Envea SM-4 Manuale utente

Manual

Mercury Stack Monitor

SM-4

with integrated

Calibration Unit

MC-3000

Version 4.7

N:\Bedienungsanleitungen-Serviceanleitungen\SM-4\SM-4 + MC3000 E V4.7.doc

Manufacturer: ENVEA GmbH

Liebigstrasse 5

85757 Karlsfeld/Germany

[email protected]lobal

SM-4 page 2

General Safety Instructions

While operating the SM-4, parts of its interior are under high voltage and UV-beams

are produced inside the photometer. If safety regulations are ignored physical and/or

material damages could occur. Only qualified personnel should be allowed to

operate the SM-4. Following conditions for correct function of the SM-4 are to be

held: careful and correct storage, proficient operation and maintenance.

Do not operate instrument if it is damaged.

When connecting the SM-4 system to a power source please note the related

safety regulations.

The SM-4 should be operated from the type of power source indicated on the

rating plate.

Make sure that the power cords are not damaged.

Regulations for prevention of accidents are to be followed.

Before opening the SM-4 system disconnect it from the mains power supply.

Repairs and maintenance on the opened and powered instrument should only be

carried out by trained personnel.

Operate the SM-4 on a stable and dry surface. The interior of the SM-4 should

never get moist or wet. In case it happens, consult an expert.

The SM-4 is dedicated for the measurement of mercury concentration in stack

gases. Do regard the related dangers especially while operating with toxic gases.

Make sure that these parts of the instrument guiding the gas are not damaged

and that the gas is guided back to the source or into an appropriate absorber.

The SM-4 must not be used to measure explosive gases and must not be

operated in hazardous areas.

SM-4 page 3
 
Contents 
GENERAL DESCRIPTION............................................................................................................................6 
1 FIELDS OF APPLICATION.................................................................................................................................6 
2 PRINCIPLE OF OPERATION..............................................................................................................................6 
3 TYPICAL ARRANGEMENT...............................................................................................................................7 
COMPONENTS OF THE SM-4 .....................................................................................................................8 
1 GAS FLOW DIAGRAM................................................................................................................................8 
2 SAMPLING PROBE..........................................................................................................................................9 
2 SAMPLING PROBE..........................................................................................................................................9 
3 PROBE CONTROLLER UNIT ..........................................................................................................................11 
4 HEATED BUNDLE.........................................................................................................................................13 
5 ANALYZER CABINET ...................................................................................................................................14 
5.1 Mercury Detector.................................................................................................................................16 
5.2 Calibration Gas Generator..............................................................................................................17 
INSTALLATION............................................................................................................................................19 
1 PLACE FOR INSTALLATION...........................................................................................................................19 
2 INSTALLATION OF THE SAMPLING PROBE....................................................................................................20 
3 ELECTRICAL CONNECTIONS.........................................................................................................................22 
3.1 Power Supply of the Analyzer Cabinet ................................................................................................22 
3.2 Heated Bundle Power Connection.......................................................................................................24 
3.3 Power Supply of the Probe Controller Unit.........................................................................................25 
3.4 Communication Connection of Probe Controller Unit to Analyzer Cabinet. ......................................27 
3.5 Connection of Probe and Probe Controller.........................................................................................27 
3.6 Signals: Analyzer cabinet Connector Strip X2 ....................................................................................28 
3.7 Analog 4-20 mA Signal........................................................................................................................29 
3.8 Status Signals.......................................................................................................................................29 
3.9 External Cleaning Function.................................................................................................................29 
3.10 Serial Data Output (RS 232)..............................................................................................................30 
4 HOSE CONNECTIONS....................................................................................................................................31 
4.1 Air Connection.....................................................................................................................................31 
4.2 Outgoing Gas of the Analyzer Cabinet (Gas OUT) .............................................................................32 
4.3 Connection of the Heated Bundle to the Analyzer Cabinet..................................................................32 
4.4 Connection of the Heated Bundle to the Probe....................................................................................34 
5 INSTALLATION OF THE PROBE......................................................................................................................36 
6 CONNECTING THE CONVERTER WITH THE PROBE CONTROL UNIT...............................................................38 
8 LEAKAGE TEST............................................................................................................................................39 
9 SIGNAL OUTPUT ..........................................................................................................................................39 
9.1 Analog Output Signal (4-20 mA) .........................................................................................................39 
9.2 Status Signals.......................................................................................................................................39 
SETTING THE SYSTEM INTO OPERATION..........................................................................................41 
1 SWITCHING THE POWER ON .........................................................................................................................41 
2 MAIN MENU ................................................................................................................................................42 
3 START MEASURING .....................................................................................................................................42 
3.1 Sampling..............................................................................................................................................42 
3.2 Zeroing.................................................................................................................................................43 
3.3 Heating ................................................................................................................................................43 
3.4 First Trap Cooling...............................................................................................................................43 
3.5 Trap Cleaning......................................................................................................................................43 
3.6 Second Trap Cooling...........................................................................................................................43 
4 PARAMETRIZATION......................................................................................................................................44 
4.1 Sample Volume ....................................................................................................................................45 
4.2 Measuring Range.................................................................................................................................45 
4.3 Set System Check .................................................................................................................................46 

