Addendum Instruction Manual
Contents
1. Raw Detector Signal Absorption Spectrum Raw Detector Signal Absorption Spectrum 0 4 zT 0 019 4 0 015 02 0 010 0 0 4 0 005 02 0 000 092 4 4361 0 003 100 120 140 160 180 200 220 249 50 1 100 120 140 160 180 200 220 249 Control Mode Max Current LTS C LTS C LTCC Trans LT C gt EEXEN 30 388 Peak Position Peak Width LTSP Limits Fast Update Peak Position Peak Width LTSP Limits Fast Update va 502 _ 01 09 4003 05 32 17 01 09 4003 05 30 11 Above Zero Transmission No Signal Above 0 2 Transmission small signal IM11Y01B01 12E A 2nd Edition 23 Launch Alignment The pictures below indicates the launch unit aligned visually The colored arrows indicate the nuts used to adjust the horizontal and vertical axis Horizontal axis adjust Vertical axis adjust Alignment bellows with launch removed Please note that for the following steps you may need to use both hands to perform the alignment The arrows indicate placement of both hands while performing the alignment Placing the hands at the point of the arrows will allow for moving the assembly with the least amount of effort and provide the greatest amount of control Allen setscrews should be loose to allow for movement E aie i i_ 4 E E p e Once visual alignment is achieved on both the launch and detect and clean dry purge2. e Process Gas Flow Conditions Laminar homogenous gas concentration distribution conditions across the measurement point are recommended For circular ducts stacks this condition is generally at least three unimpaired diameters D before and after a process bend For rectangular cross sections the hydraulic duct diameter D is derived from D 4 x duct cross sectional area duct circumference If neither situation exists or is possible then distribution of the unimpaired section of duct should be 66 on the inlet side and 34 on the outlet side Profiling of the proposed measurement point may be required to ensure that a correct installation point is selected e Process Gas Temperature It is recommended that the analyzer be installed at a location where temperature fluctuations are minimized Generally as a guide if the temperature of the gas at the point where the analyzer is to be installed is to vary by more than 10 C 18 F then an Active input signal should be used for compensation Ensure the analyzer has been selected and configured to suit the maximum operating gas temperature e Process Gas Pressure It is recommended that the analyzer be installed at a location where pressure fluctuations are minimized Generally as a guide if the temperature of the gas at the point where the analyzer is to be installed is to vary by more than 0 05Bar 0 725psi then an Active input signal should be used for co
3. 1 10m 33ft atmospheric pressure 500C 930F o Oxygen 0 21 for control or monitoring o 0 5 000ppm for control monitoring or safety CH4 0 5 breakthrough monitoring and or safety 800C 1475F e Waste Incineration OPL 1 10m 33ft atmospheric pressure lt 1200C 2200F o Oxygen 0 21 for control or monitoring o 0 5 000ppm for control monitoring or safety CH4 0 5 breakthrough monitoring and or safety 800C 1475F For in situ application typically large scale combustion the optical path lengths are generally very long 7 30m for large scale combustion and ethylene furnaces Standard TDL optics and laser beam configurations are unsuitable because of the mechanical stability of these large scale combustion systems Yokogawa Laser Analysis Division therefore designed and developed the concept of a diverging beam i e a laser beam that expands over distance and a large aperture optics detector scheme i e a large target for the laser to hit The general concept of diverging beam and large aperture optics is shown below 1508 RF ANSI BELLOWS FLANGE 4 150 RF ANSI GE 3 130 E ALIGNMENT FLANGE DETECT UNIT LAUNCH UNIT IM11Y01B01 12E A 2nd Edition In a standard TruePeak TDLS200 analyzer the laser beam exiting the launch unit is normally collimated parallel before hi
4. 940 24 ANSI RF 4 1504 FLANGE PROCESS 316 SS BODY lt gt CONNECTION Above 4 150 ANSI RF option for Launch unit alignment bellows m m 1 GUERRE SEE ANALYZER QUICK CONNECT COUPLING TEV O RINGS LAUNCH DETECT ANSI RF 4 150 MOUNTING HOLES lt gt PROCESS CONNECTION ALIGNMENT ADJUSTMENT BOLTS TYP 4 5 8 11 18 8 SS STUDS 51655 BODY TEFLON ALIGNMENT RING Above 4 150 ANSI RF Large Aperture Optics detect side LAO IM11Y01B01 12E A 2nd Edition The standard flange sizes are either 2 3 or 4 150 R F ANSI as well as DN50 and DN80 Please check the exact flange size specified and provided for the particular installation Other flange sizes and a variety of materials to suit the process are available so please check these details prior to installing the flanges on the process The process isolation valves should have at least a 95 diameter clear bore size aperture to ensure there Is sufficient tolerance to align the laser beam after installation Ducts and Stacks that have thin and flexible walls should be reinforced to ensure that the laser beam alignment is maintained at all times Rigid mounting for the process flanges is highly recommended to ensure alignment is maintained In situations where the process flanges are mounted to these thin and flexible duct stack walls a larger reinforcing plate should be welded around the mounting flange area to increase the attaching region
