Hobre WIM WOBBE INDEX METER Installation, operation and maintenance manual

WIM WOBBE INDEX METER Installation, operation and maintenance manual Hobré Instuments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision:July 2004 Software version: 1.49 Hobré Instruments B.V. Document Label Definitions Symbol * Label Description WARNING: Consists of conditions, practices, or procedures that must be observed to prevent personal injury. CAUTION: Consists of conditions, practices, or procedures that must be observed to prevent injury or equipment damage. CAUTION: Risk of electric shock. May result in injury if proper precautions are not taken. NOTE: Emphasises important or essential information. Please refer to Chapter 1 for important safety information and instructions on how to use this manual. © Copyright 2004 by Hobré Instruments All rights reserved Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 1. SAFETY CONSIDERATIONS ....................................................................................................................... 5 1.2 INSTRUCTIONS AND PROCEDURES .............................................................................................................. 6 1.3 GENERAL SAFETY AND OPERATING INFORMATION..................................................................................... 6 1.4 GENERAL PRECAUTIONS ............................................................................................................................. 6 1.5 ELECTRICAL POWER .................................................................................................................................... 7 1.6 SYSTEM LOCATION ...................................................................................................................................... 7 1.7 BOTTLE GAS ................................................................................................................................................ 7 1.8 FILTERS ........................................................................................................................................................ 8 1.9 VALVES ........................................................................................................................................................ 8 1.10 VENTS ........................................................................................................................................................ 8 1.11 SPECIFIC SAFETY CONSIDERATIONS FOR EX- UNITS ................................................................................ 1 2. THE WIM-9900 WOBBE INDEX METER .................................................................................................. 12 2.1 FIELDS OF APPLICATION ............................................................................................................................ 12 2.2 FEATURES .................................................................................................................................................. 12 2.3 INPUTS AND OUTPUTS ................................................................................................................................ 12 2.4 CONSUMABLES .......................................................................................................................................... 13 3. THE PRINCIPLE OF OPERATION ............................................................................................................ 14 3.1 OXYGEN IS THE BASE FOR THE WOBBE INDEX MEASUREMENT ................................................................ 14 3.2 THE DETERMINATION OF THE AMOUNT OF RESIDUAL OXYGEN ................................................................ 14 3.3 CALCULATING RESIDUAL OXYGEN FROM THE CELL MVOLT SIGNAL. (NERNST-EQUATION) .................... 15 3.4 WHY MEASURE BOTH WOBBE AND CARI INDEX ....................................................................................... 16 3.5 ANALYSER CALIBRATION AND THE TERMS SLOPE AND OFFSET. ............................................................... 17 3.6 THE TERMS "UPPER HEATING VALUE" AND "LOWER HEATING VALUE" ..................................................... 18 4. SAMPLE CONDITIONING SYSTEM.......................................................................................................... 19 4.1 THE MAIN EXECUTIONS .............................................................................................................................. 19 4.2 BASIC OPERATION OF THE SAMPLE CONDITIONING SYSTEM (SCS)......................................................... 19 4.3 FUNCTION OF THE INSTRUMENT AIR .......................................................................................................... 19 4.4 PRESSURE VERSION SAMPLE CONDITIONING SYSTEM (WIM-9900P) ..................................................... 20 4.5 LOW PRESSURE VERSION SAMPLE CONDITIONING SYSTEM (WIM-9900LP)........................................... 21 4.6 THE EXTENDED RANGE VERSION ............................................................................................................... 22 4.7 THE DENSITY (OR SPECIFIC GRAVITY) METER ......................................................................................... 22 5.0 THE ELECTRONICS .................................................................................................................................. 23 5.1 GENERAL ................................................................................................................................................... 23 6.0 INSTALLATION........................................................................................................................................... 24 6.1 MECHANICAL HOOK-UP .............................................................................................................................. 24 6.2 POINTS OF ATTENTION FOR SAMPLE SUPPLY ............................................................................................ 24 6.3 POINTS OF ATTENTION FOR OVEN VENT AND DRAIN. ................................................................................ 24 6.4 POINTS OF ATTENTION FOR ATMOSPHERIC VENT LINES............................................................................ 24 6.5 SWAGELOK INSTRUCTION .......................................................................................................................... 26 6.6 ELECTRICAL HOOK-UP ............................................................................................................................... 27 6.7 CONNECTING POWER ................................................................................................................................ 27 6.8 CONNECTING DIGITAL IN- & OUTPUT ......................................................................................................... 27 6.9 CONNECTING ANALOGUE SIGNALS ............................................................................................................ 27 7.0 START-UP.................................................................................................................................................... 29 7.1 GENERAL ................................................................................................................................................... 29 7.2 ON-SITE SUPPORT & TRAINING .................................................................................................................. 29 2 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 7.3 PRECAUTIONS UPON START-UP ................................................................................................................. 29 7.4 START-UP SAMPLE SYSTEM ...................................................................................................................... 30 7.5 SETTING THE BOOSTER REGULATOR ......................................................................................................... 30 7.6 DETERMINING THE CORRECT ORIFICE SIZE AND CALIBRATION GASSES ................................................... 31 8.0 IN OPERATION ........................................................................................................................................... 32 8.1 GENERAL ................................................................................................................................................... 32 8.2 HOW TO READ THE DISPLAY ...................................................................................................................... 32 8.3 DISPLAYED OUTPUT ABBREVIATIONS ........................................................................................................ 32 8.4 DISPLAYED INPUT ABBREVIATIONS ............................................................................................................ 33 8.5 THE SOFTWARE MENUS ............................................................................................................................. 33 (8.5) 1. Global Settings Menu...................................................................................................................... 34 (8.5) 1.1 Calibration Settings ...................................................................................................................... 34 (8.5) 1.2 Current Outputs A, B .................................................................................................................... 35 (8.5) 1.3 Current Outputs C, D.................................................................................................................... 35 (8.5) 1.4 Oxygen Parameters....................................................................................................................... 35 (8.5) 1.5 Wobbe, Cari, Calorific Options .................................................................................................... 36 (8.5) 1.5.1 Wobbe Index Parameters ........................................................................................................... 36 (8.5) 1.5.2 CARI Index Parameters ............................................................................................................. 36 (8.5) 1.5.3 Calorific Value Parameters ....................................................................................................... 37 (8.5) 1.6 Other Options ............................................................................................................................... 37 (8.5) 1.6.1.1 Mode ‘Normal’ Layout............................................................................................................ 38 (8.5) 1.6.1.2 Mode ‘Values’ Layout............................................................................................................. 38 (8.5) 1.6.1.3 Mode ‘Others’ Layout............................................................................................................. 38 (8.5) 1.6.1.4 Mode ‘Calibrating’ Layout ..................................................................................................... 38 (8.5) 1.6.2 Temperature Settings ................................................................................................................. 38 (8.5) 1.6.3 Dual Range Parameters............................................................................................................. 39 (8.5) 1.6.4 Multi-stream Parameters ........................................................................................................... 39 (8.5) 3. Calibration...................................................................................................................................... 41 (8.5) 3.1 Edit Cal Gas Parameters .............................................................................................................. 41 (8.5) 3.2 Calibration Schedule (Weekly) ..................................................................................................... 41 (8.5) 3.2 Calibration Schedule (Repeat)...................................................................................................... 42 (8.5) 3.3 Start Calibration ........................................................................................................................... 42 (8.5) 3.4 Start Validation............................................................................................................................. 43 (8.5) 4. Alarm Reset..................................................................................................................................... 43 (8.5) 5. Login ............................................................................................................................................... 43 (8.5) 5.1 Login Menu ................................................................................................................................... 44 (8.5) 5.* Logged In ...................................................................................................................................... 44 *(8.5) 6 Measuring Menu ............................................................................................................................ 45 (8.5) 7.* Test Menu...................................................................................................................................... 46 (8.5) 7.1* Test Digital Outputs I.................................................................................................................. 46 (8.5) 7.2* Test Digital Outputs II ................................................................................................................ 46 (8.5) 7.3* Test Analogue Outputs A/B ......................................................................................................... 46 (8.5) 7.4* Test Analogue Outputs C/D ........................................................................................................ 47 (8.5) 8. System Settings................................................................................................................................ 47 (8.5) 8.1* Channel Routing Inputs .............................................................................................................. 