SERVOTOUGH Fluegas 2700 v1:Layout 1.qxd
Contents
1. Note Add 1 extra twisted pair if the optional sensor head temperature readout is required to be displayed by the Control Unit Part numbers for supplier Alpha Wire Company www alphawire com Oxygen only M9700040 Combustibles only M9700080 Oxygen and combustibles M9700120 POWER REQUIREMENTS Voltage 100 120V ac 50 60 Hz or 220 240V ac 50 60 Hz Rated Power Control Unit 250VA Sensor Head 600VA Note Control Unit and Sensor Head are powered separately Control Unit power supply is fixed at time of order but is field configurable Sensor Head supply voltage is factory set SENSOR HEAD COMPRESSED AIR REQUIREMENTS Aspirator Air Pressure 3 5psig typical 3 to 5psig 0 2 to 0 3barg Flow 1 5 litres min typical Page 5 DESCRIPTION Analyser controller The analyser consists of a sensor head and a control unit which includes a backlit liquid crystal display 2 line x 16 characters and an eight button keypad The sensor head is suitable for installation in non hazardous areas hazardous area available when used with suitable purge There are four versions of the control unit available GEN for installation in non hazardous areas EU2 for installation in European Zone 2 hazardous areas FM2 for installation in US Class amp 11 Division 2 and Class Ill Division 1 amp 2 hazardous areas CSA for installation in Canadian Class amp 11 Division 2 and Class Ill Division 1 amp 2 hazardous areas Measurement and2. entries Sensor head The analyser sensor head is fitted as standard with a breather port to prevent pressurisation of the enclosure These can be replaced with fittings for the addition of a corrosive PZ purge for the sensor head and terminal box if required The oxygen only analyser can also be supplied equipped to use nitrogen instead of compressed air to power the internal aspirator Sensor head There are six sensor head mounting options A standard mounting option a probe retention option which allows mounting option the sensor head to be removed whilst the sample probe is retained within the flue a thermal spacer which separates the sensor head from the flue wall with a high surface temperature 350 C to 500 C a stand off flange which increases the separation between the sensor head and the heat radiation from the flue wall 350 C to 500 C a combined thermal spacer and probe retention and a combined probe retention and stand off flange Adaptor flange The sensor head is supplied with an equivalent PCD 4 ANSI 150lbs flange as standard option Adaptors are available to suit other flange sizes The analyser is not designed to withstand 150lbs pressure The flue pressure should be a maximum of 5psig Control unit The control unit is available for either wall or rack panel mounting monitoring The rack panel mounting controller is supplied with an additional panel Control unit The analyser can be fitted
3. for safe or hazardous area use SERVOMEX LES Close coupled low flow extractive design The close coupled and low flow extractive design of the SERVOTOUGH Fluegas delivers market leading sensor life reliability and stability By extracting the sample at low flow rates as oppose to measuring the sample in the process stream the Fluegas is not vulnerable to the effects of the harsh process environment In addition the unique low flow rate design ensures the probe and filters are not compromised by dust and particulates that regularly affect high flow rate extractive analysers All these benefits are achieved without compromising the response time of the measurement Servomex Zirconium Oxide cell Our Zirconium Oxide cell designed specifically for the combustion analysis market is highly robust with excellent resistance to thermal and mechanical shock and unlike many others available it is resistant even in reducing process conditions offering instant recovery and operation when process conditions return to normal Acknowledged as one of the most reliable on the market it offers world class accuracy and stability together with extended calibration intervals Thick Film Catalytic Sensors Combined with the measurement of the measurement of COe is a major advantage in improving combustion efficiency Our Thick Film Catalytic Sensors offer fast response and high sensitivity to combustible gas breakthrough the first sign of inco