5. CLEAR APERTURE TOP VIEW ERTURE MINIMUM 3 40 CLEAR A SIDE WIEN APERTURE R OFFSET LATERAL IM11Y01B01 12E A 2nd Edition PROCESS T M I ar SER Mtas OFFSET OF NOZZLES MUST BE MINIMIZED AS CLEAR APERTURE TOLERANCE LATERAL TO ALLOW FOR MINIMUM 3 40 45MM CLEA BEST INSTALLATION WILL HAVE NO 15 PROCESS FLANGE ANGULAR TOLERANCE vd m 4 PROCESS FLANGE BOLT ALIGNMENT fj M NOTE 3 EN NEN 1 I 4 A y ae PRA HOLE CENTERS IN FURNACE WALLS TO BE CONCENTRIC TOP VIEW B HOLE_ WITHIN 0 25 Ig NOZZLE FLANGE BOLT PATTERN MUST BE AS INDICATED TO ASSURE PROPER MOUNTING e us OF ANALYZER LAUNCH AND DETECT UNITS SIDE VIEW COMBINED ANGULAR OFFSET OF BOTH MOZZLES MUST NOT EXCEED 2 IN ANY DIRECTION BEST INSTALLATION WILL HAVE NO ANGULAR OFFSET NOTES 1 STRENGTHENING OF NOZZLES TO HEATER FURNACE WALLS USE VERTICAL amp HORIZONTAL ANGLE ON NOZZLE CENTER OR ANGLED GUSSETS IN CONJUNCTION WITH STIFFENER PLATE 2 REFER TO ADDITIONAL DRAWINGS FOR DETAILS a 3 FOR USE OF 3 150 ALIGNMENT FLANGE LAUNCH SIDE ONLY BOLTHOLES STAGGER CENTERLINE IM11Y01B01 12E A 2nd Edition 16 Details of supporting structural steel for long optical path length systems gt 7m 21ft It is import
6. Enter these new resistor values into the analyzer configuration under Advanced Menu gt Configure gt System gt Adjustable Resistors gt Detect R21 Detect R22 and Detect R23 All resistor values are entered in K ohm unit 11 Keep the resistor bag and this procedure document by customer DO NOT leave them in the detector box or throw them away TIPS e How to remove a gain resistor On the detector board find the location of the gain resistor Please note that the resistor is not soldered but resting in sockets Carefully remove the resistor from the socket on the board Since the analyzer is still powered on please take extreme caution to prevent a short circuit on the board i e loose wires or touching adjacent components with pliers or tool used to remove resistor e How to install a new gain resistor First try the new resistor by molding and clipping the resistor leads to fit into the socket Then carefully insert the resistor into the socket on the detector board Since the analyzer is still powered on please take extreme caution to prevent a short circuit on the board i e loose wires or touching adjacent components with pliers or tool used to install resistor e Please keep the factory original gain resistors in the resistor bag as they will be used in the future for offline calibration or test e The raw detector signal MAX MIN is proportional to R21 R22 R23 Usually R21 is maintained as factory value R22 and R2
7. The figure below depicts a typical suggestion however it is the installer s responsibility to ensure appropriately rigid installation is provided for the analyzer Below Typical 24 x 24 x 3 8 reinforcement plate 3 8 THICK S gt gt 2 PLATE 3 8 THICK S rn m ER ne VIEW DUCT STACK WALL END VIE W This approach is NOT suitable for systems that use the Large Aperture Optics LAO detect unit these are typically installed on applications with at least 7m 21ft optical path length For these long path length installations more significant bracing and structural rigidity is required refer to following section IM11Y01B01 12E A 2nd Edition Process Flange Welding Alignment and Line Up The Launch and Detect units are provided with alignment mechanisms that allow for some manual adjustment of the laser beam direction in both planes It is however recommended that the following angular tolerances be adhered to as closely as possible PROCESS FLANGE BOLT ALIGNMENT 4 HOLE PATTERN NOZZLE FLANGE BOLT PATTERN MUST BE AS INDICATED TO ASSURE PROPER MOUNTING OF ANALYZER LAUNCH AND DETECT UNITS IM11Y01B01 12E A 2nd Edition 14 FLANGE 3 40 MINIMUM
8. assembly so that a maximum signal is achieved This may require loosening the 4 bolts and moving the LAO assembly and detector in different directions Repeat these steps to ensure maximum transmission before proceeding Improper Alignment Vertical axis This alignment will indicate a strong signal but is susceptible to any wall flexing and may cause the alignment to be lost Ensure that some signal strength transmission and ramp is present even as little as 0 1 is acceptable to begin the alignment process IM11Y01B01 12E A 2nd Edition 34 e Sweeping the laser across the detector Vertical axis A Vertical axis B Vertical axis i Make turn adjustments counting the number of turns to sweep the laser across the detector Horizontal axis C Horizontal axis A Beam Detector Begin by turning the vertical axis nuts until the signal is extremely weak or lost Do not go past losing the signal e Sweeping the laser across the detector Vertical axis Horizantal axis o N P Beam Detector Beam ector Turn the nut back the direction you came from counting the turns so that the signal begins to increase and a maximum value is reached IM11Y01B01 12E A 2nd Edition 35 e Sweeping the laser across the detector Continue turning the nuts until you begin to lose the signal again at the opposite edge of the detector Remember the number of turns it takes to accomplish this pr