47 (8.5) 8.2* Channel Routing Outputs I ......................................................................................................... 48 (8.5) 8.3* Channel Routing Outputs II ........................................................................................................ 48 (8.5) 8.4* Channel Routing Outputs III....................................................................................................... 48 (7.5) 8.5* Polarity Inputs ............................................................................................................................ 48 (8.5) 8.6* Polarity Outputs I ....................................................................................................................... 48 (8.5) 8.7* Polarity Outputs II ...................................................................................................................... 48 (8.5) 8.8* Save Changes And Restart .......................................................................................................... 48 3 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 9.0 MAINTENANCE AND INSPECTION ....................................................................................................... 53 9.1 GENERAL MAINTENANCE ........................................................................................................................... 53 9.2 MAINTAINING THE SAMPLE FILTER ............................................................................................................. 53 9.3 MAINTAINING THE PRESSURE REGULATOR STATIONS (PILOT & COMBUSTION AIR) ................................. 53 9.4 MAINTAINING THE SAMPLE PRESSURE REGULATOR .................................................................................. 54 9.5 MAINTAINING THE BOOSTER REGULATOR ................................................................................................. 54 9.6 REPLACING THE ORIFICES TUBES IN THE MIXING CHAMBER ..................................................................... 54 9.7 INSPECTION OF THE FLOW METERS ........................................................................................................... 54 9.8 INSPECTION OF THE PRESSURE RELIEF VALVES ....................................................................................... 54 9.9 REPLACEMENT OF THE ZIRCONIA OXIDE CELL.......................................................................................... 55 9.10 SPARE PARTS .......................................................................................................................................... 55 10.0 TROUBLESHOOTING AND ERROR MESSAGES ............................................................................ 56 10.1 TROUBLESHOOTING................................................................................................................................. 56 10.2 ERROR MESSAGES .................................................................................................................................. 57 11. SPECIFICATIONS ...................................................................................................................................... 59 11.1 PERFORMANCE ........................................................................................................................................ 59 11.2 UTILITIES CONSUMPTION ........................................................................................................................ 59 11.3 ENVIRONMENTAL REQUIREMENTS ........................................................................................................... 59 11.4 DIMENSIONS & WEIGHT .......................................................................................................................... 59 11.5 LIST OF AVAILABLE OPTIONS ................................................................................................................... 59 12. CE DECLARATION OF CONFORMITY.................................................................................................. 61 4 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 1. Safety Considerations WARNING: Failure to follow appropriate safety procedures or inappropriate use of the equipment described in this manual can lead to equipment damage or injury to personnel. Any person working with or on the equipment described in this manual is required to evaluate all functions and operations for potential safety hazards before commencing work. Appropriate precautions must be taken as necessary to prevent potential damage to equipment or injury to personnel. The information in this manual is designed to aid personnel in the correct and safe installation, operation, and maintenance of the systems described. However, personnel must consider all actions and procedures for potential hazards or conditions that may not have been anticipated in the written procedures. If a procedure cannot be performed safely, it must not be performed until appropriate actions can be taken to ensure the safety of equipment and personnel. The procedures in this manual are not designed to replace or supersede required or common sense safety practices. All safety warnings listed in any documents applicable to equipment and parts used in or with the system described in this manual must be read and paid attention to before commencing work on any part of the system. Failure to correctly perform the instructions and procedures in this manual or other documents pertaining to this system can result in equipment malfunction, equipment damage, and injury to personnel. The following symbols are used throughout this manual to alert users to potential hazards or important information. Document Label Definitions Symbol * Label Description WARNING: Consists of conditions, practices, or procedures that must be observed to prevent personal injury. CAUTION: Consists of conditions, practices, or procedures that must be observed to prevent injury or equipment damage. CAUTION: Risk of electric shock. May result in injury if proper precautions are not taken. NOTE: Emphasises important or essential information. 5 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 1.2 Instructions and Procedures This manual makes extensive use of step-by-step instructions and procedures. The listed functions should be performed in the order shown to ensure proper functioning of the equipment. Particular attention must be paid to any safety warnings or cautions that may be listed. WARNING: Deviation from the specified instruction or procedure steps may result in equipment malfunction, equipment damage, or injury to personnel. 1.3 General Safety and Operating Information This section contains general safety and operating information applicable to analyser systems. This information must be understood by all persons installing, using, or maintaining the analyser system. This information is designed to aid personnel in safe installation, operation, and service of the analyser and sample systems. It is not designed to replace or limit appropriate safety measures applicable to work performed by personnel. Any additional safety and operating measures that are required must be determined by and followed by personnel performing work on the system. WARNING: Failure to pay attention to the following information may lead to equipment damage or injury to personnel. 1.4 General Precautions Protective eyewear (glasses with side shields or goggles as appropriate) must be worn when servicing any part of the analyser or sample system. When servicing the sample system, chemical resistant gloves appropriate for the materials in the system must be worn. When servicing the hot analyser oven, internal components, or hot sample system components, appropriate gloves must be worn. Heated components should be allowed to cool before servicing if possible. Other appropriate equipment or clothing must be used as required by the type of work performed. WARNING: Ovens, internal components, and sample system components may be hot even when power is not applied to the unit. Take appropriate precautions to prevent injury from contact with hot items. All applicable regulations and procedures must be followed for the work performed. Before beginning any work on the system, carefully consider all the potential hazards 6 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. and ensure that appropriate measures are taken to prevent injury to personnel or equipment damage. 1.5 Electrical Power CAUTION: Attempting to perform electrical procedures without turning off the power could result in an electrical shock hazard to personnel and damage to the Wobbe analyser! The system uses AC power at 115 or 220 volts. The AC power is converted to DC at several voltage levels. Appropriate precautions must be taken to prevent sparks that may ignite combustible materials that may be present in the analyser environment. Precautions must also be taken to prevent electrical shock if the analyser or sample system enclosures are opened. The AC power to the system must be free from noise, surges, sags, and spikes for proper operation of the system. AC power circuit breakers and wiring must be sized properly for the required current. All wiring installations must meet applicable electrical codes. 1.6 System Location The analyser and sample system must be located suitably. The system must not be installed in an area classification for which it is not rated. The equipment must be protected from temperature and humidity extremes. The analyser must not be mounted in an area with potentially corrosive atmosphere or high vibration. The system components must be attached securely and appropriately to a floor or wall. The system must be mounted to permit adequate access for operation and maintenance. 1.7 Bottle Gas WARNING: Bottles typically have very high pressures and may result in serious injury to personnel if the bottle valve is opened without a regulator attached or if the valve is broken off the bottle. See the following paragraphs for more information. The analyser system typically uses bottled gasses. The bottled gases are typically maintained at very high pressure. Severe injury to personnel and equipment can occur if the bottle gas valve is damaged or opened without installing an appropriate regulator. A protective cap must be in place over the bottle valve any time the bottle is moved. Do not move a bottle with the regulator attached or if the protective cap is missing. Bottles must be secureled chained in place at all times when the protective cap is removed. To permit replacing empty bottles, valves must be installed with extra bottle regulators to permit selecting between two bottles of gas without interrupting gas flow 7 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. to the system. Appropriate pressure relief systems must also be installed. Gas type and locations must be clearly marked to prevent connecting the wrong gas type to the system. 1.8 Filters Filters are used to reduce sample system maintenance requirements by removing particulate material from the sample. Periodically, filters must be replaced or cleaned. All pressure must be removed from the filter before servicing. The filter and associated sample system must be decontaminated appropriately before removal or service. Used filters or filter elements must be dispose in compliance with all applicable regulations for the potential materials filtered and the material from which the filter was constructed. Filters or elements which need replacement should be replaced by original parts only. 1.9 Valves Valves can leak through or leak out. When opening the sample system, precautions must be taken to prevent injury to personnel or damage to equipment in the event that a valve leaks or is misaligned. Before removing or disconnecting any valve, hazardous materials must be thoroughly removed from the valve internals and all pressure must be relieved. When installing a new or serviced valve, all fittings and surfaces must be checked for leaks. 1.10 Vents Vents are used to expel the spent gases from the analyser system. The vents must be routed to a safe location as necessary to prevent injury to personnel. Backpressure must be kept to an absolute minimum to prevent degrading system performance. Long vent runs must be avoided. 8 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 1.11 Specific safety considerations for Ex- units - Make sure that the "special conditions for safe use" as described within the Excertificate, Kema 03.ATEX.2410 X have been read and understood. Make sure that the area for which the unit is intended complies with the gasgroup and temperature class for which the unit has been certified. Make sure that the power supply tension complies with the power supply dat as mentioned on the type plate. 9 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Power connection to the unit has to be done in the Exd power connection box. Hook up of the power cable and transit into the power box has to comply with the regulations of EN 50 018. Signal connection to the unit has to be done in the Exd signal connection box. Hook up of the signal cables and transit into the signal box has to comply with the regulations of EN 50 018. Make sure that the manual has been read and understood in its full before operating or servicing the unit Make sure that all mechanical utility, sample, vent and drain connections are made in accordance with the instruments drawings. The unit contains hot surfaces in both the sampling conditioning compartment (left hand) and the oven compartment (right hand bottom). Window may only be cleaned with a damped cloth to avoid built-up and release of static energy. Don not use dry cloth !! 