statistical evaluations, among others, or to start test routines for validation of the results. A comprehensive reporting module that can be tailored to customer requirements is available to document the evaluation.

■

Benefits

ASM is ideal for all systems and plants which require high reliability of the measured values and documentation for analyzer performance. Remote analyzers can also be monitored from a central workstation using various communications network protocols.

ASM is particularly suitable for use in the oil & gas, petrochemical, and chemical industries, and can be applied in new plants or also in existing plants to optimize the analyzer landscape.

■

Design

System design

• Monitoring, verification and management of different analyzers in a single system

• PC-based HMI system

• Visualization and operation of analyzers using a single-user system or distributed multiuser systems with redundant servers

• Visualization and operation is possible using a single-user system or distributed multi-user systems with redundant servers

• Assessment of the measured value reliability by testing the analyzers using various validation routines, e.g. based on the industry standard ASTM D 3764

• Logging and archiving of process and system data in a central database

• Integration of different analyzers in a uniform communications network

• Increase in analyzer online time by employing the line sample method

System software

• ASM is based on standard SIMATIC products

• Statistical evaluation of operating statuses and determination of key performance indicators (KPI) such as availability, error rate and maintenance frequency

• Microsoft SQL Server for archiving and data collection

• Microsoft Windows / Windows Server as the operating system

• Reduction in maintenance costs through device-specific planning, implementation and checking of maintenance work

Communication

• Documentation of the performance of individual analyzers up to the complete plant using the reporting module. The reports can be saved in the ASM or exported for further use.

• The Ethernet protocol serves as the communication basis for

ASM

• Integration of analyzers using PROFINET, ModbusTCP or OPC data exchange

• Analyzes without a communication interface can be integrated by connecting the signals to Siemens SIMATIC components

• Data exchange with other systems possible using OPC

Networking

• Siemens Scalance Ethernet switches for design of electrical and optical Industrial Ethernet in line and star structures; design in ring structures is possible to increase the fail-safety of the network

• ASM can be integrated in an existing Ethernet network

4

View of the process module


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© Siemens AG 2015




■

Function

General information

Information of the analyzers is collected over the communications network and saved in the central ASM database for further analysis. ASM is operated from a PCS 7 environment, and it is possible to navigate between overview screens, device-specific displays and general functions.

View of the maintenance module

4

Overview of analyzers in a plant

ASM has the following function modules for each analyzer for performing operator control and monitoring tasks:

Module

Process

Task

Provides a detailed overview of the selected analyzer. The current analyzer status, planned maintenance work, and configuration data are displayed. The current measured values are displayed in a table, historical values can be analyzed with the trend display using selectable time windows.

Validation Checking the reliability of the measured values of analyzers using various routines and methods. This test can be started automatically at specific intervals or manually by the ASM.

Calibration Carries out a calibration on the analyzer and monitors the results (this module is only available for analyzers which support remote calibration, e.g. Siemens MAXUM Ed. II, Siemens

MicroSAM, …).

Maintenance

Device-specific maintenance tasks can be specified here, their timing defined, and checked. Documentation such as maintenance procedures or manuals can be opened to support the maintenance work. The view of key performance indicators

(KPI) provides a fast overview of the analyzer's performance such as availability, error rate and maintenance frequency

Reporting This is a comprehensive function for producing customized reports. The module permits analysis of current and historical data in selectable time periods for documentation of the performance of individual analyzers up to the complete plant using the reporting module. The reports can be saved in the ASM or exported for further use.

Examples of generated reports

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Further functions are:

Function

SCADA

Network screen

Reference bottle management

Task

ASM provides all typical SCADA functions, for example:

• Password protection and different access privileges

• User administration

• Signaling, acknowledgment and archiving of alarms and events

Status display of the network devices. This overview displays the statuses of the Ethernet switches

(online/uncertain/fault). The analyzer alarms are integrated in the ASM signaling system.

Management and assignment of reference gas cylinders. This information serves as reference values for the validation using the reference sampling method.

Equipment engineering For configuring the analyzers. Among others, the analyzer-specific data is entered here, the type of validation is defined, and the number of measured values and units is entered.

MAXUM software

View of the validation module

Direct calling of the comprehensive Siemens configuration and operation software for Siemens MAXUM edition II and MicroSAM. It is then possible to access the connected analyzers for maintenance, configuration, or viewing of chromatograms.

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Operating system

Validation

• Windows for Client 7

• Windows 2008 Server

One of the core functions of ASM is checking the analyzers for reliability of the measured values. Two different methods of measurement are available for recording the values, namely the reference sample method and the line sample method. The resulting values can be checked using different evaluation methods

(based on ASTM D3764 or deviation). The objective of the validation is to recognize fluctuations and deviations with respect to a comparison value, and to thus permit a statement to be made on the reliability and drift of the measurement.

PC hardware requirements

• Processor type (recommended)

• RAM (recommended)

• Graphics card (recommended)

• Hard disk (recommended)

• Hard disk (free space for installation, recommended)

• DVD-ROM/ USB port

• Server: dual core, 3 GHz

• Client: Client: dual core, 2 GHz

• Server: 4 GB

• Client: 2 GB

1)

32 MB, 1280 x 1024

1)

• Server: 2 x 160 GB (Raid 1)

• Client: 80 GB

• Server: > 40 GB

• Client: > 1.5 GB

For software installation

Method of measurement: reference sample method

The analyzer is disconnected from the process gas, and a reference gas connected for measurement. The composition of this reference gas has previously been specified in the "Reference bottle management" of the ASM. ASM uses these values to determine the deviation between the measurement and the reference.

1)

Hardware requirement when using Microsoft Windows 7

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Please contact your Siemens sales partner for further information and for ordering.

Method of measurement: line sample method

With this method, a gas sample is extracted from the stream of sample gas to the analyzer, and analyzed in the laboratory. The resulting measured values are passed on to ASM and compared with the analyzer's measured values. With this method, the analyzer need not be disconnected from the process gas, and permanently remains available for the process measurement.

Evaluation based on ASTM D3764

Based on the international standard ASTM D3764, the results are checked using various statistical methods, including standard deviation, Dixon outlier test, and systematic error.

Evaluation using deviation method

Limit values are defined for this evaluation: the warning limit and the control limit. Simple rules are used to define how the reliability of the measurement is to be assessed when these limits are violated. For example, it can be defined that a single violation of the limit can be tolerated, but that repeated violation is an impermissible condition.

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Notes

© Siemens AG 2015

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Analytical Application Sets - Automation Technology

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