3. System Configurations
Contents
1. 1 Calibration gas x pi lt 3 gt ZR40H Auto Calibration unit 2 Zero gas cylinder Note 1 Shield cable Use shielded signal cables and connect the shield to the FG terminal of the converter Note 2 When a zirconia oxygen analyzer is used 100 N gas cannot be used as the zero gas Use F0306 EPS All Rights Reserved Copyright O 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 3 6 3 System Configurations lt Toc gt lt Ind gt ion Based on Sample Examples of System Component Select Gas Conditions 3 3 1 Detector and its accessories 543 20604 Z lON 6 PINOUS S0BUIN y Ul UONEm nil inss id ON Ed G 0 G 0 aqoud WG LOD 104 UONPSUSdUIOD DINSSIIA WJOMSd ISNUI nok edy G sp x SOBUIN y UI 95 out U UAA ainssaid eu NOA jeu PEPUSUWIUIODS J SI ll egy 6 Sp x DOLUUNI y UI 95 out U UAA 1 30N VNEZY6 UHM JO 1 1202 UM dddz Z lON 4 lli DIS UHM JO 1 9901d YUM 1019819p as0dand eJauar Jeu 10199 01d YUM 1 as0dind eJauar sse 10 sWN B 007 OD Aan 1 6 UHM JO ON EZ76M UM OGGHZ JOY DIS UHM JO 10198 01d ISNP YIM 10109 ap 01 1 6 YUM JO 7 12 2 1622 GI souoddns aqoid2. loq 809 ULM 10 99 9p p zu Alnd 001 0 1800 SAISBIGY L 0N Ed 0SZ 0 S sse 10 lN 6 OL U IH TatcOZ UM dduz Z lON 10109101d UHA 10198 2p 01 6 01 SS l 10 sUIN B G 0 MOT asodind eJauar ul GT uey 5597 Puel UOIJSSUJ n l eng ann TI 11M12A01 01E May 31 2004 00 All Rights Reserved Copyright 2004 Yokogawa Electric Corporation 3 7 3 System Configurations lt Toc gt lt lnd gt Sd3 80604 aqoud e119 eWw piepueis e s pnioul 191depe 1 ay N49Y024 10 90394023 H d120Z 910 02247 xew WW 00 uon9aloid p rddns N394023 NX JOU A PA D N 40 1105409 lt 2 59394023 eseaid Yk XA H d120Z H d120Z H d120Z SOLESNS 008 PJEPUEIS JON N G10 07ZHZ G10 022HZ 910 0227 OIS 0071 SOLESNS 008 AIPA lp u JO Joyala 10109 9p a1ne19du8 UDIH l Joldepe 21N1819dW921 U6IH 1010919p eineJodue u IH 0071 01 dn 002 Jeeyeuu 9 b p nb Sinba edy G ugy SSI SI 99 u sn JNSUON Da 10N 10N 10N 10N pent 4 L 910N ANEA 10 2 f 10 909 101909 WINLUIXEN Kaeijixny Kaeixny Kaeiixny Soro ease
3. Suction Blower ron amp steel heating furnace Temperature 900 to 1400 C Pressure 0 03 to 0 05 kPa Dust Minute Fuel Gas F0452 EPS All Rights Reserved Copyright 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt lnd gt 4 Applications 4 6 b Hot blast stove blast furnace facility The hot blast stove is a facility used to heat the air used in a blast furnace to provide the high temperature hot air blast The air is heated by combustion of the gas generated from the coke ovens The O analyzer is used to control or monitor this combustion EZ 13 If pressure is high Combustion monitoring a pressure compensated Oo control detector is selected T0404 EPS ES Furnace Top Pressure Recovery Unit Q Precipitator m ez W lt V Q Hot Blast Stove Waste nd Recovery P IG 222 SN Vas Hot blast stove Ome 9 Temperature 20 to 350 C ec G Pressure 3 5 to 10 kPa 28 Dust 50 mg Nm3 Ne Fuel Gas 0404 5 All Rights Reserved Copyright 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 4 7 T0405 EPS Obiective Combustion monitoring 4 Applications Detector D1 D2 System type L2 L3 Flue Coking Chamber The O analyzer is used to monitor the exhaust gas from the heater combustion used for destruc Sample point This facility is used to produce the coke used in the blast furnace tive dist
4. 1 g Nm3max F0413 EPS All Rights Reserved Copyright O 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt Ind gt 4 Application 4 14 4 5 Garbage Incinerator This is a facility to handle by incineration the combustible waste generally contained in municipal garbage The exhaust gas of the incinerator outlet contains large quantities of dust and corrosive gasses and a large water vapor component Yokogawa should be consulted concerning the installation of the unit H2 H3 Note depending on the conditions at the sample Combustion monitoring point a sampling type system may be required Scrubber outlet L2 L3 D1 D3 Combustion monitoring or stack T0414 EPS Incinerator outlet gas cooler outlet Fluidized Bed Incinerator Plant en rama 2 o Air Preheater 1 Scrubber Electric Denitration M Precipitator Tower 2 1 1 Measured Feed S ll AR Co AIK UI H 5 A Extraction Blower 5 Deconsolidator o d TN Control Oil Gun s nana an nr A Dust Dust gt Auxiliary Blower Hot Blast Furnace Pressurizing Blower Garbage incinerator Scrubber outlet Incinerator outlet 700 to 750 C Exhaust gas temperature 80 to 120 C Exhaust gas temperature 700 to 750 C Dust 0 1 g Nm maximum Dust 20 to 30 g Nm3 Exhaust gas compone
