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Revision 1

6/27/2017

Section 8

The Product Quality Assurance Program

8.1 Overview

The Galvanic Applied Sciences product quality assurance program is designed to ensure that

the system meets all manufacturing specifications and is built to meet the customer’s specific

requirements. This chapter consists of a number of forms which provide the overall QA

procedure and should be retained.

8.2 Overall System Identification

Proposal

Purchase Order Number

Sales Order Reference

Serial Number

Customer Name

Facility Address

Primary Contact Name

Primary Contact Telephone Number

Primary Contact e-mail

Inspection

Software Revision

Summary of Contents for 943-TGS

Page 1: ... Gas Analysis Split Oven OPERATION MANUAL P N MA7474 Revision 1 June 27 2017 Galvanic Applied Sciences Inc 7000 Fisher Road S E Calgary Alberta T2H 0W3 Canada Phone 403 252 8470 Fax 403 255 6287 E mail info galvanic com World Wide Web http www galvanic com ...

Page 2: ...this manual is subject to change without notice and does not represent a commitment on the part of Galvanic Applied Sciences Inc No part of this manual may be reproduced or transmitted in any form or by any means without the written permission of Galvanic Applied Sciences Inc Note Changes or modifications not expressly approved by Galvanic Applied Sciences Inc could void the user s authority to op...

Page 3: ...Flanges 20 2 4 4 Connection of the Interconnecting Cables 22 2 4 5 Installing the Fiber Optics Cables 22 2 4 6 Connection of the AC Power Service 26 2 4 7 Connection of the Analog Signal Cables 26 2 4 8 Connection of the Digital Signal Cables 27 2 4 9 Connection of Instrument Air Services 27 2 4 7 Connection s of Steam 27 2 4 8 Connection of the Loss of Purge Signal 27 SECTION 3 OPERATION 28 3 1 O...

Page 4: ... 52 5 2 1 1 Value Display 52 5 2 1 2 Status and Control 53 5 2 1 3 Relay Indicator Fields 54 5 2 1 4 Graphic Display 55 5 2 2 Calibration Matrix Page 56 5 2 3 Indicators Page 57 5 2 4 Spectrum Curve Page 58 5 2 5 Absorbance Page 59 5 3 PARAMETERS SECTION 61 5 3 1 Parameters 61 5 3 2 Modbus 62 5 3 2 1 Overview 62 5 3 2 2 The Enron Modbus Protocol 64 5 3 2 3 The Modicon 16 Protocol 64 5 3 2 4 Modico...

Page 5: ...Y 89 7 10 SPECTROMETER REPLACEMENT 90 SECTION 8 THE PRODUCT QUALITY ASSURANCE PROGRAM 91 8 1 OVERVIEW 91 8 2 OVERALL SYSTEM IDENTIFICATION 91 8 3 QA DOCUMENT PACKAGE CHECK LIST AND REQUIREMENTS 92 SECTION 9 DRAWINGS 93 SECTION 10 SPECIFICATIONS 102 SECTION 11 RECOMMENDED SPARE PARTS 103 SECTION 12 THE PERIPHERAL BOARD 105 12 1 ACCESSING THE BOARD 105 12 2 THE STATUS TAB 106 12 2 1 Information on t...

Page 6: ...n 1 6 6 27 2017 Tables TABLE 6 1 NORMAL VALUES OF KEY OPERATING PARAMETERS 69 TABLE 7 1 ANALYZER FAULT TABLE 78 TABLE 8 1 DOCUMENT PACKAGE CHECK LIST 92 TABLE 11 1 ONE YEAR KIT 104 TABLE 11 2 TWO YEAR KIT 104 ...

Page 7: ...indicates a hazardous situation that if not avoided could result in death or serious injury The Caution symbol with the safety alert symbol indicates a hazardous situation that if not avoided could result in minor or moderate injury The Notice symbol is used to highlight information that will optimize the use and reliability of the system Applies to the 943 TGS CE only 943 TGS CE ...

Page 8: ...mentation of these suggested procedures This system when operating in its normal mode and or when it is being serviced maintained installed and commissioned contains items which may be hazardous to humans if handled or operated incorrectly or negligently These items include but are not limited to High Voltage Electrical Energy Toxic and Explosive Gases Intense Ultraviolet Radiation High Temperatur...

Page 9: ...he condensation of sulfur Maintenance performed before the cooling of the oven and hardware should be done while wearing suitable protective clothing eye wear and gloves to prevent burns to the hands and arms The system includes an Ultraviolet spectrometer which employs a source that generates intense UV radiation that is transmitted to the measurement cell and spectrometer through fibre optic cab...

Page 10: ...lity transportation charges prepaid or accept the return of the defective Product and refund the purchase price paid by Buyer for that Product If requested by Buyer Seller will use its best efforts to perform warranty services at Buyer s facility as soon as reasonably practicable after notification by the Buyer of a possible defect provided that Buyer agrees to pay for travel time mileage from the...