10 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation instructions for ATEX Ex units (Inserted copy of certificate texts from 03.ATEX.2410 X) The intrinsically safe circuits of the above mentioned barriers and/or isolators shall be installed in such a way that separation is guaranteed between the different circuits or voltage and/or current addition shall be taken into account at places where the circuits can come into contact with each other. Where applicable the earth connection of the above mentioned barriers shall be connected to the potential equalizing system within the hazardous area. This may also be achieved via an earth collecting rail within the analyser. The screens of the cables shall be connected to the enclosure of the analyser. This may also be achieved via an earth collecting rail within the analyser. When the screens are also earthed at the other side of the cable, the potential equalizing system shall assure that the current capability of the screen is capable for the expected currents through it. The cable entry devices and closing devices for unused openings on the pressurized enclosure shall be in type of explosion protection flameproof enclosure "d" or increased safety "e", suitable for the conditions of use and correctly installed. The cable entry devices and closing devices for unused openings on the control boxes shall be in type of explosion protection flameproof enclosure "d", suitable for the conditions of use and correctly installed. For external earthing or bonding connection a cable lug shall be used so that the conductor is secured against loosening and twisting and that contact pressure is permanently secured. Special conditions for safe use for ATEX Ex units (Inserted copy of certificate texts from 03.ATEX.2410 X) Energizing the electrical apparatus by using the bypass function of the purge control unit or remote bypass switch located near the control unit is only permitted with permission of the works manager or his proxy. This permission may only be given when it is made sure that during the time the system is energized by using this switch an explosive atmosphere is not present or when the necessary protective measures against explosion hazard have been taken ("hot permit"). The enclosure may not be opened when an explosive gas atmosphere is present. All externally powered input signals into the pressurized enclosure shall be isolated by external relays controlled by the purge control unit. 11 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. GENERAL LAY-OUT WOBBE INDEX METER WIM-9900 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 2. The WIM-9900 Wobbe Index Meter 2.1 Fields of application Hobré instruments Wobbe Index Meter has specifically been designed for process control applications. Its most common use is analysis of fuel gas supply for feed forward or feed backward control of burners and boilers that can be exposed to sudden changes in the fuel gas composition. The analyser enables users to control the air / fuel ratio with a maximum efficiency and minimum temperature disturbance. Another main field of application is mixture control of gasses based on heating value. Its rugged design makes it suitable for usage in chemical and petrochemical environments. When desired it can be supplied in an explosion proof execution for both European as well as American markets. Hobré instruments is by its origin an analyser system integrator and has experience in designing and building of instrumentation systems for almost 25 years. This experience enables us to offer user specific applications to the analyser system, for instance for the measurement of very wet gasses or multiple fuel lines. 2.2 Features Especially the response time of the analyser makes it superior to competitive types of analysers. Since the measuring principle is based on a electrochemical reaction in a Zirconium Oxide cell it can operate on a flame-less base, this enables the fast response time over most conservative analysers that are usually based on a flame and thermocouple measurement. This also enables the analyser to measure gasses with low Wobbe Indexes. The analyser operates without any moving parts which results in a minimum of maintenance. Its design enables easy replacement of parts. These benefits result in a low cost of ownership and minimum down time. Its controller is based on a normal PC and features user friendly software and trend display on the control screen. The software enables users to do automatic (remote) calibration based on a time interval or a calibration time schedule. Input of a calibration or validation command can be given from a control room or DCS system. The measurement itself is insensitive to ambient temperature variations, there is no specific need for an air-conditioned environment. Without specific applications it can be used in ambiences varying between 0 and 40°C. With some applications it can be used in ambiences between -15 and +60°C. 2.3 Inputs and outputs The analyser features as a standard two analogue output channels. As an option this can be extended to four. Output possibilities are Wobbe, CARI (Combustion Air Requirement Index), Specific Gravity (when equipped with the optional Density meter) and calorific value. These indexes can be programmed to several dimensions (European and American dimensions). A wide range of alarm outputs is available. When desired these can be relay isolated contacts. 12 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 2.4 Consumables The Wobbe Index Meter requires the supply of dry and oil free instrument air and as a minimum two calibration gasses, in case of an extended range version three calibration gasses. For details please refer to the utilities and specifications section. 13 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. SAMPLE COMBUSTION OVEN WIM-9900 ZIRCONIUM OXIDE CELL WIM-9900 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 3. The principle of operation 3.1 Oxygen is the base for the Wobbe Index measurement For the combustion of gas, air is required. When supplying the right quantity of air, the gas will completely burn. This is the so-called stoichiometric air requirement of the gas. Because of this, the Wobbe-index can also be seen as a value for the need of air in gas. By burning the gas with a small excess of air, the flue gas will contain the remaining oxygen from the air, which has not taken part in the combustion. When the Wobbe-index of a gas changes, the stoichiometric air requirement and the percentage of the remaining oxygen in the flue gas will change simultaneously. The above makes the residual Oxygen a good parameter to base a Wobbe Index value on and that is exactly what is being done within the WIM-9900. 3.2 The determination of the amount of Residual Oxygen Within the analyser the sample gas is mixed with an excess of air. This mixture is directed to an oven heated to a temperature over 800°C. In the first stage of the oven the mixture is burnt catalytically. In the second stage the mixture that has now become a flue gas with residual Oxygen is introduced to an Oxygen sensor. The oxygen sensor in the oven is a Zirconium oxide cell. This cell is a hollow rod from which the outside is exposed to the flue gas whilst the inside has an open connection to atmosphere. To the cell two Pt-electrodes are fixed, the positive one on the outside (gas-side) and the negative one on the inside (atmospheric side). At high temperatures, over 600°C, Oxygen molecules can diffuse through the Zirconium oxide by picking up two electrons from the negative Pt electrode. The Oxygen than moves through as Oxygen-ions, at the outer side of the Zirconium oxide they are converted back again to gaseous Oxygen by release of the two electrons. The thus created electrochemical process can be compared with that of a battery, but with gaseous reactants. The driving force of this process is manifested as an electrical potential difference over the two electrodes in the form of a mV signal. As long as the oxygen concentration of the burning gas is equal to that of the outside air there will be no driving force. However, as soon as there is a difference in partial oxygen presence a potential difference will develop over the electrodes. So the extent of this potential difference is a function of the difference in oxygen concentration. 14 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 3.3 Calculating residual Oxygen from the cell mVolt signal. (Nernst-equation) The relation between the cell voltage and the oxygen concentration in the flue gas is given by the Nernst equation. E= R ⋅T α ⋅ ln 0 4⋅ F α With: E R F T α0 α = Cell voltage in V = Gas constant in J/molK = Constant of Faraday in C/mol = Temperature in the oven in K = Oxygen concentration in the outside air in % = Oxygen concentration in the flue gas % The millivoltage is not completely linear with the Oxygen concentration, this relation is linearised within the analysers control unit. The now linearised milli voltage signal is now used to determine the residual Oxygen percentage. This is done using the formula hereunder. α = α0 ⋅ e With: α α0 E R F T e − E ⋅ 4⋅ F R ⋅T = Oxygen concentration in the burning gas in % = Oxygen concentration in the outside air in % = Cell voltage in V = Gas constant in J/molK = Constant of Faraday in C/mol = Temperature in the oven in K = Constant 2,718 To convert the residual Oxygen percentage to a Wobbe Index value the analyser is calibrated with two gasses with known Wobbe Index values. A low calibration gas with a low (known) Wobbe Index value and a high calibration gas with a high (known) Wobbe Index value. Now the (unknown) Wobbe index value of sample gas can be determined using the following formula. Wobbe = Wh − Wl ⋅ (α − α h ) + Wh α h − αl With: Wh Wl αh = Calibration gas, high Wobbe-value in MJ/Nm3 = Calibration gas, low Wobbe-value in MJ/Nm3 = Oxygen concentration in burning gas at high Wobbe in % 15 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. αl α = Oxygen concentration in burning gas at low Wobbe in % = Oxygen concentration in burning gas in % 3.4 Why measure both Wobbe and CARI index The Wobbe Index value indicates the amount of energy that is generated when combusting 1Nm3 of gas under standard conditions. The CARI index indicates the amount of air needed to burn 1Nm3 of gas. The calorific value of a gas is the amount of energy that is generated with the combustion of 1Nm3 of this gas. However due to pressure differentials in a supply line, for instance caused by valves or flow restrictions, its Density and flow will be influenced and therefor the amount of energy produced will change. The implications of these fluctuations can be red from the flow formula over a restriction as specified hereunder. Qv = α ⋅ A0 ⋅ √ 2∆ρ ÷ ρ With: Qv α A0 ρ = Flow = Restriction factor (resulting valve or other restriction (-s)) = Orifice diameter = Density For this reason the Wobbe Index value is introduced. The Wobbe Index is defined as: W = Hs ÷ √ SG With: W Hs SG = Wobbe index value = Upper heating value (Gross calorific value) = Specific Gravity By using this value the amount of heat that is actually fed to a burner can be determined. To determine the need for air here from one can use fixed values as long as there is no presence of both CO and H2 in the gas. Mixtures of inert gasses and Hydrocarbons have a fixed relationship between air requirement (CARI) and energy contents (Wobbe), knowingly 4,16. Mixtures of inert gasses, CO and H2 also have fixed relationship between air requirement (CARI) and energy contents (Wobbe), knowingly 5,3. The Wobbe Index Meter operates on measuring the amount of residual Oxygen after combustion (for details please refer to the more specific chapters further in this manual). There is a linear relationship between the residual Oxygen content and the CARI, even with the presence of both CO and H2. Also the Wobbe has a linear relationship with the residual Oxygen content, but with the presence of both CO and H2 this is non-linear. 16 van 61 α α Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. SLOPE & OFFSET WIM-9900 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. The typical accuracy on lines with both CO and H2 present is about 0.4% on CARI, on Wobbe this is 2% (due to non-linearity). For this reason we can optionally offer a built-in Density measurement. By using this extra parameter in the calculations we can offer an analogue signal of the Calorific value. 3.5 Analyser calibration and the terms slope and offset. Upon calibration two gasses are offered to the analyser with known Wobbe index values. The known Wobbe index values are entered into the software prior to performing the calibration. Upon a manual or automatic calibration command the analyser will switch from sample to low calibration gas. After stabilisation of the measurement a residual Oxygen percentage corresponding with the low calibration gasses is determined, this value is called αl. The same is done on the high calibration gas. The high calibration gas will produce a lower residual Oxygen percentage than the low calibration gas, the residual Oxygen percentage for the high calibration gas is called αh. The analyser control unit will now calculate a "slope" and an "offset" factor from the following formula; a (Slope) = (Wh - Wl) ÷ (αh - αl) b (Offset) = Wh - a ⋅ αh With: a b Wh Wl αh αl = Slope = Offset = Wobbe Index calibration gas high = Wobbe Index calibration gas low = Residual Oxygen percentage high calibration gas = Residual Oxygen percentage low calibration gas This results in a formula that will give a Wobbe Index value with each residual Oxygen percentage Wobbe Index = a ⋅ α + b With: a α b = Slope = Measured residual Oxygen percentage = Offset 17 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 3.6 The terms "Upper heating value" and "Lower heating value" There is often mentioning of the terms "upper & lower heating value". These terms can also be mentioned as "Upper & lower calorific value" or may be referred to as "Inferior value". These terms all describe the same, knowingly determining the calorific value with or without taking into account the energy that is lost through condensation into water during the combustion process. During the combustion process the Hydrocarbons are converted into Carbon-dioxide and Water. The condensation process into water consumes some energy, as a guideline one can state that every Hydrogen atom attached to the gas molecule will consume about 1mJ of the heating value. Please note; this is only a rough guideline not a rule. Example; The upper Calorific value for Methane (CH4) is 39.816 mJ/Nm3. The lower Calorific value for Methane (CH4) is 35.882mJ/Nm3. The definition of the "Calorific value" is the amount of heat generated at complete combustion of 1Nm3 of gas at standard pressure and temperature. For the European mainland the standard pressure and temperature are defined as 0°C and 1.1013 barA. Since water is under such conditions a liquid the heat of condensation is to included in the calculation. This than is the "Upper Calorific value". In practice one will rarely utilise the heat of condensation from water as this would imply that liquid water is coming out of the combustion process. Therefor this heat of condensation is not included in the "Low or Inferior Calorific value". 