4. The unit can be supplied as an oxygen only measurement combustibles COe only measurement or an oxygen supply voltage and combustibles measurement analyser The analyser can also be supplied with specially coated pcbs for use in very humid environments 110 and 220V ac available natural gas and light oil applications with fuels with sulphur contents lt 1 our high sensitivity combustibles sensor is recommended For sour gas heavy oils coal and incinerators with fuels with sulphur content gt 1 our sulphur resistant combustible sensor is recommended For applications with fuels 22 596 sulphur refer to Servomex Sample probes A range of sample probes are available for use in different sampling environments Fo samples with a relatively low dust loading lt 0 2 g m open ended probes are available in stainless steel high temperature alloy and ceramic materials suitable for a range of temperatures up to 1750 C Filtered probes are also available for samples with higher dust loading up to 20 g m and temperatures below 1500 C The stainless steel filtered probe can also be supplied with additional mechanical support and shroud Note for higher dust loadings and temperatures refer to Servomex Internal filter The analyser is supplied fitted with flame arrestors and an internal filter as standard Electrical threaded Choose from 74 NPT M20 M25 PG13 5 or PG21 entries Select entry size to suit cables and glands used
5. with blanking plugs a breather port or fittings to allow the use of a corrosive or PZ enclosure option type purge system Utilities A utilities unit can be configured with one or more of the following Aspirator air set provides filtration and pressure regulation of the compressed air for the aspirator in the analyser Autocalibration provides the necessary components to allow automatic calibration of the analyser with calibration gases not supplied Manual calibration provides the necessary components to allow manual calibration of the analyser with calibration gases not supplied Blowback provides the necessary components to allow the blowback of the sample probe and internal filter When nitrogen aspiration is used the calibration versions of the utilities units cannot be used Recommended with N aspiration unless other suitable device made available separately Consult Servomex Page 6 DESCRIPTION Analyser controller Safe Area a Hazardous Area European Cat 3 Zone 2 Q Hazardous Area FM Div 2 Hazardous Area CSA Div 2 a UK MCERTS Approval required Not required Uncoated pcbs Coated pcbs supply voltage L1110 120V L1220 240V L1110 120V L1220 240V O5 Combustibles only a Oxygen amp combustibles Q High sensitivity Sulphur resistant a Aspirator supply Air Nitrogen Sample probes None a Length m 0 5 E SS sa
