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DF180 GAS FLOW AND TEMPERATURE MONITOR 

 

Operation and Maintenance Manual 

 
 

 
 
 
 
 

Teledyne Monitor Labs 

35 Inverness Drive East 

Englewood, CO  80112 

 

TML DOCUMENT 99702200  

Revision A 

 
 

www.teledyne-ml.com

 

 

Summary of Contents for Deltaflow DF180

Page 1: ...DF180 GAS FLOW AND TEMPERATURE MONITOR Operation and Maintenance Manual Teledyne Monitor Labs 35 Inverness Drive East Englewood CO 80112 TML DOCUMENT 99702200 Revision A www teledyne ml com ...

Page 2: ...he interests of Teledyne Monitor Labs Please contact your local Teledyne Monitor Labs regional sales or service representative or call our home office if you require assistance Sales 800 422 1499 Technical Support 800 846 6062 Parts 800 934 2319 Transfer of EAR99 technical information Use and Disclosure of Data Information contained herein is classified as EAR99 under the U S Export Administration...

Page 3: ...on Differential Pressure Switch 11 1 1 8 Sample Filters 12 1 1 9 Power Supplies 12 1 1 10 Precision Regulator 12 1 2 Probe 13 1 3 Sample Line 13 2 Theory of Operation 14 3 Installation 16 3 1 Pre Installation Planning and Preparation 16 3 2 Site Selection 16 3 2 1 Representative Sampling Location 16 3 2 2 Access to Sampling Location 16 3 2 3 Environmental Conditions at Instrument Panel Location 17...

Page 4: ...mputed Velocity 25 4 3 3 1 3 Configuration Outputs Computed Actual Volumetric Flow 26 4 3 3 1 4 Configuration Outputs Computed Standard Volumetric Flow 26 4 3 3 2 Configuration Outputs Analog 27 4 3 4 Configuration Calibrations 27 4 3 4 1 Configuration Calibrations Timing 27 4 3 4 2 Configuration Calibrations Evaluations 28 4 4 Administrator 29 5 Operation 29 5 1 Calibration and Adjustment 29 5 2 ...

Page 5: ...January 2018 Page 5 6 5 System Leak Test Procedure 33 7 Troubleshooting 34 Appendix A Spare Parts 35 Appendix B Drawings 36 ...

Page 6: ...160 F 40 to 71 C Instrument Enclosure 20 F to 104 F 7 C to 40 C Relative Humidity Probe Assembly 5 to 100 humidity condensing Instrument Enclosure 0 to 95 non condensing Instrument Enclosure Ratings NEMA 4 IP66 is standard Ex Py purge protection can be added as an option for Class I Division 2 and Zone 2 applications Mounting Process Connection 4 150 ANSI flange Sizes Weights Instrument Enclosure ...

Page 7: ...r Daily quality assurance checks signal processing and monitor configuration are all handled by the controller The controller module I O consists of 8 relays and 8 digital inputs The relays are used to control solenoid valves located on the instrument panel during calibration checks interference checks and blowback sequences The digital inputs are used to initiate different modes such calibration ...

Page 8: ...elay 6 Solenoid Valve 6 Span Calibration Low Pressure Instrument Air Delivery Relay 7 Solenoid Valve 7 Span Calibration Isolate DP Pressure Switch Relay 8 Not Used Digital input 1 External Calibration Start Digital input 2 External Interference Check Start Digital input 3 External Blowback Start Digital input 4 Maintenance Digital input 5 Calibration Start Digital input 6 Interference Check Start ...

Page 9: ...eltaflow controller to flag its data as invalid 1 1 4 Valve Manifold Assembly This assembly consists of 7 solenoid valves installed on a custom designed manifold Static pressure impact pressure and instrument air are directed through the manifold by the valves During normal sampling mode none of the valves are actuated impact pressure and static pressure are directed to the high and low sides of t...

Page 10: ...Pressure Transmitter 1 1 6 Temperature Transmitter Stack temperature is needed to calculated stack velocity and standard volumetric flow The probe is equipped with a type K thermocouple to accurately measure stack temperature The thermocouple signal is carried down to the instrument panel via thermocouple messenger cable in the sample line where it is terminated on a DIN rail mounted transmitter T...

Page 11: ...eck this DP switch will shut off SV6 when it senses the correct pressure has been achieved on the high side of the DP transmitter This provides a repeatable and stable differential pressure to check the pneumatic and electrical drift of the DP transmitter The DP switch set point is adjustable via a screw at the left end of the switch spring housing These switches come in various ranges see Appendi...

Page 12: ...ectronics valves and switches A 10W 12 VDC power supply is used as loop power for the analog outputs Both power supplies inputs are rated 100 240VAC 50 60Hz and are automatically adapting Both power supplies have DC Voltage OK indicating LEDs to aid in troubleshooting The 24 VDC power supply has a DC voltage output adjustment potentiometer 1 1 10 Precision Regulator In order to minimize the drift ...