Page 11: ...he processor or software or firmware will be uninterrupted or error free The warranty herein applies only to Products within the agreed country of original end destination Products transferred outside the country of original end destination either by the Seller at the direction of the Buyer or by Buyer s actions subsequent to delivery may be subject to additional charges prior to warranty repair o...

Page 12: ...in factor F when the operating ratio Rop is two 2 When the plant specific gain factor F is established for a particular process the units of Air Demand become percent change required in process air i e a computed Air Demand of 1 5 means that the process is 1 5 excess in air To achieve optimum performance of the Claus Sulfur Recovery Plant the Air Demand should be kept near zero The sample gas obta...

Page 13: ...iber optics cables power cables and RTD signal cables run between the two cabinets The two cabinets can be mounted a distance apart such that the length of the fiber optics cables does not exceed 6 meters 1 4 Sampling System The Analyzer system utilizes a close coupled mounting arrangement of the measurement cell to the tail gas process sampling point to minimize the sample system length The short...

Page 14: ...rolled by a dedicated data acquisition system which provides supervisory control performs all calculations and provides the user interface The system includes an onboard computer system which provides a graphic display of key system control parameters and their status a digital display of the instantaneous value of the Air Demand H2S SO2 and COS and historical graphic displays of the Air Demand H2...

Page 15: ...utine operation of the analyzer Section 8 Maintenance and Troubleshooting includes a discussion of required maintenance activities and presents information that is useful in diagnosing problems with the analyzer Section 9 Wiring Book includes information about interfacing auxiliary components such as relays solenoids etc to the controller module Section 10 Spare Parts lists a number of items which...

Page 16: ...ment 2 2 1 Electrical Requirements The power input is 100 240 V 1 phase 50 60 Hz 800 W The operating voltage is specified on the serial number name plate 2 2 2 Temperature The system is designed to be operated at ambient temperatures from 20 oC to 60 oC Galvanic offers complete analyzer shelters from sun shades to complete building please contact Galvanic Applied Sciences Inc or your local represe...

Page 17: ...hat no major damage has occurred If damage has occurred contact the shipping company and Galvanic Applied Sciences Place the small packages and the sample probe aside in a safe secure storage area as they are not needed at this stage of the system installation The control cabinet weighs approximately 62 kg and the oven cabinet weighs approximately 60 kg Use suitable precautions when removing it fr...

Page 18: ...ce claim or equipment warranty k If no damage is apparent the analyzer system is ready for transport to the installation sample point site 2 4 Installation Steps The user should read each step and make certain that it is fully understood before proceeding to installing the analyzer 2 4 1 Mounting of the Oven Cabinet The oven cabinet is supported by a cradle that mounts to the process pipe structur...

Page 19: ...Revision 1 19 6 27 2017 The Steam jacketed ball valve must remain closed until the sample probe is installed and connected in the sample handling oven Figure 2 1 Oven Cabinet Dimensions ...

Page 20: ...yzer is shipped with a 316 SS blind flange plate and gasket mounted inside the oven compartment to prevent the process gas from flowing into the compartment before installation of the sample probe assembly Check to ensure that this blind flange is in place and secure 943 TGS CE Refer to the 943 TGS CE User Manual Section 2 7 2 ...

Page 21: ... so that it provides a minimum of 25 penetration into the process pipe The diameter of the pipe is provided by the customer If all of the above conditions are satisfied a Put the new gasket in place and move the analyzer system into position placing the four 4 bolts through the steam jacketed nozzle flange holes b Place the four 4 nuts onto the bolts and tighten c Inspect the flange connection usi...

Page 22: ...l have deemed the atmosphere to be safe breathing apparatus may now be removed 2 4 4 Connection of the Interconnecting Cables All interconnecting electrical cables must comply with local standards Heater Power Refer to drawing 9 5 in Section 9 of this manual for heater power connection detail Solenoid Control Refer to drawing 9 5 in Section 9 of this manual for the solnoid valve control connection...

Page 23: ...Revision 1 23 6 27 2017 Figure 2 3 Potted Fixture Figure 2 4 Control Cabinet Fiber Optics Entries ...

Page 24: ...e Spectrometer as shown in Figure 2 5 Figure 2 5 Fiber Optics Cables Connections Inside Control Cabinet Route the fiber optics cables from the control cabinet to the oven cabinet Pass the fiber optics cables into the oven enclosure entries located at the rear of the oven enclosure as shown in Figure 2 6 ...

Page 25: ...igure 2 6 Fiber Optics Cables Entries for the Oven Enclosure Connect the Source Fiber to the top of the measurement cell inside the oven and the Spectrometer Fiber into the bottom of the measurement cell as shown in Figure 2 7 ...