SM-4 page 4
 
4.4 Set Calibration Device.........................................................................................................................48 
4.5 Set Probe Purge Duration ...................................................................................................................48 
4.6 Set External Cleaning..........................................................................................................................49 
4.7 Set Orifice Cleaning Duration.............................................................................................................49 
4.8 Set Fan Temperature ...........................................................................................................................50 
4.9 Speciation (if this option is installed) ..................................................................................................50 
5 CALIBRATION ..............................................................................................................................................51 
5.1 Show actual calibration.......................................................................................................................51 
5.2 Show all calibrations ...........................................................................................................................52 
5.3 Perform new calibration......................................................................................................................52 
6 DATA LOGGER.............................................................................................................................................53 
6.1 Show Measurements ............................................................................................................................54 
6.2 Show Error Records ............................................................................................................................54 
SERVICE ........................................................................................................................................................55 
1 SET DATE AND TIME....................................................................................................................................56 
2 DEVICE DATA..............................................................................................................................................57 
3 SHOW INSTRUMENT STATUS........................................................................................................................58 
3.1 Show Analyzer Status...........................................................................................................................58 
3.2 Show Probe Status...............................................................................................................................59 
3.3 Status of the MC-3000.........................................................................................................................60 
4 MANUAL TEST OF COMPONENTS.................................................................................................................60 
4.1 Test Analyzer Components...................................................................................................................61 
4.2 Test Probe Components.......................................................................................................................63 
4.3 Test MC-3000 Components .................................................................................................................63 
4.4 Leakage Check.....................................................................................................................................64 
5 SET MEASURING CALIBRATION...................................................................................................................66 
6 SET STATUS CONTACTS...............................................................................................................................66 
7 SET OFFSETS................................................................................................................................................67 
8 SEND SETTINGS TO RS232...........................................................................................................................67 
9 SET LANGUAGE ...........................................................................................................................................67 
CALIBRATION UNIT MC-3000 INTEGRATED IN SM-4 ......................................................................68 
1 GENERAL INFORMATION FOR SAFE OPERATION ...........................................................................................68 
2 OPERATION PRINCIPLE.................................................................................................................................69 
3 SOFTWARE MC-3000 ..................................................................................................................................69 
3.1 Device Data.........................................................................................................................................71 
SERVICE AND MAINTENANCE ...............................................................................................................72 
1 ROUTINE MAINTENANCE.............................................................................................................................72 
2. SPARE PARTS/WEAR PARTS.......................................................................................................................72 
2.1. UT-3000 Detector...............................................................................................................................73 
2.2. Tubing inside the photometer .............................................................................................................75 
3 LEAKAGE CHECK.........................................................................................................................................75 
4 UFO-FILTER EXCHANGE..............................................................................................................................78 
5 EXCHANGE OF THE CATALYTIC CONVERTER...............................................................................................79 
6 CLEANING OF THE SAMPLE TUBE ................................................................................................................80 
7 EXCHANGE OF THE GOLDTRAP....................................................................................................................80 
8 EXCHANGE OF THE FILTERS AND OF THE ACTIVATED CHARCOAL IN THE PHOTOMETER..............................81 
9 EXCHANGE OF THE DUST FILTER..................................................................................................................83 
10 ERROR MESSAGES......................................................................................................................................85 
11.1 Error message: HEATING FLOW! ...................................................................................................85 
11.2 Error message: SAMPLING FLOW!.................................................................................................85 
11.3. Error message: LAMP!.....................................................................................................................85 
11.4. Error message: LOW INPUT PRESSURE! ......................................................................................85 
11.5. Error message: TEMP PROBE!.......................................................................................................86 
11.6 Error message GOLD TRAP!............................................................................................................86 

SM-4 page 5

8. APPENDIX .....................................................................................................................................................87