18 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. GENERAL LAY-OUT WIM-990 IN P EXECUTION WITH SG CELL & GENERAL LAY-OUT WIM-990 IN LP EXECUTION Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 4. Sample conditioning system 4.1 The main executions For the sample conditioning system there are a few main executions. The sample systems can be divided in an LP and a P version. The LP or low-pressure version is meant for services with low, less than 2.0 barG, or atmospherical sample pressure. The P or pressure version is meant for services with higher sample pressures with a maximum of 10 barG. Both the P as well as the LP version can optionally be equipped with a second mixing chamber to extend the measuring range. The base model with one mixing chamber has a range of 40mJ, with a second mixing chamber this can be extended to 90mJ. The base model is identified as a model 9901, with a second mixing chamber it is identified with 9902. Optionally a density meter can be part of the sample system, this density meter will than be placed directly after the sample pressure regulator. For explanation of the function of this density meter please refer to the specific chapter further in this manual. 4.2 Basic operation of the Sample conditioning system (SCS) Purpose of the Sample conditioning system, or SCS, is to mix air and gas, thus creating a mixture with a residual Oxygen content between 1.5 and 20% after combustion. Mixing of sample gas and combustion air is done in a mixing chamber where both are inserted over an orifice. These orifices result into a critical flow into the mixing chamber. Critical mixing is created by placing two orifices in the mixing chamber directly opposite to each other and have air and sample gas flow in at the speed of sound. Critical mixing is the best way to eliminate influence of pressure and temperature fluctuations in the process and ensure a low lag time through the system. The sample enters the analyser via an air-operated manifold of the double block & bleed type. This manifold is piloted by the electronics of the analyser and switches between the sample gas and the different calibration gasses. Directly after the manifold a filter is mounted which filters to a size of 7 micron. From this point on the sample systems for a P or LP version have a different principle of operation. For a further description please refer to the specific chapters hereafter. 4.3 Function of the instrument air The instrument air introduced to the analyser has a double function, it is used both as pilot air as well as combustion air. For the instrument air a minimum supply pressure of 3.5barG is required. Directly after entering the analyser the air is split into pilot and combustion air. Both lines enter their own pressure regulator and filtration unit (air station). The pilot air pressure is reduced to 3.5barG and routed to the electronics compartment. Inside the electronics compartment it is connected into an electrically (solenoid) operated small manifold. This electrically operated manifold controls the actuation of the different sample and calibration lines on the (block & bleed) sample manifold inside the scs. 19 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. SCHEMATIC DIAGRAM WIM-9900 IN P EXECUTION Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 4.4 Pressure version Sample conditioning system (WIM-9900P) After filtration of the sample gas its pressure is reduced to a setting of 3barG by the pressure regulator directly after the filter. The combustion air is regulated to a slightly higher pressure of 3.5barG. Both sample and combustion airline are routed to a dome loaded pressure regulator (or booster relay) after their individual pressure pre- regulation. The sample gas is connected to the dome side of the booster, the air is connected to the regulating side of the booster. Purpose of this booster regulator is to equalise the pressure of both sample and combustion air. The air pressure is regulated to the sample pressure. This booster regulator has a temperature reducing effect, this can influence the mixing proportion of gas and air due to variations in viscosity. To reduce this effect both sample and combustion air are routed to a tube in tube heat exchanger. The air is introduced to the outer tube and the sample is introduced to the inner tube coil. From here both lines enter the mixing chamber. The difference in pressure drop over the tube in tube heat exchanger is compensated by an offset that is set on the air line by the adjusting screw of the booster regulator. Both sample and air inlet on the mixing chamber are executed with orifices. The gas and airflow are determined by a critical expansion over the orifices. The diameter ratio of the orifices, together with the ratio between air and gas pressure determine the mixing proportion. After the mixing chamber the combustible mixture is divided into an excess flow to atmospheric vent and a flow to the oven where the actual combustion takes place. The flow to the oven is limited by a capillary tube in the line to the oven and secondary by a pressure relief valve directly before the capillary. The relief will open upon to much pressure built-up in the line to the oven. Whenever insufficient sample is vented via the excess sample flow meter the pressure in the line to the oven will rise, causing the relief to open and vent the excess. 20 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. SCHEMATIC DIAGRAM WIM-9900 IN LP EXECUTION Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 4.5 Low pressure version Sample conditioning system (WIM-9900LP) The low-pressure version is meant for applications where pressurisation of the sample gas by a pump is not desired. For instance on applications where the sample is saturated with water or heavy Hydrocarbons on atmospheric pressure and temperature. Pressurisation will than result in condensation which will influence the measurement. Upon presence of Acetylene it is necessary to maintain a low pressure because of the danger of detonation. To ensure critical flow over an orifice the absolute pressure before the orifice must at least be twice as high as after the orifice. In the LP version the pressure in the mixing chamber is about atmospherically. Therefor the pressure in the mixing chamber may not exceed 0.5barA. This under-pressure is created by a bellow type suction pump after the mixing chamber. To ensure a proper mixing of sample gas and combustion air, pressure and temperature must be equal upon entering the mixing chamber. The pressure is being equalised in an LP version by an open connection to atmosphere in both air and sample line where an excess is vented. The excess flow is limited by orifices in the air and sample line. The orifices in the mixing chamber are chosen in such a way that a positive flow is endured through the atmospheric equalisation lines (a gas will never flow faster than the speed of sound, regardless of the pressure drop over a critical orifice). The bellows type suction pump is mounted in between mixing chamber and the oven. The pump is placed after the mixing chamber to eliminate condensation of the sample. Since the sample has been mixed in 1:10 ratio with air, its dew point is lowered sufficient to avoid condensation. After the pump the combustible mixture is divided into an excess flow to atmospheric vent and a flow to the oven where the actual combustion takes place. The flow to the oven is limited by the flowrate of 1Nl/min of the oven and the setting of the flowmeter in the excess sample vent line. 21 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. SCHEMATIC DIAGRAM WIM-9900 IN EXTENDED RANGE EXECUTION & FLIP - FLOP LOGICS Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 4.6 The extended range version The measuring span of the Wobbe index meter can be extended from 40MJ to 95MJ. This is accomplished by adding a second gas-mixing chamber with its own set of orifices and selection valves. The dilution ratio of each mixing chamber is chosen such that the measuring ranges overlap. Via the software it is possible to create a mA signal that covers the whole range. It is necessary to establish a switch over point that must be calibrated. For this reason the calibration system is expanded with a third calibration gas. In the figure 4.6 the relationship between the output voltage from the Zirconia cell versus the Wobbe Index value is shown. The instrument activates as a default the low range valves. During the calibration the voltage which causes a change over to the high range is determined. This so called “flip voltage” is shown at position A. And is calculated from the calibration voltage at B. The computer adds a fixed voltage to create a hysteresis to prevent multiple changeovers due to small process fluctuations. The same situation occurs when the Wobbe index is decreasing in the high range position. When the voltage is below position C, the valves are switched over to the low range. The “flip voltage” is calculated from the calibration voltage at D, subtracted with a predetermined hysteresis voltage. The arrows in the figure indicates how the Zirconia cells voltage changes when the system changes over from low range to high range or vica versa. After a change over the measured value is kept constant during the “range switch hold” time. During a 3-point calibration, the switching voltage will be calculated, as well as the calibration parameters (zero and span coefficients) for the low and high range. 4.7 The density (or Specific Gravity) Meter To start with, the definitions; The density of a gas is the weight of the gas per Nm3. The Specific Gravity (or SG) of a gas is the density of a gas relative to the density of air. Meaning the density of the gas is divided by the density of air. Example; The density at standard conditions of Methane is 0.7175 kg/Nm3. The density at standard conditions of air is 1.293 kg/Nm3. The Specific Gravity of Methane than is 0.7175 ÷1.293 = 0.5448 Optionally a density meter can be added to the Wobbe Index Meter. The meter is placed after the sample pressure regulator where pressure is constant. Because the pressure is constant the unit can be calibrated as if the received signal is a Specific gravity signal. The known Specific gravity values for the high and low calibration gasses are entered and linked to the meters 4mA and 20mA (low cal is 4mA and high cal is 20mA). This signal is used to display and output the Specific Gravity and calculate the Calorific value. 22 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. GENERAL LAY-OUT ELECTRONICS COMPARTMENT Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 5.0 The electronics 5.1 General CAUTION: Attempting to perform electrical procedures without turning off the power could result in an electrical shock hazard to personnel and damage to the Wobbe analyser! The electronics of the analyser can roughly be divided into power distribution components, the computer plus display and the interface prints. First component in the power line is the over-voltage protector, this protects the analyser against too high currents. Second in the power feed line is the interference filter, this is only applicable to EMC compliant units. After these the power is fed to three different powersupply modules. One converts the Ac current to 24 volts DC for the interface board and its outputs. The other converts the Ac feed to 12 and 5 volt DC, these are used for the PC and the display. The third is a transformer that converts either the 230Vac or the 115Vac to 60Vac to power the oven. Calculations in the analyser are made by the PC, this is a normal PC built-up from a CPU an IO and an AD card. The display is a TFT type. Hart of the electronics is the by Hobré instruments developed interface board. On this PCB the mV signal from the oven is converted to a mA signal which the computer can use for its calculations. The interface board also bears isolation relays for incoming digital signals. An isolation relays print for digital output signals can be added as an option. The board also controls the switching of several solenoids inside the analyser and features a watchdog function to detect malfunctioning of the PC and generate an alarm when necessary. There is also a temperature sensor mounted on the interface board to measure the temperature inside the electronics compartment and display it on screen. Last function of the board is, as its name already implies, interfacing. All incoming and outgoing signals are routed via this board. The signals are terminated on terminal strips to ensure easy access and connection by clients. The oven temperature controller is also mounted inside the electronics compartment as well as a small electrically actuated manifold. This manifold controls on its turn the mechanical sample / calibration manifold inside the sample conditioning system. 23 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 6.0 Installation 6.1 Mechanical hook-up All mechanical connections on the WIM-9900 are compression type fittings. They are of the double ferule type from the make Swagelok in imperial sizes. These fittings may not be overtightened, upon connection please act according the instructions further in this manual. 6.2 Points of attention for sample supply * To avoid condensation in the sample supply line to the analyser it is advisable to heat trace and insulate the line to maintain a temperature above dew-point. This temperature is depending on the process data. * To ensure a fast response of the analyser the length between take-off point and analyser should be as short as possible. If possible route line sloped back to the take-off point. A pre-pressure regulation to 3.5barG can best be done directly on the take-off point, the diameter of the supply line should also be as small as possible, advised is a line of 1/8" or 3mm. The combination of pressure and low diameter result in a fast flow to, and therefor response of, the analyser. 