5. ZR402G Converter Needle A 5 m valve m IK a T l J E rr Signal Ejector ASSY J 17 6 core shield cable 100 to 566 Rene 5757757555 111 0 240 VAC Heater 2 core 270775 Contact input 2 gt Analog output lt 3 gt ZABF flow setting unit contact output 3 Reference Flowmeter Needle Digital output HART 1 gas Air Set 2 4 Instrument air Calibration gas ne Span gas Bod Zero gas cylinder Note 2 Selection of Needle valve or Ejector O Necessary Note 3 Selection of high temperature probe material Needle Ejector Ejector valve ASSY ASSY3 05 0 5 to 0 05 77 Horizontal Check Maximum orientation mountin temperature C g SUS310S 1400 ol 005005 1 foss e 1 K9473XH K9473XJ 2 E7046EC E7046EN 3 consult with YOKOGAWA F0305 EPS All Rights Reserved Copyright O 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt Ind gt 3 System Configurations 3 5 6 Type H3 with auto calibration with safety purge lt 1 gt High temperature detector ZR22G 015 a supply lt 2 gt ZR402G Converter Needle valve 2 KR T Ejector ASSY m seg 1 _ 6 core shield cable 200 100 to 240 VAC Heater 2 core we 5 Contact input Analog output contact output Digital output HART TH Check ae
6. EME sa 21 0 02 FG AO 1 AO 1 AO 2 A0 2 CJ CJ HTR HTR CELL CELL TC TC ENON gt x 90 9 amp EE GN MN INF EN CN ef amp amp amp 5 S oh da H amp All Rights Reserved Copyright 2003 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 Blank Page nn lt Toc gt lt lnd gt 2 Installation Guide 2 1 2 Installation Guide 2 1 Selecting an Installation Site Improper installation of the detector may cause inaccurate measurement or damage in short term service 1 2 3 4 Easy access for inspection and maintenance Ambient temperature does not exceed 150 C and the terminal box is not exposed to radiant heat A clean environment free from corrosive gases Minimum vibration Typical good bad installation examples are shown below for your reference Instructions for installation NS NR 2 NR Bad Example Good Example Oriented W against O Luz O 4 Installed on a a bend in yo duct f Mounted above the gt gt il amp D Probe Protector J Guard Protector f Subjected to condensation W 8 F0201 EPS ce Installation Site of the Converter in case of ZR402G our o Allovvs the operator to easily read the display and operated the keys Easy access for inspection and maintenance Ambient temperature does not exceed 55 C and tempe
7. for wide application in industries which consume considerable energy such as steel electric power oil and petro chemical ceramics paper and pulp food or textiles as well as incinerators and medium small boilers It can help conserve energy in these industries The ZR402G also contributes to preserva tion of the earth s environment in preventing global warming and air pollution by controlling complete combustion to reduce CO SOx and NOx ZR22G Detector uses a high reliability Zirconia sensor and its heater assembly can be replaced on site The detector is mounted for example on the wall of a flue and can measure the gases directly For use in combustion gases at temperatures up to 1400 C choose the general use 0 15m long detector which is combined with ZO21P H the high temperature probe protector The converter is equipped with an LCD touch screen which has various setting displays a calibration display oxygen concentration trend display with easier operation and improvement of display functions The converter is equipped with various standard functions such as measurement and calculation as well as maintenance functions including self test Analyzer calibration can also be fully auto mated and ZR40H an automatic calibration unit is available Choose the detector version which best suits your needs so that an optimal combustion control system can be obtained Use this Tl as a system selection guide and application note
8. recovery boiler Gas temperature 170 to 200 C Gas pressure 2 kPa Dust 6 to 15 g Nm3 Main dust components Na S0 90 Na CO3s 10 amsn F0451 EPS All Rights Reserved Copyright 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt Ind gt 4 Applications 4 5 4 2 ron and Steel Furnaces a ron amp steel heating furnace These furnaces are for the heating of steel slabs and generally the measured gas is at a high temperature of 1000 C or above The oxygen concentration is controlled to a low level to prevent oxidation of the slabs These are also some cases in vvhich there is some amount of CO in the gas and in which magnetic oxygen analyzers or infrared type CO analyzers are used Sample point System type Detector 1 Objective 1 Preheat zone heating zone H2 H3 Combustion monitoring soaking zone T0452 EPS Hot Blast Emission PCV Pat To individual Zones Individual Zones FCV Fuel Thinning out M Gas FCV Valve at Pas Shutoff Valve at Pat PCV Throttling Valve To Burners Heating Soaking Zone Zone Furnace Pressure Damper insertion Door yas Extraction Door Ji Steel Slabs Extractor PLEIE IO II A an S as d ee E a G an G a r p N e J i x ur induced Draft Fan i Se 4 g l g 1 g Skid P Hydraulic Pressure N D AB So Recuperator Walking Beam Delivery Damper 1
