Cosa 9610 Manuale utente

INSTALLATION,

OPERATION

AND

MAINTENANCE

MANUAL

COSA 9610™

GENERAL PURPOSE & EXPLOSION

PROOF

Version:

1.4.2

Revision date: June 7th 2019

CAL.01.

.9826

INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA

9610™

Page 2 of 48

COSA INSTRUMENT CORPORATION

New York Texas Corporate Headquarters,

Manufacturing Offices: Sales & Service Offices:

84F Horseblock Rd. 4140 World Houston Parkway

Yaphank, NY 11980 Suite 180

Tel: 631-345-3434 Houston, TX 77032

Fax: 631-345-5349 Tel: 713-947-9591

Fax: 713-947-7549

E-mail:

sales@cosaxentaur.com

http://www.cosaxentaur.com

2019

All rights reserve

The contents of this publication are presented for informational purposes only. While every effort has

been

made to ensure this document error-free, it should not be construed as warranties or

guarantees,

expressed or implied, regarding the product or services described herein or its use or

applicability.

COSA Instrument Corporation reserves the right to revise or to improve the design or specifications of

the

COSA 9610™ at any time and without

notice.

INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA

9610™

Page 3 of 48

Table of Contents

1. INTRODUCTION

.................................................................

1.1.

NTRODUCTION

................................................................................

1.1.1. Purpose of the

anal

yzer..........................................................................5

1.2. THE COSA 9610™ ANALYZER

............................................................

1.2.1. Oven with oxygen sensor........................................................................6

1.2.2. The sample system

(SCS)

.......................................................................7

1.3. CALIBRATION

ROCEDURE

.................................................................

1.4. EXTENDED (DUAL) RANGE

PTION

....................................................

1.4.1. Operation ...........................................................................................10

1.5. SPECIFICATIONS COSA 9610™ WOBBE INDEX ANALYZER ....................... 11

1.5.1. Analyzer performance..........................................................................11

1.5.2.

Utilities.................................................................................................

..11

1.5.3. Installation..........................................................................................11

1.6 X-Purge option…………………………………………………………………… 12

INSTALLATION.................................................................

2.1. GENERAL

...................................................................................

2.2. STORAGE

...................................................................................

2.3. PLACEMENT

................................................................................

2.3.1. Ge

era

l.................................................................................................

2.3.2. COSA 9610™ in general purpose execution (Type 01 &

02)

.................... 17

2.3.3. COSA 9610™ in explosion proof execution (Type 01-Ex &

02-Ex)

.............17

2.4. MECHANICAL CONNECTIONS

..............................................................

2.4.1. Ge

era

l.................................................................................................

..18

2.4.2. Sample supply......................................................................................19

2.4.3. Calibration gasses ................................................................................19

2.5. ELECTRICAL CONNECTIONS..............................................................20

2.5.1. COSA 9610™ in general purpose execution............................................20

2.5.2. COSA 9610™ in explosion proof execut

ion

.............................................20

3. IN

OPERATION.................................................................

3.1. START-UP SAMPLE CONDITIONING SYSTEM

..........................................

3.1.1. Inspection, visual and external connections ...........................................21

3.1.2. Air orifice se

ect

ion

...............................................................................21

3.1.3. Opening of shut-off v

ves

.....................................................................

3.1.4. Setting of gas pressure reducer.............................................................22

3.1.5. Adjusting flow with flow meters ............................................................22

3.1.6. Adjusting booster relays

........................................................................

INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA

9610™

Page 4 of 48

3.2. START-UP OF THE CONTROL

NIT

.....................................................

3.2.1. Description ..........................................................................................25

3.2.2. Programming the measurement

rameters

............................................

3.2.3. Main screen

..........................................................................................

3.3. PROGRAMMING MENUS

..................................................................

3.3.1. Calibration

Menu...................................................................................

3.3.2. Operation Menu

....................................................................................

3.3.3. Measurement

...............................................................................

3.3.4. Output

nu.........................................................................................

3.3.5. Communications

nu...........................................................................

3.3.6. System

........................................................................................

3.3.7. Display Menu

........................................................................................

3.3.8. Reset Alarms

nu................................................................................

3.4. TEMPERATURE CONTROLLED OVEN

....................................................

3.4.1. Furnace temperature control

uni

...........................................................

3.4.2. Adjustment procedure temperature re

gula

..........................................

