Continuous Gas Analysis In situ laser gas analyzers TÜV and MCERTS add-on for LDS 6 operating instructions Compact Operating Instructions

Transcription

1 Continuous Gas Analysis In situ laser gas analyzers Compact Operating Instructions 1 LDS 6 TÜV/MCERTS certified analyzers for NH3/H2O, NH3 and H2O 1.1 Operation requirements Please observe the following: 1. The LDS 6 measuring instrument requires a purge gas supply. 2. Temperature and pressure values of the measurement gas should be input into the LDS 6 for compensation. These values can be provided as a 4-20 ma analog signal or, if conditions are very stable, specified as a fixed value parameter. 3. To check linearity, zero point and reference point positions, a suitable measuring section and certified test gases, or the calibration verification kit provided by Siemens must be used. For safe and smooth operation we recommend to use the kit provided by Siemens. 4. Analyzers with type approval from TÜV/MCERTS are not allowed to be updated with any new software version not released by TÜV/MCERTS. 5. Maintenance intervals of the device: check the optics every 2 weeks for optical fouling and misalignment and every 9 months for zero and reference point drift. 6. Set the alarm level for the relative transmission due to fouling or sensor misalignment error reports to a minimum of 85 %. A decline of the transmission level may be a hint for a possible misalignment. 7. The protection class of the central unit housing is IP20. If the operational conditions should require a higher protection class install the central unit in a cabinet with an appropriate protection class. 8. H2O, O2 and CO2 compensation must be used during measurement with the LDS 6 systems but not during verification. 1.2 Test equipment Calibration gas equipment Two options are available to check the setting of zero and reference points and the linearity: 1. Calibration verification kits available from Siemens consisting of cells containing well-defined gas mixtures. 2. A test gas measuring section to be used with a certified sample gas provided by the end user Calibration verification kits Two kinds of kits are available from Siemens, one for customer use and one for use by accredited measurement institutes. To test the H2O adjustment cells similar to those for NH3 are used. The H2O cells contain gas mixtures of nitrogen and acetylene used as a water vapor equivalent. Siemens AG All rights reserved Siemens Parts 1

2 Figure 1-1 Calibration verification kit for customers (verification interval 9 months, to be calibrated every 3rd year) A5E (NH3) 1 28 mg/nm 3 NH3 cell (80% of range) A5E (H2O) 1 acetylene cell equivalent to 24 vol% H2O (80% of range) A5E (NH3 / H2O) 1 28 mg/nm 3 NH3 cell (80% of range) 1 acetylene cell equivalent to 24 vol% H2O (80% of range) 2

3 Figure 1-2 Calibration verification kit for accredited measurement institutes (verification interval 12 months, to be calibrated every 3rd year) A5E (NH3) 1 28 mg/nm 3 NH3 cell (80% of range) 1 21 mg/nm 3 NH3 cell (60% of range) 1 14 mg/nm 3 NH3 cell (40% of range) 1 7 mg/nm 3 NH3 cell (20% of range) A5E (H2O) 1 acetylene cell equivalent to 24 vol% H2O (80% of range) 1 acetylene cell equivalent to 18 vol% H2O (60% of range) 1 acetylene cell equivalent to 12 vol% H2O (40% of range) 1 acetylene cell equivalent to 6 vol% H2O (20% of range) Instructions for use can be found enclosed with the corresponding calibration verification kit. Siemens Parts 3