Page 26: ...iber Optics Cables Connection Inside Oven Enclosure 2 4 6 Connection of the AC Power Service 2 4 7 Connection of the Analog Signal Cables 943 TGS CE Refer to the User Manual Section 2 7 4 943 TGS CE Refer to the User Manual Section 2 7 5 ...

Page 27: ...ervices 2 4 7 Connection s of Steam 2 4 8 Connection of the Loss of Purge Signal 943 TGS CE The loss of purge is an integral function of the purge controller 943 TGS CE Refer to the User Manual Section 2 7 6 943 TGS CE Refer to the User Manual Section 2 7 8 943 TGS CE Refer to the User Manual Section 2 7 7 ...

Page 28: ...r streams Flow adjustment valves for the zero purge gas flow rate the aspirator drive air flow rate and the sulfur condenser air flow rate are provided and located according to Oven Cabinet Component Locations drawing All valves are clearly labeled according to their title and function The Flow Diagram drawing provides a schematic of the flow streams in the analyzer system Isolation on off block v...

Page 29: ...operation is NOT the sulphur vapour concentration in the process sample gas The desired situation is that the concentration of the sulphur vapour in the process sample gas exiting the sample probe is lower than with the probe cooling air off without causing plugging of the sample probe 3 2 3 Zero Air Flow Adjust Valve The Zero Air Flow Adjust Valve controls the flow rate of air used in the zeroing...

Page 30: ...equired the system regulator may be adjusted to its maximum output of 50 psig without harming the analyzer 3 3 Analyzer Outputs The 943 TGS analyzer generates both analog and digital output signals for connection to the users plant control system The analog signals include the calculated Air Demand and the measured concentrations of H2S SO2 and optionally a user selectable signal for analog output...

Page 31: ... be in the Normal state only when ALL of the following are true the analyzer is receiving mains power the cell temperature is between the cell Low Alarm temperature and High Alarm temperature set points the probe temperature is between the probe Low Alarm and cell High Alarm temperature setpoints or the sulphur vapour signal is less than the High Svap alarm the last spectrometer Measure scan was w...

Page 32: ...or returns to the Run state d Control Manual Auto Indicator The Control Manual Auto output indicates the validity of the analog output signals When this indication is in the Auto state the analyzer believes that output data are real and current measurements of the tail gas process stream Under conditions where the validity of the output data is suspect the analyzer places the Control flag in the M...

Page 33: ...board Display and Hand Held Keypad 4 2 1 The Onboard Display The main screen of the onboard display is presented in Figure 4 1 There are six panels which are accessed via pressing the Panel Prev or Panel Next buttons on the keypad Figure 4 2 The various panels are described in Section 4 3 4 8 The main panel presents the present air demand historical air demand the present level of various gases st...

Page 34: ...erican version of the analyzer Figure 4 2 Hand Held Keypad North American Version The buttons on the keypad provide the following Panel Prev Changes the active panel to the previous panel Panel Next Changes the active panel to the next panel Field Prev Moves the cursor to the previous entry on the active panel for editing Field Next Moves the cursor to the next entry on the active panel for editin...

Page 35: ...Sample Del Deletes the last numerical value Exit Erases the current input Enter Used to enter numerical information on various tabs 4 3 The Analysis 1 Tab The Analysis 1 tab Figure 4 1 presents a summary of the present status of the system 4 3 1 Online Offline Button Clicking the Online Off Line button changes the status from On Line green to Off Line red and vice versa When the analyzer is change...

Page 36: ...ors show the state of the analyzer outputs a Status Normal Green status indicates that the system is working properly Fault Red status indicates that the computer has detected an error in one of the critical analyzer functions The Status indicator and alarm relay are placed in a fault state The analyzer will go into the backpurge mode and instrument air will flow through the cell An occurrence of ...

Page 37: ...b Zero gas is introduced into the measurement cell and is allowed to purge the measurement cell for the number of seconds specified by the Zero Purge Interval configuration parameter Section 4 8 c At the conclusion of the Zero Purge Interval the computer averages the last ten 10 spectrometer scans and determines a new reference scan vector captures the new zero value d The analyzer waits for the n...

Page 38: ...e analog output concentration The default full scale values are determined at software restart to a range between the configured full scale analog output value for the Air Demand signal Figure 4 4 Analysis 2 Panel The default full scale values and the time scale can be set on the Config panel Section 4 8 using a range between 0 and the configured full scale analog output concentration The default ...

Page 39: ...the items is indicated on the right side and the last 25 events are indicated on the grid Green System is functioning within the accepted range Yellow System requires service Red System is not functioning properly To clear the present display use the Field Next or Field Prev buttons to activate the Clear Fault Warning History button and press Esc Figure 4 5 Indicators Panel ...