4. PREVENTIVE MAINTENANCE .............................................

4.1. WEEKLY / MONTHLY MAINTENANCE

...................................................

4.1.1. Compressor

(optional)...........................................................................

4.1.2.

Filters...................................................................................................

4.2. THREE (3) MONTH MAINTENANCE

.....................................................41

4.2.1. Compressor

(optional)..........................................................................

4.3. ANNUAL MAINTENANCE

..................................................................

4.4. TROUBLESHOOTING

......................................................................

4.5. REPLACEMENT OF RESIDUAL OXYGEN SENSOR

.......................................

5. INSTALLATION

DRAWING.................................................45

6. ORDERING OF SPARE PARTS ............................................

7. CERTIFICATIONS .............................................................

INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA

9610™

Page 5 of 48

1. INTRODUCTION

1.1. INTRODUCTION

1.1.1. Purpose of the analyzer

The continuous COSA 9610™ analyzer determines online the Wobbe-index of a gas. The

COSA 9610™ can be used both, as feed forward and feedback analyzer for gases mixing

or as a feed forward analyzer for burning control. In order to achieve an optimal

performance of the analyzer system it is necessary to read this manual thoroughly before

installation and start-up.

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. By measuring the

concentration of oxygen in the flue gas, after calibrating the instrument with two gasses

with known Wobbe-index, the Wobbe index can be calculated.

1.2. THE COSA 9610™ ANALYZER

The COSA 9610™ features fast response time and high accuracy. These features make it

unique over conventional Wobbe index analyzers. The oxygen concentration in the air is

considered as constant, namely 20.95%. Functionally we can divide the analyzer-unit in 3

major parts:

•

Sample System

•

Electronics compartment

•

Oven compartment

Optionally the COSA 9610™ can be built in an explosion proof execution. In explosion

proof execution, the analyzer is protected with a purge system.

WARNING - Potential Electrostatic Charging Hazard.

Due to the materials construction of the viewing port, there is a potential to build up an

electrostatic charge across the surface. Suitable precautions should be taken to reduce

this risk.

Risque potentiel de charge électrostatiqueEn raison de la construction en matériaux du

port d'observation, il est possible que des charges électrostatiques se forment sur la

surface. Des précautions appropriées doivent être prises pour réduire ce risque.

INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA

9610™

Page 6 of 48

1.2.1. Oven with oxygen sensor

The gas/air mixture is burnt catalytically in an oven, which is kept at 812ºC with a heating

spiral. The temperature is maintained with temperature control using a K-type

thermocouple. The oxygen sensor in the oven is a zirconium oxide cell. This is mounted

such, that one side is in contact with the outside air and the other side with the flue

gasses. At high temperatures, (600ºC) O2-ions in the ZrO2 grating become mobile through

vacancies therein. By fixing porous Pt-electrodes at both sides of the ZrO2, O2, gas

molecules can, through diffusion by and uptake of two electrons from the Pt electrode,

enter the ZrO2 as O2-ion, move to the other electrodes and be converted in gaseous O2

again by release of the two electrons.

OvenVent

Inlet

Air/Gas

Mixture

Heating Spiral

Oxygen Sensor

Drain

INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA

9610™

Page 7 of 48

1.2.2. The sample system (SCS)

In the sample conditioning system (SCS), gas and air are mixed in a constant proportion,

such that a small excess of air is present (± 2.5% oxygen) in the flue gas. The gas and air

pressure, are equalized by a dome-loaded pressure reducer (or booster relay), where the

gas pressure governs the air pressure.

The booster relay has a temperature reducing effect; the gas/air mixing proportion can

therefore vary as consequence of variations in viscosity. Therefore, the temperature of the

gas and the air are equalized in a heat exchanger. The gas and air temperature are still at

surrounding temperatures, however, as long as gas and air fluctuate to the same extent

this hardly influences the mixing proportion. In case of large surrounding temperature

fluctuations, the calibration sequence has to be performed more often. Hereafter gas and

air are mixed in the mixing chamber. The mixing chamber is equipped with orifices in the

inlet nozzles. The gas and airflow are determined by a critical expansion over the orifices.

The turbulence created provides a homogeneous mixture.

The diameter ratio of the orifices, together with the ratio between gas and air pressure,

determine the mixing proportion.