9. is generally beneficial to make the flange of the Launch and Detect Units and the flange of the process concentric with each other Due to the large clearance provided by standard flanges and bolts it is possible to mount the two flanges in an un concentric manner this should be avoided to aid laser beam alignment IM11Y01B01 12E A 2nd Edition 20 3 Installation 3 1 Adjustment and Optimization of Alignment lt 600 C 1100 F Installations The following procedure will aide in performing an alignment of the TDLS200 analyzer The procedure will guide the technician through the necessary steps to align and optimize the signal of the analyzer Please read the entire procedure before starting work and ask your local Yokogawa service group for further information if required This procedure can also be performed by local Yokogawa service personnel if required please contact for further details The alignment of the analyzer will be accomplished by first visually aligning the analyzer horizontally and vertically By performing this first step the signal should be adequate to begin the alignment procedure Once a visual alignment is achieved and a signal is present the optimization of the alignment will be accomplished by sweeping the launch beam across the detector beam Alignment of the detector may be necessary to insure a signal is present This is accomplished by monitoring the transmission strength while adjusting the
10. t PROCESS CONNECTION ie 22 5 16 567 ed SIDE VIEW RECOMMENDED CLEARANCE B BOUNDARY TYPICAL CUSTOMER SUPPLIED PROCESS CONNECTION PLAN VIEW IM11Y01B01 12E A 2nd Edition 10 Clearance for Detect Unit Ensure there is sufficient clearance and access for the Detect unit DETECT UNIT CUSTOMER SUPPLIED PROCESS CONNECTION SIDE VIEW SECOMWENTED CLEARANCE 4 BOUNDARY TYPICAL 102 ID rr TID X CUSTOMER SUPPLIED if 127 15 PROCESS CONNECTION ian p 305 381 4 n 102 PLAN VIEW IM11Y01B01 12E A 2nd Edition Dimensions for combustion process interface devices ALIGNMENT ADJUSTMENT 5 500 NUTS TYP 4 T ANALYZER QUICK 65 250 T3 CONNECT COUPLING gt wie 86 000 M 2152 zz L1 EN p e ar tr 55 AR zz i 25 E lt a 0 880 22 LAUNCH DETECT MOUNTING HOLES TYP 4 316 SS BODY Above 3 150 ANSI RF option for Launch unit alignment bellows ALIGNMENT ADJUSTMENT NUTS TYP 4 9 029 992 25 250 2133 T 5 563 C A QUICK CONNECT OUPLING EM 5 5 5 5 Pa e a 55 5 n4 sa 55 nan nan Ar BEN 26 000 2152 lt LAUNCH DETECT MOUNTING HOLES TYP 4 0
11. 1 SERVICE 1 800 524 7378 USA toll free Service Support us yokogawa com website www us yokogawa com TDLS website www truepeaktdis com IM11Y01B01 12E A 2nd Edition
12. 3 are optimized in the field We want to avoid the situation where one of R22 and R23 resistors has extreme low resistance and the other one has extreme high resistance The analyzer gives best performance when R22 and R23 are balanced Based on this relation between raw detector signal and gain resistors service technician or customer can select R22 and R23 faster with the help of a calculator e Multiple alignment actions might be needed if Detector Signal High fault happens Reduce the gain resistor first as described in STEP 8 a and then optimize the alignment again NOTE If the alignment has been performed on a cold shut down heater furnace then it is highly recommended when the heater furnace is at normal operating temperature the transmission alignment be checked again to ensure gt 10 ideally gt 25 transmission exists and that there are no alarms Validation gas should also be introduced through the validation cell to ensure peak response especially if a line locking gas is not being used IM11Y01B01 12E A 2nd Edition 39 4 Contact for Further Assistance Should you require any further information or details not contained herein then please contact your local Yokogawa Office Yokogawa Distributor or Yokogawa Sales Representative or Yokogawa Laser Analysis Division directly as listed below Yokogawa Laser Analysis Division 910 Gemini Street Houston Texas 7 058 USA Telephone 281 488 0409 Facsimile 281 488 497
13. 3 values are 11kO the new R22 and R23 values should be 7 5kO NOTE please access Active Alarm in the main user interface panel to check if Detector Signal High fault is active b If the raw detector signal is within requirement remove R22 and R23 and R21 if it was changed to 1000 in STEP 3 and cut their leads properly to fit the sockets tight and low and then go to STEP 9 NOTE 1 for a low process temperature analyzer with no capacitor on R3 the raw detector signal is within requirement if MAX is between 0 0 and 4 0 2 for a IM11Y01B01 12E A 2nd Edition 38 high process temperature analyzer with a capacitor on R3 the raw detector signal is within requirement if MIN is between 4 0 and 8 5 c Ifthe raw detector signal is too low other than a and b change either R22 or R23 to the next greater value available in the resistor bag and then go back to STEP 7 How to decide which resistor to change i If the current R22 value is greater than the current R23 value change R23 to the next greater value available in the resistor bag ii If the current R22 value is same as the current R23 value change R22 to the next greater value available in the resistor bag iii If the current R22 and R23 are already 24 3kQ the greatest value available in the resistor bag please contact Yokogawa for assistance 9 Close the detector enclosure Write down the final values of R21 R22 and R23 below for record R21 R22 R23 10