Page 40: ...ime refers to the period of time for which the data is collected to provide a data point See Section 6 4 for information about how to optimize the spectrometer signal The optimum integration time for the present set of conditions can be obtained by pressing the Optimize Integ Time button If desired the operator can select the integration time by selecting the Set Integ Time button which will prese...

Page 41: ...tory If the Show Factory Reference check box is selected the spectrum will be superimposed on the same set of axes as the active spectrum Figure 4 7 Figure 4 8 Factory Reference Spectrum Superimposed on Spectrum New Reference saves the scan to be used as a reference for calculation without running a Zero Calibration The analyzer must be backpurging zero gas before this feature can be used ...

Page 42: ...g wavelength for the analysis and is spectrometer dependent Dark Level the signal from dark current 4 7 Absorbance Panel The Absorbance panel Figure 4 8 presents the Absorbance spectrum and reports the concentration of H2 S SO2 COS and Svap The range can be edited on the Config panel Section 4 8 Figure 4 9 Absorbance Tab ...

Page 43: ...t a broad range of operating parameters and includes 8 sub panels The Configuration Panel should be accessed only by qualified personnel 4 8 1 Outputs Sub Panel The Outputs sub panel Figure 4 9 is used to define analog outputs and SVAP control Figure 4 10 Outputs Sub Panel ...

Page 44: ...is to hold the last valid reading while the analyzer is in back purge or performing a zero calibration Full Scale Enter the value of the desired full scale for the output 4 8 2 Calculation Sub Panel The Calculation sub panel Figure 4 10 is used to set a broad range of calibration parameters Figure 4 11 Calculation Sub Panel To edit a parameter use the Field Prev or Field Next button to access the ...

Page 45: ...and should be kept near zero c H2S Span This parameter specifies the span factor utilized for the H2S concentration display and output This value should always be close to 1 0 Any deviation of the H2S span parameter will impact the output calibration of the analyzer d SO2 Span This parameter specifies the span factor utilized for the SO2 concentration display and output This value should always be...

Page 46: ... the analyzer will use the pressure indicated here when calculating the concentration of the various gases If the x is not present the analyzer will use the live value for cell pressure when calculating the concentration of the various gases 4 8 3 Display The Display sub panel Figure 4 11 is used to set the X and Y range for the display on the Analysis 1 and Analysis 2 panels Figure 4 12 Display S...

Page 47: ...values that were used before the start of the editing process 4 8 4 Timers Alarms The Timers Alarm panel is presented in Figure 4 12 Figure 4 13 Timers Alarms Sub pane To edit a parameter use the Field Prev or Field Next button to access the field A dialog box similar Figure 4 6 will be presented Enter the desired value for the parameter via the keypad and press Enter When all desired changes have...

Page 48: ...ss sample gas is aspirated into the measurement cell and the concentration outputs climb to actual readings At the expiration of this interval relay outputs and indicators are returned to a valid data state This value is typically fifteen 15 seconds b Temperature Control Cell Setpoint This parameter specifies the temperature control setpoint of the measurement cell in degrees C ºC This set point i...

Page 49: ...e temperature falls below this value the analyzer is placed in a Fault Delay condition The relay outputs and Status indicator are forced to Fault and the Control indicator is forced to Manual There is a three 3 degree deadband imposed on this alarm The alarm will clear when the measured probe temperature rises to more than 3ºC above the set point If at the time of clearing no other fault condition...

Page 50: ...Revision 1 50 6 27 2017 Figure 4 14 Network Sub Panel ...

Page 51: ...f the analyzer into the address line of any web browser Changes that are made via the Web GUI and saved to the analyzer will be shown on the local display When communication between the remote computer and the analyzer is established the Analysis page is presented The left side of the page contains a menu which is used to access the various pages of the program and the right side presents informat...

Page 52: ... concentration of SO2 COS The present value of the concentration of COS CS2 The present value of the concentration of CS2 Optionally Sulfur Vapor The present value of the concentration of Sulfur vapor Cell Pressure The pressure inside the measuring cell Cell Temperature The present temperature of the measuring cell in degrees C ºC Probe Temperature The present temperature of the probe outlet gas i...

Page 53: ...ired under normal circumstances on an installed analyzer The calibration sequence is identical whether trigger manually or automatically When triggered the calibration sequence proceeds in the following order a The Mode relay outputs changes to Calibrate and the Control relay changes to Manual b The zero gas solenoid is de energized and zero gas is introduced into the measurement cell The zero gas...

Page 54: ...t service is not required Warning Red Flashing indicates that the computer has detected that one of the parameters for a warning condition is out of range This indicates that service is requested but not required immediately The analyzer continues to function normally producing usable outputs c Mode Run Green status indicates that the system is in Run mode Calibrate Red Flashing indicates that a z...

Page 55: ...ed once per second Figure 5 3 The latest reading is at the extreme right of the plot Figure 5 3 Air Demand Trend and H2S SO2 Trend Plots If desired the Y axis scaling can be changed Right click on the plot to present a dialog box Figure 5 4 in which the desired Ymin and Ymax can be entered Figure 5 4 Y Axis Range Dialog Box ...