9. selection guides for direct in situ zirconia oxygen analyzers The reader should refer first the examples of system selection by application and then examine the system block diagram and component device overviews 3 1 ZR402G Direct In Situ Zirconia Oxygen Analyzer System Block Diagrams 1 System Selection Examples by Application 0 to 700 C 0 to 1400 C De Ben mg Common Boiler fuel oil gas 1258 Droa HM gt Boter pulverized coal is m mm Borer bak vote RU men mm Hamato av r mem Heating sintering amp melting furnaces Petroleum Fired heaters 8 cracking furnaces Petrochemical og vem Oen emnenmentemupmen uzu m s The meanings of these codes are explained on the pages that follow Note 1 Sampling system is required due to the high pressure T0301 EPS The symbols such as L1 and D1 used in the Types of System Configuration and Detector are only applicable in this Technical Information document for quick reference They do not appear in other literatures including the bulletin general specifications or user s manual All Rights Reserved Copyright 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt Ind gt 3 System Configurations 3 2 2 System Block Diagram Types O Yes X None System Calibration SES Simple nat type General General purpose using s
10. 8 4 3 Ceramic Brick Glass amp Cement Furnaces Kilns 4 9 a Rotary type lime ET 4 9 b Cement kiln cyclone outlet gas 4 10 4 4 Petroleum Refining and Petrochemical Fired Heaters 4 11 a Petroleum refinery process fired heater example 4 12 b Naphtha cracking furnace 4 4 13 4 5 Garbage Incinerator Luse Da alamda d abr n 4 14 4 6 Non Combustion 555 4 15 a Oxygen enrichment facility 4 15 b Power generation boiler window box 4 16 G AST AOT ARK cata amaya daaa OE NE 4 17 All Rights Reserved Copyright O 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Int gt lt Ind gt 4 7 Difficult Measurement Applications rrvnnnvrnnnnvrnnnnunnnnnnvennnnnennnnnvennnnnvnnnnnvennn 4 18 a Glass melting furnace in furnace gas 4 18 D KE 6 Ela Le Uu ar 4 19 4 19 c Facilities vvith reducing gas atmospheres All Rights Reserved Copyright 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt lnd gt 1 Overview 1 1 Overview The EXAxt Zircon Oxygen Analyzer Model ZR402G is used to monitor and control the oxygen concentration in combustion gases in boilers and industrial furnaces
11. Technical ZR22G ZR402G EX Information Direct In Situ Zirconia Oxygen Analyzer TI 11M12A01 01E Applications Volume YOKOGAWA 9 ist Edition May 2004 KP Yokogawa Electric Corporation lt Int gt lt Ind gt Toc 1 ZR22G ZR402G Direct In Situ Zirconia Oxygen Analyzer Applications Volume TI 11M12A01 01E 1st Edition CONTENTS 1 SETT ea aaa ay la aaa aaa aybaay ard 1 1 2 Installation QUI na css aaa uba asari esse 2 1 2 1 Selecting an Installation 5 55555 ana nenne 2 1 3 System ConfigurationS annxarnannnennnnnnnnnnnnnnnnnnnennnnnvennnnnnennnnnennnnnnennnnnne 3 1 3 1 ZR402G Direct In Situ Zirconia Oxygen Analyzer System Block Diagrams Lae 3 1 3 2 Selection According to Use 8888 8888888888888383333888 33 3 2 3 3 Examples of System Component Selection Based on Sample Gas Conditions aaa N 3 6 4 ee e d Le CC 4 1 4 1 BONGE mo a ayda li b s 4 1 a Package boiler 4 1 b Power generation boiler Heavy oil Gas 4 2 c Pulverized coal boiler 8838828333 333 4 3 d Black liquor recovery boiler 8883 anna aaaeean 4 4 4 2 Iron and Steel Furnaces eegene 4 5 a Iron amp steel heating 4 5 b Hot blast stove blast furnace facility 4 6 KO EON GE EE 4 7 SAN 4
12. There are cases in which O CO and CO measurements are performed using a sampling system at the kiln outlet Cyclone outlet L2 L3 D4 D3 Combustion monitoring Exhaust Gas Electric Precipitator SONU VA Stack Main Exhaust Biower Raw Materials End ge Raw Material Flow m Gas Flow T0410 EPS NSP Cement Kiln Stage 1 Cyclone Exhaust Gas Stage 2 Cyclone SP Electric Precipitator SF Stage 3 Sm 1 Cyclone Burner Air draft FF Combustion Furnace Stage 4 Cyclone Bucket Elevator xe Clinker Cooler Clinker Cement kiln Temperature 350 to 400 C Pressure 3 to 5 kPa Dust 2200 g Nm3 CO 20 2 F0410 EPS All Rights Reserved Copyright 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt Ind gt 4 11 4 Applications 4 4 Petroleum Refining and Petrochemical Fired Heaters In petroleum refining and petrochemical plants fired heaters are so numerous that you could almost say that there is one in almost every process Also since a site consists not of just a single petroleum refining process but rather of ten or more processes this means that you have that many fired heaters too located at the arrows in the diagram above In addition to the fired heaters there will also be a number of boilers Thus combustion monitoring or control is a vital element Tanker Gasoline Platformin
