ABB SCK User guide

Sample conditioning for kiln
SCK
Sampling system for dry gas sampling
at rotary cement kiln gas exit and calciner gas exit
System manual 42/2381 EN Rev. 4

Sample conditioning for kiln
SCK
Sampling system for dry gas sampling
at rotary cement kiln gas exit and calciner gas exit
System manual
Publication No. 42/2381 EN
Revision 4
Edition November 2016

4 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4
Contents
Chapter 1General .....................................................................................................................7
About these operating instructions ............................................................................8
Safety instructions in this document........................................................................10
System identification................................................................................................12
Service.....................................................................................................................15
Chapter 2Description of the sampling system....................................................................17
Technical data..........................................................................................................18
Intended conditions of use.......................................................................................19
Structure and function..............................................................................................20
Mode of functioning and operating modes ..............................................................21
Process monitoring..................................................................................................22
Controls and displays ..............................................................................................24
Probe retractor.........................................................................................................26
Gas sampling probe H.............................................................................................28
Gas sampling probe 60S .........................................................................................30
Cooling module........................................................................................................32
Transformer .............................................................................................................34
Compressed-air tank and pneumatic system ..........................................................35
Chapter 3Description of control system..............................................................................37
Structure and function of the control system ...........................................................38
User interface: Operation screen.............................................................................40
User interface: Trend screen ...................................................................................42
User interface: Message screen..............................................................................44
User interface: Parameter screen............................................................................46
Error message display.............................................................................................48
Access permissions.................................................................................................49
Default operating parameter settings ......................................................................50
Optimizing operating parameters ............................................................................53
Chapter 4Safety ......................................................................................................................55
Basic safety rules ....................................................................................................56
Overview of dangers................................................................................................58
Protective installations.............................................................................................60
Warning signs on the system ..................................................................................63
Requirements to be met by personnel, work places ...............................................65
Personal safety equipment ......................................................................................67
Safety measures: Transport and unpacking............................................................68
Safety measures: Installation ..................................................................................69
Safety measures: Start-up .......................................................................................72
Safety measures: Operation....................................................................................75
Safety measures: Maintenance and troubleshooting ..............................................78
Chapter 5Transport and unpacking......................................................................................83
General transport information..................................................................................84
Transport the system in the company .....................................................................87
Unpacking the system .............................................................................................89
Scope of delivery .....................................................................................................90

42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System 5
Chapter 6Installation..............................................................................................................91
Overview: installation...............................................................................................92
Checking site conditions..........................................................................................93
Installing the probe retractor....................................................................................95
Installing the control cabinet ....................................................................................98
Installing the compressed-air supply .......................................................................99
Installing the cooling module .................................................................................101
Installing the cooling water circuit..........................................................................103
Connecting the sample gas line to the retractor....................................................104
Connecting internal electric cables........................................................................105
Connecting external electric cables.......................................................................107
Chapter 7Start-up ................................................................................................................. 111
Overview: Start-up .................................................................................................112
Installation check ...................................................................................................113
Preparing the cooling-water circuit ........................................................................ 114
Preparing the compressed-air supply....................................................................116
Activation ...............................................................................................................118
After switching on: working on the cooling module ...............................................121
Checking the pneumatic system............................................................................123
Starting frequency converter and adapting control parameters ............................124
Checking/correcting operating parameters ...........................................................127
Checks to perform when using probe H ................................................................128
Inserting the probe and switching to automatic mode...........................................131
Chapter 8Operation..............................................................................................................135
Safety regulations for operation.............................................................................136
Monitoring automatic mode ...................................................................................138
Checking general condition ...................................................................................140
Cleaning gas sampling probe H ............................................................................142
Cleaning gas sampling probe 60S.........................................................................144
Using the EMERGENCY-STOP switch..................................................................146
Chapter 9Maintenance .........................................................................................................147
Maintenance plan ..................................................................................................148
Equipment layout plan ...........................................................................................152
Acquiring spare parts and wear parts ....................................................................155
Safety regulations for maintenance work ..............................................................156
Operating the service switch .................................................................................159
Checking the condition of the system, cleaning the system..................................161
Evaluating trend displays.......................................................................................164
Checking the residual current circuit breaker ........................................................165
Checking protective installations ...........................................................................167
Checking for leaks .................................................................................................171
Gas sampling probe H: Removing incrustations ...................................................174
Gas sampling probe H: Replacing the intake filter ................................................176
Gas sampling probe H: Replacing membrane pump membranes ........................179
Gas sampling probe 60S: Removing incrustations ...............................................182
Gas sampling probe 60S: Cleaning or replacing the outlet filter ...........................184
Gas sampling probe 60S: Replacing the seal set .................................................187
Probe retractor: Checking filter/pressure control combination ..............................189
Probe retractor: Checking and replacing the filter muffler .....................................191
Probe retractor: Checking and topping up the oiler...............................................193