Page 56: ...the calibration matrix used by the spectrometer for the analysis of the gas Click on the page to present the calibration matrix used by the spectrometer Figure 5 3 in the determination of the gas concentrations The calibration matrix is uniquely determined for a particular spectrometer Figure 5 5 Calibration Matrix ...

Page 57: ...h the specific spectral resolution and sensitivity characteristics of a particular spectrometer The purpose of displaying the contents of the calibration matrix is to provide a means of matrix identification should the need arise 5 2 3 Indicators Page The Indicators page Figure 5 6 is used to present details of the last 25 fault and warning events The last 25 events are indicated on the grid and t...

Page 58: ...rve The X and Y coordinates of a data point on the curve can be determined by moving the mouse over the desired point on the spectrum The Display Factory Reference check box is used to indicate that the factory reference spectrum should be superimposed on the collected spectrum This feature is useful in checking the system The Peak Height First Vector Pixel and Dark Level refer to the instantaneou...

Page 59: ...n Backpurge mode before the spectrometer s integration time can be optimized If desired the operator can select the integration time by selecting the Set Integ Time button this will present the Integration Period dialog box to set the time The Panorama field can be used to select a sub section of the spectrum for viewing To zoom in on a section of the spectrum click the Stop Polling check box and ...

Page 60: ...iewed The Stop Polling box must be checked before the Panorama View can be used to zoom in on areas of the absorbance curve If desired the operator can edit the Y by selecting the Change Absorbance Curve Display Y Axis button This will present a dialog box to enter the desired upper and lower limits similar to Figure 5 2 The present concentration of each gas is indicated on the bottom of the page ...

Page 61: ...edited Figure 5 9 Parameters Page When the page is opened the Read Only mode is active The pink background color groups all temperature related parameters The blue background color groups all concentration related parameters The gray background color groups all timer zero operation related parameters The green background color groups all other parameters ...

Page 62: ...mented in the analyzer Pressing the Revert button before pressing the Save to Unit button will undo the edit 5 3 2 Modbus 5 3 2 1 Overview The Modbus page Figure 5 10 allows the user to set up the tail gas analyzer to output data in 3 varieties of MODBUS communication protocol Enron Modicon 16 and Modicon Floating Point As there are a large number of possible configurations for Modbus and every us...

Page 63: ...alog box Figure 5 11 Figure 5 11 Modbus Type Dialog Box Select the desired Modbus type and press OK As an example if the ENRON selection is made the presentation appears as shown in Figure 5 12 Figure 5 12 MODBUS ENRON Format The bottom two lines of the page include a number of items that relate to communications parameters The user should indicate the desired Modbus address for the analyzer in th...

Page 64: ...would be off and if the value is 1 the status would be on Short integers are 16 bit whole numbers with either positive or negative sign Long integers are 32 bit whole numbers with either positive or negative sign Floating point values are also 32 bit numbers but unlike the integers they do not have a sign but they do have decimal points 5 3 2 3 The Modicon 16 Protocol A Modicon 16 Modbus list cont...

Page 65: ...ill appear The default password is 9713 b Click on the parameter that requires editing The field for that parameter will change to a white background c Edit the parameter by typing in a new value Some parameters such as Fixed Temperature Enable can be edited by using the pull down selection menu d Press Enter on the keyboard e Press the Save to Unit button This will cause the changed parameters to...

Page 66: ...hange the operator password a Click on the Change to Update Mode field and enter the factory password The default factory password is 9713 b Click on the Change Password button The Change Password dialog box will be presented as shown in Figure 5 12 Leave the Factory Password box unchecked c Enter the current operator password in the Enter Old Password field Enter the desired new password in each ...

Page 67: ...rogram These are reproduced as Chapter 9 of this manual 5 5 2 User Manual This manual can be accessed via the User Manual page 5 5 3 Revision History The Revision History page Figure 5 15 presents the release ID number of the software Please refer to it when making inquiries about the system Figure 5 15 Revision History ...

Page 68: ...ers displayed on the front panel of the analyzer and verification of certain flow change of various gases and response changes on the analyzer Section 6 2 1 Weekly performance of the Maintenance Check out Procedure Section 6 2 2 The operator should complete the Maintenance Record Sheet included in this section and maintain a file of record sheets to provide a time based record of system operation ...

Page 69: ... Range Green Dark Range Green I O Board green 5 Cell Temperature Typical Cell Temperature 150o C 302oF Analysis 2 Panel Digital Indicator within set point 6 Probe Temperature Typical Cell Temperature 150o C 302oF Analysis 2 Panel Digital Indicator within set point This parameter is used only when a probe RTD is installed and the Control with RTD function is selected 7 Cabinet Temperature Analysis ...