13. and converter meters 3 7 Calibration method Manual 1 Automatic Note 3 6m or more is available only in the U S 4 Quotation data Quotation Model ZR22G General use Probe Model ZO21P H High Temperature Use Probe Adapter E7046EC E7046EN Auxiliary Ejector for high temperature use Options Model ZO21R Probe Protector for Oxgen Analyzer for general use K9471UA Filter for Oxgen Analyzer Model ZR402G Separate type Analyzer Converter Model ZO21S Standard Gas Unit Model ZA8F Flow Setting Unit Model ZR40H Automatic Calibration Unit L9852CB G7016XH Stop Valve K9292DN K9292DS Check Valve G7011XF E7040EL G7004XF K9473XG Air Set G7013XF G7014XF Pressure Regulator ZR22A ZR202A Heater Assembly Spare Parts All Rights Reserved Copyright 2004 Yokogawa Electric Corporation Qantity Description Refer to the GS11M12A01 01E for probe selection Select any one of ZO21S ZA8F ZR40H Not required if probe options are specified T0418 EPS TI 11M12A01 01E May 31 2004 00 nn Blank Page
14. best mounting position Pulverized coal boiler Abrasion Due to Dust Gas temperature 300 to 400 C Gas pressure 1 5 to 1 5 kPa Dust Approximately 15 g Nm3 Probe Protector Fuel Pulverized coal Probe Pipe F0403 EPS All Rights Reserved Copyright 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt Ind gt 4 Applications 4 4 d Black liquor recovery boiler The spent liquor in a pulp production process is commonly referred to as black liquor The sodium carbonate and sulfate components in this black liquor are recovered by burning it and using the heat to generate steam The oxygen analyzer is used to monitor or control the combus tion in the combustion facility boiler Since the exhaust gas includes large amounts of dust hydrated sodium sulfate and water vapor a detector with filter is selected Economizer Outlet economizer feedwater mr Combustion monitoring preheater detector with filter T0451 EPS Steam an ALA o x 2 Water Supply v l 0 2s b o gt gt re Le s bai oo ZI 2 o 2 o o SE AE Es 52 ES 1 a TT o O 5 Auxiliary Heating Burners 2 units at Furnace Front N N Primary Air Secondary Air Black Liquor Nozzies Ash N Starter Burners Tertiary Air 4 units left and right n Secondary Air mm Primary Air Black liquor
15. ctional top section combustion soaking pit Soaking pit Temperature 1000 to 1200 C Pressure 0 03 to 0 05 kPa Dust 0 5 g Nm3 Fuel Gas F0406 EPS All Rights Reserved Copyright O 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt Ind gt 4 Applications 4 9 4 3 Ceramic Brick Glass amp Cement Furnaces Kilns a Rotary type lime kiln The O analyzer is used for combustion monitoring to conserve energy Careful attention to detector mounting position and orientation is required due to the presence of large amounts of abrasive particulates and intrusion air Sample point System type Detector Objective 1 5 D4 T0407 EPS Raw Materials Intrusion Air lt Exhaust Gas Intrusion Air Exhaust Gas Exhaust Gas Rotary type lime kiln Temperature 250 to 500 C 1 Note 1 Depending on the kiln there will be cases when the temperature at the measuring point will be 600 C or greater 600 to 750 C Under these conditions the high temperature type should be used F0407 EPS All Rights Reserved Copyright O 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt Ind gt 4 Application 4 10 b Cement kiln cyclone outlet gas Cement production consumes approximately 100 liters or more of fuel heavy oil per ton of cement Thus combustion management by means of O analyzers has become a critical ele ment