14. If the transmission does not return to its original value then the process windows will have to be cleaned to ensure optimal operation It is best to repeat this procedure two or three times to ensure repeatable results that establish confidence in the readings This can be repeated at any time at a later date to verify the process readings A similar method can also be used by comparing ratios of the path lengths and measurements with and without window purge flow Using the analyzers integral Trend function observe the measurement values when both launch and detect window purge gas flows are simultaneously stopped for approx 30 seconds or until the reading stabilizes and then resume window purge flow back to the initial flow rates As with the other method observe the transmission note if there is a sudden large decrease in transmission then probably contamination fouling has occurred on the windows Once the process measurement has re stabilized with window purge gas flow repeat the simultaneous stopping of window purge gas flow Repeat this several times until the trend screen clearly shows repeatable measurement results with and without window purge If the transmission does not return to its original value then the process windows will have to be cleaned to ensure optimal operation The ratio of these two measurements can now be established based on the repeatable results obtained Establish the distance between the launch unit window and th
15. Ms HIE Note that the LAO is not level correctthis by a visual check before beginning alignment procedure Perform a visual alignment so that the launch and detect are as level and straight as possible This needs to performed both vertically and horizontally IM11Y01B01 12E A 2nd Edition Proper Visual Alignment After visually lining up the LAO assembly Once a good visual alignment is achieved and the analyzer and optics have been purged with clean dry purge gas power on the units and proceed with the alignment process Launch Alignment The pictures below indicates the launch unit aligned visually The colored arrows indicate the nuts used to adjust the horizontal and vertical axis Horizontal axis adjust Vertical axis adjust Alignment bellows with launch removed 29 IM11Y01B01 12E A 2nd Edition 30 Please note that for the following steps you may need to use both hands to perform the alignment The arrows indicate placement of both hands while performing the alignment Placing the hands at the point of the arrows will allow for moving the assembly with the least amount of effort and provide the greatest amount of control Allen screws should be ESS cd Ener m 2 This procedure will address the use of an oscilloscope to aide in the alignment of an LAO system using a high temperature laser The following procedure will not attempt to
16. TDLS200 Tunable Diode Laser Analyzer Addendum Instruction Manual Furnaces Heaters amp Large Scale Combustion IM11Y01B01 12E A 2nd Edition YOKOGAWA gt This ADDENDUM to Instruction Manual has been compiled for Owners Operators of the Model TDLS200 Tunable Diode Laser Analyzer specifically for installations on Furnaces Heaters and Large Scale Combustion process Copyright 2012 by Yokogawa Laser Analysis Division All Rights Reserved Product development is a continuous policy of Yokogawa Laser Analysis Division and therefore specifications may be subject to change without notice SAFETY should be considered first and foremost importance when working on the equipment described in this manual All persons using this manual in conjunction with the equipment must evaluate all aspects of the task for potential risks hazards and dangerous situations that may exist or potentially exist Please take appropriate action to prevent ALL POTENTIAL ACCIDENTS AVOID SHOCK AND IMPACT TO THE ANALYZER THE LASERS CAN BE PERMANENTLY DAMAGED Laser Safety amp Classification according to FDA Regulations The TDLS200 is registered with the United States FDA as a Laser Product Please carefully read the appropriate Sections of this User Guide The TDLS200 Tunable Diode Laser TDL Analyzer is a technologically advanced instrument that requires the appropriate care when handling installing and operating Failure to do so may result in d
17. amage and can void any warranties If there is any doubt about any aspect of the Instrument or its use the please contact Yokogawa Laser Analysis Division and or your authorized Representative Distributor In this addendum to the Users Guide for TDLS200 the installation to Furnaces Heaters and Large Scale Combustion is specifically outlined Items contained IM11Y01B01 12E A 2nd Edition within this addendum supersede any conflicting statement contained within the standard Users Guide IM11Y01B01 12E A 2nd Edition 1 Combustion Overview 1 1 Introduction In this addendum to the Users Guide for TDLS200 the installation for combustion is detailed This information pertains to oxygen and CO CH4 analyzers Some typical combustion related installations are outlined below e Ethylene Cracking Furnaces Refinery Heaters Reformer Units VCM Cracking Furnaces Waste Incineration Power Generation systems etc Radiant section OPL 1 30m 99ft atmospheric pressure lt 1200C 2200F o Oxygen 0 21 for control or monitoring o 0 5 000ppm for control monitoring or safety CHA 0 5 breakthrough monitoring and or safety lt 800C 1475F e Convection Economizer section OPL 1 30m 99ft atmospheric pressure lt 1200C 2200F o Oxygen 0 21 for control or monitoring o 0 5 000ppm for control monitoring or safety CH4 0 5 breakthrough monitoring and or safety 800C 1475F e Combustion flue OPL