Page 70: ...his offset from zero will vary based on length of time since the last calibration cycle whether manual or automatic d Access the Spectrum panel Observe the raw scan signal and compare the shape of the scan trace to the standard Note any extreme deviations from the standard scan trace Record the peak value of the trace in approximate A D counts 1 000 e If the signal peak height is less than 16 000 ...

Page 71: ...e Integration Period Air Demand H2S SO2 Forced Zero On Time to Stabilize Air Demand H2S SO2 Spectrum Spectrum Peak Height Standard Spectrum Shape Yes No Optimize Integration Time Yes No New Integration Time Configuration Configuration Changed Yes No New Configuration Saved Yes No Forced Zero Off Time to Stabilize As Left Fault Condition Cell Temperature Cabinet Temperature Cell Pressure Integratio...

Page 72: ...each 32 000 counts the most probable cause is degraded Anti Solarant Solution Wear protective UV eye glasses at all times if the optical fibres are removed while the UV Source is powered up The control cabinet door should NOT be opened while the analyzer is energized UNLESS the area is known to be non hazardous The Anti Solarant Solution is to be changed only by authorized personnel The fluid hold...

Page 73: ...older to remove any air bubbles that may form Take care not to touch the Anti Solarant Solution directly as the oils from your hands will contaminate the solution i Replace the fluid holder filler plug j Replace the fluid holder into the bracket Orient the fluid holder so that the face with the word LAMP engraved on it is towards the UV Lamp Supply DO NOT touch the fluid holder windows as dirt gre...

Page 74: ...tion will always target 32000 counts Before proceeding with either procedure below ensure that the analyzer is Off Line and is being purged with zero gas 6 4 1 Automated Optimization a Place the analyzer in back purge mode This can be done by accessing the Back Purge field on the Analysis 1 panel and pressing Enter to place an X in the box b Access the Spectrum panel navigate to the Optimize Integ...

Page 75: ...e peak height is 32 000 counts 1000 counts e Once the peak height has been optimized record the peak height value and the resulting integration period f Return to the Analysis 1 panel g Request a Manual Zero by pressing the Manual Zero button and pressing Enter f Remove the Zero mode by navigating to the Sample field and pressing Enter to put an x in the box thus allowing the analyzer to return to...

Page 76: ...yzer For Service and or Assistance Contact Galvanic Applied Sciences Inc 7000 Fisher Road SE Calgary Alberta T2H 0W3 Canada Tel 403 252 8470 TOLL FREE CANADA US 1 866 252 8470 Fax 403 255 6287 Email info galvanic com For service emergencies please phone our 24 hour technical support cell phone at 1 403 651 0344 7 2 Analyzer Fault Table The Indicators panel Figure 7 1 presents a running record of t...

Page 77: ...Revision 1 77 6 27 2017 Figure 7 1 Indicators Panel The Analyzer Fault table is presented in Table 7 1 and a listing of some other issues that may be observed is presented in Table 7 2 ...

Page 78: ...communicating with the controller board Check ArcNet wiring Cabinet Temperature RTD problem Computer temperature control is malfunctioning Air supply to Vortec cooler is turned off High Absorbance The H2S and or SO2 concentration is out of range The analyzer is not zeroed High Integration Period UV lamp is nearing the end of its useful life see Section 7 3 UV lamp is not operating see Section 7 3 ...

Page 79: ...ed below The normal lifespan of a UV Source Lamp is about six 6 months but longer life spans are possible in circumstances where the restart count is low The lamp life is inversely proportional to the number of restarts on a particular lamp and the lamp should not be turned off and on often An iris is installed on the lamp holder between the lamp and the fluid holder The iris is preset at the fact...

Page 80: ... Supply fuse ACTS 28 or place the UV Lamp power switch to the Off position see Figure 7 2 for the location of the switch e Remove the UV Lamp Power Supply cabinet lid by removing the four 4 s and pulling the cabinet lid towards you f Remove the two 2 plastic hole plugs from the top of the UV Lamp Power Supply to gain access to the lamp retaining screws g Disconnect the three 3 lamp connection wire...

Page 81: ...tic plugs m Reconnect the three 3 wires from the lamp to the terminal strip Connect Red to Red Blue to Blue and Black to Black If the lamp has two 2 black wires connect one of the Black wires to the Blue terminal n Reinstall the UV Lamp Power Supply cover Tighten the cover cap screws o Reconnect the AC terminal block fuse terminal on terminal block ACTS 28 by pressing down and snapping it into pla...

Page 82: ...urge field on the Analysis 1 page and pressing Enter to place an x in the box c Access the purged control cabinet following proper user company and or regulatory agency procedure The control cabinet door may NOT be opened while the analyzer is energized UNLESS the area is known to be non hazardous Observe all the warning labels on the analyzer enclosures DO NOT disconnect and or replace Fibre Opti...