6.3 Points of attention for oven vent and drain. * Whilst the sample supply line should be traced to avoid condensation it is advisable to trace both vent and drain of oven to avoid freezing up of condense after combustion. * The drain connection will bleed droplets of condense, when not connected to a drain collection header it is advisable to put a drain collection bottle under it that is emptied on a regular basis. Determine the regularity upon experience. 6.4 Points of attention for atmospheric vent lines On all executions of the WIM-9900 there are three atmospheric vents: First is the bleed vent of the manifold block. When the sample manifold block is switched to another line (upon calibration), it first bleeds its own internal volume to avoid crosstermination. This bleed will vent pure sample or calibration gas, this is only a few cc's, knowingly the internal volume of the manifold. 24 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. * Best is to leave the bleed vent of the manifold block as an open atmospheric vent. Second vent is the atmospheric vent for the excess sample. Since this is behind the mixing chamber the sample will have been diluted with air (1 sample : 10 air). In case of a P version analyser the safety relief of the sample pressure regulator is also connected to this vent. In case of failure of the sample pressure regulator the sample will be routed to this vent. Third vent is the vent of the oven. In normal operation no flammable substances will be vented. * The vent for excess sample and the oven vent may be manifold into a flare collection header as long as back-pressure from such a line is limited. 25 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 6.5 Swagelok instruction 26 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 6.6 Electrical hook-up CAUTION: Attempting to perform electrical procedures without turning off the power could result in an electrical shock hazard to personnel and damage to the Wobbe analyser! Electrical hook-up can be split into power supply connections, digital alarm in- & output and analogue in- & output. Due to the project specific character of each unit, Ex- or non Exexecutions with or without EMC features and with or without isolating relays boards for instance, the electrical connections for each analyser differ. We therefor refer to the project specific drawings for each analyser that are included in this manual. Because of differences in local regulations and different styles of explosion protection (European and American style) cable glands are not included in the supply of the analyser. We will be happy to assist in determining the correct cable glands for your specific need taking into account the your plants regulations on cable types (armoured or non-armoured, etc). 6.7 Connecting power CAUTION: Attempting to perform electrical procedures without turning off the power could result in an electrical shock hazard to personnel and damage to the Wobbe analyser! Before applying power to the analyser unit check that the unit has been configured for the correct power supply, 115Vac or 230Vac, 50Hz. Before actually connecting the power main power supply to the analyser open all fuse terminals. Leave them in the open position until start-up. There are two power connections to the analyser unit, first is the main power in which feeds the analysers electronics. This consumes about 350Watts, main user is the 300Watt oven. Second power supply is the power feed to the optional heating circuit inside the sample conditioning system. Optionally the WIM-9900 is equipped with a 600Watt heater. For connection details please refer to the project specific drawings. 6.8 Connecting Digital in- & output The Wobbe Index Meter features 16 different digital alarms as output and 8 digital input possibilities. The signals can best be connected using a multi-core cable. Routing of the digital alarms to their output terminals is selectable and can be changed within the software. For connection details please refer to the project specific drawings. 6.9 Connecting analogue signals The base unit normally features two analogue outputs, and one analogue input. Optionally the number of analogue outputs can be extended to 4 outputs. It is advisable to use individually screened paired cables to prevent interference. 27 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. When your Wobbe Index Meter is supplied in an Ex- execution it is advisable to add isolation barriers on the signal on control room side. For connection details please refer to project specific drawings. 28 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 7.0 Start-up 7.1 General We strongly recommend to have one of our service engineers present upon start-up. To do a proper start-up it is necessary to have calibration gasses present that are representative for the sample to be measured. Determining the correct calibration gasses and orifices is a specialisation in which the Hobré sales department will be happy to advise. No special tools are required, except for the calibre needed to exchange orifices in the mixing chamber. The calibre is supplied with the unit. 7.2 On-site support & training The Hobré Instruments scope of supply does not end upon delivery of equipment. The Hobré service department can provide you with technical assistance, on-site support, training and spare parts. We have a well equipped workshop for repairs. Hobré Instruments has a well equipped and well trained service department that can be hired for commissioning, start-up and maintenance. Service contracts can be concluded to secure proper preventive maintenance on the equipment without putting a burden on customers service department. Our service department can provide you with on-site training or at our location in Purmerend, The Netherlands. Standard training courses are available and can be adjusted to meet individual client's requirements. Please inquire. 7.3 Precautions upon start-up WARNING: Bottles typically have very high pressures and may result in serious injury to personnel if the bottle valve is opened without a regulator attached or if the valve is broken off the bottle. See the following paragraphs for more information. CAUTION: Attempting to perform electrical procedures without turning off the power could result in an electrical shock hazard to personnel and damage to the Wobbe analyser! Perform a visual inspection of the system and close all shut-off valves in the system. Before applying gas and air to the apparatus check that the correct lines are connected to the correct entries on the analyser against the project specific drawings. Leak test the connections with nitrogen and soap (snoop). Before applying power also check that electrical connections have been made in accordance with the project specific drawings. 29 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. ADJUSTMENT BOOSTER REGULATOR Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 7.4 Start-up Sample system WARNING: Ovens, internal components, and sample system components may be hot even when power is not applied to the unit. Take appropriate precautions to prevent injury from contact with hot items. After the leak test and check of correct connections both electrically and mechanically the shut-off valve on the air line may be opened. Please note; the electronics of the analyser will keep the sample / calibration manifold closed until the oven is on temperature. This will result in noisy venting of the air via the booster regulator. As soon as the oven is on temperature the analyser will open the sample line and the noisy venting will stop. Keep the air shut-off valve closed until the oven is on temperature. When the oven is on temperature check the setting of the sample pressure regulator, again check against project specific drawings for settings for P or LP versions differ. Also check the flow rate to the oven. Adjustment can be done via the flow over the excess sample flow meter. This may be a bit of its setting due to transport and the hook-up of vent lines, set it to such a value that the reading of the flow to analyser on the flow meter right next to the excess meter is about in the middle of its scale. 7.5 Setting the booster regulator Function of the pressure booster relay is equalisation of both sample and air pressure. It also deletes pressure differences due to different pressure drop over the tube in tube cooler. This is also described in the text of the different sample systems. It can also be used to fine-tune the desired residual Oxygen percentage. Purpose is to achieve a mV signal of maximum 70mV on the high end of the measuring range. The residual Oxygen percentage is mainly determined by the choice of the orifices. With this booster relay it can be fine-tuned. This is achieved by setting a small negative or positive offset. Keep such an offset within 0.5 bar. In order to achieve the necessary offset pressure, the insert with internal hexagon at the top of the booster relay must be removed. By doing this, the slotted adjusting screw is accessible, refer to figure 7.5. By means of a small rotation counter clockwise, a bigger negative offset is reached. In other words, the air pressure is lowered in comparison with the gas pressure. CAUTION: The adjusting screw is located in the gas compartment of the relay. When the insert is released, gas will escape. Be prepared before the relay is going to be adjusted, e.g. have the right equipment readily available, so the gas compartment has to be open for only a minimum of time. The adjusting screw is located in the gas compartment of the relay. When the insert is released, gas will escape. Be prepared before the relay is going to be adjusted, e.g. have the right equipment readily available, so the gas compartment has to be open for only a minimum of time. After this adjustment the insert must be fitted again and the offset can be checked. The offset adjustment can be checked by reading the air and gas pressure indicators. This operation must be repeated until the desired residual oxygen concentration is reached. After this the 30 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. insert is fitted with sealing tape, assembled and then checked for leakage by means of either a gas leak detector or soap. * It is advisable, to carry out a check on the booster relay adjustment with high Wobbe-Index calibration gas, directly after setting up the booster set point. It is advisable, to carry out a check on the booster relay adjustment with high Wobbe-Index calibration gas, directly after setting up the booster set point. Choose the option “manual calibration” in the option menu and select the “High Wobbe Index calibration gas”. The display will now show the mV-value suitable to this calibration gas. The setting of the booster relay is right when the mV-value stays below 67 mV. If not, a positive offset should be set with help of the booster relay, so that relative more air will be added and the mV value will fall. The required mV-signal should be around 65mV for the highest expected Wobbe value. CAUTION: Attempting to perform electrical procedures without turning off the power could result in an electrical shock hazard to personnel and damage to the Wobbe analyser! Before connecting the power cables all fuse terminals inside the electronics have been opened. These may now be closed one by one. This will result in an automatic start-up of the analysers computer and the screen will come to live. For an explanation of readings on the display please refer to the software chapter of this manual. The oven will start to heat itself up, this may take about half an hour. The analyser is now operative. 7.6 Determining the correct orifice size and calibration gasses Upon proper supply of sample composition with the placing of the purchase order Hobré instruments will set-up and fine tune your analyser to the desired measuring range. The analyser will than be foreseen with the correct orifices. To enable us to do so it is of the utmost importance that the questionnaire received with the acknowledgement of the order has been filled out and returned. Determining the correct calibration gasses and orifices is a specialism in which Hobré's sales department will be happy to advise. Please make sure to have a sample composition data sheet present upon inquiry. Especially when high and fluctuating concentrations of CO, H2 or CO2 are present within the gas this is critical information we need to properly determine the calibration gasses and orifice sizes. Calibration gasses should always have a similar composition as the sample gas analysed. 31 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 8.0 In operation 8.1 General When the analyser is started up it is controlled by the software settings and the readings on the internal display. This chapter will describe the structure and function of individual fields in the program. To start with we like to explain the different fields on the display. 8.2 How to read the display The main display can roughly be divided in three sections. The left top section is normally identified as the "Small display". Here are multiple parameters displayed such as cell millivoltage and residual Oxygen percentage. What exactly is displayed and in what order is programmable and will be explained further on in this manual. In the right hand top the analyser version, software version plus time and date are displayed, directly under here the measured value is displayed. Normally the Wobbe value is displayed, but it can be programmed to display for instance CARI. How this can be changed is explained further on in this manual. The lower half of the screen is divided into two charts where the measured values are displayed as a graph. Normally the Wobbe value and the residual Oxygen percentage are displayed but these can be changed to for instance CARI and SG values. In the middle of the screen a small strip with two digit codes is displayed. These codes are abbreviations of the in- and outputs. When a square green box is displayed around a code this indicates that the specific in- or output is active. The first 8 codes indicate internal actions within the analyser. The sequence of these is fixed. The 8th until 16th code are status indications of the alarm outputs. Please note; there are more output codes than shown on screen, which codes are displayed is depending on their routing to terminals (the screen follows the sequence of termination). The 8 codes to the right hand side indicate the status of input codes. Hereunder is a list with the abbreviations and their meaning. 