4 1.2.3 Using a different range on the LDS 6 The concentrations of the cells are given in % of the range, where the range for NH3 is 35 mg/nm 3 and for H2O 30 vol%. A prerequisite for the cells to show correct values is that the path length parameter on the LDS 6 is set to 5 meters. If different ranges than those given above are to be tested, the path length parameter should be adjusted. This is possible since the product of the shown concentration and the path length parameter always is constant. If for example the range is twice the default range, the path length parameter should be set to 2.5 meters which is half the default value. In this way the cell will show the same value expressed in % of the range Calibration certificate Depending on gas filling conditions the cell concentrations may deviate from the concentrations defined by the %-of-therange values. As an example an 80%-of-the-range cell for NH3 may show a slight deviation from the expected value of 28 mg/nm 3. The exact concentrations of the cells are measured at the factory and are stated on the calibration certificate which is enclosed with each calibration verification kit. 1.3 Recommendations for use in practice Test procedures The LDS 6 with TÜV/MCERTS type approval shall be tested according to the European guideline EN In addition to this usual test, the following procedures are suggested for performance of QAL3 (Ongoing Quality Assurance During Operation) and AST (Annual Surveillance Test) Check every 2 weeks Every 2 weeks check the optics for misalignment, transmission errors and optical fouling QAL3 Checks at maintenance intervals (9 months intervals). These checks include: 1. Regular visual check of the measuring instrument. 2. Regular check of the purge gas supply. 3. Check of the diagnostic values (transmission, temperature, pressure and path length). 4. Check of logbook entries. 5. Check of the system time (after a power failure the system time is reset). 6. Check of the alignment of the sensor unit using the LDS 6 alignment kit. 7. If necessary, cleaning of the optical surfaces and the purging tubes. 8. Check the zero point and reference point settings using zero gas and test gas over a gas measuring section or using the calibration verification kits A5E , A5E or A5E

5 1.3.4 Annual surveillance test These tests should be performed by a measurement institute accredited to 26, 28 of the German Federal Immission Protection Act (BImSchG). 1. Visually check the instrument including the sensor system. 2. Check the diagnostic parameters (relative and absolute transmission value, temperature, pressure, path length). 3. Check the optical surfaces and purging tubes and clean them if necessary. 4. Check the purge gas supply. 5. Check the alignment of the sensor unit using the alignment instrument. 6. Check the configuration parameters for cross sensitivity compensation for O2 and CO2, and the dynamic H2O compensation. 7. Check the effectiveness of the compensation parameters and assess the validity of the parameters. 8. Check the parameterization and functional capability of the pressure and temperature compensation. 9. Check the documentation (logbook entries, maintenance book). 10. Check the linearity using zero gas and test gas over a gas measuring section or using the calibration verification kits A5E and/or A5E Check the zero point and reference point settings using zero gas and test gas over a gas measuring section or using the calibration verification kits A5E , A5E or A5E Siemens Parts 5

6 2 TÜV/MCERTS certified LDS 6 analyzers for HCl/H2O and HCl 2.1 Operation requirements Please observe the following: 1. The LDS 6 measuring instrument requires a purge gas supply. 2. Temperature and pressure values of the measurement gas should be input into the LDS 6 for compensation. These values can be provided as a 4-20 ma analog signal or, if conditions are very stable, specified as a fixed value parameter. 3. To check linearity, zero point and reference point positions, a suitable measuring section and certified test gases, or the calibration verification kit provided by Siemens must be used. For safe and smooth operation we recommend to use the kit provided by Siemens. 4. Analyzers with type approval from TÜV/MCERTS are not allowed to be updated with any new software version not released by TÜV/MCERTS. 5. Maintenance intervals of the device: check the optics every 2 weeks for optical fouling and misalignment and every 9 months for zero and reference point drift. 6. Set the alarm level for the relative transmission due to fouling or sensor misalignment error reports to a minimum of 75 %. A decline of the transmission level may be a hint for a possible misalignment. 7. The protection class of the central unit housing is IP20. If the operational conditions should require a higher protection class install the central unit in a cabinet with an appropriate protection class. 2.2 Test equipment Calibration gas equipment Two options are available to check the setting of zero and reference points and the linearity: 1. Calibration verification kits available from Siemens consisting of cells containing well-defined gas mixtures. 2. A test gas measuring section to be used with a certified sample gas provided by the end user. 6

7 2.2.2 Calibration verification kits Two kinds of kits are available from Siemens, one for customer use and one for use by accredited measurement institutes. To test the H2O adjustment cells similar to those for HCl are used. The H2O cells contain gas mixtures of nitrogen and methane used as a water vapor equivalent. Figure 2-1 Calibration verification kit for customers (verification interval 12 months, to be calibrated every 3rd year) A5E (HCl) 1 12 mg/nm 3 HCl cell (80% of range) A5E (HCl / H2O) 1 12 mg/nm 3 HCl cell (80% of range) 1 methane cell equivalent to 24 vol% H2O (80% of range) Siemens Parts 7

