Galvanic Applied Sciences 943-TGX Operation Manual Download Page 89

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Revision 4

August 02, 2019

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-TGX

Page 1: ...Tail Gas Analysis OPERATION MANUAL P N MA7428 Revision 4 August 2019 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...

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...

Page 3: ...8 2 4 1 Mounting of the Analyzer System 18 2 4 2 Mating of the Process and Analyzer System Flanges 20 2 4 3 Connection of the AC Power Service 22 2 4 4 Connection of the Analog Signal Cables 22 2 4 5...

Page 4: ...8 2 Calculation Sub Panel 41 4 8 3 Display 44 4 8 4 Timers Alarms 45 4 8 5 Network Sub Panel 47 SECTION 5 WEB BASED OPERATION 49 5 1 OVERVIEW 49 5 2 ANALYSIS SECTION 50 5 2 1 Analysis Page 50 5 2 1 1...

Page 5: ...7 6 CELL WINDOWS REPLACEMENT 84 7 8 MEASUREMENT CELL INSTALLATION 85 7 9 STEAM PURGING THE SAMPLE PROBE ASSEMBLY 87 7 10 SPECTROMETER REPLACEMENT 88 SECTION 8 THE PRODUCT QUALITY ASSURANCE PROGRAM 89...

Page 6: ...6 August 02 2019 Tables TABLE 6 1 NORMAL VALUES OF KEY OPERATING PARAMETERS 67 TABLE 7 1 ANALYZER FAULT TABLE 76 TABLE 8 1 DOCUMENT PACKAGE CHECK LIST 90 TABLE 11 1 ONE YEAR KIT 101 TABLE 11 2 TWO YE...

Page 7: ...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 min...

Page 8: ...suggested guidelines only Galvanic Applied Sciences Inc bears no responsibility and assumes no liability for the use and or implementation of these suggested procedures This system when operating in i...

Page 9: ...sed in an oven cabinet that is heated and maintained at approximately 150 C 300 F to prevent the condensation of sulfur Maintenance performed before the cooling of the oven and hardware should be done...

Page 10: ...ility 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 t...

Page 11: ...the processor or software or firmware will be uninterrupted or error free The warranty herein applies only to Products within the agreed country of original end destination Products transferred outsid...

Page 12: ...implified Air Demand equation is Air Demand F H2S Rop SO2 where F plant specific gain factor H2S concentration of H2S SO2 concentration of SO2 Rop operating ratio typically 2 When the stoichiometric c...

Page 13: ...lution and fewer elements in the detector are also less precise If as is frequently the case more than one of the sulfur containing compounds indicated above are present their spectra will overlap The...

Page 14: ...ng Incoming sample gas is filtered to 60 micron and drawn through the measurement cell by the aspirator The measurement cell exposes a known length of sample to UV radiation for spectroscopic analysis...

Page 15: ...be used to view and enter information on a remote basis Section 4 3 1 6 Contents of this Manual This manual contains the following information Section 1 Model 943 TGX Tail Gas Analyzer Spectrophotomet...

Page 16: ...Requirements The power input is 100 240 Vac 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 ambien...

Page 17: ...ntact 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 installati...

Page 18: ...stallation of the 943 TGX analyzer system consists of the following steps Mounting of the Analyzer System Section 2 4 1 Mating of the Process and Analyzer System Flanges Section 2 4 2 Connection of th...

Page 19: ...team jacketed ball valve must remain closed until the sample probe is installed and connected in the sample handling oven Figure 2 1 Analyzer Dimensions Figure 2 2 indicates the location of the variou...

Page 20: ...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 Explosive toxic and hot gases and molte...

Page 21: ...ons 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 bolt...

Page 22: ...flange contacts the packing gland c Tighten the packing gland and connect the tubing to the probe If the connections are leak tight and company safety personnel have deemed the atmosphere to be safe b...

Page 23: ...ust 02 2019 2 4 7 Connection s of Steam 2 4 8 Connection of the Loss of Purge Signal 943 TGX CE The loss of purge is an integral function of the purge controller 943 TGX CE Refer to the User Manual Se...

Page 24: ...air streams Flow adjustment valves for the zero purge gas flow rate the aspirator drive air flow rate and the sulfur condenser air flow rate are provided and located according to Oven Cabinet Componen...