Page 83: ...y pushing the fibre end into the SMA connector Hand tighten the nut l Route the fibre out of the oven making sure that the fibre is routed in the indents to avoid damage when the oven compartment cover is secure m Replace the oven compartment cover and securely fasten both latches n Slide the end of the new Fibre Optic Cable through the sealing retaining cap the rubber seal and the fitting o Conne...

Page 84: ...working with hot surfaces or wait until surface have cooled to safe temperatures before performing maintenance tasks The control cabinet door may NOT be opened while the analyzer is energized UNLESS the area is known to be non hazardous Observe all the warning labels on the analyzer enclosures Procedure a Click the On Line Off Line switch to indicate that the system is Off Line b Place the analyze...

Page 85: ...es in a location where the ends of the cables cannot not make contact with anything It is recommended that the ends be covered with the orange protectors after the fibres have cooled j Loosen one of the cell tubing fittings to vent positive pressure zero gas that may be trapped in the sample system k To remove the measurement cell assembly disconnect the three 3 interconnecting tubing lines These ...

Page 86: ...ur 4 sided nut Leave the SMA fibre connector in place in the cell end cap body c Remove the top O ring If it is not on the cell window then it will be in the end cap O ring groove Discard if there is any sign of damage or deformation d Turn the measurement cell over holding your hand over the open end and gently shake until the cell window drops into your hand Set the window aside on a clean surfa...

Page 87: ...n Section 7 8 7 8 Measurement Cell Installation Refer to the Flow Diagram the Sample System Components and the Measurement Cell Assembly drawings while performing these steps The measurement cell is to be removed by trained and authorized personnel only The oven compartment and all of its components are HOT 150o C Wear appropriate personal protective equipment gloves eye wear clothing etc if worki...

Page 88: ...o the On position n Close and latch the control cabinet door o Access the Spectrum panel and optimize the spectrometer energy level by clicking on the Optimize Integ Time button p Return to the Analysis 1 panel and perform a Manual Zero by clicking the Manual Zero button q Remove the Zero mode by removing the x from the Back Purge box r Press the On Line Off Line switch to place the system On Line...

Page 89: ... sample and vent line valves The recommended procedure is to remove sections of tubing on the measurement cell side of valves V1 and V3 and install fitting plugs on these valves This will guarantee that the measurement cell is not inadvertently exposed to steam or condensate Steam can be connected to the Steam port located at the rear of the oven enclosure e The steam supply line should be blown d...

Page 90: ...e when the oven compartment cover is secure m Close and latch the oven cabinet door n Allow the back purge to continue for five to ten minutes o Perform a Manual Zero by clicking the Manual Zero button p Remove the Zero mode by clicking the Manual Zero button again q Click the On Line Off Line to show On Line The system will automatically restart itself The analyzer may show a fault and be in Manu...

Page 91: ...pecifications and is built to meet the customer s specific requirements This chapter consists of a number of forms which provide the overall QA procedure and should be retained 8 2 Overall System Identification Proposal Purchase Order Number Sales Order Reference Serial Number Customer Name Facility Address Primary Contact Name Primary Contact Telephone Number Primary Contact e mail Inspection Sof...

Page 92: ... Purge System Checked Aspirator Performance Tested Gas Runs Complete Calibration Data Sheet Temperature Sensor Inputs Checked and Calibrated Analog Output Calibration Checked Digital Output Checked System 24VDC Supply Checked Span Factor Set Condenser Solenoid Function Checked Zero Solenoid Function Checked Control Cabinet Air Solenoid Function Checked Operation of Cell Heaters Checked Burn Oven f...

Page 93: ...wing page of the Help section of the computer software Figure 9 1 Mounting Detail Figure 9 2 Oven Cabinet Detail Figure 9 3 Control Cabinet Detail Figure 9 4 Power Air Steam Requirements and Input Output Detail Figure 9 5 Control Cabinet to Oven Cabinet Interconnect Detail Figure 9 6 AC Wiring Detail Figure 9 7 DC and Signal Wiring Detail ...

Page 94: ...Revision 1 94 6 27 2017 Figure 9 1 Mounting Detail ...

Page 95: ...Revision 1 95 6 27 2017 Figure 9 2 Oven Cabinet Detail ...

Page 96: ...Revision 1 96 6 27 2017 Figure 9 3 Control Cabinet Detail ...

Page 97: ...Revision 1 97 6 27 2017 Figure 9 4 Power Air Steam Requirements and Input Output Detail ...

Page 98: ...Revision 1 98 6 27 2017 Figure 9 5 Control Cabinet to Oven Cabinet Interconnect Detail ...

Page 99: ...Revision 1 99 6 27 2017 Figure 9 6 AC Wiring Detail ...

Page 100: ...Revision 1 100 6 27 2017 Figure 9 7 DC and Signal Wiring Detail ...