8.3 Displayed Output abbreviations 1 2 3 4 5 6 7 8 9 10 Status code c1 c2 c3 ra rb s0 s1 s2 s3 hi Signal Description Digital out gas 1 Digital out gas 2 Digital out gas 3 Digital out Range 1 Digital out Range 2 Digital out Stream 0 Digital out Stream 1 Digital out Stream 2 Digital out Stream 3 Digital out Wobbe High Low calibration gas valve activated Middle calibration gas valve activated High calibration gas valve activated 1st mixing chamber active 2nd mixing chamber active (extended range only) Sample stream 1 active Sample stream 2 active (multi-stream only) Sample stream 3 active (multi-stream only) Sample stream 4 active (multi-stream only) High Wobbe alarm output active 32 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 11 12 13 14 15 16 17 18 19 20 21 22 23 24 lo ca va cf io sf be sp ap wd g0 g1 v0 v1 Digital out Wobbe Low Digital out Calibrating Digital out Validating Digital out calibration Fault Digital out In Operation Digital out Fault Digital out Pressure Cal Digital out Pressure Sample Digital out Pressure Air Digital out Watchdog Pulse Gas 1 active Gas 2 active Gas 1 valid Gas 2 valid Low Wobbe alarm output active Analyser in calibration active Analyser in validation active Calibration error Analyser in operation active Collective alarm active (system fault) Pressure switch calibration bottle active (optional) Pressure switch sample line active (optional) Pressure switch air line active (optional) Watchdog communication error active Sample 1 being measured Sample 2 being measured Sample 1 valid measurement Sample 2 valid measurement 8.4 Displayed Input abbreviations 1 2 3 4 5 6 7 8 9 Status code wd ca va fa fb be ap sp ss Signal Description Digital input Watchdog Dig. in Calibration requirement Dig. in Validation requirement Flow alarm A Flow alarm B Digital Input Pressure Calgas Digital Input Pressure air Digital input Pressure sample Select stream Watchdog communication error active (input PC) External calibration command active External validation command active Flow switch A active Flow switch B active Pressure switch calibration bottle active (optional) Pressure switch sample line active (optional) Pressure switch air line active (optional) External stream switch command On the bottom of the screen alarm messages are displayed. Whenever an alarm is activated the descriptive text, for instance "Wobbe too high", will be displayed on a flickering background. All alarms have to be acknowledged via the function "Reset alarm". If the cause of the alarm has been solved the message will disappear. If the alarm is acknowledged by "Reset alarm" but still current the message will remain to be displayed but its background will stop flickering. 8.5 The software menus From the main display lay-out that indicates measured values and status information one can enter the settings and parameters menus by pushing either < ESC > or < ENTER >. From the main screen one will end up in the "measuring menu" screen. The different menus hereunder can be reached by entering the number corresponding with the desired menu. At the end of this chapter an overview of the software tree for ease of navigation. 33 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. (8.5) < ESC > or < ENTER > Measuring Menu In the measuring menu the following sub-menus are available: 1. Change Parameters: Set-up of the global analyser parameters like oven temperature, measurement range, etc. 2. Display Options: Set-up of display options. 3. Calibration: Set-up of calibration parameters. 4. Reset Alarm: Reset alarm indication. 5. Login: Enter a password to enter protected menus. (8.5) 1. Global Settings Menu 1. 2. 3. 4. 5. 6. 7. Calibration: Temperature: Current Outputs A, B: Current Outputs C, D: Oxygen Parameters: Wobbe, Cari, Calorific: Other Options: Set up of calibration settings. Set up of oven parameters. Set up of current outputs. Set up of current outputs. Set up of oxygen parameters. Set up of Wobbe Index, Cari and Calorific parameters. Several other settings, for instance dual (or extended) range parameters. (8.5) 1.1 Calibration Settings 1. Automatic Calibration: 2. Timed Calibration: 3. Timed Calibration Method: 4. Remote Calibration: 5. Cal Start Delay: 6. Cal Gas Switch Time: 7. Calib Error Detect: 8. Calib Error Perc.: Switched off when calibration valves are operated manually Here the time to the first calibration can be set. This field offers two options; “Weekly” and “Repeat”. When “Weekly” is chosen the automatic calibration schedule can be programmed to a schedule that is repeated weekly. Separate calibration times can be entered per day of the week. When “Repeat” is chosen the automatic calibration schedule can be entered for one fixed point in time and a repeat interval is entered. For details please refer to “Calibration schedule”. When "on" is selected, it is possible to start external calibration or validation, by activating an input contact. Delay between closing the calibration contact and the actual start of calibration. Stabilisation time is entered, which is needed after switching the solenoid valves. Switch off/on calibration fault alarm. Deviation percentage slope or offset value activation alarm. 34 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. (8.5) 1.2 Current Outputs A, B 1. Output A Signal: 2. 0/4 mA Value: 3. 20 mA Value: 4. During Cal: 5. Output B Signal: 6. 0/4 mA Value: 7. 20 mA Value: 8. During Cal: The dimension for output A can be chosen, options are; OFF / Cari / Wobbe / Oxy / Calorif / 25% / 50% / 75% / High / SG. Enter the lowest value of the measurement range. Enter the highest value of the measurement range. Select display method during calibration for Output A, options are; Hold / Track / 0-4mA. The dimension for output B can be chosen, options are; OFF / Cari / Wobbe / Oxy / Calorif / 25% / 50% / 75% / High / SG. This is the lowest value of the measurement range. This is the highest value of the measurement range. Select display method during calibration for Output B, options are; Hold / Track / 0-4mA. (8.5) 1.3 Current Outputs C, D 1. Output C Signal: 2. 0/4 mA Value: 3. 20 mA Value: 4. During Cal: 5. Output D Signal: 6. 0/4 mA Value: 7. 20 mA Value: 8. During Cal: The dimension for output C can be chosen, options are; OFF / Cari / Wobbe / Oxy / Calorif / 25% / 50% / 75% / High / SG. Enter the lowest value of the measurement range. Enter the highest value of the measurement range. Select display method during calibration for Output A, options are; Hold / Track / 0-4mA. The dimension for output D can be chosen, options are; OFF / Cari / Wobbe / Oxy / Calorif / 25% / 50% / 75% / High / SG. Enter the lowest value of the measurement range. Enter the highest value of the measurement range. Select display method during calibration for Output B, options are; Hold / Track / 0-4mA. (8.5) 1.4 Oxygen Parameters 1. Oxygen Low Alarm: Alarm level for low cell voltage 2. Oxygen High Alarm: Alarm level for high cell voltage 3. Z Factor Normal: Factor for “Advanced averages” "Advanced averages"; The measurement signal shows a noise. To reduce noise as much as possible, the signal will be filtered by an algorithm; the advanced averages. A higher Z-factor will give more noise suppression and the signal will be more stable. A lower Z-factor will give less noise suppression but a faster response. 4. Z Factor Calibration: See 3 Z factor normal. 5. Oxy Cal. Offset: Correction for difference in the actual 02 signal and reproduced value at a low mV voltage. (<5 mV) 6. Oxy Slope: Correction for difference in the actual versus the reproduced oxygen content at a high mV voltage (> 80mV) 35 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. (8.5) 1.5 Wobbe, Cari, Calorific Options 1. Wobbe Index Parameters: 2. Cari Index Parameters: 3. Calorific Value Parameters: Set-up of Wobbe Index Measurement. Set-up of CARI Index Measurement. Set-up of Calorific value parameters. (8.5) 1.5.1 Wobbe Index Parameters 1. Wobbe Dimension: 2. Wobbe C0 (offset): 3. Wobbe C1 (span): 4. Wobbe HR C0 (offset): 5. Wobbe HR C1 (span): 6. Wobbe High alarm: 7. Wobbe Low alarm: 8. Wobbe Chart Step-size: 9. Wobbe Chart Step-count: The following units can be selected: MJ/ Nm3, Kcal/ Nm3, BTU/SCF, MJ/Sm3. Intercept low range calibration. Span coefficient for low range calibration. Intercept high range calibration (Extended range only WIM 9902) Span coefficient for high range calibration (Extended range only WIM 9902) High alarm level for Wobbe Index. Low alarm level for Wobbe Index. Field where step-size (chart scale) for Wobbe chart on display can be entered Field where no off steps for Wobbe chart on display can be entered (8.5) 1.5.2 CARI Index Parameters 1. Cari C0 (Offset): 2. Cari C1 (Slope): 3. Cari HR C0 (Offset): 4. Cari HR C1 (Slope): 5. Cari High Alarm: 6. Cari Low Alarm: Intercept low range calibration. Slope coefficient for low range calibration. Intercept high range calibration.(Extended range only WIM 9902). Slope coefficient for high range calibration (Extended range only WIM 9902). High alarm level for CARI index. Low alarm level for CARI index. 36 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. (8.5) 1.5.3 Calorific Value Parameters 1. Spec Grav Input: 2. 3. 4. 5. 6. 7. 8. Enable or disable current input from specific gravity meter. Low Voltage: Lowest current value from specific gravity meter. Low SG: Enter known specific gravity value for low calibration gas. High Voltage: Highest current value from specific gravity meter. High SG: Enter known specific gravity value for high calibration gas. SG Low Alarm: Enter low alarm level for specific gravity. SG High Alarm: Enter high alarm level for specific gravity Calor. dimension The following units can be selected: MJ/Nm3, kcal/Nm3, BTU/SCF, MJ/Sm3, kJ/kg, MJ/kg (8.5) 1.5.4 Density Parameters 1. Density dimension: 2. Gr chart stepsize 3. Gr chart stepcount: 4. Process pressure: The following units can be selected: kg/Nm3, lbs/CF Field where step-size (chart scale) for Density chart on display can be entered Field where the no of steps for Density chart on display can be entered Enter the pressure the analysers sample pressure is set to. Thus enable unit to calculate a proper Density output signal under standard conditions Both H2 and CO have a non linearity in the relation Wobbe Index - residual Oxygen after combustion. Because of this effect the compensation formula Value = Value + (A:SG) + B is introduced where the A and B are correction factors. The determination of these fixed compensation factors is to be done on a case to case basis by Hobré instruments. 5. H2 factor A: 6. H2 factor B: Correction factor A for compensation of non linear components Correction factor B for compensation of non linear components (8.5) 1.6 Other Options 1. 2. 3. 4. Values Display Layout: Temperature: Dual Range Parameters Multi-Stream Parameters Set-up of values layout on display. Set-up of oven parameters. Set up for Extended Range parameters (9902 only). Set up for Multiple sample streams 37 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. (8.5) 1.6.1 Values Display Layout The top left-hand display area (normally called “Small display”) can display several parameters on the 6 text lines available. One can choose from the following parameters: None / Wobbe / Cari / Oxy mV / Oxy % / Oven Temp / SG / Calorif / Board Temp / Board Po / SG Voltage. Via this screen one can built 4 different sets (of 6 parameter lines) which can be easily switched between. Please refer to “Small display mode” for details on how to switch between the screens. 1. 2. 3. 4. Mode ‘Normal’: Mode ‘Values’: Mode ‘Others’: Mode ‘Calibrating’: Field to adapt first parameter set on small display. Field to adapt second parameter set on small display Field to adapt third parameter set on small display Field to adapt fourth parameter set on small display. (8.5) 1.6.1.1 Mode ‘Normal’ Layout 1. 2. 3. 4. 5. 6. Normal 0: Normal 1: Normal 2: Normal 3: Normal 4: Normal 5: Select parameter to be displayed on first text line. Select parameter to be displayed on second text line. Select parameter to be displayed on third text line. Select parameter to be displayed on fourth text line. Select parameter to be displayed on fifth text line. Select parameter to be displayed on sixth text line. (8.5) 1.6.1.2 Mode ‘Values’ Layout Identical as Mode ‘normal’ layout (8.5) 1.6.1.3 Mode ‘Others’ Layout Identical as Mode ‘normal’ layout (8.5) 1.6.1.4 Mode ‘Calibrating’ Layout Identical as Mode ‘normal’ layout (8.5) 1.6.2 Temperature Settings 1. Oven Temp Required: 2. 3. 4. 5. Oven Temp Low Alarm: Oven Temp High Alarm: Oven Temp Z Factor: Oven Temp Adjustment: 6. Warm-up Delay: 7. Operation Delay: 8. Oven Cal Offset: 9. Oven Cal Slope: Temperature to be equal to the oven temp set point. The value is used in the cell mV to oxygen calculation. Low temperature alarm level. High temperature alarm level. Averaging factor, used in algorithm to minimise noise. Can be switched ON/OFF. When switched on the actual oven temperature is used in the calculation, Normally off. No reproduction measurement signal during the initial heating period. No reproduction measurement signal during the delay period. Value to correct the offset between the regulated temperature and the displayed temperature. Value to correct the difference in span between the regulated temperature and the displayed temperature. 