Page 13: ... probe using 3 8 compression fittings The K type thermocouple comes in various lengths and has a fixed insertion depth The thermocouple wires from the sample line are easily terminate in the head of the thermocouple assembly Figure 1 8 Deltaflow Probe 1 3 Sample Line The Deltaflow sample line consists of a two 3 8 PFA Teflon sample lines a K type thermocouple messenger cable a small amount of insu...

Page 14: ...it stagnates in the tube creating an elevated pressure at point B see Figure 2 1 This is referred to as the impact pressure Static pressure is the stack or duct pressure not resulting from any velocity energy conversion The pressure at points A C and D are all equal and can all be thought of as the static pressure also known as the absolute pressure or just pressure A differential pressure transdu...

Page 15: ...he gas stream O2 Percent by volume of oxygen in the gas stream CO2 Percent by volume of carbon dioxide in the gas stream After velocity has been calculated volumetric flow rate can be calculated based on Equation 2 4 Eq 2 4 𝑄𝑄𝑠𝑠 𝑉𝑉 𝑠𝑠 𝑥𝑥 𝐴𝐴 𝑠𝑠 𝑥𝑥 3600 Where A Cross sectional area of stack m2 ft2 QAct Volumetric stack gas flow rate m3 hr ft3 hr To adjust the stack volumetric flow to a standard temp...

Page 16: ...e downloaded off the Teledyne Monitor Labs website 3 2 Site Selection Without question the single most important factor affecting overall performance of any continuous monitoring device is that of site selection If this decision is not made prudently then monitor accuracy and reliability will suffer 3 2 1 Representative Sampling Location Complex flow patterns in the vicinity of bends or obstructio...

Page 17: ...nnect with DF180 button The web interface is configured at the Teledyne Monitor Labs Factory so you do not need to click Create New Configuration the first time you access You should only need to create a new configuration if you find that the engineering units British Imperial or Metric of the configuration are incorrect When creating a new configuration you will need to configure all the screens...

Page 18: ...2018 Page 18 Click the Configure Device link to start the configuration process A dialog box with all detected devices will be displayed Using the check box select the device you want to configure and click OK ...

Page 19: ...b interface 4 1 Data The Data screen will be the first screen displayed once connected This section will outline all the data screens and their functionality 4 1 1 Data Values The Values screen displays live data that is updated every five seconds Each widget can be renamed by clicking on it A RED border around a widget means that data is invalid due to the value being out of range or a failed QA ...

Page 20: ...s that have occurred Examples of alarms that will show up here are QA check failures communication failures DP temp pressure out of range faults and value alarms Value alarms are user defined Lo and Hi alarms and can be configured for almost any parameter in the appropriate Configuration screen 4 1 3 Data Calibrations This screen will show you the results of the most recent calibration check and i...

Page 21: ...ignificant bit bit 15 not used 14 In interference test 13 Interference test failure 12 Full scale exceeded 11 not used 10 In Calibration 9 fatal fault 8 non fatal fault 7 not used 6 In Maintenance 5 not used 4 Communication Failure 3 not used 2 Data valid 1 In Span Calibration 0 In Zero Calibration 4 1 5 Data Tools This screen provides information on firmware version IP address and communication s...

Page 22: ...dicator that will turn GREEN to show the valve or mode is active When activating some of the valves SVx other valves may automatically activate to avoid damaging the instrument Clicking any of the buttons in the Valves section will automatically put the DeltaFlow in Maintenance mode until you manually put it back in service by clicking the Maintenance button When initiating a calibration or interf...

Page 23: ...n the user completed installation checklist but can easily be changed by the user in the field IMPORTANT ANY CHANGE TO THE CONFIGURATION MUST BE WRITTEN TO THE CONTROLLER BY GOING TO THE ADMINISTATOR SCREEN AND PRESSING THE WRITE CONFIGURATION TO DF180 BUTTON 4 3 1 Configuration General See screenshot below for configurable parameters available If engineering units need to be changed refresh the w...

Page 24: ...ing units is the value that corresponds to 4mA Full scale corresponds to 20mA The user can enable low or high value alarms if desired Analog input 4 can be used by the user to pass through a signal such as steam load or megawatt load This is done by providing a 4 20mA signal to terminal block TBAI see Wiring and Interconnect Diagram Click add new Analog input and follow prompts to specify a name a...

Page 25: ...to be utilized Digital input 8 must be used Once configured this signal can then be displayed on the main Data screen or passed through via Modbus see Modbus Map screen for address for the data acquisition system to use 4 3 2 4 Configuration Inputs Temperature This screen is used to configure the instrument panel ambient temperature parameter Engineering units and Hi Lo value alarms can be specifi...

