IGOA Inert Gas Oxygen - tmp.consilium.plushost.setmp.consilium.plushost.se/cmab/Manuals/6701597_Inert_Gas_Oxygen... · E-mail: Service:[email protected] Spares:[email protected]

IGOA Inert Gas Oxygen

Analyzing System Manual

Consilium Marine & Safety ABFire & Gas Marine DivisionPhone: +46 31 710 77 00Fax: +46 31 710 78 00E-mail: Service: [email protected]

Spares: [email protected] Consilium Marine & Safety ABNavigation DivisionPhone: +46 8 563 05 100Fax: +46 8 563 05 199E-mail: Service, APT: [email protected]

Spares: [email protected] The contents of this document are subject to revision without noticedue to continued progress in methodology, design and manufacturing.Consilium assumes no legal responsibility for any error or damageresulting from the usage of this document. E1 11 1 E, Jan 2011Part no. 6701597

© 2010-2011, Consilium AB

Inert Gas O2 Analyzing System

Content

1. INTRODUCTION 5 1.1 ABOUT THIS MANUAL 5 1.2 INQUIRIES AND FEEDBACK 6

2. SYSTEM SPECIFICATIONS 7

3. SYSTEM INSTALLATION 8 3.1 CONTROL AT DELIVERY 8 3.2 WHERE TO INSTALL THE SYSTEM 8 3.3 SAFETY ASPECTS 9 3.4 SINGLE BOARD 9

3.4.1 Mounting Panel 9 3.4.2 Sample Gas Connection 9 3.4.3 Calibration Gas Connection 10 3.4.4 Vent Line Connection 12 3.4.5 Analyzer and Electrical Connection 12 3.4.6 Digital Flow Switch (Optional) 12

3.5 DOUBLE BOARD 12

4. SYSTEM COMMISSIONING 16 4.1 INSTALLATION CHECKS OF THE SAMPLING BOARD 16 4.2 COMMISSIONING OF THE ANALYZER 16 4.3 START OF SYSTEM 16

5. ROUTINE MAINTENANCE 18 5.1 SAMPLE AND TEST GAS FLOW SYSTEM 18 5.2 FILTER AND BUBBLE GLASS 18 5.3 ANALYZER 19

6. SPARE PARTS 20

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Content

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1. Introduction

1.1 About this Manual

The Consiliums’ Inert Gas Oxygen Analyzing System, thereafter named as the IGOA System, consists of the G36 Inert Gas Oxygen Analyzer(s) for monitoring O2 content in the inert gas (N2 or CO2 based) mounted on a gas sampling board.

This manual gives instructions for the installation, operation and maintenance of the gas sampling board and the IGOA System as a whole system.

The instructions for installation, operation, and maintenance of the G36 Oxygen Analyzer are provided in a separate manual – the G36 Oxygen Analyzer manual (Part No. 01245).

Therefore, for the installation, operation and maintenance of the Consiliums’ IGOA System, both manuals must be read carefully in their entirety.

The instructions have been made in general terms and do not take into considera-tion the existing equipment of the Inert Gas System and its installation. As such, this instruction manual and the G36 Oxygen Analyzer manual are designed for the standard IGOA System.

The two manuals do not describe all possible situations but only the most com-mon and known situations, and cannot replace the necessary instruction and edu-cation of the personnel.

Should situations not described in the manual occur, which cannot be solved in accordance with normal known practice and good workmanship, the operator should contact Consiliums for instructions.

Consiliums reserves the right to minor alterations and improvements owing to de-velopments without being obliged to enter the corresponding changes in this man-ual.

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Introduction

6

Consiliums reserves the copyright of the manual. Without prior written permission of Consiliums, the manual may not be copied and given to unauthorized people.

1.2 Inquiries and Feedback

All claims and inquiries for spares shall be addressed to Consilium Marine & Safety AB or our distributors.

In all correspondence or when ordering spare parts, please state carefully the equipment type and serial number, which you can find on the label on the right side of the blue analyzer box.