6. H Laser ll sERVOTOUGH 1900 Digital SERVOTOUGH Oxy 1900 IR SERVOTOUGH Spectra 2200 SERVOTOUGH OxyExact 2500 SERVOTOUGH SpectraExact 2900 SERVOTOUGH Laser 1800 SERVOPRO ll seRvopRO Bl sERVOPRO Gute fes 4900 5400 SERVOPRO MultiExact 4100 SERVOFLEX Bl sERVOFLEX B SERVOFLEX Portables 5100 i s SERVOFLEX Micro i s 5100 i s SERVOFLEX Micro i s 5100 Marine SERVOFLEX MicroMarine BUSINESS CENTRES EUROPE Europe and Africa USA amp CANADA LATIN AMERICA MEXICO ASIA PACIFIC INDIA AND MIDDLE EAST Tel 31 0 79 330 1581 Tel 41281 295 5800 Tel 55 11 5188 8166 Tel 86 0 21 6489 7570 Tel 491 22 67100359 60 Fax 31 0 79 342 0819 Toll Free 00800 7378 6639 Fax 1 281 295 5899 Toll Free 1 800 862 0200 Fax 455 11 5188 8169 Fax 86 0 21 6442 6498 Fax 491 22 66778896 TECHNICAL CENTRE SYSTEMS ENGINEERING CENTRES Servomex Group Limited Crowborough UK Tel 44 0 1892 652181 Crowborough Houston USA Tel 1 281 295 5800 East Sussex UK Shanghai China Tel 86 0 21 6489 7570 TN6 3FB Mumbai India Tel 91 22 67100359 60 Tel 44 0 1892 652181 Fax 44 0 1892 662253 HUMMINGBIRD SERVOMEX A MEASURABLE ADVANTAGE www servomex com gt SENSING TECHNOLOGY www hummingbirdsensing com Servomex has a policy of constant product improvement and reserves the right to change specifications without notice Servomex Group Limited 2010 A Spectris company All rights reserved
7. PB2700 Rev 2 04 10 E
8. SERVOMEX COMBUSTION ANALYSERS SERVOTOUGH Fluegas 2700 For maximum efficiency and fuel cost savings the SERVOTOUGH Fluegas 2700 is a high performance gas analyser ideal for monitoring the oxygen and combustibles wide variety of combustion processes The Fluegas is designed to meet the needs of power generation process heaters thermal crackers and incinerators where it is your perfect partner for harsh environments high temperatures and dusty conditions FEATURES APPLICATIONS e Close coupled low flow extracted volume design e Process heaters compared to in situ analysers the Fluegas is not subject e Thermal crackers to the harsh process conditions ensuring a lower cost of ownership while simultaneously delivering fast stable e Incinerators and highly reliable O and COe measurements e Power generation boilers e Servomex zirconium oxide cell an accurate long life e High temperatures low drift and highly robust O measurement able to gt us e High dust loading withstand reducing process conditions e Thick Film Catalytic Sensors a sensitive fast response and reliable COe measurement that responds to COe even in low process O conditions e Safety First protective BASEEFA tested flametraps as standard prevent possible ignition of flue gases in fuel rich conditions e Highly Flexible wide variety of probes mounting flanges calibration and air panels available e Configurations
9. e 93 68 EEC Page 10 DIMENSIONS TYPICAL ANALYSER MOUNTING ORIENTATION WITH 4 ANSI FLANGE OTHER FLANGES ARE AVAILABLE 1 2 OD TO 1 2 NPT M16 NUTS AND ADAPTOR FOR PROBE WASHERS 250mm 9 9 FITTING 4 POSITIONS 1 8 NPT INT ASPIRATOR AIR SUPPLY IN 188mm 7 4 256mm 10 1 4 OD FITTING FOR COMBUSTIBLES COe SENSOR AUXILIARY AIR SUPPLY 1 4 OD CALIBRATION GAS IN TYPICAL FLUE 1 4 NPT INT PURGE EXIT WALL SECTION OR BREATHER FITTING TYPICAL FLUE WALL SECTION 391mm 15 4 260mm 10 2 180mm 7 1 301mm 11 9 MOUNTING HOLES 4 x M8 CLEARANCE 3 4 NPT INT MAINS CABLE ENTRY 1 4 NPT INT PURGE OPTION ENTRY 3 4 NPT INT SIGNAL CABLE ENTRY 3 4 NPT INT SPARE CABLE ENTRY 5 x 3 A NPT INT CABLE GLAND ENTRIES 1 4 NPT INT BREATHER OR BLANKING PLUG 167mm 6 6 EMC EARTH STUD 1 4 NPT INT PURGE FITTINGS OR BLANKING SCREWS SERVICE ACCESS REQUIRED FOR DOOR TO BE OPENED 365mmy 14 4 IN FRONT Dimensions shown in millimetres 11 Servomex range of products for the Hydrocarbon Processing Industry SERVOMEX EMISSIONS ANALYSERS SERVOMEX COMBUSTION ANALYSERS SERVOMEX PROCESS ANALYSERS SERVOTOUGH J SERVOTOUGH 2500 SERVOTOUGH SpectraExact 2900 SERVOTOUGH Laser Hazardous Area ll sERVOTOUGH 2700 SERVOTOUGH Fluegas 2900 SERVOTOUG