38 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. (8.5) 1.6.3 Dual Range Parameters 1. Enable Dual Range System: 2. Oxygen Flip Above: 3. Oxygen Flop Below: 4. Range Hysteresis +mV: 5. Range Hysteresis +mV: 6. Range Switch Hold: When a dual range system is physically present, this. value is set to on. This voltage sets the change pint from low to high range. It can be set manually, but it is also calculated automatically during a calibration. This voltage sets the change pint from high to low range. It can be set manually, but it is also calculated automatically during a calibration. This voltage is added to the medium calibration gas mV signal, during a calibration when the low range is selected. This voltage is subtracted to the medium calibration gas mV signal, during a calibration when the high range is selected. This value determines the stabilisation time after a range change. During the stabilisation time, the output signal will be frozen. Range switching will not be initialised. (8.5) 1.6.4 Multi-stream Parameters The analyser can switch between multiple sample streams. Please note that the composition of the streams must be equal or near equal since the analyser utilises one set of calibration parameters for all measured lines. After a stream switch action the analyser will transmit a live signal for the measured stream. The signals for other streams will be frozen and permanently transmitted on the last known value. There are 4 different operation modes: "Off" : All multi-stream features de-activated "Remote" : Stream switching activated by external input command "Continue" : The analyser will continuously measure the stream selected "Timer" : The analyser will measure each stream for the time period entered Note: When the analyser is set to one of the 4 operation modes switch commands from other modes will be ignored. For instance: If the analyser is set to "Timer" an external switch command via the inputs will be ignored. 1. Multi-stream mode: 2. Number of streams: 3. Continuous stream: 4. Measuring time stream 0: 5. Measuring time stream 1: 6. Switch delay: Select the operation mode for stream switching Set this field to the number of streams connected to the analyser Set to the desired stream to be measured continuously Enter the time period the analyser is to continuously measure stream 0 Enter the time period the analyser is to continuously measure stream 1 Enter stabilisation period after stream switch command. During this fixed time period the analyser will remain the analogue signal outputs on the last known value and delay the actuation of the stream valid contact. 39 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. (8.5) 2. Display Options 1. Large Display Mode: 2. Small Display Mode: 3. Top Chart Mode: 4. Bottom Chart Mode: Parameter shown in the large display can be selected here. Parameters shown in the upper left screen can be selected here. Parameter shown in the top chart can be selected here. Parameter shown in the bottom chart can be selected here. 40 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. (8.5) 3. Calibration 1. Edit Cal Gas Parameters: 2. Calibration Schedule: 3. Start Calibration: 4. Start Validation: In this selection the calibration gas definitions are entered. Here a weekly calibration schedule is established. Start an automatic or a manual calibration. Start an automatic or a manual validation. (8.5) 3.1 Edit Cal Gas Parameters 1. 2. 3. 4. 5. 6. 7. 8. Cal Gas 1 Wobbe: Cal Gas 1 Cari: Cal Gas 1 SG: Cal Gas 2 Wobbe: Cal Gas 2 Cari: Cal Gas 2 SG: Cal Gas 3 Wobbe: Cal Gas 3 Cari: Wobbe index value low calibration gas. Cari value low calibration gas. Specific gravity value low calibration gas. Wobbe index value medium calibration gas. Cari value medium calibration gas. Specific gravity value high calibration gas. Wobbe index value high calibration gas. Cari value high calibration gas. (8.5) 3.2 Calibration Schedule (Weekly) This screen appears when “Timed calibration method” is set to “Weekly”. This screen reproduces a schedule of the established calibration or validation times over a week. ‘C’ stands for calibration and ‘V’ stands for validation. Adaptations are possible by choosing a day. For example when you press number 4, the schedule for Thursday will appear. Changes can be done by simply typing in the required time. By choosing VAL, slope and offset will not be adjusted (’V’ will appear behind the point of time in the main menu). 41 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. (8.5) 3.2 Calibration Schedule (Repeat) This screen appears when the “Timed calibration method” is set to “Repeat”. Via this screen one can enter a point in time for calibration and a repeat interval. (8.5) 3.3 Start Calibration 1. Start Automatic Calibration: An automatic calibration cycle is going to be started; intercept C0 and the slope C1 will be calculated. 2. Manual One-Point Calibration: Only one calibration gas is used for manual calibration, only C0 will be adjusted. 3. Manual Two-Point Calibration: Two calibration gasses are being used during the manual calibration. 4. Manual Dual-Range Calibration: Three calibration gasses are being used for manual calibration (Extended range only WIM 9902). If chosen for a manual calibration (Figure Manual one point Calibration), the instructions for the operator will appear on the display. Opening or closing the valves must only be done when the measurement value is stable. 42 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. (8.5) 3.4 Start Validation 1. Start Automatic Validation: 2. Manual One-Point Validation: 3. Manual Two-Point Validation: 4. Manual Dual-Range Validation: An automatic validation cycle is going to be started. Only one validation gas is used for manual calibration. Two validation gasses are being used during the manual calibration. Three validation gasses are being used for manual validation. (Extended range only WIM 9902). If chosen for a Manual validation (Figure Manual one point validation), the instructions for the operator will appear on the display. Opening or closing the valves must only be done when the measurement value is stable. (8.5) 4. Alarm Reset When the cause of the signal fault is solved, the alarm indication on the screen and the output contact will disappear. (8.5) 5. Login By choosing option 5 “Login”, the secured menu will appear. After entering the 4-digit pincode, entrance to the secured menus is possible. 43 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. (8.5) 5.1 Login Menu After pressing 1, it is possible to fill in the pin-code (Figure Login). Enter the 4-digit pin-code (3224). Then press “Enter”. (8.5) 5.* Logged In After you have entered the 4-digit PIN-code and pressed “Enter”, ‘Login’ appears in the lower right corner. After pressing “Enter” again the following screen will appear: 1. Exit Program: 2. Restart: 3. Load Update: 4. Logout: 5. Change PIN: return to DOS. Restart program. Only when a disk drive is connected to the CPU, A software update floppy can be loaded. Protected menu exit. Change pin code. 44 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. *(8.5) 6 Measuring Menu The following menu will be available by giving a return in the ‘Logged In’ menu. 1. 1– 4. Same as before login: 5. Exit/Restart/Logout: 6. Test Menu: 7. System Settings: In this menu the digital and analogue outputs can be tested. Various system settings can be changed here. This menu option is only available after logging in as Hobré. Only Qualified personnel is allowed to change the system settings 45 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. (8.5) 7.* Test Menu The analogue and digital in- and outputs can be tested in this menu. By activating the test menu, the normal program stops. This means that measures should be taken first to prevent that the process will be influenced. In the test menu the digital outlets can be manually activated and tested and the analogue outputs can be tuned. (8.5) 7.1* Test Digital Outputs I By entering a number (1-8) the corresponding outputs can be activated (1) or deactivated (0). This is also shown at the status bar. For example, by pressing 7 and then 1, the outlet contact of stream 2 will be activated. The indication S2 in the status bar will lighten up. Range 1 is for testing the high/low measuring range in case of a dual range, execution. (8.5) 7.2* Test Digital Outputs II Identical to "Test Digital Outputs I" (8.5) 7.3* Test Analogue Outputs A/B The analogue outputs can be tested by entering a percentage under 1 (output A), or 4 (output B). If a deviation is noticed, it can be corrected with 2 for output A (and 5 for output B) to correct the 0mA. The 20mA can be corrected by 3 for output A(and 6 for output B). The stream outlets are 16 bits, essentially 4000 equals 20mA and 800 equals 4mA. 46 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. (8.5) 7.4* Test Analogue Outputs C/D Identical to "Test Analogue outputs A/B (8.5) 8. System Settings 1. 2. 3. 4. 5. 6. 7. 8. Dig Inputs I Dig Outputs I Dig Outputs II Dig Outputs III Dig Inputs Polarity Dig Outputs Polarity I Dig Outputs Polarity II Save Changes And Restart (8.5) 8.1* Channel Routing Inputs In this menu several digital inputs signals can be assigned to the corresponding required actions on inputs. 47 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. (8.5) 8.2* Channel Routing Outputs I With this menu the several internal control signals can be coupled to the physical digital output. For example: choice 3, the signal “calibration “ is assigned with contact outlet 10. When “-1” will appear, it means that there is no output selected. (8.5) 8.3* Channel Routing Outputs II Identical to "Channel Routing Outputs I". (8.5) 8.4* Channel Routing Outputs III Identical to "Channel Routing Outputs I". (7.5) 8.5* Polarity Inputs In this menu it is possible to record if the inlets are normally opened (0) or closed (1) (8.5) 8.6* Polarity Outputs I In this menu it is possible to record if the outputs are normally opened (0) or closed (1). (8.5) 8.7* Polarity Outputs II Identical to "Polarity Outputs I". (8.5) 8.8* Save Changes And Restart This option must be chosen after changing the in- and output status in order to activate the changes. 48 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 49 van 61 WIM WOBBE INDEX METER Installation, operation and maintenance manual Measuring Menu 1.Change Parameters Global Settings 1. Calibration 2. Current Outputs A,B 3. Current Outputs C, D 4. Oxygen Parameters 5. Wobbe, Cari, Calorific Menu Tree V1.49 Oxygen Parameters 1.Oxygen Low Alarm 2.Oxygen High Alarm 3.Z Factor Normal 4.Z Factor Calibrating 5.Oxy Cal Offset 6.Oxy Cal Slope Wobbe, Cari, Calorific Options 1.Wobbe Index Parameters 2.Cari Index Parameters 3.Calorific Value Parameters Calorific Value Parameters 1.Specific Gravity Input 2.Low Voltage 3.Low SG 4.High Voltage 5.High SG 6. SG Low Alarm 7. SG High Alarm 8. Calorific dimension 4. Density parameters 6. Other Options Current Outputs C,D 1.Output C Signal 2. 0/4 mA Value 3. 20 mA Value 4.During Cal 5.Output D Signal 6. 0/4 mA Value 7. 20 mA Value 8.During cal Other Options 1.Values Display Layout 2.Temperature 3.DualRange Parameters Current Outputs A,B 1.Output A Signal 2. 0/4 mA Value 3. 20 mA Value 4.During cal 5.Output B Signal 6. 0/4 mA Value 7. 20 mA Value 8.During cal Cari Index Parameters 1.Cari C0 (Offset) 2.Cari C1 (Slope) 3.Cari HR C0 (Offset) 4.Cari HR C1 (Slope) 5.Cari High Alarm 6.Cari Low Alarm Calibration Settings 1.Automatic Calibration 2.Timed Calibration 3.Timed Calibration Method* 4.Remote Calibration 5.Cal Start Delay 6.Cal Gas Switch Time 7.Cal Error Detect 8.Cal Error Perc. Wobbe Index Parameters 1.Wobbe Dimension 2.Wobbe C0 (Offset) 3.Wobbe C1 (Slope) 4.Wobbe HR C0 (Offset) 5.Wobbe HR C1 (Slope) 6.Wobbe High Alarm 7.Wobbe Low Alarm 8. Wobbe Chart Step size 9. Wobbe Chart Step count Density parameters 1. Density dimension 2. Graphic chart step size 3. Graphic chart step count 4. Process pressure 5. H2 factor A 6. H2 factor B Dual Range Parameters 1.Enable Dual-range System Temperature Settings 1.Oven Temp Required 2.Oven Temp Low Alarm Values Display Layout 1.Mode ‘Normal’ 2.Mode ‘Values’ 3.Mode ‘Others’ Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 2.Oxygen Flip Above 3.Oxygen Flip Below 4.Range Hysteresys +mV 5.Range Hysteresys -mV 6.Range Switch Hold 4. Multi-stream Parameters 2.Display Options Display Option 1.Large Display Mode 2.Small Display Mode 3.Top Chart Mode 4.Bottom Chart Mode 3.Calibration Calibration 1.Edit Cal Gas Parameters 2.Calibration Schedule 3.Start Calibration 4.Start Validation Start Manual Validation 1.Start Automatic Validation 2.Manual One-point Validation 3.Manual Two-point Validation 4.Manual Dual-range Validation 4.Reset Alarm 5.Login Login Menu 1.Login Login 1.Enter PIN Code 3.Oven Temp High Alarm 4.Oven Temp Z Factor 5.Oven Temp Adjustment 6.Warmup Delay 7.Operation Delay 8.Oven Cal Offset 9.Oven Cal Slope 4.Mode ‘Calibrating’ Multi-stream Parameters 1. Multi-stream mode 2. Number of streams 3. Continuous stream 4. Measuring time stream 0 5. Measuring time stream 1 6. Switch delay Calibration Schedule (Weekly)* 1.Monday Start Calibration 1.Start Automatic Calibration 2.Tuesday 2.Manual One-point Calibration 3.Wednesday 3.Manual Two-point Calibration 4.Thursday 4.Manual Dual-range Calibration 5.Friday 6.Saterday 7.Sunday Next calibration Time/Date (Repeat)* 1.Next calibration: Year 2. Month 3. Day 4. Time 5.Repeat calibration every Edit Cal Gas Parameters 1.Cal Gas 1 Wobbe 2.Cal Gas 1 Cari 3.Cal Gas 1 SG 4.Cal Gas 2 Wobbe 5.Cal Gas 2 Cari 6.Cal Gas 2 SG 7.Cal Gas 3 Wobbe 8.Cal Gas 3 Cari * Depend on setting “Weekly” or “Repeat” , a different screen will appear under 3.2. 