18. ant that the angle support steel used for supporting the nozzle be welded directly to both the walls and the adjacent heater furnace structural steel as shown conceptually below Note horizontal vertical bracing tied to the adjacent structural steel and walls of the unit Structure Steel frame Unequal leg angle steel L shape steel Structure Steel frame Structure Steel frame Structure Steel frame Diagram below shows the preferred nozzle reinforcement method NOTE Ensure you have sufficient clearance behind the flange between the angle support to allow for the alignment flange and LAO attachment using appropriate nuts and bolts studs IM11Y01B01 12E A 2nd Edition 17 re Y At least m 3 inches Yooo OO 210 Unequal leg angle steel L shape steel Furnace Wall 210 Note The TDLS200 flange must be at least 10 from the furnace wall Heat will damage the optics at distances less than 10 from the furnace wall The above preferred method may not be possible in every site specific situation The actual dimensions may have to be adjusted to suit the practical installation considerations in each case but it should remain as close as possible to the above preferred method IM11Y01B01 12E A 2nd Edition 18 Case A below shows this preferred method and case B below shows an alternative method if the oreferred method cannot be accommoda
19. centered as best as possible Pia KEN 4 nn ms PROSE PICTURE GRID 8 6 O IM11Y01B01 12E A 2nd Edition 32 e Once visual alignment is achieved on both the launch and detect power may be applied to the analyzer e Begin the alignment process by starting at the launch unit to maximize the signal by moving the launch around using the alignment bellows while watching the scope screen e Once maximum signal is achieved Note that the signal may be very small initially as low as 0 1 volts move to the detect end and using the method described in the previous slide move the LAO detect assembly around until maximum signal is achieved e launch and detect alignment steps may need be repeated several times to ensure maximum transmission e Once maximum transmission is achieved move to the next step and ensure the laser is centered e This is done by sweeping the laser across the detector in both the horizontal and vertical axis To accomplish this use the nuts on the alignment bellows to sweep the beam Alignment ET JHEEEHEE Lern uet unt d Move the launch unit around both axis to achieve a maximum signal Move to the detect side forthe next step IM11Y01B01 12E A 2nd Edition 33 Alignment Launch aligned properly but detect LAO not refocusing beam on detector Move to the detect side while monitoring the transmission adjust the LAO
20. e Note that the LAO is not level correct this by a visual check before beginning alignment procedure Perform a visual alignment so that the launch and detect are as level and straight as possible This needs to performed both vertically and horizontally Proper Visual Alignment After visually lining up the LAO assembly Once a good visual alignment is achieved and the analyzer and optics have been purged with clean dry purge gas power on the units and proceed with the alignment process IM11Y01B01 12E A 2nd Edition 22 Improperly aligned Launch indicating good reading but not optimally aligned Launch Detect Vertical axis Horizontal axis Detector This alignment will indicate a strong signal butis susceptible to any wall flexing and may cause the alignment to be lost Ensure that some signal strength transmission and ramp is present even as little as 0 1 is acceptable to begin the alignment process sweeping across the entire window is important to insure proper alignment oem vxaluyBj px 10 0 3 65 TAS oem vxaluyBj7px 10 0 3 65 B7 s D 90 3 C3 o 1 10 03 65 eem wDnexososs 10 03 65 lem f ing 0 g 1 E T B I A oe EIE 1 jiUj Aj Advanced Config Laser Spectra amp Control Advanced Config Laser Spectra amp Control
21. e detect unit window and calculate the ratio with respect to the normal Process Path Length The ratio of measurement without purge gas to measurement with purge gas should be equal to path length window window to process path length thus indicating that the connection nozzles are purged correctly IM11Y01B01 12E A 2nd Edition 2 2 Position of Process Flanges for Launch and Detect Units Process flanges should be located on the process such that the Launch and Detect Units can be installed accessed removed in a safe and convenient manner The following criteria Check List should be met at a minimum e Good Safe Engineering practices e Local codes and regulations for such equipment installation e Appropriate hazardous area if applicable precautions e Owner Company best practice and engineering standards e Access for personnel to stand in front of launch and Detect Units e Clearance for installation and removal of Launch and Detect see below e Clearance for installation and removal of purge insertion tubes if applicable e Access to process isolation valves e Safe routing for interconnecting cables e Ambient conditions in accordance with analyzer limits e Access to appropriate utilities e Adjacent space for mounting to Calibration Cell when off line IM11Y01B01 12E A 2nd Edition Clearance for Launch Unit Ensure there is sufficient clearance and access for the Launch unit 42 1 2 1080 CUSTOMER SUPPLIED