16. g Unit n Unifining Unit d 7 Kerosene Unifying Unit Light Oil Unifining Unit Kerosene Light Oil Atmospheric Crude Tower Topper Atmospheric Residue Stripper Unit Vacuum Residue Vacuum Distillation Unit vacuur OA Residue maun Vacuum Residue Visbreaking Unit Vacuum Flashing Unit All Rights Reserved Copyright O 2004 Yokogawa Electric Corporation LPG recovery Unit MEK Stripper Unit Fluid Catalytic J Cracking Unit PGC Furfural Hydrogenation Refining Unit refining unit Gasoline Biending Unit Kerosene Light Diesel Oil D Heavy Oil Blending Various Heavy Unit Oils N Lubricating Distillates Heavy Oil blending Unit High quality Lube Oil Sulfur Recovery Unit SRU F0411 EPS TI 11M12A01 01E May 31 2004 00 lt Toc gt lt Ind gt 4 Application 4 12 a Petroleum refinery process fired heater example There are two possible locations for the sample point in fired heaters for petroleum refining and petrochemicals in the stack or in the vicinity of the furnace outlet convection zone Furi tlet Explosion proof type with terminal box H2 H3 D5 D6 may also be selected T0411 EPS O m Stack Approx 300 to 500 m Convection Approx 600 to 900 T0412 EPS o m lt Petroleum refinery process SE AE fired heater m 0900 00 o Furnace 00 00 Saction 2 Window Box Inlet 3 g
17. gt 4 Applications 4 17 c Aeration tank In one type of sludge processing oxygen gas is introduced into the processing tanks to maintain the dissolved oxygen concentration in the sludge liquid at a proper level Efficiency is checked by measuring the oxygen concentration in the exhaust gas from the processing tank Sample point System type Objective Exhaust line L2 L3 Efficiency monitoring amp alarm T0417 EPS Activated Sludge Processing Facility Surface Aeration System Aeration Tank 29 Gas Recycle Compressor Control Valve Agitator m lt N N Exhaust Oxygen K MERE CS ER VVaste Water Fe ENG De 1135 1 LEE 4 EN ATEN GE 4 pe et Returned Sludge Aeration tank Temperature Normal temperature Pressure 0 to 1 kPa Concentration Approximately 5096 O 0 to 100 range F0417 EPS All Rights Reserved Copyright O 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt ind gt 4 Application 4 18 4 7 Difficult Measurement Applications a Glass melting furnace in furnace gas Oxygen concentration in glass melting furnace stacks can be measured with no problems the same as in other general combusion exhaust gas applications Glass melting furnace stack Temperature 0 to 600 C System block diagram type No L2 L3 On the other hand when we come to measurement of the gas inside the furnace continuous measurement with a direct in situ zirconia oxyge
18. h check valve Fe Detector with probe protector same as above lt H EH Detector vvith filter same as above See the detector section for details concerning detectors F0302 EPS 3 Type L3 auto calibration lt 1 gt ZR22G Zirconia Oxygen lt 2 gt ZR402G Converter Analyzer Detector Signal 1 6 core shield cable Check valve 100 to 240 VAC Contact input Analog output contact output Digital output HART Flowmeter 5 Air Set Instrument air lt 3 gt ZR40H Auto Calibration unit 2 Zero gas cylinder Note 1 Shield cable Use shielded signal cables and connect the shield to the FG terminal of the converter Note 2 When a zirconia oxygen analyzer is used 100 N gas cannot be used as the zero gas Use approximately 1 of Oo gas N2 based F0303 EPS All Rights Reserved Copyright O 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt Ind gt 3 System Configurations 3 4 4 Type H1 simple measurement system lt 1 gt High temperature detector ZR22G 015 Air supply 1 5kgf cm2 Pressure gauge ASSY lt 2 gt ZR402G Converter Needle valve Ejector ASSY Contact input Analog output contact output Digital output HART F0304 EPS 5 Type H2 no auto calibration no safety purge lt 1 gt High temperature detector ZR22G 015 Air supply 1 5kgf cm2 Pressure gauge ASSY qar lt 2 gt
19. ight 2004 Yokogawa Electric Corporation lt Toc gt lt Ind gt 4 Applications 4 1 4 Applications This section takes up typical application examples for the zirconia oxygen analyzer These individual applications are structured as follows Application examples Overview of individual devices and sample points Sample gas condition examples Examples of sample gas conditions and block diagrams and 4 1 Boiler a Package boiler type numbers for zirconia oxygen analyzer systems to be used under those conditions This is the most common application Although the system is generally used for combustion monitoring there are also cases in which it will be used for VVVF or other such combustion control schemes pe L1 L2 D1 D2 Combustion monitoring economizer outlet Viewport Gas Flow Combustion Chamber 1 Flame eame up adr vs ae vag on D 1 LI Waites 7 ev av dee Front View All Rights Reserved Copyright O 2004 Yokogawa Electric Corporation T0401 EPS Package boiler Gas temperature 150 to 300 C Gas pressure 0 5 kPa Dust 1 g Nm3 Fuel Fuel oil kerosene or gas Main Tubes F0401 EPS TI 11M12A01 01E May 31 2004 00 lt Toc gt lt Ind gt 4 Applications 4 2 b Power generation boiler Heavy oil Gas This is a large scale facility in which use for combustion control is more common than for combus tion mo