51 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 5.Exit/Restart/Logout Logged In 1.Exit Program 2.Restart 3.Load Update 4.Logout 5.Change PIN 6.Test Menu Test Menu 1.Test Digital Outputs 1-8 2.Test Digital Outputs 9-16 3.Test Analog Outputs A/B 4.Test Analog Outputs C/D 7.System Settings** ** = Hpbré login only System Settings 1.Dig Inputs I 2.Dig Outputs I 3.Dig Outputs II 4.Dig Outputs III 5.Dig Inputs Polarity 6.Dig Outputs Polarity I 7.Dig Outputs Polarity II 8.Save Changes And Restart Menu Tree Test Analog Outputs C/D 1.Analog Output A 2.Out A DAC Trim 4 mA 3.Out A DAC Trim 20 mA 4.Analog Output B 5.Out B DAC Trim 4 mA 6.Out B DAC Trim 20 mA Channel Routing Outputs III 1.Dig Out Watched Pulse 2.Dig Out Press Sample 3.Dig Out Press Air 4.Dig Out Press Cal 5.Dig Out In Operation 6.Dig Out Cal Fault 7.Dig out flow A 8.Dig out flow B After Login V1.49 Test Analog Outputs A/B 1.Analog Output A 2.Out A DAC Trim 4 mA 3.Out A DAC Trim 20 mA 4.Analog Output B 5.Out B DAC Trim 4 mA 6.Out B DAC Trim 20 mA Test Digital Outputs II 1.Wobbe High Alarm 2.Wobbe Low Alarm 3.Calibrating 4.Validating 5.Cal Fault 6.Bottle Empty 7.In Operation 8.System Fault Channel Routing Outputs I Channel Routing Outputs II 1.Dig Out Gas 1 2.Dig Out Gas 2 1.Dig Out Wobbe High 2.Dig Out Wobbe low 3.Dig Out Gas 3 3.Dig Out Calibrating 4.Dig Out Range 1 4.Dig Out Validating 5.Dig Out Stream 0 5.Dig Out Range 2 6.Dig Out Stream 1 6.Dig out Stream 1 valid 7.Dig Out Stream 2 7.Dig Out Stream 2 valid 8.Dig Out Stream 3 8.Dig Out System Fault Polarity Outputs II 1.Polarity Output 8 2.Polarity Output 9 3.Polarity Output 10 4.Polarity Output 11 Polarity Outputs I 1.Polarity Output 0 2.Polarity Output 1 3.Polarity Output 2 4.Polarity Output 3 5.Polarity Output 4 Test Digital Outputs I 1.Cal Gas 1 2.Cal Gas 2 3.Cal Gas 3 4.Range 1 5.Stream 0 6.Stream 1 7.Stream 2 8.Stream 3 Channel Routing Inputs I 1.Dig Inp Watchdog 2.Dig Inp Calib Req 3.Dig Inp Valid Req 4.Dig Inp Flow Alarm A 5.Dig Inp Flow Alarm B 6.Dig Inp Press Sample 7.Dig Inp Press Air 8.Dig Inp Press Calgas Polarity Inputs 1.Polarity Input 0 2.Polarity Input 1 3.Polarity Input 2 4.Polarity Input 3 5.Polarity Input 4 6.Polarity Input 5 52 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. WIM WOBBE INDEX METER Installation, operation and maintenance manual 9.0 Maintenance and inspection 9.1 General maintenance WARNING: Bottles typically have very high pressures and may result in serious injury to personnel if the bottle valve is opened without a regulator attached or if the valve is broken off the bottle. See the following paragraphs for more information. CAUTION: Attempting to perform electrical procedures without turning off the power could result in an electrical shock hazard to personnel and damage to the Wobbe analyser! There are only a few items that require maintenance. Within the sample conditioning system this is limited to the sample filter, the pressure regulator station for pilot air and combustion air, the sample pressure regulator and the booster regulator. The orifices in the mixing chamber are subject to wear. It is advisable to replace them every 2 years. A few items need to be checked for proper functioning on a regular basis. These are the flow meters and the relief valves. Electronically there are no items that need maintenance. On the combustion oven some maintenance is required, but this is limited to exchanging the Zirconia Oxide cell every 2 years. With replacement or spare parts the original instructions of the manufacturer are enclosed. For details on how to maintain or replace a certain part please refer to those instructions. When your analyser is an Ex- execution equipped with a purge back-up bottle make sure that its pressure remains above 190bars, a pressure drop under this value will cause a power shut-off. Inspect on a regular basis. 9.2 Maintaining the sample filter The sample filter contains a stainless steel sintered element. Check this filter regularly. The replacement rate can be based upon experience since the contamination is dependant on how clean the sampled gas is. 9.3 Maintaining the pressure regulator stations (Pilot & combustion air) Check the sintered filter elements in these stations on a regular basis. The replacement rate is depending on how clean the air offered to the analyser is. Check the condense collection bowls for moisture and drain if necessary. When larger than normal fluctuations are visible on the outlet pressure gauge it is advisable to replace the membrane. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. ORIFICE TUBE REPLACEMENT IN MIXING CHAMBER Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 9.4 Maintaining the sample pressure regulator When the sample pressure gauge shows fluctuations it is advisable to replace the regulators membrane. 9.5 Maintaining the booster regulator When the combustion air pressure indicator show fluctuations in pressure it is advisable to replace the booster membrane. Adjust the setting of the booster relay to the desired residual Oxygen value as described under "Start-up of the analyser". 9.6 Replacing the orifices tubes in the mixing chamber Upon replacement of the orifices in the mixing chamber take out the whole mixing chamber. Loosen the nut of the connectors on both sides of the mixing chamber. Now take out the two orifice tubes. With every unit a calibre is supplied. Unscrew the big nut on top of the mixing chamber and take-off the top. Now insert the calibre into the mixing chamber. Make sure that the flat sides of the calibre face the orifice ports. Insert the new orifice tubes and push their tips to the flat sides of the calibre. This way it is ensured that the two orifices face each other precisely and are on a distance of 7.5mm (thickness of calibre). Now re-tighten the nuts on the connectors or the orifices. Take out the calibre, mount the cover and the big nut on the top and re-fit the mixing chamber. After replacement of orifices the unit must be re-calibrated. 9.7 Inspection of the flow meters Check the flow rates on both the excess vent flow meter and the analyser flow meter on a regular basis. These flow rates should remain on a stable setting, if not adjust them by means of their needle valve. 9.8 Inspection of the pressure relief valves Inspect both the pressure relief valve on the sample pressure regulator and the one on the excess sample vent line at least once a year. These items are normally non-operative but are critical for safe operation. Check the opening, closing and cracking pressure to be within acceptable limits. 54 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. REPLACEMENT OF THE ZIRCONIA OXIDE CELL Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 9.9 Replacement of the Zirconia Oxide cell Before actually exchanging the measuring cell make sure that the oven has cooled down to a temperature on which it is possible to work on it without injury. Remove the plus and the minus contact clips on the cell. Un-screw the cell from the cell house, retain the cell house using a size 23 wrench. Insert the new cell in the reversed order. Make sure that the new cell does not come into contact with dirt or grease. After replacement of the Zirconia cell the analyser must be re-calibrated. 9.10 Spare parts There is always the risk of a component breaking down. It is therefor advisable to have those spares marked in the column "Critical" of the spare parts list on stock. Spare parts can be obtained via Hobré 's spare parts department. Please make sure to always refer to your analysers serial no to enable us to send out the correct spare part. For a detailed spares advice and quote specific to your analyser unit please inquire. Hobré Instruments B.V. Netwerk 4 PO Box 328 1440 AH Purmerend The Netherlands Telephone: 0031 - (0) 299 - 420 871 Telefax: 0031 - (0) 299 - 423 302 55 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 10.0 Troubleshooting and error messages CAUTION: Attempting to perform electrical procedures without turning off the power could result in an electrical shock hazard to personnel and damage to the Wobbe analyser! WARNING: Ovens, internal components, and sample system components may be hot even when power is not applied to the unit. Take appropriate precautions to prevent injury from contact with hot items. Hereunder the most common causes of troubles are described. When your problem can not be found and solved using the hints hereunder please do not hesitate to contact our service department for further assistance. Please make sure to have the unit's serial no. available upon contacting us to enable us good reference to your specific analyser. 10.1 Troubleshooting Malfunction: No or low air pressure No or low gas pressure Oven temperature too low Analyser shows slow response No response from analyser Probable cause Check air regulator to function properly. Check supply pressure to be sufficient. Check system for blockages and clean when necessary. Check sample pressure on booster regulator, low sample pressure will result in venting or air through booster. Tube fracture, close shut-off valve immediately and replace tube. Tube fracture, close shut-off valve immediately and replace tube. Check for obstruction in sample line, inspect sample lines and sample filter. Check sample regulator to function properly. Check supply pressure to be sufficient. Check setpoint on oven temperature controller. Check fuses in TB1 for 60Vac transformer. Check 60Vac to oven. Check oven resistance to be approximately 13 Ohm. Check all flows and pressures to be on correct value. If not clean system and adjust to correct values. Check resistance of Zirconia cell to be less than 100 Ohm, if not replace cell Check electronics for problem with interface board or PC. Check for mV signal from Zirconia cell. 56 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Leak in mixing system. No mA signal Analyser is performing an automatic calibration. Check for other problem by simulating mA signal via test menu, set output to 0, 25, 50, 75 and 100%. No mV signal Loose connection on cell, check cell clips. Unstable measurement Loose AD cable between PC and electronics. Too much back-pressure on the oven vent / drain line. Check for blockages in oven vent / drain line. Check collection bowl under combustion air pressure regulator for condense and drain if necessary. Check sample and air pressure regulators for fluctuations on their outlets. When fluctuating replace membranes. Unexpected low measurement value Very wet sample fed to analyser. Power failure Wrong voltage on power feed, power shut-off by over-voltage protector. A fuse has blown inside the electronics. Check all fuses in the power terminal strip. Pressure differential between air and sample The booster pressure regulator is of its pressure setting. Check for wear of boosters membrane. 10.2 Error messages On the very bottom of the display several error messages may occur. Following is a list with description of the cause. Error message: 24Vdc too high 24Vdc too low Air pressure Bottle empty Cabinet temperature to high Cabinet temperature to low Calibration error Probable cause 24Vdc feed to interface board is tool high. 24Vdc feed to interface board is too low. Low pressure on airline detected by optional air pressure switch. Low pressure on calibration supply line detected by optional pressure switch. Calibration bottle is running empty or blockage in supply line. The temperature inside the electronics compartment has risen above alarm level. The temperature inside the electronics compartment has dropped under alarm level. Calibration has been cancelled. New values have not been accepted. Either the deviation from last calibration was higher than set calibration error percentage or another fault 57 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. CARI to high CARI to low Logged in Oven temperature to high Oven temperature to low Oxygen mV to high Oxygen mV to low Sample pressure SG to high SG to low System fault Watchdog error Wobbe to high Wobbe to low occurred during calibration. The CARI value has risen above its alarm level. The CARI value has dropped under its alarm level. Indicates that one is navigating through the password protected menus. The oven temperature has risen above its alarm level. The oven temperature has dropped under its alarm level. The mV signal has risen above its alarm level. The mV signal has dropped under its alarm level. Low pressure on sample line detected by optional sample pressure switch. The SG value has dropped under its alarm level. The SG value has dropped under its alarm level. Collective alarm. One of the other alarms has occurred. An error has occurred in communication between PC and interface board. The Wobbe value has risen above its alarm level. The Wobbe value has dropped under its alarm level. 58 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 11. Specifications 11.1 Performance ƒ ƒ ƒ ƒ ƒ ƒ Wobbe Index range: Span standard: Span extended: Repeatability: Drift: Response time: 0 - 95 mJ/ Nm3 40 mJ/ Nm3. 65 mJ/ Nm3 30 kJ/ Nm3 < 15 kJ/ Nm3 over 24 hours T 90 in < 5 seconds 11.2 Utilities Consumption ƒ ƒ ƒ ƒ ƒ Analyser Power: Heating Power: Sample: Instrument air: Purge air (Ex- only): 350 VA, on 230 Vac or 115Vac, 50 Hz 600 VA, on 230 Vac or 115Vac, 50 Hz 1Nl/ min at 3 barG 10Nl/ min at 3 barG 30Nl/ min at 4 barG 11.3 Environmental requirements ƒ ƒ ƒ Ambient temperature: Ambient temperature variation: Humidity: 0 - +40° C extendable to -15 - +60° C Approximately 7°C per 24 hours 0 - 90% 11.4 Dimensions & Weight ƒ ƒ Dimensions: 1.0 mtr(W) x 1.0 mtr(H) x 0.4 mtr(D) Weight: Approximately 175 kg 11.5 List of available options An extensive list of options is available for the WIM-9900 Wobbe Index Meter. Hereunder a list of the most common options, simply add the short code to the end of the type number. 4MA C CE F FL H P R SG : 2 off additional analogue outputs (extra to standard 2 off) : Epoxy coated cabinet in Ice Blue (leatherette) : CE/EMC components (Option for non-European market) : Free standing galvanised frame (Stainless steel upon request) : Integrated fastloop (Swirlclean filter, flowmeter and isolation valves) : Heating Sample Conditioning Compartment (ATEX certified) : Purgeable cabinet, including flame arresters : Relay isolated alarm outputs for general purpose executions : Specific gravity cell incorporated 59 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. T TR TR ATX VO WH WM : Tropicalization of electronics : Tracing package for sample supply line : Identical to TR option for ATEX Ex zones. : Vortex cooler (for ambients up to 60degC ) : Winterising heating electronics compartment (for ambients up to -15°C) : Stream selection manifold make Whitey 60 van 61 Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. Installation, Operation and Maintenance manual WIM-9900 series Wobbe Index Meter Revision: July 2004 Software version: 1.49 Hobré Instruments B.V. 12. CE Declaration of conformity Manufacture : Hobré instruments B.V. Adress : Netwerk 4, Purmerend, The Netherlands Declares that the system mentioned hereunder WIM-9900 Wobbe Index Meter Meets the regulations of the following latest CE-guidelines.: Pressure Equipment Directive 97/23/EG EMC directive 89/336/EG Low Voltage directive 93/68/EEG And furthermore that the following harmonised standards are applied.: EN 50 014 EN 50 016 EN 50 018 EN 50 081-2 EN 50 082-2 Place: Purmerend Date: November 19, 2002 Name: B. Poortier Function: Manager engineering & production Signature: …………………………………. 61 van 61