Page 101: ...Revision 1 101 6 27 2017 This page intentionally left blank ...

Page 102: ...imensions including Mounting Frame 57 W x 41 25 H x16 D 145 cm x 105 cm x 41 cm Analyzer cabinets Two cabinets each 24 W x 30 H x 12 D 61 cm x 76 2 cm x 30 cm Weight Total System on Frame Approximately 275 lbs 125 kg varies with options Services Required Electrical 100 240 V 1 phase 50 60 Hz 800 W Instrument Air 17 SCFM at 80 psi maximum case with Vortec Cooler Steam Nozzle 50 psi Oven Heater 150 ...

Page 103: ...ite maintenance and service procedures Spare Parts can be obtained from Galvanic Applied Sciences 7000 Fisher Road S E Calgary AB Canada T2H 0W3 Main Telephone 1 403 252 8470 Toll Free Canada US 1 866 252 8470 Fax 1 403 255 6287 Email gasparts galvanic com www galvanic com For emergencies please phone our 24 hour technical support cell phone at 1 403 651 0344 ...

Page 104: ...g of 5 Fuse 5 Amp Slo Blo PC7087 1 Pkg of 5 Source Fiber Optic Cable 1 each Spectrometer Fiber Optic Cable 1 each Table 11 2 Two Year Kit Item Description Part Number Quantity Unit of Measurement Cell Window BA7118 4 each O Rings for Cell Windows CO7134 32 each UV Source Lamp BA1795 2 each Anti Solarant Solution CO7312 2 Bottle Fuse 1 5 Amp PC7090 1 Pkg of 5 Fuse 2 Amp PC7089 1 Pkg of 5 Fuse 5 Amp...

Page 105: ...is 123 456 789 123 and the port number is 12345 enter http 123 456 789 123 12345 userio htm The Peripheral Board menu includes the following two tabs The Status tab Section 1 2 presents the status of the analog and digital inputs and outputs The Manual Override tab Section 1 3 is used to calibrate analog outputs and activate deactivate digital relays and solenoids The Manual Override tab allows th...

Page 106: ... and red if the system is off line The Relays Solenoids and Digital Inputs LEDs are red if the function is active and gray if the function is not active The On Board Temperature field provides the temperature of the peripheral board and is an indication of temperature inside the analyzer cabinet The Analog Inputs box shows the current value of each of the four analog inputs in their calibrated uni...

Page 107: ...ual control of the outputs place a checkmark in the Direct Peripheral Board Control check box This tab allows the operator to make changes to the peripheral board of the instrument Any change will permanently delete the present value Access to these tabs should be restricted to qualified individuals who understand the impact of any change Figure 12 2 Manual Override Tab ...

Page 108: ... power d Press the Output Zero button The analog output will attempt to output 4 mA however it may not read exactly 4 e Enter the reading from the meter in the Meter Reading field and press the Auto Cal button This will adjust the Zero output to exactly 4 mA f Press the Output Span button The analog output will attempt to output 20 mA however it may not read exactly 20 g Enter the reading from the...

Page 109: ...al input d When the discrete input is open the Digital Input indicator on the Status page will be grey not active e When the discrete input is closed the Digital Input indicator on the Status page will be red active 12 3 3 Testing Digital Outputs To test a digital output a Access the Manual Override tab b Select Direct Peripheral Board Control c For each digital output deselect the check box The o...

Page 110: ... Cell Setpoint 48 Cell Windows Replacement 86 Check Out Procedure 70 Condenser Cooling Air Flow Adjust Valve 29 Config Panel 43 Control Indicator 32 Control Relay Indicator 37 COS Span 45 CS2 Span 45 D Dark Level 42 Digital Inputs Testing 109 Digital Outputs 31 Testing 109 Digital Signal Cables Connection 27 Display 46 E Electrical Requirements 16 Endian Swap 64 Enron Modbus Protocol 64 Environmen...

Page 111: ... Peripheral Board 105 Plant Factor 45 Preventative Maintenance 68 Probe Deadband 48 Probe Set Point 48 Purge Fail Indicator 32 Q Quality Assurance Program 91 R Receiving the System 16 Register Swap 64 Relay Indicator Fields 36 Relay Indicator Fields Web GUI 54 Routine Maintenance 68 S Safety Guidelines 8 Safety Symbols 7 Sampling System 13 Service 76 Service Indicator 31 Service Relay Indicator 36...

Page 112: ...Digital Inputs 109 Timers 47 U Unpacking 17 User Interaction Program 33 UV Source Lamp Changing 79 V Value Display Web GUI 52 W WARRANTY 10 Web Based Operation 51 Z Zero Air Flow Adjust Valve 29 Zero Hold Interval 48 Zero Purge Interval 48 ...

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Galvanic Applied Sciences 943-TGS, Operation Manual

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