20. illation of the coal c Coke oven facility Dust Fuel lt Toc gt lt Ind gt Stack Heat Protection Chamber Rich Gas Tube Combustion Chamber Backstay GI NSN 44 N I CS a I N SI i mex N MANN Si a o unu A ETR A X muun SSS KR LALLLEBLLALRES TT bx SIIN GC See RSS msi xx IN S les ee ININ ANNEES NAM N a N E N q N NU Combustion Chamber SY che SSS NST NE SANN 4 am gt N NESEN i R RCE TP Se iz F0405 EPS Flue TI 11M12A01 01E May 31 2004 00 Temperature 250 to 350 C Pressure 0 1 to 0 3 kPa Dust 100 mg Nm3 Coke oven facility Fuel Gas All Rights Reserved Copyright 2004 Yokogawa Electric Corporation 4 Applications 4 8 lt Toc gt lt Ind gt d Soaking pit The soaking pit is a type of furnace used to maintain the ingots at a constant temperature Oxygen concentration is controlled at a low level to suppress ingot surface oxidation H2 H3 T0406 EPS f Cover Remover E Preheat Air Duct 9 Recuperator TO OT D no E Furnace Cover 7 Ger Burner E i E7 4 Combustion Chamber g 4 Dr f f nooi Furnace Bed A ATHLE 9 Material ALI CU f PRE f f AN Cinder Removal Device Exhaust Gas Port Cinder Transport Car Construction of unidire
21. lace checkmarks in the appropriate boxes and fill in the necessary information in the blanks 1 General information Customer Object indication record control alarm Destination of delivery Fuel gas LT oil coal Plant name Power requirements V AC Hz Measurement points 2 Process conditions 2 1 Measurement gas components 2 2 Oxygen concentration Nor Min Max vol Oz O 2 3 Temperature Nor Min Max O C LI 2 4 Pressure Nor Min Max kPa EI 2 5 Gas flow Nor Min Max m sec O 2 6 Dust type Size Nor Min um quantity g Nm3 O 2 7 Corrosive gas Nogas Gas quantity 1 ppm L guantity ppm L 2 8 Combustible gas INogas L Gas quantity CI ppm quantity ppm 2 9 Others 3 Installation site conditions 3 1 Ambient temperature 1 Around Probe temp from to C 2 Around Converter temp from to C 3 2 Vibration L No vibration Vibration 3 3 1 Probe installation location Furnace Stack Others 2 Probe position 1 Horizontal Vertical _ Others Indoor L Outdoor Covered 3 Probe insertion length m Note 104 1107 110 11 5 02 0 12 5 0180 0136 0142 1148 1154 4 Flange DIN C ANSI L Others 3 4 Instrument air Supply L Cannot be used Can be used kPa 3 5 Converter location C Indoor 1 Outdoor Covered under roof 3 6 Cable length between probe
22. n analyzer high temperature system is either extremely difficult or impossible due to the dust and fumes from the components of the glass However since continuous measurements are being performed in some cases by the method shown in the diagram we offer this for your reference Glass melting furnace configuration amp with detail of ZR226 installation O Temperature Norm 1 200 C Filter Max 1 300 C Fiber Flux Bulk 2 Fuel Butane gas Replace Periodically gt 5 O Dust level Normal Low ZR22G During material charging High 3 to 4 cycles hour 9 2021 N Note 1 High temperature detector with probe adapter with high temperature probe pipe erst removed ot Water Probe alumina etc ee Of non reducing material treated as a Partial Side View consumable item Exhaust go ND Pulled by Hood IDF Sampling Port O Cover Material Charging Inlet Burner F0418 EPS All Rights Reserved Copyright O 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt lnd gt 4 Applications 4 19 b Calcinating furnace Exhaust gas oxygen concentration measurement for fluidized bed calcination roasting furnaces sulfur combustion furnaces and other such furnaces which burn sulfur containing materials or elemental sulfur presents sample conditions such as the following so direct in situ type zirconia oxygen analyzers cannot be used for measureme
23. nitoring In cogeneration the majority of cases involve measurement at a single point In electric power companies measurements are performed at multiple points in a single flue Boiler furnace outlet or L2 L3 D1 D2 Combustion monitoring economizer outlet O control T0402 EPS Power generation boiler Temperature 250 to 350 C Pressure 0 1 to 0 8 kPa Dust 1 g Nm3 Fuel Heavy oil crude gas High Pressure Steam Medium Pressure Steam Reheater Heavy Oil Forced Draft Fan Gas e Fuel Pump F0402 EPS All Rights Reserved Copyright 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt lnd gt 4 Applications 4 3 c Pulverized coal boiler These are almost always large facilities such as power generation boilers the O analyzer is used for combustion monitoring and combustion control Since the exhaust gas entrains a rather large amount of ash dust a detector with dust protector will be used Economizer outlet L2 L3 oe Combustion monitoring Oo control economizer feedwater detector with probe afterheater protector T0403 EPS Steam Drum Superheater Dust Guard a gt lt Horizontal Superheater Fuel ex Ei T ue Air X Electric Cai Heater Precipitator Exhaust ES Boiler Main Gas NN Unit High Density Dust Ash Centrifugal Force I Ash Dust Flow Direction Optimum mounting position O Second