22. e beam is centered Proper Alignment Horizontal axis Vertical axis Beam Centered Beam Centered Detector Turn the nuts 5 the number of turns required to lose the signal from one side to the other This will ensure the beam is centered Repeat the process for the horizontal axis Make sure all nuts are secure and tight to complete the alignment centering Adjusting the detector gain may be required to ensure adequate detector voltage and transmission IM11Y01B01 12E A 2nd Edition 28 3 2 Adjustment and Optimization of Alignment lt 1200 C 2200 F Installations This section will aide in the alignment of the large aperture optics assembly in a high temperature i e with variable degree of background radiation gt 800 C application using an oscilloscope or scope meter Please read the entire procedure before starting work and ask your local Yokogawa service group for further information if required This procedure can also be performed by local Yokogawa service personnel if required please contact for further details Please note that this procedure is not intended to teach train someone how to use an oscilloscope If you do not know how to use an oscilloscope please align the analyzer by using the method mentioned in the user manual Initial Installation No Alignment Performed Note that Screws are loose and a gap exists This will need to be corrected before an alignment can take place
23. gas has been flowing power may be applied to the analyzer e Begin the alignment process by starting at the launch end maximize the signal using the transmission signal and value by moving the launch around using the alignment bellows e Once maximum signal is achieved move to the detect end and using the method described in the previous slide move the LAO detect assembly around until maximum signal is achieved Note CO detectors are more sensitive to miss alignment than the O2 detector IM11Y01B01 12E A 2nd Edition 24 launch and detect alignment steps may need be repeated several times to ensure maximum transmission e Once maximum transmission is achieved move to the next step and ensure the laser is centered e This is done by sweeping the laser across the detector in both the horizontal and vertical axis To accomplish this use the nuts on the launch alignment bellows to sweep the beam Alignment Move the launch unit around both axis to achieve a maximum signal Move to the detect side for the next step Improperly Aligned Detector Move to the detect side while monitoring the transmission adjust the LAO assembly so that a maximum signal is achieved This may require loosening the 4 bolts and moving the LAO assembly and detector in different directions Repeat these steps to ensure maximum transmission before proceeding IM11Y01B01 12E A 2nd Edition 25 Improperly Ali
24. gawa PHOTOS OF DETECTOR BOARD arie me Yokogawa Corporation of America 1 1 Laser Analysis Division i i lt PART NUMBER 2000 1028 l 8 UNIVERSAL DET 5 RESISTOR KIT BAG e For a TDLS200 analyzer with diverging laser beam configuration either with or without large aperture detector lens a resistor bag is attached inside the detector box The resistor bag contains the resistors with the following values All of them are W 5 tolerance metal film through hole resistors Resistor Bag for Analyzers With Diverging Beam Optics IM11Y01B01 12E A 2nd Edition 37 e Factory gain resistors the detector board R21 R22 R23 PROCEDURE 1 This procedure requires wearing a grounding strap connected to one of the grounding lugs of the analyzer to prevent any electrostatic damage 2 Open the detector enclosure and put on a grounding strap 3 Identify the gain resistors R21 R22 and R23 on the detector board as shown in the photo above They are all plugged in sockets instead of being soldered easy to be modified by a pair of small pliers The existing gain resistors have factory resistance values optimized on a calibration cell 4 Optional For a high process temperature application and if the current process temperature is higher than 600 C apply a multi meter to measure the voltage across R21 If the measured voltage absolute value i
25. gned Launch Launch Detect Horizontal axis Vertical axis This alignment will indicate a strong signal but is susceptible to any wall flexing and may cause the alignment to be lost Ensure that some signal strength transmission and ramp is present even as little as 0 1 is acceptable to begin the alignment process The next process will center the beam on the detector e Sweeping the laser across the detector Launch Detect Wir Vertical axis Begin by turning the vertical axis nuts until the signal is extremely weak or lost Do not go past losing the signal IM11Y01B01 12E A 2nd Edition 26 e Sweeping the laser across the detector Vertical axis Turn the nut back the direction you came from counting the turns so that the signal begins to increase and a maximum value is reached e Sweeping the laser across the detector Launch Detect Vertical axis Continue turning the nuts until you begin to lose the signal again at the opposite edge of the detector Remember the number of turns it takes to accomplish this process IM11Y01B01 12E A 2nd Edition 27 e Sweeping the laser across the detector Vertical axis A Vertical axis B Vertical axis t Make turn adjustments counting the number of turns to sweep the laser across the detector Horizontal axis A The steps required to sweep the beam across the detector It is important to insure the entire sweep process so that th