Consilium Marine & Safety AB appreciates all feedback and suggestions for the improvement. If you have any questions or find any errors in the manual, you are welcome to contact us at the following address:

Consilium Marine & Safety AB

Phone: Fax:

+46 31 710 77 00 +46 31 710 78 00

E-mail:

Service: [email protected] Spare: [email protected]

mailto:[email protected]

mailto:[email protected]


2. System Specifications

Sampling Board for Inert gas application

Sample pressure & flow 0.05 to 1 bar – 2 to 8 l/min

Sample temperature 0°C to 70°C

Sample manifold 3 ports – 1/8” BSP connection

Span gas reduction regulator with filter 25 µm

Max. 8 bar – 1/8” BSP connection

Zero gas reduction regulator Max. 8 bar – 1/8” BSP connection

Flow control valve 8 turn control valve

Sample selector valve 5-way and 4-position switching valve SS 316

Test gas selector valve 3-way and 2-position switching valve SS 316

Inert Gas Single Board Dimensions: 60 × 50 × 14 cm (H × W × D) Weight: Ca. 12 kg without water & packaging

Inert Gas Double Board Dimensions: 61 × 79 × 14 cm (H × W × D) Weight: Ca. 20 kg without water & packaging

Analyzer

See details in the G36 Oxygen Analyzer Manual – Section 2

Optional Equipment

Digital flow Switch 0.2–10 l/min, 1 analog output 4–20 mA & 1 NPN out-put, display with LED type 3 digits, 1 alarm set point with the NPN output.

Remote digital display 22…250 VAC/DC with 2 configurable alarm relays Ambient Temperature: –20°C to 60°C Panel cut-out: 44.5 × 91.5 mm

Other optional equipment Pre-filter for sample gas Signal amplifier Signal amplifier for logarithmic output Visualization, recording, and data logging

Specifications are subject to changes without notice.

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System Installation

3. System Installation

Read this chapter in its entirety before installing the system.

3.1 Control at Delivery

Upon receipt of the Consiliums’ Inert Gas Oxygen Analyzing System – (IGOA System), please inspect and confirm that the received scope of supply is in accor-dance with the packing list and not damaged. Any discrepancy should be reported to the supplier immediately. If any of the received parts are damaged, the shipping company should be informed, and new parts should be made available before completing the installation.

3.2 Where to install the system

Satisfactory operation of Consiliums’ IGOA System, faultless functions and minimal maintenance are achieved by paying attention to the following notes:

The IGOA System including the Inert Gas Sampling Board should be in-stalled in a clean area away from dust, oil mist and moisture. The system elements should all be installed at viewing level in an area with good access for operating and servicing the system.

It is recommended that the IGOA System is located very close to the sam-pling point of the inert gas system in order to have current and accurate readings. Large bore sample lines as well as longer sample lines will in-crease the response time due to dead volume.

The location and installation of the system must be chosen, so that the am-bient temperature at any time is below 55C.

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3.3 Safety Aspects

Hot sensor The sensor is hot and can cause sever burning of personnel if not handled with care.

Analyzer(s) Before working with the analyzer(s), please read the G36 Oxygen Analyzer Man-ual (Part No. 01245) in its entirety.

Installation and operation It should be pointed out that installation and operation of the Inert Gas Oxygen Analyzing System and associated equipment must be carried out by skilled, trained and certified personnel, and that Consiliums does not take any responsibil-ity of the operation of the system and associated equipment whatsoever. The successful and safe operation of this equipment is dependent upon proper handling, installation, operation, and maintenance.

Recycling Do not dispose any part of the IGOA System with regular refuse. Disposal should be in accordance with the requirements of the current statutory regulations.

3.4 Single Board

3.4.1 Mounting Panel

The mounting panel has two (2) angle iron mounting brackets. The brackets are made from ordinary mild steel and can be directly welded or bolted to a chosen structure as required. The two mounting brackets are mounted horizontal and par-allel with a distance of 550 mm. For dimensions and layout, see Figure 3-1 and Figure 3-2.