After the mixing chamber, the mixture flow is divided into an excess flow to vent and a

flow to oven. The flow to the burning oven will be approximately 30-50 Nl/hr. The vented

stream is approximately 500 Nl/hr with a maximum 1000 Nl/hr.

INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA

9610™

Page 8 of 48

1.3. CALIBRATION PROCEDURE

The analyzer can be calibrated in three different ways:

•

Single point calibration

Only one calibration gas is used. The value of the gas is chosen middle of the

measuring range. This is only used to correct any offset error to the measurements.

•

Two point calibration

Two calibration gases are used. The low calibration gas is set at ± 20% of the

measuring range. The high calibration gas is set at ± 80% of the measuring range.

The advantage over a single point calibration is the increased accuracy over the entire

span.

•

Three point calibration

This method uses three calibration gases and is mandatory for a dual range analyzer.

The medium range calibration gas must be in the middle of the measuring range.

All three calibration methods can be performed both manually and automatically:

•

Manually

The operator navigates the procedure via on-screen menu to open the correct gas

valves to the analyzer. The operator controls the timing.

•

Automatically

The analyzer itself controls the timing of the valves

switching.

When the measured

values stay within the specified tolerances, the newly calculated calibration

parameters will be accepted. Otherwise, the analyzer will keep the old value and

generates a CAL ERROR on the display and switch the system fault contact and

calibration fault contact.

The automatic calibration can be started as followed:

•

Programmable time schedule (Timed calibration)

•

Initiated manually via on-screen menu (Semi-automatic calibration)

•

External host activates the calibration request contact (Remote calibration)

The one-point calibration/validation procedure will be executed as followed:

1. Analyzer activates calibration/validation contact.

2. The procedure pauses for the specified “Calibration Start Delay” time for the

external host to prepare for calibration/validation.

3. Process gas is switched off and the calibration gas is switch on.

4. The analyzer waits for the readings to stabilize up to the “Switch Time”.

5. Calibration gas is switched off and the process gas is switched on.

6. Analyzer deactivates calibration/validation contact.

INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA

9610™

Page 9 of 48

The two-point calibration/validation procedure will be executed as followed:

1. Analyzer activates calibration/validation contact.

2. The procedure pauses for the specified “Calibration Start Delay” time for the

external host to prepare for calibration/validation.

3. Process gas is switched off and the low calibration gas is switch on.

4. The analyzer waits for the readings to stabilize up to the “Switch Time”.

5. Low calibration gas is switched off and thehigh calibration gas is switched on.

6. The analyzer waits for the readings to stabilize up to the “Switch Time”.

7. High calibration gas is switched off and the process gas is switched on.

8. Analyzer deactivates calibration/validation contact.

The three-point calibration/validation procedure will be executed as followed:

1. Analyzer activates calibration/validation contact.

2. The procedure pauses for the specified “Calibration Start Delay” time for the

external host to prepare for calibration/validation.

3. Process gas is switched off and the low calibration gas is switch on.

4. The analyzer waits for the readings to stabilize up to the “Switch Time”.

5. Low calibration gas is switched off and the medium calibration gas is switched on.

6. The analyzer waits for the readings to stabilize up to the “Switch Time”.

7. The analyzer switched the gas stream to the high rangemixing chamber.

8. The analyzer waits for the readings to stabilize up to the “Switch Time”.

9. Medium calibration gas is switched off and the high calibration gas is switched on.

10.

The analyzer waits for the readings to stabilize up to the “Switch Time”.

11.

High calibration gas is switched off and the process gas is switched on.

12.

Analyzer deactivates calibration/validation contact.

Between each step of the calibration process a switch time is programmed enabling the

analyzer to stabilize. After the switch time the new value is used in the calibration

algorithm. The calibration gas switch time is user programmable. By default, it is set at

120 seconds. Depending on the distance to the calibration gases it may be necessary to

change to a longer or shorter delay.

INSTALLATION, OPERATION AND MAINTENANCE MANUAL – COSA

9610™

Page 10 of 48

1.4. EXTENDED (DUAL) RANGE OPTION

1.4.1. Operation

When the measuring range of the analyzer is larger than 1150BTU/SCF, an extended range

option is available which covers a Wobbe index of 2850.BTU/SCF. This is accomplished by

adding a second gas-mixing orifice and selection valves to make changeover possible.

The dilution ratios of each mixing orifice are chosen such that the measuring ranges overlap.

Via the software it is possible to create a 4/20mA current loop 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 an extra solenoid valve.

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