Page 26: ...tail From the factory Velocity is always the same as Raw Velocity The constants shown below result in a correction curve of y x or Velocity Raw Velocity 4 3 3 1 3 Configuration Outputs Computed Actual Volumetric Flow Actual Flow is the volumetric flow rate at stack temperature and pressure 4 3 3 1 4 Configuration Outputs Computed Standard Volumetric Flow Standard Flow is the volumetric flow rate c...

Page 27: ...A checks A daily calibration check consists of a zero and upscale DP check The Deltaflow controller can be programmed to automatically perform this check at a certain time on any given day of the week If the appropriate box is checked an interference check will also be conducted at that time An interference check consists of taking an average DP sample over a length of time defined by the user per...

Page 28: ...rence check blowback cleared out the clog 4 3 4 2 Configuration Calibrations Evaluations This screen details the pass fail tolerances and reference points for the daily QA checks The span is defined based on the maximum potential flow MPF Span is typically 125 of the MPF The upscale reference set point is typically set to 50 70 of the span ...

Page 29: ...he Cal Check button on the front of the instrument panel The cal check will not begin until the top of the next minute according to the Deltaflow controller clock The cal check will take approximately 4 minutes After it is complete check the Data Calibrations screen in the web interface to verify results are acceptable New from the factory the zero 4mA and full scale 20mA outputs should not need a...

Page 30: ...low takes only a point measurement A reference method like EPA Method 2 takes an average of many sample points to get a more accurate measurement of the overall average velocity in the stack Creating a correction curve is done using the following procedure First Deltaflow Raw Velocity data is collected along with a reference method velocity measurement such as EPA Method 2 It is important to synch...

Page 31: ...ite the configuration to the controller Now the Velocity and Raw Velocity parameters will differ in the Deltaflow as a result of the correction curve Examining the graph in Figure 5 1 a Raw Velocity of 40 ft s would result in a Velocity of 45 5 4 Long Term Shutdown If the Deltaflow is to remain out of service for an extended period of time greater than 24 hours without power perform the following ...

Page 32: ... out The cleaner used depends on the process and what has accumulated in the sample line Many lines can be cleaned by flushing with water Simple Green or vinegar In other cases Acetone may needed The best way to determine what will work is to start with water move to Simple Green or Vinegar and finally Acetone Below is a sample of how to flush a line using Simple Green 1 Put the Deltaflow into Mai...

Page 33: ... is leak free This includes the probe sample line and all the instrument panel plumbing To check this use TML P N 99701100 1 DF180 Leak Check Kit and follow the procedure below This procedure requires a person at the probe location and another person at the instrument panel 1 The probe person disconnects the impact and pressure lines from the Pitot tube 2 Make sure the syringe is pulled out Connec...

Page 34: ...low readings Check Probe for debris Leak check entire system components prone to leaks are solenoid valves and tube connections Check variables in Configuration screen Failed calibration Leak check instrument panel Verify upscale reference value in the DeltaFlow matches the value in the data acquisition system Check that DP transmitter gauge display matches web interface values during zero and ups...

Page 35: ...10 H2O Emergency N A 55000046 3 DP Transmitter w display 0 6 H2O Emergency N A 55000046 4 DP Transmitter w display 0 3 H2O Emergency N A 55000046 5 DP Transmitter w display 0 0 5 H2O Emergency N A 55000046 6 DP Transmitter w display 0 1500 Pa Emergency N A 55000046 7 DP Transmitter w display 0 500 Pa Emergency N A 55000046 8 DP Transmitter w display 0 125 Pa Emergency N A 55000049 1 Precision Pres...

Page 36: ...January 2018 Page 36 Appendix B Drawings ...

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Page 38: ... BY REV DESCRIPTION 20NOV2017 X1 PRELIMINARY DRAWING 22JAN2018 A RELEASED PER ECO7228 A A B B C C D D 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 N A N A 2NOV2017 D CONNELLY SIZE TITLE DATE FINISH DF180 PLATE INSTALLATION DWG NO D UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES 0 X 0 1 0 XX 0 02 0 XXX 0 010 ANGULAR MACH 0 30 BEND MATERIAL REV SCALE 1 5 99702102 DRAWN BY SHEET 1 OF 1 A PART NO D...

Page 39: ...D INTO BOOT PRIOR TO APPPLYING HEAT OBTAINING A PROPER SEAL ON THE THERMOCOUPLE WIRE IS CRITICAL REVISIONS DATE APPROVED BY REV DESCRIPTION 8AUG2017 X1 PRELIMINARY INSTALLATION DRAWING DETAIL 22JAN2018 A RELEASED PER ECO7228 A A B B C C D D 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY AND CONFIDENTIAL TO TELEDYNE MONITOR LABS INC AND IS FURNISHED UPON THE EXPRESS ...

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