3.4.2 Sample Gas Connection

The sample gas has to be taken from a suitable location representative for the gas to be tested.

The connection for sample gas is arranged in the top left corner of the system board at the sample manifold. Up to three (3) samples can be connected to the manifold. The three connections are all arranged as 1/8" BSP female connections, and marked from bottom: 1, 2, and 3. The system is supplied with the manifold sample ports plugged.

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System Installation

Figure 3-1: Piping & Instrumentation Diagram of the IGOAS - Single Sampling Board

3.4.3 Calibration Gas Connection

For test and calibration, a calibration gas with known oxygen content is used, e.g. a test gas with 2% oxygen content in pure nitrogen. For linearization, clean and dry compressed instrument air is normally used as span calibration gas. Both gas-es are connected direct to the respective reduction stations. The lower reduction station with filter and drain is for the span gas (instrument air). The upper reduc-tion station without filter is for the zero calibration gas taken from a bottle. Con-nections for both reduction stations are a 1/8" BSP female connection.

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Figure 3-2: IGOA System - Single Sampling Board

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System Installation

3.4.4 Vent Line Connection

A vent line connection for the bubble glass is arranged right below the sample ports. It is for the connection to an external vent line which allows venting the sampled inert gas from the bubble glass to the outside air. The vent line must be dimensioned to allow a gas flow of at least 10 l/min and arranged in such a way that it avoids backpressure and secures a sufficient sample gas flow (i.e. bubbles in the water). The vent line must be uninterrupted and easily bring away the inert gas.

3.4.5 Analyzer and Electrical Connection

The G36 Oxygen Analyzer is placed in the bottom right corner of the mounting panel. For lay out of an Inert Gas Oxygen Analyzing System with Single Sam-pling Board, see Figure 3-1 and Figure 3-2.

The instructions for electrical connections are described in the G36 Oxygen Ana-lyzer Manual – Section 3.

3.4.6 Digital Flow Switch (Optional)

Consiliums’ Inert Gas Oxygen Analyzing System may be configured with a digital flow switch for a sample flow alarm to assure there is always a sample flow via sensor.

The installing and operating instructions of the digital flow switch are described in the G36 Oxygen Analyzer Manual – Section 10.4.

For instrumentation diagram, please see Figure 3-1.

3.5 Double Board

The double board is designed for an analyzing system with the configuration of two sensors and two inert gas oxygen analyzers.

The double sampling board consists of a single sampling board described in the previous section and an extension board mounted on the right hand side of the single board. This extension board consists of a mounting panel, a G36 Oxygen Analyzer and a selector box for switching the output signals between the two ana-lyzers.

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Figure 3-3: Double Sampling Board

13

System Installation

Figure 3-4: Piping & Instrumentation Diagram for Double Sampling Board

Installation of the Double Board

The installation of the double board is carried out equivalent to the installation of the single board as described in the previous section. See Figure 3-3 and Figure 3-4 for the layout and P/I diagram of a Double Sampling Board.

The analyzers are prewired with the selector box. The interfaces of each G36 Oxy-gen Analyzer are the same as described in the G36 Oxygen Analyzer Manual.

The power supply and signal output cables are connected to the selector box. The electrical connections are dependent on the actual system configuration. Only those functions to be used shall be connected. For details of all standard connec-tions to the Selector Box, please see Figure 3-5.

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Figure 3-5: Electrical connections of the Selector Box

Protective earth Mains IN Neutral Live Power lead Power Unit 1 - prewired Neutral Live Power lead Power Unit 2 - prewired Neutral Live Power lead

Power Supply

Spade J3 - Terminal 1 J3 - Terminal 2 J2 - Terminal 1 J2 - Terminal 2 J4 - Terminal 1 J4 - Terminal 2

R4–not used by default R4–not used by default R3–System failure alarm R3–System failure alarm R2–Alarm HI-HI O2 % R2–Alarm HI-HI O2 % R1–Alarm LOW HI O2 % R1–Alarm LOW HI O2 %