8 Figure 2-2 Calibration verification kit for accredited measurement institutes (verification interval 12 months, to be calibrated every 3rd year) A5E (HCl) 1 12 mg/nm 3 HCl cell (80% of range) 1 9 mg/nm 3 HCl cell (60% of range) 1 6 mg/nm 3 HCl cell (40% of range) 1 3 mg/nm 3 HCl cell (20% of range) A5E (H2O) 1 methane cell equivalent to 24 vol% H2O (80% of range) 1 methane cell equivalent to 18 vol% H2O (60% of range) 1 methane cell equivalent to 12 vol% H2O (40% of range) 1 methane cell equivalent to 6 vol% H2O (20% of range) Instructions for use can be found enclosed with the corresponding calibration verification kit. 8

9 2.2.3 Using a different range on the LDS 6 The concentrations of the cells are given in % of the range, where the range for HCl is 15 mg/nm 3 and for H2O 30 vol%. A prerequisite for the cells to show correct values is that the path length parameter on the LDS 6 is set to 1 meter. If different ranges than those given above are to be tested, the path length parameter should be adjusted. This is possible since the product of the shown concentration and the path length parameter always is constant. If for example the range is twice the default range, the path length parameter should be set to 0.5 meters that is half the default value. In this way the cell will show the same value expressed in % of the range Calibration certificate Depending on gas filling conditions the cell concentrations may deviate from the concentrations defined by the %-of-therange values. As an example an 80%-of-the-range cell for HCl may show a sight deviation from the expected value of 12 mg/nm 3. The exact concentrations of the cells are measured at factory and are stated on the calibration certificate which is enclosed with each calibration verification kit. 2.3 Recommendations for use in practice Test procedures The LDS 6 with TÜV/MCERTS type approval shall be tested according to the European guideline EN In addition to this usual test, the following procedures are suggested for performance of QAL3 (Ongoing Quality Assurance During Operation) and AST (Annual Surveillance Test) Check every 2 weeks Every 2 weeks check the optics for misalignment, transmission errors and optical fouling QAL3 Checks at maintenance intervals (12 months intervals). These checks include: 1. Regular visual check of the measuring instrument. 2. Regular check of the purge gas supply. 3. Check of the diagnostic values (transmission, temperature, pressure and path length). 4. Check of logbook entries. 5. Check of the system time (after a power failure the system time is reset). 6. Check of the alignment of the sensor unit using the LDS 6 alignment kit. 7. If necessary, cleaning of the optical surfaces and the purging tubes. 8. Check of zero point and reference point settings using zero gas and test gas over a gas measuring section or using the calibration verification kits A5E or A5E Siemens Parts 9

10 2.3.4 Annual surveillance test These tests should be performed by a measurement institute accredited to 26, 28 of the German Federal Immission Protection Act (BImSchG). 1. Visually check of the instrument including the sensor system. 2. Check the diagnostic parameters (relative and absolute transmission value, temperature, pressure, path length). 3. Check the optical surfaces and purging tubes and clean them if necessary. 4. Check the purge gas supply. 5. Check the alignment of the sensor unit using the alignment instrument. 6. Check the parameterization and functional capability of the pressure and temperature compensation. 7. Check the documentation (logbook entries, maintenance book). 8. Check the requirements for cross interference compensation (< 4%) for conformance. Doing so it must be considered that the concentration limit for methane is 15 mg/m Check the linearity using zero gas and test gas over a gas measuring section or using the calibration verification kits A5E and/or A5E Check the zero point and reference point settings using zero gas and test gas over a gas measuring section or using the calibration verification kits A5E or A5E A Appendix Product information on the internet The instructions are also available on the internet as a part of the range of technical documentation, online catalogs, and the online ordering system for process analytics products and systems at ( Here you will find: Products & solutions, including our newsletter containing up-to-date information on your products. Electronic trading over the Internet. Support with e.g. certificates, brochures and catalogs. Siemens AG Industry Sector Postfach NÜRNBERG 10 A5E , 05/2013