26. mpensation Ensure the analyzer has been selected and configured to suit the maximum operating gas pressure Ensure the process isolation windows have been selected and configured to suite the maximum design gas pressure e Process Dust Particulate Matter It is recommended that the analyzer be installed at location where dust loadings are minimized Dust and other particulate matter will reduce the optical transmission of the measuring laser beam Within limits the loss of optical transmission does not affect the measurement however a Warning alarm will be initiated when the transmission falls below allowable limits The amount of dust loading is also dependent upon the optical path length Consult Factory for further details IM11Y01B01 12E A 2nd Edition Window Purge Gas Flow Adjustment While there is no specific formula for this purge gas flow rate due to the many variables complexity we include the following information that might help optimize the window purge gas flow rates actually at site As mentioned in the User s Guide the window purge flow rate can vary by application from as little as 5 Its min up to as much as 50 Its min for typical process applications There are a couple of methods that can be used to help establish a suitable flow rate For relatively short optical path lengths such as process O2 measurements if there is too much flow the purge gas will protrude mix into the process gas slightly and
27. ocess Proper Alignment Vertical axis Turn the nuts the number of turns required to lose the signal from one side to the other This will ensure the beam is centered Repeat the process for the horizontal axis Make sure all nuts are secure and tight to complete the alignment IM11Y01B01 12E A 2nd Edition 36 Adjustment of Detector Gain after Optimization of Alignment Please read these directions carefully before attempting work and contact your local Yokogawa service center if there is any doubt about how to perform this procedure Alternatively Yokogawa service personnel can perform this procedure please contact you local service center for details rates availability etc Caution Electrostatic Sensitive INTRODUCTION e For TDLS200 measurement over long optical path length the laser beam is usually configured with a small diverging angle either with or without large aperture detector lens In factory the detector signal gain is not optimized for the real installation During the analyzer field start up service the detector gain needs to be adjusted to achieve the best analyzer performance e This document gives the guidance and procedures to adjust the detector board gain for services and customers after the analyzer is installed and powered up e This operation should be done by qualified personnel Read instructions fully before starting this operation Any doubts or questions please contact Yoko
28. s greater than 5V change R21 to the 1000 resistor from the resistor bag Keep the original R21 in the resistor bag as it can be used for future off line calibration 5 Remove R22 and R23 from the detector board and replace them with the 11kQ resistors from the resistor bag Please keep the original R22 and R23 in the resistor bag as they can be used for future offline calibration 6 Optimize the analyzer alignment for both the launch and detector sides Stop the alignment if Detector Signal High fault activates 7 In the TruePeak user interface software navigate to Advanced Menu password gt Configure gt Laser Spectra amp Control screen to check the raw detector signal Write down the raw detector signal MAX and MIN values for later use gem xk7 0kmblbbp 10 0 8 32 KITE i B c D S 50 e3 Co 2 1 10 0 8 32 Advanced Config Laser Spectra amp Control Raw Detector Signal Absorption Spectrum Be 100 120 140 160 180 200 220 249 O2 Temp C Control Mode Cur Center 14 55 M 2110 EZ 6000 Trans X Pres psiA LTS C 72 15 14 700 21 053 Peak Pos 21 053 175 3 07 08 2011 16 50 07 8 Change R22 and R23 accordingly based on the current raw detector signal Perform one item of the following selections a b or c a If Detector Signal High fault is active change both R22 and R23 to the next smaller value available in the resistor bag and then go back to STEP 6 For example if the current R22 and R2
29. teach the use of an oscilloscope It will be assumed that the person performing this procedure will know how to use the necessary equipment Launch Board Connection points for scope meter leads Jr Detector Board Connection points for scope meter leads ary ET A H f PN cepactormesi stor Yat i E pnag indicates EC SB 2w TP2 Papplicatio Es ud vit m Ede IP1 Negative BEEN de IM11Y01B01 12E A 2nd Edition 31 Oscilloscope attached to the launch test points Begin by monitoring the signal for a waveform similar to that listed below As the signal strength begins to increase the wave should begin to increase in height The image on the left indicates a small amount of signal reaching the detector The image on the right indicate a stronger signal Note that you will still need to perform the sweep across the detector to ensure that the beam is centered as best as possible VOFF F 197 di Er i Ja PROBE PICTURE Oscilloscope attached to the detect test points Begin by monitoring the signal for a waveform similar to that listed below As the signal strength begins to increase the wave should begin to increase in height The image on the left indicates a small amount of signal reaching the detector The image on the right indicate a stronger signal Note that you will still need to perform the sweep across the detector to ensure that the beam is