10. e probe with sample filter lt 17s lt 1000 C 1m long H556 alloy sample probe with sample filter lt 17s lt 1750 C 1m long ceramic sample probe with sample filter lt 20s SERVICE amp SUPPORT For new installations and replacement of older Servomex and competitor products we will work with you to develop a bespoke service and support package ensuring full measurement availability and plant operation within your timescales and budget l EseRVOSPARES To ensure the integrity and optimum performance of your Servomex product we recommend fitting only factory authorised spare parts This is particularly important for all hazardous area certified products la seERVOSURE Ensure your Servomex analyser is properly commissioned and delivers optimum performance with a maintenance contract service programme and extended warranty la EseRVOTECH Make the most of your Servomex gas analyser by attending a training course at one of our training centres in Europe USA or Asia or on your own site B EsERVOHELP Whether you have a simple question or complex process challenge our local offices and global support network are here to help you Page 9 ACCESSORIES AND STANDARD PROBE OPTIONS Utilities unit specification Temperature Operating 10 C to 50 14 to 122 F Storage 20 C to 55 C 4 F to 131 F Compressed air amp blowback air requirements Pressure 1 to 5barg 15 to 72 5psig Flow 4 5 t
11. ls with sulphur contents 196 Fuels with sulphur contents gt 1 consult Servomex for fuels with sulphur content gt 2 5 below 196 display shows low oxygen level warning whichever is greater The performance specification has been written and verified in accordance with the international standard IEC 1207 1 1994 Expression of performance of gas analysers Page 4 SPECIFICATIONS PHYSICAL Ingress protection IP66 NEMA 4X Weight Control unit lt 11kg 24 3lbs Sensor head lt 17kg lt 37 5165 Dual transducer Dimensions WxDxH Control unit 391 x 167 x 260mm 15 4 x 6 6 x 10 3 Sensor head 301 x 330 x 256mm 11 9 x 13 0 x 10 1 Mounting Control unit Wall 19 rack and panel mounting Sensor head Choice of mounting flanges and adaptors Max altitude 2000m 6500 feet Ambient temperature Operation Storage Control unit 10 C to 55 C 14 F to 131 F 20 C to 55 C 4 F to 131 F Sensor head 20 C to 70 C 4 F to 158 F 30 C to 80 C 22 F to 176 F INTERCONNECTING CABLE REQUIREMENTS Cross Section Max Oxygen only 3 twisted pairs with overall screen 1 0mm 100m 1 5mm 150m 2 5mm 300m Combustibles only 6 twisted pairs with individual and overall screens 100m Oxygen and Combustibles 9 twisted pairs with individual and overall screens 100m Maximum loop resistance of 4O is required for the heater connections and use cables with a minimum of 0 5mm cross section
12. mple probe unsupported open ended lt 700 C 1292 F SS sample probe unsupported filtered lt 700 C 1292 F SS sample probe supported filtered with shroud lt 700 C 1292 F SS sample probe supported dual filtered with shroud lt 700 C 1292 F High temperature alloy unsupported open ended lt 1000 C 1832 F High temperature alloy unsupported filtered lt 1000 C 1832 F Ceramic sample probe open ended lt 1750 C 3182 F Ceramic sample probe unsupported filtered lt 1500 C 2732 F Hastelloy sample probe unsupported open SSISISIS NSISISISIG Non standard probes Q Internal filter Internal flame arrestors and internal sample filter Electrical threaded X4 NPT O and COe entries M20 or COe M25 O and COe PG 13 5 O or COe PG21 Oz and COe Sensor head Breather port enclosure Purge fittings Sensor head Standard 4 ANSI 150lbs mounting option Probe retention excluding supported probes Thermal spacer excluding supported probes Probe retention amp thermal excluding supported probes High temperature stand off excluding supported probes High temperature stand off amp probe retention excluding supported probes Adaptor flange None 4 ANSI 150165 option 3 ANSI 150lbs equivalent DIN 65 equivalent DIN 80 equivalent JIS 65 equivalent JIS 80 equivalent Weld on flange c