Page 25: ...ciated with this adjustment Several factors can impact the temperature of the gas exiting the probe These factors include changes in process gas temperature changes in cooling air temperature changes...

Page 26: ...e process duct and vented at the wall of the process duct through the same access port Ideally enough aspirator drive air is provided to present a measurement cell pressure of 2 3 H2O below the proces...

Page 27: ...ncentrations CS2 or H2S SO2 ratio Analog outputs for H2S and SO2 concentrations can be programmed to be either Track or Hold If the output is programmed to be Track the output will track the calculate...

Page 28: ...n the High Svap alarm the last spectrometer Measure scan was within range the last spectrometer Reference scan was within range the last spectrometer Dark scan was within range The purpose of this ind...

Page 29: ...output data are real and current measurements of the tail gas process stream Under conditions where the validity of the output data is suspect the analyzer places the Control flag in the Manual state...

Page 30: ...nboard 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 P...

Page 31: ...between the various panels and enter information Figure 4 2 Hand Held Keypad The buttons on the keypad provide the following Panel Prev Changes the active panel to the previous panel Panel Next Change...

Page 32: ...ience to the user The On Line Off Line function essentially provides a method of signaling that the analyzer data is invalid undergoing maintenance or servicing When returning the analyzer to On Line...

Page 33: ...function normally producing usable outputs c Mode Run Green status indicates that the system is in Run mode Calibrate Amber indicates that a zero calibrate sequence is in progress At the end of the c...

Page 34: ...s the new zero value d The analyzer waits for the number of seconds specified by the Zero Hold Interval parameter of the configuration data Section 4 8 4 e During this period process sample gas is dra...

Page 35: ...oftware restart to a range between the configured full scale analog output value for the Air Demand signal Figure 4 3 Analysis 2 Panel The default full scale values and the time scale can be set on th...

Page 36: ...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 functi...

Page 37: ...while minimizing the noise in the spectrum A short integration time will optimize the resolution however the noise may be relatively high If a long integration period is employed the resolution may be...

Page 38: ...fers to a spectrum of zero gas that was saved at the time of analyzer calibration at the factory If the Show Factory Reference check box is selected the spectrum will be superimposed on the same set o...

Page 39: ...Height Height of the highest point in the spectrum First Vector Pixel corresponds to starting wavelength for the analysis and is spectrometer dependent Dark Level the signal from dark current 4 7 Abso...

Page 40: ...set a broad range of operating parameters and includes 8 sub panels The Configuration Panel should be accessed only by qualified personnel 4 8 1 Outputs Sub Panel The Outputs sub panel Figure 4 9 is u...

Page 41: ...oling finger is at the optimum temperature The probe s cooling finger temperature is controlled by using a solenoid valve to direct the flow of instrument air through the finger off and on The cooling...

Page 42: ...less of the plant specific gain factor F when the operating ratio Rop is two 2 When the plant specific gain factor F is established for a particular process the units of Air Demand become percent chan...

Page 43: ...ulating the concentration of the various gases If the x is not present the analyzer will use the live value for cell temperature when calculating the concentration of the various gases j Fixed Pressur...

Page 44: ...esired value for the parameter via the keypad and press Enter The X range is from 1 15 min and the Y range is from 0 1 to 1000 The LCD Backlight field is used to adjust the backlighting of the display...

Page 45: ...arameter 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...

Page 46: ...process sample gas is aspirated into the measurement cell and the concentration outputs climb to actual readings At the expiration of this interval relay outputs and indicators are returned to a vali...

Page 47: ...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...

Page 48: ...Revision 4 48 August 02 2019 Figure 4 13 Network Sub Panel...

Page 49: ...of 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 compu...

Page 50: ...H2S SO2 The present value of the concentration of SO2 COS The present value of the concentration of COS Sulfur Vapor The present value of the concentration of Sulfur vapor Cell Pressure The pressure...

Page 51: ...quired 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 follo...

Page 52: ...hat 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 bu...

Page 53: ...ted 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 th...

Page 54: ...f 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 co...

Page 55: ...th 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 identi...

Page 56: ...urve 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...

Page 57: ...teg Time button The analyzer must be in 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 Ti...

Page 58: ...viewed 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 C...

Page 59: ...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 concent...