Relay Output – J8

J8 - Terminal 8 J8 - Terminal 7 J8 - Terminal 6 J8 - Terminal 5 J8 - Terminal 4 J8 - Terminal 3 J8 - Terminal 2 J8 - Terminal 1

R4–not used by default R3–System failure alarm R2–Alarm HI-HI O2 % R1–Alarm LOW HI O2 %

Relay Input from Unit 2 – J7 - prewired

J7 - Terminal 8&7 J7 - Terminal 6&5 J7 - Terminal 4&3 J7 - Terminal 2&1

R4–not used by default R3–System failure alarm R2–Alarm HI-HI O2 % R1–Alarm LOW HI O2 %

Relay Input from Unit 1 – J6

J6 - Terminal 8&7 J6 - Terminal 6&5 J6 - Terminal 4&3 J6 - Terminal 2&1

Analog output 2 (-) Analog output 2 (+) Analog output 1 (-) Analog output 1 (+)

Analog Outputs– J12

J12 - Terminal 4 J12 - Terminal 3 J12 - Terminal 2 J12 - Terminal 1



Analog Inputs from Unit 1 – J10


Analog Inputs from Unit 2 – J11


System Commissioning

4. System Commissioning

Before starting the system for the first time after completing the installation, please check the installation of the system.

4.1 Installation checks of the sampling board

Check that the span and zero calibration gases are connected, and that all connections are secured and not leaking. A leaking connection will result in loss of calibration gas and may result in poor calibration.

Check that the sample gases are connected, and that the connections are se-cured and not leaking. Sample gas connections should be as close to the process as possible, preferably made from 6 mm stainless piping in order to reduce the dead volume in the sampling system. If the sample gas is heavily contaminated with particles, a pre-filter should be installed. The sample gas has to be taken from a suitable location representative for the gas to be tested.

4.2 Commissioning of the analyzer

Check connection and setting of the analyzer following the instructions in the G36 Oxygen Analyzer Manual – Sections 3 – 5. When working with a Double Sampling Board, this step needs to be carried out for each analyzer separately.

4.3 Start of system

Start the analyzer following the instructions in the G36 Oxygen Analyzer Manual - Section 5.

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Fill up the bubble glass with clean (preferably distilled) water to the water line marked on the glass.

Introduce sample gas to a sample port and turn the selector valve to the se-lected sample port, 1-3.

Open the flow control valve slowly until bubbles are noted. Open the flow control valve so much that there is a steady stream of bubbles from both the by-pass and sample return pipes inside the bubble glass. The longest pipe is for by-passing of sample gas against the water static pressure to secure a sufficient flow rate and constant sample pressure at the sensor. The short pipe is the return of sample gas from the sensor(s). Increased gas flow indi-cating by more bubbles from both pipes will reduce the sampling delay time. However, too high velocity – indicated by an enormous amount of bubbles – will change the sensor temperature and consequently the read-ings.

Turn the selector valve to Test Gas and the calibration selector valve to Zero Gas, and adjust the zero gas reduction station until the flow is about the same as noted for the sample gas by observing the bubble flow.

Turn the calibration selector valve to Span Gas, and adjust the span gas re-duction station until the flow is about the same as noted for the sample gas by observing the bubble flow.

Now, the system is ready for calibration following the instructions in the G36 Oxygen Analyzer Manual - Section 6.

Routine Maintenance

5. Routine Maintenance

5.1 Sample and Test Gas Flow System

Routine inspection and maintenance of the sampling system is required to make sure no gas is leaking from the test or calibration gas supply. Failure to periodi-cally inspect and maintain the above requirements may lead to imprecise analyzer readings and thus a malfunction of the inert gas system.

The system with the sample and test gas selector valves and flow control valves is tested from the factory.

For the selector valve packing, adjustment may be required for leak-tight per-formance. Adjust the packing by turning the packing bolt clockwise in 1/16-turn increments until leak-tight performance is achieved. Always verify proper opera-tion upon installation.

Protect the reduction units from the ultraviolet rays and adhesion of organic sol-vents. Depressurize the reduction stations before cleaning and service.