13. mplete combustion By reducing O levels close to those of incomplete combustion significant fuel savings and a reduction in NOx emmisions can be readily achieved For added piece of mind and continuous operational performance all our catalytic sensors are supplied with excess auxiliary air Unlike traditional pellistor type measurements this allows COe measurements even if the flue gas O levels drop significantly below that required for complete combustion Two sensor versions are available depending on application usage a high sensitivity version for natural and clean gas applications and a sulphur resistant version for sour gas and sulphur resistant fuels Safety First During process upset start up and shut down conditions there is always a chance that a flue rich mixture is temporarily in the process To help protect against the Fluegas being a source of ignition to these flue rich gases the Fluegas has in built flame traps that prevents gas ignition within the hot Zirconium Oxide cell passing back to the process flue HAZARDOUS AREA APPROVALS Control Unit Approved as EEx nC IIC T5 20 lt Ta lt 55 C for ATEX Group Il Category 3 Gas and Dust Hazardous Atmospheres T75 C BASEEFA No BASO2ATEX3205 Factory Mutual FMRC approved as non incendive for Class 1 Div 2 Groups A B C amp D Class II Div 2 Groups F amp G Class Ill Div 1 amp 2 Enclosure Type 4X T5 Ambient Temperature 55 C max Canadian Sta
14. ndards Association CSA suitable for use in Class I Div 2 Groups A B C amp D Class Il Div 1 Groups E F amp G Class III Div 1 T5 Ambient Temperature 55 C max Enclosure Type 4X Sensor Head Use purge for installation in hazardous locations EUROPE ATEX Group II Category 3 Gases Zone 2 when fitted with a suitable purge USA Class and Il Div 2 and Class 111 Div 1 and 2 when fitted with a suitable purge Page 2 EC DIRECTIVE COMPLIANCE The SERVOTOUGH Fluegas is in compliance with Low Voltage Directive EMC Directive And all other applicable Directives REGIONAL APPROVALS China Pattern Approval TUV tested and notification by BMU to the requirements of BlmSchV 13 large combustion plant and 17 waste incineration and similar processes GOST Pattern Approval for Russia UK MCERTS Approval ELECTRICAL SAFETY Electrical safety to IEC 61010 1 The product is rated for Overvoltage Category II The product is rated for Pollution Degree 2 Electrical Safety USA Canada Complies with FM approval class number 3810 CAN CSA C22 2 No 1010 1 92 Page 3 SPECIFICATIONS Gas measured TECHNOLOGY Typical applications PERFORMANCE Intrinsic error accuracy Resolution options Drift zero Min recommended range Max COe in stream Linearity Repeatability Recommended Calibration frequency Cross sensitivity under normal plant opera
15. o 10 litres min Instrument grade compressed air free of oil water amp dirt 173mm Utilities units 02730701 Aspirator air set single or dual sensor W 93mm x D 99mm x H 165mm W 3 7 x D 3 9 x H 6 5 lt 400gms lt 1 0165 02730731 Aspirator air set and manual calibration single or dual sensors W 390mm x D 174mm x H 265mm W 15 5 x D 6 8 x H 10 4 4 5Kgs 10lbs 450mm 390mm 360mm 320mm HIE sesso Aspirator air set and automatic calibration units Ingress protection IP65 NEMA 12 Auto cal units only 02730711 single sensor 02730721 Power supply 100 ac 50 60Hz lt 20VA 110 120V single sensor with blowback 02730713C dual sensor 02730723C dual sensor with blowback W 400mm x D 220mm x H 500mm W 16 x D 9 x H 20 lt 16Kgs 35lbs 227mm 220mm 10mm 400mm 50 60Hz lt 20VA or 220 240V ac 50 60Hz lt 20VA field configurable The Nickel plated brass bulkhead connections are suitable for NPT and BSP male fittings amp tubing Internal components are brass plastic fittings and tubing nitrogen if analyser equipped for nitrogen aspiration single measurement oxygen units only The autocalibration versions of the utility units comply with the CE Marking Directiv