Page 60: ...lemented 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 t...

Page 61: ...dialog 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 Figu...

Page 62: ...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...

Page 63: ...will 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 Som...

Page 64: ...change 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 di...

Page 65: ...program 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 th...

Page 66: ...ters 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 Chec...

Page 67: ...ce 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 Temperatur...

Page 68: ...This 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 th...

Page 69: ...re 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 Integrati...

Page 70: ...reach 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 cont...

Page 71: ...holder 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 pl...

Page 72: ...ometer signal the normal target value for the peak value is 32000 counts 500 The spectrometer energy level can be optimized manually for special cases or automatically as a function of the analyzer Th...

Page 73: ...he Integration Period dialog box Type the new integration period in the New Value field and press Enter After several seconds the new raw signal will be displayed New values for the Integration Period...

Page 74: ...alyzer 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...

Page 75: ...Revision 4 75 August 02 2019 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 76: ...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 Th...

Page 77: ...bed 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 th...

Page 78: ...er 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 pu...

Page 79: ...astic 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...

Page 80: ...Purge 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...

Page 81: ...tly 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 co...

Page 82: ...f 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...

Page 83: ...les 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...

Page 84: ...our 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...

Page 85: ...in 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...

Page 86: ...to 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 Analy...

Page 87: ...es V1 and V3 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...

Page 88: ...artment 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...

Page 89: ...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 Ide...

Page 90: ...m 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 S...

Page 91: ...be viewed on the Drawing page of the Help section of the computer software Figure 9 1 Mounting and Service Connection Detail Figure 9 2 Oven Cabinet Detail Figure 9 3 Control Cabinet Detail Figure 9 4...

Page 92: ...Revision 4 92 August 02 2019 Figure 9 1 Mounting and Service Connection 943 TGX CE There are no oven steam supply fittings on the 943 TGX CE...

Page 93: ...Revision 4 93 August 02 2019 Figure 9 2 Oven Cabinet Detail 943 TGX CE There are no oven steam supply fittings on the 943 TGX CE...

Page 94: ...Revision 4 94 August 02 2019 Figure 9 3 Control Cabinet Detail...

Page 95: ...Revision 4 95 August 02 2019 Figure 9 4 Power Air Steam Requirements and Input Output Detail 943 TGX CE There is no requirement for oven heater steam on the 943 TGX CE...

Page 96: ...Revision 4 96 August 02 2019 Figure 9 5 AC Wiring Diagram...

Page 97: ...Revision 4 97 August 02 2019 Figure 9 6 DC Signal and Wiring Diagram...

Page 98: ...Revision 4 98 August 02 2019 This Page Intentionally Blank...

Page 99: ...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 Approximatel...

Page 100: ...edite 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 8...

Page 101: ...n CO7312 1 Bottle Fuse 1 5 Amp PC7090 1 Pkg of 5 Fuse 2 Amp PC7089 1 Pkg of 5 Fuse 5 Amp Slo Blo PC7087 1 Pkg of 5 Table 11 2 Two Year Kit Item Description Part Number Quantity Unit of Measurement Cel...

Page 102: ...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...

Page 103: ...e 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 te...

Page 104: ...nual 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 pe...

Page 105: ...p 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...

Page 106: ...ital 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 w...

Page 107: ...eb GUI 55 Cell Length 44 Cell Prop Band 47 Cell Setpoint 47 Cell Windows Replacement 85 Check Out Procedure 69 Condenser Cooling Air Flow Adjust Valve 26 Config Panel 41 Control Indicator 30 Control R...

Page 108: ...t Factor 43 Preventative Maintenance 67 Probe Deadband 47 Probe Set Point 47 Purge Fail Indicator 30 Q Quality Assurance Program 90 R Receiving the System 16 Register Swap 63 Relay Indicator Fields 34...

Page 109: ...t 02 2019 U Unpacking 17 User Interaction Program 31 UV Source Lamp Changing 78 V Value Display Web GUI 51 W WARRANTY 10 Web Based Operation 50 Z Zero Air Flow Adjust Valve 27 Zero Hold Interval 47 Ze...

Page 110: ...19 Reason for Revision The changes incorporated in Revision 3 1 of the Operation Manual are in the addition of the level of detail for clarity only and do not affect product processes or methods of pr...

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