Clean with neutral detergent.

5.2 Filter and Bubble glass

The system with filter, bubble glass and sensor is tested from the factory.

Filter

The filter element located on top of the bubble glass will require periodical re-placement. The changing period will be determined based on actual sample condi-tion and how dirty the filter gets. When changing the filter, the sample flow con-trol valve must be closed so that the system must be completely isolated from the

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sample or calibration gas. The filter element is removed by unscrewing the filter top using 5 mm allen-key.

Check the condition of the filter O-ring seals and replace if required. For spare parts, see the list of spare parts in Section 6 of this manual.

Bubble glass

Check daily the level in the bubble glass and re-fill with clean (preferably dis-tilled) water as required. It is recommended to drain the bubble glass monthly and re-fill with clean (preferably distilled) water. The bubble glass may need internal cleaning. Clean with neutral detergent. O-rings for the bubble glass may require replacement for leak free operation.

Prevent the glass from ultraviolet rays and adhesion of organic solvents. For spare parts, see the list of spare parts in Section 6 of this manual.

Please also check that the vent line functions uninterrupted and secures a suffi-cient gas flow. There must not be a build-up of pressure in the bubble glass.

5.3 Analyzer

Refer to the G36 Oxygen Analyzer Manual - Section 7 for the routine maintenance of the analyzer.

Spare Parts

6. Spare Parts

When ordering spare parts, please quote the serial number of the analyzer, which you can find on the label on the right side of the blue analyzer box.

Part No. Part Description the specific appearance of the

spare parts is subject change with-out notice; the function however will

not change

6700328-00A O-ring for IG sensor

6700358-00A Selector valve sample/test gases

6700373-00A O-ring for filter house

6700379-00A Bubble glass tube

6700380-00A Sample filter glass

6700390-00A SEN1 Oxygen sensor plug type – complete with O ring (includes 00328)

6700395-00A Filter Elements (pkg of 5)

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the specific appearance of the Part No. Part Description spare parts is subject change with-out notice; the function however will

not change

6700657-00A Span gas filter regulator – 1/8” 0-2 bar

6700659-00A Zero gas regulator – 1/8” 0.02–2 bar

6700477-00A Sensor cable complete 0.8 m



6700605-00A Gasket for drain plug

6700739-00A Selector valve test gases

6700754-00A Gasket set bubble glass (2 teflon gaskets, 2 big O-rings, 1 small O-ring)

6701047-00A Cable glands – M20

6701101-00A Selector Box – 90-230 VAC

6701251-00A Fuse 2 AT (pkg of 10)

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Spare Parts

the specific appearance of the Part No. Part Description spare parts is subject change with-out notice; the function however will

not change

6701471-00A

SD card with G36 software & standard set-tings files – Please quote the serial num-ber of the analyzer when you order an SD card.

6701475-00A Bubble glass complete

6701477-00A Needle consol valve for bubble glass

6701241-00A G36a Oxygen Analyzer 100-230 VAC

6701242-00A G36d Oxygen Analyzer 24 VDC

6701597-00A This Instruction/Manual

Optional

6701453-00A Digital flow switch 0.2-10 l/min (optional)

6733594-00A Pre-Filter incl. filter cartridge

6700980-00A Filter cartridge for pre-filter

Other optional equipment – e.g. flow alarm, visualization, recording and data logging, monitoring of IG temperature, pressure, and load – can be supplied.

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Global Service and Support

Own companies

Sales- and service representatives

Consilium is constantly increasing and improving its global sales and serviceorganisation in order to provide our customers with the most competentservice and support. Today Consilium has established own companies in16 countries plus sales and service representatives in more than 50 countries.You will find updated contact information on our web-site www.consilium.se.

www.consilium.se

Documents

IGOA Inert Gas Oxygen - tmp.consilium.plushost.setmp.consilium.plushost.se/cmab/Manuals/6701597_Inert_Gas_Oxygen... · E-mail: Service:[email protected] Spares:[email protected]