8.1 DATA OUTPUT VIA RS232 SERIAL COMMUNICATION..................................................................................87

8.2 DISPLAY OVERVIEW....................................................................................................................................90

8.3 ELECTRIC FUSES ..........................................................................................................................................93

8.4. SAFETY DATA SHEET..................................................................................................................................94

SM-4 page 6

1. General description

1.1 Fields of application

The SM-4 is the ideal tool for continuous measurement of the mercury concentration in stack

gases from plants like power plants, waste incinerators, sewage sludge incinerators, cement

kilns or recycling furnaces. The SM-4 detects –as standard version- total mercury, i.e.

elemental mercury, ionic mercury, mercury compounds and particle bound mercury. As

option a speciation function is available, this allows separate measurements of elemental and

total mercury, which results in the amount of ionic mercury as the difference of both.

The outstanding features of the SM-4 are high availability, high sensitivity and virtually no

influence from the sample matrix.

1.2 Principle of Operation

The sample is continuously taken from the stack through a heated probe (180°C) by means of

an air-driven ejector pump. It passes through a heated sample filter and is then diluted with

air at a constant ratio. A partial stream of the diluted sample is treated in the thermo-catalytic

reactor where all mercury compounds are cracked and ionic mercury is reduced to the

elemental form. After this the sample travels through the heated sample line and enters the

detector inside the analyzer cabinet.

Basis for determination of the mercury concentration is the resonance absorption of the

mercury (Hg)-atoms at a wavelength of 253.7 nm (AAS, Atomic Absorption Spectroscopy).

A GoldTrap amalgamation system provides mercury pre-concentration and matrix separation.

SM-4 page 7

1.3 Typical Arrangement

The SM-4 measuring system consists of 4 modules:

1) The sampling system with probe, filter, dilution system and thermo catalytic converter

2) The probe controller

3) The heated sample bundle

4) The analyzer enclosure with bypass pump, detector, compressed air conditioning and

the calibrator

Ejector

Pump

Mass flow

controller

Optical Cell

GoldTrap

Zero air

filter

Mercury Detector Sample

out

Sample Conditioning System

heated sample line

Critical

orifice

Ejector pump-

dilutor unit

Thermo-catalytic

reactor

Heated Probe

Dilution

air in

SM-4 Typical Arrangement

Dilution

air out

Elemental Mercury Calibration Gas Generator

Particle

filter

Calibration

valve

Sample in

Mass flow

controller

Mass flow

controller

Air in

Dilutor

saturation

chamber evaporation

chamber

Hg Hg

1. Probe with Sample

Conditioning System

4. Anqalyzer Enclosure

with Calibration Unit

3. Heated

Bundle

SM-4 page 8

2. Components of the SM-4

2.1 Gas Flow Diagram

SM-4 page 9

2.2 Sampling Probe

Figure: SM-4 Sampling Probe

The probe comprises two main parts:

(a) the Heated probe, containing inner tubing made of PFA (sample temperature up to

200 °C) or optionally made of SS316 tubing with glass inliner (sample temperature up

to 375 °C),

(b) the Converter Unit with sample dilution system and thermo-catalytic converter.

Both units can easily be disconnected. If the probe has been installed, the box

containing the dilution system and the thermo-catalytic converter can be removed

whilst the probe is remaining at the stack.

heated probe

converter

SM-4 page 10

Specifications Probe

Size and Weight: 14.2” (L) x 14.2” (W) x 26” (H), 79 lbs. (total weight including

mounting flange and heated probe); 62 lbs. (reactor unit only)

Materials: Main enclosure: resin coated aluminum

Structural parts (flange, probe cylinder walls): SS316

Sample wetted parts: ceramic, PFA, glass

Catalytic converter: Proprietary active material, temperature 400 °F (200 °C

Sample temperature: 400 °F max. (200 °C), up to 700 °F (375 °C) as an option

Installation: Mounting flange size: DIN 2527 DN65 PN6 (USA option: 4”

150 lbs.)

Operating temperature: -13 °F to 122 °F (-25 °C to 50 °C)

Power requirements: 230 VAC/50 Hz (USA option: 115 VAC/50/60 Hz) all power

supplied by Probe Controller Unit

Air requirements: Instrument air 6 bar –7 bar (90 psig –100 psig), ~12 l/min

Dilution ratio: 1:40 to 1:50 (1:100 as option for special applications)

Sample flow: 10-12 l/h

Figure: Dimensions of the probe with stinger

Indice

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