6 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4
Probe retractor: Checking and tightening the drive chain .....................................196
Probe retractor: Checking and, if necessary, adjusting the position of the probe .198
Probe retractor: Checking and, if necessary, adjusting the position indicator
(probe end position)...............................................................................................202
Probe retractor: Checking the bellows ..................................................................205
Cooling module: Vent the cooling-water circuit .....................................................206
Cooling module: Checking and topping up cooling water .....................................208
Pneumatic system: Replacing the compressed-air filter .......................................211
Chapter 10Errors ....................................................................................................................213
Errors and irregularities .........................................................................................214
Touchscreen error displays....................................................................................216
Handling error messages ......................................................................................221
Chapter 11Shutting down, storing, putting back into operation, disposal ......................223
Shutting down the system .....................................................................................224
Disassembling the system.....................................................................................227
Storing the system .................................................................................................229
Putting the system back into operation .................................................................230
Disposing of the system ........................................................................................231
Chapter 12Appendix ..............................................................................................................233
Pneumatic/hydraulic interface plan........................................................................234
Electrical connection plan......................................................................................236
Transformer connection plan .................................................................................238
Index 239

42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System 7
Chapter 1 General
Topic Page
About these operating instructions .................................................................... 8
Safety instructions in this document................................................................ 10
System identification........................................................................................ 12
Service............................................................................................................. 15

8 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4
About these operating instructions
These operating instructions apply to the SCK gas sampling system, product num-
ber: 23919.
These operating instructions are intended to give all personnel handling the gas
sampling system the information required to perform the following tasks correctly
and safely:
Transport at the company (for first-time delivery, relocation, storage, putting
back into operation)
Set-up, unpacking and connection
Start-up
Operation
Diagnostics and troubleshooting
Maintenance
Shutting down, disassembly, putting back into operation, storage and disposal
These operating instructions are intended for the following groups:
Process engineers and design engineers (for preparation of the installation site)
Transporter
Assembly personnel
Start-up personnel
Operating personnel
Maintenance personnel
Storage personnel
Disposal personnel
The illustrations in the operating instructions do not always depict the actual layout
of a gas sampling system as delivered. Therefore, the drawings in the supplied
system documentation are always authoritative.
Failing to observe the information in this document can lead to a risk of damage to
property, injuries or even death.
In order to ensure safety, all personnel handling the gas sampling system must
have read and understood the following sections of this document before com-
mencing any work:
the section on Safety on page 55
the sections describing the work to be performed
The manufacturer retains copyright to these operating instructions:
ABB Automation GmbH
Geschäftsgebiet Analysentechnik
Stierstädter Straße 5
60488 Frankfurt am Main
GERMANY
These operating instructions contain regulations and drawings of a technical nature
that must not, either in part or in whole, be reproduced, disseminated or exploited
for the purpose of competition or passed on to third parties without permission.
The manufacturer is not liable for damage and disruptions resulting from a failure to
observe these operating instructions and other applicable documents.
Scope and purpose
Target group
Illustrations in the
operating
instructions
Copyright
Liability

42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System 9
Identifies safety information to be heeded when handling the
gas sampling system in order to avoid risks to the operator.
Identifies special information regarding handling of the gas
sampling system as well as use of these operating instruc-
tions.
1, 2, 3, ... Identifies reference numbers in the figures.
Further information on ABB Analytical products and services is available on the
Internet at "http://www.abb.com/analytical".
Symbols and
typefaces
Further information

10 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4
Safety instructions in this document
Safety instructions are information intended to prevent physical injuries. Safety
instructions contain the following information:
Type of danger
Possible consequences if you fail to observe the instruction
Action to prevent physical injury
This document contains the following types of safety instruction:
Type of safety
instruction
Description Indicated by
Basic safety instruc-
tions
Generic safety instructions not
pertaining to a particular task:
They provide a general descrip-
tion of dangers and safety
measures when handling the
system.
They are intended to educate
the operator about existing
dangers and to instruct him in
general safety behavior.
They are suitable for safety
instruction of all personnel han-
dling the gas sampling system.
Indicated by the title
of the section.
Safety regulations
for specific sections
Safety instructions pertaining to all
tasks described in this section
Indicated by the title
of the section
Safety instructions at
the beginning of an
instruction
Safety instructions with specific
instructions pertaining to the entire
instruction
Safety instructions
on a particular step
Safety instructions with specific
instructions pertaining to one step
only
DANGER
WARNING
CAUTION
What are safety
instructions for?
Types of safety
instruction