24. nt Corrosive gas in exhaust gas SO 7 to 18 Note however that the Yokogawa direct in situ type zirconia oxygen analyzers are fully capable of measurement in exhaust gases containing SO concentrations up to 5000ppm c Facilities with reducing gas atmospheres The term reducing gases refers to those gases which react with metal oxides to reduce them either to metal or to oxides of a lower degree of oxidation These gases are composed of a reducing component of which H is the primary example and an inert gas component such as N These reducing gases are used for purposes such as protecting metal surfaces from oxidation or dacarbonization during heat treatment or to improve certain properties If an attempt is made to use a direct in situ type zirconia oxyen analyzer in such a metal treatment furnace the combus tible gas reducing gas and oxygen in the sample gas will incite a combustion reaction like that shown below in the high temperature cell section generally above 600 C causing a negative measurement error so that measurement is generally impossible under these conditions 200 0 gt 2C0 2H 0 gt 2H 0 CH 20 gt CO0 2H 0 Reference Bulletin 11M12A01 01E GS 11M12A01 01E All Rights Reserved Copyright 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 nn Blank Page lt Toc gt lt lnd gt Inquiry Sheet for Models ZR22G and ZR402G Direct In Situ Zirconia Oxygen Analyzer Please p
25. nts SOx Several hundred ppm HCl 100ppm F0414 EPS All Rights Reserved Copyright 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt Ind gt 4 Applications 4 15 4 6 Non Combustion Applications a Oxygen enrichment facility Although in most combustion systems air is used as is there are cases such as in blast furnaces in steel plants where the air will be enriched with oxygen gas to raise efficiency When this is done oxygen analyzers are used to monitor the oxygen generation unit air separator etc and or to check the condition of the mixing with the air in later process stages n these cases the oxygen analyzer will be measuring values higher than the concentration of oxygen in the air approximately 21 277 ine H3 Note 1 Note 1 Operational monitoring Oxygen compressor outlet 3 Air oxygen mixing line H3 Note 1 Operational monitoring T0415 EPS Note 1 Measurement will be done using a sampling system since all the points are at high pressure Intake Tower Air 75 to 100 0 75 to 100 0 Oxygen Gas 5117 490 to 780 kPa Blast Furnace Blovver Blast Furnace Hot Blast Stove Air Compressor 490 kPa Oxygen Generation Unit Air Separation Unit Air 0 to 50960 420 kPa Blast Furnace Oxygen Enrichment Example Note 1 Due to the high pressure measurement will be done with a sampling type system A Regula
26. rature variations are minimal Humidity is moderate 40 to 7596 RH and no corrosive gases are present Minimum vibration Near to the detector Not exposed to direct sun light All Rights Reserved Copyright 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt Ind gt 2 Installation Guide 2 2 Instument air is not wailabe ZR22G Zirconia Oxygen ZR402G Converter Analyzer Detector Signal 6 core shield cable Stop valve a Contact input uz o gt Analog output contact output Digital output HART Calibration gas Olnstall the stop valve securely so that the gas does not leak Use the standard gas unit Use a shielded cable for the signal line F0202 EPS Instument air is ailakbe ZR402G Converter ZR22G Zirconia Oxygen Analyzer Detector Signal Check valve or Stop Valve 1 L i Heater 2 core D ass ase Contact input 7 x Analog output contact output Digital output HART Needle valve Instrument air Span gas Zero gas cylinder Olnstall the stop valve or check valve securely so that the gas does not leak Use the flow setting unit and zero gas cylinder Use a shielded cable for the signal line F0203 EPS All Rights Reserved Copyright 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt Ind gt 3 System Configurations 3 1 3 System Configurations This section includes two types of system