30. ted at the particular site installations CASE A CASE T Unequal leg angle steel Fa Furnace Wall Furnace Wall Above Preferred angle mounting above Alternate angle mounting Below Image of actual installation as Case A preferred method IM11Y01B01 12E A 2nd Edition 19 Mounting the Launch and Detect Units to the Process Flange Securely bolt the Launch and Detect LAO Units to the process flanges using the standard bolt holes studs provided Ensure the correct size bolts nuts and gasket are used in accordance with the flange specifications and in accordance with the process specifications when applicable CAUTION Use anti seize paste on threads to avoid possible metallic galling on nuts bolts studs START flow to the clean dry window purge gases as soon as possible if the process valve is open this will prevent contamination to the optical surfaces Before starting the actual purge flows ensure the lines have been blown out to remove all debris dirt oil water and other media that could contaminate the optical surfaces and impaired the optical transmission measurement performance NOTE the optical surface temperatures MUST NOT exceed 70degC NOTE If the process isolation valve flange is excessively hot due to the process temperature or radiant heat then a thermal insolating flange gasket should be used in order to minimize the heat transfer to the analyzer flange face It
31. therefore possibly cause a slightly shorter actual optical path length readings lower than expected Conversely if there is too little window purge flow the process gas may protrude mix with the purge gas worst case contaminate the windows in the connection nozzle and possibly cause a slightly longer actual optical path readings higher than expected One method that can be used if the process gas is not excessively dirty or wet would be to measure the process gas without purge for a short period of time Before starting this test the process measurement O2 concentration should be relatively stable and not expected to change within a few minutes First establish the distance between the launch unit window and the detect unit window and enter this value as the Process Path Length under Advanced Menu Configure Then stop the process window purge gas flow to both the launch and detect units while observing the transmission note if there is a sudden large decrease in transmission then probably contamination fouling has occurred on the windows Wait for the process reading to stabilize i e the process gas has filled the nozzle and alignment bellows sections up to each window take note of the measurement value and resume some window purge flow Change the Process Path Length back to the normal value and now resume agjust the launch and detect unit window purges until the process reading matches the value noted when there was no purge flow
32. top bottom and left right nuts on the alignment bellows The adjustments are performed on one axis at a time The intent is to use the alignment bellows adjustments to move the beam from one edge of the detector to the other both horizontally and vertically while counting the number of 1 4 turns of the nuts required to sweep across the detector The beam is then centered by taking the number of 1 4 turns necessary to sweep the analyzer from one signal edge to the other and dividing this number in half and returning the analyzer to the center by turning the nuts so that the beam is centered Example begin by monitoring the transmission and turning the top bottom screws so that that the beam reaches one edge of the detector this will be noticed by a drop in transmission Once on the edge begin turning the nuts the opposite direction a 1 4 turn at a time until you see an increase in the transmission and then a decrease and eventually a loss of transmission again If this required 18 1 4 turns to accomplish turn the nuts back 1 2 of that amount or 9 1 4 turns to center the beam Repeat this process for the left right axis The launch unit will then be centered Please refer to the following pictorial guide for further details IM11Y01B01 12E A 2nd Edition 21 Initial Installation No Alignment Performed Note that screws are loose and a gap exists This will need to be corrected before an alignment can take plac
33. tting the opposing detect unit The collimated beam size is typically less than 1 diameter However this optical layout is not appropriate for long path applications the dimension of process is longer than 23 During the initial installation it is also not so easy to align the laser beam so that it can hit the targeted detect unit over a long distance small changes in the launch unit angle are magnified over long distances Also it is almost impossible to keep good alignment with varying ambient and process conditions especially during cold starts and shut downs the most extreme thermal changes on the mechanical structures To resolve the above issues Yokogawa Laser Analysis Division has developed diverging beam and large aperture optics strategy At the launch side the output laser beam has a small diverging angle For example the beam size is about 20 50cm diameter at 60 18m optical distance The optical aperture at the detect unit is enlarged from original diameter With these two changes it is much easier to do initial alignment and keep good transmission at all operating conditions It is however still important to mechanically strengthen the analyzer attachment nozzles onto the combustion unit walls IM11Y01B01 12E A 2nd Edition 2 Installation 2 1 Process Measurement Point Considerations The following criteria should be considered when selecting the installation point in respect to the process conditions
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