16. omplete with studs 4 ANSI 150lbs equivalent Model 700B N to 2700 adaptor flange excluding high temperature stand off Thermox to 2700 adaptor flange excluding supported probes Control unit Wall mounted monitoring Rack or panel mounted Control unit Blanking plugs only enclosure option Breather port Purge fittings Special consult Servomex a DO OOOOO DOD OO DODODOCOO DODOCODO Page 7 DESCRIPTION Utilities None Air set single dual Autocal air set single Autocal and blowback single Manual cal single dual Pump unit 110V ac pump 240V ac pump Quickstart amp Installation manual English French German Service manual trained service personnel None English Default software interface language English French German CALIBRATION GAS REQUIREMENTS Calibration gas requirements Pressure 1barg 15psig Flow 600ml min typical dual dual DDDCOLD Consult Servomex Q Consult Servomex Spanish a Chinese a Russian Q m Q Q Q OO The 2700 Analyser is supplied with a Quickstart and installation manual A service manual containing technical descriptions fault diagnosis information parts removal refitting and test instructions tool and test equipment lists and electrical drawings is available It is intended for use by Servomex The analyser is supplied with English French and German software installed The active language i
17. s user selectable The default software interface language will be active when the analyser is shipped Calibration gas composition Oxygen Combustibles sensor Zr sensor Tfx UT Air 20 95 in nitrogen Air must be free from combustible gases eg CO hydrocarbons etc 0 396 in nitrogen Zero low N A Gas composition can be between 0 25 and 2 5 O in Nitrogen 500ppm carbon monoxide in air N A Span Gas composition can be between 500ppm and 1000ppm in air SAMPLE WETTED MATERIALS Item Materials Sensor head Stainless steel 303 and 316 gasket sealing material Klinger grade SLS 150 Stainless steel 310 and 316 zirconia platinum alumina Ni Fe Cr alloy high temperature sealing glasses Oxygen sensor Combustibles sensor Stainless steel 316 platinum platinum iridium zirconia alumina corrosion resistant glass Item Unfiltered sample probe 700 C Filtered sample probe 700 C Unfiltered sample probe 700 C 1000 C Filtered sample probe 700 C 1000 C High temperature sample probe lt 1750 C Materials Stainless steel 316 Stainless steel 316 stainless steel 310 silicon carbide Haynes alloy 556 stainless steel 316 Stainless steel 310 Haynes alloy 556 Stainless steel 316 silicon carbide High temperature ceramic stainless steel 316 Page 8 SYSTEM RESPONSE TIMES Top typical lt 700 C 1m long stainless steel sampl
18. ting conditions SIGNAL INPUTS OUTPUTS Analogue output Alarms amp relays Digital inputs Oxygen O5 Combustibles COe Carbon Monoxide Equivalent Zirconium oxide zirconia All combustion 1 of reading or 0 1 O5 0 0196 O Per 3 months 0 596 of range or 0 0596 O5 0 01 to 25 0 1 O5 Not applicable lt 0 1 O gt lt 0 1 O gt 12 months No significant effect Patented thick film catalytic sensor High Sensitivity Natural Gas Light Oil Sulphur Resistant Sour Gas Heavy Oils Coal Incinerators 25ppm or 5 75ppm or 5 of reading of reading 1 recommended 10ppm recommended lt 25ppm week lt 35ppm week Oppm to 10 000ppm 0 500ppm 6000ppm lt 3 FSR lt 1 FSR 1 month Effect of common combustible flue gases per 1000 ppm 50 lt 30ppm lt 100ppm CH lt 10ppm lt 50ppm H gt lt 2500ppm lt 2500ppm One configurable isolated 0 4 20mA per measurement recommended impedance 6000 or less 1 max O output configurable from 0 196 min to 0 25 max O in 1 steps COe output configurable from 0 500ppm to 0 15 000ppm measurement range remains as above Four SPCO relays 250V ac 3A or 28V dc 1A max configurable for Concentration Alarms Faults In Calibration In Blowback and solenoid valves for blowback and autocalibration Two non isolated digital inputs provided to remotely initiate autocalibration and perform blowback 1 Fue
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