27. t O Air Preheater gt Steam O Stack d Ge Superheater 2 Draft Blower Section D Exhaust Blower Inlet Process Fluid Preheat 3 SI Section CS ON J T T Outlet lt All Rights Reserved Copyright 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 Radiant Heating Section F0412 EPS lt Toc gt lt Ind gt 4 Applications 4 13 b Naphtha cracking furnace This is the first process in a petrochemical facility in which the Naphtha supplied from the petro leum refinery is heated and cracked to produce a variety of products There will be not just one but rather anyvvhere from six to tvvelve fired heaters each vvith its ovvn stack Analyzer installation Sample point L2 L3 Fired Stack or H2 H3 Combustion e E gt heaters convection Explosionproof type external terminal monitoring box may also be selected T0413 EPS 2 g Gasoline 6 5 N Fractionater O D D N MN s n vp ert 8 CO MO Gasoline O Naphtha Heater Inorganic Oil Propylene Methane Hydrogen Rich Gas Rich Gas H HS Ethane Heater Ethylene Debutanizer Propylene Fractionater Depropanizer Ethylene Fractionater Acetylene Lightener De ethanizaer Gasoline Propane H Naphtha cracking furnace Temperature Stack 300 to 600 C Convection 110 to 600 C Pressure 0 2 to 0 kPa Dust
28. tandard gas unit ama sanan 0 5 HK m ompoae O x O x Juan narumentar a ange Ea x x O using instrument a zr gas ji T0302 EPS 3 2 Selection According to Use Examples of selection according to use System type No For monitoring package boilers etc L1 H1 For high precision measurement for control purposes etc L2 H2 For auto calibration options L3 H3 T0303 EPS 1 Type L1 simple measurement system lt 1 gt ZR22G Zirconia Oxygen lt 2 gt ZR402G Converter Analyzer Detector Signal 1 6 core shield cable Stop valve EEE NE Contact input 7755 gt Analog output contact output Digital output HART F0301 EPS AlI Rights Reserved Copyright 2004 Yokogavva Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt Ind gt 3 System Configurations 3 3 2 Type L2 no auto calibration lt 1 gt ZR22G Zirconia Oxygen lt 2 gt ZR402G Converter Analyzer Detector Signal 1 Check valve or Stop Valve 1 i 240 V AC Heater 2 core 4550077 Contact input 7 gt Analog output contact output lt 3 gt ZA8F flow setting unit Digital output HART Needle Reference Flowmeter valve gas Instrument air Calibration gas Span gas Zero gas cylinder Note 1 Detector can be selected from among the following No Check Ne Sketch of shade fa General purpose detector wit
29. tor Valve or Needle Valve Q F0415 EPS All Rights Reserved Copyright 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt Ind gt 4 Application 4 16 b Power generation boiler window box In large boilers such as those for power generation part of the combustion exhaust gas is re cycled to the combustion intake and the oxygen concentration in the recycled gas is monitored so that it does not drop too low The analyzer range will be a partial range that includes the atmospheric oxygen concentration such as 15 to 22 0 T0416 EPS Note 1 The ZO21DW terminal box explosionproof type detector pressure compensated type or the ZR22G pressure compensated type will be used These are many cases in which the AV8C averaging converter will be used FEE 2 k a Boiler High Pressure Steam Medium Pressure Steam eg Reheater Window Box NZ Gi TN Oh x s l RENN VE VS AES sm AEE An ux Economizer Precipitator CH Air Preheater M Heavy oil Forced Draft Blower Gas Fuel Pump CH EK Gas Recycle Blower ERT MEET D SR IEE Ee ie a Me ae ae yosun ke Combustion Exhaust Gas Power generation boiler window box Temperature Max 550 C Pressure 5 to 20 kPa F0416 EPS All Rights Reserved Copyright 2004 Yokogawa Electric Corporation TI 11M12A01 01E May 31 2004 00 lt Toc gt lt Ind
30. x SEU 19yBIU H Sn ynsuo9 SSI 10 z lN 1 MOT jono 1sng SUONPIIJIDIdS 3 SUOIIPUON TI 11M12A01 01E May 31 2004 00 All Rights Reserved Copyright O 2004 Yokogawa Electric Corporation 3 8 3 System Configurations lt Toc gt lt lnd gt etc ion gas calibrat ing uni 2 Converter and accessories flow sett 543 6080 10 99 9p odA xoq jueu JO01duolIsojdxa YIM SSN o BINS og pue uln yon d JO seweuwuos uoneiedo uonelgi eo au SOILWOINE UoNeINBLUOO SIU Siojeou PAI 6214 9001 10 10 WSIS S A10Ssa00e ue SE lQEIIPAE ul 566 JUINQUN Huljpuey 10 HUN PlousjOS UoNeJNBIUOD UOUWIUWO9 ISON ULOTUOUL JejIOq Lus 40 UONEINDIJUOO WNWIUIN 52 9880 dAXE 10 9 IX 10 9 1o7en6ey 9Z100 9 5 Le 4XE 10 9 IX 1025 ssoyeinBoy OZ 100250 19pullAo uun 586 piepue s v U Ll S ZOZ 586 uoneiqije9 papnjoul jou 195 112 Vel 1 48 2 papnjoul jou los 112 d yuz p pnioul jou DK 1 48 2 F R d yuz nun Bunes 1 1 M AUODQ jyooiduoisojdxy lQEHEAB JON uoneu q le ony o 0 0 o 3 o o 3 O uone1ql e9 one EI III TI 11M12A01 01E May 31 2004 